Functional contactor

A functional contactor is provided. The functional contactor according to one embodiment of the present invention comprises: a conductive elastic portion having elasticity and electrically contacting one of a circuit board of an electronic device, a bracket coupled to the circuit board, and a conductor which can come into contact with the human body; a substrate made from a dielectric material and having a groove in either the upper surface or the lower surface thereof; and a functional element comprising a high dielectric material inserted into the groove and made from sintered ceramic having a higher dielectric constant than a dielectric material, a first electrode disposed on the upper surface of the substrate and electrically connected in series to the conductive elastic portion, and a second electrode disposed on the lower surface of the substrate and opposite to the first electrode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national phase application under 35 U.S.C. § 371 of International Application No. PCT/KR2017/012302, filed Nov. 2, 2017, which claims priority to and the benefit of Korean Patent Applications No. 10-2016-0146491, filed Nov. 4, 2016, and No. 10-2016-0146489, filed Nov. 4, 2016. The contents of the referenced patent applications are incorporated into the present application by reference.

FIELD OF THE DISCLOSURE

The present invention relates to a contactor for an electronic device such as a smart phone, and more particularly, to a functional contactor which is capable of being easily manufactured and mass-produced while using sintered ceramic having a high dielectric constant.

BACKGROUND

In recent portable electronic devices, there is an increasing tendency to employ a metal housing so as to improve an aesthetic impression and robustness. The portable electronic device employs a conductive elastic portion, such as a conductive gasket or a conductive clip, between an external housing and an internal circuit substrate of the portable electronic device for alleviating impact from the outside and, simultaneously, reducing electromagnetic waves penetrating into the portable electronic devices or being leaked therefrom, and for an electrical contact between an antenna disposed in the external housing and the internal circuit substrate.

However, since an electrical path between the external housing and the internal circuit substrate may be formed due to the conductive elastic portion, when static electricity having high voltage instantaneously flows through a conductor such as an external metal housing, the static electricity can flow into the internal circuit substrate through the elastic portion to damage an integrated circuit (IC) and the like, and a leakage current generated by an alternating current (AC) power source flows to the external housing along a ground of a circuit so that a user is uncomfortable, and, in the worst case, the leakage current results in electric shock which may cause injury to the user.

A protective element for protecting the user from the static electricity or the leakage current is provided together with a conductive elastic portion connecting the metal housing and the circuit substrate. As a conductor such as a metal case is used, it is required for a functional contactor which has various functions for not only a simple electrical contact but also for protecting a user or a circuit in a portable electronic device or smoothly transferring a communication signal.

Meanwhile, since a protective element used in a conventional functional contactor is formed of sintered ceramic, it is difficult to manufacture the conventional functional contactor due to applying complicated and various electrode structures and thus mass production is not easy such that a manufacturing cost cannot be reduced such as to become a hindrance factor for commercialization. Consequently, there is a pressing need for a strategy of mass production.

Further, during a process of bonding the conductive elastic portion to the protective element by soldering, since the conductive elastic portion and the protective element are individually bonded, it is difficult to manufacture the conventional functional contactor. In particular, since both of the conductive elastic portion and the protective element have a small size, a great deal of time and effort are put into a precise bonding between the conductive elastic portion and the protective element and mass production of the conventional functional contactor is difficult such that there is a pressing need for improvement of bonding the conductive elastic portion to the protective element.

SUMMARY OF THE INVENTION

The present invention is directed to providing a functional contactor which is capable of being mass-produced by implementing a functional element using sintered ceramic having a high dielectric constant and a large-area substrate.

Further, the present invention is directed to providing a functional contactor which is capable of being easily manufactured by performing a soldering process of a conductive elastic portion using a large-area substrate with a functional element.

One aspect of the present invention provides a functional contactor including a conductive elastic portion configured to come into electrical contact with one among a circuit substrate of an electronic device, a bracket coupled to the circuit substrate, and a conductor contactable with a human body and having an elastic force; a substrate made of a dielectric material and having a groove formed in either an upper surface or a lower surface of the substrate; and a functional element inserted into the groove and including a high dielectric material made of sintered ceramic having a dielectric constant that is higher than that of the dielectric material, a first electrode disposed on an upper surface of the substrate and electrically connected to the conductive elastic portion in series, and a second electrode opposite to the first electrode and disposed on a lower surface of the substrate.

