Patent Description:
An energization test is conventionally performed on test objects, such as semiconductor integrated circuits, to determine whether the test objects are produced in accordance with exact specifications. Such an energization test is performed using a contact inspection device, such as a probe card, probe unit, and probe block, having plural contacts which are individually pressed against a part to be inspected of a test object. A contact inspection device of this type is used to electrically connect the parts to be inspected of a test object with a tester in order to perform inspection.

As a contact inspection device of this type, Patent Literature <NUM> discloses a contact inspection device including a probe substrate having a lower side on which plural probes, each having a first end to be brought into contact with an electrode of a test object, are disposed, a rigid wiring board to be electrically connected to a tester, a reinforcing plate for supporting the rigid wiring board, and a probe support, connected to the probe substrate, for retaining the plural probes in contact with the probe substrate at predetermined positions.

Patent Literature <NUM> discloses a contact inspection device produced by temporarily connecting first ends of probes to a probe substrate by softening a conductive joining material attached to the first ends of the probes by heating, inserting second ends of the probes, which will serve as needle tips when brought into contact with a test object, through plural positioning members, positioning the second ends of the probes by moving the positioning members relative to one another, and heating and cooling the joining material again so that the probes can be positioned with respect to the probe substrate and joined thereto.

<CIT>
discloses features falling under the preamble of claim <NUM>. <CIT> and <CIT> are further prior art.

In the contact inspection device disclosed in Patent Literature <NUM>, the probe support includes first and second plates facing each other in the axial direction of the probes with a gap therebetween. The probes extend through the first and second plates. The probes extending through the probe support correspond one-to-one to electrodes of the probe substrate and to electrodes of the test object, and electrically connect the probe substrate and the test object.

Each probe of the contact inspection device includes a dogleg-shaped coupling portion located between the first and second plates of the probe support. The coupling portion is elastically deformable under a pressure that acts in the axial direction of the probe, and the elastic force that is generated by the elastic deformation of the coupling portion helps to establish electrical connection between the probe and its corresponding electrode.

When a probe having such a coupling portion rotates about its axis, it may contact an adjacent probe and cause a short-circuit. Also, when such a probe rotates about its axis, the electrode of the probe card in contact with the probe may be worn or damaged. Thus, in this contact inspection device, each probe has protrusions extending radially from a portion thereof. The protrusions are received in elongated grooves in a circular hole formed through the second plate, which faces the test object, and function, in conjunction with the elongated grooves, as rotation prevention means that prevents the probe from rotating about its axis.

In this contact inspection device, however, because the coupling portions of the probes must be located between the first and second plates of the probe support, the second ends of the plural probes must be simultaneously inserted through the first plate with the first ends of the plural probes inserted through the second plate. In other words, when any of the probes in this contact inspection device need replacing, the probes cannot be replaced without disassembling the probe support. This results in lower work efficiency. In addition, in assembling the probe support, the second ends of the plural probes must be simultaneously inserted through the first plate with the first ends of the plural probes inserted through the second plate. This is troublesome and results in lower work efficiency.

In the contact inspection device disclosed in Patent Literature <NUM>, the probes cannot be replaced without softening the joining material by heating. This also results in lower work efficiency. In addition, the second ends of the probes must be inserted through the plural positioning members after the joining material is softened by heating to temporarily join the plural probes to the probe substrate. This complicates the assembling process and results in a further decrease in work efficiency.

The present invention has been made in view of the above problems, and it is, therefore, an object of the present invention to provide a contact inspection device configured to reduce wear and damage of the contact portions of the probe substrate in contact with the probes and to facilitate the replacement and assembly of the probes.

For the purpose of accomplishing the above object, a contact inspection device according to a first aspect of the present invention is a contact inspection device that performs contact inspection of a test object, including: plural probes each having a first end to be brought into contact with the test object; a probe substrate including contact portions in contact with respective second ends of the probes; a probe head through which the plural probes extend and which are detachably attached to the probe substrate; and plural positioning members which are provided on a surface of the probe head facing the probe substrate and through which the plural probes extends, each of the probes having a rotation restricted portion provided on the side of the second end, each of the plural positioning members having rotation restricting portions adapted to engage the rotation restricted portions, in which, when the plural positioning members are moved relative to each other, the rotation restricting portions align the probes and switch the probes from a rotation unrestricted state to a rotation restricted state.

According to this aspect, when the plural positioning members are moved relative to each other, the rotation restricting portions align the probes and switch the probes from a rotation unrestricted state to a rotation restricted state. Thus, because the probes are prevented from rotating relative to the contact portions of the probe substrate in contact with the probes, wear or damage of the contact portions of the probe substrate can be reduced.

In addition, according to this aspect, because the probes can be aligned by moving the plural positioning members relative to each other, the probes can be easily positioned and the positional accuracy of the probes can be improved. Thus, the contact portions of the probe substrate can be reduced in size, enabling them to cope with further reduction in pitch.

