Probe Head Assembly Using Raising Jig for Fine-Pitch Alignment
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Solution Overview
Problem
The assembly of probe heads with small pitch probe pins is challenging due to the fragility of thin pins and difficulties in drilling holes in guide plates, leading to low manufacturing yield and damage to materials.
Innovation Solution
The use of a probe head structure where upper and lower guide plates are aligned with vertically corresponding through-holes, and probe pins are inserted with stoppers that prevent damage, followed by spacing using raising jigs, spacers with bevels, or counter-rotating spacers to maintain alignment and distance, facilitating assembly without increasing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling is used for inserting probe pins into guide plates, then flexibility in assembly is maintained, but probe pins are prone to damage due to their thin diameters (1-4 mils)
Solution Approach 1:
A raising jig is introduced as an intermediary tool to hold and position the upper guide plate during assembly. The jig provides controlled support and alignment, eliminating direct manual handling of fragile probe pins while maintaining assembly flexibility. The jig can be easily removed after positioning, leaving the final assembly unchanged.
2Ease of manufacture
If drilling holes in upper and lower guide plates is performed conventionally, then hole formation is achieved, but guide plate material is damaged and manufacturing yield decreases at small pitches (40 μm)
Solution Approach 1:
Holes are pre-drilled in the lower guide plate before final assembly, allowing for precise positioning and alignment. The upper guide plate is then raised to a predetermined height using the raising jig, ensuring that holes align correctly without requiring forceful insertion or repositioning that could damage the material.
Solution Approach 2:
The raising jig provides controlled support and cushioning during the assembly process, preventing excessive force from being applied to the guide plates. This cushioning effect protects the fragile material between holes from being ripped apart during alignment and insertion operations.
3Adaptability or versatility
If probe pins with small pitch (40 μm) are assembled, then testing capability for fine-pitch contact pads is achieved, but assembly yield decreases due to material damage
Solution Approach 1:
The raising jig serves as a mediator that enables precise assembly of fine-pitch probe pins without direct manual manipulation. By providing controlled positioning and support, the jig allows high-yield assembly of 40 μm pitch probe pins while maintaining the ability to test fine-pitch contact pads.
Data Source
AI summary
An assembly includes a lower guide plate having a first plurality of through-holes therein, and an upper guide plate over the lower guide plate. The upper guide plate includes a second plurality of through-holes therein. The assembly further includes a plurality of probe pins. Each of the probe pins is inserted through one of the first plurality of through-holes and one of the second plurality of through-holes. The assembly further includes a plurality of probe pin stoppers, each attached to one of the probe pins, wherein the plurality of probe pin stoppers has lateral sizes greater than lateral sizes of the second plurality of through-holes. The plurality of probe pin stoppers is located over the upper guide plate.