TW202314898A - Transfer apparatus and transfer method - Google Patents
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Abstract
Description
本發明是有關於一種轉移設備及轉移方法,且特別是有關於一種用以轉移電子元件的轉移設備及轉移方法。The present invention relates to a transfer device and a transfer method, and in particular to a transfer device and a transfer method for transferring electronic components.
發光二極體(Light Emitting Diode;LED)為一種發光元件,因其具低功耗、高亮度、高解析度及高色彩飽和度等特性,因而適用於構建發光二極體顯示面板之畫素結構。將所製作出的數量龐大的微發光二極體(micro-LED)晶粒轉移/接合到具有畫素電路之基板上的技術稱為巨量轉移(Mass Transfer)。Light Emitting Diode (Light Emitting Diode; LED) is a light-emitting element, because of its low power consumption, high brightness, high resolution and high color saturation, it is suitable for building pixels of light-emitting diode display panels structure. The technique of transferring/bonding a large number of produced micro-LEDs to a substrate with pixel circuits is called Mass Transfer.
在習知的接合設備中,一般是在進行接合作業之前,先藉由電容式感測器或電感式感測器對設備本身的接合頭及載台進行共平面度的量測及校正,然後再實際進行接合作業。或者,在接合頭增設氣囊或類似緩衝材,以半主動的方式補償接合頭與載台的共平面度的誤差。然而,以巨量轉移而言,需轉移的發光二極體晶粒的數量龐大且基板的面積大,些微的誤差就會導致接合品質不佳,習知的校正/補償方法無法滿足巨量轉移對於接合精準度的需求。In conventional bonding equipment, generally before performing the bonding operation, the bonding head and the carrier of the device itself are measured and corrected for coplanarity by capacitive sensors or inductive sensors, and then Then actually perform the joining work. Alternatively, airbags or similar cushioning materials are added to the bonding head to compensate the coplanarity error between the bonding head and the stage in a semi-active manner. However, in terms of mass transfer, the number of light-emitting diode grains to be transferred is large and the area of the substrate is large, and a slight error will lead to poor bonding quality. The conventional correction/compensation methods cannot meet the requirements of mass transfer. The need for joint precision.
本發明提供一種轉移設備及轉移方法,可提升電子元件的接合品質。The invention provides a transfer device and a transfer method, which can improve the bonding quality of electronic components.
本發明的轉移設備包括一載台、一接合頭、一感測器及一控制單元。一基板適於置於載台上且具有一接合面。接合頭適於連接一載體,載體的一承載面承載至少一電子元件。感測器適於量測接合面與感測器之間的距離及承載面與感測器之間的距離而獲得一誤差值。控制單元適於依據誤差值控制接合頭調整承載面的角度,並適於控制接合頭將電子元件接合至接合面。The transfer device of the present invention includes a stage, a bonding head, a sensor and a control unit. A substrate is suitable for being placed on a stage and has a bonding surface. The bonding head is suitable for connecting a carrier, and a carrier surface of the carrier carries at least one electronic component. The sensor is suitable for measuring the distance between the joint surface and the sensor and the distance between the bearing surface and the sensor to obtain an error value. The control unit is suitable for controlling the bonding head to adjust the angle of the carrying surface according to the error value, and is suitable for controlling the bonding head to bond the electronic component to the bonding surface.
在本發明的一實施例中,上述的感測器為光學感測器。In an embodiment of the present invention, the aforementioned sensors are optical sensors.
在本發明的一實施例中,上述的移設備包括一隔熱結構,其中隔熱結構罩覆感測器。In an embodiment of the present invention, the aforementioned mobile device includes a heat insulation structure, wherein the heat insulation structure covers the sensor.
在本發明的一實施例中,上述的隔熱結構包括一主體及一隔熱層,主體具有一中空部,中空部容納感測器,隔熱層配置於中空部的內壁。In an embodiment of the present invention, the above-mentioned heat insulation structure includes a main body and a heat insulation layer, the main body has a hollow portion, the hollow portion accommodates the sensor, and the heat insulation layer is disposed on the inner wall of the hollow portion.
