WO2010087249A1 - 基板切断方法および電子素子の製造方法 - Google Patents
基板切断方法および電子素子の製造方法 Download PDFInfo
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- WO2010087249A1 WO2010087249A1 PCT/JP2010/050557 JP2010050557W WO2010087249A1 WO 2010087249 A1 WO2010087249 A1 WO 2010087249A1 JP 2010050557 W JP2010050557 W JP 2010050557W WO 2010087249 A1 WO2010087249 A1 WO 2010087249A1
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- Prior art keywords
- substrate
- cutting
- targets
- blade
- distance
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- 239000000758 substrate Substances 0.000 title claims abstract description 246
- 238000005520 cutting process Methods 0.000 title claims abstract description 187
- 238000000034 method Methods 0.000 title claims abstract description 70
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000000284 extract Substances 0.000 claims abstract description 13
- 238000003384 imaging method Methods 0.000 claims description 37
- 238000003825 pressing Methods 0.000 claims description 32
- 238000005259 measurement Methods 0.000 claims description 25
- 239000000853 adhesive Substances 0.000 claims description 24
- 230000001070 adhesive effect Effects 0.000 claims description 24
- 238000000605 extraction Methods 0.000 claims description 14
- 229910052751 metal Inorganic materials 0.000 description 15
- 239000002184 metal Substances 0.000 description 15
- 239000004065 semiconductor Substances 0.000 description 13
- 229910052594 sapphire Inorganic materials 0.000 description 8
- 239000010980 sapphire Substances 0.000 description 8
- 238000003860 storage Methods 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 7
- 229910010271 silicon carbide Inorganic materials 0.000 description 7
- 239000013078 crystal Substances 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 230000006378 damage Effects 0.000 description 3
- 229910003460 diamond Inorganic materials 0.000 description 3
- 239000010432 diamond Substances 0.000 description 3
- AJNVQOSZGJRYEI-UHFFFAOYSA-N digallium;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Ga+3].[Ga+3] AJNVQOSZGJRYEI-UHFFFAOYSA-N 0.000 description 3
- 229910001195 gallium oxide Inorganic materials 0.000 description 3
- 229910002601 GaN Inorganic materials 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 2
- 229910052744 lithium Inorganic materials 0.000 description 2
- -1 nitride compound Chemical class 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- 229910001218 Gallium arsenide Inorganic materials 0.000 description 1
- JMASRVWKEDWRBT-UHFFFAOYSA-N Gallium nitride Chemical compound [Ga]#N JMASRVWKEDWRBT-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- GSWGDDYIUCWADU-UHFFFAOYSA-N aluminum magnesium oxygen(2-) Chemical compound [O--].[Mg++].[Al+3] GSWGDDYIUCWADU-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000003776 cleavage reaction Methods 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 239000002223 garnet Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 229910003437 indium oxide Inorganic materials 0.000 description 1
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- YQNQTEBHHUSESQ-UHFFFAOYSA-N lithium aluminate Chemical compound [Li+].[O-][Al]=O YQNQTEBHHUSESQ-UHFFFAOYSA-N 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 238000002488 metal-organic chemical vapour deposition Methods 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- VEALVRVVWBQVSL-UHFFFAOYSA-N strontium titanate Chemical compound [Sr+2].[O-][Ti]([O-])=O VEALVRVVWBQVSL-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- AXWLFOKLQGDQFR-UHFFFAOYSA-N zinc iron(2+) manganese(2+) oxygen(2-) Chemical compound [O-2].[Fe+2].[Zn+2].[Mn+2].[O-2].[O-2] AXWLFOKLQGDQFR-UHFFFAOYSA-N 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
- B23K26/359—Working by laser beam, e.g. welding, cutting or boring for surface treatment by providing a line or line pattern, e.g. a dotted break initiation line
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/40—Removing material taking account of the properties of the material involved
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/50—Working by transmitting the laser beam through or within the workpiece
- B23K26/53—Working by transmitting the laser beam through or within the workpiece for modifying or reforming the material inside the workpiece, e.g. for producing break initiation cracks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
- B23K2103/52—Ceramics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
- B23K2103/54—Glass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
- B23K2103/56—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26 semiconducting
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0095—Post-treatment of devices, e.g. annealing, recrystallisation or short-circuit elimination
Definitions
- the present invention relates to a substrate cutting method for thinning (chiping) a substrate such as a semiconductor wafer on which a large number of electronic devices are formed, and a method for manufacturing an electronic device using the substrate cutting method.
- the substrate surface is scratched with a diamond tool, and then mechanically cut by pressing a roller using the cleavage property of the substrate.
- a braking method and a dicing method in which a substrate is cut by rotating a disk-shaped diamond saw are widely used. Also in the dicing method using a diamond saw, in addition to completely cutting the substrate, cutting is made partway through the substrate and then cutting into chips by braking.
- a laser beam having a transparent wavelength is condensed by an objective lens optical system and irradiated so as to focus on the inside of the substrate, thereby forming a region having a lower intensity than before irradiation inside the substrate.
- stealth dicing method has been developed. In this method, an end face with less cutting allowance and less chipping can be obtained.
- the substrate is not cut and is in a connected state. For this reason, it is necessary to cut the substrate into chips by braking.
- Patent Document 1 describes a method of cutting a substrate into chips and an apparatus therefor.
- a groove or work-affected layer is formed in advance on the substrate to be cut by laser, scribe, dicer, or the like, and (2) the tip is on the opposite surface of the groove that is the fracture start point.
- the substrate is cut by braking by applying an impact force and pushing the blade into the substrate.
- An object of the present invention is to provide a substrate cutting method capable of determining the cutting state of a substrate and a method for manufacturing an electronic device using the substrate cutting method.
- the substrate cutting method to which the present invention is applied includes a step of forming a cutting region on a substrate having a plurality of electronic elements formed on one surface and a position on the other surface of the substrate where the cutting region is formed.
- the step in which the driving unit presses the blade to the corresponding position and the step of pressing the blade the step in which the imaging unit images at least one set of targets formed on one surface of the substrate, and the imaging result of the target
- the extraction unit extracts a set of targets, and the measurement unit measures a change in the distance between the targets in the step of pressing the blade, and the change in the measured distance between the targets is determined in advance.
- the set of targets is preferably a set of targets adjacent to each other across the cutting line.
- the method further includes a step of repeating from the step of pressing the blade when the change amount is smaller than a predetermined set value.
- a predetermined set value e.g., a predetermined set value.
- each of the pair of targets is formed by sandwiching a blade pressed against the substrate.
- the amount of change in the measured distance between the targets is measured by the imaging unit and the measurement unit repeatedly during the period from the reception of the blade pressing start signal from the driving unit to the reception of the blade pressing end signal. It can be characterized by the amount of change in the maximum distance between.
- the cutting region is a region having a lower strength than that before groove processing or laser processing by groove processing or laser processing.
