CN109314058A - 在衬底中形成通孔的制品和方法 - Google Patents
在衬底中形成通孔的制品和方法 Download PDFInfo
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- CN109314058A CN109314058A CN201780034352.0A CN201780034352A CN109314058A CN 109314058 A CN109314058 A CN 109314058A CN 201780034352 A CN201780034352 A CN 201780034352A CN 109314058 A CN109314058 A CN 109314058A
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Classifications
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- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
- H01L21/4814—Conductive parts
- H01L21/4846—Leads on or in insulating or insulated substrates, e.g. metallisation
- H01L21/486—Via connections through the substrate with or without pins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C15/00—Surface treatment of glass, not in the form of fibres or filaments, by etching
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/22—Surface treatment of glass, not in the form of fibres or filaments, by coating with other inorganic material
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/28—Surface treatment of glass, not in the form of fibres or filaments, by coating with organic material
- C03C17/30—Surface treatment of glass, not in the form of fibres or filaments, by coating with organic material with silicon-containing compounds
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C23/00—Other surface treatment of glass not in the form of fibres or filaments
- C03C23/0005—Other surface treatment of glass not in the form of fibres or filaments by irradiation
- C03C23/0025—Other surface treatment of glass not in the form of fibres or filaments by irradiation by a laser beam
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/26—Deposition of carbon only
- C23C16/27—Diamond only
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- 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
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
- H01L21/302—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
- H01L21/306—Chemical or electrical treatment, e.g. electrolytic etching
