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`United States Patent 19
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`Negoro
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`CARAA
`US005411921A
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`[11] Patent Number:
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`[45] Date of Patent:
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`5,411,921
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`May 2, 1995
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`[54] SEMICONDUCTOR CHIP DIE BONDING
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`USING A DOUBLE-SIDED ADHESIVE TAPE
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`Inventor: Atsuhito Negoro, Kyoto, Japan
`[75]
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`[73] Assignee: Rohm Co., Ltd., Kyoto, Japan
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`[21] Appl. No.: 218,764
`[22] Filed:
`Mar.28, 1994
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`4,590,667 5/1986 Simo cseesssseccsesseeceeee 148/DIG.28
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`4,667,402
`5/1987 Wilde.....
`sesees 437/224
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`5,110,388
`5/1952 Komiyamaet
`.. 156/249
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`5,270,260 12/1993 Scheunenpflug .casenstensesensess 437/212
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`Primary Examiner—Brian E. Hearn
`Assistant Examiner—Kevin M.Picardat
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`Attorney, Agent, or Firm—Brambaugh, Graves,
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`Donohue & Raymond
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`ABSTRACT
`[57]
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`Related U.S. Application Data
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`A semiconductor wafer is stuck on an expandable tape
`Division of Ser. No. 13,754, Feb. 4, 1993.
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`via a double-sided adhesive tape, and the semiconductor
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`Foreign Application Priority Data
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`wafer is diced into semiconductor chips such that the
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`double-sided adhesive tape is also cut into tape sections.
`Feb. 10, 1992 [JP]Japanwaccsccsscsscssssescssssccssssens 4.023731
`Japan ......
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`Then, the expandable tape is expanded to deform plasti-
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`FSU] Mint, CLS ccccccceccccsessssssssssssesseevesssens HO1L 21/60
`cally to thereby part the semiconductor chips from each
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`TS2] US. CL. cessccccsccscsssssecessesesseseees 437/217; 437/209:
`other. Then, the semiconductor chip and the tape sec-
`437/215; 437/219; 437/220
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`tion stuck thereto is removed from the expandabletape,
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`[58] Field of Search .............. 437/209, 211, 212, 213,
`in which the semiconductor chip is pushed by a bar
`437/214, 215, 216, 217, 218, 219, 220; 156/247,
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`having a pointed tip while the expandable tape is vacu-
`248, 249, 250; 148/DIG. 28
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`um-sucked. Finally, the semiconductor chip is bonded
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`to a die pad of a lead frame via the tape section stuck to
`References Cited
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`the semiconductor chip.
`U.S. PATENT DOCUMENTS
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`6/1975 Hartleroad et al... 437/209
`5 Claims, 2 Drawing Sheets
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`[56]
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`3,887,996
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`MICRON 1031
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`MICRON 1031
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`U.S. Patent
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`May 2, 1995
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`Sheet 1 of 2
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`5,411,921
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`FIG.
`7
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`Eee
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`FIG. 2
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`EtenLAnaaLALVlLLLLLhha9
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`MICRON 1031
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`MICRON 1031
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`U.S. Patent
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`May 2, 1995
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`Sheet 2 of 2
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`5,411,921
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`FIG. 6 PRIOR ART
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`4
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`MICRON 1031
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`MICRON 1031
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`This application is a division of application Ser. No.
`08/013,754, filed on Feb. 4, 1993.
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`BACKGROUND OF THE INVENTION
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`The present invention relates to an improvement of
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`bonding of a semiconductor chip to a die pad of a lead
`frame.
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`Conventionally, a semiconductor device is produced
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`by first bonding a semiconductor chip to a die pad of a
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`lead frame (whatis called the die bonding), performing
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`electrical connections such as wire bonding to the re-
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`spective leads, and finally sealing this structure by form-
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`ing a resin (hereinafter called molding). As shown in
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`FIG.6, in the die bonding of a semiconductorchip 4, a
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`preform material 10 that is a bonding material such as
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`Au, Au—Si, a solder ora paste is applied to a die pad 8
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`of a lead frame that is a metal thin plate madeof, e.g., a
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`42—Nialloy.
