Lamp Socket Contact with Backup Spring for Ceramic Tolerance
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Solution Overview
Problem
High-power lamps with ceramic sockets face challenges in maintaining both adequate electrical contact and mechanical holding ability due to the greater tolerances of ceramic materials and the perpendicular orientation of electrical lead-ins, which complicates the design of contacts.
Innovation Solution
The electrical contact system consists of a conductive segment and a back-up spring in a laminate configuration, using different materials for conductivity and tension, with a specific design that includes reentrant portions, beams, and gaps to ensure secure engagement and prevent binding, allowing for adjustable tension through the spring beam's form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic materials are used for high-power lamp sockets, then temperature resistance and durability are improved, but manufacturing tolerances worsen leading to inadequate electrical contact
Solution Approach 1:
The contact assembly combines a conductive segment made of electrically conductive material with a backup spring made of spring material, creating a composite structure that leverages the electrical conductivity of the first material and the elastic properties of the second material to compensate for ceramic socket tolerances
Solution Approach 2:
The backup spring is designed with specific geometric parameters (beam dimensions, reentrant portions, gap distances) that allow it to deform elastically and adjust the contact pressure, compensating for variations in ceramic socket manufacturing tolerances and maintaining reliable electrical contact
2Adaptability or versatility
If electrical lead-ins extend perpendicular to the lamp axis, then lamp mounting flexibility is improved, but maintaining adequate electrical contact and mechanical holding ability becomes more difficult
Solution Approach 1:
The contact design incorporates reentrant portions and beams that extend in multiple directions, creating a three-dimensional engagement structure that can accommodate perpendicular lead-ins while maintaining contact through geometric interlocking rather than relying solely on linear contact pressure
3Ease of manufacture
If a single material is used for the electrical contact, then manufacturing simplicity is improved, but it is impossible to optimize both conductivity and tension-providing qualities
Solution Approach 1:
The contact assembly uses two different materials: an electrically conductive material for the conductive segment to ensure low electrical resistance, and a spring material for the backup spring to provide elastic restoring force and maintain contact pressure, optimizing both electrical and mechanical performance
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 configuration provides reliable electrical contact and mechanical holding for high-power lamps, ensuring consistent connection and preventing binding, while allowing for customizable tension to suit various applications.
Implementation Method 1
a back-up spring having a configuration substantially conforming to the electrical contact and having a spring first segment leading to a first spring reentrant portion, a first spring beam extending from the first spring reentrant portion to a position adjacent the electrical lead-in engager
Data Source
AI summary
An electrical contact (100) for a lamp (10) that includes electrical lead-ins (20) projecting away from a longitudinal lamp axis (40), said electrical contact (100) has a first electrically conductive segment (110) including a first segment (120) leading to a first reentrant portion (130), a first beam (140) that extends from the first reentrant portion (130) to an electrical lead-in engager (150), and a second reentrant portion (160) that connects to a second beam (170) that at least partially extends over the electrical lead-in engager (150). A back-up spring (220) is provided having a configuration substantially conforming to the conductive segment (110). The back-up spring has a spring first segment (240) that leads to a first spring reentrant portion (250), thereafter to a first spring beam (260) that extends from the first spring reentrant portion (250) to a junction (261) at a region adjacent the electrical lead-in engager (150), the junction (261) connecting, in turn, the first spring beam (260) to a second spring reentrant portion (270), the second spring reentrant portion (270) connecting to a second spring beam (280) that abuts the second beam (170) of the conductive segment (110). The electrical contact (100) is preferably employed in combination with a socket (101) for receiving a lamp (10), the socket (101) formed of a first socket body portion (141) and a second socket body portion (147), with the electrical contact (100) being disposed between the first and second body portions.