- the substrate is preferably affixed to an adhesive sheet, which has the advantage of reducing chip scattering.
- the method of manufacturing an electronic device to which the present invention is applied is a method of manufacturing an electronic device formed on a substrate, and is cut into a substrate having a plurality of electronic devices formed on one surface.
- the step of the drive unit pressing the blade to the position corresponding to the position where the cutting region is formed on the other surface of the substrate, and the step of pressing the blade.
- the determination unit determines the cutting state of the substrate based on the measured amount of change in the distance between the targets and a predetermined set value.
- the set of targets is preferably a set of targets adjacent to each other across the cutting line.
- the manufacturing method of an electronic device may be a manufacturing method of a light emitting device (LED).
- the substrate cutting process can be automated. As a result, the yield of cutting products can be improved, and productivity can be increased and costs can be significantly reduced, compared with methods for determining the state of substrate cutting by conventional human work.
- FIG. 1 is a diagram illustrating an example of a substrate 10 used in this embodiment.
- FIG. 1 is a view of the substrate 10 as viewed from the surface, and also shows a metal ring 16 to which an adhesive sheet 15 to which the substrate 10 is attached is attached.
- the substrate 10 is, for example, a single crystal sapphire substrate having an outer diameter of 4 inches (about 100 mm) and a thickness of 120 ⁇ m.
- an n-type semiconductor layer made of a group III nitride semiconductor, a light emitting layer, and a p-type semiconductor layer are laminated on the substrate 10 in this order, and a plurality of light emitting diode (LED) elements 11 ( Hereinafter, it is referred to as an LED 11).
- the substrate 10 is provided with electrodes 12 a and 12 b for supplying current to the respective LEDs 11.
- Each of the electrodes 12a and 12b has a circular shape with a diameter of 100 ⁇ m, for example.
- the substrate 10 and the n-type semiconductor layer for example, an intermediate layer or a base layer made of a group III nitride compound is formed, and the n-type semiconductor layer, the light emitting layer, and the p-type semiconductor layer are sequentially stacked.
- a manufacturing method for example, according to the method described in Japanese Patent Application Laid-Open No. 2008-124060, a plurality of layers having an intermediate layer, an underlayer, an n-type semiconductor layer, a light emitting layer, a p-type semiconductor layer, an electrode, You may prepare the board
- the outer diameter size (inch) of the substrate 10 and the thickness of the substrate material are arbitrarily selected.
- the thickness of the substrate material is suitably adjusted in the range of about 50 ⁇ m to 300 ⁇ m by the polishing / grinding process.
- the substrate material that can be used in the present invention is not particularly limited, and various materials can be selected and used.
- sapphire, silicon carbide (silicon carbide: SiC), silicon, zinc oxide, magnesium oxide, manganese oxide. , Zirconium oxide, manganese zinc iron oxide, magnesium aluminum oxide, zirconium boride, gallium oxide, indium oxide, lithium gallium oxide, lithium aluminum oxide, neodymium gallium oxide, lanthanum strontium aluminum tantalum, strontium titanium oxide, titanium oxide, hafnium, Tungsten, molybdenum, gallium nitride and the like can be mentioned, among which sapphire and silicon carbide (silicon carbide: SiC) are preferable.
- the LEDs 11 provided with the electrodes 12a and 12b are arranged on the substrate 10 at regular intervals.
- a plurality of marks (targets) formed on the substrate 10 are imaged with a camera, and when cutting into chips 20, the distance between them is measured to determine the cutting state of the substrate 10.
- the electrodes 12a and 12b formed on the substrate 10 are used as an example of the target.
- the distance between the adjacent electrodes 12a and 12b of the two adjacent chips 20 is measured.
- the distance dh between the electrode 12a and the electrode 12b adjacent to each other with the blade 57 (see FIG. 2 described later) interposed therebetween that is, adjacent to the cutting line H3 is measured.
- the distance between the electrodes 12b of the two adjacent chips 20 is measured. For example, the distance dv between the two electrodes 12b adjacent to each other across the cutting line V4 is measured.
- the substrate 10 is provided with a cutting region 21 having a low intensity formed by irradiating the condensed excimer-excited pulsed laser light along the cutting lines V1 to V7 and H1 to H5. Since the cutting area 21 has a lower strength than before irradiation, it becomes a starting point of destruction when the substrate 10 is cut into the chips 20. A method for forming the cut region 21 having a low intensity by irradiation with excimer-excited pulsed laser light will be described later.
- FIG. 1 shows a state where the substrate 10 is viewed through the adhesive sheet 15. Since the adhesive sheet 15 is transparent, the target formed on the substrate 10 can be imaged with a camera.
- the metal ring 16 has an inner diameter of 190 mm and is set to be larger than the diameter of the substrate 10 of 4 inches (about 100 mm).
- the substrate 10 is affixed inside the metal ring 16 so as not to contact the metal ring 16.
- the adhesive sheet 15 is pushed up by the cylinder inside the metal ring 16, and is extended. As a result, the gaps between the respective chips 20 are widened to facilitate the mounting work on the package.
- FIG. 2 is a diagram illustrating an example of a substrate cutting apparatus 50 to which the present embodiment is applied.
- the substrate cutting apparatus 50 includes a stage 52 that is provided on a base 51 to be installed on a table or the like and is movable on the base 51 in the front-rear direction (referred to as the y direction).
- the stage 52 includes a ring table 54 formed of a ring-shaped frame that can rotate on the stage 52 (the rotation direction is referred to as a ⁇ -axis direction).
- the substrate cutting device 50 includes a cradle 53 that is provided on the base 51 and holds the substrate 10 attached to the adhesive sheet 15.
- the substrate cutting apparatus 50 includes a gate-shaped support body 55 provided on the base body 51.
- the support body 55 includes a blade holder 56.
- the blade holder 56 holds the blade 57 at one end.
- the blade holder 56 is set so as to be movable in the vertical direction (referred to as the z-axis direction) with respect to the base body 51.
- the blade 57 cuts the substrate 10 by being pushed into the substrate 10.
- the blade 57 is, for example, a knife having a tip of 60 °, and is made of, for example, high-hardness super steel or zirconia.
- the width of the blade 57 is set larger than the diameter of the substrate 10.
- the width of the blade 57 is 110 mm.
- the cradle 53 is composed of two cradles 53a and 53b arranged to face each other. The respective surfaces of the cradles 53 a and 53 b are made of, for example, super steel so as not to be deformed when the blade 57 is pushed into the substrate 10.
- the blade 57 When the blade 57 is moved in the direction of the cradle 53 ( ⁇ z-axis direction), the blade 57 is set so as to enter the gap between the cradles 53a and 53b. Further, the surface of the cradle 53 and the surface of the ring table 54 are set so as to be substantially in one plane.
- the substrate cutting device 50 includes an imaging unit 61 formed of, for example, a CCD camera below the cradle 53.
