Patterned carrier assemblies having an integrated adhesive film

Introduced here are carrier assemblies that include a rigid tray having a deck area with a patterned surface of cavities for receiving semiconductor components. The cavities can be designed to accommodate semiconductor components of different form factors (e.g., having different shapes, sizes, etc.). Moreover, an adhesive film can be affixed to the deck area to ensure that the semiconductor components are securely held against the top surface of the rigid tray. In some instances the adhesive film substantially conforms to the deck area, while in other instances the adhesive film extends across the opening of each cavity located in the deck area. Semiconductor component(s) can be secured to the carrier assembly based on the adhesiveness provided by the adhesive film, mechanical force provided the cavities, electrostatic force provided by the cavities, or any combination thereof.

RELATED FIELD

The present technology relates to carrier assemblies for handling, transporting, and/or storing semiconductor components and, more specifically, to rigid trays having a patterned surface of cavities for holding semiconductor components in a predetermined arrangement.

BACKGROUND

Several different products have been used to transport semiconductor components between different manufacturing/testing sites, including stick magazines, injection-molded trays, and carrier tapes. Examples of semiconductor components include semiconductor wafers and semiconductor dies. Entities will often transport semiconductor components from one location to another location to facilitate the manufacture of integrated circuits (ICs) from the semiconductor components. This is especially true for entities who are members of the Joint Electron Device Engineering Council (JEDEC), which has established standards for safely handling, transporting, and storing ICs, modules, and other semiconductor components.

Stick magazines (also referred to as a “shipping tubes”) may be used to transport semiconductor components between the manufacturing site and the assembly site, as well as to store the semiconductor components at the manufacturing site and/or the assembly site. Stick magazines can also be used to feed semiconductor components to automatic-placement machines for surface mounting and through-hole mounting.

Injection-molded trays (also referred to as “shipping trays” or “carrier trays”) can be designed to retain semiconductor components during component-assembly operations, during transport from the manufacturing site to the assembly site, and while feeding the semiconductor components to automatic-placement machines for surface mounting on board assemblies. Normally, injection-molded trays are designed for semiconductor components that have leads on four sides (e.g., Quad Flat Package (QFP) and thin QFP (TQFP) packages) and require lead isolation during shipping, handling, or processing.

Carrier tapes may be used to transport semiconductor components from the manufacturing site to the assembly site, as well as to store the semiconductor components at the manufacturing site and/or the assembly site. Carrier tape is often wound around a central reel. Accordingly, carrier tape may be designed such that the semiconductor components stored therein can be readily fed to an automatic-placement machine (or multiple automatic-placement machines) for surface mounting on board assemblies.

However, these technologies exhibit several limitations. For example, each technology limits the optimum quantity of semiconductor components per square area due to the inherent limits in retaining individual semiconductor components. As another example, each technology limits lateral movement during the manufacturing/testing processes due to the design limitations of individually-punched cavities, which can lead to semiconductor components being inadvertently damaged from handling. Such limitations lead to decreases in capacity/output and increases in costs.

The drawings depict various embodiments for the purpose of illustration only. Those skilled in the art will recognize that alternative embodiments may be employed without departing from the principles of the technology. Accordingly, while specific embodiments are shown in the drawings, the technology is amenable to various modifications.

DETAILED DESCRIPTION

One option for handling, transporting, and storing semiconductor components is a carrier tray. Generally, carrier trays are designed to restrict movement of the semiconductor component(s) installed therein. For example, a carrier tray may include a conical depression designed to support a circular semiconductor wafer on its bottom surface along its outer perimeter with minimum pressure. Each carrier tray is designed for a certain kind of semiconductor component, such as semiconductor wafers which are generally thin and circular. Carrier trays have historically restricted the movement of the semiconductor component(s) installed therein by maintaining physical contact with the semiconductor component(s). For example, the aforementioned carrier tray having the conical depression may secure the circular semiconductor wafer in place with a spring-tensioned cap that encloses the circular semiconductor wafer. The spring-tensioned cap may apply pressure on the top surface of the circular semiconductor wafer along its outer perimeter to counteract the pressure applied on the bottom surface.

However, such an approach requires that the entity responsible for handling, transporting, or storing semiconductor components maintain an inventory of carrier trays having different designs (e.g., a first type of carrier tray for a first type of semiconductor component, a second type of carrier tray for a second type of semiconductor component, etc.). Maintaining the inventory can be burdensome and expensive, especially given that manufacturers have begun producing more types of semiconductor components but smaller quantities of each type of semiconductor component. This increase in personalized manufacture of semiconductor components has prompted entities to begin considering alternative options for handling, transporting, and storing semiconductor components.

