Experimental verification/comparison between standard sphere against flat and a new wave structured contact surface topography developed using a numerical contact model; as applied to an existing MQS contact design

By using a Papkovich Neuber potential based 3D numerical contact modeling method [1], it has been shown that using a wave structured contact surface topography can reduce contact interface resistance by a factor of 2 at a given normal load. It has been proposed that a wave structured topography can be used to reduce contact normal force as a method to reduce connector mating forces. Since there is more and more pressure to manage/minimize connector engagement forces as advancing technology calls for greater connector circuit/pin counts, using these wave structured topographies represents a way that these demands could be met. A comparative study will show that contacts with wave structured contact surface topographies can meet and exceed the mechanical and electrical performance of similar standard sphere against flat contact interfaces. By applying a wave structure to an existing standard `sphere on flat' contact interface design and subsequently reducing the contact normal force by 50% to cut the contact engagement force in half; the current carrying capability of a contact design still increased by 16% and the specified vibration stability requirement for the contacts was still met. If this is done with no normal force reduction, a 22% increase in interface current carrying capacity can be achieved with a vibration stability superior to the standard sphere against flat surfaced contact design. The functionally evaluated electrical characteristics of such wave structured and standard contact interfaces are in agreement with the numerical predictions.