Resilient Contact Element for High Current Transmission
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Solution Overview
Problem
Existing electrical connectors face challenges in providing high current capabilities while maintaining reliable connections under harsh conditions, such as high vibrations and temperature variations, due to expensive manufacturing costs, complex assembly processes, and potential for foreign object debris and disconnection issues.
Innovation Solution
A spring contact element with multiple resilient contact arms that provide increased contact points and a compact design, allowing for high amperage current transmission with low resistance and low temperature operation, and facilitating easy connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded studs and nuts are used to achieve secure electrical connection, then connection reliability is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent removes the threaded stud and nut components from the electrical connector design, extracting only the essential function of securing the contact while eliminating the complex threading mechanism. This reduces assembly complexity and manufacturing cost while maintaining connection reliability through the spring-loaded contact design.
Solution Approach 2:
The spring-loaded contact element automatically secures itself to the mating contact through resilient force, eliminating the need for separate fastening components like nuts and bolts. The contact element performs both the electrical connection and mechanical securing functions simultaneously, reducing overall device complexity.
2Power
If multiple contact points are provided to accommodate high current carrying capacity, then current capability is improved, but device complexity increases
Solution Approach 1:
The contact element is divided into multiple contact arms (first and second contact arms) that can be closely spaced to provide multiple contact points. This segmentation allows the distribution of high current across multiple parallel paths while keeping each individual contact arm simple in structure, thus managing complexity through modular design.
Solution Approach 2:
The contact arms are arranged in a compact, nested configuration where multiple arms are closely spaced within a small area. This nesting approach allows multiple contact points to be accommodated in a compact footprint, increasing current capacity without proportionally increasing device complexity or size.
3Reliability
If spring-loaded contact elements are used to achieve secure electrical connection, then connection reliability is improved, but insertion force requirements increase
Solution Approach 1:
The contact element uses a dynamic spring mechanism that provides resilient force to maintain reliable electrical connection. The spring allows for automatic adjustment and compensation, maintaining consistent contact pressure without requiring excessive insertion force, as the spring gradually engages and distributes the insertion force over the engagement stroke.
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 enables reliable high current transmission with reduced assembly complexity, lower insertion forces, and improved environmental sealing, enhancing the durability and performance of electrical connections in harsh environments.
Implementation Method 1
The first resilient contact arms extend from a first contact strip to a second contact strip. The first resilient contact arms have first contact sections and second contact sections.
Data Source
AI summary
A contact element for providing high current capabilities between an electrical contact and a mating contact. The contact element has multiple first resilient contact arms and multiple second resilient contact arms. The first resilient contact arms extend from a first contact strip to a second contact strip. The second resilient contact arms extend from the second contact strip and are formed to extend toward the first contact strip. The second resilient contact arms are offset from the first resilient contact arms, wherein free ends of the second resilient contact arms positioned proximate the first contact strip. The first resilient contact arms and the second resilient contact arms provide contact sections which allow for the passage of a high amperage current with low resistance and low temperature.