Introduced here, therefore, are carrier assemblies designed to address the limitations of conventional carrier trays. The carrier assemblies described herein can include a rigid tray having a deck area with a patterned surface of cavities for receiving semiconductor components. The cavities can be designed to accommodate semiconductor components having different form factors. For example, the cavities may be designed to accommodate semiconductor having different shapes, sizes, etc. Examples of semiconductor components include semiconductor wafers (e.g., singulated wafers or diced wafers), semiconductor dies (e.g., bumped dies or bare dies), and other components used in the fabrication of integrated circuits (ICs). Although embodiments may be described in the context of semiconductor components, those skilled in the art will recognize that the carrier assemblies described herein could be designed to accommodate components to be used in the fabrication of hard disk drives (HDDs), mobile phones, laptop computers, and other electronic devices. As such, the carried assemblies described herein may be designed to accommodate “microelectronic components” or “electronic components” instead of, or in addition to, semiconductor components.

Carrier assemblies may be used to transport semiconductor components between different facilities during the manufacturing process, during the testing process, or between the manufacturing and testing processes. Carrier assemblies could also be used to store semiconductor components within a storage facility before, during, or after such processes. In some embodiments, a carrier assembly may be designed to prevent the semiconductor components installed therein from contacting each other, thereby preventing physical damage resulting from direct contact. Moreover, the carrier assembly may be designed to present the semiconductor components to a manual placement tool or an automatic placement tool (also referred to as a “pick-and-place machine”) for testing, dicing, processing, etc. During a dicing procedure, a semiconductor component (e.g., a wafer) may be diced into multiple pieces, and these pieces may be used in the fabrication of one or more ICs.

Historically, carrier trays have been used in the semiconductor industry for transporting semiconductor components due to their reliability in protecting the semiconductor component(s) installed therein from damage. However, conventional carrier trays exhibit several limitations that restrict their ability to provide adequate protection to sensitive semiconductor components prone to physical damage and/or electrical damage. For example, carrier trays have traditionally been produced via an injection molding process, but an injection-molded carrier tray may inadvertently damage the semiconductor component(s) installed therein due to the external force applied to part(s) of the injection-molded carrier tray in contact with the semiconductor component(s). Moreover, an injection-molded carrier tray may fail to properly dissipate static electricity, which can further damage the semiconductor component(s) due to electrostatic discharge (ESD). Such limitations can lead to damaged semiconductor components, greater transport costs, and lower efficiency in manufacturing, testing, and storing.

To address these limitations, the carrier assemblies described herein can be provided with an adhesive film affixed to the deck area (e.g., through lamination). As further described below, the deck area may have a patterned surface of cavities for receiving semiconductor component(s). Thus, a carrier assembly may include raised wall(s) that extend upwardly from a top surface of the deck area to form void(s) for receiving a semiconductor component. In some embodiments, the adhesive film is bonded along the patterned surface as a single continuous sheet. In such embodiments, the adhesive film may conform to the patterned surface of the deck area. In other embodiments, the adhesive film is only bonded along the raised portions of the patterned surface of the deck area. Semiconductor component(s) can be secured to the carrier assembly based on the adhesion provided by the adhesive film, mechanical force provided the cavities, electrostatic force provided by the cavities, or any combination thereof. Accordingly, proper securement of semiconductor component(s) to a carrier assembly may depend on the tackiness of the constituent material(s) of the adhesive film and/or the design of the cavities.

Semiconductor components can be removed from the cavities (and thus detached from the adhesive film) either manually or automatically. For example, some entities may prefer to manually remove each semiconductor component using a tool such as a high-precision tweezers, while other entities may prefer to automatically remove each semiconductor component using a computer-implemented machine such as a pick-and-place robotic system. Accordingly, the semiconductor components may be readily separated when transported to a manufacturing facility, a testing facility, or a storage facility, though the semiconductor components may remain stable when the carrier assembly is rotated along the x-axis, y-axis, or z-axis.

One object of the technology described herein is to provide a simple carrier assembly for reliably securing semiconductor components of different sizes, shapes, etc. An entity may use the deck area of the carrier assembly as the positioning/seating plane upon which semiconductor component(s) can be secured. Such technology enables the carrier assembly to be rotated and moved, vertically and laterally, without displacing or damaging the semiconductor component(s).

Terminology

References in this description to “an embodiment” or “one embodiment” means that the particular feature, function, structure, or characteristic being described is included in at least one embodiment. Occurrences of such phrases do not necessarily refer to the same embodiment, nor are they necessarily referring to alternative embodiments that are mutually exclusive of one another.

Unless the context clearly requires otherwise, the words “comprise” and “comprising” are to be construed in an inclusive sense rather than an exclusive or exhaustive sense (i.e., in the sense of “including but not limited to”). The terms “connected,” “coupled,” or any variant thereof is intended to include any connection or coupling between two or more elements, either direct or indirect. The coupling/connection can be physical, logical, or a combination thereof. For example, devices may be electrically or communicatively coupled to one another despite not sharing a physical connection.

The term “based on” is also to be construed in an inclusive sense rather than an exclusive or exhaustive sense. Thus, unless otherwise noted, the term “based on” is intended to mean “based at least in part on.”

When used in reference to a list of multiple items, the word “or” is intended to cover all of the following interpretations: any of the items in the list, all of the items in the list, and any combination of items in the list.