- the imaging unit 61 is set so that the substrate 10 on the cradle 53 can be imaged through a gap between the two cradles 53a and 53b.
- the substrate cutting device 50 includes a display unit 62 that displays image data captured by the imaging unit 61.
- the substrate cutting device 50 includes a stepping motor for moving the blade holder 56 in the z-axis direction, a motor for moving the stage 52 in the y-axis direction, and a ring table 54 in the ⁇ -axis direction.
- a driving unit 63 including a motor to be operated and an electronic circuit for controlling these motors.
- the substrate cutting device 50 extracts a pair of adjacent targets across the cutting line from the image data captured by the imaging unit 61, measures the distance between the targets, and determines the amount of change in the distance between the targets.
- the control part 64 which determines a cutting condition is provided.
- FIG. 3 is a block diagram centering on the control unit 64 of the substrate cutting apparatus 50 to which the present embodiment is applied.
- the control unit 64 includes an extraction unit 66 that extracts a target that matches a pre-registered target shape from the image data captured by the imaging unit 61, a measurement unit 67 that measures a distance between a pair of targets, A determination unit 68 that determines the cutting state from the amount of change with respect to the set value of distance is provided.
- Image data captured by the imaging unit 61, targets extracted by the extraction unit 66, distances between targets measured by the measurement unit 67, changes to the set values of the distances between targets used by the determination unit 68 to determine the cutting state, etc. Is displayed on the display unit 62.
- the drive unit 63 is controlled based on the determination result of the determination unit 68. As will be described later, the imaging unit 61, the drive unit 63, and the control unit 64 operate in cooperation.
- FIGS. 4A to 4D are diagrams for explaining an outline of a substrate cutting method and an electronic device manufacturing method using the substrate cutting method according to the present embodiment.
- the substrate 10 shown in FIGS. 4A to 4D is a cross-sectional view taken along the line AA ′ of the substrate 10 shown in FIG. In this section, four chips 20 are visible.
- the chip 20 is formed with an LED 11 and electrodes 12a and 12b as examples of electronic elements.
- the LED 11 and the electrodes 12a and 12b are formed by a well-known method, the description of the details of the method for forming the LED 11 and the electrodes 12a and 12b is omitted.
- a cutting region 21 having a low strength is formed in the substrate 10 as shown in FIG.
- the case where the cutting region 21 is formed along the cutting line H2 will be described.
- Excimer-excited pulsed laser light 41 condensed by the objective lens 42 is irradiated to the inside of the substrate 10 corresponding to the cutting line H2.
- the excimer-excited pulse laser beam 41 is scanned while being irradiated on the substrate 10 along the cutting line H2.
- the material of the substrate 10 is heated and volatilized, so that a cutting region 21 having a low strength that becomes a starting point of destruction at the time of cutting is formed inside the substrate 10 along the cutting line H2.
- the process of forming the cutting region 21 having a low strength which is the starting point of breakage at the time of cutting, is referred to as the process of forming the cutting region.
- the excimer-excited pulse laser beam 41 has a wavelength of 355 nm and a pulse period of 10 kHz to 50 kHz.
- the scanning speed is 50 mm / sec to 300 mm / sec.
- the excimer excitation pulsed laser beam 41 is scanned with respect to the cutting lines H1, H3 to H5, thereby forming a cutting region 21 having a low intensity inside the substrate 10 corresponding to the cutting lines H1 to H5. Further, similarly, a cutting region 21 having a low strength is formed inside the substrate 10 corresponding to the cutting lines V1 to V7.
- the surface 10 a on which the LEDs 11 and the like of the substrate 10 are formed is attached to the adhesive surface 15 a of the adhesive sheet 15 attached to the metal ring 16. Since the inner diameter of the metal ring 16 is larger than the outer diameter of the substrate 10, the metal ring 16 is attached so that the substrate 10 is disposed inside the metal ring 16. Here, since the metal ring 16 is also attached to the adhesive surface 15 a of the adhesive sheet 15, the substrate 10 and the metal ring 16 are arranged on the same side with respect to the adhesive sheet 15.
- the substrate 10 attached to the adhesive sheet 15 and the metal ring 16 holding them are placed on the ring table 54 of the substrate cutting apparatus 50 shown in FIG. To do.
- the cradles 53a and 53b, the ring table 54, and the blade 57 shown in FIG. 4C show a cross section cut along a plane including the BB ′ line and the z axis in FIG. Therefore, in FIG.4 (c), the acute-angled blade edge
- the substrate 10 is installed on the cradles 53a and 53b.
- FIG. 4C as an example, the case where the cutting at the cutting lines H1 and H2 is completed and the cutting is performed at the cutting line H3 is shown.
- adjustment is made so that the cutting line H3 of the substrate 10 and the position of the blade edge of the blade 57 coincide.
- the adjustment of the cutting line of the substrate 10 and the position of the blade edge of the blade 57 is performed as follows. Before the substrate 10 is placed on the cradle 53, the mark on the imaging unit 61 is adjusted so that the reference mark provided on the imaging unit 61 matches the position of the blade 57. Thereafter, the substrate 10 is placed on the cradle 53, and the mark and the cutting line H3 of the substrate 10 are matched.
- the drive unit 63 adjusts the rotation of the substrate 10 in the ⁇ -axis direction using the rotation mechanism of the ring table 54 based on the image data of the substrate 10 from the imaging unit 61, and further uses the moving mechanism of the stage 52. The position of the substrate 10 in the y-axis direction is adjusted.
- the drive unit 63 moves the blade holder 56 in the ⁇ z-axis direction (toward the substrate 10). Then, the blade 57 attached to the blade holder 56 is moved from the state indicated by the solid line to the state indicated by the wavy line, and is brought into contact (contact) with the back surface 10 b of the substrate 10.
- the blade 57 is pushed into the substrate 10 by a preset pushing amount b.
- the pushing amount b is 100 ⁇ m.
- the pushing amount b means that the position of the substrate 10 in contact with the blade 57 (the position of the substrate 10 indicated by a broken line) is 0, and the blade 57 is moved in the ⁇ z-axis direction. This is the distance that you let go.
- substrate 10 is cut
- the blade 57 immediately returns to the original position when the pushing is completed.
- the process in which the drive unit 63 brings the blade 57 into contact with the cutting line of the substrate 10 and further pushes the blade 57 into the substrate 10 is referred to as a process of pressing the blade.
- the substrate 10 is cut at the positions of the cutting lines H4 and H5. Further, similarly, by performing a step of pressing the blade at the positions of the cutting lines V1 to V7, the substrate 10 is cut at the positions of the cutting lines V1 to V7. In this way, an electronic element divided into LED chips is manufactured.
- FIG. 5 is a flowchart of a first method for determining the cutting state of the substrate 10.
- a first method for determining the cutting state will be described with reference to FIGS. 3, 4 (c), 4 (d), and 5.
