Stamped Contact Element Layout for Buckling-Resistant Plug Connections
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Solution Overview
Problem
Existing plug connection units face challenges in secure assembly due to manufacturing and assembly tolerances, particularly with small cross-sections and large axial distances between press-in sections and shoulders, leading to buckling and increased electromagnetic interference in data lines.
Innovation Solution
A plug connection unit with contact elements featuring a plastic plug connection body surrounding stamped sheet metal elements, having parallel and laterally offset sections with varying cross-sections, and a press-in shoulder design that allows secure pressing and reduced electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cross-section of the contact element between press-in section and press-in shoulder is reduced, then the space utilization is improved, but the buckling resistance deteriorates
Solution Approach 1:
The contact element is divided into multiple sections with different cross-sectional areas: a first section with larger cross-section for buckling resistance, and a second section with smaller cross-section for space optimization. This segmentation allows each part to fulfill its specific functional requirement independently.
Solution Approach 2:
Different sections of the contact element have different local properties - the first section has larger cross-section and higher rigidity where buckling resistance is needed, while the second section has smaller cross-section where space is constrained. This local quality variation optimizes both structural integrity and space utilization.
2Manufacturing precision
If the axial distance between press-in section and press-in shoulder is increased, then the assembly tolerance is improved, but the buckling tendency worsens
Solution Approach 1:
The contact element is segmented into a first section with larger cross-section between press-in section and press-in shoulder, and a second section with smaller cross-section extending to the plug contact area. This segmentation allows the first section to provide buckling resistance over the required axial distance while the second section maintains compact dimensions.
Solution Approach 2:
The cross-sectional dimension parameter is changed along the axial direction - larger in the first section for buckling resistance, smaller in the second section for compactness. This parameter variation resolves the contradiction between axial distance requirements and buckling resistance.
3Object-affected harmful factors
If the distance between two contact elements in data line is reduced, then the electromagnetic interference is reduced, but the assembly complexity increases
Solution Approach 1:
Two contact elements forming a data line are integrated into a single plug connection unit with a common plastic housing. The housing provides standardized positioning features that simplify assembly while maintaining reduced spacing between contact elements to minimize electromagnetic interference.
Solution Approach 2:
The plastic housing serves multiple functions: it holds and positions multiple contact elements, provides standardized mounting interfaces, and maintains precise spacing between contact elements. This multi-functionality reduces overall assembly complexity while achieving the goal of reduced electromagnetic interference.
Data Source
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AI summary
The invention relates to a contact element (10) for forming an electrical connection between a circuit carrier (2) in a control appliance (100) and a line (4 to 6) in a plug (1000), comprising a first sub-section (11) having a pressing section (14) for pressing into an opening (1) of the circuit carrier (2), at least one pressing shoulder (20) arranged at a distance (L) from the pressing section (14), for applying a pressing force oriented in the direction of a first longitudinal axis (15) of the first sub-section (11), and a second sub-section (12) having a second longitudinal axis (26), for contacting the line (4 to 6), the contact element (10) being embodied as a stamp element.