Simultaneous Break and Expansion System for Integrated Circuit Wafers
20180323105 ยท 2018-11-08
Inventors
Cpc classification
B26F3/002
PERFORMING OPERATIONS; TRANSPORTING
B28D5/0011
PERFORMING OPERATIONS; TRANSPORTING
H01L21/78
ELECTRICITY
B28D5/0052
PERFORMING OPERATIONS; TRANSPORTING
B28D1/225
PERFORMING OPERATIONS; TRANSPORTING
International classification
H01L21/78
ELECTRICITY
Abstract
Improved methods and apparatuses for singulating integrated circuit (IC) dies that reduce or eliminate die collisions and work well with very small dies. Embodiments simultaneously separate dies in two dimensions by utilizing a break and expansion system that avoids die collisions by maintaining IC die separation after singulation. Singulation is achieved by placing the joined dies of the wafer substrate on a dicing tape, scoring the wafer substrate between the joined dies, and imposing a bending action by pressing a curved surface against the scored wafer substrate, which also expands the wafer substrate by stretching the dicing tape. After breaking, an inner expansion grip ring is pressed into an outer expansion grip ring in a nested configuration so as to maintain the stretched state of the dicing tape after the curved surface is fully removed, thereby maintaining the dicing tape in tension and the singulated die in spaced apart relation.
Claims
1. A method for singulating and separating joined integrated circuit (IC) dies from a wafer substrate, including: (a) pressing a 2-dimensionally curved surface directly or indirectly against a scored wafer substrate affixed to a dicing tape, the dicing tape being affixed to a frame, to impose a bending force on the scored wafer substrate sufficient to break and separate at least some of the joined IC dies apart from the scored wafer substrate and stretch the dicing tape so as to space apart the separated IC dies; and (b) applying a tension maintenance device to the dicing tape to maintain the stretched dicing tape in tension while or after the bending force imposed by the 2-dimensionally curved surface is removed.
2. The method of claim 1, wherein the 2-dimensionally curved surface is moved to pressed engagement against the scored wafer substrate.
3. The method of claim 1, wherein the scored wafer substrate is moved to pressed engagement against the 2-dimensionally curved surface.
4. The method of claim 1, wherein the 2-dimensionally curved surface and the scored wafer substrate are mutually moved to pressed engagement against each other.
5. The method of claim 1, wherein the 2-dimensionally curved surface is pressed against the scored wafer substrate through the dicing tape.
6. The method of claim 1, wherein the 2-dimensionally curved surface is pressed directly against the scored wafer substrate.
7. The method of claim 1, wherein the 2-dimensionally curved surface has a lateral diameter sized to be only slightly larger than the diameter of the scored wafer substrate.
8. The method of claim 1, wherein the 2-dimensionally curved surface has a lateral diameter sized to be substantially larger than the diameter of the scored wafer substrate.
9. (canceled)
10. (canceled)
11. The method of claim 1, wherein applying the tension maintenance device includes pressing an inner expansion grip ring into an outer expansion grip ring in a nested configuration.
12. (canceled)
13. The method of claim 1, wherein the scored wafer substrate is patterned with a non-uniform grid layout of IC dies.
14. (canceled)
15. A method for singulating and separating joined integrated circuit (IC) dies from a wafer substrate, including: (a) affixing, in a selected order, the wafer substrate to a dicing tape and the dicing tape to a frame; (b) scoring the wafer substrate between the joined dies; (c) pressing a 2-dimensionally curved surface directly or indirectly against the scored wafer substrate to impose a bending force on the scored wafer substrate sufficient to break and separate at least some of the joined IC dies apart from the scored wafer substrate and stretch the dicing tape so as to space apart the separated IC dies; and (d) applying a tension maintenance device to the dicing tape to maintain the stretched dicing tape in tension while or after the bending force imposed by the 2-dimensionally curved surface is removed.
16. The method of claim 15, wherein the 2-dimensionally curved surface is moved to pressed engagement against the scored wafer substrate.
17. The method of claim 15, wherein the scored wafer substrate is moved to pressed engagement against the 2-dimensionally curved surface.
18. The method of claim 15, wherein the 2-dimensionally curved surface and the scored wafer substrate are mutually moved to pressed engagement against each other.
19. The method of claim 15, wherein the 2-dimensionally curved surface is pressed against the scored wafer substrate through the dicing tape.
20. The method of claim 15, wherein the 2-dimensionally curved surface is pressed directly against the scored wafer substrate.
21. The method of claim 15, wherein the 2-dimensionally curved surface has a lateral diameter sized to be only slightly larger than the diameter of the scored wafer substrate.
22. The method of claim 15, wherein the 2-dimensionally curved surface has a lateral diameter sized to be substantially larger than the diameter of the scored wafer substrate.
