Method of making electrical connector on a flexible carrier
AssigneeNeoconix, Inc.
InventorJohn David Williams
Life of this patent
Estimating the term…
Abstract
A compliant, scalable, thermal-electrical-mechanical, flexible electrical connector. In one configuration, the flexible electrical connector comprises a flexible substrate, a first and second conductive layer, and a plating contiguously applied over the conductive layers and holes through the substrate. The first and second conductive layers are adhered to opposite sides of the flexible substrate and have a plurality of raised contact elements in registration with at least a subset of the holes. At least some contact elements on the first and second conductive layers that oppose each other are in electrical communication with one another by way of the plating.
Claims21
A method of making an electrical connector, comprising:
- forming a plurality of through holes in a flexible substrate;
- securing a conductive sheet to the flexible substrate with adhesive material, the conductive sheet including a plurality of contact elements in registration with the plurality of through holes, the contact elements having a contact flange extending away from the flexible substrate;
- singulating portions of the conductive sheet to isolate respective ones of the contact elements;
- and
- providing a region between the flexible substrate and the conductive sheet into which excess adhesive material can flow away from the contact flange.
A method of making an electrical connector, comprising the steps of:
- forming a flexible insulating substrate with a plurality of through holes;
- and
- securing a plurality of compliant electrical contact elements to the flexible insulating substrate, at least some of the electrical contact elements in registration with at least one of the plurality of through holes, with the compliant electrical contact elements having contact flanges extending away from the flexible substrate;
- and
- providing an electrically-conductive material to electrically interconnect the through hole and at least one compliant electrical contact elements to form an electrical path through at least one electrical contact element and the through hole with which it is in registration.
A method of making an electrical connector comprising the steps of:
- forming a flexible substrate with a plurality of through holes;
- etching a first conductive sheet into the shape of a plurality of two dimensional electrical contacts, then forming the sheet of electrical contacts into a three-dimensional shape;
- stacking the first conductive sheet with etched and formed electrical contacts on the flexible substrate;
- securing the first conductive sheet with etched and formed electrical contacts to the flexible substrate in a first plane;
- depositing plating contiguously over the electrical contacts and within through holes in the flexible substrate;
- singulating individual ones of the electrical contacts;
- and
- mounting a second conductive sheet to the flexible substrate on a second plane different from the first plane.
Dependencies are inferred from the claim text.