Conductive Contact Terminal with Elastic Core and Adhesive Layer
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Solution Overview
Problem
Conductive contact terminals used in surface mounting face challenges such as deformation and loss of conductivity during high-temperature reflow soldering, and have issues with electrical resistance and durability due to the limitations of existing materials like Be-Cu alloys and foamed rubber-based solutions.
Innovation Solution
A conductive contact terminal design featuring an elastic core with a conductive adhesive layer and a metal layer, where the metal layer is applied on both sides of a heat-resistant film with holes, allowing electrical connection through the film's walls, ensuring elasticity and maintaining conductivity even if the metal layer is broken.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a typical conductive material is simply used, then the product can be manufactured easily, but the product is deformed and loses conductivity during high-temperature reflow soldering
Solution Approach 1:
The patent uses a composite structure consisting of an elastic core made of heat-resistant elastic rubber and a metal layer formed on its surface. This composite material combines the thermal stability of the elastic rubber with the electrical conductivity of the metal layer, allowing the contact terminal to maintain both ease of manufacture and reliability during high-temperature reflow soldering processes.
2Stability of the object's composition
If a Be-Cu alloy contact terminal is used to prevent thermal deformation, then the contact terminal resists thermal deformation, but the limited elasticity makes it difficult to apply when the bonding section height is high
Solution Approach 1:
The patent changes the material parameters by using heat-resistant elastic rubber with specific physical properties (hardness of 20-70 degrees Shore, specific gravity of 0.9-1.2, tensile strength of 1-20 kgf/mm², and elongation of 50-500%). These parameter changes allow the elastic core to provide both thermal stability and sufficient elasticity, enabling the contact terminal to adapt to high bonding sections while resisting thermal deformation.
3Strength
If foamed elastic rubber or tubular elastic rubber with pores is used to provide elasticity, then the contact terminal has elastic properties, but it is difficult to fabricate small contact terminals and costs are increased
Solution Approach 1:
The patent extracts the unnecessary complexity of foamed or porous structures and uses a solid elastic rubber core instead. This simplification removes the fabrication difficulties and cost increases associated with creating small foamed or porous contact terminals, while still providing the required elasticity through the inherent properties of the elastic rubber material.
4Extent of automation
If vacuum pickup is used in automatic reflow soldering, then the soldering process can be automated, but the large motion causes poor yield
Solution Approach 1:
The patent employs a metal layer formed on the elastic core that provides a flexible yet stable surface for vacuum pickup. This thin metal coating allows for effective vacuum gripping with minimal motion, enabling automation while maintaining high production yield by reducing the motion-related problems associated with larger pickup mechanisms.
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 solution provides a low electrical resistance, maintains conductivity at high temperatures, and retains functionality even after repeated expansion and contraction, enhancing the terminal's stability and longevity.
Implementation Method 1
a conductive adhesive layer (30), which is interposed between the elastic core and the metal layer to bond the elastic core and the metal layer to each other
Implementation Method 2
an elastic core (10), which imparts elasticity to the contact terminal
Implementation Method 3
a metal layer (20), which covers the outer portion of the elastic core
Implementation Method 4
the film layer has a plurality of holes therein, and the first and second metal coating layers are electrically connected to each other through walls of the holes in the film layer
Data Source
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AI summary
The present invention provides a conductive contact terminal for surface mounting on a substrate. In the conductive contact terminal, an elastic core imparts elasticity to the contact terminal. A metal layer covers the outer portion of the elastic core. A conductive adhesive layer is interposed between the elastic core and the metal layer to bond the elastic core and the metal layer to each other. The conductive contact terminal has a low electrical resistance, does not exhibit a deformation in the material even in a high-temperature reflow soldering process, and does not lose conductivity even though a metal layer, which imparts electrical conductivity to the conductive contact terminal, is broken.