Spring-Loaded Compression Connector for Maintaining Contact Force
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Solution Overview
Problem
Compression connectors lack the capability to maintain a consistent mechanical contact load over time due to stress relaxation, metal creep, and differential thermal expansion, leading to electrical degradation and failure.
Innovation Solution
Incorporating an elastic-energy storage device, such as a resilient metal or polymeric spring, within the compression connector to generate and maintain a constant contact force by storing elastic energy during compression and releasing it to counteract degrading mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression connectors are mechanically squeezed over conductors to create electrical connection, then electrical connection is established, but mechanical contact load is lost over time due to stress relaxation and metal creep
Solution Approach 1:
The patent introduces a dynamic spring mechanism within the compression connector that continuously exerts elastic force on the conductors. Unlike static compression connectors that rely solely on initial mechanical deformation, the spring dynamically adapts to maintain constant contact pressure despite stress relaxation and metal creep over time, thereby sustaining electrical connection reliability.
Solution Approach 2:
The patent changes the mechanical parameters of the connector by incorporating a spring with specific elastic properties. The spring's force constant and material characteristics are selected to compensate for the gradual loss of contact load, transforming the connector from a static to a self-regulating system that maintains optimal electrical contact parameters throughout its service life.
2Reliability
If larger mechanical contact force is applied to reduce electrical contact resistance, then electrical contact resistance decreases, but stress relaxation and metal creep increase leading to faster loss of contact load
Solution Approach 1:
The spring mechanism provides a dynamic response to conductor deformation. As the conductors undergo stress relaxation or creep, the spring automatically adjusts its compression, maintaining the necessary contact force without requiring excessive initial force that would accelerate degradation. This dynamic adjustment stabilizes the mechanical contact load over time.
Solution Approach 2:
The spring is pre-loaded during connector assembly to establish the required initial contact force. This preliminary action ensures that the conductors are immediately subjected to sufficient compression for low electrical contact resistance, while the spring's elastic properties prevent over-compression that would cause rapid stress relaxation or metal creep.
3Device complexity
If compression connectors are designed without elastic-energy storage devices, then device complexity is reduced, but capability to maintain contact load during service is lost
Solution Approach 1:
The spring acts as a self-service mechanism within the connector, automatically compensating for contact load loss without requiring external intervention or complex control systems. The elastic-energy storage device self-regulates the contact force, maintaining electrical connection reliability through its inherent mechanical properties rather than through complex electronic or mechanical control systems.
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 approach enhances the reliability and longevity of electrical connections by maintaining a nearly constant mechanical contact load, reducing electrical resistance and resisting environmental stresses, thereby extending the service life of compression connectors.
Implementation Method 1
utilizing an elastic-energy storage device fabricated from a strong metal or a polymeric material... On compression of the sleeve/barrel of the connector over the conductor(s), the elastic-energy storage device springs back to generate and maintain a sufficiently large contact force
Implementation Method 2
to mitigate the deleterious effects of contact degradation mechanisms such as stress relaxation, metal creep, differential thermal expansion etc.
Implementation Method 3
to mitigate the deleterious effects of contact degradation mechanisms such as stress relaxation, metal creep, differential thermal expansion etc.
Implementation Method 4
to mitigate the deleterious effects of contact degradation mechanisms such as stress relaxation, metal creep, differential thermal expansion etc.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A connector having a spring inserted internally in a compression or crimp connector, or in a bolted compression connector, in contact with the electrical conductors to be connected electrically wherein the spring is capable of being mechanically deformed during compression of the connector and wherein the spring is capable of maintaining its elastic resilience and elastic springback properties to generate and maintain the required compression force on the conductor. The spring may be a metal mechanical spring or formed of a resiliently flexible material, particularly a polymeric material.