Offset Contact Lamella Part for Low Insertion Force
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Solution Overview
Problem
Conventional contact lamella parts require high insertion forces for coupling and fail to provide reliable low contact resistance, especially for high current and high-frequency signal transmission over the long term.
Innovation Solution
The contact lamella part features offset contact zones along the longitudinal direction of adjacent lamellae, allowing for sequential elastic deformation during coupling, reducing the maximum insertion force and providing stable electrical and mechanical contact through twisted or inclined contact zones, which also enhance shielding effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact lamellae are designed to be elastic and bear tightly against contact elements under mechanical preload, then low contact resistance is achieved, but high insertion forces are required for coupling
Solution Approach 1:
The contact zone of each contact lamella is divided into multiple contact sections arranged along the longitudinal direction. These contact sections are offset from each other, creating segmented contact points that distribute the deformation load across multiple locations rather than requiring simultaneous deformation of the entire contact zone, thereby reducing the peak insertion force while maintaining reliable electrical contact
Solution Approach 2:
Different sections of the contact lamella are given different functional qualities: the contact sections are designed with specific elastic properties to ensure tight bearing against contact elements for low contact resistance, while the spacing and offset arrangement of these sections locally reduce the overall insertion force requirement by avoiding simultaneous deformation of the entire lamella length
2Force
If contact lamellae are arranged with offset contact zones, then insertion force is reduced, but assembly complexity increases
Solution Approach 1:
The contact sections of adjacent contact lamellae are arranged asymmetrically with longitudinal offsets, creating a staggered pattern. This asymmetric arrangement reduces insertion force by avoiding simultaneous deformation of all contact zones, while the regular repeating pattern of the offset sections maintains manufacturing and assembly simplicity through predictable, periodic geometry
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 reduces the required insertion force by half, ensures reliable low contact resistance, and provides improved stability and shielding, making it suitable for high current and high-frequency signal transmission.
Implementation Method 1
The contact lamella can be elastically deformable in the contact zone transversely to its longitudinal direction, so that when the first and second contact elements, between which the contact lamella acts, are coupled, it is pressed under mechanical preload into close contact with at least one of the contact elements
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The invention comprises a contact lamella part (100; 200) for transmitting an electrical current or signal between a first contact element, such as a contact socket, and a second contact element which can be coupled thereto, such as a contact pin, comprising a plurality of contact lamellae (120, 121; 220, 221) extending substantially parallel to one another in a longitudinal direction (L), each having a contact zone (130, 131; 230, 231) for contacting the first contact element and/or the second contact element, wherein the contact zone (130, 230) of a first contact lamella (130; 230) is arranged offset in the longitudinal direction (L) in relation to the contact zone (131; 231) of a second contact lamella (131; 231).