Sleeveless Stamped Socket Contact Design
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Solution Overview
Problem
Manufacturers of stamped and formed socket contacts face high production costs due to the need for stainless steel sleeves, which increase material and assembly costs without improving product quality.
Innovation Solution
A sleeveless design for socket contacts featuring insulation and conductor crimping members with tapered edges, ribs, and fixed engagement members within a flute section that securely attach wires and pins without the need for a sleeve, enhancing the crimping and engagement mechanisms for improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel sleeves are used to cover and protect the socket finger region, then product protection and durability are improved, but material costs and assembly costs increase
Solution Approach 1:
The patent removes the stainless steel sleeve component entirely from the design. The socket finger region is protected and defined directly by the formed plastic housing structure itself, eliminating the need for a separate sleeve component and its associated assembly operations, thereby reducing material and assembly costs while maintaining product protection
Solution Approach 2:
The protective function previously performed by the separate stainless steel sleeve is merged into the plastic housing structure. The housing is formed with integrated features including the socket finger region, locking collar, and protective structures, combining multiple functions into a single component to eliminate the sleeve and reduce complexity
2Strength
If stainless steel sleeves are used to cover the socket finger region, then structural protection is improved, but assembly complexity and time increase
Solution Approach 1:
The separate sleeve component and its assembly operations are completely removed from the system. The structural protection function is achieved through the formed plastic housing structure that integrates all necessary protective features, eliminating assembly steps and reducing device complexity
Solution Approach 2:
The structural protection features are merged into the single plastic housing component. The housing includes integrated socket finger region, locking collar, and protective structures that work together as one piece, eliminating the need for separate sleeve assembly and reducing overall assembly complexity
Data Source
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AI summary
An electrical contact includes a crimping section (102) for securing a wire and a flute section (104) for receiving a pin. The flute section includes fixed engagement members (140) and a resilient cantilever member (150) that engages the pin within the flute section.