Sheet Metal Hood Contact With Interlocking Connection Portions

Solution Overview

Problem

Existing contacts for electrical connectors, particularly those used in motor vehicles, face manufacturing complexities due to the need for welding or soldering steps in forming the box-shaped hood, which complicates the manufacturing process and tool design.

Innovation Solution

The contact design eliminates the need for welding or soldering by using form-fitting connection portions with abutment edges that engage as a seam, allowing the first and second connection elements to secure the hood without additional mechanical closure, and incorporates flaps and slots for additional locking mechanisms to prevent movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding or soldering steps are used to secure the connection portions, then the mechanical strength and reliability of the hood are improved, but the manufacturing complexity and process time increase

Engineering Contradiction:

Improvemechanical connection reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the thermal joining process (welding/soldering) with a mechanical interlocking system. The first and second connection portions are designed with complementary geometries that engage through form-fitting connection, eliminating the need for thermal processes while maintaining structural integrity through mechanical engagement alone.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection portions are designed to self-secure through their geometric configuration. The abutment edges and engaging surfaces are shaped such that when assembled, the connection portions automatically lock together without requiring additional fastening operations, tools, or external intervention, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #25Self-service

2Strength

If welding or soldering steps are used to secure the connection portions, then the structural integrity of the hood is improved, but the production time and productivity are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the thermal joining process (welding/soldering) with a mechanical interlocking system. The first and second connection portions are designed with complementary geometries that engage through form-fitting connection, eliminating the need for thermal processes while maintaining structural integrity through mechanical engagement alone.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection portions are pre-formed with their final geometric configuration during the sheet metal forming process. The abutment edges and engaging surfaces are created in advance with precise dimensions and shapes, allowing the parts to self-assemble and lock together immediately without requiring subsequent welding or assembly operations.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If complex mechanical closing elements are provided at the abutment edges, then the securing reliability of the connection portions is improved, but the tool design and manufacturing complexity increase

Engineering Contradiction:

Improveconnection securing reliabilityVSAvoidtool design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection portions are designed to self-secure through their geometric configuration. The abutment edges and engaging surfaces are shaped such that when assembled, the connection portions automatically lock together without requiring additional fastening operations, tools, or external intervention, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The hood is divided into separate connection portions (first and second connection portions) that are formed from the sheet metal part and then joined through their abutment edges. This segmentation allows each portion to be independently formed and then assembled through simple geometric engagement, reducing the complexity of the overall tooling required compared to forming a fully enclosed box shape in one piece.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3096409B1A contact for electrical connectors

Publication Date: 2020.02.19 YAZAKI EUROPE LTD

Figure 1
Figure 2
Figure 3

AI summary

A contact for electrical connectors, said contact comprising: a contact member 1, a box-shaped hood 2 extending along a longitudinal axis L and enclosing at least partially the contact member 1, said hood 2 being bent from a sheet-metal part into the box-shape having four outer walls 11, 12, 13, 14 extend along the longitudinal axis L and having a front side 15 with an opening 16 for inserting a counter contact member in the direction of the longitudinal axis L into the box-shaped hood 2 for contacting the contact member 1, said sheet-metal part having a first connection portion 21 with a first abutment edge 23 and a second connection portion 22 with a second abutment edge 24 wherein the first and second abutment edges 23, 24 abut each other, wherein the first connection portion 21 is provided with a first connection element 27 at the front side 15, and the second connection portion 22 is provided with a second connection element 28 at the front side 15, and the first connection element 27 and the second connection element 28 engage each other so as to lock the first connection portion 21 and the second connection portion 22 against detaching the first and second connection portions 21, 22 away from each other.