PATENT DOCUMENT

Publication Number: US-9404842-B2
Application Number: US-201313968166-A
Country: US
Kind Code: B2

Title: Methodology and apparatus for testing conductive adhesive within antenna assembly

Abstract:
Damage to conductive material that serves as bridging connections between conductive structures within an electronic device may result in deficiencies in radio-frequency (RF) and other wireless communications. A test system for testing device structures under test is provided. Device structures under test may include substrates and a conductive material between the substrates. The test system may include a test fixture for increasing tensile or compressive stress on the device structures under test to evaluate the resilience of the conductive material. The test system may also include a test unit for transmitting RF test signals and receiving test data from the device structures under test. The received test data may include scattered parameter measurements from the device structures under test that may be used to determine if the device structures under test meet desired RF performance criteria.

Claims:
What is claimed is: 
     
       1. A method for using a test system to characterize device structures under test, where the test system includes a test unit and a test fixture, the method comprising:
 activating pressure-sensitive adhesive material in the device structures under test by applying pressure to the adhesive material; 
 once the pressure-sensitive adhesive material has been activated, applying stress to the device structures under test with the test fixture; and 
 while the stress is applied to the device structures under test, gathering test data on the device structures under test with the test unit, wherein the gathered test data comprises radio-frequency scattering parameter measurements. 
 
     
     
       2. The method defined in  claim 1 , wherein applying the stress to the device structures under test further comprises applying compressive stress to the device structures under test and applying tensile stress to the device structures under test. 
     
     
       3. The method defined in  claim 1 , wherein applying the stress to the device structures under test comprises applying different amounts of stress to the device structures under test. 
     
     
       4. A method for using a test system to characterize device structures under test, wherein the test system includes a test unit and a test fixture and wherein the device structures under test include an adhesive material, the method comprising:
 with the test fixture, applying tensile stress to the device structures under test; 
 while the tensile stress is applied to the device structures under test, gathering radio-frequency scattering parameter measurements on the device structures under test with the test unit; and 
 with the test unit, determining whether the adhesive material exhibits any defects by analyzing the gathered radio-frequency scattering parameter measurements. 
 
     
     
       5. The method defined in  claim 4 , further comprising:
 applying compressive stress to the device structures under test with the test fixture. 
 
     
     
       6. The method defined in  claim 4 , wherein the adhesive material is conductive, the method further comprising:
 analyzing the gathered radio-frequency scattering parameter measurements to determine whether the adhesive material satisfies design criteria. 
 
     
     
       7. The method defined in  claim 4 , wherein gathering the radio-frequency scattering parameter measurements comprises gathering reflection coefficient measurements on the device structures under test. 
     
     
       8. The method defined in  claim 4 , wherein gathering the radio-frequency scattering parameter measurements comprises gathering multiport scattering parameter measurements on the device structures under test. 
     
     
       9. The method defined in  claim 4 , wherein applying the tensile stress comprises increasing the applied tensile stress at regular increments. 
     
     
       10. A test system, comprising:
 a test fixture that is configured to receive device structures under test and that is configured to apply tensile stress on device structures under test while the device structures under test are received within the test fixture; 
 a test unit configured to gather test data on the device structures under test; and 
 a test probe that receives radio-frequency test signals from the test unit and that is coupled to the device structures under test. 
 
     
     
       11. The test system defined in  claim 10 , wherein the test fixture is further configured to activate an adhesive material in the device structures under test while the device structures under test are received within the test fixture. 
     
     
       12. The test system defined in  claim 10 , wherein the test probe comprises a signal conductor and a ground conductor, and wherein the device structures under test are interposed between the signal conductor and the ground conductor while the device structures under test are received within the test fixture. 
     
     
       13. The test system defined in  claim 10 , further comprising:
 a radio-frequency cable having a first end that is coupled to the test unit and a second end that is mated to a corresponding coaxial cable in the device structures under test via a radio-frequency coaxial test connector. 
 
     
     
       14. The test system defined in  claim 10 , wherein the test unit comprises a radio-frequency tester operable to gather scattering parameter measurements on the device structures under test.

