Sheet Metal Electric Contact with Plastically Elongated Latching Tongue
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Solution Overview
Problem
There is a risk of plastic deformation during the installation or removal of electric contacts, which can lead to a loose or weak fixation within the connector, potentially causing the contact to be released during connection or disconnection, and existing methods are costly to manufacture in high volumes.
Innovation Solution
The electric contact features a latching tongue with a limit stop that absorbs forces through elastic deflection, preventing plastic deformation, and is manufactured using stamping and bending operations, with embossing to enhance elongation and leverage, ensuring the latching tongue and limit stop overlap to maintain geometry and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the latching tongue is deflected with high forces during installation or removal, then the latching operation can be performed, but plastic deformation may occur reducing latching force and affecting contact position
Solution Approach 1:
A limit stop is provided on the latching tongue before plastic deformation can occur during normal operation. This limit stop preliminarily defines the maximum deflection position, preventing the latching tongue from being deflected beyond the elastic region during installation or removal operations.
Solution Approach 2:
The limit stop acts as a protective measure that cushions against excessive forces being applied to the latching tongue. By providing this physical barrier beforehand, the design prevents harmful plastic deformation before it can occur during high-force operations.
2Reliability
If a limit stop is added to the latching tongue to prevent plastic deformation, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The limit stop is merged with the latching tongue as an integrated component rather than a separate part. This is achieved through stamping and bending operations that form the limit stop directly from the sheet metal body, combining two functions (latching and limiting) into a single piece.
Solution Approach 2:
The limit stop is created by plastic deformation (embossing) of the sheet metal body, changing the physical parameters of the material locally to form the limiting structure. This allows the limit stop to be formed as part of the stamping process without requiring additional manufacturing steps.
3Ease of manufacture
If the limit stop and latching tongue are formed as separate parts, then manufacturing flexibility is improved, but production costs increase for high-volume manufacturing
Solution Approach 1:
The limit stop and latching tongue are combined into a single integrated component formed from the sheet metal body through stamping and bending operations. This integration eliminates the need for separate manufacturing and assembly steps, reducing costs for high-volume production while maintaining manufacturing flexibility.
Solution Approach 2:
The sheet metal body serves multiple functions: it forms the main contact structure, provides the latching tongue, and creates the limit stop. This multi-functionality reduces the total number of parts and manufacturing operations needed, improving productivity for high-volume manufacturing.
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
The solution effectively reduces the risk of plastic deformation, maintaining the electric contact's geometry and ensuring secure fixation within the connector while allowing for high-volume, low-cost manufacturing.
Implementation Method 1
the latching tongue may be elastically deflected to allow the latching operation and to be moved out of the way when the electric contact is inserted into or removed from the electric connector
Implementation Method 2
By providing the limit stop, the deflection of the latching tongue can be limited to a region where there is only elastic deflection. Any remaining plastic deflection of the latching tongue can thus be avoided
Implementation Method 3
the latching tongue and/or the limit stop are elongated by plastic deformation. Due to this plastic elongation, the latching tongue and the limit stop overlap and the limit stop may thus perform its function
Data Source
Figure 1~2
Figure 3~6
Figure 7A~9B
AI summary
The invention relates to an electric contact (1) and to a method for manufacturing such an electric contact (1). The electric contact (1) is provided with a latching tongue (8). The latching tongue (8) may be used to anchor the electric contact (1) in a connector (2) by using a positive or form-fit. The latching tongue (8) is attached to a body (12) of the electric contact (1) via a base (10). If too high a force (29) is applied to the latching tongue (8), the latching tongue (8) may be plastically deformed and thus no more be able to safely anchor the electric contact (1) within the electric connector (2). To avoid this, a limit stop (38) is provided, on which the latching tongue (8) rests in a deflected position (40). In one embodiment, at least one of the latching tongue (8) and the limit stop (38) is elongated plastically by at least one embossing (48). This generates an overlap (42) and allows forming the limit stop (38) and the latching tongue (8) by simply cutting the piece (6) of sheet metal from which the electric contact (1) is made.