Shock-Resistant Electrical Connector Leaf Contact Deflection
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Solution Overview
Problem
Conventional pin-and-socket electrical connectors are prone to electrical discontinuity and permanent deformation when subjected to repeated shocks and vibrations, particularly in seismic applications, leading to interruptions in digital signal transmission and equipment malfunction.
Innovation Solution
A shock-resistant electrical connector design featuring a socket assembly with a sleeve or hood element having a non-uniform stepped inner sidewall profile that limits the outward deflection of leaf contacts, preventing permanent deformation and maintaining electrical continuity under mechanical disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pin-and-socket connectors are used in seismic environments, then the connector structure is simple and easy to manufacture, but the electrical continuity is interrupted under shock and vibration forces
Solution Approach 1:
The connector employs a dynamic retention mechanism where the pin contact is resiliently retained within the socket contact. The pin contact can deflect radially outward under shock forces and then return to its original position, maintaining continuous electrical connection. This dynamic behavior allows the connector to adapt to seismic forces while preserving reliability.
Solution Approach 2:
The connector is divided into distinct functional components: a socket contact with retention structure, a pin contact with resilient properties, and a cable assembly. This segmentation allows each component to be optimized independently - the socket provides structural support and retention, while the pin provides resilient contact and signal transmission.
2Reliability
If the pin contact is resiliently retained in the socket contact to maintain continuity, then the electrical reliability improves under shock, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The retention structure is integrated directly into the socket contact body, combining the functions of electrical contact and mechanical retention in a single component. This eliminates the need for separate retention mechanisms, simplifying the overall assembly process while maintaining the resilient retention functionality needed for shock resistance.
3Strength
If the pin contact can deflect radially outward under shock forces, then the connector withstands mechanical disturbances, but permanent deformation may occur compromising spring tension
Solution Approach 1:
The connector design anticipates shock forces by providing a controlled deflection path for the pin contact. The resilient pin is designed to deflect radially outward under shock loads and then return to its original position, with the retention structure preventing excessive deflection that would cause permanent deformation. This prior cushioning approach protects the spring tension while allowing necessary movement.
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 connector effectively withstands repeated shock forces, maintaining consistent electrical contact and insertion/retention forces, significantly improving reliability and preventing permanent deformation, as demonstrated by experimental shock testing.
Implementation Method 1
a resilient pin contact (male) is received in a substantially hollow cylindrical socket contact (female)... the pin contact can deflect radially outward in response to shocks
Implementation Method 2
The leaf contacts abut the sidewalls of the pin contact providing electrical continuity
Data Source
Figure 1~3
Figure 4~9
Figure 10~20a
AI summary
An electrical connector (50) in the form of a socket assembly (62) defining a plurality of arcuate leaf contacts (74) adapted for insertion of a pin contact therein. The socket assembly comprises an elongate socket core (64) having the leaf contacts formed at a distal end thereof, and a substantially cylindrical hood (66) surrounding the leaf contacts. In one embodiment of the invention, the hood is provided with structure for limiting the radial outward deflection of the leaf contacts when the electrical connector is subjected to shock forces. The limiting structure can be a stepped inner cylindrical sidewall (78) of the hood, defining a reduced inner diameter portion (80) of the hood surrounding at least a distal portion of each leaf contact.