Compression Spring Electrical Connection for Corrosion Resistance
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Solution Overview
Problem
Existing connection arrangements for solenoid valves to circuit boards are prone to fretting and chemical corrosion, especially under vibration and climatic influences, leading to unreliable electrical contacts and high production costs due to complex geometries and the need for gold plating with nickel barrier layers, which are sensitive to environmental conditions.
Innovation Solution
A connection arrangement using a mechanically prestressed compression spring with a contact end section resting against a copper-tin alloy contact plate, which is passivated with silver, eliminating the need for gold plating and allowing for axial tolerance compensation, and featuring a design that is resistant to fretting and chemical corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gold plating with nickel barrier layer is used for corrosion-resistant electrical connections, then corrosion resistance is improved, but device complexity and production costs increase due to additional barrier layers and complex geometries
Solution Approach 1:
The patent removes the nickel barrier layer from the contact structure, extracting only the essential copper-tin alloy contact plate with silver passivation. This eliminates the complex multi-layer gold-nickel-copper structure while maintaining corrosion resistance through the simplified copper-tin-silver system.
Solution Approach 2:
The patent employs a composite material system consisting of copper-tin alloy as the base material with silver passivation layer. This composite provides both mechanical strength and corrosion resistance, replacing the need for multiple metal layers (gold, nickel, copper) with a single optimized composite structure.
2Reliability
If nickel barrier layer is used to prevent diffusion, then electrical connection reliability is improved, but sensitivity to climatic conditions increases leading to cracks and local corrosion
Solution Approach 1:
The patent changes the material parameters by replacing nickel with silver passivation on copper-tin alloy. This parameter change transforms the material's chemical properties, making it resistant to climatic conditions while maintaining diffusion prevention capabilities through the passivation layer.
Solution Approach 2:
The patent uses a simpler, more robust copper-tin-silver contact structure that is less sensitive to environmental degradation. The design accepts that materials will eventually degrade but ensures the contact maintains reliability throughout the expected service life without requiring fragile barrier layers.
3Reliability
If complex spring elements and connection structures are used for reliable electrical connections, then electrical conductivity is improved, but production costs increase and installation space requirements increase
Solution Approach 1:
The contact plate serves multiple functions simultaneously: it provides electrical conductivity, mechanical support for the compression spring, corrosion resistance through silver passivation, and structural stability. This multi-functionality eliminates the need for separate complex connection structures.
Solution Approach 2:
The patent merges the electrical contact function, mechanical connection function, and corrosion protection function into a single integrated copper-tin-silver contact plate structure, replacing what would traditionally require multiple separate components.
4Ease of manufacture
If press-fit technology is used to mechanically fasten components, then ease of manufacture is improved, but reliability deteriorates due to cracks and infiltration in contact points
Solution Approach 1:
The compression spring is pre-loaded to apply continuous contact pressure on the contact plate, cushioning against any gaps or cracks that might form during press-fit assembly. This preliminary mechanical cushioning prevents infiltration and maintains contact integrity.
Solution Approach 2:
The copper-tin alloy contact plate with silver passivation provides a material composite that is more resistant to crack formation and infiltration under press-fit conditions, combining the ductility of copper-tin with the protective properties of silver.
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 solution provides a reliable, corrosion-resistant, and vibration-resistant electrical connection for solenoid valves to circuit boards, reducing production costs and maintaining electrical conductivity while being compatible with press-fit technology.
Implementation Method 1
the at least one compression spring being mechanically prestressed between the at least one solenoid valve and the circuit board
Implementation Method 2
which is passivated with silver
Data Source
Figure 1
Figure 2~5
AI summary
The invention relates to a connection arrangement (10) for electrically connecting at least one sensor (12) or actuator to at least one conductor track (22) on a printed circuit board (24), wherein the at least one sensor (12) or actuator has at least one compression spring (18) for electrically conductive connection, and the at least one compression spring (18) is arranged between the at least one sensor (12) or actuator and the printed circuit board (24) so as to have an initial mechanical stress. According to the invention, this connection arrangement (10) has provision for a contact end section (36) – facing the printed circuit board (24) – of the at least one compression spring (18) to ensure reliable electrical connection by abutting a contact plate (20, 70, 80, 90) that is electrically conductively connected to the conductor track (22). As a result, the connection arrangement (10) achieves a high level of electrical contact reliability and has outstanding resistance towards corrosion processes of all kinds, particularly towards environment-related chemical corrosion processes and frictionally corrosive processes. Furthermore, the connection arrangement (10) can also be used without difficulty in the event of parallel use of press-fit technology.