APPARATUS FOR BONDING A SEMICONDUCTOR CHIP AND METHOD OF FORMING A SEMICONDUCTOR DEVICE

An apparatus for bonding a semiconductor chip to a package substrate, the apparatus comprising: a die-bonding unit configured to attach the semiconductor chip to the package substrate; a load-measuring unit installed at the die-bonding unit, the load-measuring unit including a panel having a plurality of regions and a plurality of load-measuring members with at least one load-measuring member arranged in each of the regions of the panel to measure load values applied to each of the regions; and a controller configured to determine a load and a flatness of the semiconductor chip based on the load values measured by the load-measuring members.

CROSS-REFERENCES TO RELATED APPLICATION

The present application claims priority under 35 U.S.C. §119(a) to Korean Patent Application number 10-2016-0068828, filed on Jun. 2, 2016. In the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

Various embodiments generally relate to an apparatus for manufacturing a semiconductor device and, more particularly, to an apparatus for bonding a semiconductor chip and a method of forming a semiconductor device.

BACKGROUND

Generally, a semiconductor package may be manufactured by a process for singulating semiconductor chips from a wafer, a process for attaching the semiconductor chips to a package substrate, a process for molding the package substrate with the semiconductor chip, and a process for testing the package substrate with the semiconductor chip.

Typically, attaching a semiconductor chip to a package substrate, involves positioning the semiconductor chip on the package substrate using an adhesive and applying a pressure and a temperature to securely attach the semiconductor chip to the package substrate.

The attaching process may require predetermined recipes to improve a yield for manufacturing the semiconductor package.

SUMMARY

According to an embodiment, there is provided an apparatus for bonding a semiconductor chip to a package substrate. The apparatus may include a die-bonding unit configured to attach the semiconductor chip to the package substrate; a load-measuring unit installed at the die-bonding unit, the load-measuring unit including a panel having a plurality of regions and a plurality of load-measuring members with at least one load-measuring member arranged in each of the regions of the panel to measure load values applied to each of the regions; and a controller configured to determine a load and a flatness of the semiconductor chip based on the load values measured by the load-measuring members.

In an embodiment, an apparatus for bonding a semiconductor chip, the apparatus comprising: a die-bonding unit attaching a chip on a package substrate; a load-measuring unit including a plurality of regions arranged in a plurality of rows and a plurality of columns disposed in the die-bonding unit; and a controller connected to the load-measuring unit and configured to determine a load and a flatness with respect to the chip, wherein each of the plurality of regions includes at least one load-measuring member.

In an embodiment, a method of forming a semiconductor device includes: attaching a chip on a package substrate in a die-bonding unit; sensing a signal from a load-measuring unit in the die-bonding unit, the load-measuring unit includes a plurality of regions arranged in a plurality of rows and a plurality of columns; and determining a load and a flatness with respect to the chip based on the signal by a controller connected to the load-measuring unit, wherein each of the plurality of regions includes at least one load-measuring member.

DETAILED DESCRIPTION

Various embodiments will be described hereinafter with reference to the accompanying drawings. The embodiments may, however, be embodied in many different forms and should not be construed as limited to the examples of embodiments set forth herein. Rather, these examples of embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the present disclosure to those skilled in the art. In the drawings, the sizes and relative sizes of layers and regions may be exaggerated for clarity.

It is also noted, that in some instances, as would be apparent to those skilled in the relevant art, an element (also referred to as a feature) described in connection with one embodiment may be used singly or in combination with other elements of another embodiment, unless specifically indicated otherwise.

Hereinafter, examples of the embodiments will be explained with reference to the accompanying drawings.

FIG. 1is a simplified block diagram illustrating an apparatus10for bonding a semiconductor chip, in accordance with an embodiment.

The controller110may be configured to control operations of the die-bonding apparatus10. As illustrated inFIG. 1, the controller110may be positioned outside the die-bonding unit120. In another embodiment, the controller110may be positioned in the die-bonding unit120. In yet another embodiment, the controller110may be implemented using two controllers, one external to the die bonding unit120and one internal to the die bonding unit120.

The die-bonding unit120may be configured to attach a semiconductor chip to a package substrate.

As illustrated in the embodiment ofFIG. 1, the load-measuring unit130may be external to the die-bonding unit120. In another embodiment (not illustrated), the load-measuring unit130may be arranged in the die-bonding unit120. The load-measuring unit130may be configured to measure a load applied to the semiconductor chip and/or a flatness of the semiconductor chip in real time during operation of the die-bonding unit120. The load-measuring unit130may measure the load applied to the semiconductor chip and/or the flatness of the semiconductor chip directly or indirectly.

