Abstract:
A method for manufacturing a probe card includes inserting an attaching portion of each probe into one of first through holes provided on a probe substrate at least in a row, inserting a probe tip portion of each probe into second through holes respectively provided on a plurality of plate-like positioning members piled in their thickness directions at least in a row, relatively displacing the adjacent positioning members in opposite directions to two-dimensionally position the probe tip portions of the probes, and thereafter softening a conductive jointing material to position the attaching portions of the respective probes against the first through holes.

Description:
PRIORITY CLAIM 
       [0001]    The instant application claims priority to Japanese Patent Application No. 2010-183660, filed Aug. 19, 2010, which application is incorporated herein by reference in its entirely. 
       TECHNICAL FIELD 
       [0002]    The embodiment of the subject matter relates to a method for manufacturing a probe card for use in an electrical test of a flat-plate-shaped device under test such as an integrated circuit. 
       BACKGROUND 
       [0003]    Multiple integrated circuits formed on a semiconductor wafer undergo an inspection or a test to determine whether or not they have functions in accordance with the specification before being separated from the wafer. The multiple integrated circuits on one wafer are tested simultaneously at a time or in several batches. An example of a probe card to be used in a test of this kind is a vertical one with use of plural bar-like probes (Patent Document 1). 
         [0004]    This known probe card includes a probe assembly having a supporting frame coupling an upper plate and a lower plate each having a plurality of through holes in a state of being spaced in an up-down direction and a plurality of probes passing through the through holes of the upper plate and the lower plate at their upper portions and lower portions. This probe assembly is attached to the lower side of a supporting substrate in a state where the probes extend downward. 
         [0005]    An upper end of each probe is thrust on a connecting portion such as an end portion of a wire inserted in a through hole of the supporting substrate or a probe land provided on the lower surface of the supporting substrate and the supporting substrate. Also, as for each probe, its lower end portion is locked on the lower plate to be prevented from falling and passes through a through hole of the lower plate so as for a lower end (that is, a probe tip) to be positioned two-dimensionally. In this conventional art, the upper plate functions as a probe substrate while combination of the supporting frame and probes functions as a probe assembly. 
         [0006]    However, in the above conventional probe card, since the upper end portion of each probe is just inserted in the through hole of the upper plate and is just thrust on the connecting portion on the supporting substrate, the upper end portion of each probe is unstable against the upper plate, the lower plate, and the supporting substrate due to looseness between the upper plate or lower plate and the probes. As a result, a relative position among the probe tips changes. Such a probe card cannot arrange the probes in a high-density manner. 
       CITATION LIST 
       [0007]    Patent Document 1: Japanese Patent Appln. Public Disclosure No. 2009-162483 
       SUMMARY 
       [0008]    It is an object of the embodiment of the subject matter to fix probes in a probe substrate in a state where relative positions of probe tips of the plurality of probes are positioned. 
         [0009]    The embodiment of the subject matter is basically characterized in that a method for manufacturing a probe card comprises the following steps. 
         [0010]    A first step of preparing a probe substrate, a plurality of probes each having an attaching portion and a probe tip portion, and plate-like first and second positioning members collaboratively positioning relative positions of the probe tip portions of the plurality of probes, wherein the first and second positioning members respectively have a plurality of first and second through holes that penetrate the respective positioning members in their thickness directions and in which the probe tip portions can be inserted and can perform parallel movement relatively between an inserting position at which the mutually corresponding first and second through holes are communicated and at which insertion of the probe tip portions of the corresponding probes is allowed in a state where the first and second positioning members are piled on each other and a clamping position at which edge portions of the first and second through holes collaboratively clamp the probe tip portions in a state where the probe tip portions are inserted in the first and second through holes. 
         [0011]    A second step including placing the first and second positioning members at the inserting position and inserting the probe tip portions of the corresponding probes into the first and second through holes of the first and second positioning members placed in the inserting position. 
         [0012]    A third step of making the first and second positioning members perform parallel movement relatively from the inserting position to the clamping position in a state where the probe tip portions are inserted in the first and second through holes to position the relative positions of the plurality of probe tip portions. 
         [0013]    A fourth step of fixing the attaching portions of the probes in relation to the probe substrate to hold the probes in the probe substrate in a state where the probe tip portions are clamped by the first and second positioning members. 
         [0014]    Each of the attaching portions may be formed in a columnar shape having a circumferential surface, and the probe substrate may have a plurality of third through holes penetrating in its thickness direction and allowing insertion of the attaching portions of the probes. The first step may include forming a metal layer having higher wettability than that of the attaching portion at a part of the circumferential surface of the probe and forming a layer of a hot-melt material to cover the metal layer and at least a part of the circumferential surface exposed from the metal layer. 
