Blocking-Bar Canted Coil Structure to Prevent Connector Tangling
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Solution Overview
Problem
Canted coils in connectors often become entangled during storage or handling due to the separation of their turns, which complicates their manufacture and assembly.
Innovation Solution
A non-tangling canted coil design featuring a substantially cylindrical body with adjacent loops and gaps, incorporating a blocking bar that extends through the coil to prevent entanglement, ensuring the coils remain separated and can be easily mounted without tangling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the turns of the canted coil are separated from each other, then the electrical connection capability is improved, but the coil becomes entangled during storage or handling
Solution Approach 1:
The canted coil is segmented into multiple separated turns with gaps between them, allowing each turn to function as an independent electrical contact point. This segmentation improves electrical connection capability by providing multiple contact points while the turns remain physically separated to prevent entanglement.
Solution Approach 2:
A blocking bar is introduced as an intermediary element that extends through the coil body. This blocking bar acts as a mechanical mediator that maintains the spatial separation between turns and prevents the coil from tangling during handling, while allowing the electrical function to proceed normally.
2Reliability
If the spacing between turns is greater than the wire thickness, then the electrical contact surface area is increased, but the manufacturing complexity increases
Solution Approach 1:
The coil is designed with deliberately spaced segments (turns) separated by gaps larger than the wire thickness. This segmentation increases the effective electrical contact surface area by distributing contact points across multiple separated turns, while the regular spacing pattern simplifies the manufacturing process by providing a predictable geometry.
Solution Approach 2:
The blocking bar serves multiple functions: it maintains turn spacing to increase electrical contact area, prevents entanglement during handling, and provides a structural framework that simplifies manufacturing. This multi-functionality reduces overall device complexity despite the increased spacing requirements.
3Adaptability or versatility
If the canted coil is designed with separated turns, then the flexibility is improved, but the coil becomes prone to entanglement
Solution Approach 1:
The coil is divided into segmented turns with gaps between them, which enhances flexibility by allowing each segment to move independently. This segmentation also inherently reduces entanglement probability by maintaining physical separation between adjacent turns.
Solution Approach 2:
The blocking bar acts as a mechanical intermediary that reinforces the separation between flexible turns. It allows the coil to maintain its flexibility for adaptation to different connector configurations while preventing the turns from becoming entangled during assembly and handling.
Data Source
AI summary
A canted coil for use in a connector to make an electrical connection between conductors to form a conductor assembly. The canted coil includes a substantially cylindrical body formed from at least one length of conductive wire and having a series of adjacent loops with gaps in-between. The body has opposing first and second end portions. A blocking bar extends through the body of the canted coil, between the first and second end portions of the body.