Preparation process of conductive structure adopting elastic insulating material
By dispersing conductive units in an elastic insulating substrate and forming conductive paths through axial compression under gravity, the problems of poor contact and durability in electronic product charging devices are solved, achieving stable charging and improved corrosion resistance.
Patent Information
- Application Number
- CN202511329531.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-17
- Publication Date
- 2025-12-12
AI Technical Summary
The rigid metal contact structure between existing electronic products and charging equipment is prone to overvoltage damage or poor contact due to assembly tolerances and differences in thermal expansion. Furthermore, it generates fretting friction and insulation oxidation in vibration environments, leading to contact interface problems.
The process employs an elastic insulating material manufacturing process, in which conductive units are dispersed in an elastic insulating substrate, and conductive paths are formed by axial compression under gravity. This is combined with a composite corrosion-resistant functional layer to improve connection stability and durability.
Stable charging was achieved under assembly tolerances and dynamic environments, avoiding overvoltage damage and poor contact, and improving contact reliability and corrosion resistance.
Smart Images
Figure CN121105418A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of conductive structures, and more specifically to a process for preparing a conductive structure using an elastic insulating material. Background Technology
[0002] The connection terminals of existing electronic products and charging devices (such as charging docks, car mounts, and wireless power banks) generally adopt rigid metal contact structures (such as the metal springs or Pogo Pin probes of USB-C interfaces). Because the structure is incompressible, rigid terminals rely on the limited deformation of the metal springs (usually ≤0.2mm) to provide contact pressure. When there are assembly tolerances (commonly ±0.5mm) or differences in thermal expansion between the phone and the charging dock, it is easy to cause overpressure damage or poor contact. For example, a magnetic alignment deviation of >1mm in the iPhone MagSafe charger will cause charging interruption, while excessive pressure will accelerate the wear of the gold plating layer. In addition, the dynamic environment is unstable. In vibration scenarios (such as car charging), rigid terminals generate micro-friction due to the lack of a buffer structure, resulting in the formation of insulating oxide debris (such as Cu2O) at the contact interface. Summary of the Invention
[0003] To address the aforementioned problems, this invention provides a process for preparing a conductive structure using an elastic insulating material, comprising the following steps: Step 1: Methyl vinyl silicone rubber raw material is subjected to thin-pass plasticizing on a two-roll mill to soften it. The plasticized raw material is then rolled over a roller, and fumed silica and iron oxide red are added sequentially and slowly, followed by the addition of hydroxyl silicone oil. The mixture is then thoroughly stirred and rolled to ensure the filler is uniformly dispersed in the rubber compound, forming a gel-like elastic insulating substrate. Step 2: After surface acidification treatment of the conductive unit, it is injected into the gel-like elastic insulating substrate according to two preset ratios. Then, using an upper and lower opposing... An electromagnetic field causes the conductive units to arrange themselves vertically within an elastic insulating substrate. The elastic insulating substrate is mixed with a high proportion of conductive units to form a high-density aggregated region. The elastic insulating substrate is mixed with a high proportion of conductive units to form a low-density transition region. The high-density aggregated region and the low-density transition region are then pressed into a sheet of suitable thickness and cooled to form a mold. Step 3: The high-density aggregated region and the low-density transition region of the sheet are stacked alternately in a preset order and thickness, and then subjected to preliminary rolling to achieve preliminary adhesion between the layers. Step 4: The bonded sheet is placed in a flat vulcanizing machine, and then a peroxide crosslinking agent is added at a temperature of 160°C - 180°C.
[0004] Furthermore, in step one, the material of the elastic insulating substrate (100) is high-temperature vulcanized silicone rubber, and its composition by weight percentage is: 68% methyl vinyl silicone rubber raw rubber, 27.2% fumed silica, 2.7% hydroxyl silicone oil, 1.36% iron oxide red, and the remainder is peroxide crosslinking agent. When the elastic insulating substrate (100) is subjected to axial compression, the conductive units (200) in the low-density transition region (120) can make contact and form a continuous conductive path.