         [0015]    The above method for manufacturing a probe card may further comprise, between the first step and the second step, a fifth step including inserting the attaching portion of each of the plurality of probes into each of the plurality of third through holes of the probe substrate so that at least a part of the metal layer may be located in the third through hole and melting the hot-melt material of each attaching portion and thereafter solidifying the hot-melt material in a state where the hot-melt material contacts the part of the metal layer and a part of a wall surface of the third through hole to temporarily hold each probe in the probe substrate. 
         [0016]    The fourth step may include, in a state where each of the probe tip portions is clamped by the first and second positioning members, melting the hot-melt material solidified in the fifth step and thereafter solidifying the hot-melt material in a state where the hot-melt material contacts the part of the metal layer and the part of the wall surface of the third through hole to fix the probe to the probe substrate. 
         [0017]    The above method for manufacturing a probe card may further comprising a sixth step including preparing a wiring board with a plurality of coupling portions formed on one surface thereof, arranging the probe substrate on the one surface of the wiring board, and jointing one end portions of the attaching portions projecting from the third through holes to the corresponding coupling portions formed on the wiring board and a seventh step for removing the positioning members from the probes after the sixth step. 
         [0018]    The above method for manufacturing a probe card may further comprising the sixth step for removing the positioning members from the probes after the fourth step, and a seventh step including preparing a wiring board with a plurality of jointing portions formed on one surface thereof, arranging the probe substrate on the one surface of the wiring board, and jointing the one end portions of the attaching portions projecting from the third through holes to the corresponding coupling portions formed on the wiring board. 
         [0019]    A method for manufacturing a probe card according to the embodiment of the subject matter comprises the following steps. 
         [0020]    A first step of manufacturing a plurality of bar-like probes, wherein each probe has a probe main body portion extending in an up-down direction, a probe tip portion extending downward from a lower end of the probe main body portion, an attaching portion extending upward from an upper end of the probe main body portion, and a layer of a conductive jointing material provided on an outer surface of an upper portion of the attaching portion. 
         [0021]    A second step including preparing a probe substrate having a plurality of first through holes penetrating in its up-down direction and arrayed on the probe substrate at least in a row and inserting the attaching portion of each of the plurality of probes into the corresponding first through hole. 
         [0022]    A third step including inserting the probe tip portions of the corresponding probes into second through holes provided respectively on at least two plate-like positioning members piled in their thickness directions at least in a row and thereafter relatively displacing the adjacent positioning members to two-dimensionally position the probe tip portions of the probes against the probe substrate. 
         [0023]    A fourth step of softening the conductive jointing material to eliminate a stress that may be generated in the probes by positioning of the probe tip portions of the probes against the probe substrate to position the attaching portions of the respective probes against the first through holes. 
         [0024]    The method according to the embodiment of the subject matter may further comprise, after the second step, a fifth step of melting the jointing material and solidifying the molten jointing material to fix the attaching portion of each probe in the first through hole of the probe substrate. 
         [0025]    The probe tip portion of each probe and each second through hole of each positioning member may have rectangular cross-sectional shapes, and the third step may include piling the adjacent positioning members so that the corresponding second through holes of the adjacent positioning members may be aligned to one another and relatively displacing the adjacent positioning members in a diagonal direction of the rectangle of the second through hole to maintain the adjacent positioning members in a state where the rectangle of the probe tip portion and each communicating part of the second through holes of the adjacent positioning members are in equal shapes, and where the probe tip portion is clamped by edge portions of the second through holes. 
         [0026]    Each probe may have at a border between the probe main body portion and the probe tip portion a step abutting on an outer edge of the second through hole of the positioning member when the probe tip portion is inserted into the corresponding second through holes. 
         [0027]    The first step may include manufacturing a probe plate, the probe plate may have the plurality of probes and a tab integrally coupling the probes and detachable from each probe at the proximity of the probe tip portion of each probe, and the third step may include separating the tab from each probe before the probe tip portion is inserted in the second through holes. 
         [0028]    Each probe may have a leading portion extending upward from the upper portion of the attaching portion, inserting the attaching portion into the first through hole may include inserting the attaching portion of each probe into the first through hole from a side of the leading portion, and the method according to the embodiment of the subject matter may further comprise, after the second step, a step of removing the leading portion of the probe from the attaching portion, and after the fourth step, a step of removing the positioning members from the probes. 
