Split Chip Contact Element for High-Current Connector Assembly
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Solution Overview
Problem
Existing chip-type contact elements have complex processing processes, high production costs, and limited current-carrying capacity, failing to meet market demands for high-performance and low-cost connectors.
Innovation Solution
A chip-type contact element with a split symmetrical structure, comprising first and second contact assemblies with spring claws and a steel outer shell, and a copper inner assembly, allowing for simple assembly and enhanced contact force through third spring claws, facilitating efficient integration and low-cost production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel clad copper structure with external supporting element wrapping is used, then the contact element has good electrical conductivity and mechanical strength, but the processing and forming process becomes complex
Solution Approach 1:
The contact element is divided into three distinct parts: copper contact pieces for electrical conduction, steel supporting elements for mechanical strength, and spring claws for contact force. This segmentation allows each component to be optimized independently and assembled through simple stacking, eliminating complex wrapping processes while maintaining both electrical conductivity and mechanical strength
Solution Approach 2:
The invention merges the functions of conductivity (copper), structural support (steel), and contact force (spring claws) into a single integrated assembly. The stacked configuration combines these different materials and functions in a unified structure that achieves the benefits of steel clad copper without the complex forming processes
2Stability of the object's composition
If an external supporting element wraps the conductive sheet to be integrally fixed, then the contact element has good structural integrity, but only a single-structure adaptive connector can be adapted
Solution Approach 1:
The spring claw design with unified dimensions and stacking configuration creates a universal contact element that can adapt to multiple connector types and configurations. The standardized interface allows the same contact element structure to be used across different applications, enhancing versatility while maintaining structural integrity through the stacked assembly
3Productivity
If a chip-type contact element is designed to be smaller than circular contact element, then the production cost decreases and performance increases, but the current-carrying capacity is limited
Solution Approach 1:
The contact element uses composite materials combining copper (for electrical conductivity), steel (for mechanical strength and current capacity), and spring material (for contact force). This composite structure enables a compact chip-type design that maintains high current-carrying capacity despite the reduced size, while the modular stacking configuration facilitates efficient production
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 achieves simple processing, low-cost production, and high assembly efficiency with enhanced connection stability, including in vibration environments, while supporting various end connection modes without additional processing costs.
Implementation Method 1
first spring claws arranged at intervals in a width direction of the outer shell being oppositely arranged at front and rear ends of the first contact assembly, and the first spring claws being used to be in conductive contact with an adaptive contact element
Data Source
AI summary
The present application provides a chip-type contact element, including: an outer shell, a first contact assembly and a second contact assembly, where the first contact assembly is arranged in the outer shell, a plurality of first spring claws are arranged oppositely at front and rear ends of the first contact assembly, the second contact assembly is arranged outside the first contact assembly and located in the outer shell, second spring claws arranged between two adjacent first spring claws are arranged at front and rear ends of the second contact assembly, and a plurality of third spring claws in contact with the second spring claws are arranged oppositely at front and rear ends of the shell. The present application has the advantages of simple processing process, low cost and high assembling and production efficiencies. In addition, the present application further discloses a connector including the chip-type contact element.