Fretting-Resistant Connector With Organic Ether Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current connectors, especially multi-way connectors for electrical signals in vehicles, face challenges with increased force requirements for insertion due to wear and oxidation of tin plating, leading to reduced fretting resistance and corrosion, and existing solutions do not effectively combine fretting and corrosion resistance simultaneously.
Innovation Solution
A fretting-resistant connector with an organic ether compound coating on electrically conductive metal terminals, specifically using dipropyl ether, allyl phenyl ether, or tetraphenyl ether, applied between 0.0001 µm and 0.1 µm thick, combined with a tin, tin-copper, or tin-silver alloy surface layer, and an intermediate nickel or copper layer, to reduce friction and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin plating is applied on metal terminals to improve corrosion resistance, then corrosion resistance is improved, but the tin wears away easily due to vibration causing oxidation and worsening electrical conduction
Solution Approach 1:
The patent applies a composite coating structure consisting of multiple layers: a base metal layer, a tin plating layer, and a fluorinated organic coating layer. This composite structure combines the corrosion resistance of tin plating with the wear and oxidation resistance of the fluorinated organic coating, solving the problem of tin wearing away due to vibration while maintaining electrical conduction.
Solution Approach 2:
The patent modifies the chemical composition of the organic coating by introducing fluorinated groups (such as CF3 and CF2 groups). This parameter change in the coating's chemical structure enhances its resistance to oxidation and wear, preventing the tin plating from wearing away easily under vibrational conditions while maintaining the desired corrosion protection.
2Adaptability or versatility
If multiple male and female terminals are designed to be inserted simultaneously in a multi-way connector, then connectivity is improved, but the insertion force becomes too large requiring special tools
Solution Approach 1:
The patent changes the friction characteristics of the terminal surfaces by applying a fluorinated organic coating with low surface energy. This parameter change in surface properties reduces the coefficient of friction between mating terminals, thereby reducing the insertion force required for simultaneous multi-way connection while maintaining reliable electrical contact.
3Volume of moving object
If space is reduced between male and female terminals to maintain compact design, then size is reduced, but insertion force increases and fretting resistance decreases
Solution Approach 1:
The patent employs a composite coating system that includes a fluorinated organic coating layer over the tin plating. This composite structure provides enhanced fretting resistance through the durable fluorinated outer layer, allowing reduced spacing between terminals while maintaining reliability even under compact dimensions.
Solution Approach 2:
The fluorinated organic coating changes the tribological parameters of the terminal surface, providing low friction and high wear resistance. This parameter change enables the connector to maintain fretting resistance with reduced terminal spacing, as the coating protects against wear and oxidation in the tighter configuration.
4Reliability
If surface active agents are applied to improve solder wettability, then wettability is improved, but the agents bind to moisture and acidic substances causing discoloration and corrosion
Solution Approach 1:
The patent uses a composite coating structure where the fluorinated organic coating layer is applied over the tin plating. This composite approach provides solder wettability through the fluorinated groups while the stable fluorocarbon backbone resists binding to moisture and acidic substances, preventing discoloration and corrosion that plague traditional surface active agents.
Solution Approach 2:
The patent changes the chemical composition of the organic coating by introducing fluorinated groups (CF3 and CF2) which provide both solder wettability and resistance to environmental degradation. This parameter change in chemical composition allows the coating to maintain wettability without the harmful side effects of conventional surface active agents.
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 significantly reduces the force required for insertion while enhancing fretting and corrosion resistance, maintaining electrical conductivity and preventing oxidation, even under vibration and temperature variations.
Implementation Method 1
wherein the organic coating is provided into the tin, the tin-copper alloy, the tin-silver alloy, or the tin-silver-copper alloy with adsorption of the organic coating
Implementation Method 2
there becomes easier for such the tin that is plated on a surface thereof to be worn away as easily and then to be oxidized due to a slight vibration thereon
Data Source
Figure 1~3
Figure 4~5
AI summary
A fretting-resistant connector, having an organic coating that is formed of an organic compound which has an ether linkage group at least a part on a surface of an electrically conductive metal material.