Description:
BACKGROUND 
     This relates generally to wireless communications circuitry, and more particularly, to electronic devices having wireless communications circuitry. 
     Electronic devices such as portable computers and cellular telephones are often provided with wireless communications capabilities. For example, electronic devices may use communications circuitry such as cellular telephone circuitry, wireless local area network communications circuitry, satellite navigation system receivers, and other antenna systems. Integration of increasingly complex antenna systems into electronic devices requires the materials that join separate structural modules in the circuitry to have particular properties, such as characteristics that establish and maintain conductivity between separate structural modules when under a specified amount of tension. 
     It may therefore be desired to have improved methods and systems for testing materials that are used to join structures in an electronic device for desired performance qualities. 
     SUMMARY 
     A test system for characterizing device structures under test may be provided. The test system may include a test unit and a test fixture. The device structures under test may include a conductive material, which may be an adhesive material. The adhesive material may be a pressure-sensitive adhesive. The test fixture may receive the device structures under test. The test fixture may activate the adhesive material in the device structures under test by applying pressure to it while the device structures under test are received in the test fixture. Activating the adhesive material may include applying compressive stress to the device structures under test. 
     The test fixture may apply stress to the device structures under test once the adhesive material has been activated. The type of stress applied to the device structures under test is different than the type of stress applied to activate the adhesive material. The test fixture may apply tensile stress to the device structures. Different amounts of stress may be applied to the device structures under test during testing. The applied tensile stress on device structures under test may be increased at regular increments. 
     While tensile stress is applied to the device structures under test, the test unit may gather test data on the device structures under test. The test unit may include a radio-frequency tester operable to gather scattering parameter measurements on the device structures under test. The gathered test data may include reflection coefficient measurements and multiport scattering parameter measurements on the device structures under test. The gathered test data may be analyzed to determine whether the conductive material (e.g. adhesive material) satisfies design criteria. 
     The test system may include a test probe that receives radio-frequency test signals from the test unit. The test probe may be coupled to the device structures under test. The test probe may include a signal conductor and a ground conductor. The device structures under test may be interposed between the signal conductor and the ground conductor while the device structures under test are received within the test fixture. 
     The test system may also have a radio-frequency cable that has a first end coupled to the test unit and a second end mated to a corresponding coaxial cable in the device structures under test via a radio-frequency coaxial test connector. 
     Further features of the present invention, its nature, and various advantages will be more apparent from the accompanying drawings and the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an illustrative test system for testing device structures in an electronic device in accordance with an embodiment of the present invention. 
         FIG. 2  is a diagram of device structures under test in accordance with an embodiment of the present invention. 
         FIG. 3A  is a plot showing how force may be applied to the device structures under test in accordance with an embodiment of the present invention. 
         FIGS. 3B and 3C  are plots showing the conductivity of different device structures under test while force is applied to the device structures as shown in  FIG. 3A  in accordance with an embodiment of the present invention. 
         FIGS. 4A, 4B, and 4C  are diagrams of a test system for exerting different types of forces on device structures under test in accordance with an embodiment of the present invention. 
         FIG. 5  is a diagram of an illustrative test system for gathering test data from device structures with a signal trace in accordance with an embodiment of the present invention. 
         FIGS. 6A, 6B, and 6C  are diagrams of a test system for exerting different types of forces on device structures under test in accordance with an embodiment of the present invention. 
         FIG. 7  is a diagram of an illustrative test system for characterizing device structures under test using multiple test probes in accordance with an embodiment of the present invention. 
         FIG. 8  is a diagram of an illustrative test system for characterizing device structures under test using coaxial cable connectors in accordance with an embodiment of the present invention. 
         FIG. 9  is a flowchart of illustrative steps used to characterize device structures under test in a test system to evaluate radio-frequency performance of the device structures under test in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device may contain antenna structures or systems that include separate components. Conductive materials may be required to establish conductivity between separate components in the antenna system to maintain functionality of the communication circuitry. It may be desirable to test individual components in the electronic device prior to actually assembling the components within the device. Testing parts prior to assembly can help identify (at an early stage) potentially problematic issues that can negatively affect the performance of device  10  during normal user operation. For example, it may be desirable to characterize structures associated with antennas, because the integrity of these structures can often impact the antenna/wireless performance of device  10 . Such types of structures that can potentially impact the radio-frequency (RF) performance of device  10  are sometimes referred to as device structures under test (DSUTs). A test system such as test system  100  of  FIG. 1  may be used for testing the RF characteristics of device structures under test such as DSUTs  10 . DSUTs  10  may be any structures within an electronic device that needs to be tested for functionality in accordance with desired performance standards. 
