Nested Spring Connector for Extended Mating Stroke
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Solution Overview
Problem
Designing a reliable multi-electrical contact connector for down-hole applications is complex, as existing single-contact connectors lack compatibility with existing interfaces, and accommodating increased mating strokes within constrained internal spaces is challenging, especially when trying to make multi-contact connectors compatible with single-band interfaces.
Innovation Solution
The use of a nested shuttle pin return spring mechanism, which combines two springs with different lengths and a coupling device to reduce the overall compressed length, allowing for a greater mating stroke within the original single-band space envelope, and the over-moulding of conductive cores with insulating material to create a watertight seal and multiple electrical paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-contact connector is designed to provide multiple electrical contacts, then the electrical functionality is improved, but the device complexity and internal space requirements increase
Solution Approach 1:
The patent implements a nested spring mechanism where a first spring and a second spring are positioned one inside the other within the same connector housing. The first spring is associated with a first contact element, while the second spring is associated with a second contact element. This nesting arrangement allows multiple electrical contacts to be accommodated within the same spatial envelope, effectively providing multi-contact functionality without proportionally increasing the overall connector size or structural complexity.
2Reliability
If the mating stroke is increased to accommodate multiple contacts, then the electrical contact reliability is improved, but the connector length increases
Solution Approach 1:
By nesting the second spring within the space occupied by the first spring, the patent enables both springs to contribute to the mating stroke without requiring the connector length to increase proportionally. The nested arrangement allows the cumulative effect of both springs to provide an extended mating stroke that enhances contact reliability, while the overall connector length remains constrained by the larger of the two spring lengths rather than their sum.
Solution Approach 2:
The patent transitions from a single-dimensional spring arrangement to a multi-dimensional nested configuration. Instead of placing springs in series along the length of the connector, the springs are arranged concentrically in the radial dimension, with the second spring positioned inside the first spring. This dimensional change allows the mating stroke to be extended through the combined action of both springs while maintaining a compact overall length.
3Volume of moving object
If a nested spring mechanism is used to reduce connector length, then the space utilization is improved, but the device complexity increases
Solution Approach 1:
The nested spring mechanism comprises a first spring with a first end and a second end, and a second spring with a first end and a second end. The first spring is positioned such that its second end is in contact with the second end of the second spring, creating a compact nested arrangement. This configuration maximizes space utilization by allowing both springs to occupy overlapping spatial volumes, thereby reducing the overall connector length while the mechanical coupling through end-to-end contact keeps the mechanism relatively simple.
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 solution enables a compact, reliable multi-contact connector that can be retrofitted into existing single-band connectors, reducing the overall length by approximately 50% and ensuring a watertight seal, while maintaining compatibility with existing interfaces and accommodating increased mating strokes.
Implementation Method 1
During assembly, the insulating material around the cores and in the airgap between the cores shrinks onto the conductive cores to form a watertight seal with the cores
Data Source
AI summary
An electrical connector having a first connector part and a second connector part, the first connector part with at least one electrically conductive pin and the second connector part with at least one shuttle pin, the conductive pin having two or more electrically conductive cores, each conductive core being provided with an external electrical contact and an insulating material forming a watertight seal with the conductive core and the electrical contact. The conductive cores include two or more cores spaced from one another to form the conductive pin. Facing surfaces of the two or more cores are spaced by an air gap with insulating material in the air gap and overmoulded insulating material is in contact with other surfaces of the conductive cores.