Continuous Wireform Connector Segmented Contact Design
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving low and stable electrical resistance while being compact and durable, with conventional connectors often requiring high normal contact forces that can lead to connector failure and increased energy expenditure due to friction.
Innovation Solution
The development of multi-contact electrical connectors featuring a conductive wire with sections of peaks and valleys that form passageways, combined with loading elements that bias peaks into contact, allowing for low normal contact forces and reduced electrical resistance through a woven structure that is compliant and minimizes friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors use high normal contact forces to achieve stable electrical connection, then electrical contact reliability is improved, but device durability deteriorates due to connector failure and increased energy expenditure
Solution Approach 1:
The connector contact surface is segmented into multiple peaks and valleys, creating numerous discrete contact points. This segmentation distributes the contact force across many small points rather than requiring high force on few points, achieving stable electrical connection with lower overall normal contact force, thereby improving durability while maintaining reliability
Solution Approach 2:
The connector incorporates compliant woven structure that dynamically adapts to mating surfaces. The peaks and valleys provide dynamic contact adjustment, allowing the connector to self-align and maintain stable electrical contact through elastic deformation rather than rigid high-force contact, reducing stress and improving durability
2Reliability
If conventional connectors apply high normal contact forces to ensure stable connection, then electrical contact reliability is improved, but energy consumption increases due to friction
Solution Approach 1:
The contact surface is divided into multiple peaks and valleys, creating numerous small contact points. This segmentation reduces the friction force at each point, and since friction is proportional to normal force, the total energy expenditure for insertion and movement is reduced while maintaining reliable electrical contact through the distributed contact network
Solution Approach 2:
The connector uses a compliant woven structure with peaks and valleys that flexibly conforms to the mating surface. This flexibility reduces insertion force and friction during connection, lowering energy expenditure while ensuring stable electrical contact through adaptive conformal contact
3Volume of moving object
If conventional connectors are designed to be compact, then device size is reduced, but manufacturing complexity increases
Solution Approach 1:
The connector integrates multiple functions into a single woven structure: the peaks and valleys provide both the electrical contact surfaces and the mechanical compliance, while the woven construction itself provides both structural integrity and the desired compact form factor. This merging of functions achieves compact size without proportionally increasing manufacturing complexity
Solution Approach 2:
The connector achieves compact size by changing the geometric parameters of the wireform structure, creating peaks and valleys within a small volume. The wire diameter, peak height, and valley depth are optimized to provide sufficient electrical contact and mechanical compliance within a compact envelope, maintaining ease of manufacture through standard wireforming processes
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 solution enables a significant reduction in electrical contact resistance, increased connector reliability, and improved power density with lower insertion forces, achieving an order of magnitude reduction in normal contact forces compared to conventional connectors.
Implementation Method 1
a biasing element positioned within the passageways of the continuous wireform connector... enabling low normal contact forces
Data Source
AI summary
Apparatuses and methods of manufacturing woven electrical connectors is disclosed. In one embodiment, the connector is formed with a continuous wire having adjacent sections with passageways formed from the wire through which loading elements may be inserted. In some embodiments, the loading elements include spring band clips and/or helical spring coils.