Patent Description:
Such an IC chip mounting apparatus and method is known from <CIT>, which is considered to represent the closest prior art. In detail, <CIT> discloses an apparatus and method where an antenna continuous body is conveyed along a path where a series of operations are performed, including the application of a thermosetting adhesive and the placement of IC chips onto the adhesive-coated antenna. <CIT> further describes the use of ultraviolet (UV) light irradiating units to cure the adhesive and secure the IC chips to the antenna continuous body.

<CIT> pertains to a production method for electronic apparatuses where a circuit chip is mounted on a film-shaped base. This document emphasizes a two-step heating process involving preheating and main heating steps for a thermosetting adhesive, aimed at preventing deformation of the base and voids in the adhesive, thereby enhancing the reliability of the electronic apparatus by improving the adhesive connection between the chip and its substrate.

<CIT> describes a manufacturing method for a non-contact communication member by electrically connecting an IC chip to an antenna. It focuses on a process that includes applying an adhesive to an antenna base material, placing the IC chip using the adhesive, and curing the adhesive while pressing the IC chip towards the antenna conductor. This method aims to manufacture high-precision non-contact communication components at low cost by improving the reliability of the adhesive bond.

With the spread of RFID tags, production of sheet-shaped inlays having an antenna and an IC chip electrically connected to the antenna is increasing. Manufacturing of an inlay involves a process of: providing an adhesive at a predetermined reference position on an antenna formed on a base material; and placing an IC chip at the reference position. The reference position is a reference for mounting the IC chip. Subsequently, the IC chip is fixed by curing with the adhesive.

For example, <CIT> discloses that a component such as an IC chip is mounted with a photo-curable adhesive.

Incidentally, there is a problem that an IC chip is unstable on an adhesive and thus likely to shift or tilt, due to a fact that viscosity of the adhesive is relatively low when the adhesive is applied on the antenna (that is, before cured). A shift or a tilt of the IC chip, if happens, reflects accuracy of a position where the IC chip is mounted, even after the adhesive is cured.

In view of this, an object of one aspect of the present invention is to improve accuracy in a position on which an IC chip is mounted, when an IC chip is mounted in an inlay manufacturing process.

This object is achieved by an IC chip mounting apparatus having the features specified in independent claim <NUM>, and an IC chip mounting method having the features specified in independent claim <NUM>.

According to the present invention, an IC chip mounting apparatus comprises a conveyor configured to convey an antenna continuous body on a conveying surface, the antenna continuous body having a base material and plural inlay antennas continuously formed on the base material; an ejection unit configured to eject a thermosetting adhesive toward a reference position of each antenna in the antenna continuous body; an IC chip placement unit configured to place an IC chip on the adhesive that is located on the reference position of each antenna in the antenna continuous body; a first light irradiator configured to irradiate the adhesive of each antenna with a first light, in the vicinity of a position where an IC chip is located on the conveying surface; and a second light irradiator configured to irradiate the adhesive of each antenna with a second light, at a position downstream from a position where the adhesive is irradiated with the first light.

An embodiment of the present invention improves accuracy in a position on which an IC chip is mounted, when an IC chip is mounted in an inlay manufacturing process.

The present invention is related to <CIT><CIT> and <CIT> respectively filed with the Japan Patent Office on December <NUM>, <NUM> and on December <NUM>, <NUM>, the entire contents of which are incorporated into this specification by reference.

Hereinafter, an IC chip mounting apparatus and an IC chip mounting method according to an embodiment will be described with reference to drawings.

An IC chip mounting apparatus <NUM> according to the embodiment is an apparatus for mounting an IC chip on a thin film antenna in manufacturing a contactless communication inlay, such as an RFID inlay.

<FIG> shows an exemplary antenna AN having a predetermined antenna pattern, but there is no intention to limit the antenna pattern thereto. <FIG> also shows enlarged views of an "E" part before and after an IC chip "C" is mounted on the antenna AN. In this example, an IC chip "C" is mounted at a predetermined reference position Pref that is determined in advance based on the antenna pattern. The IC chip "C" has such a very small size as several hundreds of micrometers in length and width dimensions, and this very small IC chip "C" is required to be mounted exactly at the reference position Pref.

Mounting the IC chip "C" on the antenna AN involves an IC chip placement process and a curing process. In the IC chip placement process, an adhesive is applied to the reference position Pref of the antenna AN, and the IC chip "C" is placed on the adhesive. In the curing process, the adhesive is cured to strongly connect the antenna AN and the IC chip "C".

In the IC chip placement process (described later), a roll PR of a strip antenna sheet AS (an example of an antenna continuous body), as shown in <FIG>, is set. The antenna sheet AS includes a plurality of antennas AN formed on a base material BM with constant pitches. The antenna sheet AS is continuously pulled out of the roll PR and is provided to a line of the IC chip placement process.

Examples of the material that can be used for the base material BM include, but not specifically limited to, paper base materials such as fine paper, coated paper, and art paper, synthetic resin films made of polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), or polystyrene (PS), sheets made of a plurality of these synthetic resins, and composite sheets of a synthetic resin film and paper.

The antenna AN is formed, for example, by attaching a metal foil to a base material BM or by screen-printing or vapor-depositing a conductive material into a predetermined pattern on a base material BM.

In the following description, an XYZ coordinate system is defined as shown in <FIG>. The following describes a front view as a YZ-plane view, a plane view as an XY-plane view, and a side view as an XZ-plane view in referring to the drawings of components set in each process.

The X-direction is a direction of conveying the antenna sheet AS, which is pulled out of the roll PR, in each process described below, and it is also called a "conveying direction D1" as appropriate. In addition, the Y-direction is a width direction of the antenna sheet AS and is also called a "width direction D2" as appropriate. The Z-direction is a direction orthogonal to the antenna sheet AS.

