Irregularly shaped gasket and method for manufacturing an irregularly shaped gasket

Abstract

The present invention provides a highly conductive irregularly shaped gasket and a method for manufacturing the same, which is free from metal contamination, exhibits low deformation and low rebound. [Solution] The metallic foil 11 is made of a specific metal that does not cause metal contamination, including aluminum, and is configured as a rectangular thin film whose longitudinal size corresponds to the longitudinal size of the insulating fabric, and is provided on the surface of the rectangular insulating fabric 10. The elastic member 12 is configured as an elongated shape whose longitudinal size corresponds to the longitudinal size of the insulating fabric, and has an irregular cross-sectional shape that bulges upward from the bottom surface. In the irregular gasket of the present invention, one end of the insulating fabric in the short direction is attached to the lower surface of the elastic member in the short direction, the back surface of the insulating fabric is attached to the surface of the elastic member, and the other end of the insulating fabric in the short direction is attached to the elastic member, so that the metallic foil is continuously arranged from the upper surface to the lower surface of the elastic member in the short direction via the insulating fabric.

Description

Technical Field

[0005]

[0001] The present invention relates to a shaped gasket and a method for manufacturing the shaped gasket.

Background Art

[0002] A gasket is a member for electromagnetic wave noise countermeasures (EMI countermeasures) and heat conduction and heat dissipation. For example, by embedding a gasket in the gap of the housing of an electronic device, it is possible to prevent leakage of electromagnetic waves generated from the electronic device and efficiently release the heat generated from the electronic device to the outside.

[0003] Here, a gasket is usually manufactured by using a flexible sponge or foam elastic body member as a base material and attaching a conductive material (for example, conductive fibers, metal foil, etc.) to the surface of the base material. Various configurations have been proposed for such gaskets in the past.

[0004] For example, Japanese Patent Application Laid-Open No. 2002-329993 (Patent Document 1) discloses a method for manufacturing a shaped shield gasket. In this manufacturing method, first, a cut elastic body (2) obtained by cutting an elastic body block (1) into a strip or string shape is prepared. Next, a grindstone part (6) of a grinding means is pressed against a specific part of the outer peripheral surface of the cut elastic body (2), and the cut elastic body (2) is ground in the longitudinal direction to grind and remove unnecessary parts to obtain a shaped cross-section grinding processed body (3). Further, in this manufacturing method, a conductive outer covering (4) is wound around the outer periphery of the shaped cross-section grinding processed body (3) in a circumferential shape through an adhesive layer to obtain a shield gasket (5). Thereby, when attaching to a housing or the like, it is not necessary to apply an excessive force for press contact, so that the shaped shield gasket is not excessively deformed, and it is said that electromagnetic wave shielding can be made complete.

[0005] Furthermore, Japanese Patent Publication No. 2004-036739 (Patent Document 2) discloses an integrated aluminum gasket. In this integrated aluminum gasket, aluminum with a surface roughness Ra of 3 to 100 μm is treated with a positive oxide film and has a porosity of 40% or less, and a fluororubber vulcanized material is directly integrated into the aluminum without the use of an adhesive. As a result, sufficient adhesion between the aluminum and the fluororubber vulcanized material is ensured without the need for processing such as metal drilling, and without the use of an adhesive, and it is also said to be excellent in terms of outgassing resistance.

[0006] Furthermore, Japanese Patent Publication No. 2008-530818 (Patent Document 3) discloses a flame-retardant electromagnetic interference (EMI) shielding gasket. Here, the gasket includes an elastic core member having an outer surface and a core formed of an elastomer polymer material. Furthermore, an electrically conductive fabric member surrounding the outer surface of the core member has an inner surface positioned facing the outer surface of the core member and an outer surface facing the opposite side, and has a first edge and a second edge that joins with the first edge and forms a seam between the first edge and the fabric member, the seam extending along at least a portion of the core member. Furthermore, a layer of cured thermosetting flame-retardant film adhesive sandwiched between the inner surface of the fabric member and the outer surface of the core member effectively adheres the first and second edges of the fabric member to the core member along at least a portion of the seam in order to give the gasket a flammability rating of V-0 under the Underwriter Laboratory (UL) Criteria Section 94. This means that such a film adhesive layer can be applied to one side of the fabric by heat nip or other methods without weakening the electrical surface conductivity of the other side of the fabric.

[0007] Furthermore, Japanese Patent Publication No. 2010-283008 (Patent Document 4) discloses an electromagnetic wave shielding gasket. This gasket is formed by joining a joining surface, which is part of the outer surface of a long core material made of a heat-resistant elastic polymer material, to the other surface of a heat-resistant resin film forming film, on which at least one of the two surfaces of the heat-resistant resin film has an easily solderable conductive thin film layer formed. In addition, the electromagnetic wave shielding gasket has an easily solderable conductive wire spirally wound and fixed around the outer circumference of the shielding material body, which consists of the joined long core material and conductive thin film forming film. As a result, it is said to have a simple structure, be easy to manufacture, have high conductivity and heat resistance, and be suitable for reflow soldering.

