Abstract:
A method for preparing a film carrier for sputtering of IC units placed thereon, the method comprising the steps of: providing a carrier of IC units; removing said units from the carrier; delivering said IC units to a flipper; inverting and delivering said units to a sputtering film frame; placing the units on said sputtering film frame in an array having a pre-determined clearance about adjacent units.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to the processing of IC units following their singulation from a substrate. In particular, the invention relates to processing of said IC units intended for a sputtering process. 
       BACKGROUND 
       [0002]    With the growth in smart phone technology, the pressure for the placement of analog components in close proximity is also growing, and consequently, the requirement for, the elimination of interference from adjacent components. EMI shielding which is used to block noise and electromagnetic interference generated from RF modules is developing as a new technology and is seen as the process of choice in order to overcome these issues. 
         [0003]    To this end, components received a sputtered metal coating of a variety of suitable materials providing high electrical conductivity and electromagnetic shielding efficiency. The introduction of the sputtered process for the processing of IC units complicates the manufacturing process by not only introducing a new process but interrupting that process to remove the IC units to a special environment for the application of the sputtered coating. 
         [0004]    Further, the arrangement of the IC units in order for the sputtering process to be successful, is contrary to the efficient processing of these units, and so the interruption is not only in the process, but in the handling of the individual units. 
       SUMMARY OF INVENTION 
       [0005]    In a first aspect the invention provides a method for preparing a film carrier for sputtering of IC units placed thereon, the method comprising the steps of: providing a carrier of IC units; removing said units from the carrier; delivering said IC units to a flipper; inverting and delivering said units to a sputtering film frame; placing the units on said sputtering film frame in an array having a pre-determined clearance about adjacent units. 
         [0006]    In a second aspect the invention provides a method for re-distributing IC units on a sputtering film frame, the method comprising the steps of: providing the sputtering film frame of sputtered IC units in an array having a pre-determined clearance about adjacent units, and; inspecting the units from below the sputtering film frame; removing said units from the sputtering film frame. 
         [0007]    In a third aspect the invention provides a device for preparing a film carrier for sputtering of IC units placed thereon comprising: a loading station for loading a carrier of IC units into said device; a unit picker arranged to remove said units from the carrier and deliver said IC units to a flipper, said flipper arranged to invert said units; wherein said unit picker is arranged to deliver said units from the flipper to a sputtering film frame in an array having a pre-determined clearance about adjacent units. 
         [0008]    In a fourth aspect the invention provides a device for re-distributing IC units on a sputtering film frame, the device comprising: a loading station for loading the sputtering film frame of sputtered IC units in an array having a pre-determined clearance about adjacent units into said device; a unit picker arranged to remove said units from the sputtering film frame and; wherein said unit picker is further arranged to place the sputtered units in a tray and a tray picker arranged to deliver the tray to an unloading station. 
         [0009]    Accordingly, the invention provides for a preparatory process for the delivery of IC units from a singulation process to an arrangement suitable for sputtering under clean room conditions. 
         [0010]    The invention further provides for the conversion of this arrangement in a post-sputtering process to repackage the IC units for delivery to components assembly clients. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0011]    It will be convenient to further describe the present invention with respect to the accompanying drawings that illustrate possible arrangements of the invention. Other arrangements of the invention are possible and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention. 
           [0012]      FIG. 1  is a schematic view of a process according to one embodiment of the present invention; 
           [0013]      FIG. 2  is a schematic view of a preparatory process according to one embodiment of the present invention; 
           [0014]      FIG. 3  is a schematic view of a preparatory process according to a further embodiment of the present invention; 
           [0015]      FIG. 4  is a schematic view of a supplementary process according to one embodiment of the present invention; 
           [0016]      FIG. 5  is a plan view of a preparatory device according to one embodiment of the present invention; 
           [0017]      FIG. 6  is a plan view of a preparatory device according to a further embodiment of the present invention; 
           [0018]      FIG. 7  is a plan view of a supplementary device according to a further embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]      FIG. 1  shows a schematic view for the preparation  10 ,  15  of IC units prior to sputtering  25  and a supplementary process  20  for packaging the sputtered IC units. Various aspects of the invention relate to each of the preparatory processes  10 ,  15  and supplementary process  20 , as well as the overall process  5 . 
         [0020]    Looking at the first preparatory process  10  shown in  FIG. 2 , a film carrier frame  30  is provided to the process. The units undergo an alignment inspection  35 , and then delivered  40  to a flipper  45  and in the process undergo a mark inspection  35  for checking of fiduciary marks. The units are then inverted and delivered  55  from the flipper  45  to a carrier frame  60 . During the delivery step  55  the units undergo a side vision inspection  50 . The unit picker, during the delivery step  55 , is arranged to place the units onto the carrier frame  60  in an array  65  such that each of the units  70  are separated  75 ,  80  by a predetermined spacing. For instance, the spacing  75 ,  80  may be in a range 0.5 to 2.0 mm. 
         [0021]    The delivery steps  40 ,  55  may be achieved by separate unit pickers or alternatively by the same unit picker having a rail spanning from the film carrier frame  30  to the sputtering film frame  60 . The sputtering film frame  60  is then unloaded so as to undergo this sputtering process. 
         [0022]      FIG. 3  shows a schematic view of an alternative preparatory process  15 . This process is arranged to receive the IC units in the form of a carrier  90  having the IC units secured through tape  85 . The carrier  90  and tape  85  are delivered  100  to a tape removal unit  105 . A pilot pin type device (not shown) is used for aligning the units between the carrier and tape removal unit  105 . 
