Abstract:
Detection of bumps&#39; contact is enabled correctly, and the trouble of crushing a bump too much by an overshoot and connecting with an adjacent bump is abolished. The manufacturing apparatus of a semiconductor device and the manufacturing method of a semiconductor device which make it possible to perform stable flip chip bonding by an easy mechanism. 
     The manufacturing apparatus of the semiconductor device concerning the present invention has a stage where a substrate is arranged, a movable member formed made it possible to advance or retreat towards the stage, an elastic member formed in the movable member, a chip adsorption means which can adsorb the chip supported by the elastic member made it possible to advance or retreat towards a stage, a press means which can be pressed towards a stage about a chip adsorption means, a stopper which is formed in a movable member and can specify displacement of the direction close to a stage of a chip adsorption means by contacting a chip adsorption means from the stage side, a driving means which a movable member drives, and a control unit which controls operation of a driving means.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority from Japanese patent application No. 2006-163703 filed on Jun. 13, 2006, the content of which is hereby incorporated by reference into this application. 
         [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a manufacturing apparatus of a semiconductor device and a manufacturing method of a semiconductor device, and especially relates to a manufacturing apparatus of a semiconductor device and a manufacturing method of a semiconductor device by which the bump of a chip and the bump of a substrate are joined, and a semiconductor is manufactured. 
         [0004]    2. Description of the Background Art 
         [0005]    The bonding device which connects a chip and a substrate is known from the former (refer to following Patent Reference 1). 
         [0006]    Generally a bonding device has the chip adsorption means which adsorbs a chip, the bonding stage where a substrate is arranged, a heating means to heat a bump, the driving means which makes a chip adsorption means move towards a bonding stage, and the load cell which measures the external force applied to a chip adsorption means. 
         [0007]    In order to do bonding of a chip and the substrate using such a bonding device, where a chip is adsorbed, a chip adsorption means descends towards a bonding stage first. 
         [0008]    Here, when the bump of a chip and the bump of a substrate contact, slight external force will be applied to a chip adsorption means, and when a load cell senses change of this external force, contact with a chip and a substrate will be detected. When a chip and a substrate contact, lowering of a chip adsorption means will stop and a heating means will drive. And when the temperature of a heating means turns into more than prescribed temperature, a chip adsorption means will descend slightly, will stop and release adsorption of a chip after that, and will do bonding of a chip and the substrate. 
         [0009]    In such a conventional bonding device, since a chip adsorption means is guided by the linear guide, the frictional force by friction of a linear guide is also included in the external force which a load cell senses. 
         [0010]    This frictional force changing, it is very difficult to do correctly sensing of the external force change generated when a chip and a substrate contact. 
         [0011]    Then, the various proposals of the bonding device with which the device for doing sensing of the contact with a chip and a substrate correctly was made are made from the former (refer to Patent References 2 and 3). 
         [0012]    For example, the bonding device described to Japanese Unexamined Patent Publication No. 2004-319599 is provided with the capillary which adsorbs a chip, and the support member which was arranged on the outside of a capillary, with which the clearance between capillaries was sealed, and which was supported with the flat spring. 
         [0013]    The mechanisms accompanied by friction, such as linear bearing, are not included in the mechanism in which thrust is applied to a chip, and this bonding device can control very minute thrust with high precision. 
         [0014]    [Patent Reference 1] Japanese Unexamined Patent Publication No. Hei 11-297749 
         [0015]    [Patent Reference 2] Japanese Unexamined Patent Publication No. 2004-319599 
         [0016]    [Patent Reference 3] Japanese Unexamined Patent Publication No. Hei 11-340273 
       SUMMARY OF THE INVENTION 
       [0017]    In the bonding device described to the above-mentioned Japanese Unexamined Patent Publication No. 2004-319599, lowering of the tool holding a flip chip is electrically controlled. Therefore, when contacting the electrically conductive bump of a flip chip, and a wiring substrate, heating them and adhering, it is difficult to control the height of a flip chip, forcing a flip chip on a wiring substrate by a predetermined bonding weight. For example, the adjoining bump was crushed too much by the overshoot, the circuit might be short-circuited and the joining defect of solder etc. might happen with the lack of load. 
