Abstract:
A removal apparatus for a semiconductor chip may include a stage configured to support a board on which the semiconductor chip is mounted by bumps, a laser configured to irradiate a laser beam into the board over an area larger than the semiconductor chip, and a picker configured to cause the laser beam to penetrate the semiconductor chip locally and to separate the semiconductor chip from the board. A method of removing a semiconductor chip from a board may include loading the board, on which the semiconductor chip is mounted by bumps, on a stage; irradiating a laser beam into the semiconductor chip to melt the bumps and to separate the semiconductor chip from the board; continuously irradiating the laser beam into the board on which solder pillars, that are residues of the bumps, remain to melt the solder pillars; and removing the solder pillars.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
       [0001]    This application is a divisional of U.S. application Ser. No. 14/632,657 filed on Feb. 26, 2015; which is a divisional of U.S. application Ser. No. 13/527,777 filed Jun. 20, 2012; which claims priority from Korean Patent Application No. 10-2011-0066942, filed on Jul. 6, 2011, in the Korean Intellectual Property Office (KIPO), the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Example embodiments relate to semiconductor manufacturing apparatuses and/or methods of manufacturing semiconductors. Example embodiments may relate to an apparatuses for removing failed semiconductor chips from boards and/or methods of removing failed semiconductor chips from boards. 
         [0003]    Recently, the demand for a board manufactured by a flip chip method among printed circuit boards (PCB) is increasingly growing. The board manufactured by a flip chip method is a board of which a functional characteristic and an electrical characteristic are improved by connecting a semiconductor chip and a board with a solder bump replacing an existing wire. The board manufactured by a flip chip method may be shipped after goods pass the installation test which is one of module processes. The goods which failed to pass the installation test may be repaired after a failed semiconductor chip is removed from the board. However, a conventional technique of removing a failed semiconductor chip is not standardized and depends on a manual labor of an engineer. 
       SUMMARY 
       [0004]    Example embodiments may provide removal apparatuses for semiconductor chips. Example embodiments also may provide methods of removing semiconductor chips from boards. 
         [0005]    In some example embodiments, a removal apparatus for a semiconductor chip may include a stage configured to support a board on which the semiconductor chip is mounted by bumps, a laser configured to irradiate a laser beam into the board over an area larger than the semiconductor chip, and/or a picker configured to cause the laser beam to penetrate the semiconductor chip locally and to separate the semiconductor chip from the board. 
         [0006]    In some example embodiments, the picker may include a lens configured to focus the laser beam on the semiconductor chip. 
         [0007]    In some example embodiments, the removal apparatus may further include a vacuum portion configured to provide a vacuum to the picker. 
         [0008]    In some example embodiments, the picker may further define an open hole configured to draw the semiconductor chip using the vacuum provided from the vacuum portion and/or to cause the laser beam focused by the lens to penetrate the semiconductor chip. 
         [0009]    In some example embodiments, the picker may further define an open hole configured to draw the semiconductor chip using the vacuum provided from the vacuum portion and/or to cause the laser beam focused by the lens to penetrate the semiconductor chip. 
         [0010]    In some example embodiments, the removal apparatus may further include a drive portion configured to move the picker and the intake around the stage. 
         [0011]    In some example embodiments, the removal apparatus may further include an air knife configured to blow high temperature air on the solder pillars. 
         [0012]    In some example embodiments, the removal apparatus may further include a coining plate configured to compress the solder pillars. 
         [0013]    In some example embodiments, the removal apparatus may further include a nozzle configured to spray flux on the solder pillars. 
         [0014]    In some example embodiments, the removal apparatus may further include a loader configured to load the board on the stage and/or an unloader configured to unload the board from the stage. 
         [0015]    In some example embodiments, the removal apparatus may further include a semiconductor chip recognition portion configured to recognize the semiconductor chip on the board. 
         [0016]    In some example embodiments, an apparatus for removing a semiconductor chip from a board may include a laser configured to irradiate the board with a laser beam to heat bumps mounting the semiconductor chip on the board and/or a picker configured to separate the semiconductor chip from the board. 
         [0017]    In some example embodiments, the laser beam may be configured to irradiate the board over a first area of the board that is larger than the semiconductor chip. 
         [0018]    In some example embodiments, the apparatus may further include a vacuum portion configured to provide a vacuum to the picker. 