         [0029]    The plurality of first through holes may be arrayed in plural rows, the first step may include manufacturing a plurality of probe plates, each probe plate may have the plurality of probes and a tab integrally coupling the probes and detachable from each probe at the proximity of the probe tip portion of each probe, and the third step may include separating the tab from each probe before the probe tip portion is inserted in the second through holes. 
         [0030]    The method according to the embodiment of the subject matter may further comprise a sixth step including arranging the probe substrate on one surface of a wiring board and jointing the upper portions of the attaching portions projecting from the first through holes to a plurality of coupling portions formed on the one surface of the wiring board. 
         [0031]    Each probe may have at a border between the probe main body portion and the attaching portion a step abutting on an outer edge of the first through hole of the probe substrate when the attaching portion is inserted into the first through hole. Also, the probe main body portion of each probe may have a curve bent or curved in an equal direction. 
         [0032]    In the embodiment of the subject matter, in order to hold the probes in the probe substrate, the first and second positioning members are made to perform parallel movement relatively from the inserting position to the clamping position in a state where the probe tip portions are inserted in the first and second through holes to position the relative positions of the probe tip portions of the plurality of probes, and the probe tip portions are clamped by the first and second positioning members. Thus, the plurality of probes are held in the positioning members in a state where the relative positions of the probe tips of the plurality of probes are positioned. Consequently, with the embodiment of the subject matter, it is possible to fix in the probe substrate the plurality of probes held so that the relative positions of the probe tips may be positioned. 
         [0033]    That is, in the embodiment of the subject matter, since the jointing material is softened in a state where the probe tip portions of the probes are positioned two-dimensionally by the positioning members, the attaching portions of the respective probes can be displaced against the first through holes by deforming the jointing material. Thus, even in a case where a stress such as a strain is effected to the probes by the probe substrate and the positioning members and remains in the probes due to positioning of the probe tip portions by the positioning members, such a stress is eliminated as the attaching portions are displaced against the first through holes along with softening of the jointing material. Consequently, with the embodiment of the subject matter, the probes are held by the positioning members in a state where the relative positions of the probe tips of the probes are positioned, and the probes can be fixed in the probe substrate in the state. 
         [0034]    In a case where each second through hole and the probe tip portion inserted in the second through hole have rectangular cross-sectional shapes, the adjacent positioning members are piled so that diagonal directions of the rectangles of the second through holes may be aligned, and these positioning members are relatively displaced in the diagonal directions, the probe tip portions of the probes are moved accurately and reliably along with the relative displacement of the positioning members. Consequently, two-dimensional positions of the probe tips of the probes can be positioned easily and accurately. 
         [0035]    Since the plurality of probes have the steps that can abut on the outer edges of the second through holes of the positioning member formed at equal positions at the borders between the probe main body portions and the probe tip portions, inserting the probe tip portions into the second through holes until the steps of the respective probes abut on the outer edges of the second through holes and relatively displacing the positioning members in the state enable three-dimensional positions of the probe tips of the probes to be positioned easily and accurately. 
         [0036]    Since the plurality of probes have the steps that can abut on the outer edges of the first through holes of the probe substrate formed at equal positions at the borders between the probe main body portions and the attaching portions, inserting the respective probes into the corresponding first through holes until the steps of the respective probes abut on the outer edges of the first through holes of the probe substrate enables the length dimensions of the attaching portions to be inserted in the first through holes to be uniform. 
         [0037]    In a case where the probe plate in which the plurality of probes are detachably coupled in a state of being arrayed in parallel by the tab integrally coupled with the plurality of probes is manufactured, and then each probe is separated from the tab, an inserting operation of the attaching portions in the first through holes becomes easy. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0038]      FIG. 1  is a front view showing an embodiment of a probe card. 
           [0039]      FIG. 2  (A) is a top view showing an embodiment of a probe substrate, and  FIG. 2  (B) is a cross-sectional view obtained along the line  2 B- 2 B in  FIG. 2  (A). 
           [0040]      FIG. 3  is a flowchart illustrating a manufacturing method according to the embodiment of the subject matter. 
           [0041]      FIG. 4  is a front view showing an embodiment of a probe plate used in the embodiment of the subject matter. 
           [0042]      FIG. 5  shows a state in which attaching portions of probes coupled with the probe plate are inserted in through holes of the probe substrate. 
           [0043]      FIG. 6  shows a state in which a leading portion of each probe has been removed. 
           [0044]      FIG. 7  (A) is a front view, and  FIG. 7  (B) is a right side view, showing a state in which each probe has been separated from a tab. 
           [0045]      FIG. 8  shows a state in which two-dimensional relative positioning of probe tips is done by a plurality of positioning members. 
           [0046]      FIG. 9  shows a state in which a probe assembly is coupled with a wiring board. 
