WO2020096638A1 - Holding chucks having compartmentalized holding cavities and uses for such holding chucks - Google Patents

Holding chucks having compartmentalized holding cavities and uses for such holding chucks Download PDF

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Publication number
WO2020096638A1
WO2020096638A1 PCT/US2019/025606 US2019025606W WO2020096638A1 WO 2020096638 A1 WO2020096638 A1 WO 2020096638A1 US 2019025606 W US2019025606 W US 2019025606W WO 2020096638 A1 WO2020096638 A1 WO 2020096638A1
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WO
WIPO (PCT)
Prior art keywords
cavities
holding chuck
working face
controllable release
substrate
Prior art date
Application number
PCT/US2019/025606
Other languages
French (fr)
Inventor
Ajaykumar R. Jain
Original Assignee
VerLASE TECHNOLOGIES LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by VerLASE TECHNOLOGIES LLC filed Critical VerLASE TECHNOLOGIES LLC
Publication of WO2020096638A1 publication Critical patent/WO2020096638A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/683—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L21/687—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches
    • H01L21/68714—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support
    • H01L21/6875—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support characterised by a plurality of individual support members, e.g. support posts or protrusions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005—Apparatus not specifically provided for elsewhere
    • H01L21/67011—Apparatus for manufacture or treatment
    • H01L21/67098—Apparatus for thermal treatment
    • H01L21/67103—Apparatus for thermal treatment mainly by conduction
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/673—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere using specially adapted carriers or holders; Fixing the workpieces on such carriers or holders
    • H01L21/67346—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere using specially adapted carriers or holders; Fixing the workpieces on such carriers or holders characterized by being specially adapted for supporting a single substrate or by comprising a stack of such individual supports
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/683—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L21/6835—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/683—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L21/687—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches
    • H01L21/68714—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support
    • H01L21/68785—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support characterised by the mechanical construction of the susceptor, stage or support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68327—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used during dicing or grinding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68354—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used to support diced chips prior to mounting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68363—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used in a transfer process involving transfer directly from an origin substrate to a target substrate without use of an intermediate handle substrate
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68381—Details of chemical or physical process used for separating the auxiliary support from a device or wafer

Definitions

  • the present invention generally relates to the field of holding platforms that are used to hold semiconductor substrates.
  • the present invention is directed to holding chucks having compartmentalized holding cavities and uses for such holding chucks.
  • the present disclosure is directed to a method of making an electronic device.
  • the method includes removably securing a microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face of the holding chuck, each of the cavities being compartmentalized and spaced from adjacent cavities, and the cavities spatially arranged in a predetermined arrangement and having associated therewith a controllable release component;
  • the microelectronics substrate includes microelectronic devices spatially arranged relative to one another in concert with the predetermined arrangement of the cavities of the holding chuck; and when the microelectronics substrate is removably secured to the holding chuck, ones of the microelectronic devices are in registration with corresponding respective ones of the cavities; while the microelectronics substrate is removably secured to the holding chuck, partitioning the microelectronics substrate to separate ones of the microelectronics devices from one another to create individual microelectronic-device dies
  • the present disclosure is directed to a holding chuck for manufacturing an electronic device.
  • the holding chuck includes a body having a working face that confronts a plurality of individual microelectronic-device dies during use; a plurality of cavities formed in the body, the plurality of cavities arranged in a predetermined arrangement on the working face of the body, each of the plurality of cavities being compartmentalized and having
  • the present disclosure is directed to a method of making a holding chuck for use in manufacturing an electronic device, wherein the manufacturing utilizes a plurality of individual microelectronic-device dies arranged in a predetermined arrangement during at least one step of the manufacturing.
  • the present disclosure is directed to a method of making an electronic device.
  • the method includes providing individual microelectronic-device dies, the individual microelectronic-device dies arranged in a predetermined arrangement and removably engaged with a support; providing a holding chuck, the holding chuck having a working face and including cavities formed in the working face of the holding chuck, each of the cavities being compartmentalized and spaced from adjacent cavities, and arranged in the predetermined arrangement of the individual microelectronic -device dies engaged with the support, wherein each of the cavities has associated therewith a controllable release component; registering the individual microelectronic-device dies and the cavities with one another; when the individual microelectronic- device dies and the cavities are in registration with one another, contacting the individual microelectronic-device dies and the working face of the holding chuck with one another; removably securing the individual microelectronic-device dies to the working face of
  • the present disclosure is directed to a method of working a microelectronics substrate.
  • the method includes removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face, each of the cavities being compartmentalized and spaced from adjacent cavities, the cavities having associated therewith at least one controllable release component; while the microelectronics substrate is removably secured to the holding chuck, processing the
  • FIG. 1 is a cross-sectional view of an example holding chuck made in accordance with aspects of the present invention
  • FIG. 2 is a cross-sectional view the holding chuck of FIG. 1 showing cavities formed in the body
  • FIG. 3 is a top view of the holding chuck and cavities of FIG. 2;
  • FIG. 4 is a flow diagram of an example method of fabricating the holding chuck of
  • FIGS. 5A to 5E illustrate various blocks of the example method of FIG. 4;
  • FIG. 6 is a flow diagram of an example method of fabricating the holding chuck of
  • FIGS . 1 to 3 made in accordance with aspects of the present disclosure
  • FIGS. 9A to 9E illustrate various blocks of the method of FIG. 8;
  • FIG. 10 is a diagram illustrating in-plane resistive-type heaters
  • FIGS. 11A and 1 IB illustrate example method of utilizing the holding chuck of FIG. 1;
  • FIGS. 12A and 12B illustrate another method of utilizing the holding chuck of FIG. 1;
  • FIG. 13 illustrates yet another method of utilizing the holding chuck of FIG. 1;
  • FIGS. 14A to 14C illustrate, respectively, alternate methods of utilizing the holding chuck of FIG. 1;
  • FIGS. 15 illustrates still another method of utilizing the holding chuck of FIG. 1;
  • FIG. 16 is a flow diagram of a further method of utilizing the holding chuck of FIG. 1;
  • FIGS. 17A to 17C illustrate various blocks of the method of FIG. 16;
  • FIG. 18 is a flow diagram of an example method of utilizing the holding chuck of FIG. 1 for the purpose of mass transfer;
  • FIGS. 19A to 19E illustrate various blocks of the method of FIG. 18
  • FIGS. 20A to 20E are cross-sectional views each illustrating another example variant of a holding chuck made in accordance with aspects of the present disclosure
  • FIG. 21A is a cross-sectional view of a holding chuck made in accordance with aspects of the present disclosure that includes a porous film extending over the compartmentalized cavities;
  • FIG. 21B is an enlarged cross-sectional view of the porous film of FIG. 21A;
  • FIG. 22A is cross-sectional view of a single compartmentalized cavity in isolation containing a piezoelectric element, illustrating the piezoelectric element in each of an unactuated and actuated configuration;
  • FIG. 22C is a cross-sectional view of a holding chuck comprising a plurality of compartmentalized cavities like the compartmentalized cavity of FIG. 22A and 22B and the holding chuck in engagement with a microelectronics substrate;
  • FIGS. 23 A and 23 A' each illustrate a single compartmentalized cavity overlain by a microelectromechanical system (MEMS) membrane and show, respectively, the MEMS membrane in an unactuated state and an actuated state;
  • MEMS microelectromechanical system
  • FIGS. 23B and 23B' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in an unactuated state and an actuated state so as to create a vacuum between the MEMS membrane and the microelectronics substrate;
  • FIGS. 23C and 23C' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in an actuated state and an unactuated state so as to release the microelectronics substrate;
  • FIGS. 23D and 23D' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in a first actuated state causing a concave configuration so as to generate a holding vacuum and second actuated state causing a convex configuration so as to release the microelectronics substrate;
  • FIG. 24 is a diagram illustrating an example holding chuck and corresponding activation circuity and control system for controlling the actuation and/or de-actuation of the controllable release components aboard the holding chuck.
  • One such embodiment includes a method of making an electronic device, such a microLED display device, a detector device, or a sensor device, among others.
  • This method may include removably securing a microelectronics substrate to a working face of a holding chuck.
  • the holding chuck includes cavities formed in the working face of the holding chuck, with each cavity being compartmentalized and spaced from adjacent cavities.
  • the cavities are spatially arranged in a predetermined arrangement and have associated therewith at least one controllable release component.
  • the microelectronics substrate includes microelectronic devices spacially arranged relative to one another in concert with the predetermined arrangement of the cavities of the holding chuck.
  • microelectronics substrate While the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is partitioned to separate ones of the microelectronics devices from one another to create individual microelectronic-device dies. After partitioning the microelectronics substrate, one or more of the controllable release components are controlled so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a predetermined location.
  • Another revealed embodiment includes a holding chuck for manufacturing an electronic device such as a microLED display device, a detector device, and a sensor device, among others.
  • the holding chuck comprises a body having a working face that confronts a plurality of individual microelectronic-device dies during use.
  • a plurality of cavities are formed in the body and are arranged in a predetermined arrangement on the working face of the body.
  • Each of the cavities is compartmentalized and has correspondingly associated therewith a controllable release component that controls release of the plurality of individual microelectronic-device dies when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
  • Activation circuitry is in electrical communication with each of the controllable release components and is designed and configured to electrically communicate with the controllable release components to control release of the plurality of individual microelectronic -device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
  • the plurality of cavities are compartmentalized and formed in the working face when the holding chuck is completed.
  • At least one controllable release component is provided. Each controllable release component is releasing one or more of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the working face of the holding chuck.
  • Activation circuitry is provided so as to be in electrical communication with each of the at least one controllable release component.
  • the activation circuitry is designed and configured to electrically communicate with the at least one controllable release component to control release of the plurality of individual microelectronic -device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
  • Yet another revealed embodiment includes a method of making an electronic device, such as a microLED display device, a detector device, or a sensor device, among others. The method comprises providing individual microelectronic-device dies, the individual microelectronic- device dies arranged in a predetermined arrangement and removably engaged with a support. A holding chuck is provided.
  • the holding chuck has a working face and including cavities formed in the working face of the holding chuck.
  • Each of the cavities is compartmentalized and spaced from adjacent cavities and arranged in the predetermined arrangement of the individual microelectronic- device dies engaged with the support, wherein each of the cavities has associated therewith a controllable release component.
  • the individual microelectronic-device dies and the cavities are registered relative to one another. When the individual microelectronic-device dies and the cavities are in registration with one another, the individual microelectronic-device dies and the working face of the holding chuck are contacted with one another.
  • the individual microelectronic-device dies are removably secured to the working face of the holding chuck.
  • the individual microelectronic-device dies are disengaged from the support.
  • One or more of the controllable release components are controlled so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a desired location.
  • Still another revealed embodiment includes a method of working a microelectronics substrate.
  • the method comprises, removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face and each of the cavities being compartmentalized and spaced from adjacent cavities.
  • the cavities have associated therewith at least one controllable release component. While the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is processed. After processing the microelectronics substrate, each of the at least one controllable release component is controlled so as to release the microelectronics substrate from the holding chuck.
  • Still yet a further revealed embodiment includes a method of working a microelectronics substrate.
  • the method comprises removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face and each of the cavities being compartmentalized and spaced from adjacent cavities.
  • Removably securing the microelectronics substrate includes creating a gas seal between the holding chuck and the microelectronics substrate so that interiors of the cavities are gaseously sealed from an ambient environment adjacent to the microelectronics substrate.
  • the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is processed. After processing the microelectronics substrate, differential pressure between the ambient environment and the interiors of the cavities is changed so as to release the microelectronics substrate from the holding chuck.
  • Microelectronics substrate any substrate, semiconductor or otherwise (such as a wafer), used for creating microelectronic devices and can also the stmcture(s) that results from processing to form microelectronics on the substrate when such structure(s) are present.
  • Electronic device any electronic device, such as an electronic display, a sensor array, and a detector array, and any combination thereof, among others.
  • Microelectronic device any individual electrical component, e.g., LED, laser diode, transistor, etc. or any collection of such components that make up an overall device, such as a microprocessor, memory, etc.
  • Controllable release component any component that is controllable so as to release one or more individual microelectronic-device dies from the holding chuck, such as a heater, piezoelectric element, getter, active membrane, pyrophoric element, etc.
  • the controllable release component e.g., resistance-type heater, piezoelectric element, active membrane, etc.
  • the controllable release component may be activated by an electrical signal.
  • the controllable release component may be activated by another means, such as heat from a heater (e.g., getter, pyrophoric, etc.), and vacuum among others.
  • “Individual microelectronic-device die” the structure that contains a microelectronic device, typically formed by partitioning a microelectronic substrate into individual bodies that are separate and distinct from one another.
  • “Working face” the face of the holding chuck that confronts a microelectronics substrate or a plurality of individual microelectronic-device dies.
  • this face can be the face of the outermost coating that may be applied to the bare holding chuck.
  • “Receiving support” anything that receives one or more individual microelectronic- device dies when released from the holding chuck; can be, e.g., a backplane of an electronic device, an intermediate substrate, or a temporary holder such as another holding chuck of the present disclosure, among other things.
  • activation circuitry - electronic circuitry that activates the controllable release components so as to change pressure within the cavities.
  • FIG. 1 illustrates an example holding chuck 100 made in accordance with aspects of the present disclosure.
  • holding chuck 100 includes a substrate body 104, a plurality of controllable release components 108 located, here, respective, in a plurality of compartmentalized substrate cavities 112, one or more optional coatings 116 on each of the controllable release components, and one or more optional coatings 120 on the front surface of the substrate body.
  • the combination of the substrate 104 and controllable release components 108 in the compartmentalized substrate cavities 112 without any additional treatment(s) applied thereto may be considered as a holding chuck structure 124.
  • the optional coating(s) 116 on the controllable release component 108 and the optional coating(s) 120 on the front surface of substrate body 104 may be present as a particular design may require.
  • holding chuck structure 124 may be used to removably secure a microelectronics substrate wafer (not shown) atop the working face of the holding chuck structure, here the front surface of optional
  • Each coating 116 and 120 on the controllable release components 108 and the front surface of substrate body 104 may be chosen to enhance the performance of holding chuck 100.
  • the coating(s) 116 on the controllable release component 104 may be selected to amplify and expedite the release process of the reversible bonding.
  • the front surface coating(s) 120 may be selected to prevent damage to the underside of the removably secured microelectronics substrate (not shown), and/or enhance the seal between the removably secured microelectronics substrate (not shown) and the holding chuck 100. Additional details each of these elements and their functions, as well as examples of each of these elements, are described and provided below.
  • Substrate body 104 may be rigid or flexible and may be composed of one or more polymers, one or more ceramics, one or more metals, one or more papers, one or more fabrics, or one or more glasses, or any combination thereof, among other things. Substrate body 104 may be transparent, opaque, or translucent, or any combination thereof. Each material of substrate body 104 may be a conductor, an insulator, or a semiconductor, or any combination thereof. Each material may be inorganic or organic or a combination thereof and may be single crystal, polycrystalline, oriented (or textured) polycrystalline, or amorphous in morphology.
  • Material for substrate body 104 may be porous or non-porous or a combination thereof.
  • the pores (not shown), if present, in substrate body 104 may be created artificially or may exist naturally.
  • the pores in substrate body 104 may be randomly located or deterministically placed. There are fundamentally no limits on the size and shape of the pores in substrate body 104.
  • substrate body 104 There are fundamentally no limits on the thickness of substrate body 104, and in some embodiments the thickness may range from a few microns to several millimeters as desired by the application at issue.
  • other functionality/functional coating 120 may be deposited in or on the surfaces of the substrate body 104.
  • the coating 120 may act as a gasket layer, flex / compliant layer, anti-stick /anti-abrasion layer, barrier layer, passivation layer, planarizing layer, adhesive layer, etc.
  • These functional layers include, but are not limited to, organic or inorganic layers. While certain representative examples have been mentioned for purposes of illustrating the wide variety of substrates that can be used for substrate body 104, it will be apparent to those skilled in the art that substrates not disclosed herein may be made without departing from the scope of the invention.
  • a resistive-type heater element as a controllable release component 108 is a miniaturized heating element, such as a microelectromechanical system (MEMS) heating element or a micro heating element, having a complex interplay of many disciplines in physics, such as thermal, electrical and mechanical.
  • MEMS microelectromechanical system
  • Archetypical designs includes a substrate, a conductive pad, a resistive heating element, oxidation passivation layers, etc.
  • a wide variety of methods exist to manufacture a suitable resistive-type heater element and are well known in the prior art and are not repeated here.
  • Resistive-type heater elements are routinely used in a variety of applications including inkjet printheads, actuators, bio-mems, chemical detectors, gas flow sensors, etc. These heater elements can rapidly be heated to temperatures in excess of -300 C.
  • a piezoelectric element as controllable release component 108 comprise one or more piezoelectric materials. These piezoelectric materials undergo physical distortion (mechanical expansion/contraction) when an electric field is applied. It is this physical distortion that is exploited in the present disclosure to mechanically create the reversible“holding force” in the holding chuck 100 of FIG. 1.
  • piezoelectric materials and architectures including, tube, edge, face, moving wall, piston, etc. Any of these may be utilized in the holding chuck structure 100.
  • An active membrane as controllable release component may comprise a MEMS membrane.
  • An active membrane may be a continuous, impermeable, suspended membrane in a MEMS architecture. Active MEMS membrane materials and deposition techniques are widely known in the prior art and are not repeated here. These materials may be organic, inorganic, or hybrid in composition.
  • An active MEMS membrane may also be composed of an adhesive material. The adhesive layer may be deposited on top of the membrane, all over, or over just some sections of the membrane.
  • An active MEMS membrane can be deposited atop the compartmentalized cavities 112 of the holding chuck structure 124. Upon actuation, the active MEMS membrane undergoes physical distortion, and it is this physical distortion that may be exploited to mechanically create the reversible“holding force” of the holding chuck 100.
  • Each controllable release component 108 can be manufactured in-situ, in the compartmentalized cavities 112, during the construction of the holding chuck structure 124, or alternatively, it can be built ex-situ, and then during the construction of the holding chuck 100; it can be incorporated into the compartmentalized cavities 112 as desired. There is no specific location in the compartmentalized cavity 112 that the controllable release component 108 needs to be placed. The controllable release component 108 may be placed at the bottom of the cavity, or it might be placed midway thru the cavity, or it may be placed on the walls of the cavity, etc.
  • controllable release components 108 can be placed in each and every
  • compartmentalized cavity 112 of the holding chuck structure 124 if so desired.
  • a single controllable release component may address or occupy multiple cavities in the holding chuck structure.
  • controllable release components 108 may be individually addressable (triggered to actuate) via additional electrical circuits/electronics, if so desired.
  • the controllable release components may also be globally addressable (triggered all together, all at once).
  • controllable release component 108 comprises a heater
  • optional coating(s) 116 on controllable release component 108 may include one or more heat activated materials, such as getters, pyrophorics, or vacuum activated materials, among others.
  • Optional coating(s) 116 might comprise of materials that are general classified as getter materials. Getters are chemical substances, that when placed in a partial vacuum such as might exist in compartmentalized cavity 112, will react chemically with any residual gas (if present) in the cavity to increase the vacuum in such cavity. This act of reducing pressure of a chamber or cavity is called“gettering.”
  • These materials work on a multitude of mechanisms depending on their specific composition and intent. These mechanisms can broadly be stated as: adsorption, absorption, chemisorption/diffusion or chemical binding, physisorption, surface dissociation, surface sorption, bulk diffusion, bulk sorption, occlusion, etc. These mechanisms and therefore the associated getters may work reversibly, or irreversibly.
  • These materials can take the form of bulk getters (sheets, strips, wires, pellets, etc), coating/film getters: comprising of thin film getters, thick film getters, solid or porous coating/film getters, powder getters: comprising of macro powders, micro powders, nano powders, and pellets of getters.
  • getter materials are in use. Below are a few materials; note, however, that the list is not comprehensive, and any getter material not listed below might be used without departing from the scope of the invention.
  • Materials such as chemically reactive metals such as: barium, barium alloys, cesium, columbium, tantalum, titanium, titanium/molybdenum, zirconium, vanadium, hafnium, rare earths, iron, aluminum, cobalt, copper, silicon, phosphorous, strontium, calcium, nickel, BaAU, terbium, magnesium, niobium, thorium, vanadium, uranium, palladium, alkali metals and their alloys, amongst others. Physical getters like zeolites might also be utilized.
  • getter materials may be activated in-situ or ex-situ.
  • The maybe activated in vacuum, inert gas, or any other ambient as needed. They may be activated pre/during/post their deposition in the cavity or their intended space. They may be activated by heat, electromagnetic radiation, light, microwave, moisture, etc.).
  • the getter materials may be inorganic, organic, or hybrid (inorganic + organic) in chemical composition.
  • the getter may be used once and dispensed, or may be used many times until it is capacity to getter is exhausted, or it may be replenished after every transfer event, if so desired.
  • Coating(s) 116 may comprise one or more materials that are general classified as pyrophoric materials. These are chemical substances that will ignite spontaneously at or below room temperature and may be solids, liquids, or gases. These materials may be inorganic or organic in composition.
  • Pyrophoric materials may include, but are not limited to: alkali metals and their hydrids such as: lithium, sodium, potassium, lithium aluminium hydride, sodium hydrid, finely powdered metals such as aluminum, cerium, iron, bismuth copper, Cu/ZnO/ANO,, magnesium, nickel, Raney nickel, calcium, titanium, tantalum, hafnium, zirconium, uranium, plutonium, etc.
  • alkali metals and their hydrids such as: lithium, sodium, potassium, lithium aluminium hydride, sodium hydrid
  • finely powdered metals such as aluminum, cerium, iron, bismuth copper, Cu/ZnO/ANO, magnesium, nickel, Raney nickel, calcium, titanium, tantalum, hafnium, zirconium, uranium, plutonium, etc.
  • iron sulfide, fire steel yellow phosphorus, white phosphorus, diethylethoxyaluminium, dichloro(methyl)silane, diethylaluminium hydride, trimethylaluminium, butyllithium, triethylboron, dicobalt octacarbonyl, nickel carbonyl, CH ;TcH.
  • arsine Germane, diborane, phosphine, silane, hydrazine, metalorganics of main group metals (e.g. aluminium, gallium, indium, zinc and cadmium etc.), triethylborane etc.
  • coating(s) 116 might comprise any one or more of a variety of materials, chemistries, substances that may be coated in the compartmentalized cavity 112, as outlined below.
  • polymers / monomers / organic materials outgas when put under vacuum conditions.
  • the compartmentalized cavity 112 can be coated with any such material. This coating will then keep on outgassing and the pressure deferential between the gas pressure in the cavity 112 and the gas pressure of the ambient will keep on reducing, until that time that both the gas pressures (that of gas in the cavity 112, and that of ambient) are similar and the removably secured microelectronics substrate detaches.
  • This outgassing can be accelerated by using temperature either localized or global heating using the controllable release component 108, in compartmentalized cavity 112 of holding chuck 100. This allows the user to create“timed” detaching processes for the removably secured microelectronics substrate.
  • organics such as photo-resist, benzocyclobutene (BCB), polyimides, spin-on polymers, etc., may also be used since these are compatible with semiconductor processing tools.
  • Another example might be the deposition of selenium (or another suitable material that sublimes: goes from solid to vapor state) in the compartmentalized cavity 112.
  • the gaseous expansion due to sublimation
  • the gaseous expansion will detach the removably secured microelectronics substrate.
  • controllable release component 108 may be deposited on or proximate to controllable release component 108 in one or more of the compartmentalized cavities 112.
  • Each compartmentalized cavity 112 in substrate body 104 may be a region wherein the substrate body 104 is removed to form a well, depression, or like void.
  • the compartmentalized cavities 112 in substrate body 104 in the holding chuck structure 124 are instrumental in removably secured microelectronics substrate (not shown) firmly in place, during processing, due to the forces exerted by the partial vacuum created in the cavities 112, as will be discussed.
  • Compartmentalized cavities 112 may be created using a variety of techniques such as wet chemical etching processes, electrolyte anodizing of semiconductors, dry etching processes such as reactive ion etching (RIE), plasma / planar etching, plasma enhanced etching (PE), inductively coupled plasma etching (ICP), deep reactive ion etching (DRIE), sputtering, ion enhanced etching, ion beam milling, chemically assisted ion beam milling, electron cyclotron resonance plasma (ECR), high density plasma (HDP), microwave and RF plasma assisted etching, laser induced / assisted chemical etching, may be employed for the same effect.
  • the chemical source maybe introduced as flood, time-varying, spatially varying, or continuous.
  • Compartmentalized cavities 112 may be created by one or more alternative techniques, such as laser ablation, laser photo-ablation, laser induced etching, laser assisted direct imprint (LADI), laser chemical etching, femto second laser ablation and other ultra- fast laser based etching phenomenon.
  • alternative techniques such as laser ablation, laser photo-ablation, laser induced etching, laser assisted direct imprint (LADI), laser chemical etching, femto second laser ablation and other ultra- fast laser based etching phenomenon.
  • Each compartmentalized cavity 112 in the holding chuck structure 124 is distinct from a thru hole in that the cavity 112 does not extend through the entire thickness of the substrate body 104. (See, e.g., FIG. 2, FIG. 3). That said, as described below, some techniques for making holding chuck structure 124 can involve providing a layer containing thru-holes in one or more layers that are then mated with another layer that closes one end of the thru-holes. [0116] There are no limits on the depth of each compartmentalized cavity 112 in relation to the thickness of substrate body 104. There are no restrictions on the shape, size, and pitch of the compartmentalized cavities 112.
  • the plurality of compartmentalized cavities 112 created in substrate body 104 may be identical through the entire thickness of the substrate body 104 chuck, or the shape and size of the compartmentalized cavities 112 created in the substrate body 104 may not be identical for the entire thickness of the substrate body 104.
  • a plurality of compartmentalized cavities 112 can be positioned with sub-micron accuracy down to even sub nanometer accuracy relative to their desired spatial positions, depending on the choice of substrate body 104 and the choice of patterning and formation techniques.
  • a plurality of compartmentalized cavities 112 can be made of any size from sub-micron diameters to several microns, to 10’ s of microns in diameter. There are no fundamental limits on the size of compartmentalized cavities 112. This is dictated by the particular application.
  • a plurality of compartmentalized cavities 112 can be made of any geometrical shape.
  • the shape and size of the plurality of compartmentalized cavities 112 may be identical through the entire thickness of the substrate body 104, or the shape and size of the plurality of
  • compartmentalized cavities 112 may not be identical for the entire thickness of the substrate body 104.
  • Plurality of compartmentalized cavities 112 can be as close or as far apart from each other.
  • the plurality of compartmentalized cavities 112 can be separated from each other by 10’ s of microns, or less than a micron, or sub-micron, as dictated by intended application.
