SYSTEMS AND METHODS FOR FORMING PARTIAL NANO-PERFORATIONS WITH VARIABLE BESSEL BEAM
20220134475 · 2022-05-05
Inventors
- Andreas Simon Gaab (Grobenzell, DE)
- Anping Liu (Horseheads, NY, US)
- Jian-Zhi Jay Zhang (Ithaca, NY, US)
Cpc classification
B23K26/53
PERFORMING OPERATIONS; TRANSPORTING
C03B33/0222
CHEMISTRY; METALLURGY
B23K26/0665
PERFORMING OPERATIONS; TRANSPORTING
H01L21/4803
ELECTRICITY
B23K26/402
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
Embodiments of the present disclosure include a optical assembly comprising: an axicon lens with spherical aberration configured to generate the laser beam focal line, an optical element set spaced part from the optical lens, and a focusing optical element spaced apart from the optical element set, wherein the axicon lens and the optical element set are translatable relative to each other along the laser beam propagation direction and wherein the focusing optical element is in a fixed position along the laser beam propagation direction.
Claims
1. A method comprising: focusing a pulsed laser beam into a laser beam focal line oriented along the laser beam propagation direction via an optical assembly positioned in the beam path of the laser on the beam emergence side of the optical assembly, the optical assembly including: an axicon lens with spherical aberration configured to generate the laser beam focal line, an optical element set spaced part from the axicon lens, and a focusing optical element spaced apart from the optical element set, wherein the axicon lens and the optical element set are translatable relative to each other along the laser beam propagation direction and wherein the focusing optical element is in a fixed position along the laser beam propagation direction; directing the laser beam focal line into a glass material having a thickness of less than 5 mm, the laser beam focal line generating an induced absorption within the glass material, the induced absorption producing a perforation along the laser beam focal line within the material; adjusting the distance between the axicon lens and the optical element to adjust the depth of the laser beam focal line within the material; translating the glass material and the laser beam relative to each other, thereby laser drilling a plurality of perforations along a first plane within the material, wherein the depth of the perforation is less than half of the thickness of the material;
2. The method of claim 1, further comprising thinning the glass material to expose a first end of the plurality of perforations to at least one surface; and expanding the plurality of perforations through the thickness.
3. The method of claim 1, wherein a distance between the axicon lens and the optical element set is about 85 to about 110 mm.
4. The method of claim 1, wherein a distance between the optical element set and the focusing optical element is about 30 to about 90 mm.
5. The method of claim 1, wherein a depth of the laser beam focal line within the glass material is about 0.32 mm to about 0.98 mm.
6. The method of claim 1, wherein the optical element set comprises two lenses spaced a second distance apart.
7. The method of claim 6, wherein the second distance is about 1 mm to about 50 mm.
8. The method of claim 1, further comprising forming a semiconductor device on the surface of the glass material after drilling a plurality of perforations along a first plane within the material.
9. The method of claim 8, further comprising thinning the glass material after forming the semiconductor device on the surface of the glass material to expose an opening of the perforations.
10. A method comprising: focusing a pulsed laser beam into a laser beam focal line oriented along the laser beam propagation direction via an optical assembly positioned in the beam path of the laser on the beam emergence side of the optical assembly, the optical assembly including: a first optical element set comprising an axicon lens, a collimation lens, and a focusing lens, wherein the axicon lens, the collimation lens, and the focusing lens are in a fixed position, a second optical element set comprising three aspherical lens, wherein the first aspherical lens and the second aspherical lens are translatable relative to each other along the laser beam propagation direction and wherein the third aspherical lens is in a fixed position along the laser beam propagation direction; directing the laser beam focal line into a glass material having a thickness of less than 5 mm, the laser beam focal line generating an induced absorption within the glass material, the induced absorption producing a perforation along the laser beam focal line within the material; adjusting the distance between the first aspherical lens and the second aspherical lens to adjust the depth of the laser beam focal line within the material; translating the glass material and the laser beam relative to each other, thereby laser drilling a plurality of perforations along a first plane within the material, wherein the depth of the perforation is less than half of the thickness of the material.
11. The method of claim 10, further comprising thinning the glass material to expose a first end of the plurality of perforations to at least one surface; and expanding the plurality of perforations through the thickness.
12. The method of claim 10, wherein a distance between the first aspherical lens and the second aspherical lens is about 50 to about 71 mm.
