Cylindrical Plug Contact With Elongated Hole for Reliable Connection
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Solution Overview
Problem
Existing electrical plug contacts are complex and costly to produce, making them unsuitable for use as test adapters and lacking in reliable contact due to inadequate force absorption and deformation, leading to potential permanent deformation.
Innovation Solution
A simplified design featuring a cylindrical socket with an elongated hole and diametrically opposite longitudinal slot, allowing for symmetrical force absorption and elastic deformation, combined with a locking mechanism for secure contact, reduces production complexity and enhances reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing electrical plug contacts are used, then electrical connection is achieved, but the design is complex and production is costly
Solution Approach 1:
The socket is divided into functionally distinct regions: a contact area with an elongated hole for force absorption, a longitudinal slot for symmetry, and laterally offset locking recesses for secure positioning. This segmentation allows each region to perform its specific function optimally while simplifying the overall design and manufacturing process.
2Reliability
If existing electrical plug contacts are used, then electrical connection is achieved, but reliable contact is not ensured due to inadequate force absorption
Solution Approach 1:
The socket features an asymmetric design with an elongated hole that is significantly longer in one direction (at least 3 times the perpendicular extent), creating symmetrical force absorption paths when the electrical conductor is inserted. This asymmetric geometry ensures even distribution of insertion forces while maintaining structural simplicity.
Solution Approach 2:
The socket dimensions are specifically designed with the elongated hole having an extension of at least 3 times the perpendicular extent, and the expansion perpendicular to the longitudinal axis being at least 40% in non-constriction areas and 25% in constriction areas. These parameter changes ensure optimal elastic deformation and force absorption while preventing permanent deformation.
3Stability of the object's composition
If existing electrical plug contacts are used, then connection is made, but permanent deformation occurs due to inadequate elastic deformation capability
Solution Approach 1:
The socket is designed as a thin-walled cylindrical structure with strategically placed elongated holes and longitudinal slots that enable controlled elastic deformation. The wall thickness and hole geometry are optimized to allow the socket to flex symmetrically during insertion while maintaining structural integrity and returning to its original shape, preventing permanent deformation.
4Reliability
If the socket is designed to compress elastically, then good contact is achieved, but the structure becomes more complex
Solution Approach 1:
Multiple functions are merged into the single socket structure: the elongated hole and longitudinal slot work together to provide symmetrical force absorption and elastic deformation, while the laterally offset locking recesses provide mechanical interlocking. This merging of functions into one integrated component achieves reliable contact without increasing overall structural 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 design ensures a large-area contact with the electrical conductor, providing a reliable and cost-effective electrical connection without permanent deformation, enabling easier production and versatile application as a test adapter.
Implementation Method 1
The plug-in sleeve, which in particular can be of cylindrical design, can deform elastically over a large area. This results in good contact between the socket and the electrical conductor in the plugged-in position of the electrical plug contact and thus a good electrically conductive connection without the electrical plug contact being plastically, i.e. permanently deformed.
Data Source
Figure 1~2
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AI summary
The invention relates to an electrical plug-in contact, comprising a first region for electrical contact with an electrical connection and a second region for electrical contact with an electrical conductor, wherein the two regions are connected to each other in an electrically conductive manner. In order to provide a plug-in contact that has a simpler design and is more reliable in use, according to the invention the second region is designed as a plug-in sleeve, in particular a cylindrical plug-in sleeve, which, in the contact region thereof with the electrical conductor, comprises an elongated hole parallel to the longitudinal axis of the plug-in sleeve, and a longitudinal slot located diametrically opposite of the elongated hole. Furthermore, a system is provided, consisting of an electrical plug-in contact and an electrical conductor, in particular a current bar, wherein an angular, in particular quadrangular, hole for receiving the, in particular cylindrical, plug-in sleeve in the inserted position thereof is formed in the electrical conductor.