Conductive Paste for Flexible Electrode Contact
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Solution Overview
Problem
Existing methods for contacting electrically conductive fabrics, such as seat heaters, face challenges with high contact resistance, visibility of electrodes, and inability to withstand dynamic and climatic loads, leading to inconsistent heating and potential electrical failures under high currents.
Innovation Solution
The use of an electrically conductive, curable polymeric paste with three-dimensionally branched dendritic particles to create a uniform, flexible, and resilient contact between electrodes and a conductive plastic layer, allowing for any positioning of electrodes without visible surface impact and maintaining low contact resistance under various loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact electrodes are sewn to the heating elements, then electrical contact is established, but the seam is visible on the surface and contact resistance becomes non-uniform
Solution Approach 1:
A conductive adhesive layer is introduced as an intermediary between the contact electrode and the heating element. This adhesive layer distributes the electrical contact across a larger area and eliminates the need for visible seams, while maintaining low and uniform contact resistance throughout the contact region.
Solution Approach 2:
The contact method is changed from mechanical (sewing) to chemical bonding (adhesive). This parameter change allows the contact electrode to be bonded to the heating element without creating visible seams, while the adhesive's conductive properties ensure uniform electrical contact across the interface.
2Reliability
If contact electrodes are sewn to the heating elements, then electrical contact is established, but contact resistance becomes non-uniform under dynamic loads
Solution Approach 1:
The contact method transitions from mechanical interlocking (sewing) to chemical bonding with electrical conduction (conductive adhesive). This enables uniform distribution of contact pressure and electrical current across the entire contact area, eliminating localized high-resistance points that occur with sewing methods under dynamic loads.
Solution Approach 2:
The contact system uses a composite structure combining the adhesive's bonding properties with conductive fillers (such as metal particles or carbon). This composite material simultaneously provides mechanical adhesion to maintain contact under dynamic loads and electrical conductivity to ensure uniform current distribution across the contact interface.
3Adaptability or versatility
If rigid adhesives are used to bond contact electrodes, then positioning flexibility is improved, but the bond cannot withstand dynamic loads
Solution Approach 1:
The adhesive comprises a flexible polymer matrix combined with conductive fillers. The flexible matrix provides elasticity to withstand dynamic loads and repeated bending, while the conductive fillers maintain electrical connectivity. This composite formulation allows the adhesive to bond electrodes in any position while remaining durable under mechanical stress.
4Power
If high current flows through local heating areas, then heating function is achieved, but contact resistance irregularities cause hot spots and electrical line failure
Solution Approach 1:
The contact interface transitions from discrete point contacts (sewing) to a continuous conductive layer. This parameter change distributes the high current across a larger contact area, preventing current concentration at specific points and eliminating hot spots that would otherwise lead to electrical line failure under high-power heating conditions.
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 solution provides a stable, flexible, and resistant contact that maintains low contact resistance even under high currents and prolonged exposure to heat and moisture, preventing hotspots and ensuring reliable electrical connectivity over time.
Implementation Method 1
The use of an electrically conductive, curable polymeric paste with three-dimensionally branched dendritic particles to create a uniform, flexible, and resilient contact between electrodes and a conductive plastic layer
Implementation Method 2
an electrically conductive, curable polymeric paste with three-dimensionally branched dendritic particles
Data Source
Figure 1~2
Figure 3~4
AI summary
Electrically conductive connection of an electrically conductive planar structure with a current supply in the form of an electrode, wherein the conductive connection between the electrode and the layer of conductive plastic material is made by an electrically conductive, curable polymeric paste, which has three-dimensionally branched, conductive, dendritic particles, wherein the electrode has conductive filaments, wherein the filaments are arranged and spaced relative to each other and the viscosity of the paste is such that the paste surrounds or penetrates the electrode by embedding and enclosing the filaments and bonds to the layer of conductive plastic material in a curing manner.