The present invention relates in general to substrate-to-substrate transfer of microelectronic devices aided by laser-lift-off ablation of a gallium-nitride layer. The present invention relates in particular to the removal of residual gallium after laser lift-off.
To meet the consumer demand for thinner and lighter electronic devices with higher performance, the microelectronics industry is pushing toward making ever smaller microelectronic devices. For example, micro light-emitting diodes (μLEDs) less than 70 microns×70 microns in size and as small as about 3 microns×3 microns are being developed for the purpose of making high-resolution LED displays. μLED displays are an emerging display technology expected to offer higher brightness, lower power consumption, and faster response than organic LED displays and liquid-crystal displays.
Wafer-level manufacturing has long been the most cost-effective mass-production method for microelectronic devices, with the capability to manufacture millions of identical microelectronic devices simultaneously on the same wafer. Although in some situations it is possible to separate out individual microelectronic devices from a wafer by dicing the wafer, thinner form factors may be achieved by instead detaching the microelectronic devices completely from the wafer. Therefore, wafer-level manufacturing of microelectronic devices may involve one or more steps of detaching the microelectronic devices from a substrate. For example, one type of microelectronic devices (e.g., red LEDs) may be grown at high density on a growth wafer and then detached from the growth wafer to be implemented at lower density on a substrate of a final device (e.g., a color display), possibly in conjunction with other types of microelectronic devices (e.g., blue and green LEDs) grown on other growth wafers. The production of microelectronic devices also often involves processing of both the top and the bottom of the microelectronic devices after growing at least some layers of the microelectronic devices on a growth wafer. Such double-sided processing may require one or more operations of transferring the microelectronic devices from one substrate to another in order to flip them over. Additionally, pick-and-place technology may be used to replace faulty microelectronic devices in an array of microelectronic devices.
Laser lift-off has emerged as a promising transfer technology. The laser lift-off process releases a microelectronic device from a substrate by laser ablating a sacrificial layer located between the substrate and the microelectronic device. Laser lift-off typically utilizes ultraviolet (UV) light generated by an excimer laser, and a microelectronic device may be released from a substrate by a single laser pulse. Laser lift-off may be applied to a single individual microelectronic device, a subset of the total number of microelectronic devices on a substrate, or all microelectronic devices on a substrate. In laser lift-off of multiple microelectronic devices, the laser beam may be scanned across selected portions of a substrate to release microelectronic devices one by one, or a larger-area laser pulse may be applied to multiple microelectronic devices simultaneously. The larger-area laser pulse may be masked to exclusively expose the footprints of the individual microelectronic devices.
Transfer of microelectronic devices may utilize laser lift-off in a stamp-based transfer scheme, a bond-release scheme, or a laser-induced forward transfer scheme. In the stamp-based scheme, microelectronic devices are released from a donor substrate by laser lift-off, and picked up from the donor substrate by an elastomer stamp. The stamp then places the microelectronic devices on a receiver substrate. In the bond-release scheme, the microelectronic devices are bonded to the receiver substrate before being released from the donor substrate. In the laser-induced forward transfer scheme, the receiver substrate is held a distance from the microelectronic devices, and the ablation of the sacrificial layer not only releases the microelectronic devices from the donor substrate but also propels the microelectronic devices across the gap to the receiver substrate. The bond-release and laser-induced forward transfer schemes elegantly eliminate the need for robotic equipment to handle the individual microelectronic devices in the transfer.
The sacrificial layer ablated to release microelectronic devices from the donor substrate in laser lift-off is typically made of gallium nitride (GaN). Laser ablation of GaN produces nitrogen gas and liquid gallium. While all of the nitrogen gas escapes, a residue of liquid gallium remains on the newly exposed surface of the microelectronic device. For most applications, it is necessary to remove this residue since the residue may impede the performance of the microelectronic device or be in the way of subsequent processing of the microelectronic device. In particular, when the microelectronic device is a μLED, the residue may block light emission from the μLED. The gallium residue is usually etched away with a caustic liquid. For example, with an aqueous solution of ammonia (NH3) or hydrochloric acid (HCl).
