IC CHIP MOUNTING DEVICE AND IC CHIP MOUNTING METHOD

The present invention is an IC chip mounting apparatus including: an ejection unit configured to eject an adhesive toward a reference position of each antenna of an antenna continuous body, the antenna continuous body having a base material and plural inlay antennas continuously formed on the base material; a nozzle movable between a first position and a second position, the nozzle being configured to suck an IC chip, when located at the first position, and to place the IC chip on the adhesive at the reference position of each antenna, when located at the second position; a determination unit configured to determine whether an IC chip is sucked by the nozzle while the nozzle is moved from the first position to the second position; and a moving machine configured to move the nozzle away from the second position when it is determined by the determination unit that an IC chip is not sucked by the nozzle.

FIELD

The present invention relates to an IC chip mounting apparatus and an IC chip mounting method.

BACKGROUND

With the spread of RFID tags, production of sheet-shaped inlays having an antenna and an IC chip electrically connected to the antenna is increasing. Manufacturing of an inlay involves a process of: providing an adhesive at a predetermined reference position on an antenna formed on a base material; and placing an IC chip at the reference position. The reference position is a reference for mounting the IC chip. Subsequently, the IC chip is fixed by curing with the adhesive.

For example, Japanese Unexamined Patent Application Publication No. 2005-209144 discloses the followings. That is, a synchronization roller is rotated with a suction hole thereof sucking an IC chip. The synchronization roller causes a film base plate and the IC chip to abut at a predetermined position, and releases the IC chip from the suction hole to place the IC chip on the film base plate.

BRIEF SUMMARY

Technical Problem

Incidentally, a method of sucking an IC chip to hold the IC chip and then placing the IC chip at a reference position of an antenna has a possibility that a base material and/or an IC chip mounting apparatus are contaminated, when failing to suck the IC chip. For example, when air is discharged to release an IC chip from a nozzle having failed to suck an IC chip, an adhesive before cured, with low viscosity, on the antenna formed on the base material may be scattered, and thereby contaminating the base material and/or the IC chip mounting apparatus.

In view of this, an object of one aspect of the present invention is to prevent a base material and/or an IC chip mounting apparatus from being contaminated, when an IC chip is mounted on an antenna by the IC chip mounting apparatus in an inlay manufacturing process.

Solution to Problem

An embodiment of the present invention is an IC chip mounting apparatus including: an ejection unit configured to eject an adhesive toward a reference position of each antenna of an antenna continuous body, the antenna continuous body having a base material and plural inlay antennas continuously formed on the base material; a nozzle movable between a first position and a second position, the nozzle being configured to suck an IC chip, when located at the first position, and to place the IC chip on the adhesive at the reference position of each antenna, when located at the second position; a determination unit configured to determine whether an IC chip is sucked by the nozzle while the nozzle is moved from the first position to the second position; and a moving machine configured to move the nozzle away from the second position when it is determined by the determination unit that an IC chip is not sucked by the nozzle.

Advantageous Effects

An embodiment of the present invention prevents a base material and/or an IC chip mounting apparatus from being contaminated, when an IC chip is mounted on an antenna by the IC chip mounting apparatus in an inlay manufacturing process.

DETAILED DESCRIPTION

The present invention is related to Japanese Patent Application Nos. 2019-235417 and 2020-216457 respectively filed with the Japan Patent Office on Dec. 26, 2019 and on Dec. 25, 2020, the entire contents of which are incorporated into this specification by reference.

Hereinafter, an IC chip mounting apparatus and an IC chip mounting method according to an embodiment will be described with reference to drawings.

An IC chip mounting apparatus1according to the embodiment is an apparatus for mounting an IC chip on a thin film antenna in manufacturing a contactless communication inlay, such as an RFID inlay.

FIG.1shows an exemplary antenna AN having a predetermined antenna pattern, but there is no intention to limit the antenna pattern thereto.FIG.1also shows enlarged views of an “E” part before and after an IC chip “C” is mounted on the antenna AN. In this example, an IC chip “C” is mounted at a predetermined reference position Pref that is determined in advance based on the antenna pattern. The IC chip “C” has such a very small size as several hundreds of micrometers in length and width dimensions, and this very small IC chip “C” is required to be mounted exactly at the reference position Pref.

Mounting the IC chip “C” on the antenna AN involves an IC chip placement process and a curing process. In the IC chip placement process, an adhesive is applied to the reference position Pref of the antenna AN, and the IC chip “C” is placed on the adhesive. In the curing process, the adhesive is cured to strongly connect the antenna AN and the IC chip “C”.

In the IC chip placement process (described later), a roll PR of a strip antenna sheet AS (an example of an antenna continuous body), as shown inFIG.2, is set. The antenna sheet AS includes a plurality of antennas AN formed on a base material BM with constant pitches. The antenna sheet AS is continuously pulled out of the roll PR and is provided to a line of the IC chip placement process.

Examples of the material that can be used for the base material BM include, but not specifically limited to, paper base materials such as fine paper, coated paper, and art paper, synthetic resin films made of polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), or polystyrene (PS), sheets made of a plurality of these synthetic resins, and composite sheets of a synthetic resin film and paper.

