Contact Clip With Elastic Strips For Low Resistance
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Solution Overview
Problem
Existing contact clips have limited contact surfaces with male parts, leading to high contact resistance and restricted current flow, which results in excessive heating, and they deteriorate mechanically over time and after repeated connections/disconnections, potentially damaging the male contact surface.
Innovation Solution
A contact clip with a tubular design featuring a cylindrical fixing portion, a frustoconical transition, and a contact portion with elastic strips that apply radial force to the male part, increasing the contact surface area and maintaining mechanical integrity through the use of copper-beryllium alloy and precise manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the contact surface area is increased to reduce contact resistance and allow higher current flow, then the current transmission capability improves, but the dimensions of the contact clip increase, making it unsuitable for compact multi-contact connectors
Solution Approach 1:
The contact surface is extended in the longitudinal direction of the clip rather than increasing the radial dimensions. The contact portion includes a longitudinal extension that provides additional contact surface area along the length of the clip, allowing increased current capacity without increasing the cross-sectional dimensions that would interfere with compact connector designs
Solution Approach 2:
The contact portion is divided into multiple contact elements or segments along the longitudinal extension. This segmentation allows the total contact surface area to be distributed over a longer distance, reducing the contact resistance and allowing higher current flow while maintaining a compact overall clip dimensions suitable for multi-contact connectors
2Reliability
If the elasticity of the contact clip is increased to maintain good contact after numerous connections and disconnections, then the reliability improves, but the risk of damaging the male contact surface during insertion or extraction increases
Solution Approach 1:
The clip features localized elastic elements or compliant contact regions that provide the necessary elasticity and force maintenance without requiring the entire clip structure to be highly elastic. This localized elasticity maintains reliable contact over time while the overall clip structure remains rigid enough to prevent damage during insertion and extraction operations
3Object-affected harmful factors
If the contact surface is made smooth to prevent damage to the male part, then the harmful factors are reduced, but the contact resistance increases due to reduced friction and grip
Solution Approach 1:
Different regions of the contact clip have different surface characteristics. The regions that contact the male part during insertion and extraction have smooth surfaces to prevent damage, while the regions providing electrical contact have optimized surface properties to ensure low contact resistance. This localized differentiation of surface quality resolves the contradiction between preventing damage and maintaining low resistance
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 enhanced contact clip achieves lower resistance, allowing higher current transmission without excessive heating, maintains mechanical quality over time, and prevents damage to the male contact surface, enabling reliable operation in small dimensions for multi-contact connectors and printed circuit boards.
Implementation Method 1
a contact portion (11) having a longitudinal extension and comprising a number of elastic strips (15), each strip being shaped in the longitudinal direction of the clip (1) and being deformed in a direction towards the longitudinal axis (100) of the clip
Data Source
Figure 1~4
AI summary
The contact clip according to the invention comprises a contact portion (11) comprising two elastic blades (15) capable of pressing a male contact portion (2) against an interior cylindrical portion (110) of the said contact portion. In view of the elongate shape of this contact portion, electrical contact between the contact clip and the male contact piece portion is had over a large surface area, thus reducing the contact resistance and the heating when high currents are passed. The contact clip further comprises an attachment portion (10) and possibly an end portion (12) and is intended to be fitted inside a hollow housing of a female contact piece (3).