Terminal Coil Spring Wire Routing for High Current
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Solution Overview
Problem
Existing power supply devices with coil springs cannot accommodate wires with diameters larger than the inner diameter of the coil spring, limiting their use for high current applications.
Innovation Solution
A terminal design where a coil spring is compressed within a case, with conductive members sandwiched between the coil spring and the case walls, allowing a flexible wire to be connected externally, enabling the use of thicker wires and maintaining high contact pressure with minimal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the wire is arranged inside the coil spring, then the structure is compact, but the wire diameter is limited by the inner diameter of the coil spring
Solution Approach 1:
The wire is repositioned from an internal arrangement (inside the coil spring) to an external arrangement (outside the coil spring), changing the spatial dimension of wire placement. This allows the wire diameter to exceed the inner diameter of the coil spring while maintaining structural compactness through the external routing configuration
2Power
If a thicker wire is used for high current applications, then the current carrying capacity increases, but the wire cannot fit inside the coil spring
Solution Approach 1:
By moving the wire outside the coil spring, the patent enables the use of thicker wires with larger diameters that would not fit inside the spring. This external arrangement removes the dimensional constraint imposed by the coil spring's inner diameter, allowing selection of wires based on current carrying requirements rather than spatial constraints
3Stress or pressure
If the contact portion moves a small distance, then the contact pressure is maintained, but the spring force must be very large
Solution Approach 1:
The patent divides the force transmission path into multiple segments: the coil spring generates force, the first and second conductive members transmit this force through sandwiching positions, and the contact portion delivers the concentrated pressure. The first and second conductive members act as intermediate force transmission elements that distribute and redirect the spring force, enabling effective contact pressure with moderate spring force
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
Enables the use of thicker wires than previously possible, achieving high contact pressure and efficient electrical connection without the need for larger coil springs or wire diameters, thus supporting higher current applications.
Implementation Method 1
a coil spring which is accommodated in a compressed state inside the case (20)
Data Source
AI summary
A terminal (10) includes a case (20), and a coil spring (30) is accommodated in a compressed state inside the case (20). A first conductive member (40) is sandwiched between one end of the coil spring (30) and an inner wall of the case (20) and has a contact portion (43) movable in a direction to compress the coil spring (30) farther. A flexible wire (60) is connected to the first conductive member (40) and is disposed outside the coil spring (30).