The sequences of steps performed in any of the processes described herein are exemplary. However, unless contrary to physical possibility, the steps may be performed in various sequences and combinations. For example, steps could be added to, or removed from, the processes described here. Similarly, steps could be replaced or reordered. Thus, descriptions of any processes are intended to be open-ended.

Technology Overview

FIG.1Adepicts an example of a carrier assembly100that includes a structural body102having a patterned deck area104that is at least partially covered by an adhesive film106. As further described below, the carrier assembly100can be designed to handle semiconductor components of different sizes (e.g., different heights, widths, lengths, etc.), different shapes, etc. Said another way, the carrier assembly100can be designed to accommodate semiconductor components having different form factors. Accordingly, the carrier assembly100may be able to simultaneously or sequentially accommodate semiconductor components designed for different fabrication plants, processes, electronic devices, etc. The patterned deck area104of the carrier assembly100can be designed to maximize the density of semiconductor components for more efficient transporting, storing, etc.

In some embodiments, the carrier assembly100is designed to be compliant with Joint Electron Device Engineering Council (JEDEC), which sets standards for electrostatic discharge, handling, packing, and shipping of surface-mount devices. To comply with various standards, the carrier assembly100may be comprised of certain materials, manufactured in certain shapes/sizes, etc. Additional information on standards can be found in the related publications as maintained by JEDEC, an organization responsible for developing open standards for the microelectronics industry.

The shape and/or size of the structural body102may also be adapted to suit particular manufacturing, transportation, or storage needs. In some embodiments, the carrier assembly100includes a rectangular structural body102. In other embodiments, the carrier assembly100includes a non-rectangular structural body in the form of, for example, a square, a parallelogram, an ellipse, etc. The size and/or shape of the structural body102may be based on, for example, the design of the semiconductor component(s) to be installed therein or a container in which the carrier assembly100is to be placed. For example, rectangular structural bodies may be used in combination with containers having rectangular cavities, which are commonly used in the semiconductor industry. As another example, non-rectangular structural bodies may be used in combination with containers having non-rectangular cavities (e.g., clamshell-type containers).

In some embodiments, the structural body102includes an outer edge108that defines the periphery of the carrier assembly100and an inner edge110that defines the periphery of the deck area104. The outer edge108may extend along the entire outer periphery of the carrier assembly100in an uninterrupted manner. The inner edge110, meanwhile, may be substantially parallel to the outer edge108. Together, the outer edge108and the inner edge110may define opposing edges of a rim that extends upward from the top surface of the deck area104. The rim may extend around at least a portion of the deck area104. Here, for example, the rim extends around the entire periphery of the deck area104of the structural body102. Note, however, that the rim could include interlock component(s) to facilitate connections between adjacent carrier assemblies. When a semiconductor component is set within the deck area104of the structural body102, the top surface of the deck area104may be substantially parallel to the bottom surface of the semiconductor component and substantially perpendicular to the outer edge of the semiconductor component. In some embodiments the rim sidewall defined by the inner edge110is substantially orthogonal to the bottom surface of the structural body102, while in other embodiments the rim sidewall defined by the inner edge110has a pitch (i.e., is angled).

Generally, the structural body102is comprised of a rigid material, such as a molded plastic or molded resin. Examples of such materials include polyethylene thermoplastics, polypropylene, polycarbonate, ethylene chlorotrifluoroethylene (ECTFE), and other materials suitable for creating injection-molded objects. In some embodiments, however, the structural body102is comprised of a pliable material (e.g., to better absorb external forces). Examples of such materials include elastomers, such as silicone rubber, and polyurethane thermoplastics. Additionally or alternatively, the structural body102may be comprised of a conductive material, such as silver, copper, aluminum, or a ceramic. In some embodiments the structural body102is comprised of a single material, while in other embodiments the structural body102is comprised of multiple materials. For example, the structural body102may be comprised of multiple materials that are mixed together prior to molding into its final form. As another example, the structural body102may be created using a first material able to resist physical damage and a second material (also referred to as an “anti-static material” or a “static-dissipative material”) able to facilitate the dissipation of collected electricity. The second material may be sprayed onto the surface of the first material, adhered to the first material, or otherwise incorporated into the first material (e.g., during the manufacturing process).

As further described below, the structural body102may be comprised of material(s) known to be suitable for injection molding with the goal of producing a carrier assembly100that is resistant to moisture and/or electricity (e.g., to prevent static electricity collection and electrostatic discharge). For example, the structural body102may include a thermoformable material that, when cured (e.g., by heat, air, or radiation), forms a resilient material capable of protecting semiconductor components from physical damage and an anti-static material or a static-dissipative material.

