Electrical Terminal Interface Forming via Precious Metal Transfer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high cost of electrical connectors due to the use of expensive electrically conductive metals like copper and precious metals in manufacturing electrical terminals, with existing methods either altering mechanical properties, causing oxidation, or requiring costly additional processes such as electro-plating and hazardous waste management.

Innovation Solution

A method of forming electrical terminals by transferring and bonding discrete portions of electrically conductive material to a conductive material stock, such as aluminum, to create a conductive interface, reducing the need for precious metals and minimizing manufacturing costs through precise stamping and bonding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to add a clad interface layer to an electrical terminal base, then the electrical terminal can be formed with conductive material, but the mechanical properties of the welded material are altered and oxidation occurs

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with an electro-plating process (electrochemical system). Instead of using heat and pressure to bond the clad layer, the invention uses electrical current to deposit precious metal onto the aluminum base, thereby preserving the mechanical properties of the base material while achieving reliable electrical conductivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental parameter of the bonding process from thermal (welding temperature) to electrochemical (electro-plating current and composition). This parameter change allows the clad interface layer to be formed without subjecting the aluminum base to temperatures that would alter its mechanical properties or cause oxidation.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If electro-plating is used to add precious metal to selected portions of an electrical terminal base, then the amount of precious metal is reduced, but additional process steps and hazardous waste management are required

Engineering Contradiction:

Improveprecious metal usageVSAvoidprocess steps

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention applies electro-plating only to selected portions of the electrical terminal base where electrical conductivity is needed, rather than coating the entire component. This local application reduces precious metal consumption while minimizing the complexity of the plating process by limiting the treatment area to specific contact surfaces.

Inventive Principle:

Principle #3Local quality

3Productivity

If copper clad aluminum is used as the base material, then process efficiencies are improved, but the increased cost of copper negates the savings

Engineering Contradiction:

Improveprocess efficiencyVSAvoidcopper content

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The invention changes the material composition parameter by using pure aluminum as the base material instead of copper-clad aluminum. This eliminates the need for copper in the base material while maintaining process efficiency through the electro-plating method, thereby reducing material costs without sacrificing productivity.

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If aluminum is used as the base material instead of copper, then manufacturing costs are reduced, but a transition layer is required for soldering and surface oxides must be removed

Engineering Contradiction:

Improvebase material costVSAvoidadditional process steps

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention replaces the soldering process (which requires a transition layer and oxide removal) with an electro-plating process. The electro-plating method directly deposits precious metal onto the aluminum surface, creating a bond without requiring intermediate layers or extensive surface preparation, thus maintaining cost advantages while reducing process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method effectively reduces manufacturing costs by minimizing the use of expensive metals while maintaining mechanical integrity and electrical conductivity, avoiding the drawbacks of previous methods like welding and electro-plating.

Implementation Method 1

bonding the portion of electrically conductive material to the surface of the electrically conductive material stock

Methodology Applied

Scientific EffectBonding: Welding

Data Source

PatentUS9711926B2Method of forming an interface for an electrical terminal

Publication Date: 2017.07.18 LEAR CORP

AI summary

A method of forming an electrical terminal includes the steps of: transferring a portion of electrically conductive material to a selected location on a surface of electrically conductive material stock; bonding the portion of electrically conductive material to the surface of the electrically conductive material stock; forming the portion of electrically conductive material to the surface of the electrically conductive material stock to define a conductive interface; and forming the electrical terminal from the electrically conductive material stock.