  • compartmentalized cavities 112 While certain representative features of the compartmentalized cavities 112 have been mentioned for purposes of illustrating aspects the invention, it will be apparent to those skilled in the art that other features may be incorporated in compartmentalized cavity 112 without departing from the scope of the invention, which is defined in the appended claims. [0124] II .D Optional Coating(s) on Front Surface
  • Coating(s) 120 on front surface of substrate body 104 may be considered to form the working face of the holding chuck 100, i.e., the fact of the holding chuck that engages a microelectronics substrate or other workpiece.
  • Coating(s) 120 may include functional materials that assist with removably securing a microelectronics substrate, such as sealing gasket materials, adhesives, magnetic films, and electret films, among others.
  • coating(s) 120 may comprise one or more of the following materials: metals such as copper, aluminum, indium, gallium, solders, eutectics, gold, nickel, vanadium, platinum, graphite (graphene), among others; organic compounds such as nitrile, nitrile rubber, fluorocarbon, fluorosilicone, ethylene propylene, perfluoro elastomer, perfluorinated elastomer, silicone, silicon rubbers, butyl, neoprene, isoprene, chloroprene, polyurethane, rubber, etc.
  • metals such as copper, aluminum, indium, gallium, solders, eutectics, gold, nickel, vanadium, platinum, graphite (graphene), among others
  • organic compounds such as nitrile, nitrile rubber, fluorocarbon, fluorosilicone, ethylene propylene, perfluoro elastomer, perfluorinated elastomer, silicone
  • a purpose of this/these coating(s) 120 is to act as a compressible cushion so that even if the surface quality / features on the front surface of substrate body 104 of the holding chuck structure 124 and the back surface of the microelectronics substrate are not perfect, when the surfaces are reversibly secured, they will allow the formation of a vacuum seal. Note that the metal layers (if used) are not used to bond / solder the two surfaces; they simply act as compressible seals.
  • Coating(s) 120 may comprise of an adhesive layer.
  • the adhesive layer material may be naturally occurring or synthetic.
  • the adhesive layer material may be organic, inorganic, or hybrid in composition.
  • the adhesive layer material may comprise of monomers, polymers in composition.
  • the adhesive layer material may be one part, or multi-part compound.
  • the adhesive layer may be single use, or multi-use.
  • the adhesive material has low tack (low adhesion force).
  • the adhesive material does not leave residue (or leaves minimum residue), on the device wafer / semiconductor wafer post its release.
  • adhesive materials include: natural materials such as: plant resins, animal by-products, collagen, rubber, honey, syrup, pitch, cement; synthetic materials such as non reactive adhesive materials like pressure sensitive adhesive (PSA), solvent based adhesives, polymer dispersion adhesives, contact adhesives, hot melt adhesives (thermoplastics), glues, parylenes.
  • PSA pressure sensitive adhesive
  • multi part adhesives - reactive adhesives such as acrylics, cyanoacrylates, RTV, silicones, PDMS, elastomers, urethanes, epoxies, emulsions, thermosetting polymers, polyester resin - polyurethane resin, polyols - polyurethane resin, acrylic polymers - polyurethane resins. These may also include water or solvent soluble adhesive, etc.
  • the adhesive chemistries may be cured / activated using plasma, light, UV, temperature, pressure, anaerobic environment, moisture, etc.
  • the thickness of the adhesive layer may range from a few nanometers to several microns or more as desired by application.
  • This adhesive layer may be deposited on the back surface of the microelectronics substrate or may be deposited on the front surface of substrate body 104 of holding chuck structure 124, or may be deposited on both surfaces, if so desired.
  • the adhesive layer coating may be deposited by any known conventional deposition means such as: PVD, filament evaporation, RF heating, electron beam, ion assisted electron beam, sputtering, diode sputtering, magnetron sputtering, DC sputtering, bias sputtering, RF sputtering, CVD/thermal CVD/LPCVD /PECVD/APCVD/HDPCVD/ECR-PECVD/ LTPECVD/MOCVD/ PVD/hot-wire CVD, sol gel, evaporation, molecular beam (MBE) evaporation, molecular vapor deposition (MVD), ALD, ion-plating, electro-plating, dip-plating (dipping), hot dipping, and electroless-plating.
  • PVD molecular beam
  • MBE molecular beam
  • ALD ion-plating
  • electro-plating electro-plating
  • dip-plating dip-plating (dipping), hot
  • coating processes such as a Langmuir-Blodgett process, spin-coating process, spray-coating process, and roll-on coating process; printing processes, transfer processes, ink-jet processes, and powder-jet processes, etc., may also be utilized.
  • coating(s) 120 may comprise a magnetic or paramagnetic material. If the microelectronics substrate can be coated with a functional material (material that has intrinsic use and purpose in the final device) that is magnetic or paramagnetic, then such a microelectronics substrate can be removably secured by using one or more permanent magnetic coating(s) 120 on the top surface of the substrate body 104 of holding chuck structure 124. Techniques for making permanent magnetic coating 120 are well known in literature and not elaborated on here. [0137] II.D.4 Electret Layer
  • Coating(s) 120 may compose an electret layer.
  • Electrets are dielectrics that retain an electric moment even after the externally- applied field has been reduced to zero.
  • PVC poly vinyl chloride
  • PS polystyrene
  • PE polyethylene
  • PETP polyethylene terephthalate
  • PTFE polyethylene terephthalate
  • PVDF polyvinylidene difluoride
  • amorphous TEFLON® type PTFE polyvinylidene difluoride
  • COCs cyclic olefin co-polymers
  • Electro-static electric field / force exerted by an electret coating can be used to removably secure a microelectronics substrate by depositing an electret coating 120 on the top surface of the substrate body 104 of holding chuck 100.
  • Techniques for making electret coating 120 are well known in literature and not elaborated on here.
  • FIG. 4 illustrates a method 400 of forming the holding chuck 100 (FIG. 1), with FIG. 5E illustrating the particular components of the holding chuck resulting from performing the method 400 of FIG. 4.
  • FIG. 4 illustrates a method 400 of forming the holding chuck 100 (FIG. 1), with FIG. 5E illustrating the particular components of the holding chuck resulting from performing the method 400 of FIG. 4.
  • the activities of the blocks of method 400 need not necessarily be performed in the order presented to achieve an equivalent result.
  • a suitable substrate body 512 (FIG. 5A) is selected based on factors and criteria discussed elsewhere in this disclosure.
  • compartmentalized cavities 520 FIG. 5B can be create in front surface 516 of the substrate body 512 at block 410.
  • corresponding respective controllable release components in the form of resistive-type heater 524 (FIG. 5C) can be created or placed in compartmentalized cavities 520 in substrate body 512.
  • a coating 528 (FIG. 5D) can be deposited on the resistive-type heaters 524 in compartmentalized cavities 520.
  • a working face coating 532 (FIG. 5E; see also optional coating(s) 120 of FIG. 1) can be deposited on front surface 516 of substrate body 512.
  • FIG. 6 illustrates a method 600 of forming the holding chuck 100 FIG. 1, with FIG. 7C illustrating the particular components of the holding chuck resulting from performing the method of FIG. 6.
  • the activities of the blocks of method 600 need not necessarily be performed in the order presented to achieve an equivalent result.
  • a monolithic silicon substrate body 712 (FIG. 7A) is selected.
  • Silicon wafers are widely available, large area (300 mm in diameter and even greater), and low cost. Furthermore, there is a large existing silicon manufacturing base that can shape and tailor the silicon wafer and its surfaces with very high precision at low cost. Furthermore, by leveraging existing silicon processes it is possible to create micron sized, and nanometer sized features / cavities in silicon readily. Any silicon crystal orientation, for example, Si (100), Si (111), etc., may be used. In lieu of silicon, a glass substrate may be used.
  • the substrate material and its associated thickness chosen for the holding chuck has high rigidity. It can also be advantageous to manufacture the holding chuck with very high level of optical flatness (both local and global flatness) and with high levels of parallelism between the front and back surfaces 716, 728, respectively, of the holding chuck. There are no constraints or absolute values on this flatness and parallelism and the desired values are typically dependent on the end application. It would further be advantageous to polish both the front and back surfaces 716, 728, respectively, of the holding chuck to a very low surface roughness. There are no constraints or absolute values on this surface roughness figure and the desired values are typically very dependent on end application. The back surface 728 could just be left ground and not polished, if so desired.
  • compartmentalized cavities 720 can be create in front surface 716 of the substrate body 712 at block 610.
  • controllable release components in the form of resistive-type heaters 724 (FIG. 7C) can be created or placed in compartmentalized cavities 720.
  • the resistive-type heaters 724 may be created in-situ in the compartmentalized cavities 720 of the silicon 712 holding chuck, or they may be built ex-situ and then assembled in the compartmentalized cavities 720 of the silicon 712 holding chuck.
  • Each resistive-type heater 724 may be the same as or similar to any of the resistive-type heaters disclosed herein and may be individually controlled or controlled in one or more groups in the same or similar manner(s) described herein.
  • any one or more of coatings 116 and any one or more of coatings 120 may be incorporated into method 600 of FIG. 6 as desired to suit a particular application.
  • FIG. 8 illustrates a method 800 of forming the holding chuck 100 of FIG. 1, with FIG. 9E illustrating the particular components of the holding chuck resulting from performing the method of FIG. 8.
  • the activities of the blocks of method 800 need not necessarily be performed in the order presented to achieve an equivalent result.
  • a first substrate 912 (FIG. 9A) is selected.
  • the first substrate 912 may be made of silicon or any other material(s).
  • controllable release components in the form of resistive-type heaters 924 (FIGS. 9B and 9C) can be created or placed in or on front surface 916 of the first substrate 912 at block 810.
  • the resistive- type heater 924 are substantially in-plane 932 and may be the same or similar to any one or more of the heaters described in this disclosure.
  • substantially in-plane refers to the height difference between the top or bottom surface of the resistive-type heater 924 with the front surface 916 of the first substrate 912, with this height difference being less than 1 mm for in-planeness.
  • the resistive-type heaters 924 are substantially out-of-plane.
  • substantially in-plane resistive-type heaters are depicted in method 800, the resistive-type heaters could also be substantially out-of-plane.
  • FIG. 9C depicts a top view of the resistive-type heater 924 created in front surface 916 of first substrate 912.
  • a second substrate 928 (FIG. 9D) is selected.
  • Second substrate 928 too, many be silicon or any other suitable material(s).
  • thm-holes 920 are created in the second substrate 928 (FIG. 9D).
  • Thru-holes 920 are also commonly referred to as “vias” or“orifices” in the industry. Thm-holes 920 are formed through the entire thickness of the second substrate 928.
  • first substrate 912 and second substrate 928 are aligned and bonded together at surface 916 on substrate body 912. Ideally the alignment is done such that thru-holes 920 in substrate body 928 line up with the resistive-type heaters 924 on substrate body 912 (FIG.9E).
  • substrate body 912 can be incorporated into a holding chuck made in accordance with the present disclosure, including holding chuck 100 of FIG. 1 and as a substitute for any unitary monolithic substrate body described herein.
  • Alignment techniques to align a wafer with a secondary substrate are well known in prior art and not repeated here. Alignment techniques using fiduciary marks on some or all relevant wafers / surfaces, with or without secondary optical elements likes microscopes, objectives etc. are well known in the semiconductor industry and not detailed here. Toolsets that allow for relative motion of the wafer and secondary substrate in the x, y, z, and theta axis are well known, and not detailed here. Similarly, the use of illumination optics in the visible, UV, NIR, and MWIR spectral regions are well known and not detailed here.
  • Bonding processes may include microwave bonding, anodic bonding, fusion bonding, adhesive bonding (including glues, silicones, RTV, urethanes, etc.), epoxy bonding, polyimide bonding, BCB (benzocyclobutene) bonding, photo resist / photo polymer bonding, UV curable materials bonding, metallic bonding, eutectic bonding, solder bonding, indium bonding, thermo-compression bonding, thermo-sonic compression bonding, and / or low temperature glass bonding, glass frit bonding, hybrid bonding (metal + dielectric), plasma enhanced bonding, oxide bonding, DBI (direct bond interconnect), wax bonding, mechanical contact bonding, micro-tube bonding, silicide bonding, laser welding, ultrasonic welding, etc.
  • Bonding may also be initiated by surface treatments using chemicals, activated plasma treatments, vacuum processes etc. These chemicals may be cured / activated using plasma, light, UV, temperature, pressure, anaerobic environment, etc.
  • FIG. 11 A and 11B illustrate various aspects utilizing a holding chuck 1100 in removably securing a microelectronics substrate 1124 to the holding chuck.
  • the holding chuck 1100 may be the same as or similar to any suitable holding chuck disclosed herein.
  • example holding chuck 1100 includes a substrate body 1104 having a front surface 1108 and incorporating controllable release components in the form of resistive-type heaters 1112 located correspondingly and respectively in a plurality of
  • compartmentalized cavities 1116 Facing the front surface 1108 is the microelectronics substrate 1124 having front surface 1128 and back surface 1132. As depicted, back surface 1132 of microelectronics substrate 1124 is facing front surface 1108 of the holding chuck 1100.
  • One or more optional coatings 1108 on front surface may function as a sealing gasket as describe elsewhere in this disclosure.
  • the holding chuck 1100 may be affixed to a separate holding fixture (not shown) in any suitable manner, as desired or needed.
  • Holding fixtures are commonly known in prior art and may comprise of porous / non-porous vacuum chucks, electro- static chucks, clamps, jigs, mounts, thermal or non-thermal adhesive tapes, UV tapes, etc.
  • FIG. 11B illustrates the removably securing process, wherein the back surface 1132 of the microelectronics substrate 1124 is secured to the front surface 1108 of the holding chuck 1100 by bringing the microelectronics substrate 1124 proximate to the holding chuck 1100 at the front surface 1108 and holding them firmly against each other during or post evacuating the gaseous component in the compartmentalized cavities 1116 of the holding chuck 1100.
  • the wafer assembly 1136 is bonded due to differential pressure between the partial vacuum created in the compartmentalized cavity 1116, versus ambient pressure (atmospheric pressure, if atmosphere is the ambient). Ideally, this bonding between the wafers is temporary and reversible.
  • Evacuation of the gaseous component(s) in the compartmentalized cavities 1116 can be performed utilizing any of a number of active / passive techniques for generation of vacuum, as described below. One or more of the described techniques might be used together, if so desired.
  • a vacuum is a physical space / region that is partially or completely exhausted of any air (or gaseous component), by an artificial means to the highest degree possible.
  • External method for evacuating the gaseous component may include dynamic / active systems such as, but not limited to: suction pumps, positive displacement pumps, external vane pumps, internal vane pumps, rotary vane pumps, Roots-type blower or pump, single and multi-stage Roots-type blower, diaphragm pump, liquid ring, piston pump, scroll pump, screw pump, Wankel-type pump, Toepler-type pump, lobe pump, Venturi vacuum pump, steam ejector, etc.
  • Momentum transfer pumps for example, molecular pumps, diffusion pump, turbomolecular pump, etc., and entrapment pumps, such as cryopumps, getters, ion pumps, sputter ion pumps, etc., can also be used, as can regenerative pumps.
  • compartmentalized cavities 1116 for evacuating the gaseous component for generating vacuum may be used. Examples of such methods may include, but are not limited to the following.
  • Two substrates can be joined face to face, with one (or both) substrate(s) containing exposed depressions in / on its surface (cavities) facing the joining seam, in a vacuum environment. This physical joining can be performed with or without heating the joined assemblage. On removal from the vacuum chamber into air and at room temperature, the two substrates will be held, or bonded, together. Atmospheric pressure forces the substrates together due to the partial vacuum (removal of air / gas) created in the cavities.
  • Vacuum can also be generated, in-situ, by heating the resistive-type heaters 1112 in the compartmentalized cavities 1116.
  • the resistive-type heaters 1112 will heat the gas in their proximity. This heated gas expands and thus displaces some volume of gas from the
  • Vacuum can also be generated, in-situ, by burning (e.g., using a pyrophoric substance) or heating a contained volume of air/ gas with an orifice (air outlet) to allow for gas expansion and leaking and then plugging the orifice (air outlet) rapidly, prior to cool down of the remainder, contained volume of air / gas. This can be readily achieved by depositing pyrophoric materials in the compartmentalized cavities 1116, then by heating the resistive-type heaters 1112 in the compartmentalized cavities.
  • Vacuum can also be generated, in-situ, by employing one or more getter materials in the compartmentalized cavities 1116.
  • getters can be deposited in the compartmentalized cavities 1116 in between the two joining the holding chuck 1100 and the microelectronics substrate 1124, and then the getters can be discharged (heated or somehow activated (heat, light, moisture, electro-magnetic radiation, microwaves, etc.) to release their air / gas components).
  • the holding chuck 1100 and the microelectronics substrate 1124 will be bonded together, because the getter materials will re-adsorb any residual air / gas / moisture in the cavity creating partial vacuum.
  • This discharging can be readily achieved by heating the resistive-type heaters 1112 in the compartmentalized cavities 1116.
  • Vacuum can also be generated, in-situ, by joining the holding chuck 1100 and the microelectronics substrate 1124 face to face, with one (or both) substrate(s) containing exposed depressions in / on its surface (compartmentalized cavities 1116) facing the joining seam.
  • the getter material may be activated using a suitable impulse to adsorb some portion of the gaseous component in the compartmentalized cavities 1116 to create partial vacuum, which leads to bonding.
  • the now discharged getter material will re-adsorb some portion of the gaseous component in the cavities to create partial vacuum, resulting in bonding.
  • Example Joining the holding chuck 1100 and the microelectronics substrate 1124 together. Annealing the assembly of the holding chuck 1100 and the microelectronics
  • compartmentalized cavities with the material making up the substrate body of the holding chuck 1100, and / or the microelectronics substrate 1124.
  • the by-product of the chemical reaction consumes some volume of the gaseous component in the compartmentalized cavities 1116, leading to reduction in partial pressure and thereby resulting in bonding.
  • Level of vacuum required to create functionality A figure of merit for the amount of vacuum, also called“vacuum quality,” for a system can be sub-divided into ranges. These ranges do not have universally agreed definitions, but typical distributions are as follows:
  • the vacuum levels utilized in this work might also extend from 760 Torr (atmospheric pressure) to the“Rough” vacuum range.
  • the gases in the compartmentalized cavities 1116 might be a pure gas (pure oxygen, pure nitrogen, etc.), a mixture of gases (oxygen + nitrogen, 20 % oxygen, air, etc.).
  • the gases may be active or inert, if so desired.
  • microelectronics substrate 1124 As an example of microelectronics substrate 1124, consider an inorganic LED wafer below.
  • the starting growth substrate / platforms for III - V Nitrides are well known in prior art. Some of them, but not all, are outlined below: GaN on GaN, GaN on Sapphire, GaN on SiC, GaN on Si, GaN on AIN, GaN on Ga203, GaN on hBN, GaN on Graphene, GaN on WSe2, etc.
  • the growth substrate can be transparent or opaque. The growth films, once grown can be processed further on the growth substrates into microLEDs.
  • III - V Nitride film growth techniques are known in prior art and in production.
  • the growth techniques may involve any known conventional deposition means such as PVD processes such as: MBE or, CVD processes such as, but not limited to: MOCVD, HVPE, LPCVD, HDPCVD, ECR-PECVD/ LTPECVD/ /PVD/, LPE, PLD, etc.
  • III - V Nitride LEDs may include electro luminescent devices in the form of simple P/N junctions, PIN junctions (homo and heterojunctions), single heterojunction, dual heterojunction, multi-heterojunctions, band-gap engineered Quantum confined structures such as: quantum wells, strained quantum wells, superlattices (Type I, Type II), quantum wires, quantum dots, quantum nanotubes (hollow cylinder), quantum nanowires (solid cylinder), quantum nanobelts (solid rectangular cross section), quantum nanoshells, quantum nanofiber, quantum nanorods, quantum nanoribbons, quantum nanosheets, etc.
  • GaN / InGaN III - V Nitride
  • the GaN / InGaN might be Wurtzite or cubic in crystal phase.
  • the growth films can be transferred onto another, secondary substrate prior to being processed into microLEDs.
  • Laser lift off techniques may include using an excimer layer, using a YAG laser, etc. Techniques and absorbing layers have been developed such that thin film removal can be effected by using lasers from the UV - Vis - NIR - MWIR range of wavelengths.
  • Chemical lift off techniques such as: photo-electro chemical etching (PEC etching), electro chemical etching, liquid etching, molten chemical etching, etc.
  • the sacrificial growth layers may include, but not limited to, GaN, Ga 2 0 3 , CrN, ZnO, A1N.
  • Stress induced transfer techniques such as natural stress induced lift off, thermal stress induced lift off, ion implanted stress lift off, hydrogen / helium implanted stress lift off, etc., can be used
  • Mechanical stress induced transfer techniques can include deposition and physical peeling of the GaN / InGaN stack from a 2D sacrificial growth layer of hBN, MoS 2 , MoSe 2 , WS 2 , graphene, mica, etc.
  • LED device architectures are elaborated on, it is self-evident that other electronic and opto-electronic devices manufactured in silicon (Si), silicon germanium (SiGe), germanium (Ge), silicon-on-insulator (SOI), silicon on sapphire, germanium on insulator, GaP, GaAs, etc., substrates could be utilized.
  • Electronic devices might include, but not limited to, devices such as RFIDs, MEMs, ICs, Photovoltaic Solar Cells (PV), Focal Plane Arrays (Sensors), CMOS detectors, CCD detectors, Quartz oscillators, etc.
  • the devices might work in any electro -magnetic / spectral region, from UV- Vis-NIR-MWIR-FIR spectral regions or beyond.
  • FIG. 12A-12B illustrate alternate blocks in utilizing the holding chuck of FIG. 1 in removably securing a microelectronics substrate.
  • FIG. 12A illustrates an example holding chuck 1200 that includes a substrate 1204 having a front surface 1208 and incorporating controllable release components in the form of resistive-type heaters 1212 located in compartmentalized cavities 1216.
  • Facing front surface 1208 is a microelectronics substrate 1224 having a front surface 1228 and a back surface 1232.
  • the back surface 1232 of microelectronics substrate 1224 is the facing front surface 1208 of the holding chuck 1200.
  • Surfaces 1232 and 1208 that will confront and engage one another during the bonding process are first conditioned and prepped for bonding.
  • FIG. 12B illustrates the securing process, wherein the back surface 1232 of the microelectronics substrate 1224 is bonded to the front surface 1208 of the holding chuck 1200 by bringing the microelectronics substrate 1224 proximate to the holding chuck 1200 at the front surface 1208 and holding them proximate or in intimate contact with each other.
  • the assembly 1236 is bonded due to the prepped surface chemistries of these cleaned surfaces, the bonding occurs so called spontaneously.
  • the bonding between the holding chuck 1200 and the microelectronics substrate 1224 can occur under controlled ambient (vacuum environment, elevated or low temperature, etc.) or at room temperature.
  • Initial bonding strength is dependent on many factors including nature and quality of the cleaning, additional surface preparations (flatness, roughness, additional chemical treatments), reactive surface species (hydrophobic, hydrophilic, etc.), environment, bonding temperature, etc. In most cases, it is typical to anneal the bonded assembly at high temperature to increase the bond strength and make it permanent.
  • the initially bonded wafers are used as is to allow for removably securing, without any subsequent high temperature annealing blocks.
  • This bonding technique of FIG. 12A and 12B may be used along with the bonding technique revealed in FIGS. 11A and 1 IB earlier, if so desired.
  • FIG. 13 illustrates an alternate method in utilizing an example holding chuck 1300 of the present disclosure in removably securing a microelectronics substrate.
  • holding chuck 1300 includes a substrate body 1304 having a front surface 1308 and incorporating controllable release components in the form of resistive-type heaters 1312 located in the compartmentalized cavity 1316. Facing the front surface 1308 is the microelectronics substrate 1324 having front surface 1328 and back surface 1332. As depicted, the back surface 1332 of the microelectronics substrate 1324 is facing the front surface 1308 of the holding chuck 1300.
  • an adhesive coating layer 1340 can be preferentially deposited atop surface 1308 so as not to obscure compartmentalized cavity 1316.
  • an adhesive coating layer 1336 can be deposited over surface 1332. This prepares the holding chuck 1300 and microelectronics substrate 1324 for adhesive bonding.
  • the adhesive layer or layer can serve to planarize and remove any surface mis-match / errors between the surfaces 1332 and 1308.
  • the adhesive layer(s), here layers 1336, 1340 serve(s) as an intermediary to bond the two surfaces 1332, 1308 together.
  • This bonding technique of FIG. 13 may be used along with the bonding technique revealed in FIGS. 11A and 11B earlier, if so desired.
  • FIG. 14A to 14C illustrate some example alternative methods of utilizing holding chucks 1400A to 1400C of the present disclosure for removably securing a microelectronics substrate 1424 thereto.
  • FIG. 14A shows holding chuck 1400A that includes a substrate body 1404 having front surface 1408 and including controllable release component in the form of resistive-type heaters 1412 located correspondingly and respectively in compartmentalized cavities 1416. Facing the front surface 1408 is microelectronics substrate 1424 having a front surface 1428 and a back surface 1432. As depicted, the back surface 1432 of the microelectronics substrate 1424 is facing the front surface 1408 of the holding chuck 1400A. [0223] As depicted, one or more magnetic coating layer 1436 can be preferentially deposited atop surface 1408 so as not to obscure compartmentalized cavity 1416.
  • the microelectronics substrate 1424 can be coated with a functional material (material that has intrinsic use and purpose in the final device) that is magnetic or paramagnetic, then such a microelectronics substrate could be removably secured by using the permanent magnetic coating layer(s) 1436 on the front surface 1408 of the holding chuck 1400A.
  • a functional material material that has intrinsic use and purpose in the final device
  • the permanent magnetic coating layer(s) 1436 could be removably secured by using the permanent magnetic coating layer(s) 1436 on the front surface 1408 of the holding chuck 1400A.
  • FIG. 14B is identical to FIG. 14A with the exception that one or more electret coating layer 1440 is deposited atop front surface 1408 of the holding chuck 1400B.
  • Each electret coating layer 1440 may any one or more of the electret materials described herein, among others.
  • Electro-static electric field / force exerted by an electret coating can be used to removably secure the microelectronics substrate 1424 onto the holding chuck 1400B.
  • FIG. 14C is identical to each of FIGS. 14A and 14B with the exceptions that a liquid layer 1444 is housed in the compartmentalized cavities 1416 of the holding chuck 1400C, atop the controllable release components that here are in the form of resistive-type heaters 1412.
  • liquid layer 1444 can be used to removably secure the microelectronics substrate 1424 onto the holding chuck 1400C.
  • the liquid layer 1444 can be organic or inorganic or hybrid in composition. Furthermore, the liquid layer 1444 might also have a gel-like consistency.
