PATENT DOCUMENT

Publication Number: US-9773750-B2
Application Number: US-201313749647-A
Country: US
Kind Code: B2

Title: Method of transferring and bonding an array of micro devices

Abstract:
Electrostatic transfer head array assemblies and methods of transferring and bonding an array of micro devices to a receiving substrate are described. In an embodiment, a method includes picking up an array of micro devices from a carrier substrate with an electrostatic transfer head assembly supporting an array of electrostatic transfer heads, contacting a receiving substrate with the array of micro devices, transferring energy from the electrostatic transfer head assembly to bond the array of micro devices to the receiving substrate, and releasing the array of micro devices onto the receiving substrate.

Claims:
What is claimed is: 
     
       1. A method comprising:
 picking up an array of micro devices from a carrier substrate with an electrostatic transfer head assembly supporting an array of electrostatic transfer heads; 
 contacting a micro device bonding layer with a receiving substrate bonding layer on a receiving substrate for each respective micro device, wherein each receiving substrate bonding layer has a lower ambient liquidus temperature than a respective micro device bonding layer, and each receiving substrate bonding layer is characterized by a width extending in a direction parallel to a corresponding micro device bonding layer contact surface that contacts the receiving substrate bonding layer in which each micro device bonding layer contact surface is wider than each receiving substrate bonding layer; 
 transferring thermal energy from the electrostatic transfer head assembly, liquefying the receiving substrate bonding layers, and bonding the array of micro devices to the receiving substrate; 
 releasing the array of micro devices onto the receiving substrate; 
 wherein each micro device has a maximum width of 1-100 μm parallel to a contact surface of the array of electrostatic transfer heads for picking up the array of micro devices; 
 wherein the array of electrostatic transfer heads includes an array of mesa structures protruding from a base substrate supporting the array of electrostatic transfer heads, with each mesa structure corresponding to a separate electrostatic transfer head, and each electrostatic transfer head has a contact surface for picking up a single micro device and each electrostatic transfer head contact surface has a maximum width of 1-100 μm; 
 wherein a substrate supporting the array of electrostatic transfer heads is maintained above room temperature during the sequence of: 
 picking up the array of micro devices from the carrier substrate with the electrostatic transfer head assembly supporting the array of electrostatic transfer heads; 
 contacting the micro device bonding layer with the receiving substrate bonding layer on the receiving substrate for each respective micro device; 
 transferring thermal energy from the electrostatic transfer head assembly to liquefy the receiving substrate bonding layers, and bonding the array of micro devices to the receiving substrate; and 
 releasing the array of micro devices onto the receiving substrate; and 
 wherein the substrate supporting the array of electrostatic transfer heads is maintained above the ambient liquidus temperature of the receiving substrate bonding layers and below the ambient liquidus temperature of the micro device bonding layers. 
 
     
     
