Patent Publication Number: US-8974259-B2

Title: Electrical connectors with encapsulated corrosion inhibitor

Description:
TECHNICAL FIELD 
     The field of the invention relates generally to electronic components, and more specifically, to a heat sink a fan structure for providing cooling to electronic components. 
     BACKGROUND 
     Computer systems typically include a combination of computer programs and hardware, such as semiconductors, transistors, chips, circuit boards, storage devices, and processors. The computer programs are stored in the storage devices and are executed by the processors. A common feature of many computer systems may be the presence of one or more circuit boards. Circuit boards may contain a variety of electronic components mounted to them. It may also be common for one or more of the electronic components to be electrically connected to a circuit board and to each other by one or more electrical connectors. 
     SUMMARY 
     According to embodiments of the invention, an electrical connector structure with an encapsulated corrosion inhibitor may be provided. The structure may include a first electrical connector having a first contact surface. The structure may also include an encapsulated corrosion inhibitor applied to at least a portion of the first contact surface. 
     According to other embodiments, the structure may include a first electrical connector having a first electrical connector body and a plurality of electrically conductive pins, wherein at least a portion of the surface of the pins comprise a first electrically conductive contact surface. The structure may also include a second electrical connector having a second electrical connector body and a plurality of receptacles containing one or more electrically conductive contacts, wherein the electrically conductive contacts comprise a second electrically conductive contact surface and the receptacles are adapted to receive the pins in a coupled position, and the second contact surface is adapted to contact the first contact surface. The structure may also include an encapsulated corrosion inhibitor applied to at least a portion of the first contact surface, wherein at least a portion of the encapsulated corrosion inhibitor is adapted to rupture and release the corrosion inhibitor when the first electrical connector and the second electrical connector are coupled. 
     According to other embodiments, a method for providing an electrical connector structure with an encapsulated corrosion inhibitor may be provided. The method may include providing a first electrical connector having a first contact surface. The method may also include providing an encapsulated corrosion inhibitor applied to at least a portion of the first contact surface. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1A  is a side view of an assembly in an exploded position, according to an embodiment of the invention. 
         FIG. 1B  is a side view of the assembly of  FIG. 1A  in an assembled position, according to an embodiment of the invention. 
         FIG. 2A  is a zoomed view of an area of  FIG. 1A  with a partial cross-section, according to an embodiment of the invention. 
         FIG. 2B  is a zoomed view of an area of  FIG. 1B  with a partial cross-section, according to an embodiment of the invention. 
         FIG. 3  is a flow chart of a method of creating an electrical connector structure with an encapsulated corrosion inhibitor, according to an embodiment of the invention. 
     
    
    
     In the drawings and the Detailed Description, like numbers generally refer to like components, parts, steps, and processes. 
     DETAILED DESCRIPTION 
     Many modern day electronic components may operate in environments where corrosive contaminants, such as chlorine and sulfides, are present. These contaminants may pose a threat to the electrical connectors of those electronic components. The functional lifespan of those electrical connectors may be significantly diminished when corrosive contaminants are allowed to come in contact with them, which may affect the functionality of the electronic components associated with those electrical connectors. In order to reduce the damage that may be caused by corrosive contaminants, a corrosion inhibitor may be applied to one or more of the contact surfaces of the electrical contacts. A corrosion inhibitor may be any substance which inhibits corrosion. Examples of corrosion inhibitors are the Cor-Ban® products from the Zip-Chem® Company of Morgan Hill, Calif. 
     However, since corrosion inhibitors may often be liquids, their presence may serve to collect contamination from the time the inhibitor has been applied to the contact surface to the time it may be installed. For example, a computer system may have a component which has failed and needs to be replaced. The owner of the computer system orders a replacement from the manufacturer of the component. Part of the manufacturing process of the replacement component may be to apply a corrosion inhibitor to the electrical connectors that will connect the replacement component to the computer system. Between the time at which the corrosion inhibitor may be applied and the replacement component&#39;s installation in the computer system, the component may be subject to contamination inherent in the shipping and handling of the component. It may be desirable for the corrosion inhibitor not to attract contamination during that time as the contamination may affect the functionality or the lifespan of the replacement component after it is installed in the computer system. 
     Embodiments of the invention provide an electrical connector with an electrical contact surface and an encapsulated corrosion inhibitor applied to a portion of the contact surface. A capsule may be a small or microscopic capsule adapted to release its contents when ruptured. By encapsulating the corrosion inhibitor it may be protected from exposure to contamination. Upon installation of the electrical connector, the proximity of the contact surfaces of the electrical connector and its mating connector may rupture the capsules and release the corrosion inhibitor. Upon rupture and release of the corrosion inhibitor from the capsules, it may be free to flow around the contact area of the electrical connectors in order to create a barrier to contaminants. 
