Elastomeric Electrical Contact with Surface Conductive Trace
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Solution Overview
Problem
Elastomeric electrical contacts with exterior conductive pathways face challenges in balancing current carrying capability and elastic working range, often resulting in cracking or fracture due to limited pathway dimensions.
Innovation Solution
The design includes an elastomeric body with a ledge and an electrically conductive trace on its surface, extending from the mating end to the base, which is in electrical contact with a conductive pad, allowing for a larger current carrying capability while maintaining a predetermined elastic working range without cracking or fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electrically conductive pathway is formed larger to increase current carrying capability, then the current carrying capability is improved, but the elastic working range is limited and the pathway may crack or fracture during compression
Solution Approach 1:
The conductive pathway is segmented into a trace portion and a pad portion, with the trace forming a continuous pattern on the elastomeric body surface that connects to the pad. This segmentation allows the trace to be designed with sufficient width for current carrying while the overall pathway geometry can be optimized for elastic deformation without cracking
Solution Approach 2:
Different portions of the conductive pathway have different geometries optimized for their specific functions: the pad portion has larger dimensions for electrical contact and current carrying, while the trace portion has dimensions optimized for maintaining elasticity and avoiding fracture during compression of the elastomeric body
2Reliability
If the electrically conductive pathway is formed smaller to maintain elastic working range, then the elastic working range is improved, but the current carrying capability is reduced and the pathway may crack or fracture
Solution Approach 1:
The conductive pathway is formed on the surface of the elastomeric body, utilizing the three-dimensional surface geometry. This allows the pathway to follow contours and distribute stress more effectively, maintaining elastic working range while providing sufficient cross-sectional area for current carrying through strategic routing and width variations
3Quantity of substance
If filled elastomer is used to increase current carrying capability, then the current carrying capability is improved, but the elastic working range is limited due to the amount of conducting filler needed
Solution Approach 1:
The conductive material is extracted from the interior filling approach and placed on the exterior surface of the elastomeric body. This eliminates the need for large amounts of conducting filler that would compromise elasticity, while still providing adequate current carrying capability through the surface trace and pad configuration
Solution Approach 2:
The electrical contact utilizes a composite structure combining the elastomeric body material with a separate conductive material applied on its surface. This composite approach allows each material to perform its optimal function: the elastomer provides elasticity and compression resistance, while the conductive material provides current carrying capability without compromising the elastomer's elastic working range
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 configuration enhances the current carrying capacity of elastomeric electrical contacts while maintaining structural integrity during compression, facilitating reliable electrical connections across varying component arrays.
Implementation Method 1
Compression of the elastomeric electrical contacts also allows for some degree of nonplanarity between, and/or misalignment of, the electrical contacts of the opposing electrical component arrays
Data Source
AI summary
An electrical contact is provided that includes an elastomeric body extending between a base portion and a mating end portion. The elastomeric body includes a ledge extending from the mating end portion to the base portion of the elastomeric body. The ledge is defined by a portion of the elastomeric body. An electrically conductive pad extends over at least a portion of the mating end portion. An electrically conductive trace is formed on a surface of the ledge. The electrically conductive trace extends from the mating end portion to the base portion of the elastomeric body. The electrically conductive trace is in electrical contact with the electrically conductive pad for electrically connecting the electrically conductive pad with an electrically conductive element engaging the base portion of the elastomeric body.