       2. The method of  claim 1 , wherein each electrostatic transfer head contact surface has a maximum width of 3-20 μm.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/749,892 filed on Jan. 7, 2013 and is a continuation-in-part of U.S. patent application Ser. No. 13/436,260 filed on Mar. 30, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 13/372,422 filed on Feb. 13, 2012 now issued as U.S. Pat. No. 8,349,116, and claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/597,658 filed on Feb. 10, 2012 and U.S. Provisional Patent Application Ser. No. 61/597,109 filed on Feb. 9, 2012, the full disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     Field 
     The present invention relates to micro devices. More particularly embodiments of the present invention relate to methods for transferring and bonding an array of micro devices to a receiving substrate. 
     Background Information 
     Integration and packaging issues are one of the main obstacles for the commercialization of micro devices such as radio frequency (RF) microelectromechanical systems (MEMS) microswitches, light-emitting diode (LED) display and lighting systems, MEMS, or quartz-based oscillators. 
     Traditional technologies for transferring of devices include transfer by wafer bonding from a transfer wafer to a receiving wafer. Such implementations include “direct printing” and “transfer printing” involving wafer bonding/de-bonding steps in which a transfer wafer is de-bonded from a device after bonding the device to the receiving wafer. In addition, the entire transfer wafer with the array of devices is involved in the transfer process. 
     Other technologies for transferring of devices include transfer printing with elastomeric stamps. In one such implementation an array of elastomeric stamps with posts matching the pitch of devices on a source wafer are brought into intimate contact with the surface of the devices on the source wafer and bonded with van der Walls interaction. The array of devices can then be picked up from the source wafer, transferred to a receiving substrate, and released onto the receiving substrate. 
     SUMMARY OF THE INVENTION 
     Electrostatic transfer head array assemblies and methods of transferring and bonding an array of micro devices to a receiving substrate are described. In an embodiment, a method includes picking up an array of micro devices from a carrier substrate with an electrostatic transfer head assembly supporting an array of electrostatic transfer heads, contacting a receiving substrate with the array of micro devices, transferring energy from the electrostatic transfer head assembly to bond the array of micro devices to the receiving substrate, and releasing the array of micro devices onto the receiving substrate. In an embodiment, each micro device has a maximum width of 1-100 μm. Each electrostatic transfer head in the array of electrostatic transfer heads may also pick up a single micro device. 
     In an embodiment, contacting the receiving substrate with the array of micro devices includes contacting a micro device bonding layer with a receiving substrate bonding layer for each respective micro device. In accordance with embodiments of the invention, energy is transferred from the electrostatic transfer head assembly to bond the array of micro devices to the receiving substrate using a bonding technique such as thermal bonding or thermocompression bonding (TCB). For example, heat can be transferred from the electrostatic transfer head assembly, carrier substrate holder, or receiving substrate holder. Furthermore, the transferred energy may be utilized to bond the array of micro devices to the receiving substrate with a variety of bonding mechanisms in which one or more bonding layers may or may not be liquefied. 
     In one embodiment, the transfer of energy forms a eutectic alloy from the micro device bonding layer and the receiving substrate bonding layer. In one embodiment, the transfer of energy liquefies the receiving substrate bonding layer to form an inter-metallic compound layer having an ambient melting temperature higher than an ambient melting temperature of the receiving substrate bonding layer. In an embodiment, the transfer of energy causes solid state diffusion between the micro device bonding layer and the receiving substrate bonding layer. Annealing may also be performed after releasing the array of micro devices into the receiving substrate. 
     In some embodiments the receiving substrate bonding layer has a lower ambient liquidus temperature than the micro device bonding layer. In an embodiment the receiving substrate bonding material includes a material such as indium or tin, and the micro device bonding layer includes a material such as gold, silver, aluminum, bismuth, copper, zinc, and nickel. The micro device bonding layer may also be wider than the receiving substrate bonding layer. 
     In one embodiment, the substrate supporting the array of electrostatic transfer heads is maintained above room temperature from the time the array of micro devices are picked up from the carrier substrate until they are released onto the receiving substrate. For example, the substrate supporting the array of electrostatic transfer heads can be maintained above the ambient liquidus temperature of the receiving substrate bonding layer, such as indium or tin. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  includes top and cross-sectional side view illustrations of a carrier substrate and an array of micro LED devices in accordance with an embodiment of the invention. 
         FIG. 2  is a flow chart of a method of transferring and bonding an array of micro devices to a receiving substrate in accordance with an embodiment of the invention 
         FIGS. 3A-3G  are cross-sectional side view illustrations of a method of transferring and bonding an array of micro devices to a receiving substrate in accordance with an embodiment of the invention 
