KR20120123223A - Process of fabricating a slip ring component, a slip ring component, and molded interconnecting device including a slip ring component - Google Patents

Abstract

PURPOSE: A manufacturing process of a slip ring configuration element, a slip ring configuration element, and an interconnection apparatus including the same are provided to reduce costs of an electric connector. CONSTITUTION: A first cast unit(404) is formed. A second cast unit(402) is formed. The first cast unit and the second unit are immersion bathed. An electric conductive planting is coated on a surface exposed to the second cast unit. A slip ring component is manufactured by the injection mold.

Description

PROCESS OF FABRICATING A SLIP RING COMPONENT, A SLIP RING COMPONENT, AND MOLDED INTERCONNECTING DEVICE INCLUDING A SLIP RING COMPONENT}

The present invention relates to electrical connectors and components, electrical connector assemblies, and processes for manufacturing electrical connectors and electrical connector assemblies. In particular, the present invention relates to slip ring components and assemblies.

Electrical connectors provide power and / or signals to various products. Rotating components are challenges to overcome in electrical connectors. The rotation component prevents the source from being directly connected to the controller and / or power source due to the rotation of the rotation component. For example, a rotating component that is directly connected to the controller via a wire can be twisted and tangled after one or more rotations. Connectors with internal rotors and stators can be used for these rotating components.

Connectors with rotors and stators include expensive materials and / or can be labor intensive in manufacturing. Molding a portion of the housing to form the conductive path and / or adding the conductive path can be labor intensive, thus increasing the cost of the electrical connector.

Processes for manufacturing electrical connectors, components of electrical connectors, and components of electrical connectors free from the foregoing drawbacks will be desirable in the art.

The solution consists of a slip ring manufacturing process comprising forming a first cast, forming a second cast, and immersion bathing comprising immersion bathing the first cast and the second cast. Is provided. The dipping step applies an electrically conductive plating to the exposed surface of the second casting part.

According to the present invention, a process is provided for producing an electrical connector, a component of the electrical connector, and a component of the electrical connector free from the above-mentioned drawbacks.

Other features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the accompanying drawings, which illustrate by way of example the principles of the invention.
1 is a perspective view of a preferred molded interconnect device according to the invention, wherein the stationary housing is partially removed for clarity.
2 is a perspective view of a preferred molded interconnect device according to the present invention with a fixed housing.
3 is a perspective view of a preferred molded interconnect device according to the present invention having a lid over a stationary housing.
4 is a perspective view of a preferred slip ring component having a non-platable casting and a plateable shot according to the present invention.
Figure 5 shows the rotor shaft of a preferred molded interconnect device having one slip ring component positioned and press fit on the rotor shaft according to the present invention.
6 is a perspective view of a preferred slip ring component having a non-platable casting and a plateable casting according to the present invention.

Wherever possible, the same reference numbers will be used to refer to the same parts throughout the accompanying drawings.

In one embodiment, the process of manufacturing a slip ring component includes forming a first casting portion, forming a second casting portion, and immersing the first casting portion and the second casting portion. Steps. The immersion step is to apply an electrically conductive plating on the exposed surface of the second casting.

In another embodiment, the slip ring component includes a first casting portion and a second casting portion. The first casting portion includes an electrically conductive plating.

In another embodiment, the slip ring assembly includes a rotating portion, a fixed housing, and one or more slip ring components that electrically connect the rotating portion to the fixed housing. The one or more slip ring components include a first casting portion and a second casting portion. The first casting portion includes an electrically conductive plating.

Other features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the accompanying drawings, which illustrate by way of example the principles of the invention.

A slip ring assembly is provided that includes a preferred process for manufacturing a slip ring component, a slip ring component, and a slip ring component. Embodiments of the present invention allow signals and / or power to be transferred from rotating sources to controllers and / or power sources, using lower and / or lower cost materials, and / or simpler and / or simpler manufacturing methods and / or Or assembly methods, and combinations thereof.

1 and 2, a preferred slip ring assembly 100-for example, a molded interconnect device-is a rotary part 102, a fixed housing 104, and a source wire 108 within the rotary part 102. ) And one or more slip ring components 106 electrically connecting the controller wire 110 in the fixed housing 104. The slip ring assembly 100 may be a source (not shown) such as a camera, a rotor for a helicopter, a turbine (eg, a gas turbine, a steam turbine, or a wind turbine), or other source with rotating components (not shown). Electrical signal from one or more internal or source wires 108 connected thereto. The source wire 108 is electrically connected to the one or more slip ring components 106 (see FIG. 1) via a rotating portion 102 and to a controller (not shown) and / or a power source. Or more external or controller wires 110. In another embodiment, the controller wire may be located adjacent to the rotating portion 102 and the source wire may be located adjacent to the fixed housing 104.