在本發明的一實施例中,上述的接合頭包括一本體、一連接部及至少一調整單元,連接部可動地連接於本體且適於連接載體,調整單元配置於本體且適於被控制單元控制而調整連接部相對於本體的角度。In an embodiment of the present invention, the above-mentioned bonding head includes a body, a connecting portion and at least one adjustment unit, the connecting portion is movably connected to the body and is suitable for connecting with a carrier, the adjustment unit is configured on the body and is suitable for the controlled unit control and adjust the angle of the connecting portion relative to the body.
在本發明的一實施例中,上述的轉移設備包括一計算單元,其中計算單元至少依據接合面與感測器之間的距離及承載面與感測器之間的距離而計算出誤差值。In an embodiment of the present invention, the above transfer device includes a calculation unit, wherein the calculation unit calculates the error value at least according to the distance between the joint surface and the sensor and the distance between the bearing surface and the sensor.
在本發明的一實施例中,上述的計算單元更依據載體及基板的至少其中之一的作業溫度而計算出誤差值。In an embodiment of the present invention, the calculation unit further calculates the error value according to the operating temperature of at least one of the carrier and the substrate.
本發明的轉移方法包括以下步驟。將一基板置於一載台上,其中基板具有一接合面。將一載體連接於一接合頭,其中載體的一承載面承載至少一電子元件。藉由一感測器量測接合面的一區域與感測器之間的距離及承載面與感測器之間的距離而獲得一誤差值。藉由一控制單元依據誤差值控制接合頭調整承載面的角度。藉由控制單元控制接合頭將電子元件接合至接合面的區域。The transfer method of the present invention includes the following steps. A substrate is placed on a stage, wherein the substrate has a bonding surface. A carrier is connected to a bonding head, wherein a carrying surface of the carrier carries at least one electronic component. An error value is obtained by measuring the distance between a region of the bonding surface and the sensor and the distance between the carrying surface and the sensor by a sensor. A control unit is used to control the bonding head to adjust the angle of the bearing surface according to the error value. The bonding head is controlled by the control unit to bond the electronic component to the region of the bonding surface.
在本發明的一實施例中,上述的量測接合面與感測器之間的距離及承載面與感測器之間的距離的步驟包括:藉由感測器以光學方式感測基板及載體。In an embodiment of the present invention, the step of measuring the distance between the bonding surface and the sensor and the distance between the bearing surface and the sensor includes: optically sensing the substrate and the sensor by the sensor carrier.
在本發明的一實施例中,上述的轉移方法包括:藉由一隔熱結構罩覆感測器。In an embodiment of the present invention, the above transfer method includes: covering the sensor with a heat insulating structure.
在本發明的一實施例中,上述的接合頭包括一本體、一連接部及至少一調整單元,連接部可動地連接於本體且適於連接載體,調整單元配置於本體。調整承載面的角度的步驟包括:藉由控制單元控制調整單元調整連接部相對於本體的角度。In an embodiment of the present invention, the above-mentioned bonding head includes a body, a connection portion and at least one adjustment unit, the connection portion is movably connected to the body and is suitable for connecting with a carrier, and the adjustment unit is disposed on the body. The step of adjusting the angle of the carrying surface includes: adjusting the angle of the connection part relative to the main body by controlling the adjustment unit through the control unit.
