Nickel-Cobalt Alloy Contact for Short-Stroke Connectors
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Solution Overview
Problem
Current contact materials fail to achieve a balance between providing necessary contact force with a short stroke, high conductivity, corrosion resistance, and preventing copper damage, limiting their versatility in applications such as portable phone connectors.
Innovation Solution
A nickel-cobalt alloy composition with 1% to 20% cobalt and 0.002 to 0.1 parts by weight of sulfur per 100 parts of the alloy, having an average particle size of 0.07 to 0.35 micrometers, is used to create a contact material with high Young's modulus, 0.2% proof stress, and conductivity, while preventing copper damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the stroke of the contact is made shorter to reduce connector height, then the connector size is reduced, but the contact force becomes insufficient
Solution Approach 1:
The patent changes the material parameters of the contact by using a nickel-cobalt alloy with specific composition ranges (Co: 1-20%, S: 0.002-0.1 parts by weight per 100 parts alloy) and controlled average particle size (0.07-0.35 μm). This material parameter optimization enables the contact to achieve high Young's modulus and high strength, allowing sufficient contact force to be generated even with a shortened stroke, thus resolving the contradiction between reduced connector height and maintained contact force
Solution Approach 2:
The patent employs a composite nickel-cobalt-sulfur alloy material system that combines the advantages of nickel (high strength, corrosion resistance) with cobalt (high Young's modulus, wear resistance) and sulfur (solid solution strengthening). This composite material approach creates a contact material with superior mechanical properties, enabling short-stroke contacts to deliver adequate contact force while reducing overall connector height
2Ease of manufacture
If conventional materials are used for the contact, then manufacturing is simple, but the contact cannot simultaneously achieve high conductivity, high strength, corrosion resistance, and prevention of copper damage
Solution Approach 1:
The patent develops a multi-element nickel-cobalt-sulfur alloy that integrates multiple functional properties within a single material system. The nickel base provides conductivity and corrosion resistance, cobalt enhances strength and Young's modulus, and sulfur provides solid solution strengthening. This composite material approach achieves high conductivity, high strength, corrosion resistance, and copper damage prevention simultaneously, while the electroforming manufacturing process maintains ease of production
Solution Approach 2:
The patent optimizes the compositional parameters of the alloy within specific ranges (Co: 1-20%, S: 0.002-0.1 parts by weight per 100 parts alloy) and controls the average particle size (0.07-0.35 μm) to achieve the desired balance of properties. By precisely controlling these material parameters, the contact achieves versatile performance including high conductivity, high strength, corrosion resistance, and resistance to copper damage, while maintaining compatibility with existing electroforming manufacturing processes
Data Source
AI summary
A composition for making a contact includes a nickel-cobalt alloy containing 1% by weight or more to less than 20% by weight of cobalt, and 0.002 part by weight or more to 0.1 part by weight or less of sulfur with respect to 100 parts by weight of the nickel-cobalt alloy. The composition has an average particle size of 0.07 μm or larger to 0.35 μm or smaller.