Method and system for high-speed, precise, laser-based modification of one or more electrical elements

Information

  • Patent Application
  • 20070215575
  • Publication Number
    20070215575
  • Date Filed
    February 21, 2007
    17 years ago
  • Date Published
    September 20, 2007
    17 years ago
Abstract
A method and system for high-speed, precise, laser-based modification of at least one electrical element made of a target material is provided. The system includes a laser subsystem that generates a pulsed laser output wherein each laser pulse has a pulse energy, a laser wavelength within a range of ablation sensitivity of the target material, and a pulse duration short enough to substantially reduce ablation threshold energy density of the target material. The system further includes a beam positioner that selectively irradiates the at least one electrical element with the one or more laser pulses focused into at least one spot so as to cause the one or more laser pulses to selectively ablate a portion of the target material from the at least one element while avoiding both substantial spurious opto-electric effects and undesirable damage to the non-target material.
Description

BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1
a illustrates the operation and results obtained with various conventional functional trimming systems that utilize IR laser outputs; FIG. 1a is a top plan view, partially broken away, of a portion of an integrated circuit depicting resistors having a resistive film path between metal contacts; FIG. 1b is a block diagram of a prior art automated dynamic-trim system and device under test; FIG. 1c is a simplified schematic diagram of a multiplier cell the +Y input is switched between a specified +voltage pair while a trimming laser increases the resistance of either R1 or R2, wherein FIGS. 1b and 1c correspond to FIGS. 3 and 4, respectively, of chapter 3 of the handbook entitled “Nonlinear Circuits Handbook” published by Analog Devices Inc. in 1976; FIG. 1d is a top schematic view, partially broken away, of a die of a semiconductor wafer; there are thin film resistance elements as well as metal links (i.e., copper, gold or Al etc.) on the die; another possible combination of devices to be processed would include thick film-based devices;



FIG. 2 is a graph which illustrates the relation between the minimum relative energy required for trimming as a function of pulse width;



FIGS. 3
a-3d are graphs which illustrate a relationship of absorption and photoelectric response for certain semiconductor materials, and also the absorption of certain materials over a wide wavelength range; the graph of FIG. 3a is taken from FIG. 9.7 of Moss, “Optical Properties of Semiconductors” and illustrates spectral response of silicon containing boron and indium; FIG. 3b is taken from U.S. Pat. No. 4,399,345 to Lapham, et al. and illustrates absorption of silicon as a function of wavelength; the graphs of FIG. 3c show typical responsivity curves of silicon and indium gallium arsenide-based detectors versus wavelength as illustrated in the '995 and '272 patents; FIG. 3d is taken from the publication of Liu, et al. (hereinbelow) and illustrates the effect of wavelength and doping concentration on the damage threshold of Si, with 150 fs pulses;



FIG. 4
a is a top plan schematic view of a conventional laser trim with a relatively large HAZ; FIG. 4b is a top plan schematic view of an exemplary ultra-fast laser trim with little or no HAZ; FIG. 4c is a combined graph and side view of a resistor which illustrates a kerf size and profile to be obtained with an embodiment of the present invention; a focused laser spot and a pulse width sub-diffraction limited kerf size are shown;



FIG. 5
a is an example of a sequence of laser material processing pulses;



FIG. 5
b is an enlarged graph of power (y-axis) versus time (x-axis) for one of the laser material processing pulses of FIG. 5a generated in accordance with one embodiment of the present invention;



FIG. 6 is a schematic block diagram illustrating a system corresponding to an one embodiment of the invention;



FIG. 7 schematically illustrates a system corresponding to another embodiment of the present invention; (the system may include a short wavelength mode-locked or fiber laser having a pulse width of a one picosecond or less);



FIGS. 8
a-8b are oscilloscope traces; the trace of FIG. 8a shows an output voltage of a typical voltage regulator device undergoing laser functional processing in accordance with one embodiment of the present invention; laser output pulses with ultrashort pulse width may be directed at a resistor of an activated voltage regulator; the straight line of the oscilloscope trace of FIG. 8b depicts the output voltage of the voltage regulator and shows no momentary dips in output voltage; therefore, measurements can be made immediately after laser impingement, or at any time before or after laser impingement to obtain a true measurement value of the output voltage;



FIG. 9
a is a schematic diagram illustrating an exemplary photodetection/amplifier device which may be both trimmed and measured in accordance with the present invention; and



FIGS. 9
b and 9c illustrate systems for trimming and testing the device of FIG. 9a.