           [0047]      FIG. 10  (A) is a left side view showing an embodiment of the probe used in the embodiment of the subject matter, and  FIG. 10  (B) is a front view of the probe shown in  FIG. 10  (A). 
           [0048]      FIG. 11  is an enlarged perspective view showing the probe tip and its proximity. 
           [0049]      FIG. 12  is an enlarged view of the area  12  in  FIG. 4 . 
           [0050]      FIG. 13  is an enlarged view showing the attaching portion and the leading portion of the probe. 
           [0051]      FIG. 14  is an enlarged view of the area  14  in  FIG. 13 . 
           [0052]      FIG. 15  (A) is an enlarged view obtained along the line  15 A- 15 A in  FIG. 14 , and  FIG. 15  (B) is an enlarged view obtained along the line  15 B- 15 B in  FIG. 14 . 
           [0053]      FIG. 16  is an enlarged view seen from a direction of the arrow  16  in  FIG. 5 . 
           [0054]      FIG. 17  (A) is a cross-sectional view showing an embodiment of a coupling state of the probe with the probe substrate,  FIG. 17  (B) is a cross-sectional view obtained along the line  17 B- 17 B in  FIG. 17  (A), and  FIG. 17  (C) is a view seen from the lower side of  FIG. 17  (A) with parts of a jointing material hatched. 
           [0055]      FIG. 18  is a plan view showing an embodiment of the positioning members. 
           [0056]      FIG. 19  illustrates mutual positioning of the probe tips. 
           [0057]      FIG. 20  is a plan view showing the probe substrate after the tab is removed. 
           [0058]      FIG. 21  illustrates another embodiment of the embodiment of the subject matter. 
       
    
    
     DETAILED DESCRIPTION 
       [0059]    In the embodiment of the subject matter, in  FIG. 1 , an up-down direction is referred to an up-down direction, a right-left direction is referred to as a right-left direction, and a direction perpendicular to the drawing sheet is referred to as a front-back direction. However, these directions differ with the posture of a device under test at the time of a test. 
         [0060]    Accordingly, a probe card according to the embodiment of the subject matter may be used in any state such as a state in which a plane defined by the right-left direction and the front-back direction is a horizontal plane or a state in which it is inclined to a horizontal plane. 
       Embodiments 
       [0061]    Referring to  FIG. 1 , a probe card  20  includes a wiring board  22 , a probe substrate  24  arranged on the lower side of the wiring board  22 , and multiple bar-like probes  26  arranged in the probe substrate  24  in a state of extending downward from the probe substrate  24 . 
         [0062]    The wiring board  22  is made of an electrical insulating material such as a glass-containing epoxy resin or a ceramic in a circular plate shape. The wiring board  22  has multiple conductive coupling portions  28  provided on the lower surface, multiple internal wires  30  each electrically connected to the coupling portion  28  at one end, and multiple connecting portions  32  provided on the upper surface. 
         [0063]    The plural coupling portions  28  are arrayed on the wiring board  22  in plural rows, and each coupling portion  28  is in a land shape. The connecting portion  32  is a tester-land connected to an electric circuit of a tester in the example shown in the figure but may be a connector terminal. 
         [0064]    Each internal wire  30  electrically connects the coupling portion  28  to the connecting portion  32 . However, in a case where plural electronic components such as a capacitor, an IC relay, and an integrated circuit for a test are provided on the upper surface of the wiring board  22 , some internal wires  30  connect the coupling portions  28  to the connecting portions  32 , some internal wires  30  connect the coupling portions  28  to the electronic components, and the other internal wires  30  connect the connecting portions  32  to the electronic components. 
         [0065]    The probe substrate  24  is made of an electrical insulating material such as a ceramic in a rectangular plat plate shape, has at the central area multiple through holes  34  opened to the upper surface and lower surface and at the four corners through holes  36  respectively, as specifically shown in  FIGS. 2  (A) and  2  (B). The multiple through holes  34  are arrayed on the probe substrate  24  in plural rows, and each through hole  34  receives an upper end portion of a corresponding probe  26 . Each through hole  34  has a circular transverse cross-sectional shape. 
         [0066]    Positioning pins (not shown) positioning the probe substrate  24  against the wiring board  22  can be inserted in a pair of through holes  36  located in one diagonal direction of a rectangular of the probe substrate  24 . Bolts (not shown) attaching the probe substrate  24  to the wiring board  22  can be inserted in a pair of through holes  36  located in the other diagonal direction of the rectangular of the probe substrate  24 . However, the positioning pins may be inserted in all of the through holes  36 , and through holes in which the bolts are to be inserted may be provided at other locations. 
