Electrical Contactor Volute Spring Manufacturing
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Solution Overview
Problem
Conventional electrical contactors with multiple constituting members experience increased resistance at contact points, leading to suboptimal electrical conduction performance, particularly when forming volute spring structures with extended conduction paths, and face challenges in mechanical functionality due to material discontinuities.
Innovation Solution
A method and electrical contactor formed from a single plate-like member, where the member is wound into a barrel shape and then compressed to create overlapping volute spring structures, followed by hardening treatment to achieve a volute spring structure extending in both upward and downward directions, eliminating contact points and enhancing mechanical simplicity and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrical contactor is formed by combining a plurality of constituting members, then the electrical contactor can achieve the desired mechanical functionality and structure, but the resistance increases at contact points between members, deteriorating electrical conduction performance
Solution Approach 1:
The invention merges multiple constituting members into a single integrated member with continuous variable cross-sectional area. This eliminates contact interfaces between separate components, thereby removing contact resistance and improving electrical conduction while maintaining the necessary mechanical functionality through the continuous structural design.
Solution Approach 2:
The invention uses a single material continuously formed with varying cross-sectional area rather than composite assembly of multiple materials. This continuous monolithic structure eliminates interfacial contact resistance that would occur between different materials or components, achieving superior electrical conductivity while providing the required mechanical properties through geometric design.
2Loss of energy
If a volute spring structure is formed by winding a plate-like member, then the conduction path length is reduced and resistance is lowered, but the structure becomes difficult to form and may require welding or joining different members
Solution Approach 1:
The invention segments the winding process into stages: first forming a barrel shape by winding, then compressing it to create the volute spring structure with overlapping portions. This segmentation of the manufacturing process makes the formation of complex volute structures feasible without requiring welding or joining operations.
Solution Approach 2:
The invention performs preliminary winding to create a barrel-shaped intermediate structure before final compression into the volute spring form. This preliminary action simplifies the overall manufacturing process by breaking down the complex forming operation into manageable steps that avoid the need for difficult direct welding or joining of pre-formed components.
3Ease of operation
If the plate-like member is compressed to form overlapping volute spring structures, then the desired elasticity and mechanical functionality are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention uses periodic compression and heat treatment cycles to transform the barrel-shaped wound member into the final volute spring structure. The periodic application of compression force followed by heat treatment steps creates the desired overlapping volute structure with proper elasticity, making the complex manufacturing process systematic and controllable.
Solution Approach 2:
The invention changes physical parameters (temperature, compression force) during the manufacturing process to achieve the desired structure. By applying heat treatment at specific compression stages, the material properties are modified to enable formation of the overlapping volute structure with appropriate elasticity, systematically managing manufacturing complexity through parameter control.
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 results in an electrical contactor with reduced resistance, improved conduction performance, and mechanical stability, enabling reliable electrical connections without material discontinuities, thus enhancing both mechanical functionality and electrical conductivity.
Implementation Method 1
forming the plate-like member into a barrel shape by winding the plate-like member in a spiral pattern
Implementation Method 2
compressing the plate-like member formed into the barrel shape from a vertical direction until the plate-like member assumes a volute shape
Implementation Method 3
forming a volute-shaped electrical contactor by performing predetermined hardening treatment on the plate-like member temporarily assuming the volute shape
Data Source
AI summary
To provide a method of manufacturing an electrical contactor including a volute spring structure extending in upward and downward directions formed integrally using a single material, having mechanical simplicity and excellent functionality, and functioning as an electric circuit achieving connection without loss.The present disclosure is intended for a method of manufacturing an electrical contactor made of a plate-like member having electrical conductivity, comprising: (1) a first step of forming the plate-like member into a barrel shape by winding the plate-like member in a spiral pattern; (2) a second step of compressing the plate-like member formed into the barrel shape from a vertical direction until the plate-like member assumes a volute shape with an upper spiral structure and a lower spiral structure overlapping each other; and (3) a third step of forming a volute-shaped electrical contactor by performing predetermined hardening treatment on the plate-like member temporarily assuming the volute shape as a result of the second step.