Electrical Contact Spring Penetrating E-Coating
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Solution Overview
Problem
Electrophoretic painting (e-coating) processes electrically isolate metallic parts in electronic assemblies, preventing electromagnetic shielding unless the electrical contact spring can penetrate the coating to establish a conductive link between them.
Innovation Solution
The electrical contact spring is designed with winged portions that penetrate the e-coating through a T-shaped aperture, providing physical and electrical contact with the underlying conductive material, eliminating the need for masking during the e-coating process and ensuring electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masking is used during e-coating to maintain electrical contact, then electrical conductivity is preserved, but manufacturing complexity and time increase
Solution Approach 1:
The contact spring is designed to self-penetrate the e-coating through its winged portions during assembly, eliminating the need for external masking operations. The spring's own structural features enable it to create its own pathway through the coating, simplifying the manufacturing process.
Solution Approach 2:
The contact spring is pre-formed with winged portions specifically designed to penetrate e-coating during installation. This preliminary structural preparation allows the spring to automatically create the necessary pathway through the coating without requiring additional masking steps during the e-coating process.
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 effectively establishes electrical contact between coated metallic parts, enabling reliable electromagnetic shielding without the need for masking, as demonstrated by the spring's ability to scrape through the e-coating with a wiping motion, ensuring consistent connectivity.
Implementation Method 1
The contact spring is configured to penetrate the e-coating with a wiping motion
Data Source
AI summary
An electrical assembly includes a planar first member formed of a first electrically conductive material defining an aperture therethrough. The assembly also includes a second member distinct from the first member that is formed of a second electrically conductive material. The assembly further includes a contact spring formed of a third electrically conductive material disposed within the aperture. The contact spring is in physical and electrical contact with the first and second members. The contact spring has a planar base portion, an arcuate portion extending from the base portion in contact with the second member, and two winged portions extending from distal edges of the base portion. The two winged portions flank the base portion. Each of the two winged portions are in contact with an inner surface of the aperture.