- the case where the substrate 10 is cut along the cutting line H3 will be described as an example. It is assumed that the position of the blade 57 is set so as to contact the cutting line H3.
- the imaging unit 61 captures an image including the electrode 12a and the electrode 12b sandwiching the cutting line H3 (blade 57) (imaging step) (step 101 in FIG. 5).
- the extraction unit 66 extracts the image data of the electrodes 12a and 12b sandwiching the cutting line H3 (blade 57) (step 102).
- the image data of the electrode 12a and the electrode 12b is extracted from the luminance distribution of the image data from the imaging unit 61 based on the electrode shape registered as the target shape.
- the measuring unit 67 measures (measures) the distance d1 between the electrode 12a and the electrode 12b from the image data of the selected pair of electrodes 12a and 12b (step 103). For example, processing is performed to emphasize the edges of the image data of the selected set of electrodes 12a and 12b, and the distance is measured from the number of pixels between the edges of the set of electrodes 12a and 12b.
- the measuring unit 67 transmits a measurement end signal for the distance d ⁇ b> 1 to the driving unit 63.
- the driving unit 63 presses the blade 57 (step 104). Then, the driving unit 63 transmits a blade pressing start signal to the imaging unit 61.
- the blade 57 is pressed against the substrate 10, the substrate 10 is bent by the blade 57, and the substrate 10 starts to be broken starting from the cutting region 21 having a low strength.
- the distance between the electrode 12a and the electrode 12b increases as the substrate 10 bends.
- the blade 57 enters between the chips 20 of the cut substrate 10, and the distance between the electrode 12a and the electrode 12b further increases.
- the imaging unit 61 receives a blade pressing start signal from the driving unit 63 and captures an image including the target pair of electrodes 12a and 12b (imaging step) (step 105).
- the extraction unit 66 extracts the same set of image data of the electrode 12a and the electrode 12b extracted in step 102 (step 106).
- the measurement part 67 measures the distance d2 between 1 set of the electrodes 12a which are targets, and the electrode 12b similarly to step 103 (step 107).
- the distance d2 is stored in a storage area for storing the distance d2 provided in the measuring unit 67.
- the measurement unit 67 calculates (measures) the amount of change (d2-d1) in the inter-target distance, which is a value related to the change in the distance between the targets, and transmits it to the determination unit 68.
- the determination unit 68 determines the cutting state of the substrate 10 (determination step) based on the change amount (d2-d1) of the inter-target distance received from the measurement unit 67 (step 108).
- the storage area of the determination unit 68 stores a set value d0 as a reference (determination reference) for determining a predetermined cutting state.
- the set value d0 is set to 30 ⁇ m. If the amount of change (d2-d1) is 0 ⁇ m to 30 ⁇ m, the substrate is not cut, or is incompletely cut in the thickness direction of the substrate 10 (half) If it exceeds 30 ⁇ m, it is determined that the substrate 10 is cut.
- the cutting state is automatically determined based on a value (set value is 30 ⁇ m in this case) set by the operator as a criterion in 0 to 30 ⁇ m.
- the set value is preferably set to a value of 100 ⁇ m or less, more preferably a value of 50 ⁇ m or less, and even more desirably a value of 30 ⁇ m or less.
- this set value may be different at the time of cutting corresponding to the width and length in accordance with the shape of the LED 11, and is preferably set to a numerical value in the range of 1 ⁇ m to 50 ⁇ m.
- the determination unit 68 determines that the cutting is not performed or is incompletely cut (halved)
- the determination unit 68 causes the driving unit 63 to place the blade 57 again on the substrate 10.
- a signal instructing to be pressed may be transmitted (No in step 108).
- the drive unit 63 repeats the step of pressing the blade 57 against the substrate 10 (Step 104).
- the pushing amount b of the blade 57 may be set larger than the previous case. This is because it is considered that the substrate 10 cannot be cut with the same pushing amount b.
- Steps 105 to 107 are performed to automatically determine the cutting state of the substrate 10.
- the determination unit 68 determines that the substrate 10 has been cut, the series of operations ends. Then, the determination unit 68 transmits a cutting end signal to the driving unit 63. Then, the drive unit 63 moves the stage 52. In this way, for example, the above-described series of operations is repeated for each of the uncut cutting lines H4 and H5 on the substrate 10. Thereby, the cutting is completed for the cutting lines H1 to H5 of the substrate 10.
- the stage 52 is automatically moved in the -y direction in units of pv. You can make it. Therefore, by using the method for determining the state of cutting the substrate, the cutting lines H1 to H5 are automatically cut. At this time, if the positions of the cutting lines H1 to H5 are image-recognized and the relationship between the positions of the cutting lines H1 to H5 and the position of the blade 57 is automatically finely adjusted, more accurate cutting lines H1 to H5 are obtained.
- the substrate 10 can be cut at the position.
- the above-described series of operations is repeated in the order of numbers with respect to the cutting lines V1 to V7 of the substrate 10, thereby cutting the substrate 10 into chips 20. be able to. In this way, the substrate cutting process can be automated.
- the step 105 for imaging the target is provided after the step 104 for pressing the blade 57.
- the blade 57 returns to the original position after the blade 57 is pushed down, it can be considered that the inter-target distance d2 of the cut substrate 10 is narrower than when it is most opened.
- the measured change amount (d2-d1) of the distance between the targets becomes a value smaller than the set value d0, and the substrate cutting process (steps 104 to 108) is unnecessarily repeated.
- the step 105 for imaging the target is performed simultaneously with the step 104 for pressing the blade 57.
- the distance d2 between the targets of the cut substrate 10 becomes narrower than when it is opened most, and the amount of change in the distance between targets (d2-d1) May be smaller than the set value d0.
- FIG. 6 is a flowchart showing a second method for more accurately determining the cutting state of the substrate 10.
- the difference between the method of FIG. 5 and the method of FIG. 6 is that in FIG. 6, when the imaging unit 61 and the measuring unit 67 receive the blade pressing start signal from the driving unit 63, the blade pressing end signal from the driving unit 63. Until the distance d2 between the targets is repeatedly measured. Then, the maximum distance d3 of the inter-target distance d2 is obtained from the value of the inter-target distance d2 that has been repeatedly measured.
- the measurement unit 67 sets a storage area for storing the maximum distance d3 included in the measurement unit 67 to 0 (step 201).
- the imaging unit 61 captures an image including the electrode 12a and the electrode 12b sandwiching the cutting line H3 (blade 57) (imaging process) (step 202).
- the extraction unit 66 extracts the image data of the electrodes 12a and 12b sandwiching the cutting line H3 (blade 57) (step 203). Then, the extraction unit 66 selects the image data of the pair of electrodes 12a and 12b formed with the cutting line H3 interposed therebetween as a target.
