Why did Hank not make a bigger beryllium copper spring? He must know about the demand, no? Or does he think the spring would not sell well?
Or maybe it is just because that at the time the small beryllium copper spring was introduced, there were almost no lights which could take advanatge of their very low resistance except for the Noctigon Meteor?
Or maybe he did just think there was no market for a bigger spring.
Edit: There are a total of 841 big springs and 277 small springs.
If the small springs reach 500-600 springs, I will ping the manufacturer to make a batch of 1000 springs.
When i have done a bypass on thick springs sometimes its too hard to press after bypass. Not a huge deal i guess but i would still end up bypassing some of these unless it was just as good as 22g wire bypass.
Thicker is always better when resistance is concerned at such high currents we do(10A+).
However, there are design limitations in the case of a compression spring for a battery, mostly memory elasticity.
From the info I have gathered, 1,3mm is probably the limit, but a bit thinner for more room for elasticity is needed. So 1.2mm will probably be what I pick if there is a small cost difference, if any since I’m ordering more than a 1000pcs.
A spring is longer run of wire though so the drop is greater. However im not sure how to calculate that when the spring is compressed. Would it take a shorter path or would it have its own resistance? A 22 gauge wire and 19 gauge wire of double the length are almost the same
You do not want a spring this size in 1.2mm wire thickness, it is too thick, will be mechanically inferior and the coils will get in each others way. 1mm is plenty thick, already thicker than most steel springs the same size out there.
Since there are so many people wanting small springs too, I will now inform the manufacturer to make a batch of smaller spring with these dimensions along with the big springs:
- Spring top diameter: 4,5mm
- Spring bottom diameter: 5mm
- Spring thickness: 0,8mm
- Spring height: 8mm
- Plating: Zinc plating
Doing this allows for lower shipping costs and lower bulk costs per spring.
If anyone wants to change something about these dimensions above, say it to me.