Microconnector and method of manufacturing the same

• US 6,129,559 A
• Filed: 01/21/1997
• Issued: 10/10/2000
• Est. Priority Date: 01/19/1996
• Status: Expired due to Fees

• Current Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Inventors: Haga, Tsuyoshi, Hirata, Yoshihiro
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): STANDIG, BARRY
• Application Number:
  US08/788,889
• Time in Patent Office: 1,358 Days
• Field of Search: 439/65-69, 439/74, 439/91, 439/284, 439/931, 439/44, 361/760, 361/735, 361/771, 361/774, 361/784, 361/790, 361/792, 361/765, 361/772, 361/777, 361/785, 361/791, 361/793, 174/253, 174/255, 29/830-832, 29/843, 29/423, 29/469, 29/852, 29/847-849, 29/25.35, 430/313, 430/315, 430/5, 430/323-326, 430/8, 430/967, 430/270.1, 445/24, 257/686, 257/777, 264/401, 264/308, 264/454, 264/473, 264/488, 264/324, 264/326, 264/967, 264/908, 264/966
• US Class Current: 439/74
• CPC Class Codes: H01L 24/72 Detachable connecting means consisting of mechanical auxiliary parts connecting the device, e.g. pressure contacts using springs or clips
• CPC Class Codes: H01L 2924/01005 Boron [B]
• CPC Class Codes: H01L 2924/01006 Carbon [C]
• CPC Class Codes: H01L 2924/01013 Aluminum [Al]
• CPC Class Codes: H01L 2924/01024 Chromium [Cr]
• CPC Class Codes: H01L 2924/01025 Manganese [Mn]
• CPC Class Codes: H01L 2924/01029 Copper [Cu]
• CPC Class Codes: H01L 2924/01033 Arsenic [As]
• CPC Class Codes: H01L 2924/01038 Strontium [Sr]
• CPC Class Codes: H01L 2924/01047 Silver [Ag]
• CPC Class Codes: H01L 2924/01073 Tantalum [Ta]
• CPC Class Codes: H01L 2924/01074 Tungsten [W]
• CPC Class Codes: H01L 2924/01078 Platinum [Pt]
• CPC Class Codes: H01L 2924/01079 Gold [Au]
• CPC Class Codes: H01R 12/57 surface mounting terminals
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H05K 3/4007 Surface contacts, e.g. bumps H05K3/4092 takes precedence; deposition of finish layers on pads H05K3/24; forming solder bumps H05K3/3457
• CPC Class Codes: H05K 3/4092 Integral conductive tabs, i.e. conductive parts partly detached from the substrate
• CPC Class Codes: Y10T 29/42 Piezoelectric device making

Abstract

A microconnector provides a practically sufficient strength, and has an arrangement in which structures of electrode members and guiding members can be designed at least somewhat independently of each other for allowing a simple connecting operation. In a male connector, wiring layers are formed on a substrate, and male pin connector electrodes project from the wiring layers, whereby the electrodes are two-dimensionally arranged and enclosed with spacers. In a female connector, on the other hand, wiring layers are formed on a substrate, and female connector electrodes are formed on single ends of the wiring layers respectively. The female connector electrodes comprise holes for receiving the pin electrodes, and are arranged in correspondence to the pin electrodes. The female connector electrodes each having a spring characteristic and are enclosed with spacers. The male and female connectors are electrically connected with each other by superposing the substrates with each other while orienting electrode surfaces thereof to be opposed to each other. The pin electrodes and the female connector electrodes are naturally aligned and brought into engagement with each other due to attraction of magnetic layers formed on the male and female connectors respectively.

Claims

1. A microconnector comprising a male connector and a female connector, wherein:

said male connector comprises;

a first substrate extending along a first substrate plane;

a plurality of first wires that consist of a conductive material and that are provided on and/or in said first substrate; and

a plurality of first electrode parts that consist of a conductive material deposited on said first substrate, that respectively project from said plurality of first wires, that are arranged on a first surface of said first substrate in a first prescribed pattern, that respectively protrude from said first substrate in a protrusion direction substantially perpendicular to said first substrate plane, and that respectively have tapered free ends which protrude away from said first substrate and which have tapered shapes tapering away from said first substrate in said protrusion direction;

said female connector comprises;

a second substrate extending along a second substrate plane;

a plurality of second wires that consist of a conductive material and that are provided on and/or in said second substrate; and

