DIE BONDING SYSTEMS, AND METHODS OF USING THE SAME
20230163095 · 2023-05-25
Inventors
- Andreas Marte (Berg, CH)
- Daniel Buergi (Berg, CH)
- Urban Ernst (Berg, CH)
- Eirini Kakkava (Zurich, CH)
- Alexander Holzer (Zurich, CH)
- Mathias Moser (Zurich, CH)
- Fabian Schneider (Zurich, CH)
Cpc classification
H01L2224/8013
ELECTRICITY
H01L24/74
ELECTRICITY
H01L2224/80986
ELECTRICITY
H01L2224/80894
ELECTRICITY
H01L2224/80132
ELECTRICITY
H01L24/75
ELECTRICITY
H01L24/80
ELECTRICITY
International classification
Abstract
A die bonding system including a bond head assembly for bonding a die to a substrate is provided. The die includes a first plurality of fiducial markings, and the substrate includes a second plurality of fiducial markings. The die bonding system also includes an imaging system configured for simultaneously imaging one of the first plurality of fiducial markings and one of the second plurality of fiducial markings along a first optical path while the die is carried by the bond head assembly. The imaging system is also configured for simultaneously imaging another of the first plurality of fiducial markings and another of the second plurality of fiducial markings along a second optical path while the die is carried by the bond head assembly. Each of the first and second optical paths are independently configurable to image any area of the die including one of the first plurality of fiducial markings.
Claims
1. A die bonding system comprising: a bond head assembly for bonding a die to a substrate, the die including a first plurality of fiducial markings, the substrate including a second plurality of fiducial markings; and an imaging system configured for simultaneously imaging (i) one of the first plurality of fiducial markings and (ii) one of the second plurality of fiducial markings along a first optical path while the die is carried by the bond head assembly, the imaging system configured for simultaneously imaging (i) another of the first plurality of fiducial markings and (ii) another of the second plurality of fiducial markings along a second optical path while the die is carried by the bond head assembly, each of the first optical path and the second optical path being independently configurable to image any area of the die including one of the first plurality of fiducial markings.
2. The die bonding system of claim 1 wherein the imaging system is carried by the bond head assembly.
3. The die bonding system of claim 1 wherein the bond head assembly includes a bond tool for holding the die prior to bonding the die to the substrate.
4. The die bonding system of claim 3 wherein the bond tool holds the die at a holding portion of the bond tool, the holding portion being formed from an infrared transparent material.
5. The die bonding system of claim 1 wherein the imaging system is an infrared imaging system.
6. The die bonding system of claim 1 wherein the first optical path includes a first camera, and the second optical path includes a second camera.
7. The die bonding system of claim 6 wherein the imaging system includes an optical element, the optical element being included in each of the first optical path and the second optical path.
8. The die bonding system of claim 7 wherein the first camera is configured for imaging from a first position above the optical element, and the second camera is configured for imaging from a second position along a side of the optical element.
9. The die bonding system of claim 1 wherein the imaging system is configured for imaging (a) the one of the first plurality of fiducial markings and the one of the second plurality of fiducial markings along the first optical path and (b) the another of the first plurality of fiducial markings and the another of the second plurality of fiducial markings along the second optical path simultaneously.
10. The die bonding system of claim 1 wherein the imaging system includes a camera, the camera being included in each of the first optical path and the second optical path.
11. The die bonding system of claim 10 wherein the imaging system includes a scanning mirror, the scanning mirror being configured to alternately provide for imaging of (a) the one of the first plurality of fiducial markings and the one of the second plurality of fiducial markings along the first optical path, and (b) the another of the first plurality of fiducial markings and the another of the second plurality of fiducial markings along the second optical path.
12.-16. (canceled)
17. A die bonding system comprising: a bond head assembly for bonding a die to a substrate, the die including a first plurality of fiducial markings, the substrate including a second plurality of fiducial markings; and an imaging system configured for simultaneously imaging (i) one of the first plurality of fiducial markings and (ii) one of the second plurality of fiducial markings along a first optical path while the die is carried by the bond head assembly, the imaging system configured for simultaneously imaging (i) another of the first plurality of fiducial markings and (ii) another of the second plurality of fiducial markings along a second optical path while the die is carried by the bond head assembly, the imaging system including (a) a first camera, (b) a second camera, and (c) an optical element included in each of the first optical path and the second optical path, the first camera imaging from a first position above the optical element, and the second camera imaging from a second position along a side of the optical element.
