Electrical Connector Embedded Shell Layer Gap-Free Contact
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Solution Overview
Problem
Conventional electrical connectors for testing integrated circuit chips face challenges in maintaining secure connections due to gaps between the shell and plungers, which can lead to unreliable signal transmission and increased risk of component breakage during handling.
Innovation Solution
The electrical connector features a shell layer affixed to the internal surface of the socket cavity through a press fit, with plungers and a biasing device inserted into the shell cavity, ensuring a gap-free contact and reducing the risk of component damage by forming the shell layer directly within the socket body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the shell diameter is made smaller than the socket cavity internal surface diameter to allow insertion, then the ease of operation is improved, but gaps are formed between the shell and socket cavity leading to reduced reliability
Solution Approach 1:
The patent introduces a compliant shell layer as an intermediary component between the rigid socket cavity and the plunger. This shell layer is affixed to the internal surface of the socket cavity and provides a compliant interface that eliminates gaps while allowing the plunger to move freely. The shell layer acts as a mediator that maintains reliable electrical contact without interfering with the insertion operation.
2Ease of operation
If the plunger diameter is made smaller than the shell internal surface diameter to allow insertion, then the ease of operation is improved, but gaps are formed between the plunger and shell leading to reduced reliability
Solution Approach 1:
The compliant shell layer serves as an intermediary that fills the gap between the plunger and the socket cavity. By affixing this shell layer to the socket cavity internal surface, the patent ensures that the plunger maintains consistent electrical contact through the shell layer, eliminating the reliability issues caused by gaps while preserving the ease of insertion.
3Ease of manufacture
If conventional separate shell and plunger components are used, then the ease of manufacture is improved, but the risk of component breakage during handling increases
Solution Approach 1:
The patent merges the shell and plunger into a more integrated structure by affixing the compliant shell layer directly to the internal surface of the socket cavity. This integration reduces the number of separate components that need to be handled and assembled, thereby reducing the risk of breakage during handling while maintaining manufacturing feasibility through the press-fit process.
4Ease of operation
If gaps are allowed between shell and plunger for insertion, then the ease of operation is improved, but signal transmission reliability deteriorates
Solution Approach 1:
The compliant shell layer acts as an intermediary that ensures continuous electrical contact between the plunger and the socket cavity during insertion and operation. This intermediary component eliminates signal transmission gaps while allowing the insertion process to proceed smoothly, thereby resolving the contradiction between ease of operation and signal reliability.
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 configuration enhances the reliability of electrical connections by eliminating gaps and reducing the risk of component breakage, providing a secure and stable interface for signal transmission between IC chips and printed circuit boards.
Implementation Method 1
a biasing device configured to exert a biasing force on the at least one plunger
Implementation Method 2
affixing at least one layer to a core such that the at least one layer is isomorphic to at least a portion of on an external surface of the core and press fitting the core with the at least one layer into a socket cavity
Data Source
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AI summary
An electrical connector and method of forming the same are provided, where the method can include affixing at least one layer to a core such that the layer is isomorphic to at least a portion of on an external surface of the core, press fitting the core with the layer into a socket cavity in a socket body, and removing the core from the socket cavity while leaving at least a portion of the layer so that the layer forms a shell layer affixed to an internal surface of the socket cavity. The method can further include inserting at least one plunger and a biasing device into a shell cavity so that a tail of the plunger is slidably received in the shell cavity and the biasing device biases a tip of the plunger away from an internal surface of the shell cavity.