Patent Abstract:
An apparatus which reduces the surface area with which a carrier film adheres to a die, including a plate member including laterally spaced supports preferably, the apparatus also includes a vacuum source operatively connected to the plate member Upon placement of a carrier film having an array of semiconductor diet adhered thereto onto the plate member, the dice are proximate the supports. The vacuum pulls air from the spaces between the supports, which partially releases the carrier film from the bottom surface of at Least sonic of the dice. The apparatus may also include a die removal mechanism such as a vacuum toilet type die pick-up mechanism, an extendable member die plunge-dip mechanism, or a combination thereof. The present invention also includes a method for reducing the surface area with which a carrier film adheres to a die to facilitate removal thereof.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of application Ser. No. 09/304,566, filed May 4, 1999, now U.S. Pat. No. 6,505,395, issued Jan. 14, 2003, which is a divisional of application Ser. No. 09/140,920, filed Aug. 26, 1998, now U.S. Pat. No. 6,202,292 B1, issued Mar. 20, 2001. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to apparatus for removal of a carrier film from the bottom surface of semiconductor dice and other electronic devices. Particularly, the apparatus of the present invention reduces the surface area of the adhesive film which remains in contact with a die during removal. The present invention also relates to a method for removing semiconductor dice and other electronic devices from carrier film. 
     2. Background of Related Art 
     Several apparatus and methods are known for removing semiconductors and other electronic devices from adhesive carriers such as film. Some such methods involve degrading the adhesive properties of the carrier. Some devices employ needles, pistons, or other mechanisms which apply an upward force to push the die off of the carrier. Other devices utilize a vacuum to pull a die from a carrier. Many known apparatus and methods for removing a die from a carrier cause damage to a significant quantity of dice. 
     U.S. Pat. No. 4,778,326, issued in the names of Althouse et al., discloses a method and apparatus for transporting semiconductor dice which is commonly referred to as a “gel pack” or “die-pac.” The semiconductor dice are loaded onto and adhere to a flat, thin, flexible silicone film, which is attached to a carrier base. The carrier base has recesses formed therein, into which the silicone film may be pulled as a vacuum is applied beneath the film. As the film is pulled into the recesses, the area of the silicone film which contacts the dice is reduced, thereby reducing the magnitude of the adherence by which the dice are attached to the film. The dice may then be easily removed with a vacuum tip. 
     As mentioned above, the predominant use of gel packs is to transport dice. No semiconductor fabrication processes are performed while dice are on a gel pack. Use of gel packs is somewhat undesirable because the silicone of the films tends to contaminate dice by leaving a silicone residue thereon. 
     U.S. Pat. No. 5,590,787, issued in the name of Hodges, discloses another die-pac device for transporting semiconductor dice. The device of the &#39;787 patent includes a UV sensitive adhesive and permits the penetration of electromagnetic radiation, such as ultraviolet light, therethrough. 
     Techniques which utilize carrier films having ultraviolet light (UV) degradable adhesives thereon or other degradable adhesives are also well known in the art. The area of film attached to a die which has been selected for further manufacture is irradiated with the appropriate degradative source to remove the die from the film. Although the use of UV radiation and similar methods are desirable from the standpoint that they are unlikely to damage the die, the adhesives and carrier films required for such devices and processes are very expensive. UV-release carrier tapes have also been employed to a limited extent with gallium arsenide dice. 
     U.S. Pat. Nos. 4,990,051 and 4,850,780, each of which issued in the names of Safabakhsh et al., each describe an apparatus for removing a die from an adhesive carrier film. That apparatus concurrently applies a vacuum to the exposed surface of the die and a chuck to the film on the opposite surface of the die. The vacuum collet is moved away from the chuck, which facilitates a pre-peel of a small area of the film from the periphery of the die. A piston disposed coaxially within the chuck is then forced against the carrier film to stretch the film and further reduce the area of the film which adheres to the die, thereby facilitating removal of the die from the film. 
     Some other apparatus for removing dice flow a carrier film include a plunge-up piston which has a cap thereon to raise a selected die in relation to the adjacent dice on the film. This process is referred to as “tenting” the film. A needle disposed within the cap is actuated to contact the die from below and push it from the carrier film as a vacuum tip positioned above the die pulls the selected die away from the film. 