         [0018]    The present invention is made in view of the above-mentioned problem. Without including the mechanisms accompanied by friction, such as linear bearing, in the mechanism in which thrust is applied to a chip, minute thrust is made controllable with high precision, and detection of bumps&#39; contact is enabled correctly. It aims at abolishing the trouble of crushing a bump too much by an overshoot and connecting with an adjacent bump, and performing stable flip chip bonding. It aims at making flip chip bonding possible by an easy mechanism. 
         [0019]    A manufacturing apparatus of a semiconductor device concerning this invention comprises a stage where a substrate is arranged, a movable member formed so that it is possible to advance or retreat towards the stage, an elastic member formed in the movable member, a chip adsorption means which is supported by the elastic member so that it is possible to advance or retreat towards the stage, and which can adsorb a chip, a press means which can press the chip adsorption means towards the stage, a stopper which is formed in the movable member and which can specify displacement of a direction close to the stage of the chip adsorption means by contacting the chip adsorption means from the stage side, a driving means which drives the movable member, and a control unit which controls operation of the driving means. 
         [0020]    A manufacturing method of a semiconductor device concerning this invention comprises the steps of making a chip stick to a chip adsorption means, moving the chip towards a substrate and contacting a bump of the chip and a bump of the substrate, pushing and pressing the chip adsorption means towards the substrate when contacting a bump of the chip, and a bump of the substrate, melting the bump by heating the bump where the bumps contact and the chip adsorption means has pushed and pressed towards the substrate, and stopping the chip adsorption means in contact with a stopper further after the chip adsorption means moves only prescribed distance towards the substrate after melting the bumps. 
         [0021]    According to a manufacturing apparatus of a semiconductor device and a manufacturing method of a semiconductor device concerning the present invention, without including the mechanisms accompanied by friction, such as linear bearing in the mechanism in which thrust is applied to a chip, minute thrust is made controllable with high precision, and detection of bumps&#39; contact is enabled correctly. The trouble of crushing a bump too much by an overshoot and connecting with an adjacent bump can be abolished, and stable flip chip bonding can be performed. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a side view of the bonding device concerning this embodiment; 
           [0023]      FIG. 2  is a front view of the bonding device concerning this embodiment; 
           [0024]      FIG. 3  is a plan view showing an example of a flat spring; 
           [0025]      FIG. 4  is a plan view showing other examples of a flat spring; 
           [0026]      FIG. 5  is a plan view showing the example of further others of a flat spring; 
           [0027]      FIG. 6  is a partially sectional side view showing the first step of the manufacturing process of the semiconductor device concerning this embodiment; 
           [0028]      FIG. 7  is a partially sectional side view showing the second step of the manufacturing process of the semiconductor device concerning this embodiment; 
           [0029]      FIG. 8  is a partially sectional side view showing the third step of the manufacturing process of the semiconductor device concerning this embodiment; 
           [0030]      FIG. 9  is a partially sectional side view showing the fourth step of the manufacturing process of the semiconductor device concerning this embodiment; 
           [0031]      FIG. 10  is a cross-sectional view near a bump when the bump of a substrate and the bump of a substrate contact; 
           [0032]      FIG. 11  is a cross-sectional view when the bump of a chip and the bump of a substrate melting and unifying and being set as a bump; 
           [0033]      FIG. 12  is a flows-of-control picture when connecting the bump of a chip, and the bump of a substrate; 
           [0034]      FIG. 13  is other flows-of-control picture when connecting the bump of a chip, and the bump of a substrate; and 
           [0035]      FIG. 14  is a partially sectional side view showing the modification of the bonding device concerning this embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Bonding device  100  and a manufacturing method of a semiconductor device related to the present invention are explained using  FIG. 14  from  FIG. 1 .  FIG. 1  is a side view of bonding device  100  concerning this embodiment, and  FIG. 2  is a front view of bonding device  100 . Bonding device (manufacturing apparatus of a semiconductor device)  100  related to the present invention as shown in these  FIG. 1  and  FIG. 2  has bonding stage  17  where substrate W is arranged, movable member  27  formed in bonding head  50  via linear guide  7 , bonding mechanism  60  formed in this movable member  27 , force means  14 , actuator  8  for a drive (first actuator), and control unit  70  which controls each operation. 
