Source: https://patents.google.com/patent/US9302410B2/en
Timestamp: 2020-08-13 04:19:56+00:00
Document Index: 46547491

Matched Legal Cases: ['art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 90', 'art 90']

US9302410B2 - Method for cutting object to be processed - Google Patents
Method for cutting object to be processed Download PDF
US9302410B2
US9302410B2 US13/383,487 US201013383487A US9302410B2 US 9302410 B2 US9302410 B2 US 9302410B2 US 201013383487 A US201013383487 A US 201013383487A US 9302410 B2 US9302410 B2 US 9302410B2
US13/383,487
US20120111495A1 (en
2009-07-28 Priority to JP2009-175836 priority Critical
2009-07-28 Priority to JP2009175836A priority patent/JP5537081B2/en
2010-07-21 Application filed by Hamamatsu Photonics KK filed Critical Hamamatsu Photonics KK
2010-07-21 Priority to PCT/JP2010/062250 priority patent/WO2011013556A1/en
2012-01-11 Assigned to HAMAMATSU PHOTONICS K.K. reassignment HAMAMATSU PHOTONICS K.K. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KAWAGUCHI, DAISUKE, SHIMOI, HIDEKI, UCHIYAMA, NAOKI
2012-05-10 Publication of US20120111495A1 publication Critical patent/US20120111495A1/en
2016-04-05 Publication of US9302410B2 publication Critical patent/US9302410B2/en
239000000758 substrates Substances 0.000 claims abstract description 192
XUIMIQQOPSSXEZ-UHFFFAOYSA-N silicon Chemical compound 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[Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 134
239000011521 glasses Substances 0.000 claims description 48
238000000926 separation method Methods 0.000 abstract description 203
A silicon substrate 12 has a main face in a (100) plane, whereby a fracture 17 generated from a molten processed region 13 acting as a start point extends in a cleavage direction of the silicon substrate 12 (a direction orthogonal to the main face of the silicon substrate 12). Here, a rear face 1 b of an object to be processed 1A and a front face 10 a of an object to be processed for separation 10A are bonded to each other by anode bonding, whereby the fracture 17 reaches a front face 1a of the object 1A continuously without substantially changing its direction. When generating a stress in the object for separation 10A, the fracture 17 has reached a rear face 10 b of the object for separation 10A and thus easily extends toward the object 1A.
For achieving the above-mentioned object, the object cutting method in accordance with the present invention comprises the steps of bonding a first-side end face of a first sheet-like object to be processed comprising a silicon substrate having a main face in a (100) plane and a second-side end face of a second sheet-like object to be processed such that the second-side end face opposes the main face; irradiating the first object with laser light so as to form a molten processed region within the silicon substrate along a line to cut for the second object and cause a fracture generated from the molten processed region acting as a start point to reach a second-side end face of the first object along the line; and generating a stress in the first object so as to cause the fracture to reach a first-side end face of the second object along the line and cut the second object along the line.
In this object cutting method, since the main face of the silicon substrate is in the (100) plane, the fracture generated from the molten processed region acting as a start point extends in a cleavage direction of the silicon substrate (i.e., a direction orthogonal to the main face of the silicon substrate) in the first object. Here, since the second-side end face of the second object is bonded to the first-side end face of the first object, the fracture grown in the direction orthogonal to the main face of the silicon substrate in the first object is transmitted to the second object without substantially changing its direction, thus reaching the first-side end face of the second object. When generating a stress in the first object, the fracture generated from the molten processed region acting as a start point has reached the second-side end face of the first object and thus can easily be extended toward the second object. Therefore, forming the molten processed region within the silicon substrate of the first object along the line to cut for the second object can accurately cut the second object along the line without forming any cutting start point in the second object.
Preferably, the first-side end face of the first object and the second-side end face of the second object are bonded to each other by anode bonding. Preferably, the first-side end face of the first object and the second-side end face of the second object are bonded to each other by surface-activated direct bonding. These bonding methods directly bond the first-side end face of the first object and the second-side end face of the second object firmly to each other. Therefore, the fracture grown in the direction orthogonal to the main face of the silicon substrate in the first object can reliably be extended into the second object continuously without substantially changing its direction through an interface between the first-side end face of the first object and the second-side end face of the second object.
Preferably, the stress is generated in the first object by expanding an expandable holding member attached to the second-side end face of the first object. In this case, since the fracture generated from the molten processed region acting as a start point has reached the second-side end face of the first object, simply expanding the holding member attached to the second-side end face of the first object can easily extend the fracture toward the second object.
