Conductive Elastomeric Columns With Contact Caps For Interconnects
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Solution Overview
Problem
Existing interconnect devices face reliability issues due to height variations and material transfer between elastomeric columns and contact surfaces, leading to permanent bonding and difficulty in component removal.
Innovation Solution
The use of conductive elastomeric columns with contact caps that isolate the columns from contacts, preventing bonding and material transfer, and providing a flexible buffer to accommodate height variations while maintaining a metal-to-metal interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive elastomeric columns are directly engaged with contacts, then electrical connection is established, but bonding and material transfer occur making removal difficult
Solution Approach 1:
A release layer is introduced as an intermediary between the elastomeric column and the contact surface. This release layer prevents direct bonding and material transfer while still allowing electrical connection to be established, enabling both reliable operation and easy removal of components.
2Reliability
If elastomeric columns are compressed to accommodate height variations, then reliable contact is established, but polymer material transfers to contact surface
Solution Approach 1:
The release layer serves as a mediator that allows the elastomeric column to be compressed against the contact surface without direct polymer-to-metal contact. This maintains reliable electrical connection while preventing polymer material from transferring to and adhering on the contact surface.
3Strength
If high temperature is created between elements, then bonding occurs ensuring stable connection, but removal becomes impossible
Solution Approach 1:
The release layer acts as a thermal and bonding barrier between the elastomeric column and contact surface. It prevents high-temperature bonding from occurring while still allowing sufficient contact pressure for reliable electrical connection, thereby enabling component removal and replacement.
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
Ensures reliable and reversible electrical connections by preventing bonding and material transfer, allowing for easy removal and replacement of components while maintaining electrical conductivity.
Implementation Method 1
conductive elastomeric columns... provide a flexible buffer to accommodate height variations while maintaining a metal-to-metal interface
Implementation Method 2
elastomeric columns... provide a flexible buffer to accommodate height variations
Data Source
AI summary
An electrical interconnect device includes a substrate having opposite outer surfaces and an array of conductive elastomeric columns held by the substrate. Each of the columns have opposite ends that extend beyond respective ones of the outer surfaces of the substrate. Conductive contact caps are disposed over the opposite ends of each said column. An electrical path is defined from one of the contact caps, through the conductive elastomeric column, to another of the contact caps. Optionally, the contact caps may be sized and shaped substantially similarly as the ends of the elastomeric columns. The contact caps may be adhered to the ends of the columns, or alternatively, the contact caps may be adhered to the substrate.