Probe card with coplanar daughter card

• US 6,856,150 B2
• Filed: 04/10/2001
• Issued: 02/15/2005
• Est. Priority Date: 04/10/2001
• Status: Expired due to Fees

• Current Assignee: FormFactor Incorporated
• Original Assignee: FormFactor Incorporated
• Inventors: Sporck, A. Nicholas, Shinde, Makarand S.
• Primary Examiner(s): Tokar, Michael
• Assistant Examiner(s): HOLLINGTON, JERMELE M
• Application Number:
  US09/832,913
• Publication Number:
  US 20020145437A1
• Time in Patent Office: 1,407 Days
• Field of Search: 324754-755, 324/158.1
• US Class Current: 324/754.07
• CPC Class Codes: G01R 1/07342 the body of the probe being at an angle other than perpendicular to test object, e.g. probe card

Abstract

A probe card assembly includes a printed circuit board with tester contacts for making electrical connections to a semiconductor tester. The probe card assembly also includes a probe head assembly with probes for contacting a semiconductor device under test. One or more daughter cards is mounted to the printed circuit board such that they are substantially coplanar with the printed circuit board. The daughter cards may contain a circuit for processing test data, including test signals to be input into the semiconductor and/or response signals generated by the semiconductor device in response to the test signals.

Claims

1. A probe card assembly for electrically communicating test data between a semiconductor test apparatus and a semiconductor device under test, said probe card assembly comprising:

a substrate configured to electrically contact said semiconductor tester apparatus,

a plurality of probes configured to electrically contact said semiconductor device under test, said plurality of probes located to a first side of said substrate,

a daughter card located to a second side of said substrate, and

an electric circuit at least a portion of which is disposed on said daughter card,

wherein said electric circuit receives as input test data received at said probe card assembly from one of said tester apparatus or said semiconductor device under test, enhances said test data, and outputs enhanced test data.

2. The probe card assembly of claim 1, wherein said electric circuit comprises at least one of a digital logic element, a microprocessor, an analog circuit element, a digital-to-analog converter, or an analog-to-digital converter.

3. The probe card assembly of claim 1, wherein said plurality of probes are configured to contact a plurality of semiconductor devices under test, and said electric circuit enhances said test data by receiving test signals from said tester apparatus for testing a first number of semiconductor devices and outputting to said probes test signals for testing a second number of semiconductor devices, wherein said second number is greater than said first number.

4. The probe card assembly of claim 1, wherein said daughter card is substantially coplanar to said substrate and there is a space between said daughter card and said substrate.

5. The probe card assembly of claim 1, wherein said electric circuit enhances said test data by customizing at least a portion of said test data to test needs of said semiconductor device under test.

6. The probe card assembly of claim 5, wherein said test data comprises test signals generated by said semiconductor test apparatus and said electric circuit customizes at least a portion of said test signals.

7. The probe card assembly of claim 5, wherein said test data comprises response signals generated by said semiconductor device under test and said electric circuit customizes at least a portion of said response signals.

8. The probe card assembly of claim 1 further comprising a plurality of said daughter cards.

9. The probe card assembly of claim 8, wherein said plurality of daughter cards are disposed in stacked relationship to each other.

10. The probe card assembly of claim 8, wherein at least a portion of said electric circuit is disposed on each of said plurality of daughter cards.

11. The probe card assembly of claim 10, wherein said electric circuit comprises at least one of a digital logic element, a microprocessor, an analog circuit element, a digital-to-analog converter, or an analog-to-digital converter.

12. The probe card assembly of claim 10, wherein said electric circuit enhances said test data by customizing at least a portion of said test data to test needs of said semiconductor device under test.

13. The probe card assembly of claim 12, wherein said test data comprises test signals generated by said semiconductor test apparatus and said electric circuit customizes at least a portion of said test signals.

14. The probe card assembly of claim 12, wherein said test data comprises response signals generated by said semiconductor device under test and said electric circuit customizes at least a portion of said response signals.

15. The probe card assembly of claim 8, wherein said plurality of daughter cards includes at least three daughter cards.

16. The probe card assembly of claim 15, wherein at least a portion of said electric circuit is disposed on each of said at least three daughter cards.

17. The probe card assembly of claim 15, wherein said at least three daughter cards are disposed in stacked relationship to each other.

18. A method of making a probe card assembly, said method comprising:

providing a substrate including a plurality of tester contacts,

disposing a plurality of probes to a first side of said substrate, said probes configured to electrically contact a semiconductor device under test, and

disposing a daughter card to a second side of said substrate,

providing an electric circuit that receives as input test data received at said probe card assembly from one of said tester apparatus or said semiconductor device under test, enhances said test data, and outputs enhanced test data, and

disposing at least a portion of said electric circuit on said daughter card.

19. The method of claim 18, wherein said electric circuit comprises at least one of a digital logic element, a microprocessor, an analog circuit element, a digital-to-analog converter, or an analog-to-digital converter.

20. A probe card assembly made using the process of claim 19.

21. A probe card assembly made using the process of claim 18.

22. The method of claim 18, wherein said plurality of probes are configured to contact a plurality of semiconductor devices under test, and said electric circuit enhances said test data by receiving test signals from said tester apparatus for testing a first number of semiconductor devices and outputting to said probes test signals for testing a second number of semiconductor devices, wherein said second number is greater than said first number.

