Wound Coil Compression Connector for High-Density Electrical Interfaces
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Solution Overview
Problem
Existing electrical connectors fail to meet the increasing demand for higher current density and reliability, especially in small-scale applications, due to fragility and susceptibility to damage, and inability to maintain consistent contact force over time.
Innovation Solution
A multi-contact electrical connector design featuring conductive coils with loops that elastically deform to provide normal contact force, utilizing a body with bays and channels to position and retain the coils, ensuring high conductivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If small-scale connectors with high contact density are used, then current density increases, but the connector becomes more susceptible to damage during handling
Solution Approach 1:
The patent employs flexible wire loops instead of rigid contacts. The loops are formed from elastic conductor material that can bend and deform elastically during engagement and disengagement, providing inherent flexibility and damage resistance. This allows the connector to maintain high contact density while withstanding handling stresses that would damage rigid small-scale contacts.
Solution Approach 2:
The patent changes the mechanical parameters of the contact structure by using elastically deformable wire loops with specific wire diameters (0.002-0.005 inches) and loop dimensions. The loops are designed to deform within elastic limits during engagement, providing both high contact force and resistance to permanent damage. This parameter optimization allows simultaneous achievement of high contact density and handling durability.
2Reliability
If multiple small closely-spaced contacts are used, then conductivity increases, but the contacts become more fragile
Solution Approach 1:
The patent replaces fragile rigid contacts with flexible wire loops that can elastically deform. The loops maintain close spacing for high conductivity while their elastic nature prevents fracture during handling. The flexible structure allows the contacts to bend and return to original shape, avoiding the brittleness issues of traditional small-scale rigid contacts.
Solution Approach 2:
The patent uses composite construction where conductive wire is formed into loop structures and potentially coated or combined with elastic materials. This composite approach maintains high electrical conductivity while adding mechanical resilience and damage resistance, solving the fragility problem of small closely-spaced conductive contacts.
3Reliability
If contact force is increased to prevent separation, then connection reliability improves, but the connector becomes more susceptible to stress relaxation and creep
Solution Approach 1:
The patent optimizes the elastic parameters of the wire loops, including wire diameter, loop dimensions, and material properties, to achieve the desired contact force while remaining within elastic limits. By carefully controlling these parameters, the loops provide sufficient contact force for reliable connection without exceeding the material's elastic capacity, thereby preventing stress relaxation and creep over time.
Solution Approach 2:
The patent employs dynamically elastic wire loops that can adjust their deformation state during engagement. The loops naturally seek an equilibrium position where elastic restoring forces provide consistent contact pressure. This dynamic elastic behavior maintains stable contact force over time, resisting stress relaxation better than static rigid contact structures.
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 achieves higher contact density, mechanical reliability, and handling durability, with predictable elastic contact forces and low resistance variation across thermal cycles, supporting up to 1.5 grams of contact force per connection.
Implementation Method 1
the loops are adapted and positioned to elastically deform due to contact between a mating element and the first bight of each loop providing a contact normal force
Data Source
AI summary
A multi-contact electrical connector and method of making are provided. An embodiment of a multi-contact electrical connector includes multiple small-scale densely packed contacts in the form conductive coils with wire loops whose elastic deformation provides a normal contact force for each contact in the connectors. The connector also includes a body that is configured to position the conductive coils. In some embodiments, the body may be elongate and the wire loop may be wrapped around the elongate body. In other embodiments, the body may have channels that extend through the body in which the conductive coils are disposed.