- the measuring unit 67 measures the distance d1 between the electrode 12a and the electrode 12b from the image data of the selected pair of electrodes 12a and 12b, and stores the distance d1 provided in the measuring unit 67. Store in the area (step 204). Then, the measuring unit 67 transmits a measurement end signal for the distance d ⁇ b> 1 to the driving unit 63.
- the driving unit 63 presses the blade 57 (step 205). Then, the driving unit 63 transmits a blade pressing start signal to the imaging unit 61. Upon receiving the blade pressing start signal from the drive unit 63, the imaging unit 61 captures images of the electrodes 12a and 12b (imaging step) (step 206). When receiving the image data from the imaging unit 61, the extraction unit 66 extracts the same set of image data of the electrode 12a and the electrode 12b extracted in step 203 (step 207).
- the measurement part 67 measures the distance d2 between 1 set of the electrodes 12a and 12b which are targets similarly to step 204 (step 208).
- the distance d2 is compared with d3 stored in the storage area for storing the maximum distance d3 of the measuring unit 67 (step 209). If d3 is smaller than d2, d2 is set as d3 and stored in the storage area for storing the maximum distance d3 of the measuring unit 67 (step 210). If d3 is equal to or larger than d2, the value of the storage area of the maximum distance d3 is left as it is.
- Step 206 to Step 210 are repeated until the measurement unit 67 receives a blade pressing end signal from the drive unit 63 (Step 211). By doing so, the value of the storage area storing the maximum distance d3 becomes the maximum value of the inter-target distance d2.
- the driving unit 63 transmits a blade pressing end signal to the measuring unit 67 (step 211). Then, the measurement unit 67 calculates (measures) the amount of change (d3-d1) in the inter-target distance to the determination unit 68 and transmits it to the determination unit 68.
- the determination unit 68 compares the amount of change in the distance between targets (d3-d1) received from the measurement unit 67 with the set value d0 stored in advance in the storage area of the determination unit 68 (step 212). Then, as described in the first method for determining the cutting state, it is determined whether to press the blade 57 again against the substrate 10 or to end a series of operations based on the set value d0 for determining the cutting state. (Determination step). Thereafter, as described in the first method for determining the cutting state, when the determination unit 68 determines that the cutting state is not cut or is incomplete cutting state (half). The determination unit 68 may transmit a signal instructing the driving unit 63 to press the blade 57 against the substrate 10 again (No in step 212). Then, the drive unit 63 repeats the step of pressing the blade 57 against the substrate 10 (Step 205).
- the determination unit 68 determines that the substrate 10 has been cut, the series of operations ends. Then, the determination unit 68 transmits a cutting end signal to the driving unit 63. Then, the drive unit 63 moves the stage 52. In this way, for example, the above-described series of operations is repeated for each of the uncut cutting lines H4 and H5 on the substrate 10. Thereby, the cutting is completed for the cutting lines H1 to H5 of the substrate 10.
- the substrate 10 can be cut into chips 20 by repeating the series of operations described above in the order of numbers with respect to the cutting lines V1 to V7 of the substrate 10.
- the cutting state of the substrate 10 can be determined more accurately. And the time required for substrate cutting can be shortened by preventing the substrate cutting process from being repeated unnecessarily.
- the substrate cutting process can be automated.
- single crystal sapphire is used as the substrate 10, but silicon (Si), SiC, GaAs semiconductors, glass, ceramics, and the like may be used. Even if the substrate 10 is opaque to visible light, the substrate 10 is placed upside down so that the target can be imaged. Further, the LED 11 is formed on the substrate 10 as an example of an electronic element. However, the present invention is not limited to the LED 11, and is not limited to the LED 11, but an integrated circuit such as an LSI or a MEMS (Micro Electro Mechanical Systems) incorporating a mechanical system together with an electric / electronic circuit. ) Etc.
- the cutting region 21 having a low strength is formed inside the single crystal sapphire substrate 10 by the excimer-excited pulsed laser light 41 and is used as the starting point of the cutting.
- a groove may be formed on the surface of the substrate 10 by the laser processing, scribing processing, or dicing processing to form the cutting region 21. It suffices if a region serving as a starting point of cutting is formed on the substrate 10.
- the excimer-excited pulse laser beam 41 one having a wavelength of 266 nm can be used.
- a CO 2 laser, a YAG (yttrium / aluminum / garnet) laser, or a YLF (lithium / yttrium / fluoride) laser may be used.
- the electrodes 12a and 12b formed on the substrate surface are used as targets.
- other patterns may be used, and a dedicated pattern suitable for measuring a distance by image processing is formed. May be.
- a method using luminance distribution and edge enhancement is used for target extraction and distance measurement between a set of targets, a method using color information or other methods may be used.
- the front surface 10a of the substrate 10 on which an electronic element such as the LED 11 is formed is attached to the adhesive sheet 15, but the back surface 10b of the substrate 10 may be attached to the adhesive sheet 15.
- the camera of the imaging unit 61 images the target on the substrate 10 through the adhesive sheet 15 and the substrate 10, but the imaging is not hindered if it is transparent such as single crystal sapphire.
- the adhesive sheet 15 is attached only to the surface 10a of the substrate 10 so that the chip 20 does not scatter.
- the adhesive sheet 15 may be attached to the back surface 10b of the substrate 10 simultaneously with the front surface 10a of the substrate 10.
- an intermediate layer made of AlN having a thickness of about 40 ⁇ m is formed on a single crystal sapphire substrate having an outer diameter of 4 inches (about 100 mm) with reference to the method described in JP-A-2008-124060, and then MOCVD.
- a plurality of LEDs 11 are formed by forming a base layer made of GaN having a thickness of about 4 ⁇ m, an n-type semiconductor layer, a light emitting layer, a p-type semiconductor layer, an electrode 12a (diameter ⁇ 100 ⁇ m), an electrode 12b (diameter ⁇ 100 ⁇ m), etc.
- a substrate 10 was prepared. And the back surface 10b of the board
- Example 1 with respect to one substrate 10 on which a plurality of LEDs 11 are formed, the back surface 10b of the substrate 10 is located at a position corresponding to a street line (cutting line) in which ph and pv shown in FIG. 2, the blade 57 (driving unit 63) described in the substrate cutting apparatus 50 described in FIG. 2 is pressed, and at the time of the pressing, a pair of adjacent electrodes 12a and 12b (target) is imaged across the cutting line.
- the image is picked up by the unit 61, and then the extraction unit 66 arbitrarily selects (extracts) one set of targets from the image pickup result, and the measuring unit 67 automatically measures the amount of change in the distance between the electrodes when the blade 57 is pressed.
- Example 2 the same operation as described in Example 1 was performed except that ph shown in FIG. 1 was changed to 240 ⁇ m and pv was changed to 500 ⁇ m, and an operation for cutting the substrate 10 was performed.
