Hyperboloid Spring Contact Electrical Connector Design
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Solution Overview
Problem
Conventional electrical connectors with hyperboloid spring contact wires face challenges in high current applications due to high current densities and require high insertion forces, which are not efficiently addressed by existing designs.
Innovation Solution
A high power electrical connector design featuring a first assembly with a male contact pin and a concentric collar, and a second assembly with a sleeve, both with hyperboloid spring contact wires, allowing for a sliding push fit connection that reduces initial mating force and increases contact area, thereby managing current density and reducing ohmic heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring contact wires are made relatively stiff to ensure close contact, then contact reliability is improved, but insertion force increases
Solution Approach 1:
The connector is divided into multiple contact points distributed along the hyperboloid surface of the spring contact wires, rather than relying on a single contact point. This segmentation allows the contact force to be distributed across multiple points, maintaining reliable electrical contact while reducing the force required for insertion.
Solution Approach 2:
The spring contact wires are formed with a hyperboloid curvature that provides a progressive contact surface. This curved geometry allows the contact to engage gradually during insertion, reducing peak insertion forces while ensuring reliable contact through the distributed contact points along the curved surface.
2Reliability
If contact area is increased to reduce current density, then current handling capability is improved, but device complexity increases
Solution Approach 1:
The hyperboloid-shaped spring contact wires provide a naturally curved surface that increases the contact area with the mating pin without requiring additional components. The curved geometry inherently distributes the current across a larger surface area, improving current handling capability while maintaining a relatively simple single-piece construction.
Solution Approach 2:
The spring contact wires are designed with specific geometric parameters (hyperboloid shape, wire diameter, spacing) that optimize the contact area to current density relationship. By carefully controlling these parameters, the connector achieves high current handling capability through optimized contact geometry rather than through complex multi-component structures.
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 connector achieves a 25% greater current handling capability with reduced mating force and contact resistance, enabling efficient high power applications while minimizing power loss and size/weight.
Implementation Method 1
the collar supporting on its inner surface first resilient contact means... the first resilient contact means makes sliding electrical contact with an external surface of the sleeve
Data Source
AI summary
An electrical connector including a first (1) and second (2) assembly that are matable with one another by a sliding push fit to establish electrical interconnection between the two assemblies. The first assembly includes a male contact pin (16) element and a collar (14) extending concentrically around the pin element to define a recess there between, the collar supporting on its inner surface first resilient contact means (18). The second assembly includes the sleeve (24) open at least at one end such that the sleeve can be received in the recess of the first assembly, the sleeve supporting on its inner surface second resilient contact means (26). The two assemblies may be arranged such that when the second assembly is inserted in the first assembly, the first resilient contact means makes sliding electrical contact with an external surface of the sleeve of the second assembly, and the second resilient contact means makes sliding electrical contact with the external surface of the pin element of the first assembly.