Metal-Polymer Contact Coating for Low-Force Separable Connectors
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Solution Overview
Problem
Existing separable connector interfaces require high normal forces for stable electrical connections due to hard plated finishes, which is impractical for applications with thousands of contact pins, necessitating a solution for reliable contact resistance at low normal forces.
Innovation Solution
A metal polymer composite with conductive particles dispersed in a base polymer binder is applied to electrical contacts, reducing hardness and allowing stable contact resistance at low normal forces through increased micro-asperities for current flow, while the protective binder reduces friction and adhesive wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard plated finishes are applied to electrical contacts, then contact resistance stability and durability are improved, but the normal force required for stable connection increases
Solution Approach 1:
The patent applies a composite coating consisting of conductive particles (such as silver, gold, or copper particles) dispersed in a polymer binder matrix onto the electrical contact surfaces. This composite structure combines the electrical conductivity of metal particles with the mechanical compliance and low friction of the polymer binder, enabling stable contact resistance at lower normal forces compared to hard plated finishes.
2Duration of action of stationary object
If hard plated finishes are applied to electrical contacts, then durability and protection from environmental exposure are improved, but the mating force for connectors increases
Solution Approach 1:
The polymer binder in the composite coating provides mechanical compliance and cushioning that protects the underlying contact structure while the conductive particles maintain electrical conductivity. This composite structure achieves durability through the protective polymer matrix that resists environmental exposure, while simultaneously reducing mating force due to the compliant nature of the polymer material.
Solution Approach 2:
The patent changes the physical and mechanical parameters of the contact surface by using a soft composite coating instead of hard plating. The polymer binder provides low friction and compliance characteristics that reduce the force required for connector mating, while the conductive particles maintain adequate electrical conductivity for reliable signal and power transmission.
3Reliability
If hard plated finishes are applied to electrical contacts, then contact resistance stability is improved, but the complexity of achieving low level contact resistance at low normal forces increases
Solution Approach 1:
The composite coating combines conductive particles with a polymer binder in a single applied layer, simplifying the manufacturing process compared to multiple sequential plating operations. The conductive particles provide the necessary electrical conductivity for low contact resistance, while the polymer binder provides compliance to maintain stable contact at low normal forces, achieving both goals with a single material system.
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 metal polymer composite achieves stable and reliable low-level contact resistance (LLCR) at reduced normal forces, maintaining performance under environmental stress and reducing the risk of corrosion and wear, with lower mating forces required compared to standard plated finishes.
Implementation Method 1
The metal polymer composite includes conductive particles dispersed within a base polymer binder
Data Source
AI summary
A separable connector interface includes at least one electrically conductive element with a metal polymer composite deposited thereon. The metal polymer composite has conductive particles dispersed within a protective binder.