Copper Alloy Contact Ring with Tapered Projections
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Solution Overview
Problem
Conventional contact rings made of spring steel for connecting ground and shielding cylinders face issues with penetrating insulating surface layers and are prone to corrosion, leading to inefficient electromagnetic shielding due to air gaps and poor electrothermal performance.
Innovation Solution
A contact ring made of a copper alloy with tapered projections on one longitudinal side, which can penetrate insulating layers and provide a reliable electrically conductive connection between the ground and shielding cylinders, minimizing contact area damage and corrosion, and optionally featuring a meander structure for enhanced flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat wave-shaped contact ring made of spring steel is used, then mechanical properties are improved, but electrothermal performance deteriorates and penetration of insulating surface layers is insufficient
Solution Approach 1:
The patent employs a composite structure combining spring steel for mechanical strength with copper or copper alloy for electrical conductivity. The contact ring consists of a spring steel base material providing elasticity and mechanical properties, while copper strips or copper alloy sections are integrated to ensure excellent electrothermal performance and ability to penetrate insulating surface layers.
Solution Approach 2:
Different regions of the contact ring have different material compositions optimized for their specific functions. The contact surfaces that penetrate insulating layers are made of copper or copper alloy with high electrical conductivity, while the bulk structure maintains spring steel for mechanical elasticity. This local differentiation resolves the contradiction between mechanical strength and electrothermal performance.
2Device complexity
If contact elements are directly connected, then device complexity is reduced, but electrical connection reliability deteriorates due to insulating surface layers
Solution Approach 1:
The contact ring serves as an intermediary element between contact elements with insulating surface layers. Its tapered projections penetrate through the insulating layers to establish electrical contact, while the ring structure itself provides the necessary electrical conductivity and mechanical compliance, resolving the contradiction between simple direct connection and reliable electrical contact.
3Ease of manufacture
If conventional contact rings are used, then manufacturing is simplified, but corrosion resistance deteriorates
Solution Approach 1:
The use of copper or copper alloy in the contact ring provides inherent corrosion resistance while maintaining electrical conductivity. The copper material naturally resists corrosion better than plain spring steel, and the composite structure allows this corrosion-resistant material to be integrated without significantly complicating the manufacturing process.
4Ease of manufacture
If flat contact rings are used, then manufacturing is easier, but penetration of insulating surface layers is insufficient
Solution Approach 1:
The contact ring features tapered projections with curved surfaces instead of flat surfaces. This curvature allows the projections to concentrate force at the tip for effective penetration of insulating surface layers, while the overall ring structure remains relatively simple to manufacture. The tapered geometry achieves penetration capability without significantly increasing manufacturing complexity.
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 copper alloy contact ring with projections ensures a stable, corrosion-resistant, and efficient electrically conductive connection, eliminating air gaps and enhancing electromagnetic shielding, particularly in high-frequency applications.
Implementation Method 1
The projections electrically contact the ground cylinder and the shielding cylinder for establishing an electrically conductive connection therebetween
Data Source
AI summary
A contact system comprises a ground cylinder, a shielding cylinder press-fit with the ground cylinder, and a contact ring disposed between the ground cylinder and the shielding cylinder. The contact ring includes a strip of electrically conductive material defining a plurality of projections on at least one longitudinal side. The projections electrically contact the ground cylinder and the shielding cylinder for establishing an electrically conductive connection therebetween.