         FIGS. 3H-3J  are cross-sectional side view illustrations a micro device bonded to a receiving substrate in accordance with embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention describe electrostatic transfer head assemblies and methods of transferring and bonding an array of micro devices to a receiving substrate. For example, the receiving substrate may be, but is not limited to, a display substrate, a lighting substrate, a substrate with functional devices such as transistors or integrated circuits, or a substrate with metal distribution lines. While some embodiments of the present invention are described with specific regard to micro LED devices, it is to be appreciated that embodiments of the invention are not so limited and that certain embodiments may also be applicable to other micro devices such as diodes, transistors, dies, chips, integrated circuits, and MEMs. 
     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., in order to provide a thorough understanding of the present invention. In other instances, well-known semiconductor processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the present invention. 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 of the invention. Thus, the appearances of the phrase “in one embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     The terms “over”, “to”, “between” and “on” as used herein may refer to a relative position of one layer with respect to other layers. One layer “over” or “on” another layer or bonded “to” another layer may be directly in contact with the other layer or may have one or more intervening layers. One layer “between” layers may be directly in contact with the layers or may have one or more intervening layers. On layer in “contact” with another layer may be directly in contact with the other layer or with one or more intervening layers. 
     Without being limited to a particular theory, embodiments of the invention describe an electrostatic transfer head assembly supporting an array of electrostatic transfer heads which operate in accordance with principles of electrostatic grippers, using the attraction of opposite charges to pick up micro devices. In accordance with embodiments of the present invention, a pull-in voltage is applied to an electrostatic transfer head in order to generate a grip pressure on a micro device and pick up the micro device. The terms “micro” device or “micro” LED devices as used herein may refer to the descriptive size of certain devices or structures in accordance with embodiments of the invention. As used herein, the terms “micro” devices or structures are meant to refer to the scale of 1 to 100 μm. However, embodiments of the present invention are not necessarily so limited, and certain aspects of the embodiments may be applicable to larger, and possibly smaller size scales. In an embodiment, a single micro device in an array of micro devices, and a single electrostatic transfer head in an array of electrostatic transfer heads both have a maximum dimension, for example length or width, of 1 to 100 μm. In an embodiment, the top contact surface of each micro device or electrostatic transfer head has a maximum dimension of 1 to 100 μm. In an embodiment, the top contact surface of each micro device or electrostatic transfer head has a maximum dimension of 3 to 20 μm. In an embodiment, a pitch of an array of micro devices, and a pitch of a corresponding array of electrostatic transfer heads is (1 to 100 μm) by (1 to 100 μm), for example a 20 μm by 20 μm, or 5 μm by 5 μm pitch. At these densities a 6 inch carrier substrate, for example, can accommodate approximately 165 million micro LED devices with a 10 μm by 10 μm pitch, or approximately 660 million micro LED devices with a 5 μm by 5 μm pitch. A transfer tool including an electrostatic transfer head assembly and an array of electrostatic transfer heads matching an integer multiple of the pitch of the corresponding array of micro LED devices can be used to pick up, transfer, and bond the array of micro LED devices to a receiving substrate. In this manner, it is possible to integrate and assembly micro LED devices into heterogeneously integrated systems, including substrates of any size ranging from micro displays to large area displays, and at high transfer rates. For example, a 1 cm by 1 cm array of electrostatic transfer heads can pick up, transfer, and bond more than 100,000 micro devices, with larger arrays of electrostatic transfer heads being capable of transferring more micro devices. 
     In one aspect, embodiments of the invention describe systems and methods for transferring an array of micro devices from a carrier substrate to a receiving substrate in a matter of one tenth of a second to several seconds, and bonding the array of micro devices to the carrier substrate in one fourth (¼) the transfer time. In an embodiment, energy is transferred from an electrostatic transfer head assembly and through an array of micro devices to bond the array of micro devices to the receiving substrate. For example, a micro device may be bonded to the receiving substrate with a micro device bonding layer transferred with the micro device, a bonding layer on the receiving substrate, or the micro device bonding layer may be bonded with the receiving substrate bonding layer. The bonds between the micro devices and receiving substrate may also be electrically conductive. For example, the bond may be to an anode or cathode of a micro LED device. 
