METHOD OF DETERMINING PROBING PARAMETERS FOR PROBE SYSTEM TO TEST DEVICE UNDER TEST, PROBE SYSTEM AND METHOD OF OPERATING THE SAME, NON-TRANSITORY COMPUTER-READABLE STORAGE MEDIA, METHOD OF TESTING UNPACKAGED SEMICONDUCTOR DEVICE, TESTED SEMICONDUCTOR DEVICE AND METHOD OF PRODUCING THE SAME, AND METHOD OF GENERATING VIRTUAL MARK IMAGE

A method of determining probing parameters for a probe system to test a DUT includes defining a SD-OD relation dataset according to the probe type of the probing assembly of the probe system and the contact pad type of the DUT, and providing the controller a skate distance value, for which the probe tip is set to skate after contacting the contact pad, or an overdrive value, for which the probing assembly and the DUT are set to be relatively moved after the probe tip contacts the contact pad, and a probe target position or a present probe position, to obtain both the skate distance value and the overdrive value and a position for positioning the probing assembly and the DUT to each other, thereby conveniently and quickly obtaining the required probing parameters for operating the probe system to test the DUT for great and consistent testing performance.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to test technology with a probing assembly and more particularly, to a method of determining probing parameters for a probe system to test a device under test, and a method of operating a probe system, a probe system, a non-transitory computer-readable storage media, a method of testing an unpackaged semiconductor device, a method of producing a tested semiconductor device, and a tested semiconductor device, which use the aforementioned method of determining the probing parameters, and a method of generating a virtual mark image.

2. Description of the Related Art

Referring toFIG.1AandFIG.1B, it is well known that when a probing assembly is utilized to test a device, the device under test (also referred to as “DUT” hereinafter) is disposed on a chuck. The probing assembly and the chuck are firstly relatively moved to the status that a probe tip11of a probe10of the probing assembly is in initial contact with a contact pad12of the DUT. At this time, the probe tip11of the probe10is located at an initial contact position P1, as shown inFIG.1AandFIG.1B. Then the probing assembly and the chuck are relatively moved along a vertical axis (i.e. Z-axis) for a distance referred to as overdrive OD, which is usually performed in a way that the chuck is moved from the contact height upwardly to approach the probing assembly, making the probe tip11of the probe10and the surface of the contact pad12of the DUT forced to abutted against each other positively. Meanwhile, the probe tip11of the probe10is deflected, which means it is moved on X-axis or Y-axis, thereby skating on the surface of the contact pad12for another distance referred to as skate distance SD and then stopped at a final contact position P2, producing a probe scratch, which is also called “probe mark”, on the surface of the contact pad12. The length of the probe scratch equals to the skate distance SD. To enable the probing assembly to provide great testing performance to the DUT and keep consistent testing performance, it is usually desired to produce the identical probe scratch in every time of testing, which means it is desired to have accurate initial contact position P1, final contact position P2and the skate distance SD.

Currently, before test begins, using a calibration substrate to determine the correct overdrive OD is necessary. However, this process is inconvenient and time-consuming. For example, in practical operation, the calibration substrate and the DUT have at least the difference in material. Therefore, even if the proper overdrive OD is obtained at the calibration substrate, it is still difficult to make sure that this overdrive OD, when being applied to the DUT, can make the probe tip11of the probe10stopped at the desired final contact position P2. When a calibration standard (testing circuit) on the calibration substrate serves as the DUT, multiple calibration measurements of overdrive OD are often required to determine which initial contact position P1ensures the probe tip11stops at the desired final contact position P2. This process is not only inconvenient and time-consuming, but also causes wear and tear to the probe or the calibration standard due to repeated operation. Additionally, errors in the calibration of overdrive OD may result in inaccurate final contact positions P2during practical testing, leading to incorrect test results. Especially, in high frequency testing, the accurate final contact position P2is even more important. Further specifically speaking, once the overdrive OD is determined, this setting will be applied to all DUTs on a substrate. Therefore, individual adjustment of overdrive OD for each DUT to ensure the probe tip11stops at the desired final contact position P2are impractical for achieving consistent and optimal testing results.

In addition, during the test, the use of an image-forming device, such as a microscope, is required for observing whether the probe tip11of the probe10initially contacts the contact pad12of the DUT at the desired initial contact position P1. However, the field of view (also referred to as “FOV”) of the image-forming device is very small. Therefore, the probe tip11of the probe10and the contact pad12of the DUT usually cannot be clearly recognized at the same time, unless the probe tip11of the probe10and the contact pad12of the DUT are on the same plane. But when on the same plane, the probe tip11of the probe10and the contact pad12of the DUT are already in contact with each other. It can be seen that even if the desired initial contact position P1is known, it is still difficult to position the probe tip11of the probe10at the desired initial contact position P1accurately. Therefore, it is difficult to produce consistent probe scratch, so that it is difficult to keep the testing performance of the probing assembly on the DUT great and consistent.

SUMMARY OF THE INVENTION

The present invention has been accomplished in view of the above-noted circumstances. It is an objective of the present invention to provide a method of determining probing parameters for a probe system to test a DUT, which can obtain the required probing parameters conveniently and quickly to enable the probing assembly to provide great and consistent testing performance.