         [0067]    Each probe  26  has a rectangular cross-sectional shape such as a prismatic column in the example shown in the figure. Each probe  26  has a probe main body portion  38  extending in the up-down direction, a probe tip portion  40  extending downward from the lower end of the probe main body portion  38 , and an attaching portion  42  extending upward from the upper end of the probe main body portion  38 . Each probe  26  has at the lower end a probe tip  44  to be thrust on an electrode of a device under test. 
         [0068]    Each probe  26  is inserted in the through hole  34  of the probe substrate  24  at the attaching portion  42  in a state where the probe main body portion  38  and the probe tip portion  40  extend in the up-down direction from the probe substrate  24  and in a state where the upper portion of the attaching portion  42  is slightly projected upward from the probe substrate  24 , is fixed at the wall portion forming the through hole  34  by a conductive jointing material or a hot-melt material (not shown), and is jointed at the upper end portion to the coupling portion  28  of the wiring board  22  by a conductive jointing material (not shown). 
         [0069]    The probe main body portion  38  of each probe  26  is curved in the same direction. Each probe  26  is manufactured by a photolithographic technique in which exposure and etching are performed with use of a photoresist and a deposition technique such as electroforming and sputtering in which a metal material such as a nickel alloy represented by a nickel-boron alloy or a nickel-phosphorus alloy or nickel is deposited in a recess formed by the photolithographic technique. 
         [0070]    The shape and structure of the probe  26  and the relationship between the wiring board  22  or the probe substrate  24  and the probes  26  will be described later in details. 
         [0071]    Referring to  FIG. 3 , a method for manufacturing the above probe card will be described below. 
         [0072]    First, the probe substrate  24  shown in  FIG. 2  and plural probe plates  50  with tabs shown in  FIG. 4  are manufactured (steps  200  and  201 ). The probe substrate  24  can be obtained by forming the through holes  34  and  36  on a ceramic plate by a laser process or a drilling process. 
         [0073]    As shown in  FIG. 4 , each probe plate  50  includes plural probes  52  and a tap  54  putting the plural probes  52  together. The tab  54  is detachably coupled integrally with each probe  52  at the proximity of the probe tip  44  of each probe  52 . As shown in  FIGS. 10 to 12 , each probe  52  has the probe main body portion  38  having a curved curve, the probe tip portion  40  continuing into the lower end of the probe main body portion  38  and having the probe tip  44  at the lower end, and the attaching portion  42  continuing into the upper end of the probe main body portion  38  in addition to a leading portion  46  continuing into the upper end of the attaching portion  42  and extending upward from the attaching portion  42 . 
         [0074]    The probe main body portion  38 , the probe tip portion  40 , the attaching portion  42 , and the leading portion  46  are integrally made of a highly-resilient metal material such as a nickel alloy represented by a nickel-boron alloy or a nickel-phosphorus alloy or nickel. At least at the probe tip  44  is formed a highly hard metal film made of a metal material having higher hardness than those of materials for other portions such as the probe main body portion  38 . Such a highly hard metal film can be formed by plating. 
         [0075]    As specifically shown in  FIGS. 10 to 15 , the probe main body portion  38  has a rectangular cross-sectional shape. In the example shown in the figures, although a part of the probe main body portion  38  is curved in an arc to regard the curved portion as a curve, a part of the probe main body portion  38  may be bent in a lateral V shape to regard the bent portion as a curve. The probe main body portion  38  has a rectangular cross-sectional shape. Such a rectangle is shaped so that dimension (thickness dimension or width dimension) W 1  in the right-left direction of the probe main body portion  38  may be equal or slightly larger than dimension W 2  in the front-back direction, as shown in  FIG. 10 . 
         [0076]    The probe tip portion  40  has an upper area having a rectangular cross-sectional shape in which a dimension corresponding to dimension W 1  is smaller than a dimension corresponding to dimension W 2  and a lower area in which a dimension corresponding to dimension W 1  is decreased toward the side of the probe tip  44 . Accordingly, downward steps  56  at a border between the probe main body portion  38  and the probe tip portion  40  are formed on one side and the other side in the right-left direction, respectively. 
         [0077]    The attaching portion  42  has a rectangular cross-sectional shape in which a dimension corresponding to dimension W 1  is smaller than a dimension corresponding to dimension W 2 . The attaching portion  42  is eccentrically located on one side in the right-left direction of the upper end portion of the probe main body portion  38 . Accordingly, an upward step  58  at a border between the probe main body portion  38  and the attaching portion  42  is formed on one side in the right-left direction. 
