Linear Probe Head Asymmetric Cross-Section Dynamic Control
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Solution Overview
Problem
Conventional linear probes, particularly cylindrical needles, face challenges in dynamic behavior control, leading to inconsistent deformation and potential interference and short circuits due to their manufacturing simplicity and limited material variety, while square punched needles offer better control but are costly and difficult to manufacture accurately.
Innovation Solution
A probe head design featuring a linear probe with sections of varying widths, allowing for specific elastic bending deformation, combined with an asymmetric tail portion for orientation recognition, which enhances dynamic behavior control and stability, and can be manufactured using laser cutting for cost-effectiveness and material variety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical needles are used for linear probes, then manufacturing is simple and cost is low, but dynamic behavior control is poor leading to inconsistent deformation and potential interference
Solution Approach 1:
The patent applies asymmetry by making the linear probe body portion asymmetric in cross-section (e.g., rectangular or elliptical instead of circular). This asymmetric geometry provides a preferred bending direction that enables consistent dynamic behavior control while maintaining manufacturing simplicity through direct cutting or punching processes.
Solution Approach 2:
The patent implements local quality by varying the cross-sectional dimensions along the length of the linear probe body. Different sections have different width and thickness ratios, creating zones with different stiffness characteristics that control the deformation behavior in specific regions while keeping the overall structure simple to manufacture.
2Reliability
If square punched needles are used for linear probes, then dynamic behavior control is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses asymmetric cross-sectional geometry (rectangular or elliptical) that can be achieved through simple punching or cutting operations. This asymmetric shape provides controlled deformation characteristics without requiring complex multi-step manufacturing processes, thus maintaining ease of manufacture while improving dynamic behavior control.
Solution Approach 2:
The patent controls dynamic behavior by adjusting geometric parameters such as the width-to-thickness ratio of the linear probe body. By varying these parameters in different sections, the probe achieves desired elastic deformation characteristics using straightforward manufacturing methods without increasing complexity.
3Measurement precision
If linear probes have small pitch for fine pitch applications, then measurement precision is improved, but body portion interference and short circuit risk increase due to inconsistent deformation
Solution Approach 1:
The asymmetric cross-section of the linear probe body provides a preferred bending direction that constrains deformation to a specific plane. This prevents adjacent probes from interfering with each other even at small pitches, as the deformation is directed consistently rather than randomly in multiple directions.
Solution Approach 2:
The patent varies the cross-sectional dimensions locally along the probe body to create zones with different stiffness. This local quality control ensures that deformation occurs in controlled regions away from adjacent probes, preventing interference and short circuits while maintaining fine pitch measurement precision.
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 design ensures consistent dynamic behavior of linear probes, preventing interference and short circuits while reducing manufacturing complexity and costs, and offering more material options.
Implementation Method 1
the body portion 166 of each linear probe 16 can provide an elastically adjusting effect to cause the head portion 162 to be in contact with and electrically connected with the conductive contact pad of the device under test positively, and a buffering effect to avoid damage or excessive wear
Data Source
AI summary
A probe head includes upper and lower die units, and a linear probe inserted therethrough and thereby defined with tail, body and head portions. A first bottom surface of the upper die unit and a second top surface of the lower die unit face each other, thereby defining an inner space wherein the body portion is located and includes a plurality of sections each having front width larger than or equal to back width, including a narrowest section whose upper and lower ends have a distance from the first bottom surface and the second top surface respectively. The head and tail portions are offset from each other along two horizontal axes and the body portion is thereby curved. The present invention is favorable in dynamic behavior control of the linear probe which is easy in manufacturing, lower in cost and has more variety in material.