Optimization of the Number of Contact Springs in a Connector by means of Analytical and Numerical Analysis

In many electrical connectors multiple contact springs design is used in order to increase the stability and reliability of the contacts. By increasing the number of contact springs the number of contact points also increases and the total electrical contact resistance decreases. For a given width of the connector, the increasing number of contact springs may adversely affect the bulk resistance and the achievable normal force. The purpose of this study is to optimize the number of contact springs with regard to the total resistance of an electrical connector. The normal force, the contact resistance and the electrical conductivity of the base material are considered in order to calculate the optimal number of contact springs. An analytical model and numerical simulations by means of Finite Element Analysis (FEA) are used for calculating the electrical resistance.