- H01L21/308—Chemical or electrical treatment, e.g. electrolytic etching using masks
- H01L21/3081—Chemical or electrical treatment, e.g. electrolytic etching using masks characterised by their composition, e.g. multilayer masks, materials
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- 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
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
- H01L21/31—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to form insulating layers thereon, e.g. for masking or by using photolithographic techniques; After treatment of these layers; Selection of materials for these layers
- H01L21/3105—After-treatment
- H01L21/311—Etching the insulating layers by chemical or physical means
- H01L21/31144—Etching the insulating layers by chemical or physical means using masks
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- 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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Abstract
在具有从第一表面延伸的至少一个损伤区的衬底中形成通孔的方法,蚀刻该衬底的该至少一个损伤区以在衬底中形成通孔,其中该通孔延伸穿过衬底的厚度T,同时衬底的第一表面被掩蔽。在蚀刻之后从衬底的第一表面移除掩模,并且在移除掩模时,衬底的第一表面具有约小于1.0nm的表面粗糙度(Rq)。
Description
相关申请的交叉引用
本申请根据35 U.S.C.§119要求于2016年6月1日提交的美国临时申请序列第62/343,943号的优先权,本申请基于该临时申请的内容并且该临时申请的内容通过引用整体结合于此。
背景
领域
本公开大体上涉及在衬底中形成通孔的制品和方法。特别地,本公开涉及包括保持衬底的表面粗糙度(Rq)的蚀刻过程的在衬底中形成贯通孔的制品和方法。
技术背景
中介层可以用作在包括具有射频(RF)滤波器的设备的电子设备中的电界面,以将电连接扩展到更宽的节距或者将电连接重新路由到不同的电连接。玻璃中介层已成为硅和纤维增强聚合物的有吸引力的替代品。这部分是由于玻璃在大薄片中形成的能力。然而,对于连续更薄的电子设备,许多应用要求中介层具有300μm或更小的厚度。由于玻璃的脆性和缺乏刚性,这种薄玻璃在制造程序中可能难以处理。为了抵消玻璃衬底的脆性和缺乏刚性,已经开发了使用与玻璃衬底结合的载体的制造方法。
范德华力可用于将玻璃制品临时地结合到载体。临时结合的能量足以在平板制造中维持,同时保持可去结合。然而,当玻璃制品的表面粗糙度(Rq)太高时,范德华力可能产生弱键,如果有的话。
典型地,玻璃中介层需要通孔(孔)填充有导电材料以提供电界面连接。在玻璃中介层中创建通孔的已知方法是通过创建穿过玻璃中介层的厚度的损伤区,然后将衬底浸入蚀刻剂。然后,蚀刻剂可以从损伤区移除材料以使孔扩大。然而,蚀刻过程不是选择性的,并且可以从玻璃中介层的两个面以及扩大孔移除材料。这总是创建在可以适当地形成范德华键的范围之外的玻璃中介层表面粗糙度(Rq)。
因此,需要在衬底中形成通孔同时保持低表面粗糙度(Rq)的方法,使得衬底可以可移除地结合到载体。
发明内容
在第一方面,一种在衬底中形成通孔的方法,所述衬底具有从第一表面延伸的至少一个损伤区,所述方法包括在所述衬底的第一表面被掩蔽时蚀刻所述衬底的所述至少一个损伤区以在所述衬底中形成通孔。然后,从衬底的第一表面移除掩模,并且在移除掩模时,衬底的第一表面具有约小于1.0nm的表面粗糙度(Rq)。
