Spray-Coated Contact Element for Low-Resistance Conductor Joints
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Solution Overview
Problem
Electrical conductors in automotive and energy technology experience high contact resistance due to constriction and surface contamination resistance when connected, hindering efficient current transmission.
Innovation Solution
A contact element with a spray coating of electrically conductive solid particles is used, forming micro-contacts that reduce contact resistance by optimizing discrete contact locations and penetrating oxide layers on conductors, allowing for improved current flow without pre-treatment or coating of the conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact surfaces are pressed together to establish electrical connection, then mechanical connection is achieved, but contact resistance increases due to constriction resistance and surface contamination
Solution Approach 1:
The contact surface is segmented into multiple discrete micro-contacts formed by solid particles distributed across the surface. Instead of a continuous contact interface, the current flows through numerous small contact points created by the particles, which reduces constriction resistance and improves electrical connection quality.
Solution Approach 2:
Electrically conductive solid particles are introduced as an intermediary between the contact surfaces. These particles penetrate oxide layers and create conductive pathways, mediating the electrical connection between contacting surfaces and reducing surface contamination resistance.
2Reliability
If conductor surfaces are pre-treated or coated to remove oxide layers, then contact resistance decreases, but manufacturing complexity and costs increase
Solution Approach 1:
The solid particles perform the function of penetrating and breaking through oxide layers automatically during the contacting process itself. The particles' mechanical action during contact pressurization eliminates the need for separate pre-treatment steps to remove oxide layers, allowing untreated conductors to be used directly.
Solution Approach 2:
The contact surfaces are pre-coated with electrically conductive solid particles before the actual electrical connection is made. This preliminary coating ensures that when contact occurs, the particles are already in position to penetrate oxide layers and establish low-resistance electrical pathways, eliminating the need for post-contact treatment.
3Area of stationary object
If continuous contact surfaces are pressed together, then large contact area is achieved, but current flow is restricted at single locations increasing constriction resistance
Solution Approach 1:
The continuous contact surface is divided into multiple discrete micro-contact points formed by individual solid particles. Each particle creates its own contact location, distributing the current flow across numerous pathways rather than restricting it to single locations, thereby reducing constriction resistance while maintaining adequate overall contact area.
Solution Approach 2:
Different regions of the contact surface have different local properties due to the distributed particle coating. Each particle location provides optimized local contact conditions with high contact pressure and direct metal-to-metal contact, while the overall surface maintains sufficient area for current distribution.
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, enabling efficient current transmission while being cost-effective and universally applicable across different conductor materials and coatings, with reduced complexity and handling ease.
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
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
AI summary
A contact element includes an electrically conductive carrier body with at least one contact surface for contacting at least one electrical conductor, wherein the at least one contact surface comprises a spray coating made of electrically conductive solid particles distributed over the at least one contact surface. The presence and distribution of the solid particles lead to a reduction in the contact resistance between the contact element and the at least one conductor when the contact element is pressed with the at least one contact surface against the at least one conductor and the solid particles have there penetrated at least in part into the material of the at least one conductor. A connection assembly may be provided with such a contact element. A spray medium as well as a method for manufacturing such a contact element are further provided.