EP1400159A1

EP1400159A1 - Device for assembling components on a substrate

Info

Publication number: EP1400159A1
Application number: EP02735072A
Authority: EP
Inventors: Michael Hoehn
Original assignee: Robert Bosch GmbH
Current assignee: Robert Bosch GmbH
Priority date: 2001-06-11
Filing date: 2002-05-22
Publication date: 2004-03-24
Also published as: US20040036041A1; JP2004521514A; DE10128111A1; WO2002102127A1

Abstract

The invention relates to a device for assembling components (10), in particular semiconductor chips (10) on a substrate (4). Said device comprises a first travelling unit for picking up the component (10) at a first location using a component holder (3) and placing the component (10) on the substrate (4) at a second location. A position measuring unit (2, 11) for optically determining an actual position of the component (10), based on an actual position of the substrate (4), is mounted on an optical travelling unit (2), in order to move the position measuring unit (2, 11) from a working position in the vicinity of the substrate (4) into an idle position. Said device permits a fully-automatic assembly of various components (10) on substrates (4) and at the same time a high throughput in a production chain, in addition to exhibiting a high degree of positional accuracy. To achieve this, the substrate (4) is located on a transport device (1, 6, 7) for the largely continuous feeding and removal of numerous substrates (4) to and from the device.

Description

"Device for mounting components on a substrate"

The invention relates to a device for assembling components, in particular semiconductor chips, according to the preamble of claim 1.

State of the art

Increasing miniaturization and functional integration in electronic assemblies and micro systems require the use of automatic assembly systems for the quick and precise alignment of semiconductor chips in relation to a printed circuit board or a substrate. For this purpose, Cartesian precision pick-and-place machines are usually used, which pick up a chip at a first location from a chip carrier (sawn wafer, magazine, ...) with the aid of a gripper and laterally offset at its mounting location on the substrate drop.

Particularly in the case of highly integrated assembly technologies, such as flip-chip technology, a very high degree of assembly accuracy of a few micrometers can be achieved. In flip-chip assembly, semiconductor chips must be positioned with their structured side facing downwards on the substrate and firmly bonded by soldering or gluing. In order to comply with the ^' narrow permissible assembly tolerances, in known methods the mutually facing structures on the underside of the component and the landing surface of the substrate are recognized and compared by means of image processing. In this way, positional inaccuracies can be compensated for, such as those caused by the inaccurate presentation or tolerances of the workpieces.

Mounting devices of the type specified above are known as so-called die bonders. These systems are characterized by the spatially separate image recordings of the chip and the mounting position on the substrate. In this case, the gripped chip is first moved over a first camera which is arranged in a fixed manner in the work area and is directed upwards and an image of the underside of the chip is recorded. The placement head then moves over the substrate and uses a second camera, which is carried on the side of the placement head, to locate the mounting location on the substrate. If the position of the two image recording locations is known, the position of the chip or substrate determined in the respective camera field of view is transformed into the machine coordinate system and the positional deviation between chip and substrate is calculated in axis coordinates. This enables a correction value to be determined, which is taken into account in the subsequent positioning. Due to the long travel paths between the physically separate image exposures, this method ^is' however, associated with positioning inaccuracies. These are due to unavoidable deviations of the axis system, for example to angular errors of the guides, to division errors or measuring errors of the position measuring system or to inaccuracies in the spindle pitch of a spindle drive. In order to keep such influences of errors low, a complex and expensive mechanics with high absolute Positioning accuracy of the axes is necessary. The die bonders currently available on the market generally achieve accuracies between 20 μm and 60 μm.

Another fully automatic assembly device specially designed for flip-chip assembly was presented at the seminar "Flip-Chip Technology" in a lecture entitled "Equipment for Flip-Chip Bonding *" on December 8, 1992 at the Technical University of Dresden , organized by VDI / VDE-Technologiezentrum Informationstechnik GmbH, Berlin, and is now distributed by Karl Suss, Garching, Germany This assembly device uses so-called splitfield optics for the optical position detection of chip and substrate a measuring position is inserted between the substrate lying on an xy table and the chip located at a certain distance above it and held by the bondhead, in which measuring position the opposing structures of the chip and the substrate are inserted into an optical beam path via a semi-transparent mirror and several deflecting mirrors projected to overlay their images through a vid to represent eocamera. The deviation of the chip relative to the substrate can then be determined by means of image processing and corrected by the axes of the xy table. After aligning the chip with respect to the substrate structures, the position of the chip and substrate can be measured again with the optics and readjusted if necessary until the deviation of the two actual positions has reached a predetermined, permissible tolerance value.