     Such tenting processes for removing dice from film are undesirable for several reasons. First, tenting sometimes creates an air bubble under the die, which tends to tilt the die, preventing the vacuum tip from obtaining a good hold on the die. In such cases, the vacuum tip will likely drop the selected die, damaging and/or contaminating the die. Second, in many such apparatus, the needles which push the selected die from the film have pointed ends, which tend to score the bottom surface of the die. Dice which have been scored in such a manner tend to subsequently fail mechanically at the location where they have been scored. Third, as the film is tented, the edges of other dice which are adjacent to the selected die may be chipped, causing damage to the circuitry on their active surfaces, with consequential failure. 
     U.S. Pat. No. 4,915,565, issued in the names of Bond et al., discloses an apparatus for removing a selected die from a wafer having an array of dice which is attached to a carrier film. In the apparatus of the &#39;565 patent, the dice are positioned beneath the film during removal of each selected die. A head having an array of needles protruding therefrom is positioned over the film opposite a selected die. In operation, the head plunges toward the film, the needles penetrating the carrier film and dislodging the die from the film. The dislodged die then falls into a receptacle. U.S. Pat. No. 4,759,675, issued in the names of Bond et al., discloses the same die removal device. 
     The sole use of needles to remove a selected die from a carrier film makes the removal device of the &#39;565 and &#39;675 patents undesirable. The adhesive forces of the film to the die necessitate a large amount of force for removing the die therefrom. Further, the orientation of the plunge head relative to the die requires that the die suffer some impact when falling into a receptacle, increasing the likelihood of damage to the die. 
     U.S. Pat. No. 4,285,433, issued in the names of Garrett, Sr. et al., describes another method and apparatus for selecting and removing singulated dice from a wafer. The apparatus includes an adhesive film which is attached to the bottom of the carrier film supporting the dice. The adhesive film with adhered carrier film is pulled away from the dice through a slot. U.S. Pat. No. 4,607,744, issued in the name of Pak, discloses a similar method and device which removes carrier film from dice with a take-up drum which pulls a free end of the carrier film. The carrier film is pulled around a separator edge into a slot, the dice then passing over the separator edge and onto a conveyor which transports the dice away from the separator edge. 
     The amount of force applied to the dice as the carrier film is pulled downward through such a slot or separator edge while the dice proceed in a different direction of travel may be sufficient to break or damage the dice. Further, the processes of the &#39;433 and &#39;744 patents are undesirable in that they do not permit automated removal of selected dice from an array of dice including failed dice and die fragments, as well as functional dice. 
     As dice become thinner and are fabricated with larger surface areas (which adhere to a greater area of the carrier film), the likelihood of their being damaged by each of the foregoing mechanical removal processes increases. 
     Thus, an apparatus is needed for removing disposable carrier tape or film from semiconductor dice and other electronic devices which exerts little or no impact on a die, reduces the area of carrier tape or film adhered to a die before removal of the die, and utilizes an inexpensive yet effective carrier tape or film. 
     BRIEF SUMMARY OF THE INVENTION 
     In contrast to the deficiencies exhibited by the prior art, the low-stress die removal system of the present invention addresses each of the foregoing needs. The apparatus is useful with many disposable carrier tapes or films known and used in the art. The apparatus also exerts little, if any, impact on the die. The apparatus of the present invention also significantly reduces the surface area of carrier film adhered to a die before removal. The die removal apparatus does not require the use of expensive films which have degradable adhesives thereon. 
     One embodiment of the die removal apparatus of the present invention includes a base, including a plate member encircled by a raised periphery, a screen disposed over the plate member, and a vacuum source to create a vacuum within the base and below the screen. The plate member may include recesses therein to ensure application of the vacuum to all portions of the base within the periphery. A carrier film having dice on the upper surface thereof is placed above the plate, and the vacuum is used to pull the film against the screen and away from the dice. 
     In a variation of the die removal apparatus of the present invention, the plate member includes a series of laterally spaced supports protruding upwardly therefrom. The portions of the screen which overlay the supports may be higher than those portions which rest within the recesses. Another variation of the base of the die removal apparatus of the present invention lacks a screen and merely employs supports. Alternatively, a plate member may be formed with apertures therethrough and the film is pulled thereagainst and with the aperture upon activation of the vacuum source. In yet another variation, the upper face of the plate is provided with bumps, convolutions, or other protuberances separated by valleys into which the carrier film may be pulled. 
