Method for mount tape die release system for thin die ejection

An apparatus, system, and a method of using the apparatus or system that includes a bladder positioned between tape and an adhesive layer configured to selectively connect the tape to a semiconductor device. The bladder includes one or more chambers that may be selectively expanded to move a portion of the bladder and adhesive layer away from the tape, which may enable the removal of the semiconductor device. The flow of fluid into each of the chambers may selectively expand the chambers. The chambers may have a substantially rounded upper profile or a substantially pointed upper profile. A material within the chambers may be heated to expand the chambers. A plurality of conduits may permit the flow of fluid into the chambers. The conduits may be inserted into the bladder. The chambers may be collapsed after expansion to enable the removal of a semiconductor device from the tape.

FIELD

The embodiments described herein relate to an apparatus, system, and a method of using the apparatus or system that includes a bladder positioned between tape and an adhesive layer configured to selectively connect the tape to a semiconductor device. The bladder includes one or more chambers that may be selectively expanded to move a portion of the bladder and adhesive layer away from the tape, which may enable the removal of the semiconductor device.

BACKGROUND

A semiconductor device may include a plurality of semiconductor devices formed on a single substrate. For example, a semiconductor wafer may include a plurality of die that may be processed to form a plurality of semiconductor devices from a single semiconductor wafer. Various processes may be used to separate the semiconductor device into a plurality of semiconductor devices.

For example, stealth dicing through tape may be used to separate the semiconductor wafer into a plurality of semiconductor devices. The semiconductor device typically may comprise a circuitry layer positioned on a silicon layer. The circuitry layer comprising the top surface and the silicon layer comprising the bottom surface. The backside or bottom surface of the semiconductor wafer is applied to a tape material. Various tape materials may be used such as Lintec D-L01wtest38 tape, Lintec D-175, and/or Nitto PF-04.

Various methods may be used to form a plurality of semiconductor devices from a single semiconductor wafer mounted to tape material. For example, an infrared laser cleaves a portion of the silicon layer of the semiconductor wafer and a tape expander machine is then used to apply an expanding force to the tape material causing the silicon lattice to break apart where the infrared laser has cleaved it. Alternatively, the single semiconductor wafer could be formed into a plurality of semiconductor devices mechanically, by etching, by lasing, and/or by other methods.

Semiconductor processing and packaging techniques continue to evolve to meet industry demands for increased performance and reduced size. Electronic products, such as cell phones, smart phones, tablets, personal digital assistances, laptop computers, as well as other electronic devices, require packaged semiconductor assemblies having a high density of devices while having a relatively small footprint. The thickness of semiconductor wafers may be reduced to minimize the size of semiconductor devices, i.e. dies. As the thickness of the semiconductor device decreases, the device may be more fragile and it may be more difficult to remove from the tape. As an example, it may be difficult to remove a semiconductor die having a thickness of under 50 microns from the tape without potentially damaging the device.

Additional drawbacks and disadvantages may exist.

DETAILED DESCRIPTION

In this disclosure, numerous specific details are discussed to provide a thorough and enabling description for embodiments of the present disclosure. One of ordinary skill in the art will recognize that the disclosure can be practiced without one or more of the specific details. Well-known structures and/or operations often associated with semiconductor devices may not be shown and/or may not be described in detail to avoid obscuring other aspects of the disclosure. In general, it should be understood that various other devices, systems, and/or methods in addition to those specific embodiments disclosed herein may be within the scope of the present disclosure.

The term “semiconductor device assembly” can refer to an assembly of one or more semiconductor devices, semiconductor device packages, and/or substrates, which may include interposers, supports, and/or other suitable substrates. The semiconductor device assembly may be manufactured as, but not limited to, discrete package form, strip or matrix form, and/or wafer panel form. The term “semiconductor device” generally refers to a solid-state device that includes semiconductor material. A semiconductor device can include, for example, a semiconductor substrate, wafer, panel, or a single die from a wafer or substrate. A semiconductor device may refer herein to a semiconductor die, but semiconductor devices are not limited to semiconductor dies.

As used herein, the terms “vertical,” “lateral,” “upper,” and “lower” can refer to relative directions or positions of features in the semiconductor devices and/or semiconductor device assemblies shown in the Figures. For example, “upper” or “uppermost” can refer to a feature positioned closer to the top of a page than another feature. These terms, however, should be construed broadly to include semiconductor devices and/or semiconductor device assemblies having other orientations, such as inverted or inclined orientations where top/bottom, over/under, above/below, up/down, and left/right can be interchanged depending on the orientation.

Various embodiments of this disclosure are directed to apparatus, systems, and methods of removing a semiconductor device from tape. In one embodiment of the disclosure, an apparatus comprises tape, an adhesive layer configured to selectively connect the tape to a semiconductor device, and a bladder positioned between the tape and the adhesive layer. The bladder includes a plurality of chambers configured to be selectively expanded. The expansion of the chambers moves a portion of the bladder, as well as a portion of the adhesive layer, away from the tape, which may enable the removal of a semiconductor device from the tape, bladder, and adhesive layer assembly.

