CONDUCTIVE MEMBER AND METHOD OF MANUFACTURING THE SAME

• US 20130072075A1
• Filed: 04/19/2011
• Published: 03/21/2013
• Est. Priority Date: 04/23/2010
• Status: Abandoned Application

• Current Assignee: NHK Spring Company Limited
• Original Assignee: NHK Spring Company Limited
• Inventors: Kayamoto, Takashi
• Application Number:
  US13/642,624
• Publication Number:
  US 20130072075A1
• Time in Patent Office: Days
• US Class Current: 439/887
• CPC Class Codes: C23C 24/04 Impact or kinetic deposition of particles
• CPC Class Codes: C23C 28/021 including at least one metal alloy layer
• CPC Class Codes: C23C 28/023 only coatings of metal elements only
• CPC Class Codes: C23C 28/025 with at least one zinc-based layer
• CPC Class Codes: H01R 13/03 characterised by the material, e.g. plating, or coating materials
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 43/16 for manufacturing contact members, e.g. by punching and by bending
• CPC Class Codes: H01R 43/28 for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26

Abstract

Provided are a conductive member that is connectable to aluminum metal and can suppress a decrease in electrical conductivity, and a method of manufacturing the same. The conductive member is formed of aluminum or an alloy containing aluminum, and includes an electrical wire connection unit and a fastening unit, which are a base provided with a connection surface to be connected to another member, and a connection layer formed on the base by accelerating a powder of a metal or alloy, which has a lower ionization tendency than the base and has electrical conductivity equal to that of the base or higher, together with gas, and spraying and depositing the powder in the solid state on the connection surface.

Claims

1. A conductive member comprising:

a base formed of aluminum (Al) or an alloy containing aluminum, the base being provided with a connection surface to be connected to another member; and

a connection layer formed on the base by accelerating a powder of a metal or alloy, which has a lower ionization tendency than the base and has electrical conductivity equal to that of the base or higher, together with gas, and spraying and depositing the powder in a solid state on the connection surface.

2. The conductive member according to claim 1, wherein the connection layer is formed of any one of metals of copper (Cu), silver (Ag), and gold (Au), or an alloy containing any one of the metals.

3. The conductive member according to claim 2, further comprising a coating layer formed around a perimeter of an interface between the base and the connection layer by accelerating a powder of any one of metals of nickel (Ni), zinc (Zn), tin (Sn), and titanium (Ti), or of an alloy containing any one of the metals together with gas, and spraying and depositing the powder in a solid state around the perimeter of the interface.

4. The conductive member according to claim 2, wherein the base includes a middle layer where a powder of any one of metals of nickel (Ni), zinc (Zn), tin (Sn), and titanium (Ti), or of an alloy containing any one of the metals is accelerated together with gas to be sprayed and deposited on the aluminum or aluminum alloy while in a solid state, the middle layer forming the connection surface.

5. The conductive member according to claim 1, wherein the base includes:

an electrical wire connection unit to which an electrical wire is connected, and

a fastening unit connected to the electrical wire connection unit and provided with the connection surface.

6. The conductive member according to claim 1, wherein the base is an electrical wire whose own end face is set as the connection surface.

7. The conductive member according to claim 1, wherein the base is an electrical wire whose own end side surface is set as the connection surface.

8. A method of manufacturing a conductive member, comprising:

a base forming step of forming a base formed of aluminum (Al) or an alloy containing aluminum, the base including a connection surface to be connected to another member; and

a connection layer forming step of forming a connection layer on the base by accelerating a powder of a metal or alloy, which has a lower ionization tendency than the base and has electrical conductivity equal to that of the base or higher, together with gas, and spraying and depositing the powder in a solid state on the connection surface.

9. The method of manufacturing a conductive member according to claim 8, wherein the powder comprises any one of metals of copper (Cu), silver (Ag), and gold (Au), or an alloy containing any one of the metals.

10. The method of manufacturing a conductive member according to claim 9, further comprising a coating layer forming step of forming a coating layer around a perimeter of an interface between the base and the connection layer by accelerating a powder of any one of metals of nickel (Ni), zinc (Zn), tin (Sn), and titanium (Ti), or of an alloy containing any one of the metals together with gas, and spraying and depositing the powder in a solid state around the perimeter of the interface.

11. The method of manufacturing a conductive member according to claim 9, wherein the base forming step includes depositing a middle layer forming the connection surface by accelerating a powder of any one of metals of nickel (Ni), zinc (Zn), tin (Sn), and titanium (Ti), or of an alloy containing any one of the metals together with gas, and spraying the powder in a solid state on the aluminum or aluminum alloy.