Conductive Elastomer Connector Insert for Stray Inductance Reduction
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Solution Overview
Problem
Current electrical connector technologies, such as those using standard circuit board technology or EESeal silicone inserts, face limitations in high-frequency performance due to stray inductance introduced by filament wire interconnects and discrete surface mount devices, which corrupt the environmental seal and are labor-intensive to construct.
Innovation Solution
A connector insert comprising layers of conductive elastomer with low volume resistivity, integrated with non-conductive elastomer for capacitors and other electrical components, reducing stray inductance and allowing for effective filtering up to GHz frequencies without compromising the environmental seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If EESeal silicone inserts with filament wire interconnects are used, then the environmental seal is maintained, but stray inductance increases and high-frequency performance deteriorates
Solution Approach 1:
The patent changes the physical state and electrical properties of the elastomer by incorporating conductive particles or fillers to create a conductive elastomer material. This transforms the traditionally insulating silicone elastomer into a material that provides both sealing and electrical connectivity functions, eliminating the need for separate wire interconnects that generate stray inductance.
Solution Approach 2:
The patent creates a composite material by combining silicone elastomer with conductive particles or fillers to form conductive elastomer. This composite material simultaneously provides the environmental sealing properties of silicone and the electrical conductivity needed to eliminate stray inductance, resolving the contradiction between seal integrity and high-frequency performance.
2Adaptability or versatility
If discrete surface mount devices are incorporated, then electrical circuitry functionality is added, but stray inductance increases and high-frequency performance deteriorates
Solution Approach 1:
The patent merges the electrical circuitry functionality directly into the elastomer insert by creating conductive pathways and integrated capacitor structures within the elastomer matrix. This eliminates the need for discrete surface mount devices and their associated stray inductance, while maintaining the required electrical filtering capabilities for high-frequency operation.
Solution Approach 2:
The patent replaces the mechanical wire interconnect system and discrete component assembly with an integrated conductive elastomer system. This substitution eliminates the mechanical connections that generate stray inductance and provides a monolithic structure optimized for high-frequency performance.
3Adaptability or versatility
If standard circuit board technology is used, then electrical circuitry is added, but the environmental seal is corrupted
Solution Approach 1:
The patent uses a flexible elastomer insert that can be molded to fit within the connector housing while maintaining the environmental seal. The elastomer material provides both the structural integrity needed for sealing and the flexibility to accommodate electrical circuitry integration, unlike rigid circuit board technology that compromises the seal.
4Ease of manufacture
If filament wire interconnects are used, then electrical connections are established, but construction complexity and labor increase
Solution Approach 1:
The conductive elastomer insert is designed to be self-contained, with electrical connections established through the inherent conductivity of the elastomer material itself. The insert can be molded as a single piece with integrated conductive pathways, eliminating the need for separate wire assembly steps and reducing construction complexity.
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 ultra-low stray inductance, enabling effective electromagnetic interference (EMI) filtering well into the GHz range while maintaining the environmental seal integrity and reducing construction complexity.
Implementation Method 1
The layers have a volume resistivity less than about 0.010 ohms/cm
Implementation Method 2
separation provided by at least one layer of non-conductive material, and most preferably wherein the at least one layer of non-conductive material comprises non-conductive elastomer
Data Source
AI summary
A connector insert comprising conductive wire and a plurality of layers of conductive and non-conductive elastomers, and methods of fabrication thereof.