Vacuum lamination system and vacuum lamination method

A vacuum lamination system includes a film supply assembly, a film collection assembly, a lower lamination body, an upper lamination body, an air extractor, a moving assembly and a cutting assembly. The lower lamination body includes a first casing base and a lower heating assembly vertically movable and disposed in the first casing base. The lower heating assembly carries and moves the substrate so that the substrate is substantially flush with a top surface of the first casing base or retracted into the first casing base. The upper lamination body is vertically movable and disposed above the lower lamination body and includes an upper casing and an upper heating assembly disposed on the upper casing. The air extractor is connected to the lower lamination body. The moving assembly changes a height of a portion of the film. The cutting assembly cuts a portion of the film laminated onto the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of Taiwan application serial no. 109117478, filed on May 26, 2020. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.

BACKGROUND

Technical Field

The disclosure relates to a lamination system and a lamination method, and more particularly to a vacuum lamination system and a method thereof.

Description of Related Art

At present, one common lamination method is to use a roller to laminate a film onto a substrate in an atmospheric environment. However, for a substrate having uneven structures on the surface, air bubbles are easily formed between the film and the substrate. Another common lamination method is to first pre-laminate the film on the substrate in an atmospheric environment and then place the substrate and the pre-laminated film on the substrate into a vacuum chamber to perform vacuum lamination.

However, in the process of vacuum lamination, the film is heated and pressurized to attach to the substrate. If air bubbles are formed between the substrate and the pre-laminated film on the substrate, the air bubbles between the substrate and the film cannot be removed even if the vacuum chamber is vacuumized.

SUMMARY

The disclosure provides a vacuum lamination system capable of preventing air bubbles between a film and a substrate.

The disclosure provides a vacuum lamination method capable of preventing air bubbles between a film and a substrate.

A vacuum lamination system of the disclosure, adapted for fixing a film on a substrate, includes a film supply assembly, a film collection assembly, a lower lamination body, an upper lamination body, an air extractor, a moving assembly, and a cutting assembly. The film supply assembly is adapted for providing the film. The film collection assembly is adapted for recycling the film. The lower lamination body is located between the film supply assembly and the film collection assembly and includes a first casing base and a lower heating assembly vertically movable and arranged in the first casing base. The lower heating assembly is adapted for carrying and moving the substrate so that the substrate is flush with a top surface of the first casing base and the substrate protrudes from the top surface of the first casing base or retracts into the first casing base. The upper lamination body is vertically movable and arranged above the lower lamination body and has an upper casing and an upper heating assembly arranged on the upper casing. The air extractor is connected to the lower lamination body. The moving assembly is movably disposed between the film supply assembly and the film collection assembly and is adapted for changing a height of a portion of the film between the lower lamination body and the upper lamination body. The cutting assembly is movably disposed above the lower lamination body and is adapted for cutting a portion of the film laminated onto the substrate.

In an embodiment of the disclosure, the lower lamination body further includes a second casing base vertically movable and disposed under the first casing base, and an airtight flexible assembly arranged between the second casing base and the first casing base. The lower heating assembly moves along with the second casing base.

In an embodiment of the disclosure, the upper lamination body further includes a flexible pad. A periphery of the flexible pad is fixed to the upper casing, the upper heating assembly is located between the upper casing and the flexible pad, the upper casing has an upper hole, and a space between the upper heating assembly and the flexible pad communicates with the upper hole.

In an embodiment of the disclosure, the upper lamination body further includes an upper driving assembly connected to the upper heating assembly to move the upper heating assembly relative to the upper casing.

In an embodiment of the disclosure, the upper lamination body further includes a flexible pad disposed on the upper heating assembly.

In an embodiment of the disclosure, the upper heating assembly includes an upper heat insulation layer and an upper heating layer arranged in sequence, and the upper heating layer is close to the lower lamination body.

In an embodiment of the disclosure, the lower heating assembly includes a lower heating layer and a lower wafer carrier tray arranged in sequence, and the lower wafer carrier tray is close to the upper lamination body.

A vacuum lamination method of the disclosure includes the following steps. A film is disposed to be above a substrate so that a gap is formed between the film and the substrate. Air is extracted between the film and the substrate. The substrate is brought to be close to the film, and the substrate and the film are heated and pressurized. A portion of the film laminated onto the substrate is cut.

