Rubber-Metal Electric Contact Structure Without Surface Rubber Overflow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rubber and metal composite electric contacts face issues with rubber overflow on the working surface, which affects electrical conductivity, and previous solutions either compromised mechanical strength or failed to ensure reliable bonding under acidic or alkaline conditions.
Innovation Solution
A rubber and metal composite electric contact is developed without an isolation layer, featuring a metal sheet with through holes filled with rubber, ensuring no rubber overflow and firm bonding between rubber and metal layers, while maintaining good dust resistance and adjustable mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If an isolation layer is added between rubber and metal layers, then rubber overflow is prevented, but bonding strength and reliability under acidic or alkaline conditions deteriorate
Solution Approach 1:
The patent introduces a primer layer as an intermediary between the rubber composition and metal sheet. This primer layer serves as a chemical mediator that enhances adhesion without creating a physical barrier like an isolation layer. The primer contains functional groups that can chemically bond with both the rubber matrix and the metal surface, ensuring reliable bonding even under acidic or alkaline conditions while preventing rubber overflow during vulcanization.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the rubber composition by incorporating specific adhesion promoters and controlling the composition ratio of rubber, filler, and curing agents. These parameter changes enable the rubber to achieve optimal adhesion to the metal surface directly, eliminating the need for an isolation layer while maintaining bonding reliability in harsh environments.
2Object-generated harmful factors
If through holes are made in the metal sheet, then rubber overflow is prevented and dust resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the metal sheet into multiple regions with through holes strategically positioned and sized. Rather than creating a complex overall structure, the segmentation of holes into specific patterns (size, distribution, and arrangement) simplifies the manufacturing process while effectively preventing rubber overflow and improving dust resistance.
Solution Approach 2:
The patent utilizes a porous metal sheet structure with controlled porosity through the through holes. This porous design allows the rubber to be contained within the holes during vulcanization, preventing overflow while maintaining structural integrity. The standardized hole dimensions and distributions make the manufacturing process straightforward rather than complex.
3Strength
If rubber composition is optimized for adhesion, then bonding strength improves, but electrical conductivity may be affected
Solution Approach 1:
The patent applies local quality by concentrating adhesion promoters and functional additives specifically at the interface region between rubber and metal, while maintaining the bulk rubber composition for optimal electrical conductivity. The primer layer localized at the metal-rubber interface provides enhanced bonding without interfering with the conductive properties of the bulk rubber composition.
Solution Approach 2:
The patent creates a composite structure consisting of rubber composition, primer layer, and metal sheet. This composite material system allows each component to fulfill its specific function: the rubber provides conductivity and elasticity, the primer provides adhesion, and the metal provides structural support and electrical contact. The synergistic combination maintains both bonding strength and electrical conductivity.
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 rubber overflow, ensuring stable and reliable electrical conductivity, firm bonding between rubber and metal, and improved durability against environmental factors, making it suitable for mass production.
Implementation Method 1
heating and vulcanizing the rubber composition and the metal sheet to perform thermal vulcanization molding
Implementation Method 2
the rubber in the composite material shrinks or collapses
Data Source
AI summary
A rubber and metal composite electric contact and a preparation process therefor. The rubber and metal composite electric contact is a circular layered complex which is formed by tightly combining a metal sheet layer having a plurality of through holes and a rubber layer by means of thermal vulcanization molding and which has a thickness of 0.1 to 5 mm and a diameter of 1 to 15 mm. There is no isolation layer between the rubber layer and the metal layer of the electric contact, so no rubber overflows the outer surface of the metal layer. In the rubber and metal composite electric contact, the rubber and metal are combined firmly and the overall strength of the electric contact is adjustable; the electric contact also has good dust resistance; and the electric contact thus has stable and reliable electrical conductivity.