Contactor for testing miniaturized devices and components

A contactor has a film substrate of an insulating material and plural wiring patterns on the substrate. A first end of each wiring pattern extends out from a first edge of the substrate as a first contact terminal and a second end of each wiring pattern extends out from a second edge of the substrate as a second contact terminal, and a part of the contactor located between the first end and second end can be deformed resiliently.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is based on Japanese priority application No. 2002-002744 filed on Jan. 9, 2002, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to contactors, and especially to a contactor making a contact to electronic components such as a large-scale integrated circuit and a contact process that uses such a contactor.

In recent years, the development of production technology in the field of semiconductor substrate is remarkable. Associated with this, interconnection patterns of large-scale integrated circuits are miniaturized, and along with this, the terminals of large-scale integrated circuits are also miniaturized. Further, the number of the terminals used in an LSI is increasing with remarkable rate.

The demand of miniaturization and high-density mounting is acute especially in the apparatuses that use a large-scale integrated circuit. For example, the number of mobile apparatuses (cellular phones, mobile personal computers, video integrated cameras etc.), in which downsizing is demanded, or high-performance computers in which the distance between adjacent LSIs has to be minimized for guaranteeing high speed operation, is increasing rapidly.

The foregoing demand also affects on the shipment mode of LSIs. Thus, the cases are increasing for shipping unpackaged LSI chips while guaranteeing the operability thereof as known as KGD (Known Good Die), or shipping the LSIs in the form of CSP (Chip Size Package), which is a small-sized package having the size of a chip.

From these circumstances, there is a need of a contactor capable of making a contact with a large number of miniature pin terminals with certainty for testing the LSIs.

Also, from the viewpoint of efficient test of LSIs, there is emerging a need of full test, in which all the tests such as final test (FT) or burn-in (BI) test are conducted for each of the LSIs in the state of wafer, before the wafer is divided into individual LSI chips. By using the full test in the state of wafer, following effects are expected.

First, the efficiency of handling is improved as compared with the case of conducting the testing on separate chips. When the size of the chips is different, it should be noted that the compatibility of the handling equipment used for the testing is lost. In the case the testing is conducted in the state of wafer, on the other hand, it becomes possible to convey the wafers of standard outer size one after another. Further, it becomes possible to control the defect information in the form of wafer map.

In the case the art of wafer-level CSP, which is subjected to intensive research and development in recent years, is used, it is potentially possible to conduct the entire process steps from the wafer process up to the assembling step in the form of the wafer. Thus, if it becomes possible to realize the test process in the state of wafer, the entire steps from the wafer process to the packaging process (assembling process) can be conducted in the state of the wafer, and the efficiency of production of LSI chips would be improved significantly.

However, as noted before, it has been difficult to realize a conductor that can contact the terminals of plural LSIs on a wafer or the terminals of entire LSIs on the wafer, in view of miniaturization of individual LSIs and hence the terminals thereof, and further in view of increasing number of the terminals.

Hereinafter, typical examples of conventional contactors (probe cards or sockets) will be summarized.

(1) Needle Type Mechanical Probe

A needle type mechanical probe has a construction of disposing a plurality of needles formed of a tungsten wire and the like on a contactor substrate of an insulating material in correspondence to respective terminals of the LSIs to be tested. Generally, a cantilever structure has been used in which the needles are provided so as to extend obliquely over the LSI wafer. Further, there is a proposal of disposing needles in a vertical direction to the terminals of the tested LSIs, by providing resiliency to the needles.

(2) Membrane Type Probe

A membrane type probe has a structure of a film circuit having a metal projection (referred to hereinafter as “bump”) for the contact electrode of the probe.

An anisotropic conductive rubber uses an elastic rubber as an insulating base material and has a structure in which a conductive material that extends only in the thickness direction of the rubber base material such as a metal wire is incorporated.

Further, the Japanese Laid-Open Patent Application 10-111316 official gazette discloses a contactor in which an end part of the wire, extending out from an edge of a substrate, is used for a connection terminal that makes a contact with the semiconductor device to be tested and the terminals extending at the other edge of the substrate is used for the measurement terminal.

On the other hand, the abovementioned needle type mechanical probe has problems such as:

a) High cost of forming a large number of needles or pins individually;

b) Limitation in the precision of the needle tip due to the construction in which a large number of needles are arranged individually; and

c) Restriction imposed on the arrangement of the needles in view of the oblique arrangement of the needles.

Thus, it has been difficult to use a needle type mechanical probe for the contactor that makes a contact with plural LSIs at the same time.