In some embodiments the adhesive film106is laminated along a portion of the deck area104, while in other embodiments the adhesive film106is laminated along the entirety of the deck area104(e.g., as a single continuous sheet). As shown inFIGS.1A-B, the deck area104may have a patterned surface of cavities114for receiving semiconductor component(s). In some embodiments, the adhesive film106conforms to the patterned surface. Said another way, the adhesive film106may be secured to the entire patterned surface of the deck area104. In other embodiments, the adhesive film106is only bonded along the raised portions of the patterned surface. The adhesive film106may include one or more adhesive sheets. For example, in some embodiments, the adhesive film1056includes multiple adhesive sheets that are interconnected such that electrical current is able to flow between the adhesive sheets.

In addition to the cavities114, the structural body102could include one or more perforations in the deck area104, rim, or any combination thereof. These perforation(s) may permit air to circulate through the structural body102, as well as allow an individual to see through the structural body102.

The adhesive film106may be adhesive along both sides. That is, the adhesive film106may have a first adhesive side in contact with the deck area104and a second adhesive side in contact with the bottom surface(s) of the semiconductor component(s) secured to the carrier assembly100within the deck area104. In some embodiments, the adhesive film106is only adhesive along a single side (e.g., the outward-facing side to which semiconductor component(s) are secured). In such embodiments, the carrier assembly100may include one or more fastening mechanism arranged to hold the adhesive film104against the top surface of the deck area102. The fastening mechanism(s) may include clasps, clips, tabs, brackets, or any combination thereof.

As shown inFIG.1B, the deck area104may include a series of cavities114, each of which is designed to hold a separate semiconductor component. As further described below, the cavities114can be arranged in a geometric pattern that allows the carrier assembly100to accommodate semiconductor components having different form factors. Such a design allows an entity to use the carrier assembly100for semiconductor components manufactured in different batches, designed by different clients, designed for different products, etc. In some embodiments each cavity includes a different adhesive film, while in other embodiments a single adhesive film overlays all of the cavities114. Moreover, in some embodiments, only a subset of the cavities114may include an adhesive film. For example, inFIG.4B, the deck area104includes a set of larger cavities and a set of smaller cavities. An entity may discover that the adhesive film is only needed to secure semiconductor component(s) within the larger cavities.

The adhesive film106may be sized in such a manner to restrict subsequent movement. For example, the adhesive film106may be secured along at least a portion of the sidewall defined by the inner edge110. Alternatively, the adhesive film106may be cut such that it does not contact the sidewall defined by the inner edge110. Thus, the adhesive film106may only be in contact with the deck area104of the structural body102.

The adhesive film106can be comprised of any suitable adhesive material having sufficient tackiness. For example, the adhesive film106may be comprised of a polymer-based adhesive. The adhesive film106can be mounted to the structural body102such that the adhesive film106is laminated along the entirety of the top surface of the deck area104(including any cavities, such as pre-formed, JEDEC-compliant punched cavities). In other embodiments, the adhesive film106may itself include cavities (also referred to as “depressions”) designed to receive semiconductor component(s). For example, the adhesive film106may include raised circular depression(s) designed to receive circular semiconductor components, raised rectangular depression(s) to receive rectangular semiconductor components, or any combination thereof. In such embodiments, the adhesive film106can be affixed within a void along the top surface of the deck area104.

The adhesive film106(also referred to as a “film tape”) can be affixed to the deck area104as a single continuous sheet without any breaks. This can be done in several different ways, including via a lamination process, a spray process, or a co-extrusion process. In some embodiments, a top cover (not shown) is affixed to the top surface of the adhesive film106. The top cover may be removed from the top surface of the adhesive film106before semiconductor component(s) are affixed to the adhesive film106(and thus to the carrier assembly100). Those skilled in the art will recognize that the top cover may not always be present. For example, the top cover may be unnecessary if semiconductor component(s) are to be secured to the adhesive film106soon after the adhesive film106is affixed to the deck area104.

The carrier assembly100may also include one or more carrier components112. Each carrier component112, which may be arranged along the outer edge108of the structural body102, may be designed to allow for easier transportation of the carrier assembly100. For example, carrier component(s)112may be arranged along opposing sides of the carrier assembly100to allow it (as well as any other carrier assemblies to which it is connected) to be transported with greater ease and efficiency. Each carrier component112may be formed into a shape that can be readily held (e.g., by an individual or a machine). Examples of such shapes include rectangular tabs/handles, semicircular tabs/handles, etc. More specifically, each carrier component112could include a handle, a latch, a tab, or some other known mechanism for assisting in the transport of the carrier assembly100. In some embodiments the carrier component(s)112are separately engaged to the structural body102, while in other embodiments the structural body102and the carrier component(s)112form a single monolithic component.

FIG.2illustrates a vertical section view of the carrier assembly100taken along line B ofFIG.1A. As noted above, an adhesive film106can be integrally mounted along the surface of the carrier assembly100within the deck area104. The adhesive film106may be secured to the carrier assembly100such that the adhesive film106is substantially flush with the deck area104. As shown inFIG.1B, however, the adhesive film106may conform to any cavities formed within the deck area104.