     Examples of DSUTs  10  that may be characterized prior to being assembled within the electronic device include conductive housing structures (e.g., conductive housing structures that form part of antennas), antenna feed structures (e.g., flexible antenna circuits, shorting pins, radio-frequency cables, etc.), radio-frequency gain altering circuits such as power amplifiers and low noise amplifiers, matching circuits, filters, and other structural components of antenna structures. DSUTs  10  may include portions of antenna structures such as inverted-F antenna structures, planar inverted-F antenna structures, loop antennas, dipoles, monopoles, open and closed slot antennas, hybrid designs that include more than one antenna structure of these types, or other suitable antenna structures. Portions of DSUTs  10  may include conductive material such as conductive adhesives, foams, tapes, pressure sensitive adhesives, conductive gaskets, conductive fabric foams, ultraviolet-activated adhesives, and thermal-activated adhesives. 
     DSUTs  10  may be placed within a test fixture such as test fixture  12  of test system  100 . Test fixture  12  may include a bottom portion  12 -A which receives DSUTs  10 , and a top portion  12 -B. Portions  12 -A and  12 -B may both be part of the same test fixture  12 . Top portion  12 -B may be adjustable in multiple directions using positioner  13 . For example, top portion  12 -B may be configured to move in vertical directions  15  and  17 . Top portion  12 -B may be configured to exert a desired amount of force on DSUTs  10  during test operations. 
     A test probe such as test probe  14  may contact DSUTs  10 . Test probe  14  may include signal and ground conductors that are electrically connected to device structures under test in the mated position (i.e., the signal and ground conductors of test probe  14  may be electrically coupled to DSUTs  10  while test probe  14  is mated with DSUTs  10 ). The positioning of test probe  14  in  FIG. 1  between the bottom surface of top portion  12 -B of test fixture  12  and the upper region of DSUTs  10  is merely exemplary. In general, test probe  14  may be placed anywhere in the vicinity of DSUTs  10  in a way that enables test data to be gathered successfully. For example, test probe  14  may measure RF characteristics of DSUTs  10  when top portion  12 -B exerts a tensile force on device structures  10 . As another example, test probe  14  may gather test data from DSUTs  10  when top portion  12 -B is used to apply compressive force on device structures under test  10 . 
     Test probe  14  may relay gathered test data through a cable such as cable  16  to a test unit such as test unit  18 . Test unit  18  may be any processing unit or analyzer that receives and analyzes the gathered test data from test probe  14  to determine whether the RF characteristics of DSUTs  10  meet performance criteria. Test unit  18  may be a computer, a vector network analyzer, a spectrum analyzer, a signal generator, and/or other radio-frequency test equipment suitable for transmitting/receiving radio-frequency test signals and obtaining/storing radio-frequency test measurements. Test unit  18  may include a radio-frequency tester used to generate RF test signals that are fed to DSUTs  10  via cable  16  to the signal conductor of test probe  14 . Test unit  18  may have port P1 to which a cable such as cable  16  is connected. Cable  16  may have a first end that is connected to port P1 and a second end connected to test probe  14 . Connected using this arrangement, test unit  18  may be configured to gather desired radio-frequency measurements such as radio-frequency metrics from DSUTs  10 . 
     Even without being connected to other components to form a completed antenna assembly, DSUTs  10  may emit radio-frequency signals when being energized by the test signals generated using test unit  18 . As electromagnetic test signals are transmitted by test unit  18  and applied to DSUTs  10  through cable  16  and test probe  14 , test unit  18  may receive reflected signals via cable  16  and test probe  14  (i.e., signals that were reflected from DSUTs  10  in response to the transmitted RF test signals). The reflected signals gathered in this way may be used to compute a reflection coefficient (sometimes referred to as an input reflection scattering parameter or S11 measurement). 
     Test unit  18  may have any number of ports and any number of cables connected to the ports to gather desired measurements. For example, test unit  18  may have n number of ports and n number of cables, each connected to test unit  18  and DSUTs  10 . Test unit  18  may compute reflection coefficients for test data received via each cable and port (e.g., S22, S33 . . . Snn parameter or an Snn scattering parameter). Test unit  18  may also compute forward transfer coefficients (sometimes referred to as a forward transfer scattering parameter or S21 measurements) for any combination of test data received from the ports and cables (e.g., S12, S21, S23, S32, S13, S31, etc.). An example of obtaining multiport scattering parameter measurements is described in more detail later in connection with  FIGS. 7 and 8 . 
     Test unit  18  may, for example, analyze the scattering parameter test data to determine whether DSUTs  10  satisfy design criteria. If the gathered test data deviates from predetermined levels by an unacceptable amount, DSUTs  10  may be marked as defective. If the gathered test data deviates from the predetermined level by a tolerable amount, DSUTs  10  may be marked as a passing device. The use of test unit  18  for obtaining scattering parameter test data from DUT  10  is merely illustrative and does not serve to limit the scope of the present invention. If desired, test unit  18  may be used to gather other types of radio-frequency measurements from DSUTs  10 . 
     In some embodiments of the present invention, as shown in  FIG. 2 , DSUTs  10  may include a top substrate such as top substrate  20 , a bottom substrate such as bottom substrate  22 , and conductive material such as conductive material  24  for bonding top substrate  20  and bottom substrate  22  together (e.g., conductive material  24  may be interposed between top substrate  20  and bottom substrate  22 ). Top substrate  20 , conductive material  24 , and bottom substrate  22  may be arranged in a stack formation. DSUTs  10  (sometimes also referred to as stack under test  10 ) may be part of an antenna structure for an electronic device. 
