Optimum design of contact springs used in registered jack connectors

In this paper, the layout and shapes of flat-surface contact springs used in a registered jack for network interfacing are optimized against plastic strain while contact force constraints satisfied using the finite element method with non-linear contact models and large deformation theories. The optimum design tasks are carried out with a help from the response surface methodology (RSM) to simplify the optimization procedure. The results have shown that the optimum design demonstrated a better mechanical performance than the original design in terms of the normal contact forces and plastic strains.