JP2005228794A - Method of manufacturing chip - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a chip manufacturing method which prevents even a very thin wafer of 100 μm or smaller or a wafer with TEGs formed on streets from generation of chips or breaks/cracks at dicing, and allows the wafer to be integrated with a frame to be transported with the frame in a dicing apparatus, between a dicing apparatus and a die bonder and in the die bonder. <P>SOLUTION: The method comprises a dicing step of dicing a wafer W from its backside, after a protective sheet PS is pasted to its front side, cutting the backside into a processed very thin wafer W, and mounting it with the backside up on a first annular frame via a first adhesive sheet; and a frame re-pasting step of re-pasting the diced wafer W turned upside down to a second annular frame through a second adhesive sheet. This enables the frame transport in a dicing apparatus, between the dicing apparatus and a die bonder and inside the die bonder. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a chip manufacturing method for manufacturing a chip such as a semiconductor device or an electronic component, and in particular, a chip which is divided into individual chips by dicing after grinding the back surface of the wafer to a predetermined thickness. It relates to a manufacturing method.

  In semiconductor manufacturing processes, etc., wafers with semiconductor devices or electronic parts formed on the surface are subjected to electrical tests in the probing process and then divided into individual chips (also called dies or pellets) in the dicing process. The individual chips are then die bonded to the component base in a die bonding process. After die bonding, wire bonding is performed, and after wire bonding, resin molding is performed to obtain a finished product such as a semiconductor device or an electronic component.

  After the probing process, as shown in FIG. 10, the back surface of the wafer is bonded to an adhesive sheet S (also referred to as a dicing sheet or dicing tape) S having a thickness of about 100 μm and having an adhesive layer formed on one side. Mounted on a ring-shaped frame F. In this state, the wafer W is transferred in the dicing process, between the dicing process and the die bonding process, and in the die bonding process.

  By the way, in recent years, an ultra-thin IC chip incorporated in a thin IC card represented by a smart card has been required. Such an ultra-thin IC chip is manufactured by dividing an ultra-thin wafer W of 100 μm or less into individual chips.

  For this reason, after the probing process, the back surface of the wafer W is ground and processed into an extremely thin wafer of 100 μm or less, and then dicing has been performed.

  Against this background, as shown in FIG. 11, a conventional chip manufacturing method for semiconductor devices and electronic components first protects the surface of a wafer W on which a large number of semiconductor devices and electronic components are formed. For this purpose, a protective sheet attaching step of attaching a protective sheet (also referred to as protective tape) having an adhesive on one side to the wafer surface is performed (step S101). Next, a back surface grinding process is performed in which the wafer W is ground from the back surface and processed to a predetermined thickness (step S103).

  After the back grinding process, a frame mounting process for attaching the wafer W to the dicing frame F using a dicing sheet (also referred to as dicing tape) S having an adhesive on one side is performed, and the wafer W and the dicing frame F Are integrated (step S105). Next, in this state, a protective sheet peeling step is performed in which the wafer W is adsorbed on the dicing sheet S side and the protective sheet attached to the surface is peeled off (step S107).

  The wafer W from which the protective sheet has been peeled is transferred to the dicing saw together with the frame F, and is cut into individual chips T with a diamond blade that rotates at high speed (step S109). The individual chips T that have been cut do not fall apart while being affixed to the dicing sheet S, and maintain the wafer state. Here, for convenience, the aggregate of the chips T that maintained the wafer state is also referred to as the wafer W. I will call it.

  Next, the dicing sheet S is radially expanded in the expanding process to widen the intervals between the individual chips T (step S111), and mounted on a package substrate such as a lead frame in the chip mounting process (step S113).

  However, in this conventional chip manufacturing method, when an extremely thin wafer W having a thickness of 100 μm or less is cut with this conventional dicing saw, chipping or cracking occurs in the wafer W at the time of cutting, and a non-defective chip T is made defective. There was a problem that.

