Source: http://www.google.com/patents/US7557595?ie=ISO-8859-1&dq=5920316
Timestamp: 2014-04-21 16:33:37
Document Index: 350830945

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patent US7557595 - Cantilever microprobes for contacting electronic components and methods for ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsEmbodiments disclosed herein are directed to compliant probe structures for making temporary or permanent contact with electronic circuits and the like. In particular, embodiments are directed to various designs of cantilever-like probe structures. Some embodiments are directed to methods for fabricating...http://www.google.com/patents/US7557595?utm_source=gb-gplus-sharePatent US7557595 - Cantilever microprobes for contacting electronic components and methods for making such probesAdvanced Patent SearchPublication numberUS7557595 B2Publication typeGrantApplication numberUS 11/929,666Publication dateJul 7, 2009Filing dateOct 30, 2007Priority dateFeb 4, 2003Fee statusPaidAlso published asUS7265565, US7511523, US7679388, US20050179458, US20070170940, US20070170943, US20070182427, US20080100326, US20100176834, US20110187397, US20110187398, US20120061009, US20120062260, US20120064226, US20120064227Publication number11929666, 929666, US 7557595 B2, US 7557595B2, US-B2-7557595, US7557595 B2, US7557595B2InventorsRichard T. Chen, Ezekiel J. Kruglick, Christopher A. Bang, Dennis R. Smalley, Pavel B. LembrikovOriginal AssigneeMicrofabrica Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (53), Non-Patent Citations (8), Referenced by (3), Classifications (24), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetCantilever microprobes for contacting electronic components and methods for making such probesUS 7557595 B2Abstract Embodiments disclosed herein are directed to compliant probe structures for making temporary or permanent contact with electronic circuits and the like. In particular, embodiments are directed to various designs of cantilever-like probe structures. Some embodiments are directed to methods for fabricating such cantilever structures. In some embodiments, for example, cantilever probes have extended base structures, slide in mounting structures, multi-beam configurations, offset bonding locations to allow closer positioning of adjacent probes, compliant elements with tensional configurations, improved over travel, improved compliance, improved scrubbing capability, and/or the like.
RELATED APPLICATIONS This application is a continuation of U.S. application Ser. No. 11/695,597, filed Apr. 2, 2007, which is a continuation of U.S. application Ser. No. 11/028,960 which was filed on Jan. 3, 2005, now U.S. Pat. No. 7,265,565. Application Ser. No. 11/028,960 claims benefit of U.S. Application Nos. 60/582,689; 60/582,690 both filed on Jun. 23, 2004; 60/609,719 filed on Sep. 13, 2004; 60/611,789 filed on Sep. 20, 2004; 60/540,511 filed on Jan. 29, 2004; 60/533,933 filed on Dec. 31, 2003; 60/536,865 filed on Jan. 15, 2004; and 60/533,947 filed on Dec. 31, 2003 and is a continuation-in-part of U.S. patent application Ser. No. 10/949,738, filed on Sep. 24, 2004 now abandoned, which in turn is a continuation-in-part of U.S. patent application Ser. No. 10/772,943, filed Feb. 4, 2004 now abandoned, which in turn claims benefit of U.S. Application Nos. 60/445,186 filed on Feb. 4, 2003; 60/506,015 filed on Sep. 24, 2003; 60/533,933 filed on Dec. 31, 2003; and 60/536,865 filed on Jan. 15, 2004 furthermore the '738 application claims benefit of U.S. Application Nos. 60/506,015 filed on Sep. 24, 2003; 60/533,933 filed on Dec. 31, 2003; and 60/536,865 filed on Jan. 15, 2004. Each of these applications is incorporated herein by reference as if set forth in full herein including any appendices attached thereto.
1. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, �EFAB: Batch production of functional, fully-dense metal parts with micro-scale features�, Proc. 9th Solid Freeform Fabrication, The University of Texas at Austin, p161, August 1998. 2. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, �EFAB: Rapid, Low-Cost Desktop Micromachining of High Aspect Ratio True 3-D MEMS�, Proc. 12th IEEE Micro Electro Mechanical Systems Workshop, IEEE, p244, January 1999. 3. A. Cohen, �3-D Micromachining by Electrochemical Fabrication�, Micromachine Devices, March 1999. 4. G. Zhang, A. Cohen, U. Frodis, F. Tseng, F. Mansfeld, and P. Will, �EFAB: Rapid Desktop Manufacturing of True 3-D Microstructures�, Proc. 2nd International Conference on Integrated MicroN\anotechnology for Space Applications, The Aerospace Co., April 1999. 5. F. Tseng, U. Frodis, G. Zhang, A. Cohen, F. Mansfeld, and P. Will, �EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process�, 3rd International Workshop on High Aspect Ratio MicroStructure Technology (HARMST'99), June 1999. 6. A. Cohen, U. Frodis, F. Tseng, G. Zhang, F. Mansfeld, and P. Will, �EFAB: Low-Cost, Automated Electrochemical Batch Fabrication of Arbitrary 3-D Microstructures�, Micromachining and Microfabrication Process Technology, SPIE 1999 Symposium on Micromachining and Microfabrication, September 1999. 7. F. Tseng, G. Zhang, U. Frodis, A. Cohen, F. Mansfeld, and P. Will, �EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process�, MEMS Symposium, ASME 1999 International Mechanical Engineering Congress and Exposition, November, 1999. 8. A. Cohen, �Electrochemical Fabrication (EFAB�)�, Chapter 19 of The MEMS Handbook, edited by Mohamed Gad-El-Hak, CRC Press, 2002. 9. Microfabrication�Rapid Prototyping's Killer Application�, pages 1-5 of the Rapid Prototyping Report, CAD/CAM Publishing, Inc., June 1999. The disclosures of these nine publications are hereby incorporated herein by reference as if set forth in full herein.
FIG. 42B depicts another alternative cantilever probe structure. Cantilever probe structures of this type may be considered to be a �tensional cantilevers� as opposed to a �compressional cantilevers� since the compliant element of the cantilever is place under tension instead of under compression. As illustrated the cantilever 832 includes a beam structure 834 which is connected to a compliant structure 836 on or near one end and has a tip 838 on or near the opposite end. The structure also includes a substantially non-compliant pivot structure 840. During operation the tip 838 is pressed downward toward substrate causing compliant element 836 to bend and after the beam 834 contacts the pivot structure 840, continued downward movement of the tip causes the compliant structure 836 to be place in tension. In some alternative embodiments, the pivot structure may have a curved or pointed upper surface, and/or the beam 834 may remain in contact with the pivot structure even when no load is placed on the tip. In some alternative embodiments the pivot bar and cantilever bar may be pinned together as shown in FIG. 43A where the pivot structure 840′ may hold a pin 842 that extends cantilever bar 834 (the compliant structure and probe tip are not shown). In some variations of this embodiment, the pin, the pivot structure and the cantilever arm may be formed simultaneously in their desired positions. In some embodiments side supports 844R and 844L may retain the pivot structure 840″ and cantilever bar 834 in desired positions as shown in FIG. 43B. In still other alternative embodiments the side supports 844′ may be attached to the cantilever bar 834 as opposed to the pivot structure 840″′ as shown in FIG. 43C.