         [0019]    In some example embodiments, the picker may define an open hole configured to draw the semiconductor chip using the vacuum provided from the vacuum portion. 
         [0020]    In some example embodiments, the picker may include a lens configured to focus the laser beam on the semiconductor chip. 
         [0021]    In some example embodiments, the lens may be configured to focus the laser beam on a second area of the board that is smaller than the semiconductor chip. 
         [0022]    In some example embodiments, the lens may be configured to focus the laser beam to heat the bumps mounting the semiconductor chip on the board. 
         [0023]    In some example embodiments, the apparatus may further include a vacuum portion configured to provide a vacuum to the picker. 
         [0024]    In some example embodiments, the picker may further define an open hole drawing the semiconductor chip using the vacuum provided from the vacuum portion and/or the lens may be configured to focus the laser beam to heat the bumps mounting the semiconductor chip on the board. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    The above and/or other aspects and advantages will become more apparent and more readily appreciated from the following detailed description of example embodiments, taken in conjunction with the accompanying drawings, in which: 
           [0026]      FIG. 1  is a top plan view illustrating a removal apparatus of semiconductor chip in accordance with some example embodiments; 
           [0027]      FIG. 2  is a cross-sectional view illustrating a laser and a chip picker illustrated in  FIG. 1 ; 
           [0028]      FIG. 3  is a top plan view illustrating a second exposure area of a laser beam illustrated in  FIG. 2 ; 
           [0029]      FIG. 4  is a cross-sectional view illustrating a laser and an intake illustrated in  FIG. 1 ; 
           [0030]      FIG. 5  is a top plan view illustrating a first exposure area of a laser beam illustrated in  FIG. 4 ; 
           [0031]      FIG. 6  is a cross-sectional view illustrating a laser and a coining unit illustrated in  FIG. 1 ; 
           [0032]      FIG. 7  is a cross-sectional view illustrating a laser and a flux nozzle illustrated in  FIG. 1 ; and 
           [0033]      FIG. 8  is a flow chart illustrating a method of removing a semiconductor chip in accordance with some example embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    Example embodiments will now be described more fully with reference to the accompanying drawings. Embodiments, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope to those skilled in the art. In the drawings, the thicknesses of layers and regions may be exaggerated for clarity. 
         [0035]    It will be understood that when an element is referred to as being “on,” “connected to,” “electrically connected to,” or “coupled to” to another component, it may be directly on, connected to, electrically connected to, or coupled to the other component or intervening components may be present. In contrast, when a component is referred to as being “directly on,” “directly connected to,” “directly electrically connected to,” or “directly coupled to” another component, there are no intervening components present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0036]    It will be understood that although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, and/or section from another element, component, region, layer, and/or section. For example, a first element, component, region, layer, and/or section could be termed a second element, component, region, layer, and/or section without departing from the teachings of example embodiments. 
         [0037]    Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like may be used herein for ease of description to describe the relationship of one component and/or feature to another component and/or feature, or other component(s) and/or feature(s), as illustrated in the drawings. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. 
         [0038]    The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
         [0039]    Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
         [0040]    Reference will now be made to example embodiments, which are illustrated in the accompanying drawings, wherein like reference numerals may refer to like components throughout. 
         [0041]      FIG. 1  is a top plan view illustrating a removal apparatus of semiconductor chip in accordance with some example embodiments.  FIG. 2  is a cross-sectional view illustrating a laser and a chip picker illustrated in  FIG. 1 .  FIG. 3  is a top plan view illustrating a second exposure area of a laser beam illustrated in  FIG. 2 .  FIG. 4  is a cross-sectional view illustrating a laser and an intake illustrated in  FIG. 1 .  FIG. 5  is a top plan view illustrating a first exposure area of a laser beam illustrated in  FIG. 4 . 
         [0042]    Referring to  FIGS. 1 through 5 , a removal apparatus of semiconductor chip in accordance with some example embodiments of the inventive concept may heat a semiconductor chip  70  and solder pillars  82  using a laser beam  22  from a laser  20  and may melt solder bumps  80  under the semiconductor chip  70  and the solder pillars  82 . The laser beam  22  may be focused on the semiconductor chip  70  by a lens  33  of a picker  34 . The laser beam  22  may heat locally the semiconductor chip  70 . The solder bumps  80  are melted by thermal energy of the laser beam  22 . The semiconductor chip  70  may be removed from the board  60  by the picker  34 . Semiconductor chip  70  may include first exposure area  24  and/or second exposure area  26 . 
