The elastic structure design of small socket connectors is crucial for ensuring electrical connection stability. Its design considerations revolve around material selection, structural form, mechanical properties, manufacturing processes, and environmental adaptability. The following is a systematic analysis of the key dimensions of elastic structure design.
The elastic structure design should prioritize materials with high elastic limits and fatigue resistance. Small socket connectors typically use materials such as beryllium bronze, phosphor bronze, or stainless steel. Beryllium bronze, due to its combination of high strength and good elasticity, is the preferred choice for high-frequency insertion and extraction scenarios. Material thickness directly affects elastic recovery capability; too thin a material can lead to plastic deformation, while too thick a material increases insertion and extraction forces. A balance between rigidity and elasticity must be struck based on the application scenario. Surface treatments such as nickel plating and gold plating can improve conductivity and corrosion resistance, but must avoid affecting the stress distribution of the elastic structure.
The structural design must consider both contact stability and manufacturing feasibility. Common cantilever beam structures achieve insertion and extraction force control through a single elastic arm, suitable for low insertion and extraction force scenarios; double cantilever structures balance forces through symmetrical design, improving durability. For high-current applications, wire-spring or crown-spring structures disperse current through multi-contact contact, reducing the risk of localized overheating. Torsion spring structures utilize hyperboloidal contact to achieve dynamic resistance stabilization, suitable for high-reliability applications such as new energy vehicles. The structural design must allow for elastic deformation space to avoid stress concentration due to interference during assembly.
Mechanical performance optimization requires iterative simulation and experimentation. Finite element analysis can simulate the stress distribution of the elastic arm during insertion and extraction, identify high-stress areas, and optimize geometric parameters. For example, adjusting the radius of curvature or root width of the elastic arm can reduce the maximum stress value. The insertion and extraction force curve must meet standard requirements; excessively high initial force increases operational difficulty, while excessively low final force can easily lead to detachment. The force range can be precisely adjusted by controlling the tilt angle or preload of the elastic arm.
Manufacturing processes have a decisive impact on the performance of elastic structures. The stamping process requires controlling the die clearance and cutting edge sharpness to avoid burrs or corner collapse that could lead to elastic failure. Precision blanking can reduce material deformation and improve dimensional consistency. For complex structures, multi-stage forming processes are required, such as bending followed by springback compensation, to ensure final dimensional accuracy. Heat treatment processes, by adjusting aging temperature and time, can optimize the balance between the material's elasticity and hardness, preventing performance degradation due to internal stress during long-term use.
Environmental adaptability design must consider factors such as temperature, humidity, and vibration. In high-temperature environments, the material's elastic modulus decreases, requiring compensation by increasing the width or thickness of the elastic arm. Humidity can cause oxidation of the contact surface, necessitating the use of sealing structures or anti-corrosion coatings. In vibration scenarios, the elastic structure must possess sufficient damping characteristics to prevent resonance-induced contact failure. For example, in automotive socket connectors, adding a corrugated structure to the elastic arm can improve vibration resistance.
The assembly process has a significant impact on the performance of the elastic structure. The fit clearance between the socket connector hardware and the plastic shell must be strictly controlled; excessive clearance leads to elastic arm misalignment, while insufficient clearance increases assembly stress. The design of the guide structure can guide the hardware for correct insertion, preventing localized overload caused by elastic arm misalignment. Welding or riveting processes must ensure connection strength while preventing the heat-affected zone from extending to the elastic area, which could lead to performance degradation.
Reliability verification is the ultimate guarantee for the design of the elastic structure. Environmental testing simulates high temperature, low temperature, and humid heat conditions to verify the long-term stability of the elastic structure. Mechanical life testing simulates actual insertion and removal cycles to observe whether cracks or permanent deformation appear in the elastic arm. Electrical performance testing measures contact resistance and insulation resistance to ensure compliance with standard requirements. Failure analysis can identify design flaws and provide a basis for iterative optimization.
