Micromolded Connector for Rapid Prototyped Milli-scale Component Assembly

University of California System: University of California, Berkeley
posted on 05/23/2010

• request more info 
•   
•  LICENSE ONLINE

A new microconnector has been developed that makes rapid assembly of millimeter scale components possible. The microconnector is rapidly manufactured with a hot emboss process using inexpensive polymer films such as polyethylene. This allows the microconnector to be created in parallel with many rapid manufacturing processes, enabling the designer to integrate the microconnector with the other components. Once the components are formed with the integrated microconnectors, adhesives are not necessary to attach those components together. The components can be rapidly assembled with a low engagement force that results in a strong connection. These components can then be disconnected and reconnected in a precise, repeatable manner without impairing the engagement strength.   To be useful for the assembly of millimeter-scaled reconfigurable components, a connector with several properties is desired. The connector must form a strong connection between components through a distinct engage/disengage action. This engage/disengage action must require a minimal force to avoid damaging components, must not damage the connector to allow for repeated use and must be fast to allow for rapid assembly. The connector must also be robust to failure and external damage to allow the connector to be reused if the connection is forcefully broken. As well, the connector must be inexpensive and easy to manufacture so that it can be easily integrated with the rest of the components. Finally, the connector must have a sub-millimeter engaged thickness so that its size does not interfere with the function of the millimeter scaled components.   To address this challenge, investigators at University of California at Berkeley have developed a new microconnector. The microconnector design meets these goals through a unidirectional engage/disengage action that gives an anisotropic connection. The anisotropic connector design allows for a rapid engagement in one direction with a minimal force. This avoids putting large strains on the connector during engagement which allows for repeated use. The connector can then be designed to be much stronger in the opposing directions since disengagement in these directions is not necessary.

• Millimeter-scaled component assembly
• Low profile connector for clothing/sports equipment
• Component pick and place
• Reconfigurable assembly for varying geometry

• Fast, repeatable engagement/disengagement
• Low engagement force anisotropic connection
• Rapid assembly of millimeter scaled components
• Robust to failure and external damage
• Low sub-millimeter profile
• Low cost/easy to manufacture
• No adhesives required