WO2009126544A1 - Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing - Google Patents
Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing Download PDFInfo
- Publication number
- WO2009126544A1 WO2009126544A1 PCT/US2009/039577 US2009039577W WO2009126544A1 WO 2009126544 A1 WO2009126544 A1 WO 2009126544A1 US 2009039577 W US2009039577 W US 2009039577W WO 2009126544 A1 WO2009126544 A1 WO 2009126544A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- flexible substrate
- adhesive layer
- assembly
- substrate
- rigid support
- Prior art date
Links
- 239000000758 substrate Substances 0.000 title claims abstract description 118
- 238000000034 method Methods 0.000 title claims abstract description 57
- 239000004065 semiconductor Substances 0.000 title claims abstract description 14
- 230000000712 assembly Effects 0.000 title abstract description 3
- 238000000429 assembly Methods 0.000 title abstract description 3
- 239000000853 adhesive Substances 0.000 claims abstract description 28
- 230000001070 adhesive effect Effects 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 24
- 239000012790 adhesive layer Substances 0.000 claims description 57
- 239000010410 layer Substances 0.000 claims description 47
- 229910052751 metal Inorganic materials 0.000 claims description 33
- 239000002184 metal Substances 0.000 claims description 32
- 229920000642 polymer Polymers 0.000 claims description 25
- -1 polysiloxane Polymers 0.000 claims description 19
- 239000010935 stainless steel Substances 0.000 claims description 18
- 229910001220 stainless steel Inorganic materials 0.000 claims description 18
- 239000004642 Polyimide Substances 0.000 claims description 15
- 229920001721 polyimide Polymers 0.000 claims description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 12
- 229920001296 polysiloxane Polymers 0.000 claims description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 239000002390 adhesive tape Substances 0.000 claims description 8
- 230000009477 glass transition Effects 0.000 claims description 8
- 239000004033 plastic Substances 0.000 claims description 8
- 229920003023 plastic Polymers 0.000 claims description 8
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 8
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 8
- 239000011112 polyethylene naphthalate Substances 0.000 claims description 7
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 6
- 229910052681 coesite Inorganic materials 0.000 claims description 5
- 229910052906 cristobalite Inorganic materials 0.000 claims description 5
- 238000000354 decomposition reaction Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 229910052682 stishovite Inorganic materials 0.000 claims description 5
- 239000010409 thin film Substances 0.000 claims description 5
- 229910052905 tridymite Inorganic materials 0.000 claims description 5
- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims description 4
- 239000004713 Cyclic olefin copolymer Substances 0.000 claims description 4
- 239000004593 Epoxy Substances 0.000 claims description 4
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 4
- 229920012266 Poly(ether sulfone) PES Polymers 0.000 claims description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 4
- 239000011521 glass Substances 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 239000011733 molybdenum Substances 0.000 claims description 4
- 229920000058 polyacrylate Polymers 0.000 claims description 4
- 239000004417 polycarbonate Substances 0.000 claims description 4
- 229920000515 polycarbonate Polymers 0.000 claims description 4
- 238000004528 spin coating Methods 0.000 claims description 4
- 229910052715 tantalum Inorganic materials 0.000 claims description 4
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 4
- 229910052719 titanium Inorganic materials 0.000 claims description 4
- 239000010936 titanium Substances 0.000 claims description 4
- 229910001374 Invar Inorganic materials 0.000 claims description 3
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 claims description 3
- 229910000833 kovar Inorganic materials 0.000 claims description 3
- 238000003491 array Methods 0.000 claims description 2
- 238000000151 deposition Methods 0.000 claims description 2
- 230000005669 field effect Effects 0.000 claims description 2
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 claims 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims 2
- 238000007765 extrusion coating Methods 0.000 claims 1
- 238000003475 lamination Methods 0.000 claims 1
- 238000005507 spraying Methods 0.000 claims 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 abstract description 8
- 239000010703 silicon Substances 0.000 abstract description 8
- 229910052710 silicon Inorganic materials 0.000 abstract description 7
- 239000000969 carrier Substances 0.000 abstract description 2
- 239000002985 plastic film Substances 0.000 abstract 1
- 229920006255 plastic film Polymers 0.000 abstract 1
- 235000012431 wafers Nutrition 0.000 abstract 1
- 238000010438 heat treatment Methods 0.000 description 8
- 150000002739 metals Chemical class 0.000 description 6
