Rectangular Metal Wire Electric Connector for High Density
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Solution Overview
Problem
Conventional electric connectors with metal wires or ribbons face challenges in achieving stable electrical contact without damaging electrodes, especially as device sizes decrease, due to the rigidity of the metal components and the difficulty in reducing pitch size and increasing density.
Innovation Solution
An electric connector with rectangular metal wires arranged at equal intervals in a resin layer, where the short sides are less than 5 μm and long sides are up to 150 μm, extending diagonally through the resin layer, and a manufacturing method involving laser-machining and vulcanization of rubber sheets to form an elastic body with the wires, allowing for reduced pitch and increased density without excessive force on electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal wires with diameter 10 μm to 50 μm are used, then electrical contact stability is improved, but electrode damage occurs due to excessive load
Solution Approach 1:
The patent changes the critical parameter of metal wire diameter from the conventional 10-50 μm range to a smaller range of 1-10 μm. This parameter reduction decreases the contact pressure and load on electrodes while maintaining electrical contact stability through the combination of finer wires arranged in multiple layers and directions, thereby resolving the contradiction between contact stability and electrode damage prevention
Solution Approach 2:
The patent segments the electrical connection function by using multiple thin metal wires (1-10 μm diameter) arranged in different layers and directions rather than relying on a single thick wire. This segmentation distributes the mechanical load across multiple contact points while maintaining collective electrical conductivity, preventing electrode damage while ensuring stable contact
2Volume of moving object
If device size is reduced, then miniaturization is achieved, but pitch size reduction and density increase become difficult with conventional metal wire sizes
Solution Approach 1:
The patent applies parameter change by reducing metal wire diameter to 1-10 μm, which enables significantly smaller pitch sizes between adjacent connection points. This allows devices to be miniaturized while maintaining manufacturing feasibility, as the finer wires can be precisely positioned at reduced pitch intervals that would be impossible with conventional 10-50 μm wires
Solution Approach 2:
The patent utilizes dimensional arrangement by configuring metal wires in multiple layers and different directions within the connector structure. This multi-dimensional arrangement increases connection density without requiring proportional increases in planar pitch, enabling device miniaturization while maintaining manageable manufacturing precision requirements through spatial optimization
3Strength
If metal ribbons with thickness 0.02 mm to 0.1 mm are used, then flexibility is improved, but electrode damage and difficulty in size reduction persist
Solution Approach 1:
The patent segments the ribbon structure into multiple thin metal wires (1-10 μm diameter) arranged in parallel and across different layers. This segmentation maintains the flexibility characteristic of ribbons while reducing the contact footprint and load on individual electrode points, preventing damage that occurs with conventional thick ribbons
Solution Approach 2:
The patent applies local quality by using thin metal wires (1-10 μm) that provide localized flexible contact points rather than a continuous thick ribbon. Each wire maintains flexibility for reliable contact while the distributed arrangement across multiple locations ensures overall connector flexibility without concentrating excessive load on any single electrode
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 effectively suppresses damage to electrodes, enables smaller pitch sizes, and achieves higher connector density while maintaining stable electrical connections with reduced load requirements.
Implementation Method 1
providing a plurality of metal wires that are arranged at equal intervals along a same direction, by laser-machining the plating layer
Implementation Method 2
bonding one surface of a first uncured rubber sheet onto the metal wires provided on the one surface of the base material
Implementation Method 3
vulcanizing the first uncured rubber sheet
Data Source
AI summary
An electric connector is disposed between a connection terminal of a first device and a connection terminal of a second device, and electrically connects these connection terminals. The electric connector includes a resin layer, and a plurality of metal wires extending through the resin layer in a thickness direction, and having a rectangular shape on surfaces to be connected to the connection terminals. At least first sides of the rectangular shapes of the metal wires are arranged at equal intervals along the same direction. The length of short sides of the rectangular shapes are less than 5 μm.