Support Ring Contact Element for Lower Plugging Force
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Solution Overview
Problem
Conventional electrical contact elements require high normal contact forces, leading to high plugging forces due to increased friction, which is undesirable, especially in high-frequency applications.
Innovation Solution
The electrical contact element features spring arms arranged around an opening with annular segments that support each other in a fully compressed state, reducing plugging forces by allowing independent deflection and compensating for manufacturing tolerances and misalignments, while maintaining high normal contact forces through a support ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high normal contact forces are applied to ensure reliable contact in high-frequency range, then contact reliability is improved, but plugging forces increase due to increased friction
Solution Approach 1:
The contact element is divided into multiple spring arms (at least three) that are spaced apart from each other, allowing independent deflection. This segmentation reduces the frictional interaction during plugging while maintaining contact reliability through the collective support of multiple arms.
Solution Approach 2:
The spring arms are designed to be flexible and capable of independent deflection during the plugging process. This dynamic behavior allows the contact element to adapt to misalignments and reduce plugging forces while ensuring reliable contact establishment in the high-frequency range.
2Force
If spring arms are spaced apart to allow independent deflection and reduce plugging forces, then plugging force is reduced, but contact stability may be compromised
Solution Approach 1:
The annular segments of the spring arms are designed to merge and form a support ring in the fully compressed state. This merging provides mutual support among the spring arms, ensuring contact stability and preventing excessive deflection while allowing independent movement during plugging.
Solution Approach 2:
The support ring formed by the annular segments acts as an intermediary structure that provides mutual support to the spring arms. This intermediary structure maintains contact stability without requiring the spring arms to be rigidly connected, thus preserving their ability to deflect independently.
3Force
If annular segments form a support ring in fully compressed state to maintain high normal contact forces, then normal contact force is improved, but device complexity increases
Solution Approach 1:
The spring arms serve multiple functions: they provide individual contact points, form a support ring for mutual support, and compensate for manufacturing tolerances and misalignments. This multi-functionality reduces the need for additional components, thereby limiting the increase in device complexity.
Solution Approach 2:
The spring arms are designed with specific geometric parameters (annular segments at their ends) that change their configuration from spaced apart in the relaxed state to forming a support ring in the compressed state. This parameter change enables the transition between different functional states without adding structural complexity.
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 reduces the required plugging force and ensures stable, high normal contact forces, improving contact reliability and impedance, particularly in high-frequency applications, while maintaining compatibility with existing plug connector systems.
Implementation Method 1
The spring arms are spaced from one another in a contactless relaxed initial state and mutually support each other in a fully compressed state
Data Source
AI summary
An electrical contact element includes a common base and a plurality of spring arms extending away from the common base along a longitudinal direction. The spring arms are arranged around an opening in a circumferential direction and are spaced from one another in a contactless relaxed initial state. An end of at least two of the spring arms facing away from the common base forms an annular segment projecting in the circumferential direction on at least one side of the end. The annular segments form a support ring and mutually support each other in a fully compressed state.