Coiled Spring Wire Electrical Contact Element

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Solution Overview

Problem

Conventional electrical contact elements with spring elements formed from stamped sheet metal parts are expensive to produce and can result in burrs during manufacturing, leading to wear and instability in contact connections.

Innovation Solution

The electrical contact element features flat contact lamellae with a straight inner surface, allowing for simplified production and reduced wear, along with a spring element formed by a coiled spring wire that provides a secure and cost-effective elastic clamping force.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If spring elements are formed from stamped sheet metal parts, then elastic clamping force can be provided, but production cost increases

Engineering Contradiction:

Improveelastic clamping forceVSAvoidproduction cost

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent replaces expensive stamped sheet metal spring elements with a cost-effective alternative made from phosphor bronze wire. This wire is drawn to specific dimensions and then coiled to form the spring element, significantly reducing material and manufacturing costs while maintaining the necessary elastic clamping force for the contact element's service life

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the material form from stamped sheet metal to drawn wire, and the manufacturing process from stamping to drawing and coiling. This parameter change in material processing methodology reduces production complexity and cost while achieving the same functional outcome of providing elastic clamping force

Inventive Principle:

Principle #35Parameter changes

2Productivity

If contact elements are produced by stamping and bending, then contact elements can be manufactured, but burrs occur at contact lamellae leading to wear

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidburr formation causing wear

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent eliminates the harmful burr formation issue by completely changing the manufacturing process from stamping and bending to drawing and coiling. This alternative process produces smooth surfaces without burrs, preventing the wear problems that would result from burr contact with mating elements

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention replaces the stamping and bending mechanical processes with drawing and coiling processes. This substitution eliminates the generation of burrs during manufacturing while maintaining productivity, as the drawn and coiled structure inherently produces cleaner edges and surfaces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If spring elements are securely held in engagement with groove, then accidental removal is prevented, but device complexity increases

Engineering Contradiction:

Improvespring element retentionVSAvoidengagement structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent utilizes the natural curvature of the coiled spring element to achieve secure retention in the groove. The coiled structure inherently provides elastic pressure against the groove walls, creating a self-retaining mechanism that prevents accidental removal without requiring additional complex engagement features

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The spring element's coiled design enables it to self-retain in the groove through its own elastic properties. The coil structure naturally presses against the groove, creating friction and mechanical interference that prevent removal, eliminating the need for separate retention mechanisms

Inventive Principle:

Principle #25Self-service

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 design enhances production efficiency, reduces wear, and ensures a stable and defined electrical contact with low resistance, maintaining contact force over the service life while preventing accidental disengagement of the spring element.

Implementation Method 1

a spring element that is arranged on the groove and engages the contact lamellae to provide an elastic clamping force on the contact lamellae

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11502437B2Electrical contact element for electrical contacting with a counterpart contact element

Publication Date: 2022.11.15 PHOENIX CONTACT GMBH & CO KG

AI summary

An electrical contact element for electrically contacting a mating contact element includes: a plurality of contact lamellae which are arranged around a plug opening into which a mating contact element is pluggable along a plug direction and which together form a groove that encircles the contact lamellae around the plug direction; and a spring element that is arranged on the groove and engages the contact lamellae to provide an elastic clamping force on the contact lamellae. The contact lamellae each have an inner surface which faces the plug opening and is straight in cross section transversely to the plug direction.