In addition, according to this aspect, the probes can be switched between a rotation restricted state and a rotation unrestricted state by moving the plural positioning members relative to each other with the probe head removed from the probe substrate. This facilitates maintenance and replacement of the probes and assembly of the probe head, which in turn improves work efficiency in maintenance and replacement of the probes and in assembling the probe head.

A contact inspection device according to a second aspect of the present invention is the contact inspection device according to the first aspect, in which the rotation restricted portions have a polygonal shape, and in which the rotation restricting portions engage at least two sides, or one side and one vertex opposite the one side, of each of the rotation restricted portions to restrict rotation thereof.

According to this aspect, the rotation restricting portions engage at least two sides, or one side and one vertex opposite the one side, of each of the rotation restricted portions having a polygonal shape to restrict rotation thereof. Thus, because the probes are prevented from rotating relative to the contact portions of the probe substrate in contact with the probes, wear or damage of the contact portions of the probe substrate can be reduced.

A contact inspection device according to a third aspect of the present invention is the contact inspection device according to the first or second aspect, in which the plural positioning members include a first positioning member and a second positioning member, in which the rotation restricting portions of the first positioning member and the second positioning member have a rectangular shape, in which the rotation restricted portions have a rectangular shape, and in which, when the first positioning member and the second positioning member are moved relative to each other along a diagonal of the rectangular shape, the rotation restricting portions restrict rotation of the rotation restricted portions.

According to this aspect, the plural positioning members include a first positioning member and a second positioning member, and the rotation restricting portions of the first positioning member and the second positioning member and the rotation restricted portions both have a rectangular shape. When the first positioning member and the second positioning member are moved relative to each other along a diagonal of the rectangular shape, the rotation restricting portions restrict rotation of the rotation restricted portions. Thus, when the first positioning member and the second positioning member are moved relative to each other along a diagonal of the rectangular shape, the four sides of each of the rectangular rotation restricted portions of the probes are restrained by the rotation restricting portions of the first positioning member and the second positioning member. As a result, the probes can be maintained in a rotation restricted state more reliably. In addition, because the four sides of each of the rotation restricted portions are restrained, the probes can be positioned with higher accuracy, enabling them to cope with narrower pitches.

A contact inspection device according to a fourth aspect is the contact inspection device according to the first aspect, in which at least either the rotation restricted portions or the rotation restricting portions have a generally ellipsoidal shape.

The term "generally ellipsoidal shape" as used herein refers not only to a curve made up of the set of all points in a plane for which the sum of the distances from two fixed points is constant but also to an ellipse elongated laterally and having lateral ends pointed at an acute angle and a shape formed by joining semi-circles to opposite ends of a rectangle.

According to this aspect, at least either the rotation restricted portions or the rotation restricting portions have a generally ellipsoidal shape. Thus, when the plural positioning members are moved relative to each other, each of the generally ellipsoidal rotation restricting portions contacts a part of the corresponding one of the rotation restricted portions of the probes and the probes can be aligned and switched from a rotation unrestricted state to a rotation restricted state. Thus, because the probes are prevented from rotating relative to the contact portions of the probe substrate in contact with the probes, wear or damage of the contact portions of the probe substrate can be reduced.

A contact inspection device according to a fifth aspect is the contact inspection device according to any one of the first to fourth aspects, in which each of the probes includes a first contact portion forming the first end of the probe, a second contact portion forming the second end of the probe and having the rotation restricted portion, and an elastic portion having opposite ends to which the first contact portion and the second contact portion are connected and capable of freely expanding and contracting in the axial direction of the probe.

According to this aspect, each of the probes includes an elastic portion capable of freely expanding and contracting in the axial direction of the probe, and first and second contact portions connected to opposite ends of the elastic portion. Thus, when a force is applied to the first and the second contact portions, the elastic portion warps in the axial direction of the probe and applies an elastic force generated by the warp to the first and second contact portions. As a result, the elastic portion can apply an elastic force between the first contact portion and the test object and between the second contact portion and its corresponding contact portion of the probe substrate. This makes the contact between the first contact portion and the test object and the contact between the second contact portion and its corresponding contact portion of the probe substrate more stable, and reduces poor connection therebetween.

A contact inspection device according to a sixth aspect is the contact inspection device according to any one of the first to fifth aspects, in which the second ends of the probes make a line or surface-to-surface contact with the corresponding contact portions of the probe substrate.

According to this aspect, the second ends of the probes make a line or surface-to-surface contact with the corresponding contact portions of the probe substrate. This increases the contact area between the second end of each of the probes and its corresponding contact portion of the probe substrate, thereby providing a more stable electrical connection between the second ends of the probes and the probe substrate.

A contact inspection device according to a seventh aspect is the contact inspection device according to any one of the first to sixth aspects, in which the probe head has holes for receiving the probes, and the rotation restricted portions of the probes are larger in size than the holes.

According to this aspect, the probe head has holes for receiving the probes, and the rotation restricted portions of the probes are larger in size than the holes. Thus, when the probes are inserted through the probe head, the rotation restricted portions cannot pass through the holes. In other words, the rotation restricted portions of the probes also function as a stopper to the probe head.

