Gold Contact Surface with Discrete Hardness Zones for Fuel Sensors
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Solution Overview
Problem
Fuel level sensors face durability challenges due to harsh environments and high costs associated with using precious metals, particularly gold, where soft gold has a shorter service life and hard gold reduces the lifespan of silver-based resistive circuits.
Innovation Solution
An electrical connection with a second electrical conductor surface featuring discrete areas of gold with different hardness levels, where softer gold deposits on the first conductor surface while harder gold provides resistance, reducing the need for gold on the first surface and lowering costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soft gold is used for the contact surface, then electrical contact quality is improved, but service life is reduced
Solution Approach 1:
The contact surface is divided into two distinct areas with different gold hardness properties: a first area with soft gold (lower hardness) for optimal electrical contact and a second area with hard gold (higher hardness) for durability and wear resistance. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
2Duration of action of moving object
If hard gold is used for the contact surface, then service life is improved, but the lifespan of silver-based resistive circuit is reduced
Solution Approach 1:
The contact surface is segmented into two zones: hard gold in the second area provides durability and protects the silver-based resistive circuit from excessive wear, while soft gold in the first area ensures good electrical contact. This spatial differentiation eliminates the need for hard gold to contact the resistive circuit directly, preserving its lifespan.
Solution Approach 2:
The contact surface is divided into functionally distinct segments: a first area for electrical contact and a second area for mechanical durability. This segmentation allows the hard gold to be isolated from direct contact with the silver-based resistive circuit, preventing accelerated wear of the circuit while maintaining overall component longevity.
3Duration of action of moving object
If gold-based resistive circuit is used with hard gold contact surface, then service life is improved, but cost increases
Solution Approach 1:
The contact surface incorporates hard gold only in the second area where mechanical durability is needed, while the first area uses soft gold for electrical contact. This localized application of hard gold extends service life without requiring a complete gold-based resistive circuit, thereby reducing overall gold consumption and cost.
Solution Approach 2:
By segmenting the contact surface into areas with different gold hardness, the invention allows the use of silver-based resistive circuit material in contact with the hard gold area, eliminating the need for expensive gold-based resistive circuit while maintaining acceptable service life through the protective hard gold layer.
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 extends the service life of the electrical connection while minimizing gold usage, offering a more economical and durable solution for fuel level sensors.
Implementation Method 1
the softer gold becomes deposited on the first electrical conductor surface as the softer gold wears
Data Source
AI summary
An electrical connection includes a first electrical conductor assembly having a first electrical conductor with a first electrical conductor surface and a second electrical conductor assembly having a second electrical conductor with a second electrical conductor surface which is engaged with the first electrical conductor surface such that the second electrical conductor assembly and the first electrical conductor assembly reciprocate relative to each other along a path. The first electrical conductor surface and the second electrical conductor surface provide electrical communication between the first electrical conductor assembly and the second electrical conductor assembly along the path. The second electrical conductor surface has a first area of gold having a first magnitude of hardness which engages the first electrical conductor surface and also has a second area of gold having a second magnitude of hardness which is greater than the first magnitude of hardness.