         [0043]    The board  60  may be exposed to the laser beam  22 . A board  60  may not be damaged by the laser beam  22  when the solder bumps  80  are melted. The board  60  may be widely heated by the laser beam  22  having smaller thermal energy density than when the laser beam  22  heats the semiconductor chip  70 . Also, the thermal damage of the board  60  is minimized when the solder pillars  82  are melted by laser beam  22 . 
         [0044]    Thus, the removal apparatus of semiconductor chip in accordance with some embodiment of the inventive concept may increase or maximize productivity and production yield. 
         [0045]    The semiconductor chips  70  may be mounted on the board in a flip chip method. The semiconductor chips  70  may include a wafer level package. The semiconductor chips  70  may include a normal semiconductor chip such as a known good die and a failed semiconductor chip. Although not illustrated in the drawing, a failed semiconductor chip may include an index such as a marking or a bar code formed on a top surface thereof. The semiconductor chip  70  separated or removed from the board  60  may be a failed semiconductor chip. The board  60  may include a printed circuit board. The solder bumps  80  may electrically connect the board  60  to the semiconductor chips  70 . The solder bumps  80  may have a diameter of about 10 μm or less. The solder bumps  80  may be arrayed at intervals of several micrometers through several tens of micrometers. Although not illustrated in the drawing, an under fill may be disposed between the board  60  and the semiconductor chips  70 . The under fill may electrically insulate the solder bumps  80 . The under fill may fix the semiconductor chips  70  on the board  60 . 
         [0046]    The semiconductor chip  70  may be heated by thermal energy of the laser beam  22 . The solder bumps  80  may be melted by heat transferred from the semiconductor chips  70 . The semiconductor chip  70  may be separated from the board  60  by a picker  34  after the solder bumps  80  are melted. The solder pillars  82  may include a part of the solder bumps  80  remaining on the board  60  after the semiconductor chip  70  is removed. The solder pillars  82  may be melted by thermal energy of the laser beam  22 . 
         [0047]    A stage  10  may support the board  60  horizontally. The stage  10  may include a conveyor or a heat block moving the board  60  along a rail or a guide. The stage  10  may move or heat the board  60  depending on a control signal of control portion (not illustrated). A loader  92  may load the board  60  on the stage  10 . An unloader  94  may unload the board  60  from which all of the semiconductor chips  70  are removed. For example, the loader  92  and the unloader  94  may include a robot arm controlled by a control portion. The stage  10  may heat the board  60  to between, for example, about 200° C. and about 250° C., while moving the board  60  from under the loader  92  to under the laser  20 . A semiconductor chip recognition portion  96  may recognize an index on the semiconductor chip  70 . The semiconductor chip recognition portion  96  may include a camera or a bar code reader. 
         [0048]    The picker  34  may suck the semiconductor chip  70  using a vacuum provided from a vacuum portion  30 . The picker  34  may make the laser beam  22  penetrate the semiconductor chip  70 . The picker  34  may include the lens  33  focusing the laser beam  22 . The lens  33  may focus the laser beam  22  on a second exposure area  26  of the semiconductor chip  70 . The picker  34  may have an open hole  31  having a diameter smaller than the lens  33 . The semiconductor chip  70  may be drawn onto the open hole  31  by a vacuum of the vacuum portion  30 . Thus, the laser beam  22  penetrating the lens  33  may enter the semiconductor chip  70  through the open hole  31 . A drive portion  32  may move the picker  34  from side to side, upward and downward depending on a control signal of the control portion. The picker  34  may be moved around the board  60  by the drive portion  32  when the solder bumps  80  are melted. Thus, the semiconductor chip  70  may be detached from the board  60 . The drive portion  32  may move the picker  34 , an intake  36 , and an air knife  38  around the stage  10 . 
         [0049]    The vacuum portion  30  may provide a vacuum to the picker  34  and the intake  36 . The vacuum portion  30  may include a pump. The picker  34  and the intake  36  may be connected to the vacuum portion  30  through tubes (not illustrated). The tubes are disposed between the vacuum portion  30  and the picker  34  and between the vacuum portion  30  and the intake  36  through the drive portion  32 . The vacuum portion  30  may provide vacuums having different magnitudes to the picker  34  and the intake  36 . The intake  36  may suck or remove the melted solder pillars  82  using the laser beam  22 . The air knife  38  may blow an air  37  heated to a high temperature to the board  60 . The air  37  heated to a high temperature may shorten a melting time of the solder pillars  82 . An air blowing portion  35  may provide an air having pressure higher than atmospheric pressure to the air knife  38 . The air knife  38  and the intake  36  may move around the board while maintaining a specific distance. 