         [0023]    In order to release the IC units from the carrier  90  the tape  85  is removed by the tape removal unit  105 . Here, a gripper  130  engages the tape whilst a strong vacuum  125  is applied to the units and carrier  90 . A slide  115  to which the gripper  130  is mounted applies a uniform force, peeling the tape from the units  90 . Following removal of the tape  85 , the vision  95  inspects for unit alignment. 
         [0024]    As with the process of  FIG. 2 , the released units are then delivered  140  to a sputtering film frame  150  passing through a mark inspection  134  and then a side inspection  135  during the delivery step  140  which is performed by a unit picker. 
         [0025]    As with  FIG. 2  the process  15  of  FIG. 3  is arranged such that the unit picker places the released units  160  in a predetermined array  155  having the unit separated  165 ,  170  in a predetermined arrangement. 
         [0026]    The sputtering film frames  150  are subsequently delivered to the sputtering process (not shown). 
         [0027]      FIG. 4  shows a schematic view of a supplementary process  20  whereby sputtering film frames  180  are delivered  175  following the sputtering process. Here the units undergo a mark inspection  184 , followed by an alignment inspection  185 . 
         [0028]    The sputtered units are delivered  190  via side inspection  186 . The units are realigned by a precisor (not shown) for placement within a recess  210  of a tray  200 . The units will be inspected on all sides whilst in the tray prior to being offloaded or alternatively placed in a bin  205 . 
         [0029]      FIG. 5  shows one embodiment of a preparatory process and in particular a machine layout corresponding to the schematic flow of  FIG. 2 . 
         [0030]    As shown in  FIG. 5 , the machine layout  215  comprises two parts being the unit delivery portion  220  and the unit placement portion  225 . In this particular embodiment the machine layout may be categorized as a film to film process in that it is arranged to receive film frames through a cartridge arrangement via the unloading elevated  230 . Individual frames are engaged by a gripper  240  and brought into the apparatus via a rail  235  whereupon the frame is engaged by a frame picker  250 . 
         [0031]    The frame is delivered to a frame removal area by the frame picker  250  whereupon it is placed on a working table  260  and inspected by an alignment inspection camera  265 . The units are removed from the frame by a package picker  280  and delivered to a flipper  290 . During the delivery step, a further mark inspection  285  is carried out. 
         [0032]    On removal of the packages to the flipper  290 , the frame is ejected by an ejector  270  and removed by a frame offloader  275 . 
         [0033]    Following inversion by the flipper  290 , a sorting picker delivers the unit to a further working table  315  with the units further inspected through a side vision inspection  300  prior to placement in a designated array on a sputtering film frame placed upon a working table  315 . On successful transfer of the units, the sputtering film frame is ejected and carried to an offloading zone whereby the sputtering film frame is gripped  320  and placed within a frame picker  330  whereupon it is delivered along a rail  325  for offloading to a cartridge  335 . 
         [0034]    Units not meeting the requirement through any one of the previous inspection zones are placed in a bin  305  for disposal. 
         [0035]    The cartridge, now being full of sputtering film frames, having units placed in an array suitable for sputtering can now be delivered to a sputtering process for future processing. 
         [0036]      FIG. 6  shows an alternative arrangement whereby the machine layout  340  may be characterized as a carrier to film process. 
         [0037]    Again there is a unit delivery zone  345  and a unit placement zone  350 . However, in this arrangement the machine layout  340  has been designed for receiving carriers whereby the singulated units are engaged by a tape rather than film frames for which the units may be readily removed. 
         [0038]    In this arrangement, a cassette magazine loader  375  includes a pusher  370  for inserting the carriers into an inlet rail  360  via a gripper  365 . A carrier loading picker  355  then engages the carrier and delivers this to a tape removal device  415  whereby the units are released by removing the tape. The release carrier is then rotated on a turntable  420  and delivered along a rail whereby the units are delivered to a flipper  400  via a marked visioning inspection  395 . The empty carriers are then unloaded by a picker  385  and placed within an elevator  390  for subsequent disposal. 
         [0039]    The unit placement section  350  then follows the same path with the same equipment as that of the unit placement system of  FIG. 5 . 
         [0040]    Accordingly, the process of  FIG. 6  yields a full cartridge  335  for delivery to a sputtering process. 
         [0041]      FIG. 7  shows a supplementary process having a machine layout  470 . The machine layout includes a sputtering film frame receiving section  475  and an unloading section  480 . 
         [0042]    Following the sputtering process, the cartridge of sputtered film frames  485  is then delivered to an offloading section whereby a gripper  490  grips individual frames and draws them along a rail  495  to be engaged by a frame picker  505 . A mark vision inspection  500  inspects the sputtered units during the delivery phase. 
         [0043]    The sputtering film frame is then delivered to a work table  525  whereby a package picker  510  engages the sputtered units for subsequent offloading. An alignment vision inspection  520  adjacent to the ejector  515 , inspects from below the package picker and through the tape, checking the alignment of the units to avoid misalignment of the units. On removal of the units, the frame is ejected by an ejector  515  and removed by a frame offloader  530 . The sputtered units are delivered to a precisor  535  to realign the units into recesses of the module for subsequent placement by a sorting picker  540  into the trays for offloading  560 . The sorting picker passes the sputtered units plus a side vision arrangement  545  and either places the units into a bin  555  or onto further sorting picker  550  for delivery to the tray offloader  560 .