WO2012071003A1 - Method for the wafer-level integration of shape memory alloy wires - Google Patents

Method for the wafer-level integration of shape memory alloy wires Download PDF

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Publication number
WO2012071003A1
WO2012071003A1 PCT/SE2011/051404 SE2011051404W WO2012071003A1 WO 2012071003 A1 WO2012071003 A1 WO 2012071003A1 SE 2011051404 W SE2011051404 W SE 2011051404W WO 2012071003 A1 WO2012071003 A1 WO 2012071003A1
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WO
WIPO (PCT)
Prior art keywords
wire
substrate
free air
trench
air ball
Prior art date
Application number
PCT/SE2011/051404
Other languages
French (fr)
Inventor
Stefan Braun
Frank Niklaus
Andreas Fischer
Henrik Gradin
Original Assignee
Senseair Ab
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 Senseair Ab filed Critical Senseair Ab
Priority to JP2013539798A priority Critical patent/JP2014502422A/en
Priority to CA2818301A priority patent/CA2818301A1/en
Priority to US13/885,257 priority patent/US9054224B2/en
Priority to CN201180066886.4A priority patent/CN103502138A/en
Priority to SG2013035308A priority patent/SG190201A1/en
Priority to EP11843548.6A priority patent/EP2643261A4/en
Priority to AU2011332334A priority patent/AU2011332334B2/en
Priority to KR1020137016114A priority patent/KR101856996B1/en
Publication of WO2012071003A1 publication Critical patent/WO2012071003A1/en

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    • B81—MICROSTRUCTURAL TECHNOLOGY
    • B81B—MICROSTRUCTURAL DEVICES OR SYSTEMS, e.g. MICROMECHANICAL DEVICES
    • B81B3/00—Devices comprising flexible or deformable elements, e.g. comprising elastic tongues or membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/002—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating specially adapted for particular articles or work
    • B23K20/004—Wire welding
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Definitions

  • the wire is fed through the bond-capillary of a wire bonder.
  • the tip of the wire must be fixated on the substrate.
  • the tip of the wire is deformed, so that the diameter of the wire-tip is larger than the diameter of the remaining wire and the bond capillary. This allows to hook-in the wire tip or to squeeze the wire into squeeze-fit structures in the substrate.
  • Fel! Hittar inte referenshimlla. illustrates one concept shown already in the background paragraphs.
  • a hook-in structure is formed in the substrate (Fell Hittar inte referenshimlla.a), then the Free Air Ball is formed (Fel! Hittar inte referenshimlla.b), which is hooked into the structure in the substrate (Fel! Hittar inte referenshimlla.c) and allows to pull the SMA wire through the bond capillary (Fel! Hittar inte referenshimlla.d).
  • FIG. 2 Another concept is the anchoring using squeeze fit of the Free Air Ball into squeeze-fit structure on the substrate, as schematically illustrated in Figure 2.
  • the SMA wire (201) is fed through the bond capillary (202) and a Free Air Ball (203) is formed.
  • a trench (205) is formed with the diameter smaller than the diameter of the Free Air Ball ( Figure 2a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate ( Figure 2b).
  • the tip of the SMA wire is anchored by the squeeze fit of the Free Air Ball into the trench of the substrate ( Figure 2c).
  • the same concept is suitable for squeeze-fit of the Free Air Ball into a V formed trench as for example obtained when etching a silicon substrate with special processes.
  • the SMA wire (301) is fed through the bond capillary (302) and a Free Air Ball (303) is formed.
  • a V shaped trench (305) is formed ( Figure 3a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate ( Figure 3b).
  • the tip of the SMA wire is anchored by the squeeze fit of the Free Air Ball into the trench of the substrate ( Figure 3c).
  • Figure 4 schematically illustrates a further variation of the squeeze-fit concept, where deformable clamping structures are formed in the substrate which allow for variations in the SMA wire diameter.
  • the SMA wire (401) is fed through the bond capillary (402) and a Free Air Bail (403) is formed.