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`Where the preform material 10 is a metallic material,
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`it needs to be heated to a high temperature in the bond-
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`ing process. For example, in the case of the Au—Si
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`preform material, the die pad 8 is pre-heated at about
`300° C.for several seconds, further heated to 500°-600°
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`C. at
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`cooled.
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`In the case of metallic preform materials, such as Au,
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`Au—Si and a solder, which need to be heated to a high
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`temperature in the bonding process, a thermal stress is
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`exerted on the semiconductor chip to affect the semi-
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`conductor characteristics. Further,
`several heating
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`stages, for instance, stages for pre-heating at 300° C.,
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`bonding at 500-600° C., gradual cooling at 300° C., 100°
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`C. and 25° C. (ordinary temperature), should be pre-
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`pared, which causesan increase of costs of manufactur-
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`ing equipment.
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`Since the paste preform material is made, for instance,
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`of an epoxy resin that is made conductive by adding a
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`silver powder etc., the bonding process itself can be
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`performedat the ordinary temperature. However, to set
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`the resin, a large number of bondedstructures are col-
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`lected and subjected to aging in an oven at about 170°
`C. for 10-20 hours.
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`However, the existence of the aging step lowers the
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`efficiency of the bonding process and causes a cost
`increase. Further, there exist some factors of deteriorat-
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`ing the semiconductor characteristics: for instance, the
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`semiconductor device is placed in an environmentof a
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`relatively high temperature of about 170° C., and a
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`volatile organic gas generated from the paste may cor-
`rode the solder.
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`In addition, since MOS semiconductor devices need
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`verylittle current, it is becoming less importantto dissi-
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`pate heat through the semiconductor substrate and the
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`die pad, and to make a current flow through the back
`face of the semiconductor substrate. Thatis, it is now
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`desired that adverse influences on the semiconductor
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`characteristics be prevented and the efficiency of the
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`die bonding process be improved, rather than consider-
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`ing such properties as electrical conduction and thermal
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`conduction of the die bonding material.
`SUMMARYOF THE INVENTION
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`In view of the above circumstances, an object of the
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`present invention is to provide a semiconductor device
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`60
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`65
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`1
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`SEMICONDUCTOR CHIP DIE BONDING USING A
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`DOUBLE-SIDED ADHESIVE TAPE
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`5,411,921
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`2
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`in which the die bonding can be performed easily with-
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`out a heating process. Another object of the invention is
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`to provide a manufacturing method of such a semicon-
`ductor device.
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`According to the invention, in a semiconductor de-
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`vice of a type in which a semiconductorchip is bonded
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`to a die pad and the semiconductor chip and wires for
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`electrical connection between the semiconductor chip
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`and leads are molded by a resin, the semiconductor chip
`is bonded to the die pad via a double-sided adhesive
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`tape.
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`According to a second aspect of the invention, a
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`method of manufacturing a semiconductor device com-
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`prises the steps of:
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`sticking a semiconductor wafer on an expandable
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`tape via a double-sided adhesive tape;
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`dicing the semiconductor wafer into semiconductor
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`chips such that the double-sided adhesive tape is
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`cut into tape sections together with the semicon-
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`ductor wafer;
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`expanding the expandable tape to part the semicon-
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`ductor chips from each other;
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`removing the semiconductor chip and the tape sec-
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`tion stuck thereto from the expandable tape; and
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`bonding the semiconductorchip to a die pad of a lead
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`frame via the tape section stuck to the semiconduc-
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`tor chip.
`BRIEF DESCRIPTION OF THE DRAWINGS
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`FIGS. 1-5 are views showing manufacturing steps of
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`a semiconductor device according to an embodimentof
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`the present invention; and
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`FIG.6 is a view showing a conventional die bonding
`method.
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`DESCRIPTION OF THE PREFERRED
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`EMBODIMENT
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`A manufacturing method of a semiconductor device
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`according to the present invention is described hereinaf-
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`ter with reference to the accompanying drawings.
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`FIGS. 1-5 show respective steps of a die bonding pro-
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`cess, which is the main process of the manufacturing
`method of the invention.
