Patent ID: 12191172

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A preferred embodiment of the present invention will be described hereinbelow with reference to the accompanying drawings. The present embodiment will be described in relation to a three-dimensional coordinate system including X, Y, and Z axes extending respectively along X-axis, Y-axis, and Z-axis directions. The X-axis directions extend horizontally and include +X and −X directions, and the Y-axis directions extend horizontally perpendicularly to the X-axis directions and include +Y and −Y directions. The Z-axis directions extend vertically perpendicularly to the X-axis directions and the Y-axis directions and include +Z and −Z directions.

As illustrated inFIG.1, a wafer90that is used in the present embodiment is a semiconductor wafer that has a circular contour and that is made of a base material such as silicon. The wafer90has a face side903having a grid of areas demarcated thereon by a plurality of intersecting projected dicing lines901with a number of devices900formed in the respective areas. A protective tape95is affixed to the face side903over the devices900for protecting the face side903when the wafer90is ground, for example.

The wafer90may alternatively be made of gallium arsenide, sapphire, ceramic, resin, gallium nitride, silicon carbide, or the like, other than silicon, and may be free of the devices900.

As illustrated inFIG.1, a dicing tape93that is also affixed to the wafer90is shaped as a circular tape larger in diameter than the wafer90and includes a base layer made of polyethylene terephthalate (PET) resin or the like, with an adhesive layer disposed on the base layer.

By use of a tape mounter1according to the present embodiment that is illustrated inFIG.2and that is to be described later, an outer circumferential portion of the adhesive layer, which faces upwardly inFIG.1, of the dicing tape93is affixed to a reverse side, i.e., a lower surface, of a ring frame94having a circular opening defined therein, in a manner to close the circular opening, and a reverse side904of the wafer90is affixed to the adhesive layer of the dicing tape93that is exposed in the opening in the ring frame94. The center of the wafer90and the center of the opening in the ring frame94are substantially aligned with each other. The wafer90is supported by the ring frame94. The operator can handle the wafer90by gripping the ring frame94or having the ring frame94held under suction. In other words, the wafer90, the ring frame94, and the dicing tape93jointly make up a frame set99that can be handled as one unit.

As illustrated inFIG.2, the tape mounter1according to the present embodiment is combined with a grinding apparatus19positioned side by side, for example. The wafer90that has been ground and thinned to a desired thickness by the grinding apparatus19is housed in a wafer cassette62and delivered to the tape mounter1. Thereafter, or after the thinned wafer90is housed in a transfer cassette18illustrated inFIG.2and received by the tape mounter1, a dicing tape93is affixed to the wafer90and a ring frame94by the tape mounter1, making up a frame set99, and the protective tape95is peeled off from the face side903of the wafer90as illustrated inFIG.1.

The transfer cassette18is, for example, an open cassette having a plurality of shelves for storing wafers90thereon, respectively.

For example, the grinding apparatus19and the tape mounter1are positioned side by side with a predetermined spacing therebetween along the X-axis directions or joined to each other in a clean room. Passages for the operator to move along, for example, are provided respectively forwardly (in the −Y direction) and rearwardly (in the +Y direction) of the grinding apparatus19and the tape mounter1.

The grinding apparatus19, which has heretofore been known in the art, is an apparatus for grinding the wafer90held under suction on a chuck table with rotating grindstones. The grinding apparatus19illustrated inFIG.2incorporates therein an intra-grinding apparatus robot190including an articulated arm that has a holding pad for holding the wafer90under suction thereon.

On a front side, which faces in the −Y direction, of the grinding apparatus19, there is disposed a grinding apparatus wafer cassette stage199for placing thereon a pre-grinding wafer cassette6211that stores on respective shelves thereof a plurality of wafers90having respective face sides903to which protective tapes95are affixed and having respective reverse sides904to be ground and a wafer cassette62that stores ground wafers90. The intra-grinding apparatus robot190delivers one at a time of the wafers90from the pre-grinding wafer cassette6211on the grinding apparatus wafer cassette stage199to the chuck table in the grinding apparatus19and also delivers a wafer90whose reverse side904has been ground into the wafer cassette62on the grinding apparatus wafer cassette stage199. Alternatively, the intra-grinding apparatus robot190delivers one at a time of wafers90whose reverse sides904have been ground onto one of the shelves of the transfer cassette18disposed between the grinding apparatus19and the tape mounter1.

An OHT mechanism, for example, is disposed over the grinding apparatus19and the tape mounter1in the clean room. The wafer cassette62that stores a plurality of ground wafers90on respective shelves thereof is delivered from the grinding apparatus wafer cassette stage199to a wafer cassette stage133combined with the tape mounter1by the OHT mechanism as illustrated inFIG.2.

As illustrated inFIGS.2and3, a second frame cassette stage132, a first frame cassette stage131, and the wafer cassette stage133are disposed on a front side, which faces in the −Y direction, of an apparatus base10of the tape mounter1whose longitudinal directions are represented by the Y-axis directions. The second frame cassette stage132, the first frame cassette stage131, and the wafer cassette stage133are arrayed successively in the order described from the +X direction side to the −X direction side. As illustrated inFIG.3, a frame cassette618that houses on respective shelves thereof the frame sets99of a plurality of wafers90with protective tapes95peeled off from their face sides903is placed on the second frame cassette stage132. A frame cassette61that houses on respective shelves thereof a plurality of ring frames94to be used is placed on the first frame cassette stage131. A wafer cassette62that houses on respective shelves thereof a plurality of wafers90thinned down to a desired thickness by the grinding apparatus19that has ground their reverse sides904, for example, is placed on the wafer cassette stage133.

As illustrated inFIG.3, the tape mounter1includes a frame table477for holding the lower surface of a ring frame94that has an opening defined therein, a wafer table478for holding the protective tape95on the lower surface of a wafer90in the opening in the ring frame94, a frame delivery mechanism30for delivering a ring frame94to the frame table477, a wafer delivery mechanism5for delivering a wafer90to the wafer table478, a tape affixing mechanism47for affixing a dicing tape93to a ring frame94and a wafer90to turn them into an integral frame set99, the second frame cassette stage132for placing thereon a frame cassette618capable of housing ring frames94, i.e., frame sets99, the first frame cassette stage131for placing thereon a frame cassette61capable of storing ring frames94to be used, a robot2having a frame holder21for holding a ring frame94and being capable of removing a ring frame94from the frame cassette61on the first frame cassette stage131or storing a frame set99into the frame cassette618on the second frame cassette stage132, and a controller17including a central processing unit (CPU) for controlling the components of the tape mounter1, a storage medium such as a memory, etc.

The tape affixing mechanism47is disposed on a rear portion, which extends in the +Y direction, of the apparatus base10of the tape mounter1. The tape affixing mechanism47includes a tape affixing table470for holding a wafer90and a ring frame94under suction, for example. The tape affixing table470is movable back and forth in the Y-axis directions by a ball screw mechanism473. Specifically, the tape affixing table470is linearly movable back and forth in the Y-axis directions along a travel path defined by a pair of guide rails4782. The travel path is positioned below an unreeling roller472for unreeling an unillustrated web-shaped sheet to which dicing tapes93precut to a circular shape are affixed, from a tape roll935, a peeling plate475for peeling off dicing tapes93from the web-shaped sheet, and an affixing roller474rotatable about a rotational axis extending in the X-axis directions.

