Hollow Cylindrical Contact Spring for Vibration Damping
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Solution Overview
Problem
Miniaturized electrical switches with solid contacts experience vibrations and temporary disconnections due to high mass, leading to interrupted current flow, especially when subjected to dynamic switching processes.
Innovation Solution
The electrical switch features a hollow cylindrical contact formed from reshaped planar electrically conductive material, with surface areas forming contact surfaces that can be applied to counter-contacts, reducing mass and enhancing hardness for improved vibration damping and mechanical stress resistance, and allowing selective application of noble metal layers only where needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid material contacts are used, then the contact has sufficient structural strength, but the mass increases causing vibrations and temporary disconnections
Solution Approach 1:
The contact is divided into a carrier component and a separate contact element that can be attached or detached. This segmentation allows the contact element to be made from hard material for durability while the carrier provides structural support, reducing the overall moving mass that causes vibrations.
Solution Approach 2:
The contact system uses composite construction with a carrier made from one material and a contact element made from another material (e.g., hard material like tungsten or tungsten alloy). This composite approach optimizes both structural strength and contact durability while managing mass effectively.
2Stability of the object's composition
If solid material contacts with high mass are used, then the contact provides stable structure, but vibrations occur causing temporary lift-off from mating contact
Solution Approach 1:
The contact design incorporates dynamic characteristics by using a lighter contact element that can respond more quickly to switching operations. The reduced mass allows the contact to follow the motion profile more accurately without excessive vibrations, maintaining reliable contact with the mating surface during dynamic operation.
Solution Approach 2:
The invention changes the mass parameter of the contact by using a different construction (carrier with attached contact element) and material selection. This parameter change reduces the moment of inertia and vibrational effects, ensuring the contact maintains stable electrical connection during accelerated motion.
3Strength
If harder material is used for the contact, then the contact withstands mechanical stresses better, but the manufacturing complexity increases
Solution Approach 1:
The contact is segmented into a carrier component that can be manufactured from easier-to-work materials and a separate contact element made from hard material. This segmentation allows each component to be optimized for its specific function, with the hard contact element being a small, simple piece that is easier to manufacture than a completely hard contact of the same overall size.
Solution Approach 2:
The carrier and contact element are combined into a single assembly that functions as one contact component. The carrier provides structural support and electrical connection, while the attached contact element provides durable mating surfaces. This merging simplifies the overall manufacturing process compared to making a single-piece hard contact.
Data Source
Figure 1~2
AI summary
The switch has an electrical contact (2) formed as a hollow shaped-section of a pressing component (1) that is made of an electrically conductive material, where the contact has a hollow cylinder form. The hollow form is formed from a flat material through deformation. The contact has a contact surface (3), into which a precious metal layer is selectively introduced. The contact is formed as a single piece at the component.