     In use, a frame ring which engages a carrier film with a wafer thereon is positioned over the base. The film preferably rests upon and is supported by the plate member. As the vacuum source is activated, the portions of the carrier film which overlay the recesses are pulled against the screen, supports, or protuberances and into the recesses or valleys. Thus, the area of the film which remains adhered to the dice is reduced by an amount which depends upon the size of the recesses and the strength of the vacuum. Consequently, the adherence of each of the dice to the carrier film is reduced. Dice which have been selected for further processing (referred to individually as a “selected die”) are then completely separated from the carrier film by a removal mechanism, which removes each selected die by pushing, pulling, or pushing and pulling each selected die from the film. Preferably, separation occurs while the film is being pulled downward against the plate member. 
     The die removal apparatus according to the present invention may also include a vacuum head which is positionable above a selected die. The vacuum head pulls the die from the carrier film upon activation of a vacuum source to pull a substantial portion of the film away from the back side of the die. When combined with the significantly reduced adhesion area of the film to the die, very little force is required to remove the die from the carrier film. Further, because the die rests securely upon and remains supported by the plate member, tilting of the die is unlikely. 
     The die removal apparatus may also comprise a low-impact plunge-up head which is positionable beneath a selected die and has one or more needles which may be extended upwardly therefrom in a telescoping manner. After the plunge-up head is positioned beneath the selected die, the needle is actuated to push the die away from the carrier film. When combined with the significantly reduced adhesion area of the film to the die, afforded by the previously-mentioned base construction and application of vacuum to the back side of the film, very little force is required to remove the die from the carrier film. Preferably, the plunge-up head is used in combination with a vacuum head which is positionable above the selected die. Preferably, when used in combination, as the plunge-up head needle pushes the die upward, the vacuum head simultaneously lifts the die to transfer it to another location. As with the first embodiment of the removal mechanism, the likelihood of damaging a selected die is much less than that of methods which were previously known in the art. 
     Other advantages of the present invention will become apparent to those of ordinary skill in the art through a consideration of the appended drawings and the ensuing description. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 a  is a perspective view of a preferred embodiment of the present invention; 
     FIG. 1 b  is a cross-section of the base of the present invention, taken along line  1   b — 1   b  of FIG. 1 a  and showing an assembly including a frame ring, carrier film and a sawed wafer on the carrier film; 
     FIG. 2 a  is a cross-sectional view of a second variation of a base of an apparatus according to the present invention; 
     FIG. 2 b  is a cross-sectional view of a third variation of a base of an apparatus according to the present invention; 
     FIG. 2 c  is a cross-sectional view of a fourth variation of a base of an apparatus according to the present invention; 
     FIG. 2 d  is a cross-sectional view of a fifth variation of a base of an apparatus according to the present invention; 
     FIG. 2 e  is a cross-sectional view of a sixth variation of a base of an apparatus according to the present invention; 
     FIG. 3 is a frontal perspective view of another variation of a base of an apparatus according to the present invention; 
     FIG. 4 is a cross-sectional view of an apparatus according to the present invention, also showing a first preferred embodiment of a die removal mechanism; 
     FIG. 5 is a cross-sectional view of an apparatus according to the present invention, illustrating a second preferred embodiment of a die removal mechanism; 
     FIG. 5 a  is a top plan view of a variation of a support plate of the present invention; 
     FIG. 6 is a cross-sectional view of a die removal mechanism according to the present invention; 
     FIG. 7 is a cross-sectional view of a second die removal mechanism of this invention; 
     FIG. 8 is a frontal perspective view of a variation of the base of the present invention, wherein the base is positionable relative to a selected die; and 
     FIG. 8 a  is a frontal perspective view of another variation of the base, wherein the base is positionable relative to a selected die. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to FIGS. 1 a  and  1   b , a first preferred embodiment  100  of the low-stress die removal apparatus of the present invention is shown. Apparatus  100  includes a base  110 , including a plate member  120 , a screen  112  positioned over the plate member, and a vacuum source  114  connected to the base beneath the plate member. Preferably, embodiment  100  also includes a vacuum pick-up head  116 , positioned above base  110 . Vacuum pick-up head  116  is also operably connected to a vacuum source  117 , which may comprise vacuum source  114  or a second vacuum source. 
