Spring-Loaded Press-On Contacts for Blind Tolerance Compensation
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Solution Overview
Problem
Existing electrical connection units struggle to effectively compensate for tolerances between units to be contacted, particularly when connections are made blindly or with varying tolerances.
Innovation Solution
A connection unit featuring an insulating mounting frame with resilient press-on contacts, each equipped with a helical pressure spring and a contact element, allowing for axial displacement and tolerance compensation through the spring's elastic force, while incorporating the connector plug or socket within the spring's cavity for a space-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press-on contacts without covers are used, then the structure is simpler, but tolerance compensation between units is insufficient
Solution Approach 1:
The contact element is divided into two functional parts: the contact body (metal disc with connector) and the cover (cavity-closing component). This segmentation allows the spring force to act on the cover while the contact body remains exposed for connection, enabling independent optimization of each part's function and improving tolerance compensation capability.
Solution Approach 2:
The connector plug or socket is integrated within the cavity formed by the hollow cylinder and cover. This nesting arrangement allows the connection interface to be housed within the spring's protective cavity, space-efficiently combining multiple functional elements (spring, cover, connector) into a compact integrated structure that improves tolerance management.
2Volume of moving object
If the connector extends into the spring cavity, then space utilization is improved, but the contact body may be more vulnerable to damage
Solution Approach 1:
The cover provides localized protection by closing off the cavity while leaving the contact body accessible for connection. This local quality approach allows the spring to be protected within the closed cavity while the contact body maintains its functional exposure, optimizing both space utilization and contact body accessibility without compromising strength.
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 provides a cost-effective and efficient means to compensate for positional variations, ensuring stable electrical connections with improved tolerance management and a compact structure.
Implementation Method 1
Each press-on contact includes a helical or coiled pressure spring which can exert an elastic force on the contact body
Data Source
AI summary
A connection unit includes an insulating mounting frame and multiple resilient press-on contacts situated on the mounting frame. Each press-on contact includes a helical pressure spring that can exert an elastic force on a metal contact body. The contact body is connected in one piece to a connection plug or a connection socket. For each press-on contact, the mounting frame includes a hollow cylinder that forms a cavity within a circumferential wall, the cavity being closed off by a cover that is situated so as to be axially displaceable at the wall of the hollow cylinder. The pressure spring is situated inside the cavity, and with its elastic force acts on the cover. The contact body, in one piece, forms a contact disk that is situated on the outer side of the cover.