Material processing apparatus and operating method thereof

A material processing apparatus includes a processing chamber having an internal space, an external pressure source, a vacuum generator, a temperature regulator and a controller. The external pressure source is connected to the processing chamber for positive pressure action on the internal space. The vacuum generator is connected to the processing chamber for negative pressure action on the internal space. The temperature regulator is arranged in the processing chamber to adjust the temperature in the internal space. The controller is configured to control the external pressure source to increase the pressure in the processing chamber from a normal pressure to a first predetermined pressure, and configured to control the vacuum generator to reduce the pressure in the processing chamber to a second predetermined pressure less than the normal pressure after the pressure rises to the first predetermined pressure. An operating method of a material processing apparatus is also provided.

BACKGROUND

Technical Field

The disclosure relates to a processing apparatus and an operating method, and in particular to a material processing apparatus and an operating method thereof.

Related Art

Generally, during manufacture of an electronic product, a large number of bubbles are usually generated in a material to be processed, and these bubbles may reduce reliability and yield of the electronic product. Conventionally, negative pressure action (vacuuming) is often used to remove the bubbles. However, the above method is likely to reduce temperature uniformity of the material and cause an error between a measured temperature and an actual overall temperature of the material. As a result, accurate switching between related parameters cannot be performed, resulting in control inaccuracy.

SUMMARY

The disclosure provides a material processing apparatus and an operating method thereof, in which reliability and yield of an electronic product are able to be improved.

A material processing apparatus of the disclosure includes a processing chamber, an external pressure source, a vacuum generator, a temperature regulator and a controller. The processing chamber has an internal space. The external pressure source is connected to the processing chamber for positive pressure action on the internal space. The vacuum generator is connected to the processing chamber for negative pressure action on the internal space. The temperature regulator is arranged in the processing chamber and configured to adjust the temperature in the internal space. The controller is configured to control the external pressure source to increase the pressure in the processing chamber from a normal pressure to a first predetermined pressure, and configured to control the vacuum generator to, after the pressure in the processing chamber rises to the first predetermined pressure, reduce the pressure in the processing chamber to a second predetermined pressure less than the normal pressure.

In one embodiment of the disclosure, the material processing apparatus further includes at least one motor arranged outside the processing chamber and coupled to the processing chamber.

In one embodiment of the disclosure, the at least one motor is located in an atmospheric environment.

In one embodiment of the disclosure, the at least one motor is multiple motors, and one of the motors partially extends into the processing chamber.

In one embodiment of the disclosure, the material processing apparatus further includes a turbofan arranged in the processing chamber and connecting the temperature regulator and one of the motors.

In one embodiment of the disclosure, the at least one motor is a single motor, and the single motor is at a distance from the processing chamber.

In one embodiment of the disclosure, the material processing apparatus further includes a cooler arranged between the processing chamber and the vacuum generator and configured to cool gas pumped out of the processing chamber.

In one embodiment of the disclosure, the controller is configured to control the pressure in the processing chamber to be reduced to the second predetermined pressure before an electronic product is cooled.

In one embodiment of the disclosure, the controller is configured to control the pressure in the processing chamber to be reduced to the second predetermined pressure after an electronic product is cooled.

An operating method of a material processing apparatus of the disclosure may include the following. The material processing apparatus as described above is provided. An electronic product is placed in the processing chamber. The controller is operated to increase the pressure in the processing chamber from the normal pressure to the first predetermined pressure. After the pressure in the processing chamber rises to the first predetermined pressure, the controller is operated to reduce the pressure to the second predetermined pressure.

Based on the above, by the controller controlling the external pressure source to increase the pressure in the processing chamber from the normal pressure to the first predetermined pressure, a relatively uniform temperature is obtained throughout a material in a processing process of an electronic product (the temperature at the center of the material is close to the temperature at an edge of the material), so as to reduce an error between a measured temperature and an actual overall temperature of the material. Further, the material processing apparatus of the disclosure is able to accurately switch between related parameters, such that control inaccuracy is reduced, and reliability and yield of the electronic product are improved. In addition, after the external pressure source is controlled by the controller to increase the pressure in the processing chamber to the first predetermined pressure, by the controller controlling the vacuum generator to reduce the pressure in the processing chamber to the second predetermined pressure (at least less than the normal pressure), bubbles can be effectively removed from the material, thereby further improving the reliability and yield of the electronic product.

To make the aforementioned more comprehensible, embodiments accompanied with drawings are described in detail as follows.

