Method for aligning micro-electronic components
09799632 ยท 2017-10-24
Assignee
Inventors
Cpc classification
H01L2225/06593
ELECTRICITY
H01L2224/0401
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/80121
ELECTRICITY
H01L2224/81193
ELECTRICITY
H01L2224/81907
ELECTRICITY
H01L2224/83143
ELECTRICITY
H01L2225/06513
ELECTRICITY
H01L2224/80121
ELECTRICITY
H01L2224/81143
ELECTRICITY
H01L24/80
ELECTRICITY
H01L2225/06517
ELECTRICITY
H01L2224/80895
ELECTRICITY
H01L2224/81894
ELECTRICITY
H01L2224/81121
ELECTRICITY
H01L2224/16227
ELECTRICITY
H01L2224/16147
ELECTRICITY
H01L2224/80132
ELECTRICITY
H01L2225/06541
ELECTRICITY
H01L2224/16237
ELECTRICITY
H01L2224/80203
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/1703
ELECTRICITY
H01L2224/81007
ELECTRICITY
H01L2224/80896
ELECTRICITY
H01L2224/08225
ELECTRICITY
H01L2224/80143
ELECTRICITY
H01L2224/81191
ELECTRICITY
H01L2224/81121
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2224/8113
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/80907
ELECTRICITY
H01L2224/8013
ELECTRICITY
H01L2224/16148
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2224/0903
ELECTRICITY
H01L2224/81132
ELECTRICITY
H01L24/02
ELECTRICITY
H01L2224/80894
ELECTRICITY
H01L2224/80203
ELECTRICITY
H01L23/544
ELECTRICITY
International classification
H01L25/00
ELECTRICITY
Abstract
Alignment of a first micro-electronic component to a receiving surface of a second micro-electronic component is realized by a capillary force-induced self-alignment, combined with an electrostatic alignment. The latter is accomplished by providing at least one first electrical conductor line along the periphery of the first component, and at least one second electrical conductor along the periphery of the location on the receiving surface of the second component onto which the component is to be placed. The contact areas surrounded by the conductor lines are covered with a wetting layer. The electrical conductor lines may be embedded in a strip of anti-wetting material that runs along the peripheries to create a wettability contrast. The wettability contrast helps to maintain a drop of alignment liquid between the contact areas so as to obtain self-alignment by capillary force. By applying appropriate charges on the conductor lines, electrostatic self-alignment is realized, which improves the alignment obtained through capillary force and maintains the alignment during evaporation of the liquid.
Claims
1. An assembly of at least two components, comprising: a first component and a second component; wherein each of the first component and the second component comprises a contact area covered by a wetting layer; wherein each of the first component and the second component comprises means for containing a liquid on the respective wetting layer; wherein each of the first component and the second component comprises one or more conductor lines running along a circumference of the respective contact area, wherein the one or more conductor lines of the first component are arranged to face the one or more conductor lines of the second component; and wherein at least one of the first component or the second component is provided with means for applying an electrical charge to the respective one or more conductor lines.
2. The assembly according to claim 1, wherein on at least one of the first component or the second component, the means for containing a liquid on the respective wetting layer includes at least one strip of anti-wetting material running along a circumference of the respective contact area.
3. The assembly according to claim 2, wherein on at least one of the first component or the second component, the respective one or more conductor lines is embedded in or located on top of the respective at least one strip of anti-wetting material.
4. The assembly according to claim 1, wherein on at least one of the first component or the second component, the means for containing a liquid on the respective wetting layer includes the respective one or more conductor lines, which are provided with anti-wetting properties.
5. The assembly according to claim 4, wherein the one or more conductor lines provided with anti-wetting properties includes the one or more conductor lines being embedded in a hydrophobic material.
6. The assembly according to claim 1, wherein on at least one of the first component or the second component, the means for containing a liquid on the respective wetting layer includes a vertical sidewall around the respective contact area.
