1. Field of the Invention
The present invention relates to an inspection apparatus and method for testing microstructures such as MEMS (Micro Electro Mechanical Systems).
2. Description of Related Art
MEMS, which are devices in which various functions such as mechanical, electronic, optical and chemical functions are integrated particularly using semiconductor microfabrication technology or the like, have received great attention in recent years. A practical example adopting the MEMS technology so far is microsensors including acceleration sensors, pressure sensors, air flow sensors and so on used as various types of sensors for automobiles and medical purposes, and the MEMS devices are mounted on such microsensors.
The adoption of the MEMS technology in an inkjet printer head enables an increase in the number of nozzles for ejecting ink and precisely controlled ejection of the ink, thereby making it possible to improve image quality and printing speed. In addition, a micromirror array used in reflective projectors is also known as a general MEMS device. Further, future development of various sensors and actuators utilizing the MEMS technology is expected to be broadly applied to optical communications and mobile apparatuses, computing machines and their peripheral devices, bio-analysis, and power sources for portable apparatuses. A variety of MEMS technologies are introduced in Technology Research Report Vol. 3 (issued by the Technology Research and Information Office in the Industrial Science and Technology Policy and Environment Bureau, and the Industrial Machinery Division in the Manufacturing Industries Bureau of the Ministry of Economy, Trade and Industry, on Mar. 28, 2003) under the agenda of the current state of the art and problems encompassing MEMS.
Meanwhile, with the development of the MEMS devices, systems for appropriately inspecting the MEMS devices are of increasing importance. For example, a structure having microscopic movable parts, such as an acceleration sensor, is a device whose response characteristics change with a microscopic movement and therefore needs to be inspected with high precision to evaluate the characteristics.
One example in the inspection methods includes: previously forming a test pad to evaluate the characteristics of the device; detecting the output characteristics from the test pad according to a predetermined test pattern; and analyzing the output characteristics to evaluate the device characteristics. Alternatively, a laser displacement meter or the like is conceivably used to detect the amount of displacement of the microscopic movable parts of the microstructures in order to evaluate the device characteristics.
It is assumed to use a free pad that is not used as a test pad among the pads generally prepared on the device in advance. It is becoming increasingly difficult to use the free pad, however, with an increase of function performed by the recent devices because the number of pads is limited under the layout constraints and so on.
It might be possible to additionally form a special pad intended for test use only, however such a pad would cause the area of the chip to increase and therefore to increase the manufacturing cost.
The laser displacement meter or the like, which evaluates the device characteristics based on the measurement value responded to irradiation of laser light, is not applicable to the area of the device where the laser light cannot reach.
Furthermore, it is significantly difficult for the device to undergo nondestructive inspection to check its possible internal destruction and external destruction that cannot be readily found by visual inspection. Even though the nondestructive inspection may be executed, such an inspection requires a highly expensive tester.
The present invention is made to solve the above-described problems and has an object to provide a microstructure inspection apparatus and microstructure inspection method for readily testing structures with microscopic movable parts with high precision.
The microstructure inspection apparatus according to the present invention is to evaluate the characteristics of a microstructure with a movable part and includes electric drive means for providing motion to the movable part of the microstructure and characteristic evaluation means for detecting a sound produced by the motion of the movable part of the microstructure provided by the drive means and for evaluating the characteristics of the microstructure based on the detection results.
A plurality of microstructures are arranged in an array form on a base, for example.
The above-described characteristic evaluation means preferably includes measurement means for detecting a sound produced in response to the motion of the movable part of the microstructure and determination means for evaluating the characteristics of the microstructure based on a comparison between the signal characteristics of the sound detected by the measurement means and the signal characteristics of a sound serving as a predetermined threshold.
In one embodiment, the measurement means detects the frequency characteristics of sounds, while the determination means evaluates the characteristics of the microstructure by comparing the frequency characteristics of a sound detected by the measurement means and the frequency characteristics of a sound serving as a predetermined threshold.
In another embodiment, the measurement means detects the amplitude of sounds, while the determination means evaluates the characteristics of the microstructure by comparing the amplitude of a sound detected by the measurement means and the amplitude of a sound serving as a predetermined threshold.
In yet another embodiment, the measurement means detects the phase characteristics of sounds, while the determination means evaluates the characteristics of the microstructure by comparing the phase characteristics of a sound detected by the measurement means and the phase characteristics of a sound serving as a predetermined threshold.