- Comparative Example 1 the same size as the interval between ph and pv performed in Example 1 is used, and the blade 57 (drive) is not employed without employing the automatic measurement and automatic determination process as described in Example 1. This was carried out by a human judgment operation such as observing the cutting situation on the street line when pressing the part 63) and judging cutting or judging cutting with reference to the cutting sound at the time of cutting. In Comparative Example 2, the same human judgment operation as in Comparative Example 1 was performed with the same size as the interval between ph and pv performed in Example 2. These results are summarized in Table 1. In addition, a cutting
- Example 1 and Example 2 the cutting pass rate was remarkably improved from 99.6% to 99.8% as compared with the substrate cutting methods of Comparative Example 1 and Comparative Example 2. Further, in Comparative Example 1 and Comparative Example 2, as a judgment of the completion of cutting, for example, due to human judgment such as visual observation or listening to cutting sound, the cutting pass rate fluctuates every execution, and the workability is lowered or judged. Due to individual differences, workability was not stable, and the results were unreliable. In Examples 1 and 2, the workability and the reliability of the results were greatly improved.
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Abstract
Description
また、近年、透過性の波長のレーザ光を対物レンズ光学系で集光して基板内部に焦点を結ぶように照射することにより、照射前に比べて強度が低い領域を基板内部に形成する、いわゆるステルスダイシング法が開発されている。この方法では、切り代が少なく、チッピングが少ない端面が得られる。しかし、基板内部に強度の低い領域が形成された状態では、基板は切断されておらず、つながった状態にある。このため、ブレーキングにより基板をチップに切断することが必要である。
このため、基板にブレードを押し込んでも、基板が完全に切断されたかどうかの判断がしづらいという問題があった。すなわち、基板が切断されたかどうかを、基板にブレードを押し込む際の基板の画像や、押し込んだときの基板から発した音などにより、作業者が判断していた。そして、基板が切断されていない、または、基板の厚さ方向の一部しか切断されていない(半割)と判断された場合には、再度基板にブレードを押し込む工程を繰り返していた。
したがって、基板切断は、作業者の経験や勘に依存する面が多く、自動化できないという問題があった。
すなわち、本発明が適用される基板切断方法は、一方の面に複数の電子素子が形成された基板に切断領域を形成する工程と、基板の他方の面の、切断領域の形成された位置に対応する位置に駆動部がブレードを押圧する工程と、ブレードを押圧する工程に際して、基板の一方の面上に形成された少なくとも1組のターゲットを撮像部が撮像する工程と、ターゲットの撮像結果から、抽出部が1組のターゲットを抽出し、計測部がブレードを押圧する工程におけるターゲット間の距離の変化量を計測する工程と、計測されたターゲット間の距離の変化量と、予め定められた設定値とによって、判定部が基板の切断状況を判定する工程とを含む。さらに、1組のターゲットは、好ましくは切断線を挟んで隣り合う1組のターゲットであることを特徴とする。
また好ましくは、1組のターゲットのそれぞれは、基板に押圧したブレードを挟んで形成されていることを特徴とすることができる。
また、計測されたターゲット間の距離の変化量は、撮像部および計測部が、駆動部からのブレード押圧開始の信号の受信後からブレード押圧終了の信号の受信までの期間に、繰り返し計測したターゲット間の最大距離における変化量であることを特徴とすることができる。
またさらに、基板は、粘着シートに貼り付けられていることが好ましく、チップの飛散を軽減できる利点がある。
ここで、電子素子の製造方法は、発光素子(LED)の製造方法であってよい。
基板10は、例えば、外径4インチ(約100mm)、厚さ120μmの単結晶サファイアの基板である。基板10には、電子素子の一例として、III族窒化物半導体からなるn型半導体層、発光層およびp型半導体層がこの順で積層され、複数の発光ダイオードLED(Light Emitting Diode)素子11(以下ではLED11と呼ぶ)が形成されている。また、基板10には、それぞれのLED11に電流を供給するための電極12aおよび12bが設けられている。電極12aおよび12bは、それぞれ、例えば直径100μmの円形形状をなしている。
また、基板10の外径サイズ(インチ)や基板材料の厚さは任意に選ばれる。本発明においては、研磨・研削工程により基板材料の厚さを約50μm~300μmの範囲で好適に調整して使用される。
ここでは、ターゲットの一例として、基板10上に形成された電極12aおよび12bを使用する。具体的には、チップ20の短辺側を切断する場合(切断線H1~H5)は、隣接する2つのチップ20の隣り合う電極12aと電極12bとの距離を計測する。例えば、ブレード57(後述する図2参照)を挟んで隣り合う(すなわち切断線H3を挟んで隣り合う)、電極12aと電極12bの間の距離dhを計測する。また、チップ20の長辺側を切断する場合(切断線V1~V7)は、隣接する2つのチップ20のそれぞれの電極12bの間の距離を計測する。例えば、切断線V4を挟んで隣り合う、2つの電極12bの間の距離dvを計測する。
なお、粘着シート15は、基板10がチップ20に切断された後に、金属リング16の内側をシリンダにより押し上げられて、引き延ばされる。これにより、それぞれのチップ20間の隙間が広げられ、パッケージへのマウント作業を容易にする。
基板切断装置50は、台等の上に設置されるための基体51上に設けられ、基体51上を前後方向(y方向と呼ぶ。)に移動可能なステージ52を備える。このステージ52は、ステージ52上で回転可能(回転方向をθ軸方向と呼ぶ。)なリング状の枠からなるリングテーブル54を備える。このリングテーブル54上には、図1で示した基板10を貼り付けた粘着シート15が取り付けられた金属リング16が設置される。
さらに、基板切断装置50は、基体51上に設けられ、粘着シート15に貼り付けた基板10を保持する受け台53を備える。
受け台53は、向かい合わせに配置された2つの受け台53aと53bとから構成されている。受け台53aおよび53bのそれぞれの表面は、基板10にブレード57が押し込まれた際に変形しないよう、例えば超鋼で製作されている。そして、ブレード57を受け台53の方向(-z軸方向)に移動させた際、ブレード57が受け台53aおよび53bの隙間に入るように設定されている。
