Hyperboloid Contact Socket Segmented Design
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Solution Overview
Problem
Conventional hyperboloid contact sockets face challenges such as complex assembly, high manufacturing costs due to precision machined components, and size limitations that prevent their use in high-density applications, along with issues like wire separation leading to field failures and increased repair costs.
Innovation Solution
A hyperboloid contact socket design featuring a tubular body with a U-shaped lip and integral spline termination, where conductive wires are affixed through rolling, crimping, or swaging, allowing for automated high-speed manufacturing and reduced component count, resulting in a shorter length and smaller diameter for increased density and cost efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional hyperboloid contact sockets use press fit retention for wires, then assembly is simplified, but wire separation occurs leading to field failures
Solution Approach 1:
The contact socket is divided into multiple functional sections: a reception section with a first opening for receiving the mating pin, and a termination section with a second opening for wire termination. This segmentation allows each section to be optimized independently - the reception section focuses on low insertion force and vibration resistance, while the termination section provides secure wire retention through various termination methods (soldering, crimping, swaging), thereby resolving the contradiction between assembly simplicity and wire retention reliability.
2Strength
If conventional hyperboloid contacts use concentric inner and outer cylindrical sections, then structural integrity is maintained, but diameter increases preventing high-density applications
Solution Approach 1:
The invention transitions from a conventional concentric cylindrical structure to a more space-efficient configuration where the inner sleeve is positioned offset from the center of the outer shell. The inner sleeve extends along a portion of the longitudinal axis but is arranged to minimize the overall diameter. This dimensional reorganization allows the contact to maintain structural integrity while reducing diameter, enabling high-density applications where miniaturization is required.
3Productivity
If automated high speed manufacturing processes are used, then productivity increases, but manufacturing precision may be compromised
Solution Approach 1:
The contact wires are pre-formed into the hyperboloid shape and pre-positioned within the inner sleeve before the final assembly process. The inner sleeve with pre-positioned wires is then inserted into the outer shell and secured. This preliminary preparation of components allows automated high-speed assembly while maintaining precision, as the critical positioning work is done in advance during a controlled manufacturing step rather than during high-speed assembly.
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
The design enables cost-effective, efficient assembly and reduced component costs, allowing for use in high-density applications with improved reliability by securely attaching wires within the socket, reducing the risk of wire separation and enabling miniaturization for closer spacing.
Implementation Method 1
Permanent and conductive attachment of the wires to the tubular body is provided through deformation of the body by rolling, crimping, swaging or other suitable means
Data Source
Figure 1~3
Figure 4a~4d
Figure 5a~5g
AI summary
A hyperboloid contact socket includes a tubular body (40) formed of a conductive material, a plurality of wires (41) the first ends disposed in permanent conductive contact with said inner surface of said tubular body, and a termination member formed of a conductive material. The termination member includes a spline portion (46) and a termination portion (48), the spline portion including a plurality of spaced longitudinal wire receiving grooves for receiving the wires. The termination portion is integrally formed with the spline portion as a one piece member and has an outer dimension that is smaller than the outer diameter of the spline portion. The wires are disposed in angular relation with respect to the longitudinal axis within said tubular body to form a hyperboloid socket within the tubular body with a pin receiving aperture at said first end of said body.