[0005] Furthermore, the elastic insulating substrate is divided into several conductive segments along the axial direction. Conductive electrodes are provided at both ends of each conductive segment. The conductive units within each conductive segment are isolated from each other in the uncompressed state, and a continuous conductive path is formed only within the segment when compressed. An insulating barrier layer is provided between adjacent conductive segments. The insulating barrier layer is made of silicone rubber or polyurethane.
[0006] Furthermore, the high-density aggregation region and the low-density transition region are spaced apart within the conductive segment, and along the axial direction of the conductive segment, the high-density aggregation region is located between the conductive electrode and the low-density transition region.
[0007] Furthermore, the conductive unit is spherical in shape and is made of metal particles, carbon fiber, or graphene. Within the low-density transition region, an elastic insulating part is provided between the conductive units. When the elastic insulating part is compressed, the conductive units within the low-density transition region can make contact and form a continuous conductive path.
[0008] Furthermore, the conductive unit is conical in shape and is made of metal particles, carbon fiber, or graphene. Within the low-density transition region, an elastic insulating portion is provided between the conductive units. When the elastic insulating portion is compressed, the conductive units within the low-density transition region can make contact and form a continuous conductive path. Within the low-density transition region, the angle between the axis of the tip of the conductive unit and the axis of the conductive segment is between 30 degrees and 60 degrees. The tip of the conductive unit points towards the adjacent high-density aggregation area.
[0009] Furthermore, the conductive unit is strip-shaped and made of metal particles, carbon fiber, or graphene. In the low-density transition region, an elastic insulating part is provided between the conductive units. When the elastic insulating part is compressed, the conductive units in the low-density transition region can make contact and form a continuous conductive path. The axial axis of the conductive unit is perpendicular to the axial axis of the conductive segment.
[0010] Furthermore, a composite corrosion-resistant functional layer is provided on the outer circumferential surface of the elastic insulating substrate. The composite corrosion-resistant functional layer includes, from the inside out, a fluorosilicone resin coating, a vapor-deposited alumina film, and a hydrophobic nano-silica coating.
[0011] Compared with the prior art, the beneficial effects of the present invention are: The elastic insulating substrate produced by this process has several conductive units dispersed inside it. In the charging field, the product to be charged only needs to be placed on top of this application. When the elastic insulating substrate is axially compressed by gravity, the conductive units inside can make contact, thereby forming a charging path.
[0012] Additional aspects and advantages of the invention will be set forth in the description which follows, and in some respects will be obvious from the description or may be learned by practice of the invention. Attached Figure Description
[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0014] Figure 1 This is a schematic cross-sectional view of the structure of the first embodiment of the elastic insulating substrate of the present invention; Figure 2 This is a schematic cross-sectional view of a second embodiment of the elastic insulating substrate of the present invention; Figure 3 This is a schematic cross-sectional view of the third embodiment of the elastic insulating substrate of the present invention; Figure 4 This is a schematic diagram of the composite corrosion-resistant functional layer of the elastic insulating substrate of the present invention; Figure 5 This is a schematic cross-sectional view of the composite corrosion-resistant functional layer of the elastic insulating substrate of the present invention.
[0015] The reference numerals and names in the figure are as follows: Elastic insulating substrate 100, conductive unit 200, high-density aggregation area 110, low-density transition area 120, conductive segment 130, conductive electrode 131, insulating partition layer 140, elastic insulating part 121, composite corrosion resistant functional layer 150, fluorosilicone resin coating 151, vapor-deposited alumina film 152, hydrophobic nano silica coating 153. Detailed Implementation
[0016] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0017] The present invention will now be described in more detail. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them.
[0018] In the description of this invention, it should be noted that directional terms such as "front," "rear," "up," "down," "left," "right," "horizontal," "vertical," "horizontal," and "top," "bottom," etc., indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. These terms are used solely for the convenience of describing the invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner or outer contours of each component itself. In the description of this invention, it should be noted that the use of terms such as "first" and "second" to define components is merely for the convenience of distinguishing the corresponding components. Unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly specified.
[0019] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention.
[0020] Furthermore, the technical features involved in the different embodiments of this application described below can be combined with each other as long as they do not conflict with each other.
