Spring-Loaded Contact With Intermediate Object
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Solution Overview
Problem
Existing connector contacts, particularly spring-loaded contacts, face reliability issues due to manufacturing tolerances and high current flow, which can damage the spring and render the contact inoperable, especially when used for power supply or ground connections.
Innovation Solution
Incorporating an intermediate object between the plunger and the spring, with a unique shape and force distribution, to redirect current flow and prevent damage to the spring, along with easily alignable connector receptacles using adjustable brackets for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current flows through the spring in a spring-loaded contact, then the electrical connection is maintained, but the spring can be damaged or destroyed by excessive current
Solution Approach 1:
An intermediate insulating object is introduced between the spring and the plunger contact. This intermediary component redirects the current path to flow through the plunger and barrel instead of through the spring, thereby protecting the spring from current damage while maintaining electrical connection reliability
Solution Approach 2:
The contact structure is segmented into distinct functional components: the spring provides mechanical biasing force, the intermediate object provides electrical insulation and current redirection, and the plunger provides contact engagement. This segmentation allows each component to perform its specific function without being compromised by others
2Ease of operation
If connector receptacles are mounted on device enclosures, then connections can be established, but manufacturing tolerances make alignment difficult
Solution Approach 1:
Alignment features such as positioning protrusions and recesses are pre-formed on the connector receptacle and device enclosure during manufacturing. These preliminary structural features guide the connector into proper alignment before final engagement, compensating for manufacturing tolerances and eliminating the need for precise manual alignment
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
Enhances the reliability of connector contacts by protecting the spring from excessive current and facilitates easy alignment with electronic device openings, ensuring consistent and durable connections.
Implementation Method 1
a spring-loaded contact can have a contacting portion or plunger biased by a spring or other biasing structure
Implementation Method 2
The spring can thereby apply a force between the plunger and the corresponding contact to form an electrical connection
Implementation Method 3
If the contact is a power supply contact, such as a contact providing a power supply voltage or ground, the current can damage or destroy the spring thereby rendering the contact inoperable
Data Source
AI summary
Reliable contacts for connectors, connector receptacles that can be easily aligned to an opening in an electronic device, and connector inserts and connector receptacles that are readily manufactured. One example can provide a spring-biased contact having plunger extending through an opening in a barrel and biased by a spring. An intermediate object can be positioned between the plunger and the spring. The intermediate object can contact a barrel in at least two locations on the barrel.