Helical Electrical Contact Arms for High-Density Interconnects
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Solution Overview
Problem
Existing compressible contacts in interconnect members suffer from limited working range and increased stress when used with higher density mating contacts, leading to fatigue and reduced mating cycles.
Innovation Solution
The design features an integrally-formed electrical contact with a mating segment, a mounting segment, and arms extending along helical paths to connect these segments, providing a resilient coil spring mechanism that reduces contact force and increases working range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If known compressible contacts are used with increased number and density of mating contacts, then electrical connection is provided, but the contact force required increases leading to higher stresses and reduced reliability
Solution Approach 1:
The patent changes the geometric parameters of the contact arms by forming them along helical paths instead of straight lines. This helical configuration increases the effective length and flexibility of the arms, allowing them to compress with lower forces while maintaining electrical connection capability for high-density contacts.
Solution Approach 2:
The patent applies curvature by forming the arms along helical paths, which introduces a curved, spring-like structure. This curvature enables the arms to flex and compress more easily, reducing the contact force required and thereby lowering stresses on the contact structure during compression.
2Quantity of substance
If known compressible contacts are used with increased number and density of mating contacts, then electrical connection is provided, but the working range of the contact is limited
Solution Approach 1:
The patent changes the geometric parameters by implementing helical paths for the arms, which effectively increases the length and flexibility of the compressible structure. This allows for a greater working range as the helical arms can compress through larger displacements while maintaining structural integrity.
Solution Approach 2:
The helical (curved) path of the arms provides a spring-like mechanism that enables larger compression distances. The curvature allows the arms to flex through greater ranges of motion compared to straight arms, thereby increasing the working range of the contact.
3Quantity of substance
If known compressible contacts are used with increased number and density of mating contacts, then electrical connection is provided, but increased stresses cause contact fatigue and failure
Solution Approach 1:
The patent changes the structural parameters by forming arms along helical paths, which distributes mechanical stresses more evenly throughout the arm structure during compression. This reduces stress concentration and fatigue accumulation, thereby maintaining contact strength over repeated mating cycles.
Solution Approach 2:
The curved helical structure of the arms acts as a spring mechanism that absorbs and distributes compressive forces more uniformly. This curvature prevents stress concentration at specific points, reducing the risk of fatigue failure and maintaining structural strength during repeated compression cycles.
4Quantity of substance
If known compressible contacts are used with increased number and density of mating contacts, then electrical connection is provided, but the number of mating cycles is limited
Solution Approach 1:
The patent changes the geometric parameters to helical paths, which provide a spring-like flexibility that allows the contacts to undergo repeated compression and relaxation cycles. This reduces fatigue accumulation and extends the operational life in terms of number of mating cycles.
Solution Approach 2:
The helical curvature of the arms creates a resilient spring mechanism that can accommodate repeated compression cycles without permanent deformation. This curvature allows the contact to return to its original shape after each compression, thereby increasing the number of usable mating cycles before fatigue failure.
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 the working range and reduces the contact force required, thereby improving the reliability and longevity of the electrical connections by mitigating stress-related failures.
Implementation Method 1
The arms extend along helical paths for at least some distance as the arms extend from the mating segment to the mounting segment
Data Source
AI summary
An electrical contact is provided. The electrical contact includes an integrally-formed body having a mating segment, a mounting segment, and a pair of arms interconnect the mating segment and the mounting segment. The arms extend along helical paths for at least some distance as the arms extend from the mating segment to the mounting segment.