[0008] Furthermore, Japanese Patent Publication No. 2012-079927 (Patent Document 5) discloses a solderable conductive structure. In this conductive structure, a solderable layer (2) is provided on at least the bottom surface of the outer circumferential surface of a conductive and elastic main body (1). The conductive structure is composed of a conductive part (1A) where the bottom surface and the top surface are electrically conductive. Moreover, in the conductive structure, the solderable layer (2) consists of a layer of pressure-sensitive adhesive resin (R) with a high concentration of conductive powder (M). This allows for the formation of a layer using a pressure-sensitive adhesive resin with a high concentration of conductive powder on a conductive and elastic main body, while exhibiting excellent solderability and electrical conductivity during reflow soldering, and ensuring flexibility and durability.

[0009] Furthermore, Japanese Patent Publication No. 2014-112662 (Patent Document 6) discloses a sheet for thin electromagnetic wave shielding material. This sheet is made by laminating a conductive film to one side of a core material made of an acrylic foam resin material having flame retardancy, self-adhesiveness, and elasticity. The thickness of the electromagnetic wave shielding material sheet is 1.0 mm or less. This makes it possible to provide a thin electromagnetic wave shielding material that is extremely thin (1.0 mm or less), has excellent elasticity, adhesiveness, and adhesion, and also possesses conductive film coating and flame retardancy, simply and at low cost by directly molding it from foam resin.

[0010] Furthermore, Japanese Patent Publication No. 2018-056316 (Patent Document 7) discloses a flame-retardant thin electromagnetic wave shielding gasket. This gasket has a core made of an acrylic foam resin material that is flame-retardant, self-adhesive, and elastic, to which a conductive sheet is laminated. The acrylic foam resin material contains an acrylic resin, an acrylic resin adhesive, and a flame retardant. The proportion of the acrylic resin is 15% to 70% by weight and the proportion of the acrylic resin adhesive is 30% to 85% by weight, relative to the total solid content (100% by weight) of the acrylic resin and acrylic resin adhesive. In addition, the average particle size of the flame retardant is 40 μm or less, and the proportion of the flame retardant is 10 parts by weight to 30 parts by weight relative to the total solid content (100 parts by weight) of the acrylic resin and acrylic resin adhesive. Furthermore, at least one end of the core material, which is made of an acrylic foam resin material, is covered on both sides with a conductive sheet, and the thickness of the electromagnetic wave shielding gasket is 0.25 mm or less. This makes it possible to provide an ultra-thin shielding gasket of 0.25 mm or less with flame retardancy, while ensuring elasticity and adhesiveness with the foam core material, and without the need for double-sided tape, in a simple and economical manner. [Prior art documents] [Patent Documents]

[0011] [Patent Document 1] Japanese Patent Publication No. 2002-329993 [Patent Document 2] Japanese Patent Publication No. 2004-036739 [Patent Document 3] Special Publication No. 2008-530818 [Patent Document 4] Japanese Patent Publication No. 2010-283008 [Patent Document 5] Japanese Patent Publication No. 2012-079927 [Patent Document 6] Japanese Patent Publication No. 2014-112662 [Patent Document 7] Japanese Patent Publication No. 2018-056316 [Overview of the Initiative] [Problems that the invention aims to solve]

[0012] Conventional gaskets are manufactured by wrapping an elastic body with a conductive cloth or metal film made of copper or nickel plating, inserting it into a predetermined mold, and then heating and pressing it through the mold.

[0013] On the other hand, gaskets used in semiconductor manufacturing equipment such as silicon wafers face the challenge of metal contamination. In particular, copper diffuses rapidly into silicon wafers, and even at small concentrations, it can have a fatal impact on the device characteristics of semiconductors. Therefore, copper is considered a major source of contamination that directly affects yield and reliability.

[0014] Therefore, various gaskets using metal foil that is unaffected by metal contamination, including aluminum, have been proposed. However, when manufacturing gaskets using metal foil, while rectangular cross-sectional shapes can be manufactured without problems, when the cross-sectional shape is irregular, such as L-shaped, semi-circular, a combination of semi-circular and plate-shaped, or triangular, the gasket becomes a low-deformation, low-rebound shape, causing the metal foil to tear, making it impossible to manufacture irregularly shaped gaskets. This is thought to be because metal foil has little to no flexibility like conductive fabric and cannot conform to irregular shapes.

[0015] While the technologies described in Patent Documents 1 to 7 above can provide gaskets of various shapes and materials, it is unclear whether they can properly manufacture irregularly shaped gaskets when using metal foil, as mentioned above.

[0016] Therefore, the present invention was made to solve the above-mentioned problems, and aims to provide a non-conductively shaped gasket and a method for manufacturing a non-conductively shaped gasket that can be imparted with high conductivity even with low deformation and low rebound without causing metal contamination. [Means for solving the problem]

[0017] The irregularly shaped gasket according to the present invention comprises an insulating fabric, a metallic foil, and an elastic member. The insulating fabric is rectangular in shape. The metallic foil contains aluminum and is composed of a specific metal that does not cause metal contamination. It is formed as a thin rectangular film whose longitudinal size corresponds to the longitudinal size of the insulating fabric and is provided on the surface of the insulating fabric. The elastic member is formed as an elongated shape whose longitudinal size corresponds to the longitudinal size of the insulating fabric, and has an irregular cross-sectional shape that bulges upward from the bottom surface. The irregularly shaped gasket according to the present invention is formed by attaching one end of the insulating fabric in the short direction to the lower surface of the elastic member in the short direction, attaching the back surface of the insulating fabric to the surface of the elastic member, and attaching the other end of the insulating fabric in the short direction to the elastic member, thereby arranging the metallic foil continuously from the upper surface to the lower surface of the elastic member in the short direction via the insulating fabric.