Further, the abovementioned membrane type probe has the problems as summarized below.

a) Individual contact electrodes cannot move freely

Because the contact electrode is connected to a polyimide layer forming the insulating substrate, the movable range of the individual electrode is limited. Also, in view of the fact that the contact electrode is formed of a metal bump of a hard metal that lacks flexibility, there arises a problem in that a defective contact may be caused in the case there exists a change of height between the bump electrodes.

b) High Cost

The bump constituting a contact electrode is generally formed by plating a metal. Thus, it takes time for forming a bump and the cost is inevitably increased.

Furthermore, the anisotropic conductive rubber has problems summarized as below.

a) Limited Lifetime

In the case it is used at high temperatures, in particular (it should be noted that the BI test is carried out usually at the temperature of 125° C. or more), the rubber part undergoes plastic deformation, and it can be used for only a dozens of time at best.

b) It cannot be used for the case of narrow electrode pitch.

Because it is difficult to incorporate a conductive material into a rubber, the pitch of 200-150 μm is thought as being a practical limit.

Also, the contactor disclosed in the Japanese Laid-Open Patent Application 10-111316 official gazette has a disadvantage in that it is difficult to achieve a contact for all the electrode terminals in the case there exists a variation of height in the electrode terminals of the semiconductor device to be tested, in view of insufficient stroke of the contactor terminal in the longitudinal direction. Further, there can be a possibility that sufficient contact cannot be achieved in the case the thermal expansion coefficient of the semiconductor device to be tested is different from that of the base material of the contactor as a result of displacement caused at the time of the high temperature test such as in the case of the burn-in test.

Thus, the conventional contactors have the problems summarized as follows.

1) Insufficient stroke of the contactor contact terminals

Thus, in such a conventional contactor having insufficient stroke (elastic deformation) for the contact part, a sufficient contact is achieved only when it is caused to make a contact with an aluminum pad on a wafer, in which the variation of the height is relatively small, or in the case it is used for a narrow area of the wafer. However, in the case of a wafer level CSP or molded packages formed by a simultaneous molding process, the terminals or balls on the package generally have a large variation of height, and it becomes difficult to achieve a sufficient contact by using such a conventional contactor having a small stroke or elastic deformation in the contact part. This problem becomes especially serious in the case the contactor is used to make a simultaneous contact with a thin wafer, which tends to have a warp. It should be noted that the warp of a wafer tends to increase when the thickness of the chip is reduced.

2) Positional deviation by the difference of the thermal expansion coefficient

The LSI wafer to be tested is generally formed of silicon (Si). It should be noted that the coefficient of linear thermal expansion is about 3 ppm in the case of silicon, while in the case of an insulated substrate used for the contactor such as a resin, the value of the coefficient of linear thermal expansion becomes several ten ppm (13˜30 ppm, for example). Thus, even in the case the contactor is contacting properly at ordinary temperatures, the location of the contactor may be deviated due to the difference of the coefficient of linear thermal expansion when it is used at a high temperature as in the case of a BI test. In an extreme case, the contactor may miss the intended terminal or make a contact with a terminal next to the intended terminal. Further, a similar problem occurs also in the case of the wafer level CSP or packages molded by a simultaneous molding process, in view of the fact that the coefficient of linear thermal expansion is different between the insulated substrate material and the package material such as seal resin. In the case polyimide is used for the insulating substrate, for example, the linear thermal expansion coefficient takes a value of about 13 ppm and there can occur a displacement as much as 100 μm at the peripheral part of an 8-inch wafer, which has a diameter of about 100 mm, when it is heated to 125° C., even in the case the contactor is aligned properly at ordinary temperature.

SUMMARY OF THE INVENTION

Accordingly, it is a general object to provide a novel and useful contactor and a fabrication process as well as a contact process wherein the foregoing problems are eliminated.

Another and more specific object of the present invention is to provide a contactor that can achieve a positive contact to terminals of plural semiconductor devices as in the case of a wafer-level semiconductor device even when the semiconductor device and the terminals thereof are miniaturized.

Another object of the present invention is to provide a contactor for electrically connecting a substrate of a testing apparatus with an object to be tested, comprising:

a film substrate of an insulating material; and

a plurality of wiring patterns provided on said substrate;

a first end of each wiring pattern extending out from a first edge of said substrate as a first contact terminal,

a second end of each wiring pattern extending out from a second edge of said substrate as a second contact terminal,

wherein a part of said contactor located between said first end and second end can be deformed resiliently.

