Patent ID: 12232271

DETAILED DESCRIPTION

As used herein, a “bond head array” refers to a bond head configured for carrying a plurality of pick tools (e.g., pick and place tools, such as pipettes, grippers, etc.) in connection with placement operations.

In accordance with the invention, various exemplary “motion systems” are described herein. The term “motion system”, as used herein (including in the claims), may refer to a single motion system (e.g., a single motion system as illustrated and described in connection with the drawings) or to a plurality of motion systems. For example, referring toFIG.1, a y-axis motion system104and two x-axis motion systems108are described. Collectively, these three motion systems (i.e., the y-axis motion system104and the two x-axis motion systems108) move the bond head arrays106a,106balong the y-axis and the x-axis. Thus, collectively, these three motion systems (i.e., the y-axis motion system104and the two x-axis motion systems108) may be considered a single motion system within the scope of the invention. Accordingly, any single motion system or any group of motion systems described herein may be considered a “motion system” within the scope of the invention.

In accordance with various exemplary embodiments of the invention, component placement systems/devices are provided that pick and/or place electronic components simultaneously. Such component placement systems may include two (or more) bond head arrays residing on a single long stroke actuator (e.g., a long stroke y-axis actuator, a long stroke x-axis actuator, or both). The bond head arrays can be positioned independently from each other enabling parallel picking and/or parallel placement.

In accordance with the scope and spirit of the invention, many different variations are contemplated. Exemplary variations include: (a) one long stroke y-axis manipulator (e.g., see y-axis motion system204inFIG.2), with two bond head arrays which can be positioned independently from one another in an XY-plane using long stroke x-axis actuators (e.g., see x-axis motion systems208a,208b) and a short stroke y-axis actuator (e.g., see y-axis motion system220) (e.g., seeFIG.2); (b) one long stroke XY manipulator (e.g., where such a manipulator may include motion systems304and308ainFIG.3), one bond head (e.g., where such a bond head may include bond head arrays306a,306binFIG.3) containing two arrays that can be positioned independently in an XY-plane using two short stroke linear actuators (e.g., seeFIG.3); (c) one long stroke XY manipulator (e.g., where such a manipulator may include motion systems404and408ainFIG.4), one bond head (e.g., where such a bond head may include bond head arrays406a,406binFIG.4) containing two arrays that can be positioned independently in an XY-plane via two short stroke linear actuators, where the combination of the two arrays can be rotated, where by rotating the arrays 180 degrees the order of the arrays can be swapped (e.g., the pipettes on the right move to the left and vice versa) (e.g., seeFIG.4); (d) one long stroke XY manipulator (e.g., where such a manipulator may include motion systems504and508ainFIG.5), one bond head (e.g., where such a bond head may include bond head arrays506a,506binFIG.5) containing two arrays that can be positioned independently in an XY-plane using a single short stroke linear actuator and a rotational actuator, where by rotating the arrays another 180 degrees, the order of the arrays can be swapped (e.g., the pick up tools (e.g., pipettes) on the right move to the left and vice versa) (e.g., seeFIG.5); and (e) one long stroke XY manipulator (e.g., where such a manipulator may include motion systems604and608ainFIG.6), one bond head (e.g., where support structure622may be considered such a bond head) containing three pick up tools (e.g., pipettes) that can be positioned independently in an XY-plane via three short stroke actuators combined with a rotational actuator, where by choosing the right positioning of the linear actuators combined with the rotation angle, the three pick up tools (e.g., pipettes) can be arranged in any order (e.g., seeFIG.6). Of course, other variations within the scope of the invention are contemplated.

In accordance with certain exemplary embodiments of the invention, a reduced number of long stroke axes are utilized in a component placement system. In a specific example, for a second bond head the long stroke axis is replaced by a short stroke axis reducing COGS (i.e., cost of goods sold). The short stroke axis enables the second bond head to be positioned independently of the first (e.g., main) bond head. In such an example, there is only one (e.g., long stroke) manipulator, with the additional degrees of freedom supplied by the short stroke axis/axes.