FIG.3illustrates a horizontal sectional view of the carrier assembly100taken along line A ofFIG.1A. As noted above, the carrier assembly100may include a rim302that extends around at least a portion of the periphery of the deck area104in which semiconductor component(s) are secured. In some embodiments, the rim302includes interlock component(s) to facilitate connections between adjacent carrier assemblies. As shown inFIG.3, the interlock component(s) can include protruding features304and/or indentations306designed to complement the protruding features of an upwardly-adjacent carrier assembly or a downwardly-adjacent carrier assembly. These interlock component(s) can be arranged along the planar surface of the rim302, the underside of the structural body102, or any combination thereof.

The interlock component(s) may also make the carrier assembly100more suitable for future processes. For example, when the carrier assembly100is used for storage or transport, it may be beneficial to stack a series of carrier assemblies on top of one another. Therefore, having a mechanical feature that naturally acts as a passive locking mechanism would ensure that these carrier assemblies do not move in such a manner that would damage the semiconductor components installed therein. While the interlock component(s) represent passive locking mechanisms, those skilled in the art will recognize that more active locking mechanisms could also be used. For example, each carrier assembly may include a latch that can be used to secure it to another carrier assembly. As another example, when a mechanical device is needed to remove the semiconductor component(s) from the carrier assembly100, the interlock component(s) may serve as a support structure capable of mechanically interfacing with the mechanical device. For instance, a robotic arm may use an indentation for balancing, a protruding feature for positional reference, etc.

In some embodiments, the planar surface of the rim302is substantially co-planar with the top surface of the semiconductor component(s) secured within the carrier assembly100. Thus, the height of the rim302may be based on the thickness of the semiconductor components expected to be installed within the carrier assembly100. In other embodiments, the planar surface of the rim302is higher than the top surface of the semiconductor component(s) secured within the carrier assembly100. Since the carrier assembly100may be designed to accommodate semiconductor components of different form factors, the height of the rim302may be greater than the thickest semiconductor component expected to be secured to the deck area104. Such a design causes a space to be formed between the top surface of each semiconductor component and the bottom surface of an upwardly-adjacent carrier assembly, which may limit the likelihood that the semiconductor component suffers damage due to an external force applied by the upwardly-adjacent carrier assembly.

FIG.4includes an exploded view of multiple carrier assemblies400a-bstacked for handling, transporting, and/or storing semiconductor components. A first interlock component402disposed along the top surface of one carrier assembly400bcan be designed to interface with a second interlock component404disposed along the bottom surface of another carrier assembly400awhen the carrier assemblies400a-bare brought within close proximity of one another.

Each carrier assembly400a-bincludes a top surface406a-band a bottom surface408a-b. The top surface406a-bmay be defined by the planar surface of the uppermost point of the carrier assembly400a-b. For example, the top surface406a-bmay correspond to the planar surface of the rim (i.e., while ignoring any indentations). The bottom surface408a-bmay be defined by the planar surface of the lowermost point of the carrier assembly400a-b. In some embodiments the lowermost point of the carrier assembly400a-bis the bottom surface of the structural body, while in other embodiments the lowermost point of the carrier assembly400a-bis the planar surface of an interlock component (e.g., a downwardly-extending protruding feature).

As shown inFIG.4, the bottom surface of each carrier assembly may include interlock component(s) designed to engage with complementary interlock component(s) of a downwardly-adjacent carrier assembly. Similarly, the top surface of each carrier assembly may include interlock component(s) designed to engage with complementary interlock component(s) of an upwardly-adjacent carrier assembly. Together, these interlock component(s) enable adjacent carrier assemblies to be mechanically coupled to each other without increasing the risk of harming the semiconductor component(s) stored therein.

There are at least two different types of interlock components402,404. A first type of interlock component extends away from a reference surface. Examples of the first type of interlock component include protrusions, projections, pins, etc. A second type of interlock component is designed to receive an interlock component of the first type. Examples of the second type of interlock component include notches, slots, recesses, etc.

Generally, the first interlock component402and the second interlock component404are different types of interlock components. Here, for example, the first interlock component402is an interlock component of the first type (e.g., a protrusion), while the second interlock component is an interlock component of the second type (e.g., a notch). Accordingly, the first interlock component402can engage a corresponding interlock component of the second type on an upwardly-adjacent carrier assembly, while the second interlock component404can engage a corresponding interlock component of the first type on a downwardly-adjacent carrier assembly.

While the interlock components shown inFIG.4extend around the entirety of the top surfaces406a-band bottom surfaces408a-bof the carrier assemblies400a-b, those skilled in the art will recognize that other designs are also possible. In some embodiments, each carrier assembly400a-bincludes a single interlock component along the top surface406a-band bottom surface408a-b. For example, each carrier assembly400a-bmay include a notched rim that allows the bottom surface of a given carrier assembly to nest within the top surface of a downwardly-adjacent carrier assembly. In such embodiments, the structural body may have no deformities (e.g., notches) visible from the side. In other embodiments, each carrier assembly400a-bincludes multiple interlock components (e.g., one, two, four, or eight) arranged along the top surface406a-band/or bottom surface408a-b. These interlock component(s) can be positioned in different arrangements. For example, each carrier assembly400a-bcould include a pair of interlock components of the first type on opposing sides of the top surface406a-band a pair of interlock components of the second type on opposing sides of the bottom surface408a-b. As another example, each carrier assembly400a-bcould include four interlock components equally distributed along the top surface406a-band four interlock components equally distributed along the bottom surface408a-b. To allow for easier stacking, the number of interlock component(s) along the top surface406a-band the bottom surface408a-bare usually the same.