According to the present invention, it becomes possible to obtain a contact force by utilizing the resilient deformation of the substrate or wires of the contactor, and it becomes possible to realize a contactor of simple structure not using a special resilient member. In the present invention, the contact terminals are provided as a part of the wires, and thus, the contactor is easily formed in conformity with a minute pitch of the electrodes by way of patterning process. Further, the spring constant of the wires or the substrate is small, and it becomes possible to realize a large stroke for the contact terminals. Thereby, it becomes possible to make a contact with a large number of electrodes simultaneously in a single step. Also, it is possible to mount various electronic components on the substrate of the contactor.

Further, according to the present invention, the contact terminals can be arranged in a two-dimensional array, and thus, the contactor of the present invention can be used for testing an area-array type semiconductor device, and the like.

Further, according to the contactor of the present invention, it becomes possible to prevent the deformation of the substrate even in the case there is a difference of coefficient of thermal expansion between the substrate and a spacer provided between adjacent substrates, as the substrate follows the thermal expansion of the spacer Further, according to the contactor of the present invention, it is possible to align the contact terminals accurately to the electrodes of the tested body by using a contact terminal guide.

According to one mode of the present invention, the movement of the contact terminals caused by thermal expansion can be set substantially identical with the movement of the electrodes of the test body, and it becomes possible to eliminate the displacement of the contact terminals with respect to the electrodes on the tested body even when the testing is conducted at elevated temperatures.

Other objects and further features of the present invention will become apparent from the following detailed description when read in conjunction with the attached drawings.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is an oblique view of the contactor according to a first embodiment of a present invention.

As represented inFIG. 1, the contactor of the first embodiment of the present invention is formed of two thin substrates2-1and2-2and a plurality of wires3. The substrates2-1and2-2are thin substrates of an insulating material such as polyimide. The substrates2-1and2-2are disposed in a spaced manner and the plural wires3are provided parallel with each other so as to connect the substrates2-1and2-2.

The wires3are formed of thin lines of a conductive metal such as copper. The wires3are capable of causing elastic deformation to some extent. Each of the wires3has an end part functioning as a contact terminal3aand another end part functioning as a contact terminal3b.

FIG. 2is a diagram showing the state for the case the contactor ofFIG. 1is disposed between an electronic component and a probe substrate.

Referring toFIG. 2, it can be seen that a contactor1is disposed between a probe substrate4and electronic component5. The probe substrate4is a substrate located at the side of a circuit tester and is connected to a testing device not illustrated. On the other hand, the contact terminals3bof the contactor1are arranged so as to make a contact with corresponding electrodes4aof the probe substrate4. The electronic component5may be a semiconductor device (LSI etc.) to be tested and carries plural electrodes5aon a surface thereof. Thereby, the contact terminals3aof the wires3make a contact with the corresponding electrodes5a.

Thus, the contactor1is arranged between the probe substrate4and the electronic component5and the contact terminals3bof the wires3are contacted with the electrodes4aof the probe substrate4and the contact terminals3aare contacted with the electrode5aof the electronic component5. With this, the electrodes5aof the electronic component are connected to the probe substrate4and hence to the testing device electrically, and it becomes possible to conduct a test of the electronic component5while causing to flow an electric current to the electronic component5.

It should be noted that the wires3are arranged parallel with each other with an interval (pitch) identical with the interval of the electrodes5aof the electronic component5. In the case the electronic component5is an LSI of narrow electrode pitch and the electrodes5aare arranged with an interval of 40 μm, for example, each of the wires3may have a width of 20 μm and arranged with an interval of 20 μm. The process of forming the of contactor1will be explained later in detail.

It should be noted that, because the contactor1has a simple structure of including only the substrates2-1and2-2and the wires3, it is easy to form the wires3with a small pitch. Thus, the contactor of the present embodiment can be used successfully to the semiconductor devices of narrow electrode pitch as in the above case.

It should be noted that the contactor1is contacted to the electronic component5in the state in which it is mounted on the probe substrate4. Thereby, the contactor1is fixed to the probe substrate4by mounting the substrate2-2of the contactor1on the probe substrate4by means of a support mechanism6. The support mechanism6urges the contactor1to the probe substrate4such that the contact terminal3bs are contacted to the corresponding electrodes4aof the probe substrate4. In this state, the contactor1is urged to the electronic component5and the contact terminals3aare contacted with the electrodes5aof the electronic component5.

When the contactor1is pressed between the probe substrate4and the electronic component5, the wires3undergo elastic deformation between the substrate2-1and the substrate2-2. Thereby, it becomes possible to achieve a positive contact between the contact terminals3aand the electrodes5aof the electronic component5and also between the contact terminals3band electronic component5by the resilience of the wires3.