     FIGS. 1 a  and  1   b  also depict a diced wafer  101  disposed upon a carrier film  104 , which may also be referred to as a carrier tape, film, or tape. Diced wafer  101  includes several singulated dice  102   a ,  102   b ,  102   c , etc. A frame  106 , also referred to as a ring or a frame ring, supports carrier film  104  under tension for transport of wafer  101 . Preferably, frame  106  has a shape and dimensions which facilitate placement upon and connection with the top of base  110 . Preferably, in embodiments of the invention where a plunge-up head  550  (FIGS. 6 and 7) is employed, the perimeter ring  111  of base  110  is of similar size to flame ring  106 , there being enough lateral clearance between the perimeter ring and the periphery of wafer  101  for the plunge-up head to operate. The foregoing elements are collectively referred to as wafer assembly  108 . 
     Base  110  includes a plate member  120  having an uneven or bumpy surface, which includes a plurality of raised members  124   a ,  124   b ,  124   c , etc., extending upwardly from the surface of the plate member, which may also be referred to as supports. Spaces  122   a ,  122   b ,  122   c , etc. are formed between supports  124   a ,  124   b ,  124   c , etc. Although FIG. 1 a  shows supports  124  in a staggered arrangement, the supports may also be configured in straight rows or in any other configuration which facilitates removal of carrier film  104  from a die  102  while adequately supporting the die. Similarly, while the top of each of the supports  124  shown in FIG. 1 a  has a small surface area, other configurations of supports are also within the scope of the apparatus of the present invention, including, without limitation, horizontally elongate supports, larger supports having a shaped (e.g., circular, square, rectangular, triangular, oval, n-sided polygonal and others) orthogonal cross-section with a hollow center, concentrically arranged shaped supports, and other configurations of supports. The shape, the arrangement and the spacing of supports  124  are preferably sufficient to facilitate pulling a significant portion of carrier film  104  from each of dice  102 . Yet, the shape, arrangement and spacing of supports must also adequately support each of the dice  102  and reduce the likelihood of fracturing or otherwise damaging the die as portions of the film are removed therefrom by a vacuum. 
     Referring to FIG. 1 b , screen  112 , which is preferably flexible, rests above plate member  120 . Supports  124   a ,  124   b ,  124   c , etc., and spaces  122   a ,  122   b ,  122   c , etc. impart screen  112  with an uneven surface, which includes peaks  128  and valleys  130 . Suitable materials for manufacturing screen  112  include, but are not limited to, wire mesh, silk screens, thin layers with a plurality of fenestrations formed therethrough, and other meshes and screens which permit the flow of air therethrough. Woven as well as punched screen materials may be employed. Anti-static materials are preferred. 
     Vacuum source  114  is operatively connected to base  110  through vacuum port  115 . As vacuum source  114  is activated, air is pulled through screen  112  and the carrier film  104  is pulled away from the dice  102  until it contacts the screen material. Thus, vacuum source  114  facilitates the removal of the portions of carrier film  104  which overlie valleys  130  from the backs of dice  102 . 
     FIG. 2 a  illustrates an alternate variation of base  210 , wherein the screen  212  is a substantially flat member positioned above plate member  220 . Plate member  220  includes supports, also referred to as raised members  224 , extending upward therefrom through the screen, and forming a bumpy or uneven surface above the plate member. Supports may be arranged in straight rows, staggered, or in any other configuration which facilitates removal of the carrier film from the dice while adequately supporting the dice. 
     FIG. 2 b  depicts a third variation  310  of the base, which includes a plate member  320  with a plurality of vacuum orifices  332   a ,  332   b ,  332   c , etc. formed therethrough. Each of vacuum orifices  332  is operably connected to a vacuum source  314 . Preferably, vacuum orifices  332  are consistently spaced over substantially the entire surface of plate member  320 . Embodiment  310  also includes supports, or raised members  324 , extending upwardly from the surface of plate member  320  to create an uneven surface thereon. 
