Connector Terminal Wear Resistance via Silver Hardness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional connector terminals with silver plating layers are susceptible to wear due to repeated sliding, leading to increased connection resistance, especially in applications like in-vehicle components where vibration causes sliding between terminals.
Innovation Solution
A connector terminal with an outermost layer composed of 98% or more Ag, having a Vickers hardness of 115 HV to 160 HV, which is not too hard or too soft, and an intermediate nickel layer to prevent copper diffusion, maintaining low resistance and wear resistance during repeated sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silver plating layer is used on the outermost surface to achieve low connection resistance, then the connection resistance is low, but the plating layer is susceptible to wear due to repeated sliding
Solution Approach 1:
The patent changes the physical parameter of the silver plating layer by controlling its Vickers hardness to be within 115 HV to 160 HV. This parameter optimization allows the silver layer to maintain low connection resistance while achieving sufficient wear resistance against repeated sliding, resolving the contradiction between electrical conductivity and mechanical durability.
Solution Approach 2:
The patent creates a composite structure consisting of a base material (copper or copper-base alloy) combined with a silver plating layer (98 mass% Ag or more). This composite structure leverages the high electrical conductivity of silver for low connection resistance while the controlled hardness provides wear resistance, effectively combining the advantages of both materials to resolve the contradiction.
2Strength
If the plating layer is made harder to increase wear resistance, then wear resistance improves, but the plating layer becomes too hard and may cause damage to mating terminals
Solution Approach 1:
The patent precisely controls the Vickers hardness of the silver plating layer within the range of 115 HV to 160 HV. This parameter optimization ensures the plating layer has sufficient wear resistance while remaining soft enough to avoid damaging mating terminals, effectively resolving the contradiction between wear resistance and potential harm to other components.
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 Ag-based outermost layer maintains a low resistance connection state and withstands repeated sliding without wear, ensuring a stable connection over an extended period, even under high load and vibration conditions.
Implementation Method 1
a Vickers hardness of the outermost layer with a measuring load of 0.1 N is 115 HV to 160 HV inclusive
Implementation Method 2
an intermediate nickel layer to prevent copper diffusion
Data Source
AI summary
An object of the invention is to provide a connector terminal in which an outermost layer is not susceptible to wear due to repeated sliding, an electrical wire with terminal and a terminal pair. The connector terminal includes a base material and an outermost layer provided on at least part of the base material. A constituent material of the outermost layer contains 98 mass % or more of Ag, and a Vickers hardness of the outermost layer with a measuring load of 0.1 N is from 115 HV to 160 HV inclusive.