CN102714199B - 用于使用粘合剂粘结的微部件最优化放置的开槽配置 - Google Patents
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Abstract
一种用来在组件中改善微部件的粘合剂附加的安排利用在用来支持微部件的衬底的顶面中形成的多个并置狭槽。狭槽用来控制一个粘合剂“点”的流动和“形状”以便迅速和精确附加一个微部件到一个衬底的表面。狭槽在衬底的表面中以给予其自身从一个衬底到另一个的可复制精度的方式形成(优选蚀刻)。其它狭槽(“沟道”)可连同粘结狭槽一起形成,从而使得外来粘合剂材料流入这些沟道并且不散布进入不希望的区域。
Description
相关申请的交叉引用
本申请要求于2009年12月1日提交的美国临时申请No.61/265,459的优先权,并且该申请通过引用结合在此。
技术领域
本发明涉及一种用来在组件中改善微部件的粘合剂附加的安排,并更特别涉及在微部件有待附加到其上的表面内形成的特定开槽配置的利用,从而改善粘合剂附加的质量和微部件关于组件其余部分的定位精度。
发明背景
在许多集成电路微部件安排中,经常需要在各种组装和/或封装操作期间利用环氧树脂(或任何其它合适粘合剂)将一个部件接合到另一部件。当然,并且为本讨论的目的,假设接合涉及将微部件附加到支撑衬底。将微部件附加到衬底的需要在电子集成电路组件、光学系统子组件、光电安排等中是一个普遍工艺步骤。
由于这些微部件的大小继续收缩,因此增加了用改善的对齐精度放置元件的需要。这在光学或光电安排中特别真实,其中一个或多个微部件形成一个光信号路径的部分,该路径要求中间部件对齐从而维持信号路径完整性。例如在一个硅光子组件中,由于部件例如微透镜和光纤附加到一个共用衬底上,例如绝缘体上硅(SOI)衬底,因此它们需要以亚100nm位置精度相互对齐。
尽管在一个衬底上精确放置这些微部件的能力是一个必需的需求,但在组件寿命期内维持这些位置同样重要。一个给定的组件在其寿命期内受到温度、湿度等的变更是非常可能的,其中这些环境变化可降低粘合剂粘结的质量并导致一个部件相对于另一个移位。解决寿命问题的一个方式是在原附加工艺中利用尽可能薄的粘结线(“粘结线”被定义为被粘结的两个表面之间的粘合剂厚度)。已经发现约几十微米等级的粘结线会提高微部件组件的寿命稳定性。然而,该相对薄的粘结线在与有待相对于粘合剂总体积(相对小)而接合的相对大表面积关联的粘合剂流动的基于摩擦约束(即分子流状态)方面存在问题。这种与少量粘合剂材料相关联的摩擦问题然后也限制可执行的微部件后放置调整量,消除了在许多光学或光电系统中执行主动或半主动对齐的可能性。现有技术中存在用来解决涉及使用环氧树脂或其它粘合剂接合部件的各种问题的安排。于2009年5月7日向Z.Zhu等人颁发的美国专利公开2009/0115039涉及控制用于半导体器件附加的环氧树脂的粘结线厚度。然而,Zhu等人的安排涉及创造相对“厚”的粘结线(与在本环境中期望的“薄”粘结线相反)并围绕一个粘结区的周界使用边界墙从而用作一个堤坝以防止环氧树脂流入不希望的区域。
在本领域中存在涉及防止环氧树脂流入不希望的区域而形成‘毛细管停止’沟槽等的许多其它参考文献。在2003年2月25日向D.W.Sherrer等人颁发的美国专利6,526,204是该技术的示范,其中在“离开”一条光信号路径/光纤支持凹槽的方向上形成了一条沟槽。因此,环氧树脂的任何溢出量将被引导出信号路径并进入毛细管停止沟槽。
然而,这些沟槽在其中具有需要紧密靠近放置的多个部件的情况下具有受限制使用。即,具有其中一个或多个毛细管停止沟槽的内含物在安排中需要过多有价值表面积的许多系统安排。
