U.S. patent application number 14/490254 was filed with the patent office on 2015-01-01 for method of manufacturing a semiconductor device.
The applicant listed for this patent is Renesas Northern Japan Semiconductor, Inc., Renesas Technology Corporation. Invention is credited to Mitsuru Kinoshita, Tadashi Munakata, Shingo Oosaka, Noriyuki Takahashi, Yoshihiko Yamaguchi.
Application Number | 20150004755 14/490254 |
Document ID | / |
Family ID | 31884281 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150004755 |
Kind Code |
A1 |
Munakata; Tadashi ; et
al. |
January 1, 2015 |
Method of Manufacturing a Semiconductor Device
Abstract
A semiconductor device manufacturing method comprising the steps
of providing a matrix substrate having a main surface with plural
device areas formed thereon, fixing plural semiconductor chips to
the plural device areas respectively, then sealing the plural
semiconductor chips all together with resin to form a block sealing
member, dividing the block sealing member and the matrix substrate
for each of the device areas by dicing, thereafter rubbing a
surface of each of the diced sealing member portions with a brush,
then storing semiconductor devices formed by the dicing once into
pockets respectively of a tray, and conveying the semiconductor
devices each individually from the tray. Since the substrate
dividing work after block molding is performed by dicing while
vacuum-chucking the surface of the block sealing member, the
substrate division can be done without imposing any stress on an
external terminal mounting surface of the matrix substrate.
Inventors: |
Munakata; Tadashi; (Nanae,
JP) ; Oosaka; Shingo; (Hakodate, JP) ;
Kinoshita; Mitsuru; (Hakodate, JP) ; Yamaguchi;
Yoshihiko; (Iide, JP) ; Takahashi; Noriyuki;
(Yonezawa, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Renesas Technology Corporation
Renesas Northern Japan Semiconductor, Inc. |
Kawasaki-shi
Chitose-shi |
|
JP
JP |
|
|
Family ID: |
31884281 |
Appl. No.: |
14/490254 |
Filed: |
September 18, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12894987 |
Sep 30, 2010 |
8877613 |
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14490254 |
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12534183 |
Aug 3, 2009 |
7816185 |
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12894987 |
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12118752 |
May 12, 2008 |
7579216 |
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12534183 |
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11360512 |
Feb 24, 2006 |
7384820 |
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12118752 |
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10462463 |
Jun 17, 2003 |
7033857 |
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11360512 |
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Current U.S.
Class: |
438/113 |
Current CPC
Class: |
H01L 2224/32225
20130101; H01L 2924/15311 20130101; H01L 2924/181 20130101; H01L
21/67092 20130101; H01L 2224/48465 20130101; H01L 2924/01082
20130101; H01L 2224/48091 20130101; H01L 2224/97 20130101; H01L
2224/48465 20130101; H01L 2224/97 20130101; H01L 2924/01004
20130101; H01L 2224/45144 20130101; H01L 21/02076 20130101; H01L
2224/97 20130101; H01L 2924/01057 20130101; H01L 2224/48227
20130101; H01L 21/67126 20130101; H01L 21/67333 20130101; H01L
2224/97 20130101; H01L 2924/014 20130101; H01L 2224/48091 20130101;
H01L 2924/01006 20130101; H01L 2224/73265 20130101; H01L 2924/01039
20130101; H01L 2924/3025 20130101; H01L 2924/14 20130101; H01L
21/561 20130101; H01L 2924/01079 20130101; H01L 2224/45144
20130101; H01L 21/6838 20130101; H01L 2924/01009 20130101; H01L
24/73 20130101; H01L 2924/15183 20130101; H01L 2224/48465 20130101;
H01L 21/565 20130101; H01L 2924/01033 20130101; H01L 2924/181
20130101; H01L 2924/00 20130101; H01L 2924/00012 20130101; H01L
2224/85 20130101; H01L 2224/73265 20130101; H01L 2224/32225
20130101; H01L 2224/32225 20130101; H01L 2924/00 20130101; H01L
2924/00014 20130101; H01L 2924/00 20130101; H01L 2224/48091
20130101; H01L 2924/00 20130101; H01L 2924/00012 20130101; H01L
2224/48227 20130101; H01L 2924/00 20130101; H01L 2924/00012
20130101; H01L 2224/48227 20130101; H01L 2224/73265 20130101; H01L
2224/73265 20130101; H01L 2224/32225 20130101; H01L 2224/48227
20130101; H01L 2224/48227 20130101; H01L 2224/48227 20130101; H01L
2224/83 20130101; H01L 21/78 20130101; H01L 2224/48465 20130101;
H01L 2924/01075 20130101; H01L 2224/97 20130101; H01L 2224/73265
20130101; H01L 2924/01005 20130101; H01L 2224/48225 20130101; H01L
24/97 20130101; H01L 2924/15311 20130101; H01L 23/3128
20130101 |
Class at
Publication: |
438/113 |
International
Class: |
H01L 21/78 20060101
H01L021/78; H01L 21/56 20060101 H01L021/56 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 22, 2002 |
JP |
2002-211939 |
Claims
1-16. (canceled)
17. A method of manufacturing a semiconductor device, comprising
the steps of: (a) providing an assembled product, the assembled
product including: a base material having: a plurality of device
areas, and a dicing area arranged between the device areas, a
plurality of semiconductor chips disposed in the device areas,
respectively, and a block sealing member sealing the semiconductor
chips; (b) after the step (a), disposing the assembled product over
a dicer cutting stage via a holding jig, the holding jig including
a product support portion having a plurality of through-holes and a
groove; and (c) after the step (b), cutting the base material with
a blade along the dicing area of the base material while chucking
the block sealing member, wherein, in the step (b), the assembled
product is disposed over the holding jig such that the block
sealing member faces and contacts the product support portion, an
arrangement of the groove corresponds to the dicing area, and
arrangements of the through-holes respectively correspond to the
device areas.
18. The method according to claim 17, wherein the holding jig has a
plate-like jig body, and the product support portion is fixed on
the plate-like jig body.
19. The method according to claim 17, wherein the product support
portion is comprised of rubber.
20. The method according to claim 18, wherein the product support
portion is comprised of rubber.
21. The method according to claim 17, wherein a plurality of ball
electrodes are formed over a surface of the base material, which is
opposite to a surface over which the block sealing member is
formed.
22. The method according to claim 21, wherein, after the step (a)
and before the step (b), the assembled product is held with a jig
transfer hand while a plurality of external terminals of the base
material are contacted with a sponge of the jig transfer hand.
23. The method according to claim 22, wherein, after the step (a)
and before the step (b), the holding jig is held with the jig
transfer hand holding the assembled product such that the block
sealing member faces and contacts the product support portion.
24. The method according to claim 17, wherein: each of the device
areas has a plurality of connecting terminals therein; each of the
semiconductor chips has a plurality of pads thereon; and in each of
the device areas, the pads are electrically connected with the
connecting terminals via a plurality of wires, respectively.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a semiconductor device
manufacturing technique and more particularly to a technique which
is effectively applicable to dividing a resin-sealed portion into
individual pieces by dicing.
[0002] As a CSP (Chip Size Package) which is a small-sized
semiconductor device there has been developed one in which a
semiconductor chip is mounted on a substrate.
[0003] Regarding in what manner a substrate for CSP is to be
divided, it is described, for example, in Japanese Unexamined
Patent Publication Nos. 2001-23936, 2001-24003, 2001-77057,
2001-85449, and 2000-77363.
[0004] In the above publication 2001-23936 there is disclosed a
hole or a bar code as a jig identifying mark in a substrate
dividing apparatus. In the above publication 2001-24003 there is
disclosed a method wherein a CSP substrate is divided using a
dedicated jig to improve the productivity. In the above publication
2001-77057 there is disclosed a technique wherein a CSP substrate
is divided into individual pellets and then contamination adhered
to back surfaces of the pellets is removed before placing the
pellets onto a conveyance tray. In the above publication 2001-85449
there is disclosed a CSP substrate holding technique which is
applied at the time of dividing a CSP substrate into individual
pellets and subsequently placing the pellets onto a conveyance
tray. Further, in the above publication 2000-77363 there is
disclosed a technique wherein a CSP is cut while it is accommodated
in a dedicated jig, followed by washing and drying.
[0005] In dividing a CSP, it is important to determine what
structure of a jig is to be used in the dividing work and which of
a surface and a back of the substrate is to be used as a substrate
holding surface (a substrate chucking surface in the case of vacuum
chuck). For example, a substrate holding member (jig) disclosed in
the foregoing publication 2001-85449 has first holes for chucking
divided individual pellets, second holes for chucking pellets in
areas adjacent to the first holes during jig conveyance, and third
holes (fine through holes) for preventing a lowering of the
substrate holding force due to the leakage of air from the first
holes. Thus, the structure of this jig is complicated, resulting in
the jig being expensive, which is a problem.