The tape affixing table470includes the frame table477for holding the lower surface of a ring frame94having a circular opening defined therein as described above and the wafer table478for holding the lower surface of a wafer90in the circular opening in the ring frame94.

The frame table477and the wafer table478are integrally movable back and forth along the Y-axis directions. The frame table477surrounds the wafer table478. Each of the frame table477and the wafer table478has a flat holding surface made of a porous material or the like and can hold an object, i.e., a ring frame94or a wafer90, under suction forces generated by an unillustrated suction source, such as a vacuum generating device, held in fluid communication with the holding surface. The frame table477has a support surface that supports the lower surface of the ring frame94with a plurality of suction cups on the support surface. The suction cups hold the ring frame94under suction, and the support surface supports the lower surface of the ring frame94.

As the peeling plate475peels off a dicing tape93from the web-shaped sheet unreeled from the tape roll935by the unreeling roller472, the affixing roller474affixes the dicing tape93to the wafer90and the ring frame94that are held on the tape affixing table470that moves in one of the Y-axis directions below the affixing roller474.

In the example illustrated inFIG.3, the tape roll935, the unreeling roller472, the peeling plate475, and the affixing roller474are successively arrayed from the +Y direction side to the −Y direction side. However, the tape roll935, the unreeling roller472, the peeling plate475, and the affixing roller474may successively be arrayed from the −Y direction side to the +Y direction side.

The frame delivery mechanism30is disposed above the travel path along which the tape affixing table470is movable.

The frame delivery mechanism30includes a delivery pad300, for example. The delivery pad300includes a base301shaped as a circular plate, a plurality of, e.g., four, suction cup supports302extending radially outwardly horizontally from the outer circumferential edge of the base301, and a plurality of, e.g., four, suction cups303disposed on the lower surfaces of the respective lower ends of the suction cup supports302, for attracting the ring frame94under suction. The suction cups303are held in fluid communication with an unillustrated suction source such as a vacuum generating device that generates attracting suction forces.

The base301has an upper surface attached to the distal end of a swing arm305that extends horizontally. The proximal end of the swing arm305is connected to a swing mechanism306, which includes an electric motor, a swing shaft, etc., for rotating the swing arm305through 360 degrees in a horizontal plane. The swing arm305is also vertically movable along the Z-axis directions by an actuator or the like. The frame delivery mechanism30can deliver a frame set99from the tape affixing table470to a peeling table436of a protective tape peeling mechanism43to be described later.

The peeling table436of the protective tape peeling mechanism43illustrated inFIG.3can hold a frame set99under suction, for example. The peeling table436is disposed below a peeling member431that peels off a protective tape95from a wafer90when moved along one of the Y-axis directions by a peeling member moving mechanism435such as an electrically driven slider or the like with the peeling member431gripping an unillustrated peel-off tape affixed to the protective tape95. The peeling member431may alternatively include a peeling clamp for peeling off the protective tape95from the face side903of the wafer90by directly gripping the protective tape95.

The peel-off tape may be a heat-sealable tape that develops adhesiveness when heated, for example, but is not limited thereto.

For example, the peeling table436is linearly movable in the Y-axis directions along a travel path defined by a pair of guide rails437by drive power produced by a ball screw mechanism432.

A frame set reverser46is disposed above the travel path along which the peeling table436is movable.

As illustrated inFIGS.3and4, the frame set reverser46includes a reversing pad460, for example, that includes a base461shaped as a rectangular plate and a plurality of suction cups463disposed respectively on the four corners of the lower surface of the base461for attracting a ring frame94under suction. The peeling table436can be positioned directly below the reversing pad460.

The frame set reverser46further includes a reversing pad lifting and lowering mechanism467for lifting and lowering the reversing pad460along the Z-axis directions, a reversing motor465connected to the upper surface of the reversing pad460, and a rotational shaft464that is rotatable about its central axis extending along the Y-axis directions and that has an end connected to the reversing motor465and another end supported on a lifting and lowering block4673. The suction cups463are held in fluid communication with an unillustrated suction source that generates attracting suction forces. When the reversing motor465is energized, it rotates itself with respect to the rotational shaft464through a predetermined angle, turning the base461selectively to a position where a frame set99held under suction by the four suction cups463faces downwardly and a position where the frame set99held under suction by the four suction cups463faces upwardly. A reversing pad column469is erected on the apparatus base10behind the reversing pad460in the −Y direction. The reversing pad lifting and lowering mechanism467is disposed on the front surface of the reversing pad column469that faces in the +Y direction.

The rotational shaft464may be rotated by a rotary cylinder instead of the reversing motor465.

The reversing motor465may be disposed on the lifting and lowering block4673, and the reversing pad460may be connected to the rotational shaft464.

The reversing pad lifting and lowering mechanism467includes a ball screw4670with its central axis extending along the Z-axis directions, a pair of guide rails4671that are disposed one on each side of the ball screw4670and that extend parallel to the ball screw4670, an electric motor4672coupled to the upper end of the ball screw4670for rotating the ball screw4670about its central axis, and the lifting and lowering block4673having an internal nut threaded over the ball screw4670and a pair of side portions held in sliding contact with the respective guide rails4671. When the electric motor4672is energized, it rotates the ball screw4670about its central axis, causing the internal nut of the lifting and lowering block4673to move the lifting and lowering block4673back and forth along the Z-axis directions while the lifting and lowering block4673is being guided by the guide rails4671. Thus, the reversing pad460connected to the reversing motor465that is coupled to the lifting and lowering block4673by the rotational shaft464is lifted and lowered along the Z-axis directions.

The wafer delivery mechanism5for delivering a wafer90to the wafer table478, as illustrated inFIGS.3and5, is disposed on the apparatus base10closely to the robot2, for example. The wafer delivery mechanism5is movable along the Y-axis directions, for example, above the tape affixing table470including the frame table477and the wafer table478.

The wafer delivery mechanism5has its structural details illustrated inFIG.5. As illustrated inFIG.5, the wafer delivery mechanism5includes, for example, a suction pad moving mechanism52disposed on a column51erected on an area of the apparatus base10on the −X direction side, a suction pad lifting and lowering mechanism53interconnecting the suction pad moving mechanism52and a suction pad55, for lifting and lowering the suction pad55, and the suction pad55for receiving a wafer90that is held by a wafer holder22of the robot2.

The suction pad moving mechanism52includes a ball screw520with its central axis extending along the Y-axis directions, a pair of guide rails521that are disposed one on each side of the ball screw520and that extend parallel to the ball screw520, an electric motor522coupled to an end of the ball screw520for rotating the ball screw520about its central axis, and a movable block523having an internal nut threaded over the ball screw520and a pair of side portions held in sliding contact with the respective guide rails521. When the electric motor522is energized, it rotates the ball screw520about its central axis, causing the internal nut of the movable block523to move the movable block523linearly along the Y-axis directions while the movable block523is being guided by the guide rails521. Thus, the suction pad55that is connected to the movable block523by the suction pad lifting and lowering mechanism53is moved along the Y-axis directions.

The suction pad lifting and lowering mechanism53includes a ball screw530with its central axis extending along the Z-axis directions, a pair of guide rails531that are disposed one on each side of the ball screw530and that extend parallel to the ball screw530, an electric motor532coupled to the upper end of the ball screw530for rotating the ball screw530about its central axis, and a lifting and lowering arm533extending in the +X direction and having an internal nut threaded over the ball screw530and a pair of side portions held in sliding contact with the respective guide rails531. The suction pad55is disposed on the distal end of the lifting and lowering arm533. When the electric motor532is energized, it rotates the ball screw530about its central axis, causing the internal nut of the lifting and lowering arm533to move the lifting and lowering arm533back and forth along the Z-axis directions while the lifting and lowering arm533is being guided by the guide rails531. Therefore, the suction pad55on the lifting and lowering arm533is lifted and lowered along the Z-axis directions.