It should be noted that the wires3are formed of a thin band of a metal and has a relatively small spring constant. Therefore, an appropriate contact force is maintained even in the case the distance between the probe substrate4and the electronic component5is changed variously.

FIG. 3is an oblique view diagram showing a contactor1A according to a modification of the abovementioned contactor1.

It should the contactor1A ofFIG. 3has a construction similar to that of the contactor1ofFIG. 1, except that there is provided a deforming part3cbetween the substrate2-1and the substrate2-2in each of the wires3. In the example ofFIG. 3, the deformable part3chas a zigzag form, and thus, the wire3easily extends or shrinks in the longitudinal direction thereof.

By providing the deformable part3cin the wires3as shown inFIG. 3, it is possible to obtain a contact force by the elastic deformation of the deformable part3c, and it becomes possible to provide a contactor having a reduced spring constant. Further, it should be noted that the deformable part3cis not limited to the zigzag shape as shown inFIG. 3but can take any other forms such as a trigonometric function form or U-shaped form, as long as it can be extended or compressed in the longitudinal direction of the wires3.

Next, a second embodiment of the present invention will be explained with reference to FIG.4.

FIG. 4is an oblique view diagram of a contactor11according to a second embodiment of a present invention.

Referring toFIG. 4, the contactor11also has a construction similar to the abovementioned contactor1in that it is attached to the probe substrate4. Thus, the contactor11is provided between the probe substrate4and the electronic component5. The explanation that overlaps with those explained before will be omitted.

In contactor11shown inFIG. 4, it should be noted that the wires3are formed on a single substrate12, while the substrate12itself has a construction of causing a deformation. Thus, the wires3undergo an elastic extension or contraction in the longitudinal direction thereof together with the substrate12. In other words, the wires3undergo bending together with the deformation of the substrate12. Preferably, the substrate12is formed of an insulation material such as a thin polyimide film.

In the case of the present embodiment, the spring constant of the contactor11is decided by the spring constant of the substrate12and the spring constant of the wires3.

In the case the spring constant of the substrate12is large, it is preferable to provide a cut into the part of the substrate12that undergoes the deformation so as to facilitate the deformation.

By providing a cut into the substrate12like this, it is possible to control the spring constant of the contactor11to be substantially equal to the spring constant of the wires3.

FIGS. 5A and 5Bare oblique view diagrams showing a contactor11A according to a further modification of the contactor11of FIG.4.

Referring toFIG. 5A, there is provided an opening12ain the substrate12in the contactor11A of FIG.5A. It should be noted that the opening12ais formed in the part of the substrate12that undergoes syncline-mode deformation such that the wires3are bent inwardly. More specifically, the opening12ais provided to the substrate in correspondence to the part in which occurs accumulation of compressive strain and associated deformation in the substrate12. Thus, by cutting out the substrate12in correspondence to such a part, the deformation of the substrate12is substantially facilitated. Further, as shown inFIG. 6, the wires3can deform or deflect freely without being constrained by the substrate12at the part where the opening12ais provided. Therefore, the substrate12and the wires3are deflected smoothly without applying unusual force to the wires3, and the overall spring constant of the contactor can be reduced. Of course, it is possible to provide the opening12ato all of the deflection part as shown in FIG.5B.

Next, a third embodiment of the present invention will be explained with reference to FIG.7.

FIG. 7is a side view of the contactor according to a third embodiment of the present invention.

ReferringFIG. 7, the contactor21of the third embodiment includes a single substrate22and plural wires3formed on the substrate22. Further, plural openings22aare provided in the substrate21. In the part of the substrate22in which the opening22ais provided, the rigidity of the substrate223is decreased, and it becomes possible to curve the substrate21easily together with the wires3. In other words, the spring constant of the contactor21is reduced by providing the opening22a, and the overall the spring constant of the contactor is reduced.

It should be noted that the opening22ashown inFIG. 7is formed near the part of the substrate22in which the wires3are formed. Thereby, the substrate22is left in the part on which the wires3are provided. As shown inFIG. 8, instead of forming the openings22aof7, it is also possible to form large openings22bso as to facilitate deformation of the wires3further. In this case, the wire3can be deformed freely without constraint by the substrate22, and the spring constant of contactor21A can be reduced further.

Next, a fourth embodiment of the present invention will be explained with reference to FIG.9.

FIG. 9is an oblique view of a contactor31according to a fourth embodiment of the present invention.