The fixed housing 104 may be any suitable housing capable of accommodating the rotating part 102. The fixed housing 104 includes a semicrystalline polymer. In one embodiment, the housing 104 comprises polybutylene terephthalate. In another embodiment, the housing 104 comprises a liquid crystal polymer. The housing 104 extends around the circumferential direction of the rotating portion 102 and prevents the controller wire 110 from being exposed to the environment. In one embodiment, referring to FIG. 3, the housing 104 further includes a cover 302 that surrounds the electrical connection between the controller wire 110 and the slip ring component 106. Cover 302 further protects controller wire 110 from exposure to the environment. Additionally or alternatively, in one embodiment, a sealant is applied throughout the controller wire 110 to protect the controller wire from exposure to the environment.

The housing 104 may be any suitable structure that allows the rotary part 102 to be rotatable—for example, a cylindrical, partially cylindrical, cylindrical interior, but non-cylindrical exterior, cuboid, other suitable structure, or combinations thereof. Has- Likewise, the arrangement of the controller wires 110 on the fixed housing 104 may be any suitable arrangement. Proper arrangement is that the controller wires 110 are positioned substantially opposite (eg, about 180 degrees away from the cylindrical structure), the controller wires 110 are all located together, and the controller wires 110 are Including but not limited to being positioned along the entire periphery of the fixed housing, the controller wires 110 staggered, the controller wires going in different directions, or combinations thereof.

As shown in FIG. 2, in one embodiment, the fixed housing 104 covers the slip ring component 106 and exposes electrical connections between the controller wire 110 and the slip ring component 106. Referring again to FIGS. 1 and 2, the housing 104 includes features for joining surfaces or other devices. For example, in one embodiment, in order to extend the controller wire 110 in a direction parallel or non-parallel with the interior of the housing 104, the housing 104 has a 90 degree angled portion as in FIG. 3. Angled portions such as 60 degree angled portions, 45 degree angled portions, 30 degree angled portions, and / or 15 degree angled portions. In one embodiment, the housing 104 is secured to another structure (not shown) —eg, fasteners, adhesives, linkages, flanges, other fasteners, or combinations thereof — and the housing 104. To prevent movement.

The controller wire 110 is electrically connected to the source wire 108 in the rotor 102 via any suitable electrical connection mechanism. In one embodiment, the controller wires 110 are connected to brush wires 116 respectively connected to slip ring components 106 (see FIG. 1) in the rotor 102 at contacts 114. In one embodiment, the controller wire 110 is soldered to the brush wire 116. In another embodiment, the controller wire 110 is mechanically secured to the brush wire 116.

Brush wire 116 maintains physical contact with slip ring component 106 at one or more locations to maintain electrical communication. Brush wire 116 maintains electrical communication with slip ring component 106 during rotation of rotation 102 (eg, up to approximately 3 million revolutions). In one embodiment, brush wire 116 comprises a high conductivity metal alloy, such as an alloy comprising gold, and provides a low degree of contact resistance. The brush wire 116 may have any suitable mechanism for maintaining electrical communication—low contact resistance, high yield strength to provide an adequate amount of normal drag, and a certain amount of flexibility to provide resistance to bouncing. flexibility), other appropriate features, and combinations thereof-including, but not limited to.

The rotary part 102 is located in the housing 104. The rotary part 102 has a generally cylindrical structure and rotates partially or completely within the housing 104. For example, the rotary part 102 rotates in a clockwise direction (as seen from the source adjacent area 504 shown in FIG. 5), counterclockwise (as seen from the source adjacent area 504), or both. And / or vibrate. In one embodiment, the rotor 102 is one or more bearings 112 to facilitate nearly coincident movement of the rotor shaft 103 (FIG. 5) and the rotor 102 relative to the rotor shaft 103. ). Slip ring component 106 is located within rotation 102.

Referring to FIG. 4, the slip ring component 106 injection molds the second casting 402 (eg, plateable casting) and the first casting 404 (eg, non-conductive casting). ) Is produced by injection molding. As used herein, the term " platable " refers to being able to accommodate the application of a metal via immersion plating techniques. As used herein, "non-plating" means resistant to immersion plating techniques. In one embodiment, the first casting portion 404 is formed before the second casting portion 402. In one embodiment, the second cast 402 and the first cast 404 are glued during injection molding. In other embodiments, the second casting 402, the first casting 404 and / or the slip ring component 106 may be, for example, keying features, adhesives, ultrasonic welding, and And / or mechanically secured through interference fit with each other and / or conductive polymers. In other embodiments, all or part of the second casting portion 402 is formed of a conductive polymer.

Plated injection molding 406 and non-plated injection molding 408 are formed from second casting 402 (platable casting) and first casting 404 (non-plating casting) Is immersed. The exposed surface of the non-plated injection molding 408 electrically insulates the electrically conductive plating over the plated injection molding 406. In one embodiment, the plated injection molding 406 includes a contact interface 410. In one embodiment, the contact interface 410 protrudes over at least a portion of the non-plated injection molding 408. In another embodiment, the contact interface 410 extends inwardly to the rotor contact 502. Referring to FIG. 6, in one embodiment, the plated injection molding 406 includes protruding insulation features 602. The protruding insulation feature 602 is located opposite the contact interface 410 and electrically disconnects the connection with the brush contact 116, thereby homing and / or keying the rotator 102. To provide.