In an embodiment, the load-measuring unit130may be provided to a unit for pressing the semiconductor chip to the package substrate, for example, a bonding head of the pressing unit. In another embodiment, the load-measuring unit130may be provided to a substrate stage of the die loading unit120(see element1216ofFIG. 2). The substrate stage is configured to support the package substrate. The load-measuring unit130may be positioned near a bonding region of the die-bonding unit120.

When the load-measuring unit130is provided to the bonding head or the substrate stage, the load-measuring unit130may directly measure the load and the flatness in real time when the semiconductor chip is attached to the package substrate. When the load-measuring unit130is positioned near the bonding region of the die-bonding unit120, the load-measuring unit130may indirectly measure the load and the flatness with a time offset of a predetermined period from real time.

In an embodiment, the die-bonding unit120may include a substrate-supplying member1201, a wafer-supplying member1203, a substrate-transferring member1205, a chip pickup member1207, a bonding member1209and a substrate-receiving member1211.

FIG. 2is a plan view illustrating a die-bonding unit in accordance with an embodiment.

The substrate-supplying member1201may include a magazine configured to receive a plurality of the package substrates. The substrate-transferring member1205may be connected with a transferring mechanism1219. The substrate-transferring member1205may be configured to transfer the package substrates in the substrate-supplying member1201to a die bonding region1215.

The wafer-supplying member1203may include a cassette configured to receive a plurality of wafers W. The wafers W in the wafer-supplying member1203may be transferred to a wafer stage1213by a transferring arm (not shown).

The chip pickup member1207may be arranged under the wafer stage1213. The chip pickup member1207may be configured to separate the semiconductor chips from the wafer W.

The bonding member1209may include a substrate stage1216and a bonding head1217. The substrate stage1216may be configured to receive the package substrate S transferred by the substrate-transferring unit1206along rails1223A and1223B. The bonding head1217may be configured to transfer and attach the semiconductor chip D to the package substrate S.

The substrate-receiving member1211may include a magazine configured to receive the package substrate S with the semiconductor chip D. The package substrate S with the semiconductor chip D may be transferred to the substrate-receiving member1211by a substrate-transferring member1221.

Hereinafter, operations for bonding the semiconductor chip by the die-bonding units120and120-1may be illustrated.

The package substrate S in the substrate-supplying member1201may be transferred to the substrate stage1216of the bonding region1215in the bonding member1209along the rails1223A and1223B by the substrate-transferring member1205.

The wafer W in the wafer-supplying member1203may be transferred to the chip pickup member1207. An accurate position at which the semiconductor chips D may be separated from the wafer W may be determined by a CCD camera and a vision algorithm. When the separation position is determined, the chip pickup member1207may separate the semiconductor chip D from the wafer W.

The bonding head1217of the bonding member1209may transfer the semiconductor chip D to the bonding region1215. An accurate attaching position of the semiconductor chip D may be determined by a CCD camera and a vision algorithm. An adhesive may be coated on the package substrate S. Alternatively, an adhesive film may be attached to a rear surface of the semiconductor chip D. The bonding head1217may attach the semiconductor chip D to the package substrate S on the substrate stage1216using a pressure and a temperature. In an exemplary embodiment, a plurality of solder balls or a plurality of conductive bumps may be formed between the package substrate S and the semiconductor chip D.

The package substrate S with the semiconductor chip D may be transferred to the substrate-receiving member1211. The package substrate S with the semiconductor chip D may be received in the substrate-receiving member1211.

In an embodiment, the load-measuring unit130may be provided to the bonding head1217, the substrate stage1216, or combinations thereof. When the semiconductor chip D is attached to the package substrate D, the load-measuring unit130may measure the load and the flatness in real time.

In an embodiment, the load-measuring unit130may be positioned near the rails1223A and1223B in the bonding region1215. The bonding head1217presses the load-measuring unit130for a time period and measures the load and the flatness for the period. The load-measuring unit130may be disposed on the bonding head1217, the substrate stage1216, the rails1223A and1223B, or combinations thereof.

In order to accurately measure the load and the flatness, the load-measuring unit130may be implemented with a plurality of load measuring members installed at a plurality of regions so that multiple measurements may be taken in real time. Hence, more than one load-measuring members may be provided to the plurality of regions, respectively.

