WO2019095659A1 - 微元件的巨量转移方法 - Google Patents
微元件的巨量转移方法 Download PDFInfo
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- WO2019095659A1 WO2019095659A1 PCT/CN2018/087801 CN2018087801W WO2019095659A1 WO 2019095659 A1 WO2019095659 A1 WO 2019095659A1 CN 2018087801 W CN2018087801 W CN 2018087801W WO 2019095659 A1 WO2019095659 A1 WO 2019095659A1
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- 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
- H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
- H01L21/52—Mounting semiconductor bodies in containers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/16—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits
- H01L25/167—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits comprising optoelectronic devices, e.g. LED, photodiodes
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- H—ELECTRICITY
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- 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
- H01L21/68—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 positioning, orientation or alignment
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- 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
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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- H01L33/005—Processes
- H01L33/0093—Wafer bonding; Removal of the growth substrate
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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- H01L33/005—Processes
- H01L33/0095—Post-treatment of devices, e.g. annealing, recrystallisation or short-circuit elimination
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- H—ELECTRICITY
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- H01L2221/67—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
- H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
- H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
- H01L2221/68368—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used in a transfer process involving at least two transfer steps, i.e. including an intermediate handle substrate
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- H01L2221/683—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
- H01L2221/68304—Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
- H01L2221/68381—Details of chemical or physical process used for separating the auxiliary support from a device or wafer
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- H—ELECTRICITY
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Definitions
- the invention belongs to the field of semiconductor manufacturing, and in particular relates to a method for transferring a large amount of micro components.
- Micro-element technology refers to an array of tiny-sized components that are integrated at a high density on a substrate.
- micro-light-emitting diode (Micro LED) technology has gradually become a hot research topic, and the industry expects high-quality micro-component products to enter the market.
- High-quality micro-pitch LED products can have a profound impact on traditional display products such as LCD/OLED that are already on the market.
- the micro-element is first formed on the donor package substrate, and then the micro-element is transferred onto the receiving package substrate.
- the receiving package substrate is, for example, a display screen.
- One difficulty in the fabrication of microcomponents is how to transfer the microcomponents from the donor package substrate to the receiving package substrate.
- a conventional method of transferring a micro-element is to transfer the micro-element from the transfer package substrate to the receiving package substrate by Wafer Bonding.
- One of the implementation methods of the transfer method is direct transfer, that is, the micro-element array is directly bonded from the transfer package substrate to the receiving package substrate, and then the transfer package substrate is removed by stripping or etching, and the transfer is often sacrificed to eliminate excess epitaxy.
- Another method of implementation is indirect transfer. First, the transfer medium extracts the array of microelements, then transfers the medium and then bonds the array of microelements to the receiving package substrate, and then removes the transfer medium. Transfer media requires high temperature resistance.
- micro-component transfer includes Van der Waals force, electrostatic adsorption, phase change transfer and laser ablation.
- van der Waals force, electrostatic adsorption and laser ablation are the development direction of many manufacturers.
- various transfer methods have their own advantages and disadvantages.
- some highly elastic and easy-to-process polymers are often used, and these polymers can be solidified at room temperature after spin coating.
- the polymer material is poured into the mold, the mold is solidified, the transfer micro-column is formed, and the micro-component is grasped by the alignment of the column, and the micro-column is crushed by mechanical force after the transfer, however, this method
- the process is more complicated, and more importantly, when micro-pillars are used to grasp micro-components, precise alignment is required, which tends to cause a drop in product yield.
- an object of the present invention is to provide a method for transferring a large amount of micro-components, which is used to solve the problem that the micro-component transfer process in the prior art is complicated and the yield is low.
- the present invention provides a method for transferring a large amount of micro-components, the method comprising: 1) providing a substrate, forming a photosensitive material layer on the surface of the substrate, and at first The photosensitive material layer is subjected to a semi-curing treatment at a temperature, wherein the first temperature is lower than a full curing temperature of the photosensitive material layer to ensure that the photosensitive material layer has viscosity; 2) providing an array of micro-components, An array of the micro-components is captured on a surface of the photosensitive material layer based on surface tack of the photosensitive material layer; 3) self-aligning exposure of the photosensitive material layer with the micro-component as a photomask Processing and development processing, the photosensitive material layer is divided into a plurality of support structures corresponding to the micro-components, the support structure comprising a first support portion bonded to the micro-component and connecting the first support portion a second support portion of the substrate, and a radi
- the first support portion after the development process has a trapezoidal structure to increase the first support portion and the micro-component Bonding area
- the second support portion has a micro-cylinder structure to facilitate separation of the micro-component from the substrate.
