Modular Rubber Socket Assembly for Large-Area Semiconductor Testing
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Solution Overview
Problem
Conventional rubber sockets face challenges in high-frequency semiconductor testing due to defects from non-uniform magnetic field application, increased manufacturing costs, and difficulty in replacing individual defective parts, especially in large-area sockets with narrow pitches.
Innovation Solution
A prefabricated rubber socket is constructed by assembling individually manufactured electrically-conductive blocks onto a support member, allowing for replacement of only damaged parts and reducing manufacturing costs through separate block assembly and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional rubber socket is manufactured as a single large-area component, then it can cover large semiconductor devices, but defects from non-uniform magnetic field application increase and manufacturing costs rise
Solution Approach 1:
The rubber socket is divided into multiple small-area blocks, each manufactured separately with uniform magnetic field application. These blocks are then assembled to form the complete large-area socket, resolving the contradiction between large coverage area and manufacturing precision.
2Area of stationary object
If a conventional rubber socket is manufactured as a single component, then it provides complete coverage, but replacing individual defective parts becomes difficult
Solution Approach 1:
The socket is segmented into independent blocks that can be individually replaced. When a defect is found in one block, only that specific block needs to be replaced rather than the entire socket, significantly improving ease of repair while maintaining complete coverage.
Solution Approach 2:
Multiple independent blocks are nested together to form the complete socket structure. This modular arrangement allows individual blocks to be independently accessed, removed, and replaced while the rest of the socket remains intact.
3Ease of manufacture
If individually manufactured blocks are assembled, then manufacturing costs are reduced and defects are minimized, but assembly complexity is introduced
Solution Approach 1:
By segmenting the socket into standardized blocks with uniform interfaces, the manufacturing process is simplified and costs are reduced. The assembly complexity is managed through consistent block designs that can be systematically arranged.
Solution Approach 2:
The blocks are designed with universal characteristics including standardized shapes, sizes, and connection interfaces. This universality allows the same block design to be used throughout the socket, simplifying both manufacturing and assembly processes despite the modular structure.
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
This approach minimizes defects, reduces manufacturing costs, and ensures uniform electrical signal transmission to large-sized semiconductor devices by using independently manufactured blocks with uniform characteristics.
Implementation Method 1
when a magnetic field is applied to the electrically-conductive particle mixture in a thickness direction, the electrically-conductive particles dispersed in the liquefied elastic insulating material are oriented such that they are concentrated to positions at which the ferromagnetic bodies 41 and 51 and simultaneously lined up in the thickness direction
Data Source
AI summary
The present disclosure relates to a rubber socket formed by assembling a plurality of individually manufactured electrically-conductive blocks, the blocks having a plurality of elastic electrically-conductive parts and an insulating part, respectively, are individually manufactured, a lower protruding portion, having a thickness smaller than that of the support member, of each electrically-conductive part is inserted into the through hole of the support member, the electrically-conductive block is coupled to the support member by adhering a lower surface of the insulating part to an upper surface of the support member to enable a large-area rubber socket to be manufactured.