Solid-Lubricant Electrical Contacts for Low Friction and Stable Resistance
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Solution Overview
Problem
Existing electrical contacts face challenges in achieving a balance between low friction, high wear resistance, and stable contact resistance, with traditional lubricants often deteriorating conductivity and being costly or complex to produce.
Innovation Solution
A method for manufacturing electrical contacts involving the application of a sliding layer formed by mechanically rubbing, sputtering, or spraying a solid lubricant onto a metallic or metallized substrate, without chemical reactions, to create a tribologically advantageous surface with controlled layer thickness and particle size, enhancing tribological properties without compromising electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional lubrication methods are used to reduce friction, then coefficient of friction decreases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a self-lubricating mechanism where solid lubricant particles are applied to the contact surface and automatically distribute themselves during the contact operation. The lubricant particles embed into the contact surface and provide continuous lubrication without requiring external lubrication systems, complex application equipment, or ongoing maintenance interventions.
Solution Approach 2:
The patent uses solid lubricant particles that can be applied as a simple, inexpensive coating layer. These particles serve their lubricating function effectively and can be reapplied or replaced without requiring complex manufacturing processes, making the lubrication approach cost-effective and easily implementable.
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 method results in electrical contacts with improved tribological properties, increased temperature resistance, and stable contact resistance over high mating cycles, allowing for use at higher temperatures and under vacuum, while being cost-effective and simple to implement.
Implementation Method 1
applying a sliding layer on the metallic and/or metallized surface of the substrate (2), wherein the sliding layer (6) is formed by mechanical rubbing, polishing and/or buffing a solid lubricant; or wherein the sliding layer (6) is applied by sputtering a solid lubricant; or wherein the sliding layer (6) is applied by spraying a solid lubricant using a carrier gas
Data Source
AI summary
The present invention relates to a method for producing an electrical contact, in particular an electrical plug contact, comprising the steps of a) providing a substrate, wherein the substrate has a metallic and/or metallized surface, and b) applying a low-friction surface to the metallic and/or metallized surface of the substrate, wherein the low-friction surface is applied by mechanical rubbing, polishing and/or buffing of a solid lubricant; or wherein the low-friction surface is applied by spray application of a solid lubricant; or wherein the low-friction surface is applied by applying a solid lubricant by means of a drum washer; and wherein the low-friction surface (6) has a film thickness of 0.001 μm-4 μm.