Electrical Connector Precious Metal Plating Pattern
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Solution Overview
Problem
Electrical connectors require significant precious metal plating for optimal performance, which is costly and may not be feasible with reduced plating material usage without compromising electrical performance.
Innovation Solution
The electrical contacts feature a patterned outer plating with interstitial regions and cavities, reducing the amount of precious metal needed while maintaining effective engagement and conductivity through a wiping action during mating operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical contacts are plated with precious metal to enhance performance and durability, then electrical performance and corrosion resistance are improved, but manufacturing cost increases
Solution Approach 1:
The plating is applied selectively only to the exterior surface of the electrical contact that engages with the mating connector during mating operations, rather than plating the entire contact. This localized approach maintains electrical performance at the contact interface while reducing overall precious metal usage and manufacturing cost.
Solution Approach 2:
The electrical contact structure is divided into plated and non-plated regions, with the plating segmented to specific functional areas. This segmentation allows precise application of precious metal only where needed for electrical engagement, optimizing both performance and cost efficiency.
2Ease of manufacture
If the amount of plating material is reduced to lower costs, then manufacturing cost decreases, but electrical performance may be compromised
Solution Approach 1:
Instead of uniformly reducing plating across the entire contact surface, the invention applies plating locally only to the exterior engagement surface. This ensures sufficient precious metal is present where electrical contact occurs, maintaining performance while reducing overall material usage and cost.
3Productivity
If electrical contacts undergo repeated mating operations with wiping action, then connectivity is maintained, but plating material wears over time
Solution Approach 1:
The plating is concentrated on the exterior surface that undergoes wiping action during mating operations. This localized plating placement ensures that precious metal is positioned exactly where wear occurs, protecting the plating from unnecessary exposure in non-contact areas and extending the functional life of the connector through repeated mating cycles.
Data Source
AI summary
Electrical connector includes a connector housing configured to engage a mating connector during a mating operation. The electrical connector also includes a plurality of electrical contacts coupled to the connector housing. Each of the electrical contacts includes a proximal base coupled to the connector housing and an elongated body that extends from the proximal base to a distal end. The elongated body includes an outer plating that comprises a precious metal. The outer plating forms interstitial regions that define an array of cavities. The interstitial regions form an exterior surface of the corresponding electrical contact that engages a corresponding contact of the mating connector during the mating operation.