Some embodiments may employ diffusion bonding or the like to enhance adhesion between successive layers of material. Various teachings concerning the use of diffusion bonding in electrochemical fabrication processes are set forth in U.S. patent application Ser. No. 10/841,384 which was filed May 7, 2004 by Cohen et al., now abandoned, which is entitled �Method of Electrochemically Fabricating Multilayer Structures Having Improved Interlayer Adhesion� and which is hereby incorporated herein by reference as if set forth in full
Further teachings about microprobes and electrochemical fabrication techniques are set forth in a number of U.S. Patent Applications: (1) U.S. Patent Application No. 60/533,975 by Kim et al., which was filed on Dec. 31, 2003, and which is entitled �Microprobe Tips and Methods for Making�; (2) U.S. Patent Application No. 60/533,947 by Kumar et al., which was filed on Dec. 31, 2003, and which is entitled �Probe Arrays and Method for Making�; (3) U.S. Patent Application No. 60/574,737 by Cohen et al., which was filed May 26, 2004, and which is entitled �Electrochemical Fabrication Method for Fabricating Space Transformers or Co-Fabricating Probes and Space Transformers�; (4) U.S. Patent Application No. 60/533,897 by Cohen et al., which was filed on Dec. 31, 2003, and which is entitled �Electrochemical Fabrication Process for Forming Multilayer Multimaterial Microprobe structures�; (5) U.S. Patent Application No. 60/540,511 by Kruglick et al., which was filed on Jan. 29, 2004, and which is entitled �Electrochemically Fabricated Microprobes�, (6) U.S. patent application Ser. No. 10/772,943, by Arat et al., now abandoned, which was filed Feb. 4, 2004, and which is entitled �Electrochemically Fabricated Microprobes�; (7) U.S. Patent Application No. 60/582,690, filed Jun. 23, 2004, by Kruglick, and which is entitled �Cantilever Microprobes with Base Structures Configured for Mechanical Interlocking to a Substrate�; and (8) U.S. Patent Application No. 60/582,689, filed Jun. 23, 2004 by Kruglick, and which is entitled �Cantilever Microprobes with Improved Base Structures and Methods for Making the Same�. These patent filings are each hereby incorporated herein by reference as if set forth in full herein. The techniques disclosed explicitly herein may also benefit by combining them with the techniques disclosed in U.S. patent application Ser. No. 11/029,180, filed Jan. 3, 2005, by Chen et al., now abandoned, and entitled �Pin-Type Probes for Contacting Electronic Circuits and Methods for Making Such Probes�; U.S. Patent Application No. 60/641,341 filed concurrently herewith by Chen et al. and entitled �Vertical Microprobes for Contacting Electronic Components and Method for Making Such Probes�; U.S. patent application Set. No. 11/029,217, filed Jan. 3, 2005, by Kim et al., now U.S. Pat. No. 7,412,767, and entitled �Microprobe Tips and Methods For Making�; U.S. patent application Ser. No. 11/028,958, filed Jan. 3, 2005, by Kumar et al. and entitled �Probe Arrays and Methods for Making�; and U.S. patent application Ser. No. 11/029,221, filed Jan. 3, 2005, by Cohen et al. and entitled �Electrochemical Fabrication Process for Forming Multilayer Multimaterial Microprobe Structures�.
Further teachings about planarizing layers and setting layers thicknesses and the like are set forth in the following U.S. Patent Applications which were filed Dec. 31, 2003: (1) U.S. Patent Application No. 60/534,159 by Cohen et al. and which is entitled �Electrochemical Fabrication Methods for Producing Multilayer Structures Including the use of Diamond Machining in the Planarization of Deposits of Material� and (2) U.S. Patent Application No. 60/534,183 by Cohen et al. and which is entitled �Method and Apparatus for Maintaining Parallelism of Layers and/or Achieving Desired Thicknesses of Layers During the Electrochemical Fabrication of Structures�. These patent filings are each hereby incorporated herein by reference as if set forth in full herein. The techniques disclosed explicitly herein may also benefit by combining them with the techniques disclosed in U.S. patent application Ser. No. 11/029,221, filed Jan. 3, 2005, by Frodis et al., now U.S. Pat. No. 7,271,888, and entitled �Method and Apparatus for Maintaining Parallelism of Layers and/or Achieving Desired Thicknesses of Layers During the Electrochemical Fabrication of Structures�.