The antenna AN is formed, for example, by attaching a metal foil to a base material BM or by screen-printing or vapor-depositing a conductive material into a predetermined pattern on a base material BM.

In the following description, an XYZ coordinate system is defined as shown inFIG.2. The following describes a front view as a YZ-plane view, a plane view as an XY-plane view, and a side view as an XZ-plane view in referring to the drawings of components set in each process.

The X-direction is a direction of conveying the antenna sheet AS, which is pulled out of the roll PR, in each process described below, and it is also called a “conveying direction D1” as appropriate. In addition, the Y-direction is a width direction of the antenna sheet AS and is also called a “width direction D2” as appropriate. The Z-direction is a direction orthogonal to the antenna sheet AS.

(1) IC Chip Placement Process

Hereinafter, the IC chip placement process will be described with reference toFIGS.3to10.FIG.3shows an area corresponding to the IC chip placement process of the IC chip mounting apparatus1of this embodiment.FIG.4shows a plane view of a chip-containing tape CT and an enlarged view of an A-A section thereof.

In the IC chip placement process, the IC chip mounting apparatus1accurately places a very small IC chip at the reference position Pref (refer toFIG.1) of each antenna AN on the antenna sheet AS.

As shown inFIG.3, the IC chip mounting apparatus1includes a conveyor81, a dispenser2, a rotary mounter3, an ultraviolet irradiator41, image capture devices CA1to CA3, a tape feeder71, a tape body winding reel72, a film winding reel73, and a separation roller74, in the IC chip placement process.

The conveyor81(an example of a conveyor) conveys the antenna sheet AS that is pulled out of the roll PR (refer toFIG.2) to the downstream of the process at a predetermined conveying speed. An upper surface of the conveyor81corresponds to a conveying surface.

The dispenser2(an example of an ejection unit) ejects a fixed amount of anisotropic conductive paste (ACP; hereinafter simply called “conductive paste”) to the reference position Pref of each antenna AN that is conveyed. This conductive paste is an example of an ultraviolet light curable adhesive. The dispenser2is configured so that the ejection position can be adjusted in the width direction, in order to accurately determine the ejection position relative to the reference position Pref of each antenna AN.

The image capture device CA1is provided upstream of the dispenser2and captures an image of a part in the vicinity of the reference position Pref of each antenna AN, in order to determine the position to be applied with the conductive paste. The image capture device CA2is provided downstream of the dispenser2and captures an image of a part in the vicinity of the reference position Pref of each antenna AN, in order to inspect whether the conductive paste is applied to each antenna AN and to inspect whether the conductive paste is applied exactly to a region including the reference position Pref

The rotary mounter3is a chip mounter that places an IC chip on the conductive paste that is applied to each antenna AN, and it rotates in a counterclockwise direction inFIG.3. The rotary mounter3is mounted to and suspended by a suspension plate86. The suspension plate86is supported by a support stand85, while movable in the Y-direction. Thereby, the rotary mounter3is suspended from above by the support stand85, and moveable in the Y-direction.

As described later, the rotary mounter3sucks an IC chip from the chip-containing tape and places (mounts) the sucked IC chip by releasing it to the reference position Pref of each antenna AN on the antenna sheet AS. Meanwhile, in order to place the IC chip exactly at the reference position Pref of the antenna AN, the position and the direction of the sucked IC chip are corrected. The image capture device CA3images the IC chip in the state of being sucked by a nozzle (described later), in order to perform a correction process of correcting the position and the direction of the IC chip in preparation for mounting it on the antenna AN, and retreat the sucked IC chip. The image capture device CA3is an example of an image acquisition unit.

The tape feeder71is configured to be loaded with a wound chip-containing tape that contains IC chips and to cause the chip-containing tape to be pulled out sequentially at a speed synchronized with the rotary mounter3, in the arrow directions inFIG.3.

Herein, an example of the chip-containing tape will be described with reference toFIG.4.

As shown inFIG.4, the chip-containing tape CT includes a tape body “T” and a cover film CF. Recesses Td for containing IC chips “C” are formed at fixed intervals in the tape body “T”. The cover film CF is attached to the tape body “T” so as to cover the recesses Td. The recesses Td are formed, for example, by embossing the tape body “T”. The IC chip “C” is contained in each recess Td along the extending direction of the chip-containing tape CT. The chip-containing tape CT has fitting holes H that are formed at fixed intervals in the extending direction. These fitting holes H are provided in order to accurately perform positioning relative to a circumferential surface of the separation roller74. The fitting holes H are fitted to protrusions74p(described later), which are provided to the separation roller74, while the chip-containing tape CT is conveyed by the separation roller74.

As shown inFIG.4, a suction hole Ts is formed between a bottom surface of the recess Td and a back surface (surface on a side opposite to the surface attached with the cover film CF) of the tape body “T”. The suction hole Ts is provided so as to make the separation roller74suck an IC chip “C”, in order to prevent the IC chip “C” from falling out of the recess Td when the cover film CF is peeled off.

With reference toFIG.3again, the chip-containing tape CT is fed from the tape feeder71via one or a plurality of auxiliary rollers, and the cover film CF is peeled off from the chip-containing tape CT to be separated from the tape body “T” at the separation roller74. The IC chip “C” is exposed upon peeling off the cover film CF and is sequentially sucked by each nozzle that is provided to the rotary mounter3.

