Coated Conductive Tooth Electrical Connector for Corrosion Resistance
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Solution Overview
Problem
Conventional electrical bonding devices face challenges with corrosion susceptibility due to gaps and angles in their structure, making sealing difficult, and they often cause galvanic corrosion when used with metals of different potentials, necessitating additional sealing processes and materials.
Innovation Solution
An electrical connecting apparatus with a substantially flat body and conductive teeth having puncture points, coated with a flexible material that seals the connection when compressed, eliminating the need for post-installation sealants and reducing galvanic corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical bonding devices use serrated or pointed elements to pierce through non-conductive coatings, then electrical connection is achieved, but the device structure creates numerous gaps and spaces that make sealing difficult and increase corrosion susceptibility
Solution Approach 1:
The patent combines the electrical bonding function and sealing function into a single integrated device. The coating material is applied directly to the bonding device body, merging the sealant application step with the bonding device installation, thereby eliminating the need for separate sealing operations and reducing overall system complexity.
Solution Approach 2:
The coating is pre-applied to the bonding device before installation. This preliminary action ensures that the sealing material is already in position and properly distributed on the device surfaces that require sealing, eliminating the need for post-installation sealing operations.
2Reliability
If conventional electrical bonding devices are sealed with additional sealants during installation, then corrosion resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The bonding device and sealing coating are manufactured as an integrated unit. The coating is applied to the bonding device body during the manufacturing process, combining two previously separate manufacturing steps into one, thereby simplifying the overall manufacturing process and reducing costs.
Solution Approach 2:
The bonding device is self-sealing through the pre-applied coating. The device provides its own sealing function without requiring external sealants or additional sealing operations, making the installation process simpler and more straightforward.
3Reliability
If stainless steel bonding devices are used with other metal types, then galvanic corrosion is reduced, but the device cannot effectively pierce through non-conductive coatings on metal surfaces
Solution Approach 1:
The bonding device uses a composite structure combining stainless steel body with a specialized coating material. The stainless steel provides corrosion resistance and structural integrity, while the coating material provides enhanced cutting edges that can effectively pierce through non-conductive coatings. This composite approach allows the device to maintain galvanic corrosion resistance while achieving effective coating penetration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus provides a reliable, corrosion-resistant electrical connection that seals without additional sealants, reducing manufacturing complexity and preventing galvanic corrosion by ensuring all contact points are encapsulated, enhancing durability and performance.
Implementation Method 1
the at least one puncture point displaces the coating on the at least one puncture point
Data Source
AI summary
An electrical connecting apparatus and related systems and methods are provided. The electrical connecting apparatus includes a substantially flat body having a top surface and a bottom surface. At least one electrically conductive tooth is positioned on the body, the at least one tooth having at least one puncture point positioned beyond at least one of the top and bottom surfaces, respectively. A coating is positioned on the at least one tooth. In use, when the electrical connecting apparatus is compressed, the at least one puncture point on the at least one tooth pierces through the coating thereon.