In addition, according to this aspect, because the rotation restricted portions of the probes contact the holes of the probe head at a position close to their second ends, the probes are supported by the probe head at a position close to their second ends. As a result, the second ends of the probes are restricted from displacing in a direction orthogonal to the axial direction of the probes compared to the first ends thereof. This prevents the second ends of the probes from displacing in the orthogonal direction relative to the contact portions of the probe substrate and can therefore reduce wear or damage of the contact portions of the probe substrate.

A contact inspection device according to an eighth aspect is the contact inspection device according to any one of the first to seventh aspects, in which each of the probes has at least one slit extending spirally in the axial direction of the probe between the first end and the second end.

According to this aspect, each of the probes has at least one slit extending spirally in the axial direction of the probe between the first end and the second end. The slit can absorb the torsion applied to the probe or inclination of the probe and can therefore improve the service life of the probe. In addition, because the slit is formed spirally in the axial direction of the probe, it can also absorb some of the pressure applied in the axial direction and can therefore improve the service life of the probe. In addition, the slit can prevent the probe from breakage or the like and can therefore improve the service life of the contact inspection device.

A contact inspection device according to a ninth aspect is the contact inspection device according to any one of the first to eighth aspects, in which the plural positioning members are made of non-conductive material.

According to this aspect, because the plural positioning members are made of non-conductive material, they can provide reliable insulation between the plural probes extending through the plural positioning members.

Description is hereinafter made of embodiments of the present invention based on the drawings. The common constituent elements in all the embodiments, which are designated by the same reference numerals, are described only in the first embodiment and their description is omitted in the description of subsequent embodiments.

<FIG> and <FIG> illustrate a probe card <NUM> as one embodiment of a "contact inspection device. " The probe card <NUM> includes a probe substrate <NUM>, a reinforcing plate <NUM>, a probe head <NUM>, and plural probes <NUM>. The probe card <NUM> is electrically connected to a tester (not shown) and is attached to the tester for swingable motion relative to the tester.

In this embodiment, the probe substrate <NUM> has a disk-like (circular) shape, and is constituted as a multi-layer substrate including a ceramic substrate and a wiring substrate although not shown. Plural conductive contact portions 12a are provided on the -Z side surface as viewed in <FIG> (which is hereinafter referred to as "lower surface") of the probe substrate <NUM>. In this embodiment, the Z-axis in <FIG> indicates the vertical direction, and the +Z side and -Z side mean the upside and downside, respectively.

Although not shown, plural wiring paths are provided in the probe substrate <NUM>. Each wiring path is electrically connected at one end to one of the probes <NUM> via one of the conductive contact portions 12a provided on the lower surface of the probe substrate <NUM>, and it is connected at the other end to one of plural conductive portions (not shown) provided on the +Z side surface (which is hereinafter referred to as "upper surface") of the probe substrate <NUM>. Each conductive portion (not shown) on the upper surface of the probe substrate <NUM> is connected to a tester (not shown).

The reinforcing plate <NUM> is attached to the upper surface of the probe substrate <NUM>. The reinforcing plate <NUM> has a disk-like shape and is formed with a metal member. The - Z side surface of the reinforcing plate <NUM>, in other words, the lower surface of the reinforcing plate <NUM>, which faces the upper surface of the probe substrate <NUM>, is formed as a flat surface 14a. The flat surface 14a of the reinforcing plate <NUM> (refer to <FIG>) is formed to have a predetermined flatness (for example, <NUM>) or better. Because the probe substrate <NUM> attached to the reinforcing plate <NUM> is forced to have the same flatness as the flat surface 14a, the reinforcing plate <NUM> defines the flatness of the probe substrate <NUM>.

The probe head <NUM> is detachably attached to the lower surface of the probe substrate <NUM> via fastening members <NUM>. The probe head <NUM> includes an upper probe head <NUM>, a lower probe head <NUM>, and an intermediate retaining member <NUM>. The upper probe head <NUM> and the lower probe head <NUM> are spaced apart in the Z-axis direction, i.e., in the vertical direction. In this embodiment, the upper probe head <NUM> is placed above and the lower probe head <NUM> is placed below in the vertical direction. In this embodiment, the upper probe head <NUM> and the lower probe head <NUM> are formed of non-conductive material such as ceramic.

The intermediate retaining member <NUM> is interposed between the upper probe head <NUM> and the lower probe head <NUM> in the vertical direction. In this embodiment, the intermediate retaining member <NUM> is constituted as a film member made of non-conductive resin material.

The upper probe head <NUM>, the lower probe head <NUM>, and the intermediate retaining member <NUM> have plural holes 22a, 24a, and 26a, respectively. The plural holes 22a, 24a, and 26a extend in the vertical direction (in the Z-axis direction), and have common axes extending in the vertical direction. In other words, the holes 22a, 24a, and 26a of each set are arranged coaxially.

The plural probes <NUM> extend through the probe head <NUM>. Specifically, each probe <NUM> extends through a set of coaxially-arranged holes 22a, 24a, and 26a. In other words, the probes <NUM> extend through the upper probe head <NUM>, the lower probe head <NUM>, and the intermediate retaining member <NUM>. Here, each probe <NUM> has a first end (lower end) and a second end (upper end) that individually protrude vertically from the probe head <NUM>.

