Multiple-Contact Connector Assembly With Self-Retaining Pin Sockets
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Solution Overview
Problem
Conventional electrical connectors require tedious and time-consuming soldering processes for wire connections and additional structural elements for mechanical retention, leading to increased size, weight, and cost.
Innovation Solution
The electrical connector assembly employs a pair of contact pins and sockets for each wire, where the contact pin includes a shaft and a head with a tapered end, and the contact socket has resilient retaining members that ensure both electrical continuity and mechanical retention without soldering or additional structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering process is used to connect wires to electrical contacts, then reliable electrical connection is achieved, but assembly time increases and productivity decreases
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical connection method) with a mechanical insertion system. Electrical contacts are designed with insertion features that allow direct mechanical coupling with wire contacts, eliminating the need for soldering while maintaining reliable electrical connection. This substitution enables faster assembly and higher productivity.
Solution Approach 2:
The electrical contacts are designed with self-aligning and self-retaining features that enable automatic connection upon insertion. The contacts themselves provide the retention mechanism through their geometric design, eliminating the need for separate soldering operations or additional retention components, thereby improving assembly efficiency.
2Reliability
If additional structural elements (backpack socket insulator assembly) are added for mechanical retention, then connection reliability is improved, but connector size, weight, and cost increase
Solution Approach 1:
The patent merges the electrical contact function with the mechanical retention function into a single integrated component. The electrical contact geometry is designed to simultaneously provide electrical connection and mechanical retention through features like engagement protrusions and recesses, eliminating the need for separate retention structures such as backpack socket insulator assemblies.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate structural elements from the connector assembly. By designing direct engagement features between electrical contacts and wire contacts, the patent removes redundant components like additional insulator assemblies and retention mechanisms, thereby simplifying the overall structure while maintaining connection reliability.
3Reliability
If one-by-one wire soldering is performed, then individual wire connections are secure, but assembly time and labor cost increase
Solution Approach 1:
The patent incorporates preliminary design features into the electrical contacts that enable secure connection upon simple insertion. The contacts are pre-configured with engagement geometries that automatically align and secure wire contacts during insertion, eliminating the need for time-consuming one-by-one soldering operations while maintaining secure individual wire connections.
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 solution simplifies the connection process, reduces assembly time, and eliminates the need for soldering and additional structural elements, resulting in a more compact, lightweight, and cost-effective electrical connector assembly.
Implementation Method 1
the head portion deflects the one or more retaining members laterally toward a side of the contact socket
Implementation Method 2
the one or more retaining members press laterally against the shaft portion of the contact pin
Data Source
AI summary
An electrical connector assembly includes a connector body, electrical connector contacts mounted in the connector body, and electrical wire contacts attached to wires of an electrical cable. Rear ends of the connector contacts (either contact pins or sockets) engage front ends of the wire contacts (either contact sockets or pins). A head of each contact pins is wider than its shaft resulting in a protruding edge. Each contact socket receives the corresponding contact pin. At least one resilient retaining member extends obliquely into and at least partly across each contact socket away from its open end and is deflected laterally as the contact pin is inserted into the contact socket. Upon full insertion the retaining member presses laterally against the shaft and a distal edge of the retaining member obstructs withdrawal of the contact pin from the contact socket by engaging the protruding edge.