Additional teachings concerning the formation of structures on dielectric substrates and/or the formation of structures that incorporate dielectric materials into the formation process and possibility into the final structures as formed are set forth in a number of patent applications: (1) U.S. Patent Application No. 60/534,184, by Cohen, which as filed on Dec. 31, 2003, and which is entitled �Electrochemical Fabrication Methods Incorporating Dielectric Materials and/or Using Dielectric Substrates�; (2) U.S. Patent Application No. 60/533,932, by Cohen, which was filed on Dec. 31, 2003, and which is entitled �Electrochemical Fabrication Methods Using Dielectric Substrates�; (3) U.S. Patent Application No. 60/534,157, by Lockard et al., which was filed on Dec. 31, 2004, and which is entitled �Electrochemical Fabrication Methods Incorporating Dielectric Materials�; (4) U.S. Patent Application No. 60/574,733, by Lockard et al., which was filed on May 26, 2004, and which is entitled �Methods for Electrochemically Fabricating Structures Using Adhered Masks, Incorporating Dielectric Sheets, and/or Seed Layers that are Partially Removed Via Planarization�; and U.S. Patent Application No. 60/533,895, by Lembrikov et al., which was filed on Dec. 31, 2003, and which is entitled �Electrochemical Fabrication Method for Producing Multi-layer Three-Dimensional Structures on a Porous Dielectric�. These patent filings are each hereby incorporated herein by reference as if set forth in full herein. The techniques disclosed explicitly herein may also benefit by combining them with the techniques disclosed in U.S. patent application Ser. No. 11/029,216, filed Jan. 3, 2005, by Cohen et al., now abandoned, and entitled �Electrochemical Fabrication Methods Incorporating Dielectric Materials and/or Using Dielectric Substrates� and U.S. Patent Application No. 60/641,292 filed concurrently herewith by Dennis R. Smalley and entitled �Method of Forming Electrically Isolated Structures Using Thin Dielectric Coatings�.
Patent CitationsCited PatentFiling datePublication dateApplicantTitleUS5190637Apr 24, 1992Mar 2, 1993Wisconsin Alumni Research FoundationFormation of microstructures by multiple level deep X-ray lithography with sacrificial metal layersUS5286208Feb 4, 1992Feb 15, 1994Yamaichi Electric Co., Ltd.Contact in electric part socketUS5476211Nov 16, 1993Dec 19, 1995Form Factor, Inc.Method of manufacturing electrical contacts, using a sacrificial memberUS5545045Aug 31, 1994Aug 13, 1996Kabushiki Kaisha ToshibaIC contactorUS5599194Mar 3, 1994Feb 4, 1997Enplas CorporationIC socket and its contact pinUS5772451Oct 18, 1995Jun 30, 1998Form Factor, Inc.Sockets for electronic components and methods of connecting to electronic componentsUS5806181Jan 24, 1997Sep 15, 1998Formfactor, Inc.Contact carriers (tiles) for populating larger substrates with spring contactsUS5811982Mar 12, 1996Sep 22, 1998International Business Machines CorporationHigh density cantilevered probe for electronic devicesUS5820014Jan 11, 1996Oct 13, 1998Form Factor, Inc.Solder preformsUS5829128Nov 15, 1995Nov 3, 1998Formfactor, Inc.Method of mounting resilient contact structures to semiconductor devicesUS5917707Nov 15, 1994Jun 29, 1999Formfactor, Inc.Flexible contact structure with an electrically conductive shellUS5974662Nov 9, 1995Nov 2, 1999Formfactor, Inc.Method of planarizing tips of probe elements of a probe card assemblyUS5994152Jan 24, 1997Nov 30, 1999Formfactor, Inc.Fabricating interconnects and tips using sacrificial