23. (canceled)
24. (canceled)
25. The method of claim 15, wherein applying the tension maintenance device includes pressing an inner expansion grip ring into an outer expansion grip ring in a nested configuration.
26. (canceled)
27. The method of claim 15, wherein the scored wafer substrate is patterned with a non-uniform grid layout of IC dies.
28.-44. (canceled)
Description
DESCRIPTION OF THE DRAWINGS
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[0039] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The invention encompasses improved apparatus and methods for singulating integrated circuit (IC) dies that reduce or eliminate die collisions, work well with very small dies (e.g., less than about 1.0 mm on the shortest edge), and work well with both uniform grid patterns die layouts and non-uniform grid pattern die layouts (e.g., multi-project wafers or multi-product wafers). Further, embodiments of the invention simultaneously separate dies in two dimensions.
[0041] Embodiments of the invention utilize a simultaneous break and expansion system for separating individual IC dies from a scored wafer substrate, and avoid die collisions by maintaining IC die separation once singulation has occurred. The system may use a variety of scored wafer substrates, and works well in particular with wafer substrates that have been both laser scribed and stealth diced in accordance with the teachings of co-pending U.S. patent application Ser. No. 15/432,838, referenced above.
[0042] Overview of Concept
[0043]
[0044] Singulation by breaking is achieved by simultaneously placing the joined dies of the scored wafer substrate 402 in tension and applying a breaking torque at the scoring lines by a bending action. The bending action is imposed by pressing a 2-dimensionally curved surface 410 (e.g., an approximately spherical surface) against the scored wafer substrate 402 (through the dicing tape 404 in this example), preferably near the center line 412 of the scored wafer substrate 402 (note that the curvature of the curved surface 410 is exaggerated for purposes of illustration). When forced against the scored wafer substrate 402, the curved surface 410 simultaneously breaks the dies from each other by applying a bending force to all of the scoring lines and expands the scored wafer substrate 402 by stretching the dicing tape 404. Accordingly, at this point, the individual dies of the scored wafer substrate 402 are physically separated from each other and spaced apart from each other, essentially eliminating die collisions.
[0045] After breaking the scored wafer substrate 402 and stretching the dicing tape 404 by pressing the curved surface 410 against the scored wafer substrate 402 (through the dicing tape 404 in this example), a tension maintenance device is applied. For example, an inner expansion grip ring 414 may be pressed into the outer expansion grip ring 408 in a nested configuration so as to maintain the stretched state of the dicing tape 404 before the tension imposed by the curved surface 410 is fully removed. Such outer and inner expansion grip rings 408, 414 work on the same principle as embroidery rings, and accordingly maintain the dicing tape 404 in tension after the curved surface 410 is retracted from contact with the dicing tape 404 and scored wafer substrate 402. The tensioned dicing tape 404 thus keeps the individual dies spaced apart from each other, essentially eliminating die collisions. As should be apparent, the individual dies are never placed in compression during expansion and separation, and the dicing tape 404 is never in a slack state post-expansion; accordingly die collisions cannot occur.
Detailed Example
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[0048] In one embodiment, the curved surface 508 may be pressed against the dicing tape 504 (and hence the scored wafer substrate 502) so as to tension the dicing tape 504 about the same amount as would occur with application of standard inch expansion grip rings.
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[0054] Pressing may be accomplished using a conventional manual press or automated press configured to hold a conventional frame 406, and adapted to hold the 2-dimensionally curved-surface 508 in a position to be pressed against a scored wafer substrate 502 affixed to a dicing tape 504 held by the frame 406. More generally, the invention encompasses a mechanism configured to hold the outer expansion grip ring 506 and affixed dicing tape 504 with the affixed scored wafer substrate 502; press the 2-dimensionally curved-surface 508 against the dicing tape 504 and affixed scored wafer substrate 502 to impose a bending force on the scored wafer substrate 502 sufficient to break and separate at least some of the joined IC dies apart from the scored wafer substrate 502 and stretch the dicing tape 504 so as to space apart the separated IC dies; and press an inner expansion grip ring 510 against the dicing tape 504 and into at least partial nested engagement with the outer expansion grip ring 506 sufficient to maintain the stretched dicing tape 504 in tension while or after the bending force imposed by the 2-dimensionally curved surface 508 is removed.
Variations and Application Notes
[0055] While outer and inner expansion grip rings 506, 510 are a convenient way of maintaining post-separation tension on the dicing tape 504, other tension maintenance devices may be used to accomplish the same function. Note also that the nested outer and inner expansion grip rings 506, 510 may be separable from a handling frame so as to facilitate further IC fabrication processes, such as die picking.
