Conductive Elastic Member with Smooth Cover Layer for Vacuum Pickup
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Solution Overview
Problem
Conductive elastic members with open cell structures face challenges in vacuum pickup due to uneven surfaces and low adhesive force, leading to separation of metal powder and reduced conductivity when rubbed, especially when manufactured using existing methods.
Innovation Solution
A conductive elastic member with a smooth surface is achieved by adding a conductive polymer cover layer on top of a polymer foamed body with an open cell structure, using liquid elastic polymers mixed with conductive particles, and a conductive base material adhered to the lower side, enhancing both electrical and thermal conductivity while allowing for reliable adhesion and vacuum pickup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a non-foamed conductive polymer elastic coating layer is formed on the upper side of the polymer foamed body to provide adhesion, then adhesive force is improved, but the surface becomes uneven or rough making vacuum pickup difficult
Solution Approach 1:
The coating structure is divided into multiple layers: a lower non-foamed conductive polymer elastic coating layer for adhesion, and an upper conductive polymer cover layer with smooth surface for vacuum pickup. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the coating structure have different properties: the lower layer has high adhesion strength while the upper layer has smooth surface quality. This local differentiation resolves the contradiction between adhesion and vacuum pickup by assigning different qualities to different locations.
2Strength
If the thickness of the non-foamed conductive polymer elastic coating layer is increased to provide enough adhesive force, then adhesion is improved, but the open cell structure on the surface causes metal powder to separate easily and conductivity is low
Solution Approach 1:
The coating is segmented into a lower thick non-foamed layer for adhesion and an upper thin conductive cover layer for conductivity. This segmentation allows the lower layer to be thick enough for adhesion while the upper layer maintains conductivity and prevents metal powder separation.
Solution Approach 2:
The coating structure uses composite material organization with different polymer layers having different functions. The lower layer provides mechanical adhesion while the upper conductive layer provides electrical/thermal conductivity and protects against metal powder separation.
3Strength
If a thick non-foamed conductive polymer elastic coating layer is formed on the upper side to improve adhesion, then adhesive force is improved, but manufacturing complexity increases and the surface still has pores from the open cell structure
Solution Approach 1:
The coating system is segmented into two functional layers applied in sequence. This segmentation provides a practical manufacturing solution where each layer can be applied and controlled independently, avoiding the complexity of forming a single thick layer with uniform properties.
Solution Approach 2:
The surface quality is locally improved by adding the smooth conductive polymer cover layer over the porous lower layer. This local quality enhancement eliminates the surface pores issue without requiring complete redesign of the entire coating system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a conductive elastic member with improved conductivity, enhanced adhesive properties, and ease of vacuum pickup, preventing particle separation and enabling reliable surface mounting and reflow soldering, while maintaining high elasticity and manufacturing efficiency.
Implementation Method 1
a conductive polymer cover layer formed by adhering liquid elastic polymers including conductive particles mixed therein to an upper side of the conductive elastic rubber coating layer
Implementation Method 2
liquid elastic polymers including conductive particles mixed therein
Implementation Method 3
having one of thermal conductivity and electrical conductivity
Implementation Method 4
a polymer foamed body having elasticity and including an open cell structure having a sheet shape including a plurality of pores vertically connecting upper and lower sides
Implementation Method 5
formed by adhering liquid elastic rubber including conductive particles mixed therein to the upper and lower sides of the polymer foamed body and inner surfaces of the pores by hardening
Data Source
AI summary
A conductive elastic member includes a polymer foamed body having elasticity and including an open cell structure having a sheet shape including a plurality of pores vertically connecting upper and lower sides without skin layers, conductive elastic rubber coating layers formed by adhering liquid elastic rubber including conductive particles mixed therein to the upper and lower sides of the polymer foamed body and inner surfaces of the pores by hardening, a conductive polymer cover layer formed by adhering liquid elastic polymers including conductive particles mixed therein to an upper side of the conductive elastic rubber coating layer formed on the upper side of the polymer foamed body by hardening the polymers, and a conductive base material adhered to a lower side of the conductive elastic rubber coating layer formed on the lower side of the polymer foamed body by hardening the elastic rubber.