因此仍需要一种安排以便更好地控制用来将接合微部件接合到衬底的一种粘合剂的应用和控制。
发明概述
本发明解决现有技术中的需要,其涉及一种用来在组件中改善微部件的粘合剂附加的安排,并更特别涉及在微部件有待附加到其上的表面内形成的特定开槽配置的利用,从而改善粘合剂附加的质量和微部件关于组件其余部分的定位精度。
根据本发明,多个并置狭槽用来控制一个粘合剂“点”的流动和“形状”以便精确将微部件附加到衬底的表面上。狭槽在衬底的表面中以给予其自身从一个衬底到另一个的可复制精度的方式形成(优选蚀刻)。额外的狭槽(在下文中称为“沟道”)可连同粘结狭槽一起形成,从而使得外来粘合剂材料将流入这些沟道并且不散布进入不希望的区域。在一个优选实施方案中,沟道被形成为比狭槽更远延伸进入衬底,以便确保溢出粘合剂的全部被容纳。
能够以任何期望的配置(即矩形、圆形等)形成多个狭槽以便定义粘合剂材料的“形状”。在本发明的一个实施方案中,形状被定义为模拟被附加到衬底的微部件的表面拓扑,从而使得微部件将使其自身在粘合剂上自然“定心”,并在衬底上期望位置提供自对齐。
本发明的一方面是形成多个狭槽的单独狭槽的数目和狭槽深度允许形成期望的薄粘合线。另外,沟道的内含物允许在向外方向上(即作为压力的结果)或在向内方向上(即作为表面张力的结果)以可预测和可复制方式控制并约束在有待接合的表面下方的粘合剂流动。
在本发明的一个实施方案中,一个或多个加热器元件(例如电阻带)可嵌入一个或多个狭槽内,从而允许粘合剂材料的局部加热,按需要改变其粘度和/或提供粘合剂的固化。事实上,通过各种元件的加热的选择性控制,多个微部件可附加到一个共用衬底,其中一种热敏粘结材料用来将分离的附加操作排序。即,通过控制加热器元件的“开启”和“关闭”,数个分离微部件可安置在一个共用衬底上,其中每个微部件的粘合通过在每个部件的局部面积中控制粘合剂的温度以一个优选顺序执行。
本发明的一个优点是在支持衬底包括一种材料(例如硅)时,在CMOS器件制造中普遍的一种标准蚀刻工艺可用来形成狭槽。一种常规蚀刻工艺的利用允许狭槽图案从一个衬底到下个衬底的可复制性,因此改善了组件的可制造性。
根据本发明的粘合槽群的使用发现了在纯电气集成电路粘合操作、光学组件或光电安排中的使用。粘合剂材料自身包括如在本领域中为此使用的任何合适环氧树脂或可流动粘合剂。
本发明的其它和进一步实施方案和方面将在以下讨论的过程期间并参考附图变得明显。
附图简述
现在参考附图,其中相似数字在若干图中表示相似部件:
图1是根据本发明的利用多个狭槽形成粘合剂点的一个光学系统的一部分的等距视图;
图2是图1的安排的概略形式的顶视图,其中一个微部件被安置为有待附加到光学衬底上;
图3是图2的安排的侧视图;
图4和图5分别是图2和图3的视图的替代实施方案,展示了用来容纳溢出粘合剂的沟道的内含物;
图6是本发明的一个替代实施方案的等距视图,在此情况下使用了以具体配置形成的多个狭槽来模拟被附加到衬底上的一个微部件的表面积,该配置允许微部件在分布到狭槽上的一个粘合剂点上自定心;
图7是本发明的仍另一实施方案的顶视图,在此情况下将多个加热器元件与狭槽合并,其中粘合剂的局部加热在控制粘合剂的固化中是有用的;以及
图8是本发明的仍另一实施方案的等距视图,利用了与围绕狭槽的一个外围防护沟道结合的多个狭槽。
详细说明
图1是适合使用本发明的开槽附加安排的绝缘体上硅(SOI)光电组件10的一部分的等距视图。组件10包括在衬底14中形成并用来支持微部件例如透镜(未示出)的蚀刻腔12。根据本发明,多个狭槽16在衬底14的顶面18中形成。在一个实施方案中,介电层15可跨越衬底14的表面和使用标准CMOS光刻技术蚀刻进入介电层15的狭槽16来布置。尽管上面讨论的焦点利用光学组件作为实例,但应当理解的是使用狭槽群提供微部件到衬底的附加在电气集成电路系统、光学系统或光电系统中是有用的。
