Separable Electrical Interconnect Using Anisotropic Conductive Elastomer
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Solution Overview
Problem
Existing separable electrical connectors using anisotropic conductive elastomer (ACE) face challenges in applying compressive force without interfering with components on the substrate, often requiring frames that increase the connector's profile and restrict access, and are not suitable for applications with size limitations.
Innovation Solution
A separable electrical connector design featuring an adapter board with ACE between the device and substrate, utilizing a spring plate and rotating screw for compressive force application, and optionally including a heat sink and flexible circuit elements, which can be used without a frame by direct adhesive coupling to the adapter board, reducing the connector's profile and enhancing stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a frame is used to apply compressive force to the ACE, then the compressive force can be effectively applied, but the connector's profile increases and access to the substrate is restricted
Solution Approach 1:
The frame is extracted from the connector assembly and applied separately to the substrate. The frame is positioned on the substrate surface and the ACE is compressed between the frame and the adaptor board, eliminating the need for the frame to be part of the connector structure itself.
Solution Approach 2:
The adaptor board serves as an intermediary element between the ACE and the substrate. It provides a mounting surface for the ACE and transmits the compressive force from the frame to the ACE, enabling force application without requiring the frame to be integrated into the connector.
2Reliability
If a frame is used to support the ACE, then the ACE can be properly positioned and compressed, but the overall size of the connector increases
Solution Approach 1:
The frame is separated from the connector assembly and applied independently to the substrate. This allows the connector itself to be compact while the frame provides the necessary support and compression structure on the substrate side.
Solution Approach 2:
The system is segmented into distinct functional components: the adaptor board with ACE for electrical connection, and the frame for mechanical support and compression. This segmentation allows each component to be optimized independently for its specific function.
3Reliability
If the ACE is compressed using a backing plate and spring arrangement, then reliable electrical connection is achieved, but conflicts arise with components mounted under the device and on the back of the board
Solution Approach 1:
The adaptor board acts as an intermediary between the ACE and the substrate, providing a dedicated mounting surface that elevates the compression mechanism above the substrate surface. This allows components to be mounted on the substrate without interfering with the compression arrangement.
Solution Approach 2:
The compression mechanism is moved from the substrate plane to a higher dimension by mounting it on the adaptor board that extends beyond the substrate. This vertical displacement resolves conflicts with components mounted on the substrate surface.
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 allows for efficient electrical interconnection while minimizing interference with substrate components, reducing wear on test printed circuit boards, and enabling the use of ACE in applications with size constraints, providing a cost-effective solution for testing and interposer functions.
Implementation Method 1
Anisotropic Conductive Elastomer (ACE) is a composite of conductive metal elements in an elastomeric matrix that is normally constructed such that it conducts along one axis only. In general this type of material is made to conduct through the thickness.
Implementation Method 2
ACE achieves its anisotropic conductivity by mixing magnetic particles with a liquid resin, forming the mix into a continuous sheet and curing the sheet in the presence of a magnetic field. This results in the particles forming columns through the sheet thickness which are electrically conductive.
Implementation Method 3
ACE must be compressed between top and bottom conductors to provide the interconnection. This is normally done by compressing the system using a backing plate and spring arrangement.
Implementation Method 4
The mechanical structure may comprise a spring plate, which is preferably removable to assist in the separability. A rotating screw member may be used for the purpose of applying the compressive load from the spring plate.
Implementation Method 5
The connector may further comprise a heat sink in thermal contact with the device, and through which the compressive load is applied.
Data Source
AI summary
A separable electrical connector for electrically interconnecting an electrical device to a substrate. In one embodiment, the connector includes an adapter board electrically connected to the substrate, the adapter board having electrical contacts on both sides, and a layer of ACE between the electrical device and the adapter board. A mechanical structure is used to apply a compressive force on the ACE through the adapter board and the electrical device. In another embodiment, the connector includes a translator board having electrical contacts on both sides and electrical circuits within to expand the footprint of the fine pitch electrical device to the coarser pitch of the substrate. The connector further includes a layer of ACE between the translator board and the substrate. In a further embodiment, the separable electrical conductor includes a layer of ACE coupled to a frame and an adaptor board that includes a channel sized and shaped to engage the frame, thereby reducing the profile of the connector. In another embodiment, the layer of ACE is coupled directly to the adaptor board, without the use of the frame, by means of an adhesive contained in the channel.