     Substrates  20  and  22  may be, for example, flexible or rigid printed circuit boards. Substrates  20  and  22  may be flexible printed circuit boards, rigid printed circuit boards, rigid-flex circuits, or other suitable types of circuit boards. Substrates  20  and  22  may be formed from any suitable material, including conductive materials such as aluminum, steel, copper, and brass. Conductive material  24  may be any material that serves as a conductive mechanism between the top and bottom substrates. Conductive material  24  may be conductive adhesives, foams, tapes, pressure sensitive adhesives, conductive gaskets, conductive fabric foams, ultraviolet-activated adhesives, thermal-activated adhesives, a combination of these materials, and/or other types of conductive materials. Different types of conductive material may require different methods of activation and/or curing for maintaining conductivity between substrates  20  and  22  (e.g., pressure sensitive adhesives may be activated via mechanical pressure, thermal-activated adhesives may be activated via heat, etc.). 
     When an electronic device is in a stressed environment, the electronic device may be vulnerable to various deficiencies in wireless communications due to damage incurred in structures within the electronic device. For example, when an electronic device is dropped or is handled roughly in a way that places stress on structures within the device, conductive material that serves as bridging connections between conductive structures within the device, such as adhesive joining two flexible circuit boards in an antenna structure, may tear or crack. As shown in  FIG. 2 , when stack under test  10  is placed under stress, breaks or tears such as tear  26  may occur in conductive material  24 . 
       FIG. 3A  shows a plot of force while DSUTs  10  are being tested in test fixture  12  of  FIG. 1 . “Positive” force as shown in  FIGS. 3A-3C  indicates a force experienced by the device structures under test that compresses device structures under test  10 , whereas a “negative” force indicates a force experienced by the device structures under test that stretches the device structures under test. A decrease in force indicates that a force is exerted in a direction that will eventually apply tensile stress to DSUTs  10   a . DSUTs  10  may be a stack under test as shown in  FIG. 2  or other structures under test. 
     Test fixture  12  may initially be set to a neutral or equilibrium point  30 , where top portion  12 -A of the test fixture is in contact with test probe  14  while exerting a negligible amount of force on DSUTs  10 . Test fixture  12  may then increase the amount of force on device structures under test such that DSUTs  10  experiences a compressive force. Test fixture  12  may exert this compressive force by moving the top portion  12 -B in a downward direction toward DSUTs  10 . 
     Conductive material  24  in DSUTs  10  as shown in  FIG. 2  may be a pressure-activated adhesive (PSA). Conductive material  24 , sometimes referred to as PSA  24 , may not initially form a secure bond between substrates  20  and  22  when it is placed between the two substrates. PSA  24  may require the application of pressure in order to activate molecular interactions that allow PSA  24  to securely adhere to substrates  20  and  22  and consequently, to form a bond between the substrates in DSUTs  10 . PSA  24  may be activated when DSUTs  10  experience a certain amount of compressive force after a certain amount of time at activation point  31 . Once PSA  24  is activated, test fixture  12  may reduce the compressive force on DSUTs  10  in regular step-wise increments I (i.e., apply force in the opposite direction) as shown by line  1  of  FIG. 3A  until the force experienced by DSUTs  10  settles back to equilibrium point  30 , where the top portion  12 -B of the test fixture just contacts the DSUTs without placing the device structures under any significant amount of stress (compressive or tensile). 
     Test fixture  12  may then exert tensile stress on DSUTs  10  (a “negative” force on  FIG. 3A ) as shown by line  1 . Test fixture  12  may exert this tensile force by moving the top portion  12 -B in an upward direction away from DSUTs  10  while DSUTs  10  is still connected to top portion  12 -B of the test fixture. The tensile stress applied may be regularly increased in steps (i.e. increments I) until a maximum predetermined amount of tensile stress  33   a.    
     When a predetermined amount of tensile stress  33   a  is reached, text fixture portion  12 -B may stop moving in a direction away from DSUTs  10  and therefore stop exerting tensile stress on DSUTs  10 . Test fixture portion  12 -B may be gently lowered to a point such as equilibrium point  30  where no compressive or tensile force is exerted on DSUTs  10 . DSUTs  10  may then be removed from test fixture  12  so that another device structure under test may be placed in test fixture  12  for testing. 
     Because compressive stress may also result in damage or deterioration of PSA  24 , DSUTs  10  may also be tested for resilience against compressive stress after PSA  24  is activated. For example, instead of reducing compressive pressure on DSUTs  10  after activation point  31 , test fixture  12  may continue to increase compressive force on DSUTs  10  in regular increments until reaching a maximum predetermined amount of compressive stress  33   b , as shown by line  2  of  FIG. 3A . As another example, test fixture  12  may first reduce the compressive force after activation point  31  until equilibrium point  30  (as in  FIG. 3A ) and then apply compressive force on DSUTs  10  in regular increments as shown by line  3  of  FIG. 3A  until a predetermined amount of compressive stress. 
       FIGS. 3B and 3C  show plots of variation in conductive properties of two different examples of DSUTs  10  while force is applied to DSUTs  10  in accordance with the plot shown in  FIG. 3A .  FIG. 3B  shows an exemplary graph of the conductivity of DSUTs  10  that include a conductive material  24  (e.g., a pressure sensitive adhesive) that is resilient to the stress (e.g. compressive and/or tensile) administered to DSUTs  10  during testing. The resilience of conductive material  24  under stress may affect the ability of DSUTs  10  to successfully receive and transmit electrical signals between substrates  20  and  22  (i.e., the conductivity of DSUTs  10 ). Therefore, the resilience of conductive material  24  and the conductivity of DSUTs  10  may affect RF measurements such as scattering parameters (e.g. S11, S12, etc.) gathered in response to transmitting a RF test signal to DSUTs  10 . 
     Conductive material  24  may be able to withstand a substantial amount of tensile stress. For example, conductive material  24  may be able to maintain its integrity under a predetermined amount of tensile stress  33   a  applied during testing to DSUTs  10 . As a result of the strength of conductive material  24 , DSUTs  10  may be able to maintain conductivity under the stress administered during testing and produce desirable test data (e.g., scattering parameters such as S11). 