The suction pad55has an upper surface attached to the lower surface of the distal end of the lifting and lowering arm533by fixing bolts541, a spring support542, and support pins543including springs or the like for absorbing shocks generated upon contact with a wafer90. The suction pad55is shaped as a circular plate as viewed in plan and has a lower surface as a holding surface550made of a porous material for holding a wafer90under suction thereon. The holding surface550is held in fluid communication with an unillustrated suction source such as a vacuum generating device via a suction pipe553, a joint, etc.

The wafer table478as illustrated inFIG.3is positioned below a travel path along which the suction pad55is linearly movable in the Y-axis directions.

As illustrated inFIG.6, the frame cassette61that houses ring frames94therein is a closed-type front opening unified pod (FOUP). The frame cassette61includes at least an OHT engaging member611to be gripped by the unillustrated OHT mechanism, a top panel612on which the OHT engaging member611is mounted, a plurality of, i.e. three, side panels613extending downwardly, i.e., in the −Z direction, from the top panel612, a plurality of shelves615mounted on the respective inner side surfaces of two of the side panels613that face each other along the X-axis directions, for placing ring frames94thereon, and a bottom panel616interconnecting the lower ends of the three side panels613. For example, unillustrated handles that can be gripped by the operator may be mounted on the outer side surfaces of the side panels613.

According to the present embodiment, in order to meet demands for higher levels of cleanness that semiconductor devices to be finally manufactured from wafers90are to achieve as they are required to be smaller and smaller in size, the frame cassette61is of the closed type to protect itself against entry of dust. However, the frame cassette according to the present invention may be an open-type cassette. Furthermore, the frame cassette61may be free of the OHT engaging member611.

The frame cassette61has a front opening619that is open in the +Y direction for allowing ring frames94to be delivered in and out of the frame cassette61therethrough. The shelves615are spaced apart at predetermined vertical intervals in the frame cassette61. Two of the shelves615that confront each other along the X-axis directions can store a ring frame94thereon by supporting outer circumferential portions thereof.

When the frame cassette61is delivered from an unillustrated, predetermined cassette supply source positioned outside of the tape mounter1to the first frame cassette stage131with the OHT engaging member611gripped by the OHT mechanism, the opening619is closed by a cassette lid617, for example. For removing a ring frame94from the frame cassette61, two opening and closing handles607of a cassette opening and closing mechanism6illustrated inFIG.8are inserted into respective keyholes6170defined in the cassette lid617and are then turned to open the cassette lid617.

The OHT engaging member611that is erected on the top panel612can be hooked and held by a clamp-like gripping arm or the like of the OHT mechanism.

The frame cassette618is identical in structure to the frame cassette61illustrated inFIG.6.

The wafer cassette62illustrated inFIG.7is essentially identical in structure to the frame cassette61illustrated inFIG.6. The wafer cassette62has a front opening629that is open in the +Y direction for allowing wafers90stored on shelves625in a state in which outer circumferential portions thereof are supported to be delivered out of the wafer cassette62therethrough. The wafer cassette62is of a height larger than the frame cassette61, for example, and has a width and a depth smaller than the frame cassette61as the wafers90are smaller in diameter than the ring frames94.

When the wafer cassette62is delivered from an unillustrated, predetermined wafer supply source, e.g., the grinding apparatus wafer cassette stage199of the grinding apparatus19, positioned outside of the tape mounter1to the wafer cassette stage133illustrated inFIG.3with an OHT engaging member621gripped by the OHT mechanism, the opening629is closed by a cassette lid627. For removing a wafer90from the wafer cassette62, the opening and closing handles607of the cassette opening and closing mechanism6illustrated inFIG.8are inserted into respective keyholes6270defined in a cassette lid627and are then turned to open the cassette lid627.

According to the present embodiment, the frame cassette61and the wafer cassette62may, for example, have respective distinguishing marks for distinguishing them from each other. For example, the distinguishing marks are attached to the upper surfaces of the OHT engaging member611and the OHT engaging member621, but they are not necessarily limited to those locations.

The cassette opening and closing mechanism6illustrated inFIG.8includes an opening and closing pad60shaped as a rectangular plate, for example. The opening and closing pad60includes two wafer FOUP suction cups603and two frame FOUP suction cups606on the front surface, which faces in the −Y direction, thereof.

For example, one of the two wafer FOUP suction cups603is disposed in a position higher than the two frame FOUP suction cups606, and the other of the two wafer FOUP suction cups603is disposed in a position lower than the two frame FOUP suction cups606.

Each of the two wafer FOUP suction cups603and the two frame FOUP suction cups606is held in fluid communication with a suction source699such as a vacuum generating device through an unillustrated fluid communication passage such as a joint or a resin tube. When the suction source699is actuated, it generates suction forces that are transmitted to the wafer FOUP suction cups603and the frame FOUP suction cups606.

While the cassette lid627of the wafer cassette62illustrated inFIG.7is being held against the wafer FOUP suction cups603, the suction source699is actuated to transmit suction forces to the wafer FOUP suction cups603, so that the cassette opening and closing mechanism6can hold the cassette lid627of the wafer cassette62. At this time, the suction forces from the suction source699may also be transmitted to the frame FOUP suction cups606. In addition, while the cassette lid617of the frame cassette61illustrated inFIG.6is being held against the frame FOUP suction cups606, the suction source699is actuated to transmit suction forces to the frame FOUP suction cups606, so that the cassette opening and closing mechanism6can hold the cassette lid617of the frame cassette61.

Pressure sensors may be combined with the wafer FOUP suction cups603, for example. In a case where the pressure sensors detect contact of the wafer FOUP suction cups603with the cassette lid627of the wafer cassette62, the pressure sensors may send signals to actuate the suction source699, which generates and transmits suction forces to the wafer FOUP suction cups603.

As illustrated inFIG.8, the two opening and closing handles607are disposed on the front surface of the opening and closing pad60and laterally spaced from each other along the X-axis directions. The two opening and closing handles607can be inserted into the respective keyholes6270defined in the cassette lid627of the wafer cassette62illustrated inFIG.7and the respective keyholes6170defined in the cassette lid617of the frame cassette61illustrated inFIG.6.

The opening and closing pad60houses therein an unillustrated rotary mechanism for rotating the opening and closing handles607. The rotary mechanism has an electric motor, an encoder, etc., for example, and can rotate the opening and closing handles607through a required angle.

While the cassette lid627is engaging the wafer cassette62illustrated inFIG.7over the opening629, the opening and closing handles607are inserted into the respective keyholes6270defined in the cassette lid627and are then turned in one direction to secure the cassette lid627to the wafer cassette62. On the other hand, while the cassette lid627is being secured to the wafer cassette62, the opening and closing handles607are inserted into the respective keyholes6270defined in the cassette lid627and then turned in the opposite direction to release the cassette lid627from the wafer cassette62.

Similarly, while the cassette lid617is engaging the frame cassette61illustrated inFIG.6over the opening619, the opening and closing handles607are inserted into the respective keyholes6170defined in the cassette lid617and are then turned in one direction to secure the cassette lid617to the frame cassette61. On the other hand, while the cassette lid617is being secured to the frame cassette61, the opening and closing handles607are inserted into the respective keyholes6170defined in the cassette lid617and are then turned in the opposite direction to release the cassette lid617from the frame cassette61.

