Layered Test Connector Structure for Thermal Stability and Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing test connectors face issues with operability and lifespan due to the use of materials like polyimide, which do not compress well with conductors, and silicone rubber, which deforms thermally, leading to reduced performance and service life.
Innovation Solution
A test connector design with conductors that are elastically deformable, supported by a structure with elastic and heat-resistant insulating layers, allowing for even distribution of pressing force and preventing thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If only high hardness material like polyimide is used as insulator, then thermal stability is improved, but compressibility with conductors deteriorates
Solution Approach 1:
The insulator is divided into multiple layers with different material properties: a lower insulating layer made of elastic material (silicone rubber) that provides compressibility, and an upper insulating layer made of heat-resistant material (polyimide) that provides thermal stability. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
The insulator uses a composite structure combining elastic material and heat-resistant material in distinct layers. The elastic lower layer and heat-resistant upper layer work together to provide both compressibility and thermal stability, resolving the contradiction between these two properties.
2Ease of operation
If only elastic material like silicone rubber is used as insulator, then compressibility is improved, but thermal deformation occurs
Solution Approach 1:
The insulator is segmented into functional layers: the lower layer uses elastic material for compressibility, while the upper layer uses heat-resistant material to prevent thermal deformation. This division allows the elastic material to perform its compression function without being compromised by thermal exposure.
Solution Approach 2:
The composite insulator structure combines elastic material and heat-resistant material, where the heat-resistant upper layer protects the elastic lower layer from thermal deformation while maintaining the compressibility benefits of the elastic material.
3Stability of the object's composition
If conductors are constrained by insulator, then structural stability is improved, but elastic deformation capability deteriorates
Solution Approach 1:
The insulator provides different levels of constraint at different locations: the lower insulating layer allows greater elastic deformation of conductors for adaptability, while the upper insulating layer provides stronger constraint for structural stability. This local differentiation resolves the contradiction between stability and deformation capability.
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
Improves operability and extends the lifespan of the test connector by enabling smooth elastic deformation and thermal stability during repetitive testing.
Implementation Method 1
an insulator having at least one through hole into which the conductor is inserted in the vertical direction and being coupled to the support... The insulator includes at least one elastic insulating layer that is elastically compressively deformable in the vertical direction when pressed
Implementation Method 2
The at least one elastic insulating layer may include a heat-resistant material... the heat-resistant material may include boron nitride... the heat-resistant material may include carbon or a carbon compound
Data Source
AI summary
The present disclosure provides a test connector disposed between a test device and a device to be inspected. The test connector includes at least one conductor configured to be conductive in a vertical direction and be elastically compressively deformable in the vertical direction when pressed, a support configured to support the conductor, and an insulator having at least one through hole into which the conductor is inserted in the vertical direction and being coupled to the support. A gap is formed between an inner circumferential surface of the through hole and an outer circumferential surface of the conductor. The insulator includes at least one elastic insulating layer that is elastically compressively deformable in the vertical direction and includes an elastic material, and at least one support insulating layer that is stacked in the vertical direction together with the insulating layer and has higher hardness than the insulating layer.