PATENT DOCUMENT

Publication Number: US-11646384-B2
Application Number: US-202117174076-A
Country: US
Kind Code: B2

Title: Optoelectronic devices with non-rectangular die shapes

Abstract:
An optoelectronic module may include one or more non-rectangular optoelectronic dies e.g., light emitting diodes and photodiodes, arranged to maximize the usage of surface area when mounted to a base circuit board. Multi-axis and non-orthogonal axis dicing processes can be used to form the dies which have non-rectangular shapes.

Claims:
What is claimed is: 
     
       1. An optoelectronic module comprising:
 a base having a top surface including a plurality of bond pads; 
 an isolation barrier arranged over the top surface, wherein the isolation barrier includes one or more openings, such that a first opening of the one or more openings is positioned over a set of one or more bond pads of the plurality of bond pads; and 
 a plurality of non-rectangular shaped dies mounted on the set of one or more bond pads, and located laterally adjacent to sidewalls of the first opening; 
 wherein each of the non-rectangular shaped dies includes an inner edge facing a center of the first opening and an outer edge facing the sidewalls of the first opening such that the plurality the plurality of non-rectangular shaped dies is arranged in a ring pattern; 
 a plurality of wiring bond pads located inside of the inner edges toward the center; and 
 a plurality of wires connecting the plurality of non-rectangular shaped dies to the plurality of bond pads. 
 
     
     
       2. The optoelectronic module of  claim 1 , wherein the non-rectangular shaped dies are equidistantly spaced from each other. 
     
     
       3. The optoelectronic module of  claim 1 , wherein the plurality of non-rectangular shaped dies includes one or more trapezoid shaped dies. 
     
     
       4. The optoelectronic module of  claim 3 , wherein:
 the inner edges are shorter than the outer edges. 
 
     
     
       5. The optoelectronic module of  claim 4 , wherein the isolation barrier includes an outer frame and an inner optical barrier, wherein the plurality of non-rectangular shaped dies is between the outer frame and the inner optical barrier. 
     
     
       6. The optoelectronic module of  claim 5 , wherein the plurality of non-rectangular shaped dies is a plurality of photodiodes. 
     
     
       7. The optoelectronic module of  claim 1 , further comprising a cover over the isolation barrier, wherein the cover includes a window aligned over the first opening in the isolation barrier, wherein the window has a smaller area than the first opening. 
     
     
       8. The optoelectronic module of  claim 1 , further comprising a cover over the isolation barrier, wherein the cover includes a plurality of windows aligned over the plurality of non-rectangular shaped dies. 
     
     
       9. An optoelectronic module comprising:
 a base having a top surface; 
 an emitter assembly on the top surface; 
 a detector assembly on the top surface; and 
 an isolation barrier arranged over the top surface, wherein the isolation barrier includes a first opening around the emitter assembly, and a second opening around the detector assembly; 
 wherein one of the detector assembly and the emitter assembly includes a plurality of non-rectangular shaped dies; 
 wherein each of the non-rectangular shaped dies includes an inner edge facing a center of the first opening and an outer edge facing sidewalls of the first opening such that the plurality the plurality of non-rectangular shaped dies is arranged in a ring pattern; 
 a plurality of wiring bond pads located inside of the inner edges toward the center; and 
 a plurality of wires connecting the plurality of non-rectangular shaped dies to the plurality of bond pads. 
 
     
     
       10. The optoelectronic module of  claim 9 , wherein the each of the non-rectangular shaped dies has a shape selected from the group consisting of an isosceles trapezoid, a regular hexagon, an irregular hexagon, a regular octagon, a triangle, a disk, and a sector. 
     
     
       11. The optoelectronic module of  claim 10 , wherein the plurality of non-rectangular shaped dies is a plurality of non-rectangular shaped photodiodes of the detector assembly. 
     
     
       12. The optoelectronic module of  claim 11 , further comprising a cover over the isolation barrier, wherein the cover includes a first set of one or more first widows over the first opening, and a second set of one or more second windows over the second opening. 
     
     
       13. The optoelectronic module of  claim 12 , wherein:
 the plurality of non-rectangular shaped dies is a plurality of non-rectangular shaped photodiodes; 
 the second set of one or more second windows comprises a plurality of second windows arranged over the plurality of non-rectangular shaped photodiodes; and 
 each second window has a smaller area than a corresponding non-rectangular shaped photodiode. 
 
     
     
       14. The optoelectronic module of  claim 13 , wherein the isolation barrier includes an outer frame and an inner optical barrier, wherein the isolation barrier defines the first opening, and the outer frame defines the second opening, and the plurality of non-rectangular shaped photodiodes is between the outer frame and the inner optical barrier. 
     
