Patent ID: 12191276

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, a mounting apparatus10of the embodiment will be described with reference to the drawings. The mounting apparatus10is an apparatus that manufactures a semiconductor apparatus by mounting a plurality of semiconductor chips100on a substrate104as a mounted body.

As shown inFIG.1andFIG.2, the mounting apparatus10includes a bonding stage20, a base stand21, a mounting head17, a film arranging mechanism30, and a control unit80that controls the movement of each of these portions. In the following description, the extending direction of a cover film110will be described as X direction, the direction perpendicular to the X direction on the horizontal plane will be Y direction, and the up-and-down direction will be Z direction. Further, the side provided with a winding roller63b, which will be described later, will be referred to as one side, and the side provided with a delivery roller63awill be referred to as another side.

The bonding stage20is a stage that holds the substrate104on the upper surface. The bonding stage20is provided with, for example, a suction hole (not shown) that suctions and holds the substrate104, a heater (not shown) that heats the substrate104, and the like. The bonding stage20is supported by the base stand21.

The mounting head17is provided so as to face the bonding stage20, and is configured by a main body11, a heat insulating block12mounted on the lower side of the main body11, a heater14mounted on the lower side of the heat insulating block12, and a pressing tool16mounted on the lower side of the heater14.

The main body11may be moved in the up-and-down direction, which is a contacting/separating direction with respect to the substrate104suctioned on the bonding stage20by a drive mechanism provided inside, and may also be moved in the horizontal direction with respect to the substrate104.

The heat insulating block12is a ceramic plate-shaped member sandwiched between the main body11and the heater14to prevent the heat of the heater14from being transferred to the main body11. The heater14is formed by embedding a heat generating resistor made of platinum, tungsten, or the like inside a ceramic such as aluminum nitride.

Two cooling grooves15extending in the direction perpendicular to the paper surface ofFIG.1are provided on the upper surface of the heater14. Further, the heat insulating block12is provided with an air flow path13extending in an L shape from the side surface and communicating the side surface and the cooling grooves15provided in the heater14. When electric power is input from the control unit80, the heater14generates heat and the temperature rises, heating the pressing tool16mounted on the lower side of the heater14. Further, when the air from the fan19flow through the air flow path13of the heat insulating block12, the heater14is cooled, whereby the pressing tool16is cooled.

The pressing tool16has a top surface having substantially the same size as the heater14, and is provided with a projecting portion16aon the lower side that suctions and presses a semiconductor chip100. The size of the projecting portion16ais substantially the same as the size of the semiconductor chip100. The pressing tool16is made of ceramics. A suction hole18for suctioning and holding the semiconductor chip100is formed in the pressing tool16. The suction hole18penetrates the heater14and the heat insulating block12and communicates with a suction pump (not shown) from the main body11, and the semiconductor chip100is suctioned and held on the lower surface of the projecting portion16aof the pressing tool16by the negative pressure generated by the suction pump.

The base stand21of the mounting apparatus10is provided with the film arranging mechanism30that interposes the cover film110between the semiconductor chip100and the pressing tool16when mounting the semiconductor chip100. As the material of the cover film110, a material having excellent heat resistance and high peelability of an adhesive material108is suitable. Therefore, as the material of the cover film110, for example, a fluororesin such as polytetrafluoroethylene (PTFE) or tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) may be used.

The film arranging mechanism30includes film guides40, a linking member46, lifting mechanisms50, a film delivering mechanism60, and moving mechanisms70.

The film delivering mechanism60sequentially delivers the strip-shaped cover film110above the substrate104. It has the delivery roller63aprovided at another side of the bonding stage20and the winding roller63bprovided at one side (hereinafter, when the delivery roller63aand the winding roller63bare not distinguished, they are simply referred to as “feed-roller63”). The cover film110is hung between the pair of feed-rollers63. When the delivery roller63arotates in a predetermined delivering direction (direction of arrow91inFIG.1), new cover film110is sequentially delivered. Further, in conjunction with the delivery roller63a, the winding roller63brotates in the same direction as the delivery roller63a, so that used cover film110is wound up onto the winding roller63band collected. The delivery roller63aand the winding roller63bare each driven by a drive motor (not shown). The delivery roller63amay be a driven roller that is not driven by a motor and is driven by the rotation of the winding roller63b.

