Probe head, probe card assembly using the same, and manufacturing method thereof

A probe head includes a first substrate, a second substrate, a spacer, at least one probe, and an insulating material. The first substrate has at least one first through hole. The second substrate has at least one second through hole. The spacer is disposed between the first substrate and the second substrate. The spacer, the first substrate, and the second substrate together form a cavity. The probe is disposed in the cavity and protrudes from the first through hole and the second through hole. The insulating material is on the probe and at least partially disposed in the first through hole.

BACKGROUND

Semiconductor devices are used in countless applications throughout the world and millions upon millions of individual semiconductor devices are produced annually. Semiconductor devices are individually and completely electrically tested before they are installed within electronic or other devices. Different semiconductor devices perform different functions and therefore undergo different functional, parametric and electrical tests. In any semiconductor device fabrication or testing facility, the number of different semiconductor devices to be tested far exceeds the number of test equipment available to test the devices. As such, different semiconductor devices are tested on the same test assembly.

DETAILED DESCRIPTION

FIG. 1is a cross-sectional view of a probe card assembly in accordance with various embodiments of the present disclosure, andFIG. 2is a cross-sectional view of a probe head200ofFIG. 1. The probe card assembly includes a circuit board100, a probe head200, and a space transformer300. The probe head200includes a first substrate210, a second substrate220, a spacer230, at least one probe240, and an insulating material250. The first substrate210has at least one first through hole212. The second substrate220has at least one second through hole222. The spacer230is disposed between the first substrate210and the second substrate220. The spacer230, the first substrate210, and the second substrate220together define a cavity C. The probe240is disposed in the cavity C and protrudes (or extends) from the first through hole212and the second through hole222. The insulating material250is disposed on the probe240and at least partially disposed in the first through hole212. In other words, the insulating material250at least covers a portion of the probe240disposed in the first through hole212. The space transformer300is disposed between the circuit board100and the probe head200to electrically interconnect the probe240and the circuit board100.

In some embodiments, the first through hole212, the second through hole222, the probe240, and the insulating material250can be plural. TakingFIG. 2as an example, there are five first through holes212, five second through holes222, five probe240, and five insulating materials250, respectively. The probes240respectively protrude from the corresponding first through holes212and the corresponding second through holes222, and the insulating materials250are respectively disposed between the probes240and the first substrate210. In other embodiments, however, the amounts of the first through holes212, the second through holes222, the probes240, and the insulating materials250depend on actual situations, and are not limited in this respect.

Reference is made toFIG. 1. When testing takes place, probe head200is coupled to the space transformer300, which, in turn, is coupled to the circuit board100. The circuit board100includes a pattern of contacts112on the surface102facing the space transformer300. These contacts112cooperate with and are coupled to corresponding contacts312, such as solder balls or other suitable materials, formed on the surface302of the space transformer300facing the circuit board100. Internal leads or signal traces within the space transformer300enable the pattern of contacts312formed on the surface302of space transformer300to be different from the pattern of contacts314formed on opposed surface304of the space transformer300. The contacts314contact the corresponding probes240.

Reference is made toFIG. 2. Since the insulating materials250are respectively disposed in the first through holes212, i.e., the insulating materials250separate the probes240and the first substrate210, the insulating materials250can prevent the current passing through the probes240from leaking to the first substrate210, which may cause signal crosstalks among the probes240. Hence, the testing reliability of the probe card assembly can be improved.

InFIG. 2, the insulating materials250are further disposed in the second through holes222. In other words, the insulating materials250further cover portions of the probes240disposed in the second through holes222. In greater detail, the probes240can be Cobra probes or other suitable probes. At least one of the probes240has a testing terminal242, a connecting terminal244, and a body portion246. The testing terminal242and the connecting terminal244are opposite to each other, and the body portion246is disposed between and interconnects the testing terminal242and the connecting terminal244. The testing terminal242emerges from the first through hole212and is configured to touch a testing pad of a wafer or a die. The connecting terminal244emerges from the second through hole222and connects to one of the contacts314of the space transformer300(seeFIG. 1). The insulating material250covers the body portion246of the probe240and exposes the testing terminal242and the connecting terminal244. Since the insulating material250is further disposed in the second through hole222, i.e., the insulating material250separates the probe240and the second substrate220, the insulating material250can prevent the current passing through the probe240from leaking to the second substrate220, which may cause signal crosstalks among the probes240. Hence, the testing reliability of the probe card assembly can be further improved.