Referring toFIG. 9, the contactor31includes a substrate21and plural wires3formed on the substrate32. The substrate32, in turn, is formed of a first substrate part32A and a second substrate part32B. The first substrate part32A is formed by a material having a relatively large rigidity while the second substrate part32B is formed of a material having a smaller rigidity. Thus, when an urging force is applied to the contact terminals3aand also the terminals3bof the contactor31, the first substrate part32experiences no or little deformation, while the second substrate part32B is deformed heavily.

According to the present embodiment, the spring constant of the contactor as a whole is primarily determined by the second substrate part32B. Further, the wires3are supported by the first substrate part32A and the second substrate part32B. Therefore, the separation of the adjacent wires3can be maintained constant. Contact of adjacent wires3can be prevented.

Next, a fifth embodiment of the present invention will be described with reference toFIGS. 10A and 10B.

FIGS. 10A and 10Bare side view diagrams of a contactor41according to the fifth embodiment respectively in a normal state where the contactor41is not deformed and in a deformed state in which the contactor41is deformed.

Referring toFIGS. 10A and 10B, the contactor41is has a structure in which the contactors11of the second embodiment shown inFIG. 4are overlaid with intervening spacers42. For the spacer42, an insulating resin material or a resin film is suitable, while any insulating material that can support two of such substrates in a mutually separated state can be used for the spacer42. Thereby, the spacer42is fixed on the substrate12on the part that does not cause deformation.

It should be noted that the contactor41has plural wires3along the surface of the substrate12and a plurality of substrates12are stacked perpendicularly to the surface on which the wires3are provided. Thereby, it becomes possible to arrange the contact terminals3aand also the contact terminals3bin a two-dimensional, matrix state. Thereby, it becomes possible to test the semiconductor devices in which the electrode terminals are arranged in a two-dimensional array.

FIG. 11is a side view diagram that showing a first modification of the contactor41shown in FIG.10.

Referring toFIG. 11, the contactor41A has a construction similar to that ofFIGS. 10A and 10Bin which the spacer42is replaced with a spacer42A of wide width. By changing the width of the spacer42like this, it becomes possible to change the arrangement of the contactor terminals3aand3bof the contactor in accordance with the arrangement of the terminals5aof the electronic component5.

FIG. 12is a side view diagram showing a second modification of the contactor ofFIGS. 10A and 10B.

Referring toFIG. 12, the contactor41B has a construction in which two contactors11are stacked with an angle by interposing spacers42B therebetween. In other words, the spacer42B has a narrow width in the part close to the contact terminals3a, while the width of the spacer42B increased toward the contactor terminals3b.Therefore, it becomes possible to secure a large pitch for the contact terminals3bwhile simultaneously making a contact with the electrodes5aof narrow pitch.

It should be noted that, in the embodiment shown inFIGS. 10A and 10B, plural number of the contactors11of the second embodiment are stacked. It is of course possible to stack any of the contactors of the first embodiment, third embodiment or fourth embodiment.

In the construction in which plural contactors are overlaid via spacers, there is a possibility that the substrate may experience deformation by a thermal stress occurs in the case there is a difference of coefficient of thermal expansion between the spacer and the substrate.

In order to avoid this, it is preferable to apply a processing to the substrate as shown inFIGS. 13A and 13B.

Referring toFIG. 13A, it can be seen that there is formed a cut in the substrate12along the wires3as shown by dotted lines. Further, it is also possible to remove a part of the substrate12along the wires3with a predetermined width as shown in FIG.13B. Thereby, the substrate12is divided into a plurality of substrate pieces each corresponding to a wiring pattern3.

In the case the electronic component5is a semiconductor device formed on a silicon wafer, for example, it is possible to set the amount of movement of the contact terminals3a, caused by thermal expansion of the contactor, to be equal to the amount of movement of the electrodes of the semiconductor device caused as a result of thermal expansion of the wafer, by forming the spacer24by silicon.

Next, a sixth embodiment of the present invention will be described with reference toFIGS. 14A and 14B.

FIGS. 14A and 14Bare side views of a contactor51according to the sixth embodiment of the present invention, whereinFIG. 14Ashows the condition in which the contactor51is attached to the probe substrate4whileFIG. 14Bshows the state in which the contactor51is urged against the electrodes5aof the electronic apparatus5for making a contact.

Referring to the drawings, it should be noted that the contactor51is the one corresponding to the contactor1A ofFIG. 3in which the substrate2-2is divided in correspondence to each of the wires3. By doing so, it becomes possible that each contact terminal3acan urge the corresponding electrode5aindividually. Even in the case there is a variation in the height of the electrodes of the electronic apparatus5, the deformable part3cis extended in each of the wires3as shown inFIG. 14B, and it becomes possible to achieve an appropriate contact for all of the electrodes5aby the contact terminals3a.

