Particle Distribution Interposer and Method of Manufacture Thereof

Abstract

An interposer comprising a non-conductive carrier sheet with a pre-arranged pattern of conductive interconnect members positioned therethrough and formed from an elastomeric thermoplastic with suspended spherical and non-spherical conductive particles. The non-spherical conductive particles of the present invention are positioned, substantially perpendicularly to and partially through the contact faces of the interconnect member, thereby resulting in higher conductivity and efficiency. The interposer is formed by a mold comprising two sections with first and second sets of vias formed in the first and second mold sections, respectively, which permit the injected elastomer mixture to flow completely through the mold cavity and thereby aligns the non-spherical conductive particles. The exit side of the mold is further contacted by support posts of a separable mold interface creating a network of vent passages for venting of air and the elastomer mixture, resulting in less pressure within the mold and less mold flash.

1 - 7 . (canceled)  
   
   
       8 . A method for manufacturing an interposer said including an interconnect member having first and second end surfaces, using a mold comprising an upper mold section having a first opening formed therethrough, and a lower mold section having a pressure venting second opening formed therethrough that is at least partially axially aligned with a central axis of said first opening whereby straight flow lines are produced when a substance is injected through said first opening, and wherein said mold has a varying cross-section, said method comprising the steps of: 
 positioning a sheet having a third opening formed therethrough between said upper and lower mold sections with said third opening at least partially axially aligned with said first and second openings; and    continuously injecting an elastomeric material through said first opening until a predetermined amount of said elastomeric material flows out of said second opening.    
   
   
       9 . The method according to  claim 8 , wherein said sheet is composed of a non-conductive material.  
   
   
       10 . The method according to  claim 8 , wherein said elastomeric material comprises a mixture of a thermoplastic elastomer and a predetermined amount of conductive particles.  
   
   
       11 . The method according to  claim 10 , wherein said elastomeric material is packed with said conductive particles to about 15% to 60% by volume.  
   
   
       12 . The method according to  claim 11 , wherein said conductive particles are in part spherical in shape, and in part non-spherical in shape.  
   
   
       13 . The method according to  claim 8 , wherein said mold further comprises a plate positioned in a supporting relation to said lower mold section.  
   
   
       14 . The method according to  claim 13 , comprising the further step of allowing said elastomeric material to cure.  
   
   
       15 . The method according to  claim 14 , comprising the further step of removing said upper and lower mold sections from around said sheet.  
   
   
       16 - 19 . (canceled)  
   
   
       20 . The method according to  claim 8 , wherein said elastomeric material comprises a mixture of a thermoplastic elastomer and a predetermined amount of conductive particles, wherein said conductive particles are in part spherical in shape and in part non-spherical in shape, and wherein said non-spherical conductive particles include a plurality of elongated conductive particles.  
   
   
       21 . The method according to  claim 20 , further comprising the steps of: 
 allowing said elastomeric material to cure; and    removing said upper and lower mold sections from around said sheet conductive particles extend through said first and second end surfaces of said interconnect member respectively.    
   
   
       22 . The method according to  claim 21 , wherein said elongated conductive particles are aligned with said flow lines and are substantially perpendicular to said first and second end surfaces of said interconnect member.  
   
   
       23 . The method according to  claim 21 , wherein a portion of said sheet extends into said interconnect member, thereby securely positioning said interconnect member in said third opening.