Spring Connector with Multi-Point Plate Spring Contact
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Solution Overview
Problem
Existing spring connectors generate excessive heat and risk burning due to concentrated current flow, as they rely on a single main electrical contact between the movable pin and conductive tube, leading to stress deterioration in the spring.
Innovation Solution
A spring connector design featuring a plurality of plate springs around the movable pin's circumference for multiple-point electrical contact with the conductive tube, combined with an insulator to prevent current flow to the spring, dispersing current and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single main electrical contact is used between the movable pin and conductive tube, then the structure is simple, but high temperature heat is generated when used at high current
Solution Approach 1:
The single main electrical contact is segmented into multiple plate spring contacts (first plate spring contact and second plate spring contact) that are disposed at different angular positions around the movable pin. This segmentation distributes the electrical current across multiple contact points, reducing current density and heat generation at each individual contact while maintaining structural simplicity through the use of integrated plate spring components.
2Device complexity
If a single main electrical contact is used between the movable pin and conductive tube, then the device structure is simple, but the spring stress deteriorates due to heat generation
Solution Approach 1:
The electrical contact function is segmented into multiple plate spring contacts that distribute electrical current and associated heat across multiple locations. This reduces the thermal load and stress concentration on any single spring, thereby improving reliability and preventing spring deterioration while keeping the overall device structure relatively simple through integrated plate spring design.
Solution Approach 2:
The electrical contact is extended from a single-point contact in one dimension to multiple contacts distributed around the circumference of the movable pin in another dimension (angular/rotational dimension). This dimensional expansion distributes the electrical and thermal loads across multiple spatial locations, reducing stress on individual springs and improving overall reliability.
3Temperature
If multiple plate springs are provided around the entire circumference of the movable pin, then heat generation is prevented through current dispersion, but the device complexity increases
Solution Approach 1:
The electrical contact system is segmented into multiple discrete plate spring contacts positioned at different angular locations around the movable pin. This segmentation effectively disperses electrical current and reduces heat generation at any single contact point. The complexity is managed by integrating these plate springs into a unified contact assembly that maintains structural coherence while providing multiple contact points.
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 effectively prevents heat generation and reduces the risk of spring burning by dispersing current through multiple-point contacts and insulating the spring from electrical flow, thereby maintaining spring integrity under high current conditions.
Implementation Method 1
a spring provided in the conductive tube so as to urge the movable pin in a direction, in which the movable pin protrudes from the conductive tube
Implementation Method 2
a plate spring contact including a plurality of plate springs that electrically connect the movable pin and the conductive tube to each other
Implementation Method 3
the plurality of plate springs are provided around an entire circumference of the movable pin and are in elastic contact with an inner circumferential surface of the conductive tube
Implementation Method 4
an insulator that urges a fixing portion of the plate spring contact against the movable pin in the conductive tube by receiving a biasing force of the spring
Data Source
AI summary
A spring connector includes a movable pin, a conductive tube accommodating a base portion of the movable pin, a spring provided in the conductive tube so as to urge the movable pin in a direction, in which the movable pin protrudes from the conductive tube, and a plate spring contact including a plurality of plate springs that electrically connect the movable pin and the conductive tube to each other. The plurality of plate springs are provided around an entire circumference of the movable pin and are in elastic contact with an inner circumferential surface of the conductive tube, respectively.