When a pressure is applied to the load-measuring unit130, the load-measuring members measure the loads by the regions. The measured loads by each of the load-measuring members in the various regions are transmitted to the controller110.

The controller110may determine the loads by the regions based on the measured loads by the regions from the load-measuring members. The controller110may determine the flatness from the loads in the regions. Further, the controller110may obtain load changes in the regions based on the measured loads by the regions.

During the time the semiconductor chip D is being attached to the package substrate S, the controller110may obtain loads from the load-measuring members which are deployed in the various regions in real time. The controller110may calculate an average load, a maximum load and a minimum load based on the measured loads from the regions.

In an embodiment, the controller110may determine an average load for each region by averaging the measured loads for each region. The controller110may then determine the flatness based on the differences between the average loads of the regions. The controller110may obtain load changes for the regions using output signals from the load-measuring members deployed at the regions as a reference value under a no load condition.

FIG. 3is a plan view illustrating a load-measuring unit, in accordance with an embodiment.

Referring toFIG. 3, the load-measuring unit130may include a panel131and a plurality of load-measuring members133. The panel131may have a plurality of regions1311,1312,1313,1314,1315,1316,1317,1318and1319. The load-measuring members133may be provided to the regions1311,1312,1313,1314,1315,1316,1317,1318and1319, respectively. In an embodiment, each of the plurality of regions1311,1312,1313,1314,1315,1316,1317,1318and1319may include at least one load-measuring member133.

The controller110may determine the load in each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319based on the measured loads of the load-measuring members133in each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319.

The load-measuring members133may include various elements configured to output electrical signals corresponding to the measured loads.

Therefore, because the load-measuring unit130is divided into the regions1311,1312,1313,1314,1315,1316,1317,1318and1319and the load-measuring members133are provided to the regions1311,1312,1313,1314,1315,1316,1317,1318and1319, respectively, the loads applied to the regions1311,1312,1313,1314,1315,1316,1317,1318and1319may be accurately measured. Further, the flatness may be determined based on the load differences between the regions1311,1312,1313,1314,1315,1316,1317,1318and1319.

In an exemplary embodiment, the plurality of regions1311,1312,1313,1314,1315,1316,1317,1318and1319may be arranged in a plurality of rows and a plurality of columns. The plurality of regions1311,1312,1313,1314,1315,1316,1317,1318and1319may be arranged in 3 rows and 3 columns. A first region1311may be disposed on a first row and a first column. A fifth region1315may be disposed on a second row and a second column. A ninth region1319may be disposed on a third row and a third column. Each of the plurality of regions1311,1312,1313,1314,1315,1316,1317,1318and1319may include one or more load-measuring members133.

FIG. 4is a simplified block diagram illustrating a controller, in accordance with an embodiment.

The storing unit1101may include a main memory and an auxiliary memory. The storing unit1101may be configured to store operational programs for the apparatus10, control data, application programs, operational parameters, processed results.

The user interface1103may include an Input interface and an output interface. The user may access to the apparatus10through the user interface1103. The output interface may access the various parts of the controller via an internal bus IB.

The element-managing unit1105may be configured to manage identifiers of the load-measuring members133deployed in the regions1311,1312,1313,1314,1315,1316,1317,1318and1319of the load-measuring unit130. The element-managing unit1105may be configured to receive the measured loads of the load-measuring members133. The load-measuring members133may output the measured loads under the no load condition and the load condition of the die bonding process. The load-measuring members133may transmit the outputted loads to the element-managing unit1105. The identifiers of the load-measuring members133may include addresses or IDs of the load-measuring members133so that the element managing unit may identify the load-measuring member and/or the region of the load-measuring member for each received load.

The signal-converting unit1107may be configured to convert the loads provided from the load-measuring members133as electrical signals into load values. The signal-converting unit1107may store the load values provided from the element-managing unit1105under the no load condition as a reference value in the storing unit1101.

The load-determining unit1109may be configured to determine the loads in each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319in the die bonding process. The load-determining unit1109may be configured to receive the load values of the load-measuring members133provided from the signal-converting unit1107. The load-determining unit1109may be configured to average the load values of the load-measuring members133for each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319to calculate average load values for each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319.

The load-determining unit1109may calculate the load values in real time, the average values of the load values, a maximum load value and a minimum load value based on the load values by the regions1311,1312,1313,1314,1315,1316,1317,1318and1319during the die bonding process.