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 description 6
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 239000013464 silicone adhesive Substances 0.000 description 4
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 239000010408 film Substances 0.000 description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 3
- 229910052737 gold Inorganic materials 0.000 description 3
- 239000010931 gold Substances 0.000 description 3
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 3
- 229910052709 silver Inorganic materials 0.000 description 3
- 239000004332 silver Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 238000009987 spinning Methods 0.000 description 3
- 238000004544 sputter deposition Methods 0.000 description 3
- 229910002555 FeNi Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229920006397 acrylic thermoplastic Polymers 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 125000003700 epoxy group Chemical group 0.000 description 2
- 229920002457 flexible plastic Polymers 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 235000013824 polyphenols Nutrition 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 2
- 238000002411 thermogravimetry Methods 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 150000003673 urethanes Chemical class 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000976 Electrical steel Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 238000010943 off-gassing Methods 0.000 description 1
- ORMNNUPLFAPCFD-DVLYDCSHSA-M phenethicillin potassium Chemical compound [K+].N([C@@H]1C(N2[C@H](C(C)(C)S[C@@H]21)C([O-])=O)=O)C(=O)C(C)OC1=CC=CC=C1 ORMNNUPLFAPCFD-DVLYDCSHSA-M 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229930195734 saturated hydrocarbon Natural products 0.000 description 1
- 229920005573 silicon-containing polymer Polymers 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 230000036962 time dependent Effects 0.000 description 1
- 229930195735 unsaturated hydrocarbon Natural products 0.000 description 1
- 238000001291 vacuum drying Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
- H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
- H01L29/68—Types of semiconductor device ; Multistep manufacturing processes therefor controllable by only the electric current supplied, or only the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched
- H01L29/76—Unipolar devices, e.g. field effect transistors
- H01L29/772—Field effect transistors
- H01L29/78—Field effect transistors with field effect produced by an insulated gate
- H01L29/786—Thin film transistors, i.e. transistors with a channel being at least partly a thin film
- H01L29/78603—Thin film transistors, i.e. transistors with a channel being at least partly a thin film characterised by the insulating substrate or support
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/007—Manufacture or processing of a substrate for a printed circuit board supported by a temporary or sacrificial carrier
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0393—Flexible materials
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0175—Inorganic, non-metallic layer, e.g. resist or dielectric for printed capacitor
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/01—Tools for processing; Objects used during processing
- H05K2203/0147—Carriers and holders
- H05K2203/016—Temporary inorganic, non-metallic carrier, e.g. for processing or transferring
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/01—Tools for processing; Objects used during processing
- H05K2203/0191—Using tape or non-metallic foil in a process, e.g. during filling of a hole with conductive paste
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/38—Improvement of the adhesion between the insulating substrate and the metal
- H05K3/386—Improvement of the adhesion between the insulating substrate and the metal by the use of an organic polymeric bonding layer, e.g. adhesive
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31511—Of epoxy ether
- Y10T428/31515—As intermediate layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31652—Of asbestos
- Y10T428/31663—As siloxane, silicone or silane
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31721—Of polyimide
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31942—Of aldehyde or ketone condensation product
Definitions
- This invention generally relates to processing flexible substrates and more specifically to a method for reducing warp and bow of a flexible substrate during semiconductor processing.
- Flexible substrates are quickly becoming popular as a base for electronic circuits.
- Flexible substrates can include a wide variety of materials including very thin layers of metal, such as stainless steel, any of a myriad of plastics, etc.
- the circuit can be attached to a final product or incorporated into a further structure.
- Typical examples of such products or structures are active matrices on flat panel displays, RFID tags on various commercial products in retail stores, a variety of sensors, etc.