Since this method requires significantly smaller lateral positioning movements than the above-mentioned die bonders to compensate for the actual positions, this enables a higher assembly accuracy below 5 μm to be achieved. However, the fine adjustment takes place over the stiff and relatively heavy axes of the xy table due to the unfavorable ratio of high moving mass to drive power is relatively time-consuming.

To deposit the chip held above the optics by the bondhead, the optics are moved out of the way between the two workpieces into a rest position laterally outside the area of the substrate and the bondhead carries out the settling movement in the z coordinate.

Since the bond head can only be moved in the z direction and the splitfield optics can only be moved between two end positions (measuring position and rest position), an additional, complex handling or loading device is required to insert the workpieces (substrates and chips) into the Bring - or field of view of the optics. For this purpose, a carousel or turret head which can be moved in the xy plane takes a substrate and a chip from a substrate or chip magazine and transfers them to the xy table or the bond head. If necessary, the corresponding magazines must be replaced or refilled manually.

The machine configuration described above mainly allows the handling of individual substrates with the turret head, while the processing of multiple blanks or workpiece carriers to increase productivity does not seem possible. Due to the discontinuous, manual loading of the machine, it is not possible to link it with other production facilities in a line with a directed, continuous material flow for reasons of productivity and lot tracking (traceability, Kno n Good Die). Disadvantages are the comparatively low throughput rate of the device of approx. 200 to 3-00 components per hour, the high design effort for material handling within the machine and the associated relatively high costs and the high cost Degree of specialization exclusively for the assembly of flip chips. Furthermore, a high level of effort is required for image processing because the structures of the chip and the substrate overlap in a common image by using the optics specified above and must therefore be selected and differentiated by the image evaluation software.

Further optical principles that are capable of simultaneously depicting the actual position of the component and the actual position of the substrate are described in the publications US Pat. No. 4,608,494 or US Pat. No. 5,752,446. From US 5,457,538 or DE 195 24 475 Cl manual and semi-automatic positioning devices that use a beam splitter optics for position detection are also known. However, these are special laboratory facilities that do not meet the requirements of fully automated series production in terms of their limited productivity.

Object and advantages of the invention

In contrast, the object of the invention is to propose a device for assembling components, in particular semiconductor chips, which enables fully automated assembly of a wide variety of components on substrates and at the same time has a high throughput in a linked production and a very high positioning accuracy.

Starting from a device of the type mentioned in the introduction, this object is achieved by the characterizing features of claim 1. Advantageous designs and developments of the invention are possible through the measures mentioned in the subclaims.

Accordingly, a device according to the invention is characterized in that the substrate is arranged on a transport device for largely continuously feeding and removing numerous substrates to and from the device.

With the aid of the transport device according to the invention, a comparatively high throughput of the substrates or components in a production line is achieved with high accuracy. For example, the transport device according to the invention is designed as a transfer belt or the like and is integrated in an automatic production line with other, different production systems or systems for semiconductor components or is linked to them.

Advantageously, if necessary, is in front of and / or behind the invention _. Transport device provided a buffer segment for 'adaptation of the transport speed of the transport device with the or the transport speeds of an automatic production line. In particular, with the aid of these buffer segments, the transport speed of the substrate in the device according to the invention can be adapted to the speed of the assembly of the component on the substrate. Preferably, the

Transport speed of the substrate at least at the moment of positioning or joining, almost zero, which improves the accuracy of the positioning or assembly.

The transport speed of the substrate on the transport device is preferably outside the Positioning period at least temporarily well above the transport speed of the automatic production line, which means that a possibly provided hold of the substrate or the transport device during positioning or assembly without sacrificing the throughput rate or the continuous supply and discharge of the numerous substrates to and from the Device can be realized according to the invention.

The position measuring unit advantageously comprises at least one optical device with two opposite measuring directions for determining the two actual positions. The optical device is advantageously combined with the transport device. This optical device comprises a diametrically imaging optical head with two opposite measuring directions for simultaneous image recording of the actual positions of the substrate fed on the transport device and the component or chip held above it by a gripper or placement head. In order to obtain separate images that are relatively easy to evaluate using digital image processing, e.g. the structures of the chip and substrate are mapped onto a camera in the optical head via a deflection prism. The two cameras are arranged horizontally behind the deflection prism in order to achieve a short beam path. In particular due to the short beam path, a high numerical aperture and thus a relatively high optical resolution can be achieved with a comparatively compact and light design of the optics. Such a compact optics can be moved comparatively quickly into and out of the area between the substrate and the component due to its relatively low mass to be accelerated, as a result of which the cycle time for mounting components can be largely minimized by means of the device according to the invention.