Hereinafter, the IC chip placement process will be described with reference to <FIG>. <FIG> shows an area corresponding to the IC chip placement process of the IC chip mounting apparatus <NUM> of this embodiment. <FIG> shows a plane view of a chip-containing tape CT and an enlarged view of an A-A section thereof.

In the IC chip placement process, the IC chip mounting apparatus <NUM> accurately places a very small IC chip at the reference position Pref (refer to <FIG>) of each antenna AN on the antenna sheet AS.

As shown in <FIG>, the IC chip mounting apparatus <NUM> includes a conveyor <NUM>, a dispenser <NUM>, a rotary mounter <NUM>, an ultraviolet irradiator <NUM>, image capture devices CA1 to CA3, a tape feeder <NUM>, a tape body winding reel <NUM>, a film winding reel <NUM>, and a separation roller <NUM>, in the IC chip placement process.

The conveyor <NUM> (an example of a conveyor) conveys the antenna sheet AS that is pulled out of the roll PR (refer to <FIG>) to the downstream of the process at a predetermined conveying speed. An upper surface of the conveyor <NUM> corresponds to a conveying surface.

The dispenser <NUM> (an example of an ejection unit) ejects a fixed amount of anisotropic conductive paste (ACP; hereinafter simply called "conductive paste") to the reference position Pref of each antenna AN that is conveyed. This conductive paste is an example of an ultraviolet light curable adhesive. The dispenser <NUM> is configured so that the ejection position can be adjusted in the width direction, in order to accurately determine the ejection position relative to the reference position Pref of each antenna AN.

The image capture device CA1 is provided upstream of the dispenser <NUM> and captures an image of a part in the vicinity of the reference position Pref of each antenna AN, in order to determine the position to be applied with the conductive paste. The image capture device CA2 is provided downstream of the dispenser <NUM> and captures an image of a part in the vicinity of the reference position Pref of each antenna AN, in order to inspect whether the conductive paste is applied to each antenna AN and to inspect whether the conductive paste is applied exactly to a region including the reference position Pref.

The rotary mounter <NUM> (an example of an IC chip placement unit) is a chip mounter that places an IC chip on the conductive paste that is applied to each antenna AN, and it rotates in a counterclockwise direction in <FIG>. The rotary mounter <NUM> is mounted to a suspension plate <NUM>, and the suspension plate <NUM> is fixed to a support stand <NUM>. That is, the rotary mounter <NUM> is suspended from above by the support stand <NUM>.

As described later, the rotary mounter <NUM> sucks an IC chip from the chip-containing tape and places (mounts) the sucked IC chip by releasing it to the reference position Pref of each antenna AN on the antenna sheet AS. Meanwhile, in order to place the IC chip exactly at the reference position Pref of the antenna AN, the position and the direction of the sucked IC chip are corrected. The image capture device CA3 images the IC chip in the state of being sucked by a nozzle (described later), in order to perform a correction process of correcting the position and the direction of the IC chip in preparation for mounting it on the antenna AN.

The tape feeder <NUM> is configured to be loaded with a wound chip-containing tape that contains IC chips and to cause the chip-containing tape to be pulled out sequentially at a speed synchronized with the rotary mounter <NUM>, in the arrow directions in <FIG>.

Herein, an example of the chip-containing tape will be described with reference to <FIG>.

As shown in <FIG>, the chip-containing tape CT includes a tape body "T" and a cover film CF. Recesses Td for containing IC chips "C" are formed at fixed intervals in the tape body "T". The cover film CF is attached to the tape body "T" so as to cover the recesses Td. The recesses Td are formed, for example, by embossing the tape body "T". The IC chip "C" is contained in each recess Td along the extending direction of the chip-containing tape CT. The chip-containing tape CT has fitting holes H that are formed at fixed intervals in the extending direction. These fitting holes H are provided in order to accurately perform positioning relative to a circumferential surface of the separation roller <NUM>. The fitting holes H are fitted to protrusions 74p (described later), which are provided to the separation roller <NUM>, while the chip-containing tape CT is conveyed by the separation roller <NUM>.

As shown in <FIG>, a suction hole Ts is formed between a bottom surface of the recess Td and a back surface (surface on a side opposite to the surface attached with the cover film CF) of the tape body "T". The suction hole Ts is provided so as to make the separation roller <NUM> suck an IC chip "C", in order to prevent the IC chip "C" from falling out of the recess Td when the cover film CF is peeled off.

With reference to <FIG> again, the chip-containing tape CT is fed from the tape feeder <NUM> via one or a plurality of auxiliary rollers, and the cover film CF is peeled off from the chip-containing tape CT to be separated from the tape body "T" at the separation roller <NUM>. The IC chip "C" is exposed upon peeling off the cover film CF and is sequentially sucked by each nozzle that is provided to the rotary mounter <NUM>.

After the chip-containing tape CT is separated into the tape body "T" and the cover film CF by the separation roller <NUM>, the tape body "T" is wound by the tape body winding reel <NUM> via one or a plurality of auxiliary rollers, whereas the cover film CF is wound by the film winding reel <NUM> via one or a plurality of auxiliary rollers.

Next, the rotary mounter <NUM> will be described with reference to <FIG> and <FIG>.

<FIG> is a side view of the rotary mounter <NUM> of the IC chip mounting apparatus <NUM> of this embodiment. 6A is a plane view of a nozzle unit mounted on the rotary mounter <NUM>. 6B is a side view of nozzle units <NUM>. <FIG> schematically illustrates a relation between the rotary mounter <NUM> and the antenna sheet AS.