The high dielectric material may be made of a low temperature co-fired ceramic (LTCC) or a varistor material.

The varistor material may include a semiconductive material containing one or more of ZnO, SrTiO3, BaTiO3, and SiC, or one of Pr- and Bi-based materials.

The dielectric material may be made of flame retardant 4 (FR4) or polyimide (PI).

Another aspect of the present invention provides a functional contactor including a conductive elastic portion configured to come into electrical contact with one among a circuit substrate of an electronic device, a bracket coupled to the circuit substrate, and a conductor contactable with a human body and having an elastic force; a substrate comprised of a plurality of dielectric material layers; and a functional element including a first electrode electrically connected in series to the conductive elastic portion, and a second electrode disposed to be opposite to the first electrode at a predetermined interval. The plurality of dielectric material layers may be disposed between the first electrode and the second electrode, a first dielectric material layer, a second dielectric material layer, and a third dielectric material layer may be sequentially stacked on the second electrode, and the second dielectric material layer may be made of sintered ceramic having a dielectric constant that is higher than that of each of the first dielectric material layer and the third dielectric material layer.

The second dielectric material may be made of a low temperature co-fired ceramic (LTCC) or a varistor material.

Each of the first dielectric material layer and the third dielectric material layer may be made of flame retardant 4 (FR4) or polyimide (PI).

The first electrode and the second electrode may be formed on an entirety or part of upper and lower surfaces of the substrate, respectively.

The functional element may have an electric shock prevention function of blocking a leakage current of an external power source flowing from the ground of a circuit substrate of the electronic device, a communication signal transmission function of passing a communication signal flowed from a conductive case or the circuit substrate, and an electrostatic discharge (ESD) protection function of passing the ESD without a dielectric breakdown when the ESD flows from the conductive case.

The conductive elastic portion may include one among a conductive gasket, a silicone rubber pad, and a clip-shaped conductor having an elastic force.

The conductive elastic portion may be in line-contact or point-contact so as to reduce galvanic corrosion.

In accordance with the present invention, an electrode of a functional element is configured using a large-area substrate and sintered ceramic with a high dielectric constant is inserted into the substrate or implemented as a part of the substrate. Consequently, a functional contactor is easily manufactured and is suitable for mass production such that a manufacturing cost and a processing time can be reduced and thus efficiency of a manufacturing process can be improved.

Further, in accordance with the present invention, a conductive elastic portion is bonded onto a large-area substrate provided with a functional element through soldering such that the conductive elastic portion can be easily aligned with and stably bonded to the substrate, thereby improving reliability of a product.

Furthermore, in accordance with the present invention, since sintered ceramic having a high dielectric constant is used, it is possible to compensate for degradation in performance of the functional element implemented using the large-area substrate such that mass production is possible and a characteristic of the product can be improved.

Moreover, in accordance with the present invention, the sintered ceramic is inserted into a groove of the substrate and thus it is possible to stably and easily implement bonding between a high dielectric material and the substrate made of a different material such that reliability of the product and ease of a manufacturing process can be further improved.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be fully described in detail which is suitable for easy implementation by those skilled in the art to which the present invention pertains with reference to the accompanying drawings. The present invention may be implemented in various different forms, and thus it is not limited to embodiments which will be described herein. In the drawings, some portions not related to the description will be omitted in order to clearly describe the present invention, and the same or similar reference numerals are given to the same or similar components throughout this disclosure.

As shown inFIGS. 1 and 2, a functional contactor100according to a first embodiment of the present invention includes a conductive elastic portion110, a substrate120, and a functional element130.

In a portable electronic device, the functional contactor100is configured to electrically connect a conductive case such as an external metal case to a circuit substrate or to electrically connect the conductive case to a conductive bracket electrically coupled to one side of the circuit substrate.

