Canted Coil Spring Connector Gap Compensation
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Solution Overview
Problem
Conventional connectors are limited by a specific match of pin and housing sizes, leading to issues when a pin with a non-matching size is connected, as the larger set gap can exceed the operating deflection range of conventional spring contacts, preventing stable retention and contact.
Innovation Solution
A canted coil spring contact with a wide range of deflection capabilities, comprising interconnected coils that can accommodate varying pin sizes within a single housing groove diameter or housing sizes with a single pin diameter, allowing contact establishment across a wide set gap range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a conventional spring contact is used to bridge a large set gap, then the gap can be accommodated, but the spring contact cannot operate within its designed deflection range and cannot exert appropriate spring force
Solution Approach 1:
The patent changes the geometric parameters of the spring contact, specifically using a ratio of coil width to coil height between 0.3 and 0.7 (preferably 0.4 to 0.6), which allows the spring to operate effectively over larger deflection ranges while maintaining adequate spring force for reliable contact
2Length of stationary object
If a larger spring contact is used to bridge a larger set gap, then the gap can be covered, but the housing groove may not have proper retaining space to securely retain the spring contact
Solution Approach 1:
The patent optimizes the spring contact dimensions by controlling the coil width to coil height ratio between 0.3 and 0.7, which allows the spring to span larger gaps while maintaining a compact profile that fits within standard housing groove dimensions, avoiding the need for larger or more complex groove structures
3Adaptability or versatility
If a conventional spring contact is used with varying pin sizes, then a specific pin size can be accommodated, but the spring contact cannot accommodate a wide range of pin sizes within a single housing
Solution Approach 1:
The patent designs the spring contact with optimized coil geometry (coil width to height ratio of 0.3 to 0.7) that provides a wide operating deflection range, enabling the same spring contact to accommodate various pin sizes from approximately 0.4X to 0.89X of the housing groove bore diameter while maintaining reliable contact across different set gap conditions
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 stable contact and secure retention across a wide range of pin and housing size variations, overcoming the limitations of conventional connectors by allowing the canted coil spring to deflect and maintain contact within its operating range.
Implementation Method 1
a canted coil spring contact with a wide range of deflection capabilities... allowing contact establishment across a wide set gap range... the canted coil spring to deflect and maintain contact within its operating range
Data Source
AI summary
A connector assembly having a housing and pin and a spring contact located therebetween to take up a set gap between the pin and the housing. The spring contact can be a canted coil spring and the spring contact can be made to have a large range of deflection to take up the gap with a large range of variation, such as when the pin diameter varies for a given groove bore diameter or when the groove bore diameter varies for a given pin diameter.