A Y-axis pad moving mechanism63for moving the opening and closing pad60horizontally along the Y-axis directions is disposed below the opening and closing pad60. The Y-axis pad moving mechanism63includes a ball screw630with its central axis extending along the Y-axis directions, a pair of guide rails631that are disposed one on each side of the ball screw630and that extend parallel to the ball screw630, an electric motor632coupled to the upper end of the ball screw630for rotating the ball screw630about its central axis, and a movable member633having an internal nut threaded over the ball screw630and bottom portions held in sliding contact with the respective guide rails631. When the electric motor632is energized, it rotates the ball screw630about its central axis, causing the internal nut of the movable member633to move the movable member633along the Y-axis directions while the movable member633is being guided by the guide rails631. The opening and closing pad60is connected to the movable member633by a pad lifting and lowering mechanism64. Therefore, the opening and closing pad60can be moved along the Y-axis directions by the Y-axis pad moving mechanism63.

As illustrated inFIG.9, the pad lifting and lowering mechanism64includes a support member642that is erected vertically on the movable member633and that has a guide groove641which is defined therein and which extends along the Z-axis directions, a ball screw643with its central axis extending along the Z-axis directions, an electric motor644coupled to the lower end of the ball screw643for rotating the ball screw643about its central axis, a guide rail647that is mounted on the support member642and that extends along the Z-axis directions, and a lifting and lowering block645having an internal nut threaded over the ball screw643and a side portion held in sliding contact with the guide rail647. The opening and closing pad60is mounted on the front surface of the lifting and lowering block645that faces in the −Y direction. When the electric motor644is energized, it rotates the ball screw643about its central axis, causing the internal nut of the lifting and lowering block645to move the lifting and lowering block645along the Z-axis directions while the lifting and lowering block645is being guided by the guide rail647. Therefore, the opening and closing pad60on the lifting and lowering block645can be lifted and lowered along the Z-axis directions by the pad lifting and lowering mechanism64.

The second frame cassette stage132, the first frame cassette stage131, and the wafer cassette stage133illustrated inFIG.3may be lifted and lowered along the Z-axis directions by unillustrated respective elevators.

As illustrated inFIG.3, the cassette opening and closing mechanism6is movable back and forth along the X-axis directions by an X-axis moving mechanism69such as an electrically driven slider. The opening and closing pad60of the cassette opening and closing mechanism6can be positioned in front of the cassette lid617of the frame cassette618that is placed on the second frame cassette stage132and that houses frame sets99therein, the cassette lid617of the frame cassette61that is placed on the first frame cassette stage131and that houses ring frames94to be used therein, and the cassette lid627of the wafer cassette62that is placed on the wafer cassette stage133and that houses therein wafers90with protective tapes95affixed thereto, successively in the order described from the +X direction side to the −X direction side.

FIG.8illustrates the first frame cassette stage131in specific detail. The first frame cassette stage131illustrated inFIG.8is essentially identical in structure to the second frame cassette stage132and the wafer cassette stage133illustrated inFIG.3. Therefore, only the first frame cassette stage131will be described below.

The first frame cassette stage131is, for example, of a rectangular shape as viewed in plan. The first frame cassette stage131has three protruding members135on its upper surface. Each of the wafer cassette62and the frame cassette61has three unillustrated recesses defined in its lower surface for engagement in the respective protruding members135. When the frame cassette61, for example, is placed on the first frame cassette stage131such that the protruding members135and the recesses have their horizontal positions aligned with each other, the protruding members135are fitted respectively in the recesses, securing the frame cassette61to the first frame cassette stage131.

A wafer cassette detection sensor136having a first light emitter1361for emitting light and a first light detector1362for detecting the light emitted from the first light emitter1361is disposed on the upper surface of the first frame cassette stage131. In addition, a frame cassette detection sensor137having a second light emitter1373for emitting light and a second light detector1374for detecting the light emitted from the second light emitter1373is disposed on the upper surface of the first frame cassette stage131.

For example, the wafer cassette detection sensor136is positioned more closely to the center of the first frame cassette stage131than the frame cassette detection sensor137. Specifically, as described above, the wafer cassette62has a width and a depth smaller than the frame cassette61. The wafer cassette detection sensor136is positioned in an area of the first frame cassette stage131which can be covered with both the frame cassette61and the wafer cassette62, and the frame cassette detection sensor137is positioned outside of the area of the first frame cassette stage131and can be covered with only the frame cassette61.

When the frame cassette61illustrated inFIG.6is placed on the first frame cassette stage131, both the wafer cassette detection sensor136and the frame cassette detection sensor137are covered with the frame cassette61. The light emitted from the second light emitter1373of the frame cassette detection sensor137is reflected by the lower surface of the frame cassette61and detected by the second light detector1374. Thus, the frame cassette detection sensor137can determine that the cassette placed on the first frame cassette stage131is the frame cassette61. On the other hand, when the wafer cassette62, whose width and depth are smaller than the frame cassette61, is placed on the first frame cassette stage131, only the wafer cassette detection sensor136is covered with the wafer cassette62. The second light detector1374of the frame cassette detection sensor137cannot detect the light emitted from the second light emitter1373as the light is not reflected by the wafer cassette62, and the light emitted from the first light emitter1361of the wafer cassette detection sensor136is reflected by the lower surface of the wafer cassette62and detected by the first light detector1362. Thus, the wafer cassette detection sensor136can determine that the cassette placed on the first frame cassette stage131is the wafer cassette62.

The first frame cassette stage131and the wafer cassette stage133, etc., may be devoid of the wafer cassette detection sensor136and the frame cassette detection sensor137.

As illustrated inFIG.3, as described above, the robot2included in the tape mounter1has the frame holder21for holding a ring frame94and is capable of removing a ring frame94from the frame cassette61on the first frame cassette stage131or storing a frame set99into the frame cassette618on the second frame cassette stage132in the present embodiment. The robot2according to the present embodiment also has the wafer holder22for holding a wafer90under suction thereon.

As illustrated inFIGS.3and10, the robot2is an articulated or multi-joint robot and includes a horizontal holder moving mechanism23for horizontally moving the frame holder21and the wafer holder22and a vertical holder moving mechanism24that may be, for example, an electric actuator, for vertically moving the frame holder21and the wafer holder22.

The horizontal holder moving mechanism23is of a structure for swinging, with a swinging motor, a swinging arm assembly including a plurality of plate-shaped arms and incorporating a pulley mechanism therein, for example. Specifically, the horizontal holder moving mechanism23operates by swinging the arms about respective rotational axes extending in the Z-axis directions, i.e., vertical directions, with rotary power generated by the swinging motor, to thereby swing the wafer holder22, for example, in a horizontal plane defined by the X-axis directions and the Y-axis directions, and also by moving the arms from a mutually crossing state to a linearly aligned state to thereby linearly move the wafer holder22, for example, in a horizontal plane.

The vertical holder moving mechanism24is connected to a lower portion of the horizontal holder moving mechanism23. The vertical holder moving mechanism24moves the wafer holder22, for example, together with the horizontal holder moving mechanism23upwardly and downwardly along the Z-axis directions to thereby position the wafer holder22at a predetermined height.

