Source: http://www.google.com/patents/US20050005434?dq=6,970,917
Timestamp: 2018-01-22 08:54:34
Document Index: 88679628

Matched Legal Cases: ['art 300', 'art 900', 'art 900', 'art 900', 'art 1400', 'art 1400', 'art 1400']

Patent US20050005434 - Method, system, and apparatus for high volume transfer of dies - Google Patents
A system, method and apparatus for die transfer using a changeable or movable material is described herein. The die plate has a planar body. The body has a plurality of holes therethrough. Each die covers a corresponding hole on a first surface of the die plate. The holes are filled with a material that...http://www.google.com/patents/US20050005434?utm_source=gb-gplus-sharePatent US20050005434 - Method, system, and apparatus for high volume transfer of dies
Publication number US20050005434 A1
Application number US 10/866,149
Also published as EP1642325A2, US7223320, US7276388, US7404199, US7543316, US7795076, US20040250417, US20040250949, US20040251541, US20050007252, US20050009232, US20050015970, US20060174257, US20080271313, WO2004112096A2, WO2004112096A3
Publication number 10866149, 866149, US 2005/0005434 A1, US 2005/005434 A1, US 20050005434 A1, US 20050005434A1, US 2005005434 A1, US 2005005434A1, US-A1-20050005434, US-A1-2005005434, US2005/0005434A1, US2005/005434A1, US20050005434 A1, US20050005434A1, US2005005434 A1, US2005005434A1
Inventors Michael Arneson, William Bandy
Original Assignee Matrics, Inc.
Patent Citations (99), Referenced by (29), Classifications (94), Legal Events (2)
Method, system, and apparatus for high volume transfer of dies
US 20050005434 A1
A system, method and apparatus for die transfer using a changeable or movable material is described herein. The die plate has a planar body. The body has a plurality of holes therethrough. Each die covers a corresponding hole on a first surface of the die plate. The holes are filled with a material that can be caused to expand, exert pressure, or move when exposed to one or more stimuli. The die plate is positioned to be closely adjacent to the web of substrates. The dies can subsequently be transferred from the die plate to one or more destination substrates or other surfaces by applying one or more stimuli to the material, causing the material to expand, exert pressure, or move. The action of the material causes the dies to separate from the die plate.
1. A method for transferring a plurality of integrated circuit dies from a die plate to a substrate, comprising:
(a) receiving a die plate that has a first surface having a plurality of dies attached thereto, wherein each die of the plurality of dies covers a corresponding hole through the die plate at the first surface of the die plate;
(b) at least partially filling each hole with a material;
(c) positioning the die plate and substrate to be closely adjacent to each other such that each die of a first plurality of dies is closely adjacent to a corresponding contact area on a first surface of the substrate; and
(d) applying one or more stimulus to the material filling each hole to cause each die of the first plurality of dies to be released from the die plate.
heating the material filling each hole.
applying a voltage to the material filling each hole.
applying a force to the material filling each hole.
5. The method of claim 1, wherein the material can be caused to expand when exposed to one or more stimulus.
6. The method of claim 1, wherein the material can be caused to exert pressure in multiple directions when exposed to one or more stimulus.
7. The method of claim 1, wherein the material can be caused to move when exposed to one or more stimulus.
8. The method of claim 2, wherein said heating step includes:
using a laser to heat the hardened material.
(e) adhering each die of the first plurality of dies to the corresponding contact area on the first surface of the substrate.
10. A method for transferring an integrated circuit die that is attached to first surface of a support structure to a substrate, comprising:
(a) positioning the support structure and substrate to be closely adjacent to each other such that contact pads of a die attached to the support structure make contact with corresponding contact areas on a first surface of the substrate;
(b) allowing an adhesive material to adhere the contact pads of the die to the corresponding contact areas on the first surface of the substrate; and
(c) releasing the die from the support structure so that the die remains attached to the substrate.
12. The method of claim 10, wherein the support structure comprises an adhesive that releases when heated, wherein step (c) comprises:
applying heat to a second surface of the support structure that is opposite the die to cause the die to release from the first surface of the support structure.
13. The method of claim 10, wherein the support structure comprises an adhesive that is light releasable, wherein step (c) comprises:
using a laser to heat a second surface of the support structure that is opposite the die to cause the die to release from the first surface of the support structure.
14. The method of claim 10, wherein step (c) comprises:
moving apart the support structure and substrate.
15. The method of claim 14, wherein said moving step comprises:
moving apart the support structure and substrate so that the die remains attached to the substrate due to the adhesive material overcoming an adhesiveness of the support structure.