That is, in the functional contactor100, the conductive elastic portion110may come into contact with the circuit substrate or the conductive bracket and the substrate120may be coupled to the conductive case. Contrarily, the conductive elastic portion110may come into contact with the conductive case and the substrate120may be coupled to the circuit substrate.

For example, when the functional contactor100is a functional contactor of a surface mount technology (SMT) type, i.e., the functional contactor100is coupled through soldering, the substrate120may be bonded to the circuit substrate of the portable electronic device, and when the functional contactor100is a functional contactor of an adhesive layer type, i.e., the functional contactor100is coupled through a conductive adhesive layer, the substrate120may be coupled to the conductive case.

Meanwhile, the portable electronic device may be formed as a portable electronic device which is portable and easy to carry. For example, the portable electronic device may be a portable terminal such as a smart phone, a cellular phone, or the like and may be a smart watch, a digital camera, a digital multimedia broadcasting (DMB), an electronic book, a netbook, a tablet personal computer (PC), a portable computer, or the like. The electronic device may have any suitable electronic components including antenna structures for communicating with external devices. Further, the electronic device may be a device using a local area network communication such as Wi-Fi or Bluetooth.

Here, the conductive case may be an antenna for communication between the portable electronic device and an external device. For example, the conductive case may be provided to partially or entirely surround a side portion of the portable electronic device.

The conductive elastic portion110comes into electrical contact with any one among the circuit substrate of the electronic device, the bracket coupled to the circuit substrate, and a conductor contactable with a human body and has an elastic force.

InFIG. 1, although the conductive elastic portion110has been shown and described as being a clip-shaped conductor having an elastic force, the present invention is not limited thereto, and the conductive elastic portion110may be a conductive gasket or a silicone rubber pad.

Here, when the conductive elastic portion110comes into contact with the circuit substrate, the conductive bracket, and the conductor, the conductive elastic portion110may be contracted to the substrate120due to a pressing force, and when the conductive case is separated from the portable electronic device, the conductive elastic portion110may be restored to its original state due to the elastic force.

Meanwhile, when the conductive elastic portion110is pressurized, galvanic corrosion occurs due to a potential difference between dissimilar metals. In this case, in order to minimize galvanic corrosion, the conductive elastic portion110may be formed to have a small contact area.

That is, the conductive elastic portion110may be configured not only to be in surface-contact but also may be in line-contact and/or point-contact. In this case, when the conductive elastic portion110is the conductive gasket or the silicone rubber pad, the conductive elastic portion110may be in surface-contact, whereas, when the conductive elastic portion110is the clip-shaped conductor, the conductive elastic portion110may be in line-contact and/or point-contact.

For example, when the conductive elastic portion110is the clip-shaped conductor, the clip-shaped conductor includes a contact portion111, a bent portion112, and a terminal113.

Here, the clip-shaped conductor may be a C-shaped clip which is substantially “C” shaped. Since the clip-shaped conductor110is in line-contact or point-contact, galvanic corrosion resistance may be excellent.

The contact portion111may have a curved shape and come into electrical contact with the conductive case and either the circuit substrate or the conductive bracket. The bent portion112may be formed to extend from the contact portion111and may have an elastic force. The terminal113may be a terminal electrically connected to the substrate120.

The contact portion111, the bent portion112, and the terminal113may be integrally formed of a conductive material having an elastic force.

The substrate120is made of a dielectric material, and a groove121is formed on an upper surface of the substrate120. Here, the dielectric material may be made of flame retardant 4 (FR4) or polyimide (PI) so as to be able to be manufactured into a large-area substrate and allow an electrode to be easily formed.

In this case, as described below, a high dielectric material133made of sintered ceramic may be inserted into the groove121through an insulating adhesive layer. That is, since the substrate120and the high dielectric material133are made of different materials, the substrate120may be bonded to the high dielectric material133through the insulating adhesive layer.

However, the bonding of the substrate120and the high dielectric material133is not limited thereto, and a stacking method is not particularly limited as long as it can ensure a bonding force between the substrate120and the high dielectric material133.

