LIGA Contact Element for High-Density PCB Interconnects
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Solution Overview
Problem
Existing contact elements for connecting circuit boards are bulky and cannot be miniaturized further due to strength issues with materials, limiting the number of contact elements that can be accommodated in a given space while maintaining reliable electrical conductivity and tolerance compensation.
Innovation Solution
A contact element with a spring section and snap-lock connection, manufactured using the LIGA method, which allows for the creation of highly complex geometries in small dimensions, ensuring electrical conductivity and reliable contact pressure with minimal axial and radial dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact elements with plug connectors are used, then reliable electrical connection and tolerance compensation are achieved, but the dimensions become large and the number of contact elements per space is limited
Solution Approach 1:
The patent merges multiple functions into a single integrated contact element structure. The contact element combines the contact point, spring section for tolerance compensation, and connection features into one unified component manufactured by LIGA, eliminating the need for separate plug connectors and adapters while maintaining all required functions.
Solution Approach 2:
The patent changes the dimensional parameters of the contact element by using the LIGA manufacturing process to create micro-scale features. The contact element has a length of 0.5-2mm and width of 0.1-0.5mm, representing a significant reduction from conventional connector sizes while maintaining functional performance through precise geometric control.
2Force
If spring-loaded contact pins with helical springs are used, then contact pressure is provided, but the axial construction height increases due to long spring lengths
Solution Approach 1:
The patent replaces the helical spring design with a spring section that has curved or meandering geometry. This curved spring section provides the necessary elastic force while occupying minimal axial space, as the curvature allows the spring to store and release energy in a compact planar configuration rather than requiring extended axial length.
Solution Approach 2:
The patent transitions the spring design from a three-dimensional helical structure occupying axial space to a two-dimensional curved or meandering pattern that lies primarily in the lateral plane. This dimensional change allows the spring to provide contact pressure without increasing the axial construction height of the contact element.
3Adaptability or versatility
If coaxial plug connectors are used, then tolerance compensation is achieved, but the dimensions cannot be reduced below a certain limit due to material strength constraints
Solution Approach 1:
The patent segments the tolerance compensation function into distributed elastic elements within the contact element structure. Rather than relying on a single large connector interface, multiple contact elements with integrated spring sections provide distributed compliance, allowing each element to be miniaturized while collectively achieving the required tolerance compensation across the connector assembly.
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
Enables a high-density arrangement of contact elements with reduced dimensions, effectively compensating for tolerances and providing reliable electrical connections with low spring forces, thus accommodating more elements in a limited space while maintaining efficient signal transmission.
Implementation Method 1
a spring section which is elastically deformed when contact is made with the two contact regions
Implementation Method 2
manufactured using the LIGA method, which allows for the creation of highly complex geometries in small dimensions
Data Source
AI summary
A contact element having contact points for the electrically conductive connection of contact regions of mutually spaced elements, which is formed completely of one or more deposited materials of which at least one is electrically conductive. The contact element is produced in particular using a lithography, electroplating and molding (LiGA) method.