JP6829141B2 - Electrical connector and its manufacturing method - Google Patents

Description

The present invention relates to an electrical connector and a method for manufacturing the same.

A pressure welding type connector is used when inspecting a surface mount type semiconductor package and a circuit board, or when connecting a surface mount type semiconductor package and a circuit board.
As such a connector, for example, a plurality of sheets in which the directions of a plurality of conductive wires (conductive members) are aligned and wired while maintaining insulation with each other are laminated, and the directions of the conductive wires are kept constant, and the obtained lamination is obtained. A plurality of pieces of objects are arranged and laminated in a stepped manner at a fixed angle in the same direction to form a block body, and the obtained block body is adhered to a substrate surface for slicing and parallel to the substrate surface. A pressure-welded connector (see, for example, Patent Document 1) formed by cutting on two parallel surfaces that cross a conductive wire is known.

Japanese Patent No. 2787032

The pressure welding type connector described in Patent Document 1 has a problem that when connecting to a connection terminal of a device, an excessive force is applied to the connection terminal from a conductive member of the pressure welding type connector. Further, this pressure welding type connector has a problem that the heat resistance is not sufficient and it is difficult to stably connect to the connection terminal of the device.

The present invention has been made in view of the above circumstances, and is excellent in heat resistance without excessive force being applied from the conductive member of the electric connector to the connection terminal of the device connected to the electric connector. It is an object of the present invention to provide an electric connector capable of a stable connection and a method for manufacturing the same.

[1] An electric connector that is arranged between the connection terminal of the first device and the connection terminal of the second device and electrically connects them, and has an elastic body having a large number of through holes in the thickness direction. It comprises a composite having a conductive member joined to the through hole and electrically connecting the connection terminal of the first device and the connection terminal of the second device, and the conductive member is a conductive material and the conductive material. An electrical connector that contains an elastic material that disperses the conductive material.
[2] The electric connector according to [1], wherein the conductive material is a carbon nanotube.
[3] The electric connector according to [2], wherein the carbon nanotubes are oriented in the extending direction of the conductive member.
[4] The electric connector according to any one of [1] to [3], wherein the through hole penetrates diagonally with respect to the thickness direction of the elastic body.
[5] The electric connector according to any one of [1] to [4], wherein the composite has a protruding portion protruding in the thickness direction of the elastic body on at least one main surface side of the elastic body.
[6] The electric connector according to [5], wherein a resin sheet-like member is laminated on a region of the composite having a thickness thinner than the protruding portion on at least one main surface side of the elastic body.
[7] An elastic body having a large number of grooves arranged in parallel at arbitrary intervals is formed, and the grooves are filled with a conductive material-containing composition containing a conductive material and an elastic material for dispersing the conductive material. Then, the step of curing the conductive material-containing composition to form a conductive member to form a conductive member-containing sheet and a plurality of the conductive member-containing sheets are laminated by aligning the directions of the conductive members to conduct conductivity. It includes a step of forming a member-containing sheet laminate and a step of cutting the conductive member-containing sheet laminate in a direction perpendicular to or diagonally to the extending direction of the conductive member to obtain an electric connector. How to make an electrical connector.
[8] A conductive material-containing composition containing a conductive material and an elastic material for dispersing the conductive material is applied onto a sheet-shaped elastic body, and the conductive material-containing composition is cured to form a conductive layer. A step of forming the conductive layer-containing sheet, a step of laminating a plurality of the conductive layer-containing sheets to form a conductive layer-containing sheet laminate, and a step of forming the conductive layer-containing sheet laminate with the thickness of the conductive layer. A step of forming a conductive member-containing sheet including a conductive member made of a cured product of the conductive material-containing composition by cutting in a direction, and laminating a plurality of the conductive member-containing sheets in the same direction of the conductive member. Then, the step of forming the conductive member-containing sheet laminate via the sheet-shaped elastic body and the conductive member-containing sheet laminate in the direction perpendicular to or diagonally with respect to the extending direction of the conductive member. A method for manufacturing an electric connector, which comprises a step of cutting to obtain an electric connector and having.
[9] The method for manufacturing an electric connector according to [7] or [8], wherein the conductive material is a carbon nanotube.
[10] A part of the composite made of the elastic body and the conductive material is formed in the thickness direction from at least one main surface side of the elastic body of the electric connector obtained in the step of cutting the conductive member-containing sheet laminate. The method for manufacturing an electric connector according to any one of [7] to [9], which comprises a step of forming a protruding portion protruding in the thickness direction of the elastic body in the composite.
[11] After the step of forming the protruding portion, there is a step of laminating a resin sheet-like member on at least one main surface side of the elastic body in a region where the part of the composite is removed [11]. 10] The method for manufacturing an electric connector according to.

According to the present invention, an electric connector and an electric connector capable of stable connection with excellent heat resistance without applying excessive force from the conductive member of the electric connector to the connection terminal of the device connected to the electric connector. The manufacturing method can be provided.

It is a figure which shows the schematic structure of the electric connector of 1st Embodiment, (a) is a plan view, (b) is an enlarged view of region α in (a), (c) is line AA of (a). It is a cross-sectional view along. It is a perspective view which shows the outline of the 1st manufacturing method of the electric connector of 1st Embodiment. It is a perspective view which shows the outline of the 2nd manufacturing method of the electric connector of 1st Embodiment. It is a perspective view which shows the outline of the 2nd manufacturing method of the electric connector of 1st Embodiment. It is sectional drawing which shows the schematic structure of the electric connector of 2nd Embodiment. It is sectional drawing which shows the outline of the manufacturing method of the electric connector of 2nd Embodiment. It is sectional drawing which shows the schematic structure of the electric connector of 3rd Embodiment. It is sectional drawing which shows the outline of the manufacturing method of the electric connector of 3rd Embodiment.

