Interposer Assembly with Segmented Cantilever Springs
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Solution Overview
Problem
Conventional interposer assemblies with metal contacts have inefficient springs due to limited energy storage and increased cost from using expensive alloys like beryllium copper, leading to suboptimal compliance and frictional losses in electrical connections between substrates.
Innovation Solution
The interposer assembly features elongate metal contacts with multiple U-shaped spring units that compress and expand independently, minimizing friction and maintaining effective contact pressure through elastic strain, allowing for high compliance and low-resistance circuit paths without the need for expensive alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional single-mode spring contacts are used, then the contact structure is simple, but the energy storage capacity is limited and compliance is insufficient
Solution Approach 1:
The contact is divided into multiple discrete spring units (first spring unit, second spring unit, third spring unit) arranged in series along the contact length. Each spring unit independently stores elastic energy and provides compliance, increasing total energy storage capacity without requiring expensive alloys. The segmentation allows each unit to contribute additively to the overall spring performance.
Solution Approach 2:
The spring units are configured in a longitudinal arrangement along the contact length rather than concentrating all spring elements at the contact ends. This dimensional redistribution of spring functionality along the contact's length increases the effective spring constant and energy storage capacity while maintaining structural simplicity.
2Reliability
If expensive alloys like beryllium copper are used, then contact performance and compliance are improved, but manufacturing cost increases
Solution Approach 1:
The contact is segmented into multiple spring units that can be formed from standard copper strip stock through conventional processes. This segmentation approach achieves high compliance and reliability through geometric design rather than material selection, avoiding the need for expensive beryllium copper alloys while maintaining excellent electrical and mechanical performance.
Solution Approach 2:
The invention uses inexpensive copper strip stock instead of expensive performance-enhancing alloys. The multiple spring unit design compensates for the lower material strength by increasing the mechanical efficiency and energy storage capacity through structural design, achieving the same compliance performance at lower material cost.
3Reliability
If contacts are compressed between substrates, then electrical connections are established, but frictional loss occurs due to engagement with passage walls
Solution Approach 1:
The contact is divided into multiple discrete spring units that move independently within the passage during compression. This segmentation reduces the contact surface area between the solid contact body and the passage walls, minimizing frictional engagement. Each spring unit can deflect and compress with reduced friction compared to a solid contact, improving mechanical efficiency and reducing energy loss.
Solution Approach 2:
The spring units are designed to dynamically deflect and compress during substrate engagement, allowing the contact to adapt its shape and reduce frictional contact with the passage walls. The elastic deformation of the spring units enables smooth compression and expansion cycles with minimized energy loss to friction.
4Use of energy by moving object
If multiple spring units are used in the contact, then energy storage and compliance are enhanced, but contact structure becomes more complex
Solution Approach 1:
Multiple spring units are merged into a single continuous contact structure formed from one piece of copper strip. The spring units are connected in series along the contact length, creating a unified component that combines the energy storage benefits of multiple springs with the manufacturing simplicity of a single-piece construction. This merging eliminates the need for separate components while achieving enhanced compliance.
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 design enhances mechanical efficiency and compliance, ensuring reliable electrical connections with minimized resistance and temperature increase, while reducing material costs by using non-beryllium copper alloys.
Implementation Method 1
The springs are elastically compressed when the interposer assembly is compressed between substrates... compressed energy is stored through elastic strain in the contacts and is recovered when the substrates are removed from engagement with the contacts
Data Source
AI summary
An interposer assembly including a plate and a plurality of metal contacts extending through passages in the plate for forming electrical connections with pads on overlying and underlying substrates. The contacts include a number of contact units with elastic cantilever and torsion springs. Current flows through the contact units with minimum resistance.