     In accordance with embodiments of the invention, bonding is facilitated by the application of energy to the bonding layer(s). Elevated temperatures and thermal cycling, however, can cause interdiffusion and degradation of layers within the micro devices, oxidation of the bonding layers (both micro device bonding layers and receiving substrate bonding layers), and mechanical deformation of the structures in the electrostatic transfer head assembly and receiving or carrier substrate. Mechanical deformation of the structures in the electrostatic transfer head assembly can further result in misalignment of system components, which may be aligned within a micron or less. In certain embodiments the receiving substrate may be a display substrate including thin film transistors. Such a substrate may be susceptible to bowing if subjected to excessive temperatures. Accordingly, embodiments of the invention describe systems and methods for applying energy to form viable electrical bonds, while mitigating the side effects of elevated temperatures and thermal cycling on system components. In accordance with embodiments of the invention, energy is transferred from the electrostatic transfer head assembly to bond the array of micro devices to the receiving substrate using a bonding technique such as thermal bonding or thermocompression bonding (TCB). Furthermore, the transferred energy may be utilized to bond the array of micro devices to the receiving substrate with a variety of bonding mechanisms in which one or more bonding layers may or may not be liquefied. For example, in an embodiment, transient liquid phase bonding or eutectic alloy bonding may be accompanied by liquefying of a bonding layer or interface between bonding layers. In an embodiment, solid state diffusion bonding may be performed between bonding layers without liquefying. 
     Referring now to  FIG. 1 , top and cross-sectional side view illustrations of a carrier substrate and an array of micro LED devices are shown in accordance with an embodiment of the invention. In the particular embodiments illustrated, an individual micro LED device  150  is illustrated as a pair of concentric squares with tapered or rounded corners, with each square having a different width corresponding to the different widths of the top and bottom surfaces of the micro p-n diodes, and the corresponding tapered sidewalls spanning from the top and bottom surfaces. However, embodiments of the invention do not require tapered sidewalls, and the top and bottom surfaces of the micro p-n diodes may have the same diameter, or width, and vertical sidewalls. As illustrated, the array of micro LED devices is described as having a pitch (P), spacing (S) between each micro LED device and a maximum width (W) of each micro LED devices. In order for clarity and conciseness, only x-dimensions are illustrated by the dotted lines in the top view illustration, though it is understood that similar y-dimensions may exist, and may have the same or different dimensional values. In the particular embodiments illustrated, the x- and y-dimensional values are identical. In one embodiment, the array of micro LED devices may have a pitch (P) of 1 to 100 μm, and a maximum width (W) of 1 to 100 μm. The spacing (S) may be minimized so as to maximize the number of micro LED devices that are poised for pick up on a carrier substrate. In an embodiment, the pitch (P) is 10 μm, spacing (S) is 2 μm, and width (W) is 8 μm. In another embodiment, the pitch (P) is 5 μm, spacing (S) is 2 μm, and width (W) is 3 μm. However, embodiments of the invention are not limited to these specific dimensions, and any suitable dimension may be utilized. 
     In the particular embodiment illustrated in  FIG. 1 , the micro device is a micro LED device. For example, a micro LED device  150  may include a micro p-n diode and a top conductive contact layer  130 , a bottom conductive contact layer  120 , with the bottom conductive contact layer  120  between the micro p-n diode and a bonding layer  110  formed on a carrier substrate  101 . In an embodiment, the micro p-n diode includes a top n-doped layer  114 , one or more quantum well layers  116 , and a lower p-doped layer  118 . In other embodiments, the doping of layers  114 ,  116  may be reversed. The conductive contact layers  120 ,  130  may include one or more layers. For example, the conductive contact layers  120 ,  130  may include an electrode layer that makes ohmic contact with the micro p-n diode. In an embodiment, bottom conductive contact layer  120  includes an electrode layer and a barrier layer between the electrode layer and the bonding layer  110 . The barrier layer may protect against diffusion or alloying between the bonding layer and other layers in the electrode layer, for example during bonding to the receiving substrate. In an embodiment, the barrier layer may include a material such as Pd, Pt, Ni, Ta, Ti and TiW. The conductive contact layers  120 ,  130  may be transparent to the visible wavelength range (e.g. 380 nm-750 nm) or opaque. The conductive contact layers  120 ,  130  may optionally include a reflective layer such as Ag or Ni. In an embodiment, the bottom surface of the micro p-n diode is wider than the top surface of the conductive contact layer  120 . In an embodiment, the bottom surface of the conductive contact layer is wider than a top surface of the bonding layer  110 . A conformal dielectric barrier layer (not illustrated) may optionally be formed over the micro p-n diode and other exposed surfaces. 
     In accordance with embodiments of the invention, bonding layer  110  may be formed of a variety of materials useful for bonding the micro devices to a receiving substrate upon transfer of energy from the electrostatic transfer head assembly. Thickness of the bonding layer  110  may depend upon the bonding techniques, bonding mechanisms, and materials selections. In an embodiment, bonding layer is between 100 angstroms as 2 μm thick. In one embodiment the bonding layer  110  may be formed of a low temperature solder material for bonding the micro devices to the receiving substrate at low temperatures. Exemplary low temperature solder materials may be indium, bismuth, or tin based solder, including pure metals and metal alloys. An exemplary list of low melting solder materials which may be utilized with embodiments of the invention are provided in Table 1, in which the chemical compositions are listed by weight percent of the components. 
     