     Referring to the drawings, wherein like numbers denote like parts throughout the several views,  FIG. 1A  is a side view of the assembly  100  in an exploded position, according to an embodiment of the invention. The assembly  100  may include a first electrical connector  102 . The first electrical connector  102  of  FIG. 1A  is depicted as a male connector but in other embodiments the first electrical  102  connector may be a female connector. The first electrical connector  102  may be part of a larger assembly (not depicted), such as a circuit board, a wiring assembly, or any similar electronic component. The first electrical connector  102  may include an electrical connector body  104  and any number of electrical contact surfaces such as electrically conductive pins  106 . The pins  106  may have a surface which includes a thin layer of metal alloy. The metal alloy may contain any electrically conductive metal such as gold, silver, platinum, palladium, iridium, rhodium, or any other similar metal. An encapsulated corrosion inhibitor  108  may be applied to the surface of pins  106 . As previously stated, a corrosion inhibitor may be any substance which inhibits corrosion and a capsule may be a small or microscopic capsule adapted to release its contents when ruptured. In various embodiments, the encapsulated corrosion inhibitor may be a micro-encapsulated corrosion inhibitor in which the micro-capsules have a diameter of 2 to 2000 μm. Also in various embodiments, the outer shell of a capsule may be made from a variety of compounds such as urea formaldehyde. 
     In some embodiments, the encapsulated corrosion inhibitor  108  may be applied to the surface of the pins  106  as part of a solution. The encapsulated corrosion inhibitor  108  may be considered the solute of the solution. The solvent may include any liquid capable of holding the encapsulated corrosion inhibitor  108  in a state of liquid suspension, such as isopropyl alcohol or a ketone such as acetone or methyl ethyl ketone. This solution may be applied as an aerosol, a thin liquid film, or any other suitable forms of application. In some embodiments, the solvent may evaporate after the solution is applied and thereby leaving only the encapsulated corrosion inhibitor  108 . 
     In some embodiments, the capsule may be adapted to bond to a metal contained in an electrical contact surface. For example, if the contact surface includes gold, then the capsule may be adapted to bond to the gold thereby providing an improved adherence of the capsules to the contact surface. In some embodiments, this bonding may be accomplished by incorporating a mercaptan into the shell of the capsule. For example, an allyl mercaptan may be entangled in a urea formaldehyde capsule shell in order to functionally bind the mercaptan. A detailed prophetic description of the procedure of preparing above described capsule is listed below. 
     The assembly  100  may also include a second electrical connector  110 . The second electrical connector  110  may be a mate to the first electrical connector  102 . For example, if the first electrical connector  102  is a male connector, the second electrical connector  110  may be a female connector and vice versa. The second electrical connector  110  may also be part of a larger assembly (not depicted), such as a circuit board, a wiring assembly, or any similar electronic component. The second electrical connector  110  may include an electrical connector body  112  and receptacles  114  for receiving the pins  106 . Each receptacle  114  may include one or more electrical contact surfaces such as electrically conductive tabs  116 . The tabs  116  may also have a surface which includes a thin layer of metal alloy. As previously stated, the metal alloy may contain any electrically conductive metal such as gold, silver, platinum, palladium, iridium, rhodium, or any other similar metal. In other embodiments, the encapsulated corrosion inhibitor  108  may be applied to both the surface of the pins  106  and the surfaces of the tabs  116 , or it may be applied to just the surface of the tabs  116 . 
       FIG. 1B  is a side view of the assembly  100  in an assembled position, according to an embodiment of the invention. In the assembled position, the first electrical connector  102  may be coupled with the second electrical connector  110 . In the coupled position, the pins  106  may be located within the receptacles  114 . Also in the coupled position, the pins  106  may be in electrical contact with the tabs  116 . As the electrical connectors  102  and  110  are coupled and the pins  106  enter the receptacles  114 , the proximity of the pins  106  to the tabs  116  may result in the rupture of some of the encapsulated corrosion inhibitor  108 . The ruptured capsules may then release the corrosion inhibitor which may then be allowed to flow around the contact area of the pins  106  and the tabs  116 . 
       FIG. 2A  is a zoomed view of an area of  FIG. 1A  with a partial cross-section, according to an embodiment of the invention. This view shows in greater detail one of the pins  106  with the encapsulated corrosion inhibitor  108  applied to it. The view also shows the receptacle  114  within the connector body  112  which corresponds to the pin  106 . The receptacle  114  may contain the tabs  116  which may be intended to make electrical contact with the pin  106  in a coupled position. 