As shown in <FIG>, an inspection stage <NUM> is provided below (on the -Z side as viewed in <FIG>) the probe card <NUM>. The inspection stage <NUM> is constituted by combining an X-stage, a Y-stage, a Z-stage, and a θ-stage. A chuck top <NUM> is mounted on top of the inspection stage <NUM>. Thus, the chuck top <NUM> is positionally adjustable in an X-axis direction, a Y-axis direction orthogonal to the X-axis direction on a horizontal plane, and a vertical direction orthogonal to the horizontal plane (XY plane), i.e., a Z-axis direction. The chuck top <NUM> is also adjustable in its rotational position (θ-direction) about the Z-axis.

A mounting surface <NUM>, on which a test object <NUM> is mounted, is provided on top of the chuck top <NUM>. In this embodiment, the test object <NUM> is a semiconductor wafer into which multiple integrated circuits have been incorporated. Plural electrodes 34a are provided on an upper surface of the test object <NUM>. Because the plural electrodes 34a are brought into contact with the first ends (lower ends) of the probes <NUM> with the second ends (upper ends) of the probes <NUM> being in contact with the contact portions 12a of the probe substrate <NUM>, an electrical connection is established between the probe card <NUM> and the test object <NUM>.

As shown in <FIG>, plural positioning members <NUM> and <NUM> are attached to an upper surface of the probe head <NUM>, i.e., an upper surface of the upper probe head <NUM>, via fastening members <NUM> and positioning pins <NUM>. In this embodiment, the positioning members <NUM> and <NUM> include a first positioning member <NUM> and a second positioning member <NUM>. The positioning members <NUM> and <NUM> are described in detail later. The second ends (upper ends) of the probes <NUM> extend through the positioning members <NUM> and <NUM>, and protrude toward the probe substrate <NUM> from the positioning members <NUM> and <NUM>.

Referring now to <FIG> and <FIG>, the configuration of each probe <NUM> is described in detail. Each probe <NUM> includes a first contact portion <NUM> forming the first end (lower end) of the probe <NUM>, a second contact portion <NUM> forming the second end (upper end) of the probe <NUM>, and an elastic portion <NUM>. The first contact portion <NUM> and the second contact portion <NUM> are connected to opposite ends of the elastic portion <NUM>.

In this embodiment, the first contact portion <NUM> and the second contact portion <NUM> are welded to opposite ends of the elastic portion <NUM>. The elastic portion <NUM> has welding parts 48a and 48b at which the elastic portion <NUM> is welded to the first contact portion <NUM> and the second contact portion <NUM>. The welding parts 48a and 48b are larger in diameter than other parts of the elastic portion <NUM>. The holes 22a, 24a, and 26a of the probe head <NUM> have a diameter that is greater than that of the welding parts 48a and 48b, i.e., the maximum diameter of the probes <NUM>.

The elastic portion <NUM> has slit portions <NUM> and <NUM> as spiral "slits" that generate an elastic force in the axial direction of the elastic portion <NUM> (in the Z-axis direction i.e., in the vertical direction). The slit portions <NUM> and <NUM> are provided at two locations spaced apart in the axial direction. An intermediate portion 48c, which corresponds to the intermediate retaining member <NUM> when the probe <NUM> is inserted through the probe head <NUM>, is provided between the slit portions <NUM> and <NUM>.

The second contact portion <NUM> has a polygonal rotation restricted portion <NUM>. As shown in <FIG>, in this embodiment, the rotation restricted portion <NUM> has a rectangular shape. In this embodiment, the thickness of the rotation restricted portion <NUM> in the axial direction is at least larger than that of the first positioning member <NUM>. In other words, the rotation restricted portion <NUM> has a sufficient thickness to engage the first positioning member <NUM> and the second positioning member <NUM> when the probe <NUM> is inserted through the first positioning member <NUM> and the second positioning member <NUM>.

The rotation restricted portion <NUM> has a size that is larger than the diameter of the holes 22a, 24a, and 26a of the probe head <NUM>. In other words, when the probe <NUM> is inserted through the probe head <NUM>, the rotation restricted portion <NUM> cannot pass through the hole 22a and the lower surface of the rotation restricted portion <NUM> abuts against the upper surface of the upper probe head <NUM>. Thus, when the first contact portion <NUM> of the probe <NUM> is passed through its corresponding holes 22a, 24a, and 26a of the probe head <NUM> until it protrudes from the lower probe head <NUM>, the rotation restricted portion <NUM> is supported by the upper probe head <NUM>.

As shown in <FIG>, in this embodiment, the second contact portion <NUM> has a tip portion 46a having the shape of a triangular prism extending in a direction orthogonal to the axial direction (Z-axis direction), i.e., in the X-axis direction or Y-axis direction. One edge of the triangular prism extending in the axial direction thereof is located at the top of the tip portion 46a in the vertical direction, in other words, forms a ridge. Thus, because this edge of the tip portion 46a will be brought into contact with one of the contact portions 12a of the probe substrate <NUM>, the probe <NUM> and the contact portion 12a of the probe substrate <NUM> will make a line contact with each other.

