Contact Probe Terminal Segmentation for Projection Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing contact probes face challenges in controlling the projection amounts of terminals, leading to potential falling issues and reduced strength or conductivity when not mounted, due to dimensional mismatches between the plunger and through holes in inspecting sockets.
Innovation Solution
A contact probe design featuring a cylindrical barrel with a caulked portion, a spring, and terminal sections of varying diameters, including a stop portion and shaft sections that adjust to prevent falling and maintain conductivity, allowing controlled projection amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the barrel lower end abuts on the through hole in the base member, then the projection amount of the plunger tip end increases, but the plunger may fall from the through hole when not mounted
Solution Approach 1:
The plunger is divided into multiple shaft sections (first, second, and third shaft sections) with different diameters. The second shaft section has a larger diameter that abuts on the through hole to prevent falling, while the first and third shaft sections have smaller diameters for insertion and contact functions. This segmentation allows different parts of the plunger to serve different purposes simultaneously.
Solution Approach 2:
Different sections of the plunger are given different local qualities in terms of diameter. The second shaft section has a larger diameter specifically at the location where it needs to prevent falling from the through hole, while other sections maintain smaller diameters for their respective functions. This local variation in diameter solves the contradiction between projection amount and falling prevention.
2Reliability
If the plunger tip end is inserted into the through hole when not mounted, then falling is prevented, but the contact probe may be broken if the pedestal is forced to move
Solution Approach 1:
The plunger is segmented into multiple shaft sections with different diameters. The second shaft section with larger diameter provides mechanical support and prevents falling, while the first and third shaft sections with smaller diameters are designed for insertion and electrical contact. This segmentation allows the structure to prevent falling without requiring the entire plunger to be forced into the through hole, thus avoiding breakage.
Solution Approach 2:
The plunger is designed to be movable within the barrel along the axial direction, allowing it to dynamically adjust its position. When mounted, the plunger moves to insert the tip end into the through hole for stability. When not mounted, the plunger can retract, avoiding the risk of breakage from forced movement. This dynamic positioning resolves the contradiction between preventing falls and maintaining strength.
3Reliability
If the projection amount of the plunger tip end is increased, then electrical connection is improved, but the dimensional mismatch with through hole increases
Solution Approach 1:
The plunger is divided into multiple shaft sections with progressively different diameters. The first shaft section has a smaller diameter for precise insertion into the through hole, ensuring manufacturing precision. The second shaft section has a larger diameter that abuts on the through hole to prevent falling. The third shaft section provides the necessary projection amount for reliable electrical connection. This segmentation allows each section to optimize for its specific function without compromising the others.
Solution Approach 2:
Different local sections of the plunger are given different diameters tailored to their specific functions. The first shaft section has a smaller diameter optimized for precise insertion and manufacturing precision. The second shaft section has a larger diameter optimized for mechanical support and preventing falls. The third shaft section provides the required projection amount for electrical connection. This local quality variation resolves the contradiction between electrical connection reliability and manufacturing precision.
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 solution effectively prevents terminal falling and maintains strength and conductivity by adjusting the position of the second shaft section, ensuring reliable electrical connections and improved durability.
Implementation Method 1
a spring disposed in the barrel in a state of being in contact with the test board side terminal and the inspection device side terminal
Data Source
AI summary
The contact probe comprises a barrel 50, an inspection device side terminal 60, a test board side terminal 70, and a spring 80 disposed in a state of being in contact with the test board side terminal 70 and the inspection device side terminal 60, the test board side terminal 70 includes a stop portion 74 that can abut on the caulked portion 52 in the barrel 50 and a terminal body that projects from the other end 56 of the barrel 50, and the terminal body includes, in order from a tip end, a first shaft section 71, a second shaft section 72 having a diameter larger than a diameter of the first shaft section 71, and a third shaft section 73 having a diameter smaller than the diameter of the second shaft section 72 and having at least a part that can be housed in the barrel 50.