After the chip-containing tape CT is separated into the tape body “T” and the cover film CF by the separation roller74, the tape body “T” is wound by the tape body winding reel72via one or a plurality of auxiliary rollers, whereas the cover film CF is wound by the film winding reel73via one or a plurality of auxiliary rollers.

Next, the rotary mounter3will be described with reference toFIGS.5to7.

FIG.5is a side view of the rotary mounter3of the IC chip mounting apparatus1of this embodiment.FIG.6Ais a plane view of a nozzle unit mounted on the rotary mounter3.FIG.6Bis a side view of nozzle units30.FIG.7schematically illustrates a relation between the rotary mounter3and the antenna sheet AS.

As shown inFIG.5, a plurality of nozzle units (twelve units in the example of the drawing)30-1to30-12are arranged radially from a rotary head3H (an example of a nozzle attachment) in the rotary mounter3. The following collectively describes the nozzle units30-1to30-12as “nozzle units30” when referring to matters that are common therebetween.

Although not illustrated in detail, the rotary head3H is connected to a rotary drive motor, a vacuum pump, and a blower. The rotary drive motor rotates the nozzle units30-1to30-12in a counterclockwise direction inFIG.5. The vacuum pump causes the nozzle unit30to suck an IC chip. The blower causes the nozzle unit30to release the IC chip.

Referring toFIG.6, the nozzle unit30is comprised of a nozzle32, a sleeve33, a solenoid valve35, and a cylinder drive motor M30. The nozzle32is provided at a tip of the nozzle unit30and connected to the cylinder drive motor M30in the sleeve33. The cylinder drive motor M30is a motor (e.g., a stepping motor) that rotates the nozzle32around an axis thereof. A path that can be communicated with an suction tube36and an exhaust tube37is formed in the nozzle32.

The suction tube36and the exhaust tube37are coupled with the sleeve33. The suction tube36is connected to a vacuum pump (not illustrated), while the exhaust tube37is connected to a blower (not illustrated).

The solenoid valve35may be a three-port valve, for example, that is configured to, in response to current-applying condition, either open a path between a path34of the nozzle32and the suction tube36, thereby closing the exhaust tube37, or open a path between the path34of the nozzle32and the exhaust tube37, thereby closing the suction tube36. The solenoid valve35is configured to perform either a suction operation for sucking by the nozzle32through the suction tube36, or an exhaust operation for exhausting air from the nozzle32through the exhaust tube37.

Referring toFIG.7, the rotary head3H is rotated by a rotation drive motor (not illustrated). Thereby, a circumferential position of each nozzle unit in the rotary head3H is sequentially changed. That is, a nozzle unit30moves on a surface orthogonal to the conveying surface along a circular track, in response to rotation of the rotary head3H, and as such, the nozzle unit30is sequentially located at each of twelve circumferential positions PA to PL in the rotary head3H. The positions PA to PL are arranged from the position PA to the position PL in a counter-clockwise direction.

Herein, the position PA (an example of a first position) is a position where the nozzle unit30sucks a new IC chip “C” from the chip-containing tape CT. The position PE is a position where the image capture device CA3images the IC chip “C” in the state of being sucked by the nozzle of the nozzle unit30.

The position PK (an example of a second position) is a position where the sucked IC chip “C” is released on the conductive paste applied to the antenna AN of the antenna sheet AS that is conveyed. The moving direction of the top of the nozzle matches the conveying direction D1of the antenna sheet AS at the position PK. The nozzle unit30discharges air from the nozzle to release the IC chip “C” at the position PK.

The nozzle unit30does not suck the IC chip “C” at the position PL, as it has released the IC chip “C” at the position PK. In order to remove dust that may adhere to the nozzle, air may be jetted out from the nozzle at the position PL.FIG.6shows an example of disposing a dust collection tray TR for collecting dust that may be detached from the nozzle, at the position PL.

In an example, the following movement is repeated. InFIG.7, the nozzle unit30-1at the position PA sucks a new IC chip “C” thereat and rotates in the counterclockwise direction while sucking the IC chip “C”, and it then releases the IC chip “C” upon reaching the position PK and returns to the position PA to suck a new IC chip “C” again. Such an IC chip mounting method enables continuously placing the IC chip on each antenna AN without stopping conveyance of the antenna sheet AS, resulting in high productivity.

The angular velocity of the rotary head3H and the conveying speed of the antenna sheet AS are set or controlled so that the nozzle unit30, which sequentially reaches the position PK, will release the IC chip “C” to the reference position Pref of each antenna AN of the antenna sheet AS, which is conveyed from the upstream side. In order to accurately place the IC chip “C”, it is preferable to provide a section where the speed of the top of the nozzle unit30is equal to the conveying speed of the antenna sheet AS, in proximity to the position PK.

Note that this embodiment shows an example of arranging twelve nozzle units30to the rotary head3H, but the number of the nozzle units30is not limited thereto. The number of the nozzle units30that are arranged to the rotary head3H can be set to any number.

Next, movement of the nozzle unit30sucking the IC chip “C” will be described with reference toFIGS.8and9.

