TW202119487A - 晶圓的加工方法 - Google Patents
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Abstract
[課題]在不使品質降低的情形下形成器件晶片。
[解決手段] 一種晶圓的加工方法,是將形成有複數個器件的晶圓分割成一個個的器件晶片,前述晶圓的加工方法具備以下步驟:聚烯烴系片材配設步驟,將晶圓定位在具有容置晶圓之開口的框架的該開口內,並將聚烯烴系片材配設在晶圓的背面或正面、及框架的外周;一體化步驟,將該聚烯烴系片材加熱並藉由熱壓接來將晶圓與該框架透過該聚烯烴系片材一體化;分割步驟,沿著分割預定線對該晶圓照射對該晶圓具有穿透性之波長的雷射光束而於該晶圓形成屏護通孔,且將該晶圓分割成一個個的器件晶片;及拾取步驟,對該聚烯烴系片材賦與超音波,並將器件晶片頂推,且拾取該器件晶片。
Description
本發明是有關於一種讓已將複數個器件形成在藉由分割預定線所區劃出的正面的各區域中之晶圓分割成一個個的器件晶片之晶圓的加工方法。
在使用於行動電話或者個人電腦等之電子機器的器件晶片的製造步驟中,首先是將複數條交叉的分割預定線(切割道)設定在由半導體等之材料所構成的晶圓的正面。並且,在以該分割預定線所區劃的各區域中形成IC(積體電路,Integrated Circuit)、LSI(大型積體電路,Large-Scale Integration)、LED(發光二極體,Light Emitting Diode)等器件。
之後,將對具有開口之環狀的框架黏貼成堵塞該開口之稱為切割膠帶的黏著膠帶貼附在該晶圓的背面或正面,而形成晶圓、黏著膠帶及環狀的框架成為一體的框架單元。然後,當將包含於框架單元的晶圓沿著該分割預定線加工來分割後,即形成一個個的器件晶片。
在晶圓之分割上,所使用的是例如雷射加工裝置。雷射加工裝置具備隔著黏著膠帶來保持晶圓的工作夾台、及以將聚光點定位於該晶圓的內部之狀態來將對晶圓具有穿透性之波長的雷射光束照射於該晶圓的雷射加工單元。
在分割晶圓時,是將框架單元載置於工作夾台之上,並且使晶圓隔著黏著膠帶來保持在工作夾台。然後,一邊使工作夾台與雷射加工單元沿著平行於工作夾台的上表面之方向相對移動,一邊沿著各分割預定線來從該雷射加工單元接連地對晶圓照射該雷射光束。
當對晶圓照射該雷射光束後,即沿著分割預定線接連地形成稱為屏護通孔(shield tunnel)之絲(filament)狀的區域。此屏護通孔是由沿著晶圓的厚度方向的細孔、及圍繞該細孔之非晶質區域所構成,且成為晶圓的分割起點(參照專利文獻1)。
之後,當從雷射加工裝置搬出框架單元,並將黏著膠帶朝徑方向外側擴張後,即可將晶圓分割而形成一個個的器件晶片。在從黏著膠帶拾取已形成之器件晶片時,是預先施行對黏著膠帶照射紫外線等之處理來使黏著膠帶的黏著力降低。作為器件晶片之生產效率較高的加工裝置,已知有可以將晶圓的分割、及對黏著膠帶之紫外線的照射以一個裝置來連續實施的加工裝置(參照專利文獻2)。
先前技術文獻
專利文獻
專利文獻1:日本特許第6151557號公報
專利文獻2:日本特許第3076179號公報
發明欲解決之課題
黏著膠帶包含以例如氯乙烯片材等所形成的基材層、及配設於該基材層上的糊層。在雷射加工裝置中,會為了將成為分割起點的屏護通孔形成於晶圓而對晶圓的內部照射雷射光束。此時,該雷射光束的漏光的一部分會到達黏著膠帶的糊層。並且,因由雷射光束之照射所造成的熱的影響,而讓黏著膠帶的糊層熔融,且糊層的一部分固著在由晶圓形成的器件晶片的背面側或正面側。
在此情況下,在從黏著膠帶拾取器件晶片時即使實施對黏著膠帶照射紫外線等的處理,也會導致在所拾取之器件晶片的背面或正面側殘存有糊層的該一部分。因此,器件晶片的品質降低即成為問題。
