Rectangular Probe Piercing Oxidation Layer
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Solution Overview
Problem
Conventional rectangular probes used in probe card devices have limited signal transmission quality due to uniform material composition at the contact end, restricting further improvement in electrical connection performance.
Innovation Solution
The rectangular probes feature a conductive portion and a piercing portion made of different materials, where the piercing portion is designed to pierce through the oxidation layer on metal pads, creating a rupture surface for improved contact, with the conductive portion abutting against this surface to enhance electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end portion of the rectangular probe is made of uniform material, then the manufacturing process is simple, but the electrical connection performance is restricted and cannot be further improved
Solution Approach 1:
The probe employs different materials for different portions: the main body uses a highly conductive material (such as copper or copper alloy) while the contact end portion uses a material with higher hardness and oxidation resistance (such as nickel or nickel alloy). This local differentiation optimizes both electrical conductivity and contact reliability without complicating the overall manufacturing process.
Solution Approach 2:
The probe utilizes a composite structure where the contact end portion is formed by a different material than the main body. This composite approach combines the advantages of high conductivity from the copper-based main body with the superior contact properties (hardness and oxidation resistance) of the nickel-based contact end, thereby improving electrical connection performance while maintaining manufacturing feasibility.
2Device complexity
If the probe contact end contacts the metal pad directly, then the structure is simple, but the oxidation layer on the metal pad degrades the electrical connection
Solution Approach 1:
The invention converts the harmful effect of the oxidation layer into a beneficial one by using the harder contact end material to mechanically pierce through the oxidation layer on the metal pad surface. This creates a fresh, low-resistance contact path that eliminates the degradation caused by oxidation, transforming what was previously a harmful barrier into a temporary protective layer that gets broken through to establish better contact.
Solution Approach 2:
The probe changes the hardness parameter of the contact end material by using a material with higher Vickers hardness number than the main body. This parameter change enables the contact end to mechanically penetrate the oxidation layer on the metal pad, establishing a reliable electrical connection that is not degraded by surface oxidation.
3Strength
If the piercing portion is embedded in the conductive portion, then the structural integrity is maintained, but the conductivity at the contact point is reduced
Solution Approach 1:
The contact end portion is segmented into two distinct functional zones: an embedded piercing portion made of hard material for mechanical penetration, and an exposed conductive portion made of highly conductive material for electrical contact. This segmentation allows each portion to perform its specific function optimally while maintaining overall structural integrity through the embedded connection.
Solution Approach 2:
The piercing portion is embedded within the conductive portion, creating a three-dimensional structure where the harder material is positioned inside the softer, more conductive material. This dimensional arrangement allows the piercing portion to provide mechanical strength for penetration while the conductive portion surrounds it to ensure optimal electrical contact with the metal pad.
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
This design improves the electrical connection by forming a rupture surface on the metal pads, thereby stabilizing the contact and enhancing signal transmission quality.
Implementation Method 1
the piercing portion is designed to pierce through the oxidation layer on metal pads, creating a rupture surface for improved contact
Data Source
AI summary
A probe card device includes a first die, a second die, and a plurality of rectangular probes. Each of the rectangular probes includes a middle segment, two extending segments, and two contact end segments. In each of the rectangular probes, the two extending segments are respectively arranged in the first die and the second die, the two contact end segments respectively extend from two opposite ends of the two extending segments along a direction away from the middle segment, each of the two contact end segments includes a conductive portion, and at least one of the two contact end segments includes a piercing portion partially embedded in the conductive portion thereof. A conductivity of the piercing portion is less than that of each of the two conductive portions, and a Vickers hardness number of the piercing portion is larger than that of each of the two conductive portions.