The probes <NUM> are formed of conductive metal material. As one example, the probes <NUM> are formed of a conductive metal material having high toughness, such as nickel (Ni), nickel-phosphorus alloys (Ni-P), nickel-tungsten alloys (Ni-W), phosphor bronze, palladium-cobalt alloys (Pd-Co) and palladium-nickel-cobalt alloys (Pd-Ni-Co).

Referring next to <FIG>, the first positioning member <NUM> and the second positioning member <NUM> are described. In this embodiment, the first positioning member <NUM> and the second positioning member <NUM> are formed as plate-like members made of non-conductive material such as ceramic. It should be noted that the first positioning member <NUM> is shown in <FIG> for descriptive purposes, and description is made using the first positioning member <NUM>.

The first positioning member <NUM> has through holes <NUM>, at its four corners, for fastening members <NUM> that are used to detachably attach the first positioning member <NUM> and the second positioning member <NUM> to the upper probe head <NUM>. As shown in <FIG>, the through holes <NUM> are formed as slotted holes extending in a diagonal direction of the first positioning member <NUM> and the second positioning member <NUM>. In <FIG>, <FIG> and <FIG>, illustration of the through holes <NUM> is omitted.

The first positioning member <NUM> has plural rotation restricting portions <NUM> aligned at appropriate intervals in the X-axis direction and Y-axis direction. The rotation restricting portions <NUM> have a polygonal shape. In this embodiment, the rotation restricting portions <NUM> have a rectangular shape. The rotation restricting portions <NUM> have a size that is large enough that the rotation restricted portions <NUM> of the probes <NUM> can pass through them. The second positioning member <NUM> also has rotation restricting portions <NUM>, which are similar to the rotation restricting portions <NUM> of the first positioning member <NUM>.

The first positioning member <NUM> has plural positioning holes <NUM> and <NUM> for receiving the positioning pins <NUM>. The second positioning member <NUM> also has plural positioning holes <NUM> and <NUM>. The positioning holes <NUM> and <NUM> of the first positioning member <NUM> and the positioning holes <NUM> and <NUM> of the second positioning member <NUM> are formed such that the axes of the positioning holes <NUM> and <NUM> coincide with the axes of the positioning holes <NUM> and <NUM> when the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other, as described later.

Referring next to <FIG>, positioning and switching between a rotation unrestricted state and a rotation restricted state of the probes <NUM> extending through the probe head <NUM> are described.

<FIG> illustrates a state where the first positioning member <NUM> and the second positioning member <NUM> are attached to an upper part of the probe head <NUM>, i.e., the upper surface of the upper probe head <NUM>, via the fastening members <NUM>. In this state, the rotation restricting portions <NUM> of the first positioning member <NUM> and the rotation restricting portions <NUM> of the second positioning member <NUM> correspond in position to each other in the X-axis direction and Y-axis direction. Specifically, the rectangular rotation restricting portions <NUM> and the rectangular rotation restricting portions <NUM> are located at the same positions in the X-axis direction and Y-axis direction and overlap with each other. It should be noted that, in this state, the positioning holes <NUM> of the first positioning member <NUM> and the positioning holes <NUM> of the second positioning member <NUM> are offset from each other in the X-axis direction and Y- axis direction.

Then, as shown in <FIG>, the probes <NUM> are inserted from above the first positioning member <NUM> and the second positioning member <NUM> into the probe head <NUM> through the rotation restricting portions <NUM> and <NUM>. As a result, the rotation restricted portions <NUM> of the probes <NUM> are received in the rotation restricting portions <NUM> and <NUM>. In this state, because the rotation restricting portions <NUM> and <NUM> are larger in size than the rotation restricted portions <NUM>, the rotation restricted portions <NUM> are still unaligned, in other words, the ridges of the tip portions 46a of the second contact portions <NUM> are directed in different directions (refer to <FIG>), in the rotation restricting portions <NUM>.

In this state, the fastening members <NUM> are loosened. Then, the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other on the upper probe head <NUM> without being removed therefrom. Specifically, as shown in <FIG>, the first positioning member <NUM> and the second positioning member <NUM> are moved along a diagonal of the rectangular rotation restricting portions <NUM> and <NUM> (refer to the arrow in <FIG>).

When the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other along a diagonal of the rectangular rotation restricting portions <NUM> and <NUM> as shown in <FIG>, the rotation restricted portions <NUM> of the probes <NUM> received in the rotation restricting portions <NUM> and <NUM> are pressed by the side walls of the rotation restricting portions <NUM> and <NUM> and rotate about their axes (refer to chain double-dashed lines in <FIG>).

