Adjustment mechanism

A probe card assembly can comprise a support structure to which a plurality of probes can be directly or indirectly attached. The probes can be disposed to contact an electronic device to be tested. The probe card assembly can further comprise actuators, which can be configured to change selectively an attitude of the support structure with respect to a reference structure. The probe card assembly can also comprise a plurality of lockable compliant structures. While unlocked, the lockable compliant structures can allow the support structure to move with respect to the reference structure. While locked, however, the compliant structures can provide mechanical resistance to movement of the support structure with respect to the reference structure.

BACKGROUND

Test systems for testing electronic devices, such as semiconductor dies, are known. In some such test systems, electrically conductive probes are brought into contact with terminals of the electronic devices. Power and test signals are then provided to the electronic devices through the probes, and the responses of the electronic devices to the test signals are monitored through the probes. To establish reliable electrical connections between the probes and the terminals of the electronic devices, the probes typically must be generally aligned with the terminals. In some test scenarios, aligning the probes with the terminals includes adjusting an attitude (e.g., tilt, orientation, planarity, etc.) of the contact tips of the probes to correspond generally with an attitude of the terminals. Moreover, in some test scenarios, thermal gradients, mechanical loads placed on the probes, and other such causes can cause undesired movement of the probes. In some instances, these movements can cause the probes to become so misaligned with the terminals that electrical connections between some or all of the probes and some or all of the terminals of the electronic devices are lost during testing of the electronic devices. Embodiments of the present invention are directed to improvements in adjusting an attitude of a probe card assembly and providing mechanical stiffening of the probe card assembly.

SUMMARY

A probe card assembly according to some embodiments of the invention, can comprise a support structure to which a plurality of probes can be directly or indirectly attached. The probes can be disposed to contact an electronic device to be tested. The probe card assembly can further comprise actuators, which can be configured to change selectively an attitude of the support structure with respect to a reference structure. The probe card assembly can also comprise a plurality of lockable compliant structures. While unlocked, the lockable compliant structures can allow the support structure to move with respect to the reference structure. While locked, however, the compliant structures can provide mechanical resistance to movement of the support structure with respect to the reference structure.

A method of selectively adjusting an attitude of a plurality of probes with respect to terminals of an electronic device to be tested, according to some embodiments of the invention, can comprise attaching a probe card assembly to a reference structure. The probes can be attached directly or indirectly to a support structure of the probe card assembly, which can comprise a plurality of lockable compliant structures. The method can further comprise changing an attitude of the support structure of the probe card assembly with respect to the reference structure while the lockable compliant structures are unlocked and then locking the lockable compliant structures. While unlocked, the lockable compliant structures can allow the support structure to move with respect to the reference structure. On the other hand, while locked, each lockable compliant structure can mechanically resist movement of the compliant structure with respect to the reference structure.

An apparatus for adjusting an attitude of a plurality of probes can, according to some embodiments of the invention, comprise an adjustment mechanism configured to adjust an attitude of a support structure with respect to a reference structure. The probes can be attached directly or indirectly to the support structure. The apparatus can further comprise a clutched compliant mechanism. While a clutch of the compliant mechanism is disengaged, the compliant mechanism can allow the support structure to move with respect to the reference structure. While the clutch is engaged, however, the compliant mechanism can mechanically resist movement of the support structure with respect to the reference structure.

In some embodiments, a tool holding assembly can comprise a support structure, and a plurality of tools can be secured directly or indirectly to the support structure and disposed to operate on a work piece. Actuators can be configured to change selectively an attitude of the support structure with respect to a reference structure. The tool holding assembly can include a plurality of lockable compliant structures. While unlocked, the lockable compliant structures can allow the support structure to move with respect to the reference structure. While locked, however, the compliant structures can mechanically resist movement of the support structure with respect to the reference structure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

This specification describes exemplary embodiments and applications of the invention. The invention, however, is not limited to these exemplary embodiments and applications or to the manner in which the exemplary embodiments and applications operate or are described herein. Moreover, the Figures may show simplified or partial views, and the dimensions of elements in the Figures may be exaggerated or otherwise not in proportion. In addition, as the terms “on” and “attached to” and similar terms are used herein, one object (e.g., a material, a layer, a substrate, etc.) can be “on” or “attached to” another object regardless of whether the one object is directly on or attached to the other object or there are one or more intervening objects between the one object and the other object. Also, directions (e.g., above, below, top, bottom, side, horizontal, vertical, “x,” “y,” “z,” etc.), if provided, are relative and provided solely by way of example and for ease of illustration and discussion and not by way of limitation.

FIG. 1illustrates an exemplary test system100according to some embodiments of the invention. As shown, the test system100includes a housing132(e.g., a test apparatus, such as a semiconductor prober), which is shown inFIG. 1with cutout136revealing an interior chamber132of the housing132. As shown, a moveable chuck134can be located in the chamber132and configured to hold one or more electronic devices or DUTs130to be tested. As used herein, the acronym “DUT,” which can refer to device or devices under test, refers to any electronic device or devices to be tested or being tested. Non-limiting examples of DUTs include one or more dies of an unsingulated semiconductor wafer, one or more semiconductor dies singulated from a wafer (packaged or unpackaged), one or more dies of a plurality of singulated semiconductor dies disposed in a carrier or other holding device, one or more multi-die electronics modules, one or more printed circuit boards, and any other type of electronic device or devices.

As shown, the housing132can comprise a head plate110, which can, for example, be any rigid structure and can form part or all of an upper portion of the housing132. A probe card assembly114comprising a plurality of electrically conductive probes116configured to contact input and/or output terminals118of the DUT130can be attached to the head plate110. The probes116can be disposed, for example, in an array or other patterns. For example, the probes116can comprise contact tips configured to contact terminals118of the DUT130. As best seen inFIG. 2, the head plate110can comprise an insert ring112(e.g., a card holder) or similar structure to which the probe card assembly114can be attached (e.g., bolted, clamped, etc.). The insert ring112can include an opening120through which the probes116can extend into the chamber132.