     Similarly, conductive material  24  may be able to withstand a substantial amount of compressive stress. For example, conductive material  24  may be able to maintain its integrity under a predetermined amount of compressive stress  33   b  applied during testing to DSUTs  10 . As a result of the strength of conductive material  24 , DSUTs  10  may be able to maintain conductivity under the stress administered during testing and produce desirable test data (e.g., scattering parameters such as S11). 
     In contrast to  FIG. 3B ,  FIG. 3C  shows an exemplary graph of the conductivity of DSUTs  10  that include a conductive material  24  (e.g., a pressure sensitive adhesive) that deteriorates under the stress (e.g. compressive and/or tensile) administered to DSUTs  10  during testing. Conductive material  24  may be able to withstand a certain amount of stress but begin to lose its integrity after too much stress is applied. For example, conductive material  24  may maintain its integrity under multiple step-wise increases of stress, but begin to deteriorate under the amount of stress applied during a particular test point such as test point  38 . Conductive material  24  may be a material that is prone to breakage or tearing when a certain amount of compressive or tensile stress is applied, resulting in breaks or tears such as tear  26  as shown in  FIG. 2 . Deterioration or tears  26  in conductive material  24  may cause the conductivity of DSUTs  10  to affect its RF capabilities, resulting in undesirable test data such as scattering parameters (e.g., S11). 
       FIGS. 4A-4C  show test system  100  exerting different types of forces on DSUTs  10 . DSUTs  10  may be a stack under test as shown in  FIG. 2  or other structures under test.  FIG. 4A  shows a test system with vector network analyzer (VNA)  18  connected to test fixture  12  via coaxial cable  16 . Device structures under test  10  may rest on bottom portion  12 -A of the test fixture. Test probe  14  may be formed from a signal trace  14 -A and ground trace  14 -B. Signal trace  14 -A and ground trace  14 -B may be made of conductive sheets of metal. Signal trace  14 -A may be positioned on the top surface of DSUTs  10  such as on the top surface of top substrate  20 . Ground trace  14 -B may be positioned between bottom substrate  22  of device structures under test  10  and test fixture portion  12 -A. The positioning of signal trace  14 -A and ground trace  14 -B is merely exemplary; signal traces and ground traces may be placed in any number of positions contacting DSUTs  10  such that the signal trace may successfully transmit test RF signals and gather RF test data from DSUTs  10 . 
     Test probe  14  may transmit test signals and gather test data relating to RF characteristics of DSUTs  10  during testing. VNA  18  may receive test data such as S11 parameter test data from DSUTs  10  via test probe  14  and cable  16 . To secure device structures  10  to the test fixture, securing structures such as clamps  48  may be implemented to fix or clamp portions of DSUTs  10  to the test fixture. For example, at the beginning of testing, bottom substrate  22  may be connected to bottom portion  12 -A of the test fixture using clamp  48 . This is merely an example; device structures under test  10  may be secured to the test fixture using any number or types of fastener or attaching mechanism. 
     Upper portion  12 -B of the test fixture may be moved in a vertical direction by positioner  44 . At the beginning of testing, upper portion  12 -B may be in a position above DSUTs  10  that does not contact test probe  14 -A or DSUTs  10 . Upper portion  12 -B of the test fixture may be detached or part of the same test fixture as bottom portion  12 -B. Upper portion  12 -B of the test fixture may be connected to bottom portion  12 -A of the test fixture by additional test fixture structures. Upper portion  12 -B may be moved in downward direction  52  toward test probe  14 -A and DSUTs  10 . 
       FIG. 4B  shows the test system applying force to DSUTs  10 . Upper portion  12 -B of test fixture  12  may be moved vertically in a downward direction  52  using positioner  44  until test fixture  12 -B contacts test probe  14 -A. Upper portion  12 -B of the test fixture may be attached to top substrate  20  using an additional clamp  48 . Clamp  48  may be used to secure top substrate  20  to test fixture  12 -B. Test fixture  12 -B may continue to move in downward direction  52  even after it has contacted test probe  14 -A to compress device structures under test  10 . Conductive material  24  may be a pressure-sensitive adhesive and compression of device structures  10  may activate conductive material  24 . Activating conductive material  24  may allow top substrate  20  and bottom substrate  22  of the device structures to be securely bonded to each other so that DSUTs  10  may maintain conductivity in stressed environments. 
     Test fixture  12 -B may continue moving in a downward direction  52  after activation of conductive material  24  to administer more compressive stress on DSUTs  10  as illustrated by line  2  of  FIG. 3A . Alternatively, test fixture  12 -B may move in an upward direction to reduce compressive stress on DSUTs  10  to an equilibrium point before applying more compressive stress to DSUTs  10  as illustrated by line  3  of  FIG. 3A . Compressive stress may cause deterioration of conductive material  24 . The integrity of conductive material  24  may affect the conductivity of DSUTs  10  and consequently affect S11 scattering parameter test data collected from DSUTs  10  via cable  16 . Deterioration of conductive material  24  may cause S11 parameter test data of DSUTs  10  to deviate from desired performance data. 
     However, if conductive material  24  is formed from a material resilient to compressive stress, DSUTs  10  may maintain conductivity under a particular level of compressive stress. For example, conductive material  24  may not deteriorate when DSUTs  10  experience a predetermined level of compressive stress  33   b  administered during testing. This may result in desirable S11 parameter test data and/or other satisfactory RF performance criteria and allow DSUTs  10  to pass on to subsequent testing or be used in a product device. 
     Test fixture  12 -B may stop moving in downward direction  52  once conductive material  24  is activated to bond the top and bottom substrates in DSUTs  10  and once test fixture  12 -B is securely fastened to top substrate  20  with a clamp such as clamp  48 . After compression of DSUTs  10 , test fixture  12 -B may then begin to move in an upward vertical direction  56  using positioner  44 , as shown in  FIG. 4C . Because top substrate  20  is connected to upper portion  12 -B of the test fixture and bottom substrate  22  is connected to bottom portion  12 -A of the test fixture, DSUTs  10  may experience tensile stress. Conductive material  24  may be stretched as the top substrate  20  is slowly pulled away from bottom substrate  22 . 