When the first positioning member <NUM> and the second positioning member <NUM> are further moved relative to each other along a diagonal of the rectangular rotation restricting portions <NUM> and <NUM>, the four sides of each of the rectangular rotation restricted portions <NUM> of the probes <NUM> engage side walls of its corresponding rotation restricting portions <NUM> and <NUM> as shown in <FIG>. In this embodiment, of the four sides of each rectangular rotation restricted portion <NUM>, sides 52a and 52b engage the first positioning member <NUM> and sides 52c and 52d engage the second positioning member <NUM>.

In other words, because each of the first positioning member <NUM> and the second positioning member <NUM> engages one of the pair of opposite sides of their corresponding rectangular rotation restricted portion <NUM>, the rotation restricted portions <NUM> are restricted from moving in the X-axis direction and Y-axis direction. In other words, the rotation restricted portions <NUM> are positioned by the first positioning member <NUM> and the second positioning member <NUM>. In addition, because the rotation restricting portions <NUM> and <NUM> engage four sides 52a, 52b, 52c and 52d of the rotation restricted portions <NUM>, the rotation restricting portions <NUM> and <NUM> can restrict the rotation restricted portions <NUM> from rotating about the axes of the probes <NUM>.

As a result, as shown in <FIG>, when the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other along a diagonal of the rectangular rotation restricting portions <NUM> and <NUM>, the rotation restricted portions <NUM>, which are unaligned when received in the rotation restricting portions <NUM> and <NUM>, are positioned and restricted from rotating about the axes of the probes <NUM>.

Then, because the positioning holes <NUM> and <NUM> of the first positioning member <NUM> and the positioning holes <NUM> and <NUM> of the second positioning member <NUM> correspond in position to each other in the X-axis direction and Y-axis direction, the relative positions of the first positioning member <NUM> and the second positioning member <NUM> can be fixed and the position and rotation restricted state of each rotation restricted portion <NUM> can be maintained by inserting the positioning pins <NUM> into the positioning holes <NUM> and <NUM> and tightening the fastening members <NUM>. In other words, by moving the first positioning member <NUM> and the second positioning member <NUM> relative to each other, the probes <NUM> can be switched from a rotation unrestricted state to a rotation restricted state.

In addition, when the positioning pins <NUM> inserted into the positioning holes <NUM> and <NUM> are pulled out from the positioning holes <NUM> and <NUM> and the fastening members <NUM> are loosened from the state where the probes <NUM> are restricted from rotating as shown in <FIG>, the first positioning member <NUM> and the second positioning member <NUM> can be moved relative to each other. Then, the probes <NUM> can be switched from the rotation restricted state to the rotation unrestricted state. Then, because the probes <NUM> can be individually pulled out from the probe head <NUM>, any probes <NUM> damaged in the probe head <NUM> can be easily replaced.

In addition, because the probes <NUM> can be positioned and restricted from rotating simply by inserting the probes <NUM> into the probe head <NUM> and moving the first positioning member <NUM> and the second positioning member <NUM> relative to each other, the probe head <NUM> can be assembled easily.

The above description is summarized. In the probe card <NUM> of this embodiment, when the plural positioning members <NUM> and <NUM> are moved relative to each other, the rotation restricting portions <NUM> and <NUM> align the probes <NUM> and switch the probes <NUM> from a rotation unrestricted state to a rotation restricted state. Thus, because the probes <NUM> are prevented from rotating relative to the contact portions 12a of the probe substrate <NUM> in contact with the probes <NUM>, wear or damage of the contact portions 12a of the probe substrate <NUM> can be reduced.

In addition, in this embodiment, because the probes <NUM> can be aligned by moving the plural positioning members <NUM> and <NUM> relative to each other, the probes <NUM> can be easily positioned and the positional accuracy of the probes <NUM> can be improved. Thus, the contact portions 12a of the probe substrate <NUM> can be reduced in size, enabling them to cope with further reduction in pitch.

In addition, in this embodiment, the probes <NUM> can be switched between a rotation restricted state and a rotation unrestricted state by moving the plural positioning members <NUM> and <NUM> relative to each other with the probe head <NUM> removed from the probe substrate <NUM>. This facilitates maintenance and replacement of the probes <NUM> and assembly of the probe head <NUM>, which in turn improves work efficiency in maintenance and replacement of the probes <NUM> and in assembling the probe head <NUM>.

In addition, according to this embodiment, the plural positioning members <NUM> and <NUM> include a first positioning member <NUM> and a second positioning member <NUM>. The rotation restricting portions <NUM> and <NUM> of the first positioning member <NUM> and the second positioning member <NUM>, and the rotation restricted portions <NUM> both have a rectangular shape. Thus, when the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other along a diagonal of the rectangular shape, the rotation restricting portions <NUM> and <NUM> restrict rotation of the rotation restricted portions <NUM>. Thus, when the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other along a diagonal of the rectangular shape, the four sides of each of the rectangular rotation restricted portions <NUM> of the probes <NUM> are restrained by the rotation restricting portions <NUM> and <NUM> of the first positioning member <NUM> and the second positioning member <NUM>. As a result, the probes <NUM> can be maintained in a rotation restricted state more reliably. In addition, because the four sides of each of the rotation restricted portions <NUM> are restrained, the probes <NUM> can be positioned with higher accuracy, enabling them to cope with narrower pitches.

