Looped Spring Electrical Contact for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical connectors in environments with strong vibrations, such as vehicles or machinery, experience rapid wear of contact elements due to high-frequency oscillations, which can damage them quickly, especially when contact elements move relative to each other.
Innovation Solution
A vibration-resistant electrical contact element featuring a looped spring portion with a connecting end and a contacting end, where the contacting end is bent back towards the connecting end, forming an arc of at least 270°, and includes a convexly curved contacting portion that generates a spherical cap to increase contact pressure and penetrate oxidized layers, ensuring stable contact even under vibrational movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact elements are used in high-vibration environments, then the connector can maintain basic electrical connection, but the contact elements experience rapid wear and damage due to high-frequency oscillations
Solution Approach 1:
The contact element incorporates a looped spring portion that provides dynamic compliance, allowing the contact to adapt to vibrational movements while maintaining continuous contact force. The spring portion acts as a vibration isolator that absorbs high-frequency oscillations, preventing direct transmission to the contact interface and reducing wear.
Solution Approach 2:
The invention changes the physical parameters of the contact element by introducing a looped spring geometry with specific arc extensions (at least 180°, preferably 270° or more). This geometric parameter change creates a compliant structure that maintains contact force under vibration, transforming the contact from rigid to dynamically adaptive.
2Force
If the contact element is made rigid to maintain stable contact, then contact force is maintained, but the contact element cannot follow vibrational movements and experiences increased wear
Solution Approach 1:
The looped spring portion transforms the rigid contact element into a dynamic system that can follow vibrational movements while maintaining contact force. The spring geometry allows the contact to move with vibrations rather than resist them, reducing relative motion wear while preserving electrical connection stability.
Solution Approach 2:
The spring portion acts as a pre-compressed cushion that absorbs vibrational energy before it can cause damage to the contact interface. The elastic deformation of the looped spring portion provides beforehand cushioning against high-frequency oscillations, protecting the contact surfaces from wear.
3Reliability
If the contact element is made flexible to follow vibrations, then wear is reduced, but contact force may be insufficient to penetrate oxidized layers
Solution Approach 1:
The looped spring geometry with extended arc (at least 180°, preferably 270°) changes the mechanical parameters of the contact element, creating optimal compliance while maintaining sufficient contact pressure. The spring constant is tuned through geometry to provide both flexibility for vibration following and adequate force for penetrating oxidized layers.
Solution Approach 2:
The looped spring portion incorporates curved geometry with specific arc extensions that optimize the distribution of contact force. The curved path of the spring allows for gradual deformation that maintains consistent pressure on the contact surface, ensuring penetration of oxidized layers while accommodating vibrations.
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 contact element effectively reduces wear by maintaining contact force and flexibility, allowing it to follow vibrational movements without loss of contact, thus extending the lifespan of electrical connectors in high-vibration environments.
Implementation Method 1
a looped spring portion, the looped spring portion having a connecting end and a contacting end... the looped spring portion forms an arc extending from the connecting end to the contacting end, the arc extending for at least 270°
Implementation Method 2
the contacting portion generates a contact pressure sufficient to penetrate an oxidized layer disposed on a surface of the second contact
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An electrical contact (1) for an electric connector (76) is disclosed, the electrical contact (1) comprising a looped spring portion (14), having a connecting end (16) and a contacting end (18), the contacting end (18) being bent back towards the connecting end (16), and the looped spring portion (14) comprising at the contacting end (18) at least one contacting region (8), which is adapted to contact a corresponding mating electrical contact (2) of a mating connector (78).