To attain the above objective, the present invention provides a method of determining probing parameters for a probe system to test a DUT, which includes the steps of:defining a skate distance to overdrive relation dataset (also referred to as “SD-OD relation dataset” hereinafter) according to the type of a probe of a probing assembly of the probe system and the type of a contact pad of the DUT;providing one of a skate distance value and an overdrive value to a controller, the skate distance value being the distance, for which a probe tip of the probe is set to skate on the contact pad of the DUT after contacting the contact pad, the overdrive value being the distance, for which the probing assembly and the DUT are set to be relatively moved after the probe tip of the probe contacts the contact pad of the DUT;providing one of a probe target position and a present probe position to the controller, the probe target position being the position, at which the probe tip of the probe is predetermined to be stopped after skating on the contact pad of the DUT, the present probe position being the present position of the probe tip of the probe; andobtaining, with the controller and based on the aforementioned one of the skate distance value and the overdrive value and the SD-OD relation dataset, the other of the skate distance value and the overdrive value, and obtaining, based on the skate distance value and the aforementioned one of the probe target position and the present probe position, a position for positioning the probing assembly and the DUT to each other.

As a result, the SD-OD relation dataset can be stored in the controller beforehand. Alternatively, the relation between the skate distance and the overdrive can be measured with a calibration substrate before the test begins, and this relation dataset is then established in the controller. Afterward, providing predetermined skate distance value or overdrive value and the predetermined probe target position or the present probe position, the controller can use this relation dataset to calculate both the skate distance value and the overdrive value. Additionally, depending on the requirements of different alignment manners, the corresponding parameter can be calculated. For example, using the probe target position and the skate distance value to determine the position at which the probe tip should start contacting the contact pad of the DUT, such as the initial contact position P1shown inFIG.1B. In other words, once the SD-OD relation dataset has been established, the required parameters for testing the DUT with the probing assembly can be obtained as long as the user inputs certain parameters, such as the skate distance value and the probe target position, into the controller. It is unnecessary to perform, before every time of testing, the time-consuming initial setting steps, such as using the calibration substrate to find out the proper overdrive, performing many times of calibration measurement for the overdrive to obtain the initial contact position, and so on. Moreover, the method of the present invention ensures accurate parameters to stop the probe tip at the desired probe target position after skating on the contact pad of the DUT. Therefore, the present invention provides the method for determining the probing parameters in a probe system to test the DUT. This method not only saves time and offers convenience, but also enhances the testing accuracy by enabling the probing assembly to deliver consistent and excellent performance, thereby reducing wear on the probe and calibration substrate and extending their lifespan.

Preferably, as the example given in the previous paragraph, the probe target position is provided to the controller. The aforementioned position for positioning the probing assembly and the DUT to each other is a probe contact position. The probe contact position is the position, at which the probe tip of the probe is predetermined to start contacting the contact pad of the DUT, for the probe tip of the probe to be positioned at the probe contact position.

As a result, once the controller has determined the probe contact position, the probe tip of the probe can be directly positioned there before initiating the overdrive ON process, ensuring it reaches the desired probe target position.

More preferably, the method of determining the probing parameters for the probe system to test the DUT further includes the step of affirming that both the probe contact position and the probe target position are within an acceptable scope corresponding in position to the contact pad of the DUT.

As described above, the controller can perform the calculation through the SD-OD relation dataset to make the skate distance value, the overdrive value, the probe contact position and the probe target position all known. Therefore, after both the probe contact position and the probe target position are known, it can be further affirmed whether the two positions both fall within the acceptable scope corresponding in position to the contact pad of the DUT. This ensures that the probe tip of the probe will make positive contact with the contact pad of the DUT throughout the entire overdrive process, producing a proper probe scratch and thereby ensuring the testing accuracy even more.

More preferably, the method of determining the probing parameters for the probe system to test the DUT further includes the step of generating, with the controller, a virtual alignment mark showing the probe contact position for the probe tip of the probe to be aligned with the virtual alignment mark.

As a result, when the user performs the manual alignment, even though the microscope can only clearly show the probe tip of the probe but the contact pad of the DUT is blurred and unclear, as long as the virtual alignment mark is shown on the screen, the user can position the probe tip of the probe at the probe contact position accurately by aligning the probe tip of the probe with the virtual alignment mark. After that, when an overdrive ON process is performed, the probe tip of the probe can be ensured to be stopped at the desired probe target position. Besides, in the automatically positioning condition, the virtual alignment mark can be also shown on the screen for the user to know the present situation.

Preferably, instead of providing the probe target position to the controller, the present probe position is provided to the controller. Accordingly, the aforementioned position for positioning the probing assembly and the DUT to each other is a relative target position, wherein the relative distance between the relative target position and the present probe position equals to the skate distance value, for positioning the probing assembly and the DUT to each other by making the relative target position and the probing assembly moved relative to the DUT simultaneously and making the relative target position relatively moved to a position corresponding to the contact pad of the DUT.

As a result, the aforementioned position corresponding to the contact pad of the DUT can be visually set by the user without providing numeral value thereof to the controller. More specifically speaking, the aforementioned position corresponding to the contact pad of the DUT can be the position, at which the user predetermines the probe tip to be stopped after skating on the contact pad of the DUT, similar to the aforementioned probe target position but not set with numeral value and visually decided by the user during the operation. Based on the skate distance value and the present probe position, the relative target position can be obtained by calculation for the user to relatively move the relative target position to the probe stopped position decided by the user. Alternatively, even if the probe target position is known, the positioning can be performed without using the probe contact position, but using the relative target position obtained by calculation to relatively move the relative target position to the probe target position. In such condition, the aforementioned position corresponding to the contact pad of the DUT is the probe target position. The relative target position is moved along with the probing assembly relative to the DUT. As long as the relative target position is relatively moved to the aforementioned position corresponding to the contact pad of the DUT, the probe tip of the probe is located at a proper position on the contact pad of the DUT so that after an overdrive ON process is performed, the probe tip of the probe will be stopped at the desired position.

