Electrical Connector Roll Cladding Vibration Resistance

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Solution Overview

Problem

Existing electrical connectors are prone to damage under severe mechanical stresses such as vibrations, leading to unreliable electrical contacting, especially in applications requiring high reliability and frequent connection processes.

Innovation Solution

An electrical connector with a second material layer applied via roll cladding or additive manufacturing processes to the contact portion, creating a strong material-to-material bond that enhances vibration resistance without altering the connector's geometry, and includes features like plug blades and receptacles with strategically placed layers for improved contact and resilience.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating is applied by galvanizing to the base body, then the electrical properties and optical appearance are modified, but the coating is worn through by micro-movements under vibration loads

Engineering Contradiction:

Improveelectrical contacting reliabilityVSAvoidcoating wear resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies a second material layer (different from the base body material) to the contact portion surfaces through roll cladding or additive manufacturing. This creates a composite structure where the second material layer has superior wear resistance and is specifically designed to withstand micro-movements and vibrations, while the base body maintains its electrical conductivity. The material-to-material bond ensures the coating remains intact under mechanical stress.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The second material layer is applied selectively only to the contact portions of the electrical connector, not the entire base body. This localized application ensures that the enhanced wear resistance and vibration resistance are concentrated exactly where needed (at the contact surfaces subject to micro-movements), while the rest of the connector maintains its original properties and geometry.

Inventive Principle:

Principle #3Local quality

2Reliability

If the connector geometry is changed to improve vibration resistance, then the vibration resistance increases, but the existing plug connectors, housings, and interfaces cannot be used

Engineering Contradiction:

Improvevibration resistanceVSAvoidcompatibility with existing interfaces

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention modifies only the surface properties of the contact portions by applying the second material layer, while deliberately maintaining the original geometry, dimensions, and overall structure of the electrical connector. This ensures that the connector remains compatible with existing housings, interfaces, and mating connectors, allowing the solution to be implemented without requiring changes to the broader system architecture.

Inventive Principle:

Principle #3Local quality

3Strength

If a thick coating is applied to prevent wear, then the wear resistance improves, but the coating application process becomes more complex

Engineering Contradiction:

Improvecoating thickness for wear protectionVSAvoidcoating application process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces traditional galvanizing or electroplating processes with roll cladding or additive manufacturing technologies. These alternative methods enable the application of thicker second material layers with superior material-to-material bonding, specifically engineered to withstand the micro-movements and vibrations that cause conventional coatings to fail, while maintaining manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution provides enhanced resilience and reliable electrical contacting under high vibration loads and frequent use, preventing wear of the second layer and maintaining contact integrity without geometric changes or tool modifications.

Implementation Method 1

Roll cladding is carried out, for example, as cold roll cladding or hot roll cladding. In this process, the two materials to be joined are rolled between two plain rolls so that a material-to-material bond is created by high compressive normal stresses and the surface enlargements.

Methodology Applied

Scientific EffectRoll cladding:

Implementation Method 2

Additive manufacturing processes for applying the second layer may include, for example, direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser sintering (SLS), selective laser melting (SLM), metal binder jetting, or nano-particle jetting.

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 3

the layer of the second material is applied directly to the first material of the base body and, in particular, is materially bonded to the first material

Methodology Applied

Scientific EffectMaterial bonding: Welding

Data Source

PatentUS11489277B2Electrical connector and method of making an electrical connector

Publication Date: 2022.11.01 LEAR CORP

AI summary

An electrical connector includes at least one base body with at least one contact portion and at least one connection portion. The connection portion is provided for fastening an electrical conductor. The base body is made of a first material, and a layer of a second material is arranged in a surface area of the contact portion. An electrical connector that ensures reliable electrical contacting even under heavy mechanical stresses is realized by applying the layer of the second material by means of roll cladding or an additive manufacturing process.