Rolled Plug Contact Arms for Compact High-Current Connectors
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Solution Overview
Problem
Miniaturization of connectors leads to reduced insulation distances and narrower contacts, limiting high current transmission while maintaining electrical safety and contact reliability, as the reduction in size compromises conductor cross-sections and requires specific pressure forces.
Innovation Solution
A plug contact design with a clamping section and spring-return-elastic contact arms, featuring a free cut and cutout to maintain effective contact arm length, allowing for adjustable elasticity and reduced installation space, while maintaining spring properties and enabling defined contact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connectors are miniaturized to reduce size and increase contact density, then connector length and insulation distances are reduced, but conductor cross-sections are reduced and high current transmission capability is limited
Solution Approach 1:
The contact arms are formed by rolling the sheet metal strip laterally, creating a three-dimensional spring structure that utilizes the thickness dimension of the sheet metal to generate contact force, rather than relying solely on the planar dimensions. This allows for effective use of space in miniaturized connectors.
Solution Approach 2:
The invention changes the physical state and geometric parameters of the contact arms through lateral rolling, transforming flat sheet metal into three-dimensional spring structures with specific elastic properties. This allows optimization of contact force and electrical properties independently of connector size.
2Length of moving object
If contact arms are made longer to maintain effective contact length, then contact reliability is improved, but clamping section size must increase which complicates installation
Solution Approach 1:
The contact arm is segmented into distinct functional zones: a clamping section for anchoring, an origin area with relief cuts for elasticity, and a contact section with formed contact tips. This segmentation allows each zone to be optimized independently for its specific function.
Solution Approach 2:
Different geometric properties are applied to different sections of the contact arm: the origin area has relief cuts to increase elasticity, the contact tips are laterally rolled to enhance electrical properties, and the clamping section has a specific geometry for secure anchoring. This local differentiation optimizes performance while controlling overall dimensions.
3Reliability
If contact arms are laterally rolled to enhance electrical properties, then contact reliability is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple functions are merged into single manufacturing operations: the lateral rolling process simultaneously forms the contact tips, creates the spring structure, and enhances electrical properties in one integrated step, rather than requiring separate operations for each function.
Solution Approach 2:
The laterally rolled structure serves multiple functions simultaneously: it provides mechanical spring force, enhances electrical contact properties through increased surface area and contact pressure, and defines the geometric shape of the contact tips. This multi-functionality reduces the need for additional manufacturing steps.
4Length of moving object
If relief cuts are added to the clamping section to position contact arms, then effective contact arm length is maintained, but manufacturing steps increase
Solution Approach 1:
The relief cuts are integrated into the existing stamping and rolling tooling, combining the positioning function with the primary manufacturing operations. The same tooling that forms the contact arms also creates the relief cuts, eliminating the need for separate positioning steps.
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
Enables shorter connector lengths with retained effective contact arm length, increased elasticity, and adapted pressure forces, ensuring high current transmission and safety without compromising contact reliability.
Implementation Method 1
two spring-return elastic contact arms forming a receiving space between them
Data Source
Figure 1
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AI summary
Described and illustrated is a plug contact (10), stamped from a sheet metal strip, with stamped edges and rolled surfaces, - with a clamping section (15) which serves to anchor the plug contact in a contact carrier, - with a contact fork (13), formed by two spring-return elastic contact arms (11) forming a receiving space between them, with stamped edges facing each other, the first end of which originates from the clamping section (15) and the second end of which each forms a contact tip (18) which has rolled surfaces facing each other due to the forming of the second contact arm ends, - with rolled surfaces of the clamping section and contact arms which are aligned parallel and arranged in a common plane, - with a stop (19) formed by the stamped edge of the clamping section facing the receiving space, - with a dividing line (T) which is arranged centrally between the contact tips and divides the receiving space perpendicularly in the direction of the clamping section,wherein the clamping section in the origin area of the respective contact arm has a relief (20) so that the stop (19) projects into the receiving space in the direction of the contact tips (18).