Segmented Contact Sleeve Structure for Low Insertion Force
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Solution Overview
Problem
Electrical contact sleeves with high material robustness often result in high insertion forces due to increased friction, which is undesirable for applications requiring low insertion forces.
Innovation Solution
The design incorporates a contact spring with a recess and multiple spring legs that unite to form a free end, combined with a ring composed of segments that can deflect, reducing insertion force while maintaining high contact normal force through uniform tension distribution and mechanical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high material robustness is used in electrical contact sleeve, then mechanical strength is improved, but insertion force increases due to increased friction
Solution Approach 1:
The contact sleeve is divided into multiple spring legs (at least three) that are distributed circumferentially around the insertion direction. Each spring leg independently deflects during insertion, distributing the contact normal force across multiple separation surfaces rather than a single continuous surface. This segmentation reduces the total friction force while maintaining mechanical robustness through the combined effect of multiple spring elements.
Solution Approach 2:
The spring legs are designed to be elastically deformable, allowing them to dynamically adjust their deflection during the insertion process. As the mating contact is inserted, the spring legs progressively deflect and then recover, creating a dynamic contact mechanism that reduces insertion force through elastic energy storage and release, while maintaining sufficient contact normal force for electrical connection.
2Reliability
If high contact normal force is applied, then electrical contact reliability is improved, but insertion force increases due to friction
Solution Approach 1:
The contact normal force is segmented into multiple discrete forces applied by individual spring legs at different circumferential positions. This segmentation allows the total contact normal force to be distributed across multiple small contact surfaces, reducing the cumulative friction force while maintaining the overall contact reliability through the combined effect of multiple spring legs.
Solution Approach 2:
The spring legs are designed with specific elastic properties and geometric parameters (length, thickness, cross-section) that allow them to generate sufficient contact normal force for reliable electrical connection while controlling the deflection magnitude. By optimizing these parameters, the contact reliability is ensured without excessive insertion force.
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 configuration achieves low insertion forces while ensuring mechanical robustness and preventing incorrect insertion, with the ring segments and contact springs working together to distribute force effectively, enhancing the overall performance of the contact sleeve.
Implementation Method 1
The contact spring has a recess and a plurality of spring legs adjoining the recess in a circumferential direction. The spring legs unite to form a free end of the contact spring.
Data Source
AI summary
An electrical contact sleeve includes a contact spring extending in a longitudinal direction from a base to an end of the electrical contact sleeve on a connector side. The contact spring has a recess and a plurality of spring legs adjoining the recess in a circumferential direction. The spring legs unite to form a free end of the contact spring.