Battery Springs & Battery Contacts
- Round Wire & Strip Material
- Commonly-Stocked Nickel-Plated Carbon Steel Battery Spring Wire, Sizes .020 Inches (.5mm) & .024 Inches (.6mm)
- Produced In Custom Materials
Battery Contact Manufacturing Specifications
While we have listed some of the most common sizes, materials and manufacturing specifications, Newcomb Spring provides completely customized production on all battery spring and battery contact parts.
- Large Volume Orders, Short Runs & Prototypes – formed, assembled and packaged to meet your requirements.
- Proprietary Camera Gauge for Superior Quality – photographs and verifies each part, automatically adjusting production without shutdown.
- Kando Tech Centers – in all 8 manufacturing facilities you can work with our team and equipment to optimize designs and lower costs.
- Engineering Support – our team can provide expert design assistance on any order, or view our online spring design resources.
Material Shapes
- Round Wire
- Square Wire
- Rectangular Wire
- Special Section Wire
Factory-Stocked Battery Contact Materials
- 020 inch (.5mm) nickel-plated carbon steel spring wire
- .024 inch (.6mm) nickel-plated carbon steel spring wire
Design Of Battery Contacts
A battery contact spring typically must perform two roles - to help provide pressure to hold batteries in place as well as to conduct electrical current from the batteries to the desired circuit. The force exerted by the spring on the battery or batteries often affects the electrical conductivity, especially where surface oxidation on the battery contacts may be present. Corrosion and oxidation, as well as the battery spring's suitability for specific soldering processes, should be considered during design.
Newcomb Spring will work with you to create an effective battery contact design for your application. With state-of-the-art equipment, a highly skilled team of spring-makers and our vast specialty material capabilities, our design assistance services can help save you time and cost on your battery springs and battery contacts.
Battery Contact Material Conductivity
Generally, materials with higher mechanical properties have lower electrical conductivity. Often they are used for battery contact manufacturing where cost is a major consideration and where the needed conductivity can be achieved with a pre-plated carbon steel, such as music wire, nickel coated or with a subsequent plating process. When high conductivity is required, as in military weapon applications and computers, the designer will want to consider battery contact materials with higher copper content, such as beryllium copper, phosphor bronze or spring brass. In certain applications, battery contacts and battery springs are sometimes plated in tin, silver or gold plated-remove as a subsequent operation, which increases conductivity even more.
View our battery contact spring conductivity chart which shows the electrical resistivity and conductivity of materials most commonly used as battery contact springs, for more information.
Materials for Battery Contacts
Newcomb Spring produces battery springs and battery contacts using a wide array of materials, and manufacturers parts to meet your custom configurations. While Newcomb Spring facilities maintain an inventory of wire specially formulated for battery springs and battery contacts, other sizes and materials can also be supplied domestically, allowing us to respond quickly to your prototype and production requirements.
Materials used in the production of battery springs and battery contact components are most commonly made from the copper alloys, and nickel plated carbon steel.
Commonly-Requested Materials
- Beryllium Copper
- Phosphor Bronze
- Spring Brass
- Stainless Steel, Type 302, Type 316 & 17-7
- Music Wire, Nickel Coated
- Customer Specified
Factory-Stocked Battery Contact Spring Material Sizes & Specs
- 020 inch (.5mm) nickel-plated carbon steel spring wire
- .024 inch (.6mm) nickel-plated carbon steel spring wire
Below are just a small selection of the compression spring shapes we have produced, including:
Battery Contacts Gallery
As a custom manufacturer of battery contacts and battery contact springs, Newcomb Spring can produce components in a virtually unlimited variety of shapes, configurations and designs. Our design assistance team can work with you to assess the manufacturing and performance considerations, as well as advise on the most cost effective process to ensure efficiency.