Tin-Plated Product with Carbon Composite Coating
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Solution Overview
Problem
Conventional tin-plated products used in insertable connecting terminals suffer from high coefficient of friction and limited durability due to softness, leading to increased wear and contact resistance deterioration over time.
Innovation Solution
A tin-plated product with a composite coating containing carbon particles dispersed in a tin layer, having a thickness of 0.5 to 10.0 μm, is formed on a substrate to enhance wear resistance and reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tin coating layer is formed on a conductive substrate to provide good contact resistance stability, then contact resistance deterioration is reduced, but wear resistance is insufficient due to the softness of tin
Solution Approach 1:
The patent applies composite materials by combining tin with carbon particles (graphite) to create a composite coating layer. This composite structure allows the tin matrix to provide contact resistance stability while the dispersed carbon particles provide wear resistance and lubrication, resolving the contradiction between softness and wear resistance.
Solution Approach 2:
The patent applies local quality by creating a composite coating where carbon particles are locally dispersed within the tin matrix. The carbon particles are concentrated in specific regions to provide localized wear resistance and lubrication properties, while the tin matrix maintains its electrical conductivity and contact resistance stability throughout the coating.
2Strength
If carbon particles are added to improve wear resistance, then wear resistance increases, but coefficient of friction increases
Solution Approach 1:
The patent applies parameter changes by optimizing the carbon particle content to a specific range (0.1-10 wt%) and controlling the coating thickness (0.5-10.0 μm). By precisely controlling these parameters, the coating achieves adequate wear resistance while maintaining a low coefficient of friction, as excessive carbon content would increase friction.
Solution Approach 2:
The patent applies local quality by dispersing carbon particles locally within the tin matrix rather than creating a pure carbon layer. This local dispersion allows carbon particles to provide wear resistance at contact points while the tin matrix maintains low friction properties in non-contact regions, achieving both wear resistance and low friction simultaneously.
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 solution provides a tin-plated product with improved wear resistance and low coefficient of friction, maintaining contact resistance stability over time while reducing the inserting force required.
Implementation Method 1
a coating of a composite material containing carbon particles dispersed in a tin layer is formed on a substrate so as to have a thickness of 0.5 to 10.0 μm
Implementation Method 2
a coating of a composite material, which contains wear resistant or lubricating solid particles in a metal matrix containing tin as a principal component, is formed on a conductive substrate by electroplating
Data Source
AI summary
There is provided a tin-plated product which has a small deterioration of contact resistance with age, an excellent wear resistance and a low coefficient of friction. A coating of a composite material, which contains 0.1 to 1.0 wt % of carbon particles dispersed in a tin layer and which has a thickness of 0.5 to 10.0 μm, preferably 1.0 to 5.0 μm, is formed as the outermost layer of a substrate. Thus, the coefficient of dynamic friction between the tin-plated products of the same kind is 0.20 or less, and the coefficient of dynamic friction between the tin-plated product and a reflow tin-plated product is 0.20 or less, while the contact resistance is 1 mΩ or less.