     FIG. 2 c  depicts a fourth variation  340  of the base, wherein plate member  342  has a substantially flat bottom surface and an uneven top surface having a plurality of peaks  344  and valleys  346  formed thereon. Plate member  342  may also include vacuum orifices  348  formed therethrough which, upon activation of a vacuum source (not shown), facilitate the removal of gas from valleys  346 . Alternatively, the vacuum source may connect to outside of the base through the sidewall thereof and adjacent the bottom, as long as the peaks  344  are higher than the distance a carrier film may be drawn thereinto. 
     FIG. 2 d  illustrates a fifth variation  350  of the base, which includes a self-supporting, highly convoluted screen  352 , which includes a plurality of peaks  354  and valleys  356 . Screen  352  may be manufactured from the same materials as those described above in reference to screen  112  of FIG. 1 b . As used herein, the term “screen” not only encompasses screens having transversely dispersed woven elements, but may comprise a plurality of convoluted elongated elements extending in mutually parallel relationships, preferably with offset peaks and valleys in adjacent elements. Also, in an embodiment employing a screen without associated discrete supports, it will be understood that the laterally spaced peaks or protrusions of the screen comprise laterally spaced supports. 
     FIG. 2 e  shows a sixth variation  360  of the base, which includes a plate member  362  with a plurality of upwardly extending support pins  364  thereon. Each of the support pins  364  includes an enlarged head  366  at the top thereof, against which a carrier film may be drawn. 
     Referring now to FIG. 3, another variation  370  of the base is shown. Base  370  includes a plate member  372  which has a plurality of apertures  376  formed therethrough. A wafer assembly (not shown) is supported on supports  374 , which are located between adjacent apertures  376  of plate member  372 . Preferably, supports  374  are narrow members. Apertures  376 , which impart plate member  372  with a honeycomb-like appearance, may have any shape, including, without limitation, circular, hexagonal, square, oval, and other shapes. Further, the walls defining the aperture may be undercut, as shown in broken lines, to permit the film to be drawn lower in select areas. 
     Referring again to FIG. 1 b , as an example of the use of the base  110  of the apparatus of the present invention, the carrier film or film  104 , upon which a sawed, processed wafer  101  is positioned, is placed upon the base over screen  112 . Frame ring  106  secures wafer assembly  108  to base  110 . Next, vacuum source  114  is activated, pulling air through the spaces  122 , which pulls portions of carrier film  104  against the surfaces of screen  112  which overlay the recesses, releasing those portions of the film from dice  102 . Selected dice are then ready for removal from carrier film  104 . As defined herein, the terms “select die” and “selected die” refer to a die which has been selected for removal from sawed wafer  101  for further processing. In systems where embodiments  210 ,  310 , or other embodiments of the base of the present invention are employed, the methods for removing portions of the carrier film from the dice are substantially the same. 
     Referring now to FIG. 4, an embodiment  400  of a die removal mechanism is shown. Embodiment  400  includes vacuum head  410 , which is positionable over a base  420  and operatively connected to a vacuum source  430 . Several dice  102   a ,  102   b ,  102   e , etc., which are disposed upon a carrier film  104 , are shown. Vacuum head  410  is positionable directly above a selected die  102   a . Systems which select dice, track select dice, and position a vacuum head above a selected die, are each well known in the industry and are useful in connection with the apparatus of the present invention. Upon activation of vacuum source  430 , vacuum head  410  utilizes a vacuum to pull selected die  102   a  upward from carrier film  104 . Vacuum die pick-up mechanisms, which are well known and currently used in the industry, are useful in the system of the present invention. 
     FIG. 5 shows another embodiment of a die removal mechanism  500 , according to the present invention, which includes a vacuum head  510  and a die plunge-up head, also referred to as striking mechanism  550 . FIG. 5 also shows several dice  102   a ,  102   b ,  102   c , etc. disposed upon a carrier film  104 . The carrier film  104  is secured by a frame ring (not shown). Preferably, vacuum head  510  operates in substantially the same manner as that described above in reference to FIG.  4 . 
