Patent ID: 8729916
Filing Date: 2014-05-20
Classification: C25D,G01R

Abstract:
1. A method of creating a probe structure for contacting an electronic component wherein the probe structure comprises a contact tip and a compliant body, the method comprising: a) forming a first part of the compliant body 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 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 of the one or more multiple material layers from which the first part of the compliant body is formed, wherein the first part of the compliant body comprises at least one of the at least one structural material; b) forming the contact tip 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 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 of the one or more multiple material layers from which the contact tip portion if formed, and wherein the contact tip is formed from at least one of the at least one structural material; c) forming a second part of the compliant body 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 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 of the one or more multiple material layers from which the second part of the complaint body is formed, wherein the second part of the compliant body comprises at least one of the at least one structural material; d) after forming the first part, the contact tip portion, and the second part, 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 one or more multiple material layers of electrodeposited material for each of the first part of the compliant body, the contact tip, and the second part of the compliant body are formed in order and adhered together as each is successively formed; and wherein the compliant body provides for elastic compression of the probe structure in a plane of primary motion when making contact with an 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.