Attaching device and attaching apparatus for supporting plate, and attaching method for supporting plate

An attaching device which makes it possible to accurately perform alignment when the diameters of a substrate and a supporting plate are substantially the same includes a mounting plate for mounting a semiconductor wafer thereon, a pressing plate for pressing a supporting plate onto the semiconductor wafer, and a pair of alignment members. The pair of alignment members are arranged to freely move back and forth in a horizontal direction, and blades for supporting a lower surface of the periphery of the supporting plate and pushing members for performing positioning in a state where the supporting plate is superposed on the semiconductor wafer are provided at tip ends of the alignment members.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from Japanese patent application 2005-352594, filed 6 Dec. 2005. The entire disclosure of the referenced priority document is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an attaching device and an attaching apparatus for a supporting an attaching method for a supporting plate.

2. Description of the Background Art

There is a continuing need to make IC cards and cell phones thinner, smaller, and lighter. In order to satisfy this need, semiconductor chips to be incorporated therein must be thin. Although at present the thickness of a wafer which forms a semiconductor chip is 125-150 μm, it is expected that the thickness of a semiconductor wafer must be 25-50 μm for a next generation of chips.

A surface of a semiconductor wafer on which a circuit device has been formed needs to be supported by a tape or a sheet member in the process of thinning the semiconductor wafer with a grinder. Document 1 has disclosed an apparatus for attaching a supporting plate to a semiconductor wafer.

The apparatus of Document 1 comprises a pair of hot plates provided in the upper portion and the lower portion, and a pair of vacuum pots provided outside the hot plates, so that a layered structure of a semiconductor wafer and a supporting plate can be formed by pressing in a pressure-reduced atmosphere. Especially, according to Document 1, an air plunger which also functions as a damper is used as a means for elevating and lowering the upper hot plate instead of a hydraulic press, so that a semiconductor wafer is prevented from being damaged by adverse pressure generated when the layered structure expands due to the heat of the hot plate.

Document 1 uses a semiconductor wafer whose diameter is 150 mm, and a supporting plate whose diameter is 150.5 mm. More specifically, a positioning plate in which a hole having a diameter of 160 mm is formed in the center is prepared, and a semiconductor wafer and a supporting plate are inserted into the hole of the positioning plate and attached to each other (paragraph 0024-0028).

As described above, if the diameters of the semiconductor wafer and the supporting plate are almost the same, the layered structure can be handled as the semiconductor wafer alone when it is transferred. However, this technique has a drawback in that displacement occurs because the semiconductor wafer and the supporting plate whose diameters are about 150 mm are inserted into the hole whose diameter is 160 mm.

Also, this technique uses an epoxy resin or the like as an adhesive for attaching a supporting plate to a semiconductor wafer. Since the rigidity of an epoxy resin decreases with heating, displacement easily occurs after positioning is performed.

In order to solve the above-mentioned problems, an object of the present invention is to provide an attaching device and an attaching apparatus for a supporting plate, and an attaching method for a supporting plate which make it possible to reliably align a substrate with a supporting plate when the diameters thereof are the same, and easily correct the alignment even after the supporting plate is attached to the substrate.

SUMMARY OF THE INVENTION

In order to solve the above-mentioned problems, according to the present invention, there is provided an attaching device which attaches a supporting plate to a surface of a substrate with an adhesive comprising a mounting plate for mounting a substrate thereon, a pressing plate for pressing a supporting plate onto a substrate, and a pair of alignment members, wherein the pair of alignment members are arranged to freely move back and forth in a horizontal direction, and blades for supporting a lower surface of the periphery of the supporting plate and pushing members for performing positioning in a state where the supporting plate is superposed on the substrate are provided at the tip ends of the alignment members.

Since the attaching device for a supporting plate of the present invention has a mounting plate for mounting a substrate thereon, a pressing plate for pressing a supporting plate onto a substrate, and a pair of alignment members arranged to freely move back and forth in a horizontal direction and provided with blades for supporting a lower surface of the periphery of the supporting plate and pushing members for performing positioning in a state where the supporting plate is superposed on the substrate, it is possible to reliably align a substrate and a supporting plate when the diameters thereof are the same. Preferred examples of the pushing member include a roller.

