Co-Planar Waveguide Test Probe Assembly With Replaceable RF Connectors

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Solution Overview

Problem

Current RF characterization probes are expensive, fragile, and not field-repairable, with low manufacturing yields and limited configurability.

Innovation Solution

A lead frame assembly with a substrate, ground sheets, and a signal conductor trace forming a co-planar waveguide, allowing for customizable and field-replaceable RF connectors, supporting frequencies up to 1 THz.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional coaxial cable probes with machined contacts or soldered flanges are used, then coplanar termination is achieved, but the probes become expensive, fragile, and non-field-repairable

Engineering Contradiction:

Improveprobe durability and field-repairabilityVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The probe is divided into separate modular components: a reusable probe body and replaceable lead frame assemblies. This segmentation allows the fragile contact elements to be replaced without replacing the entire probe, improving field-repairability while reducing overall cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lead frame assemblies are designed as low-cost, replaceable components that can be easily swapped in the field. Instead of making the entire probe expensive and durable, only the contact elements are made inexpensive and replaceable, achieving cost-effectiveness and field-repairability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Adaptability or versatility

If traditional probe designs are used, then coplanar termination is provided, but configurability and manufacturing yield are limited

Engineering Contradiction:

Improveprobe configurabilityVSAvoidmanufacturing yield

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The probe body is designed as a universal platform that can accommodate multiple types of lead frame assemblies with different configurations (coplanar, non-coplanar, different pitches). This universality enables a single probe body to serve multiple testing purposes, improving configurability while simplifying manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system transitions from fixed, rigid probe configurations to dynamic, reconfigurable assemblies. Lead frames can be replaced or repositioned to adapt to different device under test requirements, enabling flexible configuration without remanufacturing entire probes.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If small coaxial cables with machined contacts are used, then precise contact geometry is achieved, but the probes become fragile and expensive

Engineering Contradiction:

Improvecontact geometry precisionVSAvoidprobe robustness

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The lead frame assemblies combine rigid materials (for precise contact geometry) with flexible materials (for robustness). This composite construction maintains manufacturing precision while improving overall probe durability and resistance to damage.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The lead frame structure incorporates flexible elements that allow the rigid contact tips to maintain precise geometry while the overall assembly can flex and withstand mechanical stress, improving robustness without sacrificing precision.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20250314695A1Test probe assembly for high frequency device characterization

Publication Date: 2025.10.09 XCERRA CORP

AI summary

A test probe assembly includes a mounting fixture, a co-planar waveguide lead frame having a device contact point, where the co-planar waveguide lead frame is mounted to the mounting fixture, and at least one radio frequency (RF) connector assembly electrically coupled with the co-planar waveguide lead frame.