Preferably, the silicon substrate has a thickness greater than that of the second object. This further enhances the straightforwardness of the fracture grown in the direction orthogonal to the main face of the silicon substrate in the first object. Therefore, the fracture can reliably be extended into the second object continuously without substantially changing its direction through the interface between the first-side end face of the first object and the second-side end face of the second object.
Preferably, the second object has a plurality of functional devices, and the line to cut is set such as to pass between the functional devices adjacent to each other. In this case, chips having the functional devices can be obtained with a favorable yield.
[FIG. 1] is a schematic structural diagram of a laser processing apparatus used for forming a modified region;
[FIG. 2] is a plan view of an object to be processed for which the modified region is formed;
[FIG. 3] is a sectional view of the object taken along the line of FIG. 2;
[FIG. 4] is a plan view of the object after laser processing;
[FIG. 7] is a view illustrating a photograph of a cut section of a silicon wafer after laser processing;
[FIG. 8] is a graph illustrating relationships between the peak power density of laser light and crack spot size;
[FIG. 9] is a graph illustrating relationships between the peak power density of laser light and crack spot size;
[FIG. 10] is a plan view of an object to be processed to which the object cutting method in accordance with a first embodiment is applied;
[FIG. 11] is a partial sectional view of the object taken along a line to cut in FIG. 10;
[FIG. 12] is a partial sectional view of the object for explaining the object cutting method in accordance with the first embodiment;
[FIG. 13] is a partial sectional view of the object for explaining the object cutting method in accordance with the first embodiment;
[FIG. 14] is a partial sectional view of the object for explaining the object cutting method in accordance with the first embodiment;
[FIG. 15] is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with a second embodiment is applied;
[FIG. 16] is a partial sectional view of the object for explaining the object cutting method in accordance with the second embodiment;
[FIG. 17] is a partial sectional view of the object for explaining the object cutting method in accordance with the second embodiment;
[FIG. 18] is a partial sectional view of the object for explaining the object cutting method in accordance with the second embodiment;
[FIG. 19] is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with a third embodiment is applied;
[FIG. 20] is a partial sectional view of the object for explaining the object cutting method in accordance with the third embodiment;
[FIG. 21] is a partial sectional view of the object for explaining the object cutting method in accordance with the third embodiment;
[FIG. 22] is a partial sectional view of the object for explaining the object cutting method in accordance with the third embodiment;
[FIG. 23] is a sectional view of the object for explaining an example of forming a molten processed region for separation in an object to be processed for separation;
[FIG. 24] is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with a fourth embodiment is applied;
[FIG. 25] is a partial sectional view of the object for explaining the object cutting method in accordance with the fourth embodiment;
[FIG. 26] is a partial sectional view of the object for explaining the object cutting method in accordance with the fourth embodiment;
[FIG. 27] is a partial sectional view of the object for explaining the object cutting method in accordance with the fourth embodiment;
[FIG. 28] is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with a fifth embodiment is applied;
[FIG. 29] is a partial sectional view of the object for explaining the object cutting method in accordance with the fifth embodiment;
[FIG. 30] is a partial sectional view of the object for explaining the object cutting method in accordance with the fifth embodiment;
[FIG. 31] is a partial sectional view of the object for explaining the object cutting method in accordance with the fifth embodiment;
[FIG. 32] is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with a sixth embodiment is applied;
[FIG. 33] is a sectional view of the object cut by the object cutting method in accordance with the sixth embodiment;
[FIG. 34] is a view representing photographs of cross sections of silicon and glass substrates in which modified regions were formed by an example;
[FIG. 35] is a view representing photographs of cross sections of silicon and glass substrates cut by the example;
[FIG. 36] is a view representing photographs of cross sections of silicon and LTCC substrates cut by an example; and
[FIG. 37] is a structural view of the object illustrating an example of forming the molten processed region for separation.
Also, modified regions formed by employing ultrashort-pulsed laser light having a pulse width of several picoseconds to femtoseconds may be utilized as described in D. Du, X. Liu, G Korn, J. Squier, and G Mourou, “Laser Induced Breakdown by Impact Ionization in SiO2 with Pulse Widths from 7 ns to 150 fs”, Appl. Phys. Lett. 64(23), Jun. 6, 1994.
FIG. 10 is a plan view of an object to be processed to which the object cutting method in accordance with the first embodiment is applied, while FIG. 11 is a partial sectional view of the object taken along a line to cut in FIG. 10. As illustrated in FIGS. 10 and 11, a sheet-like object to be processed (second object to be processed) 1A comprises an LTCC substrate 2 containing no alkali metals, a device layer 4 formed on a front face 2 a of the LTCC substrate 2, and a glass layer 6 formed on a rear face 2 b of the LTCC substrate 2. Here, a front face 4 a of the device layer 4 becomes a front face (first-side end face) 1 a of the object 1A, while a rear face 6 b of the glass layer 6 becomes a rear face (second-side end face) 1 b of the object 1A.
