Spray-Coated Contact Element for Low-Resistance Electrical Joints
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Solution Overview
Problem
Current electrical connections between conductors, such as busbars, experience high contact resistance due to constriction and surface contamination resistance, which impairs current transmission.
Innovation Solution
A contact element with an electrically conductive carrier body featuring a spray coating of conductive solid particles distributed over its surface, forming micro-contacts that reduce contact resistance by increasing contact pressure and breaking open contamination layers, while the particles' geometry and distribution optimize current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional continuous contact surfaces are pressed together, then contact pressure is distributed evenly, but contact resistance increases due to surface contamination and constriction resistance
Solution Approach 1:
The contact surface is segmented into discrete micro-contacts formed by spray-coated particles rather than a continuous surface. These particles create multiple localized contact points (a-spots) that concentrate current flow and penetrate contamination layers, reducing both constriction resistance and surface contamination resistance simultaneously
Solution Approach 2:
The contact element applies local quality by creating regions of high contact pressure at discrete particle locations rather than uniform distribution. The spray-coated particles generate localized micro-contacts with high density and pressure at specific points, optimizing current transmission pathways while maintaining lower overall contact resistance
2Reliability
If conductor surfaces are pre-treated or coated to remove oxide layers, then contact resistance decreases, but manufacturing effort and costs increase
Solution Approach 1:
The spray-coated particles are applied to the contact element in advance to perform the function of penetrating and breaking oxide layers on the conductor surface. This preliminary action eliminates the need for separate oxide removal steps such as pre-treatment or coating of conductors, as the particles themselves perform the penetration function during contact establishment
Solution Approach 2:
The contact element with spray-coated particles serves itself by using the particles to automatically penetrate and break oxide layers on the conductor surface during the connection process. The system eliminates the need for external pre-treatment processes, as the particles perform the oxide-layer-breaking function inherently when contact pressure is applied
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 contact element significantly reduces contact resistance by creating discrete high-pressure micro-contacts and evenly distributing current flow, allowing for efficient electrical connections without pre-treating or coating the conductors, thus saving effort and costs.
Implementation Method 1
the at least one contact surface comprises a spray coating made of electrically conductive solid particles distributed over the at least one contact surface
Implementation Method 2
electrically conductive solid particles distributed over the at least one contact surface
Implementation Method 3
the electrically conductive solid particles can form micro-contacts (so-called a-spots) establishing contact at discrete locations at which the current transfer takes place
Implementation Method 4
the contact pressure there is higher as compared to continuous contact surfaces pressed together using the same normal force. Any contamination layers that may be present can be broken open
Data Source
Figure 1
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Figure 4
AI summary
The present invention relates to a contact element (4) comprising an electrically conductive carrier body (10) with at least one contact surface (6, 6a, 6b) for contacting at least one electrical conductor (8, 8a, 8b), wherein the at least one contact surface (6, 6a, 6b) comprises a spray coating (22) made of electrically conductive solid particles (1) distributed over the at least one contact surface (6, 6a, 6b). The presence and distribution of the solid particles (1) lead to a reduction in the contact resistance between the contact element (4) and the at least one conductor (8, 8a, 8b) when the contact element (4) is pressed with the at least one contact surface (6, 6a, 6b) against the at least one conductor (8, 8a, 8b) and the solid particles (1) have there penetrated at least in part into the material of the at least one conductor (8, 8a, 8b). The present invention furthermore relates to a connection assembly (2) with such a contact element (4). The present invention additionally relates to the use of a spray medium (60) as well as to a method for manufacturing such a contact element (4).