[0006] There also arises the problem that the jig is large-sized
and heavy to ensure air paths for the aforesaid three holes and
that the manufacturing cost and space for a jig handling mechanism
increase.
[0007] As to which of a surface and a back of a substrate is to be
used as a substrate holding surface, there is not found a clear
description in any of the foregoing five publications.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a
semiconductor device manufacturing method which permits dividing a
wiring substrate without imposing any stress on an external
terminal mounting surface of the substrate.
[0009] It is another object of the present invention to provide a
semiconductor device manufacturing method which facilitates
recognizing dividing positions at the time of dividing a wiring
substrate.
[0010] It is a further object of the present invention to provide a
semiconductor device manufacturing method which permits easy
removal of cutting wastes adhered to an external terminal mounting
surface of a wiring substrate.
[0011] The above and other subjects and objects, as well as novel
features, of the present invention will become apparent from the
following description and the accompanying drawings.
[0012] Typical modes of the present invention as disclosed herein
will be outlined below.
[0013] In one aspect of the present invention there is provided a
method of manufacturing a semiconductor device, comprising the
steps of providing a wiring substrate having a main surface with
plural device areas formed thereon, fixing plural semiconductor
chips to the plural device areas respectively, disposing the plural
semiconductor chips in the interior of one cavity formed in a
molding die and covering the plural device areas all together with
the cavity, sealing the plural semiconductor chips all together
with resin to form a block sealing member, and dividing the block
sealing member and the wiring substrate for each of the device
areas by dicing while chucking a surface of the block sealing
member through a plate-like jig.
[0014] In another aspect of the present invention there is provided
a method of manufacturing a semiconductor device, comprising the
steps of providing a semiconductor wafer with a protective sheet
affixed beforehand to a back surface thereof, disposing the
semiconductor wafer on a porous jig in such a manner that the
protective sheet is interposed therebetween, and half-cutting the
semiconductor wafer by dicing while chucking the wafer from the
back surface side thereof through the porous jig.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a partially cut-away perspective view showing a
structural example of a semiconductor device which is assembled by
a semiconductor device manufacturing method according to a first
embodiment of the present invention;
[0016] FIG. 2 is a sectional view showing the structure of the
semiconductor device illustrated in FIG. 1;
[0017] FIG. 3 is a sectional view showing a structural example
after wire bonding in the semiconductor device manufacturing method
of the first embodiment;
[0018] FIG. 4 is a partial sectional view showing an example of a
state in block molding with resin in the semiconductor device
manufacturing method of the first embodiment;
[0019] FIG. 5 is a plan view showing a structural example of an
external terminal mounting surface side of an assembled product
after block molding with resin in the semiconductor device
manufacturing method of the first embodiment;
[0020] FIG. 6 is a side view showing the structure of the assembled
product illustrated in FIG. 5;
[0021] FIG. 7 is a plan view showing the structure on a block
sealing member side of the assembled product illustrated in FIG.
5;
[0022] FIG. 8 is a front view showing the structure of the
assembled product illustrated in FIG. 6;
[0023] FIG. 9 is a plan view showing a structural example of a
substrate holding jig used in the semiconductor device
manufacturing method of the first embodiment;
[0024] FIG. 10 is a side view showing the structure of the
substrate holding jig illustrated in FIG. 9;
[0025] FIG. 11 is a sectional view showing a structural example of
a jig transfer hand used in the semiconductor device manufacturing
method of the first embodiment;
[0026] FIG. 12 is a sectional view showing an example of a state in
which the assembled product is clamped by both the jig transfer
hand illustrated in FIG. 11 and the substrate holding jig;
[0027] FIG. 13 is a sectional view showing a structural example in
which the assembled product illustrated in FIG. 12 is disposed on a
dicer cutting stage;
[0028] FIG. 14 is a sectional view showing an example of dicing in
the substrate width direction after resin molding in the
semiconductor device manufacturing method of the first
embodiment;
[0029] FIG. 15 is a sectional view showing an example of dicing in
the substrate length direction after resin molding in the
semiconductor device manufacturing method of the first
embodiment;
[0030] FIG. 16 is a sectional view showing an example of washing
and drying for an external terminal mounting surface of a wiring
substrate after dicing in the semiconductor device manufacturing
method of the first embodiment;
[0031] FIG. 17 is a sectional view showing an example of a method
for transferring the assembled product from an inverting hand to a
drainer hand in the semiconductor device manufacturing method of
the first embodiment;
[0032] FIG. 18 is a sectional view showing an example of a state in
which the assembled product is held by the drainer hand illustrated
in FIG. 17;
[0033] FIG. 19 is a sectional view showing an example of method for
sucking water from a surface of a sealing member in the assembled
product in the semiconductor device manufacturing method of the
first embodiment;
[0034] FIG. 20 is a sectional view showing an example of a method
for cleaning the substrate holding jig in the semiconductor device
manufacturing method of the first embodiment;
[0035] FIG. 21 is a sectional view showing an example of a state in
which the assembled product is chucked by an inverting hand in the
semiconductor product manufacturing method of the first
embodiment;
[0036] FIG. 22 is a sectional view showing an example of a method
for inverting the chucked, assembled product by the inverting hand
illustrated in FIG. 21;
[0037] FIG. 23 is a sectional view showing an example of a method
for transferring the assembled product from the inverting hand
illustrated in FIG. 22 to a decontaminating zigzag stage;
[0038] FIG. 24 is a plan view showing an example of a state of a
first transfer stage in transferring the assembled product to the
decontaminating zigzag stage by the transfer method illustrated in
FIG. 23;
[0039] FIG. 25 is a plan view showing an example of a state of a
second transfer stage in transferring the assembled product to the
decontaminating zigzag stage by the transfer method illustrated in
FIG. 23;
[0040] FIG. 26 is a sectional view showing an example of a state of
the assembled product after transferred to the decontaminating
zigzag stage through the transfer stages illustrated in FIGS. 24
and 25;
[0041] FIG. 27 is a sectional view showing an example of a method
for decontaminating the surface of the sealing member in the
assembled product in the semiconductor device manufacturing method
of the first embodiment;
[0042] FIG. 28 is a sectional view showing an example of a state in
which the assembled product after decontamination is held by block
zigzag chucking;
[0043] FIG. 29 is a sectional view showing an example of a method
for transferring the assembled product as chucked by block zigzag
chucking which is illustrated in FIG. 28;
[0044] FIG. 30 is a plan view showing an example of a state after
the transfer onto a zigzag pocket tray of the assembled product as
chucked by block zigzag chucking which is illustrated in FIG.
28;
[0045] FIG. 31 is a partially cut-away side view showing an example
of an individual assembled product conveying method from the zigzag
pocket tray illustrated in FIG. 30;
[0046] FIG. 32 is a partially cut-away side view showing an example
of an electric test method after the individual product conveyance
illustrated in FIG. 31;
[0047] FIG. 33 is a partially cut-away side view showing an example
of an appearance test method after the individual product
conveyance illustrated in FIG. 32;
[0048] FIG. 34 is a side view showing an example of a state in
which individual assembled products are classified onto separate
trays in accordance with results of the tests illustrated in FIGS.
32 and 33;
[0049] FIG. 35 is a manufacturing process flow chart showing a part
of a procedural example from dicing after block molding up to
decontamination and storage in trays in the semiconductor device
manufacturing method of the first embodiment;
[0050] FIG. 36 is a manufacturing process flow chart showing a part
of the procedural example referred to in FIG. 35;
[0051] FIG. 37 is a plan view showing the structure of a substrate
holding jig according to a modification of the first
embodiment;
[0052] FIG. 38 is a sectional view thereof;
[0053] FIG. 39 is a sectional view showing how to clamp an
assembled product by both the substrate holding jig according to
the modification illustrated in FIG. 37 and a jig transfer hand
also used in the modification;
[0054] FIG. 40 is an enlarged, partial sectional view showing a
clamped, sensor OFF state in the jig transfer hand according to the
modification illustrated in FIG. 39;
[0055] FIG. 41 is an enlarged, partial sectional view showing a
clamped, sensor ON state in the jig transfer hand according to the
modification illustrated in FIG. 39;
[0056] FIG. 42 is a sectional view showing an example of a state in
which a substrate is held by a porous jig used in a semiconductor
device manufacturing method according to a second embodiment of the
present invention;
[0057] FIG. 43 is a sectional view showing a state where a
substrate is held according to a modification of the second
embodiment;
[0058] FIG. 44 is a sectional view showing a dicing method
according to another modification of the second embodiment;
[0059] FIG. 45 is a sectional view showing an assembled product
holding state according to a further modification of the second
embodiment;
[0060] FIG. 46 is a plan view showing the structure of the
assembled product according to the modification illustrated in FIG.
