Composite Contact for Fine Pitch Interconnect Assembly

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Solution Overview

Problem

Current electrical interconnect technologies face challenges such as reliability issues due to solder fatigue, limited pitch separation, and environmental sensitivity, particularly in high-density and high-frequency applications, where traditional connectors and wire bonding methods fail to provide durable and efficient connections.

Innovation Solution

A composite contact system featuring a flexible conductive member laminated with polymeric layers, which provides mechanical support and reduces the need for insulating housing, allowing for finer pitches and improved electrical performance by using polymeric layers with enhanced dielectric properties and engagement features for mechanical interlock.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If soldered contacts are used to provide mechanical support, then structural support is achieved, but reliability deteriorates due to fatigue, stress deformation, and solder bridging

Engineering Contradiction:

Improvemechanical supportVSAvoidconnection reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the traditional mechanical support function of soldered metal contacts with a polymeric contact member that provides both mechanical support and electrical connection. The polymeric material eliminates solder joints, thereby removing the sources of solder fatigue, stress deformation, and solder bridging while maintaining the necessary mechanical support through the inherent elasticity and strength of the polymer structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs composite material construction by integrating conductive elements within a polymeric matrix. This composite structure combines the mechanical support capabilities of the polymer with the electrical conductivity of embedded conductive materials, achieving both structural integrity and electrical functionality without relying on traditional soldered metal contacts.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional connectors are used, then electrical connection is achieved, but pitch separation is limited due to risk of shorting

Engineering Contradiction:

Improveelectrical connectionVSAvoidpitch separation

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The patent utilizes a thin polymeric contact member that can be flexed during insertion and then returns to its original position. This flexible membrane structure allows for closely spaced contacts without the risk of shorting, as the polymer provides reliable electrical insulation between adjacent conductive elements while enabling fine pitch configurations that would be unsafe with traditional rigid connectors.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If elastomeric connectors are used, then compliance is improved, but electrical resistance increases and non-planarity worsens

Engineering Contradiction:

ImprovecomplianceVSAvoidelectrical resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

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

The composite contact system enhances reliability and signal integrity by reducing solder stress, allowing multiple insertions, and maintaining connectivity under environmental variations, while enabling high-density and low-inductance connections with reduced housing complexity.

Implementation Method 1

A composite contact includes a flexible conductive member with at least one laminated polymeric layer

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 2

The polymeric layer preferably surrounds or encapsulates the flexible conductive member except for exposed portions that provide electrical connection points

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 3

engagement features for mechanical interlock

Methodology Applied

Scientific EffectMechanical interlock: Mechanical Fastener

Data Source

PatentUS8232632B2Composite contact for fine pitch electrical interconnect assembly

Publication Date: 2012.07.31 R&D SOCKETS INC

AI summary

An electrical interconnect assembly for electrically interconnecting terminals on a first circuit member with terminals on a second circuit member. The electrical interconnect assembly includes a housing having a plurality of through openings extending between a first surface and a second surface. A plurality of composite contacts are positioned in a plurality of the through openings. The composite contacts include a conductive member having a central portion and at least first and second interface portions. One or more polymeric layers extend along at least the central portion conductive member. One or more coupling features on the composite contacts engage with the housing. At least one engagement feature formed in the polymeric layers proximate the first interface portion mechanically couples with the terminals on the first circuit member.