Electrical Contact Assembly with Planar Interface
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Solution Overview
Problem
Hertzian contact interfaces in electrical contact assemblies suffer from non-coincident mechanical and electrical distributions, leading to higher contact resistance and mechanical degradation under shear forces, especially in non-noble metal coatings.
Innovation Solution
The electrical contact assembly design ensures that the distribution of contact pressure coincides with the distribution of electrical current flow by incorporating asperity junctions where the greatest current density and normal load overlap, and utilizing periodic surface topologies with peaks and valleys to define the contact interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Hertzian contact interface is formed with curved surfaces, then the mating elements can engage each other with contact force, but the mechanical and electrical distributions are not coincident leading to higher contact resistance
Solution Approach 1:
The patent applies local quality by creating a contact interface with a substantially planar geometry instead of curved Hertzian surfaces. This planar configuration ensures that the regions of greatest mechanical contact pressure coincide with the regions carrying the greatest electrical current density, thereby improving electrical connection reliability while reducing contact resistance.
2Reliability
If a Hertzian contact interface is formed, then electrical contact is established, but shear forces cause mechanical degradation at regions with greatest current density
Solution Approach 1:
The patent employs local quality by designing a planar contact interface where mechanical contact pressure and electrical current density are spatially coincident. This configuration ensures that regions experiencing greatest electrical current also experience greatest mechanical contact pressure, which prevents mechanical degradation under shear forces by distributing stress uniformly across the contact interface, thereby improving both contact stability and mechanical durability.
3Ease of manufacture
If non-noble metal coatings are used, then cost is reduced, but higher normal load is required to penetrate oxide film
Solution Approach 1:
The patent applies parameter changes by modifying the contact interface geometry from curved Hertzian surfaces to a substantially planar configuration. This geometric parameter change increases the contact area and distributes the normal load more uniformly, reducing the peak contact pressure required to penetrate the oxide film on non-noble metal coatings. Consequently, the patent enables the use of cost-effective non-noble metal coatings while maintaining reliable electrical contact.
4Reliability
If Hertzian contact interface is used, then electrical contact is formed, but only a portion of the contact area contributes to current flow
Solution Approach 1:
The patent utilizes local quality by creating a planar contact interface where the spatial distribution of mechanical contact pressure coincides with the spatial distribution of electrical current density. This ensures that the entire contact area contributes effectively to current flow, maximizing current carrying efficiency while maintaining reliable electrical contact formation.
Data Source
AI summary
An electrical contact assembly includes a first electrical contact having a first mating element, and a second electrical contact having a second mating element. The first and second electrical contacts being configured to mate together at the first and second mating elements such that the first and second mating elements engage each other at a contact interface. A distribution of contact pressure across the contact interface at least partially coincides with a distribution of electrical current flow across the contact interface.