Rectangular Coil-Spring Contact for Easier Probe Assembly
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Solution Overview
Problem
The miniaturization of semiconductor substrates and circuit substrates necessitates the use of probes with a diameter of 0.1 mm, which requires manual insertion of a thinner columnar guide into a tubular body, leading to time-consuming and labor-intensive manufacturing processes.
Innovation Solution
A contact design featuring a coil spring with spirally formed slits and conductors that are manufactured through a laminating process, eliminating the need for manual insertion of a columnar guide and ensuring easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional contactor with a coil, armature, and contact blades is used, then electrical connection is achieved, but foreign objects can enter the contact blade assembly and cause short circuits or contact failures
Solution Approach 1:
The contactor is divided into a sealed housing that encloses the contact blade assembly, separating the internal components from the external environment. This segmentation prevents foreign objects from entering while maintaining electrical functionality.
Solution Approach 2:
A sealed housing acts as an intermediary barrier between the contact blade assembly and the external environment. This housing allows electrical signals to pass through while blocking foreign objects, solving the contradiction between maintaining electrical connection and preventing contamination.
2Reliability
If the contactor structure is made more complex to prevent foreign object entry, then reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The contactor is segmented into a housing and internal components, with the housing serving as a simple sealed enclosure. This segmentation provides protection without requiring complex internal mechanisms, maintaining manufacturing simplicity while improving reliability.
Solution Approach 2:
The sealed housing design is self-contained and requires no additional maintenance or complex operational mechanisms. The structure itself provides the protection function without requiring external systems or complex controls.
3Reliability
If the contactor is sealed to prevent foreign object entry, then reliability improves, but heat dissipation from the coil and contact blades becomes difficult
Solution Approach 1:
The housing incorporates heat dissipation structures that allow thermal energy to pass through while maintaining the sealed barrier against foreign objects. This flexible approach to sealing enables both protection and thermal management.
Solution Approach 2:
The housing serves as an intermediary that selectively permits heat transfer while blocking foreign objects. The sealed structure includes thermal pathways that allow heat dissipation without compromising the protective barrier.
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 contact is easier to manufacture, maintains structural integrity, and reduces electrical resistance, facilitating efficient and stable electrical connections during inspections.
Implementation Method 1
a coil, an armature, and contact blades that establish electrical connection between conductors
Data Source
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AI summary
A contact that is easily manufactured, an inspection jig using the contact, an inspection device, and a method of manufacturing the contact are provided. A contact Pr includes a coil spring CS in which a slit SL is formed in a cylindrical body F and first and second conductors P1 and P2. A bottom wall portion F4, a first side wall portion F1, a second side wall portion F2, and a top wall portion F3 are configured such that a cross-sectional shape of the cylindrical body F as viewed in the axial direction is rectangular, the slit SL includes a first slit SL1, a second slit SL2, a third slit SL3, and a fourth slit SL4, the third slit SL3 is continuous with the first slit SL1 and the second slit SL2, the fourth slit SL4 is continuous with the second slit SL2, the first slit SL1 and the second slit SL2 are rectangular in a side view of the cylindrical body F, the first conductor P1 is connected to a first end portion Fx1 of the cylindrical body F, and the second conductor P2 is connected to a second end portion Fx2 of the cylindrical body F.