A method for manufacturing a conductive film as well as the structure
thereof and a probe card using the same are provided in the invention.
The conductive film is substantially a stacked structure of a specific
thickness formed by the adhering and stacking of at least a substrate in
a vacuum environment by the use of surface processing and mechanical
healing whereas each substrate has an array of metal micro-threads formed
thereon, in which the plural metal micro-threads, each being wrapped in
an insulating film, are arranged on the substrate to form the array in a
unidirectional and single-layered manner by the use of a LIGA process and
polymer thin film technology. In an exemplary embodiment, the insulating
film can be a polymer thin film of high dielectric constant, being made
of a material such as polydimethylsiloxane (PDMA) or polyimide (PI); and
the metal micro-thread is made of a high conductivity and high strength
Ni--Co alloy. Moreover, the so-formed conductive film can be cut into any
desired dimensions by the use of an energy beam, such as laser beam, ion
beam and plasma beam, etc. while combining the conductive film with a
panel so as to be used for forming a probe card with large area detection
ability that is low-cost, ease-to-maintain and capable of being adapted
for wafers of various bonding pad arrangements.