在本發明的一實施例中,上述的轉移方法更包括以下步驟。在接合頭將電子元件接合至接合面的區域上之後,藉由承載面承載至少另一電子元件。藉由感測器感測接合面的另一區域與感測器之間的距離及承載面與感測器之間的距離而獲得另一誤差值。藉由控制單元依據另一誤差值控制接合頭調整承載面的角度。藉由控制單元控制接合頭將至少另一電子元件接合至接合面的另一區域。In an embodiment of the present invention, the above transfer method further includes the following steps. After the bonding head has bonded the electronic component to the region of the bonding surface, at least another electronic component is carried by the carrier surface. Another error value is obtained by the sensor sensing the distance between another area of the bonding surface and the sensor and the distance between the carrying surface and the sensor. The control unit controls the bonding head to adjust the angle of the bearing surface according to another error value. The bonding head is controlled by the control unit to bond at least another electronic component to another area of the bonding surface.
在本發明的一實施例中,上述的獲得誤差值的步驟包括:藉由一計算單元依據接合面與感測器之間的距離及承載面與感測器之間的距離而計算出誤差值。In an embodiment of the present invention, the step of obtaining the error value includes: using a calculation unit to calculate the error value according to the distance between the joint surface and the sensor and the distance between the bearing surface and the sensor .
在本發明的一實施例中,上述的計算單元更依據載體及基板的至少其中之一的作業溫度而計算出誤差值。In an embodiment of the present invention, the calculation unit further calculates the error value according to the operating temperature of at least one of the carrier and the substrate.
基於上述,在本發明轉移設備及轉移方法中,感測器直接對載體及基板進行量測,而可獲得相關於載體及基板的實際位置與角度的誤差值。藉此,相較於習知的校正方式僅在實際作業之前間接地對設備本身的載台及接合頭進行量測,本發明所獲得的誤差值更為準確,而可據以精準地調整載體的承載面相對於基板的接合面在各軸向的傾斜角度,從而提升電子元件的接合品質。Based on the above, in the transfer device and transfer method of the present invention, the sensor directly measures the carrier and the substrate, so as to obtain error values related to the actual position and angle of the carrier and the substrate. In this way, compared with the conventional calibration method that only indirectly measures the carrier and bonding head of the equipment itself before the actual operation, the error value obtained by the present invention is more accurate, and the carrier can be precisely adjusted accordingly The inclination angle of the bearing surface relative to the bonding surface of the substrate in each axial direction improves the bonding quality of the electronic components.