     
       15. The optoelectronic module of  claim 13 , wherein each non-rectangular shaped photodiode is trapezoid shaped.

Description:
BACKGROUND 
     Field 
     Embodiments described herein relate to optoelectronic devices. More specifically, embodiments described herein relate to non-rectangular optoelectronic devices and methods of manufacture. 
     Background Information 
     Nearly all optoelectronic (light-emitting or light-detecting) semiconductor dies (light emitting diodes (LEDs), photodiodes, lasers, phototransistors, vertical surface cavity emitting lasers (VCSELs), etc.) that are used to build optical modules are rectangular in shape. Typically, “scribe-and-break” and blade dicing technologies are used to singulate each individual rectangular device (die) from a full semiconductor wafer. The design reasons why dies are rectangular shaped are primarily due to wafer utilization considerations and cost pressure to maintain a simple dicing process, while maintaining a high yield. 
     Traditional optical modules used in sensing applications or as telecommunication and/or data communication transceivers typically contain only a few (e.g., less than four) unique optoelectronic devices. In these cases, the optical module is designed, built, and optimized around industry-standard rectangular die shapes. 
     Wearable electronic devices, including electronic watches, have been outfitted with sensors of various sorts, including health sensors which can collect data representative of one or more aspects of the wearer&#39;s health. Such wearable electronic devices have proved useful, but may benefit from improved sensitivity and versatility. 
     SUMMARY 
     Optoelectronic modules are described in which non-rectangular shaped dies may be integrated into one or more emitter assemblies and detector assemblies. Additionally, various wafer processing methods are described to facilitate the formation and integration of the non-rectangular shaped dies. 
     In an embodiment, an optoelectronic module includes a base with a top surface including a plurality of bond pads. An isolation barrier is arranged over the top surface such that an opening though the isolation barrier is over the plurality of bond pads. A plurality of non-rectangular shaped dies is mounted on the plurality of bond pads, and laterally adjacent sidewalls of the opening. The non-rectangular shaped dies may be optoelectronic dies such as light emitting diodes (LEDs) for integration into an emitter assembly and/or photodiodes for integration into a detector assembly. In some embodiments a plurality of non-rectangular shaped dies is arranged in a pattern, such as a ring pattern, within the opening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention of the present disclosure will now be described in more detail with reference to exemplary embodiments of the apparatus and method, given only by way of example, and with reference to the accompanying drawings, in which: 
         FIG.  1    illustrates a system diagram of a portable electronic device in accordance with an embodiment; 
         FIG.  2 A  illustrates isometric view of a mobile telephone in accordance with an embodiment; 
         FIG.  2 B  illustrates an isometric view of a tablet computing device in accordance with an embodiment; 
         FIG.  2 C  illustrates an isometric view of a laptop computer in accordance with an embodiment; 
         FIG.  2 D  illustrates an isometric view of a wearable device in accordance with an embodiment; 
         FIG.  3    illustrates an exploded view of an optical module stack up in accordance with an embodiment; 
         FIG.  4    illustrates a top plan view of an optoelectronic module in accordance with an embodiment; 
         FIGS.  5 - 6    illustrate enlarged views of detector assemblies including rectangular and non-rectangular dies in accordance with embodiments; 
         FIG.  7    illustrates a top plan view of an optoelectronic module in accordance with an embodiment; 
         FIGS.  8 - 9    illustrate enlarged views of detector assemblies including rectangular and non-rectangular dies in accordance with embodiments; 
         FIG.  10 A  illustrates an exploded view of an optical module stack up in accordance with an embodiment; 
         FIG.  10 B  illustrates a top plan view of an optical module in accordance with an embodiment; 
         FIGS.  11 A- 13    illustrate top plan views of emitter assemblies including non-rectangular dies in accordance with embodiments; 
         FIG.  14 A  illustrates a top plan view of a prior wafer cutting pattern which produces rectangular dies; 
         FIG.  14 B  illustrates a top plan view of an embodiment of a wafer cutting pattern which produces non-rectangular dies; 
         FIG.  15    illustrates a top plan view of a first embodiment of a wafer cutting pattern incorporating multi-axis wafer dicing to produce non-rectangular dies; 
         FIG.  16    illustrates a top plan view of a second embodiment of a wafer cutting pattern incorporating multi-axis wafer dicing to produce non-rectangular dies; 
         FIG.  17    illustrates a top plan view of a third embodiment of a wafer cutting pattern incorporating multi-axis wafer dicing to produce non-rectangular dies; 
         FIG.  18    illustrates a top plan view of a yet another embodiment of an optoelectronic device with non-rectangular dies; 
         FIG.  19    illustrates a top plan view of another embodiment of a wafer cutting pattern to produce non-rectangular dies; and 
         FIG.  20    illustrates a flow diagram of a wafer-dicing process. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawing figures, like reference numerals designate identical or corresponding elements throughout the several figures. 
     Embodiments describe non-rectangular dies and processes of producing them. In various embodiments, description is made with reference to figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions, and processes, etc., to provide a thorough understanding of the embodiments. In other instances, well-known processes and manufacturing techniques have not been described in particular detail to not unnecessarily obscure the embodiments. Reference throughout this specification to “one embodiment” means that a particular feature, structure, configuration, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “in one embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a die” includes reference to one or more of such dies, and reference to “the die” includes reference to one or more of such dies. 