  • FIGS. 14A to 14C The process of bringing the holding chuck 1400C and/or the microelectronics substrate 1424 proximate to each other to initiate bonding are not depicted in FIGS. 14A to 14C, as these are known in prior art.
  • FIG. 14A-14C may be used along with the bonding technique revealed in FIGS. 11A-11B earlier, if so desired.
  • FIG. 15 illustrates an example of using a holding chuck 1500 of the present disclosure in an application wherein a microelectronics substrate 1524 is processed while being held by the holding chuck.
  • the holding chuck 1500 includes a substrate body 1504 having front surface 1508 and including controllable release components in the form of resistive-type heaters 1512 located in compartmentalized cavity 1516. Facing the front surface 1508 of the holding chuck 1500 is microelectronics substrate 1524 that has a front surface 1528 and a back surface 1532. As depicted, the back surface 1532 of the microelectronics substrate 1524 is facing the front surface 1508 of the holding chuck 1500.
  • a release process is initiated to release / de-bond the removably secured microelectronics substrate 1524 from the holding chuck 1500. This release / de bonding might be necessary post processing the device wafer 1524 or to re-position the
  • microelectronics wafer 1524 on the holding chuck 1500 among other things
  • microelectronics substrate 1524 can be performed by creating the necessary conditions to equalize or elevate, relative to surrounding ambient, the pressure in the compartmentalized cavities 1516 that removably secures the microelectronics substrate 1524 to the holding chuck 1500.
  • This pressure equalization (or elevation) to negate the partial vacuum removably securing the microelectronics substrate in place can be achieved by using, for example, any one or more of the following techniques, among others.
  • Activating the pyrophoric compound (to cause gaseous expansion) (coating 116 in FIG.l) that may be pre-deposited in the compartmentalized cavities 1516 of the holding chuck 1500. This activation may be performed using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500.
  • Global heating of the holding chuck 1500 would cause an expansion of the trapped (residual) gases in the compartmentalized cavity 1516. This expansion would result in a release of the attached microelectronics substrate 1524.
  • This global heat source could be external, or internal (e.g., heat supplied by activating the resistive-type heaters 1512).
  • Activating the vacuum activated materials to cause gaseous expansion
  • This activation may be performed using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500. Examples of vacuum-activated materials suitable here are described above.
  • substrate 1524 can also be achieved by using differential pressure so that the air / gas pressure in the compartmentalized cavities 1516 of the holding chuck 1500 is higher than the air / gas pressure surrounding the microelectronics substrate 1524. That is to say, the surface 1528 of the
  • microelectronics substrate 1528 facing away from the holding chuck 1500 is in an ambient with much higher vacuum (lower pressure) than the surface 1532 of the microelectronics substrate 1532 facing the holding chuck 1500.
  • the temperature of the assembly of the microelectronics substrate 1524 and the holding chuck 1500 at which this separating / de-bonding is initiated / performed There are no limitations / constraints on the temperature of the assembly of the microelectronics substrate 1524 and the holding chuck 1500 at which this separating / de-bonding is initiated / performed.
  • the process may be performed at ambient temperature, or a temperature lower than ambient, or a temperature higher than ambient, either or for the wafer assembly or the tool / room temperature.
  • holding chuck 1500 allows for two wafers to be secured temporarily and reversibly.
  • FIGS 16 and 17A to 17C illustrate an example method 1600 of utilizing an example holding chuck 1700 made in accordance with aspects of the present disclosure to handle a microelectronics substrate 1724 and also to hold the microelectronics substrate during creation of individual microelectronic-device dies 1744.
  • the microelectronics substrate 1724 (FIG. 17A) is removably secured to the holding chuck 1700.
  • holding chuck 1700 includes a substrate body 1704 having front surface 1708 and that includes controllable release component in the form of resistive-type heaters 1712 located correspondingly and respectively in a plurality of compartmentalized cavities 1716. Facing the front surface 1708 is a front surface 1728 of the microelectronics substrate 1724.
  • microelectronics substrate 1724 includes various microelectronic device coating layers 1736, which may be located on the front surface 1728 or the back surface 1732, or both the front and back surfaces. There are no implied limitations on orientation of the microelectronic device layers 1736 with respect to surface of the microelectronics substrate 1724. As depicted, the back surface 1732 of the microelectronics substrate 1724 is removably secured at the front surface 1708 of the holding chuck 1700 to form an assembly 1740.
  • the microelectronics substrate 1724 may further processed to create individual microelectronic-device die 1744, in-situ, in microelectronics substrate 1724.
  • the microelectronic device layers 1736 and the microelectronics substrate 1724 are partitioned / singulated into individual microelectronic- device die 1744 by an etching process 1748.
  • Spin coating for a photo-resist, patterning for the photo-resist, exposing the photoresist, and other photolithography processes are well known in prior art and not elaborated upon herein.
  • Etching techniques to create the individual microelectronic-device die 1744 may include, but not limited to wet chemical etching processes, dry etching processes such as reactive ion etching (RIE), plasma / planar etching, plasma enhanced etching (PE), inductively coupled plasma etching (ICP), deep reactive ion etching (DRIE), sputtering, ion enhanced etching, ion beam milling, chemically assisted ion beam milling, electron cyclotron resonance plasma (ECR), high density plasma (HDP), microwave and RF plasma assisted etching, laser induced / assisted chemical etching, may be individually employed for the same effect.
  • the chemical source maybe introduced as flood, time-varying, spatially varying, or continuous.
  • the etching may be performed at low temperature, ambient temperature, or high temperature, and there are fundamentally no temperature constraints on the etching process.
  • Mechanical techniques to create the individual microelectronic-device dies 1744 might include any of a variety of equipment, such as dicing saws, dicing blades, scribing and break, ablation laser, microjet (with or without liquid), and stealth dicing, among others, may be used. Techniques such as laser ablation, laser photo- ablation, laser induced etching, laser chemical etching, femto- second laser ablation and other ultra- fast laser based etching phenomenon may also or alternatively be used.
  • the assembly 1740 may be cooled so as to prevent pre-mature activation of the getter, pyrophoric material, or vacuum activated materials (if present), or prevent the destruction of the resistive-type heater elements 1712, during the etching process at block 1610 to create the individual
  • microelectronic-device dies 1744 each comprise a corresponding portion of the microelectronic device layers 1736, plus a corresponding portion of the microelectronics substrate 1724.
  • the individual microelectronic-device die 1744 with just the microelectronic device layers 1736 without the underlying microelectronics substrate 1724, or individual microelectronic-device die 1744 with the microelectronic device layers 1736 and only part of the underlying microelectronics substrate 1724 attached.
  • the physical size of the individual microelectronic-device die 1744 created by this process may be of any suitable physical size and shape and dimension. Their largest dimension may be ⁇ 100 nm, or ⁇ 1 micron, or ⁇ 5 microns, or ⁇ 10 microns, or ⁇ 20 microns, or ⁇ 50 microns, or ⁇ 100 microns, or ⁇ 1000 microns, or in mm or cm scale.
  • the holding chuck 1700 and microelectronic substrate 1724 are aligned so that the individual microelectronic-device dies 1744 sit completely over (i.e., cover) one or more underlying compartmentalized cavities 1716. Generally, it is desired that each
  • microelectronic-device die 1744 cover at least one compartmentalized cavity 1716 to provide the desired holding and release functionalities.
  • this photoresist may be removed if so desired, for example, post processing the microelectronics substrate 1724 into individual microelectronic-device dies 1744. Removal steps and techniques for photo-resist removal are well known in prior art and not elaborated herein.
  • one or more individual microelectronic-device dies 1744 may be released from the holding chuck 1700 via a suitable release process (depicted by arrow 1752), for example, as described in FIG. 15 earlier.
  • microelectronics device wafer (or substrate) is mounted on a thermal or non-thermal adhesive tape, or a UV tape, which in turn might be mounted onto a porous / non-porous vacuum chuck, or an electro-static chuck.
  • thermal or non-thermal adhesive tape or a UV tape
  • electro-static chuck or an electro-static chuck.
  • the holding chuck 1700 can be used as the base / primary platform for holding / affixing the microelectronics substrate 1724 prior to (and during) etching the microelectronics substrate into individual microelectronic-device dies.
  • the holding chuck 1700 provides for a monolithic, rigid, passive, self- contained, internal and integrated vacuum holding force, which can be individually addressed and reversed to allow for clean release of micro-die(s)
  • FIGS.18 and 19A to 19E illustrate an example method 1800 of utilizing a holding chuck 1800 for the purpose of mass transferring of individual microelectronic-device dies 1944 created from a microelectronics substrate 1924.
  • the microelectronics substrate device 1924 (FIG. 19A) is removably secured to the holding chuck 1900.
  • the holding chuck 1900 includes a substrate body 1904 having front surface 1908 and that includes controllable release component in the form of resistive-type heaters 1912 located correspondingly and respectively in a plurality of compartmentalized cavity 1916. Facing the front surface 1908 is the microelectronics substrate 1924 that has a front surface 1928 and includes microelectronic device coating layers 1936 on front surface 1928 and/or a back surface 1932 (only shown on front surface 1928 in FIG. 19A). As depicted, the back surface 1932 of the
  • microelectronics substrate 1924 is secured at the front surface 1908 of the holding chuck 1900 to form an assembly 1940.
  • the microelectronics substrate 1924 (FIG. 19B) is further processed, in this example by etching 1948, to create individual microelectronic-device dies 1944, in-situ, from the microelectronics substrate 1924.
  • holding chuck 1900 (FIG. 19C) is flipped over with the attached individual microelectronic-device dies 1944, such that the individual microelectronic- device dies 1944 are facing a receiving support 1952.
  • the assembly 1940 is aligned with the receiving support 1952.
  • the receiving support 1952 may be a final / intermediate substrate and or location
  • the receiving support 1952 may be rigid or flexible and may be composed of one or more polymers, ceramics, metals, papers, fabrics, or glasses or any combination thereof, among other things.
  • the receiving support 1952 may be transparent, opaque, or translucent.
  • Each material of the receiving support 1952 may be a conductor, an insulator, or a semiconductor.
  • Each material may be inorganic or organic or a combination thereof and may be single crystal, polycrystalline, oriented (or textured) polycrystalline, or amorphous in morphology.
  • the thickness of the receiving support 1952 may range from a few microns to several millimeters as desired by application.
  • the surface of the receiving support may be planar (flat), or may be profiled with depressions, cavities, hills, etc.
  • the coating(s) may act as a flex / compliant layer, anti-stick /anti-abrasion layer, barrier layer, passivation layer, planarizing layer, UV protection layer, adhesive layer, color filters, black mask coating, anti-static layer, conductive layer, etc., or any combination thereof.
  • These functional layers include, but are not limited to, organic or inorganic layers.
  • the receiving support 1952 may include electronic circuitry or other electrical functionality pre-built into the receiving support. Examples of such receiving supports include, but are not limited to silicon CMOS back planes, silicon NMOS backplanes, silicon PMOS backplanes, TFTs on glass, PCBs, and FR4, among many others. [0276] It is noted that intermediate substrates are sometimes referred to as“interposers” in literature, and such interposers may be used as a receiving support of the present disclosure.
  • the assembly 1940 may be proximate to, but not touching, or may be spaced a little distance from the receiving support 1952, or the assembly 1940 may be in intimate contact with receiving support 1952 as illustrated at 1964.
  • one or more of the individual microelectronic-device dies 1944 are released from holding chuck 1900 by utilizing a suitable release impulse 1956, and transferred onto the receiving support 1952.
  • the release impulse 1956 for releasing the individual microelectronic-device die 1944 from the holding chuck may be triggered globally releasing all the individual microelectronic-device die 1944 at one time, or triggered locally releasing one individual microelectronic-device die 1944 at one time.
  • the transferred individual microelectronic-device dies 1944 are affixed onto the transferred location of the receiving support 1952 via bonding agent / seam 1960.
  • bonding agent / seam 1960 [0283]
  • Bonding agent 1960 may be electrically conductive; metals, silver paste, solders, eutectics, wire meshes, graphite / graphene, CNTs, other electrically conductive formulations.
  • Bonding agent 1960 may be electrically insulating; adhesives, polymers, photo-resist, BCP, glass frits, other electrically insulating formulations. Bonding agent 1960 may allow for temporary bonding or permanent bonding at the location.
  • bonding agent 1960 may utilize vacuum forces, magnetic forces, electro magnetic forces, Static Electricity forces (also called Electrets), Electro-Static forces, electrography / xerography (electrical forces) for removably securing the individual microelectronic-device die(s) 1944.
  • block 1825 of method 1800 could be implemented prior to block 1820 of method 1800.
  • Individual microelectronic-device die 1944 are first affixed onto the receiving support 1952 (FIG. 19D') ⁇
  • the individual microelectronic-device die 1944 are then released from holding chuck 1900 by utilizing suitable impulse 1956 (FIG. 19D"). Note that the process blocks of FIG. 19D, FIG. 19D', and FIG. 19D" can be combined together.
  • Mass transfer techniques differ from traditional serial pick and place techniques and typically involve the transfer of many multiple parts (dies, micro-die(s)) simultaneously, also referred to as parallel transfer. These parallel transfer techniques can further transfer parts deterministically (by design and intent), or
  • HMDs head mounted displays
  • VR virtual reality
  • AR augmented reality
  • MR mixed reality
  • NEDs near eye displays
  • the respective pixel and sub-pixel sizes for such ILED microdisplays can be on the order of sub 20 microns, or sub 10 microns, or even sub 5 microns.
  • Holding chucks of the present disclosure such as holding chuck 1900, solve the aforementioned and other issues.
  • the holding chuck 1900 can be used not only as the base / primary platform for holding / affixing the microelectronics substrate, prior to (and during) etching the microelectronics substrate, into individual microelectronic-device die, but also for the deterministic mass transfer of these etched individual microelectronic -device onto a separate, desired receiving support with a great degree of positional accuracy.
  • Holding chuck 1900 provides a convenient way of doing this.
  • FIGS. 20A to 20E illustrate another example variant of a holding chuck 2000 made in accordance with aspects of the present invention.
  • the holding chuck 2000 includes a substrate body 2004 having a front surface 2008 that that includes controllable release components in the form of resistive-type heaters 2012 located correspondingly and respectively in a plurality of compartmentalized cavities 2016.
  • Each of the compartmentalized cavities 2016 may be considered to have a top 2020.
  • Double-headed arrow 2024 refers to the tops 2020 of the compartmentalized cavities 2016 being substantially in-plane with the front surface 2008 of holding chuck 2000.
  • holding chuck 2000' includes a substrate body 2004' having a front surface 2008' and that includes controllable release components in the form of resistive-type heaters 2012', as well as out-of-plane compartmentalized cavities 2016' and tops 2020' of the out-of- plane compartmentalized cavities.
  • Doubled-headed arrow 2024' refers to the tops 2020' of the front surface 2008'
  • 2028' refers to the tops 2020' of the out-of-plane compartmentalized cavities 2016'.
  • tops 2020' are substantially out-of-plane with the front surface 2008'.
  • holding chuck 2000 includes a substrate body 2004" having a front surface 2008" and that includes controllable release components in the form of resistive-type heaters 2012" along with out-of-plane compartmentalized cavities 2016" and tops 2020" of the out- of-plane compartmentalized cavities.
  • Double-headed arrow 2028 refers to the tops 2020" of the out-of-plane cavity 2016
  • double-headed arrow 2024 refers to the front surface 2008" and the tops of the in-plane cavities 2032".
  • Out-of-plane compartmentalized cavities 2016" and in-plane compartmentalized cavities 2032" may be of the same / similar heights or be of different heights.
  • Holding chuck 2000 may contain both sets of compartmentalized cavities, as needed.
  • microelectronics substrate 2024 has a front surface 2028 and a back surface 2032 and includes microelectronics device coating layers 2036 on the front surface 2028.
  • the back surface 2032 is removably secured to a holding chuck (not depicted). Facing front surface 2028 is a receiving support 2052.
  • Some individual microelectronic-device dies 2044 are already transferred and affixed onto the receiving support 2052.
  • Out-of-plane cavities 2016' and 2016" allow for the placement of one or more individual microelectronic-device dies 2056 in between existing individual microelectronic-device dies 2044 on the receiving support 2052. This allows for the repair and removal of defective dies and replacement with known good dies, etc. This ability to finely manipulate in-between dies is very crucial for mass transfer techniques.
  • microelectronics substrate 2024' has a front surface 2028' and a back surface 2032' and includes microelectronics device coating layers 2036' on the front surface.
  • the back surface 2032' is removably secured to a holding chuck (not depicted).
  • Facing front surface 2028' is a receiving support 2052'.
  • Some individual microelectronic-device dies 2044' are already transferred and affixed onto the receiving support 2052'.
  • Out-of-plane cavities 2016' and 2016" (FIGS. 20B and 20C, respectively) allow for the placement of individual microelectronic-device die 2056' adjacent to existing individual
  • microelectronic-device die 2044' on the receiving support 2052' could be used to transfer individual microelectronic-device die onto holding chucks with out-of-plane compartmentalized cavities for further processing.
  • FIG. 21A illustrates another example variant of a holding chuck 2100 made in accordance with aspects of the present invention.
  • the holding chuck 2100 includes a porous film 2124 applied to the holding chuck.
  • the holding chuck 2100 includes a substrate body 2104 having a front surface 2108 and including controllable release components in the form of resistive-type heaters 2112 located correspondingly and respectively in a plurality of compartmentalized cavities 2116. Facing front surface 2108 is a porous film 2124 having a front surface 2128 and a back surface 2132.
  • the porous film 2124 forms the working face of the holding chuck 2100.
  • Microelectronic device coating layers 2136 are secured at front surface 2128 of the porous film 2124 of the holding chuck 2100 to form an assembly 2140.
  • Porous film 2124 may be any suitably porous film, such as a microporous film or a nanoporous film.
  • microelectronic device coating layers 2136 are just the functional device layers, i.e., without an underlying substrate.
  • the individual microelectronic-device dies (not shown) created from microelectronic device coating layers 2136 might be very thin and fragile.
  • Underlying micro / nanoporous film 2124 is used in this example to securely hold the functional device layers 2136 during and post individual microelectronic-device die creation and subsequent mass transfer of the individual microelectronic-device dies.
  • porous film 2124 comprises random pores 2148.
  • the porous film 2124 through its porosity 2148, connects the partial vacuum created in the compartmentalized cavities 2116 (FIG. 21 A) to the overlying microelectronic device layers 2136 and thus holds the microelectronic device layers 2136 firmly in place and spreads the holding force created by the partial vacuum over a larger surface area thus preventing the microelectronic device films 2136 from cracking.
  • Porous film 2124 may be made, for example, of any one or more dielectric (metallic / semiconductor) films / coatings, thin films with void - columnar networks, aerogels, hydrogels, mesoporous film, etc., which compositions and deposition techniques are known in prior art and are not repeated here.
  • Functional device layers 2136 can be separated from their underlying microelectronics growth substrate (not shown) using a variety of techniques that have been developed for specific industries. For example, some of the techniques for removal of GaN / InGaN (IP - V nitride) device films, used for making LEDs and lasers, from their growth substrate are cited below. Note that this list is not comprehensive.
  • Laser lift off techniques Using an excimer laser, using a YAG laser, etc. Techniques and absorbing layers have been developed such that thin film device layer removal can be effected by using lasers from the UV - Vis - NIR - MWIR range of wavelengths.
  • the sacrificial growth layers may include, but not limited to: GaN, Ga203, CrN, ZnO, A1N.
  • Stress induced transfer techniques Natural stress induced lift off, thermal stress induced lift off, ion implanted stress lift off, hydrogen / helium implanted stress lift off etc.
  • FIGS. 22A to 22C illustrate another example variant of a holding chuck 2200 (FIG. 22C) made in accordance with aspects of the present disclosure.
  • FIG. 22A and 22B each depict an individual compartmentalized cavity 2216 formed in a substrate body 2204 having top surface 2208 and that includes controllable release components in the form of an piezoelectric element 2212.
  • FIGS. 22A and 22B shown piezoelectric element 2212 in is unactuated state and in an actuated state 2212'.
  • Piezoelectric element 2212 may be made of a piezoelectric material that is the same as or similar to any one or more of the piezoelectric materials described above.
  • the piezoelectric elements 2212 can be made / manufactured in-situ, in the
  • compartmentalized cavities 2216 during the construction of the holding chuck, or alternatively, they could be built ex-situ, and then during the construction of the holding chuck, they could be incorporated into the compartmentalized cavities as desired.
  • the piezoelectric elements 2212 need to be placed. They may be placed at the bottom of the compartmentalized cavities 2216, or they might be placed midway thru the compartmentalized cavities, or they may be placed on the walls of the compartmentalized cavities, among other possibilities.
  • a piezoelectric element 2212 could be placed in each and every compartmentalized cavity 2216 of the holding chuck 2200, if so desired. Alternatively, a single piezoelectric element may address / occupy multiple cavities in the holding chuck. The piezoelectric elements 2212 may be individually addressable (triggered to distort) via additional electrical circuits / electronics, if so desired. The piezoelectric elements 2212 may also be globally addressable (triggered all together, all at once).
  • FIG. 22B depicts that, when the piezoelectric element is actuated 2212', some portion of air / gas that is present in the compartmentalized cavity 2216 is displaced out of the cavity, as shown by arrows 2224.
  • FIG. 22C shows that facing front surface 2208 of holding chuck 2200 is a
  • microelectronics substrate 2224 having a front surface 2228 and a back surface 2232.
  • the back surface 2232 of microelectronics substrate 2224 is removably secured to the front surface 2208 of holding chuck 2200 by bringing the microelectronics substrate 2224 proximate to the holding chuck 2200 at the front surface 2208 and holding them firmly against each other while the piezoelectric elements 2212 are actuated.
  • FIG. 22B under actuation of the piezoelectric element 2212, some portion of air / gas that is initially present in the cavity 2216 is displaced out of the compartmentalized cavity 2216.
  • creating conditions such that the pressure in the compartmentalized cavity 2216 holding the microelectronics substrate 2224 is greater than that of the surrounding ambient can be used.
  • This type of system can be engineered to operate in room temperature ambient, or a lower ambient temperature, or a higher ambient temperature.
  • the system can be engineered to work at ambient pressure, or higher or lower ambient pressure, as desired.
  • piezoelectric elements 2212 (akin to piezoelectric element used in piezo inkjet printheads) in compartmentalized cavities 2216 can removably secure the microelectronics substrate 2224, etch this microelectronics substrate wafer into individual microelectronic-device die, and mass transfer these individual microelectronic-device die as revealed above.
  • FIGS. 23 A to 23D' illustrate an embodiment that utilizes an active membrane 2312 for the controllable release component.
  • FIG. 23 A depicts a compartmentalized cavity 2316 formed in a substrate body 2304 having a top surface 2308.
  • the controllable release component is in the form of active membrane 2312, such as a MEMS membrane located on the top surface 2308 and extending over the compartmentalized cavity 2316. Examples of active membranes suitable for use as active membrane are described above.
  • Active membrane 2312 may be deposited over the compartmentalized cavities 2316 of the substrate body 2304. In equilibrium state, the active membrane 2316 may be substantially flat (planar) as depicted in FIG. 23A. As seen in FIG. 23 A', upon actuation (visualized by arrow 2320) the active membrane undergoes physical distortion into a distorted shape 2312' (concave distortion as viewed from atop the compartmentalized cavity 2316).
  • the mechanism of actuating active membrane 2316 can include, but not be limited to, an electrical impulse (current, voltage, capacitance or electro-static), a magnetic impulse (electro-magnet etc.) or air / gas pressure, among other things.
  • FIG. 23B depicts the compartmentalized cavity 2316 with the unactuated active membrane 2312 extending over the compartmentalized cavity, with a microelectronics
  • active membrane 2312 upon actuation (visualized by arrow 2320), the active membrane 2312 undergoes physical distortion into the distorted shape 2312'.
  • This distorted shape 2312' of the active membrane 2312 creates a temporary compartmentalized cavity 2332 of sorts, thereby creating a suction force / partial vacuum in this temporary compartmentalized cavity 2332.
  • This partial vacuum removably secures the
  • microelectronics substrate 2324 in place to the underlying substrate body 2304.
  • FIG. 23C depicts the microelectronics substrate 2324 securely held in place due to partial vacuum in the temporary compartmentalized cavity 2332.
  • the active membrane 2312 is de-actuated, which causes a collapse of the temporary compartmentalized cavity 2332 (FIG. 23C), thus negating the partial vacuum therein, leading to release (visualized by arrow 2328) of the microelectronics substrate 2324.
  • FIG. 23D depicts the microelectronics substrate 2324 securely held in place due to partial vacuum in the temporary compartmentalized cavity 2332, with the partial vacuum created by actuation of active membrane 2312 to the distorted shape 232G shown. Note, however, the presence of an additional controllable release component 2336, here an unactuated resistive-type heater and / or a piezoelectric element 2336, in compartmentalized cavity 2316.
  • an additional controllable release component 2336 here an unactuated resistive-type heater and / or a piezoelectric element 2336, in compartmentalized cavity 2316.
  • FIG. 23D' depicts an alternate release strategy for the microelectronics substrate 2324.
  • the active membrane 2312 can be de-actuated as shown in FIG. 23C', or the additional controllable release component 2336 can be actuated.
  • FIG. 22D' illustrates a specific example of the additional controllable release component 2336 being a piezoelectric element that changes to a distorted shape 2336' upon actuation. If the additional controllable release component 2336 were a resistive-type heater, with or without one or more other layers (such as of a getter material and/or a pyrophoric material), then the actuation of the resistive-type heater would cause expansion by heating and/or addition of gas from the one or more other layers.
  • active membrane 2312 on top surface 2308 of compartmentalized cavity 2316 can removably secure a microelectronics substrate 2324 to the corresponding holding chuck as in other embodiments.
  • the securely held microelectronics substrate 2324 can be partitioned into individual microelectronic-device dies, which can then be mass transferred as revealed in the earlier embodiments.
  • Active structures and devices alternative to active membrane 2312 can be designed and used as a holding chuck and/or a mass transfer tool utilizing the principles outlined in this work.
  • These active structures and devices can include, but not limited to, active microphones based on active diaphragms / active membranes, active cantilevers used for acoustic devices (push air out, or pull air in / modulate air pressure), active micro valves (push or pull: air /liquid out or in, modulate pressure), and active based pressure sensors, among others.
  • FIG. 24 shows an example holding chuck system 2400 that includes a holding chuck 2404 of the present disclosure that includes a plurality of compartmentalized cavities 2408 each having associated therewith at least one controllable release component 2412, each of which can be the same as or similar to any of the controllable release components described in this disclosure.
  • the controllable release components 2412 need to be actuated and/or de-actuated in order to achieve the requisite functionality(ies) of the holding chuck 2404.