First, as illustrated in FIG. 12(a), a sheet-like object to be processed for separation (first object to be processed) 10A comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes is prepared. Here, since the object for separation 10A is made of the silicon substrate 12 alone, the front face 12 a of the silicon substrate 12 becomes a front face (first-side end face) 10 a of the object for separation 10A, while the rear face 12 b of the silicon substrate 12 becomes a rear face (second-side end face) 10 b of the object for separation 10A.
Subsequently, the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are directly bonded to each other. This makes the rear face 1 b of the object 1A oppose the main face of the silicon substrate 12. The front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are directly bonded to each other by anode bonding. That is, while the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are in contact with each other and heated to 300° C. or higher, a positive voltage of several hundred V to several kV is applied to the object for separation 10A with reference to the object 1A. This generates an electrostatic attractive force between the objects 10A, 1A, whereby the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are bonded to each other by covalent bonding.
More specifically, alkali metal ions in the glass layer 6 of the object 1A migrate toward the object for separation 10A, so that the rear face 6 b of the glass layer 6 is charged negatively (polarized). Here, the object for separation 10A side is charged positively, an electrostatic attractive force occurs between the objects 10A, 1A, so that they attract each other until they come into contact with each other in an atomic level. Then, while surplus oxygen atoms existing on the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are released as an oxygen gas, the remaining oxygen atoms are shared by silicon atoms in the silicon substrate 12 and glass layer 6, so that the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A are firmly bonded to each other.
Next, the objects 1A, 10A are secured onto a support table (not depicted) of a laser processing apparatus such that the rear face 10 b of the object for separation 10A faces up. Then, as illustrated in FIG. 12(b), the object for separation 10A is irradiated with the laser light L while using its rear face 10 b as a laser light entrance surface and locating the converging point P within the silicon substrate 12, and the support table is shifted, so as to move the converging point P relatively along each line to cut 5. The converging point P is relatively moved along each line to cut 5 for a plurality of times with respective distances from the rear face 10 b to where the converging point P is located, so as to form, one by one, a plurality of rows of molten processed regions 13 for each line to cut 5.
Here, a fracture 17 generated in the thickness direction of the object for separation 10A from the molten processed region 13 acting as a start point is caused to reach the rear face 10 b of the object for separation 10A along the line 5. The number of rows of molten processed regions 13 to be formed for each line to cut 5 varies depending on the thickness of the object for separation 10A and the like. For example, when the object for separation 10A is relatively thin, so that forming one line of molten processed region 13 for each line to cut 5 can cause the fracture 17 to reach the rear face 10 b of the object for separation 10A, it is unnecessary for a plurality of rows of molten processed regions 13 to be formed for each line to cut 5.
Subsequently, as illustrated in FIG. 13(a), an expandable tape (holding member) 21 is attached to the rear face 10 b of the object for separation 10A. Then, as illustrated in FIG. 13(b), the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10A. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the front face 1 a of the object 1A along the lines 5 through the glass layer 6 patterned into the grid, thereby cutting the object 1A along the lines 5.
As explained in the foregoing, the main faces of the silicon substrate 12 are in (100) planes in the object cutting method in accordance with the first embodiment. Therefore, the fractures 17 generated from the molten processed regions 13 acting as start points extend in a cleavage direction of the silicon substrate 12 (i.e., a direction orthogonal to the main face of the silicon substrate 12) in the object for separation 10A.
Here, the rear face 1 b of the object 1A and the front face 10 a of the object for separation 10A are bonded to each other by anode bonding. Therefore, the fractures 17 grown in the direction orthogonal to the main faces of the silicon substrate 12 in the object for separation 10A can reliably be transmitted to the object 1A continuously without substantially changing its direction through an interface between the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A, thus reaching the front face 1 a of the object 1A.
When generating a stress in the object for separation 10A, the fracture 17 generated from the molten processed region 13 acting as a start point has reached the rear face 10 b of the object for separation 10A. Therefore, simply expanding the expandable tape 21 attached to the rear face 10 b of the object for separation 10A makes it easy for the fractures 17 generated from the molten processed regions 13 acting as start points to extend toward the object 1A.
As in the foregoing, forming the molten processed regions 13 within the silicon substrate 12 of the object for separation 10A along the lines to cut 5 can accurately cut the object 1A along the lines 5 without forming any cutting start points in the object 1A. Since there are no molten processed regions 13 in the cut sections of the resulting chips 19, the bending strength of the chips 19 can be improved.