(d) applying the adhesive material to the contact areas of the substrate.
17. The method of claim 10, wherein a first surface of each die is attached to the support structure, further comprising:
(d) applying the adhesive material to a second surface of the die.
18. The method of claim 14, wherein the support structure is a tape structure, wherein said moving step comprises:
peeling the support structure from the substrate.
“Method And Apparatus For Expanding A Semiconductor Wafer,” U.S. Ser. No. ______ (Atty. Dkt. No. 1689.0520000);
“Method, System, And Apparatus For Transfer Of Dies Using A Pin Plate,” U.S. Ser. No. ______ (Atty. Dkt. No. 1689.0560000); and
Large quantities of dies can be transferred. For example, 10 s, 100 s, 1000 s, or more dies, or even all dies of a wafer, support surface, or die plate, can be simultaneously transferred to corresponding substrates of a web.
FIG. 9 shows a flowchart providing example steps for transferring dies using an expandable material, according to embodiments of the present invention.
FIGS. 10-13 show example implementations of the steps of the flowchart of FIG. 9, according to embodiments of the present invention.
FIG. 14 shows a flowchart providing example steps for transferring dies directly from a support structure to a substrate, according to embodiments of the present invention
FIGS. 15-19 show example implementations of the steps of the flowchart of FIG. 14, according to embodiments of the present invention.
FIG. 1A shows a block diagram of an exemplary RFID tag 100, according to an embodiment of the present invention. As shown in FIG. 1A, RFID tag 100 includes a die 104 and related electronics 106 located on a tag substrate 116. Related electronics 106 includes an antenna 114 in the present example. FIGS. 1B and 1C show detailed views of exemplary RFID tags 100, indicated as RFID tags 100 a and 10 b. As shown in FIGS. 1B and 1C, die 104 can be mounted onto antenna 114 of related electronics 106. As is further described elsewhere herein, die 104 may be mounted in either a pads up or pads down orientation.
In a step 306, the plurality of dies 104 on wafer 400 are separated. For example, step 306 may include scribing wafer 400 according to a process, such as laser etching. FIG. 5 shows a view of wafer 400 having example separated dies 104 that are in contact with support surface 404. FIG. 5 shows a plurality of scribe lines 502 a-1 that indicate locations where dies 104 are separated.
Example embodiments of the steps of flowchart 300, are described in co-pending applications, “Method and Apparatus for Expanding a Semiconductor Wafer,” (Atty. Dkt. 1689.0520000), “Method, System, and Apparatus for Transfer of Dies Using a Die Plate Having Die Cavities,” (Atty. Dkt. 1689.0540000), “Method, System, and Apparatus for Transfer of Dies Using a Die Plate,” (Atty. Dkt. 1689.0550000), “Method, System, and Apparatus for Transfer of Dies Using a Pin Plate,” (Atty. Dkt. 1689.056000), and “Method, System, and Apparatus for High Volume Transfer of Dies,” (Atty. Dkt. No. 1689.0580000), each of which is herein incorporated by reference in its entirety.
In a step 310, post processing is performed. For example, during step 310, assembly of RFID tag(s) 100 is completed.
In step 704, the plurality of dies are transferred to a subsequent surface. For example, dies 104 may be transferred according to embodiments of the present invention. For example, the dies may be transferred by an adhesive tape, a punch tape, a multi-barrel transport mechanism and/or process, die frame, pin plate, such as are further described below and/or in the incorporated patent applications, and may be transferred by other mechanisms and processes, or by combinations of the mechanisms/processes described or referenced herein. In embodiments, the subsequent surface can be an intermediate surface or an actual final substrate. For example, the intermediate surface can be a transfer surface, including a “blue tape,” as would be known to persons skilled in the relevant art(s). When the subsequent surface is a substrate, the subsequent surface may be a substrate structure that includes a plurality of substrates, or may be another substrate type.
2. Die Transfer to Substrates
2.1 Die Transfer from Intermediate Surface to Substrate Using Changeable or Movable Material
FIG. 9 shows a flowchart 900 of a method for transferring dies from an intermediate surface to a substrate using a changeable or movable material, according to embodiments of the present invention. The flowchart depicted in FIG. 9 is described with continued reference to FIGS. 10-13. However, flowchart 900 is not limited to those embodiments. Further operational and structural embodiments of the present invention will be apparent to persons skilled in the relevant arts based on the following discussion. Note that in alternative embodiments, steps shown in FIG. 9 can occur in an order other than that shown, and in some embodiments, not all steps shown are necessary.