DESCRIPTION OF THE EMBODIMENTS

FIG.1is a block diagram of a material processing apparatus according to an embodiment of the disclosure. The material processing apparatus herein is used in, for example, any related process for manufacturing an electronic product, such as front end of line (FEOL), back end of line (BEOL), and material processing of system-in-package (SiP) at the ball level and chip-on-wafer at the chip level. The electronic product includes, but is not limited to, an automotive electronic product or a sensing electronic product. The following description may be regarded as being of a processing process of an electronic product.

Referring toFIG.1, a material processing apparatus100includes a processing chamber110, an external pressure source120, a vacuum generator130, a temperature regulator140, and a controller150. Specifically, the processing chamber110has an internal space S. The external pressure source120is connected to the processing chamber110for positive pressure action on the internal space S. Herein, the positive pressure action may be to provide high-pressure gas to the internal space S of the processing chamber110by the external pressure source120so that the pressure in the internal space S is greater than a normal pressure. However, the disclosure is not limited thereto, and the external pressure source120may perform the positive pressure action on the internal space S in any other suitable manner. In some embodiments, the positive pressure action may cause the pressure in the internal space S to be within the range of 1 atmosphere to 100 atmospheres. However, the disclosure is not limited thereto. It is to be noted that the normal pressure mentioned in the disclosure is 1 atmosphere (atm).

The vacuum generator130is connected to the processing chamber110for negative pressure action on the internal space S. Herein, the negative pressure action may be to vacuum the internal space S of the processing chamber110by a vacuum pump so that the pressure in the internal space S is reduced to the normal pressure or less. However, the disclosure is not limited thereto, and the vacuum generator130may perform the negative pressure action on the internal space S in any other suitable manner.

The temperature regulator140is arranged in the processing chamber110to adjust the temperature in the internal space S. In the present embodiment, the temperature regulator140, for example, performs hot air circulation in a convection manner for temperature adjustment, so as to make a gas temperature in the internal space S uniform. However, the disclosure is not limited thereto, and the temperature regulator140may perform temperature adjustment in other suitable manners.

The controller150is at least configured to control the external pressure source120and the vacuum generator130. Specifically, the controller150may be configured to control the external pressure source120to increase the pressure in the processing chamber110from the normal pressure to a first predetermined pressure, and may be configured to control the vacuum generator130to, after the pressure in the processing chamber110rises to the first predetermined pressure, reduce the pressure in the processing chamber110to a second predetermined pressure less than the normal pressure.

By pressurizing the processing chamber110, the density of heat molecules in the processing chamber110can be increased, such that the heat molecules evenly heat a material in a processing process of an electronic product. Therefore, by the controller150controlling the external pressure source120to increase the pressure in the processing chamber110from the normal pressure to the first predetermined pressure, a relatively uniform temperature is obtained throughout the material in the processing process of an electronic product (the temperature at the center of the material is close to the temperature at an edge of the material), so as to reduce an error between a measured temperature and an actual overall temperature of the material. Further, the material processing apparatus100of the present embodiment is able to accurately switch between related parameters, such that control inaccuracy is reduced, and reliability and yield of the electronic product are improved.

In addition, after controlling the external pressure source120by the controller150to increase the pressure in the processing chamber110to the first predetermined pressure, by the controller150controlling the vacuum generator130to reduce the pressure in the processing chamber110to the second predetermined pressure (at least less than the normal pressure), bubbles can be effectively removed from the material, thereby further improving the reliability and yield of the electronic product.

The controller150may be, for example, a central processing unit (CPU), or other programmable general purpose or special purpose microprocessor, a digital signal processor (DSP), a programmable controller, an application specific integrated circuit (ASIC), a programmable logic device (PLD), or other similar processing device, or a combination of the above, and may include a built-in memory or be connected to an external memory.

It is to be noted that time points when the pressure in the processing chamber110is increased from the normal pressure to the first predetermined pressure and when the pressure is reduced to the second predetermined pressure (at least less than the normal pressure) may be adjusted according to actual design requirements. For example, the pressure in the processing chamber110may be increased from the normal pressure to the first predetermined pressure when the pressure in the processing chamber110is adjusted for the first time in a process. For example, the pressure in the processing chamber110may be reduced to the second predetermined pressure (at least less than the normal pressure) when the pressure in the processing chamber110is adjusted for the nth time in the process, in which n>1 and n is an integer.

In some embodiments, for example, the pressure in the processing chamber110may be increased from the normal pressure to the first predetermined pressure when the pressure in the processing chamber110is adjusted for the first time in the process. For example, the pressure in the processing chamber110may be reduced to the second predetermined pressure (at least less than the normal pressure) when the pressure in the processing chamber110is adjusted for the second time in the process. That is, the pressure may be successively reduced to the second predetermined pressure (at least less than the normal pressure) after rising from the normal pressure to the first predetermined pressure.

