Electrical Connector Contacts with Indentation for Corrosion Resistance
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Solution Overview
Problem
Electrical contacts in connectors are susceptible to corrosion due to the removal of pore-blocking substances during manufacturing or operation, which compromises their performance and durability.
Innovation Solution
The electrical contacts feature an elongated body with an indentation that retains a pore-blocking substance, allowing it to be wicked to the contact area, ensuring a sufficient amount is maintained along the exterior surface to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pore-blocking substance is applied to the exterior surface of electrical contacts, then corrosion resistance is improved, but the substance may be inadvertently removed during manufacturing or operation
Solution Approach 1:
The patent applies the preliminary action principle by pre-loading the pore-blocking substance into indentations formed on the exterior surface of electrical contacts during manufacturing. This ensures the substance is positioned and retained at critical locations before the product enters service, preventing premature loss during subsequent manufacturing or operation phases.
Solution Approach 2:
The patent implements local quality by creating indentations at specific locations on the exterior surface of electrical contacts where the pore-blocking substance is most needed. This concentrates the protective substance at critical areas rather than uniformly distributing it, maintaining corrosion resistance while reducing overall substance quantity and potential loss.
2Reliability
If the gold plating is applied to electrical contacts, then protection of underlying materials is improved, but pores form during the plating process that expose underlying materials to corrosive agents
Solution Approach 1:
The patent addresses the porosity issue by applying the local quality principle - instead of trying to eliminate all pores throughout the gold plating, it targets specific pore locations by forming indentations where corrosive agents are most likely to penetrate. The pore-blocking substance is placed locally at these critical points to seal off the harmful pathways while maintaining the overall protective function of the gold plating.
Solution Approach 2:
The patent uses the pore-blocking substance as an intermediary material between the porous gold plating and the corrosive environment. This substance fills and seals the pores in the gold plating, preventing corrosive agents from reaching the underlying materials, thus mediating the interaction between the plating structure and the external environment.
3Loss of substance
If the indentation is formed on the electrical contact, then pore-blocking substance retention is improved, but the contact geometry is modified
Solution Approach 1:
The patent minimizes the impact on overall contact geometry by applying local quality - the indentations are created only at specific locations on the exterior surface where pore-blocking substance retention is critical, rather than modifying the entire contact geometry. This localized approach preserves the overall shape and functional dimensions of the electrical contact while providing substance retention at key areas.
Solution Approach 2:
The patent uses segmentation by dividing the exterior surface of the electrical contact into distinct regions - areas with indentations for substance retention and areas maintaining original geometry for contact function. This segmentation allows the contact to simultaneously achieve substance retention and maintain appropriate geometric characteristics for electrical engagement.
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 design effectively retains a sufficient amount of pore-blocking substance on the electrical contacts, enhancing their corrosion resistance and performance by preventing exposure to corrosive agents.
Implementation Method 1
The sidewall and the contact area are joined by a transition area of the body side that is shaped to permit wicking of the pore-blocking substance from the indentation to the contact area.
Data Source
AI summary
Electrical connector including a connector housing that is configured to engage a mating connector during a mating operation. The electrical connector also includes a plurality of electrical contacts that coupled to the connector housing. Each of the electrical contacts includes a proximal base that is coupled to the connector housing and an elongated body that extends from the proximal base to a distal end. The elongated body has a body side that extends between the proximal base and the distal end and is configured to engage a corresponding mating contact of the mating connector. The body side has a stamped indentation, wherein each of the electrical contacts includes a pore-blocking substance within the corresponding stamped indentation and along a surrounding portion of the exterior surface that is adjacent to the corresponding stamped indentation.