圖1是本發明一實施例的轉移設備的部分構件示意圖。圖2是圖1的轉移設備的部分構件方塊圖。請參考圖1及圖2,本實施例的轉移設備100例如是巨量轉移(Mass Transfer)設備,用以將已製作完成的複數微發光二極體(micro-LED)晶粒轉移至一基板60上。轉移設備100包括一載台110、一接合頭120、一感測器130及一控制單元140。基板60適於置於載台110上且具有一接合面60a。接合頭120適於連接一載體70,載體70的一承載面70a承載多個電子元件50(例如為上述微發光二極體晶粒),以藉由壓印(stamp)的方式將電子元件50接合至基板60。FIG. 1 is a schematic diagram of some components of a transfer device according to an embodiment of the present invention. FIG. 2 is a block diagram of some components of the transfer device in FIG. 1 . Please refer to FIG. 1 and FIG. 2 , the
轉移設備100的各構件的製造與組裝誤差、基板60與載體70的安裝及尺寸誤差、以及作業溫度所致熱漲冷縮等因素,可能使基板60的接合面60a與接合頭120的承載面70a的共平面度存在誤差值,而導致接合品質不良。承上,本實施例的感測器130用以量測基板60的接合面60a與感測器130之間的距離及接合頭120的承載面70a與感測器130之間的距離,據以進行估算以獲得上述誤差值。控制單元140可為整合於轉移設備100之設備本體的控制電路或是外接的電腦裝置,本發明不對此加以限制。控制單元140耦接於接合頭120且適於依據上述誤差值控制接合頭120調整承載面70a的角度以對上述誤差值進行補償,並接著控制接合頭120將電子元件50接合至基板60的接合面60a。Factors such as the manufacturing and assembly errors of the various components of the
圖3是對應於圖1的轉移設備的轉移方法的流程圖。請參考圖3,本實施例的轉移方法包括以下步驟。將基板60置於載台110上,其中基板60具有接合面60a(步驟S1)。將載體70連接於接合頭120,其中載體70的承載面70a承載電子元件50(步驟S2)。藉由感測器130量測接合面60a的一區域A1與感測器130之間的距離及承載面70a與感測器130之間的距離而獲得誤差值(步驟S3)。藉由控制單元140依據誤差值控制接合頭120調整承載面70a的角度(步驟S4)。藉由控制單元140控制接合頭120將電子元件50接合至接合面60a的區域A1(步驟S5)。FIG. 3 is a flowchart corresponding to a transfer method of the transfer device of FIG. 1 . Please refer to FIG. 3 , the transfer method of this embodiment includes the following steps. The
在上述配置及作業方式之下,感測器130直接對載體70及基板60進行量測,而可獲得相關於載體70及基板60的實際位置與角度的誤差值。藉此,相較於習知的校正方式僅在實際作業之前間接地對設備本身的載台及接合頭進行量測,本實施例所獲得的誤差值更為準確,而可據以精準地調整載體70的承載面70a相對於基板60的接合面60a在各軸向的傾斜角度,從而提升電子元件50的接合品質。Under the above configuration and working method, the
在本實施例中,感測器130例如是光學感測器,其利用雷射、紅外線、白光或其他類型的光線對基板60的接合面60a及載體70的承載面70a進行測距。相較於習知接合設備利用電容式感測器或電感式感測器進行測距,本實施例的感測器130以光學方式感測基板60的接合面60a及載體70的承載面70a,而具有更佳的感測準確度。In this embodiment, the
本實施例的轉移設備100在進行轉移作業時會對接合頭120及載台110進行加熱,以利電子元件50接合之進行。承上,由於高溫會影響光學感測器(感測器130)之感測,故本實施例的轉移設備100可更包括一隔熱結構150,隔熱結構150用以罩覆感測器130,以避免高溫感測器130之感測。The
圖4是圖1的隔熱結構及感測器的示意圖。請參考圖4,具體而言,本實施例的隔熱結構150包括一主體152及一隔熱層154,主體150具有一中空部C,中空部C容納感測器130。隔熱層154配置於中空部C的內壁以提供隔熱效果。感測器130的感測光L透過隔熱結構150的開口150a而往基板60的接合面60a及載體70的承載面70a發射。在本實施例中,主體152的材質例如是鋁,隔熱層154的材質例如是玻璃纖維、發泡材料、鋁箔隔熱捲材或其他隔熱材料,本發明不對此加以限制。如上述般將隔熱層154配置於中空部C的內壁而不外露,可避免隔熱層154磨損。FIG. 4 is a schematic diagram of the heat insulation structure and the sensor in FIG. 1 . Please refer to FIG. 4 , specifically, the
