Insulation Member for Electrical Connector
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Solution Overview
Problem
Conventional electrical connectors used in test systems for IC chips lack effective insulation, leading to potential electrical shorts and impedance issues due to the use of insulative materials that do not form a coaxial structure, which can affect the reliability and accuracy of testing.
Innovation Solution
The use of an electrical connector with a contact probe that includes a tubular shell and plungers formed from conductive materials, where an insulation member made of insulative materials like PTFE is integrated to surround the plungers and shell, providing enhanced insulation and preventing electrical shorts while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulative materials are used in electrical connectors, then insulation is provided, but the coaxial structure is not formed leading to impedance issues
Solution Approach 1:
The patent applies composite materials by combining conductive materials (copper alloy, beryllium copper) with insulative materials (PTFE, polyimide) in a unified connector structure. The insulative material is integrated as an insulation member that surrounds the conductive contact members, creating a composite structure that simultaneously provides both electrical insulation and maintains precise coaxial geometry for proper impedance control.
2Ease of manufacture
If conventional insulative materials are used, then insulation is achieved, but electrical shorts may occur due to insufficient insulation
Solution Approach 1:
The patent applies local quality by providing insulation specifically where needed - the insulative material is positioned as an insulation member surrounding the conductive contact members at critical locations. This localized insulation approach ensures electrical short prevention at contact points while maintaining the overall manufacturability of the connector assembly.
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 integration of insulation members effectively prevents electrical shorts and maintains the coaxial structure, ensuring reliable and accurate electrical connections between IC chips and PCBs, enhancing the testing process by reducing tilting and contact issues within the connector assembly.
Implementation Method 1
an insulation member made of insulative materials like PTFE is integrated to surround the plungers and shell, providing enhanced insulation and preventing electrical shorts
Data Source
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AI summary
A contact probe and method of forming the same are provided, where the contact probe can include a shell including a body having a shell cavity. The contact probe can also include at least one plunger slidably received in the shell cavity and extending through at least one opening in at least one end of the shell. The contact probe can further include a biasing device configured to exert a biasing force on the at least one plunger and at least one insulation member including an insulative material. The at least one insulation member can be disposed on at least a portion of an outer surface of at least one of: the shell and the at least one plunger.