Rectangular Contact Pin Pressing for Stable High-Frequency Spacing
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Solution Overview
Problem
Conventional methods for manufacturing contact pins for electrical connectors, such as punching processes, result in corner deformations and unequal surface lengths, which deteriorate signal transmission characteristics, especially in high-frequency bands.
Innovation Solution
The use of a pressing process with a wire rod having a rectangular cross-sectional shape to form contact pins with flat inner surfaces and recessed portions, preventing corner collapses and allowing for equal surface lengths, thereby improving signal transmission characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a punching process is used to manufacture contact pins from a metal plate, then the contact pins can be produced efficiently, but corner deformations and unequal surface lengths occur which deteriorate signal transmission characteristics
Solution Approach 1:
The invention changes the manufacturing method from punching (subtractive) to pressing (formative), fundamentally altering the process parameters to avoid corner deformations. The pressing process uses controlled compression to form contact pins with equal surface lengths and accurate corner shapes, resolving the precision issue while maintaining productivity
Solution Approach 2:
The invention performs preliminary forming of the contact pin body with correct geometry through the pressing process before any cutting or separation operations. This ensures that the critical surfaces and corners are already formed with equal lengths and accurate shapes before any potentially damaging operations occur
2Ease of manufacture
If the contact pin body has unequal surface lengths due to punching deformation, then manufacturing is simpler, but signal transmission characteristics in high-frequency bands deteriorate
Solution Approach 1:
The invention changes the forming mechanism from punching-induced deformation to controlled pressing, transforming the manufacturing approach to inherently produce equal surface lengths. This resolves the contradiction by making equal surface lengths a natural outcome of the pressing process rather than a difficult-to-achieve precision requirement
Solution Approach 2:
The invention employs a composite structure with a rectangular cross-sectional body portion that integrates multiple functional surfaces (first, second, third, and fourth surfaces) of equal length. This composite geometric design ensures signal transmission reliability while maintaining manufacturing simplicity through the pressing process
3Ease of manufacture
If corner portions of the contact pin body are collapsed during punching, then material removal is easier, but the separation distance between contact pins becomes unstable
Solution Approach 1:
The invention changes the material processing method from punching (which causes collapse) to pressing (which maintains integrity). The pressing process applies controlled force to form the rectangular cross-section without collapsing corner portions, thereby maintaining stable separation distances between contact pins while still enabling efficient material forming
4Device complexity
If conventional punching and cutting processes are used, then manufacturing steps are fewer, but the contact pin geometry deviates from design specifications
Solution Approach 1:
The invention changes the primary forming operation from punching to pressing, which allows the contact pin body to be formed with correct geometry in a single step. This eliminates the need for subsequent cutting operations to correct deformations, maintaining low process complexity while achieving high geometric accuracy
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 approach prevents corner deformations and allows for equal surface lengths, enhancing signal transmission characteristics and stabilizing the separation distance between contact pins, leading to improved performance in high-frequency bands.
Implementation Method 1
pressing both end portions of a wire rod having a rectangular cross-sectional shape to form the contact pin
Data Source
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AI summary
An electrical connector 1 includes a pair of contact pins 2. Each of the pair of contact pins 2 is obtained by performing a pressing process with respect to a wire rod having a rectangular cross-sectional shape. The contact pin 2 includes a body portion 21 having a rectangular cross-sectional shape. The body portion 21 has an outer surface and an inner surface facing each other, and a third surface 213 and a fourth surface 214 facing each other. The third surface 213 and the fourth surface 214 are perpendicular to the outer surface and the inner surface The body portion 21 of each of the pair of contact pins 2 further includes a recessed portion 271 formed on the outer surface and a pair of protruding portions 27 respectively protruding from portions of the third surface 213 and the fourth surface 214 adjacent to the recessed portion 271 toward an outer side.