Parallel Multi-Finger Contact With Distal Dimples for Low-Friction Pins
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Solution Overview
Problem
Traditional pin sockets require multiple manufacturing steps, leading to high costs and inconsistent results, and cause damage to device leads due to high frictional forces during insertion and extraction.
Innovation Solution
A one-piece multi-finger contact design with a barrel, tapering region, and parallel fingers, featuring dimples at the distal end for reduced friction, allowing for a simplified manufacturing process and consistent insertion, retention, and withdrawal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional two-piece tapered finger contacts are used, then manufacturing flexibility is maintained, but manufacturing complexity and cost increase due to multiple assembly steps
Solution Approach 1:
The patent merges the contact fingers and barrel into a single integrated component manufactured from one piece of metal. This eliminates the need for separate assembly steps where tapered fingers are press-fitted into a turned pin metal terminal, reducing manufacturing complexity while maintaining design flexibility.
Solution Approach 2:
The single-piece contact is designed with distinct functional regions: a barrel portion for structural support and mounting, tapered fingers for electrical contact and lead engagement, and a lumen for lead passage. This segmentation of functions within a unified structure achieves simplicity in manufacturing while preserving functional complexity.
2Strength
If tapered fingers are used to provide wiping action, then retention force is improved, but insertion force increases causing lead damage
Solution Approach 1:
The contact design applies different geometric properties to different regions: the fingers are tapered to provide wiping action and retention force, while the lumen is designed with specific dimensions and surface characteristics to control insertion force. This local differentiation of geometric qualities allows the contact to provide high retention while minimizing insertion force and lead damage.
Solution Approach 2:
The patent optimizes geometric parameters including the angle of finger taper, lumen diameter, and finger thickness to achieve the desired balance between retention force and insertion force. By carefully controlling these parameters, the contact provides sufficient retention strength while reducing the harmful insertion forces that cause lead damage.
3Adaptability or versatility
If multiple manufacturing steps are used for traditional contacts, then design flexibility is maintained, but manufacturing cost and time increase
Solution Approach 1:
The contact is manufactured as a single piece using stamping and forming operations, combining multiple traditional manufacturing steps into one integrated process. This merging of manufacturing operations maintains design flexibility while dramatically improving manufacturing efficiency and reducing production time.
Solution Approach 2:
The patent uses stamping and forming parameters to achieve the complex geometry of the contact including tapered fingers, cylindrical lumen, and various mounting features. By controlling forming parameters such as material selection, stamping pressure, and die design, the manufacturer can produce consistent, high-quality contacts with design flexibility while maintaining high production efficiency.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An electronic device contact or socket (10) includes a barrel (16) having a lumen (14) extending therethrough. The barrel includes a proximal barrel portion (16A) having a first outer diameter; a tapering region (16B) extending distally from the proximal barrel portion, the tapering region extending both distally and radially inward towards a central axis of the barrel; a plurality of fingers (12) extending distally from the tapering region, the plurality of fingers are all parallel to one another and the central axis; and a dimple contact area (13) extending from each of the plurality of fingers extending radially inward and distally. The barrel is configured to make full contact with an electronic pin or lead (20) only at the dimple contact area (13).