Connecting Element Array Coating for Small Friction Joints

Solution Overview

Problem

The existing processes for producing small-sized connecting elements with friction-increasing properties face challenges in efficient production due to high costs and inefficiencies in using electroless plating, especially for components with diameters less than 10 mm, as they require large coating bath volumes and complex racking systems.

Innovation Solution

A process involving an array of connecting elements with a support structure and metal substrates linked by holding arms, where hard particles are fixed on the surfaces with a binder layer, allowing for the production of connecting elements with diameters up to 30 mm or more, and enabling efficient coating and separation into individual elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electroless plating is used to coat small connecting elements (diameter < 10 mm), then the connecting elements can be produced with friction-increasing properties, but the production cost becomes very high and the process becomes inefficient due to large coating bath volumes and complex racking systems being required

Engineering Contradiction:

Improvefriction-increasing propertiesVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Multiple connecting elements are combined into a single array structure where they are mutually connected through holding arms. This allows them to be coated together as one unit in the electroless plating bath, eliminating the need for individual racking of each small element and significantly improving space utilization in the coating bath.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The array is designed with holding arms that can be easily separated from the connecting elements after coating. This segmentation allows the array to function as a single unit during the coating process for efficiency, then separate into individual connecting elements for application, resolving the contradiction between batch processing efficiency and individual element requirements.

Inventive Principle:

Principle #1Segmentation

2Reliability

If electroless plating is used to coat small connecting elements (diameter < 10 mm), then the connecting elements can be produced with friction-increasing properties, but the production cost becomes very high due to inefficient use of coating bath volume

Engineering Contradiction:

Improvefriction-increasing propertiesVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Multiple connecting elements are combined into a single array structure where they are mutually connected through holding arms. This allows them to be coated together as one unit in the electroless plating bath, eliminating the need for individual racking of each small element and significantly improving space utilization in the coating bath.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If connecting elements with diameter up to 30 mm or more are produced using the array method, then coating efficiency is improved and production costs are reduced, but the array structure and holding arms must be designed to accommodate larger sizes

Engineering Contradiction:

Improvecoating efficiencyVSAvoidarray structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The holding arms are designed with a universal structure that can accommodate connecting elements of various sizes, from small elements (diameter < 10 mm) to larger elements (diameter up to 30 mm or more). This modular, scalable design allows the same basic array concept to serve multiple size requirements without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach enables the production of connecting elements with enhanced static friction coefficients, suitable for various applications, including automotive electrification and microelectronic equipment, while reducing production costs and improving coating efficiency.

Implementation Method 1

hard particles fixed on the metal substrate by a binder layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

A metal substrate, e.g. a steel foil, is coated with hard particles and a metallic binder in an electroless coating bath

Methodology Applied

Scientific EffectElectroless plating:

Implementation Method 3

The size of the force which can be respectively transmitted depends not only on the structural design but also primarily on the static friction value (coefficient of static friction) of the component surfaces connected to one another

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11976679B2Process for making a connecting element for the friction-increasing connection of components, and use of a connecting element

Publication Date: 2024.05.07 3M INNOVATIVE PROPERTIES CO

AI summary

Arrays having a support structure and a plurality of connecting elements are described. Each connecting element is associated with at least one holding arm integrally linking the connecting element to at least one of (a) the support structure and (b) one or more of the other connecting elements. The connecting element of these arrays include a metal substrate having joining surfaces on opposite sides, where each joining surface has hard particles fixed on the metal substrate by a binder layer. Processes for producing such arrays and using the connecting elements are also described.