Probe Assembly with Downward-Protruding Shield for Semiconductor Testing

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Solution Overview

Problem

Existing probe cards face limitations in throughput during semiconductor testing, which restricts the fabrication capacity of semiconductor devices.

Innovation Solution

The proposed solution involves a probe assembly with a multilayer structure, upper and lower guide plates, and a dielectric spacer plate, which allows for automated probe insertion with reduced thickness, thereby increasing throughput without compromising structural stability or probe alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the dielectric spacer plate thickness is reduced to increase probe insertion speed, then productivity improves, but structural stability and probe alignment may deteriorate

Engineering Contradiction:
Improveprobe insertion speedVSAvoidstructural stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The guide plate is divided into an upper guide plate and a lower guide plate separated by a thin dielectric spacer plate. This segmentation allows the spacer plate to be much thinner than a single solid support structure would require, while the distributed support from both guide plates maintains overall structural stability. The segmentation enables reduced spacer thickness without compromising reliability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The upper guide plate, lower guide plate, and dielectric spacer plate are combined to form an integrated probe assembly structure. The dielectric spacer plate is sandwiched between the two guide plates, creating a unified structure where the combined system provides both mechanical support and electrical isolation. This merging allows the thin spacer to function effectively within the larger stable assembly.

Inventive Principle:
Principle #5Merging (Combining)

2Productivity

If the dielectric spacer plate thickness is reduced to increase throughput, then productivity improves, but manufacturing precision requirements worsen

Engineering Contradiction:
ImprovethroughputVSAvoidalignment precision
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The dielectric spacer plate acts as an intermediary element between the upper and lower guide plates. It provides a reference surface and mechanical interface that facilitates precise alignment during assembly. The spacer plate's structured design includes features that guide probe placement and ensure accurate positioning, thereby maintaining manufacturing precision even at reduced thickness.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces thick mechanical support structures with a thin dielectric spacer plate combined with upper and lower guide plates. This substitution uses the guide plates to provide the primary mechanical strength while the thin spacer plate provides positioning and electrical isolation. The guide plates' hole arrays and structural features replace the need for thick spacer material to maintain alignment precision.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250020693A1Probe assembly with downward-protruding probe shield and methods of operating the same
Publication Date: 2025.01.16 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US20250020693A1 patent drawing
  • US20250020693A1 patent drawing
  • US20250020693A1 patent drawing

AI summary

A test apparatus includes a probe assembly, which includes: a multilayer structure including probe contact pads; an upper guide plate including an array of upper holes therethrough; a lower guide plate including an array of lower holes therethrough; a dielectric spacer plate located between the upper guide plate and the lower guide plate and including an opening; and an array of probes attached to the probe contact pads, vertically extending through the upper guide plate, the lower guide plate, and the dielectric spacer plate. The lower guide plate includes a downward-protruding portion having a first laterally-extending segment having a first width, and further includes a base portion overlying the downward-protruding portion and having a wider second width. The downward-protruding portion can be used to protect the array of probes while probing test pads on a wafer that are exposed between neighboring semiconductor dies.