The delivery roller63aand of the winding roller63bhave the supporting structure65; the only difference is that the two are symmetrical with the bonding stage20sandwiched in between. Further, the lifting mechanisms50, the film guides40, and the moving mechanisms70are each provided at one side and another side of the bonding stage20, and the only difference that the two are symmetrical with the bonding stage20sandwiched in between. Therefore, the supporting structure65of the winding roller63b, the lifting mechanism50, the film guide40, and the moving mechanism70that are arranged at one side of the bonding stage20will be described below.

As shown inFIG.3andFIG.4, the supporting structure65of the winding roller63bis configured by a base61and a frame62. The base61is mounted on a rail71, provided on the upper surface of the base stand21at one side of the bonding stage20and extending in the Y direction, so as to be movable in the Y direction. The frame62is configured by four pillars mounted on the base61and four beams connecting the upper portions of the pillars. A shaft64of the winding roller63bis rotatably mounted on the two opposing beams extending in the X direction.

The lifting mechanism50is mounted on the base61that supports the winding roller63bof the film delivering mechanism60, and the film guide40is connected to the lifting mechanism50. The film guide40defines the height of the cover film110with respect to the bonding stage20, and the lifting mechanism50lifts and lowers the film guide40with respect to the bonding stage20.

The lifting mechanism50is configured by a guide rail51, a slider54, a connecting member55, springs56, and a Z-direction actuator58. The springs56are an example of elastic members, but the present invention is not limited thereto. Elastic members such as plate panels, rubbers, or sponges may be used.

The guide rail51is mounted on the upper surface of the base61of the film delivering mechanism60so as to extend in the up-and-down direction. The slider54is configured by a main body portion52and an arm portion53. A hole52aprovided in the center of the main body portion52fits into the guide rail51and may move in the up-and-down direction along the guide rail51. Further, the tip of the Z-direction actuator58mounted on the base61is connected to the lower end of the main body portion52, and the main body portion52is driven in the up-and-down direction by the Z-direction actuator58. The arm portion53has one end connected to the main body portion52, and a hole53aprovided at another end fitted into a slider-guide57of the connecting member55to be described later, and is movably connected to the slider-guide57in the up-and-down direction.

The connecting member55is a groove-shaped cross-section member configured by a plate-shaped upper flange55a, a plate-shaped lower flange55bfacing the upper flange55a, and a plate-shaped web55cthat connects the upper flange55aand the lower flange55bin the up-and-down direction. The slider-guide57extending in the up-and-down direction is provided between the upper flange55aand the lower flange55b. With the hole53afitted into the slider-guide57, the arm portion53of the slider54is guided by the slider-guide57and is connected between the upper flange55aand the lower flange55bso as to be relatively movable in the up-and-down direction with respect to the connecting member55.

In other words, the arm portion53of the slider54is mounted so as to be relatively movable in the up-and-down direction with respect to the connecting member55by a predetermined vertical width between the lower surface of the upper flange55aand the upper surface of the lower flange55bof the connecting member55. That is, the connecting member55is mounted so as to be relatively movable in the up-and-down direction with respect to the arm portion53of the slider54by a predetermined vertical width between the lower surface of the upper flange55aand the upper surface of the lower flange55b.

The springs56are mounted between the upper surface of the lower flange55bof the connecting member55and the lower surface of the arm portion53of the slider54. The springs56urge the arm portion53upward so that the upper surface of the arm portion53of the slider54is in contact with the lower surface of the upper flange55a.

The film guide40is connected to the surface of the connecting member55at the web55cside of the bonding stage20. The film guide40is configured by a base body portion41, a lower guide roller42, an upper guide roller43, and a stopper44.

The base body portion41is a longitudinal member connected to the web55cand extending toward the bonding stage20along the side edge of the cover film110on the upper surface of the bonding stage20. The lower guide roller42is a columnar rotating body mounted on the side surface of the tip portion of the base body portion41at the bonding stage20side and extends from the base body portion41toward the cover film110in a direction perpendicular to the extending direction of the cover film110, and around which the cover film110is wrapped on the lower side. The upper guide roller43is arranged at one side of the lower guide roller42. The upper guide roller43is a columnar rotating body mounted on the side surface of the base body portion41and extends from the base body portion41toward the cover film110in a direction perpendicular to the extending direction of the cover film110, and around which the cover film110is wrapped on the upper side.

