Large deflection canted coil springs, connectors, and related methods

1. A connector assembly comprising:

a housing comprising a bore with a housing groove with a groove bore diameter X;

a pin with a pin body comprising a pin diameter;

a canted coil spring comprising a plurality of interconnected coils each with a large range of deflection, a coil base having a coil width, and a coil height, said canted coil spring being disposed in said bore of said housing;

wherein said coil width has a length dimension that is less than a length dimension of said coil height;

wherein said pin is located in said bore of said housing and said plurality of interconnected coils of said canted coil spring are deflected along each respective coil height by said pin while each respective coil base contacts said housing groove; and

wherein the canted coil spring with the plurality of interconnected coils each with the large range of deflection is configured to receive the pin diameter having any dimension within about 0.4X to about 0.89X.

2. The connector assembly according to claim 1 , wherein the coil base has a straight length.

3. The connector assembly according to claim 1 , wherein the coil height can have a length that is about 1.4 to about 5 times larger than a length of the coil base.

4. The connector assembly according to claim 1 , wherein said canted coil spring is a triangular spring in which each coil of said plurality of interconnected coils has a triangular shape with the coil base and a tipping joint.

5. The connector assembly according to claim 4 , wherein each coil has a hypotenuse providing an entry chamfer for said pin.

6. The connector assembly according to claim 4 , wherein said pin has a pin groove with a width and wherein said housing groove has a width and wherein the width of the housing groove is wider than the width of the pin groove.

7. The connector assembly according to claim 1 , wherein said pin comprises a pin groove.

8. The connector assembly according to claim 7 , wherein said canted coil spring latches onto said pin groove.

9. The connector assembly according to claim 1 , wherein said coil base is in contact with a bottom surface of said housing groove.

10. The connector assembly according to claim 9 , wherein said bottom surface is located between two side walls and wherein at least one of the two side walls is angled relative to a lengthwise axis of the pin.

11. The connector assembly according to claim 4 , wherein said tipping joint is located in a pin groove of the pin to latch the pin to the housing.

12. The connector assembly according to claim 11 , wherein the pin is separable from the housing when the pin is moved in a second direction, which is opposite a first direction to latch the pin to the housing.

13. A method of making a connector assembly for use with a range of pin sizes comprising:

providing a housing with a bore and a housing groove having a groove bore diameter X;

providing a canted coil spring comprising a plurality of interconnected coils each with a large range of deflection, a coil base having a coil width, and a coil height, said canted coil spring being disposed in said bore of said housing and in said housing groove, and wherein said coil width has a length dimension that is less than a length dimension of said coil height;

inserting a pin having a pin diameter into the bore of said housing and deflecting said canted coil spring along the respective coil height of each of the plurality of interconnected coils by said pin while each respective coil base contacts said housing groove; and

wherein the canted coil spring with the plurality of interconnected coils each with the large range of deflection is configured to receive the pin diameter having any dimension within about 0.4X to about 0.89X.

14. The method of claim 13 , wherein said canted coil spring is a triangular spring in which each coil of said plurality of interconnected coils has a triangular shape with the coil base and a tipping joint.

15. The method according to claim 14 , wherein each coil has a hypotenuse providing an entry chamfer for said pin.

16. The method according to claim 14 , wherein said tipping joint is located in a pin groove of the pin.

17. The method according to claim 13 , wherein said pin comprises a pin groove.

18. The method according to claim 17 , wherein said canted coil spring latches onto said pin groove.

19. The method according to claim 13 , wherein said coil base is in contact with a bottom surface of said housing groove.

20. The method according to claim 19 , wherein said bottom surface is located between two side walls and wherein at least one of the two side walls is angled relative to a lengthwise axis of the pin.

21. A connector assembly comprising:

a housing comprising a bore with a housing groove with a groove bore diameter X;

a pin with a pin body comprising a pin diameter and a pin groove disposed in said bore;

a set gap between said housing and said pin;

a canted coil spring comprising a plurality of interconnected coils each with a large deflection range, a coil width defined by a straight segment, and a coil height disposed in said bore of said housing;

wherein said canted coil spring is located between said housing and said pin and in contact with said housing groove and said pin groove with said coil width of each coil in contact with said pin groove or said housing groove;

wherein said coil width is less than said coil height; and

wherein the pin diameter has any dimension within about 0.4X to about 0.89X, and wherein the large deflection range of the plurality of coils of the canted coil spring deflects to accommodate the pin having the any dimension within about 0.4X to about 0.89X.