contact band for busbar and for circular connectors

press in louvered contact socket for power take off in busbars

Louver_tron contact band adds value in product design

High Current Connectors are a complex subject and among several interdependent parameters, the number of contact points and reliable contact forces are key elements to electrical connectors.

weftron Louvered contacts enable product designers to add value by making High Current Connectors part of their design.

Electrical connectors are a complex subject. Among several interdependent parameters, the number of contact points and reliable contact forces are key elements to electrical connectors.
With weftron Louver_tron contact band a product designer will be given the missing link. Everything else is standard dimensional specifying of conducting cooper or brass components. All the critical parameters that make a connector function are covered by contact band. Of course, weftron will also assist in specifying those mechanical design parameters.

Basic procedure for design integration:

Two machined mating conducting surfaces are machined according to weftron recommendation. Subsequently weftron Louver_tron contact band is inserted inbetween those surfaces. Thereafter the design inherent features of weftron contact band will take over the rest that is needed for a High Performance - High Current Connector. A very dense arrangement of individually sprung contact elements will provide multiple contact points. More current paths per footprint than most other contact systems available on the market. How a multitude of low resistance contact points arranged in parallel benefit the total resistance of a contact system is quickly understood when remembering Ohm’s law. So in fact the key feature of weftron contact band is extremely low connection resistance. A feature that is very key to High Current Connectors.  But also to other applications depending on low electrical losses such as in medical or testing equipment.
As there is a toss of benefits between higher and lower contact forces, the contact force of Louver_tron contact band is easily adjusted. This is done by altering the dimensional contact chamber layout in order to suit the application’s requirement. The rest is up to creativity in product design. So instead of adopting appearance and performance to “off the shelf connectors” Louver_tron contact band enables the economical integration of High Performance Connectors right into the product.

contact band for busbar and for circular connectors

high current contact for for switchgear applications

Louvered Contact Band
- Function

Certain technical design provisions will need to be observed when using louvered contacts.  Similarly as it is the case for any mechanical spring application. So for a spring to function properly it will require a certain deflection. With no deflection there will be no spring force and no defined conduction between the two metal connector components. Over-deflection (over-compression) of the contact band elements however will damage them. Since they will be compressed into a mode of plasticity preventing the spring elements to return to their original uncompressed state.

Grooves for performance tuning

The best suited compression state of the contact elements is achieved by inserting them inside grooves. Such grooves will be machined into one of the mating metal components. The depth of this groove will limit the maximum compression of the contact spring elements. Therfore it will need to be machined with very tight tolerances. Thus achieving dependable repeatability of connector performance. In addition to spring tuning this groove will also hold the contact band in place. Different groove geometries may be chosen for certain applications.

For large socket diameters, for installations on a pin or for installation on a flat connector pair such a geometry may have the form of a dove-tail groove. For other applications it may be sufficient to use rectangular cut grooves. Although it is possible to use contact band without these grooves when taking great care to prevent uneven spring loading and over-compression during mating of the connector components this is not a recommended method for multiple mating cycles or for series applications.

With a contact band inserted and compressed between two electrically conducting components certain power transmission will be achieved.  It is safe to say that this power transmission will always be higher as compared to having a separable pin and socket connector of same size and material without using a spring element between the two. It is also safe to say that when observing best practice this level of power transmission and connector performance will be better than with most other available connector technologies.

Continue reading about the features of louvered contacts ....

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