     Tensile stress may cause breaks or tears in conductive material  24  such as tear  26  as shown in  FIG. 4C . The integrity of conductive material  24  may affect the conductivity of DSUTs  10  and consequently affect S11 scattering parameter test data collected from DSUTs  10  via cable  16 . Tear  26  may cause S11 parameter test data of DSUTs  10  to deviate from desired performance data. 
     However, if conductive material  24  is formed from a material resilient to tensile stress, DSUTs  10  may maintain conductivity under particular level of tensile stress. For example, conductive material  24  may not deteriorate and create tear  26  when DSUTs  10  experience a predetermined level  33   a  of tensile stress administered during testing. This may result in desirable S11 parameter test data and/or other satisfactory RF performance criteria and allow DSUTs  10  to pass on to subsequent testing or be used in a product device. 
     This configuration of test system  100  is merely exemplary. Test system  100  may be configured to apply any number and type of additional stressors such as shock and vibrations to DSUTs  10  using test fixture  12  or any suitable test fixture. Test system  100  may also be configured to test DSUTs  10  after exposure to environmental or reliability testing conditions. 
       FIG. 5  shows a perspective view of DSUTs  10  with test probe  14  positioned in contact with DSUTs  10  as shown in  FIG. 4 . Signal trace  14 -A and ground trace  14 -B may be made from metal sheets. Test probe  14  may lie in contact with substrates  20  and  22  during testing. As an example, signal trace  14 -A may contact substrate  20  and ground trace  14 -B may contact substrate  22 . Signal trace  14 -A and ground trace  14 -B may be connected at a coaxial terminal  58 , which may be a metal screw. 
     Signal trace  14 -A may have a portion that slopes downwards to contact coaxial terminal  58 . The portion of signal trace  14 -A that contacts substrate  20  may have the surface area of the portion of substrate  20  that it is contacting. Signal trace  14 -A may be formed such that the surface area of the portion of signal trace  14 -A that slopes downward along slope  62  is gradually reduced until it makes contact with coaxial terminal  58 . In other words, signal trace  14 -A may be shaped such that the portion of signal trace  14 -A contacting substrate  20  has a greater surface area than other portions of signal trace  14 -A. 
     Coaxial terminal  58  may be at the same height level as ground trace  14 -B. Ground trace  14 -B may contact the entire bottom surface of substrate  22 . A portion of ground trace  14 -B may lie parallel to the sloping portion of signal trace  14 A. An insulating material such as insulating material  60  may cover top and bottom surfaces of the sloping portion of ground trace  14 -B such that insulating material  60  is interposed between signal trace  14 -A and ground trace  14 -B along slope  62 . In other words, the only distance separating contact between signal and ground traces  14 -A and  14 -B along slope  62  may be the thickness of insulating material  60 . The minimal distance between the signal and ground traces as well as the insulation provided by insulating material  60  may minimize loss of signal conducted through the metal traces from and to a test unit such as test unit  18  of  FIG. 1 . 
     In  FIGS. 6A-6C , DSUTs  10  may be tested using a test system  100  that applies pressure in a horizontal direction to DSUTs  10  rather than a vertical direction as shown in  FIGS. 4A-4C . DSUTs  10  may be a stack under test as shown in  FIG. 2  or other structures under test. DSUTs  10  may have substrates  20  and  22  and conductive material  24  interposed between the substrates. The test system may have VNA  18  connected to test probe  14  via a radio-frequency cable  16 . Test probe  14  may have a signal contact and a ground contact that make electrical connections with DSUTs  10 . Test probe  14  may gather test data about RF performance during testing from DSUTs  10  and send the test data to the vector network analyzer through cable  16 . 
     Test fixture  12  may have portion  12 -A that holds the substrate  22 . Test fixture  12  may have portion  12 -B that may be configured to apply pressure to DSUTs  10 . In  FIG. 6A , at the beginning of testing, test fixture portion  12 -B may be in an initial position that is separated by a distance from DSUTs  10 . Test fixture portion  12 -B may be moved in direction  70  using positioner  74 . Clamps  48  may be on test fixture portions  12 -A and  12 -B to secure DSUTs  10  to the test fixture. 
     During testing, test fixture portion  12 -B may be moved using positioner  74  in direction  70  until it contacts substrate  20  of DSUTs  10 , as shown in  FIG. 6B . Test fixture portion  12 -B may be attached to substrate  20  using an attaching structure such as clamp  48 . Clamp  48  or other attaching structures may secure substrate  20  to test fixture  12 -B. Test fixture  12 -B may continue to move in direction  70  even after it has contacted test probe  14  to compress DSUTs  10 . 
     Conductive material  24  may be a pressure-sensitive adhesive and compression of device structures  10  may activate conductive material  24 . Activating conductive material  24  may allow substrate  20  and substrate  22  of the device structures to be securely bonded to each other so that DSUTs  10  may maintain conductivity through substrates  20  and  22  in stressed environments. Test fixture  12 -B may continue moving in direction  70  after activation of conductive material  24  to administer more compressive stress on DSUTs  10  as illustrated by line  2  of  FIG. 3A . Alternatively, test fixture  12 -B may move in a direction opposite to direction  70  to reduce compressive stress on DSUTs  10  to an equilibrium point before applying more compressive stress to DSUTs  10  as illustrated by line  3  of  FIG. 3A . 
     Compressive stress may cause deterioration of conductive material  24 . The integrity of conductive material  24  may affect the conductivity of DSUTs  10  and consequently affect S11 scattering parameter test data collected from DSUTs  10  via cable  16 . Deterioration of conductive material  24  may cause S11 parameter test data of DSUTs  10  to deviate from desired performance data. 