The stopper44is a plate-shaped member mounted on the lower end surface of the base body portion41and extends from the base body portion41toward the minus side in the Y direction. The stopper44is arranged at a position where the lower end abuts on the upper surface of one side of the bonding stage20, and constitutes a contact portion that contacts the upper surface of the bonding stage20. The height of the stopper44is a height at which when the lower end of the stopper44abuts on the upper surface of the bonding stage20, the height of the lower surface of the cover film110becomes a height in contact with the upper surface of the semiconductor chip100temporarily crimped onto the substrate104.

The tip of the base body portion41of the film guide40at one side and the tip of the base body portion41of the film guide40at another side are connected by the linking member46. The linking member46is a longitudinal member extending in the X direction along the side end of the cover film110on the upper surface of the bonding stage20. The film guide40at another side has the same structure as the film guide40at one side except for having a symmetrical shape with respect to the bonding stage20.

As shown inFIG.1andFIG.2, the cover film110wrapped around the upper guide roller43of the film guide40at one side extends toward the winding roller63barranged at one side and is wound by the winding roller63b. Further, the cover film110wrapped around the lower guide roller42of the film guide40at one side extends to another side to be wrapped around the lower side of the lower guide roller42of the film guide40arranged at another side, and is then wrapped around the upper side of the upper guide roller43of the film guide40arranged at another side and extends toward the delivery roller63a.

In this way, the cover film110hung between the delivery roller63aat another side and the winding roller63bat one side is wrapped around the lower guide roller42and the upper guide roller43of the two film guides40arranged at two sides of the bonding stage20, respectively. The height of the cover film110from the bonding stage20is defined by lower guide rollers42at two sides.

Returning toFIG.3, the moving mechanism70is configured by the rail71provided on the upper surface of the base stand21at one side of the bonding stage20; and a Y-direction actuator72, provided above the base stand21, that drives the base61of the film delivering mechanism60, guided by the rail71, in the Y direction. Since the Y-direction actuator72moves the base61, to which the winding roller63bof the film delivering mechanism60and the lifting mechanism50are connected, in the Y direction (direction of arrow92inFIG.2), the winding roller63bof the film delivering mechanism60, the lifting mechanism50, and the film guide40connected to the lifting mechanism50are integrally moved in the Y direction.

The supporting structure65of the winding roller63b, the lifting mechanism50, the film guide40, and the moving mechanism70that are arranged at one side of the bonding stage20have been described above. The supporting structure65of the delivery roller63a, the lifting mechanism50, the film guide40, and the moving mechanism70that are arranged at another side of the bonding stage20have the same structure as those at one side except for having a symmetrical shape with respect to the bonding stage20, therefore the description thereof will be omitted.

The control unit80is connected to a main body11of the mounting head17, the heater14, a fan19, the Z-direction actuator58of the lifting mechanism50, the drive motor (not shown) of the film delivering mechanism60, the Y-direction actuator72of the moving mechanism70, and the bonding stage20, and controls the movement of the mounting head17, the movement of the slider54of the lifting mechanism50in the Z direction, the rotation of the feed-rollers63, and the movement of the base61in the Y direction, and controls the temperature of the pressing tool16by the heater14and the fan19. The control unit80includes, for example, a CPU that performs various operations and a memory that stores various data and programs. The detection results of various sensors are input to the control unit80, and the control unit80performs driving control and temperature control of each portion according to the detection results.

Next, the operation of the mounting apparatus10of the embodiment will be described with reference toFIG.3toFIG.6. The mounting apparatus10mounts the semiconductor chip100on the substrate104by the technique of flip chip bonder. Specifically, as shown inFIG.1, the mounting apparatus10electrically connects the semiconductor chip100to the substrate104by joining the protrusions, made of conductive material and referred to as bumps102formed on the bottom surface of the semiconductor chip100, to electrodes105formed on the surface of the substrate104.

As shown inFIG.2andFIG.3, on the substrate104, a plurality of electrodes105electrically connected to the bumps102of the semiconductor chip100are formed and mounting section106where the semiconductors100are mounted are defined. Each of the mounting sections106is pre-coated with the adhesive material108, which is an insulating thermosetting resin.