- the radial width of the micro-cylinder structure is not greater than the radial width of the top surface of the trapezoidal structure, and the radial width of the micro-cylinder structure is not less than the minimum width required to stably support the micro-element .
- the self-aligned exposure process includes an ultraviolet exposure process, and the light of the self-aligned exposure process is incident perpendicular to a surface of the micro-element such that the second support portion is connected to the first A central region of a support to avoid deflection of the position of the microcomponent.
- the photosensitive material layer comprises a photosensitive polymethyl methacrylate (PMMA) or a photopolymer such as polydimethylsiloxane (PDMS) or polyimide (PI), and the complete curing temperature is between Between 150 ° C and 250 ° C, the first temperature is between 60 ° C and 140 ° C to ensure that the photosensitive material layer is sticky.
- PMMA photosensitive polymethyl methacrylate
- PDMS polydimethylsiloxane
- PI polyimide
- the array of microelements is of a suspended structure such that it is easily grasped by the adhesive surface of the layer of photosensitive material.
- the floating structure includes: a support layer; a plurality of stabilizing columns on the surface of the support layer; and an array of microelements, each micro-element in the array being supported by a plurality of the stabilizing columns.
- step 2) grasping the array of microcomponents on the surface of the photosensitive material layer, further comprising the step of further curing the photosensitive material layer to increase the microcomponent and the photosensitive material layer Adhesion.
- the eutectic metal comprises one of the group consisting of AgSnCu, In and BiSn alloys, the temperature of the eutectic treatment is not higher than 300 ° C, and the eutectic treatment time Not more than 1 min to maintain the stability of the support structure during the eutectic treatment.
- step 5 an oblique mechanical pressure is applied to the substrate to break the second support portion to separate the micro-component from the substrate.
- the substrate comprises one of a group consisting of a glass substrate, a ceramic substrate, a polymer substrate, a silicon substrate, and a sapphire substrate.
- the array of microelements comprises a micro-pitch LED array.
- the giant amount transfer method of the micro-component of the present invention has the following beneficial effects:
- the invention adopts the whole surface photosensitive material to grasp the micro component, and can avoid the problem that the micro component capture precision is insufficient;
- the invention utilizes the micro-component as a lithography mask, and forms the photosensitive material into a trapezoidal structure and supports the micro-column, which is beneficial to the stability of the micro-component and the ease of subsequent separation;
- the invention only needs to use mechanical force to break the supporting microcolumn to realize the huge transfer of the micro components, and the process is simple, and the process cost can be effectively reduced.
- the overall process of the invention is simple, can effectively improve the transfer yield of the micro component, and has broad application prospects in the field of semiconductor manufacturing.
- Fig. 1 is a flow chart showing the steps of the method for transferring a large amount of microcomponents of the present invention.
- FIGS. 2 to 10 are views showing the structure of each step of the method for transferring a large amount of microcomponents of the present invention.
- the embodiment provides a method for transferring a large amount of micro components, and the method for transferring a massive amount includes the following steps:
- steps 1) to S11 are performed to provide a substrate 101, a photosensitive material layer 102 is formed on the surface of the substrate 101, and the photosensitive material layer 102 is semi-cured at a first temperature.
- the first temperature is lower than a full curing temperature of the photosensitive material layer 102 to ensure that the photosensitive material layer 102 has a viscosity.
- the substrate 101 comprises one of a group consisting of a glass substrate, a ceramic substrate, a polymer substrate, a silicon substrate, and a sapphire substrate.
- the substrate 101 is selected as a glass substrate, and the glass substrate and the photosensitive material layer 102 have good adhesion properties, can avoid cracking caused by subsequent processes, and compared to a sapphire substrate and a silicon substrate. Etc., the choice of glass substrate can effectively reduce the process cost.
- a polymer substrate having a lower light reflectivity can also be selected, based on its lower light reflectivity, which can effectively reduce the reflection of light on the substrate during exposure, thereby avoiding unnecessary light transmission to the photosensitive material layer 102.
- the joint reaction allows the subsequent support structure 106 to maintain a good topography.