     In one aspect it has been observed that it may be highly desirable to maximize component packing density, and thus overall sensor performance, by packaging a large number (e.g., 10-20) of optoelectronic devices as well as active/passive optical components as tightly as possible within an optical module. Component packing inefficiency due to conventional rectangular die shapes bounds the best achievable sensor performance, because rectangular devices require sparse packing of optoelectronic components, resulting in smaller die active areas and reduced light outputs/collection efficiencies. The rectangular shapes of individual die limit the minimum distance between two devices, prevents the placement of devices in a close-packed geometry, and constrains the maximum achievable die size. 
     In one aspect, embodiments herein describe non-rectangular die shapes which may enable sensor optical designs and technologies and, when creatively designed, processed at high wafer utilizations and/or yields. The dies may be optoelectronic devices, e.g., LEDs, photodiodes, lasers, photo transistors, and/or VCSELs, with non-rectangular shapes; however, the dies may be other microelectronic devices and are not limited to being optoelectronic devices. New die architectures such as those described herein may allow maximization of the die area and enable flexible device placement within an optoelectronic, e.g., sensor, module. For example, trapezoid-shaped dies allow placement of such devices close together in a circular geometry and octagon-shaped dies allow a significant increase in the die areas when a die must fit inside a circle. This circular constraint is common in today&#39;s consumer products, which is why a non-rectangular die shape may be uniquely beneficial. 
     By way of a non-limiting example of an optical sensor module, given a fixed optoelectronic module size, maximizing the photodiode and LED die active area may increase the received signal level, which may lead to an increase in sensor performance. For a fixed die area, flexible die placement and higher device packing density allows a reduction of module area, which may enable space savings in the module as a whole. For example, an estimated approximately 15% collection efficiency improvement may be achieved using non-rectangular photodiodes when compared to rectangular photodiodes. 
     Many die shapes can be fabricated using extensions of traditional established processes. While rectangular die shapes are obtained by dicing the wafer along two perpendicular axes, as described elsewhere herein, trapezoids, octagons, hexagonal diamonds, and triangles can be fabricated using cuts along three axes. Processes described herein may also circumvent many of the cost constraints and wafer utilization concerns associated with non-rectangular shapes. Other shapes, including circles, circle segments, and arcs can be fabricated using, for example, dry etching. 
       FIG.  1    illustrates a system diagram for an embodiment of a portable electronic device  14  including an optical module  100  described herein. The portable electronic device  14  includes a processor  16  and memory  28  for managing the system and executing instructions. The memory includes non-volatile memory, such as flash memory, and can additionally include volatile memory, such as static or dynamic random access memory (RAM). The memory  28  can additionally include a portion dedicated to read only memory (ROM) to store firmware and configuration utilities. 
     The system also includes a power module  30  (e.g., flexible batteries, wired or wireless charging circuits, etc.), a peripheral interface  38 , and one or more external ports  39  (e.g., Universal Serial Bus (USB), HDMI, Display Port, and/or others). In one embodiment, the portable electronic device  14  includes a communication module  24  configured to interface with the one or more external ports  39 . For example, the communication module  24  can include one or more transceivers functioning in accordance with IEEE standards, 3GPP standards, or other communication standards, and configured to receive and transmit data via the one or more external ports  39 . The communication module  24  can additionally include one or more WWAN transceivers configured to communicate with a wide area network including one or more cellular towers, or base stations to communicatively connect the portable electronic device  14  to additional devices or components. Further, the communication module  24  can include one or more WLAN and/or WPAN transceivers configured to connect the portable electronic device  14  to local area networks and/or personal area networks, such as a Bluetooth network. 
     The electronic device  14  can further include a sensor controller  37  to manage input from one or more ambient sensors  22  such as temperature sensor, pressure sensor, humidity sensor, magnet, etc. The sensor controller  37  may additionally be connected to one or more haptics devices  40  such as a gyroscope, accelerometer, proximity sensor, ambient light sensor, infrared transceiver, etc. configured to provide force feedback, vibratory feedback, tactile sensations, etc. In accordance with embodiments, the sensor controller  37  can additionally be connected to an optical module  100 , including one or more (photo) emitters assemblies  250  and one or more (photo) detector assemblies  150 . For example, the optical module may be a health sensor such as a pulse sensor, an oximetry sensor, or both. In accordance with embodiments, the components of the electronic device may be used as sensors for detection of a variety of physical phenomena which can be correlated to, or representative of, aspects of the health of a user. 
     Still referring to  FIG.  1   , the electronic device  14  can include an audio module  31  including one or more speakers  34  for audio output and one or more microphones  36  for receiving audio. In embodiments, the speaker  34  and the microphone  36  can be piezoelectric components. The portable electronic device  14  further includes an input/output (I/O) controller  23 , a display  18 , and optional additional I/O components  19  (e.g., keys, buttons, dials, lights, LEDs, cursor control devices, and others). The display  18  and the additional I/O components  19  may be considered to form portions of a user interface (e.g., portions of the portable electronic device  14  associated with presenting information to the user and/or receiving inputs from the user). 
