Compliant Support Backing for Electrical Contact Reliability
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Solution Overview
Problem
The reliability of electrical connections between testing modules and head gimbal assemblies (HGAs) is compromised due to degradation of electrical contacts, such as broken solder joints and worn-out surfaces, which prevents accurate testing of HGAs, especially as disc drives become smaller.
Innovation Solution
A flex circuit with raised electrical contacts and a compliant support backing that includes individual support elements to increase contact pressure and maintain consistent connection force, eliminating the need for solder joints and providing robust connections for testing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If repeated use of electrical contacts on testing module, then testing capability is maintained, but electrical contacts degrade and become unusable
Solution Approach 1:
The patent applies the dynamics principle by making the support backing compliant rather than rigid, allowing it to dynamically adapt to contact wear and maintain optimal contact pressure throughout the service life of the electrical contacts. The compliant backing deforms elastically to compensate for degradation, ensuring consistent electrical connection reliability over extended use.
Solution Approach 2:
The patent changes the mechanical parameters of the support structure by using a compliant backing material with specific elastic properties. This allows the support to change its physical state slightly under load, maintaining constant contact pressure despite wear. The raised contact geometry also changes the distribution of mechanical stress, reducing wear on the electrical contacts themselves.
2Volume of moving object
If electrical contacts are made smaller to accommodate smaller disc drives, then miniaturization is achieved, but connection reliability becomes more difficult to maintain
Solution Approach 1:
The patent applies local quality by creating raised contacts with concentrated plating only at the critical contact surfaces. This local reinforcement of the contact geometry ensures that the most important areas have enhanced durability and conductivity, while the overall structure remains miniaturized. The compliant backing also provides localized support exactly where needed at each contact point.
3Ease of manufacture
If solder joints are used to connect electrical contacts to traces, then electrical connection is established, but solder joints can break and render contacts unusable
Solution Approach 1:
The patent extracts the problematic solder joint from the connection path by using raised contacts that make direct mechanical and electrical contact with the flex circuit traces. This eliminates the intermediate solder layer that is prone to cracking and failure, while still achieving reliable electrical connection through the raised contact geometry and compliant support.
4Duration of action of stationary object
If worn electrical contact surfaces are used, then continued operation is possible, but signal degradation occurs preventing accurate testing
Solution Approach 1:
The compliant support backing dynamically compensates for contact surface wear by deforming elastically to maintain optimal contact pressure. As contacts wear over time, the backing material gradually deforms to keep the contact interfaces tight, ensuring that signal integrity and testing accuracy are maintained throughout the operational lifespan of the contacts.
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 solution ensures reliable and consistent electrical connections, even with worn contacts, enhancing the speed and accuracy of testing HGAs by maintaining a stable contact pressure and minimizing signal degradation.
Implementation Method 1
A compliant support backing that supports electrical contacts includes a plurality of fingers to support each electrical contact separately
Data Source
AI summary
An assembly comprises a flex circuit including a first set of electrical contacts on a first side of the flex circuit and a compliant support backing adjacent a second side of the flex circuit and opposite the set of electrical contacts. The first set of electrical contacts is configured to connect to a second set of electrical contacts on an electronic component. The compliant support backing includes a set of support elements that individually support the first set of electrical contacts to increase the contact pressure between the first set of electrical contacts and the second set of electrical contacts when the flex circuit is connected to the electronic component. Embodiments may provide robust electrical contracts which provide a reliable connection useful for testing electronic components, such as head gimbal assemblies.