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| CarbonConX Xerox has developed CarbonConX as an alternative to unreliable and expensive metal contacts. Originally created for use in passive devices for electrostatic discharge applications, CarbonConX has proven to be a preferred technology for electrical switch components. Xerox CarbonConX technology offers high functionality with low complexity. Useful in a variety of applications, CarbonConX makes use of pultrusion to form bundles of carbon fibers into each contact, ensuring redundancy in the contact point. The CarbonConX technology uses low-pressure pultrusion to bundle thousands of carbon fibers into each contact, ensuring redundancy in the contact point. This process involves pulling the carbon fibers and a thermoplastic or thermosetting polymer through a shaping/curing die. The result is a high-strength, electrically conductive contact. Using carbon fibers makes the CarbonConX reliable, inert, and multifunctional. Carbon fibers are less susceptible to corrosion than metal contacts. Their nonreactive nature makes them ideal for use in harsh environments, including saltwater, nuclear power, space, or medical X-ray environments. Additionally, pultruded carbon fiber contacts can act as structural members, due to the high strength material characteristics of the polymer and carbon bundle. The high number of contacting fibers makes CarbonConX attractive for applications where reliability is critical. As produced, CarbonConX surfaces are inherently contact rich , providing statistically regular, evenly distributed contact sites. The effective surface area of a CarbonConX can be greater than the simple planar surface area, depending on the engagement length of the fibers. The primary characteristics of a CarbonConX are: • High density of evenly distributed conduction sites. • Robust character of the carbon fibers results in high immunity to the formation of non-conductive films and high contact integrity in contact degrading environments. CarbonConX may be produced exhibiting conductivities in the metallic range with the application of metal coated fibers. By use of controlled carbonization techniques, the electrical conductivity of the carbon fibers can be precisely tuned. A wide range of conductivities can be achieved by the use of this process and designed directly into the CarbonConX material. Integrating the resistor function into the contact structure further simplifies component design, reduce part count, lowers cost and improves reliability. Non plated CarbonConX can be applied with advantage over metallic contacts especially in low energy circuitry. Typically, applied voltages of 100VDC or less and current levels on the order of 100 ma/mm2 are practical. CarbonConX contact resistances of a few hundred milliohms to a few hundred ohms are determined by contact geometry, fiber characteristics and normal force. ![]() CarbonConX has the following advantages over metal contacts: Reliable - CarbonConX provides more contact area (i.e., thousands of conducting fibers per contact), resist films formed on metal contacts, and have lower failure rates. Rugged - CarbonConX resists corrosion and contamination, even in harsh environments. Multifunctional - Using pultrusion to bundle the carbon fibers allows the CarbonConX to conduct electricity and provide structural support. Inert - Carbon fibers are nonfilming. Versatile - CarbonConX can be manufactured in various design shapes and configurations. Low cost - CarbonConX have commodity pricing and use simple, efficient manufacturing processes. Proven - CarbonConX have been in practice for many years in commercially available products. Manufacturing capability already exists to support future expansion of the technology.
Mechanical properties: Supplemental information for T-300/M826/dia 1.6
The CarbonConX technology encompasses a patent portfolio of over 30 patents and extensive know-how. Issued core patents relating to CarbonConX include U.S. 5,139,862 and U.S. 5,270,106 (continuous carbon fibers in pultruded polymer matrix); and U.S. 5,282,310 and U.S. 5,396,044 (method for manufacturing DFCs). Additional CarbonConX technology patents are listed below.
To learn more about licensing the CarbonConX technology, contact Xerox. Read more about the CarbonConX technology in this press release and by obtaining the following article: Y. Deng, M.G. Pecht, J.A. Swift, and S.J. Wallace, "Carbon Fiber-Based Grid Array Interconnects", IEEE Transactions on Components and Packaging Technologies, vol. 30, issue 4, pp. 716-723, Dec. 2007. Please note that CarbonConX is the brand name for Distributed Filament Contacts (DFC). The patents and EDN article refer to the technology as DFC. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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