An embodiment of the electric connector of the present invention and a method for manufacturing the same will be described.
It should be noted that the present embodiment is specifically described in order to better understand the gist of the invention, and is not limited to the present invention unless otherwise specified.

(First Embodiment)
[Electrical connector]
1A and 1B are views showing a schematic configuration of an electric connector of the present embodiment, where FIG. 1A is a plan view, FIG. 1B is an enlarged view of a region α in FIG. 1A, and FIG. 1C is A-A in FIG. It is sectional drawing which follows the A line.
As shown in FIG. 1, the electric connector 10 of the present embodiment includes a composite body 40 having an elastic body 20 and a conductive member 30.
The electric connector 10 is arranged between the connection terminal of the first device (not shown) and the connection terminal of the second device (not shown), and is for electrically connecting them. In the electric connector 10, the conductive member 30 is a member that electrically connects the connection terminal of the first device and the connection terminal of the second device. Examples of the device include a semiconductor package and a circuit board.

The elastic body 20 has a large number of through holes 21 penetrating in the thickness direction thereof. A conductive member 30 is joined to the through hole 21.

The position where the conductive member 30 is provided in the elastic body 20 (composite 40), that is, the arrangement of the through holes 21 in the elastic body 20 is not particularly limited, and the electric connector 10 (specifically, the conductive members joined to the through holes 21). It is appropriately adjusted according to the arrangement of the connection terminals of the two devices electrically connected by the member 30). In order to allow the composite 40 to be uniformly deformed (flexed), it is preferable that the conductive members 30 (through holes 21) are provided at equal intervals in the elastic body 20.

The number of conductive members 30 in the elastic body 20 (composite 40), that is, the number of through holes 21 in the elastic body 20 is not particularly limited, and the electric connector 10 (specifically, the conductive members joined to the through holes 21). It is appropriately adjusted according to the arrangement of the connection terminals of the two devices electrically connected by 30), the pressing force of the conductive member 30 against the required connection terminals, and the like.

The through hole 21 penetrates the elastic body 20 perpendicularly or diagonally with respect to the thickness direction thereof.
When the through hole 21 penetrates the elastic body 20 diagonally with respect to the thickness direction thereof, the angle of the through hole 21 with respect to the thickness direction of the elastic body 20 is preferably 10 ° to 85 °. The angle of the through hole 21 with respect to the thickness direction of the elastic body 20 depends on the arrangement of the connection terminals of the two devices electrically connected by the electric connector 10 (specifically, the conductive member 30 joined to the through hole 21). It will be adjusted accordingly.

The shape of the through hole 21, that is, the shape of the cross section perpendicular to the longitudinal direction of the through hole 21, is not particularly limited, and is appropriately adjusted in the shape of the cross section of the conductive member 30 joined to the through hole 21 in the longitudinal direction. Examples of the shape of the through hole 21 include a circle, an ellipse, a triangle, a square, a rectangle, a polygon having a pentagon or more, a semi-cylindrical shape, and a crescent shape.

The hole diameter of the through hole 21 is not particularly limited, and is appropriately adjusted according to the diameter (outer diameter) of the conductive member 30 joined to the through hole 21. The hole diameter of the through hole 21 is preferably 5 μm to 195 μm, and more preferably 10 μm to 100 μm.

The thickness of the elastic body 20 is preferably 0.03 mm to 1.0 mm. The thickness of the composite 40 is equal to the thickness of the elastic body 20.

The conductive member 30 is joined to the through hole 21 of the elastic body 20. As a result, the conductive member 30 is arranged so as to penetrate the elastic body 20 perpendicularly or diagonally with respect to the thickness direction thereof.

The distance between the two adjacent conductive members 30, that is, the distance (pitch) between the centers of the two adjacent conductive members 30 is not particularly limited, and the connection terminals of the two devices electrically connected by the electric connector 10 are not particularly limited. It is adjusted as appropriate according to the arrangement of the above. The distance between the centers of two adjacent conductive members 30 _(P 1, _{P 2} in FIG. 1 (b)) is preferably 15Myuemu～200myuemu. The distance between the centers of the two adjacent conductive members 30 corresponds to the distance between the centers of the two adjacent through holes 21.

The shape of the conductive member 30, that is, the shape of the cross section perpendicular to the longitudinal direction of the conductive member 30, is not particularly limited. The shape and the like can be mentioned.

The diameter (outer diameter) of the conductive member 30 is not particularly limited, but is preferably 5 μm to 195 μm.

The material of the elastic body 20 is not particularly limited as long as it has elasticity when the elastic body 20 is used. For example, acrylonitrile-butadiene rubber, silicone rubber, chloroprene rubber, ethylene-chloroprene rubber, and ethylene-propylene-diene rubber. , Styrene-butadiene rubber, fluorine rubber, butadiene rubber, isoprene rubber, synthetic rubber such as urethane rubber and the like. Among these, silicone rubber is preferable because of its high elasticity and excellent heat resistance.

The conductive member 30 is a composite member including a conductive material and an elastic material that disperses the conductive material.

The conductive material contained in the conductive member 30 is not particularly limited as long as it contains a movable charge and easily conducts electricity, that is, a material having high conductivity.
In the electric connector of the present embodiment, as the conductive material, in addition to long carbon nanotubes (hereinafter abbreviated as “CNT”) having a long and high aspect ratio structure, carbon nanobats, and carbon nanohorns, copper is used. Metal nanowires made of silver, gold or the like are preferable.