substratesUS6023103Jun 30, 1998Feb 8, 2000Formfactor, Inc.Chip-scale carrier for semiconductor devices including mounted spring contactsUS6027630Apr 3, 1998Feb 22, 2000University Of Southern CaliforniaMethod for electrochemical fabricationUS6043563Oct 20, 1997Mar 28, 2000Formfactor, Inc.Electronic components with terminals and spring contact elements extending from areas which are remote from the terminalsUS6064213Jan 15, 1997May 16, 2000Formfactor, Inc.Wafer-level burn-in and testUS6184053May 6, 1997Feb 6, 2001Formfactor, Inc.Method of making microelectronic spring contact elementsUS6208225Feb 25, 1999Mar 27, 2001Formfactor, Inc.Filter structures for integrated circuit interfacesUS6218910Feb 25, 1999Apr 17, 2001Formfactor, Inc.High bandwidth passive integrated circuit tester probe card assemblyUS6268015Dec 2, 1998Jul 31, 2001FormfactorMethod of making and using lithographic contact springsUS6278284Feb 16, 1999Aug 21, 2001Nec CorporationTesting IC socketUS6336269May 26, 1995Jan 8, 2002Benjamin N. EldridgeMethod of fabricating an interconnection elementUS6344752Jul 29, 1999Feb 5, 2002Tokyo Electron LimitedContactor and production method for contractorUS6426638May 2, 2000Jul 30, 2002Decision Track LlcCompliant probe apparatusUS6441315Nov 10, 1998Aug 27, 2002Formfactor, Inc.Contact structures with blades having a wiping motionUS6456099Dec 31, 1998Sep 24, 2002Formfactor, Inc.Special contact points for accessing internal circuitry of an integrated circuitUS6482013Feb 18, 1997Nov 19, 2002Formfactor, Inc.Microelectronic spring contact element and electronic component having a plurality of spring contact elementsUS6483328Dec 2, 1998Nov 19, 2002Formfactor, Inc.Probe card for probing wafers with raised contact elementsUS6491968Dec 29, 1999Dec 10, 2002Formfactor, Inc.Methods for making spring interconnect structuresUS6509751Mar 17, 2000Jan 21, 2003Formfactor, Inc.Planarizer for a semiconductor contactorUS6520778Feb 13, 1998Feb 18, 2003Formfactor, Inc.Microelectronic contact structures, and methods of making sameUS6539531Dec 1, 2000Mar 25, 2003Formfactor, Inc.Method of designing, fabricating, testing and interconnecting an IC to external circuit nodesUS6627483Mar 1, 1999Sep 30, 2003Formfactor, Inc.Method for mounting an electronic componentUS6640415Jul 25, 2002Nov 4, 2003Formfactor, Inc.Segmented contactorUS6672875Dec 29, 1999Jan 6, 2004Formfactor, Inc.Spring interconnect structuresUS6676438Dec 3, 2001Jan 13, 2004Advantest Corp.Contact structure and production method thereof and probe contact assembly using sameUS6690185Nov 19, 1998Feb 10, 2004Formfactor, Inc.Large contactor with multiple, aligned contactor unitsUS6705876Jul 13, 1998Mar 16, 2004Formfactor, Inc.Electrical interconnect assemblies and methodsUS6713374Dec 29, 2000Mar 30, 2004Formfactor, Inc.Interconnect assemblies and methodsUS6729019Jul 11, 2001May 4, 2004Formfactor, Inc.Method of manufacturing a probe cardUS6771084Jul 19, 2002Aug 3, 2004Decision Track LlcSingle-sided compliant probe apparatusUS6794890Jul 24, 2000Sep 21, 2004Mitsubishi Denki Kabushiki KaishaTest socket, method of manufacturing the test socket, test method using the test socket, and member to be testedUS6811406Apr 12, 2001Nov 2, 2004Formfactor, Inc.Microelectronic spring with additional protruding memberUS6817052Nov 9, 2001Nov 16, 2004Formfactor, Inc.Apparatuses and methods for cleaning test probesUS6838893Jun 10, 2003Jan 4, 2005Formfactor, Inc.Probe card assemblyUS6856156Mar 26, 2003Feb 15, 2005Taiwan Semiconductor Manufacturing Co., LtdAutomatically