[0018] Furthermore, the method for manufacturing a non-standard gasket according to the present invention comprises a first installation step and a second installation step. The first installation step involves placing a metallic foil on the surface of a rectangular insulating fabric, which is made of a specific metal containing aluminum and that does not cause metal contamination, and which is configured as a rectangular thin film with a longitudinal size corresponding to the longitudinal size of the insulating fabric. The second installation step involves attaching one end of the insulating fabric in the short direction to the lower surface in the short direction of an elastic member, which is configured as an elongated shape with a longitudinal size corresponding to the longitudinal size of the insulating fabric and has a non-standard cross-sectional shape that bulges upward from the bottom surface, covering and attaching the back surface of the insulating fabric to the surface of the elastic member, and attaching the other end of the insulating fabric in the short direction to the elastic member, thereby arranging the metallic foil continuously from the upper surface to the lower surface in the short direction of the elastic member via the insulating fabric. [Effects of the Invention]

[0019] According to the present invention, it is possible to impart high conductivity even with low deformation and low rebound without causing metal contamination. [Brief explanation of the drawing]

[0020] [Figure 1] In the shaped gasket according to the present invention, there are a perspective view showing an example of an insulating fabric, a metallic foil, and an elastic member before manufacturing, a cross-sectional view showing an example of the insulating fabric and the metallic foil, and a perspective view showing an example after manufacturing the shaped gasket. [Figure 2] In the shaped gasket according to the present invention, there is a cross-sectional view showing an example of four types of shapes. [Figure 3] There is a conceptual diagram showing an example of a compression test device with an electric resistance measurement function. [Figure 4] There are a perspective photograph of a right side view, a perspective photograph of a left side view, a perspective photograph of a plan view, and a perspective photograph of a bottom view showing an example of an L-shaped shaped gasket in Example 1. [Figure 5] There is a graph showing an example of the relationship between the amount of deformation and the resistance value in Example 1 and Comparative Example 1. <urchin>0000101 [Figure 6] There are a perspective photograph of a left side view and a perspective photograph of a bottom view showing an example of a D-shaped shaped gasket in Example 2. [Figure 7] There is a graph showing an example of the relationship between the amount of deformation and the resistance value in Example 2 and Comparative Example 2. [Figure 8] There are a perspective photograph of a right side view, a perspective photograph of a left side view, and a perspective photograph of a bottom view showing an example of a P-shaped shaped gasket in Example 3. [Figure 9] There is a graph showing an example of the relationship between the amount of deformation and the resistance value in Example 3 and Comparative Example 3. [Figure 10] There are a perspective photograph of a right side view, a perspective photograph of a left side view, and a perspective photograph of a bottom view showing an example of a TR-shaped shaped gasket in Example 4. [Figure 11] There is a graph showing an example of the relationship between the amount of deformation and the resistance value in Example 4 and Comparative Example 4.

Modes for Carrying Out the Invention

[0021] The embodiments of the present invention will be described below with reference to the attached drawings to facilitate understanding of the invention. Note that the following embodiments are merely examples of the present invention and are not intended to limit the technical scope of the invention.

[0022] As shown in Figure 1, the irregularly shaped gasket 1 according to the present invention comprises an insulating fabric 10, a metallic foil 11, and an elastic member 12. Here, the insulating fabric 10 is made of an electrically insulating fabric and is rectangular in shape. Furthermore, as shown in Figure 1, the size L in the longitudinal direction of the insulating fabric 10 is longer than the size W in the short direction.

[0023] Furthermore, the metallic foil 11 contains aluminum and is composed of a specific metal that does not cause metal contamination. It is configured as a rectangular thin film with a longitudinal size L corresponding to the longitudinal size L of the insulating fabric 10, and is provided on the surface of the insulating fabric 10. Here, the metallic foil 11 is composed of an electrically conductive film. Also, the metallic foil 11 refers to a sheet of metal that is a very thin film, and includes sheets of stretched metal.

[0024] Furthermore, the metallic foil 11 is provided in the center of the insulating fabric 10, for example, as shown in Figure 1, with a gap of a first size w1 from one end 10a in the short direction of the insulating fabric 10, and a gap of a second size w2 from the other end 10b in the short direction of the insulating fabric 10. This makes it possible to properly wrap the metallic foil 11 and the insulating fabric 10 around the elastic member 12 without the metallic foil 11 tearing or cracking when the insulating fabric 10 is wrapped around the elastic member 12. Depending on the type of irregularly shaped gasket 1, the first size w1 may be zero, the second size w2 may be zero, or both may be zero.

[0025] Furthermore, the elastic member 12 is configured to be elongated in length, with a longitudinal size L corresponding to the longitudinal size L of the insulating fabric 10, and has an irregular cross-sectional shape that bulges upward from the bottom surface. Here, "irregular shape" refers to a special external shape that differs from the basic shapes, which include rectangular, circular, and plate-shaped shapes. Examples include L-shaped (L-type), semicircular (D-type), a combination of semicircular and plate-shaped (P-type), and triangular (TR-type), as well as asymmetrical, elliptical, and composite shapes. The elasticity of the elastic member 12 means that it deforms when an external force is applied and returns to almost its original shape when the application of the external force is removed. Here, for example, as shown in Figure 1, the elastic member 12 has an L-shaped (bent) cross-sectional shape.