         [0037]    Bonding stage  17  comprises rigid high materials, such as ceramics and stainless steel. 
         [0038]    Via linear guide  7 , movable member  27  is formed in bonding head  50 , and is displaced by actuator  8  for a drive, and the advance or retreat of it is enabled towards bonding stage  17 . Actuator  8  for a drive comprised a servo motor and a ball screw, changed the torque of the motor into the thrust with the ball screw, and has generated the thrust which slides movable member  27 . It is good also as an air cylinder instead of actuator  8  for a drive, for example. 
         [0039]    Bonding mechanism  60  is formed in the bonding stage  17  side among movable members  27 . From bonding mechanism  60 , force means  14  is the upper part and is formed in movable member  27 . 
         [0040]    Bonding mechanism  60  has chip adsorption means  1  which can adsorb chip S, support member  26  formed in this chip adsorption means  1 , housing (case)  4  fixed to movable member  27 , flat spring (elastic member)  3  formed in this housing  4 , and load cell  6  for contact detection fixed to movable member  27 . 
         [0041]    The under surface which faces with bonding stage  17  among the front surfaces of chip adsorption means  1  is made into the bonding surface where chip S adsorbs. Heating means  25 , such as a heater, are formed above this bonding surface. 
         [0042]    Vacuum adsorption of chip adsorption means  1  is made possible by suction of air in chip S, and suction opening  1   a  is formed in the bonding surface. 
         [0043]    Support member  26  is being fixed to the upper surface of this chip adsorption means  1 , and at least a part of this support member  26  is located in housing  4 . 
         [0044]    Through hole  4   a  in which support member  26  arranged inside is inserted is formed in the upper and lower sides of housing  4 . Support member  26  is supported with flat spring  3  within housing  4 . 
         [0045]    Flat spring  3  is formed in point symmetry centering on the central point (center-of-gravity point) of flat spring  3 . This flat spring  3  is being fixed to housing  4  centering on the central point in the position of point symmetry. 
         [0046]      FIG. 3  is a plan view showing an example of flat spring  3 , and as shown in this  FIG. 3 , it is formed in flat discoid. Through hole  3   a  in which support member  26  shown in  FIG. 1  is inserted is formed in the central part comprising the central point of flat spring  3 . A plurality of slits  3   b  which are formed focusing on this through hole  3   a , and are extended and existed to a hoop direction are formed. Slit  3   b  is also arranged centering on the central point at point symmetry. Flat spring  3  formed in this way is arranged in housing  4  so that it may become parallel to the front surface of bonding stage  17 . 
         [0047]    When support member  26  which is shown in  FIG. 1  and by which chip adsorption means  1  were formed successively is supported using such a flat spring  3 , chip adsorption means  1  will be supported so that it can move towards bonding stage  17 . 
         [0048]    Since a plurality of slits  3   b  are formed especially, the deformation of flat spring  3  becomes large. Even if the stress applied to chip adsorption means  1  is minute, support member  26  and chip adsorption means  1  which are supported with flat spring  3  are displaced sensitively. Hereby when the bump of chip S which chip adsorption means  1  adsorbed, and the bump of substrate W arranged on bonding stage  17  contact, support member  26  and chip adsorption means  1  can be relatively displaced good to housing  4 . 
         [0049]    As shown in  FIG. 1 , a plurality of flat springs  3  are formed in housing  4 . Each flat spring  3  of each other is spaced out in the advance-or-retreat direction of movable member  27 . 
