Methods of creating probe structures from a plurality of planar layers
First Claim
1. A method of creating a probe structure for contacting a first electronic components wherein the probe structure comprises a contact tip for contacting the first electronic component and a compliant body, the method comprising:
- a) forming at least a portion of the compliant body and the contact tip from one or more multiple material layers of electrodeposited material, wherein during formation of each multiple material layer at least one of the multiple materials is at least one structural material and wherein at least another one of the multiple materials is at least one sacrificial material and wherein at least a plurality of the multiple materials are planarized to set a boundary level for each of the one or more multiple material layers; and
b) after forming the compliant body and the contact tip, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure formed from the at least one structural material, wherein the at least one structural material forming the compliant body comprises at least one material that is different from the at least one structural material forming the contact tip,wherein each successive layer is formed on the simultaneously adhered to a previously formed layer; and
wherein the compliant body provides for elastic compression of the probe structure in a plane of primary motion when making contact with the first electronic component and wherein during formation of the probe structure, a stacking direction of layers forming the probe structure is perpendicular to the plane of primary motion.
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Abstract
Embodiments disclosed herein are directed to compliant probe structures for making temporary or permanent contact with electronic circuits and the like. Some embodiments are directed to various designs of cantilever-like probe structures while other embodiments are directed to methods for fabricating probe structures. In some embodiments, methods of forming probe structures include formation of a plurality of planar multi-material electrodeposited layers wherein each probe structure includes a contact tip and a compliant body, wherein the compliant body is formed from at least one material that is different from the contact tip material and wherein the compliant body provides for elastic compression of the probe in a plane of primary motion during use and wherein during formation of the layers a stacking direction of the plurality of layers is perpendicular to the plane of primary motion.
113 Citations
18 Claims
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1. A method of creating a probe structure for contacting a first electronic components wherein the probe structure comprises a contact tip for contacting the first electronic component and a compliant body, the method comprising:
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a) forming at least a portion of the compliant body and the contact tip from one or more multiple material layers of electrodeposited material, wherein during formation of each multiple material layer at least one of the multiple materials is at least one structural material and wherein at least another one of the multiple materials is at least one sacrificial material and wherein at least a plurality of the multiple materials are planarized to set a boundary level for each of the one or more multiple material layers; and b) after forming the compliant body and the contact tip, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure formed from the at least one structural material, wherein the at least one structural material forming the compliant body comprises at least one material that is different from the at least one structural material forming the contact tip, wherein each successive layer is formed on the simultaneously adhered to a previously formed layer; and wherein the compliant body provides for elastic compression of the probe structure in a plane of primary motion when making contact with the first electronic component and wherein during formation of the probe structure, a stacking direction of layers forming the probe structure is perpendicular to the plane of primary motion. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of creating a probe structure for contacting a first electronic component wherein the probe structure comprises a contact tip for contacting the first electronic component and a compliant body, the method comprising:
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a. forming at least part of the compliant body; b. forming the contact tip; wherein the forming of each of the compliant body and the contact tip comprise forming one or more multiple material layers of electrodeposited material, wherein at least one of the multiple materials is at least one structural material and wherein at least another one of the multiple materials is at least one sacrificial material and wherein at least a plurality of the multiple materials are planarized to set a boundary level for each layer, wherein the compliant body and the contact tip are each formed from at least one structural material deposited during the formation of their respective layer or layers, and c. after forming the compliant body and the contact tip, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure formed from the at least one structural material; wherein successive layers are successively formed on adhered to previously formed layers; wherein the at least one structural material forming the compliant body portion of the probe comprises at least one material that is different from at least one structural material forming the contact tip; wherein the compliant body provides for elastic compression of the probe structure in a plane of primary motion when making contact with the first electronic component and wherein during formation of the probe structure, a stacking direction of layers forming the probe structure is perpendicular to the plane of primary motion. - View Dependent Claims (9, 10, 11, 12)
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13. A method of creating a probe structure for contacting a first electronic components wherein the probe structure comprises a contact tip for contacting the first electronic component and a compliant body the method comprising:
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a) forming a first part of the compliant body; b) forming the contact tip; wherein the formation of each of the compliant body and the contact tip comprise forming one or more multiple material layers of deposited material, wherein at least one of the multiple materials is at least one structural material and wherein at least another one of the multiple materials is at least one sacrificial material and wherein at least a plurality of the multiple materials are planarized to set a boundary level for each layer, and c) after forming the compliant and the contact tip, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure formed from the at least one structural material; wherein successive layers are successively formed on and adhered to previously formed layers, wherein the at least one structural material forming the compliant body portion of the probe structure comprises at least one material that is different from the at least one structural material forming the contact tip; and wherein the compliant body provides for elastic compression of the probe structure in a plane of primary motion when making contact with the first electronic component and wherein during formation of the probe structure, a stacking direction of the one or more layers forming the probe structure is perpendicular to the plane of primary motion. - View Dependent Claims (14, 15, 16, 17, 18)
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Specification