[0026] As shown in Figure 1, the irregularly shaped gasket 1 according to the present invention is constructed by attaching one end 10a in the short direction of the insulating fabric 10 to the lower surface 12a in the short direction of the elastic member 12, attaching the back surface of the insulating fabric 10 to the surface of the elastic member 12, and attaching the other end 10b of the insulating fabric 10 to the elastic member 12, thereby arranging the metallic foil 11 continuously from the upper surface to the lower surface in the short direction of the elastic member 12 via the insulating fabric 10.

[0027] In Figure 1, the other end 10b in the short direction of the insulating fabric 10 is overlapped and attached to one end 10a in the short direction of the insulating fabric 10. However, the method is not limited to this; as long as the metallic foil 11 is arranged continuously from the top surface to the bottom surface in the short direction of the elastic member 12 via the insulating fabric 10, the other end 10b in the short direction of the insulating fabric 10 can be attached in any way.

[0028] This makes it possible to impart high conductivity even with low deformation and low rebound, without causing metal contamination.

[0029] In other words, in the irregularly shaped gasket 1 according to the present invention, first, the metallic foil 11 uses a specific metal that contains aluminum and does not cause metal contamination, thus reliably preventing the occurrence of metal contamination. In particular, when the metallic foil 11 is made of aluminum, it is easy to install the metallic foil 11 onto the insulating fabric 10, and a certain degree of flexibility can be given to the metallic foil 11, making it easy to implement.

[0030] Furthermore, in the irregularly shaped gasket 1 according to the present invention, an irregular shape is used for the elastic member 12, and the back surface of the insulating fabric 10 is attached to the surface of the irregularly shaped elastic member 12. This makes it possible to prevent the metallic foil 11 from cracking or tearing even if, for example, a metallic foil 11 is provided on the insulating fabric 10 in advance, and then the insulating fabric 10 is wrapped around the elastic member 12, inserted into a predetermined mold, and heated and pressed through the mold, thereby simplifying manufacturing. In particular, by providing the metallic foil 11 on the insulating fabric 10, it becomes possible to make the metallic foil 11 conform to the flexibility of the insulating fabric 10, making it easier to attach to the irregularly shaped elastic member 12.

[0031] Furthermore, in the irregularly shaped gasket 1 according to the present invention, since the surface of the elastic member 12 is covered with the back surface of the insulating fabric 10, even if a part of the material of the elastic member 12 is conductive, the insulating fabric 10 covers the elastic member 12, allowing the entire elastic member 12 to function as an insulator. By providing a metallic foil 11 on the surface of the insulating fabric 10, it is possible to concentrate the electrical flow on the metallic foil 11, thereby ensuring that the conductivity of the metallic foil 11 functions reliably.

[0032] Furthermore, in the irregularly shaped gasket 1 according to the present invention, the metallic foil 11 is continuously arranged from the upper surface to the lower surface of the elastic member 12 via the insulating fabric 10. For example, when the irregularly shaped gasket 1 is deformed by being sandwiched between two parts, even if the irregularly shaped gasket 1 has low deformation and low rebound, the metallic foil 11 is continuous through the upper and lower parts of the elastic member 12, ensuring conductivity between the upper and lower parts. This makes it possible to impart high conductivity even with low deformation and low rebound. In other words, the irregularly shaped gasket 1 according to the present invention has three remarkable effects: prevention of metal contamination, ease of manufacture, and reliable conductivity due to low deformation and low rebound.

[0033] There are no particular limitations on the types of insulating fabrics mentioned here, but examples include polyethylene film, polypropylene film, polyester film, polyamide film, acrylic film, polyimide film, polyvinyl chloride film, polyethylene fiber cloth, polypropylene fiber cloth, polyester fiber cloth, polyamide fiber cloth, acrylic fiber cloth, natural material cotton fiber cloth, glass fiber cloth, aramid fiber cloth, silica fiber cloth, silicone-coated glass fiber cloth, fluororesin-coated cloth, acrylic resin-coated cloth, insulating kraft paper, aramid paper, etc.

[0034] Furthermore, the insulating fabric 10 is not particularly limited as long as it is rectangular in shape, with its length L being longer than its width W. It does not have to be strictly rectangular; for example, it may be polygonal or elliptical. Also, there are no particular limitations on the thickness t1 of the insulating fabric 10, but it is preferably in the range of 0.5 mm to 5.0 mm, and even more preferably in the range of 1.0 mm to 3.0 mm.

[0035] Furthermore, the specific metal in the metallic foil 11 is not particularly limited as long as it includes aluminum and is composed of a specific metal that does not cause metallic contamination, for example, aluminum, nickel, chromium, titanium, stainless steel, or alloys thereof. Metals that cause metallic contamination include copper, gold, and silver, and the specific metal does not include copper, gold, silver, or alloys thereof.

[0036] Furthermore, the position of the insulating fabric 10 on which the metallic foil 11 is provided is not particularly limited, as long as the metallic foil 11 is continuously positioned from the upper surface to the lower surface of the elastic member 12 via the insulating fabric 10 when the insulating fabric 10 is wrapped around the elastic member 12. It can be appropriately designed according to the cross-sectional shape of the elastic member 12.