As a means to solve the problem that chipping or cracking occurs in the wafer W at the time of this cutting, instead of the conventional dicing saw cutting, a laser beam having a focused point is incident on the inside of the wafer W to enter the wafer. A technique relating to a laser processing method in which a modified region by multiphoton absorption is formed and divided into individual chips T has been proposed. (For example, refer to Patent Documents 1 to 6.)
JP 2002-192367 A JP 2002-192368 A JP 2002-192369 A JP 2002-192370 A JP 2002-192371 A JP 2002-205180 A

  The techniques proposed in the above Patent Documents 1 to 6 propose a dicing apparatus based on a cleaving technique using laser light instead of a conventional dicing apparatus using a dicing saw. The problem of chipping is solved.

  However, in this dicing method using laser light, in the case of a wafer W on which a ТEG (Test Elementary Group; test pattern for evaluating and managing processes and devices) is formed on the street of the main surface of the wafer, the main surface of the wafer When laser light is incident from the side, ТEG becomes a barrier and cannot be diced well, and since a dicing sheet is stuck on the back side of the wafer W, there is a problem that it cannot be diced well from the back side.

  The present invention has been made in view of such circumstances. Even if the wafer is an ultra-thin wafer having a thickness of 100 μm or less, or a wafer having ТEG formed on the street, chipping or It is an object of the present invention to provide a chip manufacturing method that does not cause cracks and can carry a frame in the dicing apparatus, between the dicing apparatus and the die bonder, and in the die bonder in a state where the wafer is integrated with the frame.

  In order to achieve the above object, the present invention provides a chip manufacturing method in which a wafer is divided into individual chips, and is mounted on a ring-shaped first frame via a first adhesive sheet. A dicing process for dicing the wafer that has been diced, and a frame re-sticking process for turning the diced wafer upside down and attaching it to a ring-shaped second frame via a second adhesive sheet. To do.

  According to the first aspect of the present invention, since there is a frame replacement step in which the front and back sides of the wafer are reversed after the dicing step, the dicing apparatus carries the frame with the back side of the wafer up, After the dicing, the frame can be replaced with the main surface of the wafer facing up, and the frame can be conveyed between the dicing apparatus and the die bonder and within the die bonder.

  The invention described in claim 2 is a chip manufacturing method for dividing a wafer into individual chips, and a step of attaching a protective sheet to the main surface of the wafer, and processing the back surface of the wafer to which the protective sheet is attached. Then, a back surface processing step for finishing the wafer to a predetermined thickness, a dicing sheet attached to the wafer via the protective sheet, and the dicing sheet disposed on the outer side of the wafer A first frame mounting step for integrating the wafer and the first frame, laser light is incident from the back side of the wafer, and a modified region is formed inside the wafer. Forming a laser dicing process for dividing the wafer into individual chips, and By cutting a single sheet, separating the wafer and the first frame, and then sticking an expanded sheet to the back surface of the wafer, and sticking the expanded sheet to a ring-shaped second frame A second frame mounting step for integrating the wafer and the second frame; a protective sheet peeling step for peeling the protective sheet affixed to the main surface of the wafer; and radially expanding the expanded sheet. And an expanding process for expanding the interval between individual chips.

  According to the invention of claim 2, a protective sheet is attached to the main surface of the wafer to process the wafer to a predetermined thickness, and after processing, the dicing sheet is attached to the protective sheet side and mounted on the first frame. Therefore, it is possible to carry the frame inside the dicing apparatus and to perform laser dicing from the back surface of the wafer.

  In addition, after dicing, an expanded sheet is attached to the back side of the wafer and the wafer is mounted on the second frame, so that the frame is conveyed between the dicing apparatus and the die bonder and inside the die bonder as usual. Chips can be picked up.

  According to a third aspect of the present invention, in the chip manufacturing method according to the first or second aspect, the first frame and the second frame are the same type of frame.

  According to the invention of claim 3, since the first frame and the second frame are the same type of frame, the conventional frame is used as it is in the dicing apparatus, between the dicing apparatus and the die bonder, and inside the die bonder. Can be transported.

  As described above, according to the chip manufacturing method of the present invention, even an extremely thin wafer having a thickness of 100 μm or less or a wafer having ТEG formed on the street can be chipped on the wafer by laser dicing. Dicing can be performed without causing cracks, and the wafer can be conveyed in the dicing apparatus, between the dicing apparatus and the die bonder, and in the die bonder while being integrated with the frame.