Disclosed herein is a method for laser-lift-off transfer of microelectronic devices with subsequent laser cleaning of the gallium residue. In this method, both transfer and subsequent cleaning are based on UV laser ablation. First, transfer is initiated by a UV laser beam that ablates the sacrificial GaN layer. After transfer, a UV laser beam ablates the gallium residue. Conveniently, both laser ablation operations may be performed by the same UV laser. The second laser ablation operation to remove the gallium residue replaces conventional etching using a caustic liquid.
The advantages of the present method are multifold. Some substrates are not tolerant to liquid etching. For example, the display backplane of a μLED display may include a polymer or another material that is intolerant to etching with a caustic liquid. Laser cleaning is a viable approach to gallium residue cleaning in caustic-liquid-intolerant scenarios at least because it is possible to apply the UV laser beam selectively to each individual microelectronic device in need of cleaning. The UV laser beam used for cleaning may be sized or masked with relative ease to expose only the microelectronic device(s), and laser-ablation damage to h substrate areas can therefore be avoided. Even in the case of caustic-liquid-tolerant substrates, the present transfer and cleaning method offers convenience and simplicity by eliminating a wet-chemistry step and instead applying a second ablation operation after laser-lift-off transfer. The replacement of liquid etching with laser ablation has the potential to significantly reduce the overall processing time. Additionally, in most scenarios, the laser cleaning step can be performed with the apparatus and functionality already in place for laser lift-off.
In one aspect, a method for ultraviolet-laser transfer and cleaning of microelectronic devices includes a step of transferring a microelectronic device from a first substrate to a second substrate. The microelectronic device is coupled to the first substrate via a sacrificial layer that contains gallium. The transfer step includes releasing the microelectronic device from the first substrate by laser ablating the sacrificial layer with a first ultraviolet laser beam. This laser ablation leaves a gallium residue on the microelectronic device. The method further includes a step of cleaning at least a portion of the gallium residue off the microelectronic device after the transfer step. The cleaning step includes laser ablating the gallium residue with a second ultraviolet laser beam. The sacrificial layer may be a heterogenous solid layer. The method may include generating the first and second ultraviolet laser beams with the same ultraviolet laser.
The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate preferred embodiments of the present invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain principles of the present invention.
Referring now to the drawings, wherein like components are designated by like numerals,
Device 110 may be a μLED, a photodiode, a complementary metal oxide semiconductor circuit, or another microelectronic device. The transverse dimensions of device 110, e.g., width 118W indicated in
As shown in
UV laser beam 180 may be generated by a UV laser 170, such as an excimer laser. The wavelength of UV laser beam 180 may be less than 320 nanometers (nm) to effectively ablate layer 112, for example in the range between 190 and 320 nm. In one embodiment, UV laser beam 180 is pulsed and transfer step 102 ablates layer 112 with a single pulse of UV laser beam 180. In another embodiment, transfer step 102 ablates layer 112 with a sequence of pulses of UV laser beam 180. The energy density delivered to layer 112 by UV laser beam 180 may be in the range between 600 and 1500 millijoules/centimeter2 (mJ/cm2), and layer 112 may have a thickness 112T in the range between 0.5 and 5 nm.
Donor substrate 120 can withstand and is transmissive to UV light. Donor substrate 120 is, for example, made of quartz or sapphire. Receiver substrate 130 may or may not be UV transmissive. In one scenario, receiver substrate 130 is a final device substrate, for example a display backplane. In this scenario, receiver substrate 130 may include or substantially consist of a polymer. The final device substrate, whether a display backplane or not, may also include one or more functional layers. In another scenario, receiver substrate 130 is an intermediate substrate used for further processing of device 110 before transfer to yet another substrate that may be a final device substrate. In this scenario, the material composition of receiver substrate 130 may be similar to that of donor substrate 120 to enable laser transfer of device 110 away from receiver substrate 130. Receiver substrate 130 may be intolerant to caustic-liquid etching, for example due to the presence of a polymer or functional layers.