[0021] The preferred embodiment of the present invention will now be further described with reference to the accompanying drawings. The preparation process of the conductive structure using elastic insulating material includes the following steps: Step 1: Methyl vinyl silicone rubber raw rubber is plasticized on a two-roll mill to soften it. The plasticized raw rubber is then rolled and slowly mixed with fumed silica and iron oxide red in sequence, followed by hydroxyl silicone oil. The mixture is then thoroughly stirred and rolled to ensure that the filler is evenly dispersed in the rubber compound, forming a gel-like elastic insulating substrate 100. Step 2: After surface acidification treatment of the conductive units 200, they are injected into the gel-like elastic insulating substrate 100 according to two preset proportions and arrangements. Then, an opposing electromagnetic field is used to arrange the conductive units 200 along the vertical direction of the elastic insulating substrate. Within the material 100, each conductive unit 200 is arranged in a matrix with a predetermined spacing. The elastic insulating substrate 100 is mixed with a high proportion of conductive units 200 to form a high-density aggregation region 110; the elastic insulating substrate 100 is mixed with a high proportion of conductive units 200 to form a low-density transition region 120. Then, the high-density aggregation region 110 and the low-density transition region 120 are pressed into a sheet of suitable thickness and cooled for molding. Step three: The sheet-shaped high-density aggregation region 110 and low-density transition region 120 are alternately stacked according to a predetermined order and thickness, and then preliminarily rolled to achieve initial adhesion between the layers. Step four: The bonded sheet is placed in a flat vulcanizing machine, and a peroxide crosslinking agent is added at a temperature of 160°C - 180°C. This temperature is maintained for a period of time to allow the peroxide to decompose and generate free radicals, initiating a crosslinking reaction of the methyl vinyl silicone rubber molecular chains, permanently fixing the previous rubber structure, and firmly locking the conductive units 200 in their distribution positions.
[0022] Furthermore, the material includes an elastic insulating substrate 100, which is made of high-temperature vulcanized silicone rubber. By weight percentage, its components are: 68% methyl vinyl silicone rubber raw rubber, 27.2% fumed silica, 2.7% hydroxyl silicone oil, 1.36% iron oxide red, and the remainder being peroxide crosslinking agents, such as... Figure 1 As shown, a plurality of conductive units 200 are dispersed inside the elastic insulating substrate 100. The cross-section of the elastic insulating substrate 100 is a strip-shaped rectangle. The conductive units 200 are non-uniformly distributed inside the elastic insulating substrate 100 and form a plurality of high-density aggregation regions 110 and low-density transition regions 120 along the axial direction of the elastic insulating substrate 100. When the elastic insulating substrate 100 is subjected to axial compression, the conductive units 200 in the low-density transition regions 120 can make contact and form a continuous conductive path.
[0023] In the implementation of this application, a liquid elastic insulating substrate 100 mixed with conductive units 200 is first placed in a vertical magnetic field to arrange the conductive units 200 along the vertical direction within the elastic insulating substrate 100. Then, while maintaining this state, the liquid elastic insulating substrate 100 is solidified, resulting in a plurality of conductive units 200 dispersed within the elastic insulating substrate 100. A plurality of high-density aggregation regions 110 and low-density transition regions 120 are formed axially on the elastic insulating substrate 100. The conductive units 200 are densely distributed in the high-density aggregation regions 110 and spaced apart in the low-density transition regions 120. When the elastic insulating substrate 100 is subjected to axial compression, the conductive units 200 form contact in the low-density transition regions 120, thereby enabling mutual conduction between the high-density aggregation regions 110 and the low-density transition regions 120, thus forming a conductive path within the elastic insulating substrate 100, thereby reducing the overall resistance of the elastic insulating substrate 100.
[0024] Compared with the prior art, this application has a plurality of conductive units 200 dispersed inside the elastic insulating substrate 100. In the field of charging, the product to be charged only needs to be placed on top of this application. When the elastic insulating substrate 100 is axially compressed by gravity, the conductive units 200 inside can make contact, thereby forming a charging path.
[0025] Furthermore, based on the above embodiments, such as Figure 1 As shown, the elastic insulating substrate 100 is divided into several conductive segments 130 along the axial direction. Conductive electrodes 131 are provided at both ends of each conductive segment 130. The conductive units 200 within each conductive segment 130 are isolated from each other in an uncompressed state, and form a continuous conductive path only within the segment when compressed. An insulating partition layer 140 is provided between adjacent conductive segments 130. Preferably, the insulating partition layer 140 is made of silicone rubber or polyurethane. By segmenting the elastic insulating substrate 100 along the axial direction, the conductive segments 130 can better connect with the corresponding interfaces when the application is in the charging field, thereby facilitating further improvement in connection accuracy.