The control unit80of the mounting apparatus10makes the semiconductor chip100suctioned and held on the pressing tool16at the tip of the mounting head17, lowers the mounting head17and presses it on the adhesive material108of the mounting section106to temporarily crimp the semiconductor chip100onto the adhesive material108. At the time of temporary crimping, the cover film110is retracted to a position horizontally separated from the mounting section106by the moving mechanism70.

After the temporary crimping, the control unit80drives the moving mechanism70to move the cover film110in the horizontal direction, and as shown inFIG.3, moves the cover film110to a position directly above the temporarily crimped semiconductor chip100and between the semiconductor chip100and the pressing tool16. At this time, the height of the cover film110is defined by the lower guide roller42of the film guide40. The height of the cover film110is midway between the upper surface of the semiconductor chip100and the pressing tool16.

At this time, as shown inFIG.3, there is a gap having a height of Ah1between the lower end of the stopper44of the film guide40and the upper surface of the bonding stage20. Further, the arm portion53of the slider54of the lifting mechanism50is urged by the springs56and is in contact with the lower surface of the upper flange55aof the connecting member55, and there is a gap having a height of Ah0between the lower surface of the arm portion53and the lower flange55bof the connecting member55. The length of the springs56is Ah0.

As shown inFIG.5, the control unit80operates the Z-direction actuator58of the lifting mechanism50to lower the main body portion52of the slider54as shown by an arrow93. Then, the arm portion53and the film guide40also descend as shown by an arrow94inFIG.5. When the slider54is lowered by the height Ah1from the state shown inFIG.3, the lower end of the stopper44of the film guide40abuts the bonding stage20as shown inFIG.5. At this time, the lower surface of the cover film110is at a height in contact with the upper surface of the temporarily crimped semiconductor chip100.

After that, the control unit80further lowers the slider54by a height Ah2by the Z-direction actuator58. As a result, the springs56are compressed by the height Ah2, and a gap having the height Ah2is formed between the upper surface of the arm portion53of the slider54and the lower surface of the upper flange55aof the connecting member55. Then, the stopper44of the film guide40is pressed onto the bonding stage20by the reaction force due to the compression of the springs56. The pressing force keeps the height of the film guide40with respect to the bonding stage20constant.

The control unit80operates the Z-direction actuator58of the lifting mechanism50arranged at another side in the same manner as the Z-direction actuator58of the lifting mechanism50arranged at one side, and presses the stopper44of the film guide40at another side on the upper surface of the bonding stage20. As a result, the height of the film guide40at another side with respect to the bonding stage20becomes the same as the height of the film guide40at one side with respect to the bonding stage20. Thereby, the parallelism between the cover film110and the bonding stage20can be ensured. Accordingly, as shown inFIG.2, even when the cover film110covers the upper surfaces of the plurality of semiconductor chips100in the longitudinal direction, it can be brought into close contact with the upper surface of each of the semiconductor chips100.

Next, as shown by an arrow97inFIG.6, the control unit80lowers the mounting head17and presses the semiconductor chip100from the upper side of the cover film110with the projecting portion16aof the pressing tool16at the tip. By pressing, the adhesive material108protrudes around the semiconductor chip100, and a part of the adhesive material108crawls up the side surface of the semiconductor chip100and reaches the lower surface of the cover film110. Further, by pressing, the bumps102formed on the semiconductor chip100come into contact with the electrodes105of the substrate104. As described above, the parallelism between the cover film110and the upper surface of the bonding stage20is ensured, so the cover film110is in close contact with the upper surface of the semiconductor chip100, and it is possible to prevent the adhesive material108extruded by the semiconductor chip100from crawling up unevenly and generating static electricity during mounting.

Then, the control unit80starts supplying electric power to the heater14and lifts the temperature of the pressing tool16by the heater14. When the temperature of the pressing tool16rises, the semiconductor chip100is heated by the heat and the adhesive material108is softened. When the temperature is further lifted to exceed the melting temperature of the bumps102, the bumps102of the semiconductor chip100melt. Then, when the temperature rises to the curing temperature of the adhesive material108, the adhesive material108starts thermosetting.