The immersing step selectively applies electrically conductive plating to the exposed surface of the second casting part 402 so that the plated injection molded part 406 is electrically conductive. In one embodiment, the electrically conductive plating has a thickness between about 2 micro inches and about 100 micro inches, between about 5 micro inches and about 30 micro inches, between about 10 micro inches and about 20 micro inches, or about 15 micro inches. Has In one embodiment, the electrically conductive plating comprises gold, palladium-nickel, silver, any suitable non-oxidized precious metal, or combinations thereof.

In one embodiment, the dipping step is a multi-step (eg, 2-step, 3-step, or other suitable number of steps). In one embodiment, the immersing further comprises applying nickel underplating prior to applying the electrically conductive plating. Nickel underplating has a suitable thickness and provides a smooth surface that provides wear resistance to electrically conductive plating. In one embodiment, the thickness of nickel underplating is between about 500 micro inches and about 700 micro inches, between about 550 micro inches and about 650 micro inches, or about 600 micro inches. In yet another embodiment, the immersing step includes application of a copper strike layer prior to nickel underplating application. The copper strike layer has a thickness of between about 5 micro inches and about 10 micro inches, between about 5 micro inches and about 7 micro inches, or about 5 micro inches.

The non-plated injection molding 408 includes an exposed surface with electrical insulation to separate the slip ring components 106 and allow signal and / or power from the source wire 108 to the controller wire 110. Ensure transmission without electrical interference or short circuits. In one embodiment, the exposed surface of the non-plated injection molded part 408 is free of any electrically conductive plating.

Referring to FIG. 5, in the formation of the slip ring component 106, in one embodiment, the slip ring component 106 is positioned over and secured to the rotor shaft 103 (eg, friction fit). , Soldering, other attachments). In yet another embodiment, the slip ring component 106 fits on the rotor shaft 103. By fitting the slip ring component 106 on the rotor shaft 103, the source wire 108 adjacent to the rotor 102 and the controller wire 110 adjacent to the fixed housing 104 are in electrical communication. do. In yet another embodiment, one or more additional slip ring components 106 (e.g., a total of seven slip ring components, 14 slip ring components, or other suitable number of slip ring components) may be rotated. Position and / or fit over the electron axis 103.

In one embodiment, the slip ring component 106 includes keying or features corresponding to the structure of the rotor shaft 103 at a predetermined axial position. In yet another embodiment, the additional slip ring component 106 includes differently positioned keyings or features corresponding to the structure of the rotor shaft 103 at additional predetermined axial positions. As shown in FIG. 5, in one embodiment, the rotor contact 502 on the rotor shaft 103 has a variable length corresponding to the position of a given slip ring component 106 to thereby provide a contact interface ( 410 allows the slip ring component 106 to electrically connect to the corresponding source wire 108. In one embodiment, the rotor contact 502 causes the source wire 108 to be electrically connected to a slip ring component 106 located in the source proximal region 504, the source adjacent region. 504 is relatively close to where the source wire 108 enters the slip ring assembly 100, while the source distal region 506 is from where the source wire 108 enters the slip ring assembly 100. Relatively far.

100: slip ring assembly 102: rotating part
104: fixed housing 106: slip ring component
108: source wire 110: controller wire
116: brush wire 402: second casting part
404: first casting part 406: plated injection molding part
408: non-plated injection molding 410: contact interface
502: stator contacts 602: protruding insulation features

Claims (16)

Forming a first casting part;
Forming a second casting part; And
And immersion bathing the first casting part and the second casting part,
The dipping step applies an electrically conductive plating to the exposed surface of the second casting.
The process of claim 1, wherein one or more of forming the first casting and forming the second casting are performed by injection molding.
The process of claim 1, wherein one or more of forming the first casting and forming the second casting are performed by machining.
The process of claim 1, wherein the exposed surface of the first casting part electrically insulates the conductive plating of the second casting part.
The process of claim 1, wherein the exposed surface of the first casting part is free of the electrically conductive plating.
The process of claim 1, wherein the electrically conductive plating comprises gold.
The process of claim 1, wherein the immersing comprises nickel underplating prior to applying the electrically conductive plating.
8. The process of claim 7, wherein the immersing comprises copper striking prior to the nickel underplating.
2. The process of claim 1, wherein forming the second casting portion produces a slip ring component that adheres the first casting portion to the second casting portion.
The process of claim 1, wherein the second casting comprises a contact interface.
2. The process of claim 1, further comprising positioning the slip ring component over the rotor axis.
12. The process of claim 11 further comprising press fitting said slip ring component onto said rotor axis.
12. The process of claim 11 further comprising the step of securing the slip ring component by ultrasonic welding over the rotor axis.
12. The process of claim 11 further comprising adhesively securing the slip ring component over the rotor shaft.
12. The process of claim 11 further comprising the step of securing said slip ring component to an interference fit over said rotor axis.
12. The process of claim 11 further comprising placing one or more additional slip ring components over the rotor axis.

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