Modular Contact Element With Resilient Arms
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Solution Overview
Problem
Existing electrical connectors face challenges in withstanding high vibrations and temperature variations, require high contact forces, and are costly to manufacture, with threaded components making disassembly difficult and prone to foreign object debris, and spring contacts are hard to miniaturize due to space constraints.
Innovation Solution
A modular contact assembly with a spring contact element featuring closely spaced resilient contact arms that provide high current capabilities with reduced insertion force, allowing for quick connection and disconnection, and a gas-tight interface, using a conductive housing with multiple contact points to ensure reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded components are used to achieve secure electrical connection, then high contact forces are provided, but manufacturing cost increases and assembly time increases
Solution Approach 1:
The contact element is divided into multiple resilient contact arms (first, second, and third contact arms) that can independently engage with the mating terminal. This segmentation allows the contact force to be distributed across multiple points, achieving high overall contact force while using a single integrated contact element rather than multiple threaded components.
Solution Approach 2:
The patent replaces the threaded mechanical fastening system with a spring-based resilient contact system. The resilient contact arms use elastic deformation to generate and maintain contact force, eliminating the need for threads, nuts, and torque-wrench assembly procedures while providing sufficient electrical connection strength.
2Strength
If threaded components are used to achieve secure electrical connection, then high contact forces are provided, but assembly time increases
Solution Approach 1:
The threaded fastening system is replaced with a spring-based resilient contact system that requires no assembly tools or procedures. The resilient contact arms are simply inserted into the housing and automatically engage with the mating terminal through elastic deformation, enabling rapid assembly without torque wrenches or threading operations.
Solution Approach 2:
The resilient contact arms automatically generate and maintain the required contact force through their own elastic properties. Upon insertion, the springs naturally deform and exert force on the mating terminal, requiring no additional assembly steps, tooling, or adjustment procedures to achieve proper electrical connection.
3Strength
If threaded components are used to achieve secure electrical connection, then high contact forces are provided, but disassembly becomes difficult
Solution Approach 1:
The threaded fastening system is replaced with a spring-based resilient contact system. The resilient contact arms are simply removed from the housing, and the mating terminal can be easily pulled away without requiring tools or overcoming thread friction. This enables rapid disassembly for maintenance and repair.
4Strength
If threaded components are used to achieve secure electrical connection, then high contact forces are provided, but foreign object debris risk increases
Solution Approach 1:
The contact element is segmented into multiple resilient contact arms integrated into a single piece. This eliminates the separate threaded components and multiple fastening parts that could generate foreign object debris during assembly or disassembly, reducing the risk of debris damaging sensitive equipment.
5Volume of moving object
If spring contacts are miniaturized to reduce size, then compactness is achieved, but manufacturing difficulty increases
Solution Approach 1:
The spring contact element is divided into multiple discrete resilient contact arms (first, second, and third contact arms) that can be manufactured using standard stamping and forming processes. This segmentation allows each arm to be optimized for manufacturing while maintaining compact overall dimensions, avoiding the need for complex single-piece miniaturized springs.
Solution Approach 2:
The patent uses standard gauge materials (e.g., 0.032 inch gauge) and conventional spring geometries that are well-suited to existing manufacturing processes. By selecting appropriate material parameters and geometric configurations, the design achieves miniaturization without requiring specialized or difficult-to-manufacture spring components.
6Quantity of substance
If closely spaced contact arms are used to increase contact points, then current carrying capacity increases, but manufacturing precision requirements increase
Solution Approach 1:
The contact element is segmented into multiple resilient contact arms that are integrally formed as a single piece. This segmentation allows closely spaced contact points to be achieved through standard stamping and forming processes, where the spacing is determined by the tooling rather than requiring high-precision post-manufacturing adjustments.
Solution Approach 2:
The patent uses standard material gauges (e.g., 0.032 inch) and conventional spring geometries that can be manufactured with standard tolerances. By selecting appropriate material parameters and geometric configurations, the design achieves multiple closely spaced contact points without requiring exceptional manufacturing precision.
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 modular contact assembly achieves high current capabilities with lower resistance, reduced manufacturing costs, and improved reliability in harsh environments, enabling efficient power transfer with lower voltage drop and power consumption, while being scalable and adaptable for various applications.
Implementation Method 1
The spring contact element has first resilient contact arms, second resilient contact arms, and third resilient contact arms
Data Source
AI summary
A contact assembly for providing high current capabilities between an electrical terminal and a mating terminal. The contact assembly includes a conductive housing and a spring contact element. The spring contact element has first resilient contact arms, second resilient contact arms, and third resilient contact arms. The first resilient contact arms are positioned proximate the inner wall. The second resilient contact arms have second resilient contact portion bent portions which extend over the first end of the housing from the inner wall to the outer wall to retain the spring contact element in position on the housing. The third resilient contact portions have third resilient contact portion bent portions which extend over the second end of the housing from the inner wall to the outer wall to retain the spring contact element in position on the housing.