As shown in <FIG>, a plurality of nozzle units (twelve units in the example of the drawing) <NUM>-<NUM> to <NUM>-<NUM> are arranged radially from a rotary head <NUM> in the rotary mounter <NUM>. The following collectively describes the nozzle units <NUM>-<NUM> to <NUM>-<NUM> as "nozzle units <NUM>" when referring to matters that are common therebetween.

Although not illustrated in detail, the rotary head <NUM> is connected to a rotary drive motor, a vacuum pump, and a blower. The rotary drive motor rotates the nozzle units <NUM>-<NUM> to <NUM>-<NUM> in a counterclockwise direction in <FIG>. The vacuum pump causes the nozzle unit <NUM> to suck an IC chip. The blower causes the nozzle unit <NUM> to release the IC chip.

With reference to <FIG>, the rotary head <NUM> is rotated in a counterclockwise direction by the rotary drive motor (not shown), and accordingly, the positions on the circumference of the rotary head <NUM> of the nozzle units <NUM> are switched one by one. In more detail, one nozzle unit <NUM> sequentially shifts twelve positions PA to PL from the position PA to the position PL on the circumference of the rotary head <NUM> in the counterclockwise direction in such a manner as to move on a circular track on a flat plane orthogonal to the conveying surface, in accordance with rotation of the rotary head <NUM>.

Herein, the position PA is a position where the nozzle unit <NUM> sucks a new IC chip "C" from the chip-containing tape CT. The position PE is a position where the image capture device CA3 images the IC chip "C" in the state of being sucked by the nozzle of the nozzle unit <NUM>.

The position PK is a position where the sucked IC chip "C" is released on the conductive paste applied to the antenna AN of the antenna sheet AS that is conveyed. The moving direction of the top of the nozzle matches the conveying direction D1 of the antenna sheet AS at the position PK. The nozzle unit <NUM> discharges air from the nozzle to release the IC chip "C" at the position PK.

The nozzle unit <NUM> does not suck the IC chip "C" at the position PL, as it has released the IC chip "C" at the position PK. In order to remove dust that may adhere to the nozzle, air may be jetted out from the nozzle at the position PL. <FIG> shows an example of disposing a dust collection tray TR for collecting dust that may be detached from the nozzle, at the position PL.

In an example, the following movement is repeated. In <FIG>, the nozzle unit <NUM>-<NUM> at the position PA sucks a new IC chip "C" thereat and rotates in the counterclockwise direction while sucking the IC chip "C", and it then releases the IC chip "C" upon reaching the position PK and returns to the position PA to suck a new IC chip "C" again. Such an IC chip mounting method enables continuously placing the IC chip on each antenna AN without stopping conveyance of the antenna sheet AS, resulting in high productivity.

The angular velocity of the rotary head <NUM> and the conveying speed of the antenna sheet AS are set or controlled so that the nozzle unit <NUM>, which sequentially reaches the position PK, will release the IC chip "C" to the reference position Pref of each antenna AN of the antenna sheet AS, which is conveyed from the upstream side. In order to accurately place the IC chip "C", it is preferable to provide a section where the speed of the top of the nozzle unit <NUM> is equal to the conveying speed of the antenna sheet AS, in proximity to the position PK.

Note that this embodiment shows an example of arranging twelve nozzle units <NUM> to the rotary head <NUM>, but the number of the nozzle units <NUM> is not limited thereto. The number of the nozzle units <NUM> that are arranged to the rotary head <NUM> can be set to any number.

Next, movement of the nozzle unit <NUM> sucking the IC chip "C" will be described with reference to <FIG> and <FIG>.

<FIG> is a perspective view showing separation of the chip-containing tape CT by the separation roller <NUM>. <FIG> is a side view of the vicinity of the separation roller <NUM>, illustrating movement of supplying the IC chip "C" to the nozzle unit <NUM> from the chip-containing tape CT. In order to show the state of the chip-containing tape CT, only the chip-containing tape CT is illustrated in cross-section in <FIG>.

As shown in <FIG>, the chip-containing tape CT, which is supplied from the tape feeder <NUM>, is conveyed while its position in the width direction is determined by inserting the protrusions 74p of the separation roller <NUM> into the fitting holes H of the chip-containing tape CT. At this time, the cover film CF is peeled off from the chip-containing tape CT by a split member <NUM> and is sent to the film winding reel <NUM>. On the other hand, the tape body "T" of the chip-containing tape CT is sent to the tape body winding reel <NUM>.

As shown in <FIG>, the IC chip "C" that is exposed due to peeling off of the cover film CF is immediately sucked by the nozzle unit <NUM>. The separation roller <NUM> is provided with a suction path (not shown) for sucking the IC chip "C" toward the rotation center of the separation roller <NUM>, so that the IC chip "C" will not fall out during a short period from a time when the IC chip "C" is exposed until it is sucked by the nozzle unit <NUM>. The IC chip "C" is sucked through this suction path and the suction hole Ts (refer to <FIG>) provided to the tape body "T".

With reference to <FIG> again, the ultraviolet irradiator <NUM> is provided in the vicinity of the position (position PK in <FIG>) where the IC chip is released to the antenna AN from the nozzle unit <NUM> of the rotary mounter <NUM>.

The ultraviolet irradiator <NUM> (an example of a first light irradiator) emits ultraviolet light to the conductive paste on the antenna AN that is conveyed. The purpose of emission of ultraviolet light (an example of a first light) by the ultraviolet irradiator <NUM> is to adjust viscosity of the conductive paste on the antenna AN, which is different from the purpose of emission of ultraviolet light (an example of a second light) performed in a curing process (described later) following the IC chip placement process. From this point of view, an integrated light amount of ultraviolet light applied to the conductive paste by the ultraviolet irradiator <NUM> is preferably less than that of ultraviolet light applied to the conductive paste in the subsequent curing process. An integrated light amount of ultraviolet light is represented by a product of light intensity and irradiation time duration. Thus, adjustment of either light intensity or irradiation time duration enables adjustment of the integrated light amount.