[0026] Furthermore, based on the above embodiments, such as Figure 1As shown, the high-density aggregation region 110 and the low-density transition region 120 are spaced apart within the conductive segment 130, and along the axial direction of the conductive segment 130, the high-density aggregation region 110 is located between the conductive electrode 131 and the low-density transition region 120. Thus, when the conductive segment 130 is compressed, the conductive units 200 within the high-density aggregation region 110, due to their dense distribution, easily come into contact with each other and form a conductive path with the conductive electrode 131. Meanwhile, the conductive units 200 within the low-density transition region 120 are significantly compressed in distance from each other, thus also coming into contact and forming a conductive path.
[0027] Furthermore, based on the above embodiments, such as Figure 1 As shown, the conductive unit 200 is spherical in shape and is made of metal particles, carbon fiber or graphene. In the low-density transition region 120, an elastic insulating part 121 is provided between the conductive units 200. When the elastic insulating part 121 is compressed, the conductive units 200 in the low-density transition region 120 can make contact and form a continuous conductive path.
[0028] This application also provides a second embodiment, which differs from the first embodiment in that, as follows: Figure 2 As shown, the conductive unit 200 is conical in shape and is made of metal particles, carbon fiber, or graphene. Within the low-density transition region 120, an elastic insulating portion 121 is provided between the conductive units 200. When the elastic insulating portion 121 is compressed, the conductive units 200 within the low-density transition region 120 can make contact, forming a continuous conductive path. Preferably, within the low-density transition region 120, the angle between the axis of the tip of the conductive unit 200 and the axis of the conductive segment 130 is between 30 and 60 degrees. The tip of the conductive unit 200 points towards the adjacent high-density aggregation region 110. Thus, when the conductive units 200 within the low-density transition region 120 are significantly compressed, the conductive units 200 can more easily make contact with each other to form a conductive path.
[0029] This application also provides a third embodiment, which differs from the first two embodiments in that, as Figure 3As shown, the conductive unit 200 is strip-shaped and made of metal particles, carbon fiber, or graphene. Within the low-density transition region 120, an elastic insulating portion 121 is provided between the conductive units 200. When the elastic insulating portion 121 is compressed, the conductive units 200 within the low-density transition region 120 can make contact, forming a continuous conductive path. Preferably, the axial axis of the conductive unit 200 is perpendicular to the axial axis of the conductive segment 130. This significantly compresses the distance between the conductive units 200 within the low-density transition region 120, making it easier for them to make contact and form a conductive path.
[0030] Furthermore, based on the above embodiments, combined with Figure 4 and Figure 5 As shown, a composite corrosion-resistant functional layer 150 is provided on the outer circumferential surface of the elastic insulating substrate 100. The composite corrosion-resistant functional layer 150 includes, from the inside out, a fluorosilicone resin coating 151, a vapor-deposited alumina film 152, and a hydrophobic nano-silica coating 153. The layers are fixed to each other by a micron-level staggered trench structure, thereby blocking the penetration of acid / alkali / salt media. The hydrophobic coating prevents electrochemical corrosion and meets industrial-grade weather resistance requirements.
[0031] The details of the exemplary embodiments described above are provided, and the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the invention.