45;
[0061] FIG. 47 is a sectional view thereof;
[0062] FIG. 48 is a plan view showing the structure of an assembled
product according to a still further modification of the second
embodiment;
[0063] FIG. 49 is a sectional view showing a sectional structure
taken along line A-A in FIG. 48;
[0064] FIG. 50 is a partial sectional view showing a sectional
structure taken along line B-B in FIG. 48;
[0065] FIG. 51 is a back view showing a back side of the assembled
product illustrated in FIG. 48;
[0066] FIG. 52 is a plan view showing the structure of an assembled
product according to a still further modification of the second
embodiment;
[0067] FIG. 53 is a sectional view showing a sectional structure
taken along line C-C in FIG. 52;
[0068] FIG. 54 is a back view showing a back side of the assembled
product illustrated in FIG. 52;
[0069] FIG. 55 is a plan view showing the structure of an assembled
product according to a still further modification of the second
embodiment;
[0070] FIG. 56 is a sectional view showing a sectional structure
taken along line D-D in FIG. 55;
[0071] FIG. 57 is a back view showing a back side of the assembled
product illustrated in FIG. 55; and
[0072] FIG. 58 is a sectional view showing a semiconductor device
manufacturing method according to a still further modification of
the second embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0073] In the following embodiments, as to the same or similar
portions, repeated explanations thereof will be omitted except
where required in principle.
[0074] Where required for convenience' sake, the following
embodiments will be described in a divided manner into plural
sections or embodiments, but unless otherwise mentioned, they are
not unrelated to each other, but are in a relation such that one is
a modification, a description of details, or a supplementary
explanation, of part or the whole of the other.
[0075] In the following embodiments, when reference is made to the
number of elements (including the number, numerical value,
quantity, and range), no limitation is made to the number referred
to, but numerals above and below the number referred to will do as
well unless otherwise mentioned and except the case where it is
evident that limitation is made to the number referred to.
[0076] Embodiments of the present invention will be described in
detail hereinunder with reference to the accompanying drawings. In
all of the drawings for illustration of the embodiments,
constituent members having the same functions are identified by the
same reference numerals, and repeated explanations thereof will be
omitted.
First Embodiment
[0077] FIG. 1 is a partially cut-away perspective view showing a
structural example of a semiconductor device which is assembled by
a semiconductor device manufacturing method according to a first
embodiment of the present invention, FIG. 2 is a sectional view
showing the structure of the semiconductor device illustrated in
FIG. 1, FIG. 3 is a sectional view showing a structural example
after wire bonding, FIG. 4 is a partial sectional view showing an
example of a state in block molding with resin, FIG. 5 is a plan
view showing a structural example of an external terminal mounting
surface side of an assembled product after block molding with
resin, FIG. 6 is a side view showing the structure of the assembled
product illustrated in FIG. 5, FIG. 7 is a plan view showing the
structure on a block sealing member side of the assembled product
illustrated in FIG. 5, FIG. 8 is a front view showing the structure
of the assembled product illustrated in FIG. 6, FIG. 9 is a plan
view showing a structural example of a substrate holding jig used
in the semiconductor device manufacturing method of the first
embodiment, FIG. 10 is a side view showing the structure of the
substrate holding jig illustrated in FIG. 9, FIG. 11 is a sectional
view showing a structural example of a jig transfer hand used in
the semiconductor device manufacturing method of the first
embodiment, FIG. 12 is a sectional view showing an example of a
state in which the assembled product is clamped by both the jig
transfer hand illustrated in FIG. 11 and the substrate holding jig,
FIG. 13 is a sectional view showing a structural example in which
the assembled product illustrated in FIG. 12 is disposed on a dicer
cutting stage, FIG. 14 is a sectional view showing an example of
dicing in the substrate width direction after resin molding, FIG.
15 is a sectional view showing an example of dicing in the
substrate length direction after resin molding, FIG. 16 is a
sectional view showing an example of washing and drying for an
external terminal mounting surface of a wiring substrate after
dicing, FIG. 17 is a sectional view showing an example of a method
for transferring the assembled product from an inverting hand to a
drainer hand, FIG. 18 is a sectional view showing an example of a
state in which the assembled product is held by the drainer hand
illustrated in FIG. 17, FIG. 19 is a sectional view showing an
example of a method for sucking water from a surface of a sealing
member in the assembled product, FIG. 20 is a sectional view
showing an example of a method for cleaning the substrate holding
jig, FIG. 21 is a sectional view showing an example of a state in
which the assembled product is chucked by an inverting hand, FIG.
22 is a sectional view showing an example of a method for inverting
the chucked, assembled product by the inverting hand illustrated in
FIG. 21, FIG. 23 is a sectional view showing an example of a method
for transferring the assembled product from the inverting hand
illustrated in FIG. 22 to a decontaminating stage, FIG. 24 is a
plan view showing an example of a state of a first transfer stage
in transferring the assembled product to the decontaminating zigzag
stage by the transfer method illustrated in FIG. 23, FIG. 25 is a
plan view showing an example of a state of a second transfer stage
in transferring the assembled product to the decontaminating zigzag
stage by the transfer method illustrated in FIG. 23, FIG. 26 is a
sectional view showing an example of a state of the assembled
product after transferred to the decontaminating zigzag stage
through the transfer stages illustrated in FIGS. 24 and 25, FIG. 27
is a sectional view showing an example of a method for
decontaminating the surface of the sealing member in the assembled
product, FIG. 28 is a sectional view showing an example of a state
in which the assembled product after decontamination is held by
block zigzag chucking, FIG. 29 is a sectional view showing an
example of a method for transferring the assembled product as
chucked by block zigzag chucking which is illustrated in FIG. 28,
FIG. 30 is a plan view showing an example of a state after the
transfer onto a zigzag pocket tray of the assembled product as
chucked by block zigzag chucking which is illustrated in FIG. 28,
FIG. 31 is a side view showing an example of an individual
assembled product conveying method from the zigzag pocket tray
illustrated in FIG. 30, FIG. 32 is a side view showing an example
of an electric test method after the individual product conveyance
illustrated in FIG. 31, FIG. 33 is a side view showing an example
of an appearance test method after the individual product
conveyance illustrated in FIG. 32, FIG. 34 is a side view showing
an example of a state in which individual assembled products are
classified onto separate trays in accordance with results of the
tests illustrated in FIGS. 32 and 33, and FIGS. 35 and 36 are
manufacturing process flow charts showing a part of a procedural
example from dicing after block molding up to decontamination and
storage in trays.
[0078] The semiconductor device of this first embodiment
illustrated in FIGS. 1 and 2 is a resin-sealed type BGA (Ball Grid
Array) in which a semiconductor chip 1 is mounted on a main surface
3a of an individual substrate 3, the semiconductor chip 1 and the
individual substrate 3 being electrically connected with each other
through wires 4, and plural ball electrodes 11 as external
terminals are arranged in a matrix form on a back surface 3b of the
individual substrate 3.
[0079] The BGA 9 of this first embodiment is fabricated in the
following manner. There is used a matrix substrate 7 as a wiring
substrate on which such plural device areas 7a as shown in FIG. 5
are arranged in a matrix form. The matrix substrate 7 is subjected
to resin molding (hereinafter referred to as "block molding") so
that the plural device areas 7a, which are partitioned from one
another by dicing lines 7b, are covered all together with a cavity
13c of a molding die 13 shown in FIG. 4, to form such a block
sealing member 8 as shown in FIG. 6. After the resin molding, the
block sealing member 8 is diced into individual pieces.
[0080] A detailed structure of the BGA 9 shown in FIGS. 1 and 2
will now be described. The BGA 9 is made up of a semiconductor chip
1, the semiconductor chip 1 having a main surface 1b and a back
surface 1c, with plural pads 1a as surface electrodes and a
semiconductor element being formed on the main surface 1b, an
individual substrate 3, the individual substrate 3 having a main
surface 3a for supporting the semiconductor chip 1 and a back
surface 3b located on the side opposite to the main surface 3a,
with plural connecting terminals 3c being formed on the main
surface 3a, a plurality of ball electrodes 11 as external terminals
formed on the back surface 3b of the individual substrate 3, a
plurality of wires 4 for connecting the pads 1a on the
semiconductor chip 1 with corresponding connecting terminals 3c on
the individual substrate 3, and a sealing member 6 formed on the
main surface 3a of the individual substrate 3 to seal the
semiconductor chip and the plural wires 4 with resin.
