Doped Polymer Electrode Contact Area Generation
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Solution Overview
Problem
Existing polymer electrodes with conductive fillers have high input resistance due to demixing during injection-molding, leading to burn-in of contact points when high voltages are applied, especially in applications requiring high field strengths for electroporation or electrofusion.
Innovation Solution
Applying a contact material with lower specific resistance than the polymer tightly onto the doped polymer to establish close contact, potentially merging with the polymer, and using techniques like hot-embossing or pressure to ensure a low-resistance connection without exceeding the polymer's softening point, thereby reducing input resistance and preventing burn-in.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dot-like contacting is used with high voltages, then the contacting method meets specific requirements, but the contacts burn-in to the contact points
Solution Approach 1:
The conductive paste is applied beforehand to the contact areas to cushion and distribute the electrical stress and mechanical pressure. This pre-applied conductive layer prevents direct contact between the contacting element and the polymer surface, distributing the load and preventing burn-in. The paste acts as a protective intermediate layer that absorbs the stress of high voltage application.
Solution Approach 2:
The patent changes the electrical and mechanical parameters at the contact interface by introducing conductive paste with optimized conductivity and mechanical properties. This material modification allows the contact interface to withstand high voltages and pressures without burn-in, transforming the contact characteristics from direct metal-to-polymer to metal-to-paste-to-polymer, thereby improving contact durability.
2Reliability
If metal electrodes are used, then conductivity is high, but metal ions are emitted during electric discharge causing harmful effects
Solution Approach 1:
The conductive paste serves as an intermediary material between the metal contacting elements and the polymer, preventing direct metal-to-polymer contact during high voltage discharge. This intermediate layer blocks the emission of metal ions into the surrounding environment while maintaining electrical conductivity. The paste material acts as a barrier that allows current flow but prevents metal ion release.
Solution Approach 2:
The patent uses a composite structure consisting of polymer material doped with conductive substances (such as carbon black, graphite, or carbon fibers) combined with conductive paste. This composite approach provides the necessary conductivity without using pure metal electrodes, thereby eliminating metal ion emission while maintaining electrical performance. The composite material combines the benefits of polymer flexibility with conductive properties.
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 method effectively reduces the input resistance of polymer electrodes, allowing for safe dot-like contacting at high voltages without burn-in, enabling efficient electric current transmission and preventing damage to contact points.
Implementation Method 1
a contact material is applied onto the polymer so tightly that close contact between the contact material and the conductive substance is achieved, wherein the input resistance of the doped polymer is reduced
Implementation Method 2
the contact material and/or at least one part of the polymer are heated to a temperature which is higher than the softening temperature of the polymer
Implementation Method 3
a temperature which is higher than the softening temperature of the polymer
Implementation Method 4
The contact material is applied onto the polymer so tightly that close contact between the contact material and the conductive substance is achieved
Data Source
AI summary
The invention relates to a method for generating at least one electrically contactable area on a polymer which is doped with a conductive substance, wherein a contact material is applied onto the polymer, which has a lower specific resistance at 23° C. than the polymer. According to the invention the contact material is applied onto the polymer so tightly that close contact between the contact material and the conductive substance is achieved. Due to the tight application of the contact material, which has a lower specific resistance than the polymer, the input resistance of the doped polymer is effectively reduced. The invention further concerns a formed body made of a polymer which is doped with a conductive substance, which has at least one contactable area, within which a contact material is applied onto the polymer, which has a lower specific resistance at 23° C. than the polymer. According to the invention the contact material is applied onto the polymer so tightly that it is in close contact to the conductive substance. Such formed body has a significantly reduced input resistance.