As described above, since the substrate into which the sintered ceramic is inserted is used, formation of an electrode may be facilitated using a substrate manufacturing process and a large-area substrate may be used such that it is possible to easily manufacture the functional element130and mass production thereof may be possible.

Meanwhile, the substrate120may serve as a guide as a medium for fixing the conductive elastic portion110and the functional element130and coupling the conductive elastic portion110and the functional element130to the conductive case. That is, when the conductive elastic portion110is bonded to the functional element130, even though soldering is difficult, the substrate120may provide stable bonding through the conductive adhesive layer or the like.

The functional element130is electrically connected in series to the conductive elastic portion110and is integrally formed with the substrate120. Here, the functional element130may have a function of protecting a user or an internal circuit.

That is, the functional element130may block a leakage current of an external power source flowing from a ground of a circuit substrate of an electronic device. In this case, the functional element130may be configured to have a breakdown voltage Vbr or a withstanding voltage that is higher than a rated voltage of the external power source of the electronic device. Here, the rated voltage may be a standard rated voltage for each country. For example, the rated voltage may be any one among 240 V, 110 V, 220 V, 120 V, and 100 V.

Further, when the conductive case has a function of an antenna, the functional element130may serve as a capacitor to block the leakage current of the external power source and to pass a communication signal flowed from the conductor or the circuit substrate.

Further, the functional element130may pass an electrostatic discharge (ESD) flowing from the conductive case without a dielectric breakdown. In this case, the functional element130may be configured to have a breakdown voltage Vbr that is lower than a dielectric breakdown voltage Vcp of each of the substrate120and the high dielectric material133.

Accordingly, the functional contactor100may electrically connect the conductive case to the circuit substrate to allow the communication signal, the ESD, and the like to be passed, but the functional contactor100may block the leakage current of the external power source from the circuit substrate from flowing to the conductive case.

For example, as shown inFIGS. 1 and 2, the functional element130includes a first electrode131, a second electrode132, and the high dielectric material133.

The first electrode131is disposed on an upper surface of the substrate120to be electrically connected to the conductive elastic portion110. The first electrode131is disposed on the substrate120and the high dielectric material133which are made of different materials. Therefore, the first electrode131may be bonded to the upper surface of the substrate120through an insulating adhesive layer.

Further, the first electrode131may be formed on an entirety of the upper surface of the substrate120to increase capacitance.

The second electrode132is opposite to the first electrode131and is disposed on a lower surface of the substrate120. The second electrode132may be formed on an entirety of the lower surface of the substrate120.

The high dielectric material133is inserted into the groove121of the substrate120. As described above, since the high dielectric material133is confined by the groove121and thus movement of the high dielectric material133is restricted, bonding of the substrate120and the high dielectric material133which are made of different materials may be performed stably. Further, the high dielectric material133is inserted into the groove121through the insulating adhesive layer, and the high dielectric material133may be easily coupled to the substrate120only by being inserted into the groove121and disposing the first electrode131on an upper side of the high dielectric material133.

The high dielectric material133is made of sintered ceramic having a dielectric constant that is higher than that of a dielectric material of the substrate120. For example, the high dielectric material133may be made of low temperature co-fired ceramic (LTCC) or a varistor material. Here, the varistor material may include a semiconductive material containing one or more of ZnO, SrTiO3, BaTiO3, and SiC, or any one of Pr- and Bi-based materials.

As described above, the functional element130is implemented using a high dielectric material such as sintered ceramic such that a characteristic of the functional element130may be improved. In other words, when a substrate manufacturing process is used for mass production, a dielectric constant required for the functional element130cannot be provided due to a dielectric material constituting the substrate. Therefore, the existing sintered ceramic having a high dielectric constant is inserted into the substrate120such that the characteristic of the functional element130may be improved.

In the functional element130, a dielectric constant of the high dielectric material133, a thickness between the first electrode131and the second electrode132, and an area of each of the first electrode131and the second electrode132may be set such that a withstanding voltage of the functional element130is greater than a rated voltage of the external power source of the electronic device, and capacitance is formed to be able to pass a communication signal flowed from a conductor.