Forming the glass layer 6 containing an alkali metal can bond the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A to each other by anode bonding even when the LTCC substrate 2 containing no alkali metal is used for the object 1A. This can also prevent the device layer 4 from being contaminated with alkali metals when forming the device layer 4 on the front face 2 a of the LTCC substrate 2.
The object for separation 10A is irradiated with the laser light L while using its rear face 10 b as a laser light entrance surface. Therefore, the molten processed regions 13 can reliably be formed within the silicon substrate 12 of the object for separation 10A regardless of whether the object 1A to cut is easy or hard to guide the laser light L therein.
Making the silicon substrate 12 thicker than the object 1A can further enhance the straightforwardness of the fractures 17 grown in the direction orthogonal to the main faces of the silicon substrate 12 in the object for separation 10A. In this case, the fractures 17 grown in the direction orthogonal to the main faces of the silicon substrate 12 in the object for separation 10A can more reliably be transmitted to the object 1A continuously without substantially changing its direction through the interface between the front face 10 a of the object for separation 10A and the rear face 1 b of the object 1A.
FIG. 15 is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with the second embodiment is applied. As illustrated in FIG. 15, a sheet-like object to be processed (second object to be processed) 1B comprises an LTCC substrate 2 containing no alkali metals and a device layer 4 formed on a front face 2 a of the LTCC substrate 2. The device layer 4 has a plurality of functional devices 15 arranged in a matrix, while lines to cut 5 are set like a grid passing between the functional devices 15 adjacent to each other. Here, a front face 4 a of the device layer 4 becomes a front face (second-side end face) 1 a of the object 1B, while a rear face 2 b of the LTCC substrate 2 becomes a rear face (first-side end face) 1 b of the object 1B.
First, as illustrated in FIG. 16(a), a sheet-like object to be processed for separation (first object to be processed) 10B comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes and a glass layer 6 formed on the rear face 12 b of the silicon substrate 12 is prepared. Here, a front face 12 a of the silicon substrate 12 becomes a front face (second-side end face) 10 a of the object for separation 10B, while a rear face 6 b of the glass layer 6 becomes a rear face (first-side end face) 10 b of the object for separation 10B.
Subsequently, the rear face 10 b of the object for separation 10B and the front face 1 a of the object 1B are bonded to each other by anode bonding. This makes the front face 1 a of the object 1B oppose the main face of the silicon substrate 12.
Next, as illustrated in FIG. 16(b), the object for separation 10B is irradiated with the laser light L while using its front face 10 a as a laser light entrance surface and locating the converging point P within the silicon substrate 12, so as to form a plurality of rows of molten processed regions 13 for each line to cut 5 within the silicon substrate 12. Here, a fracture 17 generated in the thickness direction of the object for separation 10B from the molten processed region 13 acting as a start point is caused to reach the front face 10 a of the object for separation 10B along the lines 5.
Subsequently, as illustrated in FIG. 17(a), an expandable tape 21 is attached to the front face 10 a of the object for separation 10B. Then, as illustrated in FIG. 17(b), the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10B. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the rear face 1 b of the object 1B along the lines 5 through the glass layer 6 patterned into the grid, thereby cutting the object 1B along the lines 5.
FIG. 19 is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with the third embodiment is applied. As illustrated in FIG. 19, a sheet-like object to be processed (second object to be processed) 1C comprises an LTCC substrate 2 containing no alkali metals and a device layer 4 formed on a front face 2 a of the LTCC substrate 2. The device layer 4 has a plurality of functional devices 15 arranged in a matrix, while lines to cut 5 are set like a grid passing between the functional devices 15 adjacent to each other. Here, a front face 4 a of the device layer 4 becomes a front face (first-side end face) 1 a of the object 1C, while a rear face 2 b of the LTCC substrate 2 becomes a rear face (second-side end face) 1 b of the object 1C.
First, as illustrated in FIG. 20(a), a sheet-like object to be processed for separation (first object to be processed) 10C comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes is prepared. Here, since the object for separation 10C is made of the silicon substrate 12 alone, the front face 12 a of the silicon substrate 12 becomes a front face (first-side end face) 10 a of the object for separation 10C, while the rear face 12 b of the silicon substrate 12 becomes a rear face (second-side end face) 10 b of the object for separation 10C.