  • the holding-chuck system 2400 may include activation circuitry 2416 and a control system 2420 for controlling the activation circuitry.
  • the activation circuitry 2416 includes any circuit elements needed to actuate and/or de-actuate the controllable release components 2412 present in the holding chuck 2404.
  • the activation circuitry 2416 is shown a being located entirely aboard the holding chuck 2404. However, this need not be the case in other embodiments. Rather, the activation circuitry 2416 may be located entirely offboard the holding chuck 2404 (e.g., without only lead-lines being present within the holding chuck) or may be located partially onboard and partially offboard the holding chuck, as needed for a particular design. In some embodiments, the activation circuitry 2416 may be provided as an active backplane (not shown) to the holding chuck 2404 that may be manufactured into the holding chuck or manufactured separately and joined with the holding chuck, as examples.
  • controllable release components 2412 may be actuated using, without limitation, any one or more of the following stimuli: an electrical impulse (current, voltage, capacitance or electro-static), a magnetic impulse (electro-magnet etc.), air / gas pressure, and/or a thermal impulse, among others.
  • the activation circuitry 2416 may employ field effect transistors (FET), MOSFETs, and/or CMOS circuitry.
  • the activation circuitry 2416 may employ passive matrix or active matrix or other drive architectures.
  • the electrical contacts (not shown) to actuate the controllable release components 2412 might be adjacent to the controllable release components, they may be on the side of the holding chuck 2404, and/or they may be underneath the holding chuck.
  • the control system 2420 may comprise any suitable hardware or hardware + software combination that is able to interface with the activation circuitry 2416 to achieve the desired activation and/or de-activation functionality. Those skilled in the art will readily understand how the control system 2420 can be configured for any particular application of the holding chuck 2404. Depending on the needs of the application(s) for the holding chuck 2404, the control systems 2420 and/or activation circuitry 2416 may be configured to address the controllable release
  • controllable release components 2412 individually, globally, by type, and/or in groupings containing fewer than all of any particular type of the controllable release components.

Abstract

Holding chucks for holding microelectronics substrates and/or microelectronic-device dies made from such microelectronics substrates. The holding chucks are configured to temporarily securely hold corresponding respective microelectronics substrates for handling and/or during die portioning and/or to temporarily securely hold microelectronic -device dies, for example, for efficient mass transfer and precision placement of the microelectronic-device dies. In some embodiments, each holding chuck includes a plurality of compartmentalized cavities that each contain or are otherwise associated with one or more controllable release components that are used for temporarily securing a microelectronics substrate to the holding chuck and/or for releasing the microelectronics substrate or microelectronic-device dies from the holding chuck. Various uses of the disclosed holding chucks, such as semiconductor processing and mass transfer for making electronic devices such as microLED displays, sensor arrays, and detector arrays, are also described.

Description

HOLDING CHUCKS HAVING COMPARTMENTALIZED HOLDING CAVITIES AND USES
FOR SUCH HOLDING CHUCKS
RELATED APPLICATION DATA
[0001] This application claims the benefit of priority of U.S. Provisional Patent Application Serial No. 62/766,779, filed on November 5, 2018, and titled“Novel Holding Chuck (2)”, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of holding platforms that are used to hold semiconductor substrates. In particular, the present invention is directed to holding chucks having compartmentalized holding cavities and uses for such holding chucks.
BACKGROUND
[0003] Today’s incumbent OLED microdisplays have many shortcomings relative to AR (Augmented reality) requirements in terms of color quality, resolution, brightness, efficiency, and longevity. Inorganic III - V Nitride (GaN/InGaN/AlGaN) based microLEDs having individually addressable RGB pixels, would be hugely preferred for higher brightness (e.g., for daylight viewing), for high efficiency for long battery life and untethered use, and for very compact forms, but unfortunately such microLEDs only emit monochrome (blue/violet) light. To realize high definition, full color, RGB pixels, the respective pixel and sub-pixel sizes for such inorganic LED microdisplays (ILED) can be on the order of sub 20 microns, or sub 10 microns, or even sub 5 microns. There is currently no mass transfer technology that can allow for the manufacturing of such microdisplays from highly optimized, pre-made, inorganic LED micro dies.
SUMMARY OF THE DISCLOSURE
[0004] In one implementation, the present disclosure is directed to a method of making an electronic device. The method includes removably securing a microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face of the holding chuck, each of the cavities being compartmentalized and spaced from adjacent cavities, and the cavities spatially arranged in a predetermined arrangement and having associated therewith a controllable release component; the microelectronics substrate includes microelectronic devices spatially arranged relative to one another in concert with the predetermined arrangement of the cavities of the holding chuck; and when the microelectronics substrate is removably secured to the holding chuck, ones of the microelectronic devices are in registration with corresponding respective ones of the cavities; while the microelectronics substrate is removably secured to the holding chuck, partitioning the microelectronics substrate to separate ones of the microelectronics devices from one another to create individual microelectronic-device dies; and after partitioning the microelectronics substrate, controlling one or more of the controllable release components so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a predetermined location.
[0005] In another implementation, the present disclosure is directed to a holding chuck for manufacturing an electronic device. The holding chuck includes a body having a working face that confronts a plurality of individual microelectronic-device dies during use; a plurality of cavities formed in the body, the plurality of cavities arranged in a predetermined arrangement on the working face of the body, each of the plurality of cavities being compartmentalized and having
correspondingly associated therewith a controllable release component that controls release of the plurality of individual microelectronic-device dies when the plurality of individual microelectronic- device dies are removably secured to the holding chuck; and activation circuitry in electrical communication with each of the controllable release components, the activation circuitry designed and configured to electrically communicate with the controllable release components to control release of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
[0006] In yet another implementation, the present disclosure is directed to a method of making a holding chuck for use in manufacturing an electronic device, wherein the manufacturing utilizes a plurality of individual microelectronic-device dies arranged in a predetermined arrangement during at least one step of the manufacturing. The method includes using the predetermined arrangement of the plurality of individual microelectronic-device dies used during the manufacturing to determine a pattern of a plurality of cavities to be provided in the holding chuck; forming the plurality of cavities in the holding chuck, wherein the holding chuck includes a working face that confronts the plurality of individual microelectronic-device dies during use of the holding chuck, and the plurality of cavities are compartmentalized and formed in the working face when the holding chuck is completed; providing at least one controllable release component, each for releasing one or more of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the working face of the holding chuck; and providing activation circuitry in electrical communication with each of the at least one controllable release component, the activation circuitry designed and configured to electrically communicate with the at least one controllable release component to control release of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
[0007] In still another implementation, the present disclosure is directed to a method of making an electronic device. The method includes providing individual microelectronic-device dies, the individual microelectronic-device dies arranged in a predetermined arrangement and removably engaged with a support; providing a holding chuck, the holding chuck having a working face and including cavities formed in the working face of the holding chuck, each of the cavities being compartmentalized and spaced from adjacent cavities, and arranged in the predetermined arrangement of the individual microelectronic -device dies engaged with the support, wherein each of the cavities has associated therewith a controllable release component; registering the individual microelectronic-device dies and the cavities with one another; when the individual microelectronic- device dies and the cavities are in registration with one another, contacting the individual microelectronic-device dies and the working face of the holding chuck with one another; removably securing the individual microelectronic-device dies to the working face of the holding chuck;
disengaging the individual microelectronic-device dies from the support; and controlling one or more of the controllable release components so that at least one of the individual microelectronic- device dies is released from the holding chuck and transferred onto a receiving support at a desired location.
[0008] In still yet another implementation, the present disclosure is directed to a method of working a microelectronics substrate. The method includes removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face, each of the cavities being compartmentalized and spaced from adjacent cavities, the cavities having associated therewith at least one controllable release component; while the microelectronics substrate is removably secured to the holding chuck, processing the
microelectronics substrate; and after processing the microelectronics substrate, controlling each of the at least one controllable release component so as to release the microelectronics substrate from the holding chuck.
[0009] In another implementation, the present disclosure is directed to a method of working a microelectronics substrate. The method includes removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face, each of the cavities being compartmentalized and spaced from adjacent cavities, wherein removably securing the microelectronics substrate includes creating a gas seal between the holding chuck and the microelectronics substrate so that interiors of the cavities are gaseously sealed from an ambient environment adjacent to the microelectronics substrate; while the microelectronics substrate is removably secured to the holding chuck, processing the microelectronics substrate; and after processing the microelectronics substrate, changing differential pressure between the ambient environment and the interiors of the cavities so as to release the microelectronics substrate from the holding chuck.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
[0011] FIG. 1 is a cross-sectional view of an example holding chuck made in accordance with aspects of the present invention;
[0012] FIG. 2 is a cross-sectional view the holding chuck of FIG. 1 showing cavities formed in the body;
[0013] FIG. 3 is a top view of the holding chuck and cavities of FIG. 2;
[0014] FIG. 4 is a flow diagram of an example method of fabricating the holding chuck of
FIG. 1;
[0015] FIGS. 5A to 5E illustrate various blocks of the example method of FIG. 4;
[0016] FIG. 6 is a flow diagram of an example method of fabricating the holding chuck of
FIG. 1 made in accordance with aspects of the present disclosure;
[0017] FIGS. 7 A to 7C illustrate various blocks of the method of FIG. 6;
[0018] FIG. 8 is a flow diagram of an example method of fabricating the holding chuck of
FIGS . 1 to 3 made in accordance with aspects of the present disclosure;
[0019] FIGS. 9A to 9E illustrate various blocks of the method of FIG. 8;
[0020] FIG. 10 is a diagram illustrating in-plane resistive-type heaters;
[0021] FIGS. 11A and 1 IB illustrate example method of utilizing the holding chuck of FIG. 1;
[0022] FIGS. 12A and 12B illustrate another method of utilizing the holding chuck of FIG. 1; [0023] FIG. 13 illustrates yet another method of utilizing the holding chuck of FIG. 1;
[0024] FIGS. 14A to 14C illustrate, respectively, alternate methods of utilizing the holding chuck of FIG. 1;
[0025] FIGS. 15 illustrates still another method of utilizing the holding chuck of FIG. 1;
[0026] FIG. 16 is a flow diagram of a further method of utilizing the holding chuck of FIG. 1;
[0027] FIGS. 17A to 17C illustrate various blocks of the method of FIG. 16;
[0028] FIG. 18 is a flow diagram of an example method of utilizing the holding chuck of FIG. 1 for the purpose of mass transfer;
[0029] FIGS. 19A to 19E illustrate various blocks of the method of FIG. 18;
[0030] FIGS. 20A to 20E are cross-sectional views each illustrating another example variant of a holding chuck made in accordance with aspects of the present disclosure;
[0031] FIG. 21A is a cross-sectional view of a holding chuck made in accordance with aspects of the present disclosure that includes a porous film extending over the compartmentalized cavities;
[0032] FIG. 21B is an enlarged cross-sectional view of the porous film of FIG. 21A;
[0033] FIG. 22A is cross-sectional view of a single compartmentalized cavity in isolation containing a piezoelectric element, illustrating the piezoelectric element in each of an unactuated and actuated configuration;
[0034] FIG. 22B is a cross-sectional view of the single compartmentalized cavity of FIG. 22A, illustrating gas/air being forced out of the cavity by the change in configuration of the piezoelectric element;
[0035] FIG. 22C is a cross-sectional view of a holding chuck comprising a plurality of compartmentalized cavities like the compartmentalized cavity of FIG. 22A and 22B and the holding chuck in engagement with a microelectronics substrate;
[0036] FIGS. 23 A and 23 A' each illustrate a single compartmentalized cavity overlain by a microelectromechanical system (MEMS) membrane and show, respectively, the MEMS membrane in an unactuated state and an actuated state;
[0037] FIGS. 23B and 23B' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in an unactuated state and an actuated state so as to create a vacuum between the MEMS membrane and the microelectronics substrate;
[0038] FIGS. 23C and 23C' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in an actuated state and an unactuated state so as to release the microelectronics substrate;
[0039] FIGS. 23D and 23D' each illustrate a single compartmentalized cavity overlain by a MEMS membrane and a microelectronics substrate and show, respectively, the MEMS membrane in a first actuated state causing a concave configuration so as to generate a holding vacuum and second actuated state causing a convex configuration so as to release the microelectronics substrate; and
[0040] FIG. 24 is a diagram illustrating an example holding chuck and corresponding activation circuity and control system for controlling the actuation and/or de-actuation of the controllable release components aboard the holding chuck.
DETAILED DESCRIPTION
[0041] I. GENERAL OVERVIEW
[0042] I .A Example Embodiments
[0043] The present disclosure reveals a variety of embodiments into which broad aspects of the present disclosure can be embodied.
[0044] One such embodiment includes a method of making an electronic device, such a microLED display device, a detector device, or a sensor device, among others. This method may include removably securing a microelectronics substrate to a working face of a holding chuck. In this example, the holding chuck includes cavities formed in the working face of the holding chuck, with each cavity being compartmentalized and spaced from adjacent cavities. The cavities are spatially arranged in a predetermined arrangement and have associated therewith at least one controllable release component. The microelectronics substrate includes microelectronic devices spacially arranged relative to one another in concert with the predetermined arrangement of the cavities of the holding chuck. While the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is partitioned to separate ones of the microelectronics devices from one another to create individual microelectronic-device dies. After partitioning the microelectronics substrate, one or more of the controllable release components are controlled so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a predetermined location. [0045] Another revealed embodiment includes a holding chuck for manufacturing an electronic device such as a microLED display device, a detector device, and a sensor device, among others.
The holding chuck comprises a body having a working face that confronts a plurality of individual microelectronic-device dies during use. A plurality of cavities are formed in the body and are arranged in a predetermined arrangement on the working face of the body. Each of the cavities is compartmentalized and has correspondingly associated therewith a controllable release component that controls release of the plurality of individual microelectronic-device dies when the plurality of individual microelectronic-device dies are removably secured to the holding chuck. Activation circuitry is in electrical communication with each of the controllable release components and is designed and configured to electrically communicate with the controllable release components to control release of the plurality of individual microelectronic -device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
[0046] A further revealed embodiment includes a method of making a holding chuck for use in manufacturing an electronic device, such as, for example, a microLED display device, a detector device, and a sensor device, among others. The manufacturing utilizes a plurality of individual microelectronic-device dies arranged in a predetermined arrangement during at least one step of the manufacturing. The method comprises using the predetermined arrangement of the plurality of individual microelectronic-device dies used during the manufacturing to determine a pattern of a plurality of cavities to be provided in the holding chuck. The plurality of cavities are formed in the holding chuck, the holding chuck including a working face that confronts the plurality of individual microelectronic-device dies during use of the holding chuck. The plurality of cavities are compartmentalized and formed in the working face when the holding chuck is completed. At least one controllable release component is provided. Each controllable release component is releasing one or more of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the working face of the holding chuck. Activation circuitry is provided so as to be in electrical communication with each of the at least one controllable release component. The activation circuitry is designed and configured to electrically communicate with the at least one controllable release component to control release of the plurality of individual microelectronic -device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck. [0047] Yet another revealed embodiment includes a method of making an electronic device, such as a microLED display device, a detector device, or a sensor device, among others. The method comprises providing individual microelectronic-device dies, the individual microelectronic- device dies arranged in a predetermined arrangement and removably engaged with a support. A holding chuck is provided. The holding chuck has a working face and including cavities formed in the working face of the holding chuck. Each of the cavities is compartmentalized and spaced from adjacent cavities and arranged in the predetermined arrangement of the individual microelectronic- device dies engaged with the support, wherein each of the cavities has associated therewith a controllable release component. The individual microelectronic-device dies and the cavities are registered relative to one another. When the individual microelectronic-device dies and the cavities are in registration with one another, the individual microelectronic-device dies and the working face of the holding chuck are contacted with one another. The individual microelectronic-device dies are removably secured to the working face of the holding chuck. The individual microelectronic-device dies are disengaged from the support. One or more of the controllable release components are controlled so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a desired location.
[0048] Still another revealed embodiment includes a method of working a microelectronics substrate. The method comprises, removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face and each of the cavities being compartmentalized and spaced from adjacent cavities. The cavities have associated therewith at least one controllable release component. While the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is processed. After processing the microelectronics substrate, each of the at least one controllable release component is controlled so as to release the microelectronics substrate from the holding chuck.
[0049] Still yet a further revealed embodiment includes a method of working a microelectronics substrate. The method comprises removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face and each of the cavities being compartmentalized and spaced from adjacent cavities. Removably securing the microelectronics substrate includes creating a gas seal between the holding chuck and the microelectronics substrate so that interiors of the cavities are gaseously sealed from an ambient environment adjacent to the microelectronics substrate. While the microelectronics substrate is removably secured to the holding chuck, the microelectronics substrate is processed. After processing the microelectronics substrate, differential pressure between the ambient environment and the interiors of the cavities is changed so as to release the microelectronics substrate from the holding chuck.
[0050] These and other example embodiments are described below in detail and in the claims accompanying this disclosure upon the original filing of this disclosure. Those claims are incorporated into this detailed description section in their entireties.
[0051] I.B Terminology and Drawing Convention
[0052] Following are definitions used herein and in the appended claims. These definitions are intended to assist the reader in understanding the scope of the present disclosure and the
accompanying claims.
[0053] “Substrate” - any sort of body suitable for the intended purpose of the substrate. As a few non-limiting examples a substrate can be in the form of a microelectronics-type wafer, a sheet, or a block, among many other forms. As used herein,“substrate” does not necessarily connote that the body at issue function as a body, layer, etc., that underlies one or more layers or other structures, though is certainly can have that connotation in some uses herein.
[0054] “Microelectronics substrate” - any substrate, semiconductor or otherwise (such as a wafer), used for creating microelectronic devices and can also the stmcture(s) that results from processing to form microelectronics on the substrate when such structure(s) are present.
[0055] “Electronic device” - any electronic device, such as an electronic display, a sensor array, and a detector array, and any combination thereof, among others.
[0056] “Microelectronic device” - any individual electrical component, e.g., LED, laser diode, transistor, etc. or any collection of such components that make up an overall device, such as a microprocessor, memory, etc.
[0057] “Controllable release component” - any component that is controllable so as to release one or more individual microelectronic-device dies from the holding chuck, such as a heater, piezoelectric element, getter, active membrane, pyrophoric element, etc. In some embodiments, the controllable release component (e.g., resistance-type heater, piezoelectric element, active membrane, etc.) may be activated by an electrical signal. In some embodiments, the controllable release component may be activated by another means, such as heat from a heater (e.g., getter, pyrophoric, etc.), and vacuum among others.
[0058] “Individual microelectronic-device die” - the structure that contains a microelectronic device, typically formed by partitioning a microelectronic substrate into individual bodies that are separate and distinct from one another.
[0059] “Working face” - the face of the holding chuck that confronts a microelectronics substrate or a plurality of individual microelectronic-device dies. For the method claims, this face can be the face of the outermost coating that may be applied to the bare holding chuck.
[0060] “Receiving support” - anything that receives one or more individual microelectronic- device dies when released from the holding chuck; can be, e.g., a backplane of an electronic device, an intermediate substrate, or a temporary holder such as another holding chuck of the present disclosure, among other things.
[0061] “Compartmentalized” - used to define the cavities and means that each cavity is independent of any other structure, such as an ink reservoir or passageway in an inkjet print head.
[0062] “Activation circuitry” - electronic circuitry that activates the controllable release components so as to change pressure within the cavities.
[0063] It is noted that throughout the accompanying drawings, when a plurality of a particular component is present, only one or fewer than all of such structures, components, etc., are actually labeled to avoid clutter. Those skilled in the art will understand that like- appearing structures, components, etc., are addressed in the detailed descriptions below despite not being labeled.
[0064] II. EXAMPLE EMBODIMENTS
[0065] Turning now to the drawings, FIG. 1 illustrates an example holding chuck 100 made in accordance with aspects of the present disclosure. In this example, holding chuck 100 includes a substrate body 104, a plurality of controllable release components 108 located, here, respective, in a plurality of compartmentalized substrate cavities 112, one or more optional coatings 116 on each of the controllable release components, and one or more optional coatings 120 on the front surface of the substrate body. It is noted that the combination of the substrate 104 and controllable release components 108 in the compartmentalized substrate cavities 112 without any additional treatment(s) applied thereto, may be considered as a holding chuck structure 124. The optional coating(s) 116 on the controllable release component 108 and the optional coating(s) 120 on the front surface of substrate body 104 may be present as a particular design may require.
[0066] At a high level and as will become apparent from reading the entire disclosure, holding chuck structure 124 may be used to removably secure a microelectronics substrate wafer (not shown) atop the working face of the holding chuck structure, here the front surface of optional
coating(s) 120, for further processing for a desired purpose. Examples uses for holding chuck structure 124 include, but are not limited to, removably securing a microelectronics substrate for further processing, removably securing a microelectronics substrate during in-situ individual microelectronic-device die creation in the microelectronics substrate, and removably securing the in- situ created individual microelectronic-device die to allow for mass transfer of the individual microelectronic-device die onto a separate receiving support or location on demand, among others.
[0067] Each coating 116 and 120 on the controllable release components 108 and the front surface of substrate body 104, when provided, may be chosen to enhance the performance of holding chuck 100. For example, the coating(s) 116 on the controllable release component 104 may be selected to amplify and expedite the release process of the reversible bonding. The front surface coating(s) 120, on the other hand, may be selected to prevent damage to the underside of the removably secured microelectronics substrate (not shown), and/or enhance the seal between the removably secured microelectronics substrate (not shown) and the holding chuck 100. Additional details each of these elements and their functions, as well as examples of each of these elements, are described and provided below.
[0068] II.A Substrate Body
[0069] Substrate body 104 may be rigid or flexible and may be composed of one or more polymers, one or more ceramics, one or more metals, one or more papers, one or more fabrics, or one or more glasses, or any combination thereof, among other things. Substrate body 104 may be transparent, opaque, or translucent, or any combination thereof. Each material of substrate body 104 may be a conductor, an insulator, or a semiconductor, or any combination thereof. Each material may be inorganic or organic or a combination thereof and may be single crystal, polycrystalline, oriented (or textured) polycrystalline, or amorphous in morphology.
[0070] Material for substrate body 104 may be porous or non-porous or a combination thereof. The pores (not shown), if present, in substrate body 104 may be created artificially or may exist naturally. The pores in substrate body 104 may be randomly located or deterministically placed. There are fundamentally no limits on the size and shape of the pores in substrate body 104.
[0071] There are fundamentally no limits on the thickness of substrate body 104, and in some embodiments the thickness may range from a few microns to several millimeters as desired by the application at issue. Additionally, other functionality/functional coating 120 may be deposited in or on the surfaces of the substrate body 104. The coating 120 may act as a gasket layer, flex / compliant layer, anti-stick /anti-abrasion layer, barrier layer, passivation layer, planarizing layer, adhesive layer, etc. These functional layers include, but are not limited to, organic or inorganic layers. While certain representative examples have been mentioned for purposes of illustrating the wide variety of substrates that can be used for substrate body 104, it will be apparent to those skilled in the art that substrates not disclosed herein may be made without departing from the scope of the invention.
[0072] II.B Controllable Release Component
[0073] Each controllable release component 108 may comprise a resistive-type heater element, a piezoelectric element, an active membrane, a getter, a pyrophoric material, vacuum-activated material, or any combination thereof, among others.
[0074] II.B .1 Resistive-type Heater
[0075] A resistive-type heater element as a controllable release component 108 is a miniaturized heating element, such as a microelectromechanical system (MEMS) heating element or a micro heating element, having a complex interplay of many disciplines in physics, such as thermal, electrical and mechanical. Archetypical designs includes a substrate, a conductive pad, a resistive heating element, oxidation passivation layers, etc. A wide variety of methods exist to manufacture a suitable resistive-type heater element and are well known in the prior art and are not repeated here.
[0076] Resistive-type heater elements are routinely used in a variety of applications including inkjet printheads, actuators, bio-mems, chemical detectors, gas flow sensors, etc. These heater elements can rapidly be heated to temperatures in excess of -300 C.
[0077] Fundamentally, there are no limits on the choice of materials used to make a resistive- type heater element suitable for use as each or any of controllable release components 108, nor are there any restrictions on the choice of construction techniques and architectures used. There are no constraints on how high the resistive-type heater element may heat up or how quickly it may heat up, as long as it serves its intended purpose. [0078] II. B .2 Piezoelectric Element
[0079] A piezoelectric element as controllable release component 108 comprise one or more piezoelectric materials. These piezoelectric materials undergo physical distortion (mechanical expansion/contraction) when an electric field is applied. It is this physical distortion that is exploited in the present disclosure to mechanically create the reversible“holding force” in the holding chuck 100 of FIG. 1.
[0080] A wide variety of methods exist to manufacture piezoelectric elements and are well known in the prior art and are not repeated here. For example, MEMS-based piezoelectric elements are routinely used in inkjet printheads.
[0081] There are no limits on the choice of materials used to make the piezoelectric elements, nor are there any restrictions on the choice of construction techniques and architectures used. There are no constraints on the amount of distortion a piezoelectric element may undergo, as long as it serves its intended purpose.
[0082] There are many variants of the piezoelectric materials and architectures (thin film, thick film, bulk, single crystal, and specific piezo mode utilized) including, tube, edge, face, moving wall, piston, etc. Any of these may be utilized in the holding chuck structure 100.
[0083] II.B.3 Active Membrane
[0084] An active membrane as controllable release component may comprise a MEMS membrane. An active membrane may be a continuous, impermeable, suspended membrane in a MEMS architecture. Active MEMS membrane materials and deposition techniques are widely known in the prior art and are not repeated here. These materials may be organic, inorganic, or hybrid in composition. An active MEMS membrane may also be composed of an adhesive material. The adhesive layer may be deposited on top of the membrane, all over, or over just some sections of the membrane.
[0085] An active MEMS membrane can be deposited atop the compartmentalized cavities 112 of the holding chuck structure 124. Upon actuation, the active MEMS membrane undergoes physical distortion, and it is this physical distortion that may be exploited to mechanically create the reversible“holding force” of the holding chuck 100. [0086] Each controllable release component 108 can be manufactured in-situ, in the compartmentalized cavities 112, during the construction of the holding chuck structure 124, or alternatively, it can be built ex-situ, and then during the construction of the holding chuck 100; it can be incorporated into the compartmentalized cavities 112 as desired. There is no specific location in the compartmentalized cavity 112 that the controllable release component 108 needs to be placed. The controllable release component 108 may be placed at the bottom of the cavity, or it might be placed midway thru the cavity, or it may be placed on the walls of the cavity, etc.
[0087] The controllable release components 108 can be placed in each and every
compartmentalized cavity 112 of the holding chuck structure 124, if so desired. Alternatively, a single controllable release component may address or occupy multiple cavities in the holding chuck structure.
