Hermaphroditic Electrical Connector with Form-Fitting Contact Elements
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Solution Overview
Problem
Existing electrical connectors lack sufficient contact width and holding force when connected, leading to suboptimal electrical contact and potential misalignment issues.
Innovation Solution
The use of hermaphroditic contact elements with one leg featuring a convex projection and the other a concave recess, allowing for a form-fitting connection that increases contact width and provides a snap-in mechanism for enhanced holding force, along with an arcuate design for improved spring action and tulip-shaped configurations for easy alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If linear or punctiform contact elements are used, then the connector structure is simple, but the contact width is insufficient
Solution Approach 1:
The contact elements are designed with curved surfaces instead of linear or punctiform contacts. The first contact element has a convex curved surface while the second has a corresponding concave curved surface, creating a form-fitting connection that significantly increases the contact width from a line or point to a broad curved surface area.
Solution Approach 2:
Different regions of the contact elements have different geometric properties - one contact element features a convexly projecting formation while the other has a concave recess. This local differentiation in geometry creates the form-fitting connection that maximizes contact width at the interface while maintaining structural integrity.
2Force
If friction-based holding force is used, then the connector is simple to manufacture, but the holding force is insufficient
Solution Approach 1:
The arcuate configuration of the contact elements creates a snap-in connection mechanism. The curved geometry allows the convex formation of one contact element to engage with the concave recess of the other, generating mechanical interlocking forces that significantly exceed simple friction-based holding.
Solution Approach 2:
The contact elements feature asymmetric geometries with convex and concave formations that create a directional snap-in connection. This asymmetric design provides enhanced holding force through mechanical interlocking while maintaining manufacturability through standard forming processes.
3Reliability
If conventional contact elements are used, then assembly is straightforward, but misalignment and positional tolerance issues occur
Solution Approach 1:
The rounded, arcuate surfaces of the contact elements provide self-aligning characteristics during assembly. The curved geometry allows for tolerance compensation as the components guide themselves into proper alignment through the form-fitting engagement, reducing sensitivity to manufacturing tolerances.
Solution Approach 2:
The contact elements serve multiple functions simultaneously: they provide electrical conduction, mechanical holding force through snap-in connection, and self-alignment during assembly. This multi-functionality increases connection reliability while maintaining ease of assembly despite the enhanced features.
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 significant increase in contact width and holding force, preventing misalignment and ensuring a secure, reliable electrical connection while allowing for easy assembly and positional tolerance compensation.
Implementation Method 1
The arcuate configuration is chosen such that the arc points away from the contact element of the other connector that has the concave recess and encloses an empty space with it, for example essentially in the shape of an 'O'. This achieves a particularly good spring effect towards the concave recess.
Data Source
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AI summary
An electrical connector with hermaphroditic contact elements (100) having the following features: - the electrical contact element (100) of a first connector is fork-shaped and open towards a second electrical contact element (100), - the inner surfaces of the forks, each having two legs (110, 120), enclose - at least partially - one leg (120, 110) of the respective other contact element, is characterized by the following features: - one of the two legs (110) has a convexly projecting projection (111), - the other of the two legs (120) has a concave recess (121), - the shape of the concave recess (121) is adapted to the convexly projecting projection (111) such that, in the connected state of two connectors, the convexly projecting projection (111) of the first connector engages at least partially with the concave recess (121) of the second connector is located and vice versa.