根据第一方面的第二方面,其中所述掩模选自由二苯基硅(diphenylsilicon)、苯基硅(phenylsilicon)、甲基苯基硅(methylphenylsilicon)和类金刚石碳(DLC)组成的组。
根据第二方面的第三方面,其中掩模是DLC,并且DLC是氢化非晶碳。
根据前述方面中任一方面的第四方面,其中,在移除所述掩模时,所述衬底的所述第一表面具有约小于0.6nm的表面粗糙度(Rq)。
根据前述方面中任一方面的第五方面,其中,在蚀刻期间,所述衬底的与所述衬底的所述第一表面相对的第二表面被掩蔽。
根据前述方面中任一方面的第六方面,其中,通过氧化移除所述掩模。
根据前述方面中任一方面的第七方面,其中,所述通孔是盲孔或贯通孔。
根据前述方面中任一方面的第八方面,其中,将所述掩模选择性地施加到所述衬底的所述第一表面,使得所述损伤区未被掩蔽。
根据前述方面中任一方面的第九方面,其中,所述衬底是玻璃、陶瓷或玻璃-陶瓷。
根据前述方面中任一方面的第十方面,进一步包括通过将所述衬底的所述第一表面设置在载体的结合表面上,将所述衬底可移除地结合到载体。
根据第十方面的第十一方面,进一步包括:在将所述衬底可移除地结合到所述载体之后,通过以下中的至少一个处理所述衬底:向所述衬底应用碱性清洁溶液、湿法蚀刻所述衬底、抛光所述衬底、对所述衬底进行金属电镀、通过湿法蚀刻对所述衬底进行金属图案化、将材料沉积到所述衬底上、以及对所述衬底进行退火。
根据第十一方面的第十二方面,进一步包括从衬底移除载体。
根据第十至第十二方面中的任一方面的第十三方面,其中,将所述掩模选择性地施加到所述衬底的所述第一表面,使得所述损伤区未被掩蔽。
在第十四方面中,一种制品包括衬底,该衬底包括由厚度T分开的第一表面和第二表面。至少一个损伤区在所述衬底内并从所述第一表面延伸。第一膜层被设置在衬底的第一表面的未损伤区上。第一膜层选自由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)组成的组。
根据第十四方面的第十五方面,进一步包括第二膜层,设置在所述衬底的所述第二表面的未损伤区上,所述第二膜层选自由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)组成的组。
根据第十四或十五方面的第十六方面,其中,第一膜是DLC,并且DLC是氢化非晶碳。
根据第十四至第十六方面中的任一方面的第十七方面,其中,所述衬底是玻璃、陶瓷或玻璃-陶瓷。
将在以下详细描述中阐述本发明的附加特征和优点,这些特征和优点在某种程度上对于本领域的技术人员来说根据该描述将是显而易见的,或者通过实施包括以下详细描述、权利要求书以及附图的本文所述的实施例可认识到。
应当理解的是,以上一般描述和以下详细描述两者描述了各实施例,并且它们旨在提供用于理解所要求保护的主题的本质和特性的概观或框架。包括了附图以提供对各个实施例的进一步的理解,并且附图被结合到本说明书中并构成说明书的一部分。附图示出本文所述的各个实施例,并与说明书一起用于说明所要求保护的主题的原理和操作。
附图说明
在附图中阐述的实施例在性质上为说明性和示例性的,并不意图限制权利要求所定义的主题。示例性实施例的以下详细描述可结合以下附图阅读时被最好地理解,在附图中相同的结构使用相同的附图标记来指示,其中:
图1图示了根据本文所示和所描述的一个或多个实施例的包括衬底和掩模的制品的透视图;
图2图示了根据本文所示和所描述的一个或多个实施例的描述制造制品的方法的流程图;
图3图示了根据本文所示和所描述的一个或多个实施例的具有在其中形成一个或多个损伤区的图1的制品的横截面视图;
图4图示了根据本文所示和所描述的一个或多个实施例的浸在蚀刻剂中的图1的制品;
图5图示了根据本文所示和所描述的一个或多个实施例的具有在其中形成一个或多个通孔的图1的制品的横截面视图;
图6图示了根据本文所示和所描述的一个或多个实施例的掩模被移除的图4的制品的横截面视图;
图7图示了根据本文所示和所描述的一个或多个实施例的结合到载体的图6的制品的透视图。
具体实施方式
通常地参照附图,在本文提供的衬底中创建通孔的制品和方法的实施例允许保持衬底的表面粗糙度(Rq),使得衬底可以可移除地结合到载体以用于进一步处理。现将详细参考在衬底中形成通孔的制品和方法的各种实施例,这些实施例的示例在附图中说明。在可能时,将在所有附图中使用相同的附图标号来指示相同或类似的部件。应注意,图中所图示的实施例未按比例绘制,并且相对尺寸和宽度被选择用于仅说明的目的。
实施例通过在用于通孔形成的蚀刻过程期间利用掩模层来保持衬底的蚀刻前的表面粗糙度。通过在通孔形成期间保持衬底的低表面粗糙度,衬底可以可移除地结合到载体上以用于进一步处理。在处理之后,可以从载体移除衬底,使得载体可以重新用于处理另外的衬底。下面详细描述用于通孔形成的制品和方法的各种实施例。