InFIG. 2, the insulating materials250respectively surround the probes240, and the insulating materials250attach to the probes240. The insulating materials250may be coated on the probes240, and the claimed scope is not limited in this respect. Basically, embodiments fall within the claimed scope of the disclosure if the insulating material250is disposed on the probe240and at least disposed in the first through hole212and/or at least disposed in the second through hole222.

In some embodiments, the probe head200further includes a probe support260for supporting and separating the probes240. The probe support260has a plurality of through holes262that allow the probes240to pass therethrough, such that the spaces among the probes240are determined by the probe support260. The probe support260can be made of a nonconductive material such as polyamide mylar, and the claimed scope is not limited in this respect.

In some embodiments, the first substrate210and the second substrate220can be made of ceramic materials, and the spacer230can be made of metal, such as aluminum or other suitable materials, and the claimed scope is not limited in this respect.

FIG. 3is a cross-sectional view of a probe head200in accordance with various embodiments of the present disclosure. The difference between the probe heads200inFIGS. 2 and 3pertains to insulating layers270,275,280,285,290, and295inFIG. 3. InFIG. 3, the insulating layer270is disposed at a side214of the first substrate210facing the spacer230. The insulating layer270may be coated on the side214to prevent the current passing through the probe240from leaking to the first substrate210through the side214. The insulating layer275is disposed at a side216of the first substrate210opposite to the spacer230. The insulating layer275may be coated on the side216to prevent the current passing through the probe240from leaking to the first substrate210through the side216. Furthermore, the insulating layer280is disposed at a side224of the second substrate220facing the spacer230. The insulating layer280may be coated on the side224to prevent the current passing through the probe240from leaking to the second substrate220through the side224. The insulating layer285is disposed at a side226of the second substrate220opposite to the spacer230. The insulating layer285may be coated on the side226to prevent the current passing through the probe240from leaking to the second substrate220through the side226.

Moreover, the insulating layers290are respectively disposed in the first through holes212. The insulating layers290may be coated on the sidewalls of the first through holes212to prevent the current passing through the probe240from leaking to the first substrate210through the first through holes212. The insulating layers295are respectively disposed in the second through holes222. The insulating layers295may be coated on the sidewalls of the second through holes222to prevent the current passing through the probe240from leaking to the second substrate220through the second through holes222.

Although inFIG. 3, the probe head200includes all of the insulating layers270,275,280,285,290, and295, the claimed scope is not limited in this respect. In some embodiments, the probe head200may include the insulating layers270,275,280,285,290,295, or combinations thereof. Other features of the probe head200inFIG. 3are similar to those of the probe head200shown inFIG. 2, and therefore, a description in this regard will not be provided hereinafter.

In some embodiments, the insulating material250, the insulating layers270,275,280,285,290, and295can be made of high volume resistivity materials, such as polyamide-imides. The term “high volume resistivity material” herein represents a material whose volume resistivity is substantially greater than 2*E17 (ohm-cm).

FIG. 4Ais a top view of a probe head200in accordance with various embodiments of the present disclosure,FIG. 4Bis a top view of the spacer230, probes240aand240b, and the first substrate210of the probe head200inFIG. 4A, andFIG. 4Cis a cross-sectional view of the probe head200ofFIG. 4A. For clarity, the probe support260ofFIG. 2is omitted inFIGS. 4A-4C. InFIGS. 4A and 4B, the first through holes212are arranged along one column C1, and the second through holes222are arranged along two columns C2and C3. A projection212′ of the first through holes212on the second substrate220are disposed between the two columns C2and C3of the second through holes222.

