Interface Module With Spring-Loaded Contact for Fretting Corrosion
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Solution Overview
Problem
Existing interface modules fail to provide a reliable electrical connection to male contact elements, are costly due to metal coatings, and do not accommodate varying thicknesses of user identification cards.
Innovation Solution
A modular interface with a connector housing made of insulating material, featuring a sliding contact element and a spring mechanism that adjusts to different thicknesses, ensuring consistent contact and reducing fretting corrosion using less noble materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal coating is provided on the contact path to ensure thorough electrical connection, then the reliability of electrical connection is improved, but the manufacturing cost increases
Solution Approach 1:
The patent employs a sacrificial anode made of zinc or zinc alloy that is intentionally less noble than the contact path material. This sacrificial anode corrodes preferentially to maintain electrical connection reliability, replacing the need for expensive protective metal coatings on the contact paths themselves.
Solution Approach 2:
The patent introduces a sacrificial anode as an intermediary element between the contact path and the environment. This intermediary component absorbs the corrosive effects through galvanic corrosion, protecting the main contact path from degradation while maintaining reliable electrical connection.
2Adaptability or versatility
If the interface module is designed to accommodate different thicknesses of user identification cards, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The patent employs a spring element that provides elastic force to the contact element, enabling dynamic adjustment of the contact pressure. This spring mechanism automatically adapts to different card thicknesses by compressing or extending, maintaining reliable electrical connection without requiring complex adjustable mechanisms.
Solution Approach 2:
The patent changes the physical state of the contact element by making it elastic through the spring element. This allows the contact element to deform and adapt its position according to different card thicknesses, providing adaptability through material property changes rather than mechanical complexity.
3Ease of manufacture
If less noble materials are used on contact surfaces to reduce cost, then the manufacturing cost is reduced, but fretting corrosion occurs reducing connection reliability
Solution Approach 1:
The patent converts the harmful effect of using less noble (more corrosion-prone) materials into a beneficial protective mechanism. The sacrificial anode, being less noble than the contact path, is designed to corrode preferentially through galvanic corrosion, thereby protecting the main contact path from corrosion and maintaining connection reliability.
Solution Approach 2:
The patent applies preliminary anti-action by pre-positioning a sacrificial anode that will undergo corrosion in advance. This sacrificial component takes the hit of environmental corrosion before it can affect the main contact path, preventing fretting corrosion on the critical electrical connection surfaces.
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 provides a reliable, cost-effective, and adaptable electrical connection to male contact elements, preventing fretting corrosion and accommodating various card thicknesses, ensuring stable operation.
Implementation Method 1
a spring element (6) arranged opposite the contact element (4) in a direction perpendicular to the sliding surface, which is adapted to elastically abut against the male contact element (50) in the assembled state
Implementation Method 2
at least one contact element (4) received within said connector housing (2), which contact element (4) has a contact leg (30) adapted to directly abut against the respective contact path (46, 50) of the male contact element (50)
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention relates to an improved interface module providing a simple but effective way of connecting a male contact element within the interface module, which interface module shall avoid fretting corrosion even if less noble materials are provided on contact surfaces making electric contact between a contact path on the male contact element and a contact element making electrical contact with said contact path. As a solution to the above object, the present invention proposes an interface module comprising a base (14) defining a planar sliding surface (56) for a male contact element (50), a connector housing (2) made of an electrically insolating material, wherein the connector housing (2) is movably received in a receptacle (54) of the base (14), wherein the connector housing (2) receives at least one contact element (4), said contact element (4) being arranged above the sliding surface (56) and provided with a contact leg (30) projecting below a planar supporting surface (78) for the male contact element (50) defined by the connector housing (2) in a preassembled state, and wherein the connector housing (2) has an insertion opening (74) adapted to receive the male contact element (50), and further comprising a spring element (6) arranged opposite to the at least one contact element (4) in a direction perpendicular to the sliding surface (56) and adapted to a elastically abut against an underside of the male contact element (50) in an assembled state of the male contact element (50), wherein, in said assembled state, the male contact element (50) is received within the insertion opening (74) of the connector housing (2) and the at least one contact leg (30) of the contact element (4) abuts a contact surface (46) on an upside (48) of the male contact element (50).