Curved Contact Conductor Structure for Stable Elastic Electrical Contacts
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Solution Overview
Problem
Conventional elastic electrical contact devices suffer from structural instability and electrical loss due to indirect conduction through compression springs, and manufacturing complexities arise from minute connection bridges in flat contact conductor designs, leading to poor yield rates and mass production challenges.
Innovation Solution
The elastic electrical contact device features two identically structured contact conductors with a curved bend electrical contact portion and a guide groove, allowing for direct mutual connection and slidable extension/retraction, integrated with an elastic reset member for improved stability and conductivity, facilitating reduced volume and easier manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If compression springs are used to couple two contact conductors, then the contact conductors can be elastically extensible and retractable, but structural instability results and pin kneeling occurs due to skewed contact conductors
Solution Approach 1:
The patent merges the two contact conductors into a single integral structure with a curved bend configuration. The first and second contact conductors are formed as one piece, eliminating the need for separate compression springs to couple them. This integrated design maintains elastic extensibility and retractability while ensuring structural stability and preventing pin kneeling, as the curved bend itself provides the elastic mechanism rather than external springs.
2Adaptability or versatility
If compression springs are used for indirect electrical conduction, then the contact conductors can be coupled, but electrical loss increases due to lengthened conduction paths from helical structures
Solution Approach 1:
The patent combines the electrical conduction function directly into the curved bend structure of the contact conductor itself. The conductor material forms both the mechanical coupling element and the electrical conduction path, eliminating the need for separate compression springs. This direct conduction path through the curved bend minimizes electrical loss while maintaining the necessary coupling capability.
3Stability of the object's composition
If flat contact conductor with minute connection bridges is used, then direct coupling and electrical conduction are achieved, but manufacturing and processing complexities increase and yield rate decreases
Solution Approach 1:
The patent employs a curved bend configuration instead of flat contact conductors with minute connection bridges. The curved bend is formed by stamping a substantially U-shaped cross-section, which is then bent into an arc shape. This curved geometry provides stable coupling between contact conductors while being manufacturable through standard stamping and bending processes, avoiding the complexities of creating minute flat connection bridges.
4Stability of the object's composition
If flat contact conductor is used, then direct coupling is achieved, but volume reduction is difficult while ensuring contact stability and conductivity
Solution Approach 1:
The patent uses a curved bend configuration with a substantially U-shaped cross-section that is bent into an arc. This three-dimensional curved structure achieves contact stability through its geometric form and elastic properties, while the curved design inherently occupies less space than a flat conductor of equivalent functionality. The curved bend allows the contact conductor to maintain stability with reduced volume.
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 contact stability and conductivity while reducing the volume of contact conductors, simplifying mass production and lowering material costs by providing sufficient electrical contact areas with improved structural integrity.
Implementation Method 1
an elastic reset member, sleeving on the two contact conductors to at least cover the two electrical contact portions connected to each other, for the two contact conductors to elastic reset when extending and retracting relative to each other
Data Source
AI summary
An elastic electrical contact device and a contact conductor are introduced. The elastic electrical contact device includes two contact conductors. Each contact conductor includes a head and an electrical contact portion integrally connected with each other. The electrical contact portion has a cross section shaped as a curved bend and has a guide groove formed thereon. The electrical contact portion is bilaterally symmetrical along a second central axis, wherein a first central axis and the second central axis are parallel to each other and non-coaxial. The electrical contact portions of the two contact conductors are disposed to have openings thereof face each other and are mutually connected in respective guide grooves, are mutually slidable to extend and retract relative to each other, and are sleeved by an elastic reset member to enable the two contact conductors to be elastically reset when extending and retracting relative to each other.