Laminate Interposer Structure for Reliable Electrical Connections

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Solution Overview

Problem

The miniaturization of electronic components leads to challenges in achieving reliable electrical connections due to close contact spacing, requiring accurate alignment and flexible insulation to accommodate non-planar contacts, while surface contamination and oxide layers impede reliable contact.

Innovation Solution

A compliant interconnect assembly featuring a laminate interposer structure with opposed elastomer layers and an intermediate rigid layer, providing localized conductive paths through electrically conducting elastic columns, which allows for compliance and reduced contact force, thereby overcoming alignment and contamination issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If contacts are placed closer together to increase component density, then more components can be packed into a given space, but the pliability of insulating material between contacts is reduced and alignment accuracy requirements increase

Engineering Contradiction:

Improvecomponent densityVSAvoidpliability of insulating material

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The patent employs a composite interposer structure combining rigid and flexible materials. The interposer includes a rigid substrate providing structural support and contact support, coupled with flexible elastomeric material that provides compliance and pliability. This composite structure enables close contact spacing while maintaining the necessary flexibility to accommodate non-planar contacts and alignment variations.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by providing flexible elastomeric material specifically at contact regions where compliance is needed, while maintaining rigid structural support in other areas. The elastomeric material is positioned to contact individual device contacts, allowing localized adaptation to non-planar surfaces without compromising the overall structural integrity of the interposer.

Inventive Principle:

Principle #3Local quality

2Reliability

If connecting force between contacts is increased to ensure reliable interconnection, then connection reliability improves, but compression and potential damage to contacts occurs

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcontact damage

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the mechanical parameters of the interposer by incorporating elastomeric material with specific durometer hardness and thickness. This allows the interposer to provide controlled compliance that ensures reliable contact connection without excessive force. The elastomeric material deforms to accommodate contact variations, distributing force evenly and preventing localized compression damage while maintaining electrical connection reliability.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If rigid insulating material is used to maintain contact spacing, then structural stability is improved, but freedom of movement between contacts is reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidfreedom of movement between contacts

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent uses a composite structure with rigid substrate material providing overall structural stability and contact support, combined with flexible elastomeric material that allows individual contacts to move independently. The rigid portion maintains spacing and alignment, while the flexible elastomeric portions enable the necessary freedom of movement to accommodate non-planar contacts without compromising structural integrity.

Inventive Principle:

Principle #40Composite materials

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 solution significantly increases the operating life and reduces the contact force required for reliable electrical connections, achieving a service life nearly four times that of conventional systems by providing rigidity and flexibility in the interconnect assembly.

Implementation Method 1

opposed upper and lower elastomer layers... to provide compliance between the upper and lower elastomer layers and the elastic column

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

an electrically conducting elastic column to provide a localized conductive path through the thickness of the laminate interposer structure

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS7726984B2Compliant interconnect apparatus with laminate interposer structure

Publication Date: 2010.06.01 PHOENIX TEST ARRAYS LLC

AI summary

Apparatus to electrically connect a first electrical contact to a second electrical contact includes opposed upper and lower elastomer layers formed on either side of an electrically insulating intermediate layer together forming a laminate interposer structure having a thickness. An electrically conducting elastic column to provide a localized conductive path is formed through the thickness of the laminate interposer structure. The upper and lower elastomer layers provide compliance between the upper and lower elastomer layers and the elastic column, and the intermediate layer provides reduced compliance between the intermediate layer and the elastic column relative to the compliance between the upper and lower elastomer layers and the elastic column.