7. The assembly according to claim 1, wherein on at least one of the first component or the second component, the respective one or more conductor lines are embedded in a first passivation layer and are covered by a second passivation layer.
8. The assembly according to claim 7, wherein the wetting layer includes the second passivation layer.
9. The assembly according to claim 1, wherein the first component comprises a pair of conductor lines, wherein the second component comprises a single conductor line, wherein the first component is configured to apply a first electric potential to a first conductor line of the pair of conductor lines and to apply a second electric potential to a second conductor line of the pair of conductor lines, while the second component is configured to apply no electric potential to the single conductor line, and wherein the first electrical potential has an opposite electrical charge of the second electric potential.
10. The assembly according to claim 9, wherein the pair of conductor lines includes interdigitated lateral extensions.
11. The assembly according to claim 1, wherein the first component is configured to apply a first electric potential to its respective one or more conductor lines, wherein the second component is configured to apply a second electric potential to its respective one or more conductor lines, and wherein the first electric potential has an opposite electrical charge of the second electric potential.
12. The assembly according to claim 1, wherein the first component includes a first bonding structure in the respective contact area, and the second component includes a second bonding structure in the respective contact area, and wherein the first bonding structure is arranged to align with and face the second bonding structure.
13. The assembly according to claim 12, wherein at least one of first bonding structure or the second bonding structure includes a solder ball or microbump.
14. The assembly according to claim 1, wherein at least one of the first component or the second component includes a single conductor line that runs in a closed loop along a circumference of the respective contact area.
15. The assembly according to claim 1, wherein each of the first component and the second component includes a single conductor line, wherein the first component is configured to apply a first electric potential to its respective single conductor line, wherein the second component is configured to apply a second electric potential to its respective single conductor line, and wherein the first electric potential has an opposite electrical charge of the second electric potential.
16. The assembly according to claim 1, wherein the first component and the second component are micro-electronic components.
17. The assembly according to claim 1, wherein the means for applying an electrical charge includes a contact lead.
18. The assembly according to claim 1, wherein the one or more conductor lines of the first component are located in a recess running around a circumference of the respective contact area of the first component, and wherein the conductor lines of the second component extend outwardly from a surface of the second component, wherein the recess of the first component and the surface of the second component are configured to fit together in a lock and key fashion.
19. The assembly according to claim 1, wherein the one or more conductor lines of the first component are facing and aligned with the one or more conductor lines of the second component.
20. The assembly according to claim 19, further comprising the liquid disposed between the contact area of the first component and the contact area of the second component.
Description
BRIEF DESCRIPTION OF THE FIGURES
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DETAILED DESCRIPTION OF THE DISCLOSURE
(10) According to the disclosure, alignment of a first micro-electronic component to a receiving surface of a second micro-electronic component is realised by a capillary force-induced self-alignment as described above, combined with an electrostatic alignment, driven by an electrostatic force. The latter is accomplished by providing at least one first electrical conductor line along the periphery of a contact area of the first component, and at least one second electrical conductor line along the periphery of a contact area at the location on the receiving surface of the second component onto which the component is to be placed. The contact areas, i.e. the areas that need to be in alignment in the assembly of the two components, are complementary, meaning that they have the same shape and essentially the same size. Likewise, the conductors on the first and second component, given that these conductors are running along the circumference of the contact areas, are complementary, meaning that they have corresponding shapes in the plane of the contact areas, and that the conductor lines of the first component are facing the conductor lines of the second component when the two components are aligned.
(11) The contact areas are furthermore covered with a wetting layer or may be treated for creating the wetting properties in that area. A wetting layer or wetting material is defined in the context of this description as a layer or material that enhances wettability of a given alignment liquid to the wetting layer. An alignment liquid is defined in the context of this description as a liquid applied to establish self-alignment by capillary force, as described in the introductory portion. The most prominent example of wetting layer is a hydrophilic layer, i.e. a layer that enhances the contact to the alignment liquid water by exhibiting a very low contact angle between a drop of water applied to the layer and the layer surface. The components to be aligned are furthermore provided with a means for containing a self-alignment liquid on the wetting layers, i.e. on the contact areas. Being covered with a wetting layer means that the material on the upper surface of the contact areas has wetting properties.
