Ni-Sn Plated Connecting Material Friction Reduction
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Solution Overview
Problem
Existing materials for connecting members, such as those used in electrical contact terminals, face challenges in minimizing friction and preventing increases in contact resistance during repeated fine sliding, which can lead to oxidation and reduced reliability.
Innovation Solution
A material comprising a Ni-plated stainless steel plate with a specific roughness motif mean depth of 1.0 µm or more and a Sn plating layer of 0.3 to 5 µm thickness, where the Sn layer remains in concave portions to enhance lubricity and prevent abrasion, maintaining initial contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a Ni plating layer with smooth surface is formed on stainless steel, then manufacturing precision is improved, but friction increases and contact resistance increases during repeated sliding
Solution Approach 1:
The invention applies different surface quality requirements to different functional zones: the overall surface maintains adequate smoothness for manufacturing, while specific micro-concave portions provide localized Sn layer retention to reduce friction and maintain contact resistance. This resolves the contradiction by making different parts of the surface serve different functions.
Solution Approach 2:
The concave portions are pre-formed on the Ni plating layer before final assembly, creating predetermined zones where the Sn plating layer will be retained during sliding. This preliminary structuring ensures that when sliding occurs, the Sn layer remains in these pre-designed locations to continuously reduce friction and maintain electrical contact.
2Strength
If stainless steel is used as base material, then mechanical strength and stress relaxation resistance are improved, but friction coefficient increases during repeated sliding
Solution Approach 1:
The invention creates a composite structure with multiple layers: stainless steel base material providing mechanical strength, Ni plating layer providing adhesion and surface structure, and Sn plating layer providing low friction. The concave portions in the Ni layer create Sn-rich zones that specifically address the friction issue while the stainless steel base maintains its strength advantages.
3Reliability
If roughness motif mean depth is increased to retain Sn layer, then lubricity is improved, but manufacturing complexity increases
Solution Approach 1:
The invention optimizes the roughness motif mean depth to a specific range (0.5 µm to 2.0 µm) that provides sufficient Sn layer retention for lubricity while remaining manufacturable. This parameter optimization balances the competing requirements of surface functionality and manufacturing feasibility.
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 material effectively reduces friction and suppresses increases in contact resistance during repeated fine sliding, maintaining reliable electrical connections by preventing exposure of the stainless steel base and oxidation.
Implementation Method 1
a Sn plating layer which has a thickness of 0.3 to 5 µm is formed on the Ni plating layer
Implementation Method 2
a mean depth R of a roughness motif is 1.0 µm or more in at least one direction on a surface of the Ni plating layer
Data Source
AI summary
A connecting component material used as a material constituting a connecting component, wherein the connecting component material is obtained by using a Ni-plated metal plate in which a Ni plating layer is formed on the surface of a metal plate, and the average depth (R) of a surface roughness motif in at least one direction on the surface of the Ni plating layer is 1.0 µm or above, and by forming a Sn plating layer having a thickness of 0.3 to 5 µm on the Ni plating layer of the Ni-plated metal plate; the connection component material makes it possible to reduce friction and minimize abrasion of the material when a connecting component such as an electrical connection terminal is fitted, and to improve the reliability of a stable electrical connection; and the connecting component material can be used in e.g., electrical contact components such as lead frames, harness plugs, and connectors used in electrical and electronic devices and the like.