本發明是有鑒於所述的問題點而作成的發明,其目在於提供一種晶圓的加工方法,前述晶圓的加工方法是不讓糊層附著在形成之器件晶片的背面或正面側,以免在器件晶片產生源自糊層之附著的品質的降低。
用以解決課題之手段
根據本發明之一態樣,是提供一種晶圓的加工方法,前述晶圓的加工方法是讓已將複數個器件形成在藉由分割預定線所區劃出的正面的各區域中之晶圓分割成一個個的器件晶片,前述晶圓的加工方法的特徵在於具備以下步驟:
聚烯烴系片材配設步驟,將晶圓定位在具有容置晶圓之開口的框架的該開口內,並將聚烯烴系片材配設在該晶圓的背面或正面、及該框架的外周;
一體化步驟,將該聚烯烴系片材加熱並藉由熱壓接來將該晶圓與該框架透過該聚烯烴系片材一體化;
分割步驟,將對該晶圓具有穿透性之波長的雷射光束的聚光點定位在該晶圓的內部,並沿著該分割預定線來對該晶圓照射該雷射光束而於該晶圓連續地形成屏護通孔,且將該晶圓分割成一個個的器件晶片;及
拾取步驟,在該聚烯烴系片材之對應於各器件晶片的一個個的區域中,對該聚烯烴系片材賦與超音波,並從該聚烯烴系片材側將該器件晶片頂推,且從該聚烯烴系片材拾取該器件晶片。
較佳的是,在該一體化步驟中,藉由紅外線的照射而實施該熱壓接。
又,較佳的是,在該一體化步驟中,在實施一體化後,將從該框架之外周超出的聚烯烴系片材去除。
又,較佳的是,在該拾取步驟中,是將該聚烯烴系片材擴張,以將各器件晶片間的間隔擴大。
又,較佳的是,該聚烯烴系片材是聚乙烯片材、聚丙烯片材、聚苯乙烯片材之任一種。
此外,較佳的是,在該一體化步驟中,在該聚烯烴系片材為該聚乙烯片材的情況下,加熱溫度為120℃~140℃,在該聚烯烴系片材為該聚丙烯片材的情況下,加熱溫度為160℃~180℃,在該聚烯烴系片材為該聚苯乙烯片材的情況下,加熱溫度為220℃~240℃。
又,較佳的是,該晶圓是以矽(Si)、氮化鎵(GaN)、砷化鎵(GaAs)、玻璃之任一種所構成。
發明效果
在本發明之一態樣的晶圓的加工方法中,是在形成框架單元時,不使用具有糊層的黏著膠帶,而是使用未具備糊層的聚烯烴系片材來將框架及晶圓一體化。透過聚烯烴系片材來使框架及晶圓一體化的一體化步驟,是藉由熱壓接來實現。
實施一體化步驟後,是對晶圓照射對晶圓具有穿透性之波長的雷射光束,而沿著分割預定線連續地形成屏護通孔來分割該晶圓。之後,在聚烯烴系片材之對應於各器件晶片的一個個的區域中,對該聚烯烴系片材賦與超音波,並從該聚烯烴系片材側將該器件晶片頂推,而從該聚烯烴系片材拾取器件晶片。所拾取的器件晶片是各自組裝到預定的組裝對象。再者,若在拾取時對聚烯烴系片材賦與超音波,可以讓聚烯烴系片材的剝離變得較容易而減輕施加於器件晶片的負荷。
在晶圓的內部形成屏護通孔之時,雷射光束的漏光會到達聚烯烴系片材。然而,因為聚烯烴系片材不具備糊層,所以不會有該糊層熔融而固著於器件晶片的背面或正面側之情形。
也就是說,根據本發明的一態樣,因為可以使用不具備糊層的聚烯烴系片材來形成框架單元,所以不需要具備有糊層的黏著膠帶,結果,不會產生起因於糊層之附著的器件晶片的品質降低。
從而,根據本發明之一態樣,可提供一種晶圓的加工方法,前述晶圓的加工方法是不讓糊層附著在形成之器件晶片的背面或正面側,以免在器件晶片產生源自糊層之附著的品質的降低。
用以實施發明的形態
參照附圖,說明本發明之一態樣的實施形態。首先,說明以本實施形態之晶圓的加工方法所加工之晶圓。圖1(A)是示意地顯示晶圓1的正面的立體圖,圖1(B)是示意地顯示晶圓1的背面的立體圖。
晶圓1是例如由Si(矽)、SiC(碳化矽)、GaN(氮化鎵)、GaAs(砷化鎵)、或者是其他之半導體等的材料、又或是藍寶石、玻璃、石英等的材料所構成之大致圓板狀的基板等。該玻璃可為例如鹼玻璃、無鹼玻璃、鈉鈣玻璃、鉛玻璃、硼矽酸玻璃、石英玻璃等。