- the photosensitive material layer 102 comprises a photosensitive polymer such as photosensitive polymethyl methacrylate (PMMA), polydimethylsiloxane (PDMS) or polyimide (PI), the photosensitive material layer
- PMMA photosensitive polymethyl methacrylate
- PDMS polydimethylsiloxane
- PI polyimide
- the first temperature used for the semi-curing may be selected to be between 60 ° C and 140 ° C, such as 60 ° C, 80 ° C, 100 ° C, 120 ° C, and the like. To ensure that the photosensitive material layer is sticky.
- steps 2) S12 are then performed to provide an array of micro-elements 103, which are captured based on the surface tack of the photosensitive material layer 102.
- the surface of the photosensitive material layer 102 is then performed to provide an array of micro-elements 103, which are captured based on the surface tack of the photosensitive material layer 102.
- the array of microelements 103 comprises a micro-pitch LED array.
- other micro-elements 103 such as photodetection diode (PDA) arrays, MOS devices, MEMS devices, etc., can also be transferred using the transfer method of the present embodiment, and are not limited to the examples listed herein.
- PDA photodetection diode
- MOS devices MOS devices
- MEMS devices etc.
- the array of microelements 103 employs a floating structure to be easily grasped by the adhesive surface of the photosensitive material layer 102.
- the floating structure includes: a support layer 104; a plurality of stabilizing pillars 105 on the surface of the support layer 104; and an array of microelements 103, each of the microelements 103 in the array by a plurality of The stabilizing column 105 is supported.
- the stabilizing column 105 can ensure that the micro-element 103 can be stably supported, the area of the stabilizing post 105 is designed to be as small as possible, so that the micro-element 103 can be easily used by the photosensitive material layer. 102 crawling.
- a step of further curing the photosensitive material layer 102 is further included to increase the micro-elements 103 and the photosensitive material.
- the adhesion of layer 102 is further included.
- the invention adopts the whole surface photosensitive material to grasp the micro-element 103, and can avoid the problem that the micro-element 103 captures insufficient alignment precision.
- step 3 S13 is followed, and the micro-element 103 is used as a photomask, and the photosensitive material layer 102 is subjected to self-aligned exposure processing and development processing to make the
- the photosensitive material layer 102 is divided into a plurality of support structures 106 corresponding to the micro-element 103, the support structure 106 includes a first support portion 108 bonded to the micro-element 103 and connected to the first support portion 108 and The second support portion 107 of the substrate 101 has a radial width smaller than a radial width of the first support portion 108.
- the first support portion 108 after the development process has a trapezoidal structure to increase the adhesion of the first support portion 108 to the micro-element 103.
- the area is such that the second support portion 107 has a micro-cylinder structure to facilitate separation of the micro-element 103 from the substrate 101.
- the radial width of the micro-cylinder structure is not greater than the radial width of the top surface of the trapezoidal structure, and the radial width of the micro-cylinder structure is not less than the minimum required to stably support the micro-element 103. Width, the stable support means that the micro-element does not shift and sway.
- the self-aligned exposure process includes an ultraviolet exposure process, and the light of the self-aligned exposure process is incident perpendicular to a surface of the micro-element 103, and is incident through a gap between adjacent micro-elements 103.
- the second support portion 107 is connected to the central region of the first support portion 108 to avoid the displacement of the position of the micro-element 103.
- the invention utilizes the micro-element 103 as a photolithographic mask, and forms the photosensitive material into a trapezoidal structure and supports the microcolumn, which is beneficial to the stability of the micro-element 103 and the ease of subsequent separation.
- steps 4) to S14 are performed to provide a package substrate 109 having a eutectic metal 110 corresponding to the array of micro-elements 103 on the surface of the package substrate 109.
- the array is aligned with the eutectic metal 110 and subjected to eutectic treatment;
- the eutectic metal 110 includes one of a group consisting of AgSnCu, In, and BiSn alloys, the temperature of the eutectic treatment is not higher than 300 ° C, and the time of the eutectic treatment is not more than 1 min. The stability of the support structure 106 is maintained during the eutectic process.
- steps 5) S15 are performed, the micro-element 103 and the substrate 101 are separated from the second support portion 107, and the photosensitive material on the micro-element 103 is removed. Layer 102 is used to effect a substantial transfer of the micro-elements 103.
- an oblique mechanical pressure is applied to the substrate 101 to break the second support portion 107 to separate the micro-element 103 from the substrate 101.
- the invention only needs to use mechanical force to break the supporting microcolumn to realize the huge transfer of the micro component 103, and the process is simple, and the process cost can be effectively reduced.
