TECHNICAL FIELD
The present disclosure is generally related to devices and methods for handling microelectronic assemblies. In particular, the present disclosure is related to devices (e.g., trays) and methods for handling packaged microelectronic devices or assemblies, non-packaged microelectronic devices or assemblies, or image sensor devices or assemblies.
BACKGROUND
Typically, trays can be used to reduce damage to microelectronic assemblies, such as memory devices and microprocessors, and to increase the efficiencies in handling and shipping microelectronic assemblies. The Joint Electron Device Engineering Council (JEDEC) has promulgated design requirements to standardize trays used by the microelectronic assembly manufacturers and customers. For example, JEDEC Publication 95, Design Guide 4.10, “Generic Shipping & Handling Matrix Tray,” standardizes the physical and functional characteristics of the trays, including the length, width, thickness, capacity, stack-ability, and other characteristics of the trays.
Typically, a specific tray is developed for each specific microelectronic assembly, and a new injection mold is required to form each specific tray. The injection molds, however, are typically expensive and time consuming to develop. With injection molds costing up to twenty thousand dollars or more, the start-up cost to create a mold is relatively high, particularly when a small number of engineering samples of a multi-chip package assembly are being processed for evaluation by potential customers. Moreover, because injection molds can take eight to twelve weeks or more to develop, the time required to develop a tray can be the limiting factor in developing a new microelectronic assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a handling device for microelectronic assemblies in accordance with an embodiment of the disclosure.
FIG. 2 is a cross-sectional view illustrating a secured configuration and a released configuration of an insert panel with respect to a portion of the frame for the handling device shown in FIG. 1.
FIG. 3 shows a perspective view of a handling device for microelectronic assemblies in accordance with another embodiment of the disclosure.
FIG. 4 is a perspective view of a frame for the handling device shown in FIG. 3.
FIG. 5 is a perspective view of a handling device carrying microelectronic assemblies in accordance with yet another embodiment of the disclosure.
FIG. 6 is an enlarged view of a portion of a handling device for microelectronic assemblies in accordance with a further embodiment of the disclosure.
FIG. 7 is an exploded perspective view of a handling device for microelectronic assemblies in accordance with yet a further embodiment of the disclosure.
DETAILED DESCRIPTION
Specific details of several embodiments of the disclosure are described below with reference to microelectronic assembly handling devices and methods for handling microelectronic assemblies. As it is used in the present disclosure, the phrase “microelectronic assemblies” can include packaged microelectronic assemblies or devices, bare dies and other non-packaged microelectronic assemblies or devices, image sensor assemblies and devices, or other semiconductor components. Packaged microelectronic assemblies can include, for example, micromechanical components, data storage elements, optics, read/write components, or other features. Non-packaged microelectronic assemblies can include, for example, microelectronic dies for flash memory (e.g., NAND flash memory), SRAM, DRAM (e.g., DDR-SDRAM), processors, imagers, and other types of devices. The term “handling” can include a manual or automated method or process by which something is moved, carried, transported, delivered, shipped, worked-on, or otherwise manipulated in connection with microelectronic assemblies. The phrase “coupled” can include a physical association or structural linking of two or more components or features. Other embodiments according to the disclosure can have configurations, components, features or procedures different than those described in this section. A person of ordinary skill in the relevant art, therefore, will accordingly understand that the disclosure may have other embodiments with additional elements, or the disclosure may have other embodiments without several of the elements shown and described below with reference to FIGS. 1-7.
FIG. 1 is an exploded perspective view of a handling device 100 for microelectronic assemblies in accordance with an embodiment of the disclosure. The handling device 100 can include a frame 200, an insert (e.g., an insert panel) 300, and one or more retainers 400 that releasably secure the frame 200 and the insert panel 300.
In the embodiment shown in FIG. 1, the frame 200 has a rectangular shape and size in accordance with JEDEC design requirements. According to other embodiments, a frame can have other suitable shapes and/or sizes. The frame 200 includes a first end portion 202a and a second end portion 202b. The second end portion 202b is spaced along a longitudinal axis A1 from the first end portion 202a. The frame 200 also includes a first side portion 204a and a second side portion 204b. The second side portion 204b is spaced along a lateral axis A2 from the first side portion 204a. The first and second end portions 202a and 202b and the first and second side portions 204a and 204b define a platform 210 positioned around an aperture 206 to support the insert panel 300, and the frame 200 also includes a rim 220 that projects from the platform 210 to position the insert panel 300 on the platform 210.