图1描绘了示例制品100。本文公开的制品可以用作例如半导体封装中的中介层,该制品具有蚀刻孔(例如,通孔)和允许成功的下游处理的表面属性,该处理包括但不限于通孔金属化和用于半导体设备、射频(RF)设备(例如,天线、开关等)、中介层设备,微电子设备、光电设备、微电子机械系统(MEMS)设备和其他可以利用通孔的应用的再分布层(RDL)的应用。
图2描绘了大致上图示用于在衬底中形成通孔的示例过程的示例流程图10。在整个各种附图的描述中将更详细地描述流程图中描绘的步骤。注意到,尽管流程图10被描绘为具有特定的顺序,但是应该理解,本公开的实施例不限于图1中所示的步骤的顺序。
参见图1,制品100通常包括衬底110。衬底110具有第一表面112和第二表面114。在第一表面112上示出至少一个损伤区120。第一掩模150a和第二掩模150b形成在衬底110的第一表面112和第二表面114中的至少一个上。在一些实施例中,掩模可以仅形成在第一表面112或第二表面114中的一个上。在其他实施例中,并且如图1所示,第一掩模150a和第二掩模150b形成在衬底110的第一表面112和第二表面114两者上。衬底110可以由各种玻璃组合物形成,包括但不限于硼硅酸盐玻璃、铝硅酸盐玻璃、碱-铝硅酸盐玻璃、铝硼硅酸盐玻璃、碱-铝硼硅酸盐玻璃和钠钙玻璃。此外,衬底110可以被强化(例如,通过离子交换过程)或不被强化。示例衬底可包括但不限于Corning EAGLE玻璃,化学地强化或非强化的Corning玻璃和Corning玻璃。在又进一步的实施例中,衬底110可以由其他材料制成,诸如陶瓷和玻璃陶瓷。
现在参考图3,衬底110的第一表面112和第二表面114可以通过厚度T分开,厚度T可以取决于应用并且不受本公开的限制。作为非限制性示例,厚度T可以在约25μm至约3,000μm,约25μm至约2,000μm,约25μm至约1,000μm,约50μm至约3,000μm,约50μm至约2,000μm,约50μm至约1,000μm,约100μm至约3,000μm,约100μm至约2,000μm,约100μm至约1,000μm,约200μm至约3,000μm,约200μm至约2,000μm,约200μm至约1,000μm,约500μm至约3,000μm,约500μm至约2,000μm,约500μm至约1,000μm的范围内,约3,000μm或更小,约2,000μm或更小,约1,000μm或更小,约700μm或更小,约500μm或更小,约400μm或更小,约300μm或更小,约200μm或更小,或约100μm或更小。第一表面112和第二表面114还具有蚀刻前的表面粗糙度(Rq)。表面粗糙度(Rq)是指表面的测量的微观峰和谷的均方根(RMS)。表面粗糙度(Rq)可以使用原子力显微镜(AFM)来测量,例如Veeco Dimension Icon。表面粗糙度(Rq)可以响应于处理步骤而改变,诸如下面描述的蚀刻处理。这在下面提供的示例中可能更明显。
参考图2的框11,在衬底110中创建该至少一个损伤区120。如图3中所指示,该至少一个损伤区120延伸穿过衬底110的厚度T。该至少一个损伤区120可以是延伸穿过衬底110的厚度T的孔。在一些实施例中,该至少一个损伤区120不延伸穿过衬底的整个厚度。在一些实施例中,存在延伸穿过衬底的厚度T的损伤区与不延伸穿过衬底的整个厚度的损伤区的组合。可以以各种方式在衬底110中形成该至少一个损伤区120。在一些实施例中,可以通过应用高能激光脉冲烧蚀穿过衬底110的窄孔来创建该至少一个损伤区120。该至少一个损伤区120允许蚀刻剂在下游蚀刻过程期间在其中流动。
在另一个示例中,该至少一个损伤区120可以不是穿过衬底110的厚度T的孔,而是由脉冲激光形成的激光诱导损伤线。例如,脉冲激光可以通过非线性多光子吸收形成损伤线。在蚀刻过程期间,限定该至少一个损伤区120的激光诱导损伤线内的材料移除速率快于在该至少一个损伤区120外部的材料移除速率。用于执行激光损伤创建和随后的蚀刻的示例性方法公开在美国专利第9,278,886号和美国公开第2015/0166395号中,其各自通过引用整体并入本文。
