Divaricated-Cut Compressible Contacts for Dense Electrical Interconnects
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Solution Overview
Problem
Existing electrical contacts and interconnects face challenges in meeting the demands for smaller, denser, and lighter systems due to size limitations and non-ideal electrical paths, particularly in high-performance applications.
Innovation Solution
Compressible electrical contacts with divaricated-cut sections are manufactured using precision cutting methods like laser cutting, electroforming, or electro-etching, allowing them to vary in length and maintain a consistent shape, providing a flexible and tubular form that compensates for tolerance deviations and ensures constant electrical and mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a socket-style center conductor is used to maintain electrical connection with a male pin, then electrical connection is maintained, but the contact size must be larger in diameter
Solution Approach 1:
The contact is divided into multiple divaricated-cut sections that can independently compress and deform, allowing the contact to maintain electrical connection through distributed contact points rather than requiring a large overall diameter. Each section acts as an independent elastic element that can accommodate the male pin while maintaining reliable electrical connection.
Solution Approach 2:
The contact utilizes elastic deformation of the divaricated-cut sections to change its dimensional parameters dynamically. When compressed, the sections deform elastically to accommodate the male pin, and when released, they return to their original shape, maintaining electrical connection without requiring a large static diameter.
2Volume of moving object
If a FUZZ BUTTON interconnect is used to reduce size, then the interconnect can be formed into desired shapes, but the coily nature provides a non-ideal electrical path
Solution Approach 1:
The divaricated-cut sections create a segmented structure that provides controlled deformation paths, unlike the random coily structure of FUZZ BUTTON. Each section is precisely cut to provide predictable elastic deformation, maintaining an ideal electrical path while still allowing size reduction through compression.
Solution Approach 2:
The invention replaces the random mechanical coiling of FUZZ BUTTON with a controlled elastic deformation system based on precisely engineered divaricated-cut sections. This substitution provides both the size reduction benefit and the electrical path quality required for high-performance applications.
3Ease of operation
If a pogo pin contact with internally mounted coil spring is used to provide plunger-type contact action, then contact action is provided, but the arrangement is too large and has too many components
Solution Approach 1:
The divaricated-cut sections integrate the spring function directly into the contact body, merging what would traditionally be separate components (contact element and spring) into a single integrated structure. This eliminates the need for internally mounted coil springs while maintaining the plunger-type contact action through the elastic deformation of the integrated sections.
Solution Approach 2:
The divaricated-cut sections serve multiple functions simultaneously: they provide the contact action, the spring function, and the electrical conduction path. This multi-functionality eliminates the need for separate components, reducing device complexity while maintaining ease of operation.
4Adaptability or versatility
If precision cutting methods are used to create divaricated-cut sections, then the contact can vary length and maintain consistent shape, but manufacturing complexity increases
Solution Approach 1:
The divaricated-cut sections are precisely segmented along the contact body, allowing each section to be independently formed with specific geometric characteristics. This segmentation enables the contact to vary in length while maintaining a consistent overall shape, as each section can be precisely controlled during manufacturing to contribute to the desired final geometry.
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
These contacts effectively maintain a stable electrical path and mechanical connection across varying lengths, reducing the need for support structures and improving performance in high-density applications compared to traditional designs.
Implementation Method 1
the compressible electrical contact is configured to vary its length, compensate for tolerance ranges/deviations of mating center conductors or cables, and maintain constant electrical and mechanical connection upon assembly
Data Source
AI summary
A compressible electrical contact, manufactured from a tube, includes a first contact end, a second contact end opposing the first contact end, and a medial portion disposed between the first contact end and the second contact end. The medial portion includes a plurality of divaricated cut sections based on at least one divaricating pattern cut into the tube. The at least one divaricating pattern preferably includes an upper tapered section and a lower tapered section such that a plurality of tapered slots are formed after the tube is cut and when the compressible electrical contact is substantially compressed.