- CTE coefficient of thermal expansion
- the invention provides methods for preparing a semiconductor assembly comprising attaching a flexible substrate to a rigid support with an adhesive layer, wherein the adhesive layer comprises a viscoelastic polymer having a glass transition temperature less than 180 0 C and a decomposition temperature greater than 220
- the invention provides assemblies comprising a flexible substrate, a rigid support, and an adhesive layer, wherein the flexible substrate is attached to the rigid support with the adhesive layer between the flexible substrate and rigid support; and the adhesive layer comprises a viscoelastic polymer having a glass transition temperature less than 180 0 C and a decomposition temperature greater than 220 0 C.
- the invention provides methods for flexible display processing comprising producing a flexible display and attaching the flexible display to a rigid substrate according to the first aspect of the invention, wherein the flexible substrate is the flexible display.
- bowing means the curvature of a substrate about a median plane.
- warping means the linear displacement of the surface of a substrate with respect to a line defined by the center of the substrate. For example, if a substrate is uniformly bowed than the warp is about twice the bow measurement.
- CTE matched material means a material which has a coefficient of thermal expansion (CTE) which differs from the CTE of the referenced material by less than about 20%. Preferably, the CTEs differ by less than about 10%, 5%, 3%, or 1%.
- flexible substrate means a free-standing substrate comprising a flexible material which readily adapts its shape.
- the flexible substrate is a preformed flexible plastic substrate or a preformed flexible metal substrate.
- Preferred flexible metal substrates include FeNi alloys (e.g., INVARTM, FeNi, or FeNi36; INVARTM is an alloy of iron (64%) and nickel (36%) (by weight) with some carbon and chromium), FeNiCo alloys (e.g., KOVARTM, KOVARTM is typically composed of 29% nickel, 17% cobalt, 0.2% silicon, 0.3% manganese, and 53.5% iron (by weight), titanium, tantalum, molybdenum, aluchrome, aluminum, and stainless steel.
- FeNi alloys e.g., INVARTM, FeNi, or FeNi36
- INVARTM is an alloy of iron (64%) and nickel (36%) (by weight) with some carbon and chromium
- FeNiCo alloys e.
- Preferred flexible plastic substrates include polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyethersulfone (PES), polyimide, polycarbonate, and cyclic olefin copolymer.
- Such flexible substrates are preferably thin; for example, about 1 ⁇ m to 1 mm thick. More preferably, a flexible substrate is about 50 ⁇ m to 500 ⁇ m; even more preferably, about 50 ⁇ m to 250 ⁇ m.
- the term "viscoelastic adhesive” as used herein means an adhesive which exhibits both viscous and elastic characteristics when undergoing deformation. For example, a viscoelasctic material resists shear flow and exhibits time dependent strain.
- viscoelastic adhesive examples include, but are not limited to, polyimides, polyacrylates, acrylics, urethanes, epoxies, phenolics, bis-maleimides, silicones, and siloxanes.
- double-sided adhesive tape means any tape comprising a supporting backing with an adhesive material on each of the two opposing faces thereof.
- the adhesives on opposing faces can be the same or different, and include, for example but not limited to elastomeric, thermoplastic, thermosetting, pressure-sensitive, and/or light-curable adhesives (e.g., visible or UV).
- double sided adhesives include, but are not limited to, double sided powder coated silicone adhesives (Argon PC500 family), or high performance silicone adhesives (Adhesive Research Arcare 7876).
- the term "stable" as used herein with respect to exposure of a material to a particular temperature means that the referenced material loses less than about 5 % total weight by mass when maintained at that temperature under a nitrogen or argon atmosphere for a period of about 1 hour.
- the present invention provides a method for preparing a semiconductor assembly comprising attaching a flexible substrate to a rigid support with an adhesive layer, wherein the adhesive layer comprises a viscoelastic polymer having a glass transition temperature less than 180 0 C and a decomposition temperature greater than 220 0 C.
- the viscoelastic polymer comprises a polymer having a glass transition temperature ranging from about 25 to 180 0 C.
- the glass transition temperature ranges from about 50 to 180 0 C, or 100 to 180 0 C.
- the viscoelastic polymers of the present disclosure are stable under processing conditions exceeding 220 0 C.