In some embodiments, for example, the pressure in the processing chamber110may be increased from the normal pressure to the first predetermined pressure when the pressure in the processing chamber110is adjusted for the first time in the process. For example, the pressure in the processing chamber110may be reduced to the second predetermined pressure (at least less than the normal pressure) when the pressure in the processing chamber110is adjusted for the third time or more in the process. That is, the pressure may be indirectly reduced to the second predetermined pressure (at least less than the normal pressure) after rising from the normal pressure to the first predetermined pressure.

In some embodiments, the pressure in the processing chamber110may be increased to the first predetermined pressure in, for example, a linear manner. However, the disclosure is not limited thereto. In other embodiments, the pressure in the processing chamber110may be increased to the first predetermined pressure in, for example, a multi-stage manner. Similarly, the pressure in the processing chamber110may be reduced to the second predetermined pressure in the linear manner or multi-stage manner.

Specifically, the vacuum (V), pressure (P), temperature (T) and time (t) in the disclosure may be adjusted according to material characteristics. The disclosure may cover all modifications in which the controller150is able to be configured to control the external pressure source120to increase the pressure in the processing chamber110from the normal pressure to the first predetermined pressure, and configured to control the vacuum generator130to, after the pressure in the processing chamber110rises to the first predetermined pressure, reduce the pressure in the processing chamber110to the second predetermined pressure less than the normal pressure.

In the present embodiment, the material processing apparatus100may optionally include at least one motor160. The motor160may be arranged outside the processing chamber110and coupled to the processing chamber110. In other words, the motor160may not be arranged in the internal space S. Therefore, compared to a motor arranged in the internal space S and having the same pressure as the internal space S, the motor160of the present embodiment is prevented from damage due to a pressure change in the internal space S, and thus has an extended service life. In some embodiments, the motor160may be coupled to the processing chamber110by a rotating shaft, a pipe, or other suitable connectors. However, the disclosure is not limited thereto.

In some embodiments, the motor160may be located in an atmospheric environment. That is, the motor160may not be covered by any housing and may be directly exposed to the air. However, the disclosure is not limited thereto. In other embodiments, the motor160may be covered by a housing so as to be prevented from being impacted and damaged by an external force.

In the present embodiment, the material processing apparatus100may optionally include a turbofan170, and the at least one motor160may be multiple motors160. Specifically, one of the motors160partially extends into the processing chamber110, and the turbofan170may be arranged in the processing chamber110and may connect the temperature regulator140and one of the motors160.

As shown inFIG.1, the motor160may include a motor1601and a motor1602, and the motor1601partially extends into the processing chamber110. In addition, the turbofan170may be arranged in the processing chamber110and may connect the temperature regulator140and the motor1601. In other words, the turbofan170may be sandwiched between the temperature regulator140and the motor1601. The motor1602may be coupled to the processing chamber110to adjust a gas concentration in the processing chamber110. For example, when the gas concentration in the processing chamber110is high, the controller150may control the motor1602to pump the gas out of the processing chamber110. However, the disclosure is not limited thereto.

In some embodiments, the motor1601may be a drive motor, and may therefore drive the turbofan170to rotate to achieve a uniform gas temperature in the internal space S. However, the disclosure is not limited thereto.

In the present embodiment, the material processing apparatus100may optionally include a cooler180. The cooler180may be arranged between the processing chamber110and the vacuum generator130and configured to cool the gas pumped out of the processing chamber110. In addition, the cooler180may be arranged outside the processing chamber110and connected to the internal space S. Thus, the gas cooled by the cooler180may flow back to the processing chamber110for circulation. In some embodiments, the cooler180may be a plate heat exchanger. However, the disclosure is not limited thereto, and the cooler180may be any suitable cooling device.

In the present embodiment, the material processing apparatus100may optionally include a gas content sensor190. The gas content sensor190may be arranged outside the processing chamber110and may communicate with the internal space S. Specifically, the gas content sensor190may sense the content of a specific gas in the internal space S. The gas content sensor190may include an adjustment unit (not shown) that adjusts a specific fluid to a state suitable for being sensed before sensing the content of the fluid. The adjustment unit is, for example, a valve element configured to allow a fluid having an appropriate flow rate to pass therethrough to be sensed. Alternatively, the adjustment unit is, for example, a temperature adjustment unit configured to raise or lower the temperature to adjust the fluid to a temperature range suitable for being sensed.