         [0050]    The laser  20  may generate the laser beam  22  having a thermal energy in inverse proportion to a wavelength. For example, the laser  20  may generate the laser beam  22  having a single wavelength between, for example, about 808 nm and 1064 nm. The laser  20  may let the laser beam  22  enter the semiconductor chip  70  and the board  60  successively. The laser beam  22  may enter the board  60  of a first exposure area  24 . The first exposure area  24  may correspond to an irradiation area of the laser beam  22 . The first exposure area  24  may be greater than a planar area of the semiconductor chips  70 . For example, the first exposure area  24  may have a line width greater than a diagonal of the semiconductor chip  70  having a rectangular shape. The laser beam  22  may be focused by the lens  33  of the picker  34 . The focused laser beam  22  may enter a second exposure area  26  of the semiconductor chip  70 . The second exposure area  26  may be smaller than the first exposure area  24 . The second exposure area  26  may be smaller than the total planar area of the semiconductor chips  70 . 
         [0051]    The laser beam  22  may have a same thermal energy and a different thermal energy density with respect to the first exposure area  24  and the second exposure area  26 . That is, the laser beam  22  entering the semiconductor chip  70  and the solder pillars  82  may have a different thermal energy from each other. The laser beam  22  may have a relatively high thermal energy density in the second exposure area  26  as compared with in the first exposure area  24 . The laser beam  22  having a high thermal energy density may intensively and rapidly heat the semiconductor chip  70  in the second exposure area  26  when melting the solder bumps  80 . The laser beam  22  having a relatively low thermal energy density may heat the solder pillars  82  and the board  60  in the first exposure area  24 . The solder pillars  82  of the first exposure area  24  may be melted by a thermal energy of the laser beam  22 . A high temperature air blown by the air knife  38  may accelerate melting of the solder pillars  82 . Damage of the board due to the laser beam  22  may be minimized because a thermal energy density of the laser beam  22  is low. The laser beam  22  may successively enter the semiconductor chip  70  and the solder pillars  82 . Thus a removal apparatus of semiconductor chip in accordance with some embodiments of the inventive concept may shorten a time of removing the semiconductor chip  70  and the solder pillars  82 . 
         [0052]      FIG. 6  is a cross-sectional view illustrating a laser and a coining unit illustrated in  FIG. 1 . 
         [0053]    Referring to  FIGS. 1 and 6 , a removal apparatus of semiconductor chip in accordance with some embodiments of the inventive concept may include a coining plate  52  compressing the solder pillars  82  into the board  60 . The coining plate  52  may be moved between the laser  20  and the solder pillars  82  by the drive portion  32 . The drive portion  32  may move the coining plate  52  upwardly and downwardly near the board  60 . The coining plate  52  may be heated by the laser beam  22 . The coining plate  52  may increase a surface area of the solder pillar  82  in the first exposure area  24 . When a surface area of the solder pillars  82  becomes wide, the solder pillars  82  may rapidly be melted by the laser beam  22 . 
         [0054]      FIG. 7  is a cross-sectional view illustrating a laser and a flux nozzle illustrated in  FIG. 1 . 
         [0055]    Referring to  FIGS. 1 and 7 , a flux  53  may accelerate melting of the solder pillars  82  by the laser beam  22 . The flux  53  may be spread on the solder pillars  82  by a nozzle  54  from flux provider  36  via drive portion  32 . The nozzle  54  may be moved around the stage  10  by the drive portion  32 . The flux  53  may cover a part or an entire part of the first exposure area  24  of the board  60 . The flux  53  may be heated by obtaining a thermal energy from the laser beam  22  of the first exposure area  24 . The flux  53  may increase a thermal energy transfer of the laser beam  22  to the solder pillars  82 . The flux  53  may help the solder pillars  82  to be heated by the laser beam  22 . The flux  53  can minimize damage of the board  60  when the solder pillars  82  are melted. 