Referring now to the drawings,FIG.1illustrates a component placement system100. Component placement system100includes feeding area102for supplying various electronic components to be picked and placed onto substrate114(of course, multiple substrates114may be provided to receive electronic components). A look-up camera112(or other vision system element) is provided for alignment, inspection, etc. Exemplary bond head arrays106a,106bare illustrated inFIG.1, each including a plurality of pick up tools110(e.g., pick and place tools, such as pipettes, grippers, etc.). A y-axis motion system104is provided to move each of bond head arrays106a,106bsimultaneously along the y-axis of component placement system100. A separate x-axis motion system108is provided for each of bond head arrays106a,106b—to move them separate from one another along the x-axis of component placement system100. An additional y-axis motion system120is illustrated for bond head array106bfor moving its pick up tools110along the y-axis of component placement system100without bond head array106a.

The details of bond head arrays106a,106b(and their associated support structures, pick up tools, and motion systems) are exemplary in nature. It is understood that any of the configurations illustrated inFIG.2-6, or any other configuration within the scope of the invention, may be implemented in a component placement system including elements such as those illustrated inFIG.1(including feeding area102, substrate114, look-up camera112, etc.).

Referring now toFIG.2, bond head arrays206aand206bare illustrated. A support structure216carries each of bond head arrays206a,206b. Further, another support structure214carries support structure216(and hence each of bond head arrays206a,206b). More specifically, support structure216(and hence each of bond head arrays206a,206b) can be moved along the y-axis of the component placement system using a y-axis motion system204(e.g., a long stroke actuator). Bond head array206ais carried by an x-axis motion system208a(via a support structure218), thereby being moveable along the x-axis of the component placement system. Likewise, bond head array206bis carried by an x-axis motion system208b, thereby also being moveable along the x-axis of the component placement system. Bond head array206ais also moveable along the y-axis of the component placement system using a y-axis motion system220(e.g., a short stroke actuator). Each of bond head arrays206a,206bincludes a plurality of pick up tools210(e.g., pick and place tools, such as pipettes).

Thus, in summary,FIG.2illustrates a single long stroke y-axis motion system204for carrying the two bond head arrays206a,206b. Each of bond head arrays206a,206bcan be moved independently along the x-axis using respective x-axis motion systems208a,208b(e.g., linear actuators). Finally, bond head array206acan be moved along the y-axis using y-axis motion system220.

Referring now toFIG.3, bond head arrays306aand306bare illustrated. A support structure316carries each of bond head arrays306a,306b. Further, another support structure314carries support structure316(and hence each of bond head arrays306a,306b). More specifically, support structure316(and hence each of bond head arrays306a,306b) can be moved along the y-axis of the component placement system using a y-axis motion system304(e.g., a long stroke actuator). Bond head array306aand bond head array306bare both carried by an x-axis motion system308a(e.g., a long stroke actuator), thereby being moveable along the x-axis of the component placement system. Bond head array306ais also moveable along the each of the x-axis and the y-axis of the component placement system independently of bond head array306b(although306aofFIG.3is illustrated supported/constrained by roller bearings in both X and Y directions (thus restricting travel) for simplicity, it is understood that an additional support structure separating the directions could be used). More specifically, bond head array306amay be moved along the x-axis, independently of bond head array306b, using an x-axis motion system308b(e.g., a short stroke actuator). Further, bond head array306amay be moved along the y-axis, independently of bond head array306b, using a y-axis motion system320(e.g., a short stroke actuator). Each of bond head arrays306a,306bincludes a plurality of pick up tools310(e.g., pick and place tools, such as pipettes, grippers, etc.).

Thus, in summary,FIG.3illustrates (i) a single long stroke y-axis motion system304for carrying the two bond head arrays306a,306b; and (ii) a single long stroke x-axis motion system308afor carrying the two bond head arrays306a,306b. Further, bond head array306acan be moved independently from bond head array306balong the x-axis using x-axis motion system308b, and along the y-axis using y-axis motion system320.