Next, expiation will be made on the production process of the contactor1with reference toFIGS. 15A-18B.

The first method of producing the contactor1includes the step of forming the wires3on the substrate12as shown in FIG.15A. Further, the central part of the substrate12is removed thereafter as shown in FIG.15B.

Next, in the step ofFIG. 16A, a resist is provided on the substrate3carrying the wires3, and the resist is removed from a part where the substrate2is to be removed. Further, the substrate2is removed by conducting an etching process or laser irradiation process at the part not covered by the resist. As a result, the contactor1is obtained as represented in FIG.16B.

The second process of forming the contactor1is to divide the substrate1into two pieces and then provide the wires3as represented inFIGS. 17A and 17B. As shown inFIG. 18A, the substrate12is punched by using a mold into two separate pieces2-1and2-2, and the wires3are provided so as to bridge the substrates2-1and2-2as represented in FIG.18B. In this case, the wires3may be formed of a copper wire, and the like.

FIGS. 19A and 19Bare diagrams explains the process of producing the contactor1A of FIG.3.

Referring toFIG. 19A, the wires3are formed on the substrate2at first. It should be noted that such wires3include a deformable part3cof zigzag form, wherein such wires can be formed easily by etching a copper sheet attached on the substrate2by conducting an etching process.

Next, in the step ofFIG. 19B, the substrate2is separated into the substrates2-1and2-2according to the process similar to that ofFIGS. 16A and 16B, and the contactor1A is obtained.

FIGS. 20A and 20Bshow the example of the case in which the deformable part of the contactor1A is formed to have an S-shaped form. The process itself is the same as in the process ofFIGS. 19A and 19B.

FIG. 21is a diagram showing the case of applying a thermal treatment or plating process to the deformable part3cof the wires3for the case of the contactor ofFIGS. 20A and 20B. By applying a heat treatment, or alternatively a plating process of nickel (Ni), palladium (Pd), nickel alloy, and the like, to the deformable part3cof the wires3, it becomes possible to adjust the resiliency of the deformable part3cand hence the spring constant of the contactor.

FIG. 22is a diagram showing the process of applying an insulation coating of polyimide resin, and the like, on the deformable part3cof the wires3for the case of the contactor ofFIGS. 20A and 20B. By applying an insulation coating, it becomes possible not only to adjust the resiliency of the deformable part but also to eliminate short-circuit even in the case the deformable parts3care contacted with each other.

FIG. 23shows a modification of the contactor1in which the gap between the substrates2-1and2-1is filled with an elastic rubber resin such as a silicon rubber. Also,FIG. 24shows an example similar toFIG. 22in which the gap between the substrates2-1and2-2of the abovementioned contactor1A is filled with an elastic rubber resin like a silicon rubber. By filling the gap between the substrates2-1and2-2with the elastic rubber resin, it becomes possible to support the wires3while simultaneously insulating the same from one another. Thereby, it becomes possible to prevent contacting of the wires3with each other.

Next, a seventh embodiment of the present invention will be explained.

FIG. 25is a front view diagram explaining the principle of the contactor according to a seventh embodiment of the present invention.

Referring toFIG. 25, the contactor61shown inFIG. 25is formed of the contactor1A shown inFIG. 3 and acontact terminal guide62.The contact terminal guide62has guide holes62aeach being inserted with a corresponding contact terminal3aof the contactor1A. The contact terminal guide62is disposed in the vicinity of the electrodes5aof the electronic component5to be tested and guides the contact terminals3aso that each terminal3amakes a correct contact with the corresponding electrode5aof the electronic component5.Thus, the guide holes62aare provided in the contact terminal guide62with the same arrangement of the electrodes of the electronic component5, and the contact terminals3aare positioned correctly in correspondence to the electrodes5aof the electronic component5by being inserted into the corresponding guide holes62a.

FIGS. 26A and 26Bare cross-sectional diagrams showing the form of the guide hole62a.

Referring toFIG. 26A, it can be seen that the guide hole62ahas sloped surfaces at both lateral sides thereof. On the other hand, the guide hole62ashown inFIG. 25Bhas a sloped surface on one side thereof. These sloped surfaces facilitate the insertion of the contact terminals3aand achieve an accurate positioning of the contact terminals3a.

FIG. 27is a front view showing the contactor61in the state that the contactor61is attached on the probe substrate4.