The carbon nanotubes (Carbon Nanotube, CNT) may be single-walled carbon nanotubes (Single Wall Carbon Nanotube, SWCNT) or multi-walled carbon nanotubes (Multi-walled Carbon Nanotube, MWNT).

The diameter (outer diameter) of the CNT is not particularly limited, but is preferably 1 nm to 500 nm. The length of the CNT is not particularly limited, but is preferably 50 μm to 1 mm.

Since single-walled carbon nanotubes have high conductivity, when the electric connector 10 is used for connecting devices for high-frequency current, the CNT is preferably composed of single-walled carbon nanotubes.

The main features of the carbon nanotubes are the following (1) to (6).
(1) Thin, light and strong.
(2) It is about half as light as aluminum, has 100 times the tensile strength of steel, and has about twice the hardness of diamond.
(3) It is hard to break, has excellent resilience, and is highly flexible.
(4) It has a high current density resistance (property that can structurally withstand a high amount of electric charge), which is about 1000 times that of copper.
(5) It can transfer about 10 times as much heat as copper, and has heat resistance of about 750 ° C. in air and about 2300 ° C. in vacuum.
(6) It has excellent chemical resistance, is chemically stable, does not react with most chemicals, is insoluble, and is insoluble in hot sulfuric acid.

The elastic material contained in the conductive member 30 is not particularly limited as long as it has elasticity when the conductive member 30 is used. For example, acrylonitrile-butadiene rubber, silicone rubber, chloroprene rubber, ethylene-chloroprene rubber, ethylene- Examples thereof include synthetic rubbers such as propylene-diene rubber, styrene-butadiene rubber, fluororubber, butadiene rubber, isoprene rubber, and urethane rubber. Among these, silicone rubber is preferable because of its high elasticity and excellent heat resistance.

The conductive member 30 having such a configuration is rich in flexibility derived from CNT and elastic material.

Further, it is preferable that the CNTs are oriented in the extending direction of the conductive member 30 in the conductive member 30. The extending direction of the conductive member 30 is, for example, the thickness direction of the elastic body 20 in FIG. By orienting the CNTs in the extending direction of the conductive member 30, the CNTs form a conduction path in that direction. Therefore, the conductive member 30 has a low resistance (high conductivity) in the extending direction.

According to the electric connector 10 of the present embodiment, an elastic body 20 having a large number of through holes 21 in the thickness direction, a conductive member 30 joined to the through holes 21 and electrically connecting the connection terminals of the two devices, and a conductive member 30. The conductive member 30 includes a conductive material and an elastic material that disperses the conductive material. Therefore, with a smaller force, the composite 40 having the elastic body 20 and the highly flexible conductive member 30 is deformed (flexed) in the thickness direction of the elastic body 20. As a result, when the connection terminal of the device connected to the electric connector 10 and the conductive member 30 are connected, an excessive force is not applied from the conductive member 30 to the connection terminal of the device, and the connection terminal is damaged. Can be prevented. Further, according to the electric connector 10 of the present embodiment, since the conductive member 30 has heat resistance, the connection terminals of the two devices are stably electrically connected via the conductive member 30 even in a high temperature environment. be able to.

Further, in the electric connector 10 of the present embodiment, a plating layer may be formed on the surface of the conductive member 30. The material of the plating layer is not particularly limited, and examples thereof include gold, nickel, tin, and copper.

As a method of forming a plating layer on the surface of the conductive member 30, for example, electrolytic plating, electroless plating and the like are used.

If the plating layer is formed on the surface of the conductive member 30, the resistance on the surface of the conductive member 30 can be lowered. Further, when the electric connector 100 is used for connecting devices for high-frequency current, the high-frequency current easily flows through the plating layer formed on the surface of the conductive member 30.

[Manufacturing method of electrical connector]
"First manufacturing method"
The method for manufacturing an electric connector of the present embodiment forms an elastic body having a large number of grooves formed in parallel at arbitrary intervals, and includes a conductive material and an elastic material in which the conductive material is dispersed in the grooves. A step of filling the conductive material-containing composition, curing the conductive material-containing composition to form a conductive member, and forming a conductive member-containing sheet (hereinafter referred to as "step A1"), and a conductive member-containing sheet. A step of forming a conductive member-containing sheet laminate (hereinafter referred to as "step B1") by laminating a plurality of the sheets in the same direction in the direction of the conductive member, and a process of stacking the conductive member-containing sheet laminate with the conductive member. It has a step of obtaining an electric connector (hereinafter, referred to as “step C1”) by cutting in a direction perpendicular to or diagonally to an existing direction. The step A1 includes a step A1-1 and a step A1-2, which will be described later.

Hereinafter, the method of manufacturing the electric connector of the present embodiment will be described with reference to FIGS. 2 (a) to 2 (d).
2 (a) to 2 (d) are perspective views showing an outline of a first manufacturing method of the electric connector of the present embodiment. In FIG. 2, the same components as those of the electric connector in the present embodiment shown in FIG. 1 are designated by the same reference numerals, and redundant description will be omitted.

As shown in FIG. 2A, an elastic body 600 having a large number of grooves 610 arranged in parallel at arbitrary intervals is formed on the base material 500 (step A1-1).
In step A1-1, an elastic body 600 having a groove 610 is formed by using an imprint mold or the like.
Further, as shown in FIG. 2A, a large number of grooves 610 are arranged so as to extend in a direction perpendicular to the longitudinal direction of the base material 500.

