Electrical Contact Composite with Intermediate Thermal Expansion Layer
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Solution Overview
Problem
Flat electrical structures with conductive coatings, such as panel heating elements and planar antennas, experience high wear and breakage due to thermal stress from large temperature fluctuations, leading to functional failure and increased production costs.
Innovation Solution
A contact composite is developed with a sprayed metal or metal alloy layer between the conductive coating and the metal contact element, using thermal spraying methods like cold gas spraying, where the coefficient of thermal expansion of the sprayed layer is between that of the substrate and the contact element, reducing thermal stress and enhancing mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal contact element is directly connected to the electrode on the substrate, then electrical connection is achieved, but thermal stress causes high wear and breakage
Solution Approach 1:
A sprayed metal layer is introduced as an intermediary between the metal contact element and the electrode. This intermediate layer has a coefficient of thermal expansion that is intermediate between that of the substrate and the contact element, thereby reducing thermal stress and preventing breakage while maintaining electrical connection.
Solution Approach 2:
The coefficient of thermal expansion of the sprayed metal layer is specifically selected to be between the coefficients of thermal expansion of the substrate and the contact element. This parameter optimization reduces thermal stress during temperature fluctuations, preventing contact composite breakage.
2Reliability
If the contact composite is made more stable to resist thermal stress, then reliability improves, but production costs increase
Solution Approach 1:
The sprayed metal layer serves as a cost-effective intermediary that reduces thermal stress. This approach achieves improved reliability through a relatively simple spraying process rather than complex design modifications, thereby limiting the increase in production costs.
Solution Approach 2:
By optimizing the coefficient of thermal expansion parameter of the sprayed layer, the invention achieves thermal stress resistance through material selection rather than complex structural changes, keeping production costs relatively low while improving reliability.
3Stability of the object's composition
If a sprayed metal layer is added to reduce thermal stress, then mechanical stability improves, but device complexity increases
Solution Approach 1:
The sprayed metal layer is applied directly onto the existing electrode structure, adding only one intermediate layer rather than multiple complex components. This maintains relatively simple device architecture while achieving improved mechanical stability.
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 significantly reduces the risk of breakage by mitigating thermal stresses and improving mechanical stability, allowing for a more durable and reliable electrical contact composite.
Implementation Method 1
at least one sprayed layer produced by a thermal spraying method, preferably cold gas spraying
Implementation Method 2
the material of the sprayed layer has a coefficient of thermal expansion that is between the coefficient of thermal expansion of the substrate and the contact element
Data Source
AI summary
An electrical contact composite is described. The electrical contact composite has a substrate and an electrically conductive coating applied to the substrate, which coating is connected to an electrode. A metal contact element is connected to the electrode, which contact element is used to connect the conductive coating to a current/voltage source. Furthermore, at least one sprayed layer produced by means of a thermal spraying method, in particular gas dynamic cold spray, and is provided with at least one metal and/or metal alloy, the sprayed layer being arranged between the conductive coating and the contact element. The sprayed layer has a coefficient of thermal expansion that is between the coefficients of thermal expansion of the carrier and of the contact element. The sprayed layer can also be used as the electrode for the conductive coating.