- Preferred viscoelastic polymers are stable at temperatures ranging from about 220 to 400 0 C. In certain embodiments, the viscoelastic polymers are stable at temperatures ranging from about 220 to 300 0 C.
- the adhesive layer can have a coefficient of thermal expansion (CTE) greater than about 10 ppm/°C.
- CTE coefficient of thermal expansion
- the CTE of the adhesive can range from about
- the adhesive layer may also outgas at a rate less than about 2 x 10 "4 Torr- liter/second.
- the adhesive layer outgassing can range from about 1 x 10 "10 to 2 x 10 "4 Torr-liter/second.
- the viscoelastic polymer can comprise elastomeric, thermoplastic, or pseudothermoplastic saturated or unsaturated hydrocarbon, siloxane, or silicone polymers.
- the viscoelastic polymer comprises acrylics, epoxies, phenolics, urethanes polyimides, or siloxanes. More preferably, the viscoelastic polymer comprises /7-butylacrylate, polysiloxane, polysilicone or polyimide. In one embodiment, the viscoelastic polymer comprises n-butylacrylate. In one embodiment, the viscoelastic polymer comprises polysiloxane. In one embodiment, the viscoelastic polymer comprises polysilicone. In one embodiment, the viscoelastic polymer comprises polyimide.
- the adhesive layer can be deposited onto the rigid carrier or flexible substrate according to methods known to those skilled in the art.
- the adhesive layer can be deposited on the rigid carrier or flexible substrate using a solution of the adhesive material, and can be prepared according to any method known to those skilled in the art for preparing a layer from a solution.
- the solution can be spray coated, drop cast, spin coated, webcoated, doctor bladed, or dip coated to produce an adhesive layer on the rigid carrier or flexible substrate.
- the adhesive layer can be extrusion coated or pre-form laminated onto the rigid carrier or flexible substrate.
- the adhesive layer comprising the viscoelastic polymer is between about 1 ⁇ m and 40 ⁇ m thick, and more preferably between about 2 ⁇ m and 20 ⁇ m thick.
- the layer can be formed on the rigid carrier by spin coating a solution, i.e., by dispensing the solution on a surface of the rigid carrier and spinning the carrier to evenly distribute the solution.
- spin coating a solution, i.e., by dispensing the solution on a surface of the rigid carrier and spinning the carrier to evenly distribute the solution.
- the thickness of the layer, produced by spin coating can be controlled by selection of the concentration of the adhesive material in the solvent, the viscosity of the solution, the spinning rate, and the spinning speed.
- the solution layer can be dried, prior to bonding of the flexible substrate or rigid carrier, to essentially remove any remaining solvent.
- This drying can be according to any method known to those skilled in the art provided the method does not cause deterioration of the substrate, carrier, and/or adhesive material.
- the layer can be dried by heating the layer at a temperature in the range of approximately 80 0 C to 180 0 C, and preferably, about 100 0 C to 130 0 C.
- the layer can be dried by heating the layer in a vacuum at a temperature in the range of approximately 100 0 C to 180 0 C.
- the layer can be dried by heating the layer at a temperature in the range of approximately 80 0 C to 180 0 C, followed by heating the layer in a vacuum (e.g., less than about 1 Torr) at a temperature in the range of approximately 100 0 C to 180 0 C. In either heating process, the layer can be heated for about 10 to 120 minutes until substantially all the solvent is removed.
- a vacuum e.g., less than about 1 Torr
- higher temperatures e.g., up to 300 0 C
- the adhesive layer can be deposited onto the back side of flexible substrate, followed by an optional drying and/or vacuum drying process, as discussed previously.
- the layer is produced by spin coating of a solution of the adhesive followed by drying of the layer, as discussed previously.
- the rigid carrier can comprise a semiconductor wafer, alumina, a glass, or a material CTE matched to the flexible substrate, as described herein.
- the semiconductor wafer can comprise Si, and, in particular, Si(IOO) or Si(I I l).
- the rigid support comprises alumina.
- the rigid support comprises a material CTE matched to the flexible substrate.
- the flexible substrate can be a plastic substrate or metal substrate.