[0056] The amount of nesting between the outer and inner expansion grip rings 506, 510 necessary to maintain a desired tension on the dicing tape 504 may vary depending on the stretchiness of the dicing tape 504, but in general, the inner expansion grip ring 510 will fully nest within the outer expansion grip ring 506. Further, the timing of application of the curved surface 508 to the dicing tape 504 and scored wafer substrate 502 versus application of the inner expansion grip ring 510 to the outer expansion grip ring 506 need not be purely sequential, as depicted in
[0057] In alternative embodiments, the curved surface 508 may be pressed directly against a scored wafer substrate 50. For example, referring to
[0058] Referring to
[0059] Embodiments of the invention may be applied to both uniform grid patterns IC die layouts and non-uniform grid pattern IC die layouts, such as multi-project wafers or multi-product wafers (MPWs). For example,
[0060] As another example,
[0061] In common automated wafer substrate processing systems, a wafer substrate undergoes a backgrind process in which a backgrind tape is adhered to the front side of the wafer substrate which has been patterned with IC dies. The backside of the wafer substrate is ground down by a grinder apparatus to achieve a desired thickness for the wafer substrate; optionally, the backside of the wafer substrate may be polished after grinding. An automated tape mounting system places the backside of the unscored thinned wafer substrate onto dicing tape affixed to a frame, and then the grinding tape is removed from the front side of the wafer substrate; optionally, a protective coating may be applied to the front side of the wafer substrate. The framed and dicing taped unscored wafer substrate is then scored and singulated as described above. Additional post-singulation steps may be applied, such as dicing tape adhesion release and die picking. As should be clear to one of ordinary skill in the art, additional steps may be performed in the process as desired, and some of the steps may be performed in a different order. For example, while it is most common to attach an unscored wafer substrate to a dicing tape affixed to a frame and then scoring the wafer substrate before singulating, the inventive concepts would apply as well to embodiments in which a scored wafer substrate is attached to a dicing tape affixed to a frame and then singulated. Additional details regarding various aspects of processing wafer substrates may be found in co-pending U.S. patent application Ser. No. 15/432,838, referenced above.
[0062] It should be recognized that the simultaneous break and expansion system described above may not produce a 100% yield for some IC dies sizes and geometries and some IC layouts on wafer substrates. However, it is believed that a high yield can generally be expected using embodiments of the present invention, including with very small dies (e.g., less than about 1.0 mm on the shortest edge).
[0063] Methods
[0064] Another aspect of the invention includes methods for singulating joined integrated circuit (IC) dies from a scored wafer substrate. For example,
[0065] As another example,
[0066] Other aspects of the above methods include one or more of the following: the 2-dimensionally curved surface being moved to pressed engagement against the scored wafer substrate; the scored wafer substrate being moved to pressed engagement against the 2-dimensionally curved surface; the 2-dimensionally curved surface and the scored wafer substrate being mutually moved to pressed engagement against each other; the 2-dimensionally curved surface being pressed against the scored wafer substrate through the dicing tape; the 2-dimensionally curved surface being pressed directly against the scored wafer substrate; the 2-dimensionally curved surface having a lateral diameter sized to be only slightly larger than the diameter of the scored wafer substrate; the 2-dimensionally curved surface having a lateral diameter sized to be substantially larger than the diameter of the scored wafer substrate; the 2-dimensionally curved surface being an approximately spherical surface; the scored wafer substrate having an approximately 12 inch diameter and the approximately spherical surface having a radius R of approximately 78 inches; applying the set of expansion grip rings includes pressing an inner expansion grip ring into an outer expansion grip ring in a nested configuration; the scored wafer substrate being patterned with a uniform grid layout of IC dies; the scored wafer substrate being patterned with a non-uniform grid layout of IC dies; and/or the scored wafer substrate being a multi-project wafer or multi-product wafer.
[0067] Fabrication Technologies and Options
[0068] As should be readily apparent to one of ordinary skill in the art, various embodiments of the invention can be implemented to meet a wide variety of specifications. Unless otherwise noted above, selection of suitable component sizes and parameters is a matter of design choice, and various embodiments of the invention may be implemented in any suitable technology. As one example, the curved surface used in one experiment was formed by 3D printing to a desired contact surface radius and lateral diameter.
[0069] A number of embodiments of the invention have been described. It is to be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, some of the steps described above may be order independent, and thus can be performed in an order different from that described. Further, some of the steps described above may be optional. Various activities described with respect to the methods identified above can be executed in repetitive, serial, or parallel fashion. It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the following claims, and that other embodiments are within the scope of the claims. (Note that the parenthetical labels for claim elements are for ease of referring to such elements, and do not in themselves indicate a particular required ordering or enumeration of elements; further, such labels may be reused in dependent claims as references to additional elements without being regarded as starting a conflicting labeling sequence).