[0088] The controllable release components 108 may be individually addressable (triggered to actuate) via additional electrical circuits/electronics, if so desired. The controllable release components may also be globally addressable (triggered all together, all at once).
[0089] II.B.4 Optional coating on a controllable release component
[0090] When controllable release component 108 comprises a heater, optional coating(s) 116 on controllable release component 108 may include one or more heat activated materials, such as getters, pyrophorics, or vacuum activated materials, among others.
[0091] II.B.4. a Getters
[0092] Optional coating(s) 116 might comprise of materials that are general classified as getter materials. Getters are chemical substances, that when placed in a partial vacuum such as might exist in compartmentalized cavity 112, will react chemically with any residual gas (if present) in the cavity to increase the vacuum in such cavity. This act of reducing pressure of a chamber or cavity is called“gettering.”
[0093] These materials work on a multitude of mechanisms depending on their specific composition and intent. These mechanisms can broadly be stated as: adsorption, absorption, chemisorption/diffusion or chemical binding, physisorption, surface dissociation, surface sorption, bulk diffusion, bulk sorption, occlusion, etc. These mechanisms and therefore the associated getters may work reversibly, or irreversibly. [0094] These materials can take the form of bulk getters (sheets, strips, wires, pellets, etc), coating/film getters: comprising of thin film getters, thick film getters, solid or porous coating/film getters, powder getters: comprising of macro powders, micro powders, nano powders, and pellets of getters.
[0095] A wide variety of getter materials are in use. Below are a few materials; note, however, that the list is not comprehensive, and any getter material not listed below might be used without departing from the scope of the invention.
[0096] Materials such as chemically reactive metals such as: barium, barium alloys, cesium, columbium, tantalum, titanium, titanium/molybdenum, zirconium, vanadium, hafnium, rare earths, iron, aluminum, cobalt, copper, silicon, phosphorous, strontium, calcium, nickel, BaAU, terbium, magnesium, niobium, thorium, vanadium, uranium, palladium, alkali metals and their alloys, amongst others. Physical getters like zeolites might also be utilized.
[0097] Some of these getter materials are evaporable, whereas others are non-evaporable.
These getter materials may be activated in-situ or ex-situ. The maybe activated in vacuum, inert gas, or any other ambient as needed. They may be activated pre/during/post their deposition in the cavity or their intended space. They may be activated by heat, electromagnetic radiation, light, microwave, moisture, etc.).
[0098] In general, the getter materials may be inorganic, organic, or hybrid (inorganic + organic) in chemical composition.
[0099] The getter may be used once and dispensed, or may be used many times until it is capacity to getter is exhausted, or it may be replenished after every transfer event, if so desired.
[0100] II.B.4.b Pyrophorics
[0101] Coating(s) 116, if provided, may comprise one or more materials that are general classified as pyrophoric materials. These are chemical substances that will ignite spontaneously at or below room temperature and may be solids, liquids, or gases. These materials may be inorganic or organic in composition.
[0102] Pyrophoric materials may include, but are not limited to: alkali metals and their hydrids such as: lithium, sodium, potassium, lithium aluminium hydride, sodium hydrid, finely powdered metals such as aluminum, cerium, iron, bismuth copper, Cu/ZnO/ANO,, magnesium, nickel, Raney nickel, calcium, titanium, tantalum, hafnium, zirconium, uranium, plutonium, etc. iron sulfide, fire steel, yellow phosphorus, white phosphorus, diethylethoxyaluminium, dichloro(methyl)silane, diethylaluminium hydride, trimethylaluminium, butyllithium, triethylboron, dicobalt octacarbonyl, nickel carbonyl, CH ;TcH. arsine, Germane, diborane, phosphine, silane, hydrazine, metalorganics of main group metals (e.g. aluminium, gallium, indium, zinc and cadmium etc.), triethylborane etc.
[0103] II. B .4.C Vacuum-activated Materials
[0104] If present, coating(s) 116 might comprise any one or more of a variety of materials, chemistries, substances that may be coated in the compartmentalized cavity 112, as outlined below.
[0105] For example, it is well known that polymers / monomers / organic materials outgas when put under vacuum conditions. The compartmentalized cavity 112 can be coated with any such material. This coating will then keep on outgassing and the pressure deferential between the gas pressure in the cavity 112 and the gas pressure of the ambient will keep on reducing, until that time that both the gas pressures (that of gas in the cavity 112, and that of ambient) are similar and the removably secured microelectronics substrate detaches. This outgassing can be accelerated by using temperature either localized or global heating using the controllable release component 108, in compartmentalized cavity 112 of holding chuck 100. This allows the user to create“timed” detaching processes for the removably secured microelectronics substrate.
[0106] Herein, organics such as photo-resist, benzocyclobutene (BCB), polyimides, spin-on polymers, etc., may also be used since these are compatible with semiconductor processing tools.
[0107] Another example might be the deposition of selenium (or another suitable material that sublimes: goes from solid to vapor state) in the compartmentalized cavity 112. Upon actuation of the controllable release component 108, the gaseous expansion (due to sublimation) will detach the removably secured microelectronics substrate.
[0108] Note that these materials are neither getter nor pyrophorics, by definition. But by virtue of their physical / chemical properties, they can be exploited to yield the required results. These materials may be inorganic or organic or hybrid in composition. They may be solids, semi-solids, gel like, liquid, or gaseous prior to, during, or post decomposition. They may comprise of micro / nano fibers or dendritic shapes and compositions. [0109] Coating(s) 116 on controllable release component 108, if present, may be deposited on or proximate to controllable release component 108 in one or more of the compartmentalized cavities 112.
[0110] While certain representative materials have been shown for optional coating(s) 116, materials not disclosed herein may be used without departing from the scope of the invention.
[0111] II.C Compartmentalized Substrate Cavities
[0112] Each compartmentalized cavity 112 in substrate body 104 may be a region wherein the substrate body 104 is removed to form a well, depression, or like void. The compartmentalized cavities 112 in substrate body 104 in the holding chuck structure 124 are instrumental in removably secured microelectronics substrate (not shown) firmly in place, during processing, due to the forces exerted by the partial vacuum created in the cavities 112, as will be discussed.
[0113] Compartmentalized cavities 112 may be created using a variety of techniques such as wet chemical etching processes, electrolyte anodizing of semiconductors, dry etching processes such as reactive ion etching (RIE), plasma / planar etching, plasma enhanced etching (PE), inductively coupled plasma etching (ICP), deep reactive ion etching (DRIE), sputtering, ion enhanced etching, ion beam milling, chemically assisted ion beam milling, electron cyclotron resonance plasma (ECR), high density plasma (HDP), microwave and RF plasma assisted etching, laser induced / assisted chemical etching, may be employed for the same effect. The chemical source maybe introduced as flood, time-varying, spatially varying, or continuous.
[0114] Compartmentalized cavities 112 may be created by one or more alternative techniques, such as laser ablation, laser photo-ablation, laser induced etching, laser assisted direct imprint (LADI), laser chemical etching, femto second laser ablation and other ultra- fast laser based etching phenomenon.
[0115] Each compartmentalized cavity 112 in the holding chuck structure 124 is distinct from a thru hole in that the cavity 112 does not extend through the entire thickness of the substrate body 104. (See, e.g., FIG. 2, FIG. 3). That said, as described below, some techniques for making holding chuck structure 124 can involve providing a layer containing thru-holes in one or more layers that are then mated with another layer that closes one end of the thru-holes. [0116] There are no limits on the depth of each compartmentalized cavity 112 in relation to the thickness of substrate body 104. There are no restrictions on the shape, size, and pitch of the compartmentalized cavities 112.
[0117] The plurality of compartmentalized cavities 112 created in substrate body 104 may be identical through the entire thickness of the substrate body 104 chuck, or the shape and size of the compartmentalized cavities 112 created in the substrate body 104 may not be identical for the entire thickness of the substrate body 104.
[0118] A plurality of compartmentalized cavities 112 can be positioned with sub-micron accuracy down to even sub nanometer accuracy relative to their desired spatial positions, depending on the choice of substrate body 104 and the choice of patterning and formation techniques.
[0119] A plurality of compartmentalized cavities 112 can be made of any size from sub-micron diameters to several microns, to 10’ s of microns in diameter. There are no fundamental limits on the size of compartmentalized cavities 112. This is dictated by the particular application.
[0120] A plurality of compartmentalized cavities 112 can be made of any geometrical shape. The shape and size of the plurality of compartmentalized cavities 112 may be identical through the entire thickness of the substrate body 104, or the shape and size of the plurality of
compartmentalized cavities 112 may not be identical for the entire thickness of the substrate body 104.
[0121] Plurality of compartmentalized cavities 112 can be as close or as far apart from each other. The plurality of compartmentalized cavities 112 can be separated from each other by 10’ s of microns, or less than a micron, or sub-micron, as dictated by intended application.
[0122] There are fundamentally no restrictions on the surface quality of the plurality of compartmentalized cavities 112.
[0123] While certain representative features of the compartmentalized cavities 112 have been mentioned for purposes of illustrating aspects the invention, it will be apparent to those skilled in the art that other features may be incorporated in compartmentalized cavity 112 without departing from the scope of the invention, which is defined in the appended claims. [0124] II .D Optional Coating(s) on Front Surface
[0125] Coating(s) 120 on front surface of substrate body 104, if present, may be considered to form the working face of the holding chuck 100, i.e., the fact of the holding chuck that engages a microelectronics substrate or other workpiece. Coating(s) 120 may include functional materials that assist with removably securing a microelectronics substrate, such as sealing gasket materials, adhesives, magnetic films, and electret films, among others.
[0126] II.D.l Sealing Gasket
[0127] If provided, coating(s) 120 may comprise one or more of the following materials: metals such as copper, aluminum, indium, gallium, solders, eutectics, gold, nickel, vanadium, platinum, graphite (graphene), among others; organic compounds such as nitrile, nitrile rubber, fluorocarbon, fluorosilicone, ethylene propylene, perfluoro elastomer, perfluorinated elastomer, silicone, silicon rubbers, butyl, neoprene, isoprene, chloroprene, polyurethane, rubber, etc. A purpose of this/these coating(s) 120 (one or more materials) is to act as a compressible cushion so that even if the surface quality / features on the front surface of substrate body 104 of the holding chuck structure 124 and the back surface of the microelectronics substrate are not perfect, when the surfaces are reversibly secured, they will allow the formation of a vacuum seal. Note that the metal layers (if used) are not used to bond / solder the two surfaces; they simply act as compressible seals.
[0128] II.D.2 Adhesive Layer
[0129] Coating(s) 120, if provided, may comprise of an adhesive layer. The adhesive layer material may be naturally occurring or synthetic. The adhesive layer material may be organic, inorganic, or hybrid in composition. The adhesive layer material may comprise of monomers, polymers in composition. The adhesive layer material may be one part, or multi-part compound.
The adhesive layer may be single use, or multi-use. Preferably, the adhesive material has low tack (low adhesion force). Preferably, the adhesive material does not leave residue (or leaves minimum residue), on the device wafer / semiconductor wafer post its release.
[0130] Some examples of adhesive materials include: natural materials such as: plant resins, animal by-products, collagen, rubber, honey, syrup, pitch, cement; synthetic materials such as non reactive adhesive materials like pressure sensitive adhesive (PSA), solvent based adhesives, polymer dispersion adhesives, contact adhesives, hot melt adhesives (thermoplastics), glues, parylenes. multi part adhesives - reactive adhesives such as acrylics, cyanoacrylates, RTV, silicones, PDMS, elastomers, urethanes, epoxies, emulsions, thermosetting polymers, polyester resin - polyurethane resin, polyols - polyurethane resin, acrylic polymers - polyurethane resins. These may also include water or solvent soluble adhesive, etc. The adhesive chemistries may be cured / activated using plasma, light, UV, temperature, pressure, anaerobic environment, moisture, etc.
[0131] There are fundamentally no limits on the thickness of the adhesive layer and may range from a few nanometers to several microns or more as desired by application.
[0132] This adhesive layer may be deposited on the back surface of the microelectronics substrate or may be deposited on the front surface of substrate body 104 of holding chuck structure 124, or may be deposited on both surfaces, if so desired.
[0133] The adhesive layer coating may be deposited by any known conventional deposition means such as: PVD, filament evaporation, RF heating, electron beam, ion assisted electron beam, sputtering, diode sputtering, magnetron sputtering, DC sputtering, bias sputtering, RF sputtering, CVD/thermal CVD/LPCVD /PECVD/APCVD/HDPCVD/ECR-PECVD/ LTPECVD/MOCVD/ PVD/hot-wire CVD, sol gel, evaporation, molecular beam (MBE) evaporation, molecular vapor deposition (MVD), ALD, ion-plating, electro-plating, dip-plating (dipping), hot dipping, and electroless-plating. Other coating processes, such as a Langmuir-Blodgett process, spin-coating process, spray-coating process, and roll-on coating process; printing processes, transfer processes, ink-jet processes, and powder-jet processes, etc., may also be utilized.
[0134] While certain representative embodiments have been shown for purposes of illustrating a point, it will be apparent to those skilled in the art that adhesive layer materials not disclosed herein may be used without departing from the scope of the invention.
[0135] II.D.3 Magnetic Layer
[0136] If provided, coating(s) 120 may comprise a magnetic or paramagnetic material. If the microelectronics substrate can be coated with a functional material (material that has intrinsic use and purpose in the final device) that is magnetic or paramagnetic, then such a microelectronics substrate can be removably secured by using one or more permanent magnetic coating(s) 120 on the top surface of the substrate body 104 of holding chuck structure 124. Techniques for making permanent magnetic coating 120 are well known in literature and not elaborated on here. [0137] II.D.4 Electret Layer
[0138] Coating(s) 120, if provided, may compose an electret layer. Electrets are dielectrics that retain an electric moment even after the externally- applied field has been reduced to zero.
Heaviside, in 1885, coined the term“electret” by analogy to the established term magnet.
[0139] Many electret materials are in common use, for example: PVC (poly vinyl chloride), PS (polystyrene), PE (polyethylene), PETP (polyethylene terephthalate), PTFE
(polytetrafluoroethylene), PVDF (polyvinylidene difluoride), amorphous TEFLON® type PTFE, and COCs (cyclic olefin co-polymers), among others.
[0140] As is well known in prior art, charged particles create electric fields. This electric field has a magnitude and a direction. Electro-static electric field / force exerted by an electret coating can be used to removably secure a microelectronics substrate by depositing an electret coating 120 on the top surface of the substrate body 104 of holding chuck 100. Techniques for making electret coating 120 are well known in literature and not elaborated on here.
[0141] II.E Specific Example Holding Chucks
[0142] II.E.l Example Holding Chuck having Optional Coatings
[0143] As a particular example of the foregoing general descriptions, FIG. 4 illustrates a method 400 of forming the holding chuck 100 (FIG. 1), with FIG. 5E illustrating the particular components of the holding chuck resulting from performing the method 400 of FIG. 4. As will become apparent from reading on, the activities of the blocks of method 400 need not necessarily be performed in the order presented to achieve an equivalent result.
[0144] Referring now to FIGS. 5 A to 5E, and also to FIG. 4, at block 405 of method 400, a suitable substrate body 512 (FIG. 5A) is selected based on factors and criteria discussed elsewhere in this disclosure. After substrate body 512 has been selected, compartmentalized cavities 520 (FIG. 5B) can be create in front surface 516 of the substrate body 512 at block 410.
[0145] At block 415, corresponding respective controllable release components (see controllable release components 108 of FIG. 1) in the form of resistive-type heater 524 (FIG. 5C) can be created or placed in compartmentalized cavities 520 in substrate body 512. [0146] Depending on the intended use of the holding chuck, at optional block 420, a coating 528 (FIG. 5D) can be deposited on the resistive-type heaters 524 in compartmentalized cavities 520.
[0147] At optional block 425, a working face coating 532 (FIG. 5E; see also optional coating(s) 120 of FIG. 1) can be deposited on front surface 516 of substrate body 512.
[0148] II.E.2 Example Economical Holding Chuck
[0149] As another particular example of the above general descriptions, FIG. 6 illustrates a method 600 of forming the holding chuck 100 FIG. 1, with FIG. 7C illustrating the particular components of the holding chuck resulting from performing the method of FIG. 6. As will become apparent from reading on, the activities of the blocks of method 600 need not necessarily be performed in the order presented to achieve an equivalent result.
[0150] Referring now to FIGS. 7A to 7C, and also to FIG. 6, at block 605 of method 600, a monolithic silicon substrate body 712 (FIG. 7A) is selected. Silicon wafers are widely available, large area (300 mm in diameter and even greater), and low cost. Furthermore, there is a large existing silicon manufacturing base that can shape and tailor the silicon wafer and its surfaces with very high precision at low cost. Furthermore, by leveraging existing silicon processes it is possible to create micron sized, and nanometer sized features / cavities in silicon readily. Any silicon crystal orientation, for example, Si (100), Si (111), etc., may be used. In lieu of silicon, a glass substrate may be used. In some embodiments, the substrate material and its associated thickness chosen for the holding chuck has high rigidity. It can also be advantageous to manufacture the holding chuck with very high level of optical flatness (both local and global flatness) and with high levels of parallelism between the front and back surfaces 716, 728, respectively, of the holding chuck. There are no constraints or absolute values on this flatness and parallelism and the desired values are typically dependent on the end application. It would further be advantageous to polish both the front and back surfaces 716, 728, respectively, of the holding chuck to a very low surface roughness. There are no constraints or absolute values on this surface roughness figure and the desired values are typically very dependent on end application. The back surface 728 could just be left ground and not polished, if so desired.
[0151] After substrate body 712 has been selected, compartmentalized cavities 720 (FIG. 7B) can be create in front surface 716 of the substrate body 712 at block 610. [0152] At block 615, controllable release components (see controllable release components 108 of FIG. 1) in the form of resistive-type heaters 724 (FIG. 7C) can be created or placed in compartmentalized cavities 720. The resistive-type heaters 724 may be created in-situ in the compartmentalized cavities 720 of the silicon 712 holding chuck, or they may be built ex-situ and then assembled in the compartmentalized cavities 720 of the silicon 712 holding chuck. Each resistive-type heater 724 may be the same as or similar to any of the resistive-type heaters disclosed herein and may be individually controlled or controlled in one or more groups in the same or similar manner(s) described herein. In addition, any one or more of coatings 116 and any one or more of coatings 120 (FIG. 1) may be incorporated into method 600 of FIG. 6 as desired to suit a particular application.
[0153] II.D.3 Example Holding Chuck having Multilayer Substrate Body
[0154] As another particular example of the above general descriptions, FIG. 8 illustrates a method 800 of forming the holding chuck 100 of FIG. 1, with FIG. 9E illustrating the particular components of the holding chuck resulting from performing the method of FIG. 8. As will become apparent from reading on, the activities of the blocks of method 800 need not necessarily be performed in the order presented to achieve an equivalent result.
[0155] Referring now to FIGS. 9A to 9E, and also to FIG. 8, at block 805 of method 800, a first substrate 912 (FIG. 9A) is selected. The first substrate 912 may be made of silicon or any other material(s). After selecting first substrate 912, controllable release components (see controllable release components 108 of FIG. 1) in the form of resistive-type heaters 924 (FIGS. 9B and 9C) can be created or placed in or on front surface 916 of the first substrate 912 at block 810. The resistive- type heater 924 are substantially in-plane 932 and may be the same or similar to any one or more of the heaters described in this disclosure.
[0156] Referring briefly to FIG. 10 for illustration of in-planeness versus out-of-planeness, substantially in-plane (designated by double-arrow-headed line 932) refers to the height difference between the top or bottom surface of the resistive-type heater 924 with the front surface 916 of the first substrate 912, with this height difference being less than 1 mm for in-planeness. When the height difference is equal to or greater than 1 mm, the resistive-type heaters 924 are substantially out-of-plane. Although substantially in-plane resistive-type heaters are depicted in method 800, the resistive-type heaters could also be substantially out-of-plane. [0157] Referring again to FIGS. 9A to 9E, FIG. 9C depicts a top view of the resistive-type heater 924 created in front surface 916 of first substrate 912.
[0158] At block 815 of method 800, a second substrate 928 (FIG. 9D) is selected. Second substrate 928, too, many be silicon or any other suitable material(s). At block 820, thm-holes 920 are created in the second substrate 928 (FIG. 9D). Thru-holes 920 are also commonly referred to as “vias” or“orifices” in the industry. Thm-holes 920 are formed through the entire thickness of the second substrate 928.
[0159] At block 825, first substrate 912 and second substrate 928 are aligned and bonded together at surface 916 on substrate body 912. Ideally the alignment is done such that thru-holes 920 in substrate body 928 line up with the resistive-type heaters 924 on substrate body 912 (FIG.9E). At this point, substrate body 912 can be incorporated into a holding chuck made in accordance with the present disclosure, including holding chuck 100 of FIG. 1 and as a substitute for any unitary monolithic substrate body described herein.
[0160] Alignment techniques to align a wafer with a secondary substrate are well known in prior art and not repeated here. Alignment techniques using fiduciary marks on some or all relevant wafers / surfaces, with or without secondary optical elements likes microscopes, objectives etc. are well known in the semiconductor industry and not detailed here. Toolsets that allow for relative motion of the wafer and secondary substrate in the x, y, z, and theta axis are well known, and not detailed here. Similarly, the use of illumination optics in the visible, UV, NIR, and MWIR spectral regions are well known and not detailed here.
[0161] There are many ways to bond two substrates together. Bonding processes may include microwave bonding, anodic bonding, fusion bonding, adhesive bonding (including glues, silicones, RTV, urethanes, etc.), epoxy bonding, polyimide bonding, BCB (benzocyclobutene) bonding, photo resist / photo polymer bonding, UV curable materials bonding, metallic bonding, eutectic bonding, solder bonding, indium bonding, thermo-compression bonding, thermo-sonic compression bonding, and / or low temperature glass bonding, glass frit bonding, hybrid bonding (metal + dielectric), plasma enhanced bonding, oxide bonding, DBI (direct bond interconnect), wax bonding, mechanical contact bonding, micro-tube bonding, silicide bonding, laser welding, ultrasonic welding, etc.
Bonding may also be initiated by surface treatments using chemicals, activated plasma treatments, vacuum processes etc. These chemicals may be cured / activated using plasma, light, UV, temperature, pressure, anaerobic environment, etc. [0162] While certain representative embodiments have been shown for purposes of illustrating a point, it will be apparent to those skilled in the art that bonding methods not disclosed herein may be made without departing from the scope of the invention.
[0163] II.E.4 Example Uses of a Holding Chuck of the Present Disclosure
[0164] II .E.4.a Vacuum Generation
[0165] Referring again to the drawings, FIG. 11 A and 11B illustrate various aspects utilizing a holding chuck 1100 in removably securing a microelectronics substrate 1124 to the holding chuck. The holding chuck 1100 may be the same as or similar to any suitable holding chuck disclosed herein.
[0166] As seen in FIG. 11A, example holding chuck 1100 includes a substrate body 1104 having a front surface 1108 and incorporating controllable release components in the form of resistive-type heaters 1112 located correspondingly and respectively in a plurality of
compartmentalized cavities 1116. Facing the front surface 1108 is the microelectronics substrate 1124 having front surface 1128 and back surface 1132. As depicted, back surface 1132 of microelectronics substrate 1124 is facing front surface 1108 of the holding chuck 1100.
[0167] One or more optional coatings 1108 on front surface may function as a sealing gasket as describe elsewhere in this disclosure.
[0168] The holding chuck 1100 may be affixed to a separate holding fixture (not shown) in any suitable manner, as desired or needed. Holding fixtures are commonly known in prior art and may comprise of porous / non-porous vacuum chucks, electro- static chucks, clamps, jigs, mounts, thermal or non-thermal adhesive tapes, UV tapes, etc.
[0169] FIG. 11B illustrates the removably securing process, wherein the back surface 1132 of the microelectronics substrate 1124 is secured to the front surface 1108 of the holding chuck 1100 by bringing the microelectronics substrate 1124 proximate to the holding chuck 1100 at the front surface 1108 and holding them firmly against each other during or post evacuating the gaseous component in the compartmentalized cavities 1116 of the holding chuck 1100. The wafer assembly 1136 is bonded due to differential pressure between the partial vacuum created in the compartmentalized cavity 1116, versus ambient pressure (atmospheric pressure, if atmosphere is the ambient). Ideally, this bonding between the wafers is temporary and reversible. [0170] Evacuation of the gaseous component(s) in the compartmentalized cavities 1116 can be performed utilizing any of a number of active / passive techniques for generation of vacuum, as described below. One or more of the described techniques might be used together, if so desired.
[0171] By definition, a vacuum is a physical space / region that is partially or completely exhausted of any air (or gaseous component), by an artificial means to the highest degree possible. External method for evacuating the gaseous component may include dynamic / active systems such as, but not limited to: suction pumps, positive displacement pumps, external vane pumps, internal vane pumps, rotary vane pumps, Roots-type blower or pump, single and multi-stage Roots-type blower, diaphragm pump, liquid ring, piston pump, scroll pump, screw pump, Wankel-type pump, Toepler-type pump, lobe pump, Venturi vacuum pump, steam ejector, etc. Momentum transfer pumps, for example, molecular pumps, diffusion pump, turbomolecular pump, etc., and entrapment pumps, such as cryopumps, getters, ion pumps, sputter ion pumps, etc., can also be used, as can regenerative pumps.
[0172] Alternatively or in addition, one or more methods internal to compartmentalized cavities 1116 for evacuating the gaseous component for generating vacuum may be used. Examples of such methods may include, but are not limited to the following.
[0173] Two substrates can be joined face to face, with one (or both) substrate(s) containing exposed depressions in / on its surface (cavities) facing the joining seam, in a vacuum environment. This physical joining can be performed with or without heating the joined assemblage. On removal from the vacuum chamber into air and at room temperature, the two substrates will be held, or bonded, together. Atmospheric pressure forces the substrates together due to the partial vacuum (removal of air / gas) created in the cavities.
[0174] Vacuum can also be generated, in-situ, by heating the resistive-type heaters 1112 in the compartmentalized cavities 1116. The resistive-type heaters 1112 will heat the gas in their proximity. This heated gas expands and thus displaces some volume of gas from the
compartmentalized cavities 1116. Plugging the compartmentalized cavities 1116 rapidly (e.g., by bringing the two wafers to be bonded, proximate to each other at the bonding seam, and holding them firmly against each other), prior to cool down of the remainder of the gas contained in the cavity will result in partial vacuum inside the cavities. [0175] Vacuum can also be generated, in-situ, by burning (e.g., using a pyrophoric substance) or heating a contained volume of air/ gas with an orifice (air outlet) to allow for gas expansion and leaking and then plugging the orifice (air outlet) rapidly, prior to cool down of the remainder, contained volume of air / gas. This can be readily achieved by depositing pyrophoric materials in the compartmentalized cavities 1116, then by heating the resistive-type heaters 1112 in the compartmentalized cavities.
