The present invention pertains to a deposition apparatus.
The present invention still further pertains to a deposition method.
Laser induced forward transfer (LIFT) is an emerging high resolution technology wherein a donor material is transferred from a donor source substrate to a target substrate. LIFT renders it possible to deposit a wide range of structural and functional materials without the use of a nozzle. In this technology an optical beam is directed through a donor substrate to a layer of donor material on the donor substrate. The radiation energy of the optical beam has the effect that a portion of the donor material is released and is transferred to a surface of the target substrate. This renders it possible to form electrically conductive elements, such as electrically conductive tracks or connections at the surface of the target substrate or to fill through silicon via's (TSVs) inside the target substrate.
For example WO2011/145930 proposes a chip die TSV treatment apparatus arranged for treatment of TSVs in chip dies in a chip manufacturing process. The known apparatus is dedicated to the latter purpose. It is noted further that WO 2009/081355 A2 pertains to a direct write method. Therein an optical assembly is configured to direct a writing laser and a tracking laser. A carrier has a material layer and a tracking layer. The carrier is moveable relative to the optical assembly such that when the material layer is energized by the writing laser, direct writing is provided to a surface below the carrier. The tracking layer includes readable data which is employed to control one of the optical assembly and a position of the carrier.
It is still further noted that US 2003/178395 A1 discloses an apparatus for fabrication of miniature structures that includes a substrate, a source of energy capable of generating an energy or energetic beam, a material carrier element displaceably disposed in a gap formed between the source of energy and the substrate, a deposition layer supported on the backing material of the material carrier element, and a control unit operatively coupled to the source of energy through the communication link and to the material carrier element through the communication link. Alternatively, the control unit may be operatively coupled to the substrate.
Practical applications are often more complicated, because a surface of a target substrate may not be flat, but may have edges. It may further be desired to provide the target substrate with mutually different types of electrically conductive elements, including not only electrical connections at the target substrate surface, but also electrical connections in the form of a filling to form through silicon via's (TSVs). There is a need for an apparatus and method that are more suitable for these more complicated applications.
In accordance with the above-mentioned need, it is a first object of the invention to provide a deposition method that is better configured for one or more of the above-mentioned applications.
In accordance with the above-mentioned need, it is a second object of the invention to provide a deposition apparatus that is better configured for one or more of the above-mentioned applications.
According to the first object an improved apparatus is provided as claimed in claim 1 and in accordance with the second object an improved method is provided as claimed in claim 9
Contrary to the method and apparatus known from the prior art, the optical beam is not merely positioned to a location of the donor substrate from which the donor material is to be ejected, but in addition a spatial energy distribution of the beam is controlled to provide for a transfer of the donor material as a jet. In particular this is achieved by controlling the optical beam with a substantially asymmetric spatial distribution on the basis of a shape to be assumed by the jet according to said specification data, therewith increasing the versatility of the method. It is noted that the spatial energy distribution is defined herein as the distribution of the radiation energy of a radiation dose with which a portion of donor material is transferred. The spatial energy distribution results from an integration of the power density distribution over a time-interval during which the dose is supplied. The power density distribution may be modulated during this time-interval, but may alternatively remain constant.
In the claimed deposition method, with the claimed apparatus, the intensity profile of the optical beam is deliberately controlled to determine how portions of the donor material are ejected from the donor substrate. Upon directing the optical beam via the donor substrate a force pattern is exerted to the donor material having a spatial distribution corresponding to the spatial energy distribution.
Upon ejection, the ejected material has a momentum pattern corresponding to the force pattern induced by the optical beam. At positions where the optical beam has a relatively high intensity the viscous donor material is accelerated to a speed that is higher than at positions where the optical beam has a relatively low intensity. As a result, a deformation of the ejected material occurs during its traversal of the space between the donor substrate and the target substrate.