  • deformable clamp structures (405) are formed ( Figure 4a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the deformable structures in the substrate ( Figure 4b).
  • the clamp structures elastically deform during the squeeze of the Free Air Ball (Figure 4b) and thereby adapt to diameter variations of the SMA wire and hold them in place (Figure 4c).
  • FIGs 5 to 7 schematically illustrates the concept.
  • the SMA wire (501, 601, 701) is fed through the bond capillary (502, 602, 702) and a Free Air Ball (503, 603, 703) is formed.
  • a Free Air Ball (503, 603, 703) is formed on the substrate (504, 604, 704) trenches (505. 605) or deformable clamp structures (705) are formed.
  • a metal film (506, 606, 706) is deposited onto the substrate ( Figures 5a, 6a, 7a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate ( Figures 5b,6b, 7b).
  • the native oxide on the SMA is broken up and the SMA is in direct contact with the metal on the substrate. Thereby, the SMA can be electrically contacted (507, 607, 707) via the metal film ( Figure 5c, 6c, 7c).
  • the trenches in the substrate can be filled with adhesive to adhesively anchor the Free Air Ball and the wire in the trenches.
  • Figures 8 and 9 schematically illustrate this concept with Figure 8 for straight trenches similar to Figure 2 and Figure 9 for V-shaped trenches similar to Figure 3.
  • the SMA wire (801, 901) is fed through the bond capillary (802, 902) and a Free Air Ball (803, 903) is formed.
  • the substrate (804, 904) straight (805) or V-shaped trenches (905) are formed, which are then partially filled with adhesive (806, 906) ( Figures 8a, 9a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the adhesive in the trenches in the substrate ( Figures 8b, 9b).
  • the Free Air Ball is embedded in adhesive, which is cured (807, 907) and thereby anchors the Free Air Ball ( Figures 8c, 9c).
  • FIG 10 schematically illustrates this concept.
  • the SMA wire (1001) is fed through the bond capillary (1002) and a Free Air Ball (1003) is formed.
  • a trench (1005) is formed and on top of the substrate a thinner layer is formed (1006) which partially covers the trench (1005) but has an opening in the center of the trench, thereby creating snap-in structures (1007) ( Figure 10a).
  • the diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to push the Free Air Ball through the opening of the top layer (1005) into the trench in the substrate ( Figure 10b).
  • the top layer snaps back (1007) and holds the Free Air Ball in place (Figure 10c).
  • FIG. 10 A variation of the concept schematically illustrated in Figure 10 is to provide a spring in the trench which presses the Free Air Ball against the snap structures in the top layer.
  • Figure 11 schematically illustrates the concept
  • the SMA wire (1001) is fed through the bond capillary (1002) and a Free Air Ball (1003) is formed.
  • a trench (1005) is formed and on top of the substrate a thinner layer is formed (1006) which partially covers the trench (1005) but has an opening in the center of the trench, thereby creating snap-in structures (1007) ( Figure 11a).
  • a layer (1108) is formed which is elastically deformable.
  • Figures 12 to 14 schematically illustrate the squeeze fit schemes adapted for squeeze fitting of SMA wires.
  • the SMA wire (1201, 1301, 1401) is placed above the trench (1202, 1302, 1402) which is formed in the substrate (1203, 1303, 1403) with the diameter smaller than the diameter of the SMA wire ( Figures 12a, 13a, 14a).
  • Figure 12 and 13 illustrate squeeze fitting with straight and V- shaped trenches, respectively.
  • Figure 14 is based on the concept shown in Figure 4 and features deformable clamping structures (1405) in the substrate which allow for variations in the SMA wire diameter.
  • the wire is squeezed into the trenches and/or deformable clamping structures using a piston (1204, 1304, 1404), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder ( Figure 12b, 13b, 14b).
  • the piston is then removed and the wire remains in the trench ( Figure 12c, 13c, 14c) following the same principles as in the concepts shown in Figures 2,3,4.