FIG.8is a perspective view showing separation of the chip-containing tape CT by the separation roller74.FIG.9is a side view of the vicinity of the separation roller74, illustrating movement of supplying the IC chip “C” to the nozzle unit30from the chip-containing tape CT. In order to show the state of the chip-containing tape CT, only the chip-containing tape CT is illustrated in cross-section inFIG.9.

As shown inFIG.8, the chip-containing tape CT, which is supplied from the tape feeder71, is conveyed while its position in the width direction is determined by inserting the protrusions74pof the separation roller74into the fitting holes H of the chip-containing tape CT. At this time, the cover film CF is peeled off from the chip-containing tape CT by a split member75and is sent to the film winding reel73. On the other hand, the tape body “T” of the chip-containing tape CT is sent to the tape body winding reel72.

As shown inFIG.9, the IC chip “C” that is exposed due to peeling off of the cover film CF is immediately sucked by the nozzle unit30. The separation roller74is provided with a suction path (not shown) for sucking the IC chip “C” toward the rotation center of the separation roller74, so that the IC chip “C” will not fall out during a short period from a time when the IC chip “C” is exposed until it is sucked by the nozzle unit30. The IC chip “C” is sucked through this suction path and the suction hole Ts (refer toFIG.4) provided to the tape body “T”.

A moving machine8will be now described with reference toFIG.10. The moving machine8is configured to move the rotary head3H in the width direction D2.FIG.10is a front view of the moving machine8.

The moving machine8is provided to be able to correct a position of the IC chip “C”, which has been sucked by the nozzle unit30, in the width direction D2. As illustrated inFIG.10, the moving machine8is comprised of a bearing76, a shaft77, a suspension plate86, a guide plate87, a slider88, and a width-direction drive motor M32.

The bearing76, the shaft77, and the width-direction drive motor M32are provided on the support stand85. The shaft77is a bar-shaped member having a threaded part, and rotationally driven by the width-direction drive motor M32. The shaft77is rotatably supported by the bearings76(at two locations) fixed on an upper surface of the support stand85.

The rotary head3H is attached to the suspension plate86. A threaded hole (not illustrated) is formed at a top edge portion of the suspension plate86. The hole is fit to the threaded part of the shaft77. Thus, in response to rotation of the shaft7, the suspension plate86and the rotary head3H, which is attached to the suspension plate86, are movable in the width direction D2. An upper portion of the support stand85and the guide plate87include hollow parts formed in a movable range of the suspension plate86in the width direction D2. The slider88is attached to the suspension plate86, and slides on an upper surface of the guide plate87, in accordance with movement of the suspension plate86in the width direction D2.

With the arrangement described above, the moving machine8enables the rotary head3H to move in the width direction D2, in response to rotational drive by the width-direction drive motor M32.

In the present embodiment, the moving machine8moves the rotary head3H in the width direction D2, thereby moving the nozzle unit30attached to the rotary head3H in the width direction D2; however, other moving machine may be applied. For example, a moving machine may be applied that is able to individually translate, in the width direction D2, each nozzle unit30of the rotary head internally, without the rotary head moved in the width direction D2.

With reference toFIG.3again, the ultraviolet irradiator41is provided in the vicinity of the position (position PK inFIG.7) where the IC chip is released to the antenna AN from the nozzle unit30of the rotary mounter3.

The ultraviolet irradiator41emits ultraviolet light to the conductive paste on the antenna AN that is conveyed. The purpose of emission of ultraviolet light by the ultraviolet irradiator41is to adjust viscosity of the conductive paste on the antenna AN, which is different from the purpose of emission of ultraviolet light performed in a curing process (described later) following the IC chip placement process. From this point of view, an integrated light amount of ultraviolet light applied to the conductive paste by the ultraviolet irradiator41is preferably less than that of ultraviolet light applied to the conductive paste in the subsequent curing process. An integrated light amount of ultraviolet light is represented by a product of light intensity and irradiation time duration. Thus, adjustment of either light intensity or irradiation time duration enables adjustment of the integrated light amount.

In the IC chip mounting apparatus1of the present embodiment, the dispenser2may apply a thermosetting adhesive such as epoxy resin to the antenna AN, and a thermosetting machine may be applied in replacement of the ultraviolet irradiator41.

InFIG.3, the ultraviolet irradiator41is disposed to irradiate the adhesive with ultraviolet light after the IC chip has been located; however, other irradiation methods may be applied. For example, the ultraviolet irradiator41may be disposed so as to irradiate the adhesive with ultraviolet light before the IC chip is located, and may be disposed so as to irradiate the adhesive with ultraviolet light concurrently with the IC chip being located.

In case in which the adhesive is irradiated with ultraviolet light after the IC chip has been located, the IC chip is unlikely to shift or tilt after the IC chip has been located, as viscosity of the conductive paste decreases. In case in which the adhesive is irradiated with ultraviolet light before the IC chip is located or concurrently with the IC chip being located, the IC chip is located on the conductive paste with low viscosity. As the IC chip is unlikely to move after having been located on the conductive paste, the IC chip is unlikely to shift or tilt.

