Probe card system, probe loader device and manufacturing method of the probe loader device

A probe loader device includes a carrier board, a three-dimensional stepped structure and a probe module having a plurality of probe pin layers separately stacked together in three-dimensional stepped structure. The three-dimensional stepped structure is connected to the carrier board. Each of the probe pin layers includes a plurality of cantilever probes. The cantilever probes respectively extend outwards from different steps of the three-dimensional stepped structure, and physical touch a plurality of electrical contacts of a DUT. A portion of each of the cantilever probes extending outwards from the three-dimensional stepped structure has a moment length, and the moment lengths of the cantilever probes of the different probe pin layers are the same.

RELATED APPLICATIONS

This application claims priority to China Application Serial Number 201710302717.5, filed May 3, 2017, which is herein incorporated by reference.

BACKGROUND

Field of Disclosure

The present disclosure relates to a probe card. More particularly, the present disclosure relates to a probe card system having a cantilever probe, a probe loader device and a manufacturing method of the probe loader device.

Description of Related Art

For testing a manufactured semiconductor product (referred to as a device under test, DUT hereinafter), electrical contacts of the DUT are physically touched by cantilever probes of a testing device in the testing process respectively so as to obtain test results of the DUT after signal transmissions and signal analysis.

However, when the cantilever probes respectively touch different electrical contacts which are respectively located at an inner row and an outer row on the DUT, since the cantilever probes respectively touching different electrical contacts will have different moments of forces, the cantilever probes respectively exert different forces onto the different electrical contacts so that pressed indentation marks with different sizes are formed on the different electrical contacts which are located at different rows on the DUT. Because the electrical contacts located at different rows are exerted with different pressures, it is not guaranteed that the cantilever probes fully and accurately touch all of the electrical contacts of the DUT, thereby causing inaccurate of the test performance of the semiconductor product. Therefore, a tester must spend more time to adjust the configuration variables of the cantilever probes, thereby increasing the difficulty of reassembling the testing device.

Therefore, how to develop a solution to effectively overcome the aforementioned inconvenience and disadvantages is a serious concern for the industry.

SUMMARY

One embodiment of the disclosure is to provide a probe loader device. The probe loader device includes a carrier board, at least one three-dimensional stepped structure and at least one probe module. The three-dimensional stepped structure is connected to the carrier board, and the three-dimensional stepped structure includes a plurality of stepped portions. The stepped portions are sequentially decremented along a direction of being away from the carrier board. The probe module includes a plurality of probe pin layers separately stacked together in the three-dimensional stepped structure. Each of the probe pin layers includes a plurality of cantilever probes which are arranged abreast, and the cantilever probes of the probe pin layers respectively extend outwards from the three-dimensional stepped structure through the different ones of the stepped portions. The cantilever probes of the probe pin layers are used to touch a plurality of electrical contacts of a device under test (DUT). A portion of each of the cantilever probes extending outwards from the three-dimensional stepped structure has a moment length, and the moment lengths of the cantilever probes of the different probe pin layers are the same.

Another embodiment of the disclosure is to provide a probe card system. The probe card system includes a platform and a probe card device. The platform has a load surface for carrying a device under test (DUT). The DUT has an inner encirclement portion and an outer encirclement portion surrounding the inner encirclement portion, and the inner encirclement portion is provided with a plurality of first electrical contacts, and the outer encirclement portion is provided with a plurality of second electrical contacts. The probe card device is disposed on the platform, and the probe card device includes a circuit board and a probe loader device. The probe loader device includes a carrier board, a pin holding portion and at least one probe module. The pin holding portion is disposed on one surface of the carrier board, and the pin holding portion includes at least one three-dimensional stepped structure connected to the carrier board. The three-dimensional stepped structure includes at least one first step surface, at least one second step surface and at least one connecting surface. The first step surface surrounds to form a first space area. The second step surface surrounds to form a second space area which is in communication with the first space area and greater than the first space area. The connecting surface adjoins the first step surface and the second step surface. The probe module is electrically connected to the circuit board, and the probe module includes at least one first probe pin layer and at least one second probe pin layer. The first probe pin layer and the second probe pin layer are separately stacked together in the pin holding portion. The first probe pin layer includes a plurality of first cantilever probes respectively extending outwards from the three-dimensional stepped structure through the first step surface and touching the first electrical contacts. The second probe pin layer includes a plurality of second cantilever probes respectively extending outwards from the three-dimensional stepped structure through the second step surface and touching the second electrical contacts. A portion of each of the first cantilever probes extending outwards from the three-dimensional stepped structure has a first moment length, a portion of each of the second cantilever probes extending outwards from the three-dimensional stepped structure has a second moment length which is the same as the first moment length.