  • Figures 12 to 14 are adaptable to enable electrical contacting of the SMA wire at the same time as the mechanical fixation is performed. This allows for a simple contacting and Joule heating of the SMA wire above the conversion temperature.
  • Figures 15 to 17 schematically illustrate the concept.
  • the SMA wire (1501, 1601, 1701) is placed above the trench (1502, 1602, 1702) which is formed in the substrate (1503, 1603, 1703) and covered with a metal liner (1504, 1604, 1704).
  • the trench diameter is smaller than the diameter of the SMA wire ( Figures 15a, 16a, 17a).
  • Figure 15 and 16 illustrate squeeze fitting with straight and V-shaped trenches, respectively.
  • Figure 17 is based on the concept shown in Figures 4 andl4 and features deformable clamping structures (1707) in the substrate which allow for variations in the SMA wire diameter.
  • the wire is squeezed into the trenches and/or deformable clamping structures using a piston (1505, 1605, 1705), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder ( Figure 15b, 16b, 17b).
  • a piston 1505, 1605, 1705
  • Figure 15b, 16b, 17b a second substrate which is pressed onto the wire and the second substrate in a wafer bonder
  • the native oxide on the SMA is broken up and the SMA is in direct contact with the metal on the substrate.
  • the SMA can be electrically contacted (1506, 1606, 1706) via the metal film ( Figure 15c, 16c, 17c).
  • the trenches in the substrate can be filled with adhesive to adhesively anchor the wire in the trenches.
  • Figures 19 and 20 schematically illustrate this concept with Figure 19 for straight trenches and Figure 20 for V-shaped trenches.
  • the SMA wire (1901, 2001) is placed above the trench/groove (1902, 2002) which is formed in the substrate (1903, 2003) and partially filled with adhesive (1904, 2004) ( Figures 19a, 20a).
  • the wire is squeezed into the adhesive in the trenches using a piston (1905, 2005), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder ( Figures 19b, 20b).
  • Figures 19 and 20 can be combined with adhesive wafer bonding to support the clamping of the wire.
  • Figure 21 illustrates the concept, which is similar for both straight and V-shaped trenches.
  • the SMA wire (2101) is placed above the trench/groove (2102, 2103) which is formed in the substrate (2104) and partially filled with adhesive (2104).
  • the wire is squeezed into the adhesive in the trenches using a second substrate (2105) which is covered with adhesive (2106) and pressed onto the wire and the first substrate (2103), Then, all the adhesive is cured and the wire is anchored both by the adhesive and the second substrate on top.
  • Figure 22 illustrates the concept.
  • the wire (2201) is placed above the metal lined (2202) trench (2203) in the first substrate (2204).
  • the wire is squeezed into the metal lined trenches using a second substrate (2205) which is covered with metal (2206) and pressed onto the wire and the first substrate (2204).
  • the second substrate is bonded with its metal to the metal on the first substrate.
  • the SMA can be electrically contacted via the metal film and the clamping is supported by the bonded second substrate.
  • a snap-in structure can be fabricated to snap the wire in to.
  • Figure 23 schematically illustrates this concept.
  • a trench (2302) is formed and on top of the substrate a thinner layer is formed (2303) which partially covers the trench but has an opening in the center of the trench, thereby creating snap-in structures (2304).
  • the SMA wire (2305) is placed above the snap-in structures ( Figure 23a).
  • the wire is squeezed through the opening of the top layer into the trench in the substrate using a piston (2306), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder ( Figure 23b).
  • the top layer snaps back (2307) and holds the wire in place (Figure 23c).
  • FIG. 24 schematically illustrates the concept.
  • a trench (2302) is formed and on top of the substrate a thinner layer is formed (2403) which partially covers the trench but has an opening in the center of the trench, thereby creating snap-in structures (2404).
  • a layer (2405) is formed which is elasticaUy deformable ( Figure 24a).
  • the wire compresses the deformable layer (2408) ( Figure 22b).
