Electrical Connector Contacts with ED and Precious-Metal Alloy Coatings
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Solution Overview
Problem
Existing methods for manufacturing electrical connector contacts fail to effectively prevent corrosion on contacting regions while maintaining conductivity, as they rely on partial plating with materials like plastic or resin, which may not adequately protect against environmental exposure.
Innovation Solution
The method involves forming an electrophoretic deposition (ED) coating on non-contacting regions to prevent corrosion and removing it from contacting regions, followed by applying a precious-metal-alloy coating, such as gold, nickel, or silver, on the exposed contacting areas to ensure conductivity and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electrophoretic deposition coating is applied to contacting portions, then corrosion protection is improved, but electrical conductivity deteriorates
Solution Approach 1:
The patent applies different surface treatments to different regions of the contact. The non-contacting portions receive electrophoretic deposition coating for corrosion protection, while the contacting portions are selectively removed or treated differently to maintain electrical conductivity. This local differentiation resolves the contradiction by providing corrosion protection where needed without compromising electrical contact performance.
2Reliability
If precious-metal-alloy coating is applied to contacting regions, then electrical conductivity is improved, but corrosion protection deteriorates
Solution Approach 1:
The patent combines two different coatings with distinct functions: electrophoretic deposition coating provides corrosion protection on non-contacting portions, while precious-metal-alloy coating provides electrical conductivity on contacting portions. This spatial separation of functions resolves the contradiction between corrosion protection and electrical conductivity.
Solution Approach 2:
The contact structure comprises a composite of multiple materials with different properties: the base contact material, electrophoretic deposition coating for corrosion resistance, and precious-metal-alloy coating for electrical conductivity. This composite structure allows simultaneous achievement of both corrosion protection and electrical conductivity by leveraging the strengths of each material in appropriate locations.
3Ease of manufacture
If partial plating with plastic or resin is used, then manufacturing simplicity is improved, but corrosion protection effectiveness deteriorates
Solution Approach 1:
The patent changes the material parameter from organic coatings (plastic/resin) to inorganic electrophoretic deposition coating. This parameter change maintains manufacturing simplicity while significantly improving corrosion protection effectiveness, as inorganic coatings provide superior corrosion resistance compared to organic alternatives.
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 effectively prevents corrosion on electrical connector contacts by maintaining conductivity through the precious-metal-alloy coating on contacting regions, enhancing the durability and reliability of the connectors.
Implementation Method 1
forming an electrophoretic deposition (ED) coating on the contacting portions of the row of contacts
Implementation Method 2
forming a precious-metal-alloy coating on the front regions removed of ED coating
Data Source
AI summary
A method of manufacturing electrical connector contacts includes the steps of: forming a row of contacts each having a front contacting portion, a rear soldering portion, and a securing portion between the front contacting portion and the rear soldering portion; forming an electrophoretic deposition (ED) coating on the contacting portions of the row of contacts; removing a respective front region of ED coating on the contacting portion; and forming a precious-metal-alloy coating on the front regions removed of ED coating.