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Modular Jack Probe Cards for Auto Testing

IP.com Disclosure Number: IPCOM000112079D
Original Publication Date: 1994-Apr-01
Included in the Prior Art Database: 2005-Mar-26
Document File: 4 page(s) / 92K

Publishing Venue

IBM

Related People

Baker, JP: AUTHOR [+2]

Abstract

Described is a probe assembly which adapts tot he end of the cable. This probe assembly actually inserts into the female modular jack connector on the circuit card instead of a cable. The probe assembly maintains electrical continuity and has the endurance for thousands of insertions. The probe assembly is shown in Figures 1, 2 and 3.

This text was extracted from an ASCII text file.
This is the abbreviated version, containing approximately 52% of the total text.

Modular Jack Probe Cards for Auto Testing

Described is a probe assembly which adapts tot he end of the cable.
This probe assembly actually inserts into the female modular jack
connector on the circuit card instead of a cable.  The probe assembly
maintains electrical continuity and has the endurance for thousands
of insertions.  The probe assembly is shown in Figures 1, 2 and 3.

The requirements to produce a modular jack test tool were:

1.  It must be able to insert into a female mod-jack connector
    contacting all internal wires and it must key to the connector;

2.  No lateral motion on the internal pins will be allowed;

3.  There shall be a minimum of 20,000 insertions per connector;

4.  There will be three sizes of connectors with four different
    keyings (4 pin, 8 pin, and 16 pin, this could vary if connector
    requirements differ); and

5.  The connector must be housed so that it will not wear enough to
    cause misalignment of pins, and it must be sturdy enough to be
    handled by a pneumatic mechanism.

      In order to construct a probe, the artwork for the probe card
is developed depending on the specific requirements for the
application.  The size or shape and/or location and size and number
of holes could vary according to what is needed.

      The probe contact pins are also developed by first making
artwork.  Since all the needed connection pins are in multiples of
four (4 pin, 8 pin, and 16 pin), the pins are formed in strips of 16.
The artwork for the pins is taken, along with the material (in this
case 1/4 hard brass 0.020 inch thick) to the wet line for etching.
The pins are then plated with 100 microinches of 999 cobalt gold over

50 microinches of nickel or any hardened gold plating which would
contribute to long wear life.

      A pin forming tool is used to bend the pins.  This tool is a
two stage die which over bends the pins and scores the carrier strip
for ease of removal.

      At this point, the individual parts are assembled to produce
th...