     Die plunge-up head  550  is of the type known and commonly used in the industry. Die plunge-up head  550 , which is positionable beneath a selected die  102   a , includes one or more needles  554  slidingly disposed within a bolder  552 . Plunge-up head  550  also includes an actuator  556  disposed behind needle  554 . Preferably, the size of plunge-up head  550  is sufficient to include a plurality of needles  554 , reducing the tendency of a selected die  102  to tilt as the needles strike the die. Systems for selecting good dice, tracking select dice, and positioning plunge-up head  550  beneath a selected die  102   a  are well known in the industry and may be used in connection with the apparatus of the present invention. Alternatively, the plunge-up head  550  may include another plunge-up mechanism such as a piston or a pressurized air line. 
     Actuators which are useful with die plunge-up head  550  include, without limitation, conventional two-way pneumatic actuators and solenoid actuators, such as those which are known and used in the industry, or any other type of actuator adaptable for use with plunge-up head  550 . Actuator  556  forces needle  554  upward with the appropriate amount of force and for the appropriate time period to, either directly or indirectly, further loosen selected die  102   a  from carrier film  104  without damaging the selected die, then retract the needle into holder  552 . Preferably, in embodiments of the present invention, needle  554  extends through a base aperture  553  to directly contact selected die  102   a . 
     FIG. 5 illustrates small base apertures  553 . However, as FIG. 5 a  shows, the plate member  120 ′ may have a grid configuration. Support members  124 ′ extend upwardly from intersecting portions of plate member  120 ′, while large apertures  553 ′ are formed through plate member  120 ′ in the spaces between the support members  124 ′. 
     Preferably, the needle has a raised tip with a convex tip surface, or an otherwise blunt tip  555 , which decreases the tendency of the needle to score the underside of the selected die during actuation of the needle and contact of the needle with the selected die, collectively referred to as “striking” the die. In embodiments of the present invention where striking occurs while the frame, film and sawed wafer assembly (reference character  108  in FIG. 1 a ) is positioned over the base, blunt tip  555  also prevents perforation of carrier film  104  during striking. Perforation of carrier film  104  could came a loss of the vacuum that pulls the film away from the dice  102 . In such embodiments, needles  554  pass through the plate member and/or the screen during striking. 
     Turning again to FIG. 1 a , the preferred dimensions of frame ring  106  are such that the distance between the outer periphery of wafer  101  and the inner surface of the frame permits the plunge-up head  550  (see FIGS. 6 and 7) to further remove carrier film  104  from the outermost complete dice without contacting the frame. 
     Preferably, in operation, the plunge-up head does not disrupt the vacuum which pulls portions of the carrier film from the dice. Thus, as FIG. 6 illustrates, a preferred embodiment of base  610  includes an array of base needles  670   a ,  670   b ,  670   c , etc. therein, each of which are slidingly engaged within needle ports  676   a ,  676   b ,  676   c , etc., respectively. Needle ports  676  are each formed through plate member  620 . Each base needle  670  includes an actuation end  672  and a needle tip  674 . The activation end  672  of each base needle  670  is preferably exposed to the lower, outer surface of plate member  620 . Preferably, tip  674  of each base needle is raised, with a convex surface, or otherwise blunt to prevent scoring of a selected die  102   a  as the needle tip comes into contact with the selected die. Blunt needle tip  674  also prevents perforation of carrier film  104  as needle  670  is actuated, which facilitates maintenance of the vacuum which pulls portions of the film away from selected dice  102 . Preferably, each base needle  670 -needle port  676  assembly is scaled in order to maintain the vacuum which has been created in base  610 . Alternatively, a positive pressure collet could be employed in place of a plunge-up head by directing pressurized air upward against needle  670  to drive the needle against selected die  102   a , 
     As an example of the operation of plunge-up head  550  in the present embodiment of base  610 , the plunge-up head is positioned beneath the base needle  670  or base needles located beneath selected die  102   a . As the plunge-up head needle  554  is actuated, it moves upward, contacts actuation end  672  of base needle  670 , and forces the base needle upward against the selected die to further loosen the selected die from carrier film  104 . 
