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Phosphor Bronze Conical Spring for the LED Lighting Industry

Phosphor Bronze Contact Spring
Phosphor Bronze Contact Spring

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This conical spring is used as an electrical contact in the LED lighting industry.  Design and Manufacturing Challenges included controlling the large end diameter so that the spring properly installed to the mating base plate, controlling the taper of the body so that the body coils completely nest and allow the spring to compress to a minimum solid height, maintain minimum free length variation to control load at length within a narrow tolerance and maintain minimum 10,000 cycle fatigue life without failure.


Product Name   Phosphor Bronze Conical Spring for the LED Lighting Industry
Wire   0.032" Phosphor Bronze
Outside Diameter, Body
  0.675" OD large end, 0.3125" ID small end
Total Coils   ~ 5.3
Free Length
  0.645" +/- 0.15"
Manufacturing Processes
  Coiling, low temperature stress relief
Production Speed   ~5000/hr
Low Temperature Stress Relief
  305 degrees F, 20 minutes, inline conveyor oven
  SPC for load at installed length, 10,000 cycle life test for each lot
  Bulk pack in recyclable containers
End Use
  Contact Spring in LED lighting
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