Development of functionalised foam for electrostatic discharge applications

Abstract

Electrostatic discharge-sensitive devices (ESDS) consist of electronic systems that are easily damaged by electrostatic fields or discharges. To safely stow and transit the ESDS, Bosch Car Multimedia S.A. resorts to thermoformed trays with a specific design for each product configuration. Although efficient, the solutions’ specificity arose logistic issues that created the need for an alternative approach. This paper reports the investigation for the development of a flexible tray, based on an electrostatic-dissipative integral skin foam. First, a commercial integral skin polyurethane foam was evaluated by varying components mixing ratio. Once achieved a suitable combination of hardness and density, post-formulation additives (colour and anti-static) were investigated. Free expansion foaming stages were assessed and cured foams were characterised in terms of electrostatic discharge protection. Moulded foams with variable patterns were developed and evaluated considering the application purpose requirements. Real-scale prototypes of the most adequate concept design were produced and analysed.