As the base material 500, a material that can be easily peeled off from the conductive member-containing sheet laminate after forming the conductive member-containing sheet laminate is used. Examples of the material of the base material 500 include polyethylene terephthalate (PET) and the like.

Examples of the material of the elastic body 600 include the same materials as those of the elastic body 20.

The thickness of the elastic body 600 is not particularly limited, but is preferably 15 μm to 200 μm. The depth of the elastic body 600 in the groove 610 in the thickness direction is not particularly limited, and is appropriately adjusted according to the diameter (outer diameter) of the conductive member 30 formed in the groove 610. The depth of the elastic body 600 in the groove 610 in the thickness direction is preferably 5 μm to 190 μm. Further, the width of the groove 610 is preferably equal to or larger than the depth of the groove 610. By doing so, it becomes easy to fill the groove 610 with the conductive material-containing composition 700 described later.

The shape of the groove 610, that is, the shape of the cross section perpendicular to the longitudinal direction of the groove 610 is not particularly limited, and is appropriately adjusted in the shape of the cross section of the conductive member 30 formed in the groove 610 in the longitudinal direction. Examples of the shape of the groove 610 include a circle, an ellipse, a triangle, a square, a rectangle, a polygon having a pentagon or more, a semi-cylindrical shape, and a crescent shape.

Next, as shown in FIG. 2B, a large number of grooves 610 of the elastic body 600 are filled with the conductive material-containing composition 700 containing the above-mentioned conductive material and the above-mentioned elastic material, and the conductive material-containing composition 700 is filled. The composition 700 is cured (dried) by heating, humidifying, light irradiation, or the like to form the conductive member 30, and the conductive member-containing sheet 800 is formed (step A1-2).

The conductive material-containing composition 700 is a liquid material containing a conductive material, an elastic material, and a dispersion medium for dissolving or dispersing them, and is preferably in the form of a paste.

The dispersion medium is not particularly limited as long as it can dissolve or disperse the above conductive material and elastic material, and for example, water, methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), isopropanol (IPA), and the like. Examples thereof include ethanol, N-methylpyrrolidone (NMP), cyclohexanone, ethylene glycol, dimethyl carbonate (DMC), propylene glycol monomethyl ether (PGME), propylene glycol monomethyl ether acetate (PGMEA), dimethylformamide (DMF), liquid silicone and the like. ..

When CNT is used as the conductive material, it is preferable to use a liquid discharge device such as a dispenser in order to fill the numerous grooves 610 of the elastic body 600 with the conductive material-containing composition 700. If a liquid discharge device is used, the orientation of the CNTs is restricted when the conductive material-containing composition 700 is discharged from the tip of the syringe of the device. As a result, the grooves 610 are filled with the CNTs oriented. Can be done.

Next, as shown in FIG. 2C, a plurality of conductive member-containing sheet 800s are laminated so that the directions of the conductive members 30 are aligned with each other to form the conductive member-containing sheet laminate 900 (step B1).
In step B1, it is preferable that not only the orientations of the conductive members 30 but also the arrangement of the conductive members 30 are aligned so that a plurality of conductive member-containing sheets 800 are laminated.
In step B1, aligning the arrangement of the conductive members 30 means that the conductive members 30 included in each of the plurality of conductive member-containing sheets 800 when the conductive member-containing sheet laminate 900 is viewed from the main surface 900a thereof. Is to overlap. In addition, in FIG. 2C, the case where all the conductive members 30 are overlapped with each other is illustrated, but some of the conductive members 30 may not be overlapped with each other.

In step B1, when the conductive member-containing sheet 800 is laminated in the thickness direction thereof, the base material 500 is peeled from the conductive member-containing sheet 800 except for the conductive member-containing sheet 800 that forms the lowest layer.

In order to stack the conductive member-containing sheets 800, an adhesive may be used, or the conductive member-containing sheets 800 may be activated by surface treatment and chemically bonded to each other.
When an adhesive is used, it is preferable to use the same material as the elastic body 600.

Next, as shown in FIG. 2D, the conductive member-containing sheet laminate 900 is cut in a direction perpendicular to the extending direction of the conductive member 30 so as to have a predetermined thickness, and is shown in FIG. Obtain the electrical connector 10 (step C1).

In step C1, as a method for cutting the conductive member-containing sheet laminate 900, for example, laser processing, mechanical processing such as cutting, or the like is used.

After the above steps A1 to C1, the base material 500 is peeled off from the conductive member-containing sheet laminate 900 to obtain the electric connector 10 shown in FIG.

In the present embodiment, the case where the conductive member-containing sheet laminate 900 is cut in the direction perpendicular to the extending direction of the conductive member 30 has been illustrated, but the present invention is not limited to this. In the present invention, in step C1, the conductive member-containing sheet laminate may be cut in an oblique direction with respect to the extending direction of the conductive member.

According to the method for manufacturing an electric connector of the present embodiment, an excessive force is not applied from the conductive member 30 to the connection terminal of the device connected to the electric connector 10, the heat resistance is excellent, and the device is connected. An electric connector 10 that enables stable connection to the terminal can be obtained.

In the present embodiment, the conductive material-containing composition 700 is filled in a large number of grooves 610 formed in the elastic body 600, and the conductive material-containing composition 700 is cured (dried) to form the conductive member 30. Although the cases have been illustrated, the present invention is not limited thereto. In the present invention, the conductive material-containing composition is linearly applied to the surface of a flat (non-grooved) elastic body by a dispenser, printing, or the like, and the conductive material-containing composition is cured (dried). ) May form a conductive member.