Incidentally, the same diameters refer to a state where the diameters are exactly the same and also a state where the dimension of the semiconductor wafer overreaching the substrate is too small to be pinched by a pinching device.

Preferably, the mounting plate and the pressing plate are located within a chamber which is connected to a vacuum source so as to prevent air from entering between the substrate and the supporting plate. The alignment members are arranged to move back and forth by penetrating the side walls of the chamber.

Also, if the mounting plate doubles as a hot plate, it is possible to effectively release gas from the adhesive. In this instance, if the pressing plate is allowed to approach the hot plate for heating in advance, a heating means is not required for both of the upper portion and the lower portion. In addition, if a temperature-adjusting mechanism is provided in both the upper and lower portions, it is possible by properly adjusting the mechanism to improve the gas releasing effect and reduce warpage of the substrate, which might occur after attachment.

Also, a supporting pin for a substrate may be provided so as to move up and down with respect to the top surface of the mounting plate through a vertical penetrating hole formed in the mounting plate.

According to the present invention, there is also provided an attaching method for attaching a supporting plate to a surface of a substrate with an adhesive, comprising the steps of applying an adhesive to the surface of the substrate, heating and thereafter cooling the substrate, positioning centers of the substrate and the supporting plate to coincide with each other, and forming a layered structure by pushing the supporting plate onto the substrate in a pressure-reduced atmosphere.

Incidentally, the above-described attaching device is not necessarily used in this attaching method but can be.

Since the attaching method of the present invention comprises the steps of applying an adhesive to the surface of the substrate, heating and thereafter cooling the substrate, positioning centers of the substrate and the supporting plate to coincide with each other, and forming a layered structure by pushing the supporting plate onto the substrate in a pressure-reduced atmosphere, it is possible to finely adjust the alignment of the supporting plate and the semiconductor wafer when attached by applying an adhesive to the surface of the substrate, heating and thereafter cooling the substrate.

According to the present invention, there is also provided an attaching apparatus for attaching a supporting plate to a surface of a substrate with an adhesive, comprising a transfer robot, cassettes for storing untreated substrates and a supporting plate, an applying device which applies a treatment liquid to a surface of the substrate on which a circuit is formed, a heat treatment device which heats a coating film, a cooling device which cools the coating film, a positioning device which positions a substrate and a supporting plate, and the above-described attaching device, which are provided so as to surround the transfer robot.

Since the attaching apparatus of the present invention has at least a transfer robot, cassettes for storing untreated substrates and a supporting plate, an applying device which applies a treatment liquid to a surface of the substrate on which a circuit is formed, a heat treatment device which heats a coating film, a cooling device which cools the coating film, a positioning device which positions a substrate and a supporting plate, and the above-described attaching device, in addition to the above-described function of the attaching device, it is possible to efficiently perform a series of processes for attaching a supporting plate in a single apparatus, and also simplify the structure of the apparatus.

It is also possible to reduce the required time for transferring the substrate because the processing devices are not separately provided, and also reduce the time for the attaching process.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention will be described below with reference to the attached drawings.FIG. 1is a schematic plan view showing an embodiment of an attaching apparatus according to the present invention,FIG. 2is a front cross-sectional view of an attaching device shown inFIG. 1,FIG. 3is a cross-sectional view taken from A-A direction ofFIG. 2,FIG. 4is a side view of an alignment member, andFIG. 5is a plan view of the alignment member.

In an attaching apparatus22of the present embodiment shown inFIG. 1, a transfer robot1is provided. Also, a wafer cassette2, an applying device4, and a heat treatment device (for example, hot plate)5, a cooling device (for example, cooling plate), an attaching device7, and a supporting plate cassette8are provided to surround the transfer robot1. There are a positioning device3for positioning a semiconductor wafer before application and a positioning device9for positioning a supporting plate before attachment.

As shown inFIG. 2, the attaching device7is provided with a chamber10. An opening11connected to a vacuum pump is formed in the bottom of the chamber10. A mounting plate12is provided on the bottom surface of the chamber10. The lower portion of the mounting plate12is a hot plate13. A penetrating hole14is formed in the thickness direction of the mounting plate12, and a pin15is inserted into the penetrating hole14.

