Key aspects of the materials and processes associated with the synthesis and use of distributed filament contacts from PAN fiber based composites

Abstract

Distributed Filament Contacts (DFCs) are an emerging class of non-metallic, electrical contacts which are technically interesting and commercially useful. Conductive carbon fiber filled composites are pultruded, then laser or waterjet processed into contact surfaces that are rich in oriented and continuous carbon fiber that is distributed across the entire contact face and available to conduct current across a separable interface. The combination of a high degree of contact-spot redundancy, low mating force, and predictable contact resistance makes these contacts acceptable for certain applications requiring high reliability. This paper discusses the features and physics of novel Distributed Filament Contacts which have been developed for use as slip ring devices.

Carbon Fiber-Based Grid Array Interconnects

“…Normal force is required to push and retain the carbon fiber contacts against metal pads and ensure they remain in contact. A soft, brush-like surface can be designed into the carbon fiber contacts which may be preferred to achieve a lower electrical contact resistance, as opposed to a harder, rigid surface which is also possible [10], [25], [26].…”

“…Swift and Wallace [10] attempted different contact surface preparation approaches on carbon fiber composites (CFCs), in order to achieve a lower electrical contact resistance. The approaches included diamond cutoff wheel, laser, water-jet and flame.…”