Embodiments of the frame 200 are configured to be formed as a unitary construction of a homogeneous material. For example, the frame 200, including the first and second end portions 202a and 202b, the first and second side portions 204a and 204b, and the rim 220, can be injection molded of carbon fiber or another material having suitable resistivity/conductivity and static dissipative properties. In other embodiments, other suitable methods and materials can be used to form the frame 200 as a unitary construction of a homogeneous material. In still further embodiments of the present disclosure, a frame can include multiple pieces, possibly of diverse materials, that are assembled to form an integral construction.
The insert panel 300 includes a plurality of pockets 310. Individual pockets 310 are configured to releasably receive a respective microelectronic assembly (not shown in FIG. 1). According to other embodiments of the present disclosure, the pockets 310 can be configured to receive other microelectronic components, e.g., bare chips or wafer portions. The plurality of pockets 310 can be distributed over the insert panel 300 in a plurality of rows and in a plurality of columns. As shown in FIG. 1, individual rows extend parallel to the longitudinal axis A1 and individual columns extend parallel to the lateral axis A2. In other embodiments of the present disclosure, the pockets 310 can have any suitable distribution over the insert panel 300 that is in compliance with JEDEC Design Guide 4.10, for example.
The insert panel 300 can be thermoformed in particular embodiments of the disclosure. As it is used in the present disclosure, the term “thermoform” includes a manufacturing process wherein a thermoplastic sheet or film is heated to its forming temperature before being stretched into or onto a mold and then cooled. Examples of thermoforming in accordance with the present disclosure can include vacuum forming, pressure forming, or a combination thereof. The insert panel 300 can include any suitable thermoplastic material, including tri-laminate polystyrene. According to other embodiments of the present disclosure, the plurality of pockets 310 can be formed by stamping, machining, e.g., stereolithography, or any other suitable process.
The insert panel 300 includes a central region 320 and a peripheral region 340. The central region 320 includes the pockets 310 and the peripheral region 340 overlies the platform 210. The peripheral region 340 can include a plurality of holes 360 through which the retainers 400 extend so as to secure the insert panel 300 to the frame 200.
Continuing to refer to FIG. 1, the retainers 400 are used to releasably secure the insert panel 300 to the frame 200. The retainers 400 can be changed between a coupled arrangement (not shown in FIG. 1) and a decoupled arrangement. In the coupled arrangement, the retainers 400 secure the insert panel 300 to the frame 200 so as to prohibit or at least restrict relative movement between the frame 200 and the insert panel 300. In the decoupled arrangement shown in FIG. 1, the retainers 400 allow the insert plate 300 to be released from the frame 200 so as to permit relative movement, e.g., separation, between the frame 200 and the insert plate 300.
In the embodiment shown in FIG. 1, the retainers 400 can include threaded fasteners, e.g., screws or bolts, which pass through the holes 360 in the peripheral region 340 of the insert panel 300 and threadably engage with threaded receptacles 212 in the frame 200. In other embodiments according to the present disclosure, the retainers 400 can include clips, adhesive, threaded posts, projections carried by the frame 200, or any other suitable releasable fastener. In still other embodiments according to the present disclosure, the insert panel 300 can be retained with respect to the frame 200 without separate fasteners, e.g., via a releasable friction fit between the insert panel 300 and the frame 200. In such a case, the retainer can include mating features, e.g., contact surfaces on the frame 200 and the insert panel 300. In still further embodiments, the frame 200 and the insert panel 300 can be connected via other techniques, e.g., welding.
FIG. 2 is a cross-sectional view illustrating a secured configuration (solid lines) and a released configuration (broken lines) of the insert panel 300 with respect to a portion of the frame 200 in accordance with an embodiment of the present disclosure. In the secured configuration, the peripheral region 340 of the insert panel 300 overlies the platform 210 of the frame 200. The rim 220 of the frame 200 positions the insert panel 300 on the platform 210 so that the holes 360 are approximately aligned with the threaded receptacles 212. The insert panel 300 is disposed across the aperture 206 and the pockets 310 project into the aperture 206. In the embodiment shown in FIG. 2, an individual threaded retainer 400 passes through an individual hole 360 in the insert panel 300 and threadably engages an individual threaded receptacle 212. In the released configuration, the individual threaded retainer 400 is withdrawn from the individual threaded receptacle 212 and the insert panel 300 can be separated from the frame 200 in a release direction R.
The insert panel 300, which includes 112 pockets 310 as shown in FIG. 1, can be released from the frame 200 of the handling device 100, and a different insert panel (not shown) can be secured to the frame 200 in its place. The insert plate 300 can be released from the frame 200, for example, when the retainers 400 are in the decoupled arrangement, and a different insert panel can be secured to the frame 200 by repositioning the retainers 400 in the coupled arrangement. Accordingly, the handling device 100 can facilitate using multiple types of insert panels with different numbers, sizes and distributions of pockets, all supported by the same frame 200.
