Gas Dynamic Cold Spray Electrical Contact
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Solution Overview
Problem
Existing methods for creating areas on electrical contacts with specific mechanical and electrical properties, such as increased conductivity or corrosion resistance, are costly and require complex, multi-step processes like electroplating or chemical vapor deposition, which are not very selective.
Innovation Solution
An electrical contact is created using an electrically conductive material with particles deposited onto its surface through gas dynamic cold spraying, allowing for improved mechanical and electrical properties by penetrating into the material, and optionally further coated with additional techniques like galvanic or chemical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electroplating or chemical vapor deposition is used to create areas with different properties on electrical contacts, then the desired mechanical and electrical properties (conductivity, corrosion resistance, hardness) are achieved, but the manufacturing cost increases and the process complexity increases
Solution Approach 1:
The patent changes the physical state and deposition parameters by using cold spray technology instead of traditional electroplating or CVD. Particles are accelerated to high velocities (supersonic or hypersonic speeds) and deposited in a cold, non-thermal process, fundamentally altering the deposition mechanism to achieve the desired properties without complex chemical processes
Solution Approach 2:
The patent replaces chemical deposition mechanisms (electroplating, CVD) with a mechanical/physical deposition mechanism. High-velocity particles are mechanically propelled and deposited onto the contact surface through gas dynamic cold spraying, eliminating the need for complex chemical baths and deposition controls
2Reliability
If electroplating or chemical vapor deposition is used to produce areas with specific properties on electrical contacts, then the desired surface properties are achieved, but the manufacturing cost and material expenditure increase
Solution Approach 1:
The patent utilizes high-velocity particle impact parameters to achieve deep penetration and strong adhesion. Particles are accelerated to supersonic or hypersonic speeds, causing them to deform and embed deeply into the substrate upon impact, creating a metallurgical bond with minimal material waste
Solution Approach 2:
The patent applies particle coating selectively to specific areas of the electrical contact that require enhanced properties. The cold spray process allows for localized deposition on contact surfaces, ensuring material is applied only where needed rather than coating the entire component
3Reliability
If traditional deposition methods are used to enhance contact surface properties, then the desired conductivity and hardness are achieved, but the selectivity and spatial resolution of the coating application are reduced
Solution Approach 1:
The patent replaces chemical field-based deposition with a directed mechanical particle stream. The cold spray system uses controlled gas expansion to accelerate particles along a defined trajectory, allowing precise targeting of specific contact areas with high spatial resolution
Solution Approach 2:
The patent enables selective coating of specific contact surfaces by directing the particle stream only to areas requiring enhancement. The cold spray process can be applied locally to contact tips or specific regions, achieving high spatial selectivity and avoiding unnecessary coating of other components
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
This method provides a cost-effective and selective way to enhance the durability and lifespan of electrical contacts by improving conductivity and mechanical properties without the need for wet-chemical methods, while maintaining high spatial resolution and adhesion.
Implementation Method 1
particles deposited onto its surface through gas dynamic cold spraying
Data Source
AI summary
An electrical contact comprises an electrically conductive contact material and a plurality of particles adhered to an area of the contact material. At least some of the particles have a portion penetrating into the contact material.