     With reference to FIG. 7, another preferred embodiment of base  710  includes a scaled plunge-up head housing  780 , within which plunge-up head  550  is disposed. In addition to creating a vacuum within the base, vacuum source  714  creates a vacuum within plunge-up head housing  780 . Plunge-up head  550  is repositionable within housing  780  without disrupting the vacuum therein. Thus, base  710  permits direct contact of needle  554  through plate member  720  and the screen thereon, if any, with selected die  102   a  to further remove the selected die from carrier film  104 . 
     With reference to FIG. 8, another embodiment of the apparatus of the present invention includes a small base  810 , including an uneven film removal surface as described above in reference to FIGS. 1 b ,  2   a  through  2   e  and  3 . Base  810  is positionable beneath a selected die  102   a  on a wafer assembly  108  using known apparatus and methods. Base  810  is attachable to a vacuum source (not shown) at connector  812 . A die pick-up mechanism  820 , as described above in reference to FIG. 4, may also be used in connection with positionable base  810 . 
     In use, positionable base  810  is oriented beneath selected die  102   a  and positioned in close proximity to the carrier film attached to the selected die. The vacuum source is actuated, pulling air from the lower areas of the base and removing portions of the carrier film from selected die  102   a , thereby reducing the adhesion of the film to the die. If desired, the vacuum may be applied continuously, the base then sliding laterally to different locations beneath the carrier film. Die pick-up mechanism  820  then completely removes selected die  102   a  from the carrier film. 
     FIG. 8 a  shows an alternative embodiment  810 ′ of a positionable base. Base  810 ′ is adapted to fit over a die plunge-up mechanism  830 , having a needle  840 , piston, pressurized air line, or other plunge-up mechanism therein. 
     Referring again to FIG. 5, as an example of the use of embodiment  500  of die removal mechanism, vacuum head  510  is positioned above a selected die  102   a  and plunge-up head  550  is positioned beneath the selected die. Vacuum head  510  is lowered toward selected die  102   a . Plunge-up head  550  is raised to an appropriate position beneath selected die  102   a . Vacuum source  530  is activated to direct a vacuum through vacuum head  510  and at the exposed surface of selected die  102   a . Preferably, while vacuum head  510  is pulling selected die  102   a , needle  554  is actuated by actuator  556  to strike the selected die and further remove carrier film  104  from the selected die. In embodiments of the present method wherein removal of selected die  102   a  occurs while wafer assembly  108  is disposed upon the base, each needle  554  passes through the plate member and the screen, if any, during striking. Vacuum head  510  is then raised while holding selected die  102   a , and transfers the selected die to a desired location. When embodiment  610  of the base, discussed above in reference to FIG. 6, is used in the present method, needle  554  contacts actuation end  672  of the appropriate base needle  670 , which contacts carrier film  104  beneath selected die  102   a  to further remove the film from the die. 
     Inexpensive carrier films may be used with the present invention in lieu of those coated with UV-degradable or other expensive adhesives, or adhesives which contaminate the dice. For example, the pressure sensitive adhesive-coated polymer films manufactured by Shinkawa and Nitto, both of Japan, which are used for protectively coating sheet steel, are particularly useful in the invented system. Such films are desirable for use because of their low cost and chemical cleanliness (i.e., will not contaminate dice), both of which advantages provide a reduction in manufacturing costs. 
     Another consequent advantage of the invention is that the likelihood of dropping, contaminating, fracturing or otherwise damaging the die is much reduced when compared with methods which were previously known in the art. 
     While the invention has been described in terms of a vacuum drawing the carrier film down and away from the dice supported thereon, those of ordinary skill in the art will recognize that it is a pressure differential which effects movement of the film. Accordingly, it is also contemplated that a higher (positive) pressure may be applied to the top of the carrier film to “push” the film downward against ambient pressure therebelow. Specifically, a push-up head may be employed within a bell-type chamber placed over the frame ring and carrier film to effect withdrawal of large portions of the film from the dice. 
     Although the foregoing description contains many specificities, these should not be construed as limiting the scope of the present invention, but as merely providing illustrations of some of the presently preferred embodiments. Similarly, other embodiments of the invention may be devised which do not depart from the spirit or scope of the present invention. The scope of this invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. Additions, deletions and modifications to the embodiments of the invention as disclosed, and the combination of features of different embodiments, are specifically contemplated as falling within the scope of the invention.

Technology Classification (CPC): 8