The microstructure is at least one device selected from the group consisting of, for example, a switch, an acceleration sensor, an angular velocity sensor, a pressure sensor and a microphone. The acceleration sensor is, for example, a multiaxial acceleration sensor, while the angular velocity sensor is, for example, a multiaxial angular velocity sensor.
A microstructure inspection method according to the present invention includes the steps of providing motion to a movable part of a microstructure by using electric means, detecting a sound produced by the motion of the movable part of the microstructure, and evaluating the characteristics of the microstructure based on the detection results of the sound.
The above-described characteristic evaluation step preferably includes a step of performing comparison between the signal characteristics of the detected sound and the signal characteristics of a sound serving as a predetermined threshold.
In one embodiment, the sound detection step includes detection of the frequency characteristics of sounds, while the characteristic evaluation step includes a step of performing comparison between the frequency characteristics of the detected sound and the frequency characteristics of a sound serving as a predetermined threshold.
In another embodiment, the sound detection step includes a step of performing detection of the amplitude of sounds, while the characteristic evaluation step includes a comparison between the amplitude of the detected sound and the amplitude of a sound serving as a predetermined threshold.
In yet another embodiment, the sound detection step includes a step of performing detection of the phase characteristics of sounds, while the characteristic evaluation step includes a step of performing comparison between the phase characteristics of the detected sound and the phase characteristics of a sound serving as a predetermined threshold.
The microstructure inspection apparatus and microstructure inspection method according to the present invention detects a sound produced by the motion of the movable part of the microstructure and evaluates the characteristics of the microstructure based on the detection results. Thus, there is no need to provide a special test pad intended for inspection use only, and therefore a simple test can be achieved. In addition, nondestructive inspections to check a device's possible internal destruction and external destruction that cannot be readily found by visual inspection can be realized.
Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the same elements or equivalents are denoted with the same reference numerals and their descriptions are not reiterated.
Referring to
The tester 5 is provided with a microphone 3 for detecting sounds output from the chip TP to be tested, an input/output interface 15 for transmitting and receiving input/output data between the outside and the inside of the tester, a control unit 20 for controlling the entire tester 5 and analyzing sounds detected by a measurement unit 25, the measurement unit 25 for measuring the sound detected by the microphone 3, a voltage drive unit 30 for outputting a voltage which is an electrical signal to provide motion to the movable part of the chip TP. The microphone 3 shall be arranged in the vicinity of a test object. In
In this embodiment, a description will be made in the case where a test is executed with a cantilever-type MEMS switch (hereinafter, referred to as just “switch”) as an example.
With the use of the flow chart of
The application of the test signal effects the operation of the movable part of the chip TP under test (step S2). Specifically, as illustrated in
Next, the control unit 20 evaluates the characteristic value of the tested chip based on the sound detected by the microphone 3 (step S4).
Next, the control unit 20 determines whether the measured characteristic value, that is measured data, is within an acceptable range (step S6).
Specifically, the signal characteristics of the sound detected by the measurement unit 25 are compared with predetermined threshold signal characteristics and then evaluated based on the comparison result. Subsequently, it is determined from the comparison result whether the characteristic value of the detected sound are in the acceptable range. There may be various schemes to compare the signal characteristics of the detected sound. One of the examples is to compare with an ideal sound detected from an ideal chip as a reference sound. The sound pressure, spectrum, frequency characteristic, amplitude, phase characteristic or the like of the reference sound is defined as a reference, that is, a threshold, and is compared to make it possible to evaluate the detected sound of the chip. For instance, if the sound detected from the chip under the test shows quite different frequency characteristics after the comparison with the frequency characteristics of the reference sound, it can be determined that the tested chip is defective. Alternatively, by comparing the amplitude of the detected sound and the amplitude of the reference sound, the characteristics of the tested chip can be evaluated. Additionally, the comparison between the phase of the detected sound and the phase of the reference sound can evaluate the characteristics of the tested chip. It is also possible to compare with a combination of these factors to evaluate the characteristics of the tested chip.
When the characteristic value of the detected sound is determined to be within the acceptable range in step S6, it is recognized that the detected chip passed the test (step S7), and then it is output as data and stored (step S8). The storage of the data is not illustrated, however, the data shall be stored in a storage unit like a memory provided in the tester 5 under the direction from the control unit 20. The control unit 20 also serves as a determination unit to determine the chip under the test based on the measured data from the measurement unit 25.