The front face 10 a of the object for separation 10C (i.e., the front face 12 a of the silicon substrate 12) is formed with depressions 14 arranged in a matrix so as to oppose the functional devices 15 when seen in the thickness direction of the object for separation 10C in the case where direct bonding which will be explained is performed. Therefore, a remaining part 16 separating the adjacent depressions 14 from each other is patterned into a grid so as to include the lines to cut 5 when seen in the thickness direction of the object for separation 10C in the case where direct bonding which will be explained later is performed. A molten processed region for separation (for peeling) 18 is formed flatly in the remaining part 16.
Subsequently, the front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C are directly bonded to each other. This makes the rear face 1 b of the object 1C oppose the main face of the silicon substrate 12. The front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C are bonded to each other by surface-activated direct bonding.
More specifically, in a vacuum, the front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C are irradiated with ion beams of an inert gas or the like, so as to remove oxides, adsorbed molecules, and the like. As a consequence, in atoms exposed to the front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C, bonds for forming a chemical combination partly lose their counterparts and thus exhibit a strong binding force for other atoms. When the front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C are brought into contact with each other in this state, the front face 10 a and the rear face 1 b are firmly bonded to each other.
Next, as illustrated in FIG. 20(b), the object for separation 10C is irradiated with the laser light L while using its rear face 10 b as a laser light entrance surface and locating the converging point P within the silicon substrate 12, so as to form a plurality of rows of molten processed regions 13 for each line to cut 5. Here, a fracture 17 generated in the thickness direction of the object for separation 10C from the molten processed region 13 acting as a start point is caused to reach the rear face 10 b of the object for separation 10C along the lines 5.
Subsequently, as illustrated in FIG. 21(a), an expandable tape 21 is attached to the rear face 10 b of the object for separation 10C. Then, as illustrated in FIG. 21(b), the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10C. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the front face 1 a of the object 1C along the lines 5 through the remaining part 16 patterned into the grid, thereby cutting the object 1C along the lines 5.
The following is an example of forming the molten processed region for separation 18 for the object for separation 10C. As illustrated in FIG. 23(a), the object for separation 10C is rotated about its center line CL. Then, as illustrated in FIGS. 23(a) to (d), the object for separation 10C is irradiated with the laser light L, while using its front face 10 a as a laser light entrance surface and locating the converging point P in the vicinity of the front face 12 a of the silicon substrate 12, with the converging point P relatively moving from an outer peripheral part of the object for separation 10C toward the center part thereof. This forms the molten processed region for separation 18 flatly in the vicinity of the front face 10 a of the object for separation 10C (i.e., in the vicinity of the front face 12 a of the silicon substrate 12).
Of course, the rear face 10 b of the object for separation 10C may be used as a laser light entrance surface, and the converging point P may be moved relatively from the center part of the object for separation 10C toward the outer peripheral part. The object for separation 10C may be formed with the depressions 14 before or after forming the object for separation 10C with the molten processed region for separation 18. The object for separation 10C may also be formed with the molten processed region for separation 18 after bonding the front face 10 a of the object for separation 10C and the rear face 1 b of the object 1C to each other.
FIG. 24 is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with the fourth embodiment is applied. As illustrated in FIG. 24, a sheet-like object to be processed (second object to be processed) 1D has a structure similar to that of the above-mentioned object 1C in the third embodiment. Here, the front face 4 a of the device layer 4 becomes a front face (second-side end face) 1 a of the object 1D, while the rear face 2 b of the LTCC substrate 2 becomes a rear face (first-side end face) 1 b of the object 1D.
First, as illustrated in FIG. 25(a), a sheet-like object to be processed for separation (first object to be processed) 10D comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes is prepared. Here, since the object for separation 10D is made of the silicon substrate 12 alone, the front face 12 a of the silicon substrate 12 becomes a front face (second-side end face) 10 a of the object for separation 10D, while the rear face 12 b of the silicon substrate 12 becomes a rear face (first-side end face) 10 b of the object for separation 10D.
The rear face 10 b of the object for separation 10D (i.e., the rear face 12 b of the silicon substrate 12) is formed with depressions 14 arranged in a matrix so as to oppose the functional devices 15 when seen in the thickness direction of the object for separation 10D in the case where direct bonding which will be explained is performed. Therefore, a remaining part 16 separating the adjacent depressions 14 from each other is patterned into a grid so as to include the lines to cut 5 when seen in the thickness direction of the object for separation 10D in the case where direct bonding which will be explained later is performed. A molten processed region for separation 18 is formed flatly in the remaining part 16.
Subsequently, the rear face 10 b of the object for separation 10D and the front face 1 a of the object 1D are bonded to each other by surface-activated direct bonding. This causes the front face 1 a of the object 1D to oppose the main face of the silicon substrate 12.