In this embodiment, each probe <NUM> has an elastic portion <NUM> capable of freely expanding and contracting in the axial direction of the probe <NUM>, and the first contact portion <NUM> and the second contact portion <NUM> connected to opposite ends of the elastic portion <NUM>. When a force is applied to the first contact portion <NUM> and the second contact portion <NUM>, the elastic portion <NUM> warps in the axial direction of the probe <NUM> and applies an elastic force generated by the warp to the first contact portion <NUM> and the second contact portion <NUM>. As a result, the elastic portion <NUM> can apply an elastic force between the first contact portion <NUM> and the test object <NUM> and between the second contact portion <NUM> and its corresponding contact portion 12a of the probe substrate <NUM>. This makes the contact between the first contact portion <NUM> and the test object <NUM> and the contact between the second contact portion <NUM> and its corresponding contact portion 12a of the probe substrate <NUM> more stable, and reduces poor connection therebetween.

In this embodiment, the probe head <NUM> has the holes 22a, 24a, and 26a for receiving the probes <NUM>, and the rotation restricted portions <NUM> of the probes <NUM> are larger in size than the holes 22a, 24a, and 26a. Thus, when the probes <NUM> are inserted through the probe head <NUM>, the rotation restricted portions <NUM> cannot pass through the holes 22a, 24a, and 26a. In other words, the rotation restricted portions <NUM> of the probes <NUM> also function as a stopper to the probe head <NUM>.

In addition, according to this embodiment, because the rotation restricted portion <NUM> of each probe <NUM> contacts the holes 22a, 24a, and 26a of the probe head <NUM> at a position close to the tip portion 46a of the second contact portion <NUM> of the probe <NUM>, each probe <NUM> is supported by the probe head <NUM> at a position close to the tip portion 46a of its second contact portion <NUM>. As a result, the tip portion 46a of the second contact portion <NUM> of each probe <NUM> is restricted from displacing in a direction orthogonal to the axial direction of the probe <NUM> (Z-axis direction), i.e., in the X-axis direction or Y-axis direction compared to the first contact portion <NUM> thereof. This prevents the tip portions 46a of the second contact portions <NUM> of the probes <NUM> from displacing in the orthogonal direction (X-axis direction or Y-axis direction) relative to the contact portions 12a of the probe substrate <NUM> and can therefore reduce wear or damage of the contact portions 12a of the probe substrate <NUM>.

In addition, in this embodiment, each probe <NUM> has at least one slit portion <NUM> extending spirally in the axial direction of the probe <NUM> between the first contact portion <NUM> and the second contact portion <NUM>. The slit portion <NUM> can absorb the torsion applied to the probe <NUM> or inclination of the probe <NUM> and can therefore improve the service life of the probe <NUM>. In addition, because the slit portion <NUM> is formed spirally in the axial direction of the probe <NUM>, it can also absorb some of the pressure applied in the axial direction and can therefore improve the service life of the probe <NUM>. In addition, the slit portion <NUM> can prevent the probe <NUM> from breakage or the like and can therefore improve the service life of the probe card <NUM>.

In addition, in this embodiment, because the plural positioning members <NUM> and <NUM> are made of non-conductive material such as ceramic, they can provide reliable insulation between the plural probes <NUM> extending through the plural positioning members <NUM> and <NUM>.

Referring next to <FIG>, a first example not falling under the scope of claim <NUM> is described. This example is different from the first embodiment in that each probe <NUM> has a triangular rotation restricted portion <NUM> unlike the rotation restricted portions <NUM> of the probes <NUM> in the first embodiment.

As shown in <FIG>, each probe <NUM> according to the first example has a triangular rotation restricted portion <NUM>. The probes <NUM> are the same in other respects as the probes <NUM> according to the first embodiment, therefore their description is not therefore repeated.

<FIG> illustrates an example of a rotation restricted state of a triangular rotation restricted portion <NUM> created by a rotation restricting portion <NUM> of the first positioning member <NUM> and a rotation restricting portion <NUM> of the second positioning member <NUM>.

In this example, the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other so that two sides 66b and 66c of the three sides 66a, 66b, and 66c of the rotation restricted portion <NUM> can be restricted by the rotation restricting portions <NUM> and <NUM>, respectively. Specifically, the first positioning member <NUM> is moved in the -X direction and -Y direction and the second positioning member <NUM> is moved in the +X direction and -Y direction as viewed in <FIG>. Then, the side 66b of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM>, and the side 66c of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM>.

Thus, because two of the three sides of the rotation restricted portion <NUM> engage the rotation restricting portions <NUM> and <NUM>, the rotation restricted portion <NUM> is restricted from rotating about the axis of the probe <NUM>. In addition, as shown in <FIG>, the vertex 66e between the sides 66a and 66c of the rotation restricted portion <NUM> engages a corner of the rotation restricting portion <NUM> and the vertex 66f between the sides 66a and 66b of the rotation restricted portion <NUM> engage a corner of the rotation restricting portion <NUM>, the rotation restricted portion <NUM> is positioned by the rotation restricting portions <NUM> and <NUM>. Thus, the rotation restricted portion <NUM> is positioned and restricted from rotating about the axis of the probe <NUM> by the rotation restricting portions <NUM> and <NUM>.

