June 11, 2013 weftsparks

Contact Band for DiY - High Power - Low Loss connectors

Louver_tron contact band allows you to integrate a high power connector into your product, adding value to your design.

The function of electrical connectors is dependent on a multitude of parameters. The best connector in an electrical system is “no connector”. Commonly it is said that the next best thing is bolting two conductors. Even a bolted electrical connection though is not as trivial as it may look on first sight, with several parameters to be observed in different environments and especially at high currents.
When choosing separable connections, the simplest form would be to have a hole in one piece of conductor and to push a conducting pin of a matching diameter into this hole. Simple yes but it would not work for long. Many papers and books have been written about electrical high power connectors and it is not the intention of this writing, to go into scientific details. One thing that most all connectors and especially a separable high power electrical connector have in common though is a certain level of spring force between the one and the other connecting component. These connecting components can be of circular shape as in a - pin and socket- connector or of flat shape, as in -fork and blade- type connectors. Louver_tron contact strip is suited for both. There is no good or bad in spring force. High spring forces in electrical connections have advantages and issues, just as low spring forces have. With Louver_tron contact band the spring force may be optimally adopted to the application in question by choosing optimized dimensional parameters for the mating connector pair.
=> Contact Band for DIY High Power Connector / Low Loss Connector.
So lets go back to the example of drilling a hole in a conducting metal component and wanting to connect a mating pin. As before mentioned, the spring force will be missing in such a “connector” and it will not work reliably or not at all after a certain time. What Louver_tron contact band does, is to offer a - very high specification multiple contact point spring element - for such a self designed high power connector. When observing certain design parameters of the machined hole (socket) and the pin, it will allow to produce an excellent high current connector with very low contact resistance. The same holds true for producing a flat high power connector arrangement. Louver_tron contact band will also enable to produce  - fork and knife- type high power connectors . It will provide the same high current - low resistance multiple contact spring element in such a flat connector systems. In fact, connectors using Louver_tron contact band are far superior to most other high power connector systems available in the market. Contact cages formed of Louver_tron contact band are used in highly critical environments. They are used in medical devices, in aerospace, military, in automotive and in - power transmission & distribution - applications. The property of very low contact resistance as mentioned in the previous post on "What is a Louver_tron contact band?" allows for very high electrical power connections. For example  5000A and more in -power transmission and distribution- applications, as well as very low losses in test and measuring equipment or in medical devices.

From a - Design Standpoint - or from a - Value Added Standpoint - what is more disturbing than having to adopt a design to an off the shelf component?

In absence of a better solution and from a cost aspect, an off the shelf connector may be the preferred way to go, if the project (quantity) does not allow to invest in tooling to produce application specific high power connectors. With weftron Louver_tron contact band a Product Designer is enabled to build a high power connector or low loss connector right into the product design. For example: A - lead in pin - for a rack and panel MCC could become an electrical grounding pin at the same time…..