Axial Canted Coil Spring Electrical Contact Assembly
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Solution Overview
Problem
Electrical contact assemblies with canted coil springs face limitations in reducing the electrical conductive path length, leading to increased electrical resistance and heat buildup, which hampers current carrying capabilities.
Innovation Solution
The use of an axial canted coil spring with a groove configuration that allows the spring to contact both side walls of the housing, reducing the electrical path length by 20-50% compared to traditional radial coil springs, where the spring coil length is minimized by forming contact points with the side walls rather than the bottom wall, thereby increasing the number of contact points and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial canted coil spring is used with contact points at opposite ends of the spring coil, then the spring can provide latching and locking functions, but the electrical conductive path length is approximately half way around the spring coil, leading to increased electrical resistance and heat buildup
Solution Approach 1:
The spring orientation is changed from radial to axial, representing a dimensional reconfiguration. This axial orientation allows the spring to contact the insertion object at its midpoint, creating two separate electrical contact paths instead of one long path, thereby reducing the effective electrical conductive path length while maintaining the latching function
Solution Approach 2:
The electrical conductive path is segmented into two separate paths by positioning the spring to contact the insertion object at its midpoint. This segmentation divides the current flow into parallel paths, reducing the effective path length and electrical resistance for each individual path
2Reliability
If the spring coil length is maximized to ensure adequate contact points, then the latching reliability is improved, but the electrical conductive path length increases, reducing current carrying capabilities
Solution Approach 1:
By reorienting the spring from radial to axial configuration, the patent achieves both adequate contact reliability and reduced electrical path length. The axial orientation allows the spring to engage the insertion object at its midpoint, creating reliable mechanical contact while simultaneously shortening the electrical conductive path to approximately one-quarter of the spring coil length
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 configuration significantly reduces electrical resistance and heat buildup, enhancing the current carrying capabilities of the assembly by shortening the electrical conductive path to approximately a quarter or less of the spring coil length, improving conductivity and efficiency.
Implementation Method 1
the axial canted coil spring provides an electrical conductive path between the insertion object and the housing that is less than 50% of the spring coil length
Implementation Method 2
a clamping force of the axial canted coil spring retains the insertion object within the bore
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 2d~2e
AI summary
An electrical contact assembly including a housing defining a bore having an internal groove formed therein; an axial canted coil spring having a plurality of spring coils, each spring coil having a spring coil length, the plurality of spring coils disposed in the internal groove with a groove width having a width dimension; wherein at least one spring coil comprises a minor axis length that is greater than the width dimension. An insertion object sized for insertion into the bore of the housing; wherein a clamping force of the axial canted coil spring retains the insertion object within the bore; and wherein the axial canted coil spring provides an electrical conductive path between the insertion object and the housing that is less than 50% of the spring coil length