Conductive Silicone Contact Element for High-Current Connections
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Solution Overview
Problem
Conventional contact elements for electronic components face challenges in achieving high compliance, low contact force, high frequency signal transmission, and high current capability while maintaining durability and temperature resistance, as they often compromise between spring properties and electrical conductivity.
Innovation Solution
A contact element made of conductive silicone rubber, plated with soft metals like copper, gold, or silver, which provides elastic compliance and improved conductivity, allowing for high-frequency and high-current connections without the need for a supporting structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single metal spring structure is used for resilient conductive contact, then elastic compliance and spring properties are improved, but electrical conductivity and resistance are worsened
Solution Approach 1:
The patent employs a composite structure consisting of a resilient support (typically polymer or elastomer material) combined with conductive elements (metal contacts or conductive pathways). This composite approach allows the support to provide elastic compliance and spring properties while the conductive elements ensure low electrical resistance and high conductivity, resolving the contradiction between mechanical resilience and electrical performance
Solution Approach 2:
The contact structure is divided into functionally distinct segments: a resilient support portion that provides elastic compliance and a separate conductive contact portion that ensures electrical connectivity. This segmentation allows each component to be optimized for its specific function - the support for mechanical properties and the conductive elements for electrical properties - thereby resolving the contradiction between spring properties and conductivity
2Reliability
If multiple conductors in a bunched wire bundle or conductor structure embedded in polymer core are used, then electrical conductivity and resistance are improved, but contact force and compliance are worsened
Solution Approach 1:
The patent utilizes a resilient support structure made from flexible elastomeric or polymeric materials that can deflect and provide compliance. This flexible support accommodates the conductive elements while maintaining the ability to exert controlled contact force and absorb misalignment, thereby enabling both good electrical conductivity and adequate compliance without requiring excessive contact force
3Strength
If high strength steel is used for spring construction, then spring properties are improved, but electrical conductivity is worsened
Solution Approach 1:
The patent employs a composite structure consisting of a resilient support (typically polymer or elastomer material) combined with conductive elements (metal contacts or conductive pathways). This composite approach allows the support to provide elastic compliance and spring properties while the conductive elements ensure low electrical resistance and high conductivity, resolving the contradiction between mechanical resilience and electrical performance
4Reliability
If conventional resilient conductive contacts with barrier metal and noble metal platings are used, then corrosion prevention and surface conductivity are improved, but bulk conductivity and compliance are worsened
Solution Approach 1:
The patent employs a composite structure consisting of a resilient support (typically polymer or elastomer material) combined with conductive elements (metal contacts or conductive pathways). This composite approach allows the support to provide elastic compliance and spring properties while the conductive elements ensure low electrical resistance and high conductivity, resolving the contradiction between mechanical resilience and electrical performance
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 conductive silicone contact elements offer enhanced durability, low contact resistance, and improved electrical conductivity, enabling reliable connections with reduced force requirements and high durability, suitable for both production and test sockets, while maintaining performance across various temperatures.
Implementation Method 1
The resilient conductive contacts F have had a variety of shapes. A commonly used form of resilient conductive contact includes two free ends connected by a curved, resilient portion which provides for the storage of elastic energy during engagement with the IC package A and PCB D.
Implementation Method 2
Typically, a combination of barrier metal and noble metal platings are applied to the surface of the spring for corrosion prevention and for electrical contact enhancement. It is often the case that these platings provide improved electrical conduction only along the surface of the spring.
Implementation Method 3
The contact element is preferably made of a silicone rubber which has been plated chemically and/or electrically.
Data Source
AI summary
A contact element for use between electronic components like computer chips and printed circuit boards, or the connection between an electronic component in a test socket to provide high current, high density, and high frequency connections between the electronic components. The contact element preferably achieves a good connection between electrical components when they are connected and pressed together. The contact element is preferably made of a conductive silicone rubber which has been plated.