Claims
  • 1. A method of high-speed, precise, laser-based modification of at least one electrical element to adjust a measurable parameter, the at least one electrical element comprising a target material, and being supported on a substrate, the method comprising: generating a pulsed laser output having one or more laser pulses at a repetition rate, each laser pulse having a pulse energy, a laser wavelength, and at least one temporal characteristic that sufficiently reduces an ablation threshold energy density of the target material to avoid both substantial spurious opto-electric effects in a non-target material and undesirable damage to the non-target material; andselectively irradiating the at least one electrical element with the one or more laser pulses focused into at least one spot so as to cause the one or more laser pulses having the wavelength, energy and the at least one temporal characteristic to selectively modify a physical property of the target material of the at least one electrical element while avoiding both the substantial spurious opto-electric effects in the non-target material and undesirable damage to the non-target material.
  • 2. The method of claim 1, wherein the step of irradiating selectively ablates a portion of the target material and the wavelength is within a range of ablation sensitivity of at least the target material.
  • 3. The method of claim 1, wherein the at least one temporal characteristic includes a pulse duration and wherein the ablation threshold energy density decreases with reduced pulse duration.
  • 4. The method as claimed in claim 1, wherein the at least one electrical element is operatively connected to an electronic device having the measurable parameter, and wherein the method further comprises: activating at least a portion of the device; andmeasuring a value of the measurable parameter either during or after the step of generating.
  • 5. The method of claim 1, wherein the at least one temporal characteristic includes a pulse duration of about 25 femtoseconds or greater.
  • 6. The method of claim 1, wherein the at least one temporal characteristic includes a substantially square pulse shape, and wherein each laser pulse has a duration less than about 10 nanoseconds.
  • 7. The method of claim 1, wherein the target and non-target material are both supported on the substrate, the substrate being a non-target substrate having a substrate ablation energy density threshold.
  • 8. The method of claim 1, wherein each laser pulse has a duration greater than 25 femtoseconds and less than about 10 nanoseconds.
  • 9. The method of claim 4, wherein the laser-based modification is laser trimming, and wherein the method further comprises: comparing an actual value of the parameter with a preselected value for the parameter; anddetermining whether the target material requires additional irradiating with the laser output to satisfy the preselected value for the parameter of the device.
  • 10. The method of claim 1, wherein the target material forms part of a target structure and the non-target material comprises a material of the substrate which supports the target structure, and wherein the non-target material comprises at least one of silicon, germanium, indium gallium arsenide, semiconductor and ceramic material and the target material comprises at least one of aluminum, titanium, nickel, copper, tungsten, platinum, gold, nickel, chromide, tantalum nitride, titanium nitride, cesium silicide, doped polysilicon, disilicide, and polycide.
  • 11. The method of claim 1, wherein the non-target material comprises a portion of an electronic structure adjacent the target material.
  • 12. The method of claim 11, wherein the adjacent electronic structure comprises a semiconductor material-based substrate or a ceramic substrate.
  • 13. The method of claim 1, wherein the target material forms part of a thin film resistor, a capacitor, an inductor, an integrated circuit, or an active device.
  • 14. The method of claim 1, wherein target material forms part of an active device which includes at least one conductive link, and wherein the device is adjusted, at least in part, by removing the at least one conductive link by performing the steps of generating and irradiating.
  • 15. The method of claim 1, wherein the target material or the non-target material comprises a portion of a photo-electric sensing component.
  • 16. The method of claim 15, wherein the photo-electric sensing component comprises a photodiode or a CCD.
  • 17. The method of claim 4, wherein the device is an opto-electric device and the target material or the non-target material comprises a portion of the opto-electric device, the device including a photo-sensing element and an amplifier operatively coupled to the photo-sensing element, and wherein the laser wavelength is in a region of high quantum efficiency of the photo-sensing element, whereby the size of the at least one spot is reducible compared to a spot size produced at a wavelength greater than 1 μm.
  • 18. The method of claim 17, wherein the photo-sensing element and the amplifier are an integrated assembly, and wherein the method further comprises: generating an optical measurement signal; anddirecting the measurement signal along a path having a common portion with a path of the one or more laser pulses.