[0037] For example, as described above, if the cross-sectional shape of the elastic member 12 is L-shaped (bent), the metallic foil 11 is provided to mainly cover the central part of the insulating fabric 10. However, it is not limited to this, and for example, it may be provided on the entire surface of the insulating fabric 10, or it may be provided in the central part of the insulating fabric 10 with an appropriate distance from one end 10a and the other end 10b in the short direction of the insulating fabric 10.

[0038] There are no particular limitations on the method of attaching the metallic foil 11 to the insulating fabric 10, but examples include attaching a sheet (film) of metallic foil 11 to the insulating fabric 10 with an adhesive, vacuum deposition, sputtering, lamination, thermal transfer, and printing the metallic ink of the metallic foil 11 onto the insulating fabric 10.

[0039] Furthermore, there are no particular limitations on the thickness t2 of the metallic foil 11, but for example, it is preferable if it is in the range of 0.001 mm (1 μm) to 0.100 mm (100 μm), and even more preferable if it is in the range of 0.010 mm (10 μm) to 0.080 mm (80 μm). Also, there are no particular limitations on the relationship between the thickness t1 of the insulating fabric 10 and the thickness t2 of the metallic foil 11, but for example, it is preferable if the thickness t1 of the insulating fabric 10 is in the range of 50 to 200 times the thickness t2 of the metallic foil 11, and even more preferable if it is in the range of 80 to 150 times the thickness t2 of the metallic foil 11. This makes it possible to wrap the insulating fabric 10 around the elastic member 12 without causing tearing of the metallic foil 11, even when the insulating fabric 10 is bent appropriately.

[0040] Furthermore, there are no particular limitations on the types of elastic members 12, but examples include sponge, urethane foam, ethylene vinyl acetate foam, foam, silicone gel, hydrogel, thermoplastic elastomer gel, natural rubber, styrene butadiene rubber, ethylene propylene rubber, nitrile rubber, silicone rubber, fluororubber, thermoplastic polyurethane, polyester elastomer, crosslinked polyolefin elastomer, etc.

[0041] Furthermore, there are no particular limitations on the cross-sectional shape of the elastic member 12, but examples include L-shaped (L-type), semicircular (D-type), a combination of semicircular and plate-shaped (P-type), triangular (TR-type), etc., as shown in Figure 2.

[0042] Here, as shown in Figure 2, when the cross-sectional shape of the elastic member 12 is L-shaped (L-type-1), the metallic foil 11 is provided so as to cover the inside of the L-shape, passing from the bottom surface of the L-shape through the outside and the top surface. In this case, the other end 10b in the short direction of the insulating fabric 10 is overlapped and attached to the end of the short direction of the insulating fabric 10 at the end of the bottom surface of the L-shape. Also, when the metallic foil 11 is in another form (L-type-2), the metallic foil 11 is provided so as to cover the inside of the L-shape, passing from the bottom surface of the L-shape through the outside and the top surface. In this case, the one end 10a in the short direction of the insulating fabric 10 is attached to the end of the bottom surface of the L-shape, and the other end 10b in the short direction of the insulating fabric 10 is attached to the inner end of the L-shape, so that the insulating fabric 10 does not cover the entire surface of the elastic member 12, but covers the L-shaped ends. Furthermore, in the case of the metallic foil 11 in other forms (L-type-3), the metallic foil 11 is provided so as to cover from the outside of the L-shape, through the top surface, through the inside of the L-shape, and down to the bottom surface of the L-shape. In this case, the other end 10b in the short direction of the insulating fabric 10 is overlapped and attached to the end of the bottom surface of the L-shape, which is the end of the short direction of the insulating fabric 10. Thus, the position covered by the metallic foil 11 can be changed as appropriate in the design.

[0043] Furthermore, when the cross-sectional shape of the elastic member 12 is semicircular (D-type), the metallic foil 11 is provided so as to cover from near the center of the semicircular lower surface, through one side (right side), and from the upper surface to a part of the other side (left side). In this case, one end 10a in the short direction of the insulating fabric 10 covers one side of the semicircular lower surface, the other end 10b in the short direction of the insulating fabric 10 covers the other side of the semicircular lower surface, and the one end 10a in the short direction of the insulating fabric 10 is positioned opposite the other end 10b in the short direction of the insulating fabric 10 on the semicircular lower surface.

[0044] Furthermore, in the case where the cross-sectional shape of the elastic member 12 is a combination of a semicircular shape and a plate shape (P type), the metallic foil 11 is provided so as to cover from the end of one side (right side) of the semicircular lower surface, through the other side (left side), and from the upper surface of the semicircular shape to a part of one side (right side). Here, the metallic foil 11 is not provided in the plate-shaped portion, and the conductivity between the top and bottom is ensured by the semicircular portion. In this case, one end 10a in the short direction of the insulating fabric 10 covers the one side from near the center of the plate-shaped lower surface, the other end 10b in the short direction of the insulating fabric 10 covers the end of one side of the plate-shaped lower surface, and the one end 10a in the short direction of the insulating fabric 10 is positioned facing the other end 10b in the short direction of the insulating fabric 10 near one side of the plate-shaped lower surface.

[0045] Furthermore, if the cross-sectional shape of the elastic member 12 is triangular (TR type), the metallic foil 11 is provided so as to cover from one side of the triangular shape, through the top surface, and up to a part of the other side of the triangular shape. In this case, one end 10a in the short direction of the insulating fabric 10 covers the area near the center of the bottom surface of the triangular shape, and the other end 10b in the short direction of the insulating fabric 10 is attached overlapping the one end 10a in the short direction of the insulating fabric 10 up to the area near the center of the bottom surface of the triangular shape. In this way, even if the cross-sectional shape of the elastic member 12 is irregular, the metallic foil 11 is arranged continuously from the top surface to the bottom surface of the elastic member 12, ensuring conductivity from top to bottom.