In the IC chip mounting apparatus <NUM> of the present embodiment, the dispenser <NUM> may apply a thermosetting adhesive such as epoxy resin to the antenna AN, and a thermosetting machine may be applied in replacement of the ultraviolet irradiator <NUM>.

In <FIG>, the ultraviolet irradiator <NUM> is disposed to irradiate the adhesive with ultraviolet light after the IC chip has been located; however, other irradiation methods may be applied. For example, the ultraviolet irradiator <NUM> may be disposed so as to irradiate the adhesive with ultraviolet light before the IC chip is located, and may be disposed so as to irradiate the adhesive with ultraviolet light concurrently with the IC chip being located.

In case in which the adhesive is irradiated with ultraviolet light after the IC chip has been located, the IC chip is unlikely to shift or tilt after the IC chip has been located, as viscosity of the conductive paste decreases. In case in which the adhesive is irradiated with ultraviolet light before the IC chip is located or concurrently with the IC chip being located, the IC chip is located on the conductive paste with low viscosity. As the IC chip is unlikely to move after having been located on the conductive paste, the IC chip is unlikely to shift or tilt.

In any case, irradiation of ultraviolet light in the vicinity of a place where the IC chip is located, prevents a situation that the IC chip is unstable on the conductive paste due to viscosity of the conductive paste. That is, irradiation of the ultraviolet irradiator <NUM> has advantage that mounting accuracy of the IC chip is improved.

Next, the curing process will be described with reference to <FIG>.

The curing process involves curing the conductive paste, which is applied to each antenna and undergoes the IC chip placement process, whereby the physical connection between the antenna and the IC chip is strengthened, and the electrical conduction between the antenna and the IC chip is reliably made.

<FIG> shows an area corresponding to the curing process of the IC chip mounting apparatus <NUM> of this embodiment. <FIG> shows a part of a press unit <NUM> and ultraviolet irradiators <NUM> as seen from the arrow "J" in <FIG>. <FIG> shows the press unit <NUM> included in a curing device <NUM> of this embodiment. <FIG> is a plane view of a press unit circulation machine <NUM> included in the curing device <NUM> of this embodiment. Note that <FIG> omits a lower rail <NUM> (described later).

As shown in <FIG>, the IC chip mounting apparatus <NUM> includes a conveyor <NUM>, a curing device <NUM>, and an image capture device CA4, in the curing process.

The conveyor <NUM> conveys the antenna sheet AS that is conveyed from the upstream IC chip placement process to a downstream side at a predetermined conveying speed. An upper surface of the conveyor <NUM> corresponds to a conveying surface.

The image capture device CA4 is disposed above the antenna sheet AS on the most upstream of the curing process (that is, the most downstream of the IC chip placement process) and captures an image of each antenna AN that is conveyed from the IC chip placement process. The image capture device CA4 is provided in order to inspect whether the IC chip is placed at an appropriate position in the IC chip placement process.

As shown in <FIG>, the curing device <NUM> includes a press unit circulation machine <NUM> and ultraviolet irradiators <NUM> (examples of a second light irradiator). As shown in <FIG> and <FIG>, the press unit circulation machine <NUM> includes a circulation rail <NUM> composed of an upper rail 51U and a lower rail <NUM>, a main belt <NUM>, gears <NUM> and <NUM>, an auxiliary belt <NUM>, a feed gear <NUM>, and press units <NUM>.

The press unit circulation machine <NUM> circulates the press units <NUM> on a predetermined circular track.

The press unit <NUM> moves up and down in the direction orthogonal to the conveying surface, and it presses the IC chip, which is placed on the conductive paste of the antenna AN, while the antenna AN is being irradiated with ultraviolet light. The press unit circulation machine <NUM> may have any number of the press units <NUM>, but it is preferably configured so that the number of the press units <NUM> can be set to any number of two or more from the point of view of productivity and cost.

The ultraviolet irradiators <NUM> are arranged along the conveying direction D1. Thus, it is possible to irradiate many antennas AN on the antenna sheet AS with ultraviolet light simultaneously.

In the IC chip mounting apparatus <NUM> of this embodiment, a thermosetting adhesive, such as an epoxy resin, may be applied to the antenna AN by the dispenser <NUM>, and a thermosetting device with a heating unit, such as a heater, may be provided instead of the ultraviolet irradiator <NUM>.

As shown in <FIG>, preferably, a plurality of press units <NUM> (eight units in the example of the drawing) simultaneously and respectively press the IC chips that are placed on the conductive paste of a plurality of antennas (eight antennas in the example of the drawing) AN being conveyed. At this time, while the plurality of the press units <NUM> that are pressing and the plurality of the pressed antennas AN are moved at the same speed in the conveying direction D1 without stopping the conveyor <NUM> conveying the antenna sheet AS, the ultraviolet irradiators <NUM> irradiate each antenna AN with ultraviolet light. This leads to a very high productivity in fixing the IC chip to the antenna AN.

<FIG> shows a state in which each antenna AN is irradiated with ultraviolet light by the ultraviolet irradiators <NUM>.

The ultraviolet irradiator <NUM> has a light source 42e, such as a light emitting device (LED). The light source 42e is configured to emit ultraviolet light to the antenna AN from a direction oblique to the conveying surface.

The press unit <NUM> is open at a side surface (that is a surface on a side on which the ultraviolet irradiator <NUM> is disposed) of a pressing part <NUM>. A glass plate 61p is a pressing surface of the pressing part <NUM> and is made of glass through which ultraviolet light passes.

Next, the structure of the press unit <NUM> will be described with reference to <FIG>.