As also shown inFIG. 1, the test system100can include a tester102, which can be a computer or a computer system. A plurality of communications channels can be provided from the tester102to the probe card assembly114. The communications channels can comprise any element or elements, device or devices, etc. that can provide communication links between the tester102and the probe card assembly114for the passage of power and signals (e.g., test signals, control signals, etc.) from the tester to the probe card assembly114and the passage of signals generated by the DUT130from the probe card assembly114to the tester102.

In the example shown inFIG. 1, the communications channels can be formed by one or more communications links104(e.g., coaxial cables, fiber optic cables, wireless communications links, etc.) and electronics (e.g., receiver circuits, driver circuits, interface circuits, etc.) in a test head106. The probe card assembly114can be electrically connected to the communications channels by electrical connectors108, and the probe card assembly114can comprise electrically conductive paths between the connectors108and the probes116. A plurality of electrically conductive paths can thus be provided between the tester102and the probes116.

In operation, a DUT130can be placed on the chuck134. The chuck134can then be moved such that ones of the input and/or output terminals118of the DUT130can be brought into contact with contact tips of ones of the probes116, thereby establishing temporary electrical connections between the ones of the terminals118and the ones of the probes116. The tester102can then generate power and test signals that are provided through the communications channels (e.g., comprising the link104, circuitry in the tester head106, and connectors108) and the probe card assembly114to the DUT130. Response signals generated by the DUT130in response to the test signals can be provided through the probe card assembly114and communications channels to the tester102, which can analyze the response signals and determine whether the DUT130responded correctly to the test signals. For example, the tester102can compare the response signals to expected response signals.

In some embodiments, there may be fewer probes116than terminals118. In such a case, the chuck134can move the DUT130such that other terminals118are brought into contact with ones of the probes116at which time the tester102can provide power and test signals through the communications channels and probe card assembly114to test other portions of the DUT130. The foregoing process of bringing ones of the terminals118into contact with ones of the DUT terminals118and then testing a portion of the DUT130by providing power and test signals from the tester102to the DUT130and analyzing response signals generated by the DUT130in response to the test signals can be repeated as needed to test the entire DUT130. For example, if DUT130is a semiconductor wafer comprising a plurality of semiconductor dies (not shown), the wafer can be repositioned multiple times, as needed, in order to test all of the dies of the wafer.

Test system100is exemplary only, and many modifications and changes are possible. For example, communications channels between the tester102and the probe card assembly114can be provided by means other than the link104, test head106, and connectors108shown inFIG. 1. For example, communication channels can be provided by direct communications links (e.g., coaxial cables, wireless communications links, fiber optic cables, etc.) directly connecting the tester102and the probe card assembly110.

FIGS. 2-4illustrate in simplified block diagram form an exemplary configuration of the probe card assembly114according to some embodiments of the invention.FIGS. 2-4also show a partial view of the head plate110. As shown inFIG. 2(which shows a perspective view of the probe card assembly114and a partial perspective view of the head plate110), the insert ring112can be shaped to receive the probe card assembly114. For example, as shown inFIG. 2, the probe card assembly114can be generally annular and the insert ring112can be correspondingly annular. The probe card assembly114and insert ring112can, however, take other shapes (e.g., square, rectangular, etc.).

As shown inFIGS. 2-4and best seen inFIG. 4, the probe card assembly114can comprise an attachment/stiffening structure202, a wiring board204, a flexible electrical connector402, and a probe head assembly404. The attachment/stiffening structure202can be configured to be attached to the insert ring112of the head plate110and can further be a stiffening structure that mechanically resists movement (e.g., movement or warping due to thermal changes or gradients, movement or warping due to mechanical loads, etc.) of the probe card assembly or parts of the probe card assembly. In addition, the probe head assembly404can be attached mechanically to the attachment/stiffening structure202by mounting mechanisms214. As shown, the attachment/stiffening structure202can include a support structure206, which can be a rigid structure to which the probe head assembly404is attached by the mounting mechanisms214. For example, the support structure206can comprise a plate or a plate-like structure (e.g., comprising metal or other rigid materials). As another example, the support structure206can comprise a metal plate-like structure with empty spaces. As mentioned, the attachment/stiffening structure202can be configured to mechanically resist warping or deformation of the probe card assembly114due to, for example, thermal gradients or mechanical loads, that could otherwise affect the positions of the probes116.

The wiring substrate204can comprise a plurality of electrical connectors212configured to make electrical connections with connectors108shown inFIG. 1. Although four are shown, more or fewer could be used. The wiring substrate204can include a plurality of electrical paths (e.g., one or more electrically conductive traces and/or vias on or in the wiring substrate204) through the wiring substrate204between the electrical connectors212and flexible electrical connector402. The flexible electrical connector402can provide electrical paths to the probe head assembly404, which, in turn, can provide electrical paths through the probe head assembly404to the probes116.

As shown, mounting mechanisms214can mechanically attach the probe head assembly404to the support structure206. The mounting mechanisms214can thus be any device or mechanism suitable for attaching the probe head assembly404to the support structure206. The mounting mechanisms214can thus be as simple as bolts, screws, clamps, or other mechanical attachment mechanisms. In some embodiments, however, the mounting mechanisms214can provide additional functionality. For example, each mounting mechanism can be configured to push and/or pull the probe head assembly404away or toward the support structure206. For example, the mounting mechanisms214can comprise differential screw assemblies, each configured selectively to push the probe head assembly404away from the support structure206or pull the probe head assembly404toward the support structure206depending on which direction a rotating element of the differential screw assembly is rotated. As another example, each mounting mechanism214can comprise a pushing mechanism and a biasing mechanism. For example, the pushing mechanism can comprise a screw or bolt that, when rotated in a first direction, extends toward and thus pushes the probe head assembly404away from the support structure206. The screw or bolt can be configured to retract away from the probe head assembly404when rotated in the opposite direction, allowing the biasing mechanism (which can be, for example, a spring) to push the probe head assembly404toward the support structure206. By including a plurality of such mounting mechanisms214disposed to contact the probe head assembly404in different locations, the attitude (including, for example, a planarity, tilt, orientation, etc.) of the probe head assembly404, and thus the tips of the probes116, with respect to the support structure206can be selectively adjusted or changed. The mounting mechanisms214can also include the ability to lock mechanically in place a particular attitude of the probe head assembly404with respect to the support structure206.