FIG. 3 shows a microelectronic assembly handling device 1100 configured in accordance with another embodiment of the disclosure. In this embodiment, the handling device 1100 includes a frame 1200 that is populated with a different insert than is shown in FIG. 1, e.g., eight insert strips 1300. A ninth insert strip 1300 is shown spaced above the frame 1200 and enlarged for explanatory purposes.
Individual insert strips 1300 include a central region 1302 and two side regions 1304. The central region 1302 includes a plurality of pockets 1310 that can be configured to receive respective microelectronic assemblies. The insert strips 1300 can be lengths of embossed carrier tape, for which the Electronics Industries Alliance (EIA) has promulgated standards. For example, Standard EIA-481-B, “8 mm through 200 mm Embossed Carrier Taping and 8 mm & 12 mm Punched Carrier Taping of Surface Mounted Components for Automatic Handling,” provides dimensions and tolerances necessary to tape surface mount components such that they may be automatically handled. In the embodiment shown in FIG. 3, a single column of five pockets 1310 is disposed along an individual insert strip 1300. In other embodiments, the shape, size, capacity and other characteristics of the insert strips 1300 can be different.
The peripheral regions 1304 extend parallel to a lengthwise direction L1 of the insert strips 1300 and are disposed laterally outside of the pockets 1310 on either side of an individual insert strip 1300. A set of holes 1306 can be disposed in individual peripheral regions 1304.
The insert strips 1300, similar to the insert panel 300 described above, can be thermoformed. Accordingly, the foregoing examples of thermoforming in accordance with the present disclosure (vacuum forming, pressure forming, or a combination thereof) can be used to form the insert strips 1300. The insert strips 1300 can include any suitable thermoplastic material, including tri-laminate polystyrene. According to other embodiments of the present disclosure, the plurality of pockets 1310 can be formed by stamping, machining, e.g., stereolithography, or another suitable process.
FIG. 4 shows the frame 1200 of the handling device 1100 that is shown in FIG. 3, with the insert strips 1300 removed. According to the embodiment shown in FIG. 4, the frame 1200 has a rectangular shape and size in accordance with JEDEC design requirements. According to other embodiments, the frame can have other suitable shapes and/or sizes. The frame 1200 includes ledges 1210 to support peripheral regions 1304 of the insert strips 1300 and includes a rim 1220 for positioning the insert strips 1300 on the frame 1200.
The ledges 1210 of the frame 1200 can be spaced along a longitudinal axis A1 and extend parallel to a lateral axis A2. In the embodiment shown in FIG. 4, there are 18 ledges 1210 (only four are indicated in FIG. 4 for the sake of clarity) so as to correspond to the number of peripheral regions 1304 for nine insert strips 1300. The outer rectangular shape of the frame 1200 is interiorly partitioned by eight pairs of the ledges 1210, and each of the eight interior pairs of the ledges 1210 is separated by a respective rib 1222 (only one is indicated in FIG. 4 for the sake of clarity). The rim 1220 and the ribs 1222 position individual insert strips 1300 on the frame 1200. The spacing along the longitudinal axis A1 between adjacent ones of the rim 1220 and the ribs 1222 corresponds to a width of individual insert strips 1300, i.e., measured transversely to the lengthwise direction L of the insert strips 1300. According to other embodiments, different numbers of ledges and ribs can be disposed interiorly of a rectangular frame to accommodate different numbers and/or widths of insert strips.
The frame 1210 can also include tabs 1230 that can project parallel to the longitudinal axis A1. The tabs 1230 (only four are indicated in FIG. 4 for the sake of clarity) project from the rim 1220 and the ribs 1222 to define gaps 1232 between the tabs 1230 and respective ledges 1210. The gaps 1232 are configured to receive the peripheral regions 1304 of individual insert strips 1300. In other embodiments according to the present disclosure, any suitable structure other than the tabs 1230 can be used to prevent or at least restrict separation of individual insert strips 1300 from the frame 1200. Posts 1212 can project from the ledges 1210 for registering, e.g., locating, the insert strips 1300 with respect to the frame 1200. In the embodiment shown in FIG. 4, the tabs 1230 can prevent or at least restrict the insert strips 1300 from separating from the frame 1200 and the posts 1212 can prevent or at least restrict the insert strips 1300 from sliding on the frame 1200. In other embodiments of the present disclosure, the insert strips 1300 can be pressed onto several of the posts 1210 such that the insert strips 1300 are retained with respect to the frame 1210 via a friction fit without the tabs 1230.
In the embodiment shown in FIG. 4, the frame 1200 can include a grid 1240 that can underlie the ledges 1210 relative to the tabs 1230. The grid 1240 can contiguously support the bottom surfaces of the pockets 1310 of the insert strips 1300. According to other embodiments, any suitable structure other than the grid 1240 can be used to provide support for pockets.