18. The die bonding system of claim 17 wherein the imaging system is carried by the bond head assembly.
19. The die bonding system of claim 17 wherein the bond head assembly includes a bond tool for holding the die prior to bonding the die to the substrate.
20. The die bonding system of claim 19 wherein the bond tool holds the die at a holding portion of the bond tool, the holding portion being formed from an infrared transparent material.
21. The die bonding system of claim 17 wherein the imaging system is an infrared imaging system.
22. The die bonding system of claim 17 wherein the imaging system is configured for imaging (a) the one of the first plurality of fiducial markings and the one of the second plurality of fiducial markings along the first optical path using the first camera, and (b) the another of the first plurality of fiducial markings and the another of the second plurality of fiducial markings along the second optical path using the second camera, simultaneously.
23. A method of bonding a die to a substrate, the method comprising the steps of: (a) simultaneously imaging along a first optical path (i) one of a first plurality of fiducial markings on a die while the die is carried by a bond head assembly, and (ii) one of a second plurality of fiducial markings on a substrate; (b) simultaneously imaging along a second optical path (i) another of the first plurality of fiducial markings on the die while the die is carried by the bond head assembly and (ii) another of the second plurality of fiducial markings on the substrate; (c) adjusting a relative position of the die with respect to the substrate; and (d) bonding the die to the substrate.
24. The method of claim 23 further comprising the step of performing a coarse alignment of the die with respect to the substrate prior to each of steps (a)-(d).
25. The method of claim 23 wherein each of steps (a) and (b) is carried out by an imaging system carried by the bond head assembly.
26. The method of claim 23 wherein the bond head assembly includes a bond tool for holding the die during steps (a)-(d).
27. The method of claim 26 wherein the bond tool holds the die at a holding portion of the bond tool during steps (a)-(d), the holding portion being formed from an infrared transparent material.
28. The method of claim 23 wherein steps (a) and (b) use an infrared imaging system to perform the imaging.
29. The method of claim 23 wherein the first optical path includes a first camera, and the second optical path includes a second camera.
30. The method of claim 29 wherein an optical element is included in each of the first optical path and the second optical path.
31. The method of claim 30 wherein the first camera is configured for imaging from a first position above the optical element, and the second camera is configured for imaging from a second position along a side of the optical element.
32. The method of claim 23 wherein each of steps (a) and (b) are performed by an imaging system simultaneously.
33. The method of claim 32 wherein the imaging system includes a camera, the camera being included in each of the first optical path and the second optical path.
34. The method of claim 23 wherein steps (a) and (b) are performed by an imaging system including a scanning mirror, the scanning mirror being configured to alternately provide for imaging of (a) the one of the first plurality of fiducial markings and the one of the second plurality of fiducial markings along the first optical path, and (b) the another of the first plurality of fiducial markings and the another of the second plurality of fiducial markings along the second optical path.
35. The method of claim 23 wherein each of steps (a)-(c) are repeated until an alignment detected between the die and the substrate satisfies a predetermined accuracy criteria.
36. The method of claim 35 wherein step (d) is performed after the alignment detected between the die and the substrate satisfies the predetermined accuracy criteria.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:
[0011]
[0012]
[0013]
DETAILED DESCRIPTION
[0014] As used herein, the term “die” shall refer to any type of element including (or configured to include) a semiconductor die such as a bare semiconductor die, a packaged die, a plurality of die, etc. As used herein, the term “substrate” shall refer to any type of substrate configured to receive a die in a die bonding operation such as a wafer, another die, a semiconductor element, a panel, a leadframe, or any other type of substrate.
[0015] As used herein, the term “die bonding” refers any type of bonding (or attach) of a die to another structure (e.g., a substrate). For example, die bonding includes traditional die bonding (die attach), thermocompression bonding, flip chip bonding, pick and place bonding, hybrid bonding, etc.
[0016] Aspects of the invention relate to in situ alignment schemes on die bonding systems. More specifically, aspects of the invention relate to imaging (and/or inspecting) fiducial markings on a die and on a substrate at the same time while the die is held by a bond head above the target surface of the substrate.