As illustrated inFIG.3, an electrically driven slider249is disposed beneath the vertical holder moving mechanism24for moving the robot2in its entirety back and forth along the X-axis directions.

As illustrated inFIG.10, a housing25that supports the wafer holder22is connected to one of the arms of the horizontal holder moving mechanism23by a columnar arm joint259.

The wafer holder22is shaped as a substantially oblong rectangular flat plate and has a suction channel220which is defined therein and which extends longitudinally of the wafer holder22. The suction channel220has an end held in fluid communication with an unillustrated suction source including a vacuum generating device and a compressor, etc., and another end open as a suction port221in an upper suction surface of the distal end of the wafer holder22. A suction pad made of rubber resin or the like for increasing suction forces may be disposed in the suction port221. The suction port221may be open in both upper and lower surfaces of the wafer holder22, enabling the upper and lower surfaces to act as suction surfaces.

The wafer holder22has a rear or proximal end supported on the housing25by a holder251. The housing25houses therein a wafer holder reversing mechanism252including a spindle, an electric motor, and so on. The wafer holder reversing mechanism252is capable of reversing the wafer holder22to turn the suction surface in which the suction port221is defined upside down. The wafer holder22may not be reversible upside down.

The frame holder21is supported on a support arm26and includes two upper plates211and a lower plate212for sandwiching a ring frame94therebetween. The lower plate212is in the form of a flat steel plate, for example, having a substantially arcuate edge complementary in shape to a portion of the annular outer circumferential edge of the ring frame94.

The ring frame94, which is of a substantially annular shape as illustrated inFIG.1, has a plurality of (four in the illustrated example) positioning flat facets949defined in the outer circumferential edge thereof.

As illustrated inFIG.10, two abutment blocks213for abutment against the ring frame94are disposed on the upper surface of the lower plate212that will contact the ring frame94, at respective symmetrical positions with respect to a central line of the upper surface of the lower plate212. Each of the abutment blocks213has a contour shaped as a substantially rectangular parallelepiped, and includes a flat front surface for abutment against the ring frame94. The frame holder21can position the ring frame94in a horizontal plane by having the front surfaces of the abutment blocks213abut against one of the positional flat facets949of the ring frame94.

A plate feeding mechanism215for feeding the upper plates211toward the ring frame94in the −Y direction illustrated inFIG.10is disposed on the upper surface of the lower plate212. The plate feeding mechanism215is an air cylinder, for example, including a cylinder tube2151having an unillustrated piston slidably disposed therein and a piston rod2152that is inserted in the cylinder tube2151and that has an end connected to the piston. The two upper plates211are supported by a support bar2153connected to the other end of the piston rod2152. The support bar2153has bottom portions loosely fitted over a pair of guide rails2154that are disposed on the upper surface of the lower plate212and that extend parallel to the piston rod2152, so that the support bar2153can slide on and along the guide rails2154.

The plate feeding mechanism215is not limited to an air cylinder, and may, for example, be an electric cylinder or the like.

Gripping cylinders216are disposed respectively on both longitudinal ends of the support bar2153along the X-axis directions in the illustrated example. The gripping cylinders216have respective piston rods movable along the Z-axis directions. The piston rods have respective lower ends connected to the respective upper surfaces of the upper plates211, which are flat plates. Each of the upper plates211is shaped as a substantially oblong rectangular flat plate and has a substantially arcuate edge complementary in shape to a portion of the annular outer circumferential edge of the ring frame94. The frame holder21operates by positioning the ring frame94between the upper plates211and the lower plate212and lowering the upper plates211with the gripping cylinders216, causing the upper plates211and the lower plate212to grip the ring frame94vertically therebetween.

As illustrated inFIG.10, two sensors217for checking whether there is a ring frame94or not may be disposed on the substantially arcuate edge of the lower plate212.

The frame holder21is attached to the front surface of the support arm26that is mounted on the housing25that supports the wafer holder22by a swing shaft266. The frame holder21can swing horizontally parallel to a horizontal plate with respect to the wafer holder22and can be spaced from the wafer holder22.

The controller17illustrated inFIG.3includes a processor such as a CPU for performing arithmetic and processing operations according to control programs and a storage device such as a memory that stores the control programs or software and various kinds of data. The controller17has functions that can be performed by the processor according to the software stored in the storage device. The controller17is electrically connected by unillustrated wired or wireless communication links to the components of the tape mounter1including the electrically driven slider249for moving the robot2along the X-axis directions, the cassette opening and closing mechanism6, the robot2, the frame delivery mechanism30, the frame set reverser46, and so on. The controller17can perform motor control, sequence control, etc., on the components of the tape mounter1. Various sensors including the wafer cassette detection sensor136and the frame cassette detection sensor137illustrated inFIG.8, etc., send detection signals to the controller17.

An example of operation of the tape mounter1for forming a frame set99that can be diced after the wafer90illustrated inFIG.1has been ground by the grinding apparatus19illustrated inFIG.2will be described below.

The pre-grinding wafer cassette6211that stores a plurality of wafers90to be processed is introduced from a cassette supply source into the grinding apparatus19by the unillustrated OHT mechanism and is placed on the grinding apparatus wafer cassette stage199of the grinding apparatus19.

The wafer90illustrated inFIG.1with the protective tape95affixed to the face side903thereof is stored in the pre-grinding wafer cassette6211. The pre-grinding wafer cassette6211is of an identical structure to the wafer cassette62illustrated inFIG.7.

The grinding apparatus19also includes the cassette opening and closing mechanism6illustrated inFIG.8. The cassette opening and closing mechanism6opens the cassette lid of the pre-grinding wafer cassette6211illustrated inFIG.2on the grinding apparatus wafer cassette stage199, allowing a wafer90to be delivered from the pre-grinding wafer cassette6211. The intra-grinding apparatus robot190holds and delivers the wafer90from the pre-grinding wafer cassette6211and places the wafer90on the chuck table, which holds the wafer90under suction thereon. The rotating grindstones are then lowered to the reverse side904of the wafer90, grinding the wafer90. After the wafer90has been ground to a desired thickness, the grindstones are lifted away from the wafer90, whereupon the grinding process on the wafer90is completed.

The intra-grinding apparatus robot190delivers the ground wafer90from the chuck table and stores the wafer90into the wafer cassette62, which is empty, on the grinding apparatus wafer cassette stage199. Alternatively, the intra-grinding apparatus robot190delivers the ground wafer90from the chuck table and stores the wafer90into the transfer cassette18. The intra-grinding apparatus robot190may store the ground wafer90back into the pre-grinding wafer cassette6211.

For example, all of the wafers90stored in the pre-grinding wafer cassette6211are successively ground in the manner described above, and the successively ground wafers90are stored in the wafer cassette62. Thereafter, the unillustrated OHT mechanism delivers the wafer cassette62that stores the ground wafers90with the protective tapes95affixed thereto from the grinding apparatus wafer cassette stage199to the wafer cassette stage133of the tape mounter1and places the wafer cassette62on the wafer cassette stage133.

In the tape mounter1illustrated inFIG.3, a wafer90is delivered to the wafer table478according to one of two processes belonging to respective first and second categories.

According to the process in the first category, the wafer holder22of the robot2holds a ground wafer90stored in the wafer cassette62or the pre-grinding wafer cassette6211on the wafer cassette stage133and removes the ground wafer90from the wafer cassette62or the pre-grinding wafer cassette6211. Thereafter, the wafer delivery mechanism5receives the wafer90held by the wafer holder22of the robot2and delivers the wafer90to the wafer table478.

