Press-fit Pin With Shoulder Element For Tip Protection
Solution Overview
Problem
Press-fit pins made from wire material often suffer damage at their tips due to high forces exerted during insertion into printed circuit boards or plastic housings, as existing technologies rely on supporting the pin tips rather than providing a stable shoulder element for force transmission.
Innovation Solution
Incorporating a cross-sectional widening in the region of a shoulder element within the press-fit pin, which allows for easier support and force transmission without damaging the pin tip, and can be formed from the pin material itself through deformation or splitting, facilitating handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If press-fit tools support the pin tips during insertion, then high forces can be exerted on the pin, but the pin tips are damaged
Solution Approach 1:
The invention extracts the force transmission function from the pin tip and relocates it to a dedicated shoulder element. The shoulder element is formed by local cross-sectional widening of the pin body, which serves as an exclusive interface for tool support during insertion, thereby protecting the pin tip from damage while maintaining high force transmission capability
Solution Approach 2:
The shoulder element acts as an intermediary between the press-fit tool and the pin body. Instead of the tool directly contacting and potentially damaging the pin tip, the force is transmitted through the shoulder element which is specifically designed to bear the insertion load, thus protecting the critical pin tip region
2Ease of operation
If a shoulder element is added to the pin, then force transmission and handling are improved, but the pin structure becomes more complex
Solution Approach 1:
The invention merges the shoulder element with the pin body by forming it through local cross-sectional widening of the same wire material. This integration eliminates the need for separate shoulder components or additional assembly steps, reducing overall structural complexity while providing the necessary force transmission and handling features
Solution Approach 2:
The shoulder element is created through localized modification of the pin cross-section at specific positions, while the rest of the pin maintains its original uniform structure. This local quality change approach adds functionality only where needed, minimizing the impact on overall pin simplicity and manufacturing ease
3Strength
If cross-sectional widening is used to form the shoulder element, then sufficient material is available without mechanical weakening, but the pin cross-section changes adversely
Solution Approach 1:
The cross-sectional widening is applied locally only at the shoulder element region, allowing sufficient material to be available for force transmission while maintaining the original uniform cross-section in the critical pin body and tip regions. This localized approach ensures pin strength is not compromised while achieving the desired shoulder geometry
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 enables the press-fit pin to be inserted without damaging the tip, providing a stable shoulder element for force transmission and improved manageability, allowing for efficient assembly and reduced material usage.
Implementation Method 1
the wire material is plastically deformed to form the shoulder element therefrom
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a press-fit pin (1) made from wire material for electrical contacts, in particular plug-in connectors. The invention also relates to a method for producing a press-fit pin (1) made from wire material for electrical contacts, in particular plug-in contacts. When using press-fit pins (1) made from wire material the problem of the tips (23) of the press-fit pins (1) being damaged by the press-fit tool has previously occurred. To be able to support a tool on press-fit pins (1) made from wire material without the tips (23) being damaged the press-fit pin (1) made from wire material is provided according to the invention with a shoulder element (3).