  Hereinafter, preferred embodiments of a chip manufacturing method according to the present invention will be described in detail with reference to the accompanying drawings. In each figure, the same number or symbol is attached to the same member. In each figure, the thickness of the wafer or sheet is shown to be extremely thick so that it can be easily understood, but the actual thickness is about 100 μm.

  FIG. 1 is a flowchart for explaining the flow of steps of a chip manufacturing method according to the present invention. First, in order to protect the pattern surface of the wafer W on which the circuit pattern is formed on the main surface side, a protective sheet is attached to the pattern surface (step S11).

  FIG. 2 is a conceptual diagram of the protective sheet sticking machine. In the protective sheet sticking machine 20, the wafer W is sucked and supported on the suction table 21 with the circuit pattern WP facing up. A supply reel 22 is provided above the suction table 21, and the protective sheet PS fed from the supply reel 22 is taken up by the take-up reel 23 through the guide rollers 24 and 25.

  The protective sheet PS has an ultraviolet curable adhesive on the affixing surface, and the protective sheet PS is affixed to the circuit pattern WP of the wafer W by rolling laterally while pressing the press roller 26 downward. . Thereafter, the sheet is cut along the outer periphery of the wafer W with a cutter (not shown), and the remaining protective sheet PS is taken up on the take-up reel 23. The above is a protective sheet sticking process.

  As shown in FIG. 3, the wafer W with the protective sheet PS attached to the main surface in step S11 is adsorbed to the rotating adsorption table 31 of the back grinder 30 with the protective sheet PS side down, and the grindstone that rotates the back surface. 32 (FIG. 3A), processed to a predetermined thickness (100 μm or less), then polished by a polishing head (not shown) while being held on the suction table 31, and processed alteration formed during grinding The layer is removed (FIG. 3 (b)). Since the protective sheet PS has sufficient hardness with respect to the grinding pressure, it can be processed with high accuracy. This is the back surface processing step of the wafer W (step S13).

  Next, the wafer W is moved to the frame mounter 40 shown in FIG. 4 and is sucked and placed on the suction table 41 with the circuit pattern WP side facing up. Next, a rigid ring-shaped first frame F1 is sucked and placed on the outside of the wafer W.

  A supply reel 42 is provided above the suction table 41, and a dicing sheet S that is a first adhesive sheet fed from the supply reel 42 is wound around the take-up reel 43 through guide rollers 44 and 45. ing.

  The dicing sheet S has an adhesive on the affixing surface, and the dicing sheet S is affixed to the back surface of the wafer W and the first frame F1 by rolling the press roller 46 in the lateral direction while pressing it downward. Is done.

  Thereafter, the cutter 47 is rotated downward while being pressed downward to cut the dicing sheet S along the vicinity of the outer periphery of the first frame F 1, and the remaining dicing sheet S is taken up by the take-up reel 43. In this state, the wafer W is mounted on the first frame F1 via the dicing sheet S and integrated (step S15). This is the first frame mounting process.

  A large number of wafers W integrated with the first frame F1 are stored in a cassette and put into a laser dicing apparatus.

  FIG. 5 is a conceptual diagram illustrating a laser dicing apparatus. As shown in FIG. 5, the laser dicing apparatus 10 is provided with an XYZθ table 12 on a machine base 11, and the wafer W is sucked and placed and moved precisely in the XYZθ direction. Similarly, an optical system 13 for dicing is attached to a holder 14 provided on the machine base 11.

The optical system 13 is provided with a laser light source 13A, and laser light oscillated from the laser light source 13A is condensed inside the wafer W through an optical system such as a collimating lens, a mirror, and a condensation lens. Here, a laser beam having a peak power density at a condensing point of 1 × 10 ⁸ (W / cm ² ) or more and a pulse width of 1 μs or less is used. The position in the thickness direction of the condensing point is adjusted by fine movement in the Z direction of the XYZθ table 12.

  Further, an observation optical system (not shown) is provided, and the wafer W is aligned based on the circuit pattern WP formed on the wafer surface, and the incident position of the laser beam is positioned. When the alignment is completed, the XYZθ table 12 moves to XY, and laser light is incident along the dicing street of the wafer W.