Reference is made toFIGS. 4A-4C. In greater detail, the testing terminal242aof the probe240aprotrudes from the first through hole212, and the connecting terminal244aof the probe240aprotrudes from the second through hole222in the column C2. On the other hand, the testing terminal242bof the probe240bprotrudes from another first through hole212, and the connecting terminal244bof the probe240bprotrudes from the second through hole222in the column C3. The probes240aand240bare alternately arranged. This arrangement reduces the contact areas between the adjacent two probes240aand240b, such that crosstalks among the probes240aand240bcan be further reduced.

Reference is made toFIGS. 4A and 4B. In some embodiments, a pitch P1of adjacent two of the first through holes212is shorter than a pitch P2of adjacent two of the second through holes222. For example, the pitch P2is substantially twice the distance of the pitch P1. If the pitch P1is about 100 nm, the pitch P2can be about 200 nm. This means the space between the two adjacent probes240a(or240b) can be twice extended while keeping the same pitch at the testing end of the probe head200. Also, the current leakage (i.e., the crosstalks) among the probes240aand240bcan be further reduced.

Reference is made back toFIG. 1. InFIG. 1, the circuit board100can be a printed circuit board, and may be designed such that different circuit boards100dedicated to testing difference semiconductor devices, including substantially the same pattern of contacts112.

The space transformer300may be a multi-layered organic (MLO) or multi-layered ceramic (MLC) interconnect substrate in some embodiments. The contacts312of the space transformer300can be arranged in an array manner and are configured for mating with the corresponding contacts112of the circuit board100. The contacts314of the space transformer300can also be arranged in an array manner and are configured for engaging and mating with the connecting terminals244(seeFIG. 2) of the probes240. The contacts312may have a pitch P3defined therebetween, and the contacts314may have a pitch P4defined therebetween. The pitch P4is shorter than the pitch P3. For example, the pitch P3can be about 1 mm, and the pitch P4can be about 100 μm.

In some embodiments, the probe card assembly further includes a jig400configured to connect the space transformer300to the circuit board100. For example, the jig400has an opening402. The space transformer300is disposed and fixed in the opening402using, for example, screws (not shown) or other suitable fixing elements. The jig400and the space transformer300are then attached to the circuit board100together using, for example, screws (not shown) or other suitable fixing elements. Hence, the contacts312of the space transformer300are connected to the contacts112of the circuit board100. Substantially, the probe head200is attached to the jig400, such that the connecting terminals244(seeFIG. 2) of the probes240are respectively connected to the contacts314of the space transformer300. Since the probe card assembly ofFIG. 1is easy to assemble, the manufacturing time and repairing time thereof can be improved.

A method for manufacturing a probe head200according to various embodiments of the present disclosure, to produce a probe head200having the insulating materials250, will now be described with reference to fabrication sequence shownFIGS. 5A-5E.FIGS. 5A-5Eare cross-sectional views for manufacturing the probe head200in accordance with various embodiments of the present disclosure. Reference is made toFIG. 5A. An insulating material250is formed around a probe240. The probe240, may be a Cobra probe or other suitable probe, has a testing terminal242, a connecting terminal244, and a body portion246. The testing terminal242and the connecting terminal244are opposite to each other, and the body portion246is disposed between and interconnects the testing terminal242and the connecting terminal244. The insulating material250may be coated on the body portion246of the probe240and expose the testing terminal242and the connecting terminal244. In other words, the insulating material250is attached to and surrounds the probe240. The insulating material250may be made of high volume resistivity materials, such as polyamide-imides.

Reference is made toFIG. 5B. A first substrate210is provided. The first substrate210has at least one first through hole212that the probe240ofFIG. 5Acan pass therethrough. For example, the first substrate210inFIG. 5Bhas five first through holes212, and the claimed scope is not limited in this respect. The first substrate210further has a recess218, and the first through holes212are disposed at the bottom of the recess218. The first substrate210can be made of ceramic material or other suitable materials.