         [0078]    The leading portion  46  extends upward on the same axis as that of the attaching portion  42  and has a lower area having a rectangular cross-sectional shape that has the same size and the same shape as those of the attaching portion  42  and an upper area in which a dimension corresponding to dimension W 1  is decreased toward the upper end side. 
         [0079]    Each probe  26  also has on the upper end surface of the attaching portion  42  a recess or an opening  60  ranging from one side to the other side of two surface areas forming two opposed sides of a rectangle. A metal layer  62  is formed on an outer circumferential surface of an upper area of the attaching portion  42 , on two opposed surface areas of an area continuing into the upper area, and on a surface area forming the opening  60 . Further, a jointing material layer  64  is provided to cover exposed portions of three outer circumferential surfaces at the upper area of the attaching portion  42  and the metal layer  62  at the two opposed surface areas of the area continuing into the upper area. 
         [0080]    In the example shown in  FIGS. 14 and 15 , the metal layer  62  provided on the outer circumferential surface of the upper area of the attaching portion  42  is provided over the entirety in the circumferential direction of the upper area, and the metal layer  62  provided at the two surface areas is in a strip shape having a smaller width dimension than that of the surface area and extending along the entire area in the longitudinal direction of the attaching portion  42 . 
         [0081]    The metal layer  62  is made of a material in which wettability of the jointing material layer  64  to the metal layer  62  is higher than wettability of the jointing material layer  64  to the attaching portion  42 . Also, the jointing material layer  64  is made of a metal material having a lower melting point than those of the attaching portion  42  and the metal layer  62 . In a case where the attaching portion  42  is made of a nickel metal material such as nickel or a nickel alloy, a material for the metal layer  62  can be a gold or silver metal material such as gold, a gold alloy, silver, or a silver alloy, and a material for the jointing material layer  64  can be a tin metal material such as tin or a tin-lead alloy. 
         [0082]    As shown in  FIG. 4 , the tab  54  is in a rectangular plate shape having the same thickness dimension as a thickness dimension of the probe  26  in the front-back direction and is made of the same metal material as those for the probe main body portion  38 , the probe tip portion  40 , and the leading portion  46  of the probe  26  to be integral with the probe  26 . The tab  54  has multiple holes  66  penetrating in the thickness direction and has on one side of the rectangle multiple recesses  68  spaced in a direction of one side of the rectangle, as shown in  FIG. 4 . In each recess  68  is located the probe tip portion  40  of the probe  26 . 
         [0083]    As shown in  FIG. 12 , each recess  68  is formed in an Ω shape, and an entrance of each recess  68  is narrowed by two opposed projecting portions or coupling portions  70 . Each coupling portion  70  is in a triangular shape and makes a tip end corresponding to the apex of the triangle opposed. The probe tip portion  40  is integrally coupled with the tip ends of the coupling portions  70 . 
         [0084]    The above probe plate  50  can be manufactured by the aforementioned photolithographic technique and deposition technique. 
         [0085]    Returning to  FIG. 3 , the attaching portion  42  of the probe  52  of the above probe plate  50  is then inserted into the through hole  34  of the probe substrate  24  from the side of the leading portion  46  (step  202 ). The length dimension of the attaching portion  42  is slightly longer than the thickness dimension of the probe substrate  24 . Accordingly, as shown in  FIGS. 5 ,  16 , and  17 , when the attaching portion  42  is inserted until the step  58  abuts on the probe substrate  24 , the attaching portion  42  makes the end portion on the side of the leading portion  46  slightly project from the probe substrate. 
         [0086]    Abutment of the step  58  on the probe substrate  24  enables the attaching portion  42  of each probe  52  to be inserted into the through hole  34  easily so that the inserting lengths of the probes  52  in the through holes  34  may be equal to one another, and so that the projecting length of the attaching portion  42  from the probe substrate  24  may be equal to one another. 
         [0087]    Inserting the attaching portion  42  into the through hole  34  in a state where each probe  52  is upside down as shown in  FIG. 5  facilitates the inserting operation of the attaching portion  42  into the through hole  34 . Also, the fact that the dimension corresponding to dimension W 1  at the lower area of the leading portion  46  is decreased toward on the upper end side facilitates the inserting operation of the attaching portion  42  into the through hole  34 . 
         [0088]    Subsequently, the probe substrate  24  and the probe plate  50  are heated, the material (jointing material) for the jointing material layer  64  is melted, and thereafter the molten material is solidified (step  203 ). Consequently, each probe  52  is fixed in the through hole  34  of the probe substrate  24 . 