The wiring substrate204can be, for example, a printed circuit board substrate. The flexible connector402can be any suitable means for providing electrical connections between the wiring substrate204and the probe head assembly404that are sufficiently flexible to accommodate changes in the attitude (e.g., tilt, orientation, planarity, etc.) of the probe head assembly404with respect to the support structure206. The flexible connector402can thus be as simple as a plurality of flexible wires. As another non-limiting example, flexible connector402can comprise an interposer comprising a substrate (e.g., a ceramic substrate, a printed circuit board substrate, etc.) with electrically conductive spring contacts extending from opposite surfaces of the substrate and electrical connections between ones of the spring contacts on one surface and others of the spring contacts on the other surface of the substrate.

The probe head assembly404can be as simple as a single substrate (e.g., a probe substrate) to which the probes116are attached. Alternatively, the probe head assembly404can comprise a plurality of independently moveable substrates (e.g., a plurality of probe substrates), and a subset of the probes116can be attached to each such independently moveable substrate. Such a probe head assembly404can include mechanisms for adjusting independently the position and orientation of each of the substrates with respect to the other substrates.

As shown inFIGS. 2-4, the attachment/stiffening structure202can also include a plurality of assemblies208,210(e.g., arm assemblies) (eight are shown but more or fewer can be used). Some of the assemblies208can be adjustment assemblies208, and others of the assemblies210can be lockable (e.g., can be clamped and unclamped) compliant assemblies210(e.g., clutched compliant mechanisms). (Although three adjustment assemblies208and five lockable compliant assemblies210are shown in the exemplary probe card assembly114ofFIGS. 2-4, more or fewer of either type of assembly208,210can be included in other embodiments or implementations.)

Each of the assemblies208,210can include a mechanism (e.g., an attachment mechanism) that allows the assembly208,210to be attached to and detached from the insert ring112of the head plate110. For example, each adjustment assembly208,210can be bolted, clamped, etc. to the insert ring112. In addition, each adjustment assembly208can include an adjustment mechanism configured to move the assembly208with respect to the insert ring112(e.g., each adjustment mechanism can move the assembly208towards or away from the insert ring112) while the probe card assembly114is attached to the insert ring112. The adjustment assemblies208can thus change (e.g., adjust) the attitude (e.g., the tilt, orientation, or planarity) of the probe card assembly114with respect to the insert ring112(which can be an example of a reference structure). Each lockable compliant assembly210can include an attachment block302(which can be an example of an attachment mechanism) that can be securely attached to the insert ring112, and a compliant mechanism432that can allow the support structure206to move with respect to the attachment block302. The lockable compliant assemblies210can also include a locking mechanism430that can lock the compliant mechanism432such that the support structure206cannot appreciably move with respect to the attachment block302. In other words, locking mechanism430can lock compliant mechanism432such that the lockable compliant assembly210mechanically resists movement of the support structure with respect to the attachment block302and the insert ring112. Thus, while unlocked, each lockable compliant assembly210can allow movement of the support structure206(e.g., movement induced by the adjustment assemblies208). Thus, for example, while unlocked, each lockable compliant assembly210can allow the attitude of the support structure206to be changed with respect to the insert ring112without substantially or appreciably influencing the attitude of the support structure206. This is because, while unlocked, the lockable compliant assembly210allows the support structure206to move with respect to the insert ring112. Typically, the greater the freedom of movement (e.g., with regard to the number of degrees of freedom of motion and/or friction) of the support structure206with respect to the insert ring112provided by the lockable compliant assembly210while unlocked, the less the unlocked lockable compliant assembly210will influence the attitude of the support structure with respect to the insert ring206. Typically, if sufficient degrees of freedom of motion of the support structure206with respect to the insert ring112are provided, friction between the moving parts of the lockable compliant assembly210that provide those degrees of motion can be the only potentially significant source of influence by the unlocked lockable complaint assembly210on the attitude of the support structure206with respect to the insert ring112. In some embodiments, at least four degrees of freedom of motion (e.g., rotation about the “x,” “y,” and “z” axes and translation along one of those axes) are a sufficient number of degrees of freedom, although in other embodiments more or fewer degrees of freedom of motion can be provided. Through proper construction and/or lubrication of the moving parts of the lockable compliant assembly210, such friction can be reduced such that the influence of the unlocked lockable compliant assembly210on the attitude of the support structure206is negligible. While locked, however, each lockable compliant assembly210can provide mechanical stiffening or resistance to resist warping, deformation, or other movements of the probe card assembly114caused by, for example, thermal gradients, mechanical loading, etc. The lockable compliant assemblies210can thus be examples of lockable compliant structures.

An example of an adjustment assembly208according to some embodiments of the invention is shown inFIG. 4. As shown, the adjustment assembly208can include a foot406, an extension312(e.g., an extension arm), and an actuator314(which can be an example of an adjustment mechanism). The foot406(which can be an example of an attachment mechanism) can be configured to be attached to and detached from the insert ring112. For example, the foot406can comprise a metal block that includes holes that correspond to holes in the insert ring112. Screws or bolts (not shown inFIG. 4) can pass through the holes in the foot406and the insert ring112to secure the foot406to the insert ring112.

The extension312can comprise a block or other rigid structure comprising metal or other rigid materials integrally formed with the support structure206. Alternatively, the extension312can comprise a block or structure that is rigidly secured to the support structure206. The actuator314can be configured to attach the extension312to the foot406, and the actuator314can further be configured selectively to move the extension312toward or away from the foot406. The actuator312can comprise any device or mechanism, or combination of devices and/or mechanisms, that can attach the extension312to the foot406and provide the ability selectively to move the extension312with respect to the foot406.

