Method of manufacturing an electrically conductive extension/compression spring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices with moving components face frequent wire fatigue and breakage due to repetitive flexing, leading to open circuit conditions, particularly in applications like closed cycle cryogenic coolers where reliable flexible electrical pathways are needed.
Innovation Solution
A spring with multiple electrically conductive coils, each defining a discreet insulated pathway, is used to establish a durable and flexible electric circuit between moving components, allowing for extension and compression while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a simple insulated wire or wire bundle is used to accommodate movement between components, then flexibility is improved, but the wires quickly fatigue and break due to frequent or high-frequency movement
Solution Approach 1:
The electrical pathway is segmented into multiple discrete conductive coils (first coil, second coil, etc.) that are electrically insulated from each other. Each coil can independently flex and deform, distributing the mechanical stress of movement across multiple segments rather than concentrating it in a single wire, thereby preventing fatigue and breakage while maintaining flexibility
Solution Approach 2:
The spring structure is designed to be dynamic, allowing the conductive coils to flex, compress, and extend in response to movement between components. This dynamic capability enables the electrical connection to accommodate frequent or high-frequency movement without breaking, resolving the contradiction between flexibility and durability
2Reliability
If multiple electrically conductive coils with insulating material are used to establish durable electrical pathways, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple conductive coils with insulating material between them are merged into a single integrated spring structure. This unified spring provides both mechanical support and multiple electrical pathways simultaneously, reducing the need for separate components and simplifying the overall device structure while maintaining reliability
Solution Approach 2:
The spring structure serves multiple functions: it provides mechanical support, enables movement accommodation, and establishes electrical pathways between components. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while improving reliability through the durable spring construction
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 solution provides a reliable and flexible electrical connection that accommodates movement without premature wear, extending the lifespan of devices by preventing wire breakage and maintaining circuit integrity.
Implementation Method 1
a spring which may be an extension/compression spring having two or more conducting coils each defining a discreet electrical pathway electrically insulated from each other
Implementation Method 2
Insulating material is placed between the end portions of each coil to electrically insulate the helical coils from each other
Implementation Method 3
a spring which may be an extension/compression spring having two or more conducting coils
Data Source
AI summary
An electrically conductive spring having first and second coils defining first and second electrical pathways for completing an electric circuit between two components which may move relative to each other. In one embodiment, the spring is a double start helical spring with first and second coils extending between respective, electrically insulated ends with the coils extending in alternating, spaced relation to each other.