Flipping Station for Semiconductor Device Transfer

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Solution Overview

Problem

Current methods for loading and unloading devices onto boats for testing are inefficient, being too slow and unreliable, which hampers the overall throughput in device handling processes.

Innovation Solution

A method involving a flipping station where trays and boats form stacks, allowing devices to transfer under gravity, with the use of a grid and vibration to position devices accurately, and vacuum assistance to secure them, along with a camera system for alignment and replacement of displaced devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pick-and-place heads are used to load and unload devices, then devices can be transferred between trays and boats, but the process is too slow and shows lower reliability

Engineering Contradiction:

Improvetransfer speedVSAvoidtransfer reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Instead of using pick-and-place heads to actively pick and place devices, the patent inverts the approach by using gravity to passively transfer devices. Devices are placed on trays, which are then inverted so devices fall onto boats under gravity's influence. This reversal of the transfer mechanism eliminates the complexity and reliability issues of pick-and-place operations while dramatically increasing transfer speed.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical pick-and-place system with a gravity-based transfer system. By inverting the tray containing devices and allowing them to fall onto the boat, the system eliminates complex mechanical gripping and positioning mechanisms, thereby improving both speed and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If devices are transferred using gravity by flipping trays, then transfer speed and reliability improve, but device positioning precision may be compromised

Engineering Contradiction:

Improvetransfer efficiencyVSAvoiddevice positioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-positioning devices on the tray in the correct orientation and location before the gravity transfer. The tray is designed with specific positioning features that ensure devices are correctly oriented prior to flipping. This preliminary arrangement ensures that when devices fall onto the boat, they land in the correct positions without requiring complex post-transfer positioning adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The tray serves as an intermediary device that maintains device positioning during transfer. By designing the tray with specific structural features (such as recesses or positioning elements), the system ensures devices are held in correct positions on the tray before transfer, and these positioning features guide devices to correct locations on the boat during gravity transfer, thereby maintaining positioning precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method significantly improves the efficiency and reliability of device transfer between trays and boats, enhancing the throughput and accuracy of device handling processes.

Implementation Method 1

flipping the first stack, so that the tray is positioned over the boat, to cause the devices to fall, under the influence of gravity, away from the tray to become supported on the surface of the boat

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

positioning the tray under a boat, so that the devices which are supported on the tray are sandwiched between the tray and a surface of the boat which can support devices, to form a first stack; flipping the first stack

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentEP3403108B1Method and device for loading and unloading devices under test into a tester by flipping

Publication Date: 2022.06.15 RASCO

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Figure 2a

AI summary

According to the present invention there is provided a method of handling devices comprising the steps of, receiving a tray on which devices to be tested are supported, into a flipping station; positioning the tray under a boat, so that the devices which are supported on the tray are sandwiched between the tray and a surface of the boat which can support devices, to form a first stack; flipping the first stack, so that the tray is positioned over the boat, to cause the devices to fall, under the influence of gravity, away from the tray to become supported on the surface of the boat, thereby transferring the devices from the tray to the surface of the boat; moving the boat to a testing station and testing the devices on the boat; receiving the boat of tested devices into the flipping station; positioning a tray over the boat, so that the devices which are supported on the surface of the boat are sandwiched between the surface of the boat and tray to form a second stack; flipping the second stack so that the boat is positioned over the tray, to cause the devices to fall, under the influence of gravity, away from the surface of the boat to become supported on the tray, thereby transferring the devices from the surface of the boat to the tray.