In some embodiments, the gas content sensor190is, for example, an oxygen content analyzer. The type and components of the gas content sensor190as well as the type of gas to be measured by the gas content sensor190are not limited to the above.

It is to be noted that, in addition to controlling the external pressure source120and the vacuum generator130, the controller150is also selectively configured to control the elements such as the temperature regulator140, the motor160, the turbofan170, the cooler180, and the gas content sensor190, so as to achieve an accurate and fast parameter switching mechanism. However, the disclosure is not limited thereto.

It is to be noted that the reference numerals and a part of the content of the above embodiment apply to the following embodiments, in which the same or similar reference numerals denote the same or similar elements, and repeated description of the same technical content is omitted. For an understanding of the omitted description, reference may be made to the description of the previous embodiment, and no repeated description is contained in the following embodiments.

FIG.2is a block diagram of a material processing apparatus according to another embodiment of the disclosure. Referring toFIG.2, a material processing apparatus100aof the present embodiment differs from the material processing apparatus100of the embodiment ofFIG.1in that the at least one motor160is a single motor160, and the motor160is at a distance from the processing chamber110. Specifically, in the present embodiment, the material processing apparatus100aexcludes the turbofan170and the motor1601driving the turbofan170. In addition, the motor1602may be connected to the cooler180, such that the motor1602may be directly used to adjust the gas in the processing chamber110and flow the cooled gas from the cooler180back to the processing chamber110for circulation.

By arranging the material processing apparatus100aof the present embodiment, the number of motors used can be reduced, and the manufacturing cost of the material processing apparatus100acan therefore be effectively reduced. However, in the disclosure, the number and position of motors are not limited and may be adjusted according to actual design requirements.

An operating method of a material processing apparatus according to an embodiment of the disclosure is hereinafter described with reference to the drawings.FIG.3is a flowchart of an operating method of a material processing apparatus according to an embodiment of the disclosure.

Referring toFIG.3, step S100is performed in which a material processing apparatus such as the material processing apparatus100or the material processing apparatus100ais provided. Step S200is performed in which an electronic product is placed in the processing chamber110. Step S300is performed in which the controller150is operated to increase the pressure in the processing chamber110from the normal pressure to the first predetermined pressure. Step S400is performed in which, after the pressure in the processing chamber110rises to the first predetermined pressure, the controller150is operated to reduce the pressure to the second predetermined pressure.

In the present embodiment, by the controller150controlling the external pressure source to increase the pressure in the processing chamber110from the normal pressure to the first predetermined pressure, a relatively uniform temperature is obtained throughout the material in the processing process of the electronic product (the temperature at the center of the material is close to the temperature at an edge of the material), so as to reduce an error between a measured temperature and an actual overall temperature of the material. Further, the material processing apparatus100or the material processing apparatus100aof the disclosure is able to accurately switch between related parameters, such that control inaccuracy is reduced, and reliability and yield of the electronic product are improved. In addition, after the pressure in the processing chamber110rises to the first predetermined pressure, by the controller150controlling the vacuum generator to reduce the pressure in the processing chamber110to the second predetermined pressure (at least less than the normal pressure), bubbles can be effectively removed from the material, thereby further improving the reliability and yield of the electronic product.

Operating curves in some examples of the disclosure are hereinafter described with reference to the drawings.FIG.4AtoFIG.4Care graphs of a relationship between temperature, pressure and time according to some embodiments of the disclosure.

Referring toFIG.4A, operating curves inFIG.4Aillustrate material processing of an underfill process for manufacturing an electronic product. The material is, for example, a capillary underfill (CUF), and the underfill process is, for example, a process of filling an adhesive material between an electronic component and a substrate. In some embodiments, the capillary underfill is, for example, a polymer material, resin or a silicon dioxide additive. However, the disclosure is not limited thereto.

Referring toFIG.4B, operating curves inFIG.4Billustrate material processing of coating, printing, and potting processes for manufacturing an electronic product. The material may be one known to those skilled in the art as being applied to the above-mentioned processes, and a description thereof is omitted herein.

Specifically, as shown inFIG.4AandFIG.4B, according to material characteristics of the above-mentioned processes, the controller150may be configured to control the pressure in the processing chamber110to be reduced to the second predetermined pressure before the electronic product is cooled. That is, after the pressure in the processing chamber110rises to the first predetermined pressure, the controller150may control the temperature regulator140to adjust the temperature in the internal space S so that the temperature in the internal space S is maintained or continues to rise, and may control the vacuum generator130to perform negative pressure action on the internal space S so that the pressure in the internal space S is reduced from the first predetermined pressure to the second predetermined pressure (at least less than normal pressure).