       
         
           
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 Chemical composition 
                 Liquidus 
                 Solidus 
               
               
                 (weight %) 
                 Temperature (° C.) 
                 Temperature (° C.) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 100 In 
                 156.7 
                 156.7 
               
               
                 66.3In33.7Bi 
                 72 
                 72 
               
               
                 51In32.5Bi16.5Sn 
                 60 
                 60 
               
               
                 57Bi26In17Sn 
                 79 
                 79 
               
               
                 54.02Bi29.68In16.3Sn 
                 81 
                 81 
               
               
                 67Bi33In 
                 109 
                 109 
               
               
                 90In10Sn 
                 151 
                 143 
               
               
                 48In52Sn 
                 118 
                 118 
               
               
                 50In50Sn 
                 125 
                 118 
               
               
                 52Sn48In 
                 131 
                 118 
               
               
                 58Sn42In 
                 145 
                 118 
               
               
                 97In3Ag 
                 143 
                 143 
               
               
                 94.5In5.5Ag 
                 200 
                 — 
               
               
                 99.5In0.5Au 
                 200 
                 — 
               
               
                 95In5Bi 
                 150 
                 125 
               
               
                 99.3In0.7Ga 
                 150 
                 150 
               
               
                 99.4In0.6Ga 
                 152 
                 152 
               
               
                 99.6In0.4Ga 
                 153 
                 153 
               
               
                 99.5In0.5Ga 
                 154 
                 154 
               
               
                 58Bi42Sn 
                 138 
                 138 
               
               
                 60Sn40Bi 
                 170 
                 138 
               
               
                 100Sn 
                 232 
                 232 
               
               
                 95Sn5Sb 
                 240 
                 235 
               
               
                 100Ga 
                 30 
                 30 
               
               
                 99In1Cu 
                 200 
                 — 
               
               
                 98In2Cu 
                 182 
                 — 
               
               
                 96In4Cu 
                 253 
                 — 
               
               
                 74In26Cd 
                 123 
                 123 
               
               
                 70In30Pb 
                 175 
                 165 
               
               
                 60In40Pb 
                 181 
                 173 
               
               
                 50In50Pb 
                 210 
                 184 
               
               
                 40In60Pb 
                 231 
                 197 
               
               
                 55.5Bi44.5Pb 
                 124 
                 124 
               
               
                 58Bi42Pb 
                 126 
                 124 
               
               
                 45.5Bi54.5Pb 
                 160 
                 122 
               
               
                 60Bi40Cd 
                 144 
                 144 
               
               
                 67.8Sn32.2Cd 
                 177 
                 177 
               
               
                 45Sn55Pb 
                 227 
                 183 
               
               
                 63Sn37Pb 
                 183 
                 183 
               
               
                 62Sn38Pb 
                 183 
                 183 
               
               
                 65Sn35Pb 
                 184 
                 183 
               
               
                 70Sn30Pb 
                 186 
                 183 
               
               
                 60Sn40Pb 
                 191 
                 183 
               
               
                 75Sn25Pb 
                 192 
                 183 
               
               
                 80Sn20Pb 
                 199 
                 183 
               
               
                 85Sn15Pb 
                 205 
                 183 
               
               
                 90Sn10Pb 
                 213 
                 183 
               
               
                 91Sn9Zn 
                 199 
                 199 
               
               
                 90Sn10Au 
                 217 
                 217 
               
               
                 99Sn1Cu 
                 227 
                 227 
               
               
                 99.3Sn0.7Cu 
                 227 
                 227 
               
               
                   
               
            
           
         
       
     