(12) According to one embodiment, the electrical conductor lines are embedded in a strip of anti-wetting material that runs along the peripheries. Anti-wetting material is defined in the context of this description as the opposite of wetting material defined above, i.e. material that impedes contact between the material and a given alignment liquid. The main example here is a hydrophobic material which exhibits a high contact angle or low wettability between a layer of the material and a drop of water applied to it. The wetting and anti-wetting materials are instrumental in maintaining a drop of alignment liquid between the contact areas so as to obtain self-alignment by capillary force. By applying appropriate charges on the conductor lines, electrostatic self-alignment is realized, which improves the alignment obtained through capillary force, and maintains the alignment during evaporation of the alignment liquid. As this liquid evaporates, the gap between the components decreases, which leads to an increase in the electrostatic alignment force. In this way, high quality alignment is ensured throughout the assembly process.
(13) A number of different embodiments are described with reference to the enclosed drawings. In each case, the alignment is described of a chip 3 to a substrate 1, which represent examples of the first and second component referred to in the appended claims. It is to be noted however that the method is applicable to the alignment of any type of component to any type of substrate, including for example the alignment of a chip to another chip in a stacked assembly of IC chips. For the sake of readability of the description, the terms hydrophobic, hydrophilic are used and the alignment liquid applied is water, but throughout this description, any of these terms may be replaced by the more general wetting anti-wetting and alignment liquid.
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(15) The alignment process for this embodiment may comprise the following steps: Applying water to the substrate's contact area 2. The water spreads out over the full area 2 as a consequence of the hydrophilic character of the layer 5. The amount of water depends on the size of the contact areas 2/4. The water is contained in this area through the surrounding strips 8 of hydrophobic material. Placing the chip 3 with its contact area 4 covered with a hydrophilic layer 5 facing the substrate's contact area 2 covered with another hydrophilic layer 5, so that the water contacts both hydrophilic contact areas 2/4, thereby allowing establishing self-alignment through capillary force. This step may be done by pre-aligning the chip (placing it in approximate alignment to the substrate's contact area), holding the chip in a pre-aligned position until the water fully contacts both contact areas 2 and 4, then releasing the chip, so that it can move freely on the water so that self-alignment takes place. Applying an electric potential such as to charge the conductor lines 6 and 7 with opposite charges, thereby establishing alignment through electrostatic alignment as described above. The conductor lines may be charged before or after the chip 3 is placed above the substrate 1. The result of this step is an assembly of the substrate and chip, aligned with respect to each other, but not yet bonded together definitively, Heating the assembly to thereby remove the water through evaporation, or letting the assembly dry until the water has evaporated. As the water evaporates, the gap between the two components decreases which in return increases the electrostatic pull between the components thereby assisting in final bonding.
(16) These steps may be followed by the realization of a definitive bond between the chip and the substrate, for example by reflow bonding or direct bonding. The charges may be removed either before or after the latter step of realizing a definitive bond.
(17) A second embodiment is illustrated in
(18) A third embodiment illustrated in
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(20) The chip 3 that is to be bonded to the substrate of
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(23) The method of the disclosure may be applied for producing a stack of several components, or multiple stacks, for example one or more stacks of chips on a carrier substrate. This is illustrated in
(24) Two further embodiments are illustrated in
(25) According to an embodiment, a further alignment means is added to the electrostatic and the capillary force-induced alignment means described above. This is referred to as a conformal lock and key-based alignment, obtained by suitable processing of the conductor lines on one of the components that are to be aligned. Different approaches to conformal lock and key can be adopted depending on the requirement of the (micro)components that are to be aligned. One such approach is illustrated in
(26) Other lock and key alignment means may be present instead of or in addition to the mechanism of
(27) Other embodiments or variations on the general principle of the disclosure are within the scope of the appended claims, for example: the circumference of the contact areas may differ from a rectangular shape. According to an embodiment, the strip of anti-wetting material may be placed outside the conductor lines, when the conductor lines are incorporated in a passivation layer that is part of the component to be aligned. In the case of
(28) In the above-described embodiments where one of the components to be aligned is provided with a non-charged conductor line 11, this conductor line has been described as a closed loop. However, this is not a requirement. For example a series of conductor lines running along the circumference of the contact area could be used, each conductor line being separately chargeable through the proximity of the positively and negatively charged conductors 6/7 in the opposing component.
