Method of and apparatus for producing electrically-conductive probe tips

Claim 1

A method of making an electrically conductive probe tip, comprising the steps of: (a) inserting a wire of electrically conductive and electrolytically erodible material into an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers so that a zone on said wire is exposed to said liquid layer, said wire is guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forms a free end of said wire extending into one of said electrically insulating layers; and (b) electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said wire being inserted in step (a) from above into a bath in which said liquid layer overlies an insulating liquid layer of greater specific gravity than said electrolyte solution, said free end extending downwardly into said insulating liquid layer.

Claim 2

A method of making an electrically conductive probe tip, comprising the steps of: (a) inserting a wire of electrically conductive and electrolytically erodible material into an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers so that a zone on said wire is exposed to said liquid layer, said wire is guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forms a free end of said wire extending into one of said electrically insulating layers; and (b) electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said wire being inserted in step (a) from above into a bath in which said liquid layer overlies an insulating liquid layer of greater specific gravity than said electrolyte solution, said free end extending downwardly into said insulating liquid layer.

Claim 5

A method of making an electrically conductive probe tip, comprising the steps of: (a) inserting a wire of electrically conductive and electrolytically erodible material into an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers so that a zone on said wire is exposed to said liquid layer, said wire is guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forms a free end of said wire extending into one of said electrically insulating layers; and (b) electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said zone of said wire being electrolytically eroded by spacedly juxtaposing said zone with an annular counterelectrode and connecting an electrolytic erosion current source across said wire and said counterelectrode.

Claim 6

A method of making an electrically conductive probe tip, comprising the steps of: (a) inserting a wire of electrically conductive and electrolytically erodible material into an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers so that a zone on said wire is exposed to said liquid layer, said wire is guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forms a free end of said wire extending into one of said electrically insulating layers; and (b) electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said zone of said wire being electrolytically eroded by spacedly juxtaposing said zone with an annular counterelectrode and connecting an electrolytic erosion current source across said wire and said counterelectrode.

Claim 8

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region; and means for exerting traction on said free end in a direction away from said region.

Claim 9

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region; and means for exerting traction on said free end in a direction away from said region.

Claim 11

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; and a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said layer forming part of a bath in which said liquid layer overlies an insulating liquid layer of greater specific gravity than said electrolyte solution, said wire being inserted from above into said bath with said free end extending downwardly into said insulating liquid layer.

Claim 12

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; and a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said layer forming part of a bath in which said liquid layer overlies an insulating liquid layer of greater specific gravity than said electrolyte solution, said wire being inserted from above into said bath with said free end extending downwardly into said insulating liquid layer.

Claim 13

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; and a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said counterelectrode being a ring electrode surrounding said zone.

Claim 14

An apparatus for making an electrically conductive probe tip, comprising: means forming an electrolytically effective liquid layer formed by an electrolyte solution and flanked by electrically insulating layers; means for guiding a wire of electrically conductive and electrolytically erodible material into said liquid layer so that a zone on said wire is exposed to said liquid layer, said wire being guided in a region of said wire adjacent said zone, and a portion of said wire on an opposite side of said zone from said region forming a free end of said wire extending into one of said electrically insulating layers; a counterelectrode spacedly juxtaposed with said zone and in contact with said liquid layer; and a source of electrolytic erosion current connected to said wire and said counterelectrode for electrolytically eroding said zone of said wire to progressively reduce a cross section of said wire in said zone until said free end is separated by the electrolytic eroding of said zone from said region, thereby forming a probe tip on said region, said counterelectrode being a ring electrode surrounding said zone.