"Second manufacturing method"
In the method for manufacturing an electric connector of the present embodiment, a conductive material-containing composition containing a conductive material and an elastic material for dispersing the conductive material is applied onto a sheet-shaped elastic body, and the conductive material-containing composition is applied. A step of curing to form a conductive layer to form a conductive layer-containing sheet (hereinafter referred to as "step A2") and a plurality of sheets of the conductive layer-containing sheet are laminated to form a conductive layer-containing sheet laminate. A conductive member-containing sheet comprising a step (hereinafter referred to as "step B2") and a conductive member obtained by cutting the conductive layer-containing sheet laminate in the thickness direction of the conductive layer and made of a cured product of the conductive material-containing composition. (Hereinafter referred to as "step C2") and a plurality of conductive member-containing sheets are laminated via a sheet-like elastic body in the same direction of the conductive members, and the conductive member-containing sheets are laminated. The step of forming the body (hereinafter referred to as "step D2") and the conductive member-containing sheet laminate are cut in a direction perpendicular to or diagonally to the extending direction of the conductive member to obtain an electric connector. It has a process (hereinafter referred to as “process E2”). The step A2 includes a step A2-1 and a step A2-2, which will be described later.

Hereinafter, the method for manufacturing the electric connector of the present embodiment will be described with reference to FIGS. 3 (a) to 3 (c) and FIGS. 4 (a) to 4 (c).
3 (a) to 3 (c) and 4 (a) to 4 (c) are perspective views showing an outline of a second manufacturing method of the electric connector of the present embodiment. In addition, in FIG. 3 and FIG. 4, the same reference numerals are given to the same configurations as the electric connectors in the present embodiment shown in FIG. 1, and duplicate description will be omitted.

As shown in FIG. 3A, a sheet-shaped elastic body 1100 is formed on the entire surface of one main surface of the base material 1000 (step A2-1).

As the base material 1000, the same base material as the above base material 500 is used.

Examples of the material of the elastic body 1100 include the same materials as those of the elastic body 20.
As a method of forming the elastic body 1100 on the base material 1000, for example, a sheet-like or film-like member made of the above-mentioned material is attached on the base material 1000, or the above-mentioned material is dissolved in an organic solvent. Examples thereof include a method in which the solution is applied onto the base material 1000 and dried to form a coating film. When a sheet-like or film-like member is attached onto the base material 1000, an adhesive may be used, or the member may be activated on the base material 1000 by surface treatment and chemically bonded.

The thickness of the elastic body 1100 is not particularly limited, but is preferably 5 μm to 190 μm.

Next, as shown in FIG. 3B, a conductive material-containing composition 1200 containing the above conductive material and the above elastic material is applied onto one main surface 1100a of the elastic body 1100, and the conductivity thereof is applied. The material-containing composition 1200 is cured (dried) to form a conductive layer 1300 to form a conductive layer-containing sheet 1400 (step A-2).
In this step A-2, the conductive material (carbon nanotube) contained in the conductive material-containing composition 1200 can be oriented along the direction in which the conductive material-containing composition 1200 is applied.

As the conductive material-containing composition 1200, the same one as the above-mentioned conductive material-containing composition 700 is used.

The thickness of the conductive layer 1300 is not particularly limited, but is preferably 10 μm to 195 μm.

Next, as shown in FIG. 3C, a plurality of conductive layer-containing sheet 1400s are laminated to form a conductive layer-containing sheet laminate 1500 (step B2).

In step B2, when the conductive layer-containing sheet 1400 is laminated in the thickness direction thereof, the base material 1000 is peeled from the conductive layer-containing sheet 1400 except for the conductive layer-containing sheet 1400 forming the lowest layer.

In order to laminate the conductive layer-containing sheets 1400, an adhesive may be used, or the conductive layer-containing sheets 1400 may be welded to each other.
When an adhesive is used, it is preferable to use the same material as the elastic body 1100.

In step B2, as shown in FIG. 3C, a sheet-shaped elastic body 1100 is formed on the conductive layer-containing sheet 1400 at the uppermost portion of the conductive layer-containing sheet laminated body 1500 in the same manner as described above.

Next, as shown in FIG. 4A, the conductive layer-containing sheet laminate 1500 is cut in the thickness direction of the conductive layer 1300, and the conductive member includes a conductive member 30 made of a cured product of the conductive material-containing composition 1200. The containing sheet 1600 is formed (step C2).

Next, as shown in FIG. 4B, a plurality of conductive member-containing sheet 1600s are laminated via a sheet-shaped elastic body so that the directions of the conductive members 30 are aligned with each other, and the conductive member-containing sheet laminate 1700 is laminated. Form (step D2).
In step D2, it is preferable not only to align the directions of the conductive members 30 but also to align the arrangement of the conductive members 30 so that a plurality of conductive member-containing sheets 1600 are laminated. In step D2, the arrangement of the conductive members 30 is arranged. Aligning means that the conductive members 30 included in each of the plurality of conductive member-containing sheets 1600 overlap each other when the conductive member-containing sheet laminate 1700 is viewed from the upper surface 1700a thereof. In addition, in FIG. 4B, the case where all the conductive members 30 are overlapped with each other is illustrated, but some of the conductive members 30 may not be overlapped with each other.

In step D2, as shown in FIG. 4B, a sheet-shaped elastic body 1800 is formed on the conductive member-containing sheet 1600 at the uppermost portion of the conductive member-containing sheet laminated body 1700 in the same manner as described above.