- the second support portion 107 may also be broken by mechanical cutting or the like to separate the micro-element 103 from the substrate 101, and is not limited to the examples listed herein.
- the giant amount transfer method of the micro-component of the present invention has the following beneficial effects:
- the invention adopts the whole surface photosensitive material to grasp the micro-element 103, which can avoid the problem that the micro-element 103 captures insufficient alignment precision;
- the present invention utilizes the micro-element 103 as a photolithographic mask to form the photosensitive material into a trapezoidal structure and support the microcolumn, which is advantageous for the stability of the micro-element 103 and the ease of subsequent separation;
- the invention only needs to mechanically compress and support the microcolumn to realize the huge transfer of the micro-component 103, and the process is simple, and the process cost can be effectively reduced.
- the overall process of the invention is simple, can effectively improve the transfer yield of the micro-element 103, and has broad application prospects in the field of semiconductor manufacturing.
- the present invention effectively overcomes various shortcomings in the prior art and has high industrial utilization value.
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Abstract
Description
Claims (11)
- 一种微元件的巨量转移方法,其特征在于,所述巨量转移方法包括:1)提供一基底,于所述基底表面形成光敏材料层,并在第一温度下对所述光敏材料层进行半固化处理,其中,所述第一温度低于所述光敏材料层的完全固化温度,以保证所述光敏材料层具有粘性;2)提供微元件的阵列,基于所述光敏材料层的表面粘性,将所述微元件的阵列抓取于所述光敏材料层表面;3)以所述微元件作为光掩膜,对所述光敏材料层进行自对准曝光处理及显影处理,使所述光敏材料层分割成多个与所述微元件对应的支撑结构,所述支撑结构包含粘接于所述微元件的第一支撑部及连接所述第一支撑部与所述基底的第二支撑部,且所述第二支撑部的径向宽度小于所述第一支撑部的径向宽度;4)提供一封装基板,所述封装基板表面具有与所述微元件的阵列对应的共晶金属,将所述微元件的阵列与所述共晶金属对准接合并进行共晶处理;以及5)自所述第二支撑部分离所述微元件与所述基底,并去除所述微元件上的光敏材料层,以实现所述微元件的巨量转移。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:步骤3)中,通过控制所述自对准曝光处理的强度,使得显影处理后的所述第一支撑部呈梯形结构,以增大所述第一支撑部与所述微元件的粘接面积,所述第二支撑部呈微柱体结构,以利于所述微元件与所述基底的分离。
- 根据权利要求2所述的微元件的巨量转移方法,其特征在于:所述微柱体结构的径向宽度不大于所述梯形结构顶面的径向宽度,且所述微柱体结构的径向宽度不小于稳定支撑所述微元件所需的最小宽度。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:步骤3)中,所述自对准曝光处理包含紫外线曝光处理,所述自对准曝光处理的光线垂直于所述微元件表面入射,使得所述第二支撑部连接于所述第一支撑部的中心区域,以避免所述微元件位置的偏移。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:所述光敏材料层包含光敏聚甲基丙烯酸甲酯(PMMA)或者聚二甲基硅氧烷(PDMS)或者聚酰亚胺(PI),所述完全固化温度介于150℃~250℃之间,所述第一温度介于60℃~140℃之间,以保证所述光敏材料层具有粘性。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:步骤2)中,所述微元件的阵列采用悬浮式结构,以使其易被所述光敏材料层的粘性表面抓取。
- 根据权利要求6所述的微元件的巨量转移方法,其特征在于:所述悬浮式结构包括:支撑层;多个稳定柱,位于所述支撑层表面;以及微元件的阵列,该阵列中的每个微元件藉由若干个所述稳定柱支撑。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:步骤2)将所述微元件的阵列抓取于所述光敏材料层表面后,还包括对所述光敏材料层进一步固化处理的步骤,以增加所述微元件与所述光敏材料层的粘附力。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:步骤5)中,对所述基底施加一斜向的机械压力,将所述第二支撑部压断,以分离所述微元件与所述基底。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:所述基底包含玻璃基底、陶瓷基底、聚合物基底、硅基底及蓝宝石基 底所组成群组中的一种。
- 根据权利要求1所述的微元件的巨量转移方法,其特征在于:所述微元件的阵列包含微间距发光二极管阵列、光电探测二极管阵列、MOS阵列及MEMS阵列所组成群组中的一种。
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