さらに、受け台53の表面とリングテーブル54の表面とは、ほぼ1つの平面内にあるように設定されている。
また、基板切断装置50は、支持体55内に、ブレード保持体56をz軸方向に移動させるためのステッピングモータ、ステージ52をy軸方向に移動させるモータ、リングテーブル54をθ軸方向に回転させるモータおよびこれらのモータを制御する電子回路などからなる駆動部63を備える。
加えて、基板切断装置50は、撮像部61が撮像した画像データから、切断線を挟んで隣り合う1組のターゲットを抽出し、ターゲット間の距離を計測し、ターゲット間の距離の変化量から切断状況を判定する制御部64を備える。
なお、図4(a)~(d)に示す基板10は、図1に示した基板10のA-A’断面を示している。この断面では、4つのチップ20が見える。そして、チップ20には、それぞれ電子素子の一例としてのLED11、電極12aおよび12bが形成されている。
ここでは、LED11、電極12aおよび12bは、よく知られた方法によって形成されるので、LED11、電極12aおよび12bの形成法の詳細については説明を省略する。
対物レンズ42で集光したエキシマ励起のパルスレーザ光41を、切断線H2に対応した基板10の内部に照射する。このとき、エキシマ励起のパルスレーザ光41は、基板10上を切断線H2に沿って、照射されながら走査される。これにより、基板10の材料が加熱されて揮散することで、切断線H2に沿って、切断の際に破壊の起点となる強度が低い切断領域21が基板10の内部に形成される。ここでは、切断の際に破壊の起点となる強度が低い切断領域21を形成する工程を、切断領域を形成する工程と呼ぶ。
同様にして、エキシマ励起のパルスレーザ光41の走査を切断線H1、H3~H5について行うことにより、切断線H1~H5に対応した基板10の内部に強度が低い切断領域21を形成する。
さらに、同様にして、切断線V1~V7に対応した基板10の内部に強度が低い切断領域21を形成する。
ここで、金属リング16も粘着シート15の粘着面15aに貼り付けられているので、基板10と金属リング16とは粘着シート15に対して、同じ側に配置されている。
前述したように、リングテーブル54の表面と受け台53aおよび53bの表面とは1つの平面になるように設定されているので、基板10は、受け台53aおよび53b上に設置されている。
なお、基板10の切断線とブレード57の刃先の位置との調整は次のように行われる。基板10を受け台53に設置する前に、撮像部61に設けられた基準となるマークとブレード57の位置とが一致するように、撮像部61のマークを調整する。その後、基板10を受け台53に設置して、このマークと基板10の切断線H3とを一致させる。このとき、駆動部63は、撮像部61からの基板10の画像データにより、リングテーブル54の回転機構を用いて基板10のθ軸方向の回転を調整し、さらにステージ52の移動機構を用いて基板10のy軸方向の位置を調整する。
なお、押し込み量bとは、図4(d)に示すように、ブレード57が当接した基板10の位置(破線で示す基板10の位置)を0として、ブレード57を-z軸方向に移動させた距離をいう。
ブレード57は、押し込みが終了すると、直ちに元の位置に戻る。
ここでは、駆動部63がブレード57を基板10の切断線に当接させ、さらにブレード57を基板10に押し込む工程を、ブレードを押圧する工程と呼ぶ。
さらに、同様にして、切断線V1~V7の位置において、ブレードを押圧する工程を行うことで、基板10が切断線V1~V7の位置で切断される。
このようにして、LEDチップに分割された電子素子が製造される。
図5は、基板10の切断状況を判断する第1の方法のフローチャートである。図3、図4(c)、(d)、図5を参照しながら、切断状況を判断する第1の方法を説明する。ここでも、切断線H3で基板10を切断する場合を例として説明する。そして、ブレード57の位置は、切断線H3に当接できるように設定されているとする。
次に、計測部67が、選択された1組の電極12aと電極12bとの画像データから、電極12aと電極12bとの間の距離d1を計測する(計測する工程)(ステップ103)。例えば、選択された1組の電極12aおよび電極12bの画像データのエッジを強調するように処理し、1組の電極12aと電極12bとのエッジ間の画素数から距離を計測する。そして、その距離d1の値を計測部67が備える距離d1を格納する記憶領域に記憶する。そして、計測部67は、駆動部63に、距離d1の計測終了の信号を送信する。
基板10にブレード57が押圧されると、基板10がブレード57に押されてたわみ、強度が低い切断領域21を起点として、基板10の破壊が始まる。このとき、電極12aと電極12bと間の距離は、基板10がたわむことで広がる。さらに、基板10が切断されると、ブレード57が切断された基板10のチップ20の間に入り込み、電極12aと電極12bと間の距離がさらに広がる。
そして、計測部67が、ステップ103と同様に、ターゲットである1組の電極12aと電極12bとの間の距離d2を計測する(ステップ107)。その距離d2を計測部67が備える距離d2を格納する記憶領域に記憶する。そして、計測部67が、ターゲット間の距離の変化に関わる値である、ターゲット間距離の変化量(d2-d1)を算出(計測する工程)し、判定部68に送信する。
なお、再びブレード57を基板10に押圧するときには、ブレード57の押し込み量bを、その前の場合より大きく設定してもよい。同じ押し込み量bでは、基板10が切断できないことが考えられるためである。なお、こののち、ステップ105~ステップ107を行い、基板10の切断の状態を自動的に判定する。
このようにして、例えば、基板10上の未切断の切断線H4およびH5のそれぞれについて上記の一連の操作を繰り返す。これにより、基板10の切断線H1~H5について切断が終了する。
この後、基板10をリングテーブル54上で自動的に90°回転させた後、上記の一連の操作を、基板10の切断線V1~V7について番号順に繰り返せば、基板10をチップ20に切断することができる。
このようにすることにより、基板切断の工程を自動化することができる。
これを防ぐために、ターゲットを撮像するステップ105を、ブレード57を押圧するステップ104と同時に行うことが考えられる。しかし、この場合においても、ターゲットを撮像するステップ105のタイミングによっては、切断された基板10のターゲット間距離d2はもっとも開いたときに比べ狭くなって、ターゲット間距離の変化量(d2-d1)が、設定値d0より小さな値になることが考えられる。
図5の方法と図6の方法との違いは、図6では、撮像部61および計測部67が駆動部63からのブレード押圧開始の信号を受信すると、駆動部63からのブレード押圧終了の信号を受信するまで、ターゲット間距離d2の計測を繰り返し行うことにある。そして、繰り返し計測を行ったターゲット間距離d2の値から、ターゲット間距離d2の最大距離d3を求めることにある。
まず、計測部67は、計測部67に備える最大距離d3を格納する記憶領域を0に設定する(ステップ201)。
次に、図5のステップ101と同様に、撮像部61が切断線H3(ブレード57)を挟んだ電極12aおよび電極12bを含む画像を撮像する(撮像する工程)(ステップ202)。抽出部66は、撮像部61が撮像した画像データを受信すると、切断線H3(ブレード57)を挟んだ電極12aおよび電極12bの画像データを抽出する(ステップ203)。そして、抽出部66は、切断線H3を挟んで形成されている1組の電極12aおよび電極12bの画像データをターゲットとして選択する。
撮像部61は、駆動部63からのブレード押圧開始の信号を受信すると、電極12aおよび電極12bの画像を撮像する(撮像する工程)(ステップ206)。抽出部66は、撮像部61からの画像データを受信すると、ステップ203で抽出されたものと同じ1組の電極12aおよび電極12bの画像データを抽出する(ステップ207)。
すると、計測部67が、判定部68に、ターゲット間距離の変化量(d3-d1)を算出(計測する工程)し、判定部68に送信する。
この後は、切断状況を判断する第1の方法で説明したと同様に、判定部68が、切断がされていない状態、または、不完全な切断状態(半割)であると判定する場合には、判定部68は、駆動部63に、再度ブレード57を基板10に押圧することを指示する信号を送信してもよい(ステップ212でNo)。すると、駆動部63は、ブレード57を基板10に押圧する工程(ステップ205)を繰り返す。