The functional element130configured as described above may prevent the user from being damaged due to electric shock and the like and prevent damage to the internal circuit through a conductor such as the conductive case. For example, when a leakage current flows from the ground of the circuit substrate of the electronic device, since the withstanding voltage between the first electrode131and the second electrode132is greater than the rated voltage of the external power source, the functional element130may block the leakage current of the external power source instead of allowing the leakage current to flow through the functional element130.

Further, when a communication signal is flowed from the conductor or the circuit substrate, the functional element130may serve as a capacitor to perform a function of transferring the communication signal.

Further, when the ESD flows from the conductor, since a dielectric breakdown voltage between the first electrode131and the second electrode132is greater than a breakdown voltage therebetween, the functional element130may pass the ESD without a dielectric breakdown. The functional element130may be configured to transfer the ESD to the ground of the circuit substrate, thereby protecting the internal circuit.

Meanwhile, in the functional contactor according to the first embodiment of the present invention, the electrode and the high dielectric material may be variously modified.

As shown inFIG. 3, in order to facilitate a position alignment and bonding of the conductive elastic portion110when the conductive elastic portion110is solder-bonded, the first electrode131and the second electrode132of a functional contactor200may each be formed to have a small size that is similar to a size of a lower surface of the conductive elastic portion110. That is, a first electrode231may be formed on a portion of the upper surface of the substrate120, and a second electrode232may be formed on a portion of the lower surface of the substrate120.

As shown inFIG. 4, a functional contactor200′ may be configured such that the high dielectric material133is provided at a lower portion of a substrate120′ to be covered with the second electrode132. That is, a groove121′ may be formed in a lower surface of the substrate120′, and the high dielectric material133may be inserted into the groove121′.

In this case, the second electrode132is disposed on the lower surface of the substrate120′ and disposed below the high dielectric material133. Therefore, the second electrode132may be bonded to the lower surface of the substrate120′ through an insulating adhesive layer. Further, the first electrode131may be formed on an entirety of an upper surface of the substrate120′ using a substrate manufacturing process.

As described above, the functional elements130,230, and130′ are formed by inserting the sintered ceramic into the groove of the dielectric material substrate with which forming of the electrodes is facilitated. Therefore, as compared with the existing functional element made of only a ceramic material prepared through a sintering process, not only is it possible to easily manufacture the functional element130,230, or130′ because of being manufactured using a substrate manufacturing process, but also it may be suitable for mass production when a large-area substrate is used. Consequently, a manufacturing cost and a processing time can be reduced such that efficiency of a manufacturing process can be improved.

The functional contactor100,200, or200′ may be manufactured using a large-area substrate. For example, the functional contactor100,200, or200′ may be formed such that a plurality of functional elements130are provided on a large-area substrate120a, and each of a plurality of conductive elastic portions110is soldered to the large-area substrate120aand then cut in a unit size.

The manufacturing process of the functional contactor100,200, or200′ will be described in more detail with reference toFIGS. 4 to 6.

First, as shown inFIG. 5, grooves121may be formed on the large-area substrate120athrough a substrate manufacturing process, and the second electrode132may be formed on a lower surface of the large-area substrate120a.

Here, the second electrode132may be provided to have a size equal to an area of the lower surface of a unit substrate120. Alternatively, the second electrode232may be formed in a small size corresponding to the conductive elastic portion110(seeFIG. 3).

As described above, the second electrode132is formed below the substrate120through the substrate manufacturing process such that a process may be simplified.

In this case, a plurality of high dielectric materials133may be inserted into the grooves121formed in the large-area substrate120a. The high dielectric materials133may be inserted into and bonded to the grooves121through insulating adhesive layers.

As shown inFIG. 6, the first electrode131may be formed on the large-area substrate120a. Here, the first electrode131may be formed to have a size equal to an area of an upper surface of the unit substrate. The first electrode131may be bonded to the large-area substrate120athrough an insulating adhesive layer.

Alternatively, when the first electrode231is formed in a small size corresponding to the conductive elastic portion110(seeFIG. 8), i.e., when a plurality of first electrodes231are provided on the substrate120, the plurality of first electrodes231may be respectively bonded to the unit substrates120through insulating adhesive layers.

