Analysis of Connector Springs with Complex Geometry

Reliable and easy-to-use methods for the mechanical analysis of complex connector springs are described. The springs are classified according to their aspect ratio of length over thickness. Normal contact forces, insertion forces, and maximum stress are calculated for typical examples of low- and high-aspect-ratio springs. Experimental data are in good agreement with theoretical predictions. Friction can increase contact and insertion forces significantly. The contact force in insulation displacment connectors is not related to the third power of the beam length as predicted by elementary beam analysis. Correct analysis of the mechanical behavior of springs at the design stage reduces product development time and cost and helps to optimize connector performance.