     In another embodiment, the bonding layer  110  is formed of an electrically conductive adhesive material. For example, the adhesive can be a thermoplastic or thermosetting polymer including conductive particles (e.g. metal particles). 
     In another embodiment, the bonding layer  110  is formed of a material characterized by a liquidus or melting temperature which is above the bonding temperature used to bond the micro device  150  to the receiving substrate or above an ambient liquidus temperature of a receiving substrate bonding layer. As described in further detail below, such a bonding layer may be used for bonding mechanisms including eutectic alloy bonding, transient liquid phase bonding, or solid state diffusion bonding with another bonding layer on the receiving substrate. The bonding layer  110  material may also be selected for its ability to diffuse with a receiving substrate bonding layer material. In an embodiment, the bonding layer may have a liquidus temperature above 250° C. such as bismuth (271.4° C.), or a liquidus temperature above 350° C. such as gold (1064° C.), copper (1084° C.), silver (962° C.), aluminum (660° C.), zinc (419.5° C.), or nickel (1453° C.). The bonding layer is not limited to these exemplary materials, and may include other semiconductor, metal, or metal alloy materials characterized by a liquidus or melting temperature which is above the bonding temperature used to bond the micro device to the receiving substrate. 
       FIG. 2  is a flow chart and  FIGS. 3A-3G  are cross-sectional side view illustrations of a method of transferring and bonding an array of micro devices to a receiving substrate in accordance with an embodiment of the invention. At operation  1010  an array of micro devices is picked up from a carrier substrate with an electrostatic transfer head assembly.  FIG. 3A  is a cross-sectional side view illustration of an array of electrostatic transfer heads  204  supported by a substrate  200  and positioned over an array of micro LED devices  150  in accordance with an embodiment of the invention. As illustrated, the pitch (P) of the array of electrostatic transfer heads  204  matches an integer multiple of the pitch of the micro LED devices  150 . The array of micro LED devices  150  are then contacted with the array of electrostatic transfer heads  204  as illustrated in  FIG. 3B . The array of electrostatic transfer head may also be positioned over the array of micro devices with a suitable air gap separating them which does not significantly affect the grip pressure, for example, a 1 nm or 10 nm gap. 
     In order to pick up the array of micro devices a voltage may applied to the array of electrostatic transfer heads  204 . In an embodiment, the voltage may be applied from the working circuitry within or connected to an electrostatic transfer head assembly  206  in electrical connection with the array of electrostatic transfer heads  204 . Referring again to  FIG. 3A , in the exemplary embodiments illustrated, the electrostatic transfer heads  204  are bipolar electrostatic transfer heads including a pair of electrodes  203  covered by a dielectric layer  209 . However, embodiments are not limited to a bipolar electrode configuration and other configurations such as monopolar electrodes may be used. As illustrated, each electrostatic transfer head  204  includes a mesa structure  211  protruding from the substrate  200 . In this manner each electrostatic transfer head  204  is configured to pick up an individual micro device. The array of micro devices  150  is then picked up with the electrostatic transfer head assembly  206  as illustrated in  FIG. 3C . As illustrated, the micro device bonding layers  110  are also picked up with the array of micro devices  150 . 
     In the embodiments illustrated in  FIGS. 3A-3G , energy may be transferred to the bonding layers through the optional heaters  105 ,  205 ,  305 , illustrated with dotted lines. In the embodiments illustrated in  FIGS. 3A-3C , heat may be transferred through the electrostatic transfer head assembly  206 , through the array of electrostatic transfer heads  204  and the array of micro devices  150 , and to bonding layers  110  with one or more heaters  205 . Heat may be also or alternatively be transferred through a carrier substrate  101  and to the bonding layers  110  with one or more heaters  105 . Heat can be applied in a variety of fashions including infra red heat lamps, lasers, and resistive heating elements, amongst others. 
     The pick up operations illustrated in FIS.  3 A- 3 C may be performed at a variety of temperatures. In some embodiments the substrate  200  supporting the array of electrostatic transfer heads  204  is maintained at room temperature during the pick up operations in  FIGS. 3A-3C . In some embodiments the substrate  200  supporting the array of transfer heads  204  is maintained slightly above (e.g. 5 to 25° C. above) room temperature during the pick up operations in  FIGS. 3A-3C  to compensate for variations in room temperature. In some embodiments the substrate  200  supporting the array of electrostatic transfer heads  204  is maintained at the same temperature during the pick up operations in  FIGS. 3A-3C  as the substrate  200  supporting the array of electrostatic transfer heads  204  is maintained during bonding to the array of micro devices to the receiving substrate, for example, above an ambient liquidus temperature of a receiving substrate bonding layer. Where the bonding layer  110  has a liquidus temperature below the bonding temperature or the ambient liquidus temperature of the receiving substrate bonding layer, the bonding layer  110  may remain in the solid phase during the pick up operations in  FIGS. 3A-3C . In this manner, by not liquefying the bonding layer the pick up and transfer process may be simplified by not having to handle a material in liquid phase, and to control the phase of the material during transfer and formation of the micro devices. Furthermore, by maintaining the substrate  200  supporting the array of electrostatic transfer heads  204  at a uniform temperature, even at the elevated bonding temperature, the uniform temperature profile may protect the structural integrity of the electrostatic transfer head assembly can alignment of system components. In other embodiments the substrate  200  supporting the array of electrostatic transfer heads  204  is subjected to a thermal cycle, for example ramped up above a liquidus temperature of the bonding layer  110  to pick up the array of micro devices from the carrier substrate. 
     At operation  1020  a receiving substrate is contacted with the array of micro devices.  FIG. 3D  is a cross-sectional side view illustration of an array of electrostatic transfer heads  204  holding an array of micro devices  150  over a receiving substrate  300 . As illustrated, the array of micro devices  150  may be positioned over contact pads  302  and bonding layers  304  on the receiving substrate. In accordance with embodiments of the