As described above, the functional element130,230, or130′ is implemented on the substrate120using the large-area substrate120asuch that the functional element130,230, or130′ may be easily manufactured and mass-produced. Further, since the functional element130is implemented during the manufacturing process of the substrate120, a process may be simplified as compared with a case in which the functional element130is coupled to a guide.

As shown inFIGS. 7 and 8, the conductive elastic portion110may be bonded to the large-area substrate120aprovided with the functional element130,230, or130′ through soldering.

That is, in a state in which the first electrode131is integrally formed on the upper surface of the large-area substrate120aprovided with the functional element130, a plurality of conductive elastic portions110are soldered on the first electrode131through solder such that the conductive elastic portion110, the substrate120, and the functional element130may be integrally formed (seeFIG. 7).

Here, since the first electrode131is formed to be larger than each of the conductive elastic portions110and thus an alignment of the conductive elastic portions110may not be easy, a stopper for aligning positions of the conductive elastic portions110may be provided on the first electrode131.

Alternatively, when a plurality of first electrodes231are formed on the upper surface of the large-area substrate120aprovided with the functional elements130(seeFIG. 8), that is, when each of the first electrodes231is formed to have a size similar to that of each of the conductive elastic portions110, the plurality of conductive elastic portions110may be soldered to the plurality of first electrodes231.

As described above, since the plurality of conductive elastic portions110are soldered to the first electrode131or the plurality of first electrodes231integrally formed on the large-area substrate120ausing solder, an alignment and soldering of the conductive elastic portions110may be performed easily and accurately as compared with a conventional individual coupling such that efficiency of a manufacturing process as well as reliability of a product may be improved.

In this case, the large-area substrate120ais cut along a cutting line120bhaving a unit size such that a unit functional contactor100,200, and200′ may be manufactured in large quantities.

As described above, since the implementation of the plurality of functional elements130,230, or130′ and the soldering of the conductive elastic portions110may be carried out simultaneously in large quantities using the large-area substrate120a, mass production of the functional contactor100,200, or200′ may be possible.

Meanwhile, in the present invention, a part of a substrate may be made of a high dielectric material.

As shown inFIGS. 9 and 10, a functional contactor300according to a second embodiment of the present invention includes a conductive elastic portion310, a substrate320, and a functional element330.

A configuration of the conductive elastic portion310is identical to that of the conductive elastic portion110of the first embodiment, and thus a detailed description thereof will be omitted.

The substrate320is comprised of a plurality of dielectric layers321,322, and323. For example, the substrate320may be comprised of three dielectric layers321,322, and323. That is, the three dielectric layers321,322, and323are disposed between a first electrode331and a second electrode332and are sequentially stacked on the second electrode332. The first dielectric layer321may be disposed at a lowermost portion of the substrate320, the second dielectric layer322may be disposed on the first dielectric layer321, and the third dielectric layer323may be disposed on the second dielectric layer322.

Here, the second dielectric layer322is formed of sintered ceramic having a dielectric constant that is higher than that of each of the first dielectric layer321and the second dielectric layer322. For example, the second dielectric layer322may be made of LTCC or a varistor material. As described below, the second dielectric layer322forms a part of the functional element330.

Further, the first dielectric layer321and the third dielectric layer323may each be made of FR4 or PI so as to be able to be manufactured into a large-area substrate and allow an electrode to be easily formed. Here, the first dielectric layer321and the third dielectric layer323may be formed of materials having different dielectric constants according to a characteristic of an electrode which will be formed.

That is, one of the first dielectric layer321and the third dielectric layer323may be made of PI, and the other thereof may be made of FR4. For example, the first dielectric layer321may be made of PI, and the third dielectric layer323may be formed of FR4.