以下具體說明本實施例的接合頭與載體的相對配置關係。圖5是圖1的接合頭的局部及載體的示意圖。請參考圖1及圖5,本實施例的接合頭120包括一本體122、一連接部124及多個調整單元126(繪示為四個調整單元126)。圖5所示的連接部124可動地連接於圖1所示的本體122,且連接部124適於透過真空吸附或其他適當方式連接載體70。調整單元126配置於本體122並連接於連接部124,以適於被控制單元140(繪示於圖2)控制而調整連接部124相對於本體122的角度。這些調整單元126例如是線性馬達,其可分別改變連接部124的不同部位在軸向Z的位置,使連接部124以軸向X、軸向Y、軸向Z中的至少其中之一為轉軸而產生旋轉量,據以調整連接部124在各軸向的傾斜角度。圖6是本發明另一實施例的接合頭的局部及載體的示意圖。圖6所示實施例與圖5所示實施例的不同處在於,圖6所示實施例的調整單元126的數量為三個。在其他實施例中,可依設計上的需求改變調整單元126的數量,本發明不對此加以限制。The relative arrangement relationship between the bonding head and the carrier in this embodiment will be specifically described below. FIG. 5 is a schematic diagram of a part of the bonding head and a carrier of FIG. 1 . Please refer to FIG. 1 and FIG. 5 , the
以下具體說明本實施例中依據基板60的接合面60a與感測器130之間的距離及接合頭120的承載面70a與感測器130之間的距離而獲得誤差值的方式。請參考圖1,本實施例的轉移設備100包括一計算單元160,計算單元160例如是計算電路,其可整合於前述控制電路或是整合於外接的電腦裝置,並耦接於控制單元140及感測器130。計算單元至少依據基板60的接合面60a與感測器130之間的距離及載體70的承載面70a與感測器130之間的距離而計算出誤差值。更詳細而言,感測器130量測基板60的接合面60a的區域A1中的多個位置與感測器130之間在軸向Z上的距離,量測載體70的承載面70a的多個位置與感測器130之間在軸向Z上的距離,並據以估算接合面60a與承載面70a的實際共平面度與理想共平面度之間的誤差,即所述誤差值。所述理想共平面度,例如是指接合面60a與承載面70a完全平行的狀態。The manner in which the error value is obtained according to the distance between the
在其他實施例中,所述誤差值可為相關於接合面60a與感測器130之間的距離及承載面70a與感測器130之間的距離的其他誤差參數,本發明不對此加以限制。此外,當轉移設備100如前述般對接合頭120及載台110進行加熱時,載台110、接合頭120、載體70及基板60皆可能因溫度上升而膨脹,進而影響接合面60a與承載面70a的位置與角度。因此,計算單元160除了如上述般依據接合面60a與感測器130之間的距離及承載面70a與感測器130之間的距離而計算出誤差值,更可一併依據載體70及基板60的至少其中之一的作業溫度而計算出誤差值。舉例來說,可依據所述作業溫度及對應的構件之材料、尺寸等參數而估算出因溫差而導致的尺寸的偏移量,並將其視為誤差的一部分。In other embodiments, the error value may be other error parameters related to the distance between the
以下藉由圖式詳細說明本實施例的轉移設備的操作流程。圖7A至圖7H繪示圖1的轉移設備的操作流程。首先,如圖7A所示,將感測器130連同隔熱結構150移至基板60與載體70之間,以利用感測器130感測感測器130與基板60之接合面60a的區域A1之間的距離及感測器130與載體70之承載面70a之間的距離而獲得誤差值,其中誤差值的計算可如前述方式,於此不再贅述。感測器130及隔熱結構150可藉由機械手臂、馬達、汽缸等驅動及移動裝置而被移動,本發明不對此加以限制。接著,如圖7B所示,將感測器130連同隔熱結構150從基板60與載體70之間移離,並依據相關於感測器130之感測結果及載體70及基板60的作業溫度之誤差值來調整載體70之承載面70a的傾斜角度以補償所述誤差值,其中載體70之承載面70a的調整可如前述方式,於此不再贅述。然後,如圖7C至圖7D所示利用接合頭120將載體70及其上的電子元件50接合至基板60的接合面110的區域A1。至此,完成了基板110的接合面110的區域A1之接合作業。The operation process of the transfer device of this embodiment will be described in detail below with reference to the drawings. 7A to 7H illustrate the operation flow of the transfer device in FIG. 1 . First, as shown in FIG. 7A , move the
承上,在接合頭120將電子元件50接合至接合面110的區域A1上之後,如圖7E所示藉由載體70的承載面70a承載另一電子元件50’(繪示為多個電子元件50’),將接合頭120連同載體70移至對應於基板110的接合面110a的另一區域A2的位置,將感測器130連同隔熱結構150移至基板60與載體70之間,以利用感測器130感測感測器130與基板60之接合面60a的區域A2之間的距離及感測器130與載體70之承載面70a之間的距離而獲得另一誤差值,其中誤差值的計算可如前述方式,於此不再贅述。接著,如圖7F所示,將感測器130連同隔熱結構150從基板60與載體70之間移離,並依據相關於感測器130之感測結果及載體70及基板60的作業溫度之所述另一誤差值來調整載體70之承載面70a的傾斜角度以補償所述另一誤差值,其中載體70之承載面70a的調整可如前述方式,於此不再贅述。然後,如圖7G至圖7H所示利用接合頭120將載體70及其上的電子元件50’接合至基板60的接合面110的區域A2。至此,完成了基板110的接合面110的區域A2之接合作業。依此類推,可依序完成基板110的接合面110的更多區域的接合作業。On top of that, after the