Another embodiment of the disclosure is to provide a manufacturing method of a probe loader device. The manufacturing method of the probe loader device includes steps as follows. A first cantilever probe is disposed on a carrier board. A first colloid body is applied to cover the first cantilever probe and the carrier board. The first colloid body is cured to be a first curing layer so that the first cantilever probe is fixed in the first curing layer, and one portion of the first cantilever probe extends outwards from the first curing layer, and the portion of the first cantilever probe has a first moment length. A second cantilever probe is disposed on one surface of the first curing layer opposite to the carrier board. A second colloid body is applied to cover the second cantilever probe and the first curing layer. The second colloid body is cured to be a second curing layer which is more concaved inwardly than the first curing layer so that the second curing layer and the first curing layer collectively form a three-dimensional stepped structure, and the second cantilever probe is fixed in the second curing layer, and one portion of the second cantilever probe extends outwards from the second curing layer, and the portion of the second cantilever probe has a second moment length which is the same as the first moment length.

Therefore, through the probe card system, the probe loader device and the manufacturing method of the probe loader device, the aforementioned cantilever probes can exert to respectively touch the different electrical contacts with the same pressures so that pressed indentation marks with substantially the same size are formed on the different electrical contacts. Thereby decreasing the difficulty of reassembling the probe loader device to another DUT.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the present embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. According to the embodiments, it will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present disclosure without departing from the scope or spirit of the disclosure.

Reference is now made toFIG. 1andFIG. 2, in whichFIG. 1is a side view of a probe card system10according to one embodiment of the disclosure, andFIG. 2is a top view of a probe card device200ofFIG. 1. As shown inFIG. 1andFIG. 2, in the embodiment, the probe card system10includes a platform100and a probe card device200. The platform110has a load surface110. The load surface110is used to carry a DUT500(e.g., semiconductor product) thereon. The probe card device200is disposed above the platform100. The probe card device200includes a probe loader device201and a circuit board210. The probe loader device201includes a carrier board220, a pin holding portion300and one or more probe modules400. The pin holding portion300is connected to the carrier board220. Exemplarily, the carrier board220is disposed between the pin holding portion300and the circuit board210. One surface of the pin holding portion300is provided with a three-dimensional stepped structure310. The three-dimensional stepped structure310includes a first stepped portion311, a second stepped portion312and a third stepped portion313. The first stepped portion311, the second stepped portion312and the third stepped portion313are arranged in order along a direction of being away from the carrier board220, and the first stepped portion311, the second stepped portion312and the third stepped portion313are sequentially decremented in size along the direction of being away from the carrier board220, that is, in the pin holding portion300, the third stepped portion313is more concaved inwardly than the second stepped portion312, and the second stepped portion312is more concaved inwardly than the first stepped portion311. The probe modules400are disposed in the pin holding portion300in which a portion of each of the probe modules400is electrically connected to the circuit board210, another portion of each of the probe modules400is electrically connected to the DUT500. Thus, the circuit board210is used to be electrically connected to the DUT500though the probe modules400. Each of the probe modules400includes a plurality of probe pin layers separately stacked together in the three-dimensional stepped structure310. The probe pin layers are exemplarily referred to be a first probe pin layer410, a second probe pin layer420and a third probe pin layer430. Each of the probe pin layers includes a plurality of cantilever probes which are arranged abreast, in the embodiment, the cantilever probes are parallel to one another. However, the disclosure is not limited thereto. These cantilever probes are exemplarily divided into first cantilever probes411, second cantilever probes421and third cantilever probes431. The first cantilever probes411, the second cantilever probes421and the third cantilever probes431extend outwards from the three-dimensional stepped structure310through the first stepped portion311, the second stepped portion312and the third stepped portion313, respectively so that the first cantilever probes411, the second cantilever probes421and the third cantilever probes431are used to touch the first electrical contacts511, second electrical contacts521and third electrical contacts531, respectively.

