Probe Bonding Anti-Wicking Agent and Template Plate Alignment
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Solution Overview
Problem
The wicking of bonding material between probes in probe assemblies, particularly in closely spaced irregular arrays, interferes with proper probe motion during operation, especially at fine probe pitches, due to reduced epoxy viscosity during curing.
Innovation Solution
An anti-wicking agent, such as a solid powder, liquid, or gel, is applied to the probe assembly surface to hinder wicking, and a template plate is used to maintain probe tip position during fabrication, reducing undesirable bending and ensuring proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If probes are closely spaced to achieve fine probe pitch, then productivity and measurement capability are improved, but wicking of bonding material occurs during curing which interferes with probe motion
Solution Approach 1:
A release agent is applied as an intermediary substance between the bonding material and the probe assembly. This release agent prevents the bonding material from adhering to the probes during the bonding process, allowing probes to move freely without interference from wicking bonding material, while still enabling effective bonding in the bonding cavity
Solution Approach 2:
The viscosity of the bonding material changes during curing (decreases at elevated temperature), which exacerbates wicking. By controlling the bonding process parameters and using a release agent, the system manages the viscosity changes to prevent harmful wicking while maintaining bonding effectiveness
2Reliability
If bonding material is applied to fill the bonding cavity, then reliable probe attachment is achieved, but wicking occurs along the probes toward the tips during curing
Solution Approach 1:
The release agent serves as a mediator that prevents direct contact and adhesion between the bonding material and the probe surfaces. This intermediary layer allows the bonding material to be applied generously to fill the bonding cavity reliably while preventing it from wicking along the probes
Solution Approach 2:
The release agent is applied beforehand to the probe assembly before the bonding material is introduced. This preliminary anti-action prevents the harmful wicking effect from occurring in the first place, while still allowing the bonding material to perform its attachment function
3Ease of operation
If anti-wicking agent is applied to suppress wicking, then probe motion is maintained, but probe tip position may be affected during fabrication
Solution Approach 1:
The template plate acts as an intermediary fixture that holds the probes in precise positions during the application of the release agent and bonding material. This ensures that probe tip positions are maintained with high precision while still allowing the release agent to perform its anti-wicking function
Solution Approach 2:
The template plate is used to pre-position the probes correctly before the bonding process begins. This preliminary positioning action ensures that even when the release agent and bonding material are applied, the probe tips remain in their correct positions without bending or misalignment
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 use of anti-wicking agents effectively suppresses bonding agent wicking during curing, preventing interference with probe motion and maintaining probe alignment, even at fine probe pitches, thereby improving the reliability of probe assemblies.
Implementation Method 1
a wicking problem can arise in connection with this probe bonding approach... wicking refers to situations where bonding material ends up being disposed between probes at locations outside the main bonding cavity
Implementation Method 2
wicking of the epoxies presently used for probe bonding occurs mainly during curing of the epoxy, because the elevated temperature for curing causes a temporary reduction in epoxy viscosity
Data Source
AI summary
In assembly of probe arrays for electrical test, a problem can arise where a bonding agent undesirably wicks between probes. According to embodiments of the invention, this wicking problem is alleviated by disposing an anti-wicking agent on a surface of the probe assembly such that wicking of the bonding agent along the probes toward the probe tips is hindered. The anti-wicking agent can be a solid powder, a liquid, or a gel. Once probe assembly fabrication is complete, the anti-wicking agent is removed. In preferred embodiments, a template plate is employed to hold the probe tips in proper position during fabrication. In this manner, undesirable bending of probes caused by introduction or removal of the anti-wicking agent can be reduced or eliminated.