Multi-Coil Conductive Spring for Fatigue-Resistant Moving Circuits
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Solution Overview
Problem
Existing devices with moving components face frequent breakage of electrical wires due to repetitive flexing, leading to open circuit conditions, particularly in applications like closed cycle cryogenic coolers where high-frequency movement occurs.
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 simple insulated wire or wire bundle is used to accommodate movement, then flexibility is improved, but reliability deteriorates due to wire fatigue and breakage from high-frequency movement
Solution Approach 1:
The spring is divided into multiple discrete coils (first coil, second coil, third coil) that are electrically insulated from each other. Each coil segment can independently flex and compress, distributing the mechanical stress of high-frequency movement across multiple segments rather than concentrating it in a single wire, thereby preventing fatigue and breakage while maintaining flexibility
Solution Approach 2:
The spring structure is designed to dynamically accommodate movement through controlled compression and extension of its coils. The dynamic deformation of the spring allows it to absorb and dissipate mechanical energy from high-frequency reciprocating motion, preventing wire fatigue while maintaining electrical connectivity
2Reliability
If multiple discrete coils are used to provide separate electrical pathways, then reliability is improved by preventing open circuit conditions, but device complexity increases due to multiple insulating components
Solution Approach 1:
Multiple discrete coils that provide separate electrical pathways are merged into a single integrated spring structure. The first, second, and third coils are formed as part of the same spring body, eliminating the need for separate wire assemblies and reducing overall structural complexity while maintaining reliable electrical connectivity
Solution Approach 2:
The spring structure serves multiple functions simultaneously: it provides mechanical support through compression and extension, accommodates high-frequency movement through dynamic deformation, and establishes multiple separate electrical pathways through its segmented coil structure. This multi-functionality reduces the need for additional separate components
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 premature wear, extending the lifespan of devices by preventing wire fatigue and breakage.
Implementation Method 1
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.