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`First, as shown in FIG. 1, a double-sided adhesive
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`tape 2 is stuck on the surface of an expandable tape 1
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`made of, e.g., a polyvinyl chloride film. Then, a semi-
`conductor wafer3 is stuck on the double-sided adhesive
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`tape 2 such that the back surface of the formerfaces the
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`latter. The double-sided adhesive tape 2 is formed, for
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`instance, by applying an ordinary adhesive to a resin
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`film such as a polyimide film, and should havea size
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`larger than the semiconductor wafer3.
`Then, as shown in FIG.2, to divide the semiconduc-
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`tor wafer 3, which has onits front surface a large num-
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`ber of identical semiconductor circuits arranged in ma-
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`trix, into semiconductor chips 4, cutting lines 5 are
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`formed at the boundaries between the adjacent semi-
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`conductor circuits with a diamond cutter. The cutting
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`lines 5 are formed so as to reach the expandable tape 1
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`through the semiconductor wafer 3 and the double-
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`sided adhesive tape 2. Since the cutting lines 5 are
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`formed in the expandable tape 1 only slightly, the re-
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`spective semiconductor chips 4 thus cut remain to stick
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`to the expandable tape 1 via the double-sided adhesive
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`tape 2, so that the semiconductorchips do not part from
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`each other in this step.
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`Then, the expandable tape 1 is expanded byattaching
`its outer frame (not shown) to a container and vacuum-
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`MICRON 1031
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`MICRON 1031
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`3,411,921
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`4
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`occurno adverse influences, such as a thermalstress, on
`sucking the tape 1 or applying pressureto it. Asaresult,
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`the expandable tape 1 deformsplastically, and the semi-
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`conductorchips 4 are parted from each other as shown
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`ated no volatile gasses harmful to the semiconductor
`in FIG.3.
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`chip. Thus, it becomes possible to produce semiconduc-
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`In this state, the outer frame of the expandable tape 1
`tor devices having high reliability and superior charac-
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`is again attached to the vacuum sucking device, and
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`teristics at a high yield. Further, since the semiconduc-
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`while the bottom surface of the expandable tape 1 is
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`tor chip is completely secured to the die pad by the
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`sucked, a semiconductor chip 4 to be picked up is
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`resin, no problems will occur with the passage of time
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`pushed upward by a push-up bar6 (see FIG.4). At the
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`with respect to the bonding characteristic of the semi-
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`same time, the front surface of the semiconductor chip
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`conductor chip.
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`4 is vacuum-sucked upward through a collet 7. Since
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`Further, according to the invention, the double-sided
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`the bottom surface of the expandable tape 1 is vacuum-
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`adhesive tape is easily stuck on the semiconductor
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`sucked, when the tape 1 1s pushed upwardby a pointed
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`wafer having a large size, and is cut at the same time as
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`tip of the push-up bar 6, its portion around the pointed
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`the wafer dicing. Therefore, the increase of the number
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`tip of the bar 6 is kept sucked to peel off from the dou-
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`of manufacturing steps that is caused by the addition of
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`ble-sided adhesive tape 2 and goes down. Asa result,
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`the double-sided adhesive tape is negligible. The num-
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`the expandable tape 1 is stuck to the double-sided adhe-
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`ber of the entire steps rather decreases very much be-
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`sive tape 2 only at its very small portion that is on the
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`cause there are needed no heating, gradual cooling and
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`pointedtip of the push-up bar 6, or, exactly as shown in
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`aging in the die bonding process. In addition, since no
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`FIG.4, the bar 6 breaks through the expandable tape 1
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`equipment for heating is necessary, the manufacturing
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`while lifting the semiconductor chip 4. Thus, when the
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`cost is reduced greatly.
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`semiconductorchip4is furtherlifted while being vacu-
`Whatis claimedis:
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`um-sucked through the collet 7, the semiconductorchip
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`1. A method of manufacturing a semiconductor de-
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`4 having the double-sided adhesive tape 2 is easily re-
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`vice comprising the steps of:
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`moved from the expandable tape 1. The semiconductor
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`providing a double-sided adhesive tape having first
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`chip 4 as picked up is then carried to a die pad 8 of a lead
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`and second adhesive surfaces on opposite side. S;
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`frame by the collet 7, and can be bondedthereto simply
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`applying a semiconductor wafer to an expandable
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`by pushing (see FIG.5).