The pin15extends downward so as to penetrate the bottom of the chamber10in an airtight and slidable manner. The lower end of the pin15is fixed to a cylinder unit16. There is also provided a thermocouple17.

A pressing plate18is provided in the ceiling portion of the chamber10. A shaft19of the pressing plate18extends upward so as to penetrate the ceiling portion in an airtight and slidable manner, and the pressing plate18can be elevated and lowered by a driving unit which is not shown in the drawing. The pressing plate18is coupled to the shaft19by a ball joint so as to accept the thickness or inclination of the semiconductor wafer and the supporting plate.

Since the semiconductor wafer is heated at the time of pressing, if the pressing plate18is made of a material having a high thermal expansion coefficient, the pressing plate is distorted by heat, which makes it impossible to perform attachment with high accuracy. Thus, it is preferable to use a material having a low thermal expansion coefficient such as synthetic quartz, SiC, alumina or the like.

An opening20for inserting and taking a semiconductor wafer as a substrate and a supporting plate is formed in the front of the chamber10as shown inFIG. 3. A volume reducing block21is provided inside the chamber10opposed to the opening20so as to reduce the pressure to a desired pressure in a short period of time.

A pair of alignment members30and40are provided in both ends of the chamber10. Shafts31and41of the alignment members30and40penetrate the side walls of the chamber10, and the outer ends of the shafts31and41are coupled to cylinder units32and42so as to move back and forth in an airtight and slidable manner driven by the cylinder units32and42.

Blades34and44, and a pair of rollers33and another pair of rollers43are provided in the tip ends of the shafts31and41of the alignment members30and40, respectively. The blades34and44serve to support the lower surface of the periphery of the supporting plate51. The thickness of the rollers33and43is larger than the thickness of the semiconductor wafer52in a state where the adhesive layer is applied thereon to be contacted with the lower surface of the supporting plate51, that is, the thickness of the semiconductor wafer and the adhesive layer.

The distances between the rollers33and between the rollers43are adjusted to be smaller than the length of an orientation flat52aof the semiconductor wafer52in the alignment member30.

The supporting plate51may be a glass plate, a ceramic plate, or a resin plate. Examples of ceramic plates include alumina and SiC. Examples of resin plates include plyimide, PET, and polyethylene naphthalate. As for the shape of the supporting plate51, a simple disc shape (with a straight portion which corresponds to an orientation flat), a shape in which a number of penetrating holes are formed in the thickness direction, and a shape in which a groove is formed in the surface to distribute a solvent are possible.

The applying device4serves to apply an adhesive onto a surface of a semiconductor wafer. The heat treatment device5serves to heat the adhesive applied onto the semiconductor wafer. The cooling device6enables fine positioning at the time of attaching the supporting plate and the semiconductor wafer by cooling the heated adhesive on the semiconductor wafer. Incidentally, the above-described devices may each be a multi-stage type.

Next, processes for attaching the supporting plate51and the semiconductor wafer52to each other by using the above-described attaching apparatus22will be explained.

A single semiconductor wafer52is taken out of the wafer cassette2by the transfer robot1. After positioning the semiconductor wafer52is performed in the positioning device3, an adhesive is applied onto the top surface of the semiconductor wafer52by the applying device4.

Next, the semiconductor wafer52is heated by a hot plate as the heating device5, and thereafter transferred to the cooling device6by the transfer robot1. The adhesive whose rigidity has been decreased by heating is cured to some extent in the cooling device6, so that the alignment of the supporting plate51can be adjusted easily.

In this instance, the attaching device7is a state shown inFIG. 6. Specifically, the top end of the pin15is lower than the top surface of the mounting plate12, and the lower surface of the pressing plate18is lowered to a position near the top surface of the mounting plate12so as to be heated by the hot plate13. The alignment members30and40are in a position of moving backward.

Next, the pressing plate18is elevated as shown inFIG. 7, and the pin15is elevated by driving the cylinder unit16as shown inFIG. 8. The semiconductor wafer52whose top surface has been coated with an adhesive is transferred into the chamber10via the opening20with the transfer robot1and passed to the pin15.