In some embodiments, an insulating layer270is formed at a side214of the first substrate210. The insulating layer270may be disposed in the recess218of the first substrate210. Moreover, an insulating layer275is formed at a side216of the first substrate210, and insulating layers290are respectively formed in the first through holes212. The insulating layers270,275, and290can be made of high volume resistivity materials, such as polyamide-imides. The insulating layers270and275can be respectively coated on the sides214and216. In other embodiments, the insulating layers270,275, and290can be omitted, or at least one of the insulating layers270,275, and290is formed on the first substrate210.

Reference is made to5C. A spacer230is disposed on the first substrate210. For example, the first substrate210can be fixed to the spacer230using screws or other suitable fixing elements. The side214of the first substrate210faces the spacer230, and the side216of the first substrate210is opposite to the spacer230. InFIG. 5C, the spacer230has an opening232. The opening232can be aligned to the recess218of the first substrate210when the spacer230is disposed on the first substrate210. In some embodiments, the spacer230is made of metal, such as aluminum or other suitable materials.

Reference is made toFIG. 5D. The probe240is disposed in the opening232of the spacer230. For example, there are five probes240disposed in the opening232inFIG. 5D. The testing terminals242of the probes240are protruded from the first through holes212of the first substrate210, such that at least portions of the insulating materials250are respectively disposed in the first through holes212.

In some embodiments, the probes240can be supported by a probe support260. The probe support260has a plurality of through holes262, such that the connecting portions244of the probes240can respectively protrude from the through holes262, and the probe support260is suspended. In some embodiments, the probe support260can be made of a nonconductive material such as polyamide mylar, and the claimed scope is not limited in this respect.

Reference is made toFIG. 5E. A second substrate220is provided. The second substrate220has at least one second through hole222. For example, the second substrate220inFIG. 5Ehas five second through holes222, and the claimed scope is not limited in this respect. The second substrate220further has a recess228, and the second through holes222are disposed at the top of the recess228. The second substrate220can be made of ceramic material or other suitable materials.

In some embodiments, an insulating layer280is formed at a side224of the second substrate220. The insulating layer280may be disposed in the recess228of the second substrate220. Moreover, an insulating layer285is formed at a side226of the second substrate220, and insulating layers295are respectively formed in the second through holes222. The insulating layers280,285, and295can be made of high volume resistivity materials, such as polyamide-imides. The insulating layers280and285can be respectively coated on the sides224and226. In other embodiments, the insulating layers280,285, and290can be omitted, or at least one of the insulating layers280,285, and295is formed on the second substrate220.

Subsequently, the second substrate220is disposed on the spacer230. For example, the second substrate220can be fixed to the spacer230using screws or other suitable fixing elements. Alternatively, the first substrate210, the spacer230, and the second substrate220can be fixed together using one set of fixing elements. The side224of the second substrate220faces the spacer230, and the side226of the second substrate220is opposite to the spacer230. The recess218, the opening232, and the recess228together form a cavity C to accommodate the probes240. Hence, the connecting terminals244of the probes240respectively protrude from the second through holes222. InFIG. 5E, the insulating materials250are further respectively disposed in the second through holes222. After the probe head200ofFIG. 5Eis assembled, the probe head200can be further assembled to the jig400ofFIG. 1to be connected to the circuit board100through the space transformer300.

InFIG. 5E, the insulating materials250are respectively partially disposed in the first through holes212, i.e., the insulating materials250separate the probes240and the first substrate210. Moreover, the insulating materials250are respectively partially disposed in the second through holes222, i.e., the insulating materials250separate the probes240and the second substrate220. The insulating materials250can prevent the current passing through the probes240from leaking to the first substrate210and/or the second substrate220, which may cause signal crosstalks among the probes240. Hence, the testing reliability of the probe card assembly can be improved. Furthermore, the probe240can be individually replaced if it is damaged. Hence, the cost of the probe head200can be reduced.