Referring toFIG.4C, operating curves inFIG.4Cillustrate material processing of a process for manufacturing an electronic product (sensor). The material is, for example, silica gel. Specifically, as shown inFIG.4C, according to material characteristics of this process, the controller150may be configured to control the pressure in the processing chamber110to be reduced to the second predetermined pressure after the electronic product is cooled. That is, after the pressure in the processing chamber110rises to the first predetermined pressure, the temperature in the internal space S may continue to rise to a certain temperature before cooling is performed. Meanwhile, the pressure may alternately rise and drop without dropping below the normal pressure. After the electronic product is cooled, the pressure in the internal space S is reduced from the first predetermined pressure to the second predetermined pressure (at least less than the normal pressure).

When the material in the processing process of the electronic product is the aforementioned adhesive material with relatively high viscosity, a binding force between the bubbles and the material is increased. Therefore, the material processing apparatus of the disclosure is applied. By the controller controlling the external pressure source to increase the pressure in the processing chamber to the first predetermined pressure, when a softening point of the material is reached during heating, flowability of the material in the processing process of the electronic product can be improved and the binding force of the material with respect to the bubbles can be reduced. After the pressure in the processing chamber rises to the first predetermined pressure, by the controller controlling the vacuum generator to reduce the pressure in the processing chamber to the second predetermined pressure (at least less than the normal pressure), the bubbles can be effectively removed from the material, thereby further improving the reliability and yield of the electronic product.

In addition, in the embodiments ofFIG.4AtoFIG.4C, the pressure may be maintained at a fixed value (with no depressurization being performed) during initial cooling. Therefore, during initial cooling, warpage due to thermal reaction can be effectively prevented from occurring or bubbles can be effectively prevented from recovering, thereby further ensuring the reliability and yield of the electronic product.

It is to be noted that the first predetermined pressure and the second predetermined pressure labeled inFIG.4AtoFIG.4Conly schematically show the curves related to the temperature, pressure and time corresponding to the material characteristics of the material in the processing process of the electronic product. The values of the temperature, pressure and time may be adjusted according to actual design requirements. Hence,FIG.4AtoFIG.4Cdo not explicitly indicate the values of the temperature, pressure, and time at each node. In addition, the first predetermined pressure may be defined as being at a position of a first highest point in the pressure curve, and the second predetermined pressure may be defined as being at a position of a first lowest point when the pressure in the pressure curve is less than normal pressure for the first time.

The relationship between temperature and pressure is not limited to those shown by the curves inFIG.4AtoFIG.4C(for example, increasing the pressure in the processing chamber110from the normal pressure to the first predetermined pressure at the same time as heating the electronic product). That is, the time points of the temperature adjustment and the pressurization may be determined according to actual design requirements. The disclosure may cover all modifications in which the controller150is able to be operated to increase the pressure in the processing chamber110from the normal pressure to the first predetermined pressure, and the controller150is able to be operated to, after the pressure in the processing chamber110rises to the first predetermined pressure, reduce the pressure in the processing chamber110to the second predetermined pressure. For example, the temperature may be increased to a certain temperature before the pressure in the processing chamber110is increased, or the pressure in the processing chamber110may be increased to a certain pressure before the temperature in the processing chamber110is raised.

In summary, by the controller controlling the external pressure source to increase the pressure in the processing chamber from the normal pressure to the first predetermined pressure, a relatively uniform temperature is obtained throughout a material in a processing process of an electronic product (the temperature at the center of the material is close to the temperature at an edge of the material), so as to reduce an error between a measured temperature and an actual overall temperature of the material. Further, the material processing apparatus of the disclosure is able to accurately switch between related parameters, such that control inaccuracy is reduced, and reliability and yield of the electronic product are improved. In the case where the material in the processing process of the electronic product is an adhesive material with relatively high viscosity, by the controller controlling the external pressure source to increase the pressure in the processing chamber to the first predetermined pressure, when a softening point of the material is reached during heating, flowability of the adhesive material can be improved. After the pressure in the processing chamber rises to the first predetermined pressure, by the controller controlling the vacuum generator to reduce the pressure in the processing chamber to the second predetermined pressure (at least less than the normal pressure), bubbles can be effectively removed from the material, thereby further improving the reliability and yield of the electronic product.

Although the disclosure has been described with reference to embodiments thereof, it will be apparent to one of ordinary skill in the art that modifications and variations may be made without departing from the spirit of the disclosure. Accordingly, the scope of the disclosure will be defined by the attached claims.