The flatness-determining unit1111may be configured to determine the flatness based on the load values for each of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319. The flatness-determining unit1111may calculate differences between the load values of the regions1311,1312,1313,1314,1315,1316,1317,1318and1319. The flatness-determining unit1111may determine the flatness based on the load differences.

The load values of the load-measuring members133may be provided through the element-managing unit1105and the signal-converting unit1107so that the load changes by the load-measuring members133may be recognized. The load changes may be displayed through the user interface1103.

In an embodiment, the user interface1103may display visual data such as the load changes by the load-measuring members133, the load values by the regions, the flatness, the load values in real time, the average load value, the maximum load value and the minimum load value. The visual data may be displayed in graphs, values, images, etc.

FIGS. 5 to 7are cross-sectional views illustrating examples of the load-measuring unit, in accordance with an embodiment.

InFIG. 5, the load-measuring unit130may be installed at the bonding head1217-1.

In an embodiment, the bonding head1217-1may include a transfer arm201, a shank203, an absorbing member207and the load-measuring unit130.

The transfer arm201may be connected with the transferring mechanism1219of the die bonding unit120. The transfer arm201may be moved in vertical and horizontal directions.

The shank203may be connected to the transfer arm201. The shank203may be downwardly extended from the transfer arm201. The shank203may have a vacuum hole205formed through a central portion of the shank203in a lengthwise direction of the shank203. The shank203may include an inserting hole211. The vacuum hole205may be extended to the inserting hole211through the central portion of the shank203.

The load-measuring unit130may be arranged in the inserting hole211. The absorbing member207may be combined with a lower end of the load-measuring unit130. The absorbing member207may have a vacuum hole209configured to absorb the semiconductor chip D.

When the semiconductor chip D is pulled on the absorbing member207may then be pressed to the package substrate S. The load-measuring unit130may measure the load applied to the semiconductor chip D and the flatness of the absorbing member207in real time. The load-measuring unit130may have a structure and functions substantially the same as those of the load-measuring unit inFIG. 3.

InFIG. 6, the load-measuring unit130may be installed at the substrate stage1216.

In an embodiment, the load-measuring unit130may be combined with an upper portion of the substrate stage1216-1. When the bonding head1217presses the semiconductor chip D to the package substrate S, the load-measuring unit130may measure the load applied to the semiconductor chip D and the flatness of the absorbing member207in real time. The load-measuring unit130may have a structure and functions substantially the same as those of the load-measuring unit inFIG. 3.

As shown inFIGS. 5 and 6, the load-measuring unit130may be installed at the bonding head1217-1or the substrate stage1216-1. Alternatively, the load-measuring unit130may be installed at the bonding head1217-1and the substrate stage1216-1.

InFIG. 7, the load-measuring unit130may be installed near the die bonding region1215of the bonding unit120.

In an embodiment, the load-measuring unit130may be arranged over the rails1223A and1223B near the die bonding region1215.

The bonding head1217may be periodically moved to the load-measuring unit130to uniformly press an upper end of the load-measuring unit130. Thus, the load applied to a surface of the absorbing member207and the flatness of the absorbing member207may be measured. The period of the load measurement may be determined in accordance with the user. The load-measuring unit130may have a structure and functions substantially the same as those of the load-measuring unit inFIG. 3.

According to an embodiment, the load-measuring unit may be divided into regions. The load-measuring members may be positioned in the regions so that the load values for each of the regions may be calculated. The flatness may be determined based on the differences between the load values of the regions.

The load-measuring unit may be installed at the bonding head or the substrate stage of the die bonding apparatus to measure the load and the flatness simultaneously with the bonding process.

The bonding head may periodically press the load-measuring unit near a bonding region. The load and the flatness of the bonding head may be periodically measured.

The data such as the load changes by the regions, the load values by the regions, the flatness, the load values in real time, the average load value, the maximum load value, the minimum load value, etc., may be visually outputted so that the various states of the operation of the die bonding apparatus may be recognized in real time.

The above embodiments of the present disclosure are illustrative and are not intended to limit the present disclosure. Various alternatives and equivalents are possible. The examples of the embodiments are not limited by the embodiments described herein. Nor is the present disclosure limited to any specific type of semiconductor device. Other additions, subtractions, or modifications are obvious in view of the present disclosure and are intended to fall within the scope of the appended claims.