Plug Contact with Circular Segment Contour for PCB
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Solution Overview
Problem
Existing plug contacts for circuit boards often damage the inner wall of the contact hole due to sharp edges, leading to coating removal and limited reversibility, requiring additional work steps and tools for connection and disconnection.
Innovation Solution
The plug contact features contact legs with a circular segment contour in cross-section and longitudinal direction, reducing sharp edges and allowing multiple insertions without damaging the contact hole, along with angled legs for increased elasticity and a guide section for easy insertion, and various connection area designs such as crimp, cutting, or spring clamp.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional plug contacts with straight contact legs are used, then the connection can be made easily, but the sharp edges damage the inner wall of the contact hole and remove the coating
Solution Approach 1:
The contact legs are given a circular segment contour in cross-section instead of straight edges. This curved geometry eliminates sharp edges that would otherwise dig into the contact hole inner wall during insertion, thereby preventing coating removal and damage while maintaining ease of insertion
2Reliability
If soldering or pressing-in techniques are used to ensure good electrical contact, then reliable connection is achieved, but the connection becomes irreversible and requires additional work steps and tools
Solution Approach 1:
The contact legs are designed to be resilient and elastic, allowing them to be inserted into the contact hole and later removed without damaging the connection. This dynamic, reversible connection mechanism eliminates the need for soldering or pressing-in techniques, reducing complexity while maintaining reliable electrical contact
Solution Approach 2:
The resilient contact legs automatically establish and maintain electrical contact through their elastic properties, without requiring additional connection tools or processes. The connection is self-establishing and self-maintaining, eliminating the need for soldering irons, pressing tools, or other specialized equipment
3Adaptability or versatility
If multiple plugging cycles are performed with conventional plug contacts, then connectivity flexibility is improved, but the contact hole inner wall and coating are progressively damaged
Solution Approach 1:
The circular segment contour of the contact legs ensures that during multiple insertion and removal cycles, the curved surfaces glide along the contact hole inner wall without creating concentrated stress points. This prevents progressive damage and coating removal, maintaining contact hole integrity across multiple plugging cycles
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
Ensures reliable, reversible electrical contact with reduced risk of coating damage and easier handling, enabling multiple plugging cycles without damaging the contact hole and allowing easy connection and disconnection of conductors.
Implementation Method 1
two contact legs (4, 5) which are resilient relative to one another
Data Source
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AI summary
The invention relates to a plug contact (1) for electrically contacting a printed circuit board (2) by plugging the plug contact (1) into a contact hole (3) of the printed circuit board (2), comprising two contact limbs (4, 5) which are elastic relative to each other, a terminal region (6), and a connection region (7). The connection region (7) connects the two contact limbs (4, 5) together and to the terminal region (6), and the plug contact (1) is punched out of a flat metal material and is bent. The plug contact (1) according to the invention ensures multiple plugging and pulling cycles without the inner wall (9) of the contact hole (3) being damaged in that each of the two contact limbs (4, 5) has a contacting region (4a, 5a) which contacts the contact hole (3) in the plugged-in state. The outer contour (8) of each of the two contact limbs (4, 5) has the shape of a segment of a circle in a cross-sectional view in the contacting region (4a, 5a), and the radius of the outer contour (8) is smaller than the radius of the corresponding contact hole (3) of the printed circuit board (2).