Next, as illustrated in FIG. 25(b), the object for separation 10D is irradiated with the laser light L while using its front face 10 a as a laser light entrance surface and locating the converging point P within the silicon substrate 12, so as to form a plurality of rows of molten processed regions 13 for each line to cut 5. Here, a fracture 17 generated in the thickness direction of the object for separation 10D from the molten processed region 13 acting as a start point is caused to reach the front face 10 a of the object for separation 10D along the lines 5.
Subsequently, as illustrated in FIG. 26(a), an expandable tape 21 is attached to the front face 10 a of the object for separation 10D. Then, as illustrated in FIG. 26(b), the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10D. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the rear face 1 b of the object 1D along the lines 5 through the remaining part 16 patterned into the grid, thereby cutting the object 1D along the lines 5.
FIG. 28 is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with the fifth embodiment is applied. First, as illustrated in FIG. 28, a sheet-like object to be processed for separation (first object to be processed) 10E comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes is prepared. Here, since the object for separation 10E is made of the silicon substrate 12 alone, the front face 12 a of the silicon substrate 12 becomes a front face (first-side end face) 10 a of the object for separation 10E, while the rear face 12 b of the silicon substrate 12 becomes a rear face (second-side end face) 10 b of the object for separation 10E.
Here, a molten processed region for separation 18 is formed flatly in the vicinity of the front face 10 a of the object for separation 10E (i.e., the front face 12 a of the silicon substrate 12). The molten processed region for separation 18 is formed such as to be located at least closer to the front face 12 a than is the center position in the thickness direction of the silicon substrate 12.
Subsequently, as illustrated in FIG. 29(a), a shield layer 22 is formed on the front face 10 a of the object for separation 10E. Then, a plurality of insulating resin layers 23 and a plurality of wiring layers 24 are stacked alternately on the shield layer 22, and a connection terminal layer 25 is finally formed thereon. This yields an object to be processed (second object to be processed) 1E having a plurality of circuit modules 26 arranged in a matrix. Lines to cut 5 for cutting the object 1E into a plurality of chips are set like a grid passing between the circuit modules 26 adjacent to each other. Here, a front face 25 a of the connection terminal layer 25 becomes a front face (first-side end face) 1 a of the object 1E, while a rear face 22 b of the shield layer 22 becomes a rear face (second-side end face) 1 b of the object 1E.
Bonding the front face 10 a of the object for separation 10E and the rear face 1 b of the object 1E to each other also encompasses a mode in which the object 1E is thus directly formed on the front face 10 a of the object for separation 10E. This causes the rear face 1 b of the object 1E to oppose the main face of the silicon substrate 12.
Next, as illustrated in FIG. 29(b), the object for separation 10E is irradiated with the laser light L while using its rear face 10 b as a laser light entrance surface and locating the converging point P within the silicon substrate 12, so as to form a plurality of rows of molten processed regions 13 for each line to cut 5 within the silicon substrate 12. Here, a fracture 17 generated in the thickness direction of the object for separation 10E from the molten processed region 13 acting as a start point is caused to reach the rear face 10 b of the object for separation 10E along the lines 5.
Subsequently, as illustrated in FIG. 30(a), an expandable tape 21 is attached to the rear face 10 b of the object for separation 10E. Then, as illustrated in FIG. 30(b), the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10E. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the front face 1 a of the object 1E along the lines 5, thereby cutting the object 1E along the lines 5.
FIG. 32 is a partial sectional view, taken along a line to cut, of an object to be processed to which the object cutting method in accordance with the sixth embodiment is applied. As illustrated in FIG. 32, a sheet-like object to be processed (second object to be processed) 1F comprises a sapphire substrate 31 and a semiconductor layer 32 formed on a front face 31 a of the sapphire substrate 31. The semiconductor layer 32 has a plurality of functional devices 15 arranged in a matrix, while lines to cut 5 are set like a grid passing between functional devices 15 adjacent to each other. Here, a front face 32 a of the semiconductor layer 32 becomes a front face (first-side end face) 1 a of the object 1F, while a rear face 31 b of the sapphire substrate 31 becomes a rear face (second-side end face) 1 b of the object 1F.
First, a sheet-like object to be processed for separation (first object to be processed) 10F comprising a silicon substrate 12 having main faces (i.e., front and rear faces 12 a, 12 b) in (100) planes is prepared. Here, since the object for separation 10F is made of the silicon substrate 12 alone, the front face 12 a of the silicon substrate 12 becomes a front face (first-side end face) 10 a of the object for separation 10F, while the rear face 12 b of the silicon substrate 12 becomes a rear face (second-side end face) 10 b of the object for separation 10F.
