Spring-Loaded Contact Piston Assembly for Clip-Safe Insertion
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Solution Overview
Problem
Existing spring-loaded connectors face issues with beam damage during clip insertion and require increased wall thickness for press fit resistance, leading to increased pitch in the plug, compromising reliability and compactness.
Innovation Solution
A piston assembly with a separate piston body and head, where the clip is inserted from the piston head side and ultrasonically welded, preventing beam damage and allowing for a compact design with reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the clip is inserted into the tubular housing by pushing the beams of the clip, then the clip can be assembled into the housing, but the beams may be damaged and the reliability of the connector is reduced
Solution Approach 1:
Instead of inserting the clip by pushing the beams from the housing end, the invention inverts the insertion approach by pushing the clip from the opposite end through the piston assembly. This reverses the force application direction, allowing the clip to be inserted without damaging the beams while maintaining assembly feasibility.
2Strength
If the wall thickness is increased to achieve the required press fit resistance, then the press fit strength is improved, but the pitch of the plug is increased
Solution Approach 1:
The invention divides the piston assembly into separate components (piston body, piston head, and clip) that can be assembled together. This segmentation allows the use of thinner walls with ultrasonic welding to achieve the required strength, eliminating the need for increased wall thickness that would otherwise be required for press fit resistance.
Solution Approach 2:
The invention replaces traditional mechanical press fit connections with ultrasonic welding technology. This substitution enables the use of thinner walls while maintaining the required structural strength and press fit resistance, as ultrasonic welding provides strong bonds without requiring thick walls for mechanical interlocking.
3Reliability
If the clip is inserted from the piston head side, then the beam damage is prevented, but the insertion process becomes more complex
Solution Approach 1:
By segmenting the piston assembly into a piston body and a separate piston head, the invention creates a through-hole structure that enables clip insertion from the piston head side. This segmentation, combined with ultrasonic welding of the piston head to the piston body, provides a straightforward assembly process that prevents beam damage without introducing excessive complexity.
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
The solution ensures reliable and compact assembly by protecting the clip's beams during insertion and achieving a thin wall thickness without compromising strength, while providing secure contact and reduced heat-affected zones.
Implementation Method 1
the piston head is attached to the piston body by an ultrasonic welded portion
Data Source
AI summary
A piston assembly for a spring-loaded contact, comprising a piston body, arranged to be received into a guiding cylinder of the spring loaded contact, a piston head, with a contacting surface arranged for contacting an external part, a clip arranged to mate with a conductive portion of the spring loaded contact, wherein the piston body comprises a through hole, the clip being arranged into the through hole, and wherein the piston head is attached to the piston body by an ultrasonic welded portion.