More preferably, the method of determining the probing parameters for the probe system to test the DUT further includes the step of generating, with the controller, a virtual alignment mark showing the relative target position, for the virtual alignment mark to be relatively moved to the aforementioned position corresponding to the contact pad of the DUT, so as to make the relative target position relatively moved to the aforementioned position corresponding to the contact pad of the DUT.

As a result, when the user performs the manual alignment, even though the microscope cannot clearly show the contact pad of the DUT and the probe tip of the probe at the same time, as long as the virtual alignment mark is shown on the screen and the virtual alignment mark and the probing assembly are simultaneously moved relative to the DUT, the user can align the virtual alignment mark with the probe target position in the condition that the probe target position is also shown on the screen. Alternatively, in the condition that the contact pad of the DUT is clearly shown on the screen, the user can relatively move the virtual alignment mark to the visually set probe stopped position. In this way, the probe tip of the probe is located at a proper position on the contact pad of the DUT so that after an overdrive ON process is performed, the probe tip of the probe will be stopped at the desired position. Besides, in the automatically positioning condition, the virtual alignment mark can be also shown on the screen for the user to know the present situation.

Preferably, the SD-OD relation dataset is established with the probe system and a calibration substrate by a process including the steps of:making the probe tip of the probe in contact with the calibration substrate;making the probe and the calibration substrate relatively moved on a vertical axis for an overdrive to make the probe tip skate on the calibration substrate to generate a skate distance, and using an optical image-forming device to observe and obtain the skate distance; andgenerating the SD-OD relation dataset with the controller based on the aforementioned skate distance and overdrive.

As a result, the user can provide various overdrives to perform the respective measurements at the calibration substrate to obtain the respective corresponding skate distances, so as to establish this SD-OD relation dataset in the controller. Afterward, when the probe whose type corresponds to this dataset is to be used to test the contact pad whose type corresponds to this dataset, the already established SD-OD relation dataset can be directly used to conveniently and quickly obtain the required probing parameters, thereby enabling the probing assembly to generate great and consistent testing performance.

The present invention further provides a method of operating a probe system, which corresponds to the above-described situation of performing the positioning by using the probe contact position. The probe system includes a probing assembly and a controller. The probing assembly includes a probe. The probe includes a probe tip for probing a contact pad of a DUT. The method of operating the probe system includes the steps of:performing, with the controller, the above-described method of determining the probing parameters for the probe system to test the DUT;positioning the probe tip of the probe at the probe contact position with the controller; andperforming, with the controller, an overdrive ON process which makes the probing assembly and the DUT relatively moved for the aforementioned overdrive value, so as to deflect the probe tip of the probe to skate to and then stop at the probe target position.

Through this operating method, accurate probing parameters can be obtained conveniently and quickly. Thereafter, using the probe contact position to perform the positioning and then using the overdrive value to perform the probing can allow the probing assembly to produce great and consistent testing performance, thereby achieving high testing accuracy.

The present invention further provides a method of operating a probe system, which corresponds to the above-described situation of performing the positioning by using the relative target position. The probe system includes a probing assembly and a controller. The probing assembly includes a probe. The probe includes a probe tip for probing a contact pad of a DUT. The method of operating the probe system includes the steps of:performing, with the controller, the above-described method of determining the probing parameters for the probe system to test the DUT;moving relatively the relative target position to the aforementioned position corresponding to the contact pad of the DUT with the controller; andperforming, with the controller, an overdrive ON process which is making the probing assembly and the DUT relatively moved for the overdrive value, so as to deflect the probe tip of the probe to skate to and stop at the aforementioned position corresponding to the contact pad of the DUT.

Through this operating method, accurate probing parameters can be obtained conveniently and quickly. Thereafter, using the relative target position to perform the positioning and then using the overdrive value to perform the probing can allow the probing assembly to provide great and consistent testing performance, thereby achieving high testing accuracy.

The present invention further provides a probe system which includes a chuck, a probing assembly, an optical image-forming device, and a controller. The chuck includes a chuck support surface configured to support a substrate. The substrate includes one or more DUTs. The probing assembly includes a probe. The probe includes a probe tip. The probe is configured to test the DUT. The optical image-forming device is configured to receive the optical image of at least a part of the probe system, including the image of at least a part of the probing assembly. The controller is programmed to perform the above-described method of determining the probing parameters for the probe system to test the DUT.

With this probe system, accurate probing parameters can be obtained conveniently and quickly to enable the probing assembly to provide great and consistent testing performance, thereby achieving high testing accuracy.

The present invention further provides a non-transitory computer-readable storage media which includes computer-executable instructions that, when executed, direct a probe system to perform the above-described method of determining the probing parameters for the probe system to test the DUT.

With this non-transitory computer-readable storage media, accurate probing parameters can be obtained conveniently and quickly to enable the probing assembly to provide great and consistent testing performance, thereby achieving high testing accuracy.

The present invention further provides a method of testing an unpackaged semiconductor device, which includes the steps of:providing at least one probing assembly, the at least one probing assembly including a probe, the probe including a probe tip, the probe tip of the probe being configured to mechanically and electrically contact an unpackaged semiconductor device;providing a controller programmed to perform the above-described method of determining the probing parameters for the probe system to test the DUT to obtain a result; andaccording to the result, testing the unpackaged semiconductor device with the controller and via the probe.

Through the method of testing the unpackaged semiconductor device, accurate probing parameters can be obtained conveniently and quickly to enable the probing assembly to provide great and consistent testing performance, thereby achieving high testing accuracy.