在图1中所示的特定安排中,多个狭槽16包括布置在空腔12的一侧的第一多个狭槽16-1和布置在空腔12相反侧的第二多个狭槽16-2。一个粘合剂“点”20(例如规定体积的环氧树脂或其它合适的可流动的粘合剂材料)示作分布到狭槽16-2上。根据本发明,由于表面张力性质,预定长度和深度(以及槽间间隔)的多个狭槽的利用允许液体粘合剂的量自然取得狭槽的形状。
图2是图1的安排的框图形式的顶视图,其中,一个微部件40被布置为装入空腔12并跨越在衬底14的顶面18中形成(具体而言,穿过布置在衬底14上的介电层15)的狭槽16-1和16-2。在图2中示出了与狭槽16关联的长度l和槽间间隔s。尽管在该具体实例中每个狭槽都被形成为包括近似相同的长度并被蚀刻为近似相同的深度,但应当理解的是在其最一般实施方案中,狭槽可包括不同的长度、深度和间隔,只要它们用来容纳粘合剂材料的流动到适合附加一个特定微部件的一个区域。粘合剂20(例如环氧树脂)示作沿狭槽16并在其中布置的成形材料。在该实例中,微部件40包括布置在一个透镜支架44内的一个光学透镜42,其中透镜自身被放置为位于空腔12内,并且支架44跨越空腔并通过使用沿狭槽16-1和16-2布置的粘合剂20接合到衬底14。
在图3中具体展示了所创造的狭槽16的深度d。再次,在该实例中,由于硅衬底14可用作用于狭槽16的工艺的一个蚀刻停止物,因此每个狭槽都被蚀刻为相同深度d,并被定义为介电层15的厚度。在其最一般形式中,狭槽可被形成为各种形状。事实上,如以下将要讨论的,沟道可与狭槽关联并可更深蚀刻进入衬底。同样在该图中示出了一条单独粘结线的厚度t。根据本发明,用来形成给定数个狭槽的单独狭槽的数目、其长度l和间隔s以及单独狭槽的深度d可被设计为增加粘合剂体积对粘结表面积的比率,同时在粘结区域中维持一条非常薄(即约几十微米或更小的等级)的粘结线。狭槽的大小、形状和数目也可被最优化从而解决各种制造/工艺问题,例如一个具体组件的周期、产量和成本需求。使用根据本发明的狭槽的一个优点是在将微部件(例如透镜支架44)压入在粘合剂点20上的位置时,狭槽16的存在将允许粘合剂保持并以一种受引导的方式散布。
在本发明的另一实施方案中,一个或多个沟道可连同多个狭槽一起形成,其中沟道用来捕捉溢出粘合剂并防止粘合剂材料流入不希望的区域。图4和图5分别是图2和图3的安排的顶视图和侧视图,其中一条溢出沟道17连同狭槽16一起形成。在该具体实施方案中,溢出沟道17被形成为延伸一个更大深度D进入衬底14。这仅被考虑为一个设计选择,并且溢出沟道的深度可以可替代地大约与狭槽自身相同。如同狭槽16,沟道17可使用在CMOS加工中众所周知的一种蚀刻工艺(例如深RIE蚀刻、等离子蚀刻等)或任何其它合适工艺形成。参考图4和5,沟道17关于狭槽16安置,从而使得任何溢出粘合剂20将自然地排入沟道17并且不以其它方式跨衬底14的表面18散布进入不希望的区域。
如上面提到,本发明的一个显著方面是使用可在支持衬底的表面中容易蚀刻的狭槽允许形成粘合剂的各种成形“点”,促进了微部件自定心到衬底。图6展示一个不同SOI组件30的一部分,其在此情况下包括在多个同心圆中形成的狭槽32。如所示,分布体积的粘合剂34然后将在由狭槽32创造的圆形底座之后采取半球形。具有圆形底面形式的拓扑的特定微部件(未示出)然后将紧接着插入粘合剂34上适当位置而自然地自定心。