     However, if conductive material  24  is formed from a material resilient to compressive stress, DSUTs  10  may maintain conductivity under a particular level of compressive stress. For example, conductive material  24  may not deteriorate when DSUTs  10  experience a predetermined level of compressive stress  33   b  administered during testing. This may result in desirable S11 parameter test data and/or other satisfactory RF performance criteria and allow DSUTs  10  to pass on to subsequent testing or be used in a product device. 
     Test fixture  12 -B may stop moving in direction  70  toward the device structures once conductive material  24  is activated and test fixture  12 -B is securely fastened to substrate  20  with an attachment structure such as clamp  48 . After compression of DSUTs  10 , test fixture  12 -B may then begin to move in a direction away from the DSUTs  10  such as direction  72  using positioner  74 , as shown in  FIG. 4C . Because substrate  20  is connected to test fixture portion  12 -B and bottom substrate  22  is connected to test fixture portion  12 -A, DSUTs  10  may experience tensile stress. Conductive material  24  may be stretched as substrate  20  is slowly pulled away from substrate  22 . 
     Tensile stress may cause breaks or tears in conductive material  24  such as tear  26  as shown in  FIG. 6C . The integrity of conductive material  24  may affect the conductivity of DSUTs  10  and consequently affect S11 parameter test data collected from DSUTs  10  via cable  16 . Tear  26  may cause S11 parameter test data of DSUTs  10  to deviate from desired performance data. 
     However, if conductive material  24  is formed from a material resilient to tensile stress, DSUTs  10  may maintain conductivity under a particular level of tensile stress. For example, conductive material  24  may not deteriorate and create tear  26  when DSUTs  10  experience a predetermined level of tensile stress  33   a  administered during testing. This may result in desirable S11 parameter test data and/or other satisfactory RF performance criteria and allow DSUTs  10  to pass on to subsequent testing or be used in a product device. 
       FIG. 7  shows a test system  100  for gathering multiport scattering parameter measurements from DSUTs  10  using two test probes such as test probe  14 - 1  and test probe  14 - 2  and VNA  18  with two test ports P1 and P2. Different types of test data such as different scattering parameter measurements (e.g., S11, S12, S21, and S22) may be gathered when each of the test probes  14  is used to transmit and receive test signals. 
     DSUTs  10  may include substrates  20  and  22  and conductive material  24  interposed between substrates  20  and  22 . Conductive material  24  may be a pressure sensitive adhesive that bonds substrates  20  and  22  when activated by pressure. Test fixture  12  may hold the DSUTs  10 . Portions of test fixture  12  may be moved using positioner  13 . Test fixture portions  12 -A and  12 -B may both be connected as a part of an integral test fixture and may have clamps  48  that secure the test fixture to substrates  20  and  22  of DSUTs  10 . 
     Test probe  14 - 1  may be positioned between substrate  20  and test fixture portion  12 -B. Test probe  14 - 2  may be positioned between substrate  22  and test fixture portion  12 -A. Each test probe  14  may have signal and ground conductors for transmitting and receiving RF test signals. 
     VNA  18  may be used to generate RF test signals that are transmitted to DSUTs  10 . Port P1 may be connected to cable  16 - 1  and port  2  may be connected to cable  16 - 2 . Cable  16 - 1  may have a first end that is connected to port P1 and a second end terminating at a first test probe  14 - 1 . Similarly, cable  16 - 2  may have a first end that is connected to port P2 and a second end terminating at a second test probe  14 - 2 . 
     As in  FIGS. 1-6 , RF test signals transmitted by VNA  18  and applied to DSUTs  10  through cable  16 - 1  and test probe  14 - 1  may energize DSUTs  10  and cause reflected signals to be sent back through the same cable  16 - 1 . Test signals may also be sent to DSUTs  10  through cable  16 - 2  and test probe  14 - 2  and an energized DSUTs  10  may send reflected signals back through cable  16 - 2  to be received by VNA  18 . These reflected signals may be used to compute a reflection coefficient (sometimes referred to as an S11 or S22 parameter). 
     When VNA  18  transmits RF test signals to DSUTs  10  through cable  16 - 1 , corresponding emitted test signals may be received through cable  16 - 2 . The transmitted signals sent through cable  16 - 1  and corresponding received signals from cable  16 - 2  may be used to compute a forward transfer coefficient (sometimes referred to as an S21 parameter). VNA  18  may also transmit RF test signals through cable  16 - 2  to DSUTs  10  and receive corresponding emitted test signals through cable  16 - 1  to compute an S12 parameter. 
     This is merely exemplary and does not limit the combinations of measurements that may be obtained; test system  100  may have any number of ports on test unit  18  and any number of RF cables and test probes. Test system  100  therefore may obtain any number of scattering parameter measurements that the number of ports, cables, and test probes allow. 
       FIG. 8  shows a test system  100  for testing DSUTs  10  including a coaxial cable with parts such as portions  80  and  82  joined by a conductive material such as conductive material  84 . Conductive material  84  may be conductive adhesive, foam, tape, pressure sensitive adhesive, conductive gasket, conductive fabric foam, ultraviolet-activated adhesive, or thermal-activated adhesive. Coaxial cable portions  80  and  82  may be held by a test fixture such as test fixture  86 . Portions of test fixture  86  may be moved using positioners  87  to apply pressure to DSUTs  10  in a way that compresses or stretches conductive material  84 . 
     Conductive material  84  may be a pressure sensitive adhesive that may be activated by compressive pressure when test fixture  86  moves portions  80  and  82  toward each other. Tensile and/or compressive stress may be applied to coaxial cable portions  80  and  82  and conductive material  84  when test fixture  86  is moved using positioners  87  to pull portions  80  and  82  away from each other. Securing structures such as clamps  90  may be used to secure DSUTs  10  to testing fixture  86 . 
     Coaxial cable portions  80  and  82  may be mated to RF cables such as cables  16 - 1  and  16 - 2  via radio-frequency coaxial test connectors  88 - 1  and  88 - 2 . Cables  16 - 1  and  16 - 2  may be connected to ports P1 and P2 of VNA  18 . VNA  18  may gather RF performance testing data from DSUTs  10 . VNA  18  may transmit RF testing signals to DSUTs  10  via cables  16 - 1  and  16 - 2  and RF coaxial test connectors  88 - 1  and  88 - 2  to collect different measurements on RF performance (e.g., S11, S12, S21, S22). 