a plurality of second electrode parts that consist of a conductive material deposited on said second substrate, that are respectively connected with said plurality of second wires, that are arranged on a second surface of said second substrate in a second prescribed pattern corresponding to said first prescribed pattern, and that respectively each include a respective flexible spring part having an elongated shape extending longitudinally along an elongation direction substantially parallel to said second substrate plane and being flexibly deflectable in a deflection direction substantially parallel to said second substrate plane and a supporting part arranged and adapted to support said spring part; and

said male and female connectors are adapted to be electrically connected with each other by superposing said first substrate and said second substrates with each other while facing said first surface and said second surface opposed to each other with said first substrate plane and said second substrate plane substantially parallel to each other, and moving said male and female connectors toward each other in a connection direction that is substantially parallel to said protrusion direction, substantially perpendicular to said elongation direction and substantially perpendicular to said second substrate plane, so as to bring said plurality of first electrode parts respectively into contact with said plurality of second electrode parts, wherein said flexible spring parts of said second electrode parts are respectively deflected by said tapered free ends and press against respective ones of said first electrode parts when said first and second electrode parts are brought into contact with each other.

2. The microconnector in accordance with claim 1, wherein said plurality of first electrode parts and said plurality of second electrode parts are arranged in a density of at least 1 electrode part per mm³.

3. The microconnector in accordance with claim 1, wherein said male and female connectors each have a width of 1 to 20 mm and a length of 1 to 20 mm, and said male and female connectors being electrically connected with each other have a total thickness of 0.5 to 2.0 mm.

4. The microconnector in accordance with claim 1, wherein said first and second electrode parts are two-dimensionally arranged and not linearly arranged on said first and second substrates in said first and second prescribed patterns respectively, wherein said patterns are two-dimensional array patterns on said first and second surfaces respectively.

5. The microconnector in accordance with claim 1,

wherein said plurality of second electrode parts have holes adapted to receive said first electrode parts therein respectively to establish an electrical connection therebetween, and

wherein said first electrode parts and said holes are so arranged and adapted that said bringing of said first electrode parts respectively into contact with said second electrode parts comprises engaging said plurality of first electrode parts in said holes of said plurality of second electrode parts respectively.

6. The microconnector in accordance with claim 1, wherein:

each one of said first electrode parts respectively comprises an electrode pin,

each one of said second electrode parts respectively has an annular shape adapted to surround a respective one of said electrode pins when said male and female connectors are connected with each other, and

said spring parts of said second electrode parts are respectively arranged and adapted to press said electrode pins of said first electrode parts when said first electrode parts are respectively inserted in said annular shapes of said second electrode parts.

7. The microconnector in accordance with claim 1, wherein said male connector further comprises a guide pin extending from said first surface of said first substrate and said female connector further comprises a guide hole on said second substrate, wherein said guide pin and said guide hole are so arranged and adapted to achieve an alignment of said first and second electrode parts with each other by engaging said guide pin in said guide hole.

8. The microconnector in accordance with claim 1, wherein:

said plurality of first electrode parts define a convex electrode assembly on said first substrate,

said plurality of second electrode parts define an annular electrode assembly on said second substrate, and

said convex electrode assembly is adapted to be inserted in said annular electrode assembly, so that said first electrode parts are respectively brought into contact with said second electrode parts.

9. The microconnector in accordance with claim 8, wherein said convex electrode assembly is pressed by said spring parts of said second electrode parts when said convex electrode assembly is inserted in said annular electrode assembly.

10. The microconnector in accordance with claim 8, further comprising a solid insulating material arranged between said electrode parts in said convex electrode assembly and/or said annular electrode assembly.

11. The microconnector in accordance with claim 8, further comprising a solid electric insulating material arranged between said plurality of first electrode parts in said convex electrode assembly so as to form an integral structure including said plurality of first electrode parts and said electric insulating material.

12. The microconnector in accordance with claim 1, wherein:

a first one of said connectors further comprises a convex male guide part arranged to surround said plurality of electrode parts of said first one of said connectors,

a second one of said connectors further comprises a convex female guide part arranged to surround said plurality of electrode parts of said second one of said connectors, and

said male and female guide parts are so arranged and adapted so as to align said first and second electrode parts with each other by inserting said male guide part in said female guide part.

