Contactor Resistor Integration for Signal Interference Reduction

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Solution Overview

Problem

The increasing demand for high-density integrated circuits with reduced pad electrode pitch complicates internal wires in electrical connecting apparatuses, leading to issues like insulation failures and signal interference, and existing solutions struggle to accurately determine and achieve desired resistance values in resistors, making board repair time-consuming and inefficient.

Innovation Solution

The integration of a resistor with a higher resistance value into the contactor main body, specifically at the pedestal and contact portions, using materials like chromium-palladium alloys, and forming techniques such as electroplating or sputtering, allows for easy determination and selection of contactors with desired resistance values, simplifying internal wire configurations and improving board yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If more contactors are used to test more integrated circuits at a time, then test efficiency is improved, but internal wires become complicated and massed, leading to insulation failures and signal interference

Engineering Contradiction:

Improvetest efficiencyVSAvoidinternal wire complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts the resistor from the board-level implementation and integrates it directly into the contactor structure. This removes the need for complex board-level wire management and resistor placement, thereby reducing internal wire complexity while maintaining the ability to test multiple integrated circuits simultaneously

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the resistor function with the contactor structure by forming the resistor directly on the contactor main body. This integration combines two previously separate components (contactor and resistor) into a single unified structure, simplifying the overall system and reducing the number of separate internal connections required

Inventive Principle:

Principle #5Merging (Combining)

2Measurement precision

If resistors are provided on the board to determine resistance values, then resistance measurement is enabled, but it requires enormous amount of time and energy, preventing yield improvement

Engineering Contradiction:

Improveresistance value determinationVSAvoidboard completion time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent performs the resistance measurement function at the contactor level rather than at the final board level. By integrating the resistor directly on the contactor main body, the resistance value can be determined during contactor manufacturing or inspection, before the board is fully assembled and tested, thereby reducing the time and energy required for board-level resistance determination

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If resistors are formed in the board to achieve desired resistance values, then resistance control is improved, but it is difficult to form the resistor having a desired resistance value in the board

Engineering Contradiction:

Improveresistor resistance valueVSAvoidresistor formation difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the traditional mechanical/board-level resistor formation process with a deposition process directly on the contactor main body. This substitution enables precise control of resistance values through controlled deposition of conductive materials, achieving desired resistance values more easily than traditional board-level resistor formation methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enables the selection of contactors with precise resistance values, reducing signal interference and simplifying internal wire arrangements, thereby improving test efficiency and reducing the need for complex board repairs, enhancing overall manufacturing yield.

Implementation Method 1

forming techniques such as electroplating or sputtering

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 2

forming techniques such as electroplating or sputtering

Methodology Applied

Scientific EffectSputtering: Sputtering

Data Source

PatentUS7960988B2Contactor for electrical test, electrical connecting apparatus using the same, and method for manufacturing contactor

Publication Date: 2011.06.14 NIHON MICRONICS KK

AI summary

An electrical test contactor comprises a contactor main body including a plate-shaped attachment portion extending in the up-down direction, a plate-shaped arm portion extending from the lower end portion of the attachment portion at least to one side in the right-left direction, and a plate-shaped pedestal portion projecting downward from the tip end portion of the arm portion, a contact portion projecting downward from the lower end of the pedestal portion and having the lower end of the contact portion acting as a probe tip, and a resistor having a higher resistance value than the contactor main body and the contact portion and arranged at the contactor main body so as to heighten the resistance value of the contactor.