One embodiment is a system comprising tape, an adhesive layer configured to selectively connect the tape to a semiconductor device, and a bladder positioned between the tape and the adhesive layer. The bladder includes a plurality of chambers configured to be selectively expanded. The system includes a plurality of conduits configured to provide a fluid to expand each of the chambers. The expansion of the chambers moves a portion of the bladder as well as a portion of the adhesive layer away from the tape, which may enable the removal of a semiconductor device from the tape, bladder, and adhesive layer assembly.

One embodiment is a method of removing a semiconductor device from tape that comprises providing a bladder between tape and an adhesive layer that selectively attaches the semiconductor device to the tape. The method includes expanding a chamber within the bladder that moves the semiconductor device away from the tape, which may enable the removal of a semiconductor device from the tape, bladder, and adhesive layer assembly. The method may include removing the semiconductor device from the tape.

FIG. 1is a cross-section schematic of an embodiment of a system100that may be used to remove a semiconductor device110from tape120. The semiconductor device110has a first or top surface111and a second or bottom surface112. The bottom surface112of the semiconductor device110is attached to tape120via an adhesive layer140. The semiconductor device110may be a silicon wafer and may comprise a plurality of semiconductor devices, such as individual dies. The tape120may be expanded to break the semiconductor device110into a plurality of semiconductor devices, as discussed herein. After separating the semiconductor device110into a plurality of individual semiconductor devices, it may be difficult to remove the individual semiconductor devices from the tape120without potentially damaging the devices. InFIG. 1, a single semiconductor device110is shown for clarity. As discussed herein, various methods may be used to form a plurality of semiconductor devices from a semiconductor device110attached to tape120. It may be difficult to remove the semiconductor device110from the tape120regardless of the processing method. If the thickness of the semiconductor device110is less than 50 microns, it may be difficult to remove from the tape without potentially damaging the semiconductor device110.

The system100includes a bladder130positioned between the adhesive layer140and the tape120. The bladder130includes a plurality of chambers150that may be selectively expanded to aid in the removal of the semiconductor devices. The chambers150may be created by the thermal bonding135of portions of the bladder130to the tape120. The chambers150may be configured to have a substantially rounded upper profile when expanded, as shown inFIG. 1. The expansion of the chambers150moves portions of the adhesive layer140and bladder130away from the tape120. Thus, the semiconductor device110, or individual semiconductor devices, also moves away from the tape120, which may enable the removal of the semiconductor device110, or individual semiconductor devices, from the tape.

The chambers150of the bladder130may be selectively expanded by various mechanisms and/or methods. For example, conduits160, such as a capillary needle, may be inserted through the tape120to provide fluid communication with each chamber150of the bladder130. Fluid may flow through the conduits160to selectively expand the chambers150moving the semiconductor device110away from the tape120. Various fluids may be used to expand the chambers150as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the fluid may be, but is not limited to, air, nitrogen, oxygen, or a combination thereof. Other fluids may be used. After the expansion of the chambers150, the chambers150may then be collapsed prior to the removal of the semiconductor device110. Alternatively, the chambers150may be cycled between an expanded state and a collapsed state to enable the removal of the semiconductor device110from the tape120, bladder130, and adhesive layer140assembly.

The number, size, shape, and/or configuration of the tape120, bladder130, adhesive layer140, semiconductor device110, chambers150, bonded portions of the bladder135, and/or conduits160are shown for illustrative purposes and may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, each chamber150of the bladder130may not need to be expanded to facilitate the removal of a semiconductor device110from the tape120. Further, the system100may include a plurality of chambers150per semiconductor device110or the system100may be configured to have a single chamber150for each semiconductor device110.

FIG. 2shows a schematic of an apparatus105that is comprised of a bladder130positioned between an adhesive layer140and tape120. As discussed herein, the adhesive layer140is configured to selectively attach a semiconductor device110(not shown inFIG. 2) to the apparatus105. The bladder130includes a plurality of chambers150, which may be separated by portions135of the bladder130that are connected to the tape120.FIG. 2shows the chambers150of the bladder130in a collapsed unexpanded state.

FIG. 3shows a schematic of a system100with a semiconductor device110connected to the apparatus or assembly105ofFIG. 2. The semiconductor device110has a top surface111and a bottom surface112. The bottom surface112is connected to the apparatus105ofFIG. 2via the adhesive layer140. Various adhesives may be used to form the adhesive layer140as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the adhesive may be configured to release the semiconductor device110by the application of ultraviolet light, thermal energy, and/or mechanical force.

FIG. 4shows a schematic of the system ofFIG. 3with conduits160inserted through the tape160to provide communication with the chambers150of the bladder130.FIG. 4shows the chambers150in a collapsed or unexpanded state. Fluid may flow through the conduits160to expand the chambers150, as shown inFIG. 1. The conduits160may also be used to collapse the chamber150after expansion. For example, the fluid from expanded chambers150may be withdrawn from the chambers150via the conduits160. If necessary, the chambers150may be cycled between an expanded state and a collapsed state to aid in the removal of a semiconductor device110from the tape120.