In order to laminate the conductive member-containing sheets 1600, an adhesive may be used, or the conductive member-containing sheets 1600 may be welded to each other. It is preferable to adjust the separation distance between the conductive member-containing sheets 1600 by interposing an adhesive layer made of an adhesive so that the conductive members 30 of the conductive member-containing sheet 1600 are separated from each other.
When an adhesive is used, it is preferable to use the same material as the elastic body 1100.

Next, as shown in FIG. 4C, the conductive member-containing sheet laminate 1700 is cut in a direction perpendicular to the extending direction of the conductive member 30 so as to have a predetermined thickness, and the electric connector is cut. Obtain (step E2).

In step E2, as a method of cutting the conductive member-containing sheet laminate 1700, for example, laser processing, mechanical processing such as cutting, or the like is used.

After the above steps A1 to E2, the base material 1000 is peeled off from the conductive member-containing sheet laminate 1700 to obtain the electric connector 10 shown in FIG.

In the present embodiment, the case where the conductive member-containing sheet laminate 1700 is cut in the direction perpendicular to the extending direction of the conductive member 30 has been illustrated, but the present invention is not limited to this. In the present invention, in step E2, the conductive member-containing sheet laminate may be cut in an oblique direction with respect to the extending direction of the conductive member.

According to the method for manufacturing an electric connector of the present embodiment, an excessive force is not applied from the conductive member 30 to the connection terminal of the device connected to the electric connector 10, the heat resistance is excellent, and the device is connected. An electric connector 10 that enables stable connection to the terminal can be obtained.

(Second Embodiment)
[Electrical connector]
FIG. 5 is a cross-sectional view showing a schematic configuration of the electric connector of the present embodiment. In FIG. 5, the same components as those of the electrical connector of the first embodiment shown in FIG. 1 are designated by the same reference numerals, and redundant description will be omitted.
As shown in FIG. 5, the electric connector 100 of the present embodiment includes a composite body 40 having an elastic body 20 and a conductive member 30.

In the electric connector 100 of the present embodiment, the composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 (above the paper surface in FIG. 5) on one main surface 20a side of the elastic body 20. As a result, the electric connector 100 of the present embodiment has a protruding portion 51 and a region thinner than the protruding portion 51 on one main surface 20a side of the elastic body 20 (hereinafter, referred to as a “thin layer portion”). It has an uneven surface formed by 52.

The arrangement and number of the protrusions 51 are not particularly limited, and are appropriately adjusted according to the shape of the connection terminal of the device connected to the electric connector 100 and the like. More specifically, when the surface of the device on which the connection terminal is provided is uneven and the connection terminal is depressed, the arrangement and number of the protrusions 51 are appropriately adjusted so as to correspond to the connection terminal. To.

According to the electric connector 100 of the present embodiment, since the composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 on one main surface 20a side of the elastic body 20, it is connected to the electric connector 100. Even if the connection terminal of the device is depressed, the electrical connection state between the conductive member 30 and the connection terminal of the device can be kept stable.

In the present embodiment, the case where the composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 on one main surface 20a side of the elastic body 20 has been exemplified, but the present invention is limited to this. Not done. The composite 40 may have a protruding portion 51 protruding in the thickness direction of the elastic body 20 on one main surface 20a side and the other main surface 20b side of the elastic body 20.

Further, also in this embodiment, a plating layer may be formed on the surface of the conductive member 30.

[Manufacturing method of electrical connector]
The method for manufacturing the electric connector of the present embodiment is obtained by the steps A1 to C1 or steps A1 to E2 of the method for manufacturing the electric connector of the first embodiment described above and the step of cutting the conductive member-containing sheet laminate. A part of the composite composed of the elastic body and the conductive member is removed from one main surface side of the elastic body of the electric connector in the thickness direction, and a protruding portion protruding in the thickness direction of the elastic body is formed in the composite body. It has a step (hereinafter referred to as "step F").

Hereinafter, the method of manufacturing the electric connector of the present embodiment will be described with reference to FIGS. 6 (a) and 6 (b).
6 (a) and 6 (b) are cross-sectional views showing an outline of a method for manufacturing an electric connector according to the present embodiment. In FIG. 6, the same components as those of the method for manufacturing the electric connector of the first embodiment shown in FIGS. 2 to 4 are designated by the same reference numerals, and redundant description will be omitted.

In the method for manufacturing the electric connector of the present embodiment, steps A1 to C1 (first manufacturing method) or steps A1 to E2 (second manufacturing method) of the method for manufacturing the electric connector of the first embodiment described above. As shown in FIG. 6A, the conductive member-containing sheet laminate 900 (conductive member-containing sheet laminate 1700, corresponding to the composite 40 constituting the electric connector 10 shown in FIG. 1) cut to a predetermined thickness. ).

Next, as shown in FIG. 6B, from one main surface 900b side of the conductive member-containing sheet laminate 900 (one main surface 20a side of the elastic body 20), the conductivity composed of the elastic body 20 and the conductive member 30 A part of the member-containing sheet laminate 900 (composite 40) is removed in the thickness direction, and the conductive member-containing sheet laminate 900 (composite 40) is formed with a protruding portion 51 projecting in the thickness direction of the elastic body 20. (Step F).

In step F, as a method for removing the conductive member-containing sheet laminate 900 (composite 40), for example, mechanical processing such as laser etching and cutting is used.

The electric connector 100 shown in FIG. 5 is obtained by the above steps A1 to C1 or steps A1 to E2 and step F.

