Contact Band for DiY - High Power - Low Loss connectors
Louver_tron louvered contacts allow you to integrate a high power connector into your product, adding value to your design.
Having to resort to off the shelf componets for an otherwise awsome design may be frustrating.
For adding a connector the only reason would probably be development and tooling cost.
So let's see how weftron Louver_tron contact band may help to make your design awsome again.
The function of electrical connectors is dependent on a multitude of parameters. For system performance it is best to avoid electrical connectors wherever possible. The next best option would be to bolt two conductors together. As safe as this sounds even a bolted electrical connection is not as trivial as it may appear 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 conductor and to push a conducting pin of a matching diameter into this hole. Simple yes but it would not work for very 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 such scientific details. However, one thing that most all connectors and especially separable high power electrical connectors have in common is a certain level of spring force between the mating components. These connecting components can be of circular shape as in a - pin and socket- connector or of flat shape, such as in -fork and blade- type connectors or in busbar type connectors for example. Louver_tron contact strip is suited for both. The required spring force in connectors depends on their application. There is no good or bad in spring force. High spring forces in electrical connections have advantages and issues just as low spring forces will have. With weftron louvered contacts the spring force may be optimally adopted to the application 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. The number of points where pin and socket connect will not be definable or repeatable. There will be no spring force in such a “connector” which is required to compensate for thermal, mechanical, environmental influences. lt will not work reliably or not at all after a certain time. weftron Louvered contacts will provide this missing spring element for such a self designed high power connector. And it will provide a maximum of precisely definable contact points between the two conductors. When observing certain design parameters for socket and pin an excellent high current connector with very low contact resistance may be produced from highly conducting metals such as copper, aluminum or brass. The same holds true for producing flat high power connectors such as busbar connectors. The same high current - low resistance multiple contact spring element may be applied in such a flat connector systems. In fact, connectors using weftron louvered contacts are far superior to most other high power connector systems available in the market. Louvered contact cages 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. 5000A and more for example in -power transmission and distribution- applications, as well as very low losses in test and measuring equipment or in medical devices.