Plug Contact with Cut-Clamp Fork for Reversible PCB Mounting
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Solution Overview
Problem
Existing plug contacts for direct connectors on printed circuit boards lack reversibility and enhanced functionality, particularly in terms of secure and flexible conductor connections.
Innovation Solution
A plug contact design featuring a mounting frame with a second coupling section, insulation displacement forks, a stabilizing part, latching element, and fastening elements, which creates a continuous channel for secure conductor connections and enhances the plug contact's functionality by allowing reversible placement and increased contact reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plug contact is designed with a mounting frame and multiple coupling sections, then the functionality and contact reliability are improved, but the device complexity increases
Solution Approach 1:
The mounting frame combines multiple functions into a single structural element: it provides mechanical support for the contact, forms a continuous channel for conductor insertion, carries both first and second coupling sections for dual conductor connections, and integrates stabilizing parts for alignment. This merging of functions reduces the number of separate components needed while maintaining enhanced functionality.
Solution Approach 2:
The mounting frame serves multiple purposes simultaneously: it acts as a carrier for conductor connection sections, provides structural support for the plug contact, creates a guiding channel for insulation displacement, and incorporates stabilizing features for correct alignment during insertion. This multi-functionality allows the single component to replace what would otherwise require multiple separate parts.
2Ease of manufacture
If a mounting frame with continuous channel is used, then the ease of manufacture and automation are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The continuous channel is pre-formed as an integral part of the mounting frame during the stamping or molding process, before assembly. This preliminary formation of the guiding channel ensures that conductor connections are automatically guided into the correct position during insulation displacement, reducing the need for post-assembly adjustments and facilitating automated manufacturing.
Solution Approach 2:
The continuous channel in the mounting frame serves as a self-guiding feature that automatically aligns and positions the conductor connections during the insulation displacement process. The channel's geometry itself provides the alignment function, eliminating the need for separate alignment mechanisms or complex positioning systems, thereby simplifying manufacturing while maintaining precision.
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 design enables reversible placement of direct connectors on printed circuit boards, improves contact reliability, and reduces the number of components needed, ensuring secure and efficient electrical connections.
Implementation Method 1
the contact has spring-returning elastic contact fingers originating from the coupling section. These are pushed into the contact hole while building up a spring restoring force. On the one hand, the spring restoring force ensures that the contact is held in the contact, but in particular it ensures that the mutual contact zones are sufficiently in contact and thus that there is sufficient electrical contact.
Implementation Method 2
the mounting frame carries an insulation displacement fork as a conductor connection section
Data Source
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AI summary
A plug connector for connecting a conductor to a printed circuit board, which has a contact hole for receiving the plug connector, is shown and described, comprising a conductor connection section to which the conductor can be connected, a plug section that can be inserted into the contact hole, and a first coupling section that connects the plug section and the conductor connection section, wherein the plug section has at least two spring-return elastic contact fingers originating from a common origin, and wherein the first coupling section is part of a mounting frame that defines a channel that extends through in the plugging direction.