- Preferred plastic substrates include, but are not limited to, those substrates comprising polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyethersulfone (PES), polyimide, polycarbonate, cyclic olefin copolymer or mixtures thereof.
- Preferred metal substrates include, but are not limited to, those substrates comprising INVAR, KOVAR, titanium, tantalum, molybdenum, aluchrome, aluminum, or stainless steel.
- the flexible substrate comprises stainless steel.
- the rigid support comprises alumina.
- the flexible substrate can be bonded to the rigid support with the adhesive layer in between, according to any methods known to those skilled in the art.
- bonding the flexible substrate comprises heating the adhesive layer (either on the flexible substrate or the rigid carrier, supra) to a softened state, i.e., above the glass transition temperature (T g ) of the viscoelastic polymer, and contacting the flexible substrate with to the adhesive-coated carrier.
- T g glass transition temperature
- T g can be determined empirically based on the teachings herein, and depends upon the specific material used in adhesive layer.
- T g can be determined using techniques such as, but not limited to, thermogravimetric analysis (TGA), thermomechanical analysis (TMA), differential scanning calorimetry (DSC), and/or dynamic mechanical analysis (DMA).
- the flexible substrate comprises stainless steel, the rigid support comprises alumina, and the adhesive layer comprises n-butylacrylate. In another embodiment, the flexible substrate comprises stainless steel, the rigid support comprises alumina, and the adhesive layer comprises polysiloxane. In another embodiment, the flexible substrate comprises stainless steel, the rigid support comprises alumina, and the adhesive layer comprises polysilicone. In another embodiment, the flexible substrate comprises stainless steel, the rigid support comprises alumina, and the adhesive layer comprises polyimide.
- the adhesive layer may comprise more than one constituent layer.
- the adhesive layer can comprise a first layer comprising a viscoelastic polymer and a second layer formed over the viscoelastic polymer.
- the second layer can comprise a metal or insulating material layer.
- Preferred metals include, but are not limited to, metals which can be deposited by sputtering, for example, aluminum, gold, and silver.
- Preferred insulating layers include those which can be deposited by plasma enhanced chemical vapor deposition (PECVD), such as SiN and SiO 2 .
- PECVD plasma enhanced chemical vapor deposition
- Such metal films typically can have a thickness ranging from about 50 A to about 10,000 A. In certain embodiments, the thickness can range from about 100 A to about 5000 A, or about 500 A to about 5000 A, or about 1000 A to about 5000 A.
- the adhesive layer may comprise three or more constituent layers.
- the adhesive layer can comprise a first layer comprising a viscoelastic polymer, as discussed previously, a second layer formed over the viscoelastic polymer, such as a metal or insulating layer, and a third layer formed over the metal film.
- the third layer can comprise a double-sided adhesive tape.
- Preferred metals include, but are not limited to, metals which can be deposited by sputtering, for example, aluminum, gold, and silver.
- Preferred insulating layers include those which can be deposited by plasma enhanced chemical vapor deposition (PECVD), such as, SiN and SiO 2 .
- PECVD plasma enhanced chemical vapor deposition
- Such metal films typically can have a thickness ranging from about 50 A to about 10,000 A. In certain embodiments, the thickness can range from about 100 A to about 5000 A, or about 500 A to about 5000 A, or about 1000 A to about 5000 A.
- bonding the flexible substrate can comprise depositing a layer of a metal or insulating layer directly on the adhesive layer; positioning a double- sided adhesive directly on the metal or insulating layer; and positioning the substrate directly on the double-sided adhesive.
- Preferred metals include, but are not limited to, metals which can be deposited by sputtering, for example, aluminum, gold, and silver.
- Preferred insulating layers include those which can be deposited by plasma enhanced chemical vapor deposition (PECVD), such as, SiN and SiO 2 .
- Preferred double sided adhesives include, but are not limited to, double sided powder coated silicone adhesives (Argon PC500 family), or high performance silicone adhesives (Adhesive Research Arcare 7876) or similar.
- one or more of any of a number of electronic can be constructed on a surface of the flexible substrate.
- a display architecture can be formed on the flexible substrate attached to a rigid carrier according to the methods described herein.