       FIGS.  2 A- 2 D  illustrate various portable electronic devices  14  in which the various embodiments can be implemented.  FIG.  2 A  illustrates an exemplary mobile telephone that includes a display  18  screen and one or more optical modules  100  packaged in a housing  12 . The optical modules  100  may be located anywhere in the electronic device, inclusive of a touch button.  FIG.  2 B  illustrates an exemplary tablet computing device that includes a display  18  screen and one or more optical modules  100  packaged in a housing  12 .  FIG.  2 C  illustrates an exemplary laptop computer that includes a display  18  screen and one or more optical modules  100  packaged in a housing  12 . For example, the optical modules  100  may be located in a touch pad, key, touch bar, and panel including a display  18  screen, for example.  FIG.  2 D  illustrates the back side of an exemplary wearable device that includes one or more optical modules  100  packaged in a housing  12 . 
     Turning now to  FIG.  3   , an exploded view of an optoelectronic module  100  stack up is illustrated. As shown, the optical module  100  may include a cover  52 , an isolation barrier  54 , and a base  56  such as a printed circuit board (PCB). The cover  52  may overly the isolation barrier  54 , which in turn may overly the PCB, as suggested by their relative vertical placement in  FIG.  3   . The cover  52  may optionally include one or a plurality of first windows  58  (e.g. holes or other optical apertures) and may include one or a plurality of second windows  60  (e.g. holes or other optical apertures). In an embodiment, the first windows  58  and the second windows  60  are circular. First windows  58  may be sized and located to overly one or more LED assemblies, and second windows  60  may be sized and located to overly one or more photodiode assemblies, all described in greater detail elsewhere herein. Windows  58  and/or  60  may themselves be sealed or covered by an optically transparent element, lens, etc. According to some embodiments, first windows  58  are positioned between second windows  60  in a roughly circular arrangement, that is, a single circle may be drawn over all the first windows and the second windows together. In embodiments, cover  52  may be part of an outer enclosure of a device in which the optoelectronic module  100  is incorporated, e.g., those described with reference to  FIGS.  2 A- 2 D . 
     The isolation barrier  54  is in some respects similar to cover  52 , in that the isolation barrier may include one or a plurality of first openings  62  and may include one or a plurality of second openings  64 . Openings  62 ,  64  may be formed completely through a thickness T of the isolation barrier  54 , forming sidewalls  63 ,  65 , respectively. 
     In accordance with embodiments, the isolation barrier  54  may have a thickness T sufficient to inhibit or mitigate light from emitter assemblies (described elsewhere herein) directly impinging on a detector assembly (also described elsewhere herein), and thus first openings  62  and second openings  64  form recesses of thickness (depth) T. The isolation barrier  54  may additionally inhibit or mitigate cross-talk between emitter assemblies. Additionally, the isolation barrier  54  may be formed of a material and/or thickness to be opaque to the operable emission spectra for the optical module  100 . 
     First openings  62  may align vertically with first windows  58  of the cover  52 , and second openings  64  may align vertically with second windows  60  of the cover. First openings  62  may be sized and located to overly one or more LEDs of an emitter assembly, and second openings  64  may be sized and located to overly one or more photodiodes of a detector assembly, all described in greater detail elsewhere herein. According to some embodiments, first openings  62  are positioned between second openings  64  in a roughly circular arrangement, that is, a single circle may be drawn over all the first openings and the second openings together. In an embodiment, first openings  62  have a larger area than first windows  58 , and second openings  64  have a larger area than the second windows  60 . In this manner, area of the windows can precisely control active area of the underlying emitter assemblies and detector assemblies. 
     A top surface  57  of the base  56  may include one or more bottom electrode pads  125  and wire bond pads  120  to accept a corresponding one or more LEDs, and one or more bottom electrode pads  225  and wire bond pads  220  to accept a corresponding one or more photodiodes. The windows  58 ,  60 , and openings  62 ,  64 , and the bond pads  125 ,  225  for mounting the LEDs and photodiodes are mutually vertically aligned and positioned so that the LEDs can emit light through the first windows  58  and openings  62 , and the photodiodes can receive light through the second windows  60  and openings  64 . In some embodiments, the LEDs and photodiodes are arranged on the base  56  alternatingly in a circle in a manner similar to the positions of the windows  58 ,  60  and openings  62 ,  64 . 
       FIG.  4    illustrates a top plan view of an example optoelectronic module  100  including mounted LEDs  210  and photodiodes  110 . In embodiments, optoelectronic module  100  includes one or more non-rectangular dies (e.g. photodiodes  110  or LEDs  210 ) which can reduce unused area within the circular openings  62 ,  64  through the isolation barrier  54 , thus improving performance per unit area, cost-effectiveness, or both of the optoelectronic module  100 . As shown, the optical module  100  may include one or more detector assemblies  150 , each including one or more photodiodes  110 , and one or more emitter assemblies  250 , each including one or more LEDs  210 , which may emit the same or different color spectrums within the same emitter assembly  250 . In the illustrated embodiment, each emitter assembly  250  includes three different LEDs  210 , which can have different shapes, thickness, and emission profiles. For example, the LEDs  210  may include separate red-emitting, green-emitting, and blue-emitting LEDs  210 , though this is merely exemplary and embodiments are not so limited. LEDs  210  may also or alternatively include an infrared-emitting LED. Similarly, the photodiodes  110  may be designed to absorb specific wavelength ranges. A variety of LED  210  and photodiode  110  arrangements are possible in accordance with embodiments. 
