Stacked Metal Contact Pin with Vertical End Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrically conductive contact pins face a trade-off between wear resistance and electrical conductivity due to the need for high wear resistance materials at the end portions, which reduces overall electrical conductivity and makes it difficult to improve physical or electrical properties at the contact points.
Innovation Solution
The contact pins are designed with a structure featuring stacked horizontal metal layers and a vertical metal layer at the end portions, where the vertical layer can be made of the same or different materials, extending in the thickness direction and having higher hardness or conductivity than the horizontal layers, improving wear resistance and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal material having relatively high wear resistance is used at the end portion of the contact pin, then wear resistance is improved, but electrical conductivity is reduced
Solution Approach 1:
The contact pin is designed with a vertical metal layer at the end portion that has different material properties than the horizontal metal layers. The vertical layer uses a metal with high wear resistance for the contact surface, while the horizontal layers use metals with high electrical conductivity for current transmission. This local differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The contact pin is constructed as a composite structure with multiple metal layers stacked in different orientations. The combination of vertical and horizontal metal layers creates a composite material system that integrates the advantages of different metals - wear resistance from the vertical layer and electrical conductivity from the horizontal layers - achieving overall performance improvement.
2Strength
If the thickness of metal material having high wear resistance is increased at the end portion, then wear resistance is improved, but the content of metal material having high electrical conductivity is reduced
Solution Approach 1:
Instead of increasing the thickness of wear-resistant metal in the horizontal direction (which would reduce conductivity material content), the invention adds a vertical metal layer in the thickness direction. This dimensional approach allows the wear-resistant layer to be positioned at the contact surface without significantly reducing the overall content of conductive materials in the horizontal layers.
Solution Approach 2:
The wear-resistant metal is localized specifically at the end portion contact surface through the vertical layer, while the bulk of the contact pin maintains high electrical conductivity through the horizontal layers. This local concentration of wear resistance avoids the need to increase overall wear-resistant material thickness throughout the entire pin structure.
3Strength
If the contact pin is composed of multiple metal materials stacked vertically, then wear resistance at the end portion can be improved, but it becomes difficult to vary the metal material content specifically at the end portion
Solution Approach 1:
The contact pin is segmented into distinct vertical and horizontal metal layer components. The vertical metal layer is specifically positioned at the end portion and can be independently designed and manufactured. This segmentation allows for independent optimization of the end portion properties without being constrained by the uniform stacking of multiple metals throughout the entire pin structure.
Solution Approach 2:
By introducing a vertical layer in the thickness direction rather than relying solely on horizontal stacking, the invention creates an additional degree of freedom in material distribution. This allows the end portion to have customized material composition and properties that differ from the main body, enabling targeted improvement of physical or electrical properties at specific locations.
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
This configuration enhances the physical and electrical characteristics of the contact pins, particularly at the end portions, improving wear resistance and current carrying capacity while maintaining a balanced electrical conductivity.
Implementation Method 1
a vertical metal layer formed in a stacking direction of a plurality of horizontal metal layers... each of the first region and the second region may be formed by plating using a mold
Data Source
AI summary
Proposed are an electrically conductive contact pin formed by stacking a plurality of metal layers and a manufacturing method therefor, in which the electrically conductive contact pin has improved physical or electrical characteristics.