Specifically, the carrier board220includes a through hole221, a first main surface222, a second main surface223, one or more inner lateral surfaces225and one or more outer lateral surfaces224. The second main surface223is opposite to the first main surface222. The through hole221is surrounded by the inner lateral surfaces225. The through hole221penetrates through the carrier board220along an axial line221A of the through hole221to connect the first main surface222and the second main surface223. The outer lateral surfaces224are disposed between the first main surface222and the second main surface223, and adjoin the first main surface222and the second main surface223, and surround the inner lateral surfaces225, the through hole221, the first main surface222and the second main surface223. In the embodiment, the axial line221A of the through hole221passes through the load surface110of the platform100, and is substantially vertical to the load surface110of the platform100, however, the disclosure is not limited thereto. The pin holding portion300is connected to the first main surface222of the carrier board220, and the pin holding portion300surrounds the axial line221A. The three-dimensional stepped structure310is formed on one surface of the pin holding portion300facing towards the axial line221A. The three-dimensional stepped structure310includes a first step surface314, a second step surface315, a third step surface316, a first connecting surface317and a second connecting surface318. The first step surfaces314collectively surround the axial line221A to form a first space area320. The first space area320is in communication with the through hole221. The second step surfaces315collectively surround the axial line221A to form a second space area330. The first space area320is located between the through hole221and the second space area330, and is in communication with the through hole221and the second space area330, and the second space area330is greater than the first space area320. The third step surfaces316collectively surround the axial line221A to form a third space area340. The third space area340is greater than the second space area330and the first space area320. The second space area330is located between the first space area320and the third space area340, and is in communication with the first space area320and the third space area340. The first connecting surface317adjoins the first step surface314and the second step surface315. The second connecting surface318adjoins the second step surface315and the third step surface316.

FIG. 3is a partial three-dimensional view of a partial location of a probe card device ofFIG. 1in which the partial location is same as a local zone M of the probe card device ofFIG. 2. As shown inFIG. 1andFIG. 3, the probe modules400includes the aforementioned first probe pin layer410, second probe pin layer420and third probe pin layer430. The aforementioned first probe pin layer410, the second probe pin layer420and the third probe pin layer430are separately stacked together along the axial line221A. The aforementioned first probe pin layer410includes a plurality of first cantilever probes411which are arranged abreast. In the embodiment, the first cantilever probes411are substantially parallel to one another, however, the disclosure is not limited thereto. Each of the first cantilever probes411is partially embedded in the first stepped portion311in which one end of each of the first cantilever probes411is welded on the circuit board210, and the other end of each of the first cantilever probes411extends outwards from the first stepped portion311through the first step surface314. The aforementioned second probe pin layer420includes a plurality of second cantilever probes421which are arranged abreast. In the embodiment, the second cantilever probes421are substantially parallel to one another, however, the disclosure is not limited thereto. Each of the second cantilever probes421is partially embedded in the second stepped portion312in which one end of each of the second cantilever probes421is welded on the circuit board210, and the other end of each of the second cantilever probes421extends outwards from the second stepped portion312through the second step surface315.

The aforementioned third probe pin layer430includes a plurality of third cantilever probes431which are arranged abreast. In the embodiment, the third cantilever probes431are substantially parallel to one another, however, the disclosure is not limited thereto. Each of the third cantilever probes431is partially embedded in the third stepped portion313in which one end of each of the third cantilever probes431is welded on the circuit board210, and the other end of each of the third cantilever probes431extends outwards from the third stepped portion313through the third step surface316.

FIG. 4is a top view of a device under test (DUT)500ofFIG. 1. As shown inFIG. 3andFIG. 4, one surface of the DUT500is provided with an inner encirclement portion510, a middle encirclement portion520and an outer encirclement portion530. The middle encirclement portion520is arranged between the inner encirclement portion510and the outer encirclement portion530. The middle encirclement portion520surrounds the inner encirclement portion510. The outer encirclement portion530surrounds the inner encirclement portion510and the middle encirclement portion520. The inner encirclement portion510is provided with a plurality of first electrical contacts511. The first cantilever probes411which individually extend outwards from the first stepped portion311through the first step surface314(FIG. 1) electrically touch the first electrical contacts511, respectively. The middle encirclement portion520is provided with a plurality of second electrical contacts521. The second cantilever probes421which individually extend outwards from the second stepped portion312through the second step surface315(FIG. 1) electrically touch the second electrical contacts521, respectively. The third cantilever probes431which extend outwards from the third stepped portion313through the third step surface316(FIG. 1) electrically touch the third electrical contacts531, respectively. Compared among the outer encirclement portion530, the middle encirclement portion520and the inner encirclement portion510, the outer encirclement portion530(i.e., the third electrical contacts531) is closest to an outer edge501of the DUT500, the middle encirclement portion520(i.e., the second electrical contacts521) is the next one closest to the outer edge501of the DUT500, and the inner encirclement portion510(i.e., the first electrical contacts511) is farthest from the outer edge501of the DUT500. The first electrical contacts511of the inner encirclement portion510, the second electrical contacts521of the middle encirclement portion520and the third electrical contacts531of the outer encirclement portion530are arranged staggered one another. Thus, the corresponding first cantilever probes411, the corresponding second cantilever probes421and the corresponding third cantilever probes431are also staggered one another.

