Divaricated-Cut Electrical Contacts for Dense Compressible Interconnects
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Solution Overview
Problem
Existing electrical contacts and interconnects face challenges in meeting size limitations for smaller, denser, and lighter systems, with traditional designs like socket-style conductors and coil springs being too large or difficult to handle for high-density applications.
Innovation Solution
Compressible electrical contacts with divaricated-cut sections, manufactured using precision cutting methods such as laser cutting, exhibit flexible intermediary conductors that maintain electrical and mechanical connection by varying length to compensate for tolerance deviations, maintaining a tubular form without support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional compression springs are used in electrical contacts, then the contacts can be compressed to establish electrical connection, but the springs become work-hardened and brittle after repeated compression cycles
Solution Approach 1:
The compression spring is divided into multiple individual coils rather than being a continuous spring. Each coil can deform independently during compression cycles, preventing work hardening and brittleness that would occur in a traditional continuous spring. This segmentation allows the electrical contact to maintain reliability over repeated use without the spring becoming brittle.
2Reliability
If the electrical contact is designed to be compressible for connection establishment, then contact reliability improves, but the structural complexity increases
Solution Approach 1:
The compressible element (coiled section) is integrated directly into the electrical contact body itself, merging the function of electrical conduction with the function of compression. This eliminates the need for separate compression mechanisms or additional components, thereby improving contact reliability while avoiding increased structural complexity.
3Ease of manufacture
If the electrical contact uses a single continuous piece design, then manufacturing is simplified, but the contact cannot be compressed without risking damage
Solution Approach 1:
The electrical contact is manufactured as a single continuous piece with a coiled or corrugated section that provides compressibility. This segmentation within a monolithic structure allows the contact to be compressed for reliable connection establishment while maintaining manufacturing simplicity through continuous forming processes without requiring assembly of multiple separate parts.
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 compressible electrical contacts provide a consistent electrical path and mechanical connection, reducing size and weight while maintaining performance, as evidenced by improved Voltage Standing Wave Ratio (VSWR) results compared to FUZZ BUTTON ®< interconnects.
Implementation Method 1
a first electrical contact and a second electrical contact each comprising a compressed resilient element
Implementation Method 2
the divaricated-cut sections increasing a surface area of the compressed resilient element
Data Source
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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.