Referring now toFIG.4, bond head arrays406aand406bare illustrated. A support structure416carries each of bond head arrays406a,406b. Further, another support structure414carries support structure416(and hence each of bond head arrays406a,406b). More specifically, support structure416(and hence each of bond head arrays406a,406b) can be moved along the y-axis of the component placement system using a y-axis motion system404(e.g., a long stroke actuator). Bond head array406aand bond head array406bare both carried by an x-axis motion system408a(e.g., a long stroke actuator) (via a support structure424), thereby being moveable along the x-axis of the component placement system. Bond head array406aand bond head array406bare also both carried by a rotative motion system426(via a support structure422), and thus bond head array406aand bond head array406bare simultaneously carried about a rotative motion axis (i.e., carried about the z-axis). For example, by rotating 180 degrees, the order of the arrays can be swapped (e.g., the bond head array on the right moves to the left and vice versa).

Bond head array406ais also moveable along the each of the x-axis and the y-axis of the component placement system independently of bond head array406b(although406aofFIG.4is illustrated supported/constrained by roller bearings in both X and Y directions (thus restricting travel) for simplicity, it is understood that an additional support structure separating the directions could be used). More specifically, bond head array406amay be moved along the x-axis, independently of bond head array406b, using an x-axis motion system408b(e.g., a short stroke actuator). Further, bond head array406amay be moved along the y-axis, independently of bond head array406b, using a y-axis motion system420(e.g., a short stroke actuator). Each of bond head arrays406a,406bincludes a plurality of pick up tools410(e.g., pick and place tools, such as pipettes, grippers, etc.).

Thus, in summary,FIG.4illustrates (i) a single long stroke y-axis motion system404for carrying the two bond head arrays406a,406b; (ii) a single long stroke x-axis motion system408afor carrying the two bond head arrays406a,406b; and (iii) a single rotative motion system426for carrying bond head array406aand bond head array406babout a rotative motion axis. Further, bond head array406acan be moved independently from bond head array406balong the x-axis using x-axis motion system408b, and along the y-axis using y-axis motion system420.

Referring now toFIG.5, bond head arrays506aand506bare illustrated. A support structure516carries each of bond head arrays506a,506b. Further, another support structure514carries support structure516(and hence each of bond head arrays506a,506b). More specifically, support structure516(and hence each of bond head arrays506a,506b) can be moved along the y-axis of the component placement system using a y-axis motion system504(e.g., a long stroke actuator). Bond head array506aand bond head array506bare both carried by an x-axis motion system508a(e.g., a long stroke actuator) (via a support structure524), thereby being moveable along the x-axis of the component placement system. Bond head array506aand bond head array506bare also both carried by a rotative motion system526(via a support structure522), and thus bond head array506aand bond head array506bare simultaneously carried about a rotative motion axis (i.e., carried about the z-axis). For example, by rotating 180 degrees, the order of the arrays can be swapped (e.g., the bond head array on the right moves to the left and vice versa).

Bond head array506ais also moveable along the x-axis of the component placement system independently of bond head array506b. More specifically, bond head array506amay be moved along the x-axis, independently of bond head array506b, using an x-axis motion system508b(e.g., a short stroke actuator). Each of bond head arrays506a,506bincludes a plurality of pick up tools510(e.g., pick and place tools, such as pipettes, grippers, etc.).

Thus, in summary,FIG.5illustrates (i) a single y-axis motion system504(e.g., a long stroke motion system) for carrying the two bond head arrays506a,506b; (ii) a single x-axis motion system508a(e.g., a long stroke motion system) for carrying the two bond head arrays506a,506b; and (iii) a single rotative motion system526for carrying bond head array506aand bond head array506babout a rotative motion axis. Further, bond head array506acan be moved independently from bond head array506balong the x-axis using x-axis motion system508b.

Referring now to the overhead view ofFIG.6, three distinct pick up tools610are illustrated, each being carried by a respective one of support structures630a,630b, and630c. Each of linear motion systems628a,628b, and628care provided to move a respective one of support structures630a,630b, and630c(and hence, the respective pick up tool610) with respect to a support structure622(where support structure622may be considered a bond head).

