Socket Contact Extrusion with Alternating Wall Thickness
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Solution Overview
Problem
Current methods for producing socket contacts are time-consuming and costly, often requiring complex machining or assembly of multiple components, leading to reduced productivity and increased costs.
Innovation Solution
A method involving extrusion to create a hollow-cylindrical contacting area with alternating thicker and thinner sections, where the thinner sections are bent or folded outward to develop a spring effect, reducing production time and increasing productivity by eliminating cutting processes and optimizing material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to produce socket contacts, then manufacturing precision can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces traditional mechanical machining processes (milling, cutting) with a stamping and bending process. The contacting area is formed by stamping a hollow cylinder and then bending it to create alternating thicker and thinner sections, eliminating the need for time-consuming machining operations while maintaining dimensional accuracy and surface quality.
Solution Approach 2:
The patent changes the geometric parameters of the contacting area by creating alternating thicker and thinner sections through bending. The thinner sections are bent outward to create spring action, while the thicker sections provide structural support. This parameter variation allows the contacting area to generate contact force without requiring heavy material removal.
2Reliability
If complex assembly of multiple components is used, then functional requirements can be met, but device complexity and production costs increase
Solution Approach 1:
The patent combines multiple functions into a single integrated contacting area structure. The hollow cylinder with alternating thicker and thinner sections performs both structural support and spring action functions simultaneously, eliminating the need for separate components such as retaining rings, springs, or multiple assembly steps, thereby reducing device complexity while maintaining contact reliability.
3Manufacturing precision
If traditional machining processes are used, then contacting area can be formed, but material utilization decreases and production costs increase
Solution Approach 1:
The patent creates alternating thicker and thinner sections by bending the hollow cylinder rather than removing material. This approach maintains material utilization while achieving the required geometric variation for spring action. The thinner sections are formed by plastic deformation rather than material removal, significantly reducing material waste compared to traditional machining.
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 method significantly reduces production time, increases productivity, and lowers costs by utilizing non-cutting metal-forming techniques, achieving high dimensional accuracy and surface quality with improved spring action and material efficiency.
Implementation Method 1
the second sections having a thinner wall instead of the heavier-walled first sections inwardly, with the thinner-walled second sections bent or folded outwards. The second sections bent or folded outwards when the first sections are positioned develop a spring effect
Implementation Method 2
Production of a hollow-cylindrical contacting area at a first end of the round rod by means of extrusion, the hollow-cylindrical contacting area having first and second sections which extend in the longitudinal direction of the contacting area
Data Source
Figure 1~2
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AI summary
The invention relates to a socket contact (1) and to a method for producing a socket contact (1) from a round bar (11), comprising the following steps: • producing a hollow cylindrical contacting region (2) at a first end (3) of the round bar (11), by means of extrusion, said hollow cylindrical contacting region (2) comprising first and second sections (4, 5) that extend in the longitudinal direction (L) of said contacting region (2) and are formed adjacently and alternately in the peripheral direction of the hollow cylindrical contacting region (2), wherein the first sections (4) have a greater wall thickness (d1) and the second sections (5) have a smaller wall thickness (d2), and • setting the first sections (4) with the greater wall thickness (d1) inward, while the second sections (5) with the smaller wall thickness (d2) are curved or folded outward.