According to the method for manufacturing an electric connector of the present embodiment, even if the connection terminal of the device connected to the electric connector 100 is depressed, the electrical connection state between the conductive member 30 and the connection terminal of the device is kept stable. It is possible to manufacture an electric connector 100 capable of the above.

In the present embodiment, in step F, a case where a protruding portion 51 projecting in the thickness direction of the elastic body 20 is formed on the composite 40 on one main surface 20a side of the elastic body 20 is illustrated. The present invention is not limited to this. In step F, the composite 40 may be formed with protruding portions 51 protruding in the thickness direction of the elastic body 20 on one main surface 20a side and the other main surface 20b side of the elastic body 20.

(Third Embodiment)
[Electrical connector]
FIG. 7 is a cross-sectional view showing a schematic configuration of the electric connector of the present embodiment. In FIG. 7, the same components as those of the electric connectors of the first embodiment shown in FIG. 1 and the second embodiment shown in FIG. 5 are designated by the same reference numerals, and redundant description will be omitted.
As shown in FIG. 7, the electric connector 200 of the present embodiment includes a composite body 40 having an elastic body 20 and a conductive member 30.

In the electric connector 200 of the present embodiment, the composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 (above the paper surface in FIG. 7) on one main surface 20a side of the elastic body 20, and a protruding portion. It has a thin layer portion 52 having a thickness thinner than 51, and a resin sheet-like member 60 is laminated on the thin layer portion 52.

The thickness of the sheet-shaped member 60 is not particularly limited, and is appropriately adjusted according to the elasticity required for the composite 40. The thickness of the sheet-shaped member 60 is preferably 0.01 mm to 0.5 mm.

The material of the sheet-shaped member 60 is not particularly limited as long as it has heat resistance and dimensional stability when the sheet-shaped member 60 is used, and for example, polyimide (PI), epoxy resin, polyethylene terephthalate (PET), and the like. Polybutylene terephthalate (PBT), polyvinyl chloride, polystyrene, polyacrylonitrile, polyethylene, polypropylene, acrylic, polybutadiene, polyphenylene ether (PPE), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), liquid crystal polymer (LCP), Examples thereof include polyamideimide (PAI), polyetherimide (PEI), polyethersulfone (PES), polycarbonate (PC) and the like. Among these, polyimide (PI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), and liquid crystal polymer (LCP) are preferable from the viewpoint of excellent heat resistance and dimensional stability.
The sheet-shaped member 60 may be a non-woven fabric made of these resins.

According to the electric connector 200 of the present embodiment, the composite 40 is thinner than the protruding portion 51 protruding in the thickness direction of the elastic body 20 and the protruding portion 51 on one main surface 20a side of the elastic body 20. Since the thin layer portion 52 is provided and the sheet-shaped member 60 made of resin is laminated on the thin layer portion 52, the laminated body composed of the composite 40 and the sheet-shaped member 60 is more than the case where only the composite 40 is used. It has excellent heat resistance and dimensional stability, and devices can be connected stably.

In the present embodiment, the composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 and a thin layer portion 52 on one main surface 20a side of the elastic body 20, and the thin layer portion. Although the case where the resin sheet-like member 60 is laminated on the 52 is illustrated, the present invention is not limited to this. The composite 40 has a protruding portion 51 protruding in the thickness direction of the elastic body 20 and a thin layer portion 52 on one main surface 20a side and the other main surface 20b side of the elastic body 20, and is thin on both sides. A resin sheet-like member 60 may be laminated on the layer portion 52. Further, the resin sheet-like member 60 may be laminated on the protruding portion 51 as well.

Further, also in this embodiment, a plating layer may be formed on the surface of the conductive member 30.

[Manufacturing method of electrical connector]
The method for manufacturing the electric connector of the present embodiment includes steps A1 to C1 or steps A1 to E2 of the method for manufacturing the electric connector of the first embodiment described above, and a step of forming the above-mentioned protruding portion (step F). After the step F of forming the protruding portion, a step of laminating a resin sheet-like member on a region where a part of the composite is removed on one main surface side of the elastic body (hereinafter, "step G"). Say.) And.

Hereinafter, the method of manufacturing the electric connector of the present embodiment will be described with reference to FIGS. 8 (a) to 8 (c).
8 (a) to 8 (c) are cross-sectional views showing an outline of a method for manufacturing an electric connector according to the present embodiment. In FIG. 8, the configuration is the same as that of the method of manufacturing the electric connector of the first embodiment shown in FIGS. 3 and 4 and the method of manufacturing the electric connector of the second embodiment shown in FIG. References are given and duplicate description is omitted.

In the method for manufacturing the electric connector of the present embodiment, steps A1 to C1 (first manufacturing method) or steps A1 to E2 (second manufacturing method) of the method for manufacturing the electric connector of the first embodiment described above. As shown in FIG. 8A, the conductive member-containing sheet laminate 900 (conductive member-containing sheet laminate 1700, corresponding to the composite 40 constituting the electric connector 10 shown in FIG. 1) cut to a predetermined thickness. ).

Next, as shown in FIG. 8B, from one main surface 900b side of the conductive member-containing sheet laminate 900 (one main surface 20a side of the elastic body 20), the conductivity composed of the elastic body 20 and the conductive member 30 A part of the member-containing sheet laminate 900 (composite 40) is removed in the thickness direction, and the conductive member-containing sheet laminate 900 (composite 40) is formed with a protruding portion 51 projecting in the thickness direction of the elastic body 20. (Step F).

Next, as shown in FIG. 8C, on one main surface 20a side of the elastic body 20, a region from which a part of the conductive member-containing sheet laminate 900 (composite 40) is removed, that is, from the protruding portion 51 A resin sheet-like member 60 is laminated on the thin layer portion 52 having a thin thickness (step G).

