Conductive Gasket with Adhesive-Isolated Cover for EMI Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing EMI and RFI gaskets face issues with establishing a reliable conductive path due to adhesive migration and inconsistent compression, leading to compromised effectiveness, particularly in small sizes and varied applications.
Innovation Solution
A gasket design featuring a core with a perimeter and attachment portion, where an electrically conductive cover with end flaps is attached using adhesives that allow for retention of flaps in contact with the conductive object without relying on adhesive conductivity, enabling mechanical fasteners and varied shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive pressure sensitive adhesive is used to affix the gasket to establish an electrically conductive path, then electrical conductivity is improved, but the adhesive particles migrate under continuous pressure creating uneven conductive paths
Solution Approach 1:
The gasket is divided into distinct functional layers: a non-conductive adhesive layer for attachment and a separate electrically conductive cover layer for electrical continuity. This segmentation prevents particle migration issues by eliminating the need for conductive particles within the adhesive itself, while maintaining reliable electrical conductivity through the dedicated conductive cover.
Solution Approach 2:
The electrical conductivity function is extracted from the adhesive layer and assigned to a separate conductive cover layer. This extraction resolves the contradiction by removing the source of particle migration (conductive particles in adhesive) while preserving the essential electrical conductivity function through the isolated conductive cover component.
2Reliability
If the gasket relies on compression to force portions to flow around adhesive or fasteners, then electrical contact is achieved, but insufficient compression force results in failure to establish conductive path
Solution Approach 1:
The electrically conductive cover acts as an intermediary component that bridges the gap between the gasket core and the conductive surface. This intermediary layer ensures reliable electrical contact without requiring excessive compression force, as the conductive cover maintains continuous contact through its flexible nature and proper mechanical attachment.
Solution Approach 2:
The design changes the physical parameters by introducing a flexible conductive cover layer that can deform to maintain contact under varying compression forces. This parameter change allows the system to establish reliable electrical contact across a broader range of compression forces compared to rigid conductive paths.
3Ease of manufacture
If adhesives or mechanical fasteners are used to attach the gasket, then the gasket can be affixed to the conductive surface, but a barrier is formed between the conductive cover and the conductive surface
Solution Approach 1:
The attachment function and electrical conductivity function are segmented into separate components: the adhesive layer handles attachment to the conductive surface, while the conductive cover layer maintains electrical continuity. This segmentation allows each component to optimize its specific function without interfering with the other, eliminating the barrier effect.
Solution Approach 2:
The conductive cover serves as an intermediary that spans across the adhesive layer and the conductive surface. This intermediary component ensures that the adhesive barrier does not interrupt the electrical conductive path, as the conductive cover provides continuous electrical connectivity above the adhesive layer.
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
This design ensures consistent electrical contact and prevents adhesive migration, allowing for effective EMI and RFI shielding across various sizes and applications without the need for conductive adhesives, enhancing manufacturing flexibility and reliability.
Implementation Method 1
A second adhesive is applied to the attachment portion to affix at least one of the first and second end flaps thereto
Data Source
AI summary
An electrically conductive gasket and methods of manufacturing electrically conductive gaskets. In one embodiment, the gasket includes a core that supports an electrically conductive cover thereon. The electrically conductive cover may be attached to the core or portions of the core by one or more adhesives used to also affix the gasket to an electrically conductive object. In other embodiments, a mechanical fastener may be affixed to the core by the one or more adhesives employed to affix the electrically conductive cover to the core.