Next, the alignment members30and40are moved forward by driving the cylinder units32and42and stopped in a predetermined position as shown inFIG. 9. The supporting plate51is taken out of the supporting plate cassette8, transferred into the chamber10via the opening20, and passed to the blades34and44of the alignment members30and40by the transfer robot1. Positioning of the supporting plate51before attachment can be performed in the positioning device9.

Next, the pin15is further elevated so as to bring the adhesive layer on the semiconductor wafer52into contact with the lower surface of the supporting plate51as shown inFIG. 10, and the alignment members30and40are moved backward at the same time. This state is shown inFIG. 11.

As clearly seen fromFIG. 11, slight displacement occurs between the supporting plate51and the semiconductor wafer52when the alignment members30and40are moved backward.

In order to correct this displacement, the pin15is slightly lowered such that the height position of the layered structure (the supporting plate51and the semiconductor wafer52) is adjusted to be in the same level as the rollers33and43of the alignment members30and40. The alignment members30and40are moved forward to a predetermined position as shown inFIG. 12.

With this, the centers of the supporting plate51and the semiconductor wafer52are allowed to coincide with each other. In addition, since the distances between the rollers33and between the rollers43are adjusted to be smaller than the length of the orientation flat52aof the semiconductor wafer52, displacement of the supporting plate orientation flat can be corrected at the same time by adjusting the rollers33and43to be located in the orientation flat52a.

The above-described alignment is performed in a state where the pressure inside the chamber10is reduced (indicated by dark shading). Next, as shown inFIG. 13, after the alignment members30and40are moved backward, the pin15is lowered and the layered structure of the supporting plate51and the semiconductor wafer52is mounted on the heated mounting plate12. The layered structure is heated so as to remove gas contained in the adhesive.

Next, as shown inFIG. 14, the pressing plate18is lowered so as to press the supporting plate51and the semiconductor wafer52toward the mounting plate12. In this way, the layered structure of the supporting plate51and the semiconductor wafer52is formed. Next, as shown inFIG. 15, the pressing plate18is elevated, the pin15is also elevated, and the pressure-reduced state is released.

The layered structure of the supporting plate51and the semiconductor wafer52undergoes a subsequent thinning process using a grinder.

Incidentally, the semiconductor wafer52is transferred first in the present embodiment. However, the supporting plate51may be transferred first, and the semiconductor wafer52may be transferred next.

Since the attaching apparatus22of the present embodiment comprises the transfer robot1, and the cassettes, the applying device4, the heat treatment device5, the cooling device6, the positioning devices3and9for the semiconductor wafer52and the supporting plate51, respectively, and the attaching device7which surround the transfer robot1, it is possible to efficiently perform a series of processes for attaching the supporting plate51to the semiconductor wafer52in a single apparatus, and simplify the structure of the apparatus.

Since the attaching method comprises the steps of applying an adhesive to the surface of the semiconductor wafer52, heating and thereafter cooling the semiconductor wafer52, it is possible to cure the adhesive whose rigidity has been decreased by heating, and finely adjust positioning of the supporting plate and the semiconductor wafer after attachment, which is difficult according to a conventional technique because the adhesive is softened by heating. Also, a conventional large-scale positioning apparatus is not required.

Additionally, the attaching apparatus22of the present embodiment can be used for an image sensor. In this instance, since heating for a long period of time is required, an oven (a multistage oven) is used as the heat treatment device5instead of the hot plate. The other structures are substantially the same as above.

In this attaching apparatus, the same function can be achieved as in the above-described attaching apparatus22. This attaching apparatus has the advantage that the processing capacity can be increased and the processing time can be reduced by using the multistage oven.

Also, the attaching apparatus22of the above-described embodiment may include an attaching device for a sheet (for example, a PI sheet made of polyimide).

The present invention is not limited to the above-mentioned embodiments, and other various structures are possible within the scope of the present invention.

EFFECT OF THE INVENTION

According to the attaching device of the present invention, it is possible to accurately perform alignment when the diameters of a substrate and a supporting plate are substantially the same.

According to the attaching method of the present invention, it is possible to finely correct the alignment after attachment.

According to the attaching apparatus of the present invention, it is possible to efficiently perform attachment of the supporting plate and also simplify the structure.

Accordingly, the present invention is suitable for attaching a supporting plate to a substrate, and an attaching apparatus having high performance and reliability can be achieved.