According to the process in the second category, the robot2removes a ground wafer90from the transfer cassette18, and thereafter the wafer delivery mechanism5receives the wafer90held by the wafer holder22of the robot2and delivers the wafer90to the wafer table478.

The robot2may also function as a wafer delivery mechanism for delivering a wafer90removed from the wafer cassette62or the pre-grinding wafer cassette6211or a wafer90removed from the transfer cassette18directly to the wafer table478.

The process in the first category will be described below.

When the wafer cassette62that houses ground wafers90is placed on the wafer cassette stage133illustrated inFIG.3, for example, the wafer cassette detection sensor136illustrated inFIG.8detects the wafer cassette62. In response to the detection signal from the wafer cassette detection sensor136, the controller17controls the cassette opening and closing mechanism6. The X-axis moving mechanism69moves the cassette opening and closing mechanism6in the −X direction and positions the opening and closing pad60in front of the wafer cassette62on the wafer cassette stage133. Further, the pad lifting and lowering mechanism64is moved along one of the Z-axis directions to align the height of the keyholes6270in the cassette lid627, illustrated inFIG.7, of the wafer cassette62on the wafer cassette stage133with the height of the opening and closing handles607of the opening and closing pad60.

Then, the controller17controls the Y-axis pad moving mechanism63illustrated inFIG.8to move the opening and closing pad60an appropriate distance in the −Y direction. The wafer cassette62and the opening and closing pad60move toward each other until the opening and closing handles607enter the respective keyholes6270in the cassette lid627. When the opening and closing handles607have entered the respective keyholes6270, the front surface in the −Y direction of the opening and closing pad60and the cassette lid627are held in contact with each other. Then, the suction source699connected to the wafer FOUP suction cups603is actuated to generate suction forces, which are transmitted to the wafer FOUP suction cups603to hold the cassette lid627under suction thereon.

Thereafter, the rotary mechanism housed in the opening and closing pad60is actuated to turn the opening and closing handles607and remove the cassette lid627from the wafer cassette62. The Y-axis pad moving mechanism63moves the cassette lid627held under suction by the wafer FOUP suction cups603in the +Y direction, thereby spacing the cassette lid627away from the wafer cassette62. Then, the opening and closing pad60holding the cassette lid627under suction is lowered and retracted from the front side of the opening629in the wafer cassette62.

Then, the controller17illustrated inFIG.13controls the robot2. Specifically, the electrically driven slider249illustrated inFIG.3moves the robot2in the −X direction to position the robot2in front of the wafer cassette62placed on the wafer cassette stage133with its opening629kept open. The horizontal holder moving mechanism23turns the wafer holder22to an angular position where the wafer holder22faces the front of the opening629in the wafer cassette62, so that the longitudinal directions, i.e., the Y-axis directions, of the wafer holder22are aligned with the direction along which wafers90can be inserted into and removed from the wafer cassette62. Moreover, the vertical holder moving mechanism24vertically moves and positions the wafer holder22into alignment with the height of a wafer90to be handled that is stored on one of the shelves625of the wafer cassette62.

For example, the wafer holder reversing mechanism252illustrated inFIG.10reverses the wafer holder22upside down to set the suction surface of the wafer holder22in which the suction port221is defined, into a state where the suction surface faces upwardly.

Then, the wafer holder22enters the wafer cassette62through the opening629to a predetermined position therein in the −Y direction. The wafer holder22is positioned below the center of the wafer90.

Further, the wafer holder22is lifted until the suction surface thereof is brought into contact with the protective tape95affixed to the downwardly facing face side903of the wafer90. The unillustrated suction source is actuated to generate suction forces, which are transmitted through the suction channel220to the suction port221to act on the wafer90. The wafer90is now held under suction on the wafer holder22beneath the wafer90, with the reverse side904facing upwardly.

Then, the wafer holder22that is holding the wafer90under suction thereon is moved out of the wafer cassette62, so that the wafer90is delivered from the wafer cassette62by the robot2.

The robot2with its wafer holder22holding the wafer90under suction delivers the wafer90from the wafer cassette62. The controller17then performs a control process for controlling the wafer delivery mechanism5to receive the wafer90from the wafer holder22of the robot2and deliver the wafer90to the wafer table478.

Specifically, under the control of the controller17, the horizontal holder moving mechanism23horizontally moves, i.e., swings, the wafer holder22holding the wafer90. The suction pad moving mechanism52of the wafer delivery mechanism5illustrated inFIG.5moves the suction pad55along the Y-axis directions to position the wafer90held under suction by the wafer holder22and the suction pad55into alignment with each other in a horizontal plane. The center of the suction pad55and the center of the wafer90are brought into substantial alignment with each other, whereupon the wafer90is positioned directly below the suction pad55.

The suction pad lifting and lowering mechanism53lowers the suction pad55in the −Z direction to a vertical position where the holding surface550of the suction pad55contacts the reverse side904of the wafer90, whereupon the suction pad55stops being lowered. Suction forces generated by the unillustrated suction source are transmitted to the holding surface550of the suction pad55, causing the holding surface550to attract and hold the reverse side904of the wafer90under suction. When the wafer90is held under suction on the suction pad55, the controller17controls the robot2to stop holding the wafer90under suction. As a result, a state in which the wafer90has been transferred to the wafer delivery mechanism5is realized.

When the controller17controls the suction pad moving mechanism52and the suction pad lifting and lowering mechanism53, the wafer delivery mechanism5places the wafer90held under suction on the suction pad55on the wafer table478of the tape affixing table470illustrated inFIG.3such that the centers of the wafer90and the wafer table478are substantially aligned with each other. The wafer90is held under suction on the wafer table478with the reverse side904exposed upwardly.

The process in the second category for delivering the wafer90to the wafer table478in the tape mounter1will be described below.

Ground wafers90are delivered by the intra-grinding apparatus robot190illustrated inFIG.2to the respective shelves of the transfer cassette18disposed between the grinding apparatus19and the tape mounter1, and the controller17illustrated inFIG.3controls the robot2. The electrically driven slider249moves the robot2in the +X direction and positions the robot2in front of the transfer cassette18. The horizontal holder moving mechanism23turns the wafer holder22to an angular position where the wafer holder22faces the front of the transfer cassette18, so that the longitudinal directions, i.e., the Y-axis directions, of the wafer holder22are aligned with the direction along which wafers90can be inserted into and removed from the transfer cassette18. Moreover, the vertical holder moving mechanism24vertically moves and positions the wafer holder22in alignment with the height of a wafer90to be handled that is stored on one the shelves of the transfer cassette18.

Then, the wafer holder22is moved in the +X direction and enters the transfer cassette18to a predetermined position therein. The wafer holder22is positioned below the center of the wafer90.

Further, the wafer holder22is lifted until the suction surface thereof is brought into contact with the protective tape95affixed to the downwardly facing face side903of the wafer90in the transfer cassette18. The wafer90is now held under suction from below by the wafer holder22to which suction forces generated by the suction source are transmitted. The wafer90held under suction on the wafer holder22has the reverse side904facing upwardly.

Then, the wafer holder22holding the wafer90under suction is moved out of the transfer cassette18, and the wafer90is delivered from the transfer cassette18by the robot2. Subsequently, the wafer90is transferred from the wafer holder22to the wafer delivery mechanism5and then delivered to the wafer table478by the wafer delivery mechanism5in substantially the same manner as that in the process according to the first category.