It is noted, although the first electrical contacts511, the second electrical contacts521and the third electrical contacts531arranged on the DUT500shown inFIG. 2andFIG. 4are staggered one another, it does not mean that the electrical contacts located at inner/outer encirclement portions of all kinds of the DUT have to staggered one another. One with ordinary skill in the art of the disclosure may modify the arrangement of all of the electrical contacts located at inner/outer encirclement portions on any DUT at discretion according to actual requirements and restrictions. For example, the first electrical contacts, the second electrical contacts and the third electrical contacts are aligned linearly. Thus, one of the first cantilever probes, one of the second cantilever probes and one of the third cantilever probes are overlapped one another vertically. However, the disclosure is not limited thereto. The probe modules400and the three-dimensional stepped structures310are respectively plural, and the three-dimensional stepped structures310are separately arranged to collectively surround the axial line221A, and all of the cantilever probes extending outwards from the three-dimensional stepped structures310respectively extend towards the axial line221A.

Back toFIG. 3, as the first probe pin layer410can be plural, two neighboring ones of the first probe pin layers410are both disposed in the first stepped portion311of the three-dimensional stepped structure310; that is, the two first probe pin layers410are separately stacked in an upper sublayer311T and a lower sublayer311B of the first stepped portion311. Thus, the first cantilever probes411,411′ which are vertically stacked with each other and respectively embedded in the upper sublayer311T and the lower sublayer311B extend outwards from the first stepped portion311through the same step surface (e.g., the first step surface314,FIG. 1). Furthermore, since the first cantilever probes411,411′ which are vertically stacked with each other and respectively embedded in the upper sublayer311T and the lower sublayer311B can respectively physically touch these first electrical contacts511of the DUT500, the first cantilever probes411,411′ are arranged alternatively on the DUT500. Therefore, in the embodiment, the DUT500with more first electrical contacts511can be tested. As the second probe pin layer420can be plural, two neighboring ones of the second probe pin layers420are both disposed in the second stepped portion312of the three-dimensional stepped structure310; that is, the two second probe pin layers420are separately stacked in an upper sublayer312T and a lower sublayer312B of the second stepped portion312. Thus, the second cantilever probes421,421′ which are vertically stacked with each other and respectively embedded in the upper sublayer312T and the lower sublayer312B extend outwards from the second stepped portion312through the same step surface (e.g., the second step surface315,FIG. 1). Furthermore, since the second cantilever probes421,421′ which are vertically stacked with each other and respectively embedded in the upper sublayer312T and the lower sublayer312B can respectively physically touch these second electrical contacts521of the DUT500, the second cantilever probes421,421′ are arranged alternatively on the DUT500. Therefore, in the embodiment, the DUT500with more second electrical contacts521can be tested.

As the third probe pin layer430can be plural, two neighboring ones of the third probe pin layers430are both disposed in the third stepped portion313of the three-dimensional stepped structure310; that is, the two third probe pin layers430are separately stacked in an upper sublayer313T and a lower sublayer313B of the third stepped portion313. Thus, the third cantilever probes431,431which are vertically stacked with each other and respectively embedded in the upper sublayer313T and the lower sublayer313B extend outwards from the third stepped portion313through the same step surface (e.g., the third step surface316,FIG. 1). Furthermore, since the third cantilever probes431,431′ which are vertically stacked with each other and respectively embedded in the upper sublayer313T and the lower sublayer313B can respectively physically touch these third electrical contacts531of the DUT500, the third cantilever probes431,431′ are arranged alternatively on the DUT500. Therefore, in the embodiment, the DUT500with more third electrical contacts531can be tested.

