A comparison of metal-in-elastomer connectors-the influence of structure on mechanical and electrical performance

Three types of metal-in-elastomer connectors (A. B, and C) are characterized using scanning electron microscopy and X-ray analysis. The focus is on explaining their electrical performance as a function of the physical dimensions, structure, and materials properties. The mechanical and electrical performance of the connectors are correlated with their structure. The design of the type-A connector allows the best combination of compliance and electrical performance. Its performance is the most predictable. The design of the type-B connector is suitable for interconnecting systems where high pressures are acceptable. The rather unusual surface characteristics of the type-A connector have a limited influence on the connector electrical performance. The elastomeric film covering the outermost conductive particles is not detrimental to the contact resistance. The results of the cyclical load application test showed that some inherent damage is induced to the contact area due to compression cycling. The current carrying capacity test showed that the elastomer is the element to fail in the event of high current density