[0176] Vacuum can also be generated, in-situ, by employing one or more getter materials in the compartmentalized cavities 1116. For example, getters can be deposited in the compartmentalized cavities 1116 in between the two joining the holding chuck 1100 and the microelectronics substrate 1124, and then the getters can be discharged (heated or somehow activated (heat, light, moisture, electro-magnetic radiation, microwaves, etc.) to release their air / gas components). Post discharge, the holding chuck 1100 and the microelectronics substrate 1124 will be bonded together, because the getter materials will re-adsorb any residual air / gas / moisture in the cavity creating partial vacuum. This discharging can be readily achieved by heating the resistive-type heaters 1112 in the compartmentalized cavities 1116.
[0177] Vacuum can also be generated, in-situ, by joining the holding chuck 1100 and the microelectronics substrate 1124 face to face, with one (or both) substrate(s) containing exposed depressions in / on its surface (compartmentalized cavities 1116) facing the joining seam.
Subsequently annealing this joined assemblage at low / medium / high temperature can initiate a chemical reaction between the trapped gases and the substrate material in the compartmentalized cavities 1116 (or alternatively, a coating deposited in the cavities prior to joining). Once the assemblage is cooled to room temperature, the holding chuck 1100 and the microelectronics substrate 1124 will be held together (bonded). The chemical reaction and its by-products will reduce / remove the pressure of the trapped gases in the cavities with respect to atmospheric pressure. This could be readily achieved by heating the resistive-type heaters 1112 in the compartmentalized cavities 1116.
[0178] Example: Depositing a heat activated pyrophoric substance in the compartmentalized cavities 1116 of the holding chuck 1100. Activating the pyrophoric substance using the controllable release components 1116 in the form of resistive-type heaters 1112 in the compartmentalized cavities to create gaseous expansion of the gas in the compartmentalized cavities. Joining the holding chuck 1100 and the microelectronics substrate 1124 prior to cool down of the remaining volume of gaseous component in the compartmentalized cavities bonds the substrates together.
[0179] Example: Depositing a heat activated getter material in the compartmentalized cavities 1116 of the holding chuck 1100. Joining the holding chuck 1100 and the microelectronics substrate 1124 together, which can be performed in a vacuum chamber if so desired. The getter material may be activated using a suitable impulse to adsorb some portion of the gaseous component in the compartmentalized cavities 1116 to create partial vacuum, which leads to bonding.
[0180] Example: Depositing a heat-activated getter material in the compartmentalized cavities 1116 of the holding chuck 1100. Discharging the getter material to force the adsorbed gaseous components to evolve using the controllable release component in the form of resistive-type heaters 1112 in the compartmentalized cavities 1116 (this can be performed in a vacuum chamber if so desired). The holding chuck 1100 and the microelectronics substrate 1124are joined together.
The now discharged getter material will re-adsorb some portion of the gaseous component in the cavities to create partial vacuum, resulting in bonding.
[0181] Example: Joining the holding chuck 1100 and the microelectronics substrate 1124 together. Annealing the assembly of the holding chuck 1100 and the microelectronics
substrate 1124 to initiate a chemical reaction between the gaseous component in the
compartmentalized cavities with the material making up the substrate body of the holding chuck 1100, and / or the microelectronics substrate 1124. The by-product of the chemical reaction consumes some volume of the gaseous component in the compartmentalized cavities 1116, leading to reduction in partial pressure and thereby resulting in bonding.
[0182] There are no limitations / requirements on the magnitude of the partial vacuum, as long as the level of vacuum is sufficient to create the desired effects and functionality of removably securing the microelectronics substrate.
[0183] Level of vacuum required to create functionality: A figure of merit for the amount of vacuum, also called“vacuum quality,” for a system can be sub-divided into ranges. These ranges do not have universally agreed definitions, but typical distributions are as follows:
Low (“Rough”) Vacuum: 1 - 1 X 10 3 Torr
Medium Vacuum: Less than 1 X 10 3 Torr to 10~5 Torr High Vacuum: Less than 1 X l0~5 Torr to 10 8 Torr
Ultra-High Vacuum: 7.5 X l(T10 Torr to 7.5 X KT11 Ton- Extreme Ultra High Vacuum: Less than 7.5 X 10 13 Ton-
Note: The vacuum levels utilized in this work might also extend from 760 Torr (atmospheric pressure) to the“Rough” vacuum range.
[0184] While certain representative vacuum pressure ranges have been shown for purposes of illustration, it will be apparent to those skilled in the art that vacuum pressure ranges not disclosed herein may be utilized without departing from the scope of the invention.
[0185] There are no limitations / constraints on the chemical composition of the gaseous component in the compartmentalized cavities, prior, during or post bonding. The gases in the compartmentalized cavities 1116 might be a pure gas (pure oxygen, pure nitrogen, etc.), a mixture of gases (oxygen + nitrogen, 20 % oxygen, air, etc.). The gases may be active or inert, if so desired.
[0186] There are no limitations / constraints on the temperature at which this bonding / joining is initiated / performed. It may be performed at ambient temperature, or a temperature lower than ambient, or a temperature higher than ambient.
[0187] Prior to bonding / joining the two substrates, they may be aligned along fiducial marks / alignment marks, if so desired.
[0188] While certain representative embodiments have been shown for purposes of illustrating the wide variety of vacuum generating techniques, it will be apparent to those skilled in the art that techniques / methods not disclosed herein may be used without departing from the scope of the invention.
[0189] II.E.4.a.i Examples of Microelectronics Substrate
[0190] As an example of microelectronics substrate 1124, consider an inorganic LED wafer below.
[0191] The starting growth substrate / platforms for III - V Nitrides (InGaN LEDs) are well known in prior art. Some of them, but not all, are outlined below: GaN on GaN, GaN on Sapphire, GaN on SiC, GaN on Si, GaN on AIN, GaN on Ga203, GaN on hBN, GaN on Graphene, GaN on WSe2, etc. [0192] The growth substrate can be transparent or opaque. The growth films, once grown can be processed further on the growth substrates into microLEDs.
[0193] Note that other substrates and GaN crystal orientations, such as cubic GaN on Si, or cubic GaN on Si on SiC also exist and can be utilized without restrictions. Similarly, LED in the UV, DUV, NIR, IR regions will have different base substrates and device layers and can be utilized without restrictions. Also note that there exist architectures that combine LEDs with a down conversion phosphor together as a monolithic and these and other types of devices can be used without restrictions.
[0194] A wide variety of III - V Nitride film growth techniques are known in prior art and in production. The growth techniques may involve any known conventional deposition means such as PVD processes such as: MBE or, CVD processes such as, but not limited to: MOCVD, HVPE, LPCVD, HDPCVD, ECR-PECVD/ LTPECVD/ /PVD/, LPE, PLD, etc.
[0195] A variety of device architectures exist for III - V Nitride LEDs and may include electro luminescent devices in the form of simple P/N junctions, PIN junctions (homo and heterojunctions), single heterojunction, dual heterojunction, multi-heterojunctions, band-gap engineered Quantum confined structures such as: quantum wells, strained quantum wells, superlattices (Type I, Type II), quantum wires, quantum dots, quantum nanotubes (hollow cylinder), quantum nanowires (solid cylinder), quantum nanobelts (solid rectangular cross section), quantum nanoshells, quantum nanofiber, quantum nanorods, quantum nanoribbons, quantum nanosheets, etc.
[0196] The GaN / InGaN (III - V Nitride) might be Wurtzite or cubic in crystal phase.
[0197] Alternatively, the growth films can be transferred onto another, secondary substrate prior to being processed into microLEDs.
[0198] It is understood that any known technique for removal of GaN / InGaN (III - V nitride) films from the growth substrate might be used. Some of these techniques for substrate removal and thin film transfer are cited below, note that this list is not comprehensive:
[0199] Laser lift off techniques may include using an excimer layer, using a YAG laser, etc. Techniques and absorbing layers have been developed such that thin film removal can be effected by using lasers from the UV - Vis - NIR - MWIR range of wavelengths. [0200] Chemical lift off techniques such as: photo-electro chemical etching (PEC etching), electro chemical etching, liquid etching, molten chemical etching, etc. The sacrificial growth layers may include, but not limited to, GaN, Ga203, CrN, ZnO, A1N.
[0201] Stress induced transfer techniques such as natural stress induced lift off, thermal stress induced lift off, ion implanted stress lift off, hydrogen / helium implanted stress lift off, etc., can be used
[0202] Mechanical stress induced transfer techniques can include deposition and physical peeling of the GaN / InGaN stack from a 2D sacrificial growth layer of hBN, MoS2, MoSe2, WS2, graphene, mica, etc.
[0203] While certain representative LED device architectures have been illustrated, it will be apparent to those skilled in the art that other LED architectures and materials not disclosed herein may be used without departing from the scope of the invention.
[0204] While LED device architectures are elaborated on, it is self-evident that other electronic and opto-electronic devices manufactured in silicon (Si), silicon germanium (SiGe), germanium (Ge), silicon-on-insulator (SOI), silicon on sapphire, germanium on insulator, GaP, GaAs, etc., substrates could be utilized.
[0205] Electronic devices might include, but not limited to, devices such as RFIDs, MEMs, ICs, Photovoltaic Solar Cells (PV), Focal Plane Arrays (Sensors), CMOS detectors, CCD detectors, Quartz oscillators, etc. The devices might work in any electro -magnetic / spectral region, from UV- Vis-NIR-MWIR-FIR spectral regions or beyond.
[0206] Referring now to the drawings, FIG. 12A-12B illustrate alternate blocks in utilizing the holding chuck of FIG. 1 in removably securing a microelectronics substrate.
[0207] II.E.4.b Surface-activation Bonding
[0208] FIG. 12A illustrates an example holding chuck 1200 that includes a substrate 1204 having a front surface 1208 and incorporating controllable release components in the form of resistive-type heaters 1212 located in compartmentalized cavities 1216. Facing front surface 1208 is a microelectronics substrate 1224 having a front surface 1228 and a back surface 1232. As depicted, the back surface 1232 of microelectronics substrate 1224 is the facing front surface 1208 of the holding chuck 1200. [0209] Surfaces 1232 and 1208 that will confront and engage one another during the bonding process are first conditioned and prepped for bonding. A variety of techniques have been developed in the semiconductor industry to bond wafers of similar / dissimilar materials together at room temperature or low temperature. These techniques typically involve rigorous cleaning processes for the surfaces to be bonded e.g. surfaces 1232 and 1208 (conditioning / preparing the surfaces to be bonded), in conjunction with plasma treatments of these cleaned surfaces (with or without reactive plasma species (activated plasma), atmospheric plasma, with or without inert gases, etc.). Either one or both of the surfaces to be bonded may be conditioned, as desired.
[0210] FIG. 12B illustrates the securing process, wherein the back surface 1232 of the microelectronics substrate 1224 is bonded to the front surface 1208 of the holding chuck 1200 by bringing the microelectronics substrate 1224 proximate to the holding chuck 1200 at the front surface 1208 and holding them proximate or in intimate contact with each other. The assembly 1236 is bonded due to the prepped surface chemistries of these cleaned surfaces, the bonding occurs so called spontaneously. The bonding between the holding chuck 1200 and the microelectronics substrate 1224 can occur under controlled ambient (vacuum environment, elevated or low temperature, etc.) or at room temperature.
[0211] Initial bonding strength is dependent on many factors including nature and quality of the cleaning, additional surface preparations (flatness, roughness, additional chemical treatments), reactive surface species (hydrophobic, hydrophilic, etc.), environment, bonding temperature, etc. In most cases, it is typical to anneal the bonded assembly at high temperature to increase the bond strength and make it permanent.
[0212] For this application, the initially bonded wafers are used as is to allow for removably securing, without any subsequent high temperature annealing blocks.
[0213] This bonding technique of FIG. 12A and 12B may be used along with the bonding technique revealed in FIGS. 11A and 1 IB earlier, if so desired.
[0214] II.E.4.C Adhesive Bonding
[0215] FIG. 13 illustrates an alternate method in utilizing an example holding chuck 1300 of the present disclosure in removably securing a microelectronics substrate. In FIG. 13, holding chuck 1300 includes a substrate body 1304 having a front surface 1308 and incorporating controllable release components in the form of resistive-type heaters 1312 located in the compartmentalized cavity 1316. Facing the front surface 1308 is the microelectronics substrate 1324 having front surface 1328 and back surface 1332. As depicted, the back surface 1332 of the microelectronics substrate 1324 is facing the front surface 1308 of the holding chuck 1300.
[0216] As depicted, an adhesive coating layer 1340 can be preferentially deposited atop surface 1308 so as not to obscure compartmentalized cavity 1316. Similarly, an adhesive coating layer 1336 can be deposited over surface 1332. This prepares the holding chuck 1300 and microelectronics substrate 1324 for adhesive bonding.
[0217] As is known in manufacturing semiconductor devices, even with the best of engineering efforts the surface 1332 of the microelectronics substrate 1324 may never be perfectly flat or parallel. Similarly, the surface 1308 of the holding chuck 1300 may never be globally perfectly flat or parallel or be a perfect image of the microelectronics substrate 1324. So, the adhesive layer or layer, here layers 1336, 1340, can serve to planarize and remove any surface mis-match / errors between the surfaces 1332 and 1308. The adhesive layer(s), here layers 1336, 1340, serve(s) as an intermediary to bond the two surfaces 1332, 1308 together.
[0218] Bonding of wafers and other bodies with adhesive is known in prior art, and the process of bringing the holding chuck 1300 and/or the microelectronics substrate 1324 proximate to each other and activating the adhesive layer to complete the bond have not been depicted.
[0219] This bonding technique of FIG. 13 may be used along with the bonding technique revealed in FIGS. 11A and 11B earlier, if so desired.
[0220] II.E.4.d Magnetic Bonding
[0221] FIG. 14A to 14C illustrate some example alternative methods of utilizing holding chucks 1400A to 1400C of the present disclosure for removably securing a microelectronics substrate 1424 thereto.
[0222] FIG. 14A shows holding chuck 1400A that includes a substrate body 1404 having front surface 1408 and including controllable release component in the form of resistive-type heaters 1412 located correspondingly and respectively in compartmentalized cavities 1416. Facing the front surface 1408 is microelectronics substrate 1424 having a front surface 1428 and a back surface 1432. As depicted, the back surface 1432 of the microelectronics substrate 1424 is facing the front surface 1408 of the holding chuck 1400A. [0223] As depicted, one or more magnetic coating layer 1436 can be preferentially deposited atop surface 1408 so as not to obscure compartmentalized cavity 1416. As also depicted, if the microelectronics substrate 1424 can be coated with a functional material (material that has intrinsic use and purpose in the final device) that is magnetic or paramagnetic, then such a microelectronics substrate could be removably secured by using the permanent magnetic coating layer(s) 1436 on the front surface 1408 of the holding chuck 1400A. Techniques for making permanent magnetic coating layer(s) 1436 are well known in literature and not elaborated on here.
[0224] II.E.4.e Electret Bonding
[0225] FIG. 14B is identical to FIG. 14A with the exception that one or more electret coating layer 1440 is deposited atop front surface 1408 of the holding chuck 1400B. Each electret coating layer 1440 may any one or more of the electret materials described herein, among others.
[0226] As is well known in prior art, charged particles create electric fields. This electric field has a magnitude and a direction. Electro-static electric field / force exerted by an electret coating can be used to removably secure the microelectronics substrate 1424 onto the holding chuck 1400B.
[0227] Techniques for making electret coating layer(s) 1440 are well known in literature and not elaborated on here.
[0228] II.E.4.f Capillary-force Bonding
[0229] FIG. 14C is identical to each of FIGS. 14A and 14B with the exceptions that a liquid layer 1444 is housed in the compartmentalized cavities 1416 of the holding chuck 1400C, atop the controllable release components that here are in the form of resistive-type heaters 1412.
[0230] Capillary forces exerted by this liquid layer 1444 can be used to removably secure the microelectronics substrate 1424 onto the holding chuck 1400C. The liquid layer 1444 can be organic or inorganic or hybrid in composition. Furthermore, the liquid layer 1444 might also have a gel-like consistency.
[0231] The process of bringing the holding chuck 1400C and/or the microelectronics substrate 1424 proximate to each other to initiate bonding are not depicted in FIGS. 14A to 14C, as these are known in prior art.
[0232] The bonding techniques of FIG. 14A-14C may be used along with the bonding technique revealed in FIGS. 11A-11B earlier, if so desired. [0233] II.E.4.g Processing a Microelectronics Substrate on a Holding Chuck
[0234] FIG. 15 illustrates an example of using a holding chuck 1500 of the present disclosure in an application wherein a microelectronics substrate 1524 is processed while being held by the holding chuck.
[0235] In FIG. 15, the holding chuck 1500 includes a substrate body 1504 having front surface 1508 and including controllable release components in the form of resistive-type heaters 1512 located in compartmentalized cavity 1516. Facing the front surface 1508 of the holding chuck 1500 is microelectronics substrate 1524 that has a front surface 1528 and a back surface 1532. As depicted, the back surface 1532 of the microelectronics substrate 1524 is facing the front surface 1508 of the holding chuck 1500.
[0236] A release process, illustrated by arrows 1536, is initiated to release / de-bond the removably secured microelectronics substrate 1524 from the holding chuck 1500. This release / de bonding might be necessary post processing the device wafer 1524 or to re-position the
microelectronics wafer 1524 on the holding chuck 1500, among other things
[0237] Release process 1536 to separate / de-bond the holding chuck 1500 and the
microelectronics substrate 1524 can be performed by creating the necessary conditions to equalize or elevate, relative to surrounding ambient, the pressure in the compartmentalized cavities 1516 that removably secures the microelectronics substrate 1524 to the holding chuck 1500. This pressure equalization (or elevation) to negate the partial vacuum removably securing the microelectronics substrate in place can be achieved by using, for example, any one or more of the following techniques, among others.
[0238] Desorbing the adsorbed gases in the getter materials (coating 116 in FIG. 1) that may be pre-deposited in the compartmentalized cavities 1516 of the holding chuck 1500. This activation may be performed using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500.
[0239] Activating the pyrophoric compound (to cause gaseous expansion) (coating 116 in FIG.l) that may be pre-deposited in the compartmentalized cavities 1516 of the holding chuck 1500. This activation may be performed using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500. [0240] Global heating of the holding chuck 1500 would cause an expansion of the trapped (residual) gases in the compartmentalized cavity 1516. This expansion would result in a release of the attached microelectronics substrate 1524. This global heat source could be external, or internal (e.g., heat supplied by activating the resistive-type heaters 1512).
[0241] Local heating of the trapped (residual) gases in the compartmentalized cavities using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500 would cause an expansion of the trapped gases. This expansion would result in a release of the attached microelectronics substrate 1524.
[0242] Activating the vacuum activated materials (to cause gaseous expansion) (e.g., coating(s) 116 in FIG. l) that may be pre-deposited in the compartmentalized cavities 1516 of the holding chuck 1500. This activation may be performed using the resistive-type heaters 1512 in the compartmentalized cavities 1516 of the holding chuck 1500. Examples of vacuum-activated materials suitable here are described above.
[0243] Separating / de-bonding of the holding chuck 1500 and the microelectronics
substrate 1524 can also be achieved by using differential pressure so that the air / gas pressure in the compartmentalized cavities 1516 of the holding chuck 1500 is higher than the air / gas pressure surrounding the microelectronics substrate 1524. That is to say, the surface 1528 of the
microelectronics substrate 1528 facing away from the holding chuck 1500 is in an ambient with much higher vacuum (lower pressure) than the surface 1532 of the microelectronics substrate 1532 facing the holding chuck 1500.
[0244] There are no limitations / constraints on the temperature of the assembly of the microelectronics substrate 1524 and the holding chuck 1500 at which this separating / de-bonding is initiated / performed. The process may be performed at ambient temperature, or a temperature lower than ambient, or a temperature higher than ambient, either or for the wafer assembly or the tool / room temperature.
[0245] There are no limitations / constraints on the orientation of the microelectronics substrate 1524 and the holding chuck 1500 when this separating / de-bonding is initiated / performed. [0246] Post pressure equalization (or elevation) to negate the partial vacuum holding the microelectronics substrate 1524 in place, the microelectronics substrate may release and be allowed to fall off due to gravity.
[0247] Referring to FIG. 11 A and 11B and FIG. 15 together, holding chuck 1500 allows for two wafers to be secured temporarily and reversibly.
[0248] II.E.4.h Forming Individual Microelectronic-device dies on Holding Chuck
[0249] FIGS 16 and 17A to 17C illustrate an example method 1600 of utilizing an example holding chuck 1700 made in accordance with aspects of the present disclosure to handle a microelectronics substrate 1724 and also to hold the microelectronics substrate during creation of individual microelectronic-device dies 1744.
[0250] Referring to FIGS. 17A-17C, and also to FIG. 16, at block 1605 of method 1600, the microelectronics substrate 1724 (FIG. 17A) is removably secured to the holding chuck 1700. In this example, holding chuck 1700 includes a substrate body 1704 having front surface 1708 and that includes controllable release component in the form of resistive-type heaters 1712 located correspondingly and respectively in a plurality of compartmentalized cavities 1716. Facing the front surface 1708 is a front surface 1728 of the microelectronics substrate 1724. In this example, microelectronics substrate 1724 includes various microelectronic device coating layers 1736, which may be located on the front surface 1728 or the back surface 1732, or both the front and back surfaces. There are no implied limitations on orientation of the microelectronic device layers 1736 with respect to surface of the microelectronics substrate 1724. As depicted, the back surface 1732 of the microelectronics substrate 1724 is removably secured at the front surface 1708 of the holding chuck 1700 to form an assembly 1740.
[0251] At block 1610 of method 1600, the microelectronics substrate 1724 (FIG. 17B) may further processed to create individual microelectronic-device die 1744, in-situ, in microelectronics substrate 1724.
[0252] II.E.4.h.i Example Processing to Create Individual Microelectronic-device Dies
[0253] Still referring to FIGS. 16 and 17A to 17C, the microelectronic device layers 1736 and the microelectronics substrate 1724 are partitioned / singulated into individual microelectronic- device die 1744 by an etching process 1748. Spin coating for a photo-resist, patterning for the photo-resist, exposing the photoresist, and other photolithography processes are well known in prior art and not elaborated upon herein.
[0254] Etching techniques to create the individual microelectronic-device die 1744 may include, but not limited to wet chemical etching processes, dry etching processes such as reactive ion etching (RIE), plasma / planar etching, plasma enhanced etching (PE), inductively coupled plasma etching (ICP), deep reactive ion etching (DRIE), sputtering, ion enhanced etching, ion beam milling, chemically assisted ion beam milling, electron cyclotron resonance plasma (ECR), high density plasma (HDP), microwave and RF plasma assisted etching, laser induced / assisted chemical etching, may be individually employed for the same effect. The chemical source maybe introduced as flood, time-varying, spatially varying, or continuous. The etching may be performed at low temperature, ambient temperature, or high temperature, and there are fundamentally no temperature constraints on the etching process.
[0255] Mechanical techniques to create the individual microelectronic-device dies 1744 might include any of a variety of equipment, such as dicing saws, dicing blades, scribing and break, ablation laser, microjet (with or without liquid), and stealth dicing, among others, may be used. Techniques such as laser ablation, laser photo- ablation, laser induced etching, laser chemical etching, femto- second laser ablation and other ultra- fast laser based etching phenomenon may also or alternatively be used.
[0256] While certain representative etching methods have been shown for purposes of illustrating aspects of the present disclosure, it will be apparent to those skilled in the art that other etching / removal methods exists and may be used without departing from the scope of this disclosure, which is defined in the appended claims.
[0257] If getters, pyrophoric materials, and/or vacuum activated materials are deposited in the compartmentalized cavities 1716 of the holding chuck 1700 before the removably securing process 1605, or if the resistive-type heater elements 1712 are susceptible to high temperatures, the assembly 1740 may be cooled so as to prevent pre-mature activation of the getter, pyrophoric material, or vacuum activated materials (if present), or prevent the destruction of the resistive-type heater elements 1712, during the etching process at block 1610 to create the individual
microelectronic-device dies 1744. [0258] As depicted in FIG. 17B, 1748, the individual microelectronic-device dies 1744 each comprise a corresponding portion of the microelectronic device layers 1736, plus a corresponding portion of the microelectronics substrate 1724. Depending on application, it is possible to create the individual microelectronic-device die 1744 with just the microelectronic device layers 1736 without the underlying microelectronics substrate 1724, or individual microelectronic-device die 1744 with the microelectronic device layers 1736 and only part of the underlying microelectronics substrate 1724 attached.
[0259] There are no restrictions of the physical size of the individual microelectronic-device die 1744 created by this process. They may be of any suitable physical size and shape and dimension. Their largest dimension may be < 100 nm, or < 1 micron, or < 5 microns, or < 10 microns, or < 20 microns, or < 50 microns, or < 100 microns, or < 1000 microns, or in mm or cm scale.
[0260] In some embodiments, the holding chuck 1700 and microelectronic substrate 1724 are aligned so that the individual microelectronic-device dies 1744 sit completely over (i.e., cover) one or more underlying compartmentalized cavities 1716. Generally, it is desired that each
microelectronic-device die 1744 cover at least one compartmentalized cavity 1716 to provide the desired holding and release functionalities.
[0261] If a photoresist is used for patterning, this photoresist may be removed if so desired, for example, post processing the microelectronics substrate 1724 into individual microelectronic-device dies 1744. Removal steps and techniques for photo-resist removal are well known in prior art and not elaborated herein.
[0262] At block 1615 of method 1600, one or more individual microelectronic-device dies 1744 (FIG. 17C) may be released from the holding chuck 1700 via a suitable release process (depicted by arrow 1752), for example, as described in FIG. 15 earlier.
[0263] Specific advantages of method 1600 include the following. In current dicing / singulation (process to create individual micro-die(s)), the microelectronics device wafer (or substrate) is mounted on a thermal or non-thermal adhesive tape, or a UV tape, which in turn might be mounted onto a porous / non-porous vacuum chuck, or an electro-static chuck. These mounting techniques can be employed for larger individual die(s), for example, die(s) with sizes > 100 microns. However, various tapes (adhesive / polymer layers) used in these mounting techniques can suffer from elongation / dimensional instability as they are too compliant / flexible, and do not hold the micro-die(s) with the required / desired positional accuracy as might be needed for high finesse work. Additionally, the use of such adhesive tapes also raises the issue of tape residues and contaminants that can adhere to the micro-die(s). In addition, it is well known that removal of diced / singulated die(s) from conventional tapes requires a“peel” or“shear” force and it is typically not possible to simply“lift” the die(s) vertically.
