Dissipative Elastomer Connector Insert for ESD Bleed and Seal Integrity

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Solution Overview

Problem

Existing electrical connector technologies either corrupt the environmental seal or use discrete components like resistors that are prone to damage in electrostatic discharge (ESD) transients, failing to provide a durable electrostatic bleed.

Innovation Solution

A connector insert with an electrically dissipative elastomer layer having a volume resistivity of 10^6 to 10^11 ohms-cm, which provides a slow, durable electrostatic bleed without discrete components, ensuring electrical dissipation through an elastomer layer with openings for pins and a non-conductive elastomer layer for insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If standard circuit board technology is used, then electrical dissipation is provided, but the environmental seal of the connector is corrupted

Engineering Contradiction:

Improveelectrical dissipationVSAvoidenvironmental seal corruption

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from rigid circuit board material to flexible elastomer material with controlled volume resistivity (10^6 to 10^11 ohms-cm). This parameter change allows the material to conform to the connector geometry and maintain the environmental seal while still providing the required electrical dissipation function.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite elastomer materials that combine electrical dissipative properties with sealing capabilities. The elastomer layer integrates multiple functions: electrical dissipation, environmental sealing, and mechanical flexibility, replacing the separate circuit board and seal components.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If EESeal silicone inserts with discrete components are used, then the environmental seal is maintained, but the discrete components are easily damaged in ESD transients

Engineering Contradiction:

Improveenvironmental seal integrityVSAvoidcomponent durability in ESD

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent extracts and eliminates the discrete electronic components (resistors, wires, traces) from the connector insert. By removing these fragile components, the solution avoids their vulnerability to ESD damage while maintaining the environmental seal through the elastomer material itself.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical/discrete component system with a continuous elastomer material system. Instead of using separate resistors and conductive traces that can be damaged, the electrical dissipation is achieved through the bulk electrical properties of the elastomer material, which is inherently more resistant to ESD.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If discrete components like resistors are used for electrostatic bleed, then electrical dissipation is achieved, but the components are prone to damage and lack durability

Engineering Contradiction:

Improveelectrical dissipation functionVSAvoidcomponent lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The elastomer material provides electrical dissipation through its inherent bulk electrical properties rather than requiring separate discrete components. The material serves multiple functions simultaneously (sealing, structural support, and electrical dissipation), eliminating the need for vulnerable discrete components and improving overall durability.

Inventive Principle:

Principle #25Self-service

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 effectively prevents electrostatic discharge transients by providing a high-resistive, durable electrostatic bleed, maintaining the environmental seal and ensuring electrical insulation, while eliminating the need for discrete components.

Implementation Method 1

an electrically dissipative elastomer layer comprising a volume resistivity of about 10^6 to about 10^11 ohms-cm

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Implementation Method 2

a non-conductive elastomer having a volume resistivity greater than about 10^12 ohms-cm

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS12407123B1Electrically dissipative flexible unitary connector insert

Publication Date: 2025.09.02 QUELL CORP

AI summary

A connector insert that provides electrical dissipation for pins of an existing electrical connector that are desirable to have electrical dissipation, and which can provide electrical isolation from an electrically dissipative layer for pins which are desirable to not have electrical dissipation. The connector insert can include an electrically dissipative layer and one or more electrically non-conductive portions.