13. The microconnector in accordance with claim 1, wherein:

said male connector further comprises a first magnet,

said female connector further comprises a second magnet arranged and adapted to be attracted by said first magnet so as to align said first and second electrode parts with each other by aligning said first and second magnets with each other when said male and female connectors are connected to each other.

14. The microconnector in accordance with claim 1, wherein said conductive material of said first wires and/or said second wires has been deposited on said first substrate and/or said second substrate respectively.

15. The microconnector in accordance with claim 1, wherein said conductive material of said first wires and/or said second wires is provided in said first substrate and/or said second substrate such that said first wires and/or said second wires pass through said first substrate and/or said second substrate respectively from said first surface and/or said second surface to a respective back surface of said respective substrate opposite said first or second surface.

16. The microconnector in accordance with claim 1, wherein at least one of said male and female connectors has an air vent.

17. A method of manufacturing the microconnector in accordance with claim 1, comprising the steps of:

forming structures on said first and second substrates through lithography with synchrotron radiation; and

further working said structures by electrodischarge machining;

so as to form said male and female connectors.

18. A method of manufacturing the microconnector in accordance with claim 1, comprising the steps of:

forming a metal mold through lithography with synchrotron radiation;

forming a resin template respectively on at least one of said first and second substrates using said metal mold;

plating said substrate having said resin template thereon for obtaining a metal structure having a shape in accordance with said resin template; and

performing electrodischarge machining on said metal structure;

so as to form at least one of said male and female connectors.

19. The microconnector in accordance with claim 1, wherein each said spring part has an arcuate shape.

20. A microconnector comprising a male connector and a female connector, wherein:

said male connector comprises;

a first substrate extending along a first substrate plane;

a plurality of first wires that consist of a conductive material and that are provided on and/or in said first substrate; and

a plurality of first electrode parts that consist of a conductive material deposited on said first substrate, that respectively project from said plurality of first wires, that are arranged in a first prescribed pattern to form an annular first electrode assembly on a first surface of said first substrate, and that respectively each include a respective flexible spring part having an elongated shape extending longitudinally along an elongation direction substantially parallel to said first substrate plane and being flexibly deflectable in a deflection direction substantially parallel to said first substrate plane and a supporting part arranged and adapted to support said spring part;

said female connector comprises;

a second substrate extending along a second substrate plane;

a plurality of second wires that consist of a conductive material and that are provided on and/or in said second substrate; and

a plurality of second electrode parts that consist of a conductive material deposited on said second substrate, that are respectively connected with said plurality of second wires, that are arranged in a second prescribed pattern corresponding to said first prescribed pattern to form an annular second electrode assembly having a larger diameter than said first electrode assembly on a second surface of said second substrate, that respectively protrude from said second substrate in a protrusion direction substantially perpendicular to said second substrate plane, and that respectively have tapered free ends which protrude away from said second substrate and which have tapered shapes tapering away from said second substrate in said protrusion direction; and

said first electrode assembly is adapted to be inserted into said second electrode assembly in a connection direction that is substantially parallel to said protrusion direction, substantially perpendicular to said elongation direction and substantially perpendicular to said first substrate plane, so as to bring said plurality of first electrode parts respectively into contact with said plurality of second electrode parts, wherein said flexible spring parts of said first electrode parts are respectively deflected by said tapered free ends and press against respective ones of said second electrode parts when said first and second electrode parts are brought into contact with each other.

21. The microconnector in accordance with claim 20, wherein:

said male connector further comprises an annular first guide part arranged on said first substrate to surround said first electrode assembly,

said female connector further comprises an annular second guide part that has a larger diameter than said first guide part and that is arranged on said second substrate to surround said second electrode assembly,

at least one of said male and female connectors has an air vent that passes through said first or second substrate in communication with a space within said first or second guide part, or that passes through said first or second guide part, and

said guide parts are so arranged and adapted so that said first guide part can be inserted between said second guide part and said second electrode assembly thereby aligning said first and second electrode assemblies with each other.

22. The microconnector in accordance with claim 20, wherein:

said male connector further comprises a first magnet arranged substantially at a concentric center of said annular first electrode assembly,

said female connector further comprises a second magnet that is adapted to be attracted by said first magnet and that is arranged substantially at a concentric center of said annular second electrode assembly, and

said first and second magnets are adapted to be aligned with each other thereby bringing said first and second electrode assemblies into contact with each other.

23. The microconnector in accordance with claim 20, wherein each said spring part has an arcuate shape.