Contact Pad Surface Discontinuities for Oxide-Breaking Connections

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Solution Overview

Problem

The existing electrical connections between power-receiving and power-supplying units are unstable and inconsistent due to the formation of metal oxide layers on contact pads, which act as electrical insulators, hindering the transmission of current.

Innovation Solution

Introducing surface discontinuities on the conductive components of contact pads, such as openings, recesses, or chamfers, to create focused points of contact that increase the likelihood of penetrating the oxide layer and establishing a secure and consistent electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a planar contact pad surface is used, then the manufacturing process is simple, but the electrical connection is unstable and inconsistent due to oxide layer formation

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidcontact pad structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The contact pad surface is modified with local discontinuities (dimples, grooves, or protrusions) that create specific focal contact regions. These localized structural variations concentrate engagement force on small areas, enabling penetration of the oxide layer and direct contact with the underlying metal, thereby improving electrical connection reliability without fundamentally changing the entire contact pad structure

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The surface discontinuities are pre-formed on the contact pad during manufacturing, creating focal contact points in advance. This preliminary structuring ensures that when the connector pin engages, the force is automatically concentrated on these pre-designed weak points, facilitating oxide layer penetration and establishing reliable electrical contact before operation begins

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the contact surface area is increased, then the connection is more stable, but the oxide layer interference becomes more significant

Engineering Contradiction:

Improveelectrical connection consistencyVSAvoidoxide layer insulation effect

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of uniformly distributing contact pressure across the entire surface, the invention creates localized focal contact regions through surface discontinuities. These discontinuities concentrate the engagement force on small specific areas, enabling the connector pin to penetrate the oxide layer and reach the underlying metal, thereby overcoming the insulating effect of the oxide layer even when the overall contact area is large

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The surface discontinuities ensure continuous and consistent electrical contact by creating multiple focal contact points. This continuous focal contact maintains reliable electrical connection throughout operation, preventing intermittent connectivity issues that arise from oxide layer formation on large planar surfaces

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20240097357A1Electrical contact pads with surface discontinuities and power-receiving units and electronic devices including the same

Publication Date: 2024.03.21 ALTRIA CLIENT SERVICES LLC

AI summary

An electrical contact pad includes a conductive component having at least one surface discontinuity configured to enhance an electrical connection therewith. A power-receiving unit may include a pair of the electrical contact pads. A power-supplying unit may include connector pins configured to engage with the at least one surface discontinuity of each of the pair of electrical contact pads so as to establish an electrical connection with the power-receiving unit.