After that, the control unit80starts the fan19shown inFIG.1and allows cooling air to flow through the air flow path13of the heat insulating block12to cool the pressing tool16. As a result, the molten bumps102are cured, and the joining of the substrate104with the electrodes105is completed. Further, the temperature of the thermosetting adhesive material108also drops, and the mounting is completed in the state shown inFIG.6. When the mounting is completed, the control unit80lifts the mounting head17.

After lifting the mounting head17, the control unit80lifts the slider54by the Z-direction actuator58of the lifting mechanism50at one side and another side. When the slider54is lifted by the height Ah2shown inFIG.6, the upper surface of the arm portion53of the slider54abuts the lower surface of the upper flange55aof the connecting member55. When the slider54is further lifted, the connecting member55and the film guide40are lifted as the slider54is lifted, and the cover film110is also lifted accordingly to return to the height shown inFIG.3. When the cover film110is lifted to a height shown inFIG.3, the control unit80retracts, by the moving mechanism70, the cover film110to a position horizontally separated from the next mounting section106to which the semiconductor chip100to be temporarily crimped.

As described above, in the mounting apparatus10of the embodiment, the height of the film guide40at two sides can be adjusted by the lifting mechanism50each arranged at two sides of the bonding stage20to ensure the parallelism between the bonding stage20and the cover film110, and the cover film110can be brought into close contact with the upper surface of the semiconductor chip100. Therefore, when mounting the semiconductor chip100, it is possible to prevent the adhesive material108extruded by the semiconductor chip100from crawling up unevenly and generating static electricity during mounting.

Further, in the mounting apparatus10of the embodiment, since the film guides40at two sides are connected by the linking member46, the height difference of the film guides40at two sides can be eliminated, and the parallelism between the bonding stage20and the cover film110can be ensured. Further, since the mounting apparatus10of the embodiment presses the film guide40on the bonding stage20by the force of the springs56, the height of the film guide40with respect to the surface of the bonding stage20can be made constant, and the parallelism between the bonding stage20and the cover film110can be ensured.

Next, a mounting apparatus200of another embodiment will be described with reference toFIG.7. A film arranging mechanism230of the mounting apparatus200is configured by the film guide40and the lifting mechanism50that are provided at one side; the moving mechanisms70; the film delivering mechanism60including the delivery roller63aat another side and a winding roller63bat one side; an another-side lifting mechanism350and an another-side film guide340that are provided at another side. The film delivering mechanism60; the film guide40and the lifting mechanism50that are provided at one side; and the moving mechanisms70are configured the same as in the mounting apparatus10described above with reference toFIG.1toFIG.6, therefore the description thereof will be omitted.

The another-side lifting mechanism350provided at another side does not include the Z-direction actuator58, the slider54, and the connecting member55, and is configured by an another-side guide rail351only. The another-side guide rail351is mounted on the base61at another side and extends in the up-and-down direction to guide the another-side film guide340in the up-and-down direction. The another-side film guide340is connected to the film guide40at one side by the linking member46, and moves in the up-and-down direction following the film guide40at one side. Further, the another-side film guide340, similarly to the film guide40at one side, includes a base body portion341, a lower guide roller342, an upper guide roller343, and a stopper344. The base body portion341has the same structure as the film guide40at one side except that a hole for fitting into the another-side guide rail351is provided at the end at another side and that the length in the X direction is long; the lower guide roller342, the upper guide roller343, and the stopper344have the same structure as the lower guide roller42, the upper guide roller43, and the stopper44at one side, respectively.

The mounting apparatus200shown inFIG.7drives both the film guide40at one side and the another-side film guide340in the up-and-down direction by the Z-direction actuator58mounted on the lifting mechanism50at one side, therefore the structure can be simplified.

In the mounting apparatus200, the height of the film guide40arranged at two sides of the bonding stage20can be adjusted to ensure the parallelism between the bonding stage20and the cover film110.

The above describes the mounting apparatus10and the mounting apparatus200mounting the semiconductor chip100on the substrate104, but the present invention is not limited thereto. The semiconductor chip100may be mounted on another semiconductor chip100. In this case, the other semiconductor chip100, similarly to the substrate104, constitutes a mounted body.