     In the illustrated embodiment, the photodiodes  110  are mounted onto bottom electrode pads  125 , for example using a conductive bonding material such as solder. Top sides of the photodiodes may be additionally connected to wire bond pads  120  with wires  130 . In this manner, a bottom side (e.g. p-side or n-side) of the photodiode is mounted/bonded to a bottom electrode pad  125 , while a top side (e.g. opposite n-side or p-side) of the photodiode is electrically connected to the base with a wires  130 , and wire bond pad  120 . It is to be appreciated however that alternative photodiode configurations are contemplated, including those with bottom electrode pads for both p-side and n-side connection. LEDs  210  may be similarly mounted onto bottom electrode pads  225 , and connected to wire bond pads  220  with wire bonds  230 , or alternatively with multiple bottom electrode pads for both p-side an n-side connection. 
     The emitter assemblies  250  and detector assemblies  150  may, similar to the configuration of the embodiment illustrated in  FIG.  3   , be alternatingly arranged in a circle  55  having a center  59 . Stated somewhat differently, a single circle  55  having a center  59  may be drawn over all of the emitter assemblies  250  and detector assemblies  150  together. 
     In order to further illustrate performance of the non-rectangular dies in accordance with embodiments, enlarged top plan view illustrations are provided in  FIGS.  5  and  6    of detector assemblies  150  including a rectangular photodiode  110  in  FIG.  5    compared to a non-rectangular photodiode  110  in  FIG.  6   . Referring to  FIG.  5   , where a rectangular photodiode  110  (or any optoelectronic device described herein) is mounted within a circular opening  64  of an isolation barrier  54  there is wasted (or unused) space  78  between the photodiode  110  and the adjacent wall of the circular opening  64 . Referring to  FIG.  6   , this space  78  can be reduced with a non-rectangular photodiode  110  such as, but not limited to, the illustrated octagon shaped photodiode  110 . Furthermore, surface area of the photodiode  110  can be increased, which reduces the optically dead zone corresponding to space  78  within opening  64 . Additionally, after mounting the cover  52 , this may further reduce an amount of overlap of the photodiode  110  outside of window  60 . For example, where window  60  has a smaller area than the opening  64 , and window  60  additionally has a smaller area than the top surface of photodiode  110 . However, this arrangement is not required, and the window  60  may have a similar, or larger area than the photodiode  110 . 
     Referring now to  FIG.  7    a top plan view illustration of an optoelectronic module  100  similar to  FIG.  4    is provided in accordance with an embodiment. As shown, one difference is with the inclusion of multiple photodiodes  110  within a detector assembly  150 . More specifically, the photodiodes  110  may be non-rectangular shaped, such as a trapezoid, and can be further arranged in configurations that increase surface area use. 
     Each trapezoid-shaped photodiode  110  may include an outer edge  124  (or sidewall), a shorter inner edge  122  (or sidewall), and two side edges  126 ,  128  (or sidewalls) connecting together the ends of the edges  122 ,  124 , to form a trapezoid. When more than one trapezoid-shaped photodiode  110  is mounted to the base, the photodiodes may be mutually oriented with side edges  126 ,  128  parallel to each other, which is a configuration that may improve the efficient use of the surface area of the detector assembly  150 . The plurality of photodiodes  110  can also be equidistantly spaced from each other. 
     When a plurality of photodiodes  110  are arranged together, they may be positioned in a circular arrangement, e.g., located on a circle  136  having a center  138 , and may be equidistant from the center  138 . More specifically, photodiodes  110  can be arranged in a ring pattern. 
     Referring now to  FIGS.  10 A- 10 B ,  FIG.  10 A  illustrates exploded view of an optical module  100  stack up in accordance with an embodiment similar to  FIG.  3   , and  FIG.  10 B  illustrates a top plan view of an optoelectronic module  100  similar to  FIGS.  4  and  7    in accordance with an embodiment. Similar to previous descriptions, the optical module  100  may include a cover  52 , an isolation barrier  54 , and a base  56  such as a printed circuit board (PCB). Also, similar to module  100  of  FIG.  7   , the detector assembly  150  may include a plurality of non-rectangular shaped photodiodes  110  arranged in a ring shape. In interest of clarity and conciseness the following description focuses on differences or significant features of the optical module. Some notable differences from previously described embodiments include an optical module  100  arrangement in which a detector assembly  150  surrounds an emitter assembly  250 . As shown, the emitter assembly  250  can be located inside a ring shaped detector assembly  150 . This may be facilitated by a multiple piece isolation barrier  54 . In the illustrated embodiment, the isolation barrier includes an outer frame  72 , and an inner optical barrier  74 . 
     In an embodiment, the outer frame  72  includes the opening  64  and sidewalls  65 . The outer frame  72  may include an outer sidewall  79  and inner sidewall  65 . The outer sidewall  79  and inner sidewall  65  may have similar or the same contours, which can have a different dimension(s). For example, the outer frame  72  can be ring shaped, or annular. The inner optical barrier  74  can also include an opening  62  with inner sidewalls  63  and outer sidewalls  76 . The outer sidewall  76  and inner sidewall  63  may have similar or the same contours, which can have a different dimension(s). For example, the inner optical barrier  74  can be ring shaped, or annular. Openings  64 ,  62  may have a same geometric center  138 . Additionally, the detector assembly  150  may have a center  59 , which is the same as the geometric center  138 . Similarly, the emitter assembly  250  may optionally have the same center  59 . 
     Similar to the embodiments illustrated in  FIG.  7    and  FIG.  9   , the detector assembly  150  may include a plurality of photodiodes  110  arranged in a ring shaped pattern between the outer frame  72  and the inner optical barrier  74 . The photodiodes  110  may be equidistantly spaced from a geometric center  138  of the opening  64 , which may be the center of circle  136 . The photodiodes  110  may have a variety of shapes such as isosceles trapezoid, a regular hexagon, an irregular hexagon, a regular octagon, a triangle, a disk, a sector, etc. In an embodiment, the photodiodes each have a quadrilateral shape, such as a trapezoid. A trapezoid in particular may be selected in order to achieve the ring shaped pattern and increase surface area use. Furthermore, a trapezoid can be formed using traditional wafer dicing (e.g. blade) techniques. 