  • the elasticaUy deformed layer presses the wire into the snap-in structures, which are strong enough to withstand the forces generated by the elasticaUy deformed layer ( Figure 24c).
  • Figures 25 and 26 show process schemes for the integration of SMA wires using a wire-bonder.
  • the flow in Figure 25 illustrates a process where the first fixation is provided by anchoring the Free Air Ball. Then, all the following fixations required are performed by clamping the wire with the wire-bonder into clamping structures. After the last clamping structure in one line, the wire is cut off by a high energy wedge/stitch bond onto the substrate surface. If necessary, these steps can be repeated to integrate more wires. If not, the wire is integrated and can be further processed.
  • the flow in Figure 26 illustrates a process where the first fixation is provided by anchoring the Free Air Ball. Then, the wire is spanned over all the clamping structures in the line and finally the wire is cut off by a high energy wedge/stitch bond onto the substrate surface. If necessary, these steps can be repeated to place more wires. If all wires are in place, they are squeezed into the underlying clamping structures using a piston, if the clamping is strong enough, the substrate can be further processed. If not, additional ball bonds can be placed on the wire in the clamp structures or during the squeezing a second substrate can be bonded onto the wires and the first substrate.

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Abstract

The present invention relates to a method to attach a shape memory alloy wire to a substrate, where the wire is mechanically attached into a 3D structure on the substrate. The present invention also relates to a device comprising a shape memory alloy wire attached to a substrate, where the wire is mechanically attached into a 3D structure on the substrate.

Description

Technical Background and general description
Please see the proceedings in the attachment.
Technical details
The descriptions on page 2 to 5 explained the backround and the core concept of the method. On the following pages, different embodiments are shown for mechanical fixation as well as for the electrical connection of the Shape Memory Alloy wire.
Fixation of the Free Air Bail
The wire is fed through the bond-capillary of a wire bonder. To allow the pulling of the wire, the tip of the wire must be fixated on the substrate. In this concept, the tip of the wire is deformed, so that the diameter of the wire-tip is larger than the diameter of the remaining wire and the bond capillary. This allows to hook-in the wire tip or to squeeze the wire into squeeze-fit structures in the substrate.
Fel! Hittar inte referenskälla. illustrates one concept shown already in the background paragraphs. A hook-in structure is formed in the substrate (Fell Hittar inte referenskälla.a), then the Free Air Ball is formed (Fel! Hittar inte referenskälla.b), which is hooked into the structure in the substrate (Fel! Hittar inte referenskälla.c) and allows to pull the SMA wire through the bond capillary (Fel! Hittar inte referenskälla.d).
Another concept is the anchoring using squeeze fit of the Free Air Ball into squeeze-fit structure on the substrate, as schematically illustrated in Figure 2. The SMA wire (201) is fed through the bond capillary (202) and a Free Air Ball (203) is formed. In the substrate (204), a trench (205) is formed with the diameter smaller than the diameter of the Free Air Ball (Figure 2a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate (Figure 2b). The tip of the SMA wire is anchored by the squeeze fit of the Free Air Ball into the trench of the substrate (Figure 2c).
As schematically illustrated in Figure 3, the same concept is suitable for squeeze-fit of the Free Air Ball into a V formed trench as for example obtained when etching a silicon substrate with special processes. The SMA wire (301) is fed through the bond capillary (302) and a Free Air Ball (303) is formed. In the substrate (304), a V shaped trench (305) is formed (Figure 3a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate (Figure 3b). The tip of the SMA wire is anchored by the squeeze fit of the Free Air Ball into the trench of the substrate (Figure 3c).
Figure 4 schematically illustrates a further variation of the squeeze-fit concept, where deformable clamping structures are formed in the substrate which allow for variations in the SMA wire diameter. The SMA wire (401) is fed through the bond capillary (402) and a Free Air Bail (403) is formed. In the substrate (404), deformable clamp structures (405) are formed (Figure 4a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the deformable structures in the substrate (Figure 4b). The clamp structures elastically deform during the squeeze of the Free Air Ball (Figure 4b) and thereby adapt to diameter variations of the SMA wire and hold them in place (Figure 4c).