However, the disclosure is not limited thereto, in another embodiment, any single probe pin layer of the probe modules400also can be embedded in a single stepped portion only.

FIG. 5is a side view of cantilever probes440of a probe card system according to one embodiment of the disclosure. As shown inFIG. 5, each of the cantilever probes440includes a suspended portion441and a bending portion442which is connected to the suspended portion441. The suspended portion441is partially embedded in the three-dimensional stepped structure310, and a needle end443of the bending portion442which is out of the three-dimensional stepped structure310is used to physically touch one of the electrical contacts512. A portion of each of the cantilever probes440extending outwards from the three-dimensional stepped structure310has a moment length. The moment length of each of the cantilever probes440is a minimum straight distance D1defined between a first virtual plane P1and a second virtual plane P2in which the first virtual plane P1and the second virtual plane P2are parallel to each other, the second virtual plane P2is same as a step surface319, which one of the cantilever probes440extends through, and the first virtual plane P1passes through the needle end443of the cantilever probe440extending through the step surface319.

Thus, since the moment lengths (i.e., minimum straight distance D1, D2, D3) of the cantilever probes440are the same one another, the aforementioned cantilever probes440can exert to respectively touch the different electrical contacts512with the same pressures so that pressed indentation marks with substantially the same size are formed on the different electrical contacts512. Thereby decreasing the difficulty of reassembling the probe loader device to another DUT.

FIG. 6is a flow chart of a manufacturing method of a probe card system according to one embodiment of the disclosure.FIG. 7AtoFIG. 7Fare operational schematic views of the flow chart ofFIG. 6. As shown inFIG. 6, the manufacturing method of a probe card system includes step601to step606outlined as follows. In step601, as shown inFIG. 7A, a first cantilever probe411is disposed on a first main surface222of a carrier board220. In step602, as shown inFIG. 7B, a first colloid body710is applied on the carrier board220to cover the first cantilever probe411and the first main surface222of the carrier board220. For example, the leading directions of the first colloid body710being applied on the carrier board220can be guided by a baffle B so as to adjust the coating position of the first colloid body710. In step603, as shown inFIG. 7C, the first colloid body710(FIG. 7B) is cured to be a first curing layer730so that the first cantilever probe411is fixed in the first curing layer730in which one portion of the first cantilever probe411extends outwards from the first curing layer730, and the portion extending outwards from the first curing layer730has a first moment length L1. For example, the first colloid body710(FIG. 7B) is heated to be transformed as the first curing layer730through a heating device H. In step604, as shown inFIG. 7D, a second cantilever probe421is disposed on one surface731of the first curing layer730opposite to the carrier board220. In step605, as shown inFIG. 7E, a second colloid body720is applied on the first curing layer730to cover the second cantilever probe421and the first curing layer730. For example, the leading directions of the second colloid body720being applied on the first curing layer730can be guided by the baffle B so as to adjust the coating position of the second colloid body720for being protruded in relation to the first curing layer730. The protruding degree of the second colloid body720in relation to the first curing layer730is substantially equal to a gap between any two electrical contacts which are located in any two neighboring rows on the DUT. In step606, as shown inFIG. 7F, the second colloid body720(FIG. 7E) is cured to be a second curing layer740so that the second cantilever probe421is fixed in the second curing layer740in which one portion of the second cantilever probe421extends outwards from the second curing layer740, and the portion extending outwards from the second curing layer740has a second moment length L2which is same as the first moment length L1. For example, the second colloid body720(FIG. 7E) is heated to be transformed as the second curing layer740through a heating device H. Therefore, inFIG. 7F, the second curing layer740is more concaved inwardly than the first curing layer730so that the second curing layer740and the first curing layer730collectively form a three-dimensional stepped structure310(FIG. 1) so as to integrate a probe loader device therefore. Thereafter, in step607, a circuit board is provided to be electrically connected to the first cantilever probe and the second cantilever probe so as to integrate a probe card device (not shown in figures).

However, the number of the stepped portions of the three-dimensional stepped structure310is not limited in the disclosure; one with ordinary skill in the art of the disclosure may decide the number of the stepped portions of the three-dimensional stepped structure according to actual requirements and restrictions.

In the above embodiment, the material of the carrier board220is made of ceramic or the like. The material of the first colloid body710and the second colloid body720respectively are resins such as epoxy resin and alike. However, the present disclosure is not limited thereto.