     Each trapezoid-shaped photodiode  110  may include an outer edge  124  (or sidewall), a shorter inner edge  122  (or sidewall), and two side edges  126 ,  128  (or sidewalls) connecting together the ends of the edges  122 ,  124  to form a trapezoid. When more than one trapezoid-shaped photodiode  110  is mounted on the top surface  57  of base  56 , the photodiodes may be mutually oriented with side edges  126 ,  128  parallel to each other, which is a configuration that may improve the efficient use of the surface area of the detector assembly  150 , and facilitate placing the photodiodes  110  equidistantly spaced from each other, though trapezoid-shaped is not required for equidistant spacing. When a plurality of photodiodes  110  are arranged together, they may be positioned in a circular arrangement, e.g., located on a circle  136  having a center  138 , and may be equidistant from the center  138 . More specifically, photodiodes  110  can be arranged in a ring pattern. Additionally, the long edges  124  of the photodiodes  110  may face the inner sidewall  65  of opening  64 , and the short edges  122  of the photodiodes  110  may face the outer sidewall  76  of the inner optical barrier  74 , as well as center  138 . 
     Referring to  FIG.  10 B , the emitter assembly  250  can be located within the opening  62  defined by the inner optical barrier  74 , and the detector assembly is located within the opening  64  defined by the outer frame  72 , and between the outer frame  72  and the inner optical barrier  74 . The emitter assembly  250  may be similarly arranged as other descriptions herein, including arrangement in a circle with center. 
     Referring again to  FIG.  10 A  along with  FIG.  10 B , the windows  60  of cover  52  may be aligned directly over the photodiodes  110  mounted onto the bond pads  125  of base  56 . In an embodiment, each window  60  has smaller area than a corresponding photodiode  110 . Window  58  may be aligned directly over one or more of the LEDs  210  of the emitter assembly  250 . 
     It is to be appreciated additional components can be included within the optical module  100  stack ups described herein, such as lenses, bandpass filters, various sensors, etc. 
     In accordance with embodiments described herein, an optoelectronic module  100  may include a base  56  having a top surface  57  including a plurality of bond pads  125 ,  225 , and an isolation barrier  54  arranged over the top surface  57 . The isolation barrier  54  may include one or more openings  64 ,  62  such that a first opening  64 ,  62  is positioned over a set of one or more bond pads  125  of the plurality of bond pads  125 , and a set of one or more non-rectangular shaped dies (e.g. photodiodes  110  or LEDs  210 ) is mounted on the set of one or more bond pads and located laterally adjacent to sidewalls  65 ,  63  of the first opening. For example, the dies may be photodiodes  110 , though arrangements can also be provided for LEDs  210 . 
     Referring specifically to  FIGS.  7  and  9 - 10 B , the photodiodes  110  may be arranged in a ring pattern. The photodiodes  110  may be equidistantly spaced from a geometric center  138  of the opening  64 . The photodiodes  110  may have a variety of shapes such as isosceles trapezoid, a regular hexagon, an irregular hexagon, a regular octagon, a triangle, a disk, a sector, etc. In an embodiment, the photodiodes each have a quadrilateral shape, such as a trapezoid. A trapezoid in particular may be selected in order to achieve the ring pattern. Furthermore, a trapezoid can be formed using traditional wafer dicing (e.g. blade) techniques. 
     In a particular embodiment, each trapezoid shaped photodiode  110  includes a long edge  124  parallel to a short edge  122 , with the long edge  124  facing a sidewall  65  of the opening  64 , and the short edge  122  facing a center  138  of the opening  64 . In an embodiment, the short edge  122  faces an outer sidewall  76  of inner optical barrier  74  of the isolation barrier  54 . Each trapezoid can additionally include side edges  126 ,  128 , with each side edge parallel to a side edge of an adjacent photodiode  110 . This can facilitate placing the photodiodes  110  equidistantly spaced from each other. 
     In a particular embodiment, the ring pattern allows location of the plurality of wire bond pads  120  to be inside the ring shaped pattern. As shown, a plurality of wires  130  connect the top surfaces of the plurality of photodiodes  110  to the plurality of wire bond pads  120 . The ring shaped pattern can also allow the arrangement of an emitter assembly to be located inside the ring shaped pattern. 
     In accordance with embodiments, a cover  52  can be located over the isolation barrier  54 , and include windows  60  aligned over one or more openings  64  in the isolation barrier  54 . In an embodiment, a window  60  may have a smaller area than the opening  64 . In an embodiment, the window  60  may have a smaller area than a non-rectangular shaped photodiode  110  in the opening  64 . For example, referring again to  FIG.  5    a circular window  60  may be arranged directly over the rectangular photodiode  110  such that the underlying rectangular shape is not visible. Such an arrangement however may underutilize area of the photodiode  110 . A non-rectangular shaped photodiode  110  such as that illustrated in  FIG.  6   , assuming same circular window  60  area can reduce the amount of underutilized area of the photodiode  110 . This can increase efficiency. Furthermore, the non-rectangular shape may have an aesthetic appeal, which in this case may allow for a larger window  60 . In an embodiment, the photodiode  110  includes six or more edges, such as the illustrated octagon, or is round, or circular. Referring now to the ring shape arrangements in  FIGS.  7  and  9 - 10 B , this may also have a similar aesthetic appeal relative to rectangular photodiodes  110 . Including a plurality of photodiodes  110  can reduce power for each photodiode  110 . Each photodiode  110  in the opening  64  can have a same composition for detection of same wavelength range, or different photodiodes can be arranged together to absorb multiple spectrums. In an embodiment, the entire ring shape arrangements of photodiodes  110  fits directly under the area of the window  60 . However, the outside perimeter of edges  124  may be outside of the window  60 . Thus, the outside perimeter established by edges  124  may have a larger area than that of the window. In an embodiment, such as that illustrated in  FIGS.  10 A- 10 B , a separate window  60  may be arranged over each corresponding photodiode  110 . Thus, the windows  60  may also be arranged in a circular arrangement. 