在图2的流程图10的框12处,第一掩模150a和第二掩模150b可以分别地施加到衬底110的第一表面112和第二表面114。在一些实施例中,第一掩模150a和第二掩模150b不加区别地施加到衬底110。在这样的实施例中,第一掩模150a和第二掩模150b可以在在衬底110中创建该至少一个损伤区120之前被施加到衬底,如上所述。在这种情况下,激光脉冲可以烧蚀穿过第一掩模150a和第二掩模150b和衬底110的孔。在其他实施例中,在该至少一个损伤区已经被创建之后,第一掩模150a和第二掩模150b不加区别地施加到衬底。在这种情况下,可以在进一步处理之前从已经创建的至少一个损伤区120选择性地移除第一掩模150a和第二掩模150b。在又另外的实施例中,第一掩模150a和第二掩模150b选择性地施加到衬底110。在这样的实施例中,第一掩模150a和第二掩模150b可以被施加到衬底110,以便避免已经创建的至少一个损伤区120。这样,第一掩模150a和第二掩模150b可以具有与该至少一个损伤区120对准的开口,以便允许蚀刻剂进入该至少一个损伤区120。第一掩模150a和第二掩模150b可以以小于或等于1μm的厚度被施加。在一些实施例中,第一掩模150a和第二掩模150b可以以小于或等于300nm的厚度被施加。在又另外的实施例中,掩模150a和掩模150b可以以约60nm的厚度被施加。
第一掩模150a和第二掩模150b可以是各种材料。例如但不限制地,掩模可以由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)制成。在一些实施例中,类金刚石碳可以是氢化非晶碳。这种氢化非晶碳膜可以通过沉积诸如分子式CnHy的化合物之类的碳氢前体化合物来形成,其中n为1至6,y为2至14。在一些示例中,n为1至4,y为2至10。碳氢化合物可以是直链或支链的。在一些示例中,通过沉积碳氢前体化合物形成的涂层具有至少80重量%,至少85重量%,至少90重量%,或至少95重量%的组合的碳和氢含量。在一些示例中,沉积前体化合物以形成具有至少80重量%,至少85重量%,至少90重量%,至少95重量%,至少98重量%,至少99重量%,或大于99.5重量%的组合的碳和氢含量的涂层。
碳氢前体化合物的示例包括烷烃。烷烃可包括甲烷、乙烷、丙烷、丁烷、戊烷和己烷。在一些示例中,碳氢前体化合物包括至少一个碳-碳双键,例如烯烃。烯烃可包括乙烯、丙烯、丁烯、戊烯和己烷。烯烃中的碳-碳双键可以存在于化合物中的各种位置,例如丁-1-烯或丁-2-烯。在又其他示例中,碳氢前体化合物包括至少一个碳-碳三键,例如炔烃。炔烃可包括乙炔、丙炔、丁炔、戊炔和己炔。在一些示例中,炔烃中的碳-碳三键存在于化合物中的各个位置,例如1-丁炔或2-丁炔。
设想到第一掩模150a和第二掩模150b都可以是相同的材料。在其他实施例中,第一掩模150a和第二掩模150b可以是不同的材料。在掩模材料是二苯基硅的实施例中,可以将二苯基硅膜施加到衬底110的第一表面112和第二表面114中的至少一个上。其中二苯基硅膜被施加到第一表面112和第二表面114两者上,存在第一二苯基硅膜层和第二二苯基硅膜层。此外,尽管未示出,但是可以将二苯基硅膜施加到衬底110的边缘表面。例如,可以通过气相沉积来施加膜。作为示例而非限制,二苯基硅膜通过化学气相沉积(优选地为等离子体增强化学气相沉积)由二苯基硅烷和氢形成。二苯基硅是一种高效的掩模材料,且耐酸腐蚀。因此,二苯基硅可以经受与蚀刻过程中常用的氢氟酸-无机酸混合物的接触。此外,二苯基硅可以容易地从玻璃表面移除而不会产生过多的表面粗糙度(Rq)。
在实施例中,掩模材料是氢化非晶碳,氢化非晶碳膜可以施加到衬底110的第一表面112和第二表面114中的至少一个上。其中氢化非晶碳膜被施加到第一表面112和第二表面114两者上,存在第一氢化非晶碳膜层和第二氢化非晶碳膜层。氢化非晶碳可以通过化学气相沉积(CVD)技术和类似方法来沉积。CVD技术的具体示例包括CVD、低压CVD、常压CVD、等离子体增强CVD(PECVD)、常压等离子体CVD、原子层沉积(ALD)、等离子体ALD和化学束外延。在另一个示例中,涂层可以通过热解炬在高于600℃、高于800℃或高于1,000℃的温度(包括其间的任何范围和子范围)下沉积。用于形成包含碳氢化合物的涂层的气体混合物还可包括受控量的另一种化合物,例如载气或工作气体。另一种化合物可包括空气、氧气、一氧化二氮、二氧化碳、水蒸气或过氧化氢,和/或一种或多种惰性气体,例如氦气、氖气、氩气、氪气、氙气。
使用掩模的任何选择性蚀刻过程的最大挑战之一是掩模移除。掩模材料必须足够坚韧以抵抗蚀刻,但也必须易于移除而不损坏衬底。聚合物掩模(诸如光刻胶)通常涉及在机械搅拌下将掩蔽的衬底浸泡在热溶剂中。通常,通过等离子体蚀刻移除无机掩模。例如,通常用含氟等离子体移除PECVD沉积的碳化硅(SiC)。然而,在这种过程下,在移除期间也蚀刻衬底,因此增加了衬底的表面粗糙度(Rq)。二苯基硅对传统的掩模材料是独特的,因为它特别容易氧化。在氧化期间中,有机基团被热解并移除,硅被氧化以形成二氧化硅。该过程允许基本上保持衬底的表面粗糙度。如下面的示例3中所示,也可以氧化氢化非晶碳以移除掩模。设想到其他等离子体聚合物膜和材料可具有与二苯基硅基本上相似的益处。例如但不限于苯基硅、甲基苯基硅和类金刚石碳(DLC)。
