Socket Contact With Opening In Insertion Tab

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Solution Overview

Problem

Existing socket contacts face challenges in accommodating plug contacts of different lengths while ensuring sufficient contact overlap, due to the geometric constraints imposed by the overspring and insertion tabs, which limit the freedom of movement of the contact lamellae and result in difficulties during assembly and insertion.

Innovation Solution

The introduction of openings in the insertion tabs allows the free ends of the contact lamellae to dip or pass through, enabling greater flexibility and preventing interference during assembly, while maintaining a sufficient contact overlap by allowing the contact lamellae to adapt and optimize insertion forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the insertion tabs are designed to protect the free ends of the contact lamellae and guide the plug contact, then the reliability of assembly is improved, but the freedom of movement of the contact lamellae is restricted, worsening the ability to accommodate different plug contact lengths

Engineering Contradiction:

Improveassembly reliabilityVSAvoidaccommodation of different plug contact lengths

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The insertion tabs are segmented with openings that allow the contact lamellae to move independently. The tabs are divided into regions: solid portions for guiding and protecting during assembly, and opening regions that permit contact lamellae movement to accommodate different plug contact lengths. This segmentation resolves the contradiction by allowing both protective guidance and adaptive movement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the insertion tabs have different properties: some areas are solid to provide guidance and protection, while other areas contain openings to allow contact lamellae movement. This local differentiation enables the same component to simultaneously provide both protective guidance and adaptability for different plug contact lengths.

Inventive Principle:

Principle #3Local quality

2Reliability

If the contact lamellae are positioned to ensure sufficient contact overlap, then the electrical connection reliability is improved, but the insertion force increases, worsening the ease of operation

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinsertion force

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The contact lamellae are designed as spring elements that can dynamically deflect during insertion. The openings in the insertion tabs allow this dynamic movement, enabling the contact lamellae to gradually engage with the plug contact while maintaining sufficient contact overlap. This dynamic behavior reduces peak insertion forces while ensuring reliable electrical connection.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the free ends of the contact lamellae extend further into the contacting area, then the contact overlap is improved, but the risk of the free ends being stuck behind by the plug contact increases, worsening the reliability

Engineering Contradiction:

Improvecontact overlapVSAvoidrisk of contact lamellae being stuck

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The openings in the insertion tabs effectively remove the obstructing material that would otherwise prevent contact lamellae movement. By extracting the solid material from specific regions of the insertion tabs, the contact lamellae are freed from the risk of being stuck behind, while still maintaining sufficient contact overlap for reliable electrical connection.

Inventive Principle:

Principle #2Taking out (Extraction)

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 design enables automatic and functional assembly of socket contacts, ensures a larger contact overlap, and optimizes insertion forces, allowing for better accommodation of various plug contact lengths without compromising the contact's functionality.

Implementation Method 1

An overspring surrounds at least the contact part in the shape of a box and serves to protect contact lamellae arranged within the overspring from mechanical damage during assembly

Methodology Applied

Scientific EffectMechanical protection:

Implementation Method 2

the insertion tabs running towards one another at an angle take on the task of aligning and guiding the socket contact within the contact chamber to be assembled

Methodology Applied

Scientific EffectMechanical guidance:

Implementation Method 3

the insertion lugs of the overspring, which are inclined inwards towards the central axis, are the ones that are required for reliable contacting necessary spring deflection

Methodology Applied

Scientific EffectSpring deflection: Spring

Implementation Method 4

the contact tips touch the surfaces of the plug-in contact and thus establish the electrical plug-in connection

Methodology Applied

Scientific EffectElectrical contact: Conduction (electrical)

Data Source

PatentEP1763110B1Socket with encapsulating spring with an opening in the guiding blades

Publication Date: 2008.02.20 ROBERT BOSCH GMBH

Figure 1~3
Figure 4

AI summary

Socket contact (1) has an opening (12) in the inserted plate (10), which is provided in the area of the free end (7) of the contact bar (5), which are dimensioned in such a manner that the respective free end of the contact bar can be inserted in the opening.