ESD Safe Connector Insert with Dissipative Polymer
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Solution Overview
Problem
Existing multi-pin connectors are susceptible to electrostatic discharge (ESD) damage, particularly in environments like spacecraft assembly, where conventional techniques such as discharge gaps, metallic grounding, and dissipative surfactants are either ineffective or not compliant with stringent standards, and can be incompatible with modern sensitive microelectronics.
Innovation Solution
An electrically dissipative polymer insert with a volume resistivity of 1×10^6-1×10^10 ohm-cm is used, blended with conductive materials like carbon nanotubes, to allow electrostatic discharge from pins to be safely dissipated to the grounded outer shell while maintaining insulation resistance compliant with industry standards, preventing signal interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a highly insulating dielectric insert with high resistivity is used to prevent current paths between pins, then insulation resistance is improved, but electrostatic discharge protection deteriorates
Solution Approach 1:
The insert employs different resistivity characteristics in different regions or contexts: high resistivity (10^12-10^14 ohm-cm) for normal insulation between pins, and controlled lower resistivity (10^6-10^10 ohm-cm) for ESD discharge paths. This local differentiation allows the same material to provide both insulation and discharge protection functions.
Solution Approach 2:
The patent changes the resistivity parameter of the polymer insert from the conventional high range (10^12-10^14 ohm-cm) to a controlled lower range (10^6-10^10 ohm-cm). This parameter modification enables the material to dissipate electrostatic charges while maintaining sufficient insulation for normal signal operation, thus resolving the contradiction between insulation and ESD protection.
2Object-affected harmful factors
If discharge gaps are fabricated around pins to dissipate high voltage charge, then electrostatic discharge protection is improved, but device complexity and fabrication difficulty increase
Solution Approach 1:
The patent extracts the ESD protection function from the mechanical structure (discharge gaps, grounding strips) and transfers it to the material property (resistivity) of the polymer insert itself. This eliminates the need for additional structural elements and complex fabrication processes while maintaining effective charge dissipation.
Solution Approach 2:
The polymer insert acts as an intermediary between the pins and the outer conductor, providing a controlled resistive path for charge dissipation. This intermediary function replaces complex mechanical discharge structures with a simpler material-based solution that performs the same protective function.
3Object-affected harmful factors
If dissipative surfactants are applied to the insert surface to dissipate charge, then electrostatic discharge protection is improved, but compliance with space flight standards deteriorates
Solution Approach 1:
Instead of using dissipative surfactants that are considered surface contaminants and prohibited in space flight, the patent incorporates ESD functionality directly into the bulk polymer material. This eliminates the need for surface coatings that could wear off or contaminate, providing a permanent, compliant solution.
Solution Approach 2:
The patent uses composite polymer materials with controlled resistivity (10^6-10^10 ohm-cm) that inherently provide ESD protection without requiring additional surface treatments or coatings. This composite approach integrates multiple functions (insulation, ESD protection, space flight compliance) into a single material system.
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 dissipates tribo-electric charges to chassis ground without altering the mechanical properties of the connector, ensuring compliance with stringent resistance requirements and preventing ESD damage to microcircuits, even in environments with low humidity or high sensitivity.
Implementation Method 1
an electrically dissipative polymer insert with a volume resistivity of 1×10^6-1×10^10 ohm-cm is used, blended with conductive materials like carbon nanotubes, to allow electrostatic discharge from pins to be safely dissipated to the grounded outer shell
Implementation Method 2
maintaining insulation resistance compliant with industry standards, preventing signal interference
Data Source
AI summary
A dissipative insert provided within an electrical connector having multiple connector pins and an outer conductive housing where the insert is configured around the pins within the housing and provides structural integrity thereto and prevents a short circuit between the pins and between the pins and the housing. The insert is comprised of a mixture of a polymer and a conductive material that causes the insert to have a volume resistivity in the range of 1×106-1×1010 ohm-cm. In one embodiment, the conductive material is carbon nanotubes.