Space-saving, abrasion-resistant and conductive

With the growing demand for electric cars and the increasing prevalence of AI, the need for lithium-ion batteries and microchips is also rising. As these technologies are required to deliver ever greater performance, they are also becoming more sensitive and placing high demands on production environments. With the e-skin soft ESD, Igus is now launching a new energy chain for cleanrooms that is not only abrasion-resistant but also conductive. For designers, it is a game-changer, as it offers significantly greater flexibility and space savings in energy routing.

Tiny electrostatic discharges (ESD) are invisible to the naked eye but can damage sensitive products in semiconductor and electronics manufacturing. It is therefore crucial that all machine components used near these products have ESD protection. However, this is not a given when routing power and data cables, as these are generally not conductive.

“Many designers implement special shielding, which, however, wastes valuable space in the cleanroom,” says Kira Weller, Product Manager for e-chains and cleanroom expert at igus. Maintaining a large distance from the product is an equally impractical alternative, which can also lead to space problems. To solve this dilemma, igus has developed a new version of its cleanroom-compatible e-skin soft energy chain: the e-skin soft ESD, a compact e-chain that is not only abrasion-resistant but also conductive thanks to additives in the material. Electrostatic charges can be dissipated via the connection elements, similar to a lightning rod. Kira Weller: “For designers, the new energy chain is a game-changer, as it can be used close to the product without additional shielding.”

Space-saving e-chain enables tight bending radii

The e-skin soft ESD has a compact design and requires very little installation space. It consists of an upper and a lower shell, forming a closed tubular housing that securely encloses pipes, cables, or media conduits. It is manufactured from a proprietary high-performance plastic that allows for a tight bending radius of 55 mm. The internal height varies between 20 mm, 24 mm, 28 mm, and 40 mm, depending on the version, and the internal width between 33 mm, 48 mm, 68 mm, and 85 mm. Another special feature: Thanks to its oval geometry and defined rigidity, the e-skin soft ESD, unlike conventional corrugated tubing, can also accommodate unsupported lengths. This eliminates the need for a guide. Furthermore, the energy chain proves to be exceptionally durable, achieving a service life of more than 20 million double strokes.

On the way to the highest cleanliness level, ISO Class 1

The e-skin soft ESD meets the strictest cleanroom requirements. “The high-performance plastic is extremely abrasion-resistant, so no particles are generated during operation, even with rapid movements,” emphasizes Kira Weller. Particles from the cables also cannot escape, as the upper and lower shells can be joined together to form a closed tube using a zipper-like mechanism. “This guarantees both cleanroom compatibility and quick filling and maintenance of the cables,” says Kira Weller. The new energy chain has already passed tests with excellent results in the company's own cleanroom laboratory in Cologne, which was developed in cooperation with the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). Official certification will follow in the coming weeks.