In this case, the first dielectric layer321and the second dielectric layer322may be stacked through an insulating adhesive layer provided there between, and the second dielectric layer322and the third dielectric layer323may be stacked through an insulating adhesive layer provided there between. That is, the first dielectric layer321, the third dielectric layer323, and the second dielectric layer322disposed between the first dielectric layer321and the third dielectric layer323are made of different materials such that the first dielectric layer321, the third dielectric layer323, and the second dielectric layer322may be stacked through insulating adhesive layers.

However, the stacking of the plurality of dielectric layers321,322, and323is not limited thereto, and a stacking method is not particularly limited as long as it can ensure a bonding force between the plurality of dielectric layers321,322, and323.

As described above, since the dielectric material layers of the substrate are provided on both sides of the sintered ceramic, formation of an electrode may be facilitated using a substrate manufacturing process and a large-area substrate may be used such that it is possible to easily manufacture the functional element330and mass production thereof may be possible.

Meanwhile, the substrate320may serve as a guide as a medium for fixing the conductive elastic portion310and the functional element330and coupling the conductive elastic portion110and the functional element130to a conductive case. That is, when the conductive elastic portion310is bonded to the functional element330, even though soldering is difficult, the substrate320may provide stable bonding through the conductive adhesive layer or the like.

The functional element330is electrically connected in series to the conductive elastic portion310and is integrally formed with the substrate320. Here, a function of the functional element330is identical to that of the functional element130,230, or130′ of the first embodiment, and thus a detailed description thereof will be omitted.

For example, as shown inFIGS. 9 and 10, the functional element330includes the first electrode331, the second electrode332, and the second dielectric layer322.

The first electrode331is disposed on an upper side of the third dielectric layer323to be electrically connected to the conductive elastic portion310. The first electrode331may be formed on a part of the upper surface of the third dielectric layer323.

Further, in order to facilitate a position alignment and a bonding of the conductive elastic portion310when the conductive elastic portion310is solder-bonded, the first electrode331may be formed to have a size similar to that of a lower surface of the conductive elastic portion310.

The second electrode332is disposed opposite to the first electrode331at a regular interval and disposed below the first dielectric layer321. The second electrode332may be formed on a part of a lower surface of the third dielectric layer321. The second electrode332may be formed to have a size equal to that of the first electrode331.

The second dielectric layer322is disposed between the first dielectric layer321and the third dielectric layer323. The second dielectric layer322is made of a high dielectric material having a dielectric constant that is higher than a dielectric constant of the first dielectric layer321provided below the second dielectric layer322and is higher than a dielectric constant of the third dielectric layer323provided above the second dielectric layer322.

The second dielectric layer322may be made of sintered ceramic, e.g., LTCC or a varistor material. Here, the varistor material may include a semiconductive material containing one or more of ZnO, SrTiO3, BaTiO3, and SiC, or any one of Pr- and Bi-based materials.

As described above, the functional element330is implemented using a high dielectric material such as sintered ceramic such that a characteristic of the functional element330may be improved. In other words, when a substrate manufacturing process is used for mass production, a dielectric constant required for the functional element330cannot be provided due to the dielectric material layers constituting the substrate. Therefore, the existing sintered ceramic having a high dielectric constant is inserted into the substrate320such that the characteristic of the functional element330may be improved.

In the functional element330, a dielectric constant of the second dielectric layer322, a thickness between the first electrode331and the second electrode332, and an area of each of the first electrode331and the second electrode332may be set such that a withstanding voltage of the functional element130is greater than a rated voltage of the external power source of the electronic device, and capacitance is formed to be able to pass a communication signal flowed from a conductor.

Meanwhile, in the functional contactor according to the second embodiment of the present invention, the electrodes may be variously modified.

As shown inFIG. 11, in order to increase capacitance, a first electrode431and a second electrode432of a functional contactor400may each be formed to be large. That is, the first electrode431may be formed on an entirety of an upper surface of the third dielectric layer323, and the second electrode432may be formed on an entirety of a lower surface of the first dielectric layer321.

As described above, the functional element330or430is formed by providing the dielectric material layers, with which forming of the electrodes is facilitated, on both sides of the sintered ceramic. Therefore, as compared with the existing functional element made of only a ceramic material prepared through a sintering process, not only it is possible to easily manufacture the functional element330or430because of being manufactured using a substrate manufacturing process, but also it may be suitable for mass production when a large-area substrate is used. Consequently, a manufacturing cost and a processing time can be reduced such that efficiency of a manufacturing process can be improved.