参考图2的流程图10的框13,在已经创建该至少一个损伤区120并且已经施加第一掩模150a和第二掩模150b之后,可以蚀刻玻璃制品100。如图4所示,蚀刻过程可包括将玻璃制品100浸没在蚀刻剂180浴中。附加地或替代地,蚀刻剂180可以被喷射到玻璃制品100上。蚀刻剂180可以在衬底110的未掩蔽部分处移除衬底110的材料,以扩大该至少一个损伤区120的直径。可以利用任何合适的蚀刻剂。蚀刻剂的非限制性示例包括强无机酸,诸如硝酸、盐酸或磷酸,以及含氟蚀刻剂,诸如氢氟酸、氟化氢铵、氟化钠等。
图5图示了在蚀刻已经发生之后的衬底110。如所描绘,从图1中所图示的该至少一个损伤区120打开通孔124。通孔124被示出为贯通孔,其延伸穿过衬底的厚度。在其他实施例中,通孔可以是延伸通过衬底的仅一部分路径的盲孔。在一些实施例中,贯通孔从延伸穿过衬底的厚度的损伤区形成,并且盲孔从不延伸穿过衬底的厚度的损伤区形成。作为示例而非限制,通孔124可以具有在约5μm至约150μm,约20μm至约150μm,或约5μm至约20μm的范围内的直径。通孔可以是基本上圆柱形的,例如具有腰部(沿着通孔具有最小直径的点),其直径为在第一表面或第二表面上的通孔的开口的直径的至少70%、至少75%或至少80%。
在已经将该至少一个通孔124打开至期望的直径之后,可以从衬底110移除第一掩模150a和第二掩模150b(图2的框14)。图6图示出了已从衬底110移除第一掩模150a和第二掩模150b。在一些实施例中,可在移除第一掩模150a和第二掩模150b之前和/或之后清洁衬底100(例如,通过用去离子水冲洗)。例如但不限制,在二苯基硅是掩模材料的实施例中,可以通过氧化移除第一掩模150a和第二掩模150b。用于氧化二苯基硅膜的示例工具包括氧光刻胶剥离器或等离子灰化器。可以移除掩模150a、150b而不显著增加衬底110的第一表面112和第二表面114的表面粗糙度(Rq)(即,蚀刻后的表面粗糙度(Rq))。显著增加表面粗糙度(Rq)是指将衬底110的表面粗糙度(Rq)增加到超过本文所述的范德华结合能力。在一些实例下,在移除掩模150a、150b之后所得到的衬底110的表面粗糙度(Rq)小于约1.2nm,小于约1.1nm,小于约1.0nm,小于约0.9nm,小于约0.8nm,小于约0.7nm,小于约0.6nm,小于约0.5nm,小于约0.4nm,或小于约0.3nm。
在已经蚀刻通孔124之后,可以对衬底110进行附加的处理步骤以获得附加的中介层性质。图7图示了通过将衬底110的第二表面114设置在载体200的结合表面210上可移除地结合到示例载体200的示例衬底110。如上所讨论,玻璃中介层可以非常薄(例如,从小于300μm至700μm的任何数值)。因为衬底110的脆性和缺乏刚性,这种薄材料在制造程序中可能难以处理。为了抵消脆性和缺乏刚性,在已经形成通孔并且已经移除第一掩模150a和第二掩模150b之后,衬底110可以可移除地结合到载体200。将衬底110可移除地结合到载体的一种示例性方法是通过使用范德华结合,诸如由美国专利公开第2014/0170378号所公开的,其全部内容通过引用并入本文。范德华结合通常包括将制品的表面设置在载体的结合表面上并且升高制品的温度,然后将制品冷却至室温。结果是制品和载体可移除地结合在一起。范德华结合有利于下游处理,因为它能够形成能够经受处理(例如,高温处理)的结合,同时允许衬底的整个区域从载体200被移除(一次全部地或部分地移除)。在已经移除衬底110之后,可以重新使用载体200来处理附加的衬底。
然而,使用范德华表面结合技术用于结合衬底的挑战在于结合在一起的表面的粗糙度影响表面被结合的能力。作为非限制性示例,大于约1.0nm的表面粗糙度(Rq)可基本上防止自发结合或导致衬底110与载体200的弱结合。弱结合可允许来自一个或多个过程的液体渗透到衬底110和载体200之间,从而导致分层或处理污染,因为来自一个过程的残留物可能影响后续的过程。
例如,载体200可以具有任何合适的材料,诸如玻璃。载体200不必是玻璃,而替代地可以是例如陶瓷、玻璃陶瓷或金属。如果由玻璃制成,载体200可以具有任何合适的组合物,包括但不限于硅铝酸盐、硼硅酸盐、铝硼硅酸盐、钠钙硅酸盐,并且根据其最终应用可以是含碱的或不含碱的。载体200可具有任何合适的厚度。另外,载体200可以由一层(如图所示)或结合在一起(例如,通过层压)的多层(包括多个薄片)制成。此外,载体200的热膨胀系数可以与衬底110的热膨胀系数基本上匹配,以防止在升高的温度下的处理期间衬底110翘曲或衬底110与载体200分离。衬底110的表面粗糙度(Rq)与载体200的表面粗糙度相加。因此,通常建议载体200具有小于或等于0.6nm的表面粗糙度(Rq)。