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`tape using the double-sided adhesive tape by adher-
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`It may be the case that when the semiconductor chip
`ing the semiconductor wafer to the first adhesive
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`4is removed from the expandable tape 1, peeling occurs
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`surface and adhering the expandable tape to the
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`between the semiconductor chip 4 and the double-sided
`second adhesive surface;
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`adhesive tape 2. This can be avoided,i.e., peeling occurs
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`dicing the semiconductor wafer into a plurality of
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`between the double-sided adhesive tape 2 and the ex-
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`semiconductor chips such that
`the double-sided
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`pandable tape 1 in a positive manner where the push-up
`w 5
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`adhesive tape is cut into tape sections together with
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`bar 6 breaks through the expandable tape 1 while lifting
`the semiconductor wafer;
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`the semiconductor chip 4 as shown in FIG. 4. Even
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`expanding the expandable tape to part the semicon-
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`where the push-up bar 6 does not break through the
`ductor chips from each other;
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`expandable tape 1, the double-sided adhesive tape 1 that
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`removing each of the plurality of semiconductor
`has been cut into a small section hardly continues to
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`chips and the double-sided adhesive tape section
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`stick to the angle-bracket-like deformed portion of the
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`adhered thereto from the expandable tape; and
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`expandable tape I (that is being sucked) around the
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`bonding each of the plurality of semiconductor chips
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`push-upbar6, to assure that the peeling occurs between
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`to a die pad of a lead frame by adhering the second
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`the double-sided adhesive tape 2 and the expandable
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`adhesive surface of the double-sided adhesive tape
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`tape 1. The peeling occurrence at this location can be
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`section adhered to the semiconductor chip to the
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`moreassured byadjusting the adhesion of the surface of 45
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`die pad.
`the double-sided adhesion tape 2 to be stuck to the
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`2. The method ofclaim 1, wherein in the expanding
`expandable tape 1 to be stronger than the ether surface
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`step the expandable tape is expanded to deform plasti-
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`to be stuck to the semiconductor chip 4.
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`cally.
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`Subsequently, electrical connections, ie., wire bond-
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`3. The method of claim 1, wherein in the expanding
`ing between bonding pads on the semiconductor chip 4
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`step the expandable tape is expanded by vacuum-suck-
`and respective leads of the lead frame are made using,
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`ing it.
`e.g., a gold wire 11 (alternatively, bumps may be used),
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`and the resultant structure is molded by a resin 9. Fi-
`4. The method of claim 1, wherein the removing step
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`nally, the lead frame is cut at connecting portions of the
`comprises pushing the semiconductor chip to be re-
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`moved fromafirst side opposite to the semiconductor
`respective leads, and forming is performed. Thus, a
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`semiconductor device is produced (see FIG. 5 ).
`chip by a bar having a pointed tip while sucking the
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`expandable tape from thefirst side.
`As described above, according to the invention, the
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`double-sided adhesive tape is used to bond the semicon-
`5. The method of claim 4, wherein in the removing
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`ductor chip to the die pad of the lead frame. Therefore,
`step the semiconductor chip is pushed bythe bar until
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`neither heating to a high temperature nor aging over a
`the bar breaks through the expandable tape.
`*
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`long period is needed in the die bonding process. There
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`40
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`65
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`MICRON 1031
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`MICRON 1031
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`UNITED STATES PATENT AND TRADEMARKOFFICE
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`CERTIFICATE OF CORRECTION
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`:
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`97 421,921
`PATENTNO.
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`DATED
`> May 2, 1995
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`INVENTOR(S) :
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`
`Atsuhito Negoro
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`itis certified that error appears in the above-indentified patent and that said Letters Patentis hereby
`corrected as shown below:
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`Column 3, line 47 "ether" should read -~other--;
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`Column 4,
`line 26 "side. S;" should read --sides;--.
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`Signed and Sealed this
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`Twenty-second Day ofAugust, 1995
`Attest:USnce lh
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`Attesting Officer
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`Commissioner of Patents and Trademarks
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`BRUCE LEHMAN
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`MICRON 1031
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`MICRON 1031
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