For example, the actuator314can comprise a spring-loaded bracket and a push actuator (not separately shown). The spring-loaded bracket (not separately shown) can secure the extension312to the foot406and bias with a spring force the extension312towards the foot406. The push actuator (not separately shown) can comprise a screw assembly mounted on the extension312that, when turned in a first direction, extends toward the foot406and thus pushes the extension312away from the foot406against the biasing force of the spring-loaded bracket. The screw assembly (not shown) can, when turned in an opposite direction, retract away from the foot406, allowing the spring biasing force of the spring-loaded bracket to pull the extension312towards the foot406. In other embodiments, actuator314can be replaced by passive devices or methods for altering an attitude of the support structure206. For example, rather than or in addition to actuators314, one or more shims (not shown) could be placed between extension312and foot406in one or more of the adjustment assemblies208to alter the attitude of the support structure206with respect to the insert ring112.

As should be apparent, by utilizing a plurality of such adjustment assemblies208, the attitude (e.g., the tilt, orientation, planarity, etc.) of the support structure206can be adjusted or changed selectively with respect to the insert ring112. Moreover, because the probe head assembly404is attached to the support structure206(e.g., by mounting mechanisms214), selectively changing the attitude of the support structure206changes the attitude of the probe head assembly404and the contact tips of the probes116(which are attached to the probe head assembly404) with respect to the insert ring112. In addition, because the insert ring112and the chuck134can be part of or can be attached (directly or indirectly) to the housing132, adjusting the attitude of the support structure206, probe head assembly404, and contact tips of the probes116with respect to the insert ring112also changes the attitude of the support structure206, probe head assembly404, and contact tips of the probes116with respect to the chuck134and the DUT130(with terminals118) disposed on the chuck134. Therefore, as shown inFIGS. 5A and 5B, the attitude of the support structure206, and thus contact tips of the probes116, can be adjusted with respect to the insert ring112and the DUT terminals118.FIG. 5Ashows support structure206, and thus probe head assembly404and the contact tips of probes116, with an attitude that is tilted with respect to the insert ring112, andFIG. 5Bshows support structure206with an attitude that is tilted, in a different direction, with respect to the insert ring112. The attitude of the support structure206, and thus the contact tips of the probes116, can thus be changed with respect to any number of reference structures, including without limitation the insert ring112, the chuck234(e.g., the surface of the chuck234on which the DUT130is placed), the DUT130, and the terminals118of the DUT130. The adjustment assemblies208and the lockable compliant assemblies210thus can, but need not, be mounted to a reference structure to which the attitude of the support structure206or probes116is changed.

As discussed, while unlocked the lockable compliant assemblies210can allow the support structure206to move relatively freely with respect to the insert ring112. In some embodiments, the lockable compliant assemblies210can allow the attitude of the support structure206with respect to the insert ring112to be changed without appreciably influencing the attitude of the support structure206. The support structure206and the adjustment assemblies208can be mechanically rigid or stiff and can provide mechanical resistance to loading502(e.g., forces) on the probes116, probe head assembly404, or other elements of the probe card assembly114. The support structure206and the adjustment assemblies208can thus resist movement of the attachment/stiffening structure202(and thus the support structure206, the probe head assembly404, and the probes116) due to such loading502, which can arise from mechanical loading of the probes116(e.g., the chuck134pressing the terminals118of the DUT130against the probes116) or from other sources (e.g., thermal gradients). While locked, the lockable compliant assemblies210can provide additional stiffness to the attachment/stiffening structure202. That is, each lockable compliant assembly210can provide additional mechanical resistance to any loading502. Indeed, the more lockable compliant assemblies210that are provided, the greater the additional stiffness (e.g., resistance to movement) provided.

FIG. 6illustrates an exemplary adjustment assembly600, which can be a non-limiting exemplary implementation of an adjustment assembly208. As shown, screws612which can thread into threaded holes (not shown) in the insert ring112, can attach the foot406to the insert ring112. Access holes602can provide access through the extension312to the screws612. A differential screw assembly606, which can be an exemplary implementation of the actuator314ofFIGS. 3 and 4, can be attached to the extension312, for example, in an opening604in the extension312. A shaft620of the differential screw assembly606can be attached to the foot406as shown inFIG. 6. As is known, rotation of a differential screw assembly606in one direction can extend the shaft620toward the foot406, pushing the extension312away from the foot406. Rotating the differential screw assembly606in the opposite direction can retract the shaft620away from the foot406, pulling the extension312toward the foot406.

As discussed above, the differential screw assembly606can be replaced with a push-only actuator and a spring loaded bracket. The spring loaded bracket (not shown) can attach the extension312to the foot406and can bias (e.g., with a spring) the extension312toward the foot406. The push only actuator can include a shaft (not shown) that can be extended to push the extension312away from the foot406against the bias of the spring bracket. The shaft of the push only actuator can also be retracted away from the foot, allowing the spring biasing force of the bracket to pull the extension312toward the foot406.

Referring again toFIG. 4, an example of a lockable compliant assembly210according to some embodiments of the invention is also shown inFIG. 4. As shown, each lockable compliant assembly210can include an attachment block302, a compliant mechanism432, and a locking mechanism430. The attachment block302can be configured to be attached to and detached from the insert ring112. For example, the attachment block302can comprise a metal block that includes holes that correspond to holes in the insert ring112. Screws or bolts (not shown inFIG. 4) can pass through the holes in the attachment block302and the insert ring112to secure the attachment block302to the insert ring112.

The compliant mechanism432can comprise any mechanism that mechanically connects the attachment portion302to the support structure206while allowing the support structure206to rotate, with respect to the attachment portion302, about at least one of the “x,” “y,” and/or “z” axes and or translate along at least one of the “x,” “y,” and/or “z” axes. For example, the compliant mechanism432can comprise springs, gimbels, ball-socket structures, pivot structures, etc. The locking mechanism430can comprise any mechanism that rigidly locks the compliant mechanism432such that, while locked, the lockable compliant assembly210rigidly and generally immovably mechanically connects the support structure206to the attachment portion302. For example, the locking mechanism432can comprise clutches, screws, bolts, parallel plate structures, etc.

FIGS. 7-9illustrate an exemplary configuration700of the lockable compliant assembly210according to some embodiments of the invention. As shown, the exemplary configuration700of the lockable compliant assembly210shown inFIGS. 7-9can include an attachment block701, an interconnector block714, and an end block726.