An optical unit according to the publication is preferred JP 32 17 095 and the as yet unpublished publication DE 100 12 043 AI are used, which are characterized in particular by the features described above and thus by their relatively compact embodiment and small mass to be moved.

A relative positioning principle is preferably implemented by means of the position measuring unit or optical unit, as a result of which, for example, a first traversing unit or a handling system can be used which moves comparatively quickly and possibly inaccurately from the first location over a relatively large distance to the area of the substrate. Accordingly, for example, multi-position assembly devices, e.g. Pick-and-place devices, with a standing and / or hanging axis portal system, can be used as the first travel unit. Corresponding mounting devices have a comparatively large usable working space, it being possible, for example, for a component to be picked up from any location in the working space and to be positioned comparatively quickly and optionally roughly with the first displacement unit at any location above the substrate. The exact determination of the actual position of the component relative to the actual position of the substrate or the mounting location is advantageously carried out by means of the optical device.

In a special development of the invention, the transport device comprises at least one substrate travel unit with at least one positioning axis, which is arranged almost parallel to the plane formed by the substrate, and in particular is adjustable, for moving the substrate in the x / y plane. With the aid of the substrate travel unit, the substrate can be moved, for example, orthogonally to the transport direction. The interaction of the substrate travel unit and the transport device advantageously makes it possible to freely move the substrate in the x / y Position level.

In a preferred variant of the invention, the substrate travel unit has two, in particular _, adjustable positioning axes which are arranged almost perpendicular to one another and largely parallel to the plane formed by the substrate. With the aid of this measure, it is possible that the substrate positioning can optionally be realized along the two positioning axes, in particular parallel to the substrate plane, without additional method or positioning of the substrate with the transport device.

Advantageously, the optical movement unit has at least two, in particular, arranged almost perpendicular to one another and largely parallel to the plane formed by the substrate. adjustable positioning axes. The position measuring unit can be moved back and forth along these two positioning axes, as a result of which it can be moved flexibly and at least over the entire area of the substrate. For example, the optical device can be used to approach several different mounting locations on a substrate without the substrate having to be moved relatively strongly.

In an advantageous embodiment of the invention, the optical movement unit has a focus, which can be arranged almost perpendicular to the plane formed by the substrate, in particular an adjustable axis for focusing the first and / or the second location, in particular the respective mounting location on the substrate. This enables, for example, components to be arranged or mounted on different levels of the substrate or a plurality of components one above the other.

In a special development of the invention, at least one fine positioning unit with two to each other Almost perpendicular and, in particular, adjustable positioning axes arranged largely parallel to the plane formed by the substrate, for fine positioning of one or both actual positions or of the substrate and / or the component. With the aid of this measure, it is possible for the first travel unit for the feed movement of the component and / or the substrate travel unit to preposition the component or the substrate relatively roughly, ie with comparatively low accuracy, in the field of view of the optical device, as a result of which these travel units are carried out relatively inexpensively can. The positional deviation of the component relative to the substrate determined with the aid of the position measuring unit is then compensated for by the much more precise fine positioning drive of the fine positioning unit.

In an advantageous variant of the invention, a maximum travel range of the fine positioning unit is many times smaller than a maximum travel range of the first travel unit. With the aid of this measure, a further increase in assembly accuracy and speed is achieved, since the fine positioning unit can be controlled and regulated with high precision, in particular due to the comparatively small travel range. The much smaller displacement range of the fine positioning drive is realized, for example, in the range of a few hundred micrometers. Because of this small traversing range, the fine positioning drive can be carried out very cost-effectively even with high accuracy. In addition, only very small masses of the fine positioning drive have to be accelerated, as a result of which, in particular in the case of high-precision assembly processes, alignment or adjustment of the components to be joined to one another is made much faster via the fine positioning drive than via the axes of the other travel units.

for example, a few millimeters and can then be moved by the integrated fine positioning unit to correct the actual position of the substrate in the xy plane.

