Elastic Contact Terminal With Polymer-Coated Conductive Sheet
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Solution Overview
Problem
Conventional elastic electrical contact terminals face issues with high electrical resistance due to protruding hot-melt adhesives, difficulty in maintaining adhesion at high temperatures, and limited shape variability, especially when the electroconductive sheet is thin and woven.
Innovation Solution
An elastic electrical contact terminal is designed with a silicone rubber adhesive and an electroconductive sheet surrounding an elastic core, featuring a polymer coating layer to prevent adhesive leakage and minimize contact resistance, along with a foam or silicone rubber tube core for enhanced elasticity and restorability, allowing direct contact with electroconductive objects and reduced compressive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot-melt adhesive is used to bond the electroconductive sheet to the elastic core, then adhesion is achieved, but the adhesive protrudes through gaps in the woven filaments causing increased electrical resistance
Solution Approach 1:
A polymer coating layer is applied to the inner surface of the electroconductive sheet to act as an intermediary barrier. This coating prevents the hot-melt adhesive from protruding through the woven filament gaps while still allowing the adhesive to bond the sheet to the elastic core, thereby maintaining electrical conductivity.
Solution Approach 2:
A thin polymer coating layer is applied to the inner surface of the electroconductive sheet. This thin film serves as a barrier that prevents adhesive leakage through the woven structure while maintaining the flexibility and elasticity of the overall terminal structure.
2Strength
If hot-melt adhesive is used for bonding, then adhesion is achieved, but adhesion is not maintained at high temperatures (105°C or higher)
Solution Approach 1:
The patent changes the material parameters by selecting a hot-melt adhesive with a melting point suitable for high-temperature applications and applying a polymer coating that remains stable at elevated temperatures. This allows the terminal to maintain adhesion and functionality at temperatures of 105°C or higher.
3Volume of moving object
If the electroconductive sheet is made thin to reduce size, then compactness is achieved, but the sheet becomes more prone to adhesive protrusion through filament gaps
Solution Approach 1:
The polymer coating layer acts as an intermediary barrier on the inner surface of the thin electroconductive sheet, preventing adhesive from protruding through the woven filament gaps. This allows the sheet to remain thin and compact while maintaining reliable electrical connection.
4Device complexity
If only a urethane sponge is used as the elastic body, then simplicity is maintained, but it is difficult to economically provide various shapes
Solution Approach 1:
The patent uses a composite structure combining an elastic core (urethane sponge or other elastic bodies) with an electroconductive sheet and polymer coating. This composite approach allows for economical production of various shapes by selecting appropriate elastic core materials and configurations while maintaining structural simplicity.
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 reliable electrical connections with minimized resistance, maintains adhesion at high temperatures, and facilitates the creation of various shapes, ensuring improved elasticity and flexibility while reducing the amount of adhesive and compressive force required.
Implementation Method 1
an outer surface of the sheet directly comes into electrical contact with the facing objects
Implementation Method 2
a silicone rubber adhesive applied to an outer surface of the core, and an electroconductive sheet surrounding and adhering to the core with the adhesive interposed therebetween
Implementation Method 3
The core may be a foam which has a quadrangular cross section and in which skin layers are formed on a pair of surfaces corresponding to each other
Data Source
AI summary
An elastic electrical contact terminal capable of implementing a reliable electrical connection between objects, wherein the electrical contact terminal includes: an elastic core; a silicone rubber adhesive applied to the outer surface of the elastic core; and an electrically conductive fiber wrapped around and bonded to the elastic core by means of being interposed with the silicone rubber adhesive, wherein a sheet has a polymer coating layer formed on the inner surface thereof facing the silicone rubber adhesive, and has a metal layer formed on the outer surface thereof.