  FIG. 6 conceptually shows the state of laser dicing by the laser dicing apparatus 10. As shown in FIG. 6, the wafer W is attracted to the XYZθ table 12 through the dicing sheet S and the protective sheet PS, and the first frame F1 is attached to the frame clamper 12A fixed to the XYZθ table 12. Adsorbed.

  In this state, the wafer W is aligned from the back by an observation optical system having an infrared illumination device and an infrared camera (not shown). Since alignment from the back surface of the wafer W using infrared rays is already well known, detailed description thereof is omitted.

  After the alignment is completed, the laser beam L having a condensing point is emitted from the optical system 13 from the back surface of the wafer W to form a modified region WK inside the wafer and cleave the wafer W (step S17). ). This is the laser dicing process.

  The wafer W that has been laser diced in step S17 is then subjected to a frame replacement process in which the front and back surfaces are reversed and replaced with another frame.

  FIG. 7 shows the frame replacement device 50. In the frame replacement process, first, as shown in FIG. 7A, the wafer W is sucked and placed on the suction table 51 with the back side up, and the first frame F1 is a frame clamper 51A provided on the suction table 51. To be adsorbed. In this state, the cutter 57 descends and makes one round along the outer periphery of the wafer W, and the dicing sheet S is cut. Thereby, the wafer W is separated from the first frame (step S19).

Next, as shown in FIG. 7B, the suction table 51 rises with the wafer W sucked and placed, and the upper surface of the second frame F2 held by the frame holder 59 and the rear surface of the wafer W are the same. Position it so that it is at the height.

  On the other hand, a supply reel 52 is provided above the suction table 51 so that an expanded sheet ES, which is a second adhesive sheet fed out from the supply reel 52, is taken up by the take-up reel 53 via the guide rollers 54 and 55. It has become.

  The expand sheet ES has an ultraviolet curable adhesive on the pasting surface, and rolls in the lateral direction while pressing the press roller 56 downward, thereby forming the back surface of the wafer W and the upper surface of the second frame F2. Expand sheet ES is affixed.

  Thereafter, the cutter 57 is rotated once while being pressed against the expanded sheet ES to cut the expanded sheet ES along the vicinity of the outer periphery of the second frame F <b> 2, and the remaining expanded sheet ES is taken up by the take-up reel 23. In this state, the wafer W is reversed and attached to the second frame F2 via the expanded sheet ES, and is integrated (step S21). This is the second frame mounting process (frame replacement process).

  Note that it is preferable that the first frame F1 and the second frame F2 are the same type of frame because the frame can be transported between the dicing apparatus and the die bonder and in the die bonder using an existing transport apparatus.

  Next, the wafer W attached to the second frame F2 is transferred to the peeling device 60 shown in FIG. In the peeling apparatus 60, first, ultraviolet rays are irradiated from the dicing sheet S side on the main surface side of the wafer W by an ultraviolet irradiation apparatus (not shown). Since UV transmissive resin is used for the protective sheet PS, the UV curable pressure-sensitive adhesive layer formed on the protective sheet PS is cured, and the adhesive force with the wafer W is reduced.

  Next, the wafer W is sucked and placed on the suction table 61 with the protective sheet PS and dicing sheet S side up and the expanded sheet ES attached to the back side down, and the second frame F2 is placed on the suction table 61. It is attracted to the provided frame clamper 61A.

  Here, when the release sheet RS is attached to the dicing sheet S side on the main surface side of the wafer W, and the release sheet RS is pulled up in the direction indicated by the hatching arrow in FIG. 8A, the dicing sheet S and the protective sheet PS are formed. The wafer W is peeled off while being stuck to the peeling sheet RS.

  As a result, as shown in FIG. 8B, the wafer W is in an integrated state with the second frame F2 with the circuit pattern WP side up and the expanded sheet ES attached to the back surface (step). S23). This is a protective sheet peeling process.