     While the above description has been provided specifically with regard to photodiodes  110 , such arrangements can also be applicable with LEDs  210  and emitter assemblies  250  in accordance with embodiments. 
       FIG.  11 A  illustrates an emitter assembly  250  including a plurality of LEDs  210 . Because of the rectangular shape of the LEDs  210 , when used with a non-rectangular base, however, emitter assembly  250  does not maximize the available surface area of opening  62 , and thus potential efficiency of the emitter assembly is not realized. 
       FIG.  11 B  illustrates an embodiment of an emitter assembly  250  including a non-rectangular shaped emitter. One or more of the LEDs  210  may have a non-rectangular shape which may improve on the utilization of the surface area of the emitter assembly  250 , thus improving the overall emission performance. In the illustrated embodiment, one emitter  210  is formed as a half-disk, which may reduce unused surface area within opening  62 . Some or all the LEDS  210  may be formed in non-rectangular shapes described herein, using any process, including those described herein. 
       FIG.  12    illustrates yet another embodiment of an emitter assembly  250 . As illustrated the emitter assembly  250  may include two sector-shaped, e.g., half-disk shaped, LEDs  210 . The size, e.g., radius of one or both of the LEDs  210  may be selected to minimize the wasted surface area within opening  62 , e.g., by making the radius of one or both of the devices nearly the same as that of the circular opening  62 . An expansion and extension of the embodiment of  FIG.  12    is illustrated in  FIG.  13   , in which more than two (here, four) sector- or quadrant-shaped (i.e., “pie slice” shaped) optoelectrical devices (LEDs  210 ) are arranged with the tip of each sector near the geometric center of the base. Embodiments are not limited to four sector-shaped devices and may include five or more such devices in the same or similar configuration. As will be readily appreciated, each of the optoelectrical devices of the embodiments of  FIGS.  12  and  13    may be an emitter at any wavelength band or a photodetector. One example may include devices being emitters (e.g. LEDs  210 ) or detectors (e.g. photodiodes  110 ), and in general terms, may include alternating emitters and detectors. In more general terms, there may be any number of emitters and photodetectors, from zero to n, where n is the total number of devices mounted to the base, in any arrangement. As with the embodiment of  FIG.  12   , the radius of one or more of the sector-shaped devices may be nearly the same as that of the circular opening  62 . 
       FIG.  14 A  illustrates a plan view of a traditional wafer dicing technique to form rectangular, e.g., square, dies, in which two perpendicular sets of parallel cuts are used to make square and rectangular photodiodes with high wafer utilization. A wafer  300 , which may be roughly circular, is diced by forming cut lines (also referred to herein as cuts) in the wafer. The cuts are formed in two sets of parallel lines, a first set of parallel lines  302  and a second set of parallel lines  304 . An angle  306  is formed between the lines of the two sets, which in the traditional method is set to 90 degrees, i.e., the first set of parallel lines  302  is orthogonal (perpendicular) to the second set of parallel lines  304 . By setting the angle  306  to 90 degrees, the individual dies which are diced from the wafer  300  are rectangular, and by making the distance between lines in both sets constant and equal, the dies are square. 
       FIG.  14 B  illustrates a plan view of an embodiment of wafer dicing similar in some respects to that of  FIG.  14 A , but which produces non-rectangular dies. By forming the angle  306  between the sets of parallel lines  302 ,  304  to be other than 90 degrees, die  308  with a non-rectangular shape are formed. In the example of  FIG.  14 B , with the distance between the sets of parallel lines  302 ,  304  equal, die  308  is a parallelogram with equal-length sides. If the distance between the sets of parallel lines  302 ,  304  is not equal, then die  308  is a rhomboid with adjacent sides which are not equal in length. Both shapes may also be referred to as a diamond shape. 
       FIG.  15    illustrates a plan view of a first embodiment of multi-axis wafer dicing process. A wafer  310 , which may be generally circular or other shapes, may be diced along three sets of parallel lines  312 ,  318 , and  320 . First set of parallel lines  312  may define a first interline distance  314 , that is, a first distance between adjacent lines within the set  312 , and may define a second interline distance  314 , that is, a second distance between adjacent lines within the set  312 . Distances  314  and  316  may be the same or different. In an embodiment illustrated in  FIG.  15   , distances  314  and  316  are not equal, for reasons described in greater detail below. 
     Lines of first set  312  form an angle  322  with lines of second set  318 . According to an embodiment, angle  322  is less than 90 degrees. Lines of first set  312  form an angle  324  with lines of third set  320 . According to an embodiment, angle  324  is less than 90 degrees. Lines of second set  318  form an angle  332  with lines of third set  320 . According to an embodiment, angle  332  is less than 90 degrees. In general terms, each of the angles  322 ,  324 ,  332  may be equal to 90 degrees or not, depending on the shapes of the dies to be formed from the wafer  310 . By dicing wafer  310  with three sets of lines, several non-rectangular shaped dies may be formed. More specifically, with continued reference to  FIG.  15   , dies having the shape of trapezoids  326 , hexagons  328 , and triangles  330  may be formed. Setting distance  314  not equal to distance  316  causes dimensions of some or all the non-rectangular shaped dies to change. 