[0264] As should be apparent from the earlier description (FIG. 17C), the presently revealed release / de-bonding process can allow for vertical release, with no residue on the individual microelectronic-device die. Therefore, the holding chuck 1700, or any holding chuck made and used according to the present disclosure, can be used as the base / primary platform for holding / affixing the microelectronics substrate 1724 prior to (and during) etching the microelectronics substrate into individual microelectronic-device dies.
[0265] Furthermore, the holding chuck 1700 provides for a monolithic, rigid, passive, self- contained, internal and integrated vacuum holding force, which can be individually addressed and reversed to allow for clean release of micro-die(s)
[0266] P.E.4.Ϊ Transfer Process using Holding Chuck
[0267] FIGS.18 and 19A to 19E illustrate an example method 1800 of utilizing a holding chuck 1800 for the purpose of mass transferring of individual microelectronic-device dies 1944 created from a microelectronics substrate 1924.
[0268] Referring now to FIGS. 19A to 19E, and also to FIG. 18, at block 1805 of method 1800, the microelectronics substrate device 1924 (FIG. 19A) is removably secured to the holding chuck 1900. The holding chuck 1900 includes a substrate body 1904 having front surface 1908 and that includes controllable release component in the form of resistive-type heaters 1912 located correspondingly and respectively in a plurality of compartmentalized cavity 1916. Facing the front surface 1908 is the microelectronics substrate 1924 that has a front surface 1928 and includes microelectronic device coating layers 1936 on front surface 1928 and/or a back surface 1932 (only shown on front surface 1928 in FIG. 19A). As depicted, the back surface 1932 of the
microelectronics substrate 1924 is secured at the front surface 1908 of the holding chuck 1900 to form an assembly 1940. [0269] At block 1810 of method 1800, the microelectronics substrate 1924 (FIG. 19B) is further processed, in this example by etching 1948, to create individual microelectronic-device dies 1944, in-situ, from the microelectronics substrate 1924.
[0270] At block 1815 of method 1800, holding chuck 1900 (FIG. 19C) is flipped over with the attached individual microelectronic-device dies 1944, such that the individual microelectronic- device dies 1944 are facing a receiving support 1952. The assembly 1940 is aligned with the receiving support 1952.
[0271] II.E.4.i.i Receiving Support
[0272] The receiving support 1952 may be a final / intermediate substrate and or location The receiving support 1952 may be rigid or flexible and may be composed of one or more polymers, ceramics, metals, papers, fabrics, or glasses or any combination thereof, among other things. The receiving support 1952 may be transparent, opaque, or translucent. Each material of the receiving support 1952 may be a conductor, an insulator, or a semiconductor. Each material may be inorganic or organic or a combination thereof and may be single crystal, polycrystalline, oriented (or textured) polycrystalline, or amorphous in morphology.
[0273] There are fundamentally no limits on the thickness of the receiving support 1952, and in some embodiments the thickness may range from a few microns to several millimeters as desired by application. The surface of the receiving support may be planar (flat), or may be profiled with depressions, cavities, hills, etc.
[0274] Additionally and optionally, other functionality and/or one or more functional coatings may be added to and/or deposited in or on the surfaces of the receiving support 1952. The coating(s) may act as a flex / compliant layer, anti-stick /anti-abrasion layer, barrier layer, passivation layer, planarizing layer, UV protection layer, adhesive layer, color filters, black mask coating, anti-static layer, conductive layer, etc., or any combination thereof. These functional layers include, but are not limited to, organic or inorganic layers.
[0275] The receiving support 1952 may include electronic circuitry or other electrical functionality pre-built into the receiving support. Examples of such receiving supports include, but are not limited to silicon CMOS back planes, silicon NMOS backplanes, silicon PMOS backplanes, TFTs on glass, PCBs, and FR4, among many others. [0276] It is noted that intermediate substrates are sometimes referred to as“interposers” in literature, and such interposers may be used as a receiving support of the present disclosure.
[0277] While certain representative examples have been mentioned for purposes of illustrating the wide variety of substrates that can be used for the receiving support 1952, it will be apparent to those skilled in the art that substrates not disclosed herein may be made without departing from the scope of the invention.
[0278] As show in FIG. 19C and FIG. 19C', the assembly 1940 may be proximate to, but not touching, or may be spaced a little distance from the receiving support 1952, or the assembly 1940 may be in intimate contact with receiving support 1952 as illustrated at 1964.
[0279] Referring to FIG. 19C, in this architecture, once one set of individual microelectronic- device die 1944 are released, another set of individual microelectronic-device die 1944 can be dispensed adjacent and / or in between the first set of individual microelectronic-device die, because the wafer assembly 1940 is spaced at a distance from the receiving support 1952.
[0280] Referring to FIG. 19C, in this architecture, once one set (i.e., one or more) of individual microelectronic-device dies 1944 is released, another set of individual microelectronic-device dies can only be dispensed next to the first set of individual microelectronic-device dies, but not in- between existing individual microelectronic-device die, because the wafer assembly 1940 is in intimate contact (or almost intimate contact) with the receiving support 1952.
[0281] At block 1820 of method 1800 and as illustrated in FIG. 19D, one or more of the individual microelectronic-device dies 1944 are released from holding chuck 1900 by utilizing a suitable release impulse 1956, and transferred onto the receiving support 1952. The release impulse 1956 for releasing the individual microelectronic-device die 1944 from the holding chuck may be triggered globally releasing all the individual microelectronic-device die 1944 at one time, or triggered locally releasing one individual microelectronic-device die 1944 at one time.
[0282] At block 1825 of method 1800 and as illustrated in FIGS. 19D' to 19E, the transferred individual microelectronic-device dies 1944 are affixed onto the transferred location of the receiving support 1952 via bonding agent / seam 1960. [0283] ILE.i.ii Bonding Agent/Seam
[0284] Bonding agent 1960 may be electrically conductive; metals, silver paste, solders, eutectics, wire meshes, graphite / graphene, CNTs, other electrically conductive formulations.
Bonding agent 1960 may be electrically insulating; adhesives, polymers, photo-resist, BCP, glass frits, other electrically insulating formulations. Bonding agent 1960 may allow for temporary bonding or permanent bonding at the location.
[0285] Optionally, bonding agent 1960 may utilize vacuum forces, magnetic forces, electro magnetic forces, Static Electricity forces (also called Electrets), Electro-Static forces, electrography / xerography (electrical forces) for removably securing the individual microelectronic-device die(s) 1944.
[0286] In some variants, block 1825 of method 1800 could be implemented prior to block 1820 of method 1800. Individual microelectronic-device die 1944 are first affixed onto the receiving support 1952 (FIG. 19D')· The individual microelectronic-device die 1944 are then released from holding chuck 1900 by utilizing suitable impulse 1956 (FIG. 19D"). Note that the process blocks of FIG. 19D, FIG. 19D', and FIG. 19D" can be combined together.
[0287] Specific advantages of method 1800 include the following. Mass transfer techniques differ from traditional serial pick and place techniques and typically involve the transfer of many multiple parts (dies, micro-die(s)) simultaneously, also referred to as parallel transfer. These parallel transfer techniques can further transfer parts deterministically (by design and intent), or
stochastically (random process). A variety of mass transfer techniques have been developed / investigated over the decades. For a multitude of reasons, current mass transfer technologies are not able to provide the speed and precision of transfer required for a variety of industries.
[0288] For example, whether in head mounted displays (HMDs) for virtual reality (VR), augmented reality (AR), or mixed reality (MR), near eye displays (NEDs) portend the“next big thing,” ultimately displacing smartphones. For AR to fulfill its enormous potential, the market will demand highly mobile, untethered, discreet and stylish eyewear.
[0289] Today’s incumbent OLED microdisplays have many shortcomings vis-a-vis AR requirements, in color quality, resolution, brightness, efficiency, and longevity. Inorganic III - V Nitride (GaN / InGaN / AlGaN) based microLEDs (Inorganic LED technology) with individually addressable RGB pixels, would be hugely preferred for higher brightness (daylight viewing), high efficiency for long battery life and untethered use and very compact forms, but unfortunately such microLEDs only emit monochrome (blue / violet) light.
[0290] To realize high definition, full color, RGB pixels, the respective pixel and sub-pixel sizes for such ILED microdisplays can be on the order of sub 20 microns, or sub 10 microns, or even sub 5 microns. There is currently no mass transfer technology that can allow for the manufacturing of such microdisplays from highly optimized, pre-made, inorganic LED micro dies.
[0291] Similarly, there is a need in the solid state lighting market (SSL) to get highly optimized “white” light source and reduce cost of such devices. Having individual R,G,B inorganic LEDs on a singular platform to optimize performance has been a long unmet wish list for the U.S. Department of Energy.
[0292] Holding chucks of the present disclosure, such as holding chuck 1900, solve the aforementioned and other issues. The holding chuck 1900 can be used not only as the base / primary platform for holding / affixing the microelectronics substrate, prior to (and during) etching the microelectronics substrate, into individual microelectronic-device die, but also for the deterministic mass transfer of these etched individual microelectronic -device onto a separate, desired receiving support with a great degree of positional accuracy. Since for deterministic mass transfer, it is imperative to first know where the individual microelectronic-device die are with a great degree of accuracy, before these individual microelectronic-device die can be picked up and transferred to the desired location. Holding chuck 1900 provides a convenient way of doing this.
[0293] II.E.4.j Holding Chuck having Out-of-plane Compartmentalized Cavities
[0294] FIGS. 20A to 20E illustrate another example variant of a holding chuck 2000 made in accordance with aspects of the present invention. As seen in FIG. 20A, the holding chuck 2000 includes a substrate body 2004 having a front surface 2008 that that includes controllable release components in the form of resistive-type heaters 2012 located correspondingly and respectively in a plurality of compartmentalized cavities 2016. Each of the compartmentalized cavities 2016 may be considered to have a top 2020. Double-headed arrow 2024 refers to the tops 2020 of the compartmentalized cavities 2016 being substantially in-plane with the front surface 2008 of holding chuck 2000.
[0295] Referring to FIG. 20B, holding chuck 2000' includes a substrate body 2004' having a front surface 2008' and that includes controllable release components in the form of resistive-type heaters 2012', as well as out-of-plane compartmentalized cavities 2016' and tops 2020' of the out-of- plane compartmentalized cavities. Doubled-headed arrow 2024' refers to the tops 2020' of the front surface 2008', whereas 2028' refers to the tops 2020' of the out-of-plane compartmentalized cavities 2016'. As can be seen by double-headed arrow 2028', tops 2020' are substantially out-of-plane with the front surface 2008'.
[0296] Referring to FIG. 20C, holding chuck 2000" includes a substrate body 2004" having a front surface 2008" and that includes controllable release components in the form of resistive-type heaters 2012" along with out-of-plane compartmentalized cavities 2016" and tops 2020" of the out- of-plane compartmentalized cavities. Double-headed arrow 2028" refers to the tops 2020" of the out-of-plane cavity 2016", whereas double-headed arrow 2024" refers to the front surface 2008" and the tops of the in-plane cavities 2032".
[0297] Out-of-plane compartmentalized cavities 2016" and in-plane compartmentalized cavities 2032" may be of the same / similar heights or be of different heights. Holding chuck 2000", may contain both sets of compartmentalized cavities, as needed.
[0298] Referring now to FIG. 20D, microelectronics substrate 2024 has a front surface 2028 and a back surface 2032 and includes microelectronics device coating layers 2036 on the front surface 2028. The back surface 2032 is removably secured to a holding chuck (not depicted). Facing front surface 2028 is a receiving support 2052. Some individual microelectronic-device dies 2044 are already transferred and affixed onto the receiving support 2052.
[0299] Out-of-plane cavities 2016' and 2016" (FIGS. 20B and 20C, respectively) allow for the placement of one or more individual microelectronic-device dies 2056 in between existing individual microelectronic-device dies 2044 on the receiving support 2052. This allows for the repair and removal of defective dies and replacement with known good dies, etc. This ability to finely manipulate in-between dies is very crucial for mass transfer techniques.
[0300] Referring now to FIG. 20E, microelectronics substrate 2024' has a front surface 2028' and a back surface 2032' and includes microelectronics device coating layers 2036' on the front surface. The back surface 2032' is removably secured to a holding chuck (not depicted). Facing front surface 2028' is a receiving support 2052'. Some individual microelectronic-device dies 2044' are already transferred and affixed onto the receiving support 2052'. [0301] Out-of-plane cavities 2016' and 2016" (FIGS. 20B and 20C, respectively) allow for the placement of individual microelectronic-device die 2056' adjacent to existing individual
microelectronic-device die 2044' on the receiving support 2052'. Therefore, holding chucks with in plane compartmentalized cavities could be used to transfer individual microelectronic-device die onto holding chucks with out-of-plane compartmentalized cavities for further processing.
[0302] II.E.4.k Example Holding Chuck having Porous Film
[0303] FIG. 21A illustrates another example variant of a holding chuck 2100 made in accordance with aspects of the present invention. In this example, the holding chuck 2100 includes a porous film 2124 applied to the holding chuck. As seen in FIG. 21A, the holding chuck 2100 includes a substrate body 2104 having a front surface 2108 and including controllable release components in the form of resistive-type heaters 2112 located correspondingly and respectively in a plurality of compartmentalized cavities 2116. Facing front surface 2108 is a porous film 2124 having a front surface 2128 and a back surface 2132. The porous film 2124 forms the working face of the holding chuck 2100. Microelectronic device coating layers 2136 are secured at front surface 2128 of the porous film 2124 of the holding chuck 2100 to form an assembly 2140. Porous film 2124 may be any suitably porous film, such as a microporous film or a nanoporous film.
[0304] Here, microelectronic device coating layers 2136 are just the functional device layers, i.e., without an underlying substrate. In such a case, the individual microelectronic-device dies (not shown) created from microelectronic device coating layers 2136 might be very thin and fragile. Underlying micro / nanoporous film 2124 is used in this example to securely hold the functional device layers 2136 during and post individual microelectronic-device die creation and subsequent mass transfer of the individual microelectronic-device dies.
[0305] Referring to FIG. 21B, in this example porous film 2124 comprises random pores 2148. The porous film 2124, through its porosity 2148, connects the partial vacuum created in the compartmentalized cavities 2116 (FIG. 21 A) to the overlying microelectronic device layers 2136 and thus holds the microelectronic device layers 2136 firmly in place and spreads the holding force created by the partial vacuum over a larger surface area thus preventing the microelectronic device films 2136 from cracking.
[0306] Porous film 2124 may be made, for example, of any one or more dielectric (metallic / semiconductor) films / coatings, thin films with void - columnar networks, aerogels, hydrogels, mesoporous film, etc., which compositions and deposition techniques are known in prior art and are not repeated here.
[0307] Functional device layers 2136 can be separated from their underlying microelectronics growth substrate (not shown) using a variety of techniques that have been developed for specific industries. For example, some of the techniques for removal of GaN / InGaN (IP - V nitride) device films, used for making LEDs and lasers, from their growth substrate are cited below. Note that this list is not comprehensive.
[0308] Laser lift off techniques: Using an excimer laser, using a YAG laser, etc. Techniques and absorbing layers have been developed such that thin film device layer removal can be effected by using lasers from the UV - Vis - NIR - MWIR range of wavelengths.
[0309] Chemical lift off techniques: Photo-Electro Chemical Etching (PEC etching), Electro Chemical Etching, liquid etching, molten chemical etching, etc. The sacrificial growth layers may include, but not limited to: GaN, Ga203, CrN, ZnO, A1N.
[0310] Stress induced transfer techniques: Natural stress induced lift off, thermal stress induced lift off, ion implanted stress lift off, hydrogen / helium implanted stress lift off etc.
[0311] Mechanical stress induced transfer: Deposition and physical peeling of the GaN / InGaN stack from a 2D sacrificial growth layer of hBN, MoS2, MoSe2, WS2, graphene, mica, etc.
[0312] II.E.4.1 Piezoelectric Controllable release components
[0313] FIGS. 22A to 22C illustrate another example variant of a holding chuck 2200 (FIG. 22C) made in accordance with aspects of the present disclosure. FIG. 22A and 22B each depict an individual compartmentalized cavity 2216 formed in a substrate body 2204 having top surface 2208 and that includes controllable release components in the form of an piezoelectric element 2212.
FIGS. 22A and 22B shown piezoelectric element 2212 in is unactuated state and in an actuated state 2212'. Piezoelectric element 2212 may be made of a piezoelectric material that is the same as or similar to any one or more of the piezoelectric materials described above.
[0314] The piezoelectric elements 2212 can be made / manufactured in-situ, in the
compartmentalized cavities 2216, during the construction of the holding chuck, or alternatively, they could be built ex-situ, and then during the construction of the holding chuck, they could be incorporated into the compartmentalized cavities as desired. There is no specific location in the cavity that the piezoelectric elements 2212 need to be placed. They may be placed at the bottom of the compartmentalized cavities 2216, or they might be placed midway thru the compartmentalized cavities, or they may be placed on the walls of the compartmentalized cavities, among other possibilities.
[0315] A piezoelectric element 2212 could be placed in each and every compartmentalized cavity 2216 of the holding chuck 2200, if so desired. Alternatively, a single piezoelectric element may address / occupy multiple cavities in the holding chuck. The piezoelectric elements 2212 may be individually addressable (triggered to distort) via additional electrical circuits / electronics, if so desired. The piezoelectric elements 2212 may also be globally addressable (triggered all together, all at once).
[0316] FIG. 22B depicts that, when the piezoelectric element is actuated 2212', some portion of air / gas that is present in the compartmentalized cavity 2216 is displaced out of the cavity, as shown by arrows 2224.
[0317] FIG. 22C shows that facing front surface 2208 of holding chuck 2200 is a
microelectronics substrate 2224 having a front surface 2228 and a back surface 2232. The back surface 2232 of microelectronics substrate 2224 is removably secured to the front surface 2208 of holding chuck 2200 by bringing the microelectronics substrate 2224 proximate to the holding chuck 2200 at the front surface 2208 and holding them firmly against each other while the piezoelectric elements 2212 are actuated. As seen in FIG. 22B, under actuation of the piezoelectric element 2212, some portion of air / gas that is initially present in the cavity 2216 is displaced out of the compartmentalized cavity 2216.
[0318] Subsequently, de-actuating the piezoelectric elements 2212 to their un-distorted states results in a partial vacuum in the compartmentalized cavities 2216 of the holding chuck 2200. The assembly 2236 is, thereby, removably secured due to differential pressure between the partial vacuum created in the compartmentalized cavity 2216 and the ambient pressure (atmospheric pressure, if atmosphere is the ambient) surrounding the assembly. Ideally, this securing between the wafers is temporary and reversible.
[0319] Alternative techniques for removably securing microelectronics substrate 2224 to holding chuck 2200 using active / passive vacuum generation as illustrated in FIG. 1 IB may be used. Alternative techniques for removably securing microelectronics substrate 2224 to holding chuck 2200 as illustrated in FIG. 12B, FIG. 13, FIG. 14A-14C, may also be optionally employed.
[0320] Techniques for releasing the removably secured microelectronics substrate 2224 from the holding chuck 2200 have been detailed extensively in connection with FIG. 15 and can be performed by creating the necessary conditions to equalize pressure in the compartmentalized cavities 2216 holding the microelectronics substrate 2224 and the surrounding ambient.
Alternatively, creating conditions such that the pressure in the compartmentalized cavity 2216 holding the microelectronics substrate 2224 is greater than that of the surrounding ambient can be used.
[0321] Additional technique unique to the use of piezoelectric elements 2212 for pressure equalization (or elevation) to negate the partial vacuum holding the microelectronics substrate 2224 in place can, for example, be achieved as follows.
[0322] Assume that the piezoelectric element 2212 is mechanically distorted under an electrical (electrical current, or electrical voltage) impulse VI to create the partial vacuum for securing the microelectronics substrate 2224. Now, when the piezoelectric element 2212 is mechanically distorted under an electrical impulse V2, wherein V2 > VI (assuming that the mechanical distortion at V2 is higher than VI) the remainder of the gas contained in the compartmentalized cavities will be squeezed more, pushing out more gas, and in turn separating / de-bonding the microelectronics substrate 2224 from the holding chuck 2200.
[0323] This type of system can be engineered to operate in room temperature ambient, or a lower ambient temperature, or a higher ambient temperature. The system can be engineered to work at ambient pressure, or higher or lower ambient pressure, as desired.
Now, referring to FIG. 16 and FIG. 18, piezoelectric elements 2212 (akin to piezoelectric element used in piezo inkjet printheads) in compartmentalized cavities 2216 can removably secure the microelectronics substrate 2224, etch this microelectronics substrate wafer into individual microelectronic-device die, and mass transfer these individual microelectronic-device die as revealed above. [0324] II.E.4.m Active Membrane as a Controllable Release Component
[0325] FIGS. 23 A to 23D' illustrate an embodiment that utilizes an active membrane 2312 for the controllable release component. FIG. 23 A depicts a compartmentalized cavity 2316 formed in a substrate body 2304 having a top surface 2308. As mentioned, the controllable release component is in the form of active membrane 2312, such as a MEMS membrane located on the top surface 2308 and extending over the compartmentalized cavity 2316. Examples of active membranes suitable for use as active membrane are described above.
[0326] Active membrane 2312 may be deposited over the compartmentalized cavities 2316 of the substrate body 2304. In equilibrium state, the active membrane 2316 may be substantially flat (planar) as depicted in FIG. 23A. As seen in FIG. 23 A', upon actuation (visualized by arrow 2320) the active membrane undergoes physical distortion into a distorted shape 2312' (concave distortion as viewed from atop the compartmentalized cavity 2316). The mechanism of actuating active membrane 2316 can include, but not be limited to, an electrical impulse (current, voltage, capacitance or electro-static), a magnetic impulse (electro-magnet etc.) or air / gas pressure, among other things.
[0327] FIG. 23B depicts the compartmentalized cavity 2316 with the unactuated active membrane 2312 extending over the compartmentalized cavity, with a microelectronics
substrate 2324 atop active membrane 2312. Referring now to FIG. 23B', upon actuation (visualized by arrow 2320), the active membrane 2312 undergoes physical distortion into the distorted shape 2312'. This distorted shape 2312' of the active membrane 2312 creates a temporary compartmentalized cavity 2332 of sorts, thereby creating a suction force / partial vacuum in this temporary compartmentalized cavity 2332. This partial vacuum removably secures the
microelectronics substrate 2324 in place to the underlying substrate body 2304.
[0328] FIG. 23C depicts the microelectronics substrate 2324 securely held in place due to partial vacuum in the temporary compartmentalized cavity 2332. Referring now to FIG. 23C', the active membrane 2312 is de-actuated, which causes a collapse of the temporary compartmentalized cavity 2332 (FIG. 23C), thus negating the partial vacuum therein, leading to release (visualized by arrow 2328) of the microelectronics substrate 2324.
[0329] Like FIG. 23C, FIG. 23D depicts the microelectronics substrate 2324 securely held in place due to partial vacuum in the temporary compartmentalized cavity 2332, with the partial vacuum created by actuation of active membrane 2312 to the distorted shape 232G shown. Note, however, the presence of an additional controllable release component 2336, here an unactuated resistive-type heater and / or a piezoelectric element 2336, in compartmentalized cavity 2316.
[0330] FIG. 23D' depicts an alternate release strategy for the microelectronics substrate 2324. The active membrane 2312 can be de-actuated as shown in FIG. 23C', or the additional controllable release component 2336 can be actuated. FIG. 22D' illustrates a specific example of the additional controllable release component 2336 being a piezoelectric element that changes to a distorted shape 2336' upon actuation. If the additional controllable release component 2336 were a resistive-type heater, with or without one or more other layers (such as of a getter material and/or a pyrophoric material), then the actuation of the resistive-type heater would cause expansion by heating and/or addition of gas from the one or more other layers. Each of these processes increases the pressurize within the compartmentalized cavity 2316, which in turn forces the active membrane 2312 to physically distort convexly into another distorted shape 2312", leading to release (visualized by arrow 2328) of the microelectronics substrate 2324.
[0331] Now, referring additionally to FIGS. 16 and 18, it should be apparent that active membrane 2312 on top surface 2308 of compartmentalized cavity 2316 can removably secure a microelectronics substrate 2324 to the corresponding holding chuck as in other embodiments.
Correspondingly, the securely held microelectronics substrate 2324 can be partitioned into individual microelectronic-device dies, which can then be mass transferred as revealed in the earlier embodiments.
[0332] Active structures and devices alternative to active membrane 2312 can be designed and used as a holding chuck and/or a mass transfer tool utilizing the principles outlined in this work. These active structures and devices can include, but not limited to, active microphones based on active diaphragms / active membranes, active cantilevers used for acoustic devices (push air out, or pull air in / modulate air pressure), active micro valves (push or pull: air /liquid out or in, modulate pressure), and active based pressure sensors, among others.
[0333] II.E.4.n Activation Circuitry and Control System for Controllable Release Components
[0334] FIG. 24 shows an example holding chuck system 2400 that includes a holding chuck 2404 of the present disclosure that includes a plurality of compartmentalized cavities 2408 each having associated therewith at least one controllable release component 2412, each of which can be the same as or similar to any of the controllable release components described in this disclosure. As described above, the controllable release components 2412 need to be actuated and/or de-actuated in order to achieve the requisite functionality(ies) of the holding chuck 2404. To do this, the holding-chuck system 2400 may include activation circuitry 2416 and a control system 2420 for controlling the activation circuitry.
[0335] As those skilled in the art will appreciate, the activation circuitry 2416 includes any circuit elements needed to actuate and/or de-actuate the controllable release components 2412 present in the holding chuck 2404. Those skilled in the art will readily appreciate the type(s) of circuitry needed for the type(s) of the controllable release components 2412 aboard any particular instantiation of the holding chuck 2404, such that a detailed description is not necessary for those skilled in the art to understand and appreciate the breadth of this disclosure.
[0336] In the example shown, the activation circuitry 2416 is shown a being located entirely aboard the holding chuck 2404. However, this need not be the case in other embodiments. Rather, the activation circuitry 2416 may be located entirely offboard the holding chuck 2404 (e.g., without only lead-lines being present within the holding chuck) or may be located partially onboard and partially offboard the holding chuck, as needed for a particular design. In some embodiments, the activation circuitry 2416 may be provided as an active backplane (not shown) to the holding chuck 2404 that may be manufactured into the holding chuck or manufactured separately and joined with the holding chuck, as examples.
[0337] Depending on their type(s), the controllable release components 2412 may be actuated using, without limitation, any one or more of the following stimuli: an electrical impulse (current, voltage, capacitance or electro-static), a magnetic impulse (electro-magnet etc.), air / gas pressure, and/or a thermal impulse, among others.