FIGS. 6A-6Care top views for manufacturing the probe head200in accordance with various embodiments of the present disclosure. For clarity, the probe support260ofFIG. 2is omitted inFIGS. 6B-6C. The manufacturing process ofFIG. 5Ais performed previously. Since the relevant manufacturing details are all the same as the embodiment inFIG. 5A, and, therefore, a description in this regard will not be repeated hereinafter. Reference is made toFIG. 6A. Subsequently, a first substrate210is provided. The first substrate210has a plurality of first through holes212arranging along one column C1. A pitch P1is formed between two adjacent first through holes212. Subsequently, a spacer230is disposed on the first substrate210. Since other features of the first substrate210and the spacer230ofFIG. 6Aare similar to the first substrate210and the spacer230ofFIGS. 5B and 5C, a description in this regard will not be repeated hereinafter.

Reference is made toFIG. 6B. Probes240aand240bare alternately disposed in the opening232of the spacer230. The testing terminals242aand242b(seeFIG. 4C) of the probes240aand240brespectively protrude from the first through holes212as shown inFIG. 4C, and the connecting terminals244aand244b(seeFIG. 4C) of the probes240aand240bare extended towards opposite directions.

Reference is made toFIG. 6C. A second substrate220is provided. The second substrate220has a plurality of second through holes222arranging along two columns C2and C3. A projection212′ of the first through holes212on the second substrate220are disposed between the two columns C2and C3of the second through holes222. The connecting terminals244a(seeFIG. 4C) of the probes240aprotrude from the second through holes222in the column C2, and the connecting terminals244b(seeFIG. 4C) of the probes240bprotrude from the second through holes222in the column C3. This arrangement reduces the contact areas between the adjacent two probes240aand240b, such that crosstalks among the probes240aand240bcan be further reduced. A pitch P2is formed between two adjacent second through holes222. The pitch P1is shorter than the pitch P2. For example, the pitch P2is substantially twice the distance of the pitch P1. Since the relevant manufacturing details are all the same as inFIGS. 5A-5E, and, therefore, a description in this regard will not be repeated hereinafter.

The electrical properties of the probe card assembly ofFIG. 1were tested to be compared with a commercial probe head assembly, and the data matching (MAT) tests were all passed. These results indicate the probe card assembly ofFIG. 1is reliable as the commercial probe head assembly.

Since the insulating materials are respectively disposed on the probes and at least partially disposed in the first through holes, i.e., the insulating materials separate the probes and the first substrate, the insulating materials can prevent the current passing through the probes from leaking to the first substrate, which may cause signal crosstalks among the probes. Hence, the testing reliability of the probe card assembly can be improved. Moreover, since the insulating materials are further partially disposed in the second through holes, i.e., the insulating materials separate the probes and the second substrate, the insulating materials can prevent the current passing through the probe from leaking to the second substrate, which may cause signal crosstalks among the probes. Hence, the testing reliability of the probe card assembly can be further improved.

An aspect of the present disclosure is to provide a probe head including a first substrate, a second substrate, a spacer, at least one probe, and an insulating material. The first substrate has at least one first through hole. The second substrate has at least one second through hole. The spacer is disposed between the first substrate and the second substrate. The spacer, the first substrate, and the second substrate together form a cavity. The probe is disposed in the cavity and protrudes from the first through hole and the second through hole. The insulating material is on the probe and at least partially disposed in the first through hole.

Another aspect of the present disclosure is to provide a probe card assembly including a circuit board, a probe head, and a space transformer. The probe head includes a first substrate, a second substrate, a spacer, at least one probe, and an insulating material. The first substrate has at least one first through hole. The second substrate has at least one second through hole. The spacer is disposed between the first substrate and the second substrate. The spacer, the first substrate, and the second substrate together define a cavity. The probe is disposed in the cavity and extends from the first through hole and the second through hole. The insulating material at least covers a portion of the probe disposed in the first through hole. The space transformer is disposed between the circuit board and the probe head to electrically interconnect the probe and the circuit board.

Still another aspect of the present disclosure is to provide a method for manufacturing a probe head including forming an insulating material around a probe. A spacer is disposed on a first substrate. The probe is disposed in an opening of the spacer. The probe protrudes from a first through hole of the first substrate, such that at least a portion of the insulating material is disposed in the first through hole. A second substrate is disposed on the spacer, such that the probe further protrudes from a second through hole of the second substrate.