         [0089]    As described above, the metal layer  62  is made of the material in which wettability of the liquefied material of the jointing material layer  64  to the metal layer  62  is higher than wettability of the jointing material layer  64  to the attaching portion  42 . Accordingly, when the jointing material layer  64  covering the metal layer  62  as shown in  FIG. 15  is melted at step  203 , the molten material or the liquefied material is concentrated on the metal layer  62  by its own surface tension and is solidified in this state to become a jointing material  82  filling a gap between the outer circumferential surface of the attaching portion  42  and the inner surface forming the through hole  34  and jointing the probe  26  to the probe substrate  24 , as shown in  FIG. 17 . As a result, each probe  52  is fixed to the probe substrate  24  at the attaching portion  42 . 
         [0090]    Subsequently, as shown in  FIG. 6 , the leading portion  46  is detached from each probe  52  with the tab, and each probe  52  is separated from the tab  54  at the probe tip portion  40  and the coupling portions  70  (step  204 ). By doing so, each probe  52  is converted into the probe  26  for the probe card  20 , and a probe assembly is obtained. 
         [0091]    The detaching operation of the leading portion  46  can be done easily by breaking the leading portion  46  from the attaching portion  42  since the dimension of the probe  52  is as small as several tens of to a hundred and several tens of microns. The obtained probe assembly is shown in  FIG. 7 , and the bottom view of  FIG. 7  is shown in  FIG. 20 . By detachment of the leading portion  46 , the opening  60  existing at the border between the attaching portion  42  and the leading portion  46  functions as a groove or a recess opened to a side opposite the probe main body portion  38  and having a V cross-sectional shape. 
         [0092]    Subsequently, three plate-like positioning members  72  manufactured in a separate process from the above are prepared (step  205 ). Each positioning member  72  is formed in a rectangular shape having the same size and has at the central area multiple rectangular through holes  74  penetrating in the thickness direction in plural rows and at the four corners through holes  76  respectively, as shown in  FIG. 18 . 
         [0093]    Each positioning member  72  is made of a metal material or a resin material to prevent the through holes  76  from being deformed. The positioning member  72  can be manufactured by the photolithographic technique and the deposition technique. 
         [0094]    Each of the through holes  74  of each positioning member  72  has a larger dimension than the rectangular cross-section of the probe tip portion  40 , and the through holes  74  are provided in the positioning member  72  to have equal dimensions and equal distances to one another. Accordingly, the probe tip portions  40  are easily inserted into the three positioning members piled up in a state where the through holes  74  are aligned. 
         [0095]    The through holes  76  of the respective positioning members  72  have equal dimensions to one another and are formed in the positioning members  72  so as to be aligned with one another in a case where the respective positioning members  72  are piled up in a state where each communicating part of the through holes  74  of the piled positioning members  72  is in an equal shape to the rectangular cross-section of the probe tip portion  40 . Thus, in a state where the through holes  76  are aligned, the probe tip portion  40  inserted in each through hole  74  of the piled positioning members  72  is clamped by the three positioning members. 
         [0096]    Referring to  FIG. 8 , the probe tip portion  40  of each probe  26  is inserted in the respective through holes  74  of the three positioning members  72  piled in a state where the through holes  74  are aligned, and thereafter the positioning members  72  are moved in parallel to bring a state where the through holes  76  are aligned (refer to  FIG. 19 ). Each check  78  is inserted in the aligned through holes  76  to temporarily joint the three positioning members  72  in the positional relationship (refer to  FIG. 9 ). Accordingly, the probe tip portions  40  of the plural probes  26  are positioned to one another in the right-left direction and the front-back direction. Also, since the probe tip portion  40  of each probe  26  is inserted in the through hole  34  until the step  56  abuts on the positioning members  72 , the probe tip portions  40  of the plural probes  26  are positioned to one another in the up-down direction. 
         [0097]    At step  206 , positioning is done with use of the positioning members  72  as above, as a result of which three-dimensional positioning of the probe tip portions  40  of the plural probes  26  can be done easily and accurately. 
         [0098]    Subsequently, in a state where the relative position among the probe tip portions  40  is maintained by the three positioning members  72 , two-dimensional positions of the probe tips  44  are tested and adjusted (step  207 ). Instead of using three positioning members  72 , two or four or more positioning members  72  may be used. 
         [0099]    Subsequently, a heat treatment of the jointing materials  82  of all probes  26  is conducted (step  208 ). In this heat treatment, the jointing materials  82  are heated approximately at a half temperature of a melting temperature of the jointing material  82  (for example, in a case of tin, 150° C. to 170° C.) for several hours (for example, 2 to 3 hours) and are thereafter cooled gradually. 