<FIG> illustrates another example of a rotation restricted state of a triangular rotation restricted portion <NUM> created by a rotation restricting portion <NUM> of the first positioning member <NUM> and a rotation restricting portion <NUM> of the second positioning member <NUM>.

In this example, the first positioning member <NUM> and the second positioning member <NUM> are moved relative to each other so that a side 66a of the three sides 66a, 66b and 66c of the rotation restricted portion <NUM> and a vertex <NUM> between the sides 66b and 66c are restricted by the rotation restricting portions <NUM> and <NUM>, respectively. Specifically, the first positioning member <NUM> is moved in the -Y direction and the second positioning member <NUM> is moved in the +Y direction as viewed in <FIG>. Then, the side 66a of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM>, and the vertex <NUM> of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM>.

Thus, because one side of the rotation restricted portion <NUM> and a vertex opposite the side engage the rotation restricting portions <NUM> and <NUM>, respectively, the rotation restricted portion <NUM> is restricted from rotating about the axis of the probe <NUM>. In addition, because the side 66a of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM> and the vertex <NUM> between the sides 66b and 66c of the rotation restricted portion <NUM> engages the rotation restricting portion <NUM> as shown in <FIG>, the rotation restricted portion <NUM> is positioned by the rotation restricting portions <NUM> and <NUM>. Thus, the rotation restricted portion <NUM> is positioned and restricted from rotating about the axis of the probe <NUM> by the rotation restricting portions <NUM> and <NUM>.

According to this example, the rotation restricting portions <NUM> and <NUM> engage at least two sides 66c and 66b, or one side 66a and a vertex <NUM> opposite the side 66a, respectively, of each rotation restricted portion <NUM> having a triangular shape as one example of a polygonal shape, and thereby restricting rotation of the rotation restricted portion <NUM>. Thus, because the probes <NUM> are prevented from rotating relative to the contact portions 12a of the probe substrate <NUM> in contact with the probes <NUM>, wear or damage of the contact portions 12a of the probe substrate <NUM> can be reduced.

Referring to <FIG>, a second embodiment is described. The third embodiment is different from the first embodiment in that each probe <NUM> according to the second embodiment does not have a second contact portion and has a rotation restricted portion in the elastic portion.

Referring to <FIG>, each probe <NUM> according to the second embodiment includes a first contact portion <NUM> and an elastic portion <NUM>. The elastic portion <NUM> is connected to the first contact portion <NUM> at the -Z side end thereof as viewed in <FIG>. The elastic portion <NUM> has slit portions <NUM> and <NUM> at two locations spaced apart in the axial direction of the probe <NUM> (in the Z-axis direction in <FIG>). The elastic portion <NUM> has a contact point portion <NUM> at its +Z side end as viewed in <FIG>, and has a rotation restricted portion <NUM> in the vicinity of the contact point portion <NUM>.

Claim 1:
A contact inspection device (<NUM>) configured to perform contact inspection of a test object (<NUM>),
the contact inspection device further comprising:
plural probes (<NUM>) each having a first end to be brought into contact with the test object (<NUM>);
a probe substrate (<NUM>) including contact portions (12a) in contact with respective second ends of the probes (<NUM>);
a probe head (<NUM>) through which the plural probes (<NUM>) extend and which is detachably attached to the probe substrate (<NUM>); the probe head (<NUM>) comprising an upper probe head (<NUM>), a lower probe head (<NUM>), and an intermediate retaining member (<NUM>),
characterized in that
the contact inspection device (<NUM>) further comprises
plural positioning members (<NUM>, <NUM>) which are provided on a surface of the upper probe head (<NUM>) facing the probe substrate (<NUM>) and through which the plural probes (<NUM>) extend,
each of the probes (<NUM>) having a rotation restricted portion (<NUM>) provided on the side of the second end,
each of the plural positioning members (<NUM>, <NUM>) having rotation restricting portions (<NUM>) adapted to engage the rotation restricted portions (<NUM>),
wherein, when the plural positioning members (<NUM>, <NUM>) are moved relative to each other, in a state where the probe head (<NUM>) is removed from the probe substrate (<NUM>), the rotation restricting portions (<NUM>) align the probes (<NUM>) and switch the probes (<NUM>) from a rotation unrestricted state to a rotation restricted state, and wherein
the plural positioning members (<NUM>, <NUM>) include a first positioning member (<NUM>) and a second positioning member (<NUM>), wherein
the rotation restricting portions (<NUM>) of the first positioning member (<NUM>) and the second positioning member (<NUM>) have a rectangular shape, wherein
the rotation restricted portions (<NUM>) have a rectangular shape, and wherein
when the first positioning member (<NUM>) and the second positioning member (<NUM>) are moved relative to each other along a diagonal of the rectangular shape, the rotation restricting portions (<NUM>) restrict rotation of the rotation restricted portions (<NUM>).