このようにして、例えば、基板10上の未切断の切断線H4およびH5のそれぞれについて上記の一連の操作を繰り返す。これにより、基板10の切断線H1~H5について切断が終了する。そして、上記の一連の操作を、基板10の切断線V1~V7について番号順に繰り返せば、基板10をチップ20に切断することができる。
また、基板10上には電子素子の一例としてLED11が形成されているとしたが、LED11に限らず、LSI等の集積回路や、機構系を電気・電子回路とともに組み込んだMEMS(Micro Electro Mechanical Systems)などであってよい。
なお、エキシマ励起のパルスレーザ光41として、波長266nmのものを用いることができる。また、CO2レーザやYAG(イットリウム・アルミニウム・ガーネット)レーザ、YLF(リチウム・イットリウム・フロライド)レーザを用いてもよい。
先ず、外径4インチ(約100mm)の単結晶サファイアの基板上に、特開2008-124060号公報に記載する方法を参考に、約40μm厚さのAlNからなる中間層を形成し、次いでMOCVD法で約4μm厚さのGaNからなる下地層、n型半導体層、発光層、p型半導体層、電極12a(径φ100μm)および電極12b(径φ100μm)等を形成し、複数のLED11を備えた基板10を準備した。そして、このLED11を有する基板10の裏面10bを公知な方法で研削及び研磨により、約120μmの厚さまで薄板化した。
次に、実施例2では、図1に記載のphを240μmに、pvを500μmに変えた以外は実施例1に記載の内容と同様な操作を行なって基板10を切断する操作を実施した。
比較例2では、実施例2で実施したphとpvの間隔と同一なサイズとして、比較例1と同様な人的な判断操作を実施した。これらの結果を表1にまとめる。なお、切断合格率とは、その後の検査において切断予定部分に対する切断された部分の比率である。
Claims (10)
- 一方の面に複数の電子素子が形成された基板に切断領域を形成する工程と、
前記基板の他方の面の、前記切断領域の形成された位置に対応する位置に駆動部がブレードを押圧する工程と、
前記ブレードを押圧する工程に際して、前記基板の一方の面上に形成された少なくとも1組のターゲットを撮像部が撮像する工程と、
前記ターゲットの撮像結果から、抽出部が前記1組のターゲットを抽出し、計測部が前記ブレードを押圧する工程における当該ターゲット間の距離の変化量を計測する工程と、
前記計測されたターゲット間の距離の変化量と、予め定められた設定値とによって、判定部が前記基板の切断状況を判定する工程と
を含むことを特徴とする基板切断方法。 - 前記1組のターゲットが、切断線を挟んで隣り合う1組のターゲットであることを特徴とする請求項1に記載の基板切断方法。
- 前記変化量が予め定められた設定値より小さい場合に、前記ブレードを押圧する工程から繰り返す工程をさらに含むことを特徴とする請求項1に記載の基板切断方法。
- 前記1組のターゲットのそれぞれは、前記基板に押圧した前記ブレードを挟んで形成されていることを特徴とする請求項1に記載の基板切断方法。
- 前記計測されたターゲット間の距離の変化量は、前記撮像部および前記計測部が、前記駆動部からのブレード押圧開始の信号の受信後からブレード押圧終了の信号の受信までの期間に、繰り返し計測したターゲット間の最大距離における変化量であることを特徴とする請求項1に記載の基板切断方法。
- 前記切断領域は、溝加工またはレーザ加工によって当該溝加工または当該レーザ加工前よりも強度が低い領域であることを特徴とする請求項1に記載の基板切断方法。
- 前記基板は、粘着シートに貼り付けられていることを特徴とする請求項1に記載の基板切断方法。
- 基板上に形成された電子素子の製造方法であって、
一方の面に複数の電子素子が形成された基板に切断領域を形成する工程と、
前記基板の他方の面の、前記切断領域の形成された位置に対応する位置に駆動部がブレードを押圧する工程と、
前記ブレードを押圧する工程に際して、前記基板の一方の面上に形成された少なくとも1組のターゲットを撮像部が撮像する工程と、
前記ターゲットの撮像結果から、抽出部が前記1組のターゲットを抽出し、計測部が前記ブレードを押圧する工程における当該ターゲット間の距離の変化量を計測する工程と、
前記計測されたターゲット間の距離の変化量と、予め定められた設定値とによって、判定部が前記基板の切断状況を判定する工程と
を含むことを特徴とする電子素子の製造方法。 - 前記1組のターゲットが、切断線を挟んで隣り合う1組のターゲットであることを特徴とする請求項8に記載の電子素子の製造方法。
- 前記電子素子の製造方法が、発光素子(LED)の製造方法であることを特徴とする請求項8に記載の電子素子の製造方法。
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- 2010-01-19 WO PCT/JP2010/050557 patent/WO2010087249A1/ja active Application Filing
- 2010-01-19 KR KR1020117007572A patent/KR101240712B1/ko not_active IP Right Cessation
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JPS61280906A (ja) * | 1985-06-07 | 1986-12-11 | 三菱電機株式会社 | ウエハのブレ−ク装置 |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US20130161657A1 (en) * | 2011-12-27 | 2013-06-27 | Advanced Optoelectronic Technology, Inc. | Light emitting diode package and method for making same |
US20130171755A1 (en) * | 2011-12-30 | 2013-07-04 | Samsung Electronics Co., Ltd. | Method of cutting light-emitting device chip wafer by using laser scribing |
US9312431B2 (en) * | 2011-12-30 | 2016-04-12 | Samsung Electronics Co., Ltd. | Method of cutting light-emitting device chip wafer by using laser scribing |
JP2016043503A (ja) * | 2014-08-20 | 2016-04-04 | 三星ダイヤモンド工業株式会社 | 脆性材料基板の分断方法、脆性材料基板分断用の基板保持部材、および、脆性材料基板の分断時に使用する粘着フィルム張設用の枠体 |
Also Published As
Publication number | Publication date |
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JP2010177395A (ja) | 2010-08-12 |
DE112010000771T5 (de) | 2012-07-26 |
CN102265386A (zh) | 2011-11-30 |
US8470691B2 (en) | 2013-06-25 |
US20110287608A1 (en) | 2011-11-24 |
KR101240712B1 (ko) | 2013-03-11 |
JP5121746B2 (ja) | 2013-01-16 |
DE112010000771B4 (de) | 2015-06-18 |
KR20110063808A (ko) | 2011-06-14 |
DE112010000771T8 (de) | 2012-10-25 |
CN102265386B (zh) | 2014-03-12 |
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