The present invention further provides a method of producing a tested semiconductor device, which includes the steps of:providing at least one probing assembly, the at least one probing assembly including a probe, the probe including a probe tip, the probe tip of the probe being configured to mechanically and electrically contact an unpackaged semiconductor device;providing a controller programmed to perform the above-described method of determining the probing parameters for the probe system to test the DUT to obtain a result; andaccording to the result, testing the unpackaged semiconductor device with the controller and via the probe.

The semiconductor device produced through this method has been tested in a way with great accuracy, thereby having ensured properties.

The present invention further provides a tested semiconductor device which includes an unpackaged semiconductor device including a plurality of contact pads. The unpackaged semiconductor device has been tested through a testing process which performs the above-described method of determining the probing parameters for the probe system to test the DUT to obtain a result, and then making the contact pads mechanically and electrically contacted according to the result.

As a result, the semiconductor device has been tested in a way with great accuracy, thereby having ensured properties.

The present invention further provides a method of generating a virtual mark image which represents a portion of a probe system. The probe system includes a probe and a substrate. The substrate includes one or more DUTs. The probe is configured to test the DUT. The method includes the steps of:obtaining, with an optical image-forming device, a present probe system image of at least a part of the probe system, the present probe system image includes one or both of:the image of at least a part of the probe; andthe image of at least a part of the substrate;generating the virtual mark image with a controller based on at least a part of the present probe system image; andpresenting the virtual mark image with a display;wherein the virtual mark image includes one of:a representation of a probe contact position, the probe contact position being the position, at which a probe tip of the probe is predetermined to start contacting a contact pad of the DUT; anda representation of a probe target position, the probe target position being the position, at which the probe tip of the probe is predetermined to be stopped after skating on the contact pad.

As a result, the representation of the probe contact position may be, for example, the aforementioned virtual alignment mark showing the probe contact position. The representation of the probe target position may be, for example, the aforementioned virtual alignment mark showing the relative target position. Even though the optical image-forming device cannot clearly show the contact pad of the DUT and the probe tip of the probe at the same time, the user can still perform the manual alignment to the probe and the DUT through the virtual mark image. Alternatively, in the automatically positioning condition, the user can know the present situation through the virtual mark image.

Preferably, the controller obtains, based on one of a skate distance value and an overdrive value and a skate distance to overdrive relation dataset, the other of the skate distance value and the overdrive value, and obtains, based on the skate distance value and the probe target position, the probe contact position.

In other words, in the above-described method of generating the virtual mark image, the probe contact position can be obtained by using the above-described method of determining the probing parameters for the probe system to test the DUT, so as to show the probe contact position in the virtual mark image for the manual alignment or automatic alignment between the probe and the DUT.

Preferably, the controller obtains, based on one of a skate distance value and an overdrive value and a skate distance to overdrive relation dataset, the other of the skate distance value and the overdrive value, and obtains, based on the skate distance value and a present probe position, a relative target position. The present probe position is the present position of the probe tip of the probe. The relative distance between the relative target position and the present probe position equals to the skate distance value.

In other words, in the above-described method of generating the virtual mark image, the relative target position can be obtained by using the above-described method of determining the probing parameters for the probe system to test the DUT, so as to show the relative target position in the virtual mark image for the manual alignment or automatic alignment between the probe and the DUT.

Preferably, in the present probe system image, the DUT is clearer than at least the probe tip of the probe. The aforementioned generating the virtual mark image includes generating a virtual alignment mark showing the probe contact position.

As a result, even though the optical image-forming device cannot clearly show the probe tip and the DUT, as long as the DUT is clear in the obtained present probe system image, the probe target position can be defined through the image and the probe contact position can be calculated accordingly, so as to make the virtual mark image include the virtual alignment mark showing the probe contact position. In this way, the user can perform the manual alignment to align the probe tip with the virtual alignment mark to position the probe tip at the probe contact position accurately. In the automatically positioning condition, the virtual alignment mark can be also provided for the user to know the present situation.

Preferably, in the present probe system image, at least the probe tip of the probe is clearer than the DUT. The aforementioned generating the virtual mark image includes generating a virtual alignment mark showing a relative target position. The relation between the relative target position and the present position of the probe tip is identical to the relation between the probe target position and the probe contact position.

As a result, even though the optical image-forming device cannot clearly show the probe tip and the DUT, as long as the probe tip is clear in the obtained present probe system image, the present probe position can be defined through the image and the relative target position can be calculated accordingly, so as to make the virtual mark image include the virtual alignment mark showing the relative target position. In this way, the user can perform the manual alignment to relatively move the relative target position to the probe stopped position decided by the user, so as to position the probe tip at the proper probe contact position.

Preferably, the aforementioned generating the virtual alignment mark includes determining the relative position of the virtual alignment mark with respect to the probe tip of the probe. The aforementioned generating the virtual mark image includes altering, based on at least a part of the determined relative position of the virtual alignment mark with respect to the probe tip, the virtual mark image to make the virtual mark image include the virtual alignment mark.

As a result, no matter in the above-described situation of generating the virtual alignment mark showing the probe contact position or the above-described situation of generating the virtual alignment mark showing the relative target position, the position of the probe tip can be obtained with the optical image-forming device and the relative position of the virtual alignment mark with respect to the probe tip can be determined accordingly, so that the virtual mark image can be added with the virtual alignment mark.

