U-Shaped Direct Plug Element With Dual Spring Regions
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Solution Overview
Problem
Existing direct plug-in elements for contacting exposed electrical contacts on miniaturized printed circuit boards face challenges in maintaining reliable connections while minimizing space and avoiding assembly errors, particularly in robust automotive applications.
Innovation Solution
A direct plug-in element with U-shaped spring areas on both sides, featuring symmetrically designed spring arcs that allow 180° rotation for correct alignment without coding elements, and an integrated preload mechanism to prevent overpressing and ensure multiple contact cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If direct plug-in elements are miniaturized to reduce space on printed circuit boards, then space requirements are reduced, but assembly alignment becomes difficult and error-prone
Solution Approach 1:
The direct contact is designed with asymmetric features including a head portion with a specific geometry that differs from the contact portion, and the spring areas are positioned asymmetrically relative to the U-shaped structure. This asymmetry provides visual and functional cues for correct orientation during assembly, eliminating the need for separate coding elements while ensuring proper alignment even in miniaturized versions.
2Volume of moving object
If direct plug-in elements are miniaturized, then space is reduced, but contact reliability may be compromised
Solution Approach 1:
The direct contact incorporates spring areas that provide dynamic elastic deformation capability. These spring areas allow the contact to adapt to tolerances and maintain reliable electrical contact even in miniaturized configurations. The resilient nature of the spring areas ensures consistent contact force and reliability regardless of the reduced size of the overall element.
3Manufacturing precision
If coding elements are added to ensure correct alignment, then assembly accuracy improves, but manufacturing complexity and cost increase
Solution Approach 1:
The alignment function is merged into the basic structure of the direct contact itself. The head portion and spring area configuration inherently provide alignment guidance through their geometry, eliminating the need for separate coding elements. This integration maintains manufacturing simplicity while ensuring correct orientation during assembly.
4Reliability
If robust contact is required for automotive applications, then contact reliability improves, but space requirements increase
Solution Approach 1:
The spring areas function as flexible elements within the direct contact structure, providing robust and reliable electrical contact through elastic deformation. These flexible spring regions maintain consistent contact pressure and accommodate tolerances, ensuring automotive-grade reliability while keeping the overall element size compact and suitable for miniaturized applications.
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
Enables reliable, cost-effective, and miniaturized direct plug-in connections with enhanced tolerance compensation and robustness, reducing the risk of assembly errors and maintaining contact integrity in high-tolerance applications like vehicle control units.
Implementation Method 1
a first spring area (4) and a second spring area (5), wherein the first spring area (4) is arranged on a first leg (21) of the U-shaped direct contact and the second spring area (5) is arranged on a second leg (22)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a direct plug element for making contact with an electrical contact, comprising a spring-loaded direct contact (2), wherein the spring-loaded direct contact (2) has a first spring region (4) and a second spring region (5), wherein the direct contact (2) has a substantially U-shaped design with a first limb (21) and a second limb (22), wherein the first spring region (4) is arranged on the first limb (21) and the second spring region (5) is arranged on the second limb (22), and wherein at least one of the spring regions (4, 5) is designed as a contact region in order to make electrical contact with the electrical contact.