Spring-loaded contact pin with segmented tongues
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Solution Overview
Problem
Existing spring-loaded contact pins often experience passive intermodulation due to the piston becoming tilted within the sleeve, leading to inconsistent contact.
Innovation Solution
A spring-loaded contact pin design featuring a contact element that ensures a homogeneous contact between the piston and the sleeve through a contact ring with springy contact tongues, along with an insulating part and a threaded piston to prevent tilting, and a holding element to secure the insulating part within the sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional spring-loaded contact pin design is used, then the structure is simple, but the piston becomes tilted in the sleeve causing passive intermodulation
Solution Approach 1:
The contact element is divided into multiple springy contact tongues that can independently adapt to the piston surface, ensuring homogeneous contact across the entire contact area. This segmentation allows each contact tongue to compensate for local variations and prevent piston tilting, thereby improving contact stability without requiring a completely complex redesign of the overall structure.
Solution Approach 2:
The contact element is designed with springy contact tongues that can elastically deform to match the piston surface geometry. This parameter change from rigid to flexible contact surfaces enables homogeneous contact distribution, preventing the piston from tilting in the sleeve and reducing passive intermodulation while maintaining a relatively simple structural configuration.
2Reliability
If the contact element contacts the piston and sleeve over their entirety, then homogeneous contact is achieved reducing passive intermodulation, but the manufacturing complexity increases
Solution Approach 1:
The contact element is segmented into multiple springy contact tongues that can be formed as integral parts of a single piece or assembled from separate components. This segmentation enables the contact element to conform to the piston surface while allowing for straightforward manufacturing processes such as stamping, bending, or modular assembly, thus achieving homogeneous contact without excessive manufacturing complexity.
Solution Approach 2:
The contact element utilizes elastic deformation of springy contact tongues to achieve homogeneous contact across the piston surface. This approach allows for standard manufacturing techniques to be used while the elastic properties of the material provide the necessary adaptation, avoiding the need for complex precision machining or custom-formed contact surfaces.
3Reliability
If springy contact tongues are used for tolerance compensation, then the contact stability improves, but the device complexity increases
Solution Approach 1:
The springy contact tongues are designed with specific elastic properties that enable them to deform and adapt to variations in piston geometry and positioning. This use of material elasticity provides tolerance compensation without requiring additional adjustment mechanisms or complex mechanical structures, thereby improving contact stability while keeping the contact element design relatively simple.
Solution Approach 2:
The springy contact tongues automatically adjust their shape and position in response to variations in piston geometry, providing self-compensation for tolerances. This self-adjusting mechanism eliminates the need for external adjustment devices or complex control systems, achieving improved contact stability through the inherent elastic properties of the contact element itself.
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 provides a stable and consistent contact, reducing passive intermodulation and improving tolerance compensation, while also reducing the required spring force and enhancing the lifespan of the contact pin.
Implementation Method 1
the contact element is designed as a contact ring, in particular with springy contact elements. A complete homogeneous contact between the sleeve and the piston is thus ensured even when lateral forces are exerted.
Data Source
AI summary
Spring-loaded contact pin having a sleeve (101); a spring arranged in the sleeve (101); a piston which is arranged at least partially in the sleeve (101); and a contact element which is arranged at least partially in the sleeve (101) and which is configured so as to contact the sleeve (101) and the piston (107).