Insertion Contact Grid Pitch Reduction via Rolled Arm and Lever Support
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Solution Overview
Problem
Existing insertion contacts face challenges in miniaturizing grid pitches while maintaining high contact forces and preventing damage to finishing layers on conductive paths, particularly in plug connectors adhering to the Rast 2.5 standard.
Innovation Solution
The insertion contact design features a contact arm with a rolled side contacting the top surface and a support arm with a stamped edge contacting the bottom surface of the contact support, allowing for a narrower support arm and alternating arrangement of contact arms to reduce grid pitch, enabling nesting and increased contact forces without damaging the finishing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If insertion contacts are configured as stamped components with stamped edges for contacting, then high contact forces can be imparted, but the finishing layers on conductive paths are damaged due to burred and rough stamping edges
Solution Approach 1:
The patent applies different surface qualities to different parts of the contact component: the contact arm has a rolled surface with smooth finish for contacting the conductive path, while the support arm retains the stamped edge for structural support. This local differentiation allows the contact surface to protect the finishing layer while the support structure maintains high contact force capability.
Solution Approach 2:
The contact component is divided into functionally distinct segments: a contact arm with rolled surface for electrical contact and a support arm with stamped edge for mechanical support. This segmentation allows each part to be optimized for its specific function without compromising the other.
2Object-affected harmful factors
If rolled surfaces are used for contacting to prevent damage to finishing layers, then the contact force is reduced, but additional springs or reinforced configurations are needed to compensate
Solution Approach 1:
The patent merges the contact function and support function into a single integrated component. The support arm with stamped edge provides mechanical leverage and structural support, amplifying the contact force generated by the rolled surface contact arm, thereby eliminating the need for additional springs or reinforced configurations.
Solution Approach 2:
The patent utilizes the vertical dimension by having the support arm extend below the contact support to contact the bottom side, creating a lever arm that amplifies the contact force at the top surface without requiring additional force-generating elements.
3Length of moving object
If the support arm is made narrow to reduce grid pitch, then miniaturization is achieved, but the contact force transmission capability is reduced
Solution Approach 1:
The patent resolves the grid pitch versus force transmission contradiction by utilizing the vertical dimension. The support arm contacts the bottom side of the contact support, creating a lever arm that provides mechanical advantage. This allows the support arm to be narrow (reducing grid pitch) while still transmitting high contact forces through the lever action.
Solution Approach 2:
The component is segmented into a narrow contact arm for minimal space occupation and a support arm that leverages vertical space for force amplification. This segmentation allows the overall footprint to be minimized while maintaining force transmission capability through the lever arm mechanism.
4Length of moving object
If alternating arrangement of contact arms is implemented, then grid pitch is reduced and nesting is enabled, but the structural complexity increases
Solution Approach 1:
The contact component is segmented into distinct contact arm and support arm sections that can be alternately arranged. This segmentation enables the nesting configuration where contact arms of adjacent contacts are offset, reducing grid pitch while maintaining structural integrity through the modular design.
Solution Approach 2:
The patent implements a nesting arrangement where contact arms of adjacent contacts are offset and interlocked, similar to nested dolls. This nesting reduces the overall grid pitch while the integrated support structure maintains structural simplicity, avoiding the need for additional complex components.
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 configuration significantly reduces grid pitch while maintaining high contact forces and preventing damage to the finishing layers, facilitating miniaturization and improved electrical transmission values.
Implementation Method 1
the contact arm and/or the support arm are deflectable in a spring elastic manner
Data Source
AI summary
The invention relates to an insertion contact for arrangement at a contact support including an opposite contact, the insertion contact including a contact arm which contacts a first contact surface of an opposite contact in an electrically conductive manner which opposite contact is arranged on a top side of a contact support; a support arm which contacts a bottom side of the contact support; and a connection arm which arranges the contact arm at the support arm, wherein the contact arm and/or the support arm is deflectable in a spring elastic manner, wherein the insertion contact includes a connection member for connecting a conductor, wherein the insertion contact is configured as a stamped component. It is an object of the invention to provide insertion contacts which facilitate reducing grid pitches of plug connectors, in particular according to Rast 2.5 standard, while maintaining predetermined technical specifications.