DETAILED DESCRIPTION OF THE INVENTION

First of all, it is to be mentioned that same or similar reference numerals used in the following embodiments and the appendix drawings designate same or similar elements or the structural features thereof throughout the specification for the purpose of concise illustration of the present invention. It should be noticed that for the convenience of illustration, the components and the structure shown in the figures are not drawn according to the real scale and amount, and the features mentioned in each embodiment can be applied in the other embodiments if the application is possible in practice. Besides, when it is mentioned that an element is disposed on another element, it means that the former element is directly disposed on the latter element, or the former element is indirectly disposed on the latter element through one or more other elements between aforesaid former and latter elements. When it is mentioned that an element is directly disposed on another element, it means that no other element is disposed between aforesaid former and latter elements.

Referring toFIG.2andFIG.3, a first preferred embodiment of the present invention provides a method of operating a probe system20. The probe system20includes a chuck21, a probing assembly22, an optical image-forming device23, a controller24, a display25, and an electrically actuated positioning assembly26. The probe system20is defined with two horizontal axes, i.e. X-axis and Y-axis, and a vertical axis, i.e. Z-axis.

The chuck21includes a chuck support surface211along the X-axis and the Y-axis. The chuck support surface211is configured to support a substrate30, such as a wafter. The substrate30includes one or more DUTs31, such as unpackaged semiconductor devices sliced from the wafer. The DUT31includes a plurality of contact pads311.

The probing assembly22includes a probe221. The probe221includes a probe tip222. The probe tip222of the probe221is configured to mechanically and electrically contact the contact pad311of the DUT31, thereby testing the DUT31. According to the testing requirements, the probe221may include any proper number of probe tip222, such as one probe tip222, two probe tips222, three probe tips222, or more than three probe tips222. A common arrangement of two probe tips222includes a signal probe tip and a ground probe tip, also referred to as a GS (ground-signal) probe tip configuration. A common arrangement of three probe tips222includes a centrally located signal probe tip flanked by a pair of ground probe tips, also referred to as a GSG (ground-signal-ground) probe tip configuration.

The optical image-forming device23is configured to receive the optical image of at least a part of the probe system20, including the image of at least a part of the probing assembly22, especially the probe tip222, and usually also including the image of at least a part of the substrate30, especially the contact pad311of the DUT31.

The controller24is electrically connected with the optical image-forming device23for obtaining the image received by the optical image-forming device23. The controller24is programmed to perform the method of operating the probe system20as shown inFIG.2. The controller24is also electrically connected with the display25for showing the image related to the operation of the probe system20on the display25. The images shown on the display25during the operation of the probe system20of this embodiment are schematically drawn asFIG.4toFIG.9, which will be specified hereinafter.

The electrically actuated positioning assembly26is connected with the probing assembly22, and the electrically actuated positioning assembly26is also electrically connected with the controller24. According to the testing requirements, the controller24controls the electrically actuated positioning assembly26, so as to control the probing assembly22to move along the X-axis, Y-axis and Z-axis. In the present invention, the probing assembly22and the DUT31are relatively moved, which may be performed in a way that the electrically actuated positioning assembly26drives the probing assembly22to move, or another moving device (not shown) drives the chuck21to move. Therefore, the probe system20in the present invention is unlimited to include the electrically actuated positioning assembly26connected with the probing assembly22.

In the method of operating the probe system20in this embodiment, a method of determining probing parameters for the probe system to test the DUT is performed at first, which includes the following step a) to step f).

a) Define a skate distance to overdrive relation dataset according to the type of the probe221of the probing assembly22of the probe system20and the type of the contact pad311of the DUT31, wherein the skate distance is along the X-axis and/or Y-axis and the overdrive is along the Z-axis.

It should be mentioned here that different probe type, such as probe thickness, material, shape, and so on, and/or different contact pad type, such as contact pad material, and so on, will cause different relation between the skate distance and the overdrive, thereby corresponding to different SD-OD relation dataset. The SD-OD relation dataset, such as the diagram shown inFIG.15, can be a build-in dataset pre-established in the controller24by the manufacturer of the probe system20, or can be established into the controller24by the user of the probe system20by a process referred to as an initial setup stage. The steps of this initial setup stage are included in the method of operating the probe system20shown inFIG.2, which are the steps S1-S2described in detail hereinafter.

As shown inFIG.2andFIG.4, the step S1is defining a contact height at a calibration substrate41. The contact height will be the Z-axial position of the probe tips222initially contacting the contact pads311of the DUT31, which means when located at the contact height, the probe tips222start contacting the contact pads311of the DUT31without being deflected by the overdrive. This step is making the probing assembly22and the calibration substrate41relatively moved along the Z-axis to the status that the probe tips222are in contact with the calibration substrate41, so as to find out and record the contact height for accordingly setting the overdrive value required for the test thereafter.

As shown inFIG.2, the step S2is defining a SD-OD relation dataset at the calibration substrate41. The calibration substrate41includes a plurality of parallelization patterns (not shown) representing contact pads of different types respectively. This step is using the probing assembly22of the probe system20to perform the test in the area of the parallelization pattern of the calibration substrate41, which is the same in type with the contact pad311of the DUT31. That is making the probe tip222in contact with the parallelization pattern of the calibration substrate41and then making the probing assembly22and the calibration substrate41relatively moved on the Z-axis for an overdrive to make the probe tip222skate on the calibration substrate41to generate a skate distance. During the above-described skating, the probe tip222and the calibration substrate41are on the same X-Y plane, enabling the optical image-forming device23to take the clear image of the probe tip222and the calibration substrate41at the same time, so the skate distance can be observed and obtained with the optical image-forming device23. The user can provide a plurality of different overdrives to perform the respective measurements at the calibration substrate41to obtain the respective corresponding skate distances, and then generate the SD-OD relation dataset with the controller24based on at least a part of the observed and obtained skate distances and their corresponding overdrives. After the SD-OD relation dataset is established in the controller24, when the probe221whose type corresponds to this dataset is to be used to test the contact pad311whose type corresponds to this dataset, the already established SD-OD relation dataset can be directly used, so that in the following steps, the required probing parameters can be obtained conveniently and quickly.

b) As the step S3shown inFIG.2, provide one of a skate distance value and an overdrive value to the controller24. The skate distance value is the distance, for which the probe tip222of the probe221is set to skate on the contact pad311of the DUT31along the X-axis or Y-axis after contacting the contact pad311. The overdrive value is the distance, for which the probing assembly22and the DUT31are set to be relatively moved along the Z-axis after the probe tip222of the probe221contacts the contact pad311of the DUT31.