All the above described concepts schematically illustrated in Figures 2 to 4 are adaptable to enable electrical contacting of the SMA wire at the same time as the mechanical fixation is performed. This allows for a simple contacting and Joule heating of the SMA wire above the conversion temperature. Figures 5 to 7 schematically illustrates the concept. The SMA wire (501, 601, 701) is fed through the bond capillary (502, 602, 702) and a Free Air Ball (503, 603, 703) is formed. On the substrate (504, 604, 704) trenches (505. 605) or deformable clamp structures (705) are formed. Finally, a metal film (506, 606, 706) is deposited onto the substrate (Figures 5a, 6a, 7a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the trench in the substrate (Figures 5b,6b, 7b). During the squeezing, the native oxide on the SMA is broken up and the SMA is in direct contact with the metal on the substrate. Thereby, the SMA can be electrically contacted (507, 607, 707) via the metal film (Figure 5c, 6c, 7c).
Instead of using squeeze-fits with and/or without metal liner as illustrated in Figures 2 to 7, the trenches in the substrate can be filled with adhesive to adhesively anchor the Free Air Ball and the wire in the trenches. Figures 8 and 9 schematically illustrate this concept with Figure 8 for straight trenches similar to Figure 2 and Figure 9 for V-shaped trenches similar to Figure 3. The SMA wire (801, 901) is fed through the bond capillary (802, 902) and a Free Air Ball (803, 903) is formed. In the substrate (804, 904), straight (805) or V-shaped trenches (905) are formed, which are then partially filled with adhesive (806, 906) (Figures 8a, 9a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to squeeze the Free Air Ball into the adhesive in the trenches in the substrate (Figures 8b, 9b). The Free Air Ball is embedded in adhesive, which is cured (807, 907) and thereby anchors the Free Air Ball (Figures 8c, 9c).
Besides squeeze fit and adhesive anchoring, a snap-in structure can be fabricated to snap the Free Air Ball in to. Figure 10 schematically illustrates this concept. The SMA wire (1001) is fed through the bond capillary (1002) and a Free Air Ball (1003) is formed. In the substrate (1004), a trench (1005) is formed and on top of the substrate a thinner layer is formed (1006) which partially covers the trench (1005) but has an opening in the center of the trench, thereby creating snap-in structures (1007) (Figure 10a). The diameter of the Free Air Ball is larger than the diameter of the bond capillary, which allows to push the Free Air Ball through the opening of the top layer (1005) into the trench in the substrate (Figure 10b). The top layer snaps back (1007) and holds the Free Air Ball in place (Figure 10c).
A variation of the concept schematically illustrated in Figure 10 is to provide a spring in the trench which presses the Free Air Ball against the snap structures in the top layer. Figure 11 schematically illustrates the concept The SMA wire (1001) is fed through the bond capillary (1002) and a Free Air Ball (1003) is formed. In the substrate (1004), a trench (1005) is formed and on top of the substrate a thinner layer is formed (1006) which partially covers the trench (1005) but has an opening in the center of the trench, thereby creating snap-in structures (1007) (Figure 11a). In the bottom of the trench (1005) a layer (1108) is formed which is elastically deformable. After squeezing the Free Air Ball through the snap-in structures, the Free Air Ball compresses the deformable layer (1108) (Figure lib). When removing the bond capillary, the elastically deformed layer presses the Free Air Ball into the snap-in structures, which are strong enough to withstand the forces generated by the elastically deformed layer (Figure 1 1 c).
Fixation of the wire After fixing the tip of the wire with, the Free Air Ball, the wire is pulled through the bond capillary and spanned across the substrate to the next clamp structure. In this clamp structure, the wire is clamped and therefore all the concepts shown in Figures 2 to 11 are adaptable.
