High-Density Test Socket Conductive Unit Design
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Solution Overview
Problem
Existing test sockets with conductive reinforced layers face durability issues due to deformation and damage from frequent contacts, compromising electrical contact performance.
Innovation Solution
A test socket design featuring an elastic conductive sheet with first conductive particles in an elastic material and a dielectric support unit, along with a second conductive unit in a support sheet with higher-density, smaller particles for enhanced conductivity and durability, integrated into the through holes of the support sheet for improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive reinforced layer is added to enhance conductivity, then electrical contact performance is improved, but the contact unit becomes prone to deformation and damage from frequent contacts
Solution Approach 1:
The patent uses a composite structure combining a soft elastic conductive sheet with dispersed conductive particles and a rigid support sheet with conductive patterns. This composite design allows the elastic sheet to provide compliance and absorb mechanical shock, while the rigid support sheet maintains structural integrity and prevents deformation, resolving the contradiction between electrical contact performance and durability
Solution Approach 2:
The patent applies different material properties to different parts of the contact unit: the elastic conductive sheet provides local compliance and shock absorption at the contact interface, while the rigid support sheet provides structural support and shape maintenance. This local differentiation of material qualities allows each component to optimize its function without compromising the other
2Reliability
If a rigid conductor is plated on the conductive silicon unit, then conductivity is enhanced, but the elasticity of the contact unit decreases
Solution Approach 1:
The patent divides the contact unit into two separate functional segments: an elastic conductive sheet containing dispersed conductive particles that provides compliance and adaptability, and a rigid support sheet with conductive patterns that provides structural support. This segmentation allows each component to independently fulfill its specific function without interfering with the other's properties
Solution Approach 2:
The patent changes the physical state and distribution parameters of conductive material by using dispersed conductive particles embedded in the elastic sheet rather than a continuous rigid conductor. This parameter change allows the conductive path to maintain electrical conductivity while accommodating the elastic deformation of the contact unit during operation
3Productivity
If frequent contacts are made to establish electrical coupling, then test efficiency is improved, but the conductive unit and counterpart surfaces are damaged
Solution Approach 1:
The patent incorporates an elastic conductive sheet that acts as a cushioning element before mechanical shock or damage can occur during contact. This elastic material absorbs and dissipates mechanical energy from frequent contacts, protecting both the conductive particles and the counterpart contact surfaces from damage while maintaining test efficiency
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 enhances electrical conductivity and durability by maintaining the shape and integrity of the conductive units during frequent contacts, ensuring reliable electrical connections and extended lifespan.
Implementation Method 1
an elastic conductive sheet including a first conductive unit that is arranged to face the terminal of the device to be tested
Data Source
AI summary
The present invention relates to a test socket having a high-density conductive unit, and to a method for manufacturing same, whereby an elastic conductive sheet is arranged at a position corresponding to the terminal of the device, and includes a first conductive unit arranged in the thickness direction of an elastic material and an insulating support unit for supporting the first conductive unit. A support sheet is attached to the elastic conductive sheet and has through-holes corresponding to the terminal of the device. A second conductive unit is arranged in the through-holes of the support sheet in the thickness direction in an elastic material.