Nickel-Boron Alloy Probe for Electrical Test
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Solution Overview
Problem
Conventional probes for electrical tests face challenges in achieving a balance between mechanical and electrical characteristics, with nickel-based probes either deforming under repeated contacts or experiencing poor electrical conductivity due to Joule heat, and nickel-manganese alloy probes lacking sufficient mechanical properties.
Innovation Solution
A probe with a nickel-boron alloy main body and a harder conductive material tip, where the nickel-boron alloy has a crystal size of 50 nm or less and boron content between 0.02 wt% and 0.20 wt%, is manufactured using a deposition technique and annealed at 200° C. to 400° C. for 1 to 2 hours, providing both favorable mechanical and electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the probe main body portion is made of nickel to achieve good electrical characteristics (low electrical resistance), then electrical conductivity is improved, but mechanical characteristics deteriorate (plastic deformation or breakage by repeated contacts)
Solution Approach 1:
The probe main body portion is made of a nickel-boron alloy composite material that combines nickel (providing electrical conductivity) with boron (providing mechanical strength). This composite structure allows the probe to simultaneously achieve low electrical resistance and resistance to plastic deformation from repeated contacts.
Solution Approach 2:
By changing the material parameters - specifically adding boron content to the nickel base and controlling crystal grain size to 50 nm or less through annealing treatment - the probe achieves both excellent electrical characteristics and enhanced mechanical properties, resolving the contradiction between conductivity and strength.
2Strength
If the probe main body portion is made of nickel alloy to achieve good mechanical characteristics, then strength is improved, but electrical characteristics deteriorate (Joule heat deformation)
Solution Approach 1:
The nickel-boron alloy composite maintains nickel as the primary component (ensuring electrical conductivity) while incorporating boron for mechanical strength. This composite approach prevents Joule heat deformation by preserving nickel's electrical properties while adding thermal and mechanical stability through boron.
Solution Approach 2:
By precisely controlling the boron content (0.01-2.0 wt%) and crystal grain size (50 nm or less), the material achieves optimal balance between mechanical strength and electrical conductivity, preventing Joule heat effects while maintaining low resistance.
3Strength
If the probe tip portion is made of highly hard material to restrict abrasion, then wear resistance is improved, but the probe requires multi-material construction increasing manufacturing complexity
Solution Approach 1:
The probe is divided into two functional segments: the main body portion (nickel-boron alloy) providing electrical conductivity and elastic deformation capability, and the tip portion (highly hard material) providing wear resistance. This segmentation allows each part to be optimized for its specific function while using deposition techniques to manage manufacturing complexity.
Solution Approach 2:
Different materials are applied to different parts of the probe: the nickel-boron alloy for the main body where electrical and elastic properties are needed, and highly hard material for the tip where wear resistance is critical. This local quality approach optimizes performance while using deposition processes to control manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The nickel-boron alloy probe exhibits improved mechanical and electrical performance, withstanding repeated contacts and maintaining electrical conductivity without deformation or breakage, as demonstrated by enhanced displacement and specific resistance values.
Implementation Method 1
annealing the probe main body portion made of a nickel-manganese alloy
Implementation Method 2
heat such a spiral probe at 200° C. to 300° C. to keep the elastic deformation portion in an amorphous state
Implementation Method 3
the probe main body portion especially the arm portion is made of the metal material with excellent resiliency. Therefore the probe tip portion of the probe can be slid on the electrode of the device under test along with elastic deformation of the arm portion
Implementation Method 4
This slide of the probe tip causes an oxide film on the electrode to be scraped away
Implementation Method 5
the nickel-made probe main body portion has good electrical characteristics (low electrical resistance) but poor (weak) mechanical characteristics and will be plastically deformed or broken by repeated contacts effecting overdriving. On the other hand, the nickel alloy has good mechanical characteristics but poor electrical characteristics and will be deformed due to Joule heat when high current flows therein
Data Source
AI summary
A method for manufacturing a probed for an electrical test includes producing by a deposition technique a deposit including a probe main body portion made of a nickel-boron alloy and a probe tip portion projecting downward from the probe main body portion and made of a different conductive material from the probe main body portion. The method further includes annealing the deposit. The average grain diameter of the nickel-boron alloy is between 97 Å and 170 Å. The contained amount of boron is from 0.02 wt % to 0.20 wt %.