Multi-Coil Conductive Spring for Moving Electrical Connections
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Solution Overview
Problem
Existing devices with moving components face frequent breakage of electrical pathways due to repetitive flexing, leading to open circuit conditions, particularly in applications like closed cycle cryogenic coolers where components reciprocate frequently.
Innovation Solution
A spring with multiple electrically conductive coils, each defining a discreet insulated pathway, is used to establish a durable and flexible electric circuit between moving components, allowing for extension and compression while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a simple insulated wire or wire bundle is used to accommodate movement, then flexibility is improved, but the wires quickly fatigue and break due to frequent or high-frequency movement
Solution Approach 1:
The electrical pathway is segmented into multiple discrete conducting coils (first coil, second coil, etc.) that are electrically insulated from each other. Each coil can independently accommodate movement through elastic deformation, distributing the mechanical stress that would otherwise concentrate on a single wire. This segmentation allows the system to maintain both flexibility and reliability.
Solution Approach 2:
The patent employs dynamic spring elements that can elastically deform to accommodate reciprocating and oscillating movements. The conducting coils are designed to expand and contract dynamically, allowing the electrical pathway to adapt to frequent movements without breaking. This dynamic capability enables the system to maintain electrical connectivity while withstanding high-frequency movement.
2Reliability
If multiple conducting coils are used to establish separate electrical pathways, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple conducting coils are merged into a single integrated spring structure rather than using separate wire bundles. The first coil, second coil, and additional coils are combined in one assembly with insulating material positioned between them. This merging reduces the number of discrete components and simplifies installation while maintaining multiple independent electrical pathways for improved reliability.
Solution Approach 2:
The spring structure serves multiple functions simultaneously: it provides mechanical support through elasticity, establishes multiple independent electrical pathways through its conducting coils, and accommodates movement through dynamic deformation. This multi-functionality reduces the need for separate components and simplifies the overall device design while maintaining reliability.
3Reliability
If insulating material is placed between coil portions, then electrical insulation is improved, but manufacturing complexity increases
Solution Approach 1:
Insulating material is placed only in specific locations between the conducting coils where electrical insulation is needed, rather than coating the entire spring structure. This localized approach provides adequate electrical insulation while minimizing the amount of additional material and processing required, thereby reducing manufacturing complexity.
Solution Approach 2:
Insulating material acts as an intermediary element positioned between the conducting coils to prevent electrical shorting. This intermediary component is simple in form (such as plastic spacers or insulating sleeves) and can be easily incorporated into the spring manufacturing process, providing necessary electrical insulation without significantly complicating production.
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 solution provides a reliable and flexible electrical connection that accommodates movement without fatigue, extending the lifespan of devices by preventing premature wear and breakage of electrical pathways.
Implementation Method 1
two or more conducting coils each defining a discreet electrical pathway
Implementation Method 2
The spring easily translates between extension and/or neutral and/or compression to accommodate any movement of the load relative to the power source
Data Source
AI summary
An electrically conductive spring having first and second coils defining first and second electrical pathways for completing an electric circuit between two components which may move relative to each other. In one embodiment, the spring is a double start helical spring with first and second coils extending between respective, electrically insulated ends with the coils extending in alternating, spaced relation to each other.