The skate distance and the overdrive mentioned in the present invention are the same in definition with the skate distance SD and the overdrive OD mentioned in the description of the related art as shown inFIG.1AandFIG.1B. The skate distance value and the overdrive value are numeral values set for the skate distance and the overdrive for the controller24to perform the related calculation and control.

c) As the step S4shown inFIG.2, provide a probe target position P3as shown inFIG.5to the controller24. The probe target position P3is the position, at which the probe tip222of the probe221is predetermined to be stopped after skating on the contact pad311of the DUT31. In this embodiment, the stop position is also the position, at which the probing assembly22performs the test (electrical property test) to the DUT31.

The user can firstly move the chuck21or the FOV of the optical image-forming device23to make the optical image-forming device23roughly find out the contact pad311, and then fine adjust the FOV of the optical image-forming device23on the Z-axis to focus on the contact pad311, thereby obtaining a clear image of the contact pad311. After that, the user can define the probe target position P3on the image for the controller24to receive the numeral value of the probe target position P3, and may even show the probe target position P3on the image. The probing assembly22in this embodiment includes three probe tips222for testing three contact pads311of the DUT31. Since the three probe tips222are displaced simultaneously, this embodiment only uses a dotted line to represent the probe target positions P3of the three probe tips222collectively. However, the probe target positions P3of the three probe tips222may be shown individually, as shown inFIG.10. Since the optical image-forming device23focuses on the contact pad311in this step, the image of the probing assembly22is relatively more blurred. Therefore, the probing assembly22is represented by imaginary lines inFIG.5.

As shown inFIG.6, a present probe position P4may, but unlimited to, be further defined in this embodiment. The present probe position P4is the present position of the probe tip222. The user can firstly move the probing assembly22or the FOV of the optical image-forming device23to make the optical image-forming device23roughly find out the probe tips222, and then fine adjust the FOV of the optical image-forming device23on the Z-axis to focus on the probe tips222, thereby obtaining a clear image of the probe tips222. After that, the user can define the present probe position P4on the image for the controller24to receive the numeral value of the present probe position P4, and may even show the present probe position P4on the image. This embodiment only uses a dotted line to represent the present probe positions P4of the three probe tips222collectively. However, the present probe positions P4of the three probe tips222may be shown individually. Since the optical image-forming device23focuses on the probe tips222in the process of defining the present probe position P4, the image of the contact pads311is relatively more blurred. Therefore, the contact pads311are represented by imaginary lines inFIG.6. The sequence of the step of defining the probe target position P3as shown inFIG.5and the step of defining the present probe position P4as shown inFIG.6can be interchanged.

d) Obtain, with the controller24and based on the aforementioned one of the skate distance value and the overdrive value provided in the step b) and the SD-OD relation dataset defined in the step a), the other of the skate distance value and the overdrive value. In other words, as long as the user provides the skate distance value to the controller24, the controller24can obtain the overdrive value through the SD-OD relation dataset. Alternatively, as long as the user provides the overdrive value to the controller24, the controller24can obtain the skate distance value through the SD-OD relation dataset.

This step further obtains, with the controller24and based on the skate distance value and the probe target positions P3provided in the step c), probe contact positions P5as shown inFIG.7. The probe contact positions P5are the positions, at which the probe tips222are predetermined to start contacting the contact pads311of the DUT31, for positioning the probing assembly22and the DUT31to each other in the step thereafter.

In other words, when this step finishes, the controller24has obtained the primary probing parameters required for the probe system20to test the DUT31, which are the skate distance value, the overdrive value, the probe target position P3and the probe contact position P5, as the step S5shown inFIG.2.

e) As the step S6shown inFIG.2, after the probe contact position P5and the probe target position P3are both known, it can be further affirmed whether the two positions are both located within an acceptable scope corresponding in position to the contact pad311of the DUT31. As shown inFIG.10, the acceptable scope42may equal to the scope of the contact pad311, or may be smaller than the scope of the contact pad311. The controller24can judge, by calculation, whether the probe contact position P5and the probe target position P3are both within the acceptable scope42, and can also show the probe contact position P5, the probe target position P3and the acceptable scope42in the image for the user to affirm that. This step is arranged to ensure that the probe tip222will be positively contacted against the contact pad311of the DUT31in the entire process of the overdrive and produce a proper probe scratch, thereby ensuring and enhancing the testing accuracy. However, this step may be omitted.

f) As the step S71shown inFIG.2, generate, with the controller24, a virtual alignment mark43showing the probe contact positions P5, as shown inFIG.7, for the probe tips222to be aligned with the virtual alignment mark43, as shown inFIG.8.