[0046] In Figures 1 and 2, the metallic foil 11 is arranged continuously from the top to the bottom surface in the short direction of the elastic member 12 via the insulating fabric 10. However, the design is not limited to this configuration, and when the irregularly shaped gasket 1 is compressed, the metallic foil 11 may be arranged continuously from the top to the bottom surface in the short direction of the elastic member 12 via the insulating fabric 10. Specifically, if the cross-sectional shape is L-shaped, the first metallic foil 11 covers from the top surface of the L-shape to the inside of the L-shape, and the second metallic foil 11 covers from the bottom surface of the L-shape, passing along one side, to the inside of the L-shape. When the irregularly shaped gasket 1 is compressed, the first metallic foil 11 and the second metallic foil 11 are in electrical contact, and as a whole, the first metallic foil 11 and the second metallic foil 11 may be arranged continuously from the top to the bottom surface in the short direction of the elastic member 12 via the insulating fabric 10. In this case, when the irregularly shaped gasket 1 is not compressed, the first metallic foil 11 and the second metallic foil 11 do not make electrical contact, so there is no conductivity between the top and bottom. However, when the irregularly shaped gasket 1 is compressed, the first metallic foil 11 and the second metallic foil 11 make electrical contact, ensuring conductivity between the top and bottom.

[0047] Furthermore, there are no particular limitations on the method of attaching the back surface of the insulating fabric 10 to the surface of the elastic member 12, but examples include attaching with double-sided tape, attaching with liquid adhesive, attaching by heat fusion, attaching by heat compression, attaching using primer treatment, attaching using corona discharge treatment, attaching using plasma treatment, etc. Here, examples of double-sided tape include acrylic double-sided tape, rubber double-sided tape, urethane foam double-sided tape, etc. Also, examples of adhesives include urethane adhesive, silicone adhesive, ethylene vinyl acetate copolymer adhesive, etc.

[0048] Furthermore, in the irregularly shaped gasket 1 according to the present invention, double-sided tape may be provided on the lower surface of the insulating fabric 10 or on the lower surface of the metallic foil 11. For example, as shown in Figure 2, in the four types of irregularly shaped gaskets 1, double-sided tape 13 is provided on a part of the lower surface of the insulating fabric 10 or on the lower surface of the metallic foil 11. Here, the double-sided tape 13 has adhesive layers on both sides of a predetermined support film. This makes it possible to position and fix the irregularly shaped gasket 1 with the double-sided tape 13 when installing it at the end of an electronic device, thereby ensuring the conductivity of the irregularly shaped gasket 1.

[0049] There are no particular limitations on the placement of the double-sided tape 13. For example, it may be placed on the underside of the other end 10b in the short direction of the insulating fabric 10, or on other undersides of the insulating fabric 10 other than the other end 10b in the short direction, or it may be placed on the underside of the other end 10b in the short direction of the insulating fabric 10 and other undersides so as to cover the other end 10b in the short direction of the insulating fabric 10.

[0050] Here, for example, if the cross-sectional shape of the elastic member 12 is L-shaped (L-type-1), the metallic foil 11 covers the outside of the L-shaped corner and the inside of the L-shape, and the double-sided tape 13 is provided on one side of the bottom surface of the L-shape. In this case, when the elastic member 12 is pressed downwards from above and compressed, the corner of the L-shape may lift slightly depending on the installation position of the double-sided tape 13, potentially making the conductivity between the top and bottom unstable. Therefore, for example, if the cross-sectional shape of the elastic member 12 is L-shaped (L-type-2), the metallic foil 11 covers from the bottom surface of the L-shape, through the inside of the L-shape, to the top surface of the L-shape, and the double-sided tape 13 is provided on the bottom surface of the L-shaped corner. In this case, even if the elastic member 12 is pressed downwards from above and compressed, the double-sided tape 13 acts as a starting point, causing one side of the bottom surface of the L-shape to be pressed slightly, thus stabilizing the conductivity between the top and bottom.

[0051] Furthermore, if the cross-sectional shape of the elastic member 12 is L-shaped, increasing the radius of curvature R (mm) (bent portion) formed by the inner corner of the L-shape can prevent galling during the manufacturing of the irregularly shaped gasket 1 and the occurrence of cracks in the metallic foil 11 during compression.

[0052] Furthermore, in the irregularly shaped gasket 1 according to the present invention, a support plate having greater rigidity than the elastic member 12 may be provided on the elastic member 12, and installed along the lower surface 12a of the elastic member 12. For example, as shown in Figure 2, in the four types of irregularly shaped gaskets 1, a support 14 is provided on all or part of the lower surface 12a of the elastic member 12. Here, the support plate 14 has a predetermined rigidity and can be made of, for example, a resin plate, a wooden plate, etc. This allows the support plate 14 to provide rigidity to the entire irregularly shaped gasket 1 when it is installed at the end of an electronic device, ensuring secure fixation to the electronic device. Also, as described above, it is possible to maintain the shape of the irregularly shaped gasket 1 when the elastic member 12 is compressed, and the conductivity between the upper and lower parts can be stabilized.