In a bond-release embodiment of transfer step 102, not depicted in
Method 100 may also be used in stamp-based transfer schemes. When method 100 is applied to a stamp-based transfer scheme, receiver substrate 130 is a stamp that grabs onto the sides of device 110 (vertical sides in
As shown in
In cleaning step 104, shown in
The energy density delivered by UV laser beam 190 in cleaning step 104 may be less than the energy density delivered by UV laser beam 180 in transfer step 102, so as to prevent UV laser beam 190 from ablating or otherwise damaging device 110. In one embodiment of method 100, the energy density delivered by UV laser beam 190 in cleaning step 104 is no more than 85% (e.g., between 25% and 85%) of the energy density delivered by UV laser beam 180 in transfer step 102. In another embodiment, the energy density delivered by UV laser beam 190 in cleaning step 104 is between 500 and 1000 mJ/cm2.
Depending on the material of receiver substrate 130 (and any objects disposed on surface 132 other than device 110), it may be preferred or even necessary to restrict irradiation by UV laser beam 190 to surface 116 only. Thus, in one embodiment of cleaning step 104, the transverse size and shape of UV laser beam 190 match the transverse size and shape of surface 116. For example, as shown in
Laser ablation of gallium residue 114 frees gallium residue 114 from surface 116 but may produce gallium particulates or even airborne droplets. To prevent such gallium particulates or airborne droplets from contaminating surface 116 or other portions of receiver substrate 130 (or objects disposed thereon), method 100 may include exhausting the gallium residue freed from surface 116. Thus, in addition to one or more laser sources used for laser ablation in transfer step 102 and cleaning step 104, the apparatus performing method 100 may include a pump 178 that collects and removes freed gallium residue.
Although not shown in
In another extension, method 100 applies transfer step 102 to a plurality of devices 110 on donor substrate 120 to transfer each of these devices 110 to receiver substrate 130, whereafter method 100 may apply cleaning step 104 to each of the transferred devices 110. Optionally, this extension of method 100 further includes transferring other devices 110 from one or more other donor substrates 120 to receiver substrate 130, for example according to transfer step 102, before applying cleaning step 104 to all the transferred devices 110. Alternatively, in scenarios where different types of devices 110 from different respective donor substrates 120 are to be transferred to the same receiver substrate 130, method 100 may complete the transfer and cleaning steps for each type of device 110 before proceeding to transfer and cleaning of the next type of device 110.
In the example depicted in
The degree of selectivity of cleaning exemplified by
In the image 500 example, each device 510 was cleaned by a single laser pulse with a wavelength of 248 nm and an energy density of 900 mJ/cm2. The energy density needed for cleaning of gallium residue 114 may depend on several factors. One such factor is the thickness of the sacrificial GaN layer ablated in the transfer step (thickness 112T of layer 112 in
Currently, the majority of laser lift-off processes are based on ablation of a sacrificial GaN layer. However, the sacrificial layer may have other compositions, such as aluminum gallium nitride (AlxGa1−xN), gallium oxide (Ga2O3), amorphous gallium oxide (α-GaOx), or indium gallium nitride (InxGa1−xN). Method 100 is extendable to these compositions. Thus, more generally, layer 112 is a heterogeneous solid layer that contains gallium, and gallium residue 114 is a residue that contains gallium and possible other metals as well.
The present invention is described above in terms of a preferred embodiment and other embodiments. The invention is not limited, however, to the embodiments described and depicted herein. Rather, the invention is limited only by the claims appended hereto.
This application is a U.S. national stage application under 35 U.S.C. § 371 of International Application No. PCT/EP2023/053080, filed Feb. 8, 2023, which claims the priority of U.S. Provisional Application No. 63/309,458, filed Feb. 11, 2022. The entire contents of each priority application is incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2023/053080 | 2/8/2023 | WO |
Number | Date | Country | |
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63309458 | Feb 2022 | US |