     VNA  18  may be used to generate RF test signals that are transmitted to DSUTs  10 . Port P1 may be connected to cable  16 - 1  and port  2  may be connected to cable  16 - 2 . Cable  16 - 1  may have a first end that is connected to port P1 and a second end terminating at a first RF coaxial test connector  88 - 1 . Similarly, cable  16 - 2  may have a first end that is connected to port P2 and a second end terminating at a second RF coaxial test connector  88 - 2 . 
     As in  FIGS. 1-6 , RF test signals transmitted by VNA  18  and applied to DSUTs  10  through cable  16 - 1  and RF coaxial test connector  88 - 1  may energize DSUTs  10  and cause reflected signals to be sent back through the same cable  16 - 1 . Test signals may also be sent to DSUTs  10  through cable  16 - 2  and RF coaxial test connector  88 - 2  and the energized DSUTs  10  may send reflected signals back through cable  16 - 2  to be received by VNA  18 . These reflected signals may be used to compute a reflection coefficient (sometimes referred to as an S11 or S22 parameter). 
     When VNA  18  transmits RF test signals to DSUTs  10  through cable  16 - 1 , corresponding emitted test signals may be received through cable  16 - 2 . The transmitted signals on cable  16 - 1  and corresponding received signals on cable  16 - 2  may be used to compute a forward transfer coefficient (sometimes referred to as an S21 parameter). VNA  18  may also transmit RF test signals through cable  16 - 2  to DSUTs  10  and receive corresponding emitted test signals through cable  16 - 1  to compute an S12 parameter. 
       FIG. 9  is a flowchart of illustrative steps used to evaluate radio-frequency characteristics of DSUTs  10  and to determine whether the radio-frequency characteristics of DSUTs  10  meet performance criteria. At step  101 , calibration operations are performed on reference device structures. These reference device structures are structures that meet desired RF performance and design criteria. The test calibration data may provide a control reference point (i.e. an optimal S11 or S21 measurement) for comparison with gathered test data from DSUTs  10 . 
     At step  102 , device structures such as DSUTs  10  may be placed in a test fixture. DSUTs  10  may be a stacked structure of substrates such as substrates  20  and  22  joined by a layer of conductive material such as conductive material  24  as shown in  FIG. 2 , or a coaxial cable with portions such as coaxial cable portions  80  and  82  joined by a layer of conductive material such as conductive material  84  as shown in  FIG. 8 . Test fixtures used to test the device structures under test may be any of the test fixtures described in  FIGS. 1-8 , such as test fixture  12  and test fixture  86 . 
     At step  104 , a test probe such as test probe  14  or a connector such as RF coaxial test connector  88  may be placed in contact with the device structures under test. Test probe  14  may have a signal and a ground trace that is positioned in contact with device structures under test as shown in  FIG. 5 . There may be any number of test probes and connectors at any number of locations electrically connected to device structures under test in a way that allows signals to be successfully transmitted and received between DSUTs  10  and test unit  18 . 
     At step  106 , a test fixture such as test fixture  12  or test fixture  86  may be attached to DSUTs  10 . The test fixture may be attached to DSUTs  10  using clamps such as clamps  48  or  90 . The clamps may secure DSUTs  10  to the fixture such that when parts of the test fixture are moved during testing, DSUTs  10  stay attached to the test fixture. 
     At step  108 , a compressive force may be increased on DSUTs  10  to activate adhesive bonding as shown in  FIGS. 4B and 6B . DSUTs  10  may have a conductive material that may be a pressure sensitive adhesive. The pressure sensitive adhesive may be activated by compressive force to bond portions of the device structures that are in contact with the adhesive such as substrates  20  and  22  as shown in  FIG. 2 . 
     At step  110 , once the adhesive is activated and substrates  20  and  22  are securely bonded in the device structures under test, compressive force on the device structures may be reduced. For example, as shown in  FIG. 4B , test fixture portion  12 -B may stop moving in a downward direction and instead begin to move in an upward direction. Step  110  may be optional when testing DSUTs under compressive stress (e.g., using the force loading profile as illustrated by line  2  of  FIG. 3A ). 
     At step  112 , an increased stress (e.g. compressive and/or tensile force) may be applied to a portion of DSUTs  10 . For example, as shown in  FIGS. 4C and 6C , test fixture portion  12 -B may be moved in a direction away from test fixture portion  12 -A and consequently “stretch” the conductive material (e.g. adhesive) bonding two substrates in the device structures under test. 
     At step  114 , while applying compressive and tensile forces to the device structures, test data may be gathered with the test unit. Scattering parameter measurements (e.g., S11, S12, S21, S22) and additional RF measurements may be collected, depending on the number of ports on the test unit and the number of test probes and/or coaxial cables used, as shown in  FIGS. 4A-C ,  6 A-C,  7 , and  8 . 
     At step  116 , properties of the adhesive or other conductive material in DSUTs  10  are characterized based on the testing data. In other words, scattering parameter measurements or other measurements gathered by the test unit may be used to determine whether the resilience of the adhesive or the conductive material in DSUTs  10  is satisfactory according to desired industry standards. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20130815
Publication Date: 20160802
Grant Date: 20160802
Priority Date: 20130815
Inventors: NICKEL JOSHUA G.
CHEN CHUN-LUNG
YANG TSENG-MAU
MERZ NICHOLAS G.
SCHLUB ROBERT W.
SHIU BOON W.
TONG ERICA J.
Assignee: APPLE INC
CPC Classifications: [{"code": "G01N3/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/56", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01N3/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B17/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B17/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N19/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B17/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04B17/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N19/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N19/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N3/56", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 52467173