晶圓1的正面1a是以格子狀地配置排列之複數條分割預定線3所區劃。又,在晶圓1的正面1a之以分割預定線3所區劃出的各個區域中可形成IC或LSI、LED等的器件5。在本實施形態之晶圓1的加工方法中,是沿著分割預定線3在晶圓1連續地形成屏護通孔,且以該屏護通孔為起點來將晶圓1分割而形成一個個的器件晶片。
在晶圓1形成屏護通孔之時,是將對晶圓1具有穿透性之波長的雷射光束沿著分割預定線3對晶圓1照射,並使該雷射光束聚光於晶圓1的內部。此時,該雷射光束亦可從圖1(A)所示之正面1a側對晶圓1照射、或者亦可從圖1(B)所示之背面1b側對晶圓1照射。再者,在從背面1b側對晶圓1照射雷射光束的情況下,是使用具備有紅外線相機的校準組件來穿透晶圓1而檢測正面1a側的分割預定線3,且沿著分割預定線3來照射雷射光束。
將晶圓1搬入實施雷射加工的雷射加工裝置12(參照圖8(A))之前,將晶圓1、聚烯烴系片材與框架一體化而形成框架單元,其中前述雷射加工是在晶圓1形成屏護通孔之加工。晶圓1是以框架單元的狀態來搬入雷射加工裝置12,並進行加工。
然後,當將聚烯烴系片材擴張後,即可以分割晶圓1,並將藉由分割晶圓1而形成的一個個的器件晶片支撐於該聚烯烴系片材。之後,藉由將聚烯烴系片材進一步擴張,而將器件晶片之間的間隔擴大,並藉由拾取裝置來拾取器件晶片。
環狀的框架7(參照圖2等)是以例如金屬等之材料所形成,並且具備直徑比晶圓1的直徑更大的開口7a。在形成框架單元時,是將晶圓1定位在框架7的開口7a內,而容置在開口7a。
聚烯烴系片材9(參照圖3等)是具有柔軟性的樹脂系片材,且正面、背面平坦。並且,聚烯烴系片材9具有比框架7的外徑更大的直徑,且不具備糊層。聚烯烴系片材9是將烯烴(alkene)作為單體所合成之聚合物的片材,可為例如聚乙烯片材、聚丙烯片材或聚苯乙烯片材等之對可見光為透明或者半透明的片材。但是,聚烯烴系片材9並非限定於此,亦可為不透明。
因為聚烯烴系片材9不具備黏著性,所以在室溫下無法貼附在晶圓1及框架7。但是,因為聚烯烴系片材9具有熱可塑性,所以若一邊施加預定的壓力一邊在已使其與晶圓1及框架7接合的狀態下加熱至熔點附近的溫度時,會部分地熔融而可以接著於晶圓1及框架7。於是,在本實施形態之晶圓1的加工方法中,是藉由如以上的熱壓接,將晶圓1、框架7及聚烯烴系片材9一體化來形成框架單元。
接著,說明本實施形態之晶圓1的加工方法的各步驟。首先,是為了使晶圓1、聚烯烴系片材9及框架7一體化的準備,而實施聚烯烴系片材配設步驟。圖2是示意地顯示將晶圓1及框架7定位在工作夾台2的保持面2a上之情形的立體圖。如圖2所示,聚烯烴系片材配設步驟是在上部具備保持面2a的工作夾台2上實施。
工作夾台2於上部中央具備直徑比框架7的外徑更大的多孔質構件。該多孔質構件的上表面是成為工作夾台2的保持面2a。工作夾台2是如圖3所示地於內部具有一端通到該多孔質構件的排氣路,且於該排氣路的另一端側配設吸引源2b。於排氣路上配設有切換連通狀態及切斷狀態的切換部2c,當切換部2c為連通狀態時,即可讓藉由吸引源2b對放置於保持面2a的被保持物所產生的負壓作用,而將被保持物吸引保持在工作夾台2。
在聚烯烴系片材配設步驟中,首先,是如圖2所示,將晶圓1及框架7載置於工作夾台2的保持面2a上,並將晶圓1定位到框架7的開口7a內。
此時,是考慮將在後述之分割步驟中照射雷射光束的被照射面設成正面1a及背面1b的哪一面,來選擇晶圓1的方向。例如,當將該被照射面設為正面1a的情況下,讓正面1a側朝向下方。又,例如,當將該被照射面設為背面1b的情況下,讓背面1b側朝向下方。以下,雖然是以將雷射光束的被照射面設為正面1a的情況為例來說明本實施形態之晶圓的加工方法,但晶圓1的方向並不限定於此。