(29) The strip of anti-wetting material referred to in the above description and the claims are preferably forming a closed loop around the contact area. However, according to specific embodiments, the strip may be interrupted by areas which are not anti-wetting, provided that the size of these areas is small enough not to cause a leak of alignment liquid from the contact areas. The width of a strip is related to the size of the active area and the amount of alignment liquid to be contained, and can be determined by the skilled person. Equally, the allowable size of openings in the strips is depending on the type of liquid used.
(30) The alignment conductor lines 6/7/11/15/16 shown in the above-described embodiments or applied in any embodiment according to the disclosure need not necessarily be embedded in a strip of anti-wetting material or in a passivation layer of the component to be aligned. According to embodiments of the disclosure, the conductor lines of at least one of the components to be aligned is not embedded in any material, e.g. on top of a strip of anti-wetting material or on top of a passivation layer, such as the last metallization level of the BEOL portion of a component. Care must be taken in that case that the conductors are not in physical contact during the alignment procedure, for example by appropriately sizing the copper contact bumps.
(31) The voltage applied for charging the conductor lines via an electrical potential supplied through an external source may vary depending on the size of the contact areas and other parameters related to the components. It may be DC or an AC voltage. For example a DC voltage between 10 and 1000V may be applicable depending on specific parameters.
(32) The contact areas 2 and 4 are preferably as large as possible with respect to the component to be aligned. For example, the contact area 4 of the chip preferably corresponds to the surface area of the chip, as in the case of
(33) In any embodiment according to the disclosure, the means for containing the alignment liquid on the contact areas can be brought into practice by any means for creating a wettability contrast between a first and second area. For example, the conductor lines themselves could be given anti-wetting properties by applying a self-assembled monolayer (SAM) to the conductors. Another way of obtaining a wettability contrast is Silicon recess etching.
(34) In any embodiment where a single conductor line is shown (11 in
(35) By way of example, a possible method for producing a conductor line on a component is described hereafter. On a glass carrier substrate, a layer of molybdenum is deposited by Physical Vapour Deposition. The layer is patterned by standard litho/plasma etching to form the conductor line. On top of the conductor line and the whole of the substrate, subsequent depositions are performed of SiO2 and SiN at high temperature, by Plasma Enhanced Physical Vapour Deposition, after which these layers are again patterned to form a stack of SiO2 and SiN at least on top of the conductor line. The stack of SiO2 and SiN, possibly after being provided with an anti-wetting coating or treatment, form an anti-wetting strip 8/12 as shown in
(36) While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or by way of example and not restrictive. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed disclosure, 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. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
(37) The foregoing description details certain embodiments of the disclosure. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the disclosure may be practiced in many ways, and is therefore not limited to the embodiments disclosed. It should be noted that the use of particular terminology when describing certain features or aspects of the disclosure should not be taken to imply that the terminology is being re-defined herein to be restricted to include any specific characteristics of the features or aspects of the disclosure with which that terminology is associated.
(38) Unless specifically specified, the description of a layer being present, deposited or produced on another layer or substrate, includes the options of the layer being present, produced or deposited directly on, i.e. in physical contact with, the other layer or substrate, and the layer being present, produced or deposited on one or a stack of intermediate layers between the layer and the other layer or substrate.