According to the process in the first category or the process in the second category, the robot2that has transferred the wafer90to the wafer delivery mechanism5delivers a ring frame94to the frame delivery mechanism30concurrently while the wafer delivery mechanism5is delivering the wafer90to the wafer table478. Specifically, the controller17performs a control process for controlling the frame holder21of the robot2to hold and remove a ring frame94from the frame cassette61on the first frame cassette stage131and a control process for controlling the frame delivery mechanism30to receive the ring frame94held by the frame holder21of the robot2.

For example, the unillustrated OHT mechanism has delivered the frame cassette61housing ring frames94to be used from the supply source and placed the frame cassette61on the first frame cassette stage131. The frame cassette detection sensor137illustrated inFIG.8detects the frame cassette61. In response to the detection signal from the frame cassette detection sensor137, the controller17controls the cassette opening and closing mechanism6to remove the cassette lid617from the frame cassette61. Since the cassette opening and closing mechanism6operates in the same fashion as when the cassette lid627is removed from the wafer cassette62, the operation of the cassette opening and closing mechanism6will be omitted from description. The opening and closing pad60holding the cassette lid627under suction is lowered and retracted from the front side of the opening619in the frame cassette61illustrated inFIG.6.

Then, the controller17controls the robot2. Specifically, the electrically driven slider249illustrated inFIG.3moves the robot2in the +X direction and positions the robot2in front of the frame cassette61placed on the first frame cassette stage131with its opening619kept open. Moreover, in order to prevent the wafer holder22from impeding the entry of the frame holder21into the frame cassette61, the frame holder21illustrated inFIG.10swings about the swing shaft266away from the wafer holder22until the direction in which the frame holder21protrudes, i.e., the direction in which the upper plates211travel, extends perpendicularly to the longitudinal directions of the wafer holder22, for example.

Further, the horizontal holder moving mechanism23turns the frame holder21to an angular position where the frame holder21faces the front of the opening619in the frame cassette61. In addition, the vertical holder moving mechanism24positions the frame holder21at the height of a ring frame94to be handled that is stored on one of the shelves615of the frame cassette61.

For example, the frame holder21is positioned such that the central line of the upper surface of the lower plate212and the diameter of the ring frame94in the frame cassette61are substantially aligned with each other. When the frame holder21is thus positioned, the front surfaces of the abutment blocks213of the frame holder21illustrated inFIG.10face one of the positional flat facets949of the ring frame94illustrated inFIG.1.

Then, the frame holder21is moved toward the ring frame94in the −Y direction as illustrated inFIG.10until the front surfaces of the abutment blocks213abut against one of the positional flat facets949of the ring frame94. When the front surfaces of the abutment blocks213abut against one of the positional flat facets949of the ring frame94, the frame holder21is positioned with respect to the ring frame94and stops being moved.

Moreover, the plate feeding mechanism215illustrated inFIG.10moves the upper plates211in the −Y direction over the lower plate212until the distal ends of the upper plates211in the −Y direction illustrated inFIG.10reach the position of the substantially arcuate edge of the lower plate212. Thereafter, the frame holder21is lifted in the +Z direction until the upper surface of the lower plate212contacts the lower surface of the ring frame94. Then, the gripping cylinders216lower the upper plates211until the upper plates211and the lower plate212vertically grip the ring frame94, whereupon the process of holding the ring frame94by the frame holder21is completed.

Further, the controller17illustrated inFIG.3controls the robot2and the frame delivery mechanism30to transfer the ring frame94from the robot2to the frame delivery mechanism30. Specifically, the horizontal holder moving mechanism23horizontally moves, i.e., swings, the frame holder21holding the ring frame94, and the swing mechanism306of the frame delivery mechanism30swings the delivery pad300to position the ring frame94held by the frame holder21and the delivery pad300with respect to each other in a horizontal plane. The center of the delivery pad300and the center of the ring frame94are brought into substantial alignment with each other, whereupon the ring frame94is positioned directly below the delivery pad300.

After the delivery pad300has been lowered to a vertical position where the suction cups303thereof contact the upper surface of the ring frame94, the delivery pad300stops being lowered at the vertical position. Then, the delivery pad300attracts the upper surface of the ring frame94under suction forces transmitted from the unillustrated suction source to the suction cups303. When the delivery pad300holds the ring frame94under suction thereon, a control process for canceling the gripping of the ring frame94by the frame holder21is carried out, resulting in transferring the ring frame94from the robot2to the frame delivery mechanism30.

The controller17controls the frame delivery mechanism30to place the ring frame94held under suction by the frame delivery mechanism30on the frame table477of the tape affixing table470such that their centers are substantially aligned with each other. The ring frame94is then held under suction on the frame table477. The wafer90is now placed in the opening in the ring frame94such that the center of the wafer90is substantially aligned with the center of the opening in the ring frame94. The face side903of the wafer90illustrated inFIG.1with the protective tape95affixed thereto has been held under suction on the wafer table478, and the reverse side904of the wafer90faces upwardly. The reverse side904of the wafer90and the upper surface of the ring frame94are positioned at substantially the same height.

Then, the web-shaped sheet is unreeled from the tape roll935set unreelably near the unreeling roller472toward the peeling plate475by the unreeling roller472illustrated inFIG.3. The peeling plate475peels off the dicing tape93from the web-shaped sheet while at the same time the affixing roller474rotates at a predetermined rotational speed. Further, the ball screw mechanism473moves the tape affixing table470in the +Y direction, causing the affixing roller474to press the dicing tape93against the upper surface of the ring frame94held under suction on the frame table477and the reverse side904of the wafer90held under suction on the wafer table478from the outer circumferential sides thereof.

When the tape affixing table470is moved in the +Y direction to a predetermined position where the tape affixing table470passes the affixing roller474while the affixing roller474is pressing the dicing tape93to the ring frame94and the wafer90, the dicing tape93is affixed to the wafer90and the ring frame94. In this manner, a frame set99where the wafer90and the ring frame94are integrally joined by the dicing tape93is produced.

Then, the frame delivery mechanism30holds the upper surface of the ring frame94of the frame set99under suction, is then lifted and turned in a horizontal plane to deliver the frame set99from the tape affixing table470, and positions the frame set99above the reversing pad460of the frame set reverser46. The wafer90of the frame set99has the face side903that is protected by the protective tape95and that faces downwardly.

The reversing pad460is set in a state where the four suction cups463face upwardly. The reversing pad lifting and lowering mechanism467lifts the reversing pad460to bring the suction cups463into contact with the lower surface of the ring frame94of the frame set99.

The unillustrated suction source is actuated to produce suction forces, which are transmitted to the suction cups463to cause the suction cups463to attract the lower surface of the ring frame94under suction, whereupon the frame set99is held under suction by the frame set reverser46. Then, the frame delivery mechanism30releases the frame set99and is spaced from the frame set99.

Then, the reversing motor465is energized to rotate itself with respect to the rotational shaft464through a predetermined angle, turning the base461and the frame set99held under suction by the four suction cups463upside down. The face side903of the wafer90with the protective tape95affixed thereto faces upwardly, and the frame set99is positioned below and held under suction on the reversing pad460.

The peeling table436is moved in the −Y direction by the ball screw mechanism432and positioned below the reversing pad460that is holding the frame set99under suction thereon. Then, the reversing pad lifting and lowering mechanism467lowers the reversing pad460to place the frame set99onto the peeling table436while the center of the wafer90of the frame set99and the center of the peeling table436are being substantially aligned with each other. Then, the frame set99is held under suction on the peeling table436. The reversing pad460is lifted away from the frame set99, and the face side903, protected by the protective tape95, of the wafer90of the frame set99faces upwardly.