       FIG.  16    illustrates a plan view of a second embodiment of multi-axis wafer dicing. A wafer  350 , which may be generally circular or other shapes, may be diced along three sets of equidistant, parallel lines  352 ,  354 ,  356 . An optional fourth set of equidistant, parallel lines  358  may also be used, parallel to and equidistant between the lines of the first set  352 , for reasons detailed elsewhere herein. Dicing the wafer  350  along the set of parallel lines  358  may be equivalent to narrowing the distance between lines of the set of parallel lines  352  by half. As with the embodiment of  FIG.  15   , an angle  360  is formed between the lines of the first set  352  and the second set  354 ; an angle  362  is formed between the lines of the first set  352  and the third set  356 ; and an angle  364  is formed between the lines of the second set  354  and the third set  356 . Mutual selection of the angles  360 ,  362 , and  364 , and the distances between each line in the sets of parallel lines  352 ,  354 ,  356 , may result in wafer  350  being diced into dies having non-rectangular shapes. In an embodiment, dies cut from wafer  350  may have hexagon  366 , trapezoid  368 , and/or triangular  370  shapes. In an embodiment, when angles  360 ,  362 , and  364  are the same, the wafer  350  may be diced into dies having regular hexagon and isosceles triangular shapes. When wafer  350  is diced along sets of parallel lines  352 ,  354 ,  356 , and along at least one line from set of parallel lines  358 , trapezoid-shaped dies may be formed, by bisecting at least one set of hexagons  366  as can be seen in  FIGS.  7  and  9 - 10 B , for example. Set  358  can be one line, or many parallel lines bisecting some or all the hexagons  366 . 
       FIG.  17    illustrates a plan view of a third embodiment of multi-axis wafer dicing.  FIG.  17    illustrates a portion of a wafer  380 . Wafer  380  has been diced into square dies  382 , using a method such as, for example, that described with reference to  FIG.  14 A . Additionally, however, wafer  380  may be diced along two additional sets of equidistant, parallel lines  384 ,  386 , in such a way that the corners  388  of the square dies  382  are cut off and dies  382  becomes an octagon with eight sides  390 . A regular octagon-shaped die may be formed from wafer  380  by making: the angles  392 ,  394  between the two sets of equidistant, parallel lines  384 ,  386  to be 90 degrees; the distance between lines in two sets of equidistant, parallel lines  384 ,  386  to be the same as each other and the same as the side of die  382  when square; orienting the two sets of equidistant, parallel lines  384 ,  386  at 45 degrees to the square die  382 ; and positioning the two sets of equidistant, parallel lines  384 ,  386  so that each corner  388  area is identical. Non-regular octagons may be formed as well, by not following one of the foregoing requirements. 
       FIG.  18    illustrates another embodiment of the use of non-rectangular dies formed from a wafer. An optical module  400  may include a base  402 , which may include or be a PCB, in or over which one or more circular openings  404  are formed; this may be accomplished by the further inclusion of an isolation barrier as described elsewhere herein. Openings  404  may be similar to openings  62 ,  64 . One or more circular dies  406 , e.g., optoelectrical devices, may be positioned within the one or more openings  404 , which may be one die  406  in each opening  404 . Each die  406  may have one or more electrical leads or wire bond pads  408  connecting the die to the base  402  or to other devices on the base (not illustrated). When optoelectrical devices, e.g., LEDs and photodiodes, take better advantage of the available space and allow an increase in the area used, an increase in transmitted and/or received signal level may be achieved.  FIG.  19    illustrates a wafer  420  from which one or more dies  406  may be diced, for example using one or more of the processes described herein. 
     Turning now to  FIG.  20   , an example process  500  of dicing a microelectronic device, such as, but not limited to, any of the optoelectronic devices described herein, from a wafer is illustrated and described. Process  500  may be, or include, a plasma dicing process, which may be or include a deep reactive-ion etching (“DRIE”) etching process. In a first operation  502 , a back grinding (BG) tape may be laminated to a surface of a wafer. In a second operation  504 , which may follow operation  502 , the wafer is back-ground and dry polished. In a third operation  506 , which may follow operation  504 , the BG tape may be removed. In a fourth operation  508 , which may follow operation  506 , the wafer may be coated with a photoresist material. In a fifth operation  510 , which may follow fourth operation  508 , lithography is performed on the wafer to form patterns in a known manner. In a sixth operation  512 , which may follow fifth operation  510 , the wafer is mounted to, e.g., a mounting tape. In a seventh operation  514 , which may follow sixth operation  512 , the wafer is plasma diced into individual dies, some or all of which may have non-rectangular shapes as described herein. In an eighth operation  516 , which may follow seventh operation  514 , the diced wafer is ashed, before the individual dies are singulated in ninth operation  518 . 
     While some processes of forming non-rectangular dies have been described herein, other processes may be used, including scribe-and-breaking, plasma cutting, laser cutting, stealth dicing, sawing, and any combinations thereof. 
     In utilizing the various aspects of the embodiments, it would become apparent to one skilled in the art that combinations or variations of the above embodiments are possible for forming an optoelectronic device with non-rectangular shaped LEDs and/or photodiodes. Although the embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the appended claims are not necessarily limited to the specific features or acts described. The specific features and acts disclosed are instead to be understood as embodiments of the claims useful for illustration.

Metadata:
Filing Date: 20210211
Publication Date: 20230509
Grant Date: 20230509
Priority Date: 20210211
Inventors: CHARBONNEAU-LEFORT, MATHIEU
MEHRA, SAAHIL
JIANG, TONGBI T.
LIU, SAIJIN
Assignee: APPLE INC
CPC Classifications: [{"code": "H10F77/933", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F55/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/147", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/933", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10H20/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H10F77/147", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L25/167", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/042", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L25/167", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L25/167", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L31/035281", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L31/02005", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/042", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L31/0203", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 82704117