Sharp-Edged PCB Contact Design for Low Resistance Connections
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Summary
Problems
Existing contact elements, such as those with domed or spherical geometries, struggle to establish reliable and low-resistance electrical connections with metal housings made of materials like aluminum that form insulating oxide layers, leading to unstable contact transition resistances and EMC interference issues.
Innovation solutions
A contact element with a sharp edge and an S-shaped spring region is used, allowing it to penetrate the oxide layer and establish a low-resistance electrical connection by pressing against the oxidized contact surface with a high area pressure, minimizing oxide buildup and electrochemical corrosion.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If a domed or spherical contact element is used to contact the metal housing, then the contact element can be easily manufactured and assembled, but the contact transition resistance becomes unstable and high due to the oxide layer
Why choose this principle:
The contact element geometry is changed from a domed or spherical shape to a sharp-edged configuration. This parameter change in shape allows the contact element to effectively penetrate the oxide layer on the metal housing, achieving stable and low contact transition resistance while maintaining ease of manufacture through standard cutting and shaping processes.
Principle concept:
If a sharp-edged contact element is used to penetrate the oxide layer, then the contact transition resistance becomes low and stable, but the contact element requires precise manufacturing to avoid burrs that could compromise performance
Why choose this principle:
The sharp edge of the contact element is pre-formed during the manufacturing process with controlled cutting parameters that eliminate burrs before assembly. This preliminary action ensures that the contact element is ready for immediate use without requiring additional deburring operations, achieving both low contact transition resistance and manufacturing efficiency.
Application Domain
Data Source
AI summary:
A contact element with a sharp edge and an S-shaped spring region is used, allowing it to penetrate the oxide layer and establish a low-resistance electrical connection by pressing against the oxidized contact surface with a high area pressure, minimizing oxide buildup and electrochemical corrosion.
Abstract
A printed circuit board having at least one contact element is disclosed. A fixed end of the contact element is connected to the printed circuit board and a free end of the contact element includes a contact point for contacting an oxidized contact surface. An S-shaped spring region is disposed between the fixed end and the free end, defining a direction of compression of the contact point substantially perpendicular to a main extension plane of the printed circuit board. The contact point includes at least one sharp edge for penetrating an oxide layer of the contact surface. Flanks of the sharp edge are oriented oblique to the compression direction.