In any case, irradiation of ultraviolet light in the vicinity of a place where the IC chip is located, prevents a situation that the IC chip is unstable on the conductive paste due to viscosity of the conductive paste. That is, irradiation of the ultraviolet irradiator41has advantage that mounting accuracy of the IC chip is improved.

Next, a control of a control unit100for controlling the rotary mounter3will be described with reference toFIGS.11to13.FIG.11is a functional block diagram of the control unit100.FIG.12illustrates an exemplary image captured by the image capture device CA1.FIG.13illustrates exemplary IC chips sucked by the nozzle32before and after the nozzle32is rotated.FIG.13shows an exemplary image captured by the image capture device CA3in a condition before the nozzle32is rotated.FIG.13, in a condition after the nozzle32is rotated, includes an XYZ-axis when the nozzle is at the position PK (seeFIG.7).

The control unit100is implemented on a circuit board (not illustrated), and connected to the image capture devices CA1to CA3, the dispenser2, the cylinder drive motor M30, a rotational drive motor M31, the width-direction drive motor M32, the solenoid valve35, and the ultraviolet irradiator41. The rotational drive motor M31(an example of a rotating unit) is a drive means for rotating the nozzle units30-1to30-12in the nozzle head3H.

The control unit100is comprised of a microcomputer, memories (a random access memory (RAM) and a read only memory (ROM)), a storage, and drive circuits. The microcomputer reads out a program stored in the memory to function as each of an ejection position adjusting unit101, an IC chip correction unit102, a valve control unit103, a curing unit104, and a nozzle retreating unit105.

The ejection position adjusting unit101includes a function for determining an ejection position of the conductive paste based on an image captured by the image capture device CA1, and for adjusting an ejection time when the conductive paste is ejected and a position of the dispenser2in the width direction D2. A determination method of a position where the conductive paste is ejected, will be described with reference toFIG.12.

As exemplified byFIG.12, an image captured by the image capture device CA1is one in the vicinity of the reference position Pref of the antenna AN.

The ejection position adjusting unit101identifies the reference position Pref from geometric characters in the image. More specifically, the ejection position adjusting unit101analyzes a shape of the antenna AN in the image ofFIG.12to determine reference lines L1, L2parallel to each other in the X-direction and reference lines L3, L4parallel to each other in the Y-direction. The ejection position adjusting unit101then identifies the reference position Pref as an intersecting point between a centerline of the reference lines L1, L2and a centerline of the reference lines L3, L4.

A point Pj1in the image ofFIG.12, which is a target position for the reference position Pref in the image, is predetermined based on a result of calibration performed with an image captured by the image capture device CA1and a drop position of the conductive paste by the dispenser2. That is, an ejection time of the dispenser2and a position of the dispenser2in the width direction D2are adjusted so that the reference position Pref identified in the image matches the target position Pj1, which allows the conductive paste to be applied on the actual reference position of the antenna AN.

In the example ofFIG.12, the reference position Pref identified in the image needs to be adjusted by “x1” in the X-direction and by y1in the Y-direction, in order to match the target position Pj1. Specifically, an ejection time of the dispenser2is determined based on “x1” in consideration of speed for conveying the antenna AN, and the dispenser2is translated based on y1in the width direction D2. That is, the ejection position adjusting unit101transmits a control signal to the dispenser2for instructing the an ejection time and translational displacement in the width direction D2, and the dispenser2then perform an ejection operation based on the control signal.

An image captured by the image capture device CA2is similar to one inFIG.12, except that the conductive paste is applied.

The IC chip correction unit102includes a function for correcting a position of the IC chip sucked by the nozzle32. The correction method of the position of the IC chip will be described with reference toFIGS.12and13.

As illustrated inFIG.13in a condition before the nozzle32is rotated, the image captured by the image capture device CA3includes a nozzle end32eand an IC chip sucked by the nozzle end32e.A point Pc1is a central position of the IC chip before the nozzle is rotated. A Pj2in the image ofFIG.13is a target position for the central position of the IC chip. The Pj2is set so as to match the target position Pj1inFIG.12. That is, the central position of the IC chip is caused to match the target position Pj1, which allows the IC chip “C” to be placed at the reference position of the antenna AN that is actually conveyed.

A rotational center Prc around the axis of the nozzle32is unlikely to be a theoretical axial center of each nozzle due to attachment variation etc. of the nozzle units30-1to30-12. The rotational center Prc may be different for each nozzle unit, and is determined based on measurement data which is obtained beforehand.

First, the central position Pc1of the IC chip “C” in the image is rotated about the rotational center Prc of the nozzle32, and a rotation amount is then determined when a reference line of the IC chip “C” (for example, a reference side Sc of the IC chip “C”) becomes parallel to the Y-direction.

In the example ofFIG.13in a condition after the nozzle32is rotated, the IC chip “C” in the captured image is rotated about the rotational center Prc so that the reference side Sc of the IC chip “C” becomes parallel to the Y-direction. A rotation angle is then determined as a correction amount in a rotational direction of the IC chip “C”. Here, a central position of the IC chip “C” after being moved is defined as a point Pc2. Then, “x2” and “x3” are determined so that the point Pc2matches the target position Pj2. “x2” is a correction amount x2in the X-direction. “x3” is a correction amount y2in the Y-direction.

