Lamp Socket Contact Retention for Ceramic Tolerance
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Solution Overview
Problem
High-power lamps with ceramic sockets face challenges in achieving adequate electrical and mechanical contact due to material tolerances and lead-in orientations, leading to complexity in contact design.
Innovation Solution
A socket design featuring radially spaced contact retainers, tabs on lead-in engagers, and a contact retention spring ensures precise alignment and secure engagement of electrical contacts with lead-ins projecting orthogonally to the lamp axis, using ceramic materials for the socket body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic materials are used for high-power lamp sockets, then thermal resistance and electrical insulation are improved, but manufacturing precision and contact alignment deteriorate due to greater tolerances
Solution Approach 1:
The contact structure is divided into multiple functional elements: contact retainer (holds contact in place), lead-in engagers (engage with lamp lead-ins), tabs (provide alignment features), and bight (provides flexibility). This segmentation allows each element to be optimized for its specific function, compensating for ceramic tolerance variations through the coordinated action of discrete components rather than relying on monolithic precision
Solution Approach 2:
The contact design incorporates radial spacing between retainers and tab positions that are specifically engineered to accommodate ceramic tolerance ranges. The lead-in engagers are positioned and dimensioned to maintain proper electrical contact despite variations in lamp lead-in positions caused by ceramic socket tolerances, effectively changing the geometric parameters to work within rather than against the material constraints
2Reliability
If complex contact designs are used to compensate for ceramic tolerances, then contact reliability is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single contact component: the lead-in engager simultaneously provides electrical connection, mechanical retention, and alignment functions. The tab integrated on the lead-in engager combines positioning and retention features. This merging reduces the number of separate parts needed while maintaining the reliability benefits of a segmented functional approach
Solution Approach 2:
The contact design is created as a universal solution that handles multiple functions within a single component structure. The lead-in engager with integrated tab and bight configuration serves as a multi-functional element that works with standard high-power lamp configurations, reducing complexity by providing a standardized multi-purpose contact design rather than requiring specialized components for each function
Data Source
AI summary
A socket (10) for receiving and retaining a lamp (12) and providing electrical connection to electrical lead-ins (14a) and (14b) of the lamp (12), the electrical lead-ins (14a) and (14b) projecting from the lamp in a direction orthogonal to a longitudinal axis (18). The socket (10) comprises a first socket body half (16) arrayed about the longitudinal axis (18) and including a receptacle (20) aligned with the longitudinal axis (18) for receiving a portion (22) of the lamp (12). Lead-in receptacles (24) are formed in the socket body (16), the receptacles being laterally disposed relative to the longitudinal axis. Electrical lead-in contact receivers (26) are formed adjacent the lead-in receptacles. Radially spaced contact retainers (28, 29) are associated with the contact receivers (26). An electrical contact (30) is positioned in each contact receiver (26), each of the electrical contacts (30) comprising first and second spaced-apart lead-in engagers (32, 34) joined by a bight (36). A tab (38) extends from a distal end (40) of the first lead-in engager (32) and is confined in the contact retainer (29) and a tab (42) extends from a proximal end (44) of the second lead-in engager (34). A wire receptor (46) is affixed to the contact (30). A second socket body half (48) is affixed to the first socket body half (16) and a contact retention spring (50) is positioned between an inside surface (52) of the second socket body half and first lead-in engager (32).