綜上所述,在本發明轉移設備及轉移方法中,在進行基板的接合面的每一個區域的接合作業之前,都可利用感測器直接對基板及載體進行感測並據以對載體之承載面的傾斜角度進行補償調整。藉此,相較於習知的校正方式僅在實際作業之前間接地對設備本身的載台及接合頭進行量測,本發明的感測方式更具有即時性,且所獲得的誤差值更為準確,而可據以精準地調整載體的承載面相對於基板的接合面在各軸向的傾斜角度,從而提升電子元件的接合品質。To sum up, in the transfer equipment and transfer method of the present invention, before the bonding operation of each area of the bonding surface of the substrate is performed, the sensor can be used to directly sense the substrate and the carrier, and the difference between the carrier can be detected accordingly. The inclination angle of the bearing surface is compensated and adjusted. In this way, compared with the conventional calibration method that only indirectly measures the stage and bonding head of the equipment itself before the actual operation, the sensing method of the present invention is more real-time, and the obtained error value is more accurate. Accurate, and can precisely adjust the inclination angle of the bearing surface of the carrier relative to the bonding surface of the substrate in each axial direction, thereby improving the bonding quality of the electronic components.
50、50’:電子元件
60:基板
60a:接合面
70:載體
70a:承載面
100:轉移設備
110:載台
120:接合頭
122:本體
124:連接部
126:調整單元
130:感測器
140:控制單元
150:隔熱結構
150a:開口
152:主體
154:隔熱層
160:計算單元
A1、A2:區域
C:中空部
L:感測光
X、Y、Z:軸向
50, 50': electronic components
60:
圖1是本發明一實施例的轉移設備的部分構件示意圖。 圖2是圖1的轉移設備的部分構件方塊圖。 圖3是對應於圖1的轉移設備的轉移方法的流程圖。 圖4是圖1的隔熱結構及感測器的示意圖。 圖5是圖1的接合頭的局部及載體的示意圖。 圖6是本發明另一實施例的接合頭的局部及載體的示意圖。 圖7A至圖7H繪示圖1的轉移設備的操作流程。 FIG. 1 is a schematic diagram of some components of a transfer device according to an embodiment of the present invention. FIG. 2 is a block diagram of some components of the transfer device in FIG. 1 . FIG. 3 is a flowchart corresponding to a transfer method of the transfer device of FIG. 1 . FIG. 4 is a schematic diagram of the heat insulation structure and the sensor in FIG. 1 . FIG. 5 is a schematic diagram of a part of the bonding head and a carrier of FIG. 1 . FIG. 6 is a schematic view of a part of a bonding head and a carrier according to another embodiment of the present invention. 7A to 7H illustrate the operation flow of the transfer device in FIG. 1 .
50:電子元件 50: Electronic components
60:基板 60: Substrate
60a:接合面 60a: joint surface
70:載體 70: carrier
70a:承載面 70a: bearing surface
100:轉移設備 100:Transfer device
110:載台 110: carrier
120:接合頭 120:Joint head
122:本體 122: Ontology
126:調整單元 126: Adjustment unit
130:感測器 130: sensor
150:隔熱結構 150: Insulation structure
A1:區域 A1: area
X、Y、Z:軸向 X, Y, Z: Axial
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