In one embodiment the force pattern originates from evaporation of donor material that is heated by absorbed radiation of the optical beam. In another embodiment this force pattern originates from evaporation of material of an intermediate layer, also denoted as dynamic release layer DRL, arranged between the substrate and the layer of donor material. The nature of the force pattern further depends on a duration of the exposure to the beam. If optical radiation is provided as a pulse with a relatively long duration at a relatively low power a more smooth spatial force distribution will be obtained than in case the optical radiation is provided as a pulse with a relatively short duration at a relatively high power. According to have optimum control over the shape of the jet of donor material, the pulse duration preferably is in the picosecond range. E.g. in the range of 10 to 500 ps. Nevertheless alternative embodiments are possible wherein the pulse duration may be longer, for example in cases wherein a portion of donor material having a larger surface area is to be ejected. At present good experimental results are achieved with a pulse duration in the ns range, i.e. with a duration of about 10 ns. The relatively long duration of the pulse causes an ejection of donor material from a relatively large area of the donor substrate. Accordingly, the duration of the pulse applied to eject donor material may be used as a control parameter to determine a size of the area of the donor substrate to be ejected as an alternative or in addition to change a size of the radiation beam. It may also be contemplated to provide a pulse train with a series of relatively short pulses, for example a pulse train having a total duration of a few ns comprising a plurality of pulses with a duration of a few tens or hundreds of pc.
A viscous donor material is considered a non-solid material having a relatively high viscosity, for example in a range of 1-10 Pas. In this context a relatively high viscosity is understood to be a viscosity low enough to enable a shape deformation of ejected portions of the material. On the other hand the viscosity of the material should be sufficiently high to avoid a too rapid change of shape of the material in the time interval wherein the ejected material moves from the surface of the donor substrate to the surface of the target substrate.
In practice the surface tension of the donor material proves to be only of secondary importance. If the surface tension is relatively low e.g. lower than about 20 dyn/cm then in particular for thicker donor layers, the jet may have a tendency to disintegrate. This can be avoided by ejection of the donor material using a spatial energy distribution which has a higher average energy density in a ring shaped zone around its optical axis than an average energy density within an inner boundary of the ring shaped zone.
It is further noted that rheological properties of the donor material may be modified by additives or solvent, for example to obtain a shear-thickening, a shear-thinning, a thixotropic, a rheopectic or a Bingham plastic behavior. In particular donor materials with a shear-thinning behavior are favorable. Donor materials with this behavior have a viscosity that decreases with the rate of shear strain. Shear-thinning donor materials remain as a stable layer on the donor substrate, but are relatively easily morphed at the time of deposition.
These and other aspects are described in more detail with reference to the drawing. Therein:
Like reference symbols in the various drawings indicate like elements unless otherwise indicated.
The apparatus 100 as shown in
The donor material is a visco-elastic material, typically paste like materials. These materials do not easily break into separate droplets. For example viscous inks and pastes, containing a high metal load of Cu or Ag nano- or micronparticles, or a conductive adhesive may be used.
The apparatus further comprises an optical beam generator 130 to generate an optical beam 30 to be directed through the donor substrate 10 towards the donor material 14. The optical beam has an optical axis 32 with a point of intersection 34 in the target surface 22. The apparatus includes a positioning device 140 to control a position of the point of intersection 34. As shown in
In the embodiment shown, the apparatus further includes a positioning device 140 to position the donor substrate carrier 110.
As shown in
In an operational state of the deposition apparatus 100, the controller 160 is configured to receive specification data DS specifying a desired spatial distribution of donor material on the target surface 22. The specification data DS may for example be retrieved from a memory unit or via a communication channel from a host processor. The specification data may specify a desired distribution of donor material on the target substrate 20, for example in the form of electrically conductive tracks on the target substrate, as electrical connections functional elements as a filling to form through silicon via's (TSVs).
In the operational state, the controller 160 generates position control signals S140, S150 to control the positioning devices 140, 150, and a beam generator control signal S130 to control operation of the optical beam generator 130 in accordance with the spatial distribution specified by the specification data DS. In response to the beam generator control signal S130 the optical beam generator 130 generates the optical beam 30. When the optical beam 30 impinges on the donor substrate it causes donor material to be transferred as a jet 14j from the donor surface 12 towards a position on the target surface 22 dependent on the position control signal S150.
The optical beam generator 130 is further configured to generate the optical beam 30 to eject a portion of donor material with a controllable spatial energy distribution. Furthermore, the controller 160 is configured to generate the beam generator control signal S130 in accordance with the received specification data DS to control the spatial energy distribution.
In an embodiment the controller 160 is configured to issue a beam generator control signal S130 that causes the optical beam generator 130 to generate the optical beam with a spatial energy distribution that has a higher average energy density in a ring shaped zone 30r around its optical axis than an average energy density within an inner boundary 30ri of the ring shaped zone. In this manner is achieved that the ejected material better stays together than is the case with operation with a gaussian or uniform shaped beam. For example the ring shaped pattern may have a width/diameter ratio in the range of 1/10 to ⅕ and the diameter may be in the order of 50 to 500 micron. For example the radiation beam ring has a diameter of approximately 150 micron and a width of a approximately 20 micron. Accordingly the radiation energy density is relatively low in an inner area with a diameter of 110 micron in that example.