[0081] The semiconductor chip 1 is fixed onto the main surface 3a
of the individual substrate 3 through a die bonding material 5 as
an adhesive.
[0082] In the individual substrate 3 there are provided internal
wiring lines 3f for electric connection between the connecting
terminals 3c on the main surface 3a of the individual substrate and
bump lands 3d formed on the back surface 3b of the individual
substrate, and an insulating film 3e which covers the main surface
3a and the back surface 3b at areas other than exposed wiring
portions. The ball electrodes 11 as external terminals are provided
on the bump lands 3d respectively.
[0083] The individual substrate 3 is constituted, for example, by a
glass fabric-based epoxy resin board.
[0084] The ball electrodes 11 are formed by solder for example.
[0085] The semiconductor chip 1 is formed by silicon for example
and a semiconductor integrated circuit is formed on the main
surface 1b of the chip, further, plural pads 1a as surface
electrodes for connection are formed on a peripheral edge portion
of the main surface 1b.
[0086] The molding resin used for forming the sealing member 6 is,
for example, a thermosetting epoxy resin.
[0087] The wires 4 to be connected by wire bonding is, for example,
gold wires.
[0088] The following description is now provided about a method of
manufacturing the BGA 9 of this first embodiment.
[0089] First, there is provided such a matrix substrate (wiring
substrate) 7 as shown in FIG. 5 in which plural device areas 7a
each having plural connecting terminals 3a are arranged in a matrix
form.
[0090] There also are provided semiconductor chips 1.
[0091] Thereafter, as shown in FIG. 3, the semiconductor chips 1
are each subjected to die bonding to mount plural semiconductor
chips 1 on a single matrix substrate 7.
[0092] Further, the semiconductor chips 1 are each subjected to
wire bonding to connect pads 1a on each semiconductor chip 1 with
connecting terminals 3c in the corresponding device area 7a on the
matrix substrate 7 through wires 4.
[0093] Thereafter, block molding is performed for resin
sealing.
[0094] More specifically, as shown in FIG. 4, plural semiconductor
chips 1 on the matrix substrate 7 are placed in the interior of a
single cavity 13c of a molding die 13 and the plural device areas
7a are covered all together with the cavity 13c, thereafter the
plural semiconductor chips 1 are sealed all together with resin to
form a block sealing member 8.
[0095] In this case, first the matrix substrate 7 after wire
bonding is disposed on a mating surface of a lower mold 13b, then
the plural device areas 7a are covered all together with the cavity
13c of an upper mold 13a and both upper and lower molds 13a, 13b
are clamped.
[0096] Thereafter, a sealing resin is poured into the cavity 13c
and block molding is performed.
[0097] In this way the block sealing member 8 shown in FIGS. 6 to 8
is formed.
[0098] In this first embodiment, as shown in FIGS. 5 to 8, a
structure comprising the block sealing member 8 formed on the
matrix substrate 7 and plural ball electrodes 11 formed on a
substrate surface as an external terminal mounting surface of the
matrix substrate 7 is called the assembled product 2. However, in
the case of a semiconductor device not using the ball electrodes 11
as external terminals, the structure after formation of the block
molding member 8 is called the assembled product 2.
[0099] Next, a description will be given below about a dicing step
(division into individual pieces) for the assembled product 2 after
block molding.
[0100] First, reference will be made to a substrate holding jig 12
as a plate-like jig used in the dicing step, which is illustrated
in FIGS. 9 and 10.
[0101] The substrate holding jig 12 is made up of a plate-like jig
body 12a and a product support portions 12b formed of rubber or the
like to support the assembled product 2. In the product support
portions 12b are formed grooves 12d in a lattice shape
correspondingly to the dicing lines 7b.
[0102] Further, chucking holes (through holes) 12c are formed
respectively in quadrangular areas (each corresponding to one
product) which are defined by the grooves 12d in the product
support portions 12b, and dicing is performed while chucking
products through respective chucking holes 12c.
[0103] A positioning hole 12e is formed in the jig body 12a at a
position outside the product support portions 12b. During dicing,
positioning of the substrate holding jig 12 can be done using the
positioning hole 12e.
[0104] Description is now directed to a dicing/decontaminating
equipment used in this first embodiment.
[0105] As shown in FIG. 35, the dicing/decontaminating equipment
has a loader section comprising, for example, a ball tape loader
19, a ball substrate loader 20, and a ball-free substrate loader
21, which are used according to the type of product to be obtained.
The loader section is equipped with a first unit on which is
mounted a first rack, the first rack receiving assembled products 2
in individual grooves, and is also equipped with a second unit on
which is mounted a second rack, the second rack receiving assembled
products 2 in a stacked fashion.
[0106] The first rack has outlets for assembled products 2 which
outlets differ depending on the type of assembled products to be
received therein, for example, depending on whether the products
are tape block-molded products, i.e., the type in which a tape
substrate is affixed to a lead frame, or they are substrate
block-molded products, i.e., substrate BGA type. Each of the tape
block-molded products is pushed out by the first rack and is the
conveyed to a tape peeling mold 22 for peeling the lead frame and
the assembled product 2. On the other hand, each of the substrate
block-molded products is pushed out by the first rack and is then
conveyed to a prepositioning unit. No matter which type the product
concerned may be, the block sealing member 8 of the product
(assembled product 2) is brought into contact with the substrate
holding jig 12 and therefore the product is set beforehand in a
state in which the block sealing member 8 side faces down.
[0107] Products (assembled products 2) received in the second rack
are LGA (Land Grid Array) type products free of ball electrodes 11.
They are lifted to an upper portion of the rack by means of an
elevator and are chucked and conveyed successively from the top
one.
[0108] It is necessary that the product thus chucked and conveyed
from each loader be mounted on the substrate holding jig 12 with a
certain degree of accuracy. Therefore, the product is once
established its position by a positioning unit (step S1 in FIG.
35). For this positioning there is adopted a method wherein vacuum
chucking of the conveyance unit is once released, allowing the
product to fall by its own weight into a pocket having a contour
matching the contour of the product, and then the product is again
chucked. This is an inexpensive positioning method.
[0109] Thereafter, a jig product setting of step S2 in FIG. 35 is
performed.
[0110] First, the product (assembled product 2) which has been
positioned by the above positioning method is chucked by a jig
transfer hand 14 as shown in FIG. 11 and is set to the substrate
holding jig 12 which has been positioned in advance. At this time,
the jig transfer hand 14 is positioned relative to the substrate
holding jig 12 while being guided by positioning pins or the
like.
[0111] The jig transfer hand 14 is made up of a hand body 14a and a
sponge 14b.
[0112] Subsequently, as shown in FIG. 12, the substrate surface 7c
(the back surface 3b of the individual substrate 3) as an external
terminal mounting surface of the matrix substrate 7 in the
assembled product 2 is brought into contact with the sponge 14b of
the jig transfer hand 14 and the assembled product 2 is sandwiched
and clamped by both the jig transfer hand 14 and the substrate
holding jig 12.
[0113] The assembled product 2 thus clamped is conveyed in the
clamped state to the next processing step.
[0114] Subsequently, there is performed setting to a dicer cutting
stage which is shown in step S3.
[0115] More specifically, the assembled product 2 and the substrate
holding jig 12 are set to a dicer cutting stage 15 by the jig
transfer hand 14. At this time, the dicer cutting stage 15 and the
substrate holding jig 12 clamped by the jig transfer hand 14 are
positioned using guide pins or the like.
[0116] For checking whether the substrate holding jig 12 and the
assembled product 2 are present or not on the dicer cutting stage
15, as shown in FIG. 13, the same stage has a jig chucking hole 15b
for chucking only the substrate holding jig 12 and a product
chucking hole 15a for chucking the product on the jig.
[0117] In the substrate holding 12 shown in FIG. 9 there are formed
chucking holes (through holes) 12c corresponding respectively to
the device areas 7a on the matrix substrate 7 shown in FIG. 5. When
the block sealing member 8 in the assembled product 2 is to be
chucked, it can be vacuum-chucked through the chucking holes 12c
corresponding to the device areas 7a respectively.
[0118] Thus, when the block sealing member 8 is to be
vacuum-chucked through the substrate holding jig 12, it is possible
to vacuum-chuck both the substrate holding jig 12 and the block
sealing member 8 by vacuum evacuation from separate exhaust paths
(indicating the product chucking hole 15a and the jig chucking hole
15b) corresponding respectively to the substrate holding jig and
the block sealing member.
[0119] By utilizing such chucking holes it is possible to judge
various states, for example, judge that there is no jig, that there
is a jig but there is no product, and that both jig and product are
present.