Figures 12 to 14 schematically illustrate the squeeze fit schemes adapted for squeeze fitting of SMA wires. Using the wire-bonder, the SMA wire (1201, 1301, 1401) is placed above the trench (1202, 1302, 1402) which is formed in the substrate (1203, 1303, 1403) with the diameter smaller than the diameter of the SMA wire (Figures 12a, 13a, 14a). Figure 12 and 13 illustrate squeeze fitting with straight and V- shaped trenches, respectively. Figure 14 is based on the concept shown in Figure 4 and features deformable clamping structures (1405) in the substrate which allow for variations in the SMA wire diameter. The wire is squeezed into the trenches and/or deformable clamping structures using a piston (1204, 1304, 1404), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder (Figure 12b, 13b, 14b). The piston is then removed and the wire remains in the trench (Figure 12c, 13c, 14c) following the same principles as in the concepts shown in Figures 2,3,4.
The concepts schematically illustrated in Figures 12 to 14 are adaptable to enable electrical contacting of the SMA wire at the same time as the mechanical fixation is performed. This allows for a simple contacting and Joule heating of the SMA wire above the conversion temperature. Figures 15 to 17 schematically illustrate the concept. The SMA wire (1501, 1601, 1701) is placed above the trench (1502, 1602, 1702) which is formed in the substrate (1503, 1603, 1703) and covered with a metal liner (1504, 1604, 1704). The trench diameter is smaller than the diameter of the SMA wire (Figures 15a, 16a, 17a). Figure 15 and 16 illustrate squeeze fitting with straight and V-shaped trenches, respectively. Figure 17 is based on the concept shown in Figures 4 andl4 and features deformable clamping structures (1707) in the substrate which allow for variations in the SMA wire diameter. The wire is squeezed into the trenches and/or deformable clamping structures using a piston (1505, 1605, 1705), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder (Figure 15b, 16b, 17b). During the squeezing, the native oxide on the SMA is broken up and the SMA is in direct contact with the metal on the substrate. Thereby, the SMA can be electrically contacted (1506, 1606, 1706) via the metal film (Figure 15c, 16c, 17c).
The concept with metal liners on the clamp structures shown in Figures 15 to 17 can be enhanced with ball bonds as illustrated in Figure 18. Onto the metal on the final structures of Figures 15 to 17, several Free Air Balls are bonded to mechanically support the clamping of the wires into the clamp structures. The SMA wire (1801) is fed through the bond capillary (1802) and a Free Air Ball (1803) is formed (Figure 18 a,b,c left). The Free Air Ball is bonded onto the clamped wire (1804) and the adjoining metal liner (1805) on the substrate (1806) (Figure 18b). Then, the wire is cut using a high bond energy (1807) (Figure 18c).
Similar to the concepts illustrated in Figures 8 to 9 the trenches in the substrate can be filled with adhesive to adhesively anchor the wire in the trenches. Figures 19 and 20 schematically illustrate this concept with Figure 19 for straight trenches and Figure 20 for V-shaped trenches. The SMA wire (1901, 2001) is placed above the trench/groove (1902, 2002) which is formed in the substrate (1903, 2003) and partially filled with adhesive (1904, 2004) (Figures 19a, 20a). The wire is squeezed into the adhesive in the trenches using a piston (1905, 2005), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder (Figures 19b, 20b). Then the wire is embedded in adhesive, which is cured (1906, 2006) and thereby anchors the wire (Figures 19c, 20c). The adhesive anchoring concept illustrated in Figures 19 and 20 can be combined with adhesive wafer bonding to support the clamping of the wire. Figure 21 illustrates the concept, which is similar for both straight and V-shaped trenches. The SMA wire (2101) is placed above the trench/groove (2102, 2103) which is formed in the substrate (2104) and partially filled with adhesive (2104). The wire is squeezed into the adhesive in the trenches using a second substrate (2105) which is covered with adhesive (2106) and pressed onto the wire and the first substrate (2103), Then, all the adhesive is cured and the wire is anchored both by the adhesive and the second substrate on top. Such an approach is feasible also for the squeeze-fit with metal lined clamp structures. Figure 22 illustrates the concept. The wire (2201) is placed above the metal lined (2202) trench (2203) in the first substrate (2204). The wire is squeezed into the metal lined trenches using a second substrate (2205) which is covered with metal (2206) and pressed onto the wire and the first substrate (2204). Then, the second substrate is bonded with its metal to the metal on the first substrate. Thereby, the SMA can be electrically contacted via the metal film and the clamping is supported by the bonded second substrate.