將晶圓1、框架7載置於工作夾台2之保持面2a上之後,將聚烯烴系片材9配設於晶圓1之背面1b(或正面1a)及框架7之外周。圖3是示意地顯示聚烯烴系片材配設步驟的立體圖。如圖3所示,以覆蓋晶圓1及框架7的方式,來將聚烯烴系片材9配設在兩者之上。
再者,在聚烯烴系片材配設步驟中,是使用直徑比工作夾台2的保持面2a更大的聚烯烴系片材9。這是因為在之後所實施的一體化步驟中使由工作夾台2所形成的負壓作用在聚烯烴系片材9時,若未將保持面2a的整體以聚烯烴系片材9來覆蓋的話,會導致負壓從間隙漏出,而無法適當地對聚烯烴系片材9施加壓力的緣故。
在本實施形態之晶圓1的加工方法中,接著是實施一體化步驟,前述一體化步驟是將聚烯烴系片材9加熱,並藉由熱壓接來將晶圓1及該框架7透過該聚烯烴系片材9一體化。圖4是示意地顯示一體化步驟之一例的立體圖。在圖4中,是將可以通過對於可見光為透明或者半透明之聚烯烴系片材9來目視辨識的構成以虛線表示。
在一體化步驟中,首先,是使工作夾台2的切換部2c作動來設為連通狀態,而使由吸引源2b所形成的負壓作用於聚烯烴系片材9,其中前述連通狀態是將吸引源2b連接於工作夾台2之上部的多孔質構件的狀態。如此一來,即藉由大氣壓來使聚烯烴系片材9相對於晶圓1及框架7密合。
接著,一邊藉由吸引源2b吸引聚烯烴系片材9,一邊將聚烯烴系片材9加熱來實施熱壓接。聚烯烴系片材9的加熱是如例如圖4所示,藉由配設在工作夾台2之上方的熱風槍4來實施。
熱風槍4是在內部具備電熱線等的加熱組件及風扇等的送風機構,而可以將空氣加熱並噴射。當一邊使負壓作用在聚烯烴系片材9,一邊藉由熱風槍4從上面對聚烯烴系片材9供給熱風4a,而將聚烯烴系片材9加熱至預定的溫度時,可將聚烯烴系片材9熱壓接於晶圓1及框架7。
又,聚烯烴系片材9的加熱亦可藉由其他方法來實施,例如可藉由從上方以加熱至預定的溫度的構件來按壓晶圓1及框架7而實施。圖5是示意地顯示一體化步驟的另一例的立體圖。在圖5中,是將可以通過對於可見光為透明或者半透明之聚烯烴系片材9來目視辨識的構成以虛線表示。
在圖5所示之一體化步驟中,是使用例如在內部具備熱源的加熱滾輪6。在圖5所示之一體化步驟中,也是首先使藉由吸引源2b所形成的負壓作用在聚烯烴系片材9,並藉由大氣壓來使聚烯烴系片材9密合於晶圓1及框架7。
之後,將加熱滾輪6加熱至預定的溫度,並將該加熱滾輪6載置於工作夾台2的保持面2a的一端。然後,使加熱滾輪6旋轉,並讓加熱滾輪6在工作夾台2上從該一端滾動至另一端。如此一來,可將聚烯烴系片材9熱壓接於晶圓1及框架7。此時,若藉由加熱滾輪6朝將聚烯烴系片材9往下壓的方向施加力,即以比大氣壓更大的壓力實施熱壓接。再者,較佳的是,將加熱滾輪6的表面以氟樹脂被覆。
又,亦可使用在內部具備熱源且具有平坦之底板的熨斗狀的按壓構件來取代加熱滾輪6,而實施聚烯烴系片材9的熱壓接。在此情況下,將該按壓構件加熱至預定的溫度來作為熱板,並從上方以該按壓構件按壓保持在工作夾台2的聚烯烴系片材9。
聚烯烴系片材9的加熱亦可進一步藉由其他的方法來實施。圖6是示意地顯示一體化步驟的又另一例的立體圖。在圖6中,是將可以通過對於可見光為透明或者半透明之聚烯烴系片材9來目視辨識的構成以虛線表示。在圖6所示之一體化步驟中,是使用配設在工作夾台2的上方的紅外線燈8來加熱聚烯烴系片材9。紅外線燈8可照射至少聚烯烴系片材9之材料具有吸收性之波長的紅外線8a。
在圖6所示之一體化步驟中,也是首先使藉由吸引源2b所形成的負壓作用在聚烯烴系片材9,而使聚烯烴系片材9密合於晶圓1及框架7。接著,使紅外線燈8作動,以對聚烯烴系片材9照射紅外線8a來加熱聚烯烴系片材9。如此一來,可將聚烯烴系片材9熱壓接於晶圓1及框架7。