As shown in <FIG>, the press unit <NUM> includes a pressing part <NUM>, a housing <NUM>, a shaft <NUM>, and a roller holder <NUM>. A pair of lower rollers <NUM> and a pair of lateral rollers <NUM> that rotate on the lower rail <NUM> are attached to the housing <NUM>. A pair of upper rollers 64U that rotate on the upper rail 51U are attached to the roller holder <NUM>. The lower rollers <NUM> and the upper rollers 64U are suitable for rotating on a horizontal plane, whereas the lateral rollers <NUM> are suitable for rotating on a vertical plane.

The shaft <NUM> is coupled to the pressing part <NUM> at an end and is also coupled to the roller holder <NUM> at the other end. The shaft <NUM> is displaceable relative to the housing <NUM> in the upper-lower direction in <FIG>.

A spring (not shown) is incorporated into the housing <NUM>. <FIG> shows an external force-free state by solid lines and shows a pulled state (external force-applied state) by virtual lines, with respect to the pressing part <NUM>, the shaft <NUM>, and the roller holder <NUM>. Upon releasing the external force, the pulled state is returned to the free state by the restoring force of the spring.

Although a coil spring may be used as the spring, a magnetic spring is preferably used. A magnetic spring provides a constant pressing force irrespective of the stroke amount and thereby hardly damages the IC chip. In addition, the magnetic spring deteriorates little in characteristics after a long time use.

The housing <NUM> is formed with a pair of V groove parts <NUM>. The number of grooves of the V groove part <NUM> is not specifically limited, but each groove has a shape that fits to the main belt <NUM> and the feed gear <NUM>.

The housing <NUM> preferably contains a permanent magnet. The incorporated permanent magnets causes a plurality of the press units <NUM> to overlap one another in a waiting section due to the magnetic forces, and therefore, the press unit <NUM> is fed out at exact timing, as described later.

A space <NUM> is formed on a side having the V groove part <NUM> in the pressing part <NUM>, and the glass plate 61p that transmits ultraviolet light is attached to the bottom of the pressing part <NUM>. As shown in <FIG>, while being irradiated by the ultraviolet irradiator <NUM>, the IC chip is pressed by the bottom surface of the glass plate 61p. Providing the glass plate 61p, which transmits ultraviolet light, at the bottom of the glass plate 61p enables pressing the IC chip while irradiating it with ultraviolet light.

With reference to <FIG>, in the press unit circulation machine <NUM>, the gears <NUM> and <NUM> are driven by a main belt drive motor M41 (not shown in <FIG>) so as to rotate at a constant angular velocity in a counterclockwise direction. In accordance with rotation of the gears <NUM> and <NUM>, the main belt <NUM> that engages with each gear circulates around the gears <NUM> and <NUM> at a constant speed along the track of the press units <NUM>.

The auxiliary belt <NUM> is, for example, a flat belt or a V belt, and it is driven at a constant speed in a clockwise direction in <FIG> by an auxiliary belt drive motor M42 (not shown in <FIG>). The auxiliary belt <NUM> serves to accelerate the press unit <NUM> along the rails by engaging with the V groove part <NUM> of the press unit <NUM>.

The feed gear <NUM> is configured to engage with the V groove part <NUM> of the press unit <NUM>. The feed gear <NUM> is driven to rotate in the counterclockwise direction in <FIG> by a feed belt drive motor M43 (not shown in <FIG>). The feed gear <NUM> is provided so as to feed out the press unit <NUM> from the waiting position to the antenna sheet AS that is conveyed. The operation timing of the feed gear <NUM> is controlled by a controller <NUM> (described later). Note that a feed belt having an outside V groove part may be employed instead of the feed gear <NUM>.

Next, movement of the press unit circulation machine <NUM> will be described with reference to <FIG>.

<FIG> shows a B-B section and a C-C section in <FIG>. <FIG> illustrates positional relations of the press unit <NUM> in the pulled state and the pressing state relative to the circulation rail <NUM> in the press unit circulation machine <NUM>. <FIG> illustrates movement of feeding out the press unit <NUM>.

For convenience of the following explanation, the circulation route of the press unit <NUM> is divided into sections S1 to S5 in <FIG>, and each section will be described in turn.

As shown in <FIG>, the press unit <NUM> circulates on the circulation rail <NUM> while its pair of the upper rollers 64U rotate in contact with an upper surface <NUM> of the upper rail 51U, whereas its pair of the lower rollers <NUM> rotate in contact with a bottom surface <NUM> of the lower rail <NUM>.

Herein, the height of the bottom surface <NUM> of the lower rail <NUM> from the conveying surface of the conveyor <NUM> is constant along one round of the lower rail <NUM>.

In contrast, the height of the upper surface <NUM> of the upper rail 51U from the conveying surface of the conveyor <NUM> varies within one round. Specifically, the upper surface <NUM> of the upper rail 51U is lowest in the section S1 and is highest in the sections S3 and S4 in <FIG>. The height of the upper surface <NUM> of the upper rail 51U gradually increases in the section S2 as it goes in the counterclockwise direction in <FIG>, but it gradually decreases in the section S5 as it goes in the counterclockwise direction in <FIG>.

When the press unit <NUM> is in the section S1, due to the upper surface <NUM> of the upper rail 51U being lowest in one round, the press unit <NUM> is in the pressing state close to the free state, and the pressing part <NUM> is at the lowest position in one round. The positions of the upper surface <NUM> of the upper rail 51U and the bottom surface <NUM> of the lower rail <NUM> are set so that the press unit <NUM> in this state will come into contact with and press the antenna.

As shown in <FIG>, each press unit <NUM> moves immediately above each antenna of the antenna sheet AS along the conveying direction D1 of the antenna sheet AS, in the section S1. In the section S1, the V groove part <NUM> of each press unit <NUM> engages with the main belt <NUM>, and thus, each press unit <NUM> moves in accordance with the speed of the main belt <NUM>.

