Flexible Connector With Conductive Polymer Springfingers
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Solution Overview
Problem
Conventional interposers are limited in establishing electrical connections between non-parallel arrays of contacts, which are common in various electronic components such as devices, printed circuit boards, and arrays like LGA and BGA, as they are designed for planar connections only.
Innovation Solution
A flexible connector system utilizing conductive polymer springfingers on a flexible substrate, allowing for non-coplanar connections by being compressible and internally conductive, with the ability to accommodate curved or bent configurations, enabling electrical connections between components with varying shapes and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional interposers are used for planar connections, then manufacturing and assembly are simple, but electrical connections between non-parallel arrays of contacts cannot be established
Solution Approach 1:
The interposer uses flexible springfingers that can dynamically bend and deform to accommodate non-parallel contact arrays. The springfingers transition from a rigid planar structure to a flexible dynamic structure that can adapt to varying orientations and angles of contact arrays, enabling connections between non-parallel arrays while maintaining electrical contact.
Solution Approach 2:
The interposer incorporates flexible springfingers made from elastomeric or polymer materials that can bend and flex. These flexible elements replace rigid planar structures, allowing the interposer to conform to non-parallel contact arrays and establish electrical connections between components with different orientations.
2Adaptability or versatility
If rigid interposers are used for planar connections, then structural stability is maintained, but flexibility to accommodate curvature and bending is lost
Solution Approach 1:
The interposer transitions from a static rigid structure to a dynamic flexible structure. The springfingers can bend and deform elastically to accommodate curvature and bending requirements while maintaining structural integrity through their spring-like properties, enabling the interposer to adapt to various configurations without compromising stability.
Solution Approach 2:
The interposer changes its physical parameters by using materials with elastic properties that allow bending and flexing. The springfingers can change their shape and orientation parameters dynamically, transitioning from a straight rigid configuration to a curved flexible configuration while maintaining electrical conductivity and structural stability.
3Reliability
If precise alignment is required for planar contacts, then connection reliability is high, but manufacturing cost increases due to tight tolerances
Solution Approach 1:
The flexible springfingers can dynamically adjust their position and orientation to compensate for alignment variations. This dynamic adjustment capability allows the interposer to maintain reliable electrical connections even when there are deviations in alignment, reducing the need for tight manufacturing tolerances while preserving connection reliability.
Solution Approach 2:
The springfingers are designed with built-in compliance that cushions against misalignment issues before they become problems. The elastic properties of the springfingers provide a buffer that absorbs alignment variations, ensuring reliable connections without requiring extremely precise manufacturing tolerances.
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 flexible connector system effectively maintains electrical connections across components with different shapes and orientations, accommodating curvature and flexibility, thus enhancing the versatility and reliability of electrical interconnects in wearable and bendable devices, while reducing manufacturing costs by tolerating misalignment.
Implementation Method 1
The conductive polymer springfingers are internally conductive between the first and second ends
Implementation Method 2
The conductive polymer springfingers are compressible between the first and second ends
Data Source
AI summary
A flexible connector includes a flexible substrate having a plurality of conductive pads and a plurality of conductive polymer springfingers. Each conductive polymer springfinger extends between a first end and a second end. The conductive polymer springfingers are mechanically and electrically connected to corresponding conductive pads at the corresponding second ends and the conductive polymer springfingers are configured to be mechanically and electrically connected to conductors of an electrical component at the corresponding first ends. The conductive polymer springfingers are internally conductive and compressible between the first and second ends. The conductive polymer springfingers are discrete and separated by gaps. The flexible substrate is flexible to allow the second ends of the conductive polymer springfingers to be non-coplanar and to allow the first ends of the conductive polymer springfingers to be non-coplanar for electrical connection with the electrical component.