Probe Card Needle Electrochemical Refinement for Precise Alignment
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Solution Overview
Problem
Existing probe card needles are prone to misalignment and uneven finishing due to physical contact with polishing pads, leading to inaccurate testing and reduced lifespan.
Innovation Solution
An electrochemical refinement process using electrolytic fluid and a conductive pattern structure to form needles without physical contact, ensuring precise alignment and uniform finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polishing pads are used to form needle shape, then needle profile can be created, but misalignment and uneven finishing occur
Solution Approach 1:
The patent replaces the mechanical polishing system with an electrochemical etching system. Instead of using polishing pads that physically contact and mechanically remove material, the invention uses electrolytic fluid and electrical current to chemically etch the needle profile. This substitution eliminates the misalignment and uneven finishing problems caused by mechanical contact while maintaining the ability to create precise needle shapes.
Solution Approach 2:
The patent changes the fundamental parameter of material removal from mechanical abrasion to electrochemical dissolution. By controlling electrical parameters (current, voltage, electrolyte composition) instead of mechanical parameters (polishing pressure, pad grit size), the process achieves more consistent and precise needle formation without the alignment issues inherent in mechanical polishing.
2Manufacturing precision
If polishing pads contact needles, then material removal occurs, but uneven finishing and reduced lifespan result
Solution Approach 1:
The patent replaces mechanical polishing with electrochemical etching, eliminating the physical contact between polishing pads and needles. This substitution prevents the uneven finishing and mechanical stress that reduce probe card lifespan, while achieving uniform needle profiles through controlled electrolytic material removal.
Solution Approach 2:
The patent introduces electrolytic fluid as an intermediary medium between the power source and the needle. This fluid mediator enables material removal through electrochemical reactions without direct mechanical contact, resulting in more uniform finishing and reduced wear on the probe card components.
3Manufacturing precision
If mechanical polishing is used, then needle shape is formed, but misalignment reduces testing accuracy
Solution Approach 1:
The patent replaces mechanical polishing with electrochemical etching to form needle shapes. This substitution eliminates misalignment during the shaping process, ensuring that the needle profile is accurately formed without the positional deviations that occur with mechanical polishing, thereby maintaining both manufacturing precision and subsequent testing accuracy.
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
Reduces misalignment issues and improves needle finishing, enhancing testing accuracy and extending probe card lifespan.
Implementation Method 1
an electrochemical refinement process to remove respective portions from the conductive body
Implementation Method 2
initiating a flow of electrons in the electrolytic fluid between the conductive pattern structure and the respective tips of the plurality of conductive bodies
Data Source
AI summary
The present disclosure is directed to a method of manufacturing one or more needles of a probe card by refining and processing a conductive body that extends from the probe card to form a respective tip at the end of the respective conductive body. Forming the respective tip of a respective needle includes removing respective portions from the end of the conductive body by flowing an electrolytic fluid between a conductive pattern structure and an end of the respective conductive body. Removing the respective portions with the flow of the electrons may be performed in multiple successive steps to form various needles with various sizes, shapes, and profiles (e.g., cylindrical, rectangular, triangular, trapezoidal, etc.).