As described above, in the section S1, due to the upper surface <NUM> of the upper rail 51U being lowest in one round, each press unit <NUM> is in the pressing state close to the free state, whereby the pressing part <NUM> protrudes downward, as shown in <FIG>. As shown in <FIG>, the press unit <NUM> in the pressing state presses the IC chip, which is placed on the conductive paste on the corresponding antenna of the antenna sheet AS, by using the repulsive force of the spring contained in the press unit <NUM>.

In the section S2, as described above, the height of the upper surface <NUM> of the upper rail 51U gradually increases as it goes in the counterclockwise direction in <FIG>. Accordingly, the shaft <NUM> is gradually raised (pulled up) against the restoring force of the spring, and the pulled state in <FIG> is made at the last in the section S2. In the section S2, the V groove part <NUM> of each press unit <NUM> engages with the main belt <NUM>, and thus, each press unit <NUM> moves in accordance with the speed of the main belt <NUM>.

In the section S2, the upper surface <NUM> of the upper rail 51U gradually rises from its height in the section S1. Accordingly, the roller holder <NUM> of each press unit <NUM> is pulled up against the restoring force of the spring, and the pressing part <NUM> moves up accordingly.

Upon reaching the start position of the section S3, the press unit <NUM> is disengaged from the main belt <NUM>. That is, as appreciated with comparison between the B-B cross section and the C-C cross section in <FIG>, the upper rail 51U and the lower rail <NUM> are offset to the outside as a whole (offset amount ofs in <FIG>) in the sections S3 and S4 (refer to the C-C cross section) relative to the last position in the section S2 and the start position in the section S5 (each refer to the B-B cross section). The pair of the lateral rollers <NUM> of the press unit <NUM> rotates along an inside surface <NUM> of the lower rail <NUM>, whereby the V groove part <NUM> of the press unit <NUM> comes away from the main belt <NUM>.

In the section S3, after the press unit <NUM> is separated from the main belt <NUM>, the auxiliary belt <NUM>, which rotates in the clockwise direction in <FIG>, comes into contact with and strongly pushes out the outside V groove part <NUM> of the press unit <NUM>. This accelerates the press unit <NUM> in the counterclockwise direction along the circulation rail <NUM>. The press unit <NUM> is accelerated in the section S3 in order to avoid a situation in which a number of the press units <NUM> is insufficient in the section S4, which is a waiting section of the press units <NUM>.

In the section S3 and in the section S4 (described later), the upper surface <NUM> of the upper rail 51U is highest in one round, and each press unit <NUM> is in the pulled state as shown in <FIG>.

The section S4 is a waiting section (an example of a waiting position) where a plurality of the press units <NUM>, which have been sequentially sent from the section S3 while accelerated, waits until they are fed out. As described above, the press unit <NUM> preferably contains a permanent magnet in the housing <NUM>. In this state, the magnetic forces cause a plurality of the press units <NUM> to closely fit to each other in a mutually overlapping manner while waiting.

In the section S4, the feed gear <NUM> engages with the V groove part <NUM> of a leading press unit <NUM> among the plurality of the press units <NUM> that are waiting. Under these conditions, the feed gear <NUM> rotates in the clockwise direction in <FIG> at a time determined by the controller <NUM> (described later) to feed out the leading press unit <NUM>. The press units <NUM> overlap one another by the magnetic forces in the waiting section, and therefore, the press units <NUM> are fed out from the waiting section S4 one by one at exact times.

The operation of feeding out the press unit <NUM> will be further described with reference to <FIG> shows an engagement state of the V groove parts <NUM> with the main belt <NUM> and the feed gear <NUM> of the press units <NUM> in the vicinity of the feed gear <NUM>.

As shown in <FIG>, in the waiting section S4, the inside V groove parts <NUM> of a plurality of press units <NUM>-<NUM>, <NUM>-<NUM>, and so on do not engage with the main belt <NUM>, whereas the outside V groove part <NUM> of the leading press unit <NUM>-<NUM> engages with the feed gear <NUM>. In this state, upon rotation of the feed gear <NUM> in a clockwise direction based on an instruction from the controller <NUM> (described later), the press unit <NUM>-<NUM> moves left in <FIG> and is fed out. The lower rail <NUM> is formed so that the pair of the lateral rollers <NUM> of the press unit <NUM> will move on a track shown by the virtual lines (that is, move to the main belt <NUM> by the offset amount ofs, which is shown also in <FIG>) at this time. Thus, the press unit <NUM>-<NUM> that is pushed out moves inward to the main belt <NUM>, and the inside V groove part <NUM> comes to engage with the main belt <NUM> at the start position of the section S5. After the inside V groove part <NUM> engages with the main belt <NUM>, the press unit <NUM>-<NUM> moves following the movement of the main belt <NUM> in the section S5.

That is, in the section S5, the V groove part <NUM> of each press unit <NUM> engages with the main belt <NUM>, and thus, each press unit <NUM> moves in accordance with the speed of the main belt <NUM>.

As described above, the height of the upper surface <NUM> of the upper rail 51U gradually decreases as it goes in the counterclockwise direction in <FIG>. Accordingly, the shaft <NUM> is gradually lowered by the restoring force of the spring, and the pressing state in <FIG> is made at the last in the section S5. The pressing state is a state in which the pressing part <NUM> of the press unit <NUM> is at the lowest position in one round and is ready to press each antenna that is conveyed. Each press unit <NUM> in this state advances to the section S1 and presses the IC chip placed on the conductive paste of each antenna that is conveyed.