According to different operating manners, the virtual alignment mark43is optionally shown. In the manual operation, the virtual alignment mark43is shown on the display25for the user to align the probe tips222with the virtual alignment mark43, as the step S81shown inFIG.2. At this time, even though only the image of the probe tips222is clear but the image of the contact pads311of the DUT31is blurred and unclear, the user can still align the probe tips222with the virtual alignment mark43, so as to position the probe tips222at the probe contact positions P5accurately. In the automatic operation, as long as the present positions of the probe tips222, i.e. the present probe position P4mentioned in the above-described step c), are defined, as the step S72shown inFIG.2, the probe system20can automatically make the probe tips222relatively moved to the probe contact positions P5, as the step S82shown inFIG.2. At this time, the virtual alignment mark43may be also shown on the display25for the user to know the present situation, or the virtual alignment mark43may be omitted and this step f) of generating the virtual alignment mark43may be even not performed.

In this embodiment, the probe contact positions P5of the three probe tips222are shown by the same virtual alignment mark43. However, the probe contact positions P5of the three probe tips222may be shown by three virtual alignment marks43respectively, as shown inFIG.10. The virtual alignment mark is unlimited in shape, which may be shaped correspondingly to different probe tip shapes, or may be shaped for only position recognition, such as the shape of the virtual alignment mark43shown in FIG.12.

After the user positions the probe tips222at the probe contact positions P5by using the virtual alignment mark43, or after the probe tips222are automatically positioned at the probe contact positions P5by the controller24, an overdrive ON process can be performed with the controller24, as the step S91or S92shown inFIG.2. The overdrive ON process is making the probing assembly22and the DUT31relatively moved for the overdrive value provided in the step b) or obtained in the step d), making the probe tips222deflected to skate to and stop at the probe target position P3, as shown inFIG.9. In this way, the probe tips222can be ensured to be stopped at the desired probe target position P3when the overdrive ON process finishes.

Referring toFIG.11, a method of operating the probe system20according to a second preferred embodiment of the present invention is similar to that in the first preferred embodiment, also firstly performing the method of determining the probing parameters for the probe system to test the DUT, then performing the manual operation to position the probing assembly22and the DUT31to each other, and then performing the overdrive ON process. However, compared with the first preferred embodiment, this embodiment has the following difference.

Referring toFIG.11andFIG.12, in this embodiment, the steps S1-S3, which are the same with those in the first preferred embodiment, are performed at first. After that, instead of providing the probe target position P3to the controller, the present probe position P4is provided to the controller24in the step S4, and the present probe position P4may, but unlimited to, be shown on the image.

Based on the SD-OD relation dataset defined in the step S2and the skate distance value or overdrive value provided in the step S3, the controller24can obtain both the skate distance value and the overdrive value, and then obtain a relative target position P6by the calculation based on the skate distance value and the present probe position P4. The relative distance between the relative target position P6and the present probe position P4equals to the skate distance value, which means the relation between the relative target position P6and the present probe position P4is identical to the relation between the probe target position P3and the probe contact position P5described in the first preferred embodiment. Therefore, although the probe contact positions P5are not obtained in this embodiment, as long as the relative target positions P6are moved simultaneously with the probing assembly22relative to the DUT31and the relative target positions P6are relatively moved to the positions, at which the probe tips222of the probing assembly22are predetermined to be stopped after skating on the contact pads311of the DUT31, such as the equivalence of the probe target positions P3described in the first preferred embodiment, the probe tips222will be relatively moved to the positions equivalent to the probe contact positions P5described in the first preferred embodiment simultaneously, such that the probing assembly22and the DUT31can be positioned to each other.

In other words, in the step S5in this embodiment, the controller24has obtained the primary probing parameters required for the probe system20to test the DUT31, which are the skate distance value, the overdrive value, the present probe position P4, and the relative target position P6.

After that, as the step S6′ shown inFIG.11, a virtual alignment mark43showing the relative target position P6can be generated with the controller24. In the manual operation, the virtual alignment mark43is shown on the display25and moved simultaneously with the probing assembly22relative to the DUT31(as shown inFIG.13) for the user to relatively move the virtual alignment mark43to a position corresponding to the contact pads311of the DUT31(as shown inFIG.14), i.e. the step S7shown inFIG.11, so that the relative target positions P6are relatively moved to the aforementioned position corresponding to the contact pads311of the DUT31. More specifically speaking, the aforementioned position corresponding to the contact pads311of the DUT31is the position the user predetermines the probe tips222to be stopped after skating on the contact pads311of the DUT31, similar to the probe target position P3described in the first preferred embodiment but not set with numeral value and visually decided by the user during the operation. In the present invention, this position is also referred to as the probe stopped position decided by the user.

Further speaking, there are two ways of moving the relative target position P6relative to the DUT31. The first way is that the user operates the operating lever of the machine to control the probing assembly22to move. The relative target position P6is moved simultaneously with the probing assembly22. Meanwhile, the virtual alignment mark43is also moved on the display25simultaneously. The user can watch the moving condition of the virtual alignment mark43on the display25to control the movement of the probing assembly22, so as to move the relative target position P6(virtual alignment mark43) to the desired position. The second way is that the user uses the mouse or the touch control function of the touch panel to drag the virtual alignment mark43on the display25to the desired position. Meanwhile, the probing assembly22can be moved simultaneously to make the relative target position P6moved simultaneously with the virtual alignment mark43. Alternatively, the probing assembly22can be moved after the user decides the position to stop the virtual alignment mark43. The above two ways are both operated by the user, both belonging to the manual operation described in the present invention. It can be seen that the manual operation and the automatic operation described in the present invention are both performed with the controller24.