The IC chip correction unit102transmits a control signal to the cylinder drive motor M30. The control signal corresponds to the correction amount in the rotational direction about the axis of the nozzle32. The nozzle32is then rotated about the axis thereof, while moved from the position PE where the image of the nozzle32is captured by the image capture device CA3, to the position PK where the IC chip is released.

The IC chip correction unit102transmits a control signal to the rotational drive motor M31. The control signal corresponds to the correction amount x2in the X-direction. An angular velocity of the rotary head3H is then adjusted. The IC chip correction unit102transmits a control signal to the width-direction drive motor M32. The control signal corresponds to the correction amount y2in the Y-direction. A position of the rotary head3H in the width direction D2is then adjusted. As the position of the rotary head3H in the width direction D2is adjusted, the position of the nozzle32in the width direction D2is also adjusted.

In the IC chip mounting apparatus1of the present embodiment, the IC chip correction unit102performs corrections for positions of the IC chip in the X-direction, the Y-direction, and orientation of the IC chip in a plane orthogonal to the axis of the nozzle. Thereby, the IC chip mounting apparatus1exerts a beneficial effect that mounting accuracy of the IC chip to the antenna is very high.

The valve control unit103controls each solenoid valve35of the twelve nozzle units30-1to30-12of the rotary mounter3, so that each nozzle unit30either sucks or discharges air, depending on a position of each nozzle unit30. More specifically, the valve control unit103controls the solenoid valve35, so that the nozzle unit30sucks when located at any position of the positions PA to PJ (seeFIG.7) while the nozzle unit30discharges air when located at the position PK or the position PL.

The curing unit104transmits a drive signal to the ultraviolet irradiator41, so that the ultraviolet irradiator41emits ultraviolet light to each antenna AN that is conveyed, with predetermined integrated light amount.

The nozzle retreating unit105determines whether an IC chip is sucked by the nozzle unit30while the nozzle unit30is moved from the position PA to the position PK. If an IC chip is not sucked by the nozzle unit30, the nozzle retreating unit105then moves the nozzle unit30away from the position PK (an example of a second position). The nozzle retreating unit105is an example of a determination unit.

Regarding the nozzle retreating unit105, an operation of the rotary mounter3will now be explained with reference toFIGS.14to16, when the rotary mounter3fails to suck an IC chip “C”.FIGS.14and15show views for explaining an operation of the rotary mounter3when the rotary mounter3fails to suck an IC chip “C”, whileFIG.15shows a modified example thereof.

FIGS.14A and14Bshows a side view and a front view of the rotary mounter3respectively at some time.FIGS.15A and15Bshows a side view and a front view of the rotary mounter3respectively at the subsequent time.

In an example illustrated inFIG.14, it is assumed that the nozzle unit30-1at the position PJ fails to suck an IC chip “C”. As described with reference toFIG.7, each nozzle unit30normally discharge air to release an IC chip “C” when located at the position PK. However, in the example ofFIG.14, the nozzle unit30-1is not sucking an IC chip “C”. Thus, if the nozzle unit30-1discharged air immediately above the antenna AN-2which corresponds to the nozzle unit30-1, there would be a possibility that the conductive paste on the antenna AN-2is scattered around the antenna.

In light of the above, in the IC chip mounting apparatus1of the present embodiment, it is preferable that the nozzle unit30is moved from the position PK, if an IC chip “C” is not sucked by the nozzle unit30. Thereby, contamination can be prevented for the antenna sheet AS on the conveying surface and/or the IC chip mounting apparatus1.

More specifically, as illustrated inFIG.15, the moving machine (seeFIG.10) moves entirety of the rotary mounter3in the width direction D2(+Y-direction) to move the nozzle30-1away from the position PK in the width direction D2. Thereby, contamination can be prevented for the antenna sheet AS on the conveying surface and/or the IC chip mounting apparatus1.

After moved as shown inFIG.15, the rotary mounter3is returned to a position above the antenna sheet AS, in order to place an IC chip “C” sucked by the nozzle unit30-2, which follows the nozzle unit30-1, on the antenna AN-3.

When an operation shown inFIGS.14and15is performed, the nozzle retreating unit105determines whether the nozzle unit30, which sequentially reaches the position PE, is sucking an IC chip “C”, based on an image captured by the image capture device CA3. When detecting the nozzle unit30that is not sucking an IC chip “C”, the nozzle retreating unit105controls the moving machine8so as to move the rotary mounter3in the width direction D2, at a time when the nozzle unit30reaches the position PK, seen from the side view.

The example illustrated inFIG.15shows that the rotary mounter3is moved in the width direction D2, in order to move the nozzle unit30that is not sucking an IC chip, away from the position PK. However, other example may be applied. Only the nozzle unit30that is not sucking an IC chip may be moved away from the position PK.

In an example shown inFIG.16, a rotary mounter3A is configured to retreat each nozzle unit30along a radial direction. The rotary mounter3A is internally provided with a retreat region3efor each nozzle unit30. The nozzle unit30can be retreated to the retreat region3eby being moved in the radial direction along a nozzle axis Ax.

