Method for manufacturing at least one functional area on an electric contact element such as a switching contact or a plug contact

Patent metadata

Field	Value
Publication number	US-9667015-B2
Application number	US-201214009845-A
Country	US
Kind code	B2
Filing date	Apr 2, 2012
Priority date	Apr 6, 2011
Publication date	May 30, 2017
Grant date	May 30, 2017

Abstract

The invention relates to a method for producing at least one functional region ( 1 ) on an electrical contact element ( 30 ) such as, for example, a switching contact or a plug type contact. The at least one functional region ( 1 ), for example, a contact location or a connection region for crimping or soldering connections is limited to a partial area of the contact element. In order to prevent the high environmental burden which is disadvantageous in wet-chemical methods and to overcome the restriction to a very small number of materials caused in hot dip methods in physical technical terms, and to substantially improve the spatial possibility for selection and structuring which is insufficient in both techniques, there is provision according to the invention for at least one material coating ( 4 ) to be applied mechanically in a highly selective manner to the contact element in the functional region ( 1 ) and subsequently highly energetic thermal radiation ( 9 ) such as, for example, a particle beam in the form of an ion and/or electron beam, to be directed onto the at least one material coating ( 4 ). The material coating ( 4 ) can contain new materials or material combinations which cannot be provided by previous methods. The invention further relates to a device for producing such a functional region and a contact element having such a functional region ( 1 ), the contact element ( 30 ) being produced in accordance with the above method.

First claim

The invention claimed is:

1. Electrical contact element, comprising:
a base material having at least one functional region, the at least one functional region being limited to a partial area of the contact element, and the at least one functional region comprises at least a first functional region, a second functional region, and a third functional region; and
a material coating mechanically applied to the base material with a highly energetic thermal radiation directed on to the material coating, the material coating comprising a first material coating, a lower part of which is embedded within the base material in the first functional region by a distance corresponding to a first active depth beneath an outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, a second material coating, a lower part of which is embedded within the base material in the second functional region by a distance corresponding to a second active depth beneath the outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, a third material coating, a lower part of which is embedded within the base material in the third functional region by a distance corresponding to a third active depth beneath the outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, and a fourth material coating in contact with the first, second, and third material coatings, and the first active depth is different from the second and third active depths, and wherein the first material coating is in a side-by-side arrangement with the fourth material coating, and the first material coating is in direct contact with the base material and the fourth material coating, and the fourth material coating is in direct contact with the base material.

2. Electrical contact element according to claim 1 , wherein at least one of a density, a thermal conductivity, and a melting point of the first material coating is different from that of the second, third, and fourth material coatings.

3. Electrical contact element according to claim 1 , wherein at least one of a density, a thermal conductivity, and a melting point of the first material coating is different from that of the fourth material coating.

4. Electrical contact element according to claim 3 , wherein the first material coating is in a vertically-stacked arrangement with the fourth material coating, and the first material coating is positioned vertically intermediate the fourth material coating.

5. Electrical contact element according to claim 4 , wherein the fourth material coating vertically and laterally surrounds the first material coating and is in direct contact with the first material coating and the base material.

6. Electrical contact element, comprising:
a base material having at least one functional region, the at least one functional region being limited to a partial area of the contact element, and the at least one functional region comprises at least a first functional region, a second functional region, and a third functional region; and
a material coating mechanically applied to the base material with a highly energetic thermal radiation directed on to the material coating, the material coating comprising a first material coating, a lower part of which is embedded within the base material in the first functional region by a distance corresponding to a first active depth beneath an outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, a second material coating, a lower part of which is embedded within the base material in the second functional region by a distance corresponding to a second active depth beneath the outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, a third material coating, a lower part of which is embedded within the base material in the third functional region by a distance corresponding to a third active depth beneath the outer surface of the base material subsequent to application of the thermal radiation and an upper part of which extends above the outer surface of the base material subsequent to application of the thermal radiation, and a fourth material coating in contact with the first, second, and third material coatings, and the first active depth is different from the second and third active depths, wherein the first material coating is in a vertically-stacked arrangement with the fourth material coating, and the first material coating is positioned vertically intermediate the fourth material coating, and further wherein the fourth material coating vertically and laterally surrounds the first material coating and is in direct contact with the first material coating and the base material.

Assignees

• Schmidt Helge
• Leidner Michael
• Sachs Soenke
• Te Connectivity Germany Gmbh

Inventors

• Schmidt Helge
• Leidner Michael
• Sachs Soenke

Classifications

• H05K3/247

  Finish coating of conductors by using conductive pastes, inks or powders · CPC title

• H01R13/03

  characterised by the material, e.g. plating, or coating materials · CPC title

• H01R43/16 Primary

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• H01H11/041

  by bonding of a contact marking face to a contact body portion · CPC title

• C23C24/106

  Coating with metal alloys or metal elements only · CPC title