Flowchart 900 begins at step 902 when a die plate is received that has a first surface having a plurality of dies attached thereto. The die plate has a plurality of holes extending from the first surface to a second surface. Each attached die covers a corresponding hole at the first surface of the die plate. Example embodiments of die plates are described in co-pending applications, “Method, System, and Apparatus for Transfer of Dies Using a Die Plate Having Die Cavities,” (Atty. Dkt. 1689.0540000) and “Method, System, and Apparatus for Transfer of Dies Using a Die Plate,” (Atty. Dkt. 1689.0550000), each of which is herein incorporated by reference in its entirety.
FIG. 10 shows a die plate 1000 having a plurality of dies 104 attached to a first surface of the die plate. As shown in FIG. 10, each die 104 covers a corresponding hole 1006 through die plate 1000 at the first surface of die plate 1000.
In step 904, each hole of the die plate is at least partially filled with a material. For example, the hole may be filled with a material that can be caused to expand, a material that can be caused to exert pressure in multiple directions, or a material that moves when exposed to a certain stimulus or stimuli.
For example, as shown in FIG. 11, each hole 1006 is at least partially filled with a material. For example, as shown in FIG. 11, hole 1006 a is filled with a material 1102. Material 1102 can be any material that can be caused to expand or contract when exposed to stimuli, including an epoxy, a plastic, a polymer, a glass, or other material or combination thereof. Alternatively, the material can be any material that can be caused to exert pressure in multiple directions or change positions when exposed to stimuli including a magnetic fluid, artificial muscle material, or other material or combination thereof.
In step 906, the die plate and one or more substrates are positioned to be closely adjacent to each other such that contact pads of each die of the plurality of dies are closely adjacent to corresponding contact areas on the first surface of the substrate(s).
For example, FIG. 12 shows a die plate 1000 and substrate 116 positioned to be closely adjacent to each other such that contact pads 204 a and 204 b of die 104 are closely adjacent to corresponding contact areas 210 on a first surface of substrate 116. Note that die plate 1000 and substrate 116 in various embodiments can be positioned to varying degrees of closeness to each other, including distances other than that shown in FIG. 12.
In step 908, a stimulus (or stimuli) is applied to the material to cause the material in each hole to release a corresponding die from the die plate. For example, the material can be caused to expand, exert pressure, or move in the hole. This action by the material releases each die of the plurality of dies from the die plate. Example stimuli that can be used are heating, application of a voltage, application of a force, or application of other stimulus or combination thereof. The stimulus used is determined based on the physics and/or characteristics of the material used to fill the holes of the die plate.
For example, FIG. 13 shows a exemplary material 1102 that is caused to expand in hole 1006 a. By expanding, material 1102 detaches die 104 a from the bottom surface of die plate 1000. Thus, die 104 a is moved by material 1102 to contact with substrate 116 a.
Note that in the example of FIG. 13, a laser 1202 is depicted that causes the material 1102 filling each hole to expand. Laser 1202 directs a beam towards material 1102, which heats material 1102 to cause it to expand. Note that in alternative embodiments, other methods may be used to cause material 1102 to expand. In this manner, an expandable material can be used to transfer dies from a die plate, in place of the use of punch pins of a pin plate.
Furthermore, FIG. 13 also shows an adhesive material 1212 a adhering contact pads 204 of die 104 to the corresponding contact areas 210 on the first surface of substrate 116 a. Thus, in an embodiment, the adhesive material 1212 a is cured or otherwise treated to cause die 104 a to adhere to substrate 116 a.
2.2 Direct Die Transfer
FIG. 14 shows a flowchart 1400 of a method for transferring dies directly from a support structure to a substrate, according to embodiments of the present invention. The flowchart depicted in FIG. 14 is described with continued reference to FIGS. 15-19. However, flowchart 1400 is not limited to those embodiments. Further operational and structural embodiments of the present invention will be apparent to persons skilled in the relevant arts based on the following discussion. Note that in alternative embodiments, steps shown in FIG. 14 can occur in an order other than that shown, and in some embodiments, not all steps shown are necessary. Further operational and structural embodiments of the present invention will be apparent to persons skilled in the relevant arts based on the following discussion.
For example, FIG. 15 shows a plurality of dies 104 attached to a support surface or support structure 404. FIG. 15 further shows a single substrate 116 a of a web 608.
Flowchart 1400 begins at step 1402 when the support structure and substrate are positioned to be closely adjacent to each other such that contact pads of a die attached to the support structure make contact with corresponding contact areas on a first surface of the substrate.
For example, FIG. 16 shows an example of a support structure 404 and substrate 116 a positioned closely adjacent to each other such that contact pads 204 of die 104 a make contact with corresponding contact areas 210 of substrate 116 of web 608.