Similar to the concepts illustrated in Figures 10 and 11, a snap-in structure can be fabricated to snap the wire in to. Figure 23 schematically illustrates this concept. In the substrate (2301), a trench (2302) is formed and on top of the substrate a thinner layer is formed (2303) which partially covers the trench but has an opening in the center of the trench, thereby creating snap-in structures (2304). The SMA wire (2305) is placed above the snap-in structures (Figure 23a). The wire is squeezed through the opening of the top layer into the trench in the substrate using a piston (2306), which for example could be a second substrate which is pressed onto the wire and the second substrate in a wafer bonder (Figure 23b). The top layer snaps back (2307) and holds the wire in place (Figure 23c).
A variation of the concept schematically illustrated in Figure 23 is to provide a spring in the trench which presses the wire against the snap structures in the top layer. Figure 24 schematically illustrates the concept. In the substrate (2401), a trench (2302) is formed and on top of the substrate a thinner layer is formed (2403) which partially covers the trench but has an opening in the center of the trench, thereby creating snap-in structures (2404). In the bottom of the trench a layer (2405) is formed which is elasticaUy deformable (Figure 24a). After squeezing the wire (2406) with the piston (2407) through the snap-in structures, the wire compresses the deformable layer (2408) (Figure 22b). When removing the piston, the elasticaUy deformed layer presses the wire into the snap-in structures, which are strong enough to withstand the forces generated by the elasticaUy deformed layer (Figure 24c).
Process schemes
Figures 25 and 26 show process schemes for the integration of SMA wires using a wire-bonder. The flow in Figure 25 illustrates a process where the first fixation is provided by anchoring the Free Air Ball. Then, all the following fixations required are performed by clamping the wire with the wire-bonder into clamping structures. After the last clamping structure in one line, the wire is cut off by a high energy wedge/stitch bond onto the substrate surface. If necessary, these steps can be repeated to integrate more wires. If not, the wire is integrated and can be further processed.
The flow in Figure 26 illustrates a process where the first fixation is provided by anchoring the Free Air Ball. Then, the wire is spanned over all the clamping structures in the line and finally the wire is cut off by a high energy wedge/stitch bond onto the substrate surface. If necessary, these steps can be repeated to place more wires. If all wires are in place, they are squeezed into the underlying clamping structures using a piston, if the clamping is strong enough, the substrate can be further processed. If not, additional ball bonds can be placed on the wire in the clamp structures or during the squeezing a second substrate can be bonded onto the wires and the first substrate.
Figure imgf000007_0001
Figure imgf000008_0001
Figure imgf000009_0001
Figure imgf000010_0001

Claims

Claims
1. Method to attach a wire to a substrate, characterized in that said wire is mechanically attached into a 3D structures on said substrate.
2. Device comprising a wire attached to a substrate, characterized in that said wire is mechanically attached into a 3D structure on said substrate.
PCT/SE2011/051404 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires WO2012071003A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
JP2013539798A JP2014502422A (en) 2010-11-22 2011-11-22 Method of incorporating shape memory alloy wire at wafer level
CA2818301A CA2818301A1 (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
US13/885,257 US9054224B2 (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
CN201180066886.4A CN103502138A (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
SG2013035308A SG190201A1 (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
EP11843548.6A EP2643261A4 (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
AU2011332334A AU2011332334B2 (en) 2010-11-22 2011-11-22 Method for the wafer-level integration of shape memory alloy wires
KR1020137016114A KR101856996B1 (en) 2010-11-22 2011-11-22 Method for the wafer integration of shape memory alloy wires

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