         [0050]    Through hole  3   a  of each flat spring  3  shown in  FIG. 3  is arranged on the vertical axis to the front surface of substrate W shown in  FIG. 1 . The axis line of support member  26  is arranged so that it may become vertical to substrate W. It arranges so that the front surface of chip S which the under surface of chip adsorption means  1  adsorbs, and the front surface of substrate W may become parallel mutually by this. It can suppress that support member  26  inclines to the advance-or-retreat direction (it is a vertical direction to the front surface of substrate W) of support member  26  by separating a gap in the advance-or-retreat direction of support member  26 , and supporting support member  26  with flat spring  3 . 
         [0051]    Hereby, it can suppress that chip S with which chip adsorption means  1  connected to support member  26  was equipped inclines to substrate W. Chip S can be made to be able to approach towards substrate W, maintaining the state where the upper surface of substrate W and the under surface of chip S were made parallel. 
         [0052]      FIG. 4  is a plan view showing other examples of flat spring  3 , and as shown in this  FIG. 4 , it may form flat spring  3  disc-like.  FIG. 5  is a plan view showing the example of further others of flat spring  3 , and as shown in this  FIG. 5 , it is good also as a square shape. 
         [0053]    Namely, flat spring  3  should just be made into point symmetry form making the central point the center. Form, such as polygonal shape, circular form, and elliptical, is employable. 
         [0054]    Support member  26  is provided with containing section  26   a  which has an opening on the side surface at the side of movable member  27  of support member  26  and which consists of a recess or a through hole in  FIG. 1 . 
         [0055]    Load cell  6  for contact detection fixed to movable member  27  is stored by this containing section  26   a . Load cell  6  for contact detection is being fixed to the other end side of holddown member  6   a  by which one end was fixed to movable member  27 . This load cell  6  for contact detection is made measurable in the contact force generated between support members  26 , and it is arranged so that support member  26  can be supported from the bonding stage  17  side. 
         [0056]    The width of the direction where support member  26  moves of containing section  26   a  is formed more greatly than the width of load cell  6  for contact detection. 
         [0057]    For this reason, when external force is applied to chip adsorption means  1 , flat spring  3  will do elastic deformation and will do relative displacement of the support member  26  to movable member  27 . Since load cell  6  for contact detection is being fixed to movable member  27  within containing section  26   a  at this time, it is relatively displaced to support member  26 . 
         [0058]    Force means  14  is provided with actuator  12  for press which pushes and presses the top end of support member  26 , and load cell  13  for thrust detection which is formed in the bottom end of actuator  12  for press, and measures the thrust applied to support member  26 . Actuator  12  for press is formed in the same as the above-mentioned actuator  8  for a drive, and not only the structure of a servo motor and a ball screw but a linear motor is sufficient as actuator  12  for press. 
         [0059]    Control unit  70  is provided with memory means  10  by which each parameter was stored, and control means  9  which controls the drive of actuator  12  for press, actuator  8  for a drive, etc. 
         [0060]    How to do bonding of a chip and the substrate and to manufacture a semiconductor device is explained using bonding device  100  formed as mentioned above. 
         [0061]      FIG. 6  is a partially sectional side view showing the first step of the manufacturing process of the semiconductor device concerning this embodiment.  FIG. 12  shows the flows of control when connecting the bump of chip S, and the bump of substrate W. 
         [0062]    As shown in  FIG. 6 , chip adsorption means  1  adsorbs chip S first. And chip S is transported on bonding stage  17 . According to the alignment mechanism which is not illustrated, horizontal alignment of chip S and substrate W is done, and the bump of substrate W and the bump of chip S are made to correspond in an up-and-down direction. 
         [0063]    On this occasion, load cell  6  for contact detection touches the internal surface of containing section  26   a . Load cell  6  for contact detection is pushing and pressing support member  26  towards the upper part from the bonding stage  17  side. That is, support member  26  and chip adsorption means  1  are supported by flat spring  3  and load cell  6  for contact detection. The weight of support member  26  and chip adsorption means  1  balances with the thrust from load cell  6  for contact detection, and the thrust from flat spring  3 . 
         [0064]    Thus, the mechanism which supports support member  26  and chip adsorption means  1  is a thing like linear guide  7  which does not include the mechanism in which friction generates. 