         [0056]    Thus, the removal apparatus of semiconductor chip in accordance with some embodiment of the inventive concept may increase or maximize productivity and production yield. 
         [0057]    A method of driving a removal apparatus of semiconductor chip is described below. 
         [0058]      FIG. 8  is a flow chart illustrating a method of removing a semiconductor chip in accordance with some example embodiments. 
         [0059]    Referring to  FIGS. 1 and 8 , a loader  92  loads the board  60  on the stage  10  (S 10 ). At least one failed semiconductor chip  70  is mounted on the board  60 . The semiconductor chip  70  may include a wafer level package and may be mounted on the board  60  in a flip chip method. The semiconductor chip  70  may have an index (not illustrated) judged to be faulty in an installation test. The stage  10  may move the board  60  under a semiconductor chip recognition portion  96 . 
         [0060]    The semiconductor chip recognition portion  96  recognizes the semiconductor chip  70  on the board  60  (S 20 ). The semiconductor chip recognition portion  96  may detect an index on the semiconductor chip  70 . The semiconductor chip recognition portion  96  may include a camera obtaining an image of the semiconductor chip  70  and a bar code reader scanning a top surface of the board  60 . 
         [0061]    The stage  10  moves the semiconductor chip  70  under the laser  20  (S 30 ). The drive portion  32  move the picker  34  between the laser  20  and the semiconductor chip  70 . The lens  33  of the picker  34  may be disposed between the laser  20  and the semiconductor chip  70 . 
         [0062]    After that, the laser  20  irradiates the laser beam  22  into the semiconductor chip  70  to melt the solder bump  80  (S 40 ). The laser beam  22  may be focused on the semiconductor chip  70  in the lens  33  of the picker  34  to enter the second exposure area  26  of the semiconductor chip  70 . The semiconductor chip  70  may be locally heated by the laser beam  22 . Also, the solder bumps  80  may be melted by obtaining a thermal energy from the semiconductor chip  70 . 
         [0063]    The picker  34  separates the semiconductor chip  70  from the board  60  (S 50 ). The picker  34  may draw the semiconductor chip  70  using a vacuum provided from the vacuum portion  30 . The drive portion  32  may move the picker  34  upwardly and downwardly. The picker  34  may separate or remove the semiconductor chip  70  from the board within two seconds after the laser beam  22  is irradiated. 
         [0064]    The laser  20  irradiates the laser beam  22  into the first exposure area  24  of the board  60  successively until the solder pillars  82  are melted (S 60 ). The air knife  38  may blow a high temperature air to the solder pillar  82 . The high temperature air may shorten a melting time of the solder pillars  82 . The coining plate  52  may compress the solder pillars  82 . The coining plate  52  may be heated by a thermal energy of the laser beam  22 . The coining plate  52  may compress the solder pillars  82  to increase a surface area of the solder pillar  82 . The solder pillars  82  may be rapidly melted by obtaining a thermal energy of the laser beam  22  in proportion to a surface area of the solder pillar  82 . The nozzle  54  may spread the flux  53  on the solder pillars  82 . The flux  53  may effectively transfer a thermal energy of the laser beam  22  entering the first exposure area  24  to the solder pillars  82 . 
         [0065]    Thus, the method of removing a removal apparatus of semiconductor chip in accordance with some embodiment of the inventive concept may increase or maximize productivity and production yield. 
         [0066]    The intake  36  removes the melted solder pillar  82  (S 70 ). The intake  36  may remove the solder pillars  82  from the board  60  within five seconds after the semiconductor chip  70  is removed. 
         [0067]    An unloader  94  unloads the board  60  from the stage  10  (S 80 ). 
         [0068]    Thus, the method of removing a semiconductor chip in accordance with some embodiments of the inventive concept may minimize damage of the board  60  while irradiating the laser beam  22  into the semiconductor chip  70  and the solder pillars  82  successively. 
         [0069]    As described above, when separating a semiconductor chip from a board, a thermal damage of the board may be minimized by focusing a laser beam on the semiconductor chip. Also, even after separating the semiconductor chip from the board, the laser beam may be continuously irradiated to melt solder pillars remaining on the board. Thus, a removal apparatus of semiconductor chip and a method of removing a semiconductor chip in accordance with some embodiments of the inventive concept may maximize or increase productivity and production yield. 
         [0070]    While example embodiments have been particularly shown and described, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.