Irregular Contact Surface for Vibration-Resistant Electrical Connection
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Solution Overview
Problem
Existing connectors face issues with reliable electrical and mechanical contact, particularly under vibrations and tensile forces, as they tend to loosen or slip out due to inadequate contact pressure and contamination on electrode surfaces.
Innovation Solution
The introduction of an irregular shape with protrusions or depressions on the contact surfaces, extending in vertical and wiping directions, enhances contact pressure and sliding resistance, effectively preventing loosening and improving contact reliability by destroying contamination and oxide films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat contact surface is used, then the manufacturing process is simple, but the contact pressure is insufficient and the connection loosens under vibration
Solution Approach 1:
The contact surface is designed with an irregular pattern featuring protrusions and recesses instead of a flat symmetric surface. This asymmetric geometry creates localized high-contact-pressure zones that prevent loosening under vibration while maintaining manufacturing feasibility through stamping or molding processes.
Solution Approach 2:
The irregular pattern incorporates curved protrusions and recesses rather than sharp edges. These curved surfaces facilitate better metal-to-metal contact and distribute stress more effectively, preventing galling and wear while maintaining reliable electrical connection under dynamic conditions.
2Reliability
If a simple contact surface is used, then the manufacturing is easy, but contamination and oxide films remain on the electrode surface
Solution Approach 1:
The contact surface is segmented into multiple protrusions and recesses rather than a single flat plane. This segmentation creates multiple discrete contact points that collectively improve electrical connection reliability while breaking up contamination and oxide films through the irregular geometry during the crimping process.
3Reliability
If the contact surface is smooth, then the manufacturing precision is high, but the sliding resistance is low and the contact slips out
Solution Approach 1:
The irregular pattern with protrusions and recesses creates asymmetric contact interfaces that mechanically interlock during assembly. This asymmetric geometry provides inherent anti-slip characteristics and prevents lateral movement while maintaining compatibility with standard manufacturing tolerances for the overall connector assembly.
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 irregular shape design significantly increases contact pressure, stabilizes the connection, and enhances the reliability of electrical contact by ensuring better contact with the electrode surface, preventing slipping and loosening even under mechanical stress.
Implementation Method 1
providing the irregular shape in the contact section with the other member, such as the contact point section, can destruct a contamination and an oxide film on the electrode surface of the other member by the irregular shape and expose the electrode thereunder, so as to improve the reliability of electrical contact
Implementation Method 2
providing the irregular shape in the contact section with the other member, such as the contact point section, can destruct a contamination and an oxide film on the electrode surface of the other member by the irregular shape
Implementation Method 3
providing the irregular shape in the contact section with the other member, such as a pressure-contact section, leads to an increase in sliding resistance with the other member at the time of fitting the contact to the other member, so as to prevent the contact from being loosened or slipping out
Data Source
AI summary
A method for manufacturing a metal component includes the steps of forming a resist film on a surface of an electrode plate, making the resist film exposed to light by use of a photomask having a mask pattern, in at least part of a rim of which a fine concavity and convexity are drawn, developing the resist film, to form an opening for molding in the resist film, and epositing an electroforming material by electroforming inside the opening for molding, to mold the material.