       FIG. 2B  is a zoomed view of an area of  FIG. 1B  with a partial cross-section, according to an embodiment of the invention. This view shows in greater detail one of the pins  106  after it has entered the receptacle  114 . As previously stated, in this coupled position, the pin  106  may be in electrical contact with the tabs  116 . Also as previously stated, as the pins  106  enter the receptacles  114 , the proximity of the pins  106  to the tabs  116  may result in the rupture of some of the encapsulated corrosion inhibitor  108 . The ruptured capsules may then release the corrosion inhibitor which may then be allowed to flow around the contact area of the pins  106  and the tabs  116 . 
       FIG. 3  is a flow chart of a method of creating an electrical connector structure with an encapsulated corrosion inhibitor, according to an embodiment of the invention. Block  302  may contain the operation of providing a first electrical connector having a first contact surface. Examples of electrical connectors are electrical connectors  102  and  110  depicted in  FIGS. 1A and 1B . The Block  304  may contain the operation of providing an encapsulated corrosion inhibitor applied to at least a portion of the first contact surface. As previously stated, the encapsulated corrosion inhibitor may be part of a solution and it may be adapted to bond to a particular metal used in the first contact surface. 
     Block  306  may contain the operation of providing a second electrical connector having a second contact surface. The second electrical connector may be the mating connector to the first electrical connector and therefore may be adapted to couple with the first electrical connector. Also, the second contact surface may be adapted to contact the first contact surface. This contact may allow electrical communication between the first electrical connector and the second electrical connector. At least a portion of the encapsulated corrosion inhibitor may be adapted to rupture and release the corrosion inhibitor due to the proximity of the second contact surface to the first contact surface. This rupture may occur as the first electrical connector is coupled with the second electrical connector. As previously stated, the ruptured capsules may then release the corrosion inhibitor which may then be allowed to flow around the areas where the first contact surface contacts the second contact surface. Alternatively, the encapsulated corrosion inhibitor may be applied to both the first and second contact surface, or it may be applied to only the second contact surface. 
     The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. 
     Experimental Protocols 
     The following illustrative experimental protocols are prophetic examples which may be practiced in a laboratory environment. 
     Formation of Orthogonally Functional Resorcinol, Mercaptan Chloride 
     Solution A contains phloroglucinol and water. Solution B contains mercaptan chloride, triethyl amine, and tetrahydrofuran (THF). Solution B is added to solution A and kept in a cold bath at 0° C. 
     Formation of Orthogonally Functional Resorcinol, 3-Chloro-1-Propanethiol 
     Solution A contains phloroglucinol, KOH, and water. Solution B contains 3-Chloro-1-propanethiol, and DMSO. Solution B is added to Solution A and kept at 50 C for 1-8 hrs. 
     Preparation of Mercaptan-Functionalized Capsules 
     Capsules were prepared by in situ polymerization in an oil-in-water emulsion. At room temperature (20-24° C.), 200 ml of deionized water and 50 ml of 2.5 wt % aqueous solution of EMA copolymer were mixed in a 1000 ml beaker. The beaker was suspended in a temperature-controlled water bath on a programmable hotplate with external temperature probe (Dataplate® Digital Hotplate, Cole-Palmer®). The solution was agitated with a digital mixer (Eurostar®, IKA®) driving a three-bladed, 63.5 mm diameter low-shear mixing propeller (Cole-Parmer®) placed just above the bottom of the beaker. Under agitation, 5.00 g urea, 0.50 g ammonium chloride and 0.50 g mercaptan functionalized resorcinol were dissolved in the solution. The pH was raised from 2.60 to 3.50 by drop-wise addition of sodium hydroxide (NaOH) and hydrochloric acid (HCl). One to two drops of 1-octanol were added to eliminate surface bubbles. A slow stream of 60 ml of ZipChem® was added to form an emulsion and allowed to stabilize for 10 min. After stabilization, 12.67 g of 37 wt % aqueous solution of formaldehyde was added to obtain a 1:1.9 molar ratio of formaldehyde to urea (SANGHVI, S. P. and NAIRN, J. G., 1992, Effect of viscosity and interfacial-tension on particle-size of cellulose acetate trimellitate microspheres. Journal of Microencapsulation, 9, 215-227.). The emulsion was covered and heated at a rate of 1° C./min to the target temperature of 55° C. After 4 h of continuous agitation the mixer and hot plate were switched off. Once cooled to ambient temperature, the suspension of capsules was separated under vacuum with a coarse-fritted filter. The capsules were rinsed with deionized water and air dried for 24-48 h. A sieve was used to aid in separation of the capsules.