當藉由任一種方法來將聚烯烴系片材9加熱至其熔點附近的溫度時,即可將聚烯烴系片材9熱壓接於晶圓1及框架7。將聚烯烴系片材9熱壓接之後,使切換部2c作動而解除工作夾台2的多孔質構件與吸引源2b的連通狀態,並解除由工作夾台2所進行的吸附。
接著,將從框架7之外周超出的聚烯烴系片材9切斷並去除。圖7(A)是示意地顯示將聚烯烴系片材9切斷之情形的立體圖。切斷是如圖7(A)所示,使用圓環狀的刀具(cutter)10。該刀具10具備貫通孔,且可繞著貫穿於該貫通孔的旋轉軸旋轉。
首先,將圓環狀的刀具10定位在框架7的上方。此時,將刀具10的旋轉軸對齊於工作夾台2的徑方向。接著,使刀具10下降,並以框架7及刀具10將聚烯烴系片材9夾入,而將聚烯烴系片材9切斷。如此一來,可在聚烯烴系片材9形成切斷痕跡9a。
此外,使刀具10沿著框架7於框架7的開口7a的周圍繞行一圈,並藉由切斷痕跡9a包圍聚烯烴系片材9之預定的區域。然後,以留下聚烯烴系片材9之該區域的方式,將切斷痕跡9a之外周側的區域的聚烯烴系片材9去除。如此一來,可以將聚烯烴系片材9之包含從框架7之外周超出之區域在內的不要的部分去除。
再者,在聚烯烴系片材的切斷上,亦可使用超音波刀具,並將以超音波頻帶之頻率來使上述之圓環狀的刀具10振動的振動源連接於該刀具10。又,在切斷聚烯烴系片材9時,亦可為了容易地切斷,而將該聚烯烴系片材9冷卻來使其硬化。藉由以上,可形成將晶圓1及框架7透過聚烯烴系片材9一體化的框架單元11。圖7(B)是示意地顯示所形成的框架單元11的立體圖。
再者,在實施熱壓接時,宜將聚烯烴系片材9加熱至其熔點以下的溫度。這是因為若加熱溫度超過熔點時,會有下述情形的緣故:聚烯烴系片材9熔化而變得無法維持片材的形狀。又,較佳的是,將聚烯烴系片材9加熱至其軟化點以上的溫度。這是因為若加熱溫度未達到軟化點的話,會無法適當地實施熱壓接。也就是,較佳的是,將聚烯烴系片材9加熱至其軟化點以上且其熔點以下的溫度。
此外,也有下述情況:一部分的聚烯烴系片材9不具有明確的軟化點。於是,在實施熱壓接時,宜將聚烯烴系片材9加熱至比其熔點低20℃的溫度以上且其熔點以下的溫度。
又,在聚烯烴系片材9為聚乙烯片材的情況下,宜將加熱溫度設為120℃~140℃。又,在該聚烯烴系片材9為聚丙烯片材的情況下,宜將加熱溫度設為160℃~180℃。此外,在聚烯烴系片材9為聚苯乙烯片材的情況下,宜將加熱溫度設為220℃~240℃。
在此,加熱溫度是指在實施一體化步驟時之聚烯烴系片材9的溫度。雖然在例如熱風槍4、加熱滾輪6及紅外線燈8等的熱源中,已將可以設定輸出溫度的機種提供於實用,但即便使用該熱源來加熱聚烯烴系片材9,也會有下述情況:聚烯烴系片材9的溫度並未到達所設定之該輸出溫度。於是,為了將聚烯烴系片材9加熱至預定的溫度,亦可將熱源的輸出溫度設定得比聚烯烴系片材9的熔點更高。
接著,在本實施形態之晶圓的加工方法中,實施分割步驟,前述分割步驟是對已成為框架單元11之狀態的晶圓1進行雷射加工,而沿著分割預定線3接連地在晶圓1形成屏護通孔來分割該晶圓1。分割步驟是例如以圖8(A)所示之雷射加工裝置來實施。圖8(A)是示意地顯示分割步驟的立體圖,圖8(B)是示意地顯示分割步驟的截面圖。
雷射加工裝置12具備對晶圓1照射雷射光束16的雷射加工單元14、及保持晶圓1的工作夾台(未圖示)。雷射加工單元14具備可以振盪產生雷射的雷射振盪器(未圖示),且可以出射對晶圓1具有穿透性之波長的(可以穿透晶圓1之波長的)雷射光束16。該工作夾台可以沿著平行於上表面的方向移動(加工進給)。
雷射加工單元14是將從該雷射振盪器出射之雷射光束16照射至已保持於該工作夾台的晶圓1。雷射加工單元14所具備的加工頭14a具有將雷射光束16的聚光點14b定位在晶圓1的內部之預定的高度位置的機構。加工頭14a在內部具備聚光透鏡(未圖示)。該聚光透鏡之數值孔徑(NA)是決定成:數值孔徑(NA)除以晶圓1之折射率(N)之值落在0.05~0.2的範圍。