As shown inFIGS. 8 and 9, the attachment block701can be attached to the insert ring112by screws810, which can be threaded into holes (not shown) in the insert ring112. As shown inFIGS. 7-9, access holes702can be provided in the attachment block701for screws810. The attachment block701can thus be attached to the insert ring112. As best seen inFIGS. 7 and 9, the attachment block701can also comprise fingers704,708with a horizontal space706between the fingers704,708.

As shown inFIGS. 7-9, the end block726can comprises flanges722,732, which can be attached by screws720,730to the support structure206of the attachment/stiffening structure202(seeFIG. 2). The end block726can thus be attached to the support structure206. As also shown, the end block can comprise fingers718,724with a vertical space734between the fingers718,724.

As shown inFIGS. 7-9, the interconnector block714, which can be located between the attachment block701and the end block726, can comprise a body712, a horizontal extension710, and a vertical extension716. The vertical extension716can extend from the body712into the vertical space734between fingers718,724of the end block726as best seen inFIGS. 7 and 8. The horizontal extension710can extend from the body712into the horizontal space706between the fingers704,708of the attachment block701as best seen inFIGS. 7 and 9.

Each of the attachment block701, the interconnector block714, and the end block726can be integrally formed from a single piece of rigid material (e.g., metal). Alternatively, each of the attachment block701, the interconnector block714, and the end block726can comprise structurally distinct elements that are mechanically connected to each other.

As shown inFIG. 7and best seen inFIG. 9, the bolt of a bolt/nut pair736can pass through hole820in finger704, hole802in horizontal extension710of the connector block714, and hole822in finger708. As shown inFIGS. 10A and 10B, while the bolt/nut pair736is loosened, the horizontal extension710of the interconnector block714can rotate about the axis of the bolt/nut pair736(which is labeled the “z” axis inFIGS. 7-10B). (FIG. 704is shown inFIGS. 10A and 10Bwith cutout1002to review the shaft of the bolt in bolt/nut pair736and hole802.) While tightened, however, the bolt/nut pair736can firmly press the fingers704,708against the horizontal extension710and rigidly hold the horizontal extension710in place with respect to the fingers704,708. Thus, while the bolt/nut pair736is tightened, the horizontal extension710is not free to rotate about the axis of the screw736but is substantially immovable. The fingers704,708, and bolt/nut pair736can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pair736or disengaged (unlocked) by loosening the bolt/nut pair736. Bolt/nut pair736can be replaced with a screw that threads into threaded holes in the fingers704,708of the attachment block701.

As shown inFIGS. 7-9and best seen inFIGS. 8 and 9, the bolts of bolt/nut pairs728can pass through holes (not shown) in the fingers718,724of the end block726and through oversized slots804(seeFIG. 9) in the vertical extension716of the connector block714. As shown inFIGS. 11A and 11B, while the bolt/nut pairs728are loosened, the vertical extension716of the interconnector block714can rotate generally about what is labeled the “y” axis inFIGS. 11A and 11Bwith respect to the fingers718,724of the end block726. The oversized slots804allow the rotation. As shown inFIG. 12, the oversize slots804can also allow the vertical extension716to translate along what is labeled the “x” axis inFIG. 12with respect to the fingers718,724of the end block726. (Finger724is shown inFIGS. 11A,11B, and12with cutout1102to show the shafts of the bolts in bolt/nut pairs728and oversized slots804.) While tightened, however, the bolt/nut pairs728firmly press the fingers718,724of the end block726against the vertical extension716and rigidly hold the vertical extension716in place with respect to the fingers718,724. Thus, while the bolt/nut pairs728are tightened, the vertical extension716is not free to rotate about the “y” axis or translate along the “x” axis but is substantially immovable. The fingers718,724, and bolt/nut pairs728can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pairs728or disengaged (unlocked) by loosening the bolt/nut pair728. Bolt/nut pairs728can be replaced with screws that thread into threaded holes in the fingers718,724.

As shown inFIG. 9, a pin or dowel808can be disposed in corresponding hollow spaces806,810in, respectively, the end block726and the support structure206of the attachment/stiffening structure202(seeFIG. 2). As illustrated inFIGS. 13A and 13B, while the screws720,730through flanges722,732of the end block726are loosened, the support structure206of the attachment/stiffening structure202(seeFIG. 2) can rotate, with respect to the end block726, about the dowel808. As also shown inFIGS. 13A and 13B, oversized and/or arced slots1302,1304in the flanges722,732of the end block726allow the support structure206to rotate with respect to the otherwise stationary screws720,730. While tightened, however, screws720,730hold the flanges722,732of the end block726generally immovably and rigidly with respect to the support structure206. Thus, while screws720,730are tightened, the support structure206cannot rotate or move with respect to the end block726. The flanges722,732, support structure206, and screws720,730can thus form a clutch mechanism that is engaged (locked) by tightening the screws720,730or disengaged (unlocked) by loosening the screws720,730. The dowel808is exemplary only and can be replaced by, for example, a structure that is flexible in one direction but rigid in another direction. For example, the dowel808can be replaced with a structure that is flexible in a direction that corresponds to rotation about the “z” axis inFIGS. 8-10but rigid in directions that correspond to rotation about the “x” and “y” axes. A non-limiting example of such a structure is a C flex bearing.

As should be apparent, the attachment block701, interconnector block714, and end block726shown inFIGS. 7-13Bare a non-limiting exemplary configuration of a lockable compliant assembly210ofFIGS. 2-5Baccording to some embodiments of the invention. Generally speaking, the nut/bolt pairs736,728, fingers704,708,716,724, and the screws720,730are non-limiting examples of the locking mechanism432of the lockable compliant assembly210ofFIGS. 2-5B. The interconnector block714, hole802and oversized slots804,1302,1304are non-limiting examples of the compliant mechanism432of the lockable compliant assembly210ofFIGS. 2-5B.