In an embodiment of the disclosure, the step of disposing the film to be above the substrate further includes the following steps. A lower lamination body having a first casing base and a lower heating assembly vertically movable and arranged in the first casing base is provided. The substrate is disposed to the lower heating assembly and the lower heating assembly is lowered so that the substrate is lower than a top surface of the first casing base. The film is disposed on the top surface of the first casing base.

In an embodiment of the disclosure, the step of extracting the air between the film and the substrate further includes the following steps. An upper lamination body is lowered onto the first casing base of the lower lamination body to press against an upper surface of the film. Air is extracted between the upper lamination body and the lower lamination body.

In an embodiment of the disclosure, the step of heating and pressurizing the substrate and the film further includes the following steps. The lower heating assembly of the lower lamination body is lifted to bring the substrate close to a lower surface of the film. A flexible pad of the upper lamination body and the lower heating assembly of the lower lamination body heat and pressurize the substrate and the film so that the film is hot pressed onto the substrate.

In an embodiment of the disclosure, after heating and pressurizing the substrate and the film and before cutting the film, the method further includes the following steps. Pressurizing on the substrate and the film is stopped. A negative pressure or vacuum state between the upper lamination body and the lower lamination body is destroyed. The upper lamination body is lifted and the substrate and a portion of the film laminated onto the substrate are exposed.

Based on the above, in the vacuum lamination system and method of the disclosure, the lower heating assembly of the lower lamination body may move vertically relative to the first casing base so that the substrate is almost flush with the top surface of the first casing base or retracts into the first casing base. Therefore, when the film is placed on the top surface of the lower lamination body and the upper lamination body is pressed down to the lower lamination body, the lower heating assembly may be lowered, making the substrate to retract into the first casing base without contacting the film. Meanwhile, the air extractor may extract air from the space between the lower lamination body and the upper lamination body so that the space between the film and the substrate is in a vacuum state. Subsequently, the lower heating assembly and the flexible pad heat and pressurize the film and the substrate to laminate the film onto the substrate. In this way, no air bubbles are formed between the film and the substrate.

DESCRIPTION IN THE PRESENT EMBODIMENTS

FIG. 1is a schematic view of a vacuum lamination system according to an embodiment of the disclosure. Referring toFIG. 1, in the present embodiment, a vacuum lamination system100is suitable for fixing a film20on a substrate30. In the present embodiment, the film20is, for example, a photoresist strip made of dry film resists, and the substrate30is, for example, a wafer. However, the types of the film20and the substrate30are not limited thereto. In general, since a plurality of dies or patterns with different heights are disposed on a wafer surface, the wafer surface is uneven, making it difficult for the photoresist to be well laminated to the wafer. In the present embodiment, the vacuum lamination system100can laminate the photoresist to the wafer without causing air bubbles between the photoresist and the wafer, which is described below.

As shown inFIG. 1, the vacuum lamination system100includes a film supply assembly10, a film collection assembly14, a lower lamination body120, an upper lamination body110, an air extractor150, a moving assembly130, and a cutting assembly140. The film supply assembly10is suitable for providing the film20. In the present embodiment, initially a protective film22is attached to the film20to protect the film20. The film20is separated from the protective film22before being fed into the lower lamination body120. The vacuum lamination system100further includes a protective film winding wheel12for recycling the protective film22. The film collection assembly14is suitable for recycling the unused film20.

The lower lamination body120is located between the film supply assembly10and the film collection assembly14, and the upper lamination body110is vertically movable and disposed above the lower lamination body120. The air extractor150is connected to the lower lamination body120. When the upper lamination body110is pressed down to the lower lamination body120, the air extractor150may extract air in the space between the upper lamination body110and the lower lamination body120.

The moving assembly130is movable and disposed between the film supply assembly10and the film collection assembly14. The moving assembly130includes, for example, two rollers disposed vertically and suitable for winding the film20, and after the moving assembly130moves horizontally, the height of the portion of the film20located between the lower lamination body120and the upper lamination body110is changed.

The cutting assembly140is horizontally movable and disposed above the lower lamination body120and is suitable for cutting the portion of the film20that is laminated onto the substrate30.

FIG. 2Ais a schematic view of the upper lamination body of the vacuum lamination system ofFIG. 1. Referring toFIG. 2A, the upper lamination body110includes an upper casing111and an upper heating assembly118disposed on the upper casing111. In the present embodiment, the upper heating assembly118includes an upper heat insulation layer113and an upper heating layer114disposed in sequence. The upper heating layer114is located in the lower part (i.e., closer to the lower lamination body120). Of course, the type of the upper heating assembly118is not limited thereto.