The functional contactor300or400may be manufactured using a large-area substrate. For example, the functional contactor300or400may be formed such that a plurality of functional elements330are provided on a large-area substrate320a, and each of a plurality of conductive elastic portions310is soldered to the large-area substrate320aand then cut in a unit size.

The manufacturing process of the functional contactor300or400will be described in more detail with reference toFIGS. 12 to 14.

First, as shown inFIG. 12, a large-area substrate320acorresponding to each of the plurality of dielectric layers321,322, and323may be formed. In this case, through the substrate manufacturing process, a second electrode332may be formed on the lower surface of the first dielectric layer321, and the first electrode331may be formed on an upper surface of the third dielectric layer323. Here, the first electrode331and the second electrode332may each be formed in a small size corresponding to the conductive elastic portion310(seeFIG. 13).

Alternatively, the first electrode431may be provided to have a size equal to an area of an upper surface of a unit third dielectric layer323, and the second electrode432may be provided to have a size equal to an area of a lower surface of a unit first dielectric layer321(seeFIG. 14).

As described above, the first electrode431is formed an upper side of the third dielectric layer323, and the second electrode432is formed a lower side of the first dielectric layer321through the substrate manufacturing process such that a process may be simplified.

Here, the plurality of dielectric layers321,322, and323may be sequentially stacked (seeFIG. 12). That is, the second dielectric layer322may be disposed on the upper surface of the first dielectric layer321on which the second electrode332is not formed, and a lower surface of the third dielectric layer323on which the first electrode331is not formed may be disposed on the second dielectric layer322. In this case, the second dielectric layer322may be bonded between the third dielectric layer323on which the first electrode331is formed and the first dielectric layer321on which the second electrode332is formed through the insulating adhesive layers.

As described above, the functional elements330are implemented on the unit substrates320using the large-area substrate320asuch that the functional elements330may be easily manufactured and be mass-produced. Further, since the functional element330is implemented during the manufacturing process of the substrate320, a process may be simplified as compared with a case in which the functional element130is coupled to a guide.

As shown inFIGS. 13 and 14, conductive elastic portions310may be bonded to the large-area substrate320acomprised of the plurality of dielectric layers321,322, and323and provided with functional elements330through soldering.

That is, in a state in which a plurality of first electrodes331are formed on the upper surface of the large-area substrate120aprovided with the functional elements330, a plurality of conductive elastic portions310are soldered on the first electrodes331using solder such that the conductive elastic portions310, the substrates320, and the functional elements330may be integrally formed (seeFIG. 13).

Further, when the first electrode431is integrally formed (seeFIG. 14), i.e., when the first electrode431is formed to be larger than each of the conductive elastic portions310, since an alignment of the conductive elastic portions310may not be easy, a stopper for aligning positions of the conductive elastic portions310may be provided on the first electrode431.

As described above, since the plurality of conductive elastic portions310are soldered to the plurality of first electrodes331or the first electrode431integrally formed on the large-area substrate320ausing solder, an alignment and soldering of the conductive elastic portions310may be performed easily and accurately as compared with a conventional individual coupling such that efficiency of a manufacturing process as well as reliability of a product may be improved.

In this case, the large-area substrate320ais cut along a cutting line320bhaving a unit size such that a unit functional contactor300or400may be manufactured in large quantities.

As described above, since the implementation of the plurality of functional elements330and the soldering of the conductive elastic portions310may be carried out simultaneously in large quantities using the large-area substrate320a, mass production of the functional contactor300or400may be possible.

Although the exemplary embodiments of the present invention have been described, the spirit of the present invention is not limited to the exemplary embodiments disclosed herein, and it should be understood that numerous other embodiments can be devised by those skilled in the art that will fall within the same spirit and scope of this disclosure through addition, modification, deletion, supplement, and the like of a component, and also these other embodiments will fall within the spirit and scope of the present invention.