Management of contact spots between an electrical brush and substrate

An electrical connection system, comprising:

• an electrical brush having a plurality of current conducting elements;
• and
• a substrate having microscopic surface irregularities shaped and dimensioned to provide multiple contact spots to each current conducting element of said plurality of current conducting elements;
• wherein said surface irregularities are configured to provide contact spots spaced at least less than 100 d on each element of said plurality of current conducting elements, where d is a diameter of each element of the plurality of current conducting elements.

A method of making an electrical connection device comprising:

• providing an electrical brush having a plurality of current conducting elements;
• and
• forming microscopic surface irregularities on a substrate to produce multiple contact posts to each current conducting element of said plurality of current conducting elements;
• wherein said surface irregularities are configured to provide contact spots spaced at least less than 100 d on each element of said plurality of current conducting elements, where d is a diameter of each element of the plurality of current conducting elements.

A device for making electrical connection with an electrical brush having at least one current conducting element, said device comprising:

• a substrate having microscopic surface irregularities;
• and
• said surface irregularities shaped and dimensioned to provide plural contact spots with the at least one current conducting element,
• wherein dimensions of the surface irregularities are in the order of magnitude of a dimension of the at least one current conducting element to be electrically connected with the device;
• wherein said surface irregularities are configured to provide contact spots spaced at least less than 100 d on each element of said plurality of current conducting elements, where d is a diameter of each element of the plurality of current conducting elements.

A substrate for making electrical connection with an electrical brush, said substrate comprising:

• a plurality of microscopic asperities provide in a surface of the substrate;
• and said asperities having a density (D) in the range of:
• 2500/cm2≦D≦107/cm2,
• where the density (D) is defined as a number of asperities per square centimeter.

A substrate for making electrical connection with an electrical brush, said substrate comprising:

• a plurality of microscopic grooves provided in a surface of the substrate:
• and
• adjacent grooves of the plurality of grooves having a spacing (λ) in a range of:
• 10 μm≦(λ)≦1000 μm.