  • 19. The method of claim 9, wherein the step of determining is performed substantially instantaneously subsequent to the step of irradiating.
  • 20. The method of claim 4, wherein there is substantially no device settling time between the steps of irradiating and measuring.
  • 21. The method of claim 14, wherein the at least one electrical element includes one or more elements having substantially different optical properties, wherein the step of generating is carried out with a master-oscillator and power amplifier (MOPA), the master oscillator including a semiconductor laser diode; and wherein the method further comprises: applying a signal to the laser diode to control the at least one temporal characteristic so as to selectively modify the physical property of the target material.
  • 22. The method of claim 1, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 1.6 μm, and wherein the pulse duration is less than about 100 picoseconds.
  • 23. The method of claim 1, wherein the wavelength is about 1.55 μm, wherein the step of generating is at least partially carried out with an Erbium-doped, fiber amplifier and a seed laser diode, wherein opto-electronic sensitivity is below a detection limit of equipment which measures an operational parameter associated with the at least one element, whereby the useful dynamic range of a measurement is limited by the maximum dynamic range of the equipment.
  • 24. The method of claim 1, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 800 nm, and wherein the pulse duration is less than about 100 picoseconds.
  • 25. The method of claim 1, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 550 nm, and wherein the pulse duration is less than about 10 picoseconds.
  • 26. The method of claim 1, wherein the at least one temporal characteristic includes pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 400 nm, wherein the pulse duration is less than about 10 picoseconds, and wherein the step of generating is at least partially carried out with a UV mode-locked laser.
  • 27. The method of claim 1, wherein the step of generating is at least partially carried out using a MOPA, and wherein temporal shape of each of the laser pulses is substantially square with a rise time of about 2 nanoseconds or less.
  • 28. The method of claim 20, wherein the settling time is 0.5 milliseconds or less.
  • 29. A system for high-speed, precise, laser-based modification of at least one electrical element to adjust a measurable parameter, the at least one electrical element comprising a target material supported on a substrate, the system comprising: a laser subsystem that generates a pulsed laser output having one or more laser pulses at a repetition rate, each laser pulse having a pulse energy, a laser wavelength, and at least one temporal characteristic that sufficiently reduces an ablation threshold energy density of the target material to avoid both substantial spurious opto-electric effects in the non-target material and undesirable damage to the non-target material; anda beam positioner that selectively irradiates the at least one electrical element with the one or more laser pulses focused into at least one spot so as to cause the one or more laser pulses having the wavelength, energy and the at least one temporal characteristic to selectively modify a physical property of the target material of the at least one electrical element while avoiding both the substantial spurious opto-electric effects in the non-target material and undesirable damage to the non-target material.
  • 30. The system of claim 29, wherein the one or more focused laser pulses selectively ablate a portion of the target material and the wavelength is within a range of ablation sensitivity of at least the target material.
  • 31. The system of claim 29, wherein the at least one temporal characteristic includes a pulse duration and wherein the ablation threshold energy density decreases with reduced pulse duration.
  • 32. The system as claimed in claim 29, wherein the at least one electrical element is operatively connected to an electronic device having the measurable parameter, and wherein the system further comprises: an electrical input for activating at least a portion of the device; anda detector for measuring a value of the measurable parameter after generation of the one or more laser pulses.
  • 33. The system of claim 29, wherein the at least one temporal characteristic includes a pulse duration of about 25 femtoseconds or greater.
  • 34. The system of claim 29, wherein the at least one temporal characteristic includes a substantially square pulse shape, and wherein each laser pulse has a duration less than about 10 nanoseconds.
  • 35. The system of claim 29, wherein the target and non-target material are both supported on the substrate, the substrate being a non-target substrate having a substrate ablation energy density threshold.
  • 36. The system of claim 29, wherein each laser pulse has a duration greater than 25 femtoseconds and less than about 10 nanoseconds.