         [0065]    And after the balance of the force of support member  26 , flat spring  3 , and load cell  6  for contact detection has balanced as mentioned above, when slight external force is applied to chip adsorption means  1  from the outside, the contact force between load cell  6  for contact detection and support member  26  will be changed. Especially the rigidity of load cell  6  for contact detection and support member  26  is larger than flat spring  3 , and the elastic deformation of load cell  6  for contact detection and support member  26  is small. Therefore, load cell  6  for contact detection can detect change of the external force applied to support member  26  with high precision. 
         [0066]      FIG. 7  is a partially sectional side view showing the second step of the manufacturing method of the semiconductor device concerning this embodiment. As shown in this  FIG. 7 , after the stress state of support member  26 , flat spring  3 , and load cell  6  for contact detection has balanced, control means  9  drives actuator  8  for a drive, and descends movable member  27  towards bonding stage  17 . The alignment of substrate W and chip S is completed and let the position of movable member  27  just before movable member  27  is displaced below be a reference point of movable member  27 . 
         [0067]    And when the bump of chip S and the bump of substrate W contact, chip adsorption means  1  will be supported by the bump of substrate W. It changes so that the stress generated between load cell  6  for contact detection and support member  26  may become small. As mentioned above, since load cell  6  for contact detection can detect stress change with sufficient accuracy, it can judge that the bump of substrate W and the bump of chip S contacted. 
         [0068]    Concretely, in  FIG. 12 , control means  9  descends movable member  27  until measurement value φ which is detected by load cell  6  for contact detection, and which is generated between load cell  6  for contact detection and support member  26  reaches set value ψ stored in memory means  10  shown in  FIG. 1 . 
         [0069]    And it memorizes for memory means  10  by making the position of movable member  27  into a point of contact when measurement value φ turns into set value ψ. 
         [0070]      FIG. 10  is a cross-sectional view of the bump  19  and  20  neighborhood when bump  19  of chip S and bump  20  of substrate W contact. In this  FIG. 10 , bumps  19  and  20  are formed from hemispherical solder. And the front surface of substrate W and the front surface of chip S are spaced out distance L 1 . 
         [0071]      FIG. 8  is a partially sectional side view showing the third step of the manufacturing process of the semiconductor device concerning this embodiment. In this  FIG. 8  and  FIG. 12 , with control signal A from control means  9 , actuator  8  for a drive is made to drive further, and movable member  27  descends only prescribed distance α towards bonding stage  17 . 
         [0072]    Thus, when movable member  27  is displaced towards a lower part in the state where the bump of substrate W and the bump of chip S are in contact, while load cell  6  for contact detection fixed to movable member  27  will also be displaced below, chip adsorption means  1  and support member  26  are maintained in the above-mentioned contact position. 
         [0073]    For this reason, load cell  6  for contact detection which was in contact with the internal surface of containing section  26   a  of support member  26  spaces out only prescribed distance α from the internal surface of containing section  26   a.    
         [0074]    Since housing  4  is relatively displaced below to support member  26  and chip adsorption means  1 , to support member  26 , flat spring  3  deforms so that it may push and press towards bonding stage  17 , and pushes and presses chip S towards substrate W slightly. 
         [0075]      FIG. 9  is a partially sectional side view showing the fourth step of the manufacturing process of the semiconductor device concerning this embodiment. In this  FIG. 9  and  FIG. 12 , force means  14  is driven with control signal B from control means  9 . 
         [0076]    Hereby, actuator  12  for press drives and load cell  13  for thrust detection descends towards bonding stage  17 . And load cell  13  for thrust detection pushes and presses the upper end surface of support member  26 , and makes bump  19  and bump  20  push and press. 
         [0077]    And control means  9  controls the actuator for press so that measured value v which load cell  13  for thrust detection detects may turn into set value ω stored in memory means  10  and suppresses that excessive stress occurs between bumps  19  and  20 . 
