Terminal Conductive Pin Coating for Corrosion-Resistant Bent Contacts
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Solution Overview
Problem
Existing methods for manufacturing terminal conductive pins for contactors fail to effectively cover the bent and contact parts with a coating layer, leading to corrosion issues in salt fog environments.
Innovation Solution
A method involving pre-electroplating a blank at a first temperature, followed by reflow plating at a second, higher temperature to form a coating layer, and then stamping the blank to create a terminal conductive pin with the coating layer covering the bent and contact parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blank is electroplated before stamping, then the coating layer can be formed on the surface, but the stamping process destroys the coating layer on bent parts and contact parts
Solution Approach 1:
The patent applies preliminary electroplating to form the coating layer on the blank surface before stamping. This preliminary action ensures that the coating layer is established in advance, and subsequent stamping processes can then form bent parts and contact parts while the coating layer is subsequently restored through reflow plating to ensure complete coverage including on bent and contact parts.
2Reliability
If the blank is stamped first and then electroplated, then the coating layer can be applied, but it is not easy to form the coating layer on bent parts and contact parts
Solution Approach 1:
The patent performs electroplating as a preliminary action before stamping to create the coating layer on the blank surface. This approach allows the coating material to be applied to the entire surface including areas that will later become bent parts and contact parts, ensuring comprehensive coverage that would be difficult to achieve if electroplating were performed after stamping.
Solution Approach 2:
The patent utilizes reflow plating with temperature parameter changes to restore and complete the coating layer formation. By controlling the temperature during reflow plating, the coating material is melted and redistributed to ensure complete coverage on bent parts and contact parts that were affected by the stamping process.
3Shape
If stamping is performed after electroplating, then the conductive pin shape is formed, but the coating layer on bent parts and contact parts is destroyed or incomplete
Solution Approach 1:
The patent applies electroplating as a preliminary action before stamping to form the coating layer on the blank surface. This preliminary coating application ensures that all surfaces, including those that will become bent parts and contact parts, are covered with coating material before the stamping process deforms the blank into its final conductive pin shape.
Solution Approach 2:
The patent employs reflow plating that utilizes phase transition of the coating material from solid to liquid state through temperature control. This phase transition allows the coating material to flow and completely cover the bent parts and contact parts after stamping, restoring and ensuring complete coating coverage on the formed conductive pin geometry.
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
Ensures complete coverage of the coating layer on the bent and contact parts, enhancing corrosion resistance and reducing manufacturing costs.
Implementation Method 1
pre-electroplating the blank at a first temperature; reflow plating the blank at a second temperature different from the first temperature to form a coating layer on a surface of the blank
Implementation Method 2
reflow plating the blank at a second temperature different from the first temperature to form a coating layer on a surface of the blank
Data Source
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AI summary
A method for manufacturing a terminal conductive pin for a contactor, a terminal conductive pin and a contactor. The method includes: providing a blank; pre-electroplating the blank at a first temperature; reflow plating the blank at a second temperature different from the first temperature to form a coating layer on a surface of the blank; and stamping the blank with the coating layer to form the terminal conductive pin including at least one bent part, the coating layer completely covers a surface of the at least one bent part.