As described above, each press unit <NUM> moves up and down in the direction orthogonal to the conveying surface while circulating along the track (sections S1 to S5) of the circulation rail <NUM>, and it presses the IC chip that is placed on the conductive paste of the antenna AN. The press unit <NUM> circularly moves, whereby a predetermined number of the press units <NUM> can be continuously used for pressing.

Next, control of the curing device <NUM> performed by the controller <NUM> will be described with reference to <FIG> is a functional block diagram of the controller <NUM>.

The controller <NUM> is mounted on a circuit board (not shown) and is electrically connected to the image capture device CA4, the main belt drive motor M41, the auxiliary belt drive motor M42, the feed belt drive motor M43, and the ultraviolet irradiator <NUM>.

The controller <NUM> includes a microcomputer, memories (random access memory (RAM) and read only memory (ROM)), a storage, and drive circuits. The microcomputer reads and executes a program recorded in the memory, and it implements each function of a belt drive unit <NUM>, a feed time determination unit <NUM>, a first curing unit <NUM>, and a second curing unit <NUM>.

The belt drive unit <NUM> transmits control signals to drive circuits of the main belt drive motor M41 and the auxiliary belt drive motor M42 so that the main belt <NUM> and the auxiliary belt <NUM> will be driven at respective constant speeds. The belt drive unit <NUM> transmits a control signal to a drive circuit of the feed belt drive motor M43 in accordance with the feed time determined by the feed time determination unit <NUM>. The feed gear <NUM> rotates at the feed time accordingly. As a result, as shown in <FIG>, the leading press unit <NUM> in the waiting section is fed out.

The feed time determination unit <NUM> determines feed time when the leading press unit <NUM> is fed out among a plurality of the press units <NUM> in the waiting section of the press unit circulation machine <NUM>. The feed time is determined in consideration of each of these parameters: the speed of the main belt <NUM>, and the conveying speed of the conveyor <NUM>. That is, the feed time of each press unit <NUM> is determined based on each parameter so that each press unit <NUM> that is sequentially fed out from the waiting section S4 will meet each corresponding antenna AN passing through the image capture device CA4, at the start position of the section S1.

The first curing unit <NUM> transmits a predetermined drive signal to the ultraviolet irradiator <NUM> so that the ultraviolet irradiator <NUM> will emit ultraviolet light to each antenna AN that is conveyed, by an integrated light amount that is preliminarily set.

The second curing unit <NUM> transmits a predetermined drive signal to the ultraviolet irradiator <NUM> so that the ultraviolet irradiator <NUM> will emit ultraviolet light to each antenna AN that is conveyed, by an integrated light amount that is preliminarily set.

As described above, an integrated light amount of ultraviolet light applied to the conductive paste by the ultraviolet irradiator <NUM> is preferably less than that of ultraviolet light applied to the conductive paste by the ultraviolet irradiator <NUM>.

As aforementioned, a strip antenna sheet having a plurality of antennas that are formed on a base material at constant pitches is supplied to the line, and it is subjected to the IC chip placement process and the curing process, whereby the IC chip is mounted on each antenna. In the IC chip mounting apparatus of this embodiment, the adhesive is applied to the reference position of the antenna and then the IC chip is placed on the adhesive in the IC chip placement process, and the adhesive is cured to strongly connect the antenna and the IC chip in the curing process. Particularly in the IC chip placement process, irradiation of ultraviolet light in the vicinity of a place where an IC chip is located, increases viscosity of the conductive paste. This stabilizes the IC chip on the conductive paste. Then, additional irradiation of ultraviolet light in the subsequent curing process strengthens physical connection between the antenna and the IC chip. Consequently, accuracy is improved in a position on which an IC chip is mounted, when an IC chip is mounted in an inlay manufacturing process.

Although an embodiment of the IC chip mounting apparatus and the IC chip mounting method is described above, the present invention should not be limited to the foregoing embodiment. In addition, the embodiment described above may be variously modified and altered within the scope not departing from the gist of the present invention.

In an example, although the antenna sheet AS is conveyed on the conveyor <NUM> in one direction in the IC chip placement process in the embodiment shown in <FIG>, the conveying method is not limited thereto.

In an embodiment, as shown in <FIG>, the antenna sheet AS may be conveyed by suction drums <NUM> and <NUM> and a plurality of conveying rollers (e.g., conveying rollers <NUM>, <NUM>, and <NUM> in <FIG>) in the IC chip placement process. In <FIG>, the dispenser <NUM> ejects the conductive paste to the reference position of the antenna AN of the antenna sheet AS, at the highest position of the suction drum <NUM>. In addition, the IC chip is placed on the conductive paste at the highest position of the suction drum <NUM>. In this case, at least the suction drums <NUM> and <NUM> are preferably suction rollers that suck the back surface of the antenna sheet AS. This structure prevents dislocation of the antenna sheet AS (in particular, in the longitudinal direction), whereby ejection of the conductive paste as well as placement of the IC chip is performed with high accuracy.

In an embodiment, instead of releasing the IC chip on the conductive paste applied to the antenna AN on the conveyed antenna sheet AS, the IC chip may be placed by pressing it to the conductive paste.

<FIG> shows movement of the rotary mounter <NUM> in time series in the case of placing the IC chip by pressing it to the conductive paste. In an embodiment, nozzle units <NUM> of the rotary mounter <NUM> are configured to move in respective radial directions (diameter directions) by a built-in drive device.

The state ST1 is a state in which the nozzle unit <NUM> sucks the IC chip "C". Placement of the sucked IC chip "C" is performed in the state ST2. That is, the nozzle unit <NUM> is moved toward the reference position (that is, in the lower direction which is the Z-direction in <FIG>) in such a manner as to extend in the radial direction (diameter direction). The IC chip "C" is then placed on the conductive paste by pressing it to the conductive paste applied to the antenna AN. After the IC chip "C" is placed, the suction is released, and the nozzle unit <NUM> is returned to the position in the state ST1. For example, the movement from the state ST1 to the state ST3 is performed at the time the nozzle unit <NUM> reaches the position PK (refer to <FIG>), whereby the IC chip "C" is placed on the conductive paste applied on the antenna AN.