Here, a molten processed region for separation 18 is formed flatly in the vicinity of the front face 10 a of the object for separation 10F (i.e., the front face 12 a of the silicon substrate 12). The molten processed region for separation 18 is formed such as to be located at least closer to the front face 12 a than is the center position in the thickness direction of the silicon substrate 12.
Next, the front face 10 a of the object for separation 10F and the rear face 1 b of the object 1F are bonded to each other by surface-activated direct bonding. This causes the rear face 1 b of the object 1F to oppose the main face of the silicon substrate 12.
Subsequently, the object for separation 10F is irradiated with the laser light L while using its rear face 10 b as a laser light entrance surface and locating the converging point P within the silicon substrate 12, so as to form a plurality of rows of molten processed regions 13 for each line to cut 5 within the silicon substrate 12. Here, a fracture 17 generated in the thickness direction of the object for separation 10F from the molten processed region 13 acting as a start point is caused to reach the rear face 10 b of the object for separation 10F along the lines 5.
Thereafter, an expandable tape 21 is attached to the rear face 10 b of the object for separation 10F. Then, the expandable tape 21 is expanded, so as to generate a stress in the object for separation 10F. That is, a force is applied to the object to be processed for separation through the expandable tape (holding member). This lets the fracture 17 reach the front face 1 a of the object 1F along the lines 5, thereby cutting the object 1F along the lines 5.
Next, as illustrated in FIG. 33(a), the cut pieces of the object for separation 10F are removed from the cut pieces of the object 1F, and a heat sink 41 is attached to the rear face 31 b of each cut piece of the sapphire substrate 31, so as to yield LED chips 42A each having one functional device 15. More specifically, all the cut pieces of the objects 1F, 10F are transferred from the expandable tape 21 to the holding tape. Then, while being attached to the holding tape, the cut pieces of the objects 1F, 10F are dipped into an etching liquid such as a KOH solution. This relatively rapidly (selectively) etches away the part formed with the molten processed region for separation 18 in the object for separation 10F, so that the cut pieces of the object for separation 10F are peeled off from the cut pieces of the object 1F.
Though such a stress as to deflect the sapphire substrate 31 occurs under the influence of the GaN layer within the semiconductor layer 32, bonding the rear face 1 b of the object 1F to the front face 10 a of the object for separation 10F can prevent the sapphire substrate 31 from deflecting.
For yielding the LED chips 42A, the cut pieces of the object for separation 10F are removed from the cut pieces of the object 1F, and the heat sink 41 is attached to the rear face 31 b of each cut piece of the sapphire substrate 31. This makes the heatsink 41 approach the active layer 35 by the thickness by which the cut piece of the object for separation 10F is removed, whereby the cooling efficiency of the LED chips 42A can be improved.
As illustrated in FIG. 33(b), the heatsink 41 may be attached to the rear face 10 b of the cut piece of the object for separation 10F without removing the cut piece of the object for separation 10F from the cut piece of the object 1F, so as to yield an LED chip 42B having one functional device 15. In this case, the cut piece of the object for separation 10F becomes a reflecting layer for the light generated in the active layer 35, whereby the light emission intensity of the LED chip 42B can be improved.
As illustrated in FIG. 34(a), a rear face 9 b of a glass substrate 9 having a thickness of 0.5 mm was bonded by anode bonding to a front face 12 a of a silicon substrate 12 having a thickness of 1 mm. Then, lines to cut 5 were set such as to cut the glass substrate 9 into chips each having a square form of 2 mm×2 mm, and 18 rows of molten processed regions 13 were formed within the silicon substrate 12 for each line to cut 5. In the photograph of FIG. 34(a), the molten processed regions 13 were also formed along the lines 5 in the direction perpendicular to the sheet. Here, a fracture 17 generated in the thickness direction of the silicon substrate 12 from the molten processed region 13 acting as a start point reached the rear face 12 b of the silicon substrate 12 but not the front face 12 a thereof. That is, a leading end 17 a of the fracture 17 on the front face 12 a side was separated from the front face 12 a within the silicon substrate 12. A tensile stress occurred in a part 90 b on the rear face 9 b side of the glass substrate 9 along the lines 5, while a compressive stress occurred in a part 90 a on the front face 9 a side of the glass substrate 9 along the lines 5.