[0017] According to various exemplary embodiments of the invention, an infrared imaging system (such as a near infrared imaging and camera system) (or other type of imaging system) is used to look through the die, thereby capturing fiducial markings of the die and corresponding fiducial markings of the substrate within the same image.
[0018] Aspects of the invention relate to using the relative position of a die and a substrate (e.g., retrieved from at least two pairs of die and substrate fiducials) to adjust the die to substrate alignment prior to bonding. In certain embodiments, pairs of die and substrate fiducials are spaced far apart (e.g., in opposite die corners) in order to get the best possible angle information.
[0019] In certain embodiments of the invention, in order to achieve sub-micron level pixel and optical resolution, an optical system provides only a small field of view (i.e., FOV). However, as mentioned above, fiducial sets may be spaced quite far apart (i.e., relative to a specific die size). Therefore, according to certain embodiments of the invention, at least two separate optical systems may be utilized. Such optical systems are desirably mechanically “configurable” with respect to the application specific field of view (FOV) locations.
[0020] Aspects of the invention allow for completely independent selection of two or more FOV locations within a die area.
[0021] These exemplary embodiments (e.g.,
[0022] According to aspects of the invention, the die to substrate alignment may be improved by applying the fiducial measurements (and corresponding fine corrections) in an iterative manner.
[0023] According to aspects of the invention, fully independent access of two (or more) optical paths is provided to two or more locations over a whole die area.
[0024] In accordance with specific embodiments of the invention, a bond head including infrared (or near infrared, NIR) imaging and camera systems are provided, along with an alignment scheme, that allows for fully independent selection of two (or more) FOVs over a whole die area. Using such aspects, a very compact XYZ and θ.sub.z fine correction mechanism (e.g., fine motion system 106) is provided that acts right at the bond tool and/or bond tool holder.
[0025] Exemplary coarse motion systems illustrated and described herein may be, for example, gantry type motion systems. Exemplary fine motion systems illustrated and described herein may be, for example, piezo actuators (e.g., with nm level resolution). Such fine motion systems may provide, for example, a range of up to 50 μm-100 μm of travel (although fine motion systems with greater than 100 μm of travel may be used in connection with the invention). Such fine motion systems may move a die 10 μm-20 μm down to bring the die into contact with a substrate in connection with a bonding step. A specific exemplary fine motion system may include two piezo stacks for XYZ fine positioning and use synchronous piezo motions, where a rotational position (e.g., rotation about the Z-axis, that is θ.sub.z motion) may be adjusted using differential piezo motions. A fine motion system may include a vacuum interface for holding a bond tool and/or die.
[0026] Such a scheme (e.g., using a coarse motion system and a fine motion system) may be used to provide a high level of accuracy (and efficiency). Large motions may be made using the coarse motion system, and then small adjustments may be made with the fine motion system. Further, there may be a small z-axis movement after final alignment to complete the bonding step.
[0027] Any of a number of fiducial styles (e.g., cross-shaped, circular, etc.) may be used as is desired in the specific application. Exemplary fiducials may be approximately 50-100 μm in overall width and/or height (although fiducials of <50 μm and >100 μm may be used in connection with the invention).
[0028] To provide fiducial alignment data, an imaging system may be used. In certain exemplary embodiments of the invention, a beam splitter may be used (see optical element 116 of
[0029] In certain exemplary embodiments of the invention, a scanning mirror (sometimes referred to as a steering mirror) may be used (see mirror 126 of
[0030] Referring now to
[0031] In
[0032] In
[0033] In
[0034]
[0035] Referring specifically to
[0036] In
[0037] Referring now to
[0038] In
[0039] In
[0040] Although the invention is described primarily with respect to motion systems (e.g., coarse motion systems, fine motion systems, etc.) in a bond head assembly for aligning a die with a substrate, the invention is not limited thereto. That is, adjustments for coarse and/or fine alignment may be made by a substrate motion system (alone or in combination with motion systems in the bond head assembly).
[0041] Although the invention is largely described in connection with bond tools that are infrared transparent (or include an infrared transparent holding portion), the invention is not limited thereto. Aspects of the invention relate to imaging through a bond tool (e.g., see
[0042] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.