参见图2的框16,一旦衬底110充分地结合到载体200使得载体200和衬底110在处理期间将不分离,衬底110就可以经受进一步处理。处理衬底110可以包括步骤,诸如将碱性清洁溶液应用到衬底110,湿法蚀刻衬底110,抛光衬底110,对衬底110进行金属电镀,通过湿法蚀刻对衬底110进行金属图案化,通过沉积将材料沉积到衬底110上和对衬底110进行退火。
示例
以下比较示例和示例1与示例2比较了作为酸蚀刻和二苯基硅膜的移除的结果的表面粗糙度(Rq)的变化。在每个示例中,玻璃样本的厚度为0.7mm并且没有损伤区。通过具有以下参数的Veeco Dimension ICON AFM测量每个样本的表面粗糙度(Rq):1Hz、512次扫描/线和2微米图像尺寸。
比较示例
在该对比示例中,周期性地测量未掩蔽的Eagle玻璃样本的表面粗糙度(Rq),同时用6M氢氟酸和1.6M硝酸混合物蚀刻玻璃样本。已确定,在室温下在小于10分钟内通过机械(非超声)搅拌实现大于1nm的表面粗糙度(Rq)。该时间量对应于40μm的蚀刻深度。结果列于下表1中。注意到,在一些实例下,超过1.0nm的表面粗糙度(Rq)可能导致弱的或无效的范德华结合。
表1
时间 | 5分钟 | 10分钟 | 15分钟 |
表面粗糙度(Rq) | 1.11nm | 1.67nm | 1.46nm |
示例1
在该示例中,Eagle玻璃样本的表面粗糙度(Rq)在施加之前、施加之后和移除二苯基硅膜之后被测量。二苯基硅膜在应用材料P5000通用化学气相沉积(CVD)系统中沉积,该系统具有以下参数:390℃,体积流速为500sccm的二苯基硅烷,体积流速为600sccm的氢气(H2),9托,210密耳间隙(mils.gap),300W RF,在80℃下的二苯基硅烷起泡器。二苯基硅膜具有60nm的厚度。通过具有以下参数的Gasonics L3510光刻胶剥离器移除二苯基硅膜:200℃,1200mT,1000sccm的N2,100sccm的O2,900W,2.54GHz,具有30秒过蚀刻的终点控制。列于下表2中的结果说明表面粗糙度(Rq)仅略微增加,同时仍然很好地在如上所描述的范德华结合所需的范围内。注意到,在该示例中玻璃衬底未经历酸蚀刻。
表2
状态 | 施加前 | 施加后 | 移除后 |
表面粗糙度(Rq) | 0.193nm | 0.298nm | 0.272nm |
示例2
在该示例中,Eagle玻璃样本的表面粗糙度(Rq)在施加二苯基硅膜之后、在蚀刻15分钟之后和移除二苯基硅膜之后被测量。如在示例1中,二苯基硅膜在应用材料P5000通用CVD系统中沉积,该系统具有以下参数:390℃,体积流速为500sccm的二苯基硅烷,体积流速为600sccm的氢气(H2),9托,210密耳间隙,300W RF,在80℃下的二苯基硅烷起泡器。二苯基硅膜具有60nm的厚度。蚀刻剂是3M氢氟酸和1M硝酸的混合物,并结合机械(非超声)搅拌。如在以上示例中,通过具有以下参数的Gasonics L3510光刻胶剥离器移除二苯基硅膜:200℃,1200mT,1000sccm的N2,100sccm的O2,900W,2.54GHz,具有30秒过蚀刻的终点控制。列于下表3中的结果说明表面粗糙度(Rq)很好地在如上所描述的范德华结合所需的范围内。该示例还说明了二苯基硅对酸腐蚀的抗性,如本文所讨论的。
表3
状态 | 施加后 | 15分钟蚀刻后 | 移除后 |
表面粗糙度(Rq) | 0.269nm | 0.259nm | 0.201nm |
示例3
在该示例中,6个具有0.7mm的厚度、150mm的直径且没有损伤区的Eagle玻璃晶片样本具有所施加的非晶氢化碳膜掩模。在30sccm的乙烯,70sccm的氢气,60mT压强,800W功率和13.56MHz频率的条件下的Nextral NE500反应离子蚀刻器中由乙烯和氢气沉积掩模。掩模的沉积时间和厚度(刚沉积的)列于下表4中。还在632nm下测量(刚沉积的)掩模的折射率。使用N&K分析仪测量厚度和折射率。在沉积掩模后,在23℃下在10wt%氢氟酸和7wt%硝酸的蚀刻溶液中蚀刻样本约15分钟。在蚀刻之后使用N&K分析仪再次测量掩模的厚度和在632nm下的折射率,并列于下表4中。厚度和折射率的变化在实验误差的范围内。接着,通过具有以下参数的Gasonics L3510光刻胶剥离器移除掩模:200℃,1200mT,1000sccm的N2,100sccm的O2,900W,2.54GHz,具有30秒过蚀刻的终点控制。并且通过具有以下参数的Veeco Dimension ICON AFM测量每个样本的表面粗糙度(Rq):1Hz、512次扫描/线和2微米图像尺寸。下表4中列出了结果。
从表4中可以看出,样本7没有掩模并且在与具有掩模的六个样本的相同的条件下被蚀刻。与0.240至0.278相比,未掩蔽的样本7的表面粗糙度(Rq)为显著更高的1.13。这表明了掩模
表4