[0120] For delivery of the substrate holding jig 12 and the
assembled product 2 from the jig transfer hand 14 to the dicer
cutting stage 15, the product and jig chucking operation on the
stage side is started, and after a vacuum sensor on the stage side
has detected a level of a predetermined value, the product chucking
operation of the jig transfer hand 14 is cancelled, then the
clamped state by the jig is released, and the jig transfer hand 14
is retracted to a position not obstructing the dicing
operation.
[0121] Subsequently, there is performed dicing into individual
pieces after dicer recognition which is shown in step S4.
[0122] To be more specific, the block sealing member 8 and the
matrix substrate 7 are diced along the dicing lines 7b while a
surface 8a of the block sealing member 8 in the assembled product 2
is vacuum-chucked by the dicer cutting stage 15 through the
substrate holding jig 12, whereby a division is made into
individual device areas 7a (division into individual pieces).
[0123] In this case, after the assembled product 2 has been set
onto the dicer cutting stage 15 through the substrate holding jig
12, a wiring pattern formed on the substrate surface 7c of the
matrix substrate 7 in the assembled product 2 is recognized by a
recognition camera provided in the dicer and a cutting position is
calculated.
[0124] After completion of the recognition, the division of the
assembled product 2 into individual pieces is started in accordance
with a numerical value calculated on the basis of the recognition
information.
[0125] Dicing of the assembled product 2 is carried out in the
following manner. As shown in FIGS. 14 and 15, a dicing blade 10 is
moved ahead from the substrate surface (back surface) 7c side of
the matrix substrate 7 with plural ball electrodes 11 as external
terminals mounted on the substrate surface (back surface) 7c, and
the blade 10 is moved repeatedly in both transverse and
longitudinal directions of the matrix substrate 7 to dice the block
sealing member 8 and the matrix substrate 7.
[0126] As a result, the block sealing member 8 is divided into
individual sealing members 6 and the matrix substrate 7 is divided
into individual substrates 3.
[0127] Thus, in the semiconductor device manufacturing method of
this first embodiment, at the time of dividing the matrix substrate
after block molding, the block sealing member 8 and the matrix
substrate 7 are diced while vacuum-chucking the surface 8a of the
block sealing member 8, whereby the division can be done without
imposing any stress on the substrate surface (back surface) 7c as
an external terminal mounting surface of the matrix substrate
7.
[0128] Thus, the back surface 3b (substrate surface 7c) of each
individual substrate 3 can be prevented from being flawed.
[0129] Moreover, since the surface 8a of the block sealing member 8
is easier to be vacuum-chucked than the matrix substrate 7, it is
possible to hold the block sealing member 8 and the matrix
substrate 7 positively while ensuring stabilization of the chucking
condition, and hence possible to enhance the dicing accuracy and
reliability.
[0130] Further, since the surface 8a of the block sealing member 8
is vacuum-chucked, the substrate surface 7c of the matrix substrate
7 faces up, so that it becomes easier to recognize a wiring pattern
and the like, with the result that the recognition of a dicing
position (dividing position) can be done easily.
[0131] After completion of the cutting into individual pieces,
there is performed setting to a washing/drying stage as shown in
step S5.
[0132] In this step there is made conveyance of the assembled
product 2 and the substrate holding jig 12 using another jig
transfer hand 14 which is twinned with the jig transfer hand 14
described above.
[0133] Thus, in the dicing/decontaminating equipment used in this
first embodiment, the jig transfer hand 14 described previously and
the other jig transfer hand 14 just referred to above are used in a
pair. After the other transfer hand 14 has taken out diced
individual products from the dicer cutting stage 15, the undiced
assembled product preset to one jig transfer hand 14 is set to the
dicer cutting stage 15, so that it is possible to shorten the
processing wait time of each hand and hence possible to improve the
working efficiency of the equipment.
[0134] Washing which is conducted at this stage aims at removing
cutting wastes (contamination) resulting from dicing. The assembled
product 2 having been diced into individual pieces and held by the
other jig transfer hand 14, as well as the substrate holding jig
12, are set to a spin stage 16 for washing and drying. The setting
is carried out in the same way as is the case with the dicer
cutting stage 15. The diced, assembled product 2 on the substrate
holding jig 12 is held by the other jig transfer hand 14 and is
conveyed onto the spin stage 16 for washing and drying in the next
step while being clamped between the other transfer jig 14 and the
substrate holding jig 12.
[0135] At this time, on the other transfer hand 14 side, the
substrate holding jig 12 and the hand body 14a are established
their positions using guide pins or the like and the assembled
product after dicing is vacuum-chucked and fixed on the dicer
cutting stage. In this state the substrate surface 7c side of the
matrix substrate 7 is pressed down with sponge 14b of a material
which does not cause damage to the ball electrodes 11. Thereafter,
the substrate holding jig 12 is clamped.
[0136] Thereafter, the dicer cutting stage 15 is released from its
vacuum chucking state and the diced, assembled product 2 is
conveyed onto the spin stage 16 while being fixed so as not to move
on the substrate holding jig 12.
[0137] Subsequently, washing and drying are carried out in step
S6.
[0138] In the spin stage 16, as shown in FIG. 16, washing water 16b
held at a high pressure is injected from above the diced, assembled
product 2 while the product is chucked by a jig/product chucking
hole 16a through the substrate holding jig 12, causing the spin
stage 16 to rotate, thereby improving the washing power. After the
washing, high pressure air 16c is injected from above the assembled
product 2, also causing rotation of the spin stage 16 to dry the
product (assembled product 2).
[0139] The contamination removed by washing and drying in this
first embodiment is one deposited on the substrate surface 7c of
the matrix substrate 7 located at an upper portion of the product,
and at this time there remains contamination on the surface 8a of
the block sealing member 8. In case of removing this remaining
contamination in a later step, the removal is relatively easy.
However, the removal of contamination from the substrate surface 7c
is not easy particularly when ball electrodes 11 are provided on
the substrate surface.
[0140] According to the method of this first embodiment wherein the
surface 8a of the block sealing member 8 faces down and is chucked
by the substrate holding means 12, the surface 7c of the matrix
substrate 7 can be washed and dried while facing up and mounted on
the substrate holding jig 12. Therefore, it is possible to easily
remove cutting wastes adhered to the substrate surface 7c as an
external terminal mounting surface of the matrix substrate 7. Thus,
also in washing the substrate surface 7c, this method is very
advantageous in comparison with the method wherein chucking is
performed with the substrate surface 7c facing down.
[0141] After the washing and drying step, there is performed
inversion as in step S7.
[0142] First, the assembled product 2 after washing and drying is
transferred together with the substrate holding jig 12 onto an
inverting hand 17 shown in FIG. 17 by means of one jig transfer
hand 14. The operation for taking out the assembled product 2 and
the substrate holding jig 12 from the spin stage 16 is the same as
is the case with the dicer cutting stage 15, and guide pins or the
like are used also when the jig transfer hand 14 sets the assembled
product 2 and the substrate holding jig 12 onto the inverting hand
17.
[0143] The inverting hand 17 is provided with a hand body 17a and a
motor 17c for turning the hand body 17a upside down and has a
four-axis freedom of X, Y, Z, and .THETA.. Further, the hand body
17b is formed with an aperture 17b for chucking the assembled
product 2 through the substrate holding jig 12.
[0144] The inverting hand 17 chucks only the product (assembled
product 2) and a mechanical clamp is used for fixing the substrate
holding jig 12, whereby it is possible to simplify the vacuum
evacuation path and reduce the cost of the inverting hand 17.
[0145] A description will be given below about a drainer hand
18.
[0146] The drainer hand 18 is for once separating the assembled
product 2 from the substrate holding jig 12 and chucking only the
assembled product 2. The drainer hand 18 is provided with a hand
body 18a, a chucking aperture 18b formed in the hand body 18a, a
sponge 18c disposed in the hand body 18a, and plural through holes
28d which are formed in the sponge 18c in a one-to-one
correspondence to individual products.
[0147] As shown in FIGS. 17 and 18, the purpose of transferring the
assembled product from the inverting hand 17 to the drainer hand 18
is to remove water remaining on the surface 8a of the block sealing
member 8 in the assembled product 2, thereby preventing water drops
from lapping on the substrate surface 7c upon inversion of the
assembled product 2, and to clean the substrate holding jig 12.
[0148] The assembled product 2 which has been transferred together
with the substrate holding jig 12 onto the inverting hand 17 is
chucked by the inverting hand 17 through the aperture 17b. In this
state, the drainer hand 18 is disposed above the inverting hand 17
and thereafter the inverting hand 17 is moved upward, causing the
assembled product 2 to be pressed against the sponge 18c of the
drainer hand 18 from below.