在對晶圓1進行雷射加工時,是將框架單元11載置於工作夾台之上,並且使晶圓1隔著聚烯烴系片材9而保持在工作夾台。接著,使工作夾台旋轉,並將晶圓1的分割預定線3對齊於雷射加工裝置12的加工進給方向。又,將工作夾台及雷射加工單元14的相對位置調整成將加工頭14a配設在分割預定線3之延長線的上方。然後,將雷射光束16的聚光點14b定位在預定的高度位置上。
接著,一邊從雷射加工單元14對晶圓1的內部接連地照射雷射光束16一邊使工作夾台及雷射加工單元14沿著平行於工作夾台的上表面的加工進給方向來相對移動。亦即,將雷射光束16的聚光點14b定位在晶圓1的內部,且沿著分割預定線3來對晶圓1照射雷射光束16。
如此一來,即沿著分割預定線3接連地形成稱為屏護通孔3a之絲(filament)狀的區域。於圖8(B)示意地顯示有連續地形成有屏護通孔3a之晶圓1的截面圖。又,圖8(C)是示意地顯示屏護通孔3a的立體圖。屏護通孔3a是由沿著晶圓1的厚度方向的細孔3b、及圍繞該細孔3b之非晶質區域3c所構成。再者,在圖8(A)中是將沿著分割預定線3排列的屏護通孔3a以實線來顯示。
分割步驟中的雷射光束16的照射條件是設定為例如以下之形式。然而,雷射光束16的照射條件並非限定於此。
波長 :1030nm
平均輸出 :3W
重複頻率 :50kHz
脈衝寬度 :10ps
聚光光斑直徑 :φ10μm
進給速度 :500mm/秒
當像這樣對晶圓1照射雷射光束16後,即可沿著分割預定線3並以10μm間隔在晶圓1形成屏護通孔3a。並且,所形成的各自的屏護通孔3a包含φ1μm左右的細孔3b、及φ10μm左右的非晶質區域3c。因此,如圖8(B)所示,彼此相鄰的屏護通孔3a會成為彼此之非晶質區域3c連接的形態。
在沿著一條分割預定線3於晶圓1形成屏護通孔3a之後,使工作夾台及雷射加工單元14在與加工進給方向垂直的分度進給方向上相對地移動,並沿著其他的分割預定線3同樣地對晶圓1進行雷射加工。於沿著一個方向之全部的分割預定線3上沿著來形成屏護通孔3a後,使工作夾台繞著垂直於保持面的軸旋轉,並同樣地於沿著其他方向之分割預定線3上沿著來對晶圓1進行雷射加工。
在此,當藉由雷射加工單元14將雷射光束16朝晶圓1照射來形成屏護通孔3a時,該雷射光束16的漏光會到達晶圓1的下方的聚烯烴系片材9。
在例如對框架單元11並非使用聚烯烴系片材9而是使用黏著膠帶的情況下,當雷射光束16的漏光照射到該黏著膠帶的糊層時,會使黏著膠帶的糊層熔融,而使糊層的一部分固著於晶圓1的背面1b側。在此情況下,導致在已將晶圓1分割而形成的器件晶片的背面側殘存有糊層的該一部分。因此,器件晶片的品質的降低即成為問題。
相對於此,在本實施形態之晶圓的加工方法中,是在框架單元11使用不具備糊層的聚烯烴系片材9。因此,即使雷射光束16的漏光到達聚烯烴系片材9,也不會有糊層固著於晶圓1的背面1b側之情形。從而,可將由晶圓1所形成的器件晶片的品質保持得較良好。
其次,藉由將聚烯烴系片材9朝徑方向外側擴張來將晶圓1分割而形成器件晶片。之後,實施從聚烯烴系片材9拾取一個個的該器件晶片的拾取步驟。於聚烯烴系片材9之擴張時,是使用圖9下部所示之拾取裝置18。圖9是示意地顯示框架單元11往拾取裝置18之搬入的立體圖。
拾取裝置18具備圓筒狀的圓筒20及框架保持單元22,前述圓筒20具有比晶圓1的直徑更大的直徑,前述框架保持單元22包含框架支撐台26。框架保持單元22的框架支撐台26具備直徑比該圓筒20的直徑更大的開口,且是配設在與該圓筒20的上端部同樣的高度,而從外周側包圍該圓筒20的上端部。