In this state, an expandable tape attached to the rear face 12 b of the silicon substrate 12 was expanded, so as to generate a stress in the silicon substrate 12. This caused the fracture 17 to extend into the glass substrate 9 through the interface between the front face 12 a of the silicon substrate 12 and the rear face 9 b of the glass substrate 9, so as to reach the front face 9 a of the glass substrate 9, thereby cutting the glass substrate 9 along the lines 5. FIG. 34(b) is a photograph taken immediately after the fracture 17 entered the glass substrate 9; the fracture 17 grown in the direction orthogonal to the main face in the silicon substrate 12 was thus transmitted to the glass substrate 9 continuously without substantially changing its direction through the interface between the front face 12 a of the silicon substrate 12 and the rear face 9 b of the glass substrate 9.
FIG. 35 is a view representing photographs of cross sections of silicon and glass substrates cut by the above-mentioned example. The glass substrate 9 is seen to have been cut accurately along the lines 5 when the cut silicon substrate 12 and glass substrate 9 are observed from the front face 9 a side of the glass substrate 9 as illustrated in FIG. 35(a) or from a side face side as illustrated in FIG. 35(b). The cut section of the silicon substrate 12 and the cut section of the glass substrate 9 were continuous with each other in a direction parallel to the thickness direction without substantially shifting from each other.
FIG. 36 is a view representing photographs of cross sections of silicon and LTCC substrates cut by another example. Here, a rear face 2 b of an LTCC substrate 2 having a square form of 20 mm×20 mm with a thickness of 0.3 mm was bonded by anode bonding to a front face 12 a of a silicon substrate 12 having a square form of 25 mm×25 mm with a thickness of 1 mm. Then, lines to cut 5 were set such as to cut the LTCC substrate 2 into chips each having a square form of 2 mm×2 mm, and 18 rows of molten processed regions 13 were fanned within the silicon substrate 12 for each line to cut 5. This caused the fracture generated in the thickness direction of the silicon substrate 12 from the molten processed region 13 acting as a start point to reach the rear face 12 b of the silicon substrate 12.
In this state, an expandable tape attached to the rear face 12 b of the silicon substrate 12 was expanded, so as to generate a stress in the silicon substrate 12. This caused the fracture generated from the molten processed region 13 acting as a start point to reach the front face 2 a of the LTCC substrate 2 along the lines 5 as illustrated in FIG. 36(a), thereby cutting the LTCC substrate 2 along the lines 5. The photograph of FIG. 36(a) illustrates how the LTCC substrate 2 was cut so as to follow the cutting of the silicon substrate 12.
The LTCC substrate 2 is seen to have been cut accurately along the lines 5 when the cut silicon substrate 12 and LTCC substrate 2 are observed from the front face 2 a side of the LTCC substrate 2 as illustrated in FIG. 36(b) or from a side face side as illustrated in FIG. 36(c). The cut section of the silicon substrate 12 and the cut section of the LTCC substrate 2 were continuous with each other in a direction parallel to the thickness direction without substantially shifting from each other.
bonding a first-side end face of a first sheet-like object to be processed comprising a silicon substrate having a main face in a (100) plane and a second-side end face of a second sheet-like object to be processed such that the second-side end face of the second object opposes the main face of the first object, at least one of the first and second objects having a layer of material patterned into a grid formed thereon through which the first and second objects are bonded, an outermost periphery of the first object being located on an outer side of an outermost cutting line for the second object, such that upon completion of the bonding step, the outermost periphery of the first object is located the outer side of the outermost cutting line for the second object;
irradiating the first object with laser light, thereby forming a molten processed region within the silicon substrate along each of a plurality of intersecting cutting lines formed in a grid for the second object, and causing a fracture generated from each molten processed region which acts as a start point to reach a second-side end face of the first object along the cutting lines, wherein no molten processed region is formed in the second object upon irradiation with the laser light, and the molten processed regions are formed only within the first object, and wherein the grid of the layer of material patterned into a grid is aligned with the grid of the plurality of cutting lines formed in a grid;
generating a stress in the first object, thereby causing the fractures to reach a first-side end face of the second object along the cutting lines through the layer of material patterned into a grid, thereby cutting of second object along the cutting lines; and
etching away the layer of material patterned into a grid, thereby removing the layer of material patterned into a grid.
6. An object cutting method according to claim 1, wherein the silicon substrate has a thickness greater than that of the second object.
7. An object cutting method according to claim 1, wherein the second object comprises a plurality of functional devices; and
wherein the cutting line passes between the functional devices located adjacent to each other.
8. An object cutting method according to claim 1, wherein the second object comprises a glass substrate.
9. An object cutting method according to claim 1, wherein the second object comprises an LTCC substrate.
10. An object cutting method according to claim 1, wherein the second object comprises a sapphire substrate.
US13/383,487 2009-07-28 2010-07-21 Method for cutting object to be processed Active US9302410B2 (en)
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