Impedance Controlled Test Socket for High-Frequency Signals
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Solution Overview
Problem
Conventional test sockets made of plastic are unable to transfer high-frequency signals effectively, as they lack the necessary impedance matching and structural integrity to handle signals beyond 35 GHz.
Innovation Solution
The development of an electrical contactor assembly with a metal socket body and retainer, featuring insulation layers and dielectric materials to maintain constant impedance, allowing for the transmission of high-frequency signals by aligning the impedance at both ends of the contact probe, and using a differential pair configuration for improved signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic test sockets are used, then manufacturing cost and ease of manufacture are improved, but signal transmission capability above 35 GHz deteriorates due to impedance mismatch and structural deformation
Solution Approach 1:
The test socket is constructed using composite materials including metal components (socket body, contactors) and dielectric materials (insulation layers, PTFE coating). This combination provides both mechanical strength for structural integrity and controlled impedance characteristics for high-frequency signal transmission, resolving the contradiction between ease of manufacture and signal transmission capability.
Solution Approach 2:
The patent implements impedance control by changing the physical parameters of the socket structure, including wall thickness, contactor dimensions, and dielectric material properties. These parameter adjustments ensure characteristic impedance matching (e.g., 50 ohms) across the frequency range up to at least 45 GHz, enabling reliable high-frequency signal transmission while maintaining manufacturability.
2Device complexity
If conventional test sockets are used, then device complexity is reduced, but signal integrity deteriorates at high frequencies due to lack of impedance control
Solution Approach 1:
The patent incorporates impedance control features by adjusting structural parameters such as contactor diameter, socket wall thickness, and dielectric material placement. These parameter changes enable the socket to maintain controlled impedance characteristics without significantly increasing device complexity, achieving signal integrity up to 45 GHz with minimal added complexity.
3Reliability
If short contactors are used, then signal integrity is improved through reduced transmission path, but compliance is reduced limiting applications in large size integrated circuit packages
Solution Approach 1:
The contactor assembly uses composite construction with conductive materials for signal transmission and dielectric materials for insulation and impedance control. This composite structure maintains signal integrity over longer contactor lengths while providing the mechanical compliance needed for large size integrated circuit packages, resolving the contradiction between signal integrity and adaptability.
4Reliability
If coaxial structure is used, then high-frequency signal transmission is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent implements a segmented approach where the coaxial-like impedance control is achieved through separate components (socket body, contactors, dielectric layers) rather than a single complex coaxial structure. This segmentation maintains high-frequency signal transmission capability while simplifying manufacturing and reducing device complexity.
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 enables the transmission of high-frequency signals up to at least 45 GHz, improving signal integrity and handling capabilities compared to conventional systems, while maintaining structural strength and preventing deformation under connector force.
Implementation Method 1
an end insulation ring located in the second socket opening and around the second plunger, the end insulation ring configured to facilitate a substantially constant impedance through the signal contact probe
Implementation Method 2
Each cavity may receive a contactor, which may be a spring probe
Data Source
AI summary
Methods, systems, and apparatus for electrical connector assemblies. The assemblies include a socket defining a signal cavity, the socket having a first socket opening and a second socket opening. The assemblies include a signal contact probe located within the signal cavity. The signal contact probe includes a first plunger received in the shell cavity and extending through a first shell opening and located in the first socket opening. The signal contact probe includes a second plunger received in the shell cavity and extending through a second shell opening and located in the second socket opening. The assemblies include an end insulation ring located in the second socket opening and around the second plunger, the end insulation ring configured to facilitate substantially constant impedance through the signal spring probe, and configured to restrict lateral movement of the second plunger within the second socket opening.