A setting of the laser fluence/energy leading to a stable nice jet depends on layer thickness. A thicker layer typically requires more energy, but allows longer and more stable jets. If a very high resolution is required a smaller thickness of the donor layer is recommended and consequently a lower laser energy should be applied. The laser energy is defined here as the total energy used to release a portion of the donor material from the donor surface.
Alternatively or additionally, the controller 160 may be configured to issue a beam generator control signal S130 that causes the optical beam generator 130 to generate the optical beam 30 with a substantially asymmetric spatial distribution. Therewith an improved coverage of the donor material at edges on the target substrate can be achieved. In a ring-shaped energy distribution the ringshaped beam for example has an increased intensity in an angular portion of for example 10 to 90 degrees, for example within a region of about 50 degrees.
In the embodiment shown, the optical beam generator of the deposition apparatus comprises a main optical source 131 to generate a beam of coherent optical radiation and a beam shaper. In the embodiment shown, the main optical source 131 is a laser of type AVIA-335-4500. In this example, as shown in more detail in
Alternatively another type of beam shaper may be provided such as a digital micromirror device (DMD). In a still further embodiment a beam shaper may be integrated in the optical source, for example inside a cavity of a laser serving as the optical source.
In the embodiment shown, the monitoring apparatus is provided as a shadowgraphy arrangement that comprises a further optical source 200 of radiation, an a microscopy camera arrangement with a microscope 230 and a camera 240. The further optical source 210 generates an auxiliary beam that is directed according to an optical path via the environment including the trajectory of the jet towards the microscopy camera arrangement. Therewith the optical path extends in a direction transverse to the trajectory of the jet to be ejected. An alternative monitoring apparatus may be considered wherein the jet is observed with reflection imagery.
A controller 300 is provided that activates the further optical source 200 with a trigger signal St1, before activating the main optical source 131 with a trigger signal St2. The further optical source 210 may cooperate with a delay element 210 in the optical path to monitor the jet at different points in time. Alternatively or additionally a controllable delay may be achieved by selection of the time interval between the points in time at which the trigger signals St1, St2 are issues. Also a video camera may be employed that upon triggering by the signal St1 records the complete development of the jet in a single cycle. In the embodiment shown, the monitoring apparatus includes additional components 220 to condition the auxiliary beam. In this case a fluorescent element converts the UV-radiation issued by the further auxiliary source 200 into visible radiation. Alternatively, an alternative auxiliary radiation source may be used that renders radiation in the visible spectrum, or a microscopy camera arrangement may be employed that is suitable for UV-imaging. The additional components 220 may further include elements like lenses.
In the embodiment shown in
Alternatively or additionally a target monitoring apparatus may be included that provides target observation data indicative for observed properties of deposited donor material on the target surface as observation data.
Experiments were performed using a viscous silver nanoparticle ink with a high metal load. Specifically the ink used has a surface tension of about 35 dyn/cm, a metal load of about 70% ww, and a static viscosity of about 6 Pas.
In
Upon ejection, the jet 14j of ejected material has a momentum pattern corresponding to the force pattern induced by the optical beam, and as can be seen in
A shown in
As a first example
As a second example
In summary, in operation of a device as claimed a deposition method is executed. Therein a donor substrate 10 is arranged opposite a target substrate 20. The donor substrate 10 has a surface 12 facing the target substrate 20 that is provided with a viscous donor material 14. The donor material 14 has viscoelastic properties, in particular at an elevated temperature. Having the donor substrate 10 and the target substrate 20 so arranged, an optical beam 30 is generated, and directed via the donor substrate 10 to the donor material 14 so as to release the donor material and transfer the donor material as a jet 14j towards the target substrate. In the claimed method, an input signal is received that specifies a shape to be assumed by the jet in which the donor material is to be transferred and an energy profile of the optical beam is controlled based on the specified shape. Alternatively or in addition an energy profile of the optical beam may be controlled based on specifications for a pattern in which donor material is to be deposited on the target substrate.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. In particular, unless clear from context, aspects of various embodiments that are treated in various embodiments separately discussed are deemed disclosed in any combination variation of relevance and physically possible and the scope of the invention extends to such combinations. Other variations to the disclosed embodiments can be understood and by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
Number | Date | Country | Kind |
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18155325.6 | Feb 2018 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/NL2019/050070 | 2/5/2019 | WO | 00 |