有可能的是通过改变其温度来修改应用粘合剂的性质。根据本发明的另一实施方案,一个或多个加热器元件(例如电阻带)可连同粘结槽一起形成并用来改变粘合剂局部区域中的温度。图7是本发明的该实施方案的顶视图,其示出了连同狭槽16一起布置的数条电阻带19。多种材料(例如硅、多晶硅、硅化物或金属)可用来形成这些加热器元件。通过另外的电路(未示出),电流可经过电阻带19,该条带然后将升高狭槽16附近的局部温度。尽管图7示出邻接狭槽16安置的加热器元件的使用,但同样有可能的是将一个加热器元件与狭槽自身一起嵌入。
通过允许加热后的粘合剂保持在一个粘稠状态,可以调整布置在粘合剂上的一个微部件的位置,直到已经实现关于衬底的期望程度对齐。一旦微部件已经被适当地对齐,那么这个或这些加热器元件还可用来激活固化。另外,加热器元件的内含物可用来通过以一个受控制方式“开启”加热器元件中的各种加热器元件提供“局部”加热。事实上,通过控制电阻带19的“开启”和“关闭”,数个分离微部件可安置在一个共用衬底上,其中通过在每个微部件的局部区域中控制粘合剂的温度,以一个预定顺序执行每个微部件的粘合。
图8是连同关联以上图示描述的相同组件配置(衬底14、空腔12等)的本发明一个替代实施方案的等距视图。在此情况下,附加配置50包括围绕狭槽54的外周形成的一条沟道52,从而协助将液体粘合剂保持在位。沟道52围绕狭槽的边缘54,并示作包括一个顶部沟道部分52-T、一个底部沟道部分52-B和多个侧面沟道部分52-S。
通常,本发明的粘合剂支撑狭槽示作允许粘合剂材料在用来粘结的感兴趣的预定(和有限)区域中可控制和均匀散布。已发现在相对小区域中形成多个这些狭槽的能力减少了表面摩擦并允许薄粘结线形成。狭槽自身的存在增加了表面积/粗糙度以便改善后固化接合强度。在与所填充的环氧树脂材料一起使用时,狭槽在固化之后向环氧树脂的移动提供额外的抵抗。
如在图6的展示中具体示出,形成狭槽的各种配置的能力允许附加组件自定心,提供了部件到衬底的(基本)被动对齐。尽管没有明确示出,但应进一步理解的是以上描述的加热器元件可与任何狭槽配置一起使用,包括图6的同心圆狭槽安排。
最后,尽管此时已经结合已知的示范实施方案详细描述了本发明,但应容易理解本发明不限于所披露的实施方案。相反,可以对本发明进行修改从而纳入以前没有描述但与本发明的精神和范围相称的任何数目的变化、更改、置换或等效安排。因此,不应将本发明视为受前面描述限制,而是仅受附属于此的权利要求的范围限制。
Claims (19)
1.一种组件,包括衬底和粘结到衬底的微部件,
其中,在该衬底的顶面中形成多个狭槽,每个狭槽都具有一个关联的预定长度l并被形成为进入该衬底的顶面的一个关联深度d,该多个狭槽用来容纳和保存预定体积的液体粘合剂材料,该材料适合向该衬底提供该微部件的粘结,
其中该多个狭槽的形状对应于粘结到衬底的微部件的表面的拓扑,该多个狭槽的配置紧接着该微部件粘结到该衬底而提供该微部件关于该多个狭槽的自定心。
2.如权利要求1所述的组件,其中至少一条沟道邻接该多个狭槽布置,并用来紧接着该微部件接合到该衬底而捕捉和保持外来液体粘合剂材料。
3.如权利要求2所述的组件,其中该至少一条沟道被形成为围绕该多个狭槽的外围。
4.如权利要求2所述的组件,其中该至少一条沟道被形成为比该多个狭槽更深。
5.如权利要求1所述的组件,其中该多个狭槽被蚀刻进入该衬底的顶面中。
6.如权利要求1所述的组件,其中该多个狭槽各自都展现基本相同的长度。
7.如权利要求1所述的组件,其中该多个狭槽中的每个狭槽在该衬底表面下方被形成为基本相同的深度。
8.如权利要求1所述的组件,其中该多个狭槽由基本相同的间隔分离。
9.如权利要求1所述的组件,其中该组件进一步包括
至少一个加热器元件,该加热器元件与多个狭槽中的一个狭槽相关联地布置,从而提供布置在该关联狭槽上的该粘合剂材料的局部加热;以及
用来控制该至少一个加热器元件的“开启”和“关闭”的装置。