13. The method of claim 10, wherein a distance between the second aspherical lens and the third aspherical lens is about 31 to about 48 mm.
14. The method of claim 10, wherein a depth of the laser beam focal line within the material is about 0.43 to about 0.66 mm.
15. The method of claim 10, further comprising forming a semiconductor device on the surface of the glass material after drilling a plurality of perforations along a first plane within the material.
16. The method of claim 10, further comprising thinning the glass material forming the semiconductor device on the surface of the glass material to expose an opening of the perforations.
17. An optical assembly, comprising: an axicon lens with spherical aberration configured to generate a laser beam focal line from a laser beam; an optical element set spaced part from the axicon lens, and a focusing optical element spaced apart from the optical element set, wherein the axicon lens and the optical element set are translatable relative to each other along a laser beam propagation direction and wherein the focusing optical element is in a fixed position along the laser beam propagation direction.
18. The optical assembly of claim 17, wherein a distance between the axicon lens and the optical element set is about 85 to about 110 mm.
19. The optical assembly of claim 17, wherein a distance between the optical element set and the focusing optical element is about 30 to about 90 mm.
20. The optical assembly of claim 17, wherein the optical element set comprises two lenses spaced a second distance apart, wherein the second distance is about 1 mm to about 50 mm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the Detailed Description serve to explain principles and operation of the various embodiments. As such, the disclosure will become more fully understood from the following Detailed Description, taken in conjunction with the accompanying Figures, in which:
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
DETAILED DESCRIPTION
[0040] Reference is now made in detail to various embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same or like reference numbers and symbols are used throughout the drawings to refer to the same or like parts. The drawings are not necessarily to scale, and one skilled in the art will recognize where the drawings have been simplified to illustrate the key aspects of the disclosure.
[0041] The claims as set forth below are incorporated into and constitute part of this Detailed Description.
[0042] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.
[0043] It will be understood by one having ordinary skill in the art that construction of the described disclosure, and other components, is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
[0044]
[0045] As shown in
[0046] Embodiments of the present disclosure utilize non-diffracting beams (“NDB”) to form the laser beam focal line 2b. Typically laser processing has used Gaussian laser beams. The tight focus of a laser beam with a Gaussian intensity profile has a Rayleigh range Z.sub.R given by:
[0047] The Rayleigh range represents the distance over which the spot size wo of the beam will increase by √{square root over (2)} in a material of refractive index no at wavelength no. This limitation is imposed by diffraction. Note in Eq. (1) that the Rayleigh range is related directly to the spot size, thereby leading to the conclusion that a beam with a tight focus (i.e. small spot size) cannot have a long Rayleigh range. Such a beam will maintain this small spot size only for a very short distance. This also means that if such a beam is used to drill through a material by changing the depth of the focal region, the rapid expansion of the spot on either side of the focus will require a large region free of optical distortion that might limit the focus properties of the beam. Such a short Rayleigh range also requires multiple pulses to cut through a thick sample.
[0048] However, embodiments of the present disclosure utilize NDBs instead of the optical Gaussian beams discussed above. Non-diffracting beams may propagate for a considerable distance before diffraction effects inevitably limit the beam focus. Although an infinite NDB does not suffer from diffractive effects, a physically realizable NDB will have a limited physical extent. The central lobe of the beam can be quite small in radius and thus produce a high intensity beam. There are several types of NDBs including, but not limited to, Bessel beams, Airy beams, Weber beams and Mathieu beams whose field profiles are typically given by special functions which decay more slowly in the transverse direction than a Gaussian function.
[0049] It should be understood that, although NDBs described herein are in the context of Bessel beams, embodiments are not limited thereto. The central spot size of a Bessel beam is given by:
where NA is the numerical aperture given by the cone of plane waves making an angle of β with the optical axis. A key difference between Bessel beams and Gaussian beams is that Rayleigh range is given by:
where D is the finite extent of the beam imposed by some aperture or optical element. It is therefore shown that the aperture size D may be used to increase the Rayleigh range beyond the limit imposed by the size of the central spot. A practical method for generating Bessel beams is to pass a Gaussian beam through an axicon or an optical element with a radially linear phase element.
[0050] In general, the optical method of forming the line focus (i.e., the laser beam focal line) can take multiple forms, such as, without limitation, using donut shaped laser beams and spherical lenses, axicon lenses, diffractive elements, or other methods to form the linear region of high intensity. The type of laser (picosecond, femtosecond, and the like) and wavelength (IR, visible, UV, and the like) may also be varied, as long as sufficient optical intensities are reached to create breakdown of the substrate material.
