Horizontal Clamp Electrical Contact Assembly for High Current Testing
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Solution Overview
Problem
Existing electrical contact assemblies for integrated circuit testing struggle to handle high currents, require precise lead pin alignment, and are limited to specific lead pin shapes and sizes, making them unreliable for testing automotive IC chips with damaged or imprecisely aligned pins.
Innovation Solution
A pair of mirroring contacts with elastomers positioned in recesses near their lower ends, allowing for sideways rocking and creating a biasing force that translates into a horizontal clamping force for secure contact, accommodating a range of lead pin sizes and shapes, and tolerating imprecise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a spring probe with needle shaped design is used to create biasing force, then the contact can be simple in structure, but it cannot carry high electrical currents without creating high inductance
Solution Approach 1:
The contact assembly is segmented into two separate contacts (first contact and second contact) that mirror each other, with the electrical current path divided to flow through both contacts and the elastomer in series. This segmentation allows the current to travel a shorter horizontal distance through each contact component, reducing overall inductance while maintaining structural simplicity.
Solution Approach 2:
The design transitions from a vertical spring probe configuration to a horizontal clamping configuration where contacts rock sideways. This dimensional change allows the electrical path to be nearly vertical through the elastomer while the contacts themselves remain horizontal, separating the mechanical biasing function from the electrical conduction path and reducing inductance.
2Device complexity
If traditional contacts are used, then the structure can be simple, but the lead pins must be very precise during actuation or test fails occur
Solution Approach 1:
The contacts are designed to rock dynamically between uncompressed and compressed states rather than remaining rigid. This dynamic movement allows the contacts to self-adjust and accommodate variations in lead pin position, orientation, and slight damages, reducing the precision requirements for lead pin actuation while maintaining reliable electrical contact.
Solution Approach 2:
The elastomer material properties provide a compliant interface that can deform to accommodate lead pin variations. The elastomer's elastic properties allow it to maintain electrical contact even when lead pins are slightly damaged or misaligned, reducing manufacturing precision requirements without complicating the contact structure.
3Device complexity
If traditional contact designs are used, then each design can accommodate only one shape of lead pin with narrow size range, but the structure remains simple
Solution Approach 1:
The mirrored contact design with elastomer compression creates a universal interface that can accommodate multiple lead pin shapes and sizes. The horizontal clamping force generated by the elastomer, combined with the rocking motion capability, allows the same contact structure to reliably contact various lead pin configurations including needle form, different diameters, and slight variations in geometry.
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 design enables reliable high-current testing with reduced inductance and improved tolerance for lead pin variations, ensuring secure connections across a short electrical path.
Implementation Method 1
As a lead pin of a device under test (DUT) is lowered towards the contact, it enters the gap between the contacts' upper ends and pushes them apart. This causes the contacts to rock away from each other, which compresses the elastomers and thus creates a biasing force.
Implementation Method 2
In this way, the electrical current flowing through the contact travels across a short path as the connection between the DUT and a bottom terminal in a load board is nearly vertical. This reduces the inductance created during high current testing
Data Source
AI summary
An electrical contact assembly having a pair of contacts mirroring each other, each contact coupled with an elastomer positioned in a recess formed near a lower end of the contact. Each elastomer has a cylindrical shape with the axis of the cylinder running in a front to rear direction. Each elastomer is secured at its front and rear ends by a lower cavity formed within a housing. The contacts are able to rock sideways around their lower ends between uncompressed and compressed states.