During the above-described movement, even though only the image of the contact pads311of the DUT31is clear but the image of the probe tips222is blurred and unclear, the user can still align the virtual alignment mark43with the aforementioned position corresponding to the contact pads311of the DUT31, i.e. the position the user predetermines the probe tips222of the probing assembly22to be stopped after skating on the contact pads311of the DUT31, such as the probe target position P3described in the first preferred embodiment, so as to locate the probe tips222at proper positions on the contact pads311of the DUT31, such as the aforementioned probe contact position P5.

After the user positions the virtual alignment mark43at the position the probe tips222of the probing assembly22are predetermined to be stopped after skating on the contact pads311of the DUT31, such as the probe target position P3described in the first preferred embodiment, the overdrive ON process can be performed with the controller24, as the step S8shown inFIG.11. The overdrive ON process is making the probing assembly22and the DUT31relatively moved for the overdrive value provided in the step S3or obtained in the step S5, making the probe tips222deflected to skate to and then stop at the probe stopped position decided by the user. In this way, the probe tips222can be ensured to be stopped at the desired position when the overdrive ON process finishes.

It can be known from the above two embodiments that since the SD-OD relation dataset is established in the present invention, for performing the test, as long as the user provides the skate distance value or overdrive value and the probe target position P3or present probe position P4, the parameters required for testing the DUT31with the probing assembly22can be obtained. It is unnecessary to perform, before every time of testing, the time-consuming initial setting steps, such as using the calibration substrate to find out the proper overdrive, performing many times of calibration measurement for the overdrive to obtain the initial contact position, and so on. Besides, the method of the present invention can provide accurate parameters to make sure that the probe tip222of the probe221will be stopped at the desired position after skating on the contact pad311of the DUT31. Therefore, the method provided by the present invention not only saves time and offers convenience, but also enhances the testing accuracy by enabling the probing assembly to deliver consistent and excellent performance, thereby reducing wear on the probe and calibration substrate and extending their lifespan. The controller24may include and/or be any suitable structure, device, and/or devices that may be adapted, configured, designed, constructed, and/or programmed to perform the functions discussed herein. As examples, the controller24may include one or more of an electronic controller, a dedicated controller, a special-purpose controller, a personal computer, a special-purpose computer, a display device, a logic device, a memory device, and/or a memory device having computer-readable storage media.

The computer-readable storage media, when present, also may be referred to herein as non-transitory computer readable storage media. This non-transitory computer readable storage media may include, define, house, and/or store computer-executable instructions, programs, and/or code; and these computer-executable instructions may direct the probe system20and/or the controller24thereof to perform any suitable portion, or subset, of methods. Examples of such non-transitory computer-readable storage media include CD-ROMs, disks, hard drives, flash memory, etc. As used herein, storage, or memory, devices and/or media having computer-executable instructions, as well as computer-implemented methods and other methods according to the present disclosure, are considered to be within the scope of subject matter deemed patentable in accordance with Section 101 of Title 35 of the United States Code.

Therefore, the present invention also provides a non-transitory computer-readable storage media, which includes computer-executable instructions that, when executed, direct the probe system20to perform the aforementioned method of determining the probing parameters for the probe system to test the DUT to obtain the accurate probing parameters conveniently and quickly, enabling the probing assembly22to provide great and consistent testing performance, thereby achieving high testing accuracy.

It can be known from the above two embodiments that the present invention also provides a method of generating a virtual mark image representing a portion of the probe system20, and the method includes the step of obtaining, with the optical image-forming device23, a present probe system image of at least a part of the probe system20, such as the image shown inFIG.5. The present probe system image includes the image of at least a part of the probe221, such as the probe tip222, and/or the image of at least a part of the substrate30, such as the contact pad311of the DUT31. Then, generate a virtual mark image with the controller24based on at least a part of the present probe system image, and present the virtual mark image with the display25, such as the image shown inFIG.7. The virtual mark image includes a representation of the probe contact position or a representation of the probe target position.

In the first preferred embodiment, the virtual mark image includes the representation of the probe contact position, i.e. the virtual alignment mark43showing the probe contact position P5as shown inFIG.7. In the second preferred embodiment, the virtual mark image includes the representation of the probe target position, i.e. the virtual alignment mark43showing the relative target position P6as shown inFIG.12. The step of generating the virtual alignment mark43may include determining the relative position of the virtual alignment mark43with respect to the probe tip222. For example, the position of the probe tip222can be obtained with the optical image-forming device23and the relative position of the virtual alignment mark43with respect to the probe tip222can be determined accordingly. The step of generating the virtual mark image may include altering, based on at least a part of the determined relative position of the virtual alignment mark43with respect to the probe tip222, the virtual mark image to make the virtual mark image include the virtual alignment mark43.

Further speaking, in the first preferred embodiment, since the probe target position P3has to be provided, the probe tip222is more blurred than the DUT31in the aforementioned present probe system image. However, through the clear image of the DUT31, the probe target position P3can be defined and the probe contact position P5can be calculated accordingly, allowing the virtual mark image to include the virtual alignment mark43showing the probe contact position P5. In this way, the user can perform the manual alignment to align the probe tip222with the virtual alignment mark43, so as to position the probe tip222at the probe contact position P5accurately. In the automatically positioning condition, the virtual alignment mark43can be also provided for the user to know the present situation. In another aspect, in the second preferred embodiment, since the present probe position P4has to be provided, the probe tip222is clearer than the DUT31in the aforementioned present probe system image. Through the clear image of the probe tip222, the present probe position P4can be defined and the relative target position P6can be calculated accordingly, allowing the virtual mark image to include the virtual alignment mark43showing the relative target position P6. In this way, the user can perform the manual alignment to relatively move the relative target position P6to the probe stopped position decided by the user, so as to position the probe tip222at the proper probe contact position.