The controller17controls the peeling member moving mechanism435to move the peeling member431along one of the Y-axis directions and also controls the ball screw mechanism432to move the peeling table436along one of the Y-axis directions, positioning the outer circumferential portion of the protective tape95affixed to the face side903, i.e., a device surface, of the wafer90directly below the peeling member431. Then, the peeling member431affixes the peel-off tape to the protective tape95. The peeling member431and the peeling table436are moved along the Y-axis directions relatively to each other, peeling off the protective tape95from the face side903from an outer circumferential edge of the wafer90toward the center thereof and then from the center to an opposite outer circumferential edge of the wafer90.

After the protective tape95has completely been peeled off from the wafer90of the frame set99, the peeling table436is positioned below the reversing pad460of the frame set reverser46. The wafer90of the frame set99has the reverse side904that is protected by the dicing tape93and that faces downwardly.

The reversing pad460is set in a state where the four suction cups463face downwardly. The reversing pad lifting and lowering mechanism467lowers the reversing pad460to bring the suction cups463into contact with the upper surface of the ring frame94of the frame set99. Then, the frame set99is held under suction by the frame set reverser46, and the peeling table436releases the frame set99.

Then, the reversing pad460is turned upside down to turn the frame set99held under suction by the four suction cups463upside down, making it possible for the frame delivery mechanism30to hold the frame set99under suction from above. The frame delivery mechanism30is turned to an angular position above the frame set99held under suction by the reversing pad460. For example, the reversing pad lifting and lowering mechanism467lifts the reversing pad460to bring the side of the ring frame94to which the dicing tape93is affixed into contact with the suction cups303of the frame delivery mechanism30. Then, while the center of the frame set99and the center of the delivery pad300are being substantially aligned with each other, the frame set99is held under suction by the frame delivery mechanism30. The reversing pad460is lowered away from the frame set99.

The frame delivery mechanism30may directly hold the frame set99under suction while the face side903of the wafer90on the peeling table436is facing upwardly.

Then, the controller17performs a control process for controlling the frame holder21of the robot2to receive the frame set99held by the frame delivery mechanism30. Specifically, the controller17controls the robot2to cause the horizontal holder moving mechanism23to turn the frame holder21and also to cause the swing mechanism306of the frame delivery mechanism30illustrated inFIG.3to turn the delivery pad300holding the frame set99under suction, positioning the frame set99held by the frame delivery mechanism30and the frame holder21with respect to each other in a horizontal plane. Thereafter, the frame holder21holds the ring frame94of the frame set99in the same manner as the frame holder21holds the ring frame94in the frame cassette61as described above. Therefore, the holding of the ring frame94of the frame set99by the frame holder21will be omitted from description. After the frame holder21has held the ring frame94, the frame delivery mechanism30releases the ring frame94.

Then, the controller17performs a control process for storing the frame set99held by the frame holder21of the robot2into the frame cassette618, which is empty, on the second frame cassette stage132, for example. That is, the controller17performs a control process for controlling the frame holder21of the robot2to store the frame set99held by the frame holder21of the robot2into the frame cassette618on the second frame cassette stage132.

The electrically driven slider249illustrated inFIG.3moves the robot2in the +X direction and positions the robot2in front of the frame cassette618. The horizontal holder moving mechanism23turns the frame holder21to an angular position in front of the opening in the frame cassette618. The vertical holder moving mechanism24positions the frame holder21at the height of one, to be handled, of the shelves of the frame cassette618. The frame holder21enters the frame cassette618, places the frame set99on the shelf, and is retracted out of the frame cassette618.

The controller17may perform a control process for storing, one at a time, the frame set99held by the frame holder21of the robot2on the empty shelf615of the frame cassette61placed on the first frame cassette stage131.

When frame sets99are stored one by one on the shelves of the frame cassette618and the frame cassette618becomes full, the unillustrated OHT mechanism delivers the frame cassette618from the second frame cassette stage132to an unillustrated cutting apparatus or the like. The cutting apparatus then divides a wafer90of a frame set99removed from the frame cassette618into individual device chips.

As described above, the tape mounter1according to the present embodiment includes the first frame cassette stage131for placing thereon the frame cassette61capable of storing ring frames94, the robot2having the frame holder21for holding a ring frame94and being capable of removing a ring frame94from the frame cassette61on the first frame cassette stage131or storing a frame set99into the frame cassette618, and the controller17. The controller17performs a control process for controlling the frame holder21of the robot2to hold and remove a ring frame94from the frame cassette61on the first frame cassette stage131, a control process for controlling the frame delivery mechanism30to receive the ring frame94held by the frame holder21of the robot2, a control process for controlling the frame holder21of the robot2to receive the frame set99held by the frame delivery mechanism30, and a control process for controlling the frame holder21of the robot2to store the frame set99held by the frame holder21of the robot2into the frame cassette61. The tape mounter1does not need to use a frame stocker and does not require the operator to replenish a frame stocker with ring frames94. Specifically, as disclosed in Japanese Patent Laid-open No. 2015-082588 and Japanese Patent Laid-open No. 2019-140217, it has heretofore been customary for an AGV, an OHT mechanism, or the like to deliver a wafer cassette62storing wafers90and a cassette storing frame sets99each having a ring frame94and a wafer90that are integrally joined by a dicing tape93. According to the embodiment, the cassette that has heretofore been used to deliver only frame sets99is given a new application, and the AGV or the OHT mechanism is used to deliver the frame cassette61storing the ring frames94and supply the ring frames94to the tape mounter1. Consequently, the conventional process performed by the operator to replenish ring frames94is made unnecessary.

Further, since the controller17performs a control process for storing the frame set99held by the frame holder21of the robot2into the frame cassette618placed on the second frame cassette stage132or a control process for storing the frame set99held by the frame holder21of the robot2into the frame cassette61on the first frame cassette stage131, it is possible to store a frame set99with a dicing tape93affixed thereto into the frame cassette61supplied with ring frames94or the frame cassette618that is empty, and deliver the frame cassette61or the frame cassette618from the tape mounter1with use of the AGV or the OHT mechanism. Consequently, the operator is not required to retrieve frame sets99.

Moreover, the tape mounter1includes the wafer cassette stage133for placing thereon the wafer cassette62storing wafers90therein. The robot2includes the wafer holder22for holding a wafer90, and the controller17performs a control process for controlling the wafer holder22of the robot2to hold a wafer90stored in the wafer cassette62on the wafer cassette stage133and remove the wafer90from the wafer cassette62and a control process for controlling the wafer delivery mechanism5to receive the wafer90held by the wafer holder22of the robot2and deliver the wafer90to the wafer table478. It is thus possible to produce a frame set99that includes a wafer90and a ring frame94more smoothly in the tape mounter1.

The tape mounter according to the present invention is not limited to the details and features according to the above embodiment, and may be reduced to practice in various different forms and details within the scope of the invention. The components of the tape mounter1and the grinding apparatus19illustrated in the accompanying drawings are not limited to the illustrated configurations, and may appropriately be changed and modified insofar as such changes and modifications can achieve the advantages of the present invention.

The present invention is not limited to the details of the above described preferred embodiment. The scope of the invention is defined by the appended claims and all changes and modifications as fall within the equivalence of the scope of the claims are therefore to be embraced by the invention.