[0338] The activation circuitry 2416 may employ field effect transistors (FET), MOSFETs, and/or CMOS circuitry. The activation circuitry 2416 may employ passive matrix or active matrix or other drive architectures. The electrical contacts (not shown) to actuate the controllable release components 2412 might be adjacent to the controllable release components, they may be on the side of the holding chuck 2404, and/or they may be underneath the holding chuck.
[0339] As an example, external and internal drive circuitry for resistive type heater elements used in thermal inkjet printheads and the likes is well known in prior art, and similar circuitry can be used for activation circuitry 2416, as those skilled in the art will readily appreciate. Complex, multiplexed arrays of resistive-type heaters (one type of controllable release component 2412) can be addressed and actuated using primitive groupings of resistors coupled to associated group power sources. Detailed circuitry examples from which a designer can draw from can be found, for example, in U.S. Patents Nos.: 5,946,012; 5,635,968; 4,719,477; 4,532,530; and 4,947,192. Each of these patents is incorporated by reference for its description of relevant circuitry.
[0340] The control system 2420 may comprise any suitable hardware or hardware + software combination that is able to interface with the activation circuitry 2416 to achieve the desired activation and/or de-activation functionality. Those skilled in the art will readily understand how the control system 2420 can be configured for any particular application of the holding chuck 2404. Depending on the needs of the application(s) for the holding chuck 2404, the control systems 2420 and/or activation circuitry 2416 may be configured to address the controllable release
components 2412 individually, globally, by type, and/or in groupings containing fewer than all of any particular type of the controllable release components.
[0341] Other aspects of the holding chuck 2404 not described here may be the same as or similar to aspects described elsewhere in this disclosure.
[0342] Example embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions, and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.

Claims

What is claimed is:
1. A method of making an electronic device, the method comprising:
removably securing a microelectronics substrate to a working face of a holding chuck,
wherein:
the holding chuck includes cavities formed in the working face of the holding chuck, each of the cavities being compartmentalized and spaced from adjacent cavities, and the cavities spatially arranged in a predetermined arrangement and having associated therewith a controllable release component;
the microelectronics substrate includes microelectronic devices spatially arranged relative to one another in concert with the predetermined arrangement of the cavities of the holding chuck; and
when the microelectronics substrate is removably secured to the holding chuck, ones of the microelectronic devices are in registration with corresponding respective ones of the cavities;
while the microelectronics substrate is removably secured to the holding chuck, partitioning the microelectronics substrate to separate ones of the microelectronics devices from one another to create individual microelectronic-device dies; and
after partitioning the microelectronics substrate, controlling one or more of the controllable release components so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a
predetermined location.
2. The method of claim 1, wherein the electronic device comprises an electronic display, and each of the individual microelectronic-device dies comprises a light-emitting device.
3. The method of claim 2, wherein each of the light-emitting devices comprises a microLED.
4. The method of claim 1, wherein the electronic device comprises a detector array, and each of the individual microelectronic-device dies comprises a detector device.
5. The method of claim 1, wherein the electronic device comprises a sensor array, and each of the individual microelectronic-device dies comprises a sensor device.
6. The method of claim 1, wherein the electronic device comprises a hybrid electronic display, and each of the individual microelectronic-device dies comprises a light emitting device or a detector device or both.
7. The method of any one of claims 1 to 6, further comprising, while the microelectronics substrate is removably secured to the working face of the holding chuck, processing the microelectronics substrate to create the microelectronic devices.
8. The method of any one of claims 1 to 6, wherein the microelectronics substrate includes the microelectronic devices prior to removably securing the microelectronics substrate to the working face of the holding chuck.
9. The method of any one of claims 1 to 8, wherein the controllable release components are
individually addressable.
10. The method of any one of claims 1 to 8, wherein the controllable release components are
globally switchable.
11. The method of any one of claims 1 to 10, wherein causing one or more of the controllable release components to release at least one of the individual microelectronic-device dies includes controlling at least one of the controllable release components so as to cause a change in pressure within the cavity.
12. The method of claim 11, wherein controlling at least one of the controllable release components includes activating a heater to heat a space within a corresponding one of the cavities.
13. The method of claim 11, wherein each of the controllable release components includes a heat- activated material, and controlling at least one of the controllable release components includes activating a heater to activate the heat-activated material.
14. The method of claim 13, wherein the heat-activated material comprises a getter.
15. The method of either of claims 13 and 14, wherein the heat-activated material comprises a
pyrophoric material.
16. The method of claim 11, wherein each of the controllable release components includes a vacuum-activated material, and controlling at least one of the controllable release components includes controlling the vacuum-activated material.
17. The method of claim 11, wherein controlling at least one of the controllable release components includes actuating an addressable piezoelectric element within a corresponding one of the cavities.
18. The method of claim 11, wherein controlling at least one of the controllable release components includes actuating an addressable active membrane associated with a corresponding one of the cavities.
19. The method of claim 18, wherein the addressable active membrane is disposed atop the
corresponding one of the cavities.
20. The method of claim 11, further comprising, prior to controlling one or more of the controllable release components to release at least one of the individual microelectronic-device dies, bonding the at least one of the individual microelectronic-device dies to a final substrate or an intermediate substrate.
21. The method of claim 11, further comprising, after controlling one or more of the controllable release components to release at least one of the individual microelectronic-device dies, bonding the at least one of the individual microelectronic-device dies to a final substrate or an intermediate substrate.
22. The method of claim 11, further comprising, prior to controlling one or more of the controllable release components to release at least one of the individual microelectronic-device dies, engaging the at least one of the individual microelectronic -device dies with a final substrate or an intermediate substrate and releasing the at least one of the individual microelectronic-device dies while the at least one of the individual microelectronic-device dies is engaged with the final substrate or the intermediate substrate.
23. The method of claim 11, further comprising, prior to controlling one or more of the controllable release components to release at least one of the individual microelectronic-device dies, spacing the at least one of the individual microelectronic-device dies from a final substrate or an intermediate substrate and releasing the at least one of the individual microelectronic-device dies while the at least one of the individual microelectronic-device dies is spaced from the final substrate or the intermediate substrate.
24. The method of claim 1, wherein removably securing the microelectronics substrate to the
working face of the holding chuck includes removably adhering the microelectronics substrate to the working face of the holding chuck.
25. The method of claim 24, wherein removably adhering the microelectronics substrate to the
working face of the holding chuck includes:
evacuating gaseous components from the cavities; and
engaging the microelectronics substrate with the working face of the holding chuck so as to temporarily seal the cavities due to pressure differential.
26. The method of claim 25, wherein evacuating gaseous components from the cavities includes evacuating gaseous components using a mechanism located external to the cavities.
27. The method of claim 25, wherein evacuating gaseous components from the cavities includes evacuating gaseous components from a location internal to each of the cavities.
28. The method of claim 27, wherein evacuating gaseous components from the cavities from a
location internal to the cavities includes deactivating a heater located in each of the cavities.
29. The method of claim 27, wherein evacuating gaseous components from the cavities from a
location internal to the cavities includes activating a getter located in each of the cavities.
30. The method of claim 27, wherein evacuating gaseous components from the cavities from a
location internal to the cavities includes activating a pyrophoric located in each of the cavities.
31. The method of claim 27, wherein evacuating gaseous components from the cavities from a
location internal to the cavities includes activating a heat-activated material located in each of the cavities.
32. The method of claim 27, wherein evacuating gaseous components from the cavities from a
location internal to the cavities includes activating a vacuum-activated material located in each of the cavities.
33. The method of claim 27, wherein evacuating gaseous components from the cavities from a location internal to the cavities includes controlling a piezoelectric element located in each of the cavities.
34. The method of claim 24, wherein the controllable release components comprise corresponding respective heaters located within corresponding respective ones of the cavities, the method further including engaging the microelectronics substrate with the working face of the holding chuck and then deactivating the heaters to decrease pressure within the cavities.
35. The method of claim 25, wherein the controllable release components comprise corresponding respective getters located within corresponding respective ones of the cavities, the method further including engaging the microelectronics substrate with the working face of the holding chuck and then activating the getters within the cavities to decrease pressure within the cavities.
36. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes surface-activation bonding the microelectronics substrate to the working face of the holding chuck.
37. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes a combination of surface-activation bonding the microelectronics substrate to the working face of the holding chuck and creating a vacuum within the cavities of the holding chuck.
38. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes adhesively bonding the microelectronics substrate to the working face of the holding chuck using an adhesive disposed on the working face so as to keep the plurality of cavities open to the working face.
39. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes a combination of adhesively bonding the microelectronics substrate to the working face of the holding chuck and creating a vacuum within the cavities of the holding chuck using an adhesive disposed on the working face so as to keep the plurality of cavities open to the working face.
40. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes providing a magnetic layer to magnetically secure the microelectronics substrate to the working face of the holding chuck using a magnetic layer disposed on the working face so as to keep the plurality of cavities open to the working face.
41. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes a combination of providing a magnetic layer to magnetically secure the microelectronics substrate to the working face of the holding chuck and creating a vacuum within the cavities of the holding chuck using a magnetic layer disposed on the working face so as to keep the plurality of cavities open to the working face .
42. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes providing an electret layer to electrostatically secure the microelectronics substrate to the working face of the holding chuck using an electret layer disposed on the working face so as to keep the plurality of cavities open to the working face.
43. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes a combination of providing an electret layer to electrostatically secure the microelectronics substrate to the working face of the holding chuck and creating a vacuum within the cavities of the holding chuck using an electret layer disposed on the working face so as to keep the plurality of cavities open to the working face.
44. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes providing a liquid to each of the cavities to secure the microelectronics substrate to the working face of the holding chuck by capillary action.
45. The method of claim 24, wherein removably adhering the microelectronics substrate to the working face of the holding chuck includes a combination of providing a liquid to each of the cavities to secure the microelectronics substrate to the working face of the holding chuck by capillary action and creating a vacuum within the cavities of the holding chuck.
46. The method of claim 24, wherein controlling one or more of the controllable release components includes controlling piezoelectric elements within the cavities.
47. The method of claim 24, wherein controlling one or more of the controllable release components includes controlling active membranes.
48. The method of claim 1, wherein the receiving support comprises a backplane substrate of the electronic device.
49. The method of claim 1, wherein the receiving support comprises an intermediate substrate used in the manufacture of the electronic device.
50. The method of claim 1, wherein the receiving support comprises another holding chuck used in the manufacture of the electronic device.
51. The method of claim 50, wherein the another holding chuck has a plurality of cavities, wherein at least some of the plurality of cavities are out-of-plane cavities used in the manufacture of the electronic device.
52. The method of claim 50, wherein the another holding chuck has a plurality of cavities, wherein some of the plurality of cavities are out-of-plane cavities and some of the plurality of cavities are in-plane cavities used in the manufacture of the electronic device.
53. The method of claim 1, wherein each of the cavities is associated with a corresponding
controllable release component.
54. The method of claim 1, wherein a plurality of the cavities are associated with a corresponding controllable release component.
55. The method of claim 1, wherein the cavities are grouped into groups, and each of the groups is associated with a corresponding controllable release component.
56. The method of claim 1, further comprising, prior to removably securing the microelectronics substrate to the holding chuck, providing a gasket layer between the microelectronics substrate and the holding chuck.
57. The method of claim 56, wherein the gasket layer is provided on the holding chuck so that the gasket layer provides the working face of the holding chuck and the plurality of cavities are open to the working face.
58. The method of claim 1, wherein each of the individual microelectronic-device dies has a
maximum dimension of 100 microns or less in a plane parallel to the working face of the holding chuck.
59. The method of claim 1, wherein each of the individual microelectronic-device dies has a maximum dimension of 50 microns or less in a plane parallel to the working face of the holding chuck.
60. The method of claim 1, wherein each of the individual microelectronic-device dies has a
maximum dimension of 10 microns or less in a plane parallel to the working face of the holding chuck.
61. The method of claim 1, wherein each of the individual microelectronic-device dies has a
maximum dimension of 1 micron or less in a plane parallel to the working face of the holding chuck.
62. A holding chuck for manufacturing an electronic device, the holding chuck comprising:
a body having a working face that confronts a plurality of individual microelectronic-device dies during use;
a plurality of cavities formed in the body, the plurality of cavities arranged in a predetermined arrangement on the working face of the body, each of the plurality of cavities being compartmentalized and having correspondingly associated therewith a controllable release component that controls release of the plurality of individual microelectronic-device dies when the plurality of individual microelectronic -device dies are removably secured to the holding chuck; and
activation circuitry in electrical communication with each of the controllable release
components, the activation circuitry designed and configured to electrically communicate with the controllable release components to control release of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the holding chuck.
63. The holding chuck of claim 62, wherein the activation circuitry is configured so that the
controllable release components are individually addressable.
64. The holding chuck of claim 62, wherein the activation circuitry is configured so that the
controllable release components are globally switchable.
65. The holding chuck of any one of claims 62 to 64, wherein each of the plurality of cavities contains one or more controllable release components.
66. The holding chuck of any one of claims 62 to 64, wherein a set of the plurality of cavities is associates with a corresponding controllable release component.
67. The holding chuck of any one of claims 62 to 64, wherein the plurality of cavities are grouped into groups, and each of the groups is associated with a corresponding controllable release component.
68. The holding chuck of any one of claims 62 to 64, wherein each of the plurality of individual microelectronic-device dies has an area that confronts the holding chuck during use of the holding chuck and each of the plurality of cavities has an opening to the working face that has an area less than the area of a corresponding one of the plurality of individual microelectronic - device dies.
69. The holding chuck of claim 68, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 100 microns or less.
70. The holding chuck of claim 69, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 50 microns or less.
71. The holding chuck of claim 70, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 10 microns or less.
72. The holding chuck of claim 71, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 1 microns or less.
73. The holding chuck of any one of claims 62 to 64, wherein each of the plurality of individual microelectronic-device dies has an area that confronts the holding chuck during use of the holding chuck and the plurality of cavities are sized so that a set of two or more of the plurality of cavities confront the area during use of the holding chuck.
74. The holding chuck of claim 73, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 100 microns or less.
75. The holding chuck of claim 74, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 50 microns or less.
76. The holding chuck of claim 75, wherein the area of each of the plurality of individual microelectronic-device dies has a maximum dimension of 10 microns or less.
77. The holding chuck of claim 76, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 1 microns or less.
78. The holding chuck of claim 62, wherein the body comprises a semiconductor wafer.
79. The holding chuck of claim 62, wherein the body is composed of a single monolithic layer, and the plurality of cavities are formed in the single monolith layer.
80. The holding chuck of claim 62, wherein the body comprises first and second layers secured together to form the body.
81. The holding chuck of claim 80, wherein the first layer has a plurality of through-holes and, when the first and second layers are secured together, the second layer closes the plurality of through- holes at one end so as to provide the plurality of cavities.
82. The holding chuck of claim 62, wherein each controllable release component comprises a heater disposed within a corresponding one of the plurality of cavities.
83. The holding chuck of claim 62, wherein each controllable release component is associated with a set of at least two of the plurality of cavities.
84. The holding chuck of claim 62, wherein each controllable release component comprises a getter disposed within a corresponding one of the plurality of cavities.
85. The holding chuck of claim 62, wherein each controllable release component comprises a
pyrophoric material disposed within a corresponding one of the plurality of cavities.
86. The holding chuck of claim 62, wherein each controllable release component comprises a heat- activated material disposed within a corresponding one of the plurality of cavities, wherein the heat-activated material in each of the plurality of cavities is associated with a heater for activating the heat- activated material during use.
87. The holding chuck of claim 86, wherein the heater is located within the corresponding one of the plurality of cavities.
88. The holding chuck of claim 62, wherein each of the controllable release components includes a vacuum-activated material disposed within a corresponding one of the plurality of cavities.
89. The holding chuck of claim 62, wherein each controllable release component comprises
piezoelectric element disposed within a corresponding one of the plurality of cavities.
90. The holding chuck of claim 62, wherein each controllable release component comprises an active membrane disposed at a corresponding one of the plurality of cavities.
91. The holding chuck of claim 90, wherein the active membrane is disposed atop the corresponding one of the plurality of cavities.
92. The holding chuck of claim 62, wherein at least some of the plurality of cavities are out-of-plane cavities.
93. The holding chuck of claim 62, wherein some of the plurality of cavities are out-of-plane cavities and some of the plurality of cavities are in-plane cavities.
94. The holding chuck of any one of claims 62 to 64, wherein the holding chuck further comprises a porous layer disposed on the working face of the body so as to cover the plurality of cavities.
95. The holding chuck of claim 94, wherein the porous layer comprises a nanoporous layer having pore sizes of less than 500 nm.
96. The holding chuck of claim 94, wherein the porous layer comprises a microporous layer having pore sizes of less than 5 microns.
97. The holding chuck of claim 62, wherein the holding chuck further comprises a gasket layer disposed on the working face of the body so as to keep the plurality of cavities open to the working face.
98. The holding chuck of claim 62, wherein the holding chuck further comprises an adhesive layer disposed on the working face of the body so as to keep the plurality of cavities open to the working face.
99. The holding chuck of claim 62, wherein the holding chuck further comprises an electret layer disposed on the working face of the body so as to keep the plurality of cavities open to the working face.
100. The holding chuck of claim 62, wherein the holding chuck further comprises a magnetic layer disposed on the working face of the body so as to keep the plurality of cavities open to the working face.
101. A method of making a holding chuck for use in manufacturing an electronic device, wherein the manufacturing utilizes a plurality of individual microelectronic-device dies arranged in a predetermined arrangement during at least one step of the manufacturing, the method comprising:
using the predetermined arrangement of the plurality of individual microelectronic-device dies used during the manufacturing to determine a pattern of a plurality of cavities to be provided in the holding chuck;
forming the plurality of cavities in the holding chuck, wherein the holding chuck includes a working face that confronts the plurality of individual microelectronic-device dies during use of the holding chuck, and the plurality of cavities are compartmentalized and formed in the working face when the holding chuck is completed;
providing at least one controllable release component, each for releasing one or more of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic-device dies are removably secured to the working face of the holding chuck; and
providing activation circuitry in electrical communication with each of the at least one
controllable release component, the activation circuitry designed and configured to electrically communicate with the at least one controllable release component to control release of the plurality of individual microelectronic-device dies from the holding chuck when the plurality of individual microelectronic -device dies are removably secured to the holding chuck.
102. The method of claim 101, wherein providing at least one controllable release component
includes providing at least one controllable release component in each of the plurality of cavities.
103. The method of claim 102, wherein each controllable release component comprises a heater.
104. The method of claim 102, wherein each controllable release component comprises a
piezoelectric element.
105. The method of claim 102, wherein each controllable release component comprises an active membrane.
106. The method of claim 102, wherein each controllable release component comprises a getter.
107. The method of claim 102, wherein each controllable release component comprises a pyrophoric material.
108. The method of claim 102, wherein each controllable release component comprises a heat- activated material.
109. The method of claim 102, wherein each controllable release component includes a vacuum- activated material.
110. The method of claim 101, wherein the plurality of cavities are grouped into groups and
providing at least one controllable release component includes providing at least one controllable release component for each of the groups.
111. The method of claim 110, wherein the at least one controllable release component comprises a heater.
112. The method of claim 101, wherein forming the plurality of cavities includes forming the
plurality of cavities in a solid body.
113. The method of claim 101, wherein forming the plurality of cavities includes forming a plurality of precursor through-holes in a first component, the method further comprising securing a second component to the first component opposite the working face so as to close each of the plurality of precursor through-holes at one end so as to form the plurality of cavities.
114. The method of any one of claims 101 to 109, wherein providing the activation circuitry includes configuring the activation circuitry so that each of the at least one controllable release component is individually addressable.
115. The method of any one of claims 101 to 109, wherein providing the activation circuitry includes configuring the activation circuitry so that the at least one controllable release component is globally switchable.
116. The method of claim 101, wherein the holding chuck comprises a semiconductor wafer and the method comprising forming the plurality of cavities or a plurality of precursor apertures includes etching the semiconductor wafer to form the plurality of cavities or plurality of precursor apertures.
117. The method of claim 101, wherein each of the plurality of individual microelectronic-device dies has an area that confronts the holding chuck during use of the holding chuck and each of the plurality of cavities has an opening to the working face that has an area less than the area of a corresponding one of the plurality of individual microelectronic-device dies.
118. The method of claim 117, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 100 microns or less.
119. The method of claim 118, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 50 microns or less.
120. The method of claim 119, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 10 microns or less.
121. The method of claim 120, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 1 microns or less.
122. The method of claim 101, wherein each of the plurality of individual microelectronic-device dies has an area that confronts the holding chuck during use of the holding chuck and the plurality of cavities are sized so that a set of two or more of the plurality of cavities confront the area during use of the holding chuck.
123. The method of claim 122, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 100 microns or less.
124. The method of claim 123, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 50 microns or less.
125. The method of claim 124, wherein the area of each of the plurality of individual
microelectronic-device dies has a maximum dimension of 10 microns or less.
126. The method of claim 125, wherein the area of each of the plurality of individual microelectronic-device dies has a maximum dimension of 1 microns or less.
127. The method of claim 101, further comprising processing the holding chuck so that at least some of the plurality of cavities are out-of-plane cavities.
128. The method of claim 101, further comprising processing the holding chuck so that some of the plurality of cavities are out-of-plane cavities and some of the plurality of cavities are in-plane cavities.
129. The method of claim 101, further comprising applying a porous layer to the working face so as to cover the plurality of cavities.
130. The method of claim 129, wherein the porous layer comprises a nanoporous layer having pore sizes less than 500 nm.
131. The method of claim 129, wherein the porous layer comprises a microporous layer having pore sizes of less than 5 microns.
132. The method of claim 101, further comprising applying a gasket layer to the working face so as to keep the plurality of cavities open to the working face.
133. The method of claim 101, further comprising applying an adhesive layer to the working face so as to keep the plurality of cavities open to the working face.
134. The method of claim 101, further comprising applying an electret layer to the working face so as to keep the plurality of cavities open.
135. The method of claim 101, further comprising applying a magnetic layer to the working face so as to keep the plurality of cavities open.
136. A method of making an electronic device, the method comprising:
providing individual microelectronic-device dies, the individual microelectronic-device dies arranged in a predetermined arrangement and removably engaged with a support;
providing a holding chuck, the holding chuck having a working face and including cavities formed in the working face of the holding chuck, each of the cavities being
compartmentalized and spaced from adjacent cavities, and arranged in the predetermined arrangement of the individual microelectronic-device dies engaged with the support, wherein each of the cavities has associated therewith a controllable release component; registering the individual microelectronic-device dies and the cavities with one another; when the individual microelectronic-device dies and the cavities are in registration with one another, contacting the individual microelectronic-device dies and the working face of the holding chuck with one another;
removably securing the individual microelectronic-device dies to the working face of the holding chuck;
disengaging the individual microelectronic-device dies from the support; and
controlling one or more of the controllable release components so that at least one of the individual microelectronic-device dies is released from the holding chuck and transferred onto a receiving support at a desired location.
137. The method of claim 136, in combination with any one or more of claims 2-61 (when one of these claims is a multiple dependent claim, only the first referenced claim shall be considered).
138. A method of working a microelectronics substrate, the method comprising:
removably securing the microelectronics substrate to a working face of a holding chuck, wherein the holding chuck includes cavities formed in the working face, each of the cavities being compartmentalized and spaced from adjacent cavities, the cavities having associated therewith at least one controllable release component;
while the microelectronics substrate is removably secured to the holding chuck, processing the microelectronics substrate; and
after processing the microelectronics substrate, controlling each of the at least one controllable release component so as to release the microelectronics substrate from the holding chuck.
139. The method of claim 138, wherein processing the microelectronics substrate includes surface conditioning a surface of the microelectronics substrate.
140. The method of claim 138, wherein processing the microelectronics substrate includes reducing thickness of the microelectronics substrate.
141. The method of claim 138, wherein processing the microelectronics substrate includes forming one or more device layers on the microelectronics substrate.
142. The method of claim 138, wherein processing the microelectronics substrate includes creating vias.
143. The method of claim 142, wherein creating vias includes performing through- silicon via
creation.
144. The method of claim 138, wherein controlling each of the at least one controllable release
components includes controlling each of the at least one controllable release component in accordance with any of claims 10-19 (when one of these claims is a multiple dependent claim, only the first referenced claim shall be considered).
145. The method of claim 138, wherein removably securing the microelectronics substrate includes removably securing the microelectronics substrate in accordance with any of claims 24-47 (when one of these claims is a multiple dependent claim, only the first referenced claim shall be considered).
146. The method of claim 138, wherein each of the cavities is associated with a corresponding
controllable release component.
147. The method of claim 138, wherein a plurality of the cavities are associated with a corresponding controllable release component.
148. The method of claim 138, wherein the cavities are grouped into groups, and each of the groups is associated with a corresponding controllable release component.
149. The method of claim 138, further comprising, prior to removably securing the microelectronics substrate to the holding chuck, providing a gasket layer between the microelectronics substrate and the holding chuck.
150. The method of claim 149, wherein the gasket layer is provided on the holding chuck so that the gasket layer provides the working face of the holding chuck and the plurality of cavities are open to the working face.
151. A method of working a microelectronics substrate, the method comprising:
removably securing the microelectronics substrate to a working face of a holding chuck,
wherein the holding chuck includes cavities formed in the working face, each of the cavities being compartmentalized and spaced from adjacent cavities, wherein removably securing the microelectronics substrate includes creating a gas seal between the holding chuck and the microelectronics substrate so that interiors of the cavities are gaseously sealed from an ambient environment adjacent to the microelectronics substrate;
while the microelectronics substrate is removably secured to the holding chuck, processing the microelectronics substrate; and
after processing the microelectronics substrate, changing differential pressure between the ambient environment and the interiors of the cavities so as to release the microelectronics substrate from the holding chuck.
152. The method of claim 151, wherein changing differential pressure between the ambient
environment and the interiors of the cavities includes reducing pressure within the ambient environment.
153. The method of claim 152, wherein the ambient environment is provided by a vacuum chamber, and reducing pressure within the ambient environment includes increasing vacuum within the vacuum chamber.
154. The method of claim 152, wherein the cavities are associated with at least one controllable release component, and changing differential pressure further includes controlling each of the at least one controllable release component so as to increase pressure within the cavities.
155. The method of claim 154, wherein controlling each of the at least one controllable release
components includes controlling each of the at least one controllable release component in accordance with any of claims 10-19 (when one of these claims is a multiple dependent claim, only the first referenced claim shall be considered).
156. The method of claim 152, wherein removably securing the microelectronics substrate includes removably securing the microelectronics substrate in accordance with any of claims 24-47 (when one of these claims is a multiple dependent claim, only the first referenced claim shall be considered).
PCT/US2019/025606 2018-11-05 2019-04-03 Holding chucks having compartmentalized holding cavities and uses for such holding chucks WO2020096638A1 (en)

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