Segmented Barrel Electrical Contactor for Deformation Resistance
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Solution Overview
Problem
Conventional electrical contactors face issues with unstable contact resistance and deformation during use, particularly when the central axis is tilted or the external electrode is not flat, leading to poor electrical performance.
Innovation Solution
An electrical contactor design featuring a barrel with multiple spring parts and non-spring parts arranged in a line, along with a top plunger that contacts the electrode, helps maintain verticality and reduces deformation by distributing force effectively, ensuring stable and reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the upper end of the barrel is flattened to improve contact surface, then contact area is increased, but the circular ring shape is distorted and contact resistance becomes unstable
Solution Approach 1:
The barrel is segmented into multiple spring parts and non-spring parts along its longitudinal axis. This segmentation allows the spring parts to provide elastic recovery force while the non-spring parts (particularly the upper end) maintain their shape and provide stable electrical contact, resolving the contradiction between contact area and contact resistance stability.
Solution Approach 2:
Different sections of the barrel are given different functional properties: the spring parts provide elasticity and recovery force, while the non-spring parts (especially the upper end forming the circular ring) maintain rigid shape and dimensional stability. This local differentiation allows the contact surface to remain stable while still providing sufficient contact pressure through the elastic properties of other sections.
2Force
If overdrive is increased to improve electrical contact, then contact pressure is enhanced, but deformation occurs in the spring part position
Solution Approach 1:
By dividing the barrel into spring parts and non-spring parts, the structure can withstand higher contact pressures during overdrive without deforming. The non-spring parts act as rigid support sections that resist deformation, while the spring parts provide the necessary elastic recovery force, allowing increased overdrive without compromising structural integrity.
Solution Approach 2:
The spring parts are positioned to provide elastic cushioning before the rigid non-spring parts engage with the electrode. This beforehand cushioning absorbs excess force and prevents direct transmission of high impact loads to the spring parts during overdrive, reducing the risk of deformation while still ensuring adequate contact pressure.
3Device complexity
If a single spring part is used to simplify structure, then device complexity is reduced, but deformation resistance during overdrive is insufficient
Solution Approach 1:
The barrel is divided into multiple spring parts and non-spring parts, creating a segmented structure that combines the benefits of simplicity with enhanced strength. The multiple spring parts distribute the elastic function across several sections, while the non-spring parts provide rigid support, together achieving high deformation resistance without excessive structural complexity.
Solution Approach 2:
The barrel functions as a composite structure combining elastic materials (spring parts) and rigid materials (non-spring parts) in a single component. This composite approach allows the structure to exhibit both flexibility for energy absorption and rigidity for deformation resistance, achieving high strength without proportionally increasing complexity.
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 design achieves satisfactory electrical contact performance with reduced deformation and variation in contact resistance, enhancing the reliability and consistency of electrical connections.
Implementation Method 1
the spring parts 2b and 2d of the barrel 2 store energy and exert elastic forces in the vertical direction in response to application of external force
Data Source
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AI summary
An object of the present invention is to provide an electrical contactor highly resistant to deformation capable of achieving satisfactory performance of electrical contact with a small number of elements. An electrical contactor of this invention includes a barrel having a spring part achieving a spring function formed in a partial section, and a first plunger and a second plunger inserted in the barrel through an opening at one end and an opening at an opposite end of the barrel and fixed to the barrel. It is preferable that an end part of the first plunger in the barrel and an end part of the second plunger in the barrel are placed in internal space of the same non-spring part not to achieve a spring function. It is preferable that the barrel has three or more spring parts separated while non-spring parts are placed between the spring parts.