Twisted-Rib Contact Cage for Stable Plug Connector Spring Force
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Solution Overview
Problem
Electric plug connectors in high-voltage applications face issues with contact resistance degradation due to material fatigue and temperature instability, leading to increased friction and damage to contact elements, which affect the plug-in force and reliability.
Innovation Solution
A cage design for contact elements with twisted ribs attached at both ends, providing a torsional spring force that reduces relative movement and friction, enhances mechanical stability, and protects the contact spring arms from damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oversprings are attached to the cage on one side to provide spring force, then the contact spring arms can be contacted with constant spring force, but the oversprings are more susceptible to damage during handling and assembly
Solution Approach 1:
Instead of attaching oversprings to one side of the cage (conventional design), the patent inverts the approach by forming ribs that extend through the cage wall with both ends attached to the cage. This bilateral attachment makes the spring elements more resistant to damage during handling while still providing the necessary spring force to contact the contact spring arms.
2Reliability
If oversprings are used to contact the contact spring arms, then material fatigue of copper can be compensated, but friction arises during plugging in which increases the plug-in force
Solution Approach 1:
The patent changes the geometric parameters of the spring elements by forming twisted ribs instead of conventional oversprings. The torsion angle of the ribs is optimized to provide sufficient spring force for stable contact while minimizing friction during the plugging process, thus reducing the required plug-in force compared to conventional overspring designs.
3Reliability
If a cage with oversprings is used to prevent material fatigue, then the elasticity of contact elements can be maintained, but the device complexity increases
Solution Approach 1:
The patent merges the functions of the cage structure and the spring elements into a single integrated component. The ribs are formed directly as part of the cage wall, eliminating the need for separate overspring components and their attachments. This integration maintains the elasticity stability needed to prevent material fatigue while simplifying the overall device structure.
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 cage design maintains consistent spring force and reduces plug-in force, preventing contact resistance degradation and protecting the contact elements, ensuring reliable electrical connections in high-voltage environments.
Implementation Method 1
the rib is in each case twisted through a torsion angle relative to a longitudinal axis of the rib in such a way that the contact spring arm is contactable by a contact point of the rib with the spring force
Implementation Method 2
the elasticity or spring force of contact spring tabs or of contact spring arms of a contact element which contact an associated mating contact element decreases on account of material fatigue (relaxation) in the course of time
Data Source
AI summary
A cage for the reception of a contact element for an electric plug connector has a fixing region for fixing the cage on the contact element, and a spring region, axially adjoining the fixing region, for contacting a contact spring arm of the contact element with a spring force. The cage has a covering region, axially adjoining the spring region, for covering a plug-in end of the contact element. An aperture is formed in the spring region, in which is arranged a rib with the first axial end connected to the fixing region and the second axial end connected to the covering region. Starting from the first and second axial ends, the rib is twisted through a torsion angle relative to a longitudinal axis of the rib in such a way that the contact spring arm is contactable by a contact point of the rib with the spring force.