In case in which the rotary mounter3A is applied, the nozzle unit30-11is retreated to the retreat region3e,as shown inFIG.16. The nozzle unit30-11is assumed to be an unit detected as not sucking an IC chip. Thereby, contamination can be prevented for the antenna sheet AS on the conveying surface and/or the IC chip mounting apparatus1.

Next, the curing process will be described with reference toFIGS.17and18.

The curing process involves curing the conductive paste, which is applied to each antenna and undergoes the IC chip placement process, whereby the physical connection between the antenna and the IC chip is strengthened, and the electrical conduction between the antenna and the IC chip is reliably made.

FIG.17shows an area corresponding to the curing process of the IC chip mounting apparatus1of this embodiment.FIG.18shows a part of a press unit6and ultraviolet irradiators42as seen from the arrow “J” inFIG.17.

As shown inFIG.17, the IC chip mounting apparatus1includes a conveyor82, a curing device4, and an image capture device CA4, in the curing process.

The conveyor82conveys the antenna sheet AS that is conveyed from the upstream IC chip placement process to a downstream side at a predetermined conveying speed.

The image capture device CA4is disposed above the antenna sheet AS on the most upstream of the curing process (that is, the most downstream of the IC chip placement process) and captures an image of each antenna AN that is conveyed from the IC chip placement process. The image capture device CA4is provided in order to inspect whether the IC chip is placed at an appropriate position in the IC chip placement process.

As illustrated inFIG.17, the curing machine4is comprised of one or plural press units6and an ultraviolet irradiator42.

The press unit6rises or falls in a direction orthogonal to the conveying surface. The press unit6presses the IC chip located on the conductive paste on the antenna AN, while each antenna AN is irradiated with ultraviolet light. A quantity of the press unit6is not limited, and may be determined from aspects of productivity and cost.

The ultraviolet irradiator42is disposed along the conveying direction D1. Thus, the ultraviolet irradiator42is also able to emit ultraviolet light simultaneously to the multiple antennas AN on the antenna sheet AS.

Referring toFIG.18, it is shown that the ultraviolet irradiator42irradiates each antenna AN with ultraviolet light. As illustrated inFIG.15, the press unit6has a shaft63, a tip of which is attached to a pressing part61. A lateral face of the pressing part61of the press unit6(that is, a face in the side on which the ultraviolet irradiator42is disposed) is open. A glass plate61p, which is a pressing surface of the pressing part61, is made of glass through which ultraviolet light passes.

The ultraviolet irradiator42has a light source42esuch as a light emitting diode (LED). The light source42eis configured to emit ultraviolet light to the antenna AN from a direction slanted off the conveying surface.

Ultraviolet light irradiation is performed while the IC chip on the conductive paste, which is applied to each antenna AN, is pressed. Thereby, the conductive paste is cured to strengthen physical connection between the antenna and the IC chip, and electrical connection between the antenna and the IC chip is ensured.

As aforementioned, a belt-shaped antenna sheet is on a manufacturing line. The belt-shaped antenna sheet has plural antennas, each of which is formed on a base material with a constant pitch. The IC chip is mounted on each antenna through the IC chip placement process and the curing process. The IC chip mounting apparatus1of the present embodiment applies an adhesive to the reference position of the antenna and places an IC chip on the adhesive in the IC chip placement process. The IC chip mounting apparatus1then cures the adhesive in the curing process to strengthen connection between the antenna and the IC chip. Particularly in the IC chip placement process, if an IC chip is not sucked by the nozzle unit, the nozzle unit is moved away from a position where an IC chip should be released. Thus, the conductive paste on the antenna is prevented from being scattered by air discharged from the nozzle, and accordingly, contamination can be prevented for the antenna sheet on the conveying surface and/or the IC chip mounting apparatus.

In the example ofFIGS.14and15, the moving machine8moves entirety of the rotary mounter3in the width direction so that the nozzle unit moves away from the position PK in the width direction; however, other example may be applied. Each of the plural nozzle units in the rotary mounter may be independently moved in the width direction. In this case, entirety of the rotary mounter3in the width direction may not be necessarily moved, and a target nozzle unit alone may be moved in the width direction.

Although an embodiment of the IC chip mounting apparatus and the IC chip mounting method is described above, the present invention should not be limited to the foregoing embodiment. In addition, the embodiment described above may be variously modified and altered within the scope not departing from the gist of the present invention.

In an example, although the antenna sheet AS is conveyed on the conveyor81in one direction in the IC chip placement process in the embodiment shown inFIG.3, the conveying method is not limited thereto.

In an embodiment, as shown inFIG.19, the antenna sheet AS may be conveyed by suction drums92and94and a plurality of conveying rollers (e.g., conveying rollers91,93, and95inFIG.17) in the IC chip placement process. InFIG.19, the dispenser2ejects the conductive paste to the reference position of the antenna AN of the antenna sheet AS, at the highest position of the suction drum92. In addition, the IC chip is placed on the conductive paste at the highest position of the suction drum94. In this case, at least the suction drums92and94are preferably suction rollers that suck the back surface of the antenna sheet AS. This structure prevents dislocation of the antenna sheet AS (in particular, in the longitudinal direction), whereby ejection of the conductive paste as well as placement of the IC chip is performed with high accuracy.

