Woven Electrical Connector with Helical Spring Biasing
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Solution Overview
Problem
Conventional electrical connectors face challenges in achieving low and stable electrical resistance while being compact and durable, often requiring high normal contact forces that can lead to connector failure and increased energy expenditure due to friction.
Innovation Solution
The development of woven electrical connectors with conductive wires formed into a cylindrical or arcuate shape, incorporating a helically shaped biasing element and loading elements to provide a low normal contact force, ensuring efficient contact and reduced resistance through a woven structure that allows for multiple contact points and balanced loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional electrical connectors use high normal contact forces to achieve stable electrical resistance, then electrical contact resistance is reduced, but connector durability decreases and energy expenditure increases
Solution Approach 1:
The connector divides the contact interface into multiple discrete contact points arranged in a circular pattern, with each contact point independently biased by spring elements. This segmentation allows the total contact force to be distributed across multiple points, reducing the normal contact force at each individual point while maintaining stable electrical resistance through the cumulative effect of all contacts.
Solution Approach 2:
The connector employs spring elements that provide dynamic, elastic contact forces rather than rigid mechanical pressure. These springs can deform and recover, allowing the contact points to self-adjust and maintain optimal contact pressure under varying conditions, thereby achieving stable electrical resistance with lower overall force requirements and improved durability.
2Measurement precision
If conventional electrical connectors use high normal contact forces to ensure stable contact, then electrical contact resistance is reduced, but energy expenditure due to friction increases
Solution Approach 1:
By segmenting the contact interface into multiple discrete points, the connector reduces the normal contact force at each point. Since friction force is proportional to normal contact force, the friction at each contact point is reduced. The cumulative friction across all contact points is significantly lower than in conventional single-point or few-point contacts, thereby reducing energy expenditure during connector operation.
Solution Approach 2:
The spring-based biasing system provides dynamic contact forces that can optimize the balance between electrical contact quality and friction generation. The elastic deformation of springs allows for minimal sustained contact pressure, reducing static friction energy expenditure, while still maintaining sufficient contact for low electrical resistance.
3Volume of moving object
If conventional electrical connectors are designed to be compact, then device size is reduced, but achieving stable electrical resistance becomes difficult
Solution Approach 1:
The connector transitions from a linear or planar contact arrangement to a three-dimensional circular array of contact points. This dimensional change allows multiple contact points to be packed into a compact radial space, achieving both small overall connector size and stable electrical resistance through the combined effect of multiple contacts distributed around the circumference.
Solution Approach 2:
The circular array structure serves multiple functions simultaneously: it provides mechanical support, electrical contact, and force distribution. The spring elements integrated into this structure provide both mechanical biasing and electrical contact functions, eliminating the need for separate components and enabling compact design without compromising electrical performance.
4Ease of manufacture
If conventional electrical connectors use simple structures, then manufacturing is easier, but durability and stable contact are compromised
Solution Approach 1:
The connector is designed as an assembly of discrete, standardized components including spring elements, contact points, and housing segments. Each component can be manufactured independently using conventional processes, and the modular nature simplifies assembly and quality control while the combined structure provides enhanced durability through distributed stress and multiple contact paths.
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 woven connectors achieve an order of magnitude reduction in normal contact force, resulting in low and repeatable electrical contact resistance, increased durability, and improved power density with reduced risk of connector failure.
Implementation Method 1
a helically shaped biasing element disposed within the plurality of passageways to bias a plurality of peaks into contact with a mating connector when connected thereto
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c
AI summary
Apparatuses and methods of manufacturing woven electrical connectors is disclosed. In one embodiment, the connector is formed with a continuous wire (1100) having adjacent sections (1108) with passageways (1106, 1107) formed from the wire through which loading elements may be inserted. In some embodiments, the loading elements include spring band clips (1200) and/or helical spring coils (1250).