The challenge of this project was to transfer continuous current exceeding 50A through small contact surface area, not well suited for standard spring probes. ECT developed a technical solution that gives the customer high cycle life and compressed foot print based on the Accordion compliant contact. Compared to standard spring probe solutions, the Accordion based design supports higher current and leverages more reliable surface contact.
The Accordion compliant contact is a proven solution for high density / high current applications. Accordion contacts can be integrated into a connector to provide multiple, independent current paths. The Accordion ensures low resistance and reduces power loss and therefore heat loss. Accordion contacts placed in parallel overcome contact challenges including irregular surface topography, dirt and debris, and non-parallel connection. In addition, the probe is modular. This allows varying the current capacity as required for each test point, but uses a consistent reliable design.
Tony DeRosa, Product Manager, explains: “For this customer project we designed a compliant connector with a direct current path using multiple independent current paths. We developed this innovative solution leveraging the unique advantages of our Accordion contact: flat , single piece compliant spring design for best reliability in high current applications. This customer specific solution packed several Accordion contacts together, ensuring side to side contact and specific overlapping, redundant contact points through-out the assembly. No comparable solution had been available to the customer before. It proves once more, how the team at Everett Charles Technologies combines leading-edge technology with innovation and experience to create the best solutions for our customers.”