[0053] There are no particular limitations on the installation position of the support plate 14. For example, as shown in Figure 2, the support plate 14 may be installed along the lower surface 12a of the elastic member 12, or the support plate 14 may be embedded inside the elastic member 12 along the lower surface 12a of the elastic member 12.

[0054] Next, a method for manufacturing the irregularly shaped gasket 1 according to the present invention will be described. The method for manufacturing the irregularly shaped gasket 1 according to the present invention comprises a first installation step and a second installation step. In the first installation step, a metallic foil 11 is provided on the surface of a rectangular insulating fabric 10, which contains aluminum and is made of a specific metal that does not cause metal contamination, and is configured as a rectangular thin film with a longitudinal size L corresponding to the longitudinal size L of the insulating fabric 10. Furthermore, in the second installation step, one end 10a in the short direction of the insulating fabric 10 is attached to the short-direction lower surface 12a of the elastic member 12, which has a long length L corresponding to the length L of the insulating fabric 10 and an irregular cross-sectional shape that bulges upward from the bottom surface. The back surface of the insulating fabric 10 is then attached to the surface of the elastic member 12, and the other end 10b in the short direction of the insulating fabric 10 is attached to the elastic member 12. In this way, the metallic foil 11 is continuously arranged from the short-direction upper surface to the short-direction lower surface of the elastic member 12 via the insulating fabric 10. This makes it possible to manufacture the irregular-shaped gasket 1 according to the present invention.

[0055] Here, there are no particular limitations on the first installation process; it may be manufactured using a predetermined installation device or by hand. Furthermore, as described above, it may also be manufactured by wrapping an insulating fabric 10 having a metallic foil 11 around an elastic member 12, inserting it into a predetermined mold, and heating and pressing it through the mold. [Examples]

[0056] Examples and comparative examples of the present invention will be described below in detail, but the application of the present invention is not limited to these examples. (Evaluation method)

[0057] First, to evaluate the conductivity of the irregularly shaped gasket 1 according to the present invention, a compression test apparatus 2 with an electrical resistance measurement function was used. Here, the compression test apparatus 2 with an electrical resistance measurement function comprises, for example, a compression jig 20, an object to be evaluated 21, and a measuring device 22, as shown in Figure 3. Here, the compression jig 20 is made of metal, has electrical conductivity, and consists of a planar upper part 20a and a lower part 20b. The object to be evaluated 21 is placed between the upper part 20a and the lower part 20b of the compression jig 20, and the measuring device 22 can deform the object to be evaluated 21 by activating a compression device (not shown) and pushing the upper part 20a downward against the lower part 20b.

[0058] Furthermore, the measuring device 22 is electrically connected to the upper part 20a and the lower part 20b of the compression jig 20 by conductive wires 23. A predetermined voltage is applied, and when the object to be evaluated 21 deforms by a predetermined amount (%), the resistance value (Ω) of the object to be evaluated 21 is measured.

[0059] Here, the deformation amount (%) was defined as, for example, the original shape being 100%, and the compression amounts being 10%, 20%, 30%, 40%, 50%, and 60% relative to 100%. The conductivity of the object 21 was evaluated by measuring the resistance value (Ω) of the object 21 at each deformation amount (%). (Item to be evaluated 1)

[0060] First, based on Figure 2, an L-shaped (L-shaped-1 as described above) irregular gasket 1 was manufactured as shown in Figure 4. The L-shaped irregular gasket 1 was designated as Example 1. In addition, a gasket manufactured by wrapping conductive fabric around an elastic member similar to that in Example 1 was designated as Comparative Example 1. (Evaluation Result 1)

[0061] For Example 1 and Comparative Example 1, the resistance value (Ω) was measured against the amount of deformation (%). As shown in Figure 5, in Comparative Example 1, the resistance value (Ω) remained constant at approximately 0.7Ω when the amount of deformation (%) was in the range of 10% to 50%, and decreased to approximately 0.5Ω when the amount of deformation (%) was 60%. On the other hand, in Example 1, surprisingly, the resistance value (Ω) remained constant at approximately 0.4Ω when the amount of deformation (%) was in the range of 10% to 50%, and decreased to approximately 0.3Ω when the amount of deformation (%) was 60%, all of which were lower than the resistance value (Ω) of Comparative Example 1. (Item to be evaluated 2)

[0062] Furthermore, based on Figure 2, a D-shaped irregular gasket 1 was manufactured as shown in Figure 4. The D-shaped irregular gasket 1 was designated as Example 2. A gasket manufactured by wrapping conductive fabric around an elastic member similar to that in Example 2 was designated as Comparative Example 2. (Evaluation result 2)

[0063] For Example 2 and Comparative Example 2, the resistance value (Ω) was measured against the amount of deformation (%). As a result, in Comparative Example 2, the resistance value (Ω) decreased gradually from approximately 1.3Ω to approximately 0.7Ω and then to approximately 0.2Ω as the amount of deformation (%) ranged from 10% to 60%. On the other hand, in Example 2, surprisingly, the resistance value (Ω) decreased sharply to approximately 0.1Ω at a deformation amount (%) of 10%, and then gradually decreased from approximately 0.1Ω as the amount of deformation (%) ranged from 20% to 60%, all of which were lower than the resistance value (Ω) of Comparative Example 2, as described above. (Item to be evaluated 3)

