Non-linear Vertical Leaf Spring for Semiconductor Testing
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Solution Overview
Problem
Existing electrically conductive contact elements lack effective non-linear spring response characteristics, which limits their ability to efficiently make pressure-based electrical connections between closely spaced electronic devices, particularly in applications like semiconductor testing where precise force distribution is crucial.
Innovation Solution
The development of a vertical contact element with elongate, spaced apart leaves connected by tie bars, which compress axially before buckling, allowing for a bifurcated response to forces, enabling efficient electrical connections by distributing mechanical stress and increasing current carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional contact elements are used, then manufacturing and operation are simple, but they lack non-linear spring response characteristics and cannot efficiently distribute mechanical stress
Solution Approach 1:
The contact element is divided into multiple leaves (typically three leaves) spaced apart from each other, connected by tie bars at the ends. This segmentation allows each leaf to independently compress and buckle, providing non-linear spring response characteristics and improved force distribution while maintaining manageable structural complexity
Solution Approach 2:
The contact element transitions from a single-dimensional linear structure to a multi-dimensional structure with leaves spaced apart in space. The leaves are arranged with spacing in the lateral dimension, allowing them to buckle in different modes and provide non-linear spring response in multiple directions, enhancing force distribution capability
2Productivity
If contact elements are made to make pressure-based electrical connections between closely spaced devices, then connection efficiency improves, but force distribution becomes difficult to control
Solution Approach 1:
The contact element utilizes changes in mechanical parameters (stiffness, buckling force) as a function of compression distance. Initially, the leaves compress axially with relatively high stiffness, but as compression continues and buckling occurs, the stiffness decreases non-linearly. This parameter change allows efficient force distribution to closely spaced terminals while maintaining connection efficiency
3Reliability
If contact elements compress axially before buckling, then non-linear spring response is achieved, but the structure becomes more complex
Solution Approach 1:
The contact element structure is designed to automatically exhibit non-linear spring response through its own geometric configuration. The spaced leaves, when compressed axially, naturally buckle at predetermined forces without requiring external control mechanisms or complex active components. The structure serves itself to provide the desired non-linear force-displacement characteristic
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 contact element provides a controlled compression and buckling mechanism, ensuring reliable low-resistant contact and efficient electrical connections between closely spaced terminals, enhancing testing and interconnection applications by managing force distribution effectively.
Implementation Method 1
The first leaf and the second leaf can be sufficiently elongate to respond to a force through the contact element that is substantially parallel with the first axis and the second axis by compressing axially while the force is less than a buckling force and bending while the force is greater than the buckling force
Data Source
AI summary
An electrically conductive contact element can include a first base and a second base with elongate, spaced apart leaves between the bases. A first end of each leaf can be coupled to the first base and an opposite second end of the leaf can be coupled to the second base. A body of the leaf between the first end and the second end can be sufficiently elongate to respond to a force through said contact element substantially parallel with the first axis and the second axis by first compressing axially while said force is less than a buckling force and then bending while said force is greater than the buckling force.