Flexible Connector Insert with Conductive Elastomer for Low Inductance
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Solution Overview
Problem
Current electrical connector insert technologies, such as standard circuit board and EESeal silicone inserts, face issues with stray inductance and labor-intensive construction, limiting their effectiveness at high frequencies and reliability, especially above 100 MHz.
Innovation Solution
The use of conductive elastomer layers with low volume resistivity, integrated with non-conductive elastomer separation, and surface mount devices like capacitors, reduces stray inductance by employing a planar construction that includes a conductive elastomer shell, ground plane, and pin contact, allowing for effective filtering up to GHz frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If EESeal silicone insert technology is used, then the environmental seal is maintained, but stray inductance increases and high-frequency performance deteriorates
Solution Approach 1:
The patent changes the fundamental construction parameter from filament wire interconnects to planar conductive elastomer traces. This parameter change reduces the inductance from typical wire-level values to sub-0.5nH levels, enabling effective filtering at GHz frequencies while maintaining the silicone elastomer's environmental sealing properties
Solution Approach 2:
The patent transitions from three-dimensional wire interconnects to two-dimensional planar conductive traces embedded in the elastomer. This dimensional reduction eliminates the loop areas that generate stray inductance, achieving ultra-low inductance performance while preserving the flexible seal structure
2Adaptability or versatility
If standard circuit board technology is used, then electrical circuitry is added, but the environmental seal is corrupted
Solution Approach 1:
The patent creates a composite structure by embedding conductive elastomer traces and surface mount devices directly into the silicone elastomer matrix. This integration of conductive and insulating materials within a single sealed unit provides both electrical functionality and environmental protection without compromising the seal
Solution Approach 2:
The patent merges the connector insert body, electrical circuitry, and environmental seal into a single integrated component. The conductive elastomer traces and surface mount devices are incorporated directly into the silicone insert, eliminating separate circuit board assemblies that would breach the seal
3Device complexity
If filament wire interconnects are used in EESeal inserts, then construction is simplified, but labor intensity increases and inductance is high
Solution Approach 1:
The patent replaces the mechanical wire-wrapping or wire-insertion process with a planar trace pattern that is pre-formed in the conductive elastomer layers. This substitution eliminates the labor-intensive manual wire manipulation while achieving lower inductance through the planar geometry
Solution Approach 2:
The conductive elastomer layers with integrated trace patterns are fabricated as complete assemblies before insertion into the connector. This preliminary fabrication of the entire circuit pattern in the elastomer eliminates on-site wire manipulation and reduces assembly labor
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 solution provides ultra-low stray inductance and enhanced filtering performance, enabling reliable high-frequency operation while maintaining mechanical integrity and flexibility, suitable for high-reliability connectors and applications in various electronics.
Implementation Method 1
The present invention employs planar conductive layers rather than the wire interconnects within a connector insert... The conductive layers can be conductive elastomer or other conductive element(s)... This planar arrangement of the conductors greatly reduces unwanted stray inductance
Implementation Method 2
Electrically opposing conductive layers are insulated from each other by the non-conductive elastomer... at least one layer of non-conductive material, and most preferably wherein the at least one layer of non-conductive material comprises non-conductive elastomer
Implementation Method 3
A capacitor may be formed in the insert, preferably wherein the capacitor comprises a plurality of layers of conductive elastomer, with separation provided by at least one layer of non-conductive material
Data Source
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AI summary
A connector insert comprising a plurality of layers of conductive elastomer, and a concomitant method of employing a connector insert, the method comprising the steps of fabricating a plurality of layers of conductive elastomer as an insert and placing the insert into a connector.