FIG. 5is a cross-section schematic of an embodiment of a system200that may be used to remove a semiconductor device110from tape220. The semiconductor device110has a first or top surface111and a second or bottom surface112, which is attached to tape220via an adhesive layer240. As discussed herein, the tape220may be expanded to break the semiconductor device110into a plurality of semiconductor devices. After separating the semiconductor device110into a plurality of individual semiconductor devices, it may be difficult to remove from the tape220without potentially damaging the devices. InFIG. 5, a single semiconductor device110is shown for clarity.

The system200includes a bladder230positioned between the adhesive layer240and the tape220. The bladder230includes a plurality of chambers250that may be selectively expanded to aid in the removal of the semiconductor devices. As discussed herein, walls of the chambers250may be connected as shown at235to the tape220. The chambers250may be configured to have a substantially pointed upper profile when expanded, as shown inFIG. 5. For example, the expanded chamber250may be substantially triangular in shape, which may enable the removal of the semiconductor device110. The substantially pointed upper profile of the expanded chamber250may provide less contact area with the adhesive layer240with the semiconductor device110, which may enable the removal of the semiconductor device110.

FIG. 6Ashows an embodiment of tape120that may be used to expand and separate a semiconductor device110into a plurality of semiconductor devices, as described herein.FIG. 6Bshows a bladder130with a plurality of chambers150on the tape120. The pattern created by the bladder130and chambers150is shown for illustrative purposes and may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.

Various mechanisms and/or methods may be used to expand the chambers150,250(shown inFIGS. 1-5) of the bladder130,250. (shown inFIGS. 1-5) For example, the chambers150,250may contain a material that expands upon heating or the application of ultraviolet light. Various materials may be used to expand the chambers150,250as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Expanded polystyrene is an example of a material that expands upon the application of heat. Expanded polystyrene may be a mixture of polystyrene and a gaseous blowing agent, such as, but not limited to, pentane or carbon dioxide. Other materials may be used.

As yet another example, it may not be necessary to insert a conduit160(shown inFIGS. 1-5) through the tape.FIG. 7shows a schematic of one embodiment of a tape320having a plurality of holes or apertures325through the tape320. The holes325may enable fluid to be flowed to the chambers150,250to expand the chambers150,250with the use of conduits160. The holes325may be configured to each correspond to a chamber150,250of a bladder130,230positioned on the top surface of the tape320. Alternatively, the holes325may permit the expansion of some, but not all, of the chambers150,250of a bladder130,230.

FIG. 8is a schematic cross-section view of an embodiment of tape420having a plurality of structures425configured to align conduits160, which may be capillary needles, with a plurality of chambers150,250(shown inFIGS. 1-5) of a bladder130,230(shown inFIGS. 1-5). The structures425may be on the bottom surface of the tape420or may be positioned within the tape420as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. The structures425are configured to align a conduit160with a corresponding chamber150,250. For example, the structures may be shaped like a funnel to guide the conduit160as it is inserted into the tape420to create a hole427in the top surface426of the tape420that is aligned with a chamber150,250in an adjacent bladder130,230.

After the inserted conduit160forms a hole427in the top surface426of the tape420, fluid may then flow through the conduit160to expand the chamber150,250, as described herein. The size, number, shape, and/or configuration of the structures425as shown for illustrative purposes and may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.

FIG. 9is a flow chart of a method500of removing a semiconductor device from tape. At510, the method500includes providing a bladder between tape and an adhesive layer that selectively attaches a semiconductor device to the tape. The method includes expanding a chamber within the bladder, the expansion of the chamber moving the semiconductor device away from the tape, at520. Various methods may be used to expand the chamber within the bladder as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the method500may include heating a material within the chamber to expand the material, at560, thus, expanding the chamber. The method500may include injecting a conduit through the tape and into the chamber within the bladder, at550, and flowing a fluid into the chamber within the bladder, at540.

The method500may include removing the semiconductor device from the tape, at530. The semiconductor device may be removed after expanding the chamber within the bladder. The method500may include collapsing the chamber, at570, after expanding the chamber then removing the semiconductor device from the tape, at530. The method500may include expanding the chamber, at580, after collapsing the chamber, at570, and then removing the semiconductor device from the tape, at530, after expanding the chamber the second time. As discussed herein, various methods may be used to expand and collapse a chamber within a bladder.

The method500may include cycling the chamber between an expanded state and a collapsed state until the semiconductor device can be removed from the tape. The conduit may be used to flow fluid into the chamber and also to withdraw fluid from the chamber to repeatedly expand and cycle the chamber. Other methods may be used to expand and collapse the chamber as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.

Although this disclosure has been described in terms of certain embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. The disclosure may encompass other embodiments not expressly shown or described herein. Accordingly, the scope of the present disclosure is defined only by reference to the appended claims and equivalents thereof.