Flip chip cartridge loader

A system for bonding integrally leaded semiconductor device chips to a conductive lead frame that includes an automatic chip positioning apparatus, said system comprising:

• means for horizontally supporting a conductive lead frame structure having a plurality of sets of soft ferromagnetic spaced convergent cantilevered fingers;
• means for transferring semiconductor chips having soft ferromagnetic integral leads on one face thereof to an overlying set of lead frame fingers for bonding thereto, said transfer means having a soft ferromagnetic probe extending vertically therefrom;
• means for applying a magnetic field to said probe so that magnetic lines of flux are transmitted longitudinally therethrough, said magnetic field having a strength sufficient to raise a chip up from the probe into engagement with said lead frame fingers;
• apparatus for successively positioning semiconductor chips onto one end of the probe, said apparatus having a base member with a longitudinal groove in one surface thereof, said groove having a generally flat bottom portion, a stop member extending transversely across one end of the groove, an opening extending from said groove bottom portion to an opposite surface of said base member, said opening being centrally located in said groove bottom portion and spaced from said stop member so as to be disposed underneath a semiconductor chip in said groove which is abutted against the stop member, means contiguous said one base member surface and overlying said groove for retaining semiconductor chips in the groove, said means being spaced from said stop member and said opening so that a semiconductor chip located over the opening can be vertically raised therefrom;
• means for moving a plurality of semiconductor chips longitudinally down said groove to successively abut the chips against said stop member so that said probe can extend through the opening and raise the chip thereover closer to the overlying set of lead frame fingers, where said magnetic force transmitted through the probe can raise the chip up from the probe to the fingers and concurrently orient the chip so that the integral chip leads are precisely aligned with their corresponding fingers upon engagement therewith;
• and
• means for bonding said chip to the lead frame.

A method of positioning burred semiconductor flip chips onto a probe for magnetically aligning the chip with an overlying conductive lead frame for bonding thereto, said method comprising the steps of:

• dicing a semiconductor wafer to separate a plurality of discrete flip chips therefrom, said chips having burrs extending laterally from their lower side portions;
• placing a burred semiconductor flip chip having a plurality of soft ferromagnetic contact bumps on one face thereof into one end of an elongated groove in a positioning apparatus, said apparatus having spaced juxtapositioned guide rails overlying the substantial length of said groove, a stop member extending transversely across the opposite end of the groove, and an opening centrally located in said groove which extends completely through said apparatus with the opening being spaced from the stop member at a distance of about one-half the width of the chip including the burrs;
• positioning a conductive lead frame having sets of soft ferromagnetic spaced fingers corresponding to said flip chip contact bumps so that a finger set overlies the opening in the positioning apparatus;
• moving said chip longitudinally in said groove between said guide rails to abut the chip against said stop member and locate said chip over said opening thereby positioning the flip chip contact bumps into general spaced alignment with their overlying corresponding fingers;
• applying a magnetic field to a soft ferromagnetic probe so that magnetic lines of flux are transmitted longitudinally therethrough;
• extending said probe through said opening to engage the back side of the chip thereover;
• raising the chip with said probe to within close proximity of said lead frame fingers whereby the magnetic force from said probe raises said chip the rest of the way to the fingers and concurrently automatically orients the chip while in transit thereto so that said contact bumps are in precise aligned engagement with their corresponding lead frame fingers;
• and
• heating said contact bump-finger engagement to permanently bond said flip chip to said lead frame.