Canted Coil Spring Electrical Connector Design
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Solution Overview
Problem
Existing electrical connectors face challenges in maintaining low resistivity and robust mechanical connectivity across varying tolerances and surface eccentricities, while also requiring effective surface film removal and being cost-effective and compact, especially in high vibration environments.
Innovation Solution
A female electrical connector design featuring a canted coil spring mounted in a helical groove within a connector housing, with a connecting lug embedded in the body and a wire segment extending externally for enhanced conductivity, allowing for a high contact point density and accommodating wide tolerance ranges and surface irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional louvers, wire baskets, or strip springs are used to provide multiple contact points, then adequate normal force levels are achieved, but the connector size increases and contact point density decreases
Solution Approach 1:
The patent changes the geometric parameters of the spring element by canting it at an angle between 10-45 degrees relative to the axis of the bore. This angular parameter change allows the spring to provide adequate normal force while occupying less axial space, thereby reducing connector size while maintaining contact force requirements
Solution Approach 2:
The spring is oriented at an angle rather than purely axially, introducing a radial dimension to the force application. This dimensional change allows the spring to engage the male connector at multiple points along its length, increasing contact point density without proportionally increasing connector volume
2Adaptability or versatility
If the spring deflection range is increased to accommodate wide tolerance ranges and surface eccentricities, then adaptability improves, but the force consistency deteriorates
Solution Approach 1:
The canted geometry of the spring changes the relationship between deflection and force output. By canting the spring coils at an angle, the mechanical advantage is optimized to provide more linear force characteristics over a wider deflection range, allowing the connector to accommodate tolerances while maintaining consistent contact force
Solution Approach 2:
The spring design allows dynamic adjustment of the contact interface as the male connector is inserted at various angles or positions. The canted coils progressively engage and disengage, automatically adapting to misalignment while maintaining adequate normal force through the spring's elastic deformation
3Ease of manufacture
If the connector design is simplified to reduce cost and manufacturing complexity, then ease of manufacture improves, but the surface film removal capability deteriorates
Solution Approach 1:
The canted coil spring design creates a scraping or cleaning action during insertion and engagement. As the spring contacts the male connector, the angled geometry produces relative motion that mechanically刮es (scrapes) the contact surface, removing oxide films and contaminants without requiring additional cleaning mechanisms or complex structures
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 canted coil spring design provides consistent force over a wide deflection range, ensuring reliable electrical continuity and effective surface film removal, enabling a compact and tolerant connector with improved performance in vibration environments.
Implementation Method 1
The canted coil spring provides multiple contact points with the male portion of the connector. The spring can be fabricated from a variety of metal alloy such as platinum iridium. The spring can be plated to enhance conductivity. The canted coil spring has the advantage of nearly constant force over a wide deflection range
Implementation Method 2
A scraping or cleaning action is also desirable as an aide to oxide or surface film removal. The axial spring has excellent surface film removal qualities, particularly by spring design.
Data Source
Figure 1~2
Figure 3~8
AI summary
A female electrical connector and method of using same includes a body having a bore therethrough for receiving electrical plug and a helical groove formed in the bore. A canted coil spring is disposed in the helical groove and protrudes therefrom for providing both electrical connection to the plug and retention of the plug within the bore and a connecting lug embedded into the body, surrounding the bore and interconnected with the spring includes a wire segment extending exterior to the body.