Singulated Elastomeric Pins for High-Performance Interconnects
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Solution Overview
Problem
Existing electrical interconnect mechanisms face challenges in providing sufficient resistive force, mechanical hysteresis, compliance, and long lifetime, especially in high-speed and RF applications, where individual contactors are difficult to replace and sensitive to co-planar differences between objects, with limitations in size, contact resistance, and configurability.
Innovation Solution
The development of singulated elastomeric pins with metal retainer tabs and a housing mechanism that allows for secure placement and easy replacement of elastomeric contactors, featuring protrusions or tabs for engagement with the housing, and optional features like chamfers and metal rings for enhanced retention and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric sheets with multiple contact points are used, then electrical performance is improved, but individual contactors cannot be replaced and they cannot act independently
Solution Approach 1:
The elastomeric contactor is segmented into individual pins that can be independently replaced. Each pin is formed separately and inserted into the housing through a slot, allowing individual contactors to be accessed and replaced without affecting other contactors in the array.
Solution Approach 2:
Individual elastomeric pins are extracted from the traditional sheet structure and made replaceable. The pins are formed onto metal retainer tabs that can be removed from the housing, enabling extraction and replacement of individual contactors while maintaining the electrical performance benefits of elastomeric material.
2Reliability
If high force is applied to press objects together, then connection reliability is improved, but mechanical complexity increases
Solution Approach 1:
The elastomeric material properties are optimized to provide high contact force through material selection and durometer specification. The elastomeric pins are formulated to exert sufficient resistive force against mating objects while maintaining simple pin geometry and avoiding complex mechanical force multiplication mechanisms.
3Reliability
If elastomeric contactors are used, then contact resistance is reduced, but over-compression degradation occurs
Solution Approach 1:
The housing is designed with built-in compression stops that preliminarily limit the compression distance before over-compression can occur. These stops are formed as integral features of the housing structure, preventing the elastomeric pins from being compressed beyond their elastic limit and thereby extending their operational lifetime.
4Adaptability or versatility
If individual contactors need to act independently, then adaptability to poor co-planar properties is improved, but structural complexity increases
Solution Approach 1:
The contactor array is segmented into independently mounted pins, each capable of independent compliance movement. The pins are individually retained in the housing and can deflect independently to accommodate co-planar variations in mating objects, providing adaptability without requiring complex interconnections between contactors.
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 solution provides a reliable, configurable, and cost-effective electrical interconnect system with improved mechanical and electrical performance, allowing for independent operation of contactors and preventing over-compression, while maintaining low contact resistance and enabling easy replacement of individual contactors.
Implementation Method 1
The elastomeric pin provides the required force and mechanical hysteresis
Implementation Method 2
a compliant, mechanically resistive mechanism that allows the pads to press against aligned electrical pads
Data Source
AI summary
A method and an electrical interconnect mechanism in which elastomeric pins are printed onto metal retainer tabs having at least one protrusion or tab extending laterally therefrom to engage a catch or recess of the laminated housing so as to locate each of the elastomeric pins and secure them within the housing. In one embodiment a champher may be employed with a catch or recess to engagely secure a second protrusion or tab extending laterally from another side of said elastomeric pin. In another embodiment the elastomeric pin may have a solid metal ring or a slide collar around the center of the pin wherein the ring has one or two tabs for engaging the recess in the housing and if preferred also the recess of a champfer.