In the present embodiment, the upper lamination body110further includes a flexible pad116. The periphery of the flexible pad116is fixed to the upper casing111, but the center of the flexible pad116is not fixed to the upper casing111. The upper heating assembly118is located between the upper casing111and the flexible pad116. The upper casing111has an upper hole112, and the space between the upper heating assembly118and the flexible pad116communicates with the upper hole112.

FIG. 2Bis a schematic view of the upper lamination body ofFIG. 2Awhen air is provided. Referring toFIG. 2B, when air enters the space between the upper heating assembly118and the flexible pad116from the upper hole112, the flexible pad116, pressed by the air, is projected downward, which can help attach the film20to the uneven upper surface of the substrate30to laminate to the substrate30well.

FIG. 3Ais a schematic view of a lower lamination body of the vacuum lamination system ofFIG. 1. Referring toFIG. 3A, in the present embodiment, the lower lamination body120includes a first casing base121, a lower heating assembly129vertically movable and disposed in a space128of the first casing base121, and pins127adjustably protruding from or retracting into the lower heating assembly129. In the present embodiment, the lower heating assembly129includes a lower heating layer125and a lower wafer carrier tray126disposed in sequence. The lower wafer carrier tray126is located in the upper part (i.e., closer to the upper lamination body110). Of course, the type of the lower heating assembly129is not limited thereto.

In the present embodiment, the lower lamination body120further includes a second casing base122vertically movable and disposed under the first casing base121and an airtight flexible assembly123disposed between the second casing base122and the first casing base121. The lower heating assembly129moves along with the second casing base122. The second casing base122, for example, is connected to a motor (not shown) and can move vertically relative to the first casing base121. The airtight flexible assembly123is, for example, a vacuum bellow, which can be shortened and stretched and can maintain airtightness, but the type of the airtight flexible assembly123is not limited thereto.

FIG. 3Bis a schematic view of the lower heating assembly ofFIG. 3Awhen lifted. Referring toFIG. 3B, in the present embodiment, the second casing base122may move upward, the airtight flexible assembly123contracts accordingly, and the lower heating assembly129moves upward along with the second casing base122. The lower heating assembly129is suitable for supporting the substrate30so that the substrate30is lifted from a position which retracts into the first casing base121(FIG. 3A) to a position which is almost flush with a top surface1211of the first casing base121(FIG. 3B). The so-called “almost flush position” may be slightly higher than, coplanar with, or slightly lower than the top surface1211of the first casing base121.

FIG. 3Cis a schematic view of the pins ofFIG. 3Awhen lifted. Referring toFIG. 3C, in the present embodiment, the pins127may move vertically relative to the lower heating assembly129to protrude from or retract into the lower heating assembly129. In the present embodiment, the pins127may protrude from the top surface1211of the first casing base121to support the substrate30or separate the substrate30from the lower heating assembly129.

FIGS. 4A to 4Fare schematic views of processes of a vacuum lamination method according to an embodiment of the disclosure. Referring toFIG. 4Afirst, the vacuum lamination method in the present embodiment includes the following steps. First, the pins127are protruded from the lower heating assembly129and protruded from the top surface1211of the first casing base121. Next, the substrate30is disposed onto the pins127of the lower lamination body120.

Then, as shown inFIG. 4B, the pins127are retracted into the lower heating assembly129so that the lower heating assembly129supports the substrate30. Next, the lower heating assembly129is lowered so that the substrate30is lower than the top surface1211of the first casing base121. Next, the film20is disposed above the substrate30. In the present embodiment, the way to dispose the film20to be above the substrate30is to move the moving assembly130leftward to pass between the upper lamination body110and the lower lamination body120, and after that the film20is disposed on the top surface1211of the first casing base121.

Note that as can be seen inFIG. 4B, a gap is formed between the film20and the substrate30. In the present embodiment, since the lower heating assembly129can move vertically relative to the first casing base121, before the film20is disposed above the substrate30, the lower heating assembly129may be lowered to prevent the film20from contacting the substrate30so that a distance between the film20and the substrate30is maintained.

As shown inFIG. 4C, the upper lamination body110is lowered to the lower lamination body120. Meanwhile, the space between the upper lamination body110and the lower lamination body120is closed. Next, the air between the film20and the substrate30is extracted. In the present embodiment, the air extractor150may vacuumize the chamber between the upper lamination body110and the lower lamination body120so that the space between the film20and the substrate30is in a vacuum state.