When it is found that there is no chip to be tested in step S9, the inspection (test) of the microstructure is terminated (step S10). On the other hand, when it is found that there is another chip to be tested in step S9, the procedure returns to the first step S1 to execute the next inspection. If the control unit 20 determines that the evaluated characteristic value, that is measured data, is not within the acceptable range in step S6, it is recognized that the chip failed the test (step S11), and then reinspection is executed (step S12). Specifically, chips that are determined to be not within the acceptable range after reinspection can be removed. Alternatively, even such chips without an acceptable range can be classified into a plurality of groups. Actually, there possibly exist many chips that could not meet the strict test conditions but have no substantial problem to be shipped if maintenance and adjustment are provided. Therefore, it is also possible to screen the chips by grouping during the reinspection and to ship the chips based on the screen result.
According to the microstructure inspection method of the present invention, the characteristics of the microstructure can be evaluated by detecting the sound produced from the movable part, and therefore the special test pad intended for inspection use only is not necessary and the test can be readily executed. Furthermore, this inspection method in which devices are evaluated based on the signal characteristics of the detected sound produced by the motion of the movable part can be used for nondestructive inspection to check a devices' possible internal destruction and external destruction that cannot be found by visual inspection. Therefore, according to the inspection method of the invention, areas of the device to which laser light cannot be irradiated and areas of the device impossible to be inspected unless otherwise destructed can be readily inspected at low cost.
Next description will be made about an inspection of a microstructure having a membrane structure as a chip to be tested.
The inspection method is executed following the same steps as described in
Next description will be made about a triaxial acceleration sensor which is another microstructure.
In a concrete configuration, the masses AR in the middle are supported by four beams BM, respectively. The beams BM are formed so as to be orthogonal to each other in the two axial directions X and Y, and four piezoresistive elements are provided for each axis. Four piezoresistive elements for detecting acceleration in the axial direction Z are disposed next to the piezoresistive elements for detecting acceleration in the axial direction X, respectively. The masses AR are linked to the beams BM in the center part and thus take the shape of a four-leaf clover on their top. The adoption of this four-leaf clover-shaped structure allows the masses AR to be larger and the beams to be longer, thereby making it possible to realize a small but high-sensitive acceleration sensor.
The operating principle of this triaxial piezoresistive acceleration sensor is, when the beams BM are deformed by the masses that have received acceleration (inertial force), to detect the acceleration based on a change in the resistance value of the piezoresistive elements formed on a surface of the deformed beams BM. The outputs of this sensor are so set to be taken out from Wheatstone bridges, which will be described later, each independently incorporated in three axes.
As discussed above, the resistance values of the four piezoresistive elements along each axis change due to the strain applied to the elements. On the basis of the change, for the X axis and Y axis, for example, acceleration components applied to each axis are detected in the Wheatstone bridge circuits as independent, separate output voltages. In order to form the above circuit, metal wires or the like as shown in
This triaxial acceleration sensor can also detect the DC component of the acceleration, and therefore can be used as an inclinometer sensor, in other words, an angular velocity sensor for detecting gravitational acceleration.
Therefore, based on the frequency characteristics shown in
This triaxial acceleration sensor can be inspected in the same scheme taken with the inspection system 1# shown in
Although a triaxial piezoresistive acceleration sensor is used as an exemplary model, triaxial acceleration sensors for capacitance detection can be inspected in the same manner. In the case of the triaxial capacitive acceleration sensors, for example, a test signal to move the masses is applied to an electrode for detecting the capacitance. With the motion of the masses in response to the test signal, the same inspection as described above can be executed to make a determination. In this case, the above-mentioned electrodes embedded in the measurement jig are not necessary, thereby achieving simpler design of the tester and so on.
The environment for detecting sounds is assumed to be in the atmosphere, however, the present invention is not limited to this. The inspection can be executed in a liquid that reduces sound attenuation, thereby enabling high-sensitive detection of the sound and thus high-precision inspection.
It should be understood that the embodiments disclosed herein are to be taken as examples and are not limited in every respect. The scope of the present invention is defined not by the above described embodiments but by the following scope of claims. All changes that fall within meets and bounds of the claims, or equivalence of such meets and bounds are intended to be embraced by the claims.
The present invention can be advantageously used for microstructure inspection apparatuses and methods.
Number | Date | Country | Kind |
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2004-265385 | Sep 2004 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2005/016663 | 9/9/2005 | WO | 00 | 2/5/2008 |