[0064] Furthermore, based on Figure 2, a P-shaped irregular gasket 1 was manufactured as shown in Figure 4. This P-shaped irregular gasket 1 was designated as Example 3. A gasket manufactured by wrapping conductive fabric around an elastic member similar to that in Example 3 was designated as Comparative Example 3. (Evaluation result 3)

[0065] For Example 3 and Comparative Example 3, the resistance value (Ω) was measured in relation to the amount of deformation (%). As a result, in Comparative Example 3, the resistance value (Ω) decreased gradually from approximately 3.3Ω to approximately 1.4Ω and then to approximately 0.5Ω as the amount of deformation (%) ranged from 10% to 60%. On the other hand, in Example 3, surprisingly, the resistance value (Ω) decreased sharply to approximately 0.7Ω at a deformation amount (%) of 10%, and then gradually decreased to approximately 0.2Ω and then to approximately 0.1Ω as the amount of deformation (%) ranged from 20% to 60%, all of which were lower than the resistance value (Ω) of Comparative Example 3, as described above. (Item to be evaluated 4)

[0066] Furthermore, based on Figure 2, a TR-type irregularly shaped gasket 1 was manufactured as shown in Figure 4. This TR-type irregularly shaped gasket 1 was designated as Example 4. A gasket manufactured by wrapping conductive fabric around an elastic member similar to that in Example 4 was designated as Comparative Example 4. (Evaluation result 4)

[0067] For Example 4 and Comparative Example 4, the resistance value (Ω) was measured against the amount of deformation (%). As a result, in Comparative Example 4, the resistance value (Ω) decreased gradually from approximately 4.2Ω to approximately 0.7Ω and then to approximately 0.2Ω as the amount of deformation (%) ranged from 10% to 60%. On the other hand, in Example 4, surprisingly, the resistance value (Ω) decreased sharply to approximately 1.2Ω at a deformation amount (%) of 10%, and then gradually decreased to approximately 0.3Ω and then to approximately 0.2Ω as the amount of deformation (%) ranged from 20% to 60%. Furthermore, in Example 4, at a deformation amount (%) of 60%, the resistance value (Ω) was approximately 0.1Ω or less, indicating that the resistance value was approaching zero. And, as described above, the resistance values ​​(Ω) of Example 4 were all lower than those of Comparative Example 4.

[0068] Thus, it was found that the irregularly shaped gasket 1 according to the present invention exhibited low deformation and high conductivity in all of Examples 1-4. Furthermore, aluminum was used in all of Examples 1-4, preventing metal contamination. In this way, the irregularly shaped gasket 1 according to the present invention makes it possible to provide low deformation, low rebound, and high conductivity without causing metal contamination. [Industrial applicability]

[0069] As described above, the irregularly shaped gasket and the method for manufacturing the irregularly shaped gasket according to the present invention are useful in all fields, including not only electronic equipment but also electrical equipment, industrial machinery, plants, automobiles, transportation equipment, home appliances, daily necessities, building equipment, housing equipment, medical equipment, food processing equipment, aerospace equipment, space equipment, etc., and are effective as irregularly shaped gaskets and methods for manufacturing irregularly shaped gaskets that can provide high conductivity even with low deformation and low rebound without causing metal contamination. [Explanation of symbols]

[0070] 1. Irregular-shaped gasket 10 Insulating fabric 11 Metallic foil 12 Elastic member

Claims

1. A rectangular insulating fabric, A metallic foil is provided on the surface of the insulating fabric, comprising a specific metal that contains aluminum and does not cause metallic contamination, configured as a rectangular thin film whose longitudinal size corresponds to the longitudinal size of the insulating fabric, and which contains aluminum and is composed of a specific metal that does not cause metallic contamination, An elastic member having a longitudinal size corresponding to the longitudinal size of the insulating fabric, and having an irregular cross-sectional shape that bulges upward from the bottom surface, Equipped with, By attaching one end of the insulating fabric in the short direction to the lower surface of the elastic member in the short direction, attaching the back surface of the insulating fabric to the surface of the elastic member, and attaching the other end of the insulating fabric in the short direction to the elastic member, the metallic foil is arranged continuously from the upper surface to the lower surface of the elastic member in the short direction, via the insulating fabric. Irregularly shaped gasket.

2. The cross-sectional shape of the elastic member is one of the following: L-shaped, semicircular, a combination of semicircular and plate-shaped, or triangular. The irregularly shaped gasket according to claim 1.

3. A support plate having greater rigidity than the elastic member, installed on the elastic member along the lower surface of the elastic member. It also has, The irregularly shaped gasket according to claim 1.

4. A first installation step involves placing a metallic foil on the surface of a rectangular insulating fabric, which contains aluminum and is composed of a specific metal that does not cause metallic contamination, and which is formed as a rectangular thin film whose longitudinal size corresponds to the longitudinal size of the insulating fabric. A second installation step involves attaching one end of the insulating fabric in the short direction to the lower surface in the short direction of an elastic member having a long length corresponding to the length of the insulating fabric and an irregular cross-sectional shape that bulges upward from the bottom surface, attaching the back surface of the insulating fabric to the surface of the elastic member, and attaching the other end of the insulating fabric in the short direction to the elastic member, thereby positioning the metallic foil continuously from the upper surface to the lower surface in the short direction of the elastic member via the insulating fabric. A method for manufacturing a non-standard gasket.

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