Folded-Lamella Socket Contact for Low-Loss High-Current Insertion
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Solution Overview
Problem
Existing electrical socket contacts for high-current applications face issues such as reduced contact force due to smaller contact lamellas, increased power loss from long current paths, and higher insertion forces due to longitudinal expansion during contact insertion.
Innovation Solution
The electrical socket contact features a base body with parallel side parts and opposing lamella bodies formed as insert mats through punching and bending technology. Each lamella body consists of multiple identical contact lamellas arranged in columns and rows, with folded metal strips forming a slope for punctiform contact points, allowing for a large number of independent contact points and short current paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the contact lamellas are reduced in size to increase their number, then the number of contact points is improved, but the contact force acting on the flat contact is reduced
Solution Approach 1:
The contact lamella body is segmented into multiple individual contact lamellas arranged in rows and columns. Each lamella is a separate elastic element that can independently deflect and apply contact force, allowing the total contact force to be distributed across many contact points without sacrificing the overall force magnitude.
Solution Approach 2:
The contact lamellas are designed as elastic elements that dynamically deflect during insertion to absorb insertion forces and maintain stable contact force. This dynamic behavior allows the system to accommodate many thin lamellas while maintaining sufficient contact force through elastic energy storage and release.
2Stability of the object's composition
If contact lamellas form long current paths to the mating plug, then the structural stability is improved, but power loss increases and current carrying capacity is reduced
Solution Approach 1:
The current path is segmented into multiple parallel paths through the arrangement of multiple contact lamellas. Each lamella provides a separate current path from the flat contact to the base body, and these paths are electrically parallel, reducing the total resistance and power loss while maintaining structural stability through the collective arrangement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a high number of independent contact points, reducing thermal and electrical resistance, minimizing power loss, and maintaining a low insertion force, thereby enhancing the current carrying capacity and reliability of the socket contact.
Implementation Method 1
Each lamella has two sections of a metal strip folded against one another. The sections folded against one another form a slope that ascends in the insertion direction.
Data Source
AI summary
A socket contact for accommodating a flat contact includes a base body and two mutually opposed lamella bodies arranged on inner surfaces of two mutually opposed side parts of the base body, respectively. Each lamella body is formed as an insert mat from a metal sheet. A flat contact is insertable along an insertion direction into the base body between the lamella bodies. Each lamella body includes lamellas that are arranged in rows perpendicular to the insertion direction and in columns along the insertion direction. Each lamella includes a metal strip having first and second lamella legs that are folded against one another. The lamella legs folded against one another form a slope that ascends along the insertion direction.