可以使用具有类似参数的应用材料P5000通用CVD系统将本文提供的其他材料沉积在衬底上。例如,在具有以下条件的应用材料P5000通用CVD系统中,苯基硅膜可以从有机硅氢化物前体与氢载气一起从苯基硅烷和氢气中沉积:390℃,体积流速为120sccm的苯基硅烷,和体积流速为600sccm的氢气(H2),9托压强,210密耳间隙,和300W 13.56MHz RF。苯基硅烷安瓿可以在30℃。沉积速率可以接近1000nm/min。甲基苯基硅膜可以使用具有以下处理条件的应用材料P5000通用CVD系统沉积:390℃,体积流速为200sccm的甲基苯基硅烷,体积流速为600sccm的氢气(H2),9托,210密耳间隙和450W RF。甲基苯基硅烷安瓿可以在80℃。诸如有机硅卤化物之类的其他前体也会产生类似的结果。
应该理解的是,本文描述的实施例提供了在衬底中形成通孔而不显著增加衬底的表面粗糙度(Rq)。通过在通孔形成期间保持衬底的低表面粗糙度,衬底可以可移除地结合到载体上以用于进一步处理。在处理之后,可以从载体移除衬底,使得载体可以重新用于处理另外的衬底。此外,贯通孔可以制成基本上圆柱形,因为它们可以从两端蚀刻。
对本领域的技术人员显而易见的是,可对本文描述的实施例作出各种修改和变化而不背离要求保护的主题的精神和范围。由此,旨在使说明书覆盖本文描述的各实施例的多种修正和变化,只要这些修正和变化落在所附权利要求书及其等效方案的范围内。
Claims (17)
1.一种在衬底中形成通孔的方法,所述衬底具有从第一表面延伸的至少一个损伤区,所述方法包括:
在所述衬底的所述第一表面被掩蔽时,蚀刻所述衬底的所述至少一个损伤区以在所述衬底中形成通孔;以及
从所述衬底的所述第一表面移除掩模,其中当移除所述掩模时,所述衬底的所述第一表面具有约小于1.0nm的表面粗糙度(Rq)。
2.根据权利要求1所述的方法,其中所述掩模选自由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)组成的组。
3.根据权利要求2所述的方法,其中所述掩模是DLC,并且所述DLC是氢化非晶碳。
4.根据任何前述权利要求所述的方法,其中,在移除所述掩模时,所述衬底的所述第一表面具有约小于0.6nm的表面粗糙度(Rq)。
5.根据任何前述权利要求所述的方法,其中在蚀刻期间,所述衬底的与所述衬底的所述第一表面相对的第二表面被掩蔽。
6.根据任何前述权利要求所述的方法,其中通过氧化移除所述掩模。
7.根据任何前述权利要求所述的方法,其中所述通孔是盲孔或贯通孔。
8.根据任何前述权利要求所述的方法,其中,将所述掩模选择性地施加到所述衬底的所述第一表面,使得所述损伤区未被掩蔽。
9.根据任何前述权利要求所述的方法,其中,所述衬底是玻璃、陶瓷或玻璃-陶瓷。
10.根据任何前述权利要求所述的方法,进一步包括:
通过将所述衬底的所述第一表面设置在载体的结合表面上,将所述衬底可移除地结合到所述载体。
11.根据权利要求10所述的方法,还包括:在将所述衬底可移除地结合到所述载体之后,通过以下中的至少一个处理所述衬底:向所述衬底应用碱性清洁溶液、湿法蚀刻所述衬底、抛光所述衬底、对所述衬底进行金属电镀、通过湿法蚀刻对所述衬底进行金属图案化、将材料沉积到所述衬底上、以及对所述衬底进行退火。
12.根据权利要求11所述的方法,还包括从所述衬底移除所述载体。
13.根据权利要求10-12中任一项所述的方法,其中,使用范德华力将所述衬底可移除地结合到所述载体。
14.一种制品,包括:
衬底,包括由厚度T分开的第一表面和第二表面;
至少一个损伤区,位于所述衬底内并从所述第一表面延伸;以及
第一膜层,设置在所述衬底的所述第一表面的未损伤区上,所述第一膜层选自由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)组成的组。
15.根据权利要求14所述的制品,还包括第二膜层,设置在所述衬底的所述第二表面的未损伤区上,所述第二膜层选自由二苯基硅、苯基硅、甲基苯基硅和类金刚石碳(DLC)组成的组。
16.根据权利要求14或15所述的制品,其中所述第一膜是DLC,并且所述DLC是氢化非晶碳。
17.根据权利要求14-16中任一项所述的制品,其中,所述衬底是玻璃、陶瓷或玻璃陶瓷。
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US11114309B2 (en) | 2021-09-07 |
US20170352553A1 (en) | 2017-12-07 |
KR20190013869A (ko) | 2019-02-11 |
JP2019519457A (ja) | 2019-07-11 |
EP3465745A1 (en) | 2019-04-10 |
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