Electrical Contact Element With Conductive Recesses
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Solution Overview
Problem
Electrical contact elements used in test sockets experience increased electrical contact resistance due to the removal of coating material during plane-parallel movement, leading to deteriorated conductivity and corrosion resistance over time.
Innovation Solution
The electrical contact element incorporates a base body with a first material and a coating, where areas within the contact surface are partially replaced by a second material with higher electrical conductivity, forming new contact surfaces that increase the conductive area and reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating material is applied to the base body to improve electrical conductivity and corrosion resistance, then the electrical contact properties are improved, but the coating material is removed over time due to plane-parallel movement, leading to increased contact resistance
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the base body before applying the coating material. These recesses are strategically positioned to ensure that when coating wear occurs, the underlying base material with higher conductivity is exposed, automatically compensating for coating loss and maintaining low contact resistance throughout the service life.
Solution Approach 2:
The patent utilizes parameter changes by exploiting the difference in electrical conductivity between the coating material and the base material. By controlling the depth and positioning of recesses, the patent enables a transition from coating-dominated contact (initial state) to base material-dominated contact (wear state), thereby maintaining consistent electrical properties through parameter variation.
2Manufacturing precision
If the contact area is made small to improve precision, then the contact element is more compact, but the electrical contact resistance increases significantly when coating is removed
Solution Approach 1:
The patent applies local quality by creating recesses with specific geometric characteristics (depth, width, shape) at precise locations within the contact area. This localized structural modification ensures that when coating wear occurs, the exposed base material provides sufficient conductive area, thereby maintaining low contact resistance while preserving overall contact precision.
3Strength
If a hard base material is used to improve mechanical stability, then the structural integrity is improved, but the electrical conductivity is reduced compared to soft coating materials
Solution Approach 1:
The patent applies segmentation by dividing the contact element into functionally distinct zones: a hard base material providing mechanical stability and a softer coating material providing enhanced conductivity and corrosion resistance. The recesses create interfaces between these segments, allowing each material to fulfill its primary function while compensating for the other's limitations.
Solution Approach 2:
The patent employs composite materials by combining a hard base material (e.g., metal or ceramic) with a softer coating material (e.g., gold, silver, ruthenium, or rhodium). This composite structure leverages the mechanical properties of the base material and the electrical/conductive properties of the coating material, achieving a balance between strength and conductivity.
Data Source
AI summary
The present invention relates to an electrical contact element (1), that has a plurality of contact areas (21, 22), with a base body (6) made from a first material and a coating (7) applied to the base body (6) made from a coating material. In at least one area of the base body (6) within at least one contact area (21, 22) in each case the first material is removed and is at least partially replaced by a second material. The second material and the coating material each have a higher electrical conductivity than the first material.