Resilient Contact Geometry for Plug Connector Assembly
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Solution Overview
Problem
Existing contact elements for connectors lack improved assembly efficiency and reliable contact force distribution, leading to suboptimal contact reliability.
Innovation Solution
The contact element features a resilient contact geometry with a wavy course, present twice in the contact area, and a configuration of connected base parts with perpendicular connecting parts, allowing for efficient production and enhanced contact reliability through symmetrical design and latching mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single fixed contact geometry is used, then the structure is simple, but the insertion effort is high and contact reliability is insufficient
Solution Approach 1:
The contact geometry is segmented into multiple independent resilient contact points (first and second contact geometries) that can deflect independently. This segmentation allows each contact point to accommodate variations in insertion force and maintain reliable contact, resolving the contradiction between reliability and structural simplicity.
Solution Approach 2:
The contact geometries are designed to be resilient rather than fixed, allowing them to dynamically adapt to insertion forces and maintain optimal contact pressure. This dynamic capability improves contact reliability while the integrated stamping design keeps the overall structure relatively simple.
2Reliability
If one wave crest is fixed and the other is resilient, then the structure is asymmetric and simpler, but contact reliability is reduced
Solution Approach 1:
The patent deliberately employs symmetrical design (opposite to the usual asymmetric approach) where both contact geometries are mirror images of each other with identical wave patterns. This symmetry ensures equal load distribution and contact force characteristics, improving reliability while the repeating pattern actually simplifies the manufacturing process.
Solution Approach 2:
The wave geometry parameters (amplitude, wavelength, curvature) are optimized to provide resilient contact while maintaining symmetry. By carefully selecting these parameters, the patent achieves both improved contact reliability and manufacturability through conventional stamping processes.
3Ease of manufacture
If conventional stamping and bending methods are used, then production is efficient and inexpensive, but achieving improved contact geometry is difficult
Solution Approach 1:
The contact geometries are pre-formed with the correct wave patterns and resilient characteristics during the stamping process itself, rather than requiring subsequent complex forming operations. This preliminary action ensures manufacturing precision is achieved while maintaining the efficiency and low cost of conventional stamping methods.
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 design reduces insertion effort, ensures permanent contact forces, and improves assembly efficiency, resulting in a more reliable and stable electrical connection.
Implementation Method 1
both contact geometries are designed to be resilient. As a result, on the one hand, the effort required to insert the counter-contact element into the contact area is reduced because both contact geometries are designed to be resilient. This resilient design of the contact geometry also has the advantage that sufficient contact forces act permanently on the mating contact element
Data Source
Figure 1
Figure 2
AI summary
Contact element (1) for a connector, which has a crimp area (2) with which it is attached to an electrical conductor of a line, characterized in that in a contact area (4) the contact element (1) has a resilient contact geometry for a mating contact element, wherein this contact geometry is present in duplicate.