Referring toFIG. 27, the substrate2-1of the contactor1A is attached to the probe substrate4by a support mechanism. In addition, the terminal guide62is attached to the probe substrate by the support mechanism63. In the state that the contactor1A and the contact terminal guide62are attached to the probe substrate4, the contact terminals3bof the contactor1A make a contact to corresponding electrodes4aof the probe substrate. Thereby, it should be noted that the contact terminals3aextend by penetrating through the corresponding guide holes62aof the guide62.The top end of the contact terminals3aprotrudes slightly from the guide hole62a.

FIG. 28is a diagram showing the example in which the contact terminal guide62A is formed of a material identical with the silicon wafer or a material having a generally identical coefficient of thermal expansion, for the case in which a semiconductor device formed on a silicon wafer is used as the electronic component5to be tested.

For example, the contact terminals3aand the electrodes5amay be displaced relatively with each other at the time of high temperature test such as the burn-in test when there is a large difference of coefficient of thermal expansion between the electronic component (silicon wafer) and the substrate2-2of the contactor1A.

Thereby, there may be a problem in that the contact terminal3amisses the electrode5a.When the contact terminal guide62A is formed with the material having the same material of the electronic component (silicon wafer) or a material having a similar coefficient of thermal expansion, the amount of displacement with the thermal expansion becomes identical and the problem of relative displacement of the contact terminals3aand the electrodes5adisappears. Thereby, it becomes possible to align the contact terminals3awith the corresponding electrodes5a.

Hereinafter, examples of changing the material of the contact terminal guide according to the test body will be explained with reference toFIGS. 29,30and31.

The example ofFIG. 29shows the case in which the electronic component5is a wafer level CSP and the contact terminal guide62B is formed with a material having a coefficient of thermal expansion equivalent to that of the seal material or coating material of the wafer level CSP. The seal material of wafer level CSP includes a mold resin of a package, a polyimide resin coating, a wire substrate, and the like.

The example ofFIG. 30represents the case in which the electronic component5is a semiconductor device was attached to a dicing film and the contact terminal guide62C is formed of a material having a coefficient of thermal expansion equivalent to that of the dicing film. The dicing film is formed of a comparatively cheap material of polyethylene and generally has a relatively large coefficient of thermal expansion.

The example ofFIG. 31represents the case in which the electronic component5is a package semiconductor device formed of a simultaneous molding process. In the case ofFIG. 31, the contact terminal guide62D is formed of a material having a coefficient of thermal expansion equivalent to that of the seal material or base material of the package semiconductor device.

For example, the base material of the package semiconductor device may be formed of a printed wire board, a TAB substrate, a ceramic substrate, and the like.

By properly selecting the material forming the contact terminal guide such that the contact terminal guide has a coefficient of thermal expansion equivalent to that of the test body as noted above, the problem of positional offset of the contact terminals3aby the thermal expansion effect is prevented and the test can be conducted with high reliability.

By changing the coefficient of thermal expansion of the contact terminal guide with regard to the coefficient of thermal expansion of the test body, on the other hand, it is possible to achieve the effects as follows. In the case the coefficient of thermal expansion of the contact terminal guide62is set to be larger than the coefficient of thermal expansion of the electronic component5used for the test body as shown inFIG. 32A, for example, there occurs a movement of the contact terminals3aon the electrodes5aas a result of difference of the coefficient of thermal expansion as represented in FIG.32B. With this movement of the contact terminals3a, it is possible to attain the effect of reducing the contact resistance between the contact terminal3aand the electrode5a, by breaking the natural oxide film and the like formed on the contact electrode5a.Also, a similar effect can be achieved also in the case the coefficient of thermal expansion of the contact terminal guide62is smaller than the coefficient of thermal expansion of the electronic component5.

FIGS. 33A and 33Bare diagrams explaining the form of the guide hole62ashown inFIGS. 26A and 26B, whereinFIG. 33Ais a diagram showing the guide hole62aas viewed from the top direction whileFIG. 26Bis a diagram explains the guide of contact terminal3a.

Viewing from the direction of the electronic component5, the guide hole62ais an elongated hole and a slope surface62bis extending from an end part thereof. Thereby, it should be noted that a contact terminal3ais adjusted so as to locate right over a corresponding electrode5aof the electronic component5and makes a contact with the electrode5aby descending from the state illustrated in FIG.33B.

Now, when the position of the contact terminal3ais offset slightly and the contact terminal3ahits the slope surface62b, the tip end of the contact terminal3ais eventually guided to the electrode5aby sliding along the slope surface62b.

Furthermore, it should be noted that the slope surface62bis not limited to a flat surface but may be a curved slope surface as shown in FIG.34. Further, it is also possible to provide a curved slope surface62bso as to surround the guide hole as shown inFIGS. 35A and 35B.