在框架支撐台26的外周側配設有夾具24。當將框架單元11載置於框架支撐台26之上,且藉由夾具24把持框架單元11的框架7後,即可將框架單元11固定在框架支撐台26。
框架支撐台26是被沿著鉛直方向伸長的複數支桿件28所支撐,在各桿件28的下端部配設有使該桿件28升降的氣缸30。複數個氣缸30是支撐在圓板狀的基座32。當使各氣缸30作動時,可將框架支撐台26相對於圓筒20下拉。
在圓筒20的內部配設有頂推機構34,前述頂推機構34是從下方將支撐在聚烯烴系片材9的器件晶片頂推。頂推機構34於上端具備例如由鋯鈦酸鉛(PZT)、鈦酸鋇、鈦酸鉛等壓電陶瓷、或晶體振動器等所構成的超音波振動器34a。又,在圓筒20的上方配設有可以吸引保持器件晶片的夾頭36(參照圖10(B))。頂推機構34及夾頭36可在沿著框架支撐台26之上表面的水平方向上移動。又,夾頭36是透過切換部36b(參照圖10(B))而連接於吸引源36a(參照圖10(B))。
將聚烯烴系片材9擴張時,首先,是使氣缸30作動來調節框架支撐台26的高度,以使拾取裝置18之圓筒20的上端的高度與框架支撐台26的上表面的高度一致。接著,將從雷射加工裝置12所搬出的框架單元11載置於拾取裝置18的圓筒20及框架支撐台26之上。
之後,藉由夾具24將框架單元11的框架7固定在框架支撐台26之上。圖10(A)是示意地顯示已固定於框架支撐台26之上的框架單元11的截面圖。於晶圓1形成有沿著分割預定線3排列的屏護通孔3a。
接著,使氣缸30作動,以將框架保持單元22的框架支撐台26相對於圓筒20下拉。如此一來,如圖10(B)所示,可將聚烯烴系片材9朝徑方向外側擴張。圖10(B)是示意地顯示已擴張之聚烯烴系片材9的截面圖。
當將聚烯烴系片材9擴張後,會使朝向徑方向外側之力作用於晶圓1,而以屏護通孔3a作為起點來將晶圓1分割而形成一個個的器件晶片1c。若進一步擴張聚烯烴系片材9的話,即可將被聚烯烴系片材9所支撐之各器件晶片1c的間隔擴大,而使一個個的器件晶片1c的拾取變得較容易。
在本實施形態之晶圓的加工方法中,是在將晶圓1分割而形成一個個的器件晶片1c之後,實施從聚烯烴系片材9拾取器件晶片1c的拾取步驟。在拾取步驟中,是決定成為拾取之對象的器件晶片1c,並且使頂推機構34移動至該器件晶片1c的下方,且使夾頭36移動至該器件晶片1c的上方。
之後,使超音波振動器34a作動而產生超音波頻帶的頻率之振動,並使超音波振動器34a接觸於聚烯烴系片材9之對應於該器件晶片1c的區域來對該區域賦與超音波。此外,藉由使頂推機構34作動,而從聚烯烴系片材9側將該器件晶片1c頂推。然後,使切換部36b作動而使夾頭36連通於吸引源36a。如此一來,可藉由夾頭36吸引保持該器件晶片1c,而從聚烯烴系片材9拾取器件晶片1c。所拾取的一個個的器件晶片1c是在之後組裝到預定的配線基板等來使用。
再者,若藉由超音波振動器34a對聚烯烴系片材9的該區域賦與超音波,聚烯烴系片材9的剝離即變得較容易。因此,可將自聚烯烴系片材9的剝離時施加於器件晶片的負荷減輕。
在例如使用黏著膠帶來形成框架單元11的情況下,在分割步驟中照射於晶圓1之雷射光束16的漏光到達黏著膠帶,而使黏著膠帶的糊層固著於器件晶片的背面側。然後,由糊層之附著所造成的器件晶片的品質的降低即成為問題。
相對於此,根據本實施形態之晶圓的加工方法,因為藉由熱壓接而讓使用了不具備糊層之聚烯烴系片材9的框架單元11的形成變得可能,所以不需要具備有糊層的黏著膠帶。結果,不會產生因糊層對背面側的附著所造成的器件晶片的品質降低。
再者,本發明並不限定於上述實施形態之記載,可作各種變更而實施。例如在上述實施形態中,雖然說明了聚烯烴系片材9可為例如聚乙烯片材、聚丙烯片材或聚苯乙烯片材的情況,但本發明之一態樣並不限定於此。例如,聚烯烴系片材亦可使用其他材料,亦可是丙烯及乙烯的共聚物、或者是烯烴系彈性體等。