The frame 1200, similar to the frame 200 described above, can be formed as a unitary construction of a homogeneous material. For example, the frame 1200, including the ledges 1210, the posts 1212, the rim 1220, the ribs 1222, the tabs 1230 and the grid portion 1240 can be injection molded of carbon fiber or another material having suitable resistivity/conductivity and static dissipative properties. In other embodiments, other suitable methods and materials can be used to form the frame 1200 as a unitary construction of a homogeneous material. In still further embodiments of the present disclosure, a frame can include multiple pieces, possibly of diverse materials, that are assembled to form an integral construction.
FIG. 5 shows another embodiment according to the present disclosure that includes insert strips 2300 supported by the same frame 1200 and microelectronic assemblies M (only two are indicated in FIG. 5 for the sake of clarity) disposed in individual pockets 1310. In the embodiment shown in FIG. 5, 14-pocket insert strips 2300 have been secured to the frame 1200 in place of the five-pocket insert strips 1300 shown in FIG. 3. In particular, individual insert strips 1300 that include five pockets 1310, as shown in FIG. 3, have been released from the frame 1200, and individual insert strips 2300 that include 14 pockets, as shown in FIG. 5, have been secured to the frame 1200. Accordingly, the number, size, and other characteristics of pockets included in an inset strip can be varied to accommodate various microelectronic assemblies and/or components while the same frame can be used to support the different insert strips.
FIG. 6 is an enlarged view of a portion of a handling device similar to that shown in FIG. 3, with eight-pocket (rather than five-pocket) insert strips 3300 installed. With reference to FIG. 6, a method by which insert strips can be secured and released, thereby facilitating changing insert strips while still using the same frame, will now be described. To secure individual insert strips 3300 to the frame 1200, the insert strip 3300 can be displaced in the direction parallel to the lateral axis A2 between the ledges 1210 and the tabs 1230 so as to dispose side regions 3304 of the insert strip 3300 in the gaps 1232. At least one hole 3306 in the insert strip 3300 can then be pressed over a post 1212 to secure the insert strip 3300 on the frame 1200. To release an insert strip 3300 from the frame 1200, the insert strip 3300 is displaced, e.g., lifted, such that the posts 1212 no longer engage holes 3306 in the insert strip 3300 and the insert strip 3300 is displaced in its lengthwise direction so as to extricate side regions of the insert strip from the gaps 1232. According to other embodiments, insert strips with different numbers, sizes, distributions, or other characteristics of pockets can all be installed on the same frame 1200.
FIG. 7 is an exploded, schematic illustration of a microelectronic assembly handling device 4100 configured in accordance with an embodiment of the disclosure. In this embodiment, the handling device 4100 includes a frame 4200, an insert plate 4300, and one or more retainers 4400. In particular, the insert plate 4300 includes a peripheral region 4302 sandwiched between first and second sections 4208a and 4208b of the frame 4200, and the retainers 4400 releasably secure together the first and second sections 4208a and 4208b of the frame 200 with the insert plate 4300 sandwiched between.
In contrast to conventional microelectronic assembly/component handling devices, embodiments of handling devices in accordance with the present disclosure do not require a tray that is injection molded. Instead, one or more inserts can be thermoformed, e.g., vacuum formed, and secured to an injection molded frame. Thus, according to the present disclosure, standardized injection molded frames can be interchangeably used with a number of various vacuum formed inserts customized to a specific microelectronic assembly or component. In particular embodiments, the custom vacuum formed insert can reduce the start-up cost to create a mold to not more than two thousand dollars and can reduce the time required to build a quantity of trays to not more than four weeks. Accordingly, the time required to develop a tray can be reduced and/or excluded as the limiting factor in developing a new microelectronic assembly.
From the foregoing, it will be appreciated that specific embodiments of the disclosure have been described herein for purposes of illustration, but that various modifications may be made without deviating from the disclosure. For example, structures and/or processes described in the context of particular embodiments may be combined or eliminated in other embodiments. In particular, the attachment features described above with reference to particular embodiments can include one or more additional features or components, or one or more of the features described above can be omitted. In addition, trays according to the present disclosure can also be used to handle a variety of semiconductor components, including packaged dies, bare dies and wafers, e.g., unsingulated wafers or wafer portions and repopulated carrier wafers. In other embodiments according to the present disclosure, the inserts or strips can also be fastened to the bottom-side of the frame, e.g., to provide access for bottom-up handling of the semiconductor components. Moreover, while advantages associated with certain embodiments of the disclosure have been described in the context of these embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the disclosure. Accordingly, the disclosure can include other embodiments not shown or described above.