FIG.5includes a top plan view of a carrier assembly500that includes a deck area502on which an adhesive film504has been affixed. In some embodiments, the adhesive film504is bonded along the deck area502as a single continuous sheet. In such embodiments, the adhesive film504may conform to the cavities506formed along the deck area502. In other embodiments, the adhesive film504is only bonded along the raised portions of the deck area502. For example, if each cavity is defined by a wall that extends upwardly from the deck area, the adhesive film504may also be applied along the top surface of the wall.

In some embodiments, the adhesive film504is affixed to the deck area502using securement mechanism(s)508configured to grasp the adhesive film504. For example, a series of securement mechanisms508designed to pinch the adhesive film504may be arranged along a periphery of the deck area502. Examples of securement mechanisms include components that operate like paperclips, clamps, or binder clips. In some embodiments, the adhesive film504is integrally secured along a central mounting portion of the carrier assembly500such that the adhesive film504conforms to the deck area502as defined by the inner edge512.

The surface adhesion (also referred to as “tackiness”) of the adhesive film504can hold the semiconductor component(s) in place as the carrier assembly500is moved. For example, the adhesive film504can hold the semiconductor component(s) in a specified orientation during handling/transport/storage and while the semiconductor component(s) are separated/detached (e.g., manually or automatically) during a manufacturing process or a testing process. The adhesive film504can ensure that the semiconductor component(s) do not substantially move when the carrier assembly500is rotated along the x-axis, y-axis, or z-axis, or moved vertically/horizontally with respect to, for example, an automatic-placement machine.

As shown inFIG.5, the adhesive film504can be affixed to the deck area502in a single continuous sheet along the entire length of the carrier assembly500. That is, the adhesive film504can be affixed along the entire length of the carrier assembly500including the cavities506. In some embodiments, the adhesive film504is comprised of multiple interconnected sheets. For example, a matrix of adhesive sheets can be electrically coupled by wiring or mechanically coupled by the same material as the adhesive sheets.

Generally, the adhesive film504does not cover the side portions disposed along the outer edge510of the carrier assembly500. Said another way, the adhesive film504will typically not extend up the sidewall of the rim as defined by the inner edge512. However, in some embodiments, the adhesive film504does at least partially cover the sidewalls of the rim extending around the deck area502. With the adhesive film504, the carrier assembly500can be used to universally transport media (e.g., singulated silicon components or silicon die of the same or different sizes) as necessary for manufacturing, shipping, and/or storing.

FIG.6Aincludes a sectional view of a cavity602formed along the top surface of a rigid tray604. As shown inFIG.6A, the cavity602may be defined by raised walls606that extend upwardly from the top surface of the rigid tray604to form a void. To affix a semiconductor component to the rigid tray, a protruding feature of the semiconductor component may be secured within the cavity602. An adhesive film608can be bonded along the top surface of the rigid tray604to assist in securing the semiconductor component. In some embodiments, the adhesive film608conforms to the top surface of the rigid tray604, as shown inFIG.6A.

In other embodiments, however, the adhesive film is not perfectly flush with the deck area of the rigid tray.FIG.6Bincludes another sectional view of a cavity652formed along the top surface of a rigid tray654. Similar to the cavity602ofFIG.6A, the cavity652may be defined by raised walls656that extend upwardly from the top surface of the rigid tray654. Here, however, the adhesive film658does not conform to the top surface of the rigid tray654. Instead, the adhesive film658can extend across the cavity652. Such a design allows a protruding feature disposed along the outer surface of a semiconductor component to pierce the adhesive film658when interconnected with the cavity652.

While the sidewalls of the cavities602,652ofFIGS.6A-Bare shown to be substantially orthogonal to the top surface of the rigid tray604,654, those skilled in the art will recognize that need not be the case. For example, the sidewalls may be tapered inward (e.g., to form a truncated cone with its upper/narrower radius oriented downwards) or outward (e.g., to form a truncated cone with its upper/narrower radius oriented upwards).

FIG.7includes a top plan view of a carrier assembly700showing how an adhesive film702can be bonded to the top surface of a deck area704set within a rim706that extends around a periphery of the carrier assembly700. To simplify the top plan view, the deck area704has been shown without the cavities for receiving semiconductor components. In some embodiments the adhesive film702covers the entire deck area704, while in other embodiments the adhesive film702covers a portion of the deck area704. Here, for example, a portion of the deck area704is left uncovered to form a non-adhesive border. Together with the non-adhesive rim706, the non-adhesive border may permit the carrier assembly700to be more easily handled. In some embodiments, the adhesive film702(or at least a portion thereof) may be removable from the deck area704.

