Conductive Elastomer Interface for High-Frequency Probe Testing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing probe cards face challenges in testing high-frequency electronic devices due to the increased stiffness of short contact probes, which can lead to breakage of both the probes and contact pads, and the introduction of noise in signal transmission.

Innovation Solution

An interface element with conductive elastomer interconnection elements that fill through-openings in a support, providing mechanical and electric connection by protruding ends with reduced sections to prevent breakage and noise, and are suitable for high-frequency applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If short contact probes are used for high-frequency testing, then signal transmission quality is improved, but the risk of probe and contact pad breakage increases due to increased stiffness

Engineering Contradiction:

Improvenoise in signal transmissionVSAvoidprobe and contact pad breakage

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent changes the material parameter of the contact probes from rigid metal to elastomeric material with conductive particles. This parameter change maintains electrical conductivity while providing mechanical flexibility, allowing the probes to deform elastically during contact without breaking, thus resolving the contradiction between signal quality and reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The contact probes are made as composite structures consisting of an elastomeric base material embedded with conductive particles. This composite approach combines the mechanical flexibility of elastomers with the electrical conductivity of metals, enabling the probes to withstand repeated contact cycles without breakage while maintaining low noise signal transmission for high-frequency applications

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional rigid contact probes are used, then mechanical strength is improved, but noise is introduced in high-frequency signal transmission

Engineering Contradiction:

Improvemechanical strength of contact probesVSAvoidnoise in signal transmission

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from rigid metal to elastomeric composite, which fundamentally alters the mechanical properties. The elastomeric material with conductive particles provides sufficient mechanical strength for contact while having lower inductance and capacitance, thereby reducing noise in high-frequency signal transmission

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The contact probes are designed as flexible elastomeric elements rather than rigid structures. This flexibility allows the probes to conform to contact pad surfaces and reduces mechanical stress concentrations, while the elastomeric material's electrical properties minimize noise generation during high-frequency signal transmission

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-generated harmful factors

If the contact probes are made shorter for high-frequency applications, then noise reduction is achieved, but the stiffness increases leading to higher breakage risk

Engineering Contradiction:

Improvenoise in signal transmissionVSAvoidcontact probe length and flexibility

Core Design Contradiction:

Object-generated harmful factorsVSLength of moving object

Solution Approach 1:

The patent changes the material composition parameter of the contact probes to elastomeric composite material. This parameter change decouples the relationship between length and stiffness, allowing short probe lengths to be used for noise reduction while the elastomeric material maintains flexibility and prevents breakage through elastic deformation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the traditional mechanical rigid probe system with an elastomeric composite system. This substitution replaces the reliance on probe length for flexibility with material-based elasticity, enabling short probes to maintain both low noise characteristics and high reliability through the inherent elastic properties of the elastomeric material

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

The interface element effectively connects contact pads without adding noise and reduces the risk of breakage, ensuring reliable testing of high-frequency devices while maintaining probe integrity.

Implementation Method 1

a plurality of through-openings formed in a support thereof with a conductive elastomer, whose end portions are adapted to contact contact pads

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11293941B2Interface element for a testing apparatus of electronic devices and corresponding manufacturing method

Publication Date: 2022.04.05 TECHNOPROBE

AI summary

An interface element (20) for a testing apparatus of electronic devices comprises at least one support (21) provided with a plurality of through-openings (22) that house respective interconnections elements (23), which extend between a first end (23a) and a second end (23b). Suitably, the interconnections elements (23) are made of a conductive elastomer that fills the openings (22) of the support (21), each of the interconnection elements (23) forming a conductive channel between different and opposing faces (Fa, Fb) of the support (21).