FIGS. 14-16illustrate another exemplary lockable compliant assembly1400according to some embodiments of the invention. The lockable compliant assembly1400can be another non-limiting example of the lockable compliant assembly210ofFIGS. 2-5B. As shown, the lockable compliant assembly1400can comprise an attachment block1402, a dumbbell structure1406, and an end block1404. As will be seen, the attachment block1402can comprise metal or other rigid materials and can be attached to the insert ring112in the test system100shown inFIG. 1. The end block1404, which can also comprise metal or other rigid materials can be integrally formed with or attached to the support structure206of the attachment/stiffening structure202(seeFIG. 2) of the probe card assembly114. The dumbbell structure1406can allow the end block1404, and thus the support structure206, to move with respect to the attachment block1402. For example, the dumbbell structure1406can allow the support structure206to rotate about one or more of the “x,” “y,” and/or “z” axes and/or to translate along one or more of the “x,” “y,” and/or “z” axes.

As shown inFIG. 14, the attachment block1402can include holes1408, which can be like holes702(seeFIG. 9), and can thus be configured to receive screws (not shown inFIGS. 14-16) for attaching the attachment block1402to the insert ring112of the system100ofFIG. 1. The attachment block1402can thus be attached to the insert ring112in the same way that attachment block701is attached to an insert ring112. (SeeFIG. 9.) As also shown inFIG. 14, the attachment block1402can comprise fingers1410,1412with a space1414between the fingers1410,1412. A trench1418can be formed into one of the fingers1412and a corresponding trench1502(seeFIG. 15) can be formed into the other of the fingers1410. The trenches1418,1502can be configured to receive one of the spheres1420of the dumbbell structure1406. Bolt/nut pairs1416can be provided as shown inFIGS. 14 and 15between the fingers1410,1412. While the bolt/nut pairs1416are loosened, the sphere1420can be free to rotate about any or all of the “x,” “y,” and/or “z” axes and can also be free to translate along the length of the trenches1418,1502(which is along what is labeled inFIG. 14the “x” axis). While tightened, however, the bolt/nut pairs1416can press the fingers1410,1412firmly against the sphere1420, locking the sphere1420in place. Thus, while the bolt/nut pairs1416are tightened, the sphere1420is not free to rotate or translate but is rigidly locked in place. The fingers1410,12and bolt/nut pairs1416can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pair1416or disengaged (unlocked) by loosening the bolt/nut pair1416. Bolt/nut pairs1416can be replaced by screws that thread into threaded holes in the fingers1410,1412.

As shown inFIG. 14, the end block1404can be integrally formed with the support structure206of the attachment/stiffening structure202(seeFIG. 2). Alternatively, the end block1404can be structurally separate from the support structure206but rigidly and firmly attached to the support structure206. As shown, the end block1404can include fingers1426,1428with space1432between the fingers. Each finger1426,1428can include a matching dish-shaped feature, one1432of which is visible inFIG. 14, for receiving another sphere1424of the dumbbell structure1406. Bolt/nut pairs1430can be provided as shown inFIG. 14between the fingers1426,1428. While the bolt/nut pairs1430are loosened, the sphere1424can be free to rotate about any or all of the “x,” “y,” and/or “z” axes. While tightened, however, the bolt/nut pairs1430can press the fingers1426,1428firmly against the sphere1424, locking the sphere1424in place. Thus, while the bolt/nut pairs1430are tightened, the sphere1424is not free to rotate but is rigidly locked in place. The fingers1426,1428and bolt/nut pairs1430can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pair1430or disengaged (unlocked) by loosening the bolt/nut pair1430. Bolt/nut pairs1430can be replaced by screws that thread into threaded holes in the fingers1426,1428.

As shown inFIG. 14, the dumbbell structure1406can comprise the spheres1420,1424, which can be attached to opposite ends of a bar1422.FIG. 16illustrates a non-limiting example of the dumbbell structure1406. As shown, the spheres1420,1424can be attached to or integrally formed with the bar1422. The spheres1420,1424and the bar1422can comprise metal or other rigid materials.

As should be apparent, the bolt/nut pairs1416,1430can be non-limiting examples of the locking mechanism430ofFIGS. 2-4, and the dumbbell structure1406can be an non-limiting example of the compliant mechanism432ofFIGS. 2-4.

FIGS. 17 and 18illustrate an exemplary alternative configuration1500of the lockable compliant assembly1400ofFIGS. 14-16according to some embodiments of the invention. The lockable compliant assembly1500shown inFIGS. 17 and 18is thus another non-limiting example of the lockable compliant assembly210ofFIGS. 2-5B.

As shown inFIG. 17, the lockable compliant assembly1500can comprise the end block1404configured as shown inFIG. 14and as described above, including all alternative configurations. As also shown inFIG. 17, the lockable compliant assembly1500can also comprise an attachment block1502and a dumbbell structure1506.

The attachment block1502can be generally similar to attachment block1402ofFIG. 14except that attachment block1502can comprise a dish-shaped feature1518in finger1512and a corresponding dish-shaped feature (not visible inFIG. 17) in finger1510(which can be generally similar to the dish-shaped features inFIGS. 1426,1428of end block1404) rather than the trenches1502,1418in the fingers1410,1412of attachment block1402. Otherwise, attachment block1502can include holes1508(which can be like holes1408) for receiving screws (not shown but which can be like screws810ofFIG. 9) for attaching the attachment block1502to the insert ring112of the head plate110ofFIG. 2. Fingers1510,1512(which can be like fingers1410,1412ofFIG. 14) can provide space1514for a sphere1520of the dumbbell structure1506. Bolt/nut pairs1516can be configured to press firmly, while tightened, the fingers1510,1512against the sphere1520so that the sphere1520cannot rotate. While the bolt/nut pairs1516are loosened, however, the sphere1520can be free to rotate in dish feature1520. The fingers1510,1512and bolt/nut pairs1516can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pairs1516or disengaged (unlocked) by loosening the bolt/nut pair1516.

As shown inFIG. 17andFIG. 18(which show a cross-sectional side view of the dumbbell structure1506), the dumbbell structure1506can comprise two spheres1520,1524and a bar assembly1510. As shown inFIG. 17, sphere1520can be disposed in the dish feature1518of the attachment block1502, and the sphere1524can be disposed in the dish feature1432of the end block1404. A first bar1508can be attached to the sphere1520(for example, the first bar1508can be attached to the sphere1520in the same way that bar1422is attached to sphere1420), and the second bar1514can similarly be attached to the other sphere1524.