As noted above, the deck area of a carrier assembly may have a patterned surface of cavities designed to receive semiconductor components of various form factors.FIGS.8A-Cdepict several different geometric arrangements of cavities. To form the cavities, raised wall(s) can extend upwardly from the top surface of the deck area. However, as shown inFIGS.8A-C, these raised wall(s) can be various shapes and sizes.

In some embodiments, each cavity is defined by a separate raised wall that forms a void for receiving a protruding feature of a semiconductor component. Generally, these cavities are arranged such that semiconductor components installed in a non-overlapping manner maintain a spacing of at least 0.5 millimeters (mm), 1.0 mm, 1.5 mm, etc.

FIG.8Adepicts a symmetric, repeating pattern of raised walls. While the raised walls shown here are in the shape of an annulus, those skilled in the art will recognize that other shapes (e.g., ellipses, rectangles, squares) may be appropriate in some instances.

FIG.8Bdepicts a symmetric, repeating pattern of cavities formed by a single branching wall. InFIG.8B, the branching wall extends upwardly from the top surface of the deck area to form a series of interconnected voids that define the cavities.

FIG.8Cdepicts a pattern of cavities formed by a series of parallel raised walls. Each pair of raised walls forms an elongate cavity (also referred to as a “trough”) in which the protruding feature of a semiconductor component can be secured. In comparison to the cavities shown inFIGS.8A-B, the trough provides greater flexibility in where semiconductor component(s) are secured.

When a semiconductor component is affixed within a given cavity shown inFIGS.8A-C, a portion of the lower surface of the semiconductor component may contact the upper surface of at least one raised wall. In some embodiments, the raised walls are designed/arranged such that the portion of the lower surface, when measured in terms of percentage of the total lower surface of the semiconductor component, remains roughly consistent across different sizes of semiconductor components. The term “roughly consistent” means within about ten percent.

In some embodiments the pattern includes a single cavity design, while in other embodiments the pattern includes multiple cavity designs. For example, the pattern may include cavities having the same shape (e.g., an annulus) but different dimensions, as shown inFIG.8A. As another example, the pattern may include cavities having different shapes (e.g., an annulus and a rectangle). While the branching wall shown inFIG.8Bhas produced a series of rectangular cavities, those skilled in the art will recognize that the branching wall could produce cavities in various shapes, sizes, etc.

As noted above, an adhesive film may conform to the patterned surface of cavities in some embodiments. In other embodiments, the adhesive film is only bonded along the raised portions of the patterned surface of cavities. For example, the adhesive film may only be affixed to the top surface of the branching wall shown inFIG.8B. Semiconductor component(s) can be secured within the cavities based on adhesiveness provided by the adhesive film, mechanical force provided the cavities, electrostatic force provided by the cavities, or any combination thereof. Accordingly, proper securement of the semiconductor component(s) to the carrier assembly may depend on the tackiness of the constituent material(s) of the adhesive film and/or the design of the cavities.

FIG.9is a flowchart of a process900for transporting semiconductor component(s) using the carrier assemblies described herein. Initially, an individual receives semiconductor component (step901) that requires transport, storage, etc. Examples of semiconductor components include semiconductor wafers (e.g., singulated wafer or diced wafer), semiconductor dies (i.e., bumped die or bare die), and other electronic components used in the fabrication of integrated circuits (ICs). While the process900is described in the context of semiconductor components, those skilled in the art will recognize that the carrier assembly could additionally or alternatively be designed to handle, transport, and/or store components used in the fabrication of HDDs, mobile phones, laptop computers, and other electronic devices.

Thereafter, the individual can cause the semiconductor component to be secured within a cavity accessible along the top surface of a carrier assembly (step902). For example, the individual may manually secure the semiconductor component within the cavity or prompt an automatic-placement machine to secure the semiconductor component within the cavity. Generally, the carrier assembly includes an adhesive film that includes a tacky upper surface for securing the semiconductor component to the carrier assembly. However, in some embodiments, the semiconductor component is secured to the carrier assembly solely though mechanical force applied by the cavity, electrostatic force applied by the cavity, or any combination thereof. The cavity may be one of multiple cavities arranged in a matrix pattern designed to maximize density of semiconductor components along the deck area of the carrier assembly. For example, the individual may secure the semiconductor component in a predetermined location with respect to other semiconductor components secured to the carrier assembly.

The carrier assembly can then be transported to a desired location (step903). During transport, the carrier assembly can be moved along the x-axis, y-axis, or z-axis without substantially moving or damaging the semiconductor component. Upon receipt of the carrier assembly by a recipient (e.g., an IC manufacturer), the semiconductor component can be removed by simply overcoming the surface tackiness provided by the adhesive film, mechanical force provided the cavities, and/or electrostatic force provided by the cavities (step904). Removal may be done manually (e.g., by a human hand) or automatically (e.g., by an automatic-placement machine).