adjustable wafer probe cardUS6945827Dec 23, 2002Sep 20, 2005Formfactor, Inc.Microelectronic contact structureUS6967493Aug 25, 2004Nov 22, 2005Japan Electronic Materials CorporationProbe card and contactor of the sameUS7265565Jan 3, 2005Sep 4, 2007Microfabrica Inc.Cantilever microprobes for contacting electronic components and methods for making such probesUS20020017915Jul 3, 2001Feb 14, 2002Ando Electric Co., Ltd.Probe card, probe card restoring method, and probe card manufacturing methodUS20050108876Nov 26, 2003May 26, 2005Mathieu Gaetan L.Methods for making plated through holes usable as interconnection wire or probe attachmentsUS20070170940 *Apr 2, 2007Jul 26, 2007Microfabrica Inc.Cantilever Microprobes For Contacting Electronic Components and Methods for Making Such Probes* Cited by examinerNon-Patent CitationsReference1"Microfabrication-Rapid Prototyping's Killer Application", Rapid Prototyping Report, CAD/CAM Publishing, Inc., Jun. 1999, pp. 1-5.2Adam L. Cohen, "3-D Micromachining by Electrochemical Fabrication", Micromachine Devices, Mar. 1999, pp. 6-7.3Adam L. Cohen, "Electrochemical Fabrication (EFABTM)", Chapter 19 of the MEMS Handbook, edited by Mohamed Gad-El-Hak, CRC Press, 2002, pp. 19/1-19/23.4Adam L. Cohen, et al., "EFAB: Low-Cost, Automated Electrochemical Batch Fabrication of Arbitrary 3-D Microstructures", Micromachining and Microfabrication Process Technology, SPIE 1999 Symposium on Micromachining and Microfabrication, Sep. 1999.5Cohen, et al., "EFAB: Batch Production of Functional, Fully-Dense Metal Parts with Micron-Scale Features", Proc. 9th Solid Freeform Fabrication, The University of Texas at Austin, Aug. 1998, pp. 161.6F. Tseng, et al., "EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures Using a Low-Cost Automated Batch Process", 3rd International Workshop on High Aspect Ratio Microstructure Technology (HARMST'99), Jun. 1999.7F. Tseng, et al., "EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures Using a Low-Cost Automated Batch Process", MEMS Symposium, ASME 1999 International Mechanical Engineering Congress and Exposition, Nov. 1999.8Gang Zhang, et al., "EFAB: Rapid Desktop Manufacturing of True 3-D Microstructures", Proc. 2nd International Conference on Integrated MicroNanotechnology for Space Applications, The Aerospace Co., Apr. 1999.Referenced byCiting PatentFiling datePublication dateApplicantTitleUS7679388 *Apr 2, 2007Mar 16, 2010Microfabrica Inc.Cantilever microprobes for contacting electronic components and methods for making such probesUS8657635 *Mar 24, 2011Feb 25, 2014Omron CorporationTerminal and connector using the sameUS20120108111 *Mar 24, 2011May 3, 2012Omron CorporationTerminal and connector using the same* Cited by examinerClassifications U.S. Classification324/755.07International ClassificationG01R31/02Cooperative ClassificationG01R3/00, G01R1/06716, G01R1/06711, G01R1/06755, G01R1/06738, G01R1/06744, G01R31/2886, G01R1/0483, G01R1/07357, G01R1/07342, G01R1/06727European ClassificationG01R1/067C2C, G01R31/28G5, G01R1/073B4, G01R1/067C3B, G01R1/067C, G01R1/04S3U, G01R1/073B8, G01R3/00, G01R1/067C2, G01R1/067C4, G01R1/067C3ALegal EventsDateCodeEventDescriptionJan 7, 2013FPAYFee paymentYear of fee payment: 4Feb 5, 2008ASAssignmentOwner name: MICROFABRICA, INC., CALIFORNIAFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CHEN, RICHARD T.;KRUGLICK, EZEKIEL J.J.;BANG, CHRISTOPHER A.;AND OTHERS;REEL/FRAME:020469/0111;SIGNING DATES FROM 20050310 TO 20050422RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google