  In this state, a large number of wafers W are stored in a cassette and put into a die bonder. The die bonder irradiates ultraviolet rays from the expanded sheet ES side to reduce the adhesive strength of the ultraviolet curable adhesive material formed on the expanded sheet ES. Next, an expanding process is performed in which the expanding sheet ES is stretched by the expanding means 70 shown in FIG. 9 and the interval between the chips of the wafer W cleaved by the laser dicing apparatus is expanded.

  In the expanding process, as shown in FIG. 9, the wafer W is first placed on the suction table 71 without being sucked, and the second frame F2 is sucked and held on the frame clamper 71A. Next, the suction table 71 is raised, and the expanded sheet ES is stretched radially. As a result, the interval between individual chips is increased (step S25).

  Next, each chip T is picked up one by one with a collet and die-bonded (chip mounted) to a package substrate such as a lead frame (step S27).

  The above is the process flow of the chip manufacturing method according to the embodiment of the present invention. As described above, according to the present invention, since the wafer W is laser-diced, a chip T having no chipping or chipping can be manufactured even with an extremely thin wafer W of 100 μm or less. Further, since the laser beam L is directly incident from the back surface of the wafer without using a sheet material, stable laser cleaving can be performed, and even a wafer W having a TEG formed on the street can be cleaved sufficiently.

  Furthermore, since the wafer W is reversed and attached to another frame after the laser dicing, it is possible to carry the frame within the dicing apparatus, between the dicing apparatus and the die bonder, and within the die bonder using an existing conveying apparatus.

  In the above-described embodiment, the dicing sheet S and the expanded sheet ES are different from each other. However, since the dicing sheet S generally has a good extensibility, the expanded sheet ES is used. A dicing sheet S may be used instead.

The flowchart showing the process of the chip manufacturing method according to the present invention Conceptual diagram explaining the protective sheet application process Conceptual diagram explaining the back surface processing process Conceptual diagram explaining the first frame mounting process Conceptual diagram showing a laser dicing machine Conceptual diagram explaining the laser dicing process Conceptual diagram illustrating the second frame mounting process Conceptual diagram explaining the protective sheet peeling process Conceptual diagram explaining the expanding process Perspective view showing wafer mounted on frame Flow chart representing steps of conventional chip manufacturing method

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Laser dicing apparatus, 20 ... Protection sheet sticking machine, 30 ... Back grinder, 40 ... Frame mounter, 50 ... Frame pasting apparatus, 60 ... Stripping apparatus, 70 ... Expanding means, ES ... Expanding sheet (second adhesive sheet) ), F1 ... first frame, F2 ... second frame, L ... laser light, PS ... protective sheet, S ... dicing sheet (first adhesive sheet), T ... chip, W ... wafer, WK ... modified. Area, WP ... Circuit pattern

Claims (3)

In a chip manufacturing method for dividing a wafer into individual chips,
A dicing step of dicing the wafer mounted on the ring-shaped first frame via the first adhesive sheet;
And a frame replacement step of reversing the diced wafer upside down and attaching it to a ring-shaped second frame via a second adhesive sheet. In a chip manufacturing method for dividing a wafer into individual chips,
Attaching a protective sheet to the main surface of the wafer;
Processing the back surface of the wafer to which the protective sheet is attached, and processing the back surface to finish the wafer to a predetermined thickness;
Affixing the dicing sheet to the wafer via the protective sheet, and affixing the dicing sheet to a ring-shaped first frame disposed outside the wafer, thereby allowing the wafer, the first frame, A first frame mounting step for integrating
A laser dicing step in which laser light is incident from the back side of the wafer and the wafer is divided into individual chips by forming a modified region inside the wafer;
The dicing sheet is cut at the outer peripheral portion of the wafer to separate the wafer and the first frame, and then an expand sheet is attached to the back surface of the wafer, and the expand sheet is attached to the ring-shaped second A second frame mounting step for integrating the wafer and the second frame by attaching to the frame;
A chip manufacturing method comprising: a protective sheet peeling step for peeling off a protective sheet attached to the main surface of the wafer; and an expanding step for expanding the expand sheet radially to expand individual chip intervals. Method.   3. The chip manufacturing method according to claim 1, wherein the first frame and the second frame are the same type of frame.

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