Next, as shown inFIG. 4D, the substrate30is brought close to the film20, and the substrate30and the film20are heated and pressurized. In the present embodiment, the second casing base122is lifted, causing the lower heating assembly129to be lifted and subsequently the substrate30to be lifted so that the substrate30approaches the film20for pressurization. Since the air between the film20and the substrate30has been extracted in the previous step, at this time, after the film20is laminated down onto the substrate30, no air bubbles are found between the film20and the substrate30, which is effective to achieve the effect of no bubbles.

In addition, the flexible pad116and the lower heating assembly129heat the substrate30and the film20. When air enters the space between the upper heating assembly118and the flexible pad116from the upper hole112, the flexible pad116is pressed by the air pressure to project downward and pressurize the substrate30and the film20so that the film20is laminated onto the substrate30.

After laminating, pressurizing on the substrate30and the film20is stopped. Next, as shown inFIG. 4E, the negative pressure or vacuum state between the upper lamination body110and the lower lamination body120is destroyed. The upper lamination body110is lifted, and the portion of the film20laminated onto the substrate30and the substrate30are exposed. Next, the cutting assembly140is horizontally moved to a position between the upper lamination body110and the lower lamination body120to cut the portion of the film20laminated onto the substrate30.

As shown inFIG. 4F, the cutting assembly140is moved away from the position between the upper lamination body110and the lower lamination body120, and the moving assembly130also moves rightward to return to the original position. Finally, the pins127eject the substrate30together with the film20laminated on the substrate30to leave the lower heating assembly129, and the entire lamination process is finished.

As stated above, in the present embodiment, in order to prevent the film20from contacting the substrate30before performing the vacuum lamination, or prevent the film20from being so close to the substrate30that the film20is softened by heat and collapses to contact or adhere to the substrate30below the film20, causing air bubbles to be covered therein and unremovable, in the present embodiment, the second casing base122and the lower heating assembly129can be lowered to take the substrate30away from the film20first. Then after the chamber between the upper lamination body110and the lower lamination body120is vacuumized or the air between the film20and the substrate30is extracted, the second casing base122and the lower heating assembly129are lifted again so that the substrate is close to the film20and then the lamination is performed. In this way, no air bubbles are formed between the film20and the substrate30.

Other embodiments of the upper lamination body will be described below. In the following embodiments, components same as or similar to those in the upper lamination body ofFIG. 2Aare labeled with the same or similar reference numerals, and only the main differences are described.

FIG. 5is a schematic view of an upper lamination body of a vacuum lamination system according to another embodiment of the disclosure. Referring toFIG. 5, the main difference between the upper lamination body110bofFIG. 5and the upper lamination body110ofFIG. 2Ais that the upper lamination body110bof the present embodiment is not pressurized by air pressure but by mechanical pressure.

In detail, in the present embodiment, the upper lamination body110bfurther includes an upper driving assembly117connected to the upper heating assembly118so that the upper heating assembly118moves relative to the upper casing111. The entire flexible pad116is attached to the bottom of the upper heating assembly118and is lowered along with the upper heating assembly118. Since the flexible pad116, for example, is made of rubber or silicone, it can be compressed. Therefore, the flexible pad116still enables the film20to well contact the uneven surface of the substrate30.

FIG. 6is a schematic view of an upper lamination body of a vacuum lamination system according to yet still another embodiment of the disclosure. Referring toFIG. 6, the main difference between the upper lamination body110cofFIG. 6and the upper lamination body110bofFIG. 5is that in the present embodiment, the upper lamination body110cis not provided with the flexible pad116(labeled inFIG. 5). The upper lamination body110cin the present embodiment can be applied to directly flatten the surface of the film20after laminating the film. The upper heating layer114made from hard material may directly contact the film20. Such a configuration enables the film20to well contact the substrate30and also enables the surface of the film20to stay flat after being laminated.

Based on the above, in the vacuum lamination system and method of the disclosure, the lower heating assembly of the lower lamination body may move vertically relative to the first casing base so that the substrate is almost flush with the top surface of the first casing base or retracts into the first casing base. Therefore, when the film is placed on the top surface of the lower lamination body and the upper lamination body is pressed down to the lower lamination body, the lower heating assembly may be lowered, making the substrate retract into the first casing base without contacting the film. Meanwhile, the air extractor may extract air from the space between the lower lamination body and the upper lamination body so that the space between the film and the substrate is in a vacuum state. Subsequently, the lower heating assembly and the upper heating assembly heat and pressurize the film and the substrate to laminate the film onto the substrate. In this way, no air bubbles are formed between the film and the substrate.