Zero Force Conductive Membrane for Electronic Device Sealing
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Solution Overview
Problem
Conductive foam used in electronic devices often creates residual biasing forces that push components apart after assembly, making it difficult to form stable electrical connections and environmental seals without generating unwanted forces.
Innovation Solution
The use of zero-force membranes, which employ temporary biasing structures such as inflatable elastomeric balloons or defeatable materials to form connections and seals, allowing for the removal of residual biasing forces by depressurizing or deactivating these structures after assembly, thereby minimizing the risk of components being pushed apart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive foam is used to form electrical connections between structures, then electrical connectivity is achieved, but residual biasing forces are generated that push components apart
Solution Approach 1:
The conductive foam is segmented into multiple smaller foam pieces distributed across the membrane structure. This segmentation reduces the cumulative biasing force while maintaining electrical connectivity across multiple contact points, resolving the contradiction between connection reliability and force generation
Solution Approach 2:
The membrane structure incorporates conductive foam only in specific localized regions where electrical connections are needed, rather than using foam uniformly throughout. This local application maintains necessary electrical connectivity while minimizing overall biasing forces on device structures
2Ease of manufacture
If temporary biasing structures are used to deploy membranes, then membrane attachment to device structures is achieved, but temporary forces are applied during assembly
Solution Approach 1:
The membrane is pre-attached to the biasing structure before deployment into the final position. This preliminary attachment ensures proper positioning and orientation during installation, making the deployment process easier while allowing the biasing force to be applied only temporarily during assembly
Solution Approach 2:
The biasing force parameter is changed from permanent to temporary by using defeatable biasing structures. The force is applied only during the deployment phase and then eliminated, resolving the contradiction between ease of manufacture and force application
3Reliability
If membranes are used to bridge gaps for environmental seals and electrical connections, then sealing and connectivity are achieved, but residual forces may disrupt assembled devices
Solution Approach 1:
The biasing structures are designed as temporary, disposable elements that serve their purpose during assembly and then are removed or deactivated. This allows the membrane to be properly installed for sealing and connectivity without leaving residual forces that would disrupt device stability
Solution Approach 2:
The temporary biasing structures are discarded after serving their deployment function, while the membrane itself is recovered and retained in the final assembly. This resolves the contradiction by eliminating the source of residual forces while maintaining the beneficial sealing and connectivity functions
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
This approach ensures that electronic device components remain securely connected without residual biasing forces, maintaining their position during normal use and preventing disassembly due to unwanted pressure, while also forming effective environmental seals and electrical connections.
Implementation Method 1
an inflatable structure may be formed from an elastomeric balloon that can be pressurized by a fluid such as air
Implementation Method 2
When an inflatable structure is pressurized, the inflatable structure may form an environmental seal that bridges a gap between structures in the electronic device
Implementation Method 3
Adhesive such as conductive adhesive may be used in attaching the inflatable structure to the structures in the electronic device
Data Source
AI summary
An electronic device may include housing structures, electronic components, and other structures. A gap may be formed between the structures. A membrane structure may be used to bridge the gap to form and environmental seal and electrical pathway between the structures. The membrane structure may be deployed using a temporary biasing member or may be installed by forming an inflatable structure. The inflatable structure may include an elastomeric balloon that may be pressurized. Adhesive such as conductive adhesive may be used in attaching the membrane structure to the structures in the electronic device. An inflatable structure may be depressurized following installation in an electronic device to minimize residual forces.