In step G, as a method of laminating the sheet-shaped members 60, for example, a method of laminating the sheet-shaped members 60 via an adhesive, a method of laminating the sheet-shaped members 60 by surface treatment by irradiation with excimer, and the like are used. Used.
Further, in step G, as a positioning method when the sheet-shaped member 60 is bonded, for example, a positioning mark (marking) is shown on a portion of the conductive member-containing sheet laminate 900 where the conductive member 30 is not arranged. , A method of positioning by image recognition, a method of providing a convex portion or a concave portion for positioning in the conductive member-containing sheet laminate 900, and the like, and the like.

The electric connector 200 shown in FIG. 7 can be obtained by the above steps A1 to C1 or steps A1 to E2, step F, and step G.

According to the method for manufacturing an electric connector of the present embodiment, the laminate composed of the composite 40 and the sheet-like member 60 is superior in heat resistance and dimensional stability as compared with the case where the composite 40 alone is used, and the conductive member 30 and the electric connector are electrically connected. An electric connector 200 capable of stably maintaining an electrical connection state with a connection terminal of a device connected to the connector 200 can be manufactured.

In the present embodiment, in step F, a case where a protruding portion 51 projecting in the thickness direction of the elastic body 20 is formed on the composite 40 on one main surface 20a side of the elastic body 20 is illustrated. The present invention is not limited to this. In step F, the composite 40 may be formed with protruding portions 51 protruding in the thickness direction of the elastic body 20 on one main surface 20a side and the other main surface 20b side of the elastic body 20.

Further, in step G, as a positioning method when the sheet-shaped member 60 is bonded, for example, in the portion of the conductive member-containing sheet laminate 900 where the conductive member 30 is not arranged or near the end of the sheet-shaped member 70. Examples thereof include a method of showing a positioning mark (marking) and positioning by image recognition, a method of providing a convex portion and a concave portion for positioning on the conductive member-containing sheet laminate 900, and the like.

10,100,200 Electric connector 20 Elastic body 21 Through hole 30 Conductive member 40 Composite 51 Protruding part 52 Thin layer part 60 Sheet-like member 500, 1000 Base material 600, 1100, 1800 Elastic body 610 Groove 700, 1200 Conductive material included Composition 800, 1600 Conductive member-containing sheet 900, 1700 Conductive member-containing sheet laminate 1300 Conductive layer 1400 Conductive layer-containing sheet 1500 Conductive layer-containing sheet laminate

Claims (8)

An electrical connector that is located between the connection terminal of the first device and the connection terminal of the second device and electrically connects them.
A composite having an elastic body having a large number of through holes in the thickness direction and a conductive member joined to the through holes and electrically connecting the connection terminal of the first device and the connection terminal of the second device. With
The conductive member is seen containing a conductive material, a resilient material to disperse the conductive material, and
The composite has a protrusion that protrudes in the thickness direction of the elastic body on at least one main surface side of the elastic body.
An electric connector characterized in that a resin sheet-like member is laminated on a region of the composite having a thickness thinner than the protruding portion on at least one main surface side of the elastic body . The electric connector according to claim 1, wherein the conductive material is a carbon nanotube. The electric connector according to claim 2, wherein the carbon nanotubes are oriented in the extending direction of the conductive member. The electric connector according to any one of 1 to 3, wherein the through hole penetrates diagonally with respect to the thickness direction of the elastic body. An elastic body having a large number of grooves arranged in parallel at arbitrary intervals is formed, and the grooves are filled with a conductive material-containing composition containing a conductive material and an elastic material for dispersing the conductive material. A step of curing the conductive material-containing composition to form a conductive member to form a conductive member-containing sheet, and
A step of laminating a plurality of the conductive member-containing sheets in the same direction to form a conductive member-containing sheet laminate.
A method for manufacturing an electric connector, which comprises a step of cutting the conductive member-containing sheet laminate in a direction perpendicular to or diagonally to an extending direction of the conductive member to obtain an electric connector. A conductive material-containing composition containing a conductive material and an elastic material for dispersing the conductive material is applied onto a sheet-shaped elastic body, and the conductive material-containing composition is cured to form a conductive layer to form a conductive layer. The process of forming a layer-containing sheet and
A step of laminating a plurality of the conductive layer-containing sheets to form a conductive layer-containing sheet laminate,
A step of cutting the conductive layer-containing sheet laminate in the thickness direction of the conductive layer to form a conductive member-containing sheet containing a conductive member made of a cured product of the conductive material-containing composition.
A step of forming a laminated body of conductive member-containing sheets by laminating a plurality of the conductive member-containing sheets in the same direction via the sheet-shaped elastic body.
A step of cutting the conductive member-containing sheet laminate in a direction perpendicular to or diagonally to the extending direction of the conductive member to obtain an electric connector.
A part of the composite composed of the elastic body and the conductive material is removed in the thickness direction from at least one main surface side of the elastic body of the electric connector obtained in the step of cutting the conductive member-containing sheet laminate. A method for manufacturing an electric connector , which comprises a step of forming a protruding portion of the elastic body protruding in the thickness direction of the composite . The method for manufacturing an electric connector according to claim 5 or 6 , wherein the conductive material is a carbon nanotube. After the step of forming the protruding portion, a step of laminating a resin sheet-like member on at least one main surface side of the elastic body in a region where the part of the composite is removed is provided. The method for manufacturing an electric connector according to claim 6 or 7 .

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