FIG.10is a flowchart of a process1000for manufacturing the carrier assemblies described herein. Initially, a manufacturer can acquire an injection-molded tray (step1001). In some embodiments, rather than acquire the injection-molded tray, the manufacturer creates the tray via an injection molding process. Generally, the injection-molded tray is comprised of a rigid material, such as a molded plastic or molded resin. Examples of such materials include polyethylene thermoplastics, polypropylene, polycarbonate, ECTFE, and other materials suitable for creating injection-molded objects. In some embodiments, however, the injection-molded tray is comprised of a pliable material (e.g., to better absorb external forces). Examples of such materials include elastomers, such as silicone rubber, and polyurethane thermoplastics. Additionally or alternatively, the injection-molded tray may be comprised of a conductive material, such as silver, copper, aluminum, or a ceramic. In some embodiments the injection-molded tray is comprised of a single material, while in other embodiments the injection-molded tray is comprised of multiple materials. For example, the injection-molded tray may be comprised of multiple materials that are mixed together prior to molding into its final form. As another example, the injection-molded tray may be created using a first material able to resist physical damage and a second material (also referred to as an “anti-static material” or a “static-dissipative material”) able to facilitate the dissipation of collected electricity. The second material may be sprayed onto the surface of the first material, adhered to the first material, or otherwise incorporated into the first material (e.g., during the manufacturing process).

The manufacturer can then form a series of cavities within a deck area accessible along the top surface of the injection-molded tray (step1002). This can be done in several different ways. In some embodiments, raised wall(s) are produced during the injection molding process. In such embodiments, the raised wall(s) and tray may form a single monolithic component. In other embodiments, raised wall(s) are added to the injection-molded tray within the deck area. For example, the manufacturer may secure the raised wall(s) to the injection-molded tray using an adhesive, mechanical connectors (e.g., screws and nuts), or any combination thereof.

The manufacturer can then secure an adhesive film to at least a portion of the deck area (step1003). For example, the adhesive film may be affixed to the entirety of the deck area as a single continuous (i.e., unbroken sheet). This can be done in several different ways, including via a lamination process, a spray process, or a co-extrusion process. In some embodiments, the adhesive film is secured against the deck area using securement mechanism(s), such as clasps, clips, tabs, brackets, or any combination thereof. The adhesive film may have sufficient bonding strength such that is can be integrally mounted into any cavities formed in the deck area. Alternatively, the adhesive film may be bonded to the deck area such that it extends across each cavity. In such embodiments, a void may be formed within the cavity beneath the adhesive film, as shown inFIG.6B.

The adhesive film may be activatable with ultraviolet (UV) radiation, heat, air, time, or any combination thereof. For example, after securing a semiconductor component within a cavity (and thus affixing the semiconductor component to the adhesive film), the carrier assembly may be exposed to a curing mechanism designed to emit UV radiation, heat, or air.

In some embodiments, the manufacturer causes static electricity to be discharged from the injection-molded tray (step1004). For example, the manufacturer may discharge static electricity from the injection-molded tray by initiating contact with a grounded object. As another example, the manufacturer may discharge static electricity from the injection-molded tray by installing object(s), such as a ground plane, that will facilitate the discharge. Discharging static electricity reduces the likelihood of harming any semiconductor components stored in the carrier assembly due to static shock or electricity otherwise passing through when it should not.

Thereafter, the manufacturer can allow a semiconductor component to be secured within the cavity (step1005). Semiconductor components may utilize the mechanical force and/or electrostatic force provided by the cavities, as well as the surface energy and/or tackiness of the adhesive film for seating semiconductor components at a certain density (e.g., a maximum continuous density) along the deck area of the carrier assembly. The semiconductor component may include a protruding feature designed to mate with the cavity formed in the deck area of the carrier assembly. As noted above, in some embodiments, the protruding feature may puncture the adhesive film as it enters the cavity.

Unless contrary to physical possibility, it is envisioned that the steps described above may be performed in various sequences and combinations. For example, the manufacturer may acquire an injection-molded tray that already includes an adhesive film. Therefore, in some instances the manufacturer may only need to secure semiconductor component(s) within the cavities formed in the deck area of the carrier assembly, and then provide the carrier assembly to another entity (e.g., a manufacturer of ICs).

Additional steps could also be included in some embodiments. For example, after the semiconductor component(s) have been secured within the cavities, a cover tape may be applied to hold the semiconductor component(s) in place. The cover tape may only be used in certain situations (e.g., long-distance transport or long-term storage) where the carrier assembly is expected to undergo bumping, shaking, etc.

Remarks

Although the Detailed Description describes certain embodiments and the best mode contemplated, the technology can be practiced in many ways no matter how detailed the Detailed Description appears. Embodiments may vary considerably in their implementation details, while still being encompassed by the specification. Particular terminology used when describing certain features or aspects of various embodiments should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the technology with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the technology to the specific embodiments disclosed in the specification, unless those terms are explicitly defined herein. Accordingly, the actual scope of the technology encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the embodiments.