In step 1404, the contact pads 204 of die 104 a are adhered to the corresponding contact areas 210 on the first surface of substrate 116 a by adhesive material 1212 a.
In step 1406, the die is released from the support structure so that the die remains attached to the substrate.
In an embodiment, dies are attached to a support structure by an adhesive material that can be caused to release the dies when heat is applied thereto. In this embodiment, in step 1406, heat is applied to a second surface of the support structure, opposite the die, to cause the die to release from the first surface of the support structure.
In an embodiment, a light source is used to release dies from the support structure. For example, FIG. 17 shows a light pipe 1702 being used to release dies from the support structure. Light pipe 1702 is applied to support structure 404 on a surface of support structure 404 opposite that to which die 104 a is attached. Light pipe 1702 can be any type of optical structure, such as an optical tube, optical fiber, including a communications optical fiber, that allows light to pass through. For example, FIG. 17 shows a light 1704 being emitted from light pipe 1702. In an embodiment light 1704 is ultraviolet light. Light 1704, however, can comprise other wavelengths of light. In the current embodiment, die 104 a is attached to support structure 404 by an adhesive material that can be caused to release die 104 when a light of a particular wavelength, such as ultraviolet light is applied thereto. Thus, as shown in FIG. 19, die 104 a can be released from support structure 404, whereby die 104 a remains attached to substrate 116 a of web 608, by the application of light 1704 from light pipe 1702.
In an embodiment, in step 1406, the support structure is moved apart from the substrate so that the dies remain attached to the substrate due to the adhesive material overcoming the adhesiveness of the support structure. For example, the adhesiveness of the adhesive material between the substrate and die is stronger than the adhesiveness of the adhesive material between the dies and the support structure.
In an embodiment, in step 1406, the support structure is peeled from the substrate.
Alternatively, or additionally, a component contacts support structure 404 to cause or aid the release of dies from the support structure. Thus, as shown in FIG. 18, an end of light pipe 1702 can be used to push through support structure 404 to cause die 104 a to come into contact with the contact areas of substrate 116 a. During this process, as described above, light 1704 causes die 104 a to be released from support structure 404, and to remain attached to substrate 116 a, as shown in FIG. 19.
In the embodiments described above, an adhesive material may be applied to the contact areas of the substrate and/or to a second surface of the dies, opposite the support structure.
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U.S. Classification 29/829, 29/846, 29/825, 257/E21.511
International Classification H01L21/44, G08B13/14, H05K3/36, G06K19/077, B23P19/00, H01L29/06, H04Q5/22, H01L21/78, H01L21/00, H01L21/68, H01L21/60, H01R43/00, H05K3/00
Cooperative Classification H01L2924/00014, H01L2924/12042, Y10T156/1179, Y10T29/53178, Y10T29/4913, Y10T156/1978, Y10T29/49833, Y10T29/49155, Y10T156/1142, Y10T29/5327, Y10T29/49798, Y10T29/49165, Y10T29/53187, Y10T156/1983, Y10T29/49126, Y10T29/49117, Y10T156/1075, Y10T29/49124, Y10T156/1906, Y10T29/53422, Y10T29/49018, Y10S438/976, G11B23/0042, G11B7/26, H01L2924/3011, H01L2924/01075, H01L2221/68322, H01L2924/09701, H01L2924/01039, H01L2924/01013, H01L2221/68354, H01L2224/83192, H01L2924/014, H01L2924/01079, H01L2924/3025, G06K19/077, G11B23/0021, H01L2924/01033, H01L2224/16, H01L2223/54473, G06K19/041, H01L2924/01005, H01L21/68, H01L2924/19041, H01L2924/19042, H01L24/95, H01L21/78, H01L2924/14, H01L2224/81801, H01L2224/75, G06K19/07718, H01L2924/19043, H01L2924/01057, H01L2924/01006, H01L21/6835, H01L24/75, H01L2924/01047, H01L21/67132, G06K7/0095, H01L21/67144, H01L24/81, G06K19/045
European Classification H01L21/683T, G06K19/077, H01L24/95, H01L21/67S2T, G06K19/04K2C, G06K19/04K, G11B23/00D1A2A, H01L21/67S2P, H01L24/75, H01L21/68, G06K19/077D, G06K7/00M, H01L24/81, H01L21/78, G11B23/00D1
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ARNESON, MICHAEL R.;BANDY, WILLIAM R.;REEL/FRAME:015104/0557
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MATRICS, INC.;REEL/FRAME:015618/0640