Kelvin Contact Insulation for Inspection Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing Kelvin inspection methods face challenges due to complex manufacturing steps, increased component count, and potential deformation of insulating sheets and contact pins during repeated inspections, leading to electrical contact issues between contacts.
Innovation Solution
A Kelvin contact design featuring adjacent contacts with an insulating layer covering the main body area except for the ends, ensuring stable insulation and preventing electrical contact between contacts, along with a replaceable contact housing and optional insulating partition plates or spaces for enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sheet is interposed between contacts and fixed with lock pins, then electrical insulation between contacts is achieved, but manufacturing complexity increases due to multiple steps and components
Solution Approach 1:
The insulating layer is integrated directly onto the contact structure through coating or formation processes, merging the insulating function with the contact itself. This eliminates the need for separate insulating sheets and lock pins, reducing manufacturing steps while maintaining electrical insulation reliability
Solution Approach 2:
The insulating function is extracted from a separate component (insulating sheet) and applied directly to the contact surface. This allows the insulating layer to become an inherent part of the contact structure, simplifying assembly and reducing the number of discrete components
2Ease of manufacture
If lock pins are used to fix contacts and insulating sheet, then assembly is achieved, but deformation occurs during repeated Kelvin inspection causing contact shifting
Solution Approach 1:
The mechanical fastening system (lock pins) is replaced with a direct integration approach where the insulating layer is formed or coated onto the contact surface. This eliminates mechanical fasteners that can deform or loosen, ensuring stable contact positioning through repeated inspections
Solution Approach 2:
The insulating layer is applied to the contact surface before final assembly, creating a permanent bond between the insulating function and the contact structure. This preliminary action prevents subsequent shifting or deformation issues that would require reassembly or adjustment
3Device complexity
If contacts are arranged adjacent to each other, then compact design is achieved, but electrical contact between contacts may occur if insulating layer shifts
Solution Approach 1:
The insulating layer is applied specifically to the regions where electrical insulation is needed between adjacent contacts. This localized insulation approach maintains compact contact arrangement while ensuring electrical isolation at critical interfaces
Solution Approach 2:
The insulating function is merged with the contact structure itself through direct coating or formation, ensuring that the insulating layer and contact move together as a unified structure. This prevents relative shifting that could compromise electrical insulation between adjacent contacts
Data Source
AI summary
Provided is a Kelvin contact for inspection in which contacts and an insulating layer are less likely to be shifted relative to each other even after repeatedly performed Kelvin inspection. The Kelvin contact for inspection includes: a first contact having an upper contact point that comes into contact with one electrode terminal of an IC device and a lower contact point that comes into contact with an electrode pad of a substrate for inspection; and a second contact having an upper contact point that comes into contact with the one electrode terminal and the lower contact point that comes into contact with an electrode pad of the substrate for inspection. The first and second contacts are adjacently arranged to contact with the same one electrode terminal and provided with an insulating layer surrounding the entire main body area except upper and lower contact point areas including the upper and lower contact points, respectively.