Metal Mesh Electrical Contact with Bonding Layer for Rust Prevention
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Solution Overview
Problem
Existing key switch contacts with thin metal plates face contact failure due to dust and irregularities, while metal mesh contacts suffer from rusting and bonding issues.
Innovation Solution
An electrical contact with a metal mesh layer covering the outer and side surfaces of an elastic core body, combined with a bonding layer to prevent rust and enhance bonding, forms a conductive uneven surface for reliable contact and reduces exposure of cut edges to air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin metal plate contact with flat surface is used, then the structure is simple and easy to manufacture, but contact failure occurs when dust or irregularities are present on the contact surface
Solution Approach 1:
The invention replaces the flat contact surface with a curved surface covered by a metal mesh layer. The metal mesh forms an uneven, flexible surface that can adapt to irregularities and dust on the opposing contact surface, ensuring reliable electrical contact while maintaining manufacturing simplicity.
Solution Approach 2:
The metal mesh layer acts as a flexible thin film that can deform to conform to the opposing contact surface. This flexibility allows the contact to maintain good electrical connection even when dust or irregularities are present, resolving the reliability issue while keeping the structure simple.
2Reliability
If a metal wire, metal ribbon or metal mesh is embedded on the surface to form conductive uneven surface, then contact reliability is improved with multiple contact points, but the cut edge surface of the plated metal mesh is exposed to air causing rusting
Solution Approach 1:
A protective film layer is applied over the metal mesh layer to seal and protect the cut edge surfaces from air exposure. This prevents rusting while maintaining the flexible, conformable properties of the metal mesh that ensure reliable contact.
Solution Approach 2:
The invention creates a composite structure with multiple layers: the metal mesh layer provides electrical conductivity and flexibility, while the protective film layer provides corrosion resistance. This composite approach solves both the reliability and rusting problems simultaneously.
3Reliability
If metal mesh is used to provide multiple contact points, then contact reliability is improved, but bonding operation to key top becomes difficult
Solution Approach 1:
The protective film layer serves dual functions: it protects the metal mesh from rusting and provides a suitable bonding surface for attaching the contact to the key top. This resolves the bonding difficulty while maintaining the reliability benefits of the metal mesh structure.
Solution Approach 2:
The composite structure with the protective film layer provides both corrosion protection and improved bondability. The film layer creates a stable outer surface that is easier to bond to the key top compared to the raw metal mesh, while the underlying metal mesh maintains electrical reliability.
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 multiple contact points for reliable conduction, prevents rusting of the metal mesh, and enhances the bonding operation between the contact and the key top, ensuring effective electrical connectivity and durability.
Implementation Method 1
the metal mesh layer flexes along the other contact surface to obtain electrical conduction between the contacts
Implementation Method 2
the edge (cut surface) of the metal mesh is rarely exposed to air... the cut surface may begin to rust along a portion in contact with air. Accordingly, by covering the cut surface with the bonding layer, the rusting can be prevented
Data Source
AI summary
An electrical contact (1) that comprises a core body (3) made from elasticmaterial and having outer, inner and side surfaces, a metal mesh layer (5) extending to the outer and sidesurfaces of the core body (3) and a bonding layer (7) covering the edge of the metal mesh layer (5) at the side surface of the core body (3). Since the metal mesh layer (5) is provided to the outer surface (contact surface) of the core body (3), the outer surface comes in contact with the other contact surface with a number of contact points. By providing the bonding layer (7), the edge (cut surface) of the metal mesh (5) is rarely exposed to air and the rusting which occurs easily at the edge can be prevented. And, the bonding layer (7) has a function for preventing the key top material from coming into around the outer surface of the electrical contact at the process for attaching the contact (1) to the key top. Accordingly, an electrical contact capable of having a number of contact points, such as a metal mesh, prevents rust of the metal mesh and further failure of a bonding operation to a key top of a key switch can be provided.