Plug Connector Contact Geometry for Low-Resistance High-Current Mating
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Solution Overview
Problem
Existing electrical connectors for audio applications, such as speaker and amplifier connections, face challenges in achieving good starting slope and high current transmission with a simple structure, while maintaining low contact resistance and sufficient spring properties.
Innovation Solution
The electrical connector features a contact element curved convexly away from the central axis, deflecting resiliently to form an acute angle with the contact pin's path, allowing for gentle mechanical contact and optimal force distribution, with optional twisting for enhanced deflection and curvature to ensure secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple contact element structure is used, then manufacturing cost and device complexity are reduced, but contact resistance increases and spring properties deteriorate
Solution Approach 1:
The contact element incorporates a convex curvature on its contact surface that matches the contour of the contact pin. This curved geometry ensures optimal force distribution and gentle mechanical contact during insertion, reducing contact resistance while maintaining a relatively simple single-piece structure without complex internal mechanisms
Solution Approach 2:
The contact element's geometry is optimized by curving its contact surface to match the contact pin's contour. This parameter change in the contact element's shape transforms the contact mechanics, ensuring better force distribution and lower contact resistance while keeping the overall structure simple
2Device complexity
If a simple contact element structure is used, then device complexity is reduced, but starting slope performance deteriorates
Solution Approach 1:
The convex curvature on the contact element's contact surface is specifically designed to match the contact pin's contour. This curvature creates optimal mechanical contact from the beginning of insertion, ensuring good starting slope performance while maintaining a simple single-piece structure without complex internal mechanisms
3Reliability
If contact element is curved to match contact pin contour, then mechanical contact quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The contact element's geometry is defined by specific curvature parameters that match the contact pin's contour. By optimizing these geometric parameters, the design achieves optimal mechanical contact quality while keeping the manufacturing process relatively simple, avoiding the need for complex multi-component assemblies
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 enables efficient high-current transmission with low contact resistance and improved spring properties, ensuring reliable electrical contact and secure locking without complex structures.
Implementation Method 1
The contact element curved convexly away from the central axis, deflecting resiliently in the direction of the central axis
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrical plug connector. Said electrical plug connector has a housing (1) in which at least one insertion opening (2, 3) and at least one guide (31) for a complementary plug connector (5, 10) with at least one electrical contact pin (8, 9, 101) are arranged. At least one contact element (13, 14) which can be elastically deflected out of the path of the contact pin (8, 9, 101) is secured in the housing (1) and projects at least partially into the insertion opening when the complementary plug connector is absent. The side edge (132, 142) of the contact element (13, 14), which side edge faces the contact pin (8, 9), forms in its front section (133, 143) an acute angle with the path of the contact pin (8, 9) during insertion as seen in the direction of the deflection of the contact element (13, 14). When the cable plug connector (5) is fully inserted, a planar contact section (134, 144) of the contact element (13, 14) is in contact with the contact pin (8, 9) in a manner adjoining the side edge (132, 142) in the transverse direction.