  • 37. The system of claim 32, wherein the laser-based modification is laser trimming, and wherein the system further comprises: means for comparing an actual value of the parameter with a preselected value for the parameter; andmeans for determining whether the target material requires additional irradiating with the laser output to satisfy the preselected value for the parameter of the device.
  • 38. The system of claim 29, wherein the target material forms part of a target structure and the non-target material comprises a material of the substrate which supports the target structure, and wherein the non-target material comprises at least one of silicon, germanium, indium gallium arsenide, semiconductor and ceramic material and the target material comprises at least one of aluminum, titanium, nickel, copper, tungsten, platinum, gold, nickel, chromide, tantalum nitride, titanium nitride, cesium silicide, doped polysilicon, disilicide, and polycide.
  • 39. The system of claim 29, wherein the non-target material comprises a portion of an electronic structure adjacent the target material.
  • 40. The system of claim 39, wherein the adjacent electronic structure comprises a semiconductor material-based substrate or a ceramic substrate.
  • 41. The system of claim 29, wherein the target material forms part of a thin film resistor, a capacitor, an inductor, or an active device.
  • 42. The system of claim 29, wherein target material forms part of an active device which includes at least one conductive link, and wherein the active device is adjusted, at least in part, by removing the at least one conductive link.
  • 43. The system of claim 29, wherein the target material or the non-target material comprises a portion of a photo-electric sensing component.
  • 44. The system of claim 43, wherein the photo-electric sensing component comprises a photodiode or a CCD.
  • 45. The system of claim 32, wherein the device is an opto-electric device and the target material or the non-target material comprises a portion of the opto-electric device, the device including a photo-sensing element and an amplifier operatively coupled to the photo-sensing element, and wherein the laser wavelength is in a region of high quantum efficiency of the photo-sensing element, whereby the size of the at least one spot is reducible compared to a spot size produced at a wavelength greater than 1 μm.
  • 46. The system of claim 45, wherein the photo-sensing element and the amplifier are an integrated assembly, and wherein the system further comprises: means for generating an optical measurement signal; andmeans for directing the measurement signal along a path having a common portion with a path of the one or more laser pulses.
  • 47. The system of claim 37, wherein the means for determining determines substantially instantaneously subsequent to irradiating by the beam positioner.
  • 48. The system of claim 32, wherein there is substantially no device settling time between irradiating by the beam positioner and measuring by the detector.
  • 49. The system of claim 29, wherein the at least one electrical element includes one or more elements having substantially different optical properties, and wherein the laser subsystem includes a master oscillator and power amplifier (MOPA), the master oscillator including a semiconductor laser diode; the system further comprising a computer operatively coupled to the laser diode, the computer being programmed to apply a signal to the laser diode to control the at least one temporal characteristic so as to selectively modify the physical property of the target material.
  • 50. The system of claim 29, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 1.6 μm, and wherein the pulse duration is less than about 100 picoseconds.
  • 51. The system of claim 29, wherein the wavelength is about 1.55 μm, wherein the laser subsystem includes an Erbium-doped, fiber amplifier and a seed laser diode, wherein opto-electronic sensitivity is below a detection limit of equipment which measures an operational parameter associated with the at least one electrical element, whereby the useful dynamic range of a resistance measurement is limited by the maximum dynamic range of the equipment.
  • 52. The system of claim 29, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 800 nm, and wherein the pulse duration is less than about 100 picoseconds.
  • 53. The system of claim 29, wherein the at least one temporal characteristic includes a pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 550 nm, and wherein the pulse duration is less than about 10 picoseconds.
  • 54. The system of claim 29, wherein the at least one temporal characteristic includes pulse duration, wherein the substrate is a silicon substrate, wherein the wavelength is less than 400 nm, wherein the pulse duration is less than about 10 picoseconds, and wherein the laser subsystem includes a UV mode-locked laser.
  • 55. The system of claim 29, wherein the laser subsystem includes a MOPA configuration, and wherein temporal shape of each of the laser pulses is substantially square with a rise time of about 2 nanoseconds or less.
  • 56. The system of claim 48, wherein the settling time is 0.5 milliseconds or less.
  • 57. The system of claim 29, wherein the laser subsystem includes a fiber laser.
  • 58. The system of claim 29, wherein the laser subsystem includes a disk laser.
Continuation in Parts (1)
Number Date Country
Parent 11376527 Mar 2006 US
Child 11708918 US