         [0100]    Since the jointing material  82  of each probe  26  is softened to be deformable by the above heat treatment, the attaching portion  42  of each probe  26  can be displaced against the through hole  34  by deforming the softened jointing material  82 . Consequently, due to the fact that the relative position among the probe tips  44  is maintained by the positioning members  72 , a residual stress such as a strain existing in each probe  26  is eliminated, each probe  26  is held in the probe substrate  24  in a stable manner, and the relative positional relationship among the probe tips  44  of the probes  26  becomes stable. 
         [0101]    At step  208 , at least part of the jointing material  82  fixing the attaching portion  42  to the through hole  34  is also softened, but due to the wettability of the jointing material to the metal layer  62  and the surface tension of the jointing material, the molten or softened jointing material  82  returns to a state of filling a gap between the outer circumferential surface of the attaching portion  42  and the inner surface forming the through hole  34  after it is solidified. 
         [0102]    Subsequently, the wiring board  22  manufactured in a separate process from the above and described above is prepared (step  209 ). 
         [0103]    Subsequently, each probe  26  is fixed to the coupling portion  28  of the wiring board  22  at its end on the side of the attaching portion  42  (step  210 ). This operation is done by arranging the probe substrate  24  to one surface side of the wiring board  22  in a state where the end surface of each probe  26  on the side of the attaching portion  42  abuts on the coupling portion  28  of the wiring board  22  and melting in this state and thereafter solidifying the jointing material  82  existing at least at the end of the attaching portion  42 . 
         [0104]    At step  210 , at least part of the jointing material  82  fixing the attaching portion  42  to the through hole  34  is also melted or softened, but due to the wettability of the jointing material to the metal layer  62  and the surface tension of the jointing material, the molten or softened jointing material  82  returns to a state of filling a gap between the outer circumferential surface of the attaching portion  42  and the inner surface forming the through hole  34  after it is solidified. 
         [0105]    Thereafter, the positioning members  72  are detached from the probes  26  (step  211 ). This operation can be done by removing the checks  78  and then pulling out the respective positioning members  72  from the probe tip portions  40 . However, without detaching the positioning members  72 , that is, in a state of maintaining the two-dimensional positions of the probe tips  44  by the positioning members  72 , the probe card may be used. In this case, the positioning members  72  are made of electrical insulating materials. 
         [0106]    As a result of the above, the probe card  20  shown in  FIG. 1  is completed. In the completed probe card  20 , since the jointing material (not shown) jointing the attaching portion  42  to the coupling portion  28  exist in the opening or the recess  60  (refer to  FIG. 14 ), the contact area of the jointing material to the attaching portion  42  is large, and the jointing strength between the attaching portion  42  and the coupling portion  28  is high. 
         [0107]    The above steps can be changed arbitrarily. 
         [0108]    For example, in the operations at step  203 , the operation of melting and thereafter solidifying the material for the jointing material layer  64  to fix the attaching portion  42  in the through hole  34  may be done before or at step  211 . Also, in the operations at  211 , the operation of pulling out each positioning member  72  from the probe tip portions  40  may be done between step  208  and step  210 . Also, in the operations at step  204 , the operation of detaching the leading portion  46  from the attaching portion  42  may be done before step  203 . 
         [0109]    Instead of the plural probes  52  coupled with the plate-like tab  54 , multiple respectively independent probes  52  may be used as shown in  FIG. 21 . 
       INDUSTRIAL APPLICABILITY 
       [0110]    The embodiment of the subject matter is not limited to the above embodiments but may be altered in various ways without departing from the spirit and scope of the embodiment of the subject matter. 
       REFERENCE SIGNS LIST 
       [0111]      20  probe card 
         [0112]      22  wiring board 
         [0113]      24  probe substrate 
         [0114]      26  probe 
         [0115]      28  coupling portion 
         [0116]      30  internal wire 
         [0117]      32  connecting portion 
         [0118]      34 ,  36  through hole 
         [0119]      38  probe main body portion 
         [0120]      40  probe tip portion 
         [0121]      42  attaching portion 
         [0122]      44  probe tip 
         [0123]      46  leading portion 
         [0124]      50  probe plate 
         [0125]      52  probe 
         [0126]      54  tab 
         [0127]      56 ,  58  step 
         [0128]      60  opening (recess) 
         [0129]      62  metal layer 
         [0130]      64  jointing material layer 
         [0131]      66  hole 
         [0132]      68  recess 
         [0133]      70  coupling portion 
         [0134]      72  positioning member 
         [0135]      74 ,  76  through hole 
         [0136]      78  check 
         [0137]      82  jointing material