As shown inFIG. 18, the bar assembly1510can be configured to allow translational movement of one of the bars (e.g., the second bar1514) with respect to the other bar (e.g., the first bar1508). For example, as shown inFIG. 18, the first bar1508can be integrally formed with or rigidly attached to a housing comprising an outer casing1802that forms an interior space1806. An end of the second bar1514, which can include an elongated slot1808, can be placed in the casing1802, and a bolt of a bolt/nut pair1800can extend through the elongate slot1808in the second bar1514and holes (not shown) in the casing1802.

The bolt/nut pair1800can be tightened, which can press the casing1802against the second bar1514, locking the second bar1514in place such that the second bar1514cannot move with respect to the first bar1508. While the bolt/nut pair1800is loosened, however, the second bar1514can be free to slide within the casing and thus translate1810with respect to the first bar1508along an axis of the first bar1508. The casing1802and bolt/nut pair1800can thus form a clutch mechanism that is engaged (locked) by tightening the bolt/nut pair1800or disengaged (unlocked) by loosening the bolt/nut pair1800. The spheres1520,1424and bars1508,1514can comprise metal or other rigid materials.

FIG. 19shows an exemplary process1900that can be performed using the system100ofFIG. 1to test DUTs like DUT130. As shown inFIG. 19, at1902, a probe card assembly114can be attached to the head plate110of the housing132(seeFIG. 1). For example, the adjustment assemblies208and the lockable compliant assemblies210of the probe card assembly114ofFIGS. 2-4can be attached to the insert ring112of the head plate110. If, for example, the adjustment assemblies208are configured as shown inFIG. 6, the foot406of each adjustment assembly600can be attached by screws512to the insert ring112as shown inFIG. 6. If the lockable compliant assemblies210are configured as shown inFIGS. 7-9, the attachment block701of each lockable compliant assembly700can be attached by screws810to the insert ring112as shown inFIG. 9. Alternatively, if the lockable compliant assemblies210are configured as shown inFIG. 14orFIG. 17, the attachment block1402or the attachment block1502can be attached by screws (not shown) inserted into holes1408or1508and threaded onto corresponding holes (not shown) in the insert ring112as generally described above.

Referring again toFIG. 19, at1904, the lockable compliant assemblies210can be unlocked at1904. For example, the locking mechanism430on each of the lockable compliant assemblies210of the probe card assembly114inFIGS. 2-4can be unlocked. As discussed above, while locking mechanism430is unlocked, the compliant mechanism432of each lockable compliant assembly210can allow the support structure206of the attachment/stiffening structure202to move with respect to the attachment block302of each lockable compliant assembly210.

For example, if the lockable compliant assemblies210are configured like the lockable compliant assembly700ofFIG. 7, the lockable compliant assembly700can be unlocked by loosening bolt/nut pairs736and728and screws720,730as generally discussed above. As another example, if the lockable compliant assemblies210are configured like the lockable compliant assembly1400ofFIG. 14, the lockable compliant assemblies210can be unlocked by loosening bolt/nut pairs1416and bolt/nut pairs1430. As yet another example, if the lockable compliant assemblies210are configured like the lockable compliant assembly1700ofFIG. 17, the lockable compliant assemblies210can be unlocked by loosening bolt/nut pairs1416,1430,1800.

Referring again toFIG. 19, at1906, the attitude of the probe card assembly114can be adjusted. For example, one or more of the actuators314on one or more of the adjustable assemblies208can be activated to change or adjust selectively the position of a corresponding extension312with respect to the insert ring112. As discussed above and illustrated inFIGS. 5A and 5B, by providing a plurality such adjustable assemblies208, the attitude (e.g., tilt, orientation, planarity, etc.) of the support structure206of the attachment/stiffening structure202can be selectively changed or adjusted with respect to the insert ring112to which the probe card assembly114was attached at1902. As discussed above, because the probe head assembly404is attached to the support structure206(e.g., by mounting mechanisms214), selectively changing the attitude of the support structure206changes the attitude of the probe head assembly404and the contact tips of the probes116(which are attached to the probe head assembly404) with respect to the insert ring112. In addition, because the insert ring112and the chuck134can be part of or can be attached (directly or indirectly) to the housing132, adjusting the attitude of the support structure206, probe head assembly404, and contact tips of the probes116with respect to the insert ring112can also change the attitude of the support structure206, probe head assembly404, and contact tips of the probes116with respect to the chuck134and the DUT130(with terminals118) disposed on the chuck134. Therefore,1906inFIG. 19can accomplish selective adjustment of the attitude of the contact tips of the probes116with respect to the terminals118of the DUT130. For example, the attitude of the contact tips of the probes116can be selectively adjusted at1906to correspond to the attitude of the terminals118of the DUT130.

As discussed above, because the locking mechanisms430on each lockable compliant assembly210were unlocked at1904ofFIG. 19, the compliant mechanism432on each lockable compliant assembly210can allow the support structure206to move with respect to the attachment blocks312of each lockable compliant assembly210, which as discussed above, were attached to the insert ring112at1902. Thus, as actuators314change the attitude of the support structure206during1906ofFIG. 19, the compliant mechanisms432on each lockable compliant assembly210can allow the support structure206to move with respect to the attachment blocks302of each lockable compliant assembly210, and thus with respect to any of a number of possible reference structures including, as discussed above, the insert ring112, the chuck134, the DUT130, the terminals118of the DUT130, etc. Moreover, while unlocked, the compliant assemblies210can be configured to allow the support structure206to move, at least in one or more degrees of motion, relatively freely and thus exert negligible influence on the attitude of the support structure206.