In an embodiment, instead of releasing the IC chip on the conductive paste applied to the antenna AN on the conveyed antenna sheet AS, the IC chip may be placed by pressing it to the conductive paste.

FIG.20shows movement of the rotary mounter3in time series in the case of placing the IC chip by pressing it to the conductive paste. In an embodiment, nozzle units30of the rotary mounter3are configured to move in respective radial directions (diameter directions) by a built-in drive device.

The state ST1is a state in which the nozzle unit30sucks the IC chip “C”. Placement of the sucked IC chip “C” is performed in the state ST2. That is, the nozzle unit30is moved toward the reference position (that is, in the lower direction which is the Z-direction inFIG.2) in such a manner as to extend in the radial direction (diameter direction). The IC chip “C” is then placed on the conductive paste by pressing it to the conductive paste applied to the antenna AN. After the IC chip “C” is placed, the suction is released, and the nozzle unit30is returned to the position in the state ST1. For example, the movement from the state ST1to the state ST3is performed at the time the nozzle unit30reaches the position PK (refer toFIG.7), whereby the IC chip “C” is placed on the conductive paste applied on the antenna AN.

A curing process of an embodiment is shown inFIG.21.FIG.21shows a curing device4A that is used in the curing process of an embodiment. The curing device4A includes a plurality of ultraviolet curing units43that are detachably mounted to a mounting board44. A plurality of mounting boards44that have different mounting positions are prepared in accordance with the interval of adjacent antennas AN of the antenna sheet AS. Under these conditions, the mounting boards44are switched in response to the interval, whereby various antenna sheets AS can be used in the curing device4A.

A support shaft45supports and moves the mounting board44up and down. The antenna sheet AS that is conveyed from the IC chip placement process is sent to the curing process via conveying rollers96to98. The conveying roller97is moved up and down by a drive device (not shown).

An example of the structure of the ultraviolet curing unit43is shown inFIG.22. As shown inFIG.22, the ultraviolet curing unit43contains a light source432(e.g., an LED light source) for emitting ultraviolet light, in a housing431. The light source432is powered via a cable436(not shown inFIG.21) that is provided from the outside of the ultraviolet curing unit43. A condensing lens for condensing ultraviolet light that is emitted by the light source432may be provided in the housing431. A holding plate434is coupled to the housing431and holds a glass plate435. The ultraviolet light that is emitted from the light source432illuminates and cures the conductive paste applied to each antenna AN.

With reference toFIG.21again, the conveying state is a state in which the antenna sheet AS is conveyed from the IC chip placement process. The conveyance of the antenna sheet AS is stopped at the time the antennas AN applied with uncured conductive paste come immediately under the ultraviolet curing units43. Then, in the state (resting state) in which the conveyance of the antenna sheet AS is rested, the ultraviolet curing units43are lowered, and they emit ultraviolet light to cure the conductive paste while pressing the antennas AN with the glass plates435.

The antenna sheet AS is conveyed from the IC chip placement process during the resting state, and therefore, the conveying roller97is lowered by its own weight and absorbs the conveyed antenna sheet AS between the conveying rollers96and98while ultraviolet light is emitted. After emission of ultraviolet light is finished, the antennas AN, number of which corresponds to the number of the ultraviolet curing units43, are quickly conveyed to a downstream side, and instead, uncured antennas AN are then stopped at the positions immediately under the ultraviolet curing units43. That is, in the curing process of an embodiment, the conveying state and the resting state (ultraviolet light emission state) of the antenna sheet AS are repeated. In quickly conveying the antennas AN, the conveying roller97is raised by tension applied to the antenna sheet AS.

The curing process of an embodiment may use a thermosetting device. That is, in the case of applying a thermosetting adhesive, such as an epoxy resin, by the dispenser2, the adhesive is cured by a thermosetting treatment in the curing process.

FIG.23shows a curing device4B configured so that the conveying state and the resting state of the antenna sheet AS will be repeated as in the case inFIG.21. The curing device4B is different from the curing device4A in having a plurality of thermosetting units46. A heat source that is operated by power supplied via a cable (not shown) is disposed to each thermosetting unit46. While the antenna sheet AS is in the resting state, the support shaft45is driven so as to move down, and each thermosetting unit46heats and cures the adhesive while pressing the corresponding antenna AN. After heating is completed, the support shaft45is driven so as to move up, and the antenna sheet AS is conveyed.

In the case of curing the conductive paste with ultraviolet light inFIG.21, instead of the ultraviolet curing unit43containing the light source, a press unit for pressing the antenna AN via a glass plate may be used. In addition, an ultraviolet irradiator may also be provided in such a manner as to emit ultraviolet light from an outside in the width direction or an oblique upper side to the conductive paste on the antenna AN that is pressed in the resting state.

In an embodiment, in order to not make the antenna sheet AS in the resting state during emission of ultraviolet light, the plurality of the ultraviolet curing units43may be circulated in a manner linked to the advance speed of the antenna sheet AS, and ultraviolet light may be emitted by the internal light source while the antenna AN is pressed.

Similarly, in an embodiment, in thermally curing the conductive paste, the plurality of the thermosetting units46may be circulated in a manner linked to the advance speed of the antenna sheet AS, and the antenna AN may be heated while being pressed.