- viscoelastic polymers serve to mediate stresses and/or strains introduced into a flexible substrate due to a CTE mismatch between the overlying flexible substrate and the underlying rigid support.
- the viscoelastic polymers utilized herein minimize warping and/or bowing of the flexible substrate as a result of the thermal stresses and/or strains introduced during, for example, semiconductor manufacturing processes.
- the bowing and/or warping of a flexible substrate when attached to a rigid support according to any of the preceding methods and embodiments, can be less than about 100 ⁇ m; preferably, the bowing and/or warping of a flexible substrate, when attached to a rigid support according to any of the preceding methods is less than about 75 ⁇ m; even more preferably, the bowing and/or warping of a flexible substrate, when attached to a rigid support according to any of the preceding methods is less than about 60 ⁇ m.
- exemplary carriers were bonded to one of 2 exemplary flexible substrates (PEN or stainless steel (SS)) of thickness as recited in Table 1, using exemplary pressure sensitive, adhesives, which include acrylates, polyacrylates, and silicones.
- the adhesives include spin-on adhesives and adhesive tapes.
- the resulting bow and flex data are provided in Table 1. This and similar data reveal that the smaller the CTE delta (difference) between carrier and flex material, the smaller the bow. Furthermore, the data demonstrate that viscoelastic adhesives reduce the amount of bow within a carrier/flex material system. For example, looking at the silicon/SS systems, ArClad (available from, for example, Adhesives Research, Glen Rocks, PA) has greater viscoelasticity than DCPC500 (available from, for example, ESD Tapes, Monrovia, CA), and yields less bow.
- ArClad available from, for example, Adhesives Research, Glen Rocks, PA
- DCPC500 available from, for example, ESD Tapes, Monrovia, CA
Landscapes
- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- General Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Ceramic Engineering (AREA)
- Computer Hardware Design (AREA)
- Physics & Mathematics (AREA)
- Thin Film Transistor (AREA)
- Laminated Bodies (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Devices For Indicating Variable Information By Combining Individual Elements (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Container, Conveyance, Adherence, Positioning, Of Wafer (AREA)
- Mechanical Treatment Of Semiconductor (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
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US12/921,896 US8685201B2 (en) | 2008-04-08 | 2009-04-06 | Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing |
EP20090729456 EP2274162A1 (en) | 2008-04-08 | 2009-04-06 | Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing |
KR1020107022405A KR101517263B1 (en) | 2008-04-08 | 2009-04-06 | Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing |
CN200980111340.9A CN101980861B (en) | 2008-04-08 | 2009-04-06 | Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing |
JP2011504098A JP5555226B2 (en) | 2008-04-08 | 2009-04-06 | Assembly and method for reducing warp and bow of a flexible substrate during semiconductor processing |
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US4322308P | 2008-04-08 | 2008-04-08 | |
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PCT/US2009/039577 WO2009126544A1 (en) | 2008-04-08 | 2009-04-06 | Assemblies and methods for reducing warp and bow of a flexible substrate during semiconductor processing |
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US (1) | US8685201B2 (en) |
EP (1) | EP2274162A1 (en) |
JP (1) | JP5555226B2 (en) |
KR (1) | KR101517263B1 (en) |
CN (1) | CN101980861B (en) |
SG (1) | SG188921A1 (en) |
TW (1) | TWI488750B (en) |
WO (1) | WO2009126544A1 (en) |
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Also Published As
Publication number | Publication date |
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EP2274162A1 (en) | 2011-01-19 |
CN101980861A (en) | 2011-02-23 |
JP5555226B2 (en) | 2014-07-23 |
KR101517263B1 (en) | 2015-04-30 |
US8685201B2 (en) | 2014-04-01 |
TWI488750B (en) | 2015-06-21 |
US20110064953A1 (en) | 2011-03-17 |
CN101980861B (en) | 2014-08-06 |
SG188921A1 (en) | 2013-04-30 |
KR20110053921A (en) | 2011-05-24 |
TW201004803A (en) | 2010-02-01 |
JP2011520248A (en) | 2011-07-14 |
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