Claims
1. A process for fabricating a conductive structure using an elastic insulating material, characterized in that, It includes the following steps: Step 1: The raw methyl vinyl silicone rubber is plasticized on a two-roll mill to soften it into a gel. The plasticized raw rubber is then rolled and slowly mixed with fumed silica and iron oxide red in sequence, followed by hydroxyl silicone oil. The mixture is then thoroughly stirred and rolled to ensure that the filler is evenly dispersed in the rubber compound, forming a gel-like elastic insulating substrate (100). Step 2: After surface acidification of the conductive units (200), they are injected into the gel-like elastic insulating substrate (100) according to two preset ratios and arrangements. Then, the conductive units (200) are arranged in the elastic insulating substrate (100) along the vertical direction using an opposing electromagnetic field, so that each conductive unit (200) forms a preset spacing and a matrix arrangement. The elastic insulating substrate (100) and the high proportion of conductive units (200) are mixed to form a high-density aggregation region (110); the elastic insulating substrate (100) and the high proportion of conductive units (200) are mixed to form a low-density transition region (120). Then, the high-density aggregation region (110) and the low-density transition region (120) are pressed into a sheet of suitable thickness and cooled for molding. Step 3: The sheet-like high-density aggregated area (110) and low-density transition area (120) are stacked alternately according to a preset order and thickness, and then preliminary rolling is performed to achieve initial adhesion between the layers: Step 4: Place the bonded sheet into a flat vulcanizing machine, and then add a peroxide crosslinking agent at a temperature of 160°C - 180°C.
2. The fabrication process of the conductive structure using elastic insulating material according to claim 1, characterized in that, In step one, the material of the elastic insulating substrate (100) is high-temperature vulcanized silicone rubber, and its composition by weight percentage is: 68% methyl vinyl silicone rubber raw rubber, 27.2% fumed silica, 2.7% hydroxyl silicone oil, 1.36% iron oxide red, and the remainder is peroxide crosslinking agent. When the elastic insulating substrate (100) is subjected to axial compression, the conductive units (200) in the low-density transition region (120) can make contact and form a continuous conductive path.
3. The fabrication process of the conductive structure using elastic insulating material according to claim 2, characterized in that, The elastic insulating substrate (100) is divided into several conductive segments (130) along the axial direction. Conductive electrodes (131) are provided at both ends of the conductive segments (130). The conductive units (200) in the conductive segments (130) are isolated from each other in the uncompressed state. When compressed, a continuous conductive path is formed only in this segment. An insulating partition layer (140) is provided between adjacent conductive segments (130). The insulating partition layer (140) is made of silicone rubber or polyurethane.
4. The fabrication process of the conductive structure using elastic insulating material according to claim 3, characterized in that, The high-density aggregation region (110) and the low-density transition region (120) are spaced apart within the conductive segment (130), and the high-density aggregation region (110) is located between the conductive electrode (131) and the low-density transition region (120) along the axial direction of the conductive segment (130).
5. The fabrication process of the conductive structure using elastic insulating material according to claim 1, characterized in that, In step two, the conductive unit (200) is spherical in shape and is made of metal particles, carbon fiber or graphene. In the low-density transition region (120), an elastic insulating part (121) is provided between the conductive units (200). When the elastic insulating part (121) is compressed, the conductive units (200) in the low-density transition region (120) can make contact and form a continuous conductive path.
6. The fabrication process of the conductive structure using elastic insulating material according to claim 1, characterized in that, In step two, the conductive unit (200) is conical in shape and is made of metal particles, carbon fiber or graphene. In the low-density transition region (120), an elastic insulating part (121) is provided between the conductive units (200). When the elastic insulating part (121) is compressed, the conductive units (200) in the low-density transition region (120) can make contact and form a continuous conductive path. In the low-density transition region (120), the angle between the axis of the tip of the conductive unit (200) and the axis of the conductive segment (130) is between 30 degrees and 60 degrees. The tip of the conductive unit (200) points to the adjacent high-density aggregation region (110).
7. The fabrication process of the conductive structure using elastic insulating material according to claim 1, characterized in that, In step two, the conductive unit (200) is strip-shaped and made of metal particles, carbon fiber or graphene. In the low-density transition region (120), an elastic insulating part (121) is provided between the conductive units (200). When the elastic insulating part (121) is compressed, the conductive units (200) in the low-density transition region (120) can make contact and form a continuous conductive path. The axial axis of the conductive unit (200) is perpendicular to the axial axis of the conductive segment (130).
8. The fabrication process of the conductive structure using elastic insulating material according to claim 1, characterized in that, In step one, a composite corrosion-resistant functional layer (150) is provided on the outer circumferential surface of the elastic insulating substrate (100). The composite corrosion-resistant functional layer (150) includes, from the inside out, a fluorosilicone resin coating (151), a vapor-deposited alumina film (152), and a hydrophobic nano-silica coating (153).