23. The method of claim 18, wherein said daughter card is substantially coplanar to said substrate and there is a space between said daughter card and said substrate.

24. The method of claim 18, wherein said electric circuit enhances said test data by customizing at least a portion of said test data to test needs of said semiconductor device under test.

25. The method of claim 24, wherein said test data comprises test signals to be input into said semiconductor device under test and said electric circuit customizes at least a portion of said test signals.

26. The method of claim 24, wherein said test data comprises response signals generated by said semiconductor device under test and said electric circuit customizes at least a portion of said response signals.

27. A probe card assembly made using the process of claim 24.

28. The method of claim 18, further comprising securing a plurality of said daughter cards to said substrate.

29. The method of claim 28 further comprising securing said plurality of daughter cards to said substrate in stacked relationship to each other.

30. The method of claim 28 further comprising disposing at least a portion of said electric circuit on each of said plurality of daughter cards.

31. The method of claim 30, wherein said electric circuit comprises at least one of a digital logic element, a microprocessor, an analog circuit element, a digital-to-analog converter, or an analog-to-digital converter.

32. The method of claim 30, wherein said electric circuit enhances said test data by customizing at least a portion of said test data to test needs of said semiconductor device under test.

33. The method of claim 32, wherein said test data comprises response signals generated by said semiconductor device under test and said electric circuit customizes at least a portion of said response signals.

34. The method of claim 28, wherein said plurality of daughter cards includes at least three daughter cards.

35. The method of claim 34 further comprising disposing at least a portion of said electric circuit on each of said at least three daughter cards.

36. The method of claim 34 further comprising securing each of said at least three daughter cards to said substrate in stacked relationship to each other.

37. A probe card assembly made using the process of claim 34.

38. A probe card assembly made using the process of claim 28.

39. A probe card assembly comprising:

printed circuit means for electrically communicating with a semiconductor tester apparatus,

contact means for electrically communicating with a semiconductor device under test, said contact means being secured to a first surface of said printed circuit means,

electric circuit means for enhancing test data receive at said probe card assembly from one of said semiconductor tester apparatus or said semiconductor device under test, and

daughter card means for physically supporting at least a portion of said electric circuit means, said daughter card means secured to a second surface of said printed circuit means.

40. The probe card assembly of claim 39, wherein said daughter card means comprises a plurality of daughter cards in stacked relationship to each other, each of said plurality of daughter cards being substantially coplanar to said printed circuit means.

41. The probe card assembly of claim 40, wherein said plurality of daughter cards includes at least three daughter cards.

42. The probe assembly of claim 39, wherein said contact means electrically communications with a plurality of semiconductor devices under test, and said electric circuit means enhances said test data by receiving test signals through said printed circuit means for testing a first number of semiconductor devices and outputting to said contact means test signals for testing a second number of semiconductor devices, wherein said second number is greater than said first number.

43. The probe assembly of claim 39, wherein said daughter card means is substantially coplanar to said contact means.

44. The probe card assembly of claim 39, wherein said electric circuit means enhances said test data by customizing said test data to meet test needs of said semiconductor device under test.

45. The probe card assembly of claim 44, wherein said test data comprises test signals to be input into said semiconductor device under test and said electric circuit means customizes at least a portion of said test signals.

46. The probe card assembly of claim 44, wherein said test data comprises response signals generated by said semiconductor device under test and said electric circuit means customizes at least a portion of said response signals.

47. A probe card assembly for electrically communicating test data between a semiconductor test apparatus and a semiconductor device under test, said probe card assembly comprising:

a printed circuit board configured to electrically contact said semiconductor tester apparatus,

a plurality of probes configured to electrically contact said semiconductor device,

a daughter card secured to said printed circuit board, and

an electric circuit configured receive as input test data received at said probe card assembly from one of said tester apparatus or said semiconductor device under test, enhance said test data, and output enhanced test data, at least a portion of said electric circuit being disposed on said daughter card.

48. The probe card assembly of claim 47 further comprising a plurality of said daughter cards.

49. The probe card assembly of claim 48, wherein said daughter cards are disposed in stacked relationship to each other.

50. The probe card assembly of claim 48, wherein said plurality of daughter cards includes at least two daughter cards.

51. The probe card assembly of claim 48, wherein said plurality of daughter cards includes at least three daughter cards.

52. The probe card assembly of claim 47, wherein said test data comprises test signals generated by said semiconductor tester apparatus and said electric circuit processes at least a portion of said test signals.

53. The probe card assembly of claim 47, wherein said test data comprises response signals generated by said semiconductor device and said electric circuit processes at least a portion of said response signals.

54. The probe card assembly of claim 47, wherein said plurality of probes are configured to contact a plurality of semiconductor devices under test, and said electric circuit enhances said test data by receiving test signals from said semiconductor tester apparatus for testing a first number of semiconductor devices and outputting to said probes test signals for testing a second number of semiconductor devices, wherein said second number is greater than said first number.

55. The probe card assembly of claim 47, wherein said daughter card is substantially coplanar to said substrate and there is a space between said daughter card and said substrate.