[0149] Subsequently, chucking is started through the through holes
18d formed in the sponge 18c of the drainer hand 18 and then the
chucking in the inverting hand 17 is stopped. At this time, since
plural through holes 18d are formed in the sponge 18c in a
one-to-one correspondence respectively to the products, the
substrate surface 7c of the matrix substrate (see FIG. 15) in the
assembled product 2 can be chucked by the drainer hand 18, as shown
in FIG. 18.
[0150] Although plural ball electrodes 11 are mounted to the
substrate surface 7c, since it is the sponge 18c with which the
substrate surface 7c is brought into contact, the substrate surface
7c can be chucked without flawing the ball electrodes 11.
[0151] Then, after making it sure by a vacuum sensor that the
delivery of product has been completed, the inverting hand 17 is
brought down, and thus a positional deviation of product can be
prevented.
[0152] Now, the product chucking by drainer hand shown in step S8
is over.
[0153] Thereafter, there is performed water suction from the
sealing surface of step S9 which is shown in FIG. 36.
[0154] In this step, the substrate surface 7c of the matrix
substrate 7 with ball electrodes 11 attached thereto is chucked by
the drainer hand 18 through sponge 18c, and in this state a suction
sponge 23a is pushed against the surface 8a of the block sealing
member 8 to suck water form the surface 8a.
[0155] More specifically, as shown in FIG. 19, a suction stage 23
provided with a suction sponge 23a is disposed below the drainer
hand 18, then the suction stage 23 is raised to push the suction
sponge 23a against the surface 8a of the block sealing member 8,
and suction is made through a suction hole 23b formed in the
suction stage 23 to suck water adhered to the block sealing member
8.
[0156] In this way it is possible to prevent water drops from
lapping on the substrate surface 7c upon product inversion.
[0157] On the other hand, jig cleaning of step S10 is performed
concurrently with step S9.
[0158] In this step, the inverting band 17 is inverted so that the
substrate holding jig 12 faces down. Further, as shown in FIG. 20,
a jig cleaning stage 24 is disposed below the inverting hand 17,
thereafter the jig cleaning stage 24 and the inverting hand 17 are
brought into close contact with each other and air blow 24a is
applied to the substrate holding jig 12 within a hermetically
sealed space. At the same time, suction is made through a dust
collection hole 24b formed in the jig cleaning stage 24 to
decontaminate the substrate holding jig 12.
[0159] As a result, water and cutting wastes (e.g., broken pieces
of product, cut chips of sealing resin, and contamination) on the
substrate holding jig 12 can be prevented from being re-adhered to
the product.
[0160] Subsequently, product chucking by the inverting hand is
performed, as shown in step S11.
[0161] More specifically, a shown in FIG. 21, the assembled product
2 is again chucked onto the substrate holding jig 12 in the
inverting hand 17 in such a manner that its substrate surface 7c
faces up.
[0162] Thereafter, the product is inverted as in step S12. As shown
in FIG. 22, the inverting hand 17 is inverted while the assembled
product 2 is chucked through the substrate holding jig 12, thereby
allowing the substrate surface 7c in the assembled product 2 to
face down.
[0163] Then, a decontaminating zigzag stage is used as in step
S13.
[0164] First, as shown in FIG. 23, a decontaminating zigzag stage
(zigzag stage) 25 provided with sponge 25a is disposed below the
inverting hand 17 which chucks the assembled product 2 with the
substrate surface 7c facing down, then the inverting hand 17 is
brought down while chucking the assembled product 2, and the
assembled product 2 is delivered onto the sponge 25a of the
decontaminating zigzag stage 25.
[0165] At this time, the assembled product 2 already diced is
separated into individual products (BGA 9) and then the individual
products are arranged zigzag on the decontaminating zigzag stage
25.
[0166] That the products are arranged zigzag is for the following
reason.
[0167] First, at the time of performing decontamination as shown in
FIG. 27, spaces are formed along the four sides of each product by
zigzag arrangement, whereby brushing reaches the four side faces of
individual sealing members 4 and hence the decontamination range
can be set wide.
[0168] Secondly, in the case where products are chucked all
together in the dicer cut state on the decontaminating zigzag stage
25, and when individual products are conveyed in the next step
after the end of decontamination, if one or plural individual
products are conveyed directly at a time, there occurs vacuum leak
at unloaded empty portions resulting from the individual product
conveyance on the decontaminating zigzag stage 25, with consequent
lowering of the degree of vacuum in block chucking and occurrence
of a positional deviation of product on the decontaminating zigzag
stage 25.
[0169] For this reason, it is not preferable to perform the
individual product conveyance directly from the decontaminating
zigzag stage 25. It is necessary to once transfer individual
products from the decontaminating zigzag stage 25 onto a tray not
causing vacuum leak (in the case of such a tray it is not necessary
to effect vacuum chucking).
[0170] In this case, for improving the throughput in the transfer,
it is preferable that the individual products be transferred all
together onto the tray. However, the product transfer accuracy into
tray pockets is less strict in the case of zigzag pockets which
permit guiding the four sides of each product than in the shape of
a single assembly in the dicer cut state, thus facilitating the
product transfer work.
[0171] For example, when the spacing between adjacent individual
products is only the width (for example, 0.2 mm) of the dicing
blade 10, it is extremely difficult, with any other arrangement
than zigzag arrangement, to form pockets each for guiding the four
sides of product.
[0172] For the above first and second reasons, individual products
are taken out from the assembled product 2 which has been subjected
to dicing, and are arranged zigzag on the decontaminating zigzag
stage 25.
[0173] Next, the following description is provided about in what
manner the diced individual products with the substrate held by the
inverting hand 17 shown in FIG. 23 are arranged zigzag on the
decontaminating zigzag stage 25.
[0174] For arranging the diced individual products (BGA 9) in a
zigzag fashion, all the products are vacuum-chucked beforehand by
vacuum evacuation systems of plural different paths in the
inverting hand 17, thereafter the vacuum evacuation in any of the
plural paths is stopped selectively and the products corresponding
to the path concerned are transferred onto the decontaminating
zigzag stage (zigzag stage) 25. This is repeated successively for
each of the paths to arrange the products zigzag on the
decontaminating zigzag stage 25.
[0175] For example, in the case where vacuum evacuation systems of
four, first to fourth different types of paths are provided for
forming a zigzag arrangement in the inverting hand 17, first vacuum
evacuation of only the first evacuation system is stopped and only
the products present at the position corresponding to the first
vacuum evacuation system are chucked and transferred onto the
decontaminating zigzag stage 25. This state is shown in FIG.
24.
[0176] Subsequently, vacuum evacuation of only the second vacuum
evacuation system is stopped and only the products present at the
position corresponding to the second vacuum evacuation system are
chucked and transferred onto the decontaminating zigzag stage 25.
This state is shown in FIG. 25.
[0177] In this way the products are successively transferred onto
the decontaminating zigzag stage 25, on which all the products are
chucked in zigzag arrangement.
[0178] As shown in FIG. 26, a sponge 25a is provided on the
decontaminating zigzag stage 25 and through holes 25c are formed in
the sponge 25a in one-to-one correspondence respectively to the
zigzag-arranged products.
[0179] In the decontaminating zigzag stage 25, therefore, upon
vacuum evacuation from an aperture 25b, the back surfaces of the
zigzag-arranged products can be chucked through the through holes
25c formed in the sponge 25a. In this state, the back surface 3b of
the individual substrate 3 in each product (BGA 9) is
vacuum-chucked and the surface 8a of each sealing member 6 faces
upward.
[0180] Thereafter, decontamination is performed in step S14.
[0181] In this step, as shown in FIG. 27, a rotatable brush 26 is
rotated, whereby the back surfaces 3b of the individual substrates
3 with plural ball electrodes 11 mounted thereon rub the surfaces
8a of the sealing members 6 of the individual zigzagged and chucked
BGAs 9.
[0182] In this case, the surfaces 8a of the individual sealing
members 6 have been dried by the sealing surface water suction in
step S9 and thus the dried surfaces 8a can be rubbed with the brush
26, so that contamination such as resin wastes can be removed
positively. Such contamination as resin wastes generated in the
dicing step is easier to be removed if the surfaces 8a of the
individual sealing members 6 are dried. In the decontaminating step
adopted in this first embodiment, the sealing member surfaces 8a
are faced upward and are rubbed with the brush 26, thus permitting
positive removal of contamination.
[0183] At the time of rubbing the sealing members 6 with the brush
26, it is optional whether the brush 26 which is rotating is to be
moved along the zigzagged sealing members 6 or the decontaminating
zigzag stage 25 is to be moved, or both may be moved.
[0184] Moreover, since the BGAs 9 are zigzagged on the
decontaminating zigzag stage 25, the brush 26 which is rotating can
also be brought into contact with the four side faces of each
individual sealing member 6, whereby the four side faces can be
decontaminated.
[0185] Thus, according to the decontaminating step adopted in this
first embodiment, it is possible to eliminate contamination adhered
to nearly the whole of each individual sealing member 6, including
the four side faces and the surface 8a.
[0186] For antistatic purpose it is preferable that the brush 26 be
formed using an electrically conductive material.
[0187] During the decontaminating work with the brush 26,
contamination scatters around, but by vacuum evacuation from the
aperture 25b formed in the decontaminating zigzag stage 25 to
collect the scattered contamination it is possible to prevent the
scattering of contamination.
[0188] Thereafter, the products are transferred into zigzag pockets
in step S15.
[0189] In this step, a zigzag pocket tray (tray) 28 with pockets
formed zigzag is provided in advance and the BGAs 9 after
decontamination are once transferred onto the zigzag pocket tray 28
while being chucked all together in their zigzagged state and are
received the BGAs 9 respectively in zigzag pockets 28a formed in
the zigzag pocket tray 28.
[0190] In this case, the plural BGAs 9 on the decontaminating
zigzag stage 25 shown in FIG. 28 are chucked all together at the
surfaces 8a of the respective sealing members 6 by means of a
zigzag block chucking hand 27 which can chuck all the BGAs together
in a zigzagged state, and are transferred onto the zigzag pocket
tray 28 shown in FIGS. 29 and 30.
[0191] Since the plural BGAs 9 can thus be transferred all
together, it is possible to improve the throughput of the
transfer.
[0192] It is preferable that the zigzag pockets 28a formed in the
zigzag pocket tray 28 be each provided with guides correspondingly
to the four sides of each product.
[0193] Thereafter, individual products are conveyed in step
S16.
[0194] In this step, as shown in FIG. 31, one or plural BGAs 9 are
taken out from the zigzag pocket tray 28 and are conveyed.
[0195] In this individual product conveyance, since BGA 9 is
accommodated in each pocket, there is no fear of occurrence of
vacuum leak even if there occur empty pockets after pickup of one
or plural BGAs 9.
[0196] In the conveyance being considered, therefore, a desired
number (for example, four) of BGAs 9 are chucked at the surfaces 8a
of the respective sealing members 6 and are picked up by means of
an individual product chucking hand 29, then are conveyed to such
positioning pockets 30 as shown in FIGS. 32 and 33, or to a test
section or an appearance checking section, in accordance with a
preset program.
[0197] For example, in case of conducting an electric test in step
S17, as shown in FIG. 32, the products (BGAs 9) which have been
conveyed by a first individual product chucking hand 29a are
received, for delivery to a second individual product chucking hand
29b, into positioning pockets 30 which also serve to provide
temporary storage places. Subsequently, the products are chucked by
the second individual product chucking hand 29b and are inserted
into testing sockets 31, followed by an electric test with a tester
connected electrically to each socket. The products which have gone
through the test are then conveyed to the next step by means of a
third individual product chucking hand 29c.
[0198] The second individual product chucking hand 29b inserts
products into the testing sockets 31 and at the same time the third
individual product chucking hand 29c takes out products from the
testing sockets 31, whereby the processing capacity can be
improved.
[0199] In an appearance check of step S18, a dimensional accuracy
(distance of each of the four sides from a reference position)
after dicing is measured to prevent a defective product not
conforming to the specification tolerance from flowing to the next
step, also preventing defects caused by the dicer from being
implanted in the products concerned. Further, a check is made as to
whether there is any drop-out of ball, thereby preventing the flow
of a defective product to the next step.
[0200] An appearance checking apparatus used is of a specification
which permits the addition of checking items (e.g., the adhesion of
dust particle).
[0201] For shortening the time required for appearance check, as
shown in FIG. 33, products are conveyed up to a position above an
appearance checking camera 32 while being chucked by a fourth
individual product chucking hand 29d and are checked for appearance
there by the camera 32.
[0202] In a tray storing step S19 the products, by means of the
fourth individual product chucking hand 29d, are conveyed and
stored onto trays which are classified depending on whether the
products are good, defective in the test, or defective in
appearance.
[0203] To be more specific, in a tray storing section there are
provided three types of trays which are a good product receiving
tray 33, a test defect product receiving tray 34, and an appearance
defect product receiving tray 35. The tray storing section is
composed of a tray loader, a product storing unit, and a tray
unloader. In the event a certain number of test detects makes it
impossible to ensure a predetermined yield, the
dicing/decontaminating equipment fulfills an automatic re-checking
function. In this case, the aforesaid classification of trays into
three types becomes as follows: the good product receiving tray 33,
a primary test/appearance defect tray, and a secondary
test/appearance defect tray.
[0204] Next, a description will be given below about a substrate
holding jig 12 and a jig transfer band 14 each according to a
modification of the first embodiment.
[0205] FIG. 37 is a plan view showing the structure of a substrate
holding jig according to a modification of the first embodiment,
FIG. 38 is a sectional view thereof, FIG. 39 is a sectional view
showing how to clamp an assembled product by both the substrate
holding jig according to the modification illustrated in FIG. 37
and a jig transfer hand also used in the modification, FIG. 40 is
an enlarged, partial sectional view showing a clamped, sensor OFF
state in the jig transfer hand according to the modification
illustrated in FIG. 39, and FIG. 41 is an enlarged, partial
sectional view showing a clamped, sensor ON state in the jig
transfer hand according to the modification illustrated in FIG.
39.
[0206] The substrate holding jig 12 according to the modification
shown in FIGS. 37 and 38 is almost the same as the substrate
holding jig shown in FIG. 9, but is provided in addition to the jig
body 12a and the product support portions 12b with guide pins 12f
for guiding an assembled product 2 shown in FIG. 39 and a
projecting member 12g such as a hexagon headed bolt to be used for
the recognition of jig.
[0207] The jig transfer hand 14 according to the modification shown
in FIG. 39 is provided in addition to its components shown in FIG.
11 with a chucking pad 14c for recognizing the projecting member
12g of the substrate holding jig 12 shown in FIG. 38.
[0208] For the recognition of jig, the jig transfer hand 14 moves
up to above the projecting member 12g of the jig applied and the
projecting member 12g moves down to a predetermined height, in
accordance with preset type data. Thereafter, a vacuum sensor is
operated and if the vacuum sensor turns ON, this state is judged to
be normal, while if its does not turn ON, this state is judged to
be abnormal.
[0209] With the above operation, in case of using the substrate
holding jig 12 and the jig transfer hand 14 according to this
modification, it is possible to check whether the product to be cut
and the jig used match each other, whereby it is possible to
prevent the use of jig which does not match the product to be
cut.
[0210] In FIGS. 40 and 41, the recognition of jig is performed
using an optical sensor 14d. For example, if the projecting member
12g is not provided in the substrate holding jig 12, a pin member
lie does not shield the optical sensor 14d, while if the projecting
member 12g is provided, the pin member 14e is pushed up and shields
the optical sensor 14d.
[0211] In accordance with turning ON or OFF of the optical sensor
14d it is checked whether the product to be cut and the jig used
match each other or not.
Second Embodiment
[0212] FIG. 42 is a sectional view showing an example of a state in
which a substrate is held by a porous jig used in a semiconductor
device manufacturing method according to a second embodiment of the
present invention, FIG. 43 is a sectional view showing a state
where a substrate is held according to a modification of the second
embodiment, FIG. 44 is a sectional view showing a dicing method
according to another modification of the second embodiment, FIG. 45
is a sectional view showing an assembled product holding state
according to a further modification of the second embodiment, FIG.
46 is a plan view showing the structure of the assembled product
according to the modification illustrated in FIG. 45, FIG. 47 is a
sectional view thereof, FIG. 48 is a plan view showing the
structure of an assembled product according to a still further
modification of the second embodiment, FIG. 49 is a sectional view
showing a sectional structure taken along line A-A in FIG. 48, FIG.
50 is a partial sectional view showing a sectional structure taken
along line B-B in FIG. 48, FIG. 51 is a back view showing a back
side of the assembled product illustrated in FIG. 48, FIG. 52 is a
plan view showing the structure of an assembled product according
to a still further modification of the second embodiment, FIG. 53
is a sectional view showing a sectional structure taken along line
C-C in FIG. 52, FIG. 54 is a back view showing a back side of the
assembled product illustrated in FIG. 52, FIG. 55 is a plan view
showing the structure of an assembled product according to a still
further modification of the second embodiment, FIG. 56 is a
sectional view showing a sectional structure taken along line D-D
in FIG. 55, FIG. 57 is a back view showing a back side of the
assembled product illustrated in FIG. 55, and FIG. 58 is a
sectional view showing a semiconductor device manufacturing method
according to a still further modification of the second
embodiment.
[0213] In this second embodiment, in connection with the
manufacture of a semiconductor device, a description will be given
about a jig used in dicing after block molding and a dicing method
using the jig. A porous jig 36 having plural holes 36a is used
instead of the substrate holding jig 12 used in the first
embodiment.
[0214] As shown in FIG. 42, there is provided a support block 37
with a plate-like porous jig 36 built therein, the support block 37
being capable of holding an assembled product 2 after block
molding. Dicing is performed on the support block 37 to divide the
assembled product into individual products.
[0215] More specifically, onto the porous jig 36 built in the
support block 37 and having plural holes 36a there is disposed the
assembled product 2 through a low-adhesion sheet 38 in such a
manner that a block sealing member 8 thereof faces toward the
low-adhesion sheet 38.
[0216] In this way the assembled product 2 is disposed on the
porous jig 36 through the low-adhesion sheet 38 with its block
sealing member 8 facing toward the low-adhesion sheet 38.
[0217] In this state vacuum evacuation is made from a suction hole
37a formed in the support block 37 to vacuum-chuck the block
sealing member 8 through the low-adhesion sheet 38 and the porous
jig 36. Further, a blade 10 is advanced into a matrix substrate 7
from a substrate surface 7c side with ball electrodes 11 mounted
thereto, and dicing is carried out with the blade 10 to divide the
matrix substrate into individual substrates.
[0218] Plural holes 36a are formed throughout the whole surface of
the porous jig 36, the holes 36a penetrating both surface and back
surface of the porous jig almost uniformly. For example, the porous
jig 36 is formed of a material capable of being produced by
sintering or a metal.
[0219] Adhesive is applied to both surface and back of the
low-adhesion sheet 38 and the advancing of the blade 10 is blocked
by the some sheet.
[0220] By thus performing dicing with use of the porous jig 36 and
the low-adhesion sheet 38, not only the adhesion of cutting chips
to sealing members 6 can be prevented, but also it is possible to
let the porous jig 36 cope with grade change by only replacement of
the low-adhesion sheet 38. Thus, it is possible to let the porous
jig 36 cope with various grades.
[0221] That is, both porous jig 36 and low-adhesion sheet 38 can be
made to cope with not a single grade but various grades, whereby
the versatility of the porous jig 36 is enhanced and the reduction
of cost can be attained.
[0222] Unlike the conventional dicing tape having an
ultraviolet-curing type adhesive, the low-adhesion sheet 38 can be
used repeatedly, premising that the sheet is used with uniform
adhesion not only during dicing step but also during subsequent
pick-up step. As a result, it becomes possible to reduce the
material cost in the dicing step.
[0223] Further, even when the assembled product 2 is warped, it is
possible to prevent the occurrence of a chucking error for the
assembled product because of the presence of the low-adhesion sheet
38.
[0224] However, the low-adhesion sheet 38 is not always needed.
[0225] Reference is now made to FIG. 43 which illustrates a
modification from FIG. 42. In this modification there is used a
soft resin sheet 39 in place of the low-adhesion sheet 38. Upon
interference of the blade 10 with the soft resin sheet 39 in the
dicing step, a soft resin (gellular) causes the sheet itself to
escape, whereby the advancing of the blade 10 can be stopped.
[0226] Also as to the soft resin sheet 39, repeated use thereof in
the dicing step permits reduction of the material cost. Besides,
with use of a soft resin, it is possible to prevent damage of the
soft resin sheet 39 during dicing and hence it is possible to
increase the number of times of repeated use.
[0227] In the modification shown in FIG. 44, a surface 7c of a
matrix substrate 7 with ball electrodes 11 mounted thereto is
allowed to face downward, while a block sealing member 8 of an
assembled product 2 is allowed to face upward, and the block
sealing member 8 is chucked from an upper side thereof by the
support block 37 through the porous jig 36 and the low-adhesion
sheet 38. At the time of dicing, the dicing blade 10 is advanced
from a lower side of the matrix substrate 7.
[0228] According to the modification shown in FIG. 44, since
cutting chips 40 (contamination) produced during dicing directly
drop downward and scatter, it is possible to minimize the adhesion
thereof to the assembled product 2.
[0229] In the modification shown in FIG. 45, a tape substrate 41 is
used as a wiring substrate. As shown in FIGS. 46 and 47, dicing is
carried out in a state in which the assembled product 43 having the
tape substrate 41 is affixed to a metallic frame member 42.
[0230] The tape substrate 41 is, for example, 100 .mu.m or less in
thickness and is thus very thin, that is, the rigidity thereof is
low. For this reason, the rigidity of the tape substrate 41 is
enhanced during dicing. A block sealing member 8 formed on the tape
substrate 41 and the frame member 42 are chucked through the
low-adhesion sheet 38 and the porous jig 36 and in this state there
is performed dicing.
[0231] In this case, the step of peeling the tape substrate 41 from
the frame member 42 is not needed and therefore it is possible to
decrease the number of assembling steps.
[0232] FIGS. 48 to 57 illustrate various shapes of frame members 42
and fixing methods for tape substrates 41.
[0233] The frame member 42 shown in FIGS. 48 to 51 has a large
window 42a which corresponds to a block sealing member 8 of a tape
substrate 41, the block sealing member 8 being disposed in the
window 42a. The tape substrate 41 and the frame member 42 are fixed
with fixing pins 42b provided at four corners. The tape substrate
41 is held under tension by the fixing pins 42b. Further, outside
and around the window 42a there are formed plural slits 42c for
traveling escape of the blade 10 during dicing.
[0234] The frame member 42 shown in FIGS. 52 to 54 fix the tape
substrate 41 from both surface and back side of the tape substrate
in a sandwiching manner. For the fixing there is adopted, for
example, a magnet fixing method or a pin fixing method.
[0235] The frame member 42 shown in FIGS. 55 to 57 has bars 42d for
supporting the surface 8a of the block sealing member 8. The bars
42d are provided latticewise correspondingly to dicing lines 7b
(see FIG. 5) and are each formed with a concave 42e as a relief of
the blade 10.
[0236] In the frame member 42 shown in FIGS. 55 to 57, the tape
substrate 41 is held under tension by means of fixing pins 42b
provided at four corners of the frame member.
[0237] Next, a description will be given below about a
semiconductor device manufacturing method according to a
modification of the second embodiment.
[0238] In FIG. 58, the porous jig 36 and the support block 37 both
referred to in the second embodiment are used in case of dicing a
semiconductor wafer 44, not the assembled product 43.
[0239] The wafer dicing shown in FIG. 58 is carried out using a
protective sheet 45 pre-affixed to a back surface 44a of the
semiconductor wafer 44 instead of such a low-adhesion sheet 38 as
shown in FIG. 42.
[0240] More specifically, the semiconductor wafer 44 is disposed on
the porous jig 36 through the protective sheet 45 and is chucked
from its back surface 44a side through the porous jig 36, then is
half-cut with the blade 10.
[0241] In this case, the wafer dicing cost can be reduced because
it is not necessary to use the low-adhesion sheet 38.
[0242] Thus, if there is used the support block with the porous jig
36 in the second embodiment incorporated therein, the
dicing/decontaminating equipment in the second embodiment is
employable not only in the dicing after block molding but also in
the wafer dicing.
[0243] Although the present invention has been described above
concretely by way of embodiments thereof, it goes without saying
that the present invention is not limited to the above embodiments,
but that various changes may be made within the scope not departing
from the gist of the invention.
[0244] Although the semiconductor device referred to in the above
first and second embodiments is BGA 9, there may be used any other
semiconductor device such as, for example, LGA (Land Grid Array) or
QFN (Quad Flat Non-leaded Package) insofar as a block sealing
member 8 is formed on a wiring substrate and is subjected to dicing
for assembly into individual products.
[0245] Further, as described in a modification of the second
embodiment, the dicing/decontaminating equipment is employable also
in wafer dicing.
[0246] The following is a brief description of effects obtained by
typical modes of the present invention as disclosed herein.
[0247] By vacuum-chucking the surface of a block sealing member at
the time of dividing a matrix substrate after block molding and
carrying the dicing step in this state, the dicing can be effected
without imposing any stress on an external terminal mounting
surface of a wiring substrate and thus the external terminal
mounting surface of the wiring substrate can be prevented from
being flawed. Further, it is possible to enhance the dicing
accuracy and reliability.
* * * * *