另外,上述實施形態之構造、方法等,只要在不脫離本發明的目的之範圍下,均可適當變更而實施。
1:晶圓
1a:正面
1b:背面
1c:器件晶片
2:工作夾台
2a:保持面
2b,36a:吸引源
2c,36b:切換部
3:分割預定線
3a:屏護通孔
3b:細孔
3c:非晶質區域
4:熱風槍
4a:熱風
5:器件
6:加熱滾輪
7:框架
7a:開口
8:紅外線燈
8a:紅外線
9:聚烯烴系片材
9a:切斷痕跡
10:刀具
11:框架單元
12:雷射加工裝置
14:雷射加工單元
14a:加工頭
14b:聚光點
16:雷射光束
18:拾取裝置
20:圓筒
22:框架保持單元
24:夾具
26:框架支撐台
28:桿件
30:氣缸
32:基座
34:頂推機構
34a:超音波振動器
36:夾頭
圖1(A)是示意地顯示晶圓的正面的立體圖,圖1(B)是示意地顯示晶圓的背面的立體圖。
圖2是示意地顯示將晶圓及框架定位在工作夾台的保持面上之情形的立體圖。
圖3是示意地顯示聚烯烴系片材配設步驟的立體圖。
圖4是示意地顯示一體化步驟之一例的立體圖。
圖5是示意地顯示一體化步驟之一例的立體圖。
圖6是示意地顯示一體化步驟之一例的立體圖。
圖7(A)是示意地顯示將聚烯烴系片材切斷之情形的立體圖,圖7(B)是示意地顯示所形成的框架單元的立體圖。
圖8(A)是示意地顯示分割步驟的立體圖,圖8(B)是示意地顯示分割步驟的截面圖,圖8(C)是示意地顯示屏護通孔的立體圖。
圖9是示意地顯示框架單元往拾取裝置之搬入的立體圖。
圖10(A)是示意地顯示已固定在框架支撐台之上的框架單元的截面圖,圖10(B)是示意地顯示拾取步驟的截面圖。
1:晶圓
1b:背面
2:工作夾台
2a:保持面
2b:吸引源
2c:切換部
4:熱風槍
4a:熱風
7:框架
7a:開口
9:聚烯烴系片材
Claims (7)
- 一種晶圓的加工方法,是讓已將複數個器件形成在藉由分割預定線所區劃出的正面的各區域中之晶圓分割成一個個的器件晶片,前述晶圓的加工方法的特徵在於具備以下步驟: 聚烯烴系片材配設步驟,將晶圓定位在具有容置晶圓之開口的框架的該開口內,並將聚烯烴系片材配設在該晶圓的背面或該正面、及該框架的外周; 一體化步驟,將該聚烯烴系片材加熱並藉由熱壓接來將該晶圓與該框架透過該聚烯烴系片材一體化; 分割步驟,將對該晶圓具有穿透性之波長的雷射光束的聚光點定位在該晶圓的內部,並沿著該分割預定線來對該晶圓照射該雷射光束而於該晶圓連續地形成屏護通孔,且將該晶圓分割成一個個的器件晶片;及 拾取步驟,在該聚烯烴系片材之對應於各器件晶片的一個個的區域中,對該聚烯烴系片材賦與超音波,並從該聚烯烴系片材側將該器件晶片頂推,且從該聚烯烴系片材拾取該器件晶片。
- 如請求項1之晶圓的加工方法,其中在該一體化步驟中,藉由紅外線的照射而實施該熱壓接。
- 如請求項1之晶圓的加工方法,其中在該一體化步驟中,在實施一體化後,將從該框架之外周超出的聚烯烴系片材去除。
- 如請求項1之晶圓的加工方法,其中在該拾取步驟中,是將該聚烯烴系片材擴張,以將各器件晶片間的間隔擴大。
- 如請求項1之晶圓的加工方法,其中該聚烯烴系片材是聚乙烯片材、聚丙烯片材、聚苯乙烯片材之任一種。
- 如請求項5之晶圓的加工方法,其中在該一體化步驟中,在該聚烯烴系片材為該聚乙烯片材的情況下,加熱溫度為120℃~140℃,在該聚烯烴系片材為該聚丙烯片材的情況下,加熱溫度為160℃~180℃,在該聚烯烴系片材為該聚苯乙烯片材的情況下,加熱溫度為220℃~240℃。
- 如請求項1之晶圓的加工方法,其中該晶圓是以矽、氮化鎵、砷化鎵、玻璃之任一種所構成。
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