[0051] At step 304, and referring once again to
[0052] As
[0053] As
[0054] Representative optical assemblies 6, which can be applied to generate the focal line 2b, as well as a representative optical setup, in which these optical assemblies can be applied, are described below. All assemblies or setups are based on the description above so that identical references are used for identical components or features or those which are equal in their function. Therefore only the differences are described below.
[0055] To insure high quality (regarding breaking strength, geometric precision, roughness and avoidance of re-machining requirements) of the surface of separation after cracking along the contour defined by the series of perforations, the individual focal lines used to form the perforations that define the contour of cracking should be generated using the optical assembly described below (hereinafter, the optical assembly is alternatively also referred to as laser optics). The roughness of the separated surface is determined primarily by the spot size or the spot diameter of the focal line. A roughness of a surface can be characterized, for example, by an Ra surface roughness statistic (roughness arithmetic average of absolute values of the heights of the sampled surface). In order to achieve a small spot size of, for example, 0.5 μm to 2 μm in case of a given wavelength λ of laser 3 (interaction with the material of layer 1), certain requirements must usually be imposed on the numerical aperture of laser assembly 6.
[0056] In order to achieve the required numerical aperture, the optics must, on the one hand, dispose of the required opening for a given focal length, according to the known Abbe formulae (N.A.=n sin (theta), n: refractive index of the material to be processed, theta: half the aperture angle; and theta=arctan (D/2f); D: aperture, f: focal length). On the other hand, the laser beam must illuminate the optics up to the required aperture, which is typically achieved by means of beam widening using widening telescopes between the laser and focusing optics.
[0057] The spot size should not vary too strongly for the purpose of a uniform interaction along the focal line. This can, for example, be ensured (see the embodiment below) by illuminating the focusing optics only in a small, circular area so that the beam opening and thus the percentage of the numerical aperture only varies slightly.
[0058]
[0059] In the case shown in
[0060] In some embodiments, it is particularly advantageous to position the focal line 2b in such a way that at least one of surfaces 1a, 1b is covered by the focal line, so that the section of induced nonlinear absorption 2c starts at least on one surface of the layer or material to be processed. In this way it is possible to achieve virtually ideal cuts while avoiding ablation, feathering and particulate generation at the surface.
[0061]
[0062] At step 306, and as show in
[0063] In some embodiments, a distance d1 between the axicon lens and the optical element set is about 85 to about 110 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 95 to about 110 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 100 to about 110 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 105 to about 110 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 85 to about 105 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 85 to about 100 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 85 to about 95 mm. In some embodiments, a distance d1 between the axicon lens and the optical element set is about 85 to about 90 mm.
[0064] In some embodiments, a distance d3 between the optical element set and the focusing optical element is about 30 to about 90 mm. In some embodiments, a distance d3 between the optical element set and the focusing optical element is about 50 to about 90 mm. In some embodiments, a distance d3 between the optical element set and the focusing optical element is about 70 to about 90 mm. In some embodiments, a distance d3 between the optical element set and the focusing optical element is about 30 to about 70 mm. In some embodiments, a distance d3 between the optical element set and the focusing optical element is about 30 to about 50 mm.
[0065] In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 1 mm to about 50 mm. In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 15 mm to about 50 mm. In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 30 mm to about 50 mm. In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 45 mm to about 50 mm. In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 1 mm to about 35 mm. In some embodiments, a distance d2 between the convex lens 102a and the concave lens 102b is about 1 mm to about 20 mm.
[0066]
[0067] In some embodiments, a distance d1 between the first aspherical lens and the second aspherical lens is about 50 to about 71 mm. In some embodiments, a distance d2 between the second aspherical lens and the third aspherical lens is about 31 to about 48 mm.
[0068] At step 308, the glass material (e.g. layer 1) and the optical assembly are translatable relative to each other, thereby laser drilling a plurality of perforations along a first plane within the material.
[0069] At step 312, and referring to
[0070] It will be apparent to those skilled in the art that various modifications to the preferred embodiments of the disclosure as described herein can be made without departing from the spirit or scope of the disclosure as defined in the appended claims. Thus, the disclosure covers the modifications and variations provided they come within the scope of the appended claims and the equivalents thereto.