Referring again toFIG. 19, the lockable compliant assemblies210can be locked at1904. For example, the locking mechanism430on each of the lockable compliant assemblies210of the probe card assembly114inFIGS. 2-4can be locked. As discussed above, the locking mechanism430can lock the compliant mechanism432in each lockable compliant assembly210such that the support structure206cannot move with respect to the attachment block302of each lockable compliant assembly210. Thus, once the attitude of the support structure206with respect to the insert ring112(and thus the attitude of the contact tips of the probes116with respect to the terminals118of the DUT130) is set as desired at1906, each lockable compliant assembly210can be locked such that no further movement (or no appreciable further movement) of the support structure206with respect to the attachment blocks302is allowed. Once the locking mechanisms430on the lockable compliant assemblies210are locked, each lockable compliant assembly210can become a rigid structure that resists movement of the support structure206(and thus the probe head assembly404and the probes116) during testing of the DUT. For example, the lockable compliant assemblies210, while the locking mechanism430are locked, can provide mechanical resistance to movement of the support structure206, probe head assembly404, and probes116during testing of the DUTs130due to, for example, thermal gradients, mechanical loads placed on the probes116, etc. And the stiffness or mechanical resistance to motion (e.g., motioned induced by loading such as loading502shown inFIGS. 5A and 5B) provided by each locked lockable compliant assembly210can be in addition to stiffness or mechanical resistance to motion provided by other elements of the probe card assembly114, such as the adjustment assemblies208and the support structure206. Moreover, the compliant mechanisms432allow the lockable compliant assemblies210to provide the foregoing mechanical resistance without influencing (or without appreciably influencing) the attitude of the support portion (and thus the attitude of the probe head assembly404and contact tips of the probes116) with respect to the insert ring112(and thus the chuck134, DUT130, and terminals118of the DUT130).

As mentioned, each lockable compliant assembly210can be locked by locking its locking mechanism430. For example, if the lockable compliant assemblies210are configured like the lockable compliant assembly700ofFIG. 7, the lockable compliant assembly210can be locked by tightening bolt/nut pairs736to press fingers704,708of the attachment block701firmly against the horizontal extension710of the interconnector block714as generally described above; by tightening bolt/nut pairs728to press fingers718,724of the end block726firmly against the vertical extension716of the interconnector block1714as generally described above; and by tightening screws720,730to firmly attach the flanges722,732of the end block726to the support structure206as generally described above. As another example, if the lockable compliant assemblies210are configured like the lockable compliant assembly1400ofFIG. 14, the lockable compliant assemblies210can be locked by tightening bolt/nut pairs1416to press fingers1410,1412firmly against sphere1420as generally described above; and by tightening bolt/nut pairs1430to press fingers1426,1428of the end block1404firmly against sphere1424as generally described above (seeFIG. 14). As yet another example, if the lockable compliant assemblies210are configured like the lockable compliant assembly1500ofFIG. 17, the lockable compliant assemblies210can be locked by tightening bolt/nut pairs1516to firmly press fingers1510,1512against sphere1520as generally discussed above; by tightening bolt/nut pairs1430to firmly press fingers1426,1428against sphere1524as generally discussed above; and by tightening bolt/nut pair1800to firmly press casing1802against the second bar1514as generally discussed above.

At1910ofFIG. 19, DUTs130can be tested. For example, chuck134can be positioned to press selected ones of the DUT terminals118against selected ones of the probes116to establish electrical connections between the ones of the probes116and the ones of the terminals118. As discussed above, the tester102can then provide power and test signals through the connector104, electronics in the test head106, the connectors108, and the probe card assembly114to the DUT130. Response signals generated by the DUT130in response to the test signals can be provided to the tester102through the probe card assembly114, connectors108, electronics in the test head106, and connector104. The tester102can then evaluate the response signals to determine whether the DUT130(or elements of the DUT130) passed the testing. The chuck134can reposition the DUT130such that other terminals118are brought into contact with the probes116as many times as needed in order to test the entire DUT130. Once the DUT130is tested, a new DUT can be placed on the chuck134, and the new DUT can be tested.

Although many of the exemplary embodiments and configurations are described above in the context of a system for testing a DUT using a probe card assembly, many other embodiments of the invention are possible.FIG. 20illustrates an example of such a system according to some embodiments of the invention. As shown, a tool apparatus2000can comprise the attachment/stiffening structure202with adjustment assemblies208and lockable compliant assemblies210ofFIGS. 2-5(including the exemplary configurations shown inFIGS. 6-18) or similar structures. As also shown, the tool apparatus2000can be attached to the insert ring112of the head plate110of the housing132(not shown inFIG. 20but shown inFIG. 1) as described above with respect toFIGS. 1-18or to a similar structure configured to receive the tool apparatus2000. As shown inFIG. 20, a tool head assembly2002can be attached to the support structure206, and the tool head assembly2002can comprise a plurality of tools2004. A work piece2006, which can be any object on which the tools2004of the tool head assembly2002are to perform an operation, can be disposed on the chuck134or a similar device, which as discussed above with regard toFIG. 1, can be enclosed in or attached to the housing132(not shown inFIG. 20but shown inFIG. 1) of which the head plate110is a part. As discussed above, the chuck134can move the work piece2006into positions that allow the tools2004to operate on the work piece2006. The tools2004can be, for example and without limitation, nozzles for spraying paint or other materials onto a surface of the work piece2006. As another non-limiting example, the tools2004can be spindles or grinders configured to machine the work piece2006.

The tool apparatus2000can be attached to the insert ring112, and the lockable compliant assemblies210can be unlocked (which can be similar to1904ofFIG. 19). The attitude of the support structure206(and thus the attitude of the tools2004) can be adjusted using the adjustment assemblies210(which can be similar to1906ofFIG. 19). While unlocked, the lockable compliant assemblies210can allow the support structure206to move relatively freely (at least in one or more degrees of freedom) with respect to the insert ring112, and thus the unlocked lockable compliant assemblies210can exert little to no appreciable influence on the attitude of the support structure206. The lockable compliant assemblies210can then be locked (which can be similar to1908ofFIG. 19), and while locked, the lockable complaint assemblies210can provide additional stiffness (or mechanical resistance to movement) to the attachment/stiffness structure202to resist, for example, effects of loading2050(e.g., mechanical loading, thermally induced loading, etc.) on the tools2004or the tool head assembly2002while, for example, the tools2004operate on the work piece2006.

Although specific embodiments and applications of the invention have been described in this specification, there is no intention that the invention be limited these exemplary embodiments and applications or to the manner in which the exemplary embodiments and applications operate or are described herein.