         [0078]    Thus, after pushing and pressing bump  19  and bump  20 , heating means  25  drives with control signal C from control means  9 . In  FIG. 9 , the heat from heating means  25  heat-conducts the inside of chip adsorption means  1 , and is conducted to chip S from a bonding surface, and bumps  19  and  20  of chip S are heated. As for heating means  25 , temperature is controlled by control signal C from control means  9 , and the generation of too much heat is suppressed. 
         [0079]      FIG. 11  is a cross-sectional view when bump  20  of substrate W and bump  19  of chip S melting and unifying, and being set as bump  30 . 
         [0080]    As shown in this  FIG. 11  and  FIG. 10 , by heating means  25 , bump  20  and bump  19  are heated and melt. Since support member  26  is pushed and pressed towards bonding stage  17  in  FIG. 9  when bump  20  and bump  19  melt and they become liquid, support member  26  and chip adsorption means  1  are displaced towards bonding stage  17 . 
         [0081]    And chip adsorption means  1  and support member  26  are displaced to the bonding stage  17  side, and chip S is pushed in only prescribed distance α towards substrate W. Then, the internal surface of containing section  26   a  and the load cell for contact detection contact, the displacement to the lower part of support member  26  is specified, and lowering of chip adsorption means  1  stops. That is, after bumps  19  and  20  melt, load cell  6  for contact detection is functioning as a stopper which specifies the displacement in which chip adsorption means  1  is displaced towards bonding stage  17 . 
         [0082]    Thus, when chip adsorption means  1  is displaced towards bonding stage  17  after bumps  19  and  20  have melted, bump  19  and bump  20  becomes bump  30  of one, and chip S is connected with substrate W. 
         [0083]    Since the stress generated between bumps  19  and  20  will decrease when bump  20  of substrate W and bump  19  of chip S melt, the contact force generated between support member  26  and load cell  6  for contact detection increases. When load cell  6  for contact force detection detects change of this contact force, it is detectable that bumps  19  and  20  dissolved. 
         [0084]    Thus, when the measured value of load cell  6  for contact force detection is changed, control means  9  can stop the drive of actuator  12  for press, and can suppress too much pressurization. 
         [0085]    Thus, it can suppress that bump  30  formed is crushed too much and adjacent bumps connect, without the falling position of chip S overshooting, since chip adsorption means  1  can be stopped in mechanical. Hereby, good bonding can be performed. 
         [0086]    Though insulating films, such as an oxide film, were formed in bumps&#39;  19  and  20  front surface since it was made to dissolve after pushing bumps  19  and  20 , it can destroy, when pushing bumps  19  and  20 , and good electric connection can be performed. 
         [0087]    Moreover, the distance of chip S and substrate W can be correctly set as predetermined distance L 2 , and it can suppress that variation occurs in each semiconductor device manufactured. 
         [0088]    Force means  14  may consist of air cylinders. In that case, in  FIG. 13 , an air cylinder is sufficient as actuator  12  for press (welding pressure generating means). Pressurization control means  11  which controls the thrust of actuator  12  for press by control signal B from control means  9  should just be a precision generator regulator. Load cell  13  for thrust detection in particular shown in  FIG. 1  does not have the need. 
         [0089]      FIG. 14  is a partially sectional side view showing the modification of bonding device  100  concerning this embodiment. As shown in this  FIG. 14 , force means  14  does not need to adhere to bonding head  50 , and as shown in  FIG. 14 , it may be supported by a different structured division from bonding head  50 . 
         [0090]    The embodiment of the invention was explained as mentioned above. However, with all the points, the embodiment disclosed this time is exemplification and should be considered not to be restrictive. The range of the present invention is shown by the claim. It is meant that a claim, and all the change in a meaning and within the limits equivalent to the claim are included. 
         [0091]    The present invention relates to the manufacturing apparatus of a semiconductor device and the manufacturing method of a semiconductor device, and it is especially suitable to the manufacturing apparatus of a semiconductor device and the manufacturing method of a semiconductor device which manufacture a semiconductor device by joining the bump of a chip, and the bump of a substrate.