3D Printed Contact-Distance Transformer for Wafer Testing
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Solution Overview
Problem
Existing contact-distance transformers for electric testing devices, particularly those using multilayer ceramics, are complex and costly to manufacture, requiring a simpler and more inexpensive solution for reducing contact distances between electric contacts.
Innovation Solution
A contact-distance transformer is created using a 3D-printing method with an electrically non-conductive supporting structure and conductive connections, where the supporting structure is printed with insulating material and connections are made with conductive material, allowing for the reduction of contact distance and enabling the production of complex structures quickly and inexpensively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If multilayer ceramics are used to manufacture contact-distance transformer, then the contact distance can be reduced, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent changes the manufacturing method from traditional multilayer ceramic sintering to 3D printing technology. This parameter change allows for the production of complex three-dimensional contact patterns and internal structures without requiring multiple ceramic layers to be stacked, compressed, and sintered together, thereby reducing manufacturing complexity while achieving the same contact distance reduction
Solution Approach 2:
The patent utilizes the third dimension (vertical space) by printing conductive material through the supporting structure to create three-dimensional contact patterns. This allows contacts to be arranged in complex spatial configurations that would be difficult or impossible to achieve with traditional planar multilayer ceramic approaches, enabling compact contact distance reduction through volumetric rather than just planar arrangement
2Length of stationary object
If multilayer ceramics are used to manufacture contact-distance transformer, then the contact distance can be reduced, but the production cost increases
Solution Approach 1:
The patent changes the manufacturing method from expensive multilayer ceramic sintering to more cost-effective 3D printing technology. The 3D printing process uses standard printing materials (insulating supporting structure and conductive printing material) that are generally less expensive than precision ceramic materials and their associated multi-step processing, thereby reducing production cost while maintaining the contact distance reduction function
Solution Approach 2:
The patent employs a single-use 3D-printed contact-distance transformer that can be quickly manufactured and replaced if needed. The 3D printing process enables rapid prototyping and production of disposable or temporary testing components, eliminating the need for expensive, time-consuming ceramic fabrication processes while achieving the same functional result
3Length of stationary object
If multilayer ceramics are used to manufacture contact-distance transformer, then the contact distance can be reduced, but the production time increases
Solution Approach 1:
The patent changes the manufacturing process from a multi-step ceramic fabrication process (cutting, stacking, compressing, sintering) to a single-step 3D printing process. The 3D printer can deposit both the insulating supporting structure and conductive connections in one continuous operation, dramatically reducing production time while achieving the same contact distance reduction that previously required complex multilayer ceramic assembly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D-printed contact-distance transformer achieves a significant reduction in contact distance, simplifies the manufacturing process, and reduces production costs, making it a more efficient and cost-effective component for electric testing devices.
Implementation Method 1
both the supporting structure and the electric connections are provided as 3D-printed components
Data Source
AI summary
A contact-distance transformer of an electric testing device for testing an electric specimen such as a wafer, for reducing a distance between neighboring electric contacts, the transformer having a non-electrically conductive supporting structure with a first side with first electric contacts positioned apart a first distance and a second side with second electric contacts positioned apart a second, smaller distance. The first contacts are connected to the second contacts by electric connections passing through the support structure and/or which are positioned on the support structure.