The curing process may not use the curing device <NUM> that circulates the press units <NUM>.

The curing process of an embodiment is shown in <FIG> shows a curing device 4A that is used in the curing process of an embodiment. The curing device 4A includes a plurality of ultraviolet curing units <NUM> that are detachably mounted to a mounting board <NUM>. A plurality of mounting boards <NUM> that have different mounting positions are prepared in accordance with the interval of adjacent antennas AN of the antenna sheet AS. Under these conditions, the mounting boards <NUM> are switched in response to the interval, whereby various antenna sheets AS can be used in the curing device 4A.

A support shaft <NUM> supports and moves the mounting board <NUM> up and down. The antenna sheet AS that is conveyed from the IC chip placement process is sent to the curing process via conveying rollers <NUM> to <NUM>. The conveying roller <NUM> is moved up and down by a drive device (not shown).

An example of the structure of the ultraviolet curing unit <NUM> is shown in <FIG>. As shown in <FIG>, the ultraviolet curing unit <NUM> contains a light source <NUM> (e.g., an LED light source) for emitting ultraviolet light, in a housing <NUM>. The light source <NUM> is powered via a cable <NUM> (not shown in <FIG>) that is provided from the outside of the ultraviolet curing unit <NUM>. A condensing lens for condensing ultraviolet light that is emitted by the light source <NUM> may be provided in the housing <NUM>. A holding plate <NUM> is coupled to the housing <NUM> and holds a glass plate <NUM>. The ultraviolet light that is emitted from the light source <NUM> illuminates and cures the conductive paste applied to each antenna AN.

With reference to <FIG> again, the conveying state is a state in which the antenna sheet AS is conveyed from the IC chip placement process. The conveyance of the antenna sheet AS is stopped at the time the antennas AN applied with uncured conductive paste come immediately under the ultraviolet curing units <NUM>. Then, in the state (resting state) in which the conveyance of the antenna sheet AS is rested, the ultraviolet curing units <NUM> are lowered, and they emit ultraviolet light to cure the conductive paste while pressing the antennas AN with the glass plates <NUM>.

The antenna sheet AS is conveyed from the IC chip placement process during the resting state, and therefore, the conveying roller <NUM> is lowered by its own weight and absorbs the conveyed antenna sheet AS between the conveying rollers <NUM> and <NUM> while ultraviolet light is emitted. After emission of ultraviolet light is finished, the antennas AN, number of which corresponds to the number of the ultraviolet curing units <NUM>, are quickly conveyed to a downstream side, and instead, uncured antennas AN are then stopped at the positions immediately under the ultraviolet curing units <NUM>. That is, in the curing process of an embodiment, the conveying state and the resting state (ultraviolet light emission state) of the antenna sheet AS are repeated. In quickly conveying the antennas AN, the conveying roller <NUM> is raised by tension applied to the antenna sheet AS.

The curing process of an embodiment may use a thermosetting device. That is, in the case of applying a thermosetting adhesive, such as an epoxy resin, by the dispenser <NUM>, the adhesive is cured by a thermosetting treatment in the curing process.

<FIG> shows a curing device 4B configured so that the conveying state and the resting state of the antenna sheet AS will be repeated as in the case in <FIG>. The curing device 4B is different from the curing device 4A in having a plurality of thermosetting units <NUM>. A heat source that is operated by power supplied via a cable (not shown) is disposed to each thermosetting unit <NUM>. While the antenna sheet AS is in the resting state, the support shaft <NUM> is driven so as to move down, and each thermosetting unit <NUM> heats and cures the adhesive while pressing the corresponding antenna AN. After heating is completed, the support shaft <NUM> is driven so as to move up, and the antenna sheet AS is conveyed.

In the case of curing the conductive paste with ultraviolet light in <FIG>, instead of the ultraviolet curing unit <NUM> containing the light source, a press unit for pressing the antenna AN via a glass plate may be used. In addition, an ultraviolet irradiator may also be provided in such a manner as to emit ultraviolet light from an outside in the width direction or an oblique upper side to the conductive paste on the antenna AN that is pressed in the resting state.

In an embodiment, in order to not make the antenna sheet AS in the resting state during emission of ultraviolet light, the plurality of the ultraviolet curing units <NUM> may be circulated in a manner linked to the advance speed of the antenna sheet AS, and ultraviolet light may be emitted by the internal light source while the antenna AN is pressed, as shown in <FIG>.

Claim 1:
An IC chip mounting apparatus (<NUM>) comprising:
a conveyor (<NUM>, <NUM>) configured to convey an antenna continuous body (AS) on a conveying surface, the antenna continuous body (AS) having a base material (BM) and plural inlay antennas (AN) continuously formed on the base material (BM);
an ejection unit (<NUM>) configured to eject a thermosetting adhesive toward a reference position (Pref) of each antenna (AN) in the antenna continuous body (AS);
an IC chip placement unit (<NUM>) configured to place an IC chip (C) on the adhesive that is located on the reference position (Pref) of each antenna (AN) in the antenna continuous body (AS); and
a first light irradiator (<NUM>) configured to irradiate the adhesive of each antenna (AN) with a first light, in the vicinity of a position where an IC chip (C) is located on the conveying surface,
characterized by further comprising:
a second light irradiator (<NUM>) configured to irradiate the adhesive of each antenna (AN) with a second light, at a position downstream from a position where the adhesive is irradiated with the first light.