Methods of creating probe structures from a plurality of planar layers
First Claim
1. A method of creating a probe structure for contacting an electronic components wherein the probe structure comprises a contact tip for contacting a first electronic component, a body portion that comprises a distal end that joins the contact tip and a proximal end that provides for mounting of the probe structure to a second electronic component wherein a bonding material is provided for attaching the proximal end to the second electronic component, the method comprising:
- a) forming at least a portion of the body portion from 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 that forms a portion of the body portion, and wherein the body portion comprises at least one of the at least one structural material;
b) forming a body of a bonding material from one or more multiple material layers of electrodeposited material, wherein at least one of the multiple materials is at least one bonding 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 that comprises the bonding material; and
c) forming the contact tip from at least a portion of 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 from which the contact tip is formed, and wherein during electrodeposition the contact tip is formed from at least one of the at least one structural material,d) after forming the body portion, the body of bonding material, and the contact tip from one or more multiple materials layers, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure,wherein any successive multiple material layer or layers are formed and simultaneously adhered to a previously formed multiple material layer, and wherein forming of the body portion, the body of bonding material, and the contact tip may occur during formation of the same multi-material layer or layers or different multi-material layers.
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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 are used to form probe structures from a plurality of planar multi-material layers wherein each probe structure includes a contact tip, a compliant body, and a bonding material that can be used in bonding the probe to a substrate 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.
112 Citations
29 Claims
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1. A method of creating a probe structure for contacting an electronic components wherein the probe structure comprises a contact tip for contacting a first electronic component, a body portion that comprises a distal end that joins the contact tip and a proximal end that provides for mounting of the probe structure to a second electronic component wherein a bonding material is provided for attaching the proximal end to the second electronic component, the method comprising:
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a) forming at least a portion of the body portion from 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 that forms a portion of the body portion, and wherein the body portion comprises at least one of the at least one structural material; b) forming a body of a bonding material from one or more multiple material layers of electrodeposited material, wherein at least one of the multiple materials is at least one bonding 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 that comprises the bonding material; and c) forming the contact tip from at least a portion of 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 from which the contact tip is formed, and wherein during electrodeposition the contact tip is formed from at least one of the at least one structural material, d) after forming the body portion, the body of bonding material, and the contact tip from one or more multiple materials layers, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure, wherein any successive multiple material layer or layers are formed and simultaneously adhered to a previously formed multiple material layer, and wherein forming of the body portion, the body of bonding material, and the contact tip may occur during formation of the same multi-material layer or layers or different multi-material layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of creating a probe structure for contacting an electronic components wherein the probe structure comprises a contact tip for contacting a first electronic component, a body portion that comprises a distal end that joins the contact tip and a proximal end for mounting to a second electronic component wherein a bonding material is provided for attaching the proximal end to a second electronic component, the method comprising:
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a) forming at least part of the body portion; b) forming at body of the bonding material; and c) forming the contact tip; wherein the formation of each of the body portion, the body of bonding material, and the contact tip comprise forming one or more multiple material layers of deposited material, wherein for each of the one or more multiple material layers 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 for each of the one or more multiple material layers at least a plurality of the multiple materials are planarized to set a boundary level for each multiple material layer, wherein the body portion, the body of bonding material, and the contact tip, are each formed from at least one structural material deposited during the formation of at least one multiple material layer wherein any successive multiple material layer or layers are successively formed and adhered to a previously formed multiple material layer, and wherein forming of the body portion, the body of bonding material, and the contact tip may occur during formation of the same multi-material layer or layers or different multi-material layers, and d) after forming the body portion, the body of bonding material, and the contact tip, releasing the at least one structural material from the at least one sacrificial material to reveal the probe structure. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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Specification