As detailed below, a support structure616carries support structure622via a linear motion system608a(e.g., an x-axis motion system), a support structure624, and a rotative motion system626. Further, another support structure614carries support structure616. More specifically, support structure616(and hence each of pick up tools610) can be moved along the y-axis of the component placement system using a linear motion system604(e.g., a long stroke actuator, a y-axis motion system, etc.). Each of the three pick up tools610are carried by linear motion system608a(e.g., a long stroke actuator, an x-axis motion system, etc.) (via support structure624), thereby being moveable along the x-axis of the component placement system. Each of the three pick up tools are also both carried by rotative motion system626(via support structure622), and thus are simultaneously carried about a rotative motion axis (i.e., carried about the z-axis).

Thus, in summary,FIG.6illustrates (i) a single linear motion system604(e.g., a long stroke motion system, a y-axis motion system, etc.) for carrying the three pick up tools610; (ii) a single linear motion system608a(e.g., a long stroke motion system, an x-axis motion system, etc.) for carrying the three pick up tools610; and (iii) a single rotative motion system626for carrying the three pick up tools610about a rotative motion axis. Further, each of the three pick up tols610can be moved independently along a respective linear axis using respective linear motion system628a,628b, and628c(e.g., short stroke linear actuators). By choosing the right positioning of the linear motion systems628a,628b, and628cwith a desired rotation angle of rotative motion system626, the three pick up tools610(e.g., pipettes, grippers, etc.) can be arranged in any desired configuration.

FIGS.7-8are flow diagrams illustrating methods of operating a component placement system. As is understood by those skilled in the art, certain steps included in the flow diagrams may be omitted; certain additional steps may be added; and the order of the steps may be altered from the order illustrated-all within the scope of the invention.

Referring now toFIG.7, in Step700, a first plurality of electronic components are carried using a first bond head array. In Step702, a second plurality of electronic components is carried using a second bond head array. In Step704, the first bond head array and the second bond head array are moved along a first motion axis simultaneously using a first motion system (e.g., bond head arrays106a,106bare moved along the y-axis using motion system104; bond head arrays106a,106bare moved along the x-axis using a motion system including the two x-axis motion systems108) (e.g., bond head arrays206a,206bare moved along the y-axis using y-axis motion system204; bond head arrays206a,206bare moved along the x-axis using a motion system including the two x-axis motion systems208a,208b). Step706, the first bond head array is moved independent of the second bond head array using a second motion system (e.g., bond head array106bis moved independent of bond head array106ausing y-axis motion system120) (e.g., bond head array206ais moved independent of bond head array206busing y-axis motion system220).

Referring now toFIG.8, in Step800, a plurality of linear motion systems are carried using a first support structure, each of the plurality of linear motion systems being configured to move one of a plurality of pick up tools configured for carrying an electronic component. In Step802, the first support structure is carried with a second support structure. In Step804, the first support structure is moved with respect to the second support structure about a rotative motion axis using a rotative motion system (e.g., seeFIG.6where support structure622is moved with respect to support structure624about a rotative axis using rotative motion system626). In optional Step806, the second support structure is carried with a third support structure. In optional Step808, the second support structure is moved with respect to the third support structure along a first linear motion axis using another linear motion system (e.g., seeFIG.6where support structure624is moved with respect to support structure616using linear motion system608a). In optional Step810, the third support structure is carried with a fourth support structure. In optional Step812, the third support structure is moved with respect to the fourth support structure along a second linear motion axis using yet another linear motion system (e.g., seeFIG.6where support structure616is moved with respect to support structure614using linear motion system604).

As will be appreciated by those skilled in the art, the pick and place tools (e.g., pick up tools, pipettes, grippers, etc.) described herein are configured to pick and/or place any electronic component as needed in a given application. Exemplary electronic components include semiconductor elements, discrete components, and any other electronic component which may be placed using the inventive component placement systems described herein.

As will be appreciated by those skilled in the art, the motion systems described herein (e.g., y-axis motion systems, x-axis motion systems, linear motion systems, rotative motion systems, etc.) are shown in a simplified form. Such motion systems may include various subcomponents, and may be considered to be manipulators, actuators, motors, or any other type of motion system applicable to the inventive component placement systems described herein.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.