FIGS. 36A-36Care diagrams explaining the effect of the abovementioned slope62b.

As shown inFIG. 36A, there may be formed a deposit on the tip end of the contact terminal3a, wherein the deposit is removed from the contact terminal as a result of the tip end of the contact terminal3asliding along the slope surface62bas shown in FIG.36B. Thus, as shown inFIG. 36C, the tip end of the contact terminal3a, from which the deposits have been removed, is guided with certainty to the electrode5and achieves an excellent contact.

Next, various modifications and applications of the contactors of the abovementioned embodiment will be explained.

FIG. 37is a diagram showing the construction in which the contactors noted above are stacked in conformity with the electrode arrangement of a peripheral type semiconductor device.FIG. 38is a diagram showing the construction in which the contact terminals3aare arranged in conformity with the electrode arrangement of an area array type semiconductor device. Also,FIG. 39is a diagram showing the construction of the contactor adapted in conformity with a semiconductor device having the electrodes in two rows along a periphery thereof.

FIG. 40is an oblique view showing the example in which the wires3are provided on the substrate2in the form of a microstrip line. Thus, the substrate2is formed by a dielectric material and a conductor2bformed of Cu, for example, is provided on the entirety of on surface thereof as a ground surface. Further, the wires3are provided on the opposite surface by a patterning process of a copper layer, for example for example. With this, a contactor suitable for testing a semiconductor device that processes a high frequency signal.

As an application of the structure shown inFIG. 40, it is also conceivable to surround the signal line of the contactor by a ground wire for improving the screening effect as shown in FIG.41.

FIG. 42is an oblique view showing an example in which a testing component70is mounted on the substrate2of the contactor. The electronic component70thus tested may be an A/D converter. According to such a construction, deterioration of the signal quality is prevented in the case an analog signal is supplied from the semiconductor to be tested, by converting the analog signal to a digital signal on the contactor. It is preferable to conduct such an A/D conversion in the part close to the tested body, and thus, it is preferable to provide the A/D converter on the contactor.

FIG. 43is an oblique view showing the construction that changes the pitch of wires3on the substrate2. Thus, when the wires3are formed on the substrate2by a patterning process, for example, the pitch of the contact terminals3aat the side of the tested body is set to be smaller in conformity with the electrode pitch of the tested body. On the other hand, the pitch of the contact terminals3bat the side of the probe substrate is increased. Such a construction can be formed quite easily by forming the wires3of the contactor by conducting a patterning process.

FIGS. 44A and 44Bare diagrams showing the example of performing a plating processing on a tip end part of the contact terminals3a.It should be noted thatFIG. 44Ashows the whole contactor. On the other hand,FIG. 44Bis a diagram showing the part inside the circle that shown inFIG. 44Aby a dotted line in an enlarged scale. The smaller the better for the contact resistance between the electrode of contactor terminal3aand electronic component5. For example, the contact resistance is reduced by forming a plating layer71of gold (Au), palladium (Pd), rhodium (Rd), platinum (Pt), and the like, on the contact terminals3a, which are formed of copper.

Also, in view of the fact that the tip end of the contact terminal3amakes a contact with the contact electrode5aof the electronic component5to be tested, it is preferable that the contact terminals3ahas a low affinity to the material of the electrode5a.In the case that the electronic component5is a semiconductor device, the electrodes5aare generally formed of a solder. In such a case, it is preferable to apply nickel (Ni) plating at the tip end part of the contact terminals3a. Here, it should be noted that the plating process is not limited to form a single plating layer but may include the process of forming plural plating layers.

FIGS. 45A and 445Bare diagrams explaining the example for the case a rough surface is made at the tip end part of the contact terminals.FIG. 45Ashows the entire contact, whileFIG. 45Bshows the contactor terminal inside the circle that shows inFIG. 45Aby a dotted line in an enlarged scale.

As shown inFIG. 45B, deposits or oxidation film formed on the electrode5aof the electronic component5is removed effectively by providing such a rough surface of the tip end of the contact terminals3a.Such a rough surface can be formed by controlling the plating process or by dipping the plated tip end of the contact terminals3ainto a chemical agent.

FIG. 46is a diagram showing various examples of the tip end part of the contact terminal3aand the electrode5aof the electronic component5. Any of these shapes may be used for the tip end of the contact terminals3ain conformity with the shape of the electrode5aof the electronic component5. In the case the wires3carrying the contact terminals3a thereon are formed by a patterning process, it should be noted that the contact terminals3acan be patterned into an arbitrary shape.