Slip Ring Component Fabrication via Immersion Plating
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Solution Overview
Problem
Rotating components pose challenges for electrical connectors as they can become twisted or tangled, leading to connection failures, and existing connectors with internal rotors and stators are costly and labor-intensive to fabricate.
Innovation Solution
A slip ring component fabrication process involving a first shot and a second shot, where the second shot is immersion-bathed with electrically conductive plating, allowing for efficient electrical connection between rotating and stationary parts using a rotatable portion and a stationary housing, with the first shot being non-plateable and the second shot being plateable, reducing material costs and fabrication complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors with internal rotors and stators are used, then reliable electrical connection is achieved, but fabrication cost and labor intensity increase
Solution Approach 1:
The connector is divided into a stationary housing and a rotatable component, allowing independent fabrication and assembly. The stationary housing contains conductive paths molded into its structure, while the rotatable component carries contacts that engage with these paths, simplifying the overall fabrication process while maintaining reliable electrical connection.
Solution Approach 2:
Traditional mechanical wiring between rotating and stationary parts is replaced with a slip ring mechanism. The conductive paths are molded directly into the stationary housing, eliminating the need for complex mechanical wire connections and reducing fabrication labor while ensuring reliable electrical transmission.
2Reliability
If expensive materials are used for rotor and stator components, then electrical connector performance is improved, but overall cost increases
Solution Approach 1:
Conductive properties are localized only where needed - specifically in the conductive paths molded into the stationary housing and the contact points on the rotatable component. The majority of the connector structure uses standard, cost-effective materials, while electrical conductivity is provided only in the specific regions required for signal transmission.
Solution Approach 2:
The stationary housing is fabricated as a composite structure combining insulating material with molded-in conductive paths. This allows the use of inexpensive base materials for the housing while incorporating conductive elements only where electrical connection is required, reducing overall material cost while maintaining performance.
3Ease of manufacture
If wire connections are used for rotating components, then simple installation is achieved, but wires become twisted and break after rotation
Solution Approach 1:
The connector is designed with a rotatable component that can rotate independently within the stationary housing. The conductive paths are molded into the stationary housing to accommodate this rotation, allowing the connector to dynamically adapt to rotational movement without twisting or tangling wires, thereby maintaining both installation simplicity and connection durability.
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
Enables reliable transmission of signals and power from rotating sources to controllers with lower material costs and simpler fabrication methods, maintaining electrical communication during multiple revolutions without twisting or tangling issues.
Implementation Method 1
The immersion bathing applies an electrically conductive plating to exposed surfaces of the second shot
Data Source
AI summary
A process of fabricating a slip ring component, a slip ring component, and a slip ring assembly are disclosed. The process includes forming a first shot, forming a second shot, and immersion bathing the first shot and the second shot. The immersion bathing applies an electrically conductive plating to exposed surfaces of the second shot.