Low Friction Ramp Interface for Electrical Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors with metal-on-metal contacts experience significant wear and degradation due to friction, leading to increased resistance and eventual failure, particularly during repeated connect-disconnect cycles under load or hot mating conditions.
Innovation Solution
A low friction interface is introduced using a terminal plug with a housing featuring a ramp interface and a lug, where the ramp surface delays initial conductive contact and reduces the force required for connection by providing a low friction coefficient material, such as Teflon, to minimize wear and debris accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-on-metal contacts are used in electrical connectors, then electrical conductivity is achieved, but friction and wear increase significantly
Solution Approach 1:
A non-conductive ramp interface (made of materials like Teflon/PTFE) is introduced as an intermediary between the electrical contact and the connector housing. This ramp interface delays initial conductive contact and provides a low-friction surface for the electrical contact to slide along during insertion and removal, significantly reducing wear on the electrical contacts while maintaining electrical conductivity when needed.
Solution Approach 2:
The friction coefficient of the interface is changed by using a non-conductive material (such as PTFE/Teflon) with inherently low friction properties for the ramp interface. This material substitution changes the physical parameter of friction from high (metal-on-metal) to low (metal-on-polymer), reducing wear during connect-disconnect cycles.
2Ease of operation
If repeated connect-disconnect cycles are performed under load or hot mating conditions, then electrical connections are established, but contact degradation accelerates
Solution Approach 1:
The non-conductive ramp interface serves as a protective intermediary that reduces direct metal-on-metal contact during repeated connect-disconnect operations. By providing a low-friction sliding surface, it minimizes wear and material transfer even under load or hot mating conditions, thereby extending the operational life of the electrical contacts.
Solution Approach 2:
The ramp interface is positioned to engage the electrical contact before full metal-on-metal contact occurs during insertion. This beforehand cushioning effect reduces the impact and wear forces on the electrical contacts from the outset of each connect cycle, protecting them against degradation under demanding conditions.
3Object-affected harmful factors
If a ramp interface with low friction material is introduced, then wear is reduced, but device complexity increases
Solution Approach 1:
The ramp interface is integrated into the existing connector housing structure, merging the wear-reduction function with the housing itself. This integration approach adds the low-friction surface without requiring separate components or complex assemblies, thereby minimizing the increase in device complexity while achieving reduced wear.
Solution Approach 2:
The non-conductive ramp interface serves multiple functions: it provides a low-friction sliding surface to reduce wear, delays initial conductive contact for safety, and guides the electrical contact during insertion. This multi-functionality allows a single structural element to address multiple concerns without proportionally increasing complexity.
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 low friction interface extends the longevity of electrical contacts by reducing wear and material transfer, maintaining a durable and clean connection while easing the insertion and removal process, thus reducing the frequency of connector replacements.
Implementation Method 1
The coefficient of friction of the various material surfaces contributes to the force required for insertion. Teflon on Teflon provides a friction coefficient of 0.04.
Implementation Method 2
Lubricated metal can be in the range of 0.55 friction coefficient. In contrast Teflon on Teflon provides a friction coefficient of 0.04.
Data Source
AI summary
A durable low friction interface for electrical connections that delays contact between conductive materials until a substantial portion of insertion has been completed. A terminal plug embodiment and a coupling embodiment are disclosed, each containing a durable low friction interface.