10.如权利要求9所述的组件,其中该至少一个加热器元件邻接一个关联狭槽而布置。
11.如权利要求9所述的组件,其中该至少一个加热器元件嵌入在一个关联狭槽内。
12.如权利要求9所述的组件,其中该至少一个加热器元件包括一个电阻元件,并且用来控制“开启”和“关闭”的装置包括用来将电流通过该电阻元件的一个开关。
13.如权利要求12所述的组件,其中该电阻元件包括选自下组的一种材料,该组的构成为:硅、多晶硅、硅化物、金属。
14.如权利要求1所述的组件,其中该衬底包括一个电气集成电路衬底。
15.如权利要求1所述的组件,其中该衬底包括一个光学系统衬底。
16.如权利要求15所述的组件,其中该光学系统衬底包括一个绝缘体上硅(SOI)衬底。
17.如权利要求16所述的组件,其中该SOI衬底进一步包括布置在该SOI衬底的顶面上的一个介电层。
18.如权利要求17所述的组件,其中该多个狭槽被蚀刻进入布置在SOI衬底上的该介电层中。
19.如权利要求1所述的组件,其中该衬底包括一个光电系统衬底。
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- 2010-11-30 CN CN201510046559.2A patent/CN104614819B/zh active Active
- 2010-11-30 WO PCT/US2010/058278 patent/WO2011068777A2/en active Application Filing
- 2010-11-30 BR BR112012012778A patent/BR112012012778A8/pt not_active IP Right Cessation
- 2010-11-30 CN CN201080053263.9A patent/CN102714199B/zh active Active
- 2010-11-30 EP EP10834989.5A patent/EP2507830B1/en active Active
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2014
- 2014-07-15 US US14/331,315 patent/US10175448B2/en active Active
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US20110127633A1 (en) | 2011-06-02 |
BR112012012778A2 (pt) | 2017-12-12 |
EP2507830A2 (en) | 2012-10-10 |
CN102714199A (zh) | 2012-10-03 |
WO2011068777A2 (en) | 2011-06-09 |
CN104614819A (zh) | 2015-05-13 |
US20140362457A1 (en) | 2014-12-11 |
CN104614819B (zh) | 2017-10-31 |
EP2507830A4 (en) | 2018-01-10 |
US10175448B2 (en) | 2019-01-08 |
WO2011068777A3 (en) | 2011-09-22 |
EP2507830B1 (en) | 2021-04-21 |
US8836100B2 (en) | 2014-09-16 |
BR112012012778A8 (pt) | 2018-05-08 |
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