Compressible IC Test Contact with Bridge Ducts
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Solution Overview
Problem
Existing electrical contact designs for integrated circuit testing, such as pogo pins and pins within elastomers, face issues like unsustainable performance under high temperatures, waste generation due to entire system replacement for single faults, and lack of customization and current carrying capacity, especially during high-frequency testing.
Innovation Solution
An electrical contact design featuring a compressible layer with ducts and bridges made of elastic material, where the bridge acts as a spring to maintain contact between conductive first and second members, allowing for customizable configurations and easy replacement, and operates effectively under high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pogo pin design is used for electrical contact, then electrical contact is achieved, but the entire electrical contact must be replaced when it fails and performance degrades under high temperatures
Solution Approach 1:
The electrical contact system is divided into separate modular components: a compressible layer with ducts, bridges, and contact members. Each component can be independently replaced, allowing repair of only the faulty element rather than the entire assembly. This segmentation enables modular replacement and improves ease of repair while maintaining reliable electrical contact.
2Power
If spring loaded designs are made wider to maintain spring mass for high frequency testing, then spring mass is maintained, but height increases and finer pitching is compromised
Solution Approach 1:
The spring mechanism transitions from a traditional vertical compression design to a lateral compression design where the bridge is compressed horizontally within the duct. This dimensional change allows the spring mass to be distributed differently, maintaining the necessary spring characteristics without increasing the height of the contact member, thereby enabling finer pitching.
3Reliability
If pins within elastomer design is used, then electrical contact is achieved, but gold particles disjoin and entire mat must be replaced for single malfunction
Solution Approach 1:
The contact system is segmented into a compressible layer with discrete bridges and contact members. When a malfunction occurs, only the specific bridge or contact member needs to be replaced, not the entire mat. This segmentation eliminates waste by allowing selective replacement of individual components rather than replacing the whole assembly.
Solution Approach 2:
The bridge structure acts as an intermediary between the compressible layer and the contact members, providing a stable conductive path that prevents particle disjoining. This intermediary structure ensures reliable electrical contact while enabling modular replacement, avoiding the waste associated with replacing entire mats.
4Reliability
If traditional electrical contact designs are used, then electrical contact is established, but customization and current carrying capacity are insufficient for high-frequency testing
Solution Approach 1:
The electrical contact system is designed to be dynamically configurable, allowing the compressible layer and contact members to be customized for different testing requirements. The modular design enables adaptation to various current carrying capacity needs and testing frequencies, providing both reliability and versatility.
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
This design provides reliable, customizable, and maintainable electrical contacts that can withstand high testing temperatures and reduce waste by allowing on-site replacement of faulty components, ensuring accurate and efficient IC device testing.
Implementation Method 1
a compressible layer made of an elastic material... When the compressive force is released, the bridge, acting like a spring, expands thus pushing the first and second members apart, but still in electrical contact with each other
Data Source
AI summary
An electrical contact that employs a common compressible layer for all contacts, wherein the compressible layer is fashioned with ducts that contain bridges within them. The bridges are formed of the compressible layer. This bridge serves as a compressible member for a first and second member in electrical contact with each other, and that interact with each other such that a compression force acted on the first and second members will cause them to maintain electrical contact whilst compressing the bridge. When the compressive force is released, the bridge, acting like a spring, expands thus pushing the first and second members apart, but still in electrical contact with each other.