In general, two Substratver can for example be provided ahreintαeiten ^', wherein in particular one of the two movement units is formed as Feinpositioniereinheit for fine positioning. Accordingly, the first substrate displacement unit can, for example, move the substrate comparatively roughly and, above all, the fine positioning unit can position the substrate comparatively precisely or finely.

embodiment

An embodiment of the invention is shown in the drawing and is explained in more detail below with reference to the figures.

In detail shows:

1 shows a schematic section of a device according to the invention and

Figure 2 shows a schematic section of another device according to the invention.

1 shows a transfer belt 1, an optics module 2 and a placement head 3 of a device according to the invention. The optics module 2 essentially consists of an optics positioning unit and an optics head 11. With the aid of the transfer belt 1, a substrate 4, which is arranged individually or in a multipurpose on a workpiece carrier 5, is continuously fed or removed to the device according to the invention , The transfer belt 1 comprises φ rT * P3 PH ö g; <P- S o P tr N φ P PJ d to 3 Pl N tö 3 iQ PJ nj ^ J - <-j φ

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realizable.

The component 10 is positioned by means of the placement head 3 over the substrate 4 by means of a travel unit, not shown in detail. The moving unit, together with the placement head 3, enables the component 10 to be picked up at any location in the relatively large working space or travel range of the moving unit and a relatively coarse and rapid positioning of the component 10 over the substrate 4. A corresponding moving unit can be comparatively economical and inexpensive very flexible pick up any Baμelemente 10 at any place within the work space and position on the substrate.

In general, the optical head 11 by means of the

Optics travel unit of the optics module 2 sweep over the entire substrate 4 or a multiple use.

Especially during the picking up or the movement of the component 10 towards the position shown in FIG. 1, the optical head 11 can already be positioned via corresponding axes of the optical module 2, the substrate 4 and the substrate 4 can be securely fixed by lifting the workpiece carrier 5. If necessary, the actual position of the substrate 4 is determined while the component 10 is being moved by means of the placement head 3 or its displacement unit, and after the component 10 has been positioned above the substrate 4 or the optical head 11 of the optical module 2, the actual position of the Exactly ermi11e11.

The actual position of the component 10 is then calculated using an evaluation unit (not shown in more detail) with the actual position of the substrate 4 or the joining location on the substrate 4 and, if the two actual positions deviate too much from one another, this deviation largely compensated by means of the micromanipulator 8. Here are Both the component 10 and the mounting location on the substrate 4 are always in the field of view of the optical head 11, so that the position correction or adjustment is carried out in a closed control loop between the image processing and the axes X, Y and / or an axis of rotation theta of the micromanipulator 8 can. The axis of rotation Theta is aligned parallel to the Z axis.

After each position correction, this control circuit again detects the positional deviation of the two actual positions relative to one another and, if the permissible assembly tolerances are exceeded, initiates a repetition of the adjustment process by means of the axes X, Y, Theta of the micromanipulator 8. Only after the required accuracy of adjustment has been achieved is the optical head 11 withdrawn laterally from the joining area (Y axis of the optical module 2) and the component 10 placed or joined along the axis Z of the placement head 3 on the substrate 4 at the predetermined location.

The moving unit of the placement head 3 can be part of an automatic assembly machine, for example. Corresponding automatic assembly machines are referred to, among other things, as so-called pick-and-place devices or as so-called diε bonders.

FIG. 2 shows a further device according to the invention, similar or comparable elements being identified by the corresponding reference numerals according to FIG. 1.

In contrast to the device according to FIG. 1, the device according to FIG. 2 has a stator 12 on which a rotor 13 is arranged. In a manner not shown in more detail, the rotor 13 can additionally have a micromanipulator 8 with a comparatively small working area for fine positioning of the substrate 4 or of the workpiece carrier 5 include.

To mount the component 10 on the substrate 4, the rotor 13 moves to the input buffer segment 7, so that it receives a workpiece carrier 5 'with a substrate 4' and moves to the position shown in FIG. In this position, the actual position of the substrate 4 or the mounting location and the actual position of the component 10 are determined relative to one another by means of the optical head 11 and in accordance with the previously carried out measuring and control methods until the required adjustment accuracy along the X- or move the Y axes.

By means of the stator 12 or rotor 13, the respective mounting position on the substrate 4 can always take place in the same area ^■ below the optical head 11, even if there are several mounting locations on a substrate 4. As a result, the optical head 11 can only be moved into the joining area of the component 10 or assembly location and by means of a relatively simple, single-axis lifting drive of the optical module 2, for example a pneumatic cylinder or the like _. can be moved into a rest position, not shown, outside the area of the substrate 4. This means that different mounting positions on the substrate 4 can be achieved in that the rotor 13 is moved relative to the optical head 11 which is fixed with respect to its measuring position.

Both the approach to the assembly positions and the position correction after the measurement can be carried out by the same drive, i.e. by the rotor 13 or by means of a separate micromanipulator 8 according to FIG. 1 on the rotor 13.

Basically, only the combination of the features according to the invention enables an assembly device with high Throughput rate with high flexibility and accuracy, the directional material flow, ie the transport of the substrates 4 on the transfer belt 1 through the device according to the invention, making it possible to chain them in an automated production line for the serial production of semiconductor products.

Reference symbol list:

1 transfer band

2 optics module

3 placement head

4 substrate

5 workpiece carriers β output buffer segment

7 input buffer segment

8 micromanipulator

9 straps

10 component

11 optical head

12th stator

13 runners

14 indexers

X axis

Y axis

axis

Claims

Expectations :

1. Device for mounting components (10), in particular semiconductor chips (10), on a substrate (4) with a first displacement unit for receiving the

Component (10) with a component holder (3) at a first location and depositing the component (10) at a second location on the substrate (4), a position measuring unit (2, 11) for optically determining an actual position of the component ( 10) as a function of an actual position of the substrate (4) on an optical movement unit (2) for moving the position measuring unit (2, 11) from a working position in the region of the substrate (4) to a rest position, characterized in that the substrate (4) is arranged on a transport device (1, 6, 7) for the largely continuous feeding and removal of numerous substrates (4) to and from the device.

2. Device according to claim 1, characterized in that the position measuring unit (2, 11) comprises at least one optical device (11) with two opposite measuring directions for determining the two actual positions.

3. Device according to one of the preceding claims, characterized in that the transport device (1, 6, 7) at least one substrate displacement unit (1, 8, 13) with at least one positioning axis arranged almost parallel to the plane formed by the substrate (4) ( X, Y) for moving the substrate (4) in the direction of the positioning axis

(X, Y).

4. Device according to one of the preceding claims, characterized in that the substrate displacement unit (1, 8, 13) two almost mutually perpendicular and to the substrate (4) formed plane has largely parallel positioning axes (X, Y).

5. Device according to one of the preceding claims, characterized in that the optical movement unit (2) has at least two positioning axes (X, Y) arranged almost parallel to one another and substantially parallel to the plane formed by the substrate (4).

6. Device according to one of the preceding claims, characterized in that the optical movement unit (2) has a focusing axis (Z) arranged almost perpendicular to the plane formed by the substrate (4) for focusing the first and / or the second location.

7. Device according to one of the preceding claims, characterized in that at least one fine positioning unit (8) with two positioning axes (X, Y) arranged almost parallel to one another and substantially parallel to the plane formed by the substrate (4) for fine positioning of one or both actual positions is provided.

8. Device according to one of the preceding claims, characterized in that a maximum travel range of the fine positioning unit (8) is many times smaller than a maximum travel range of the first travel unit.

9. Device according to one of the preceding claims, characterized in that the substrate displacement unit (1, 8, 13) is designed as a fine positioning unit (8).

10. Device according to one of the preceding claims, characterized in that the first travel unit, optical travel unit (2) and substrate travel unit (1, 8, 13) each on a fixed base unit of the device to the mutually independent method of the processing units (1, 2, 8, 13) is arranged.

11. Device according to one of the preceding claims, characterized in that the transport device (1, 6, 7) has a lifting unit which can be adjusted almost perpendicularly to the plane formed by the substrate (4) for lifting and fixing a substrate carrier (5).

12. Device according to one of the preceding claims, characterized in that at least the lifting unit comprises the fine positioning unit (8).

13. A method for mounting components (10), in particular semiconductor chips (10), on a substrate (4) with a first displacement unit for receiving the

Component (10) with a component holder (3) at a first location and depositing the component (10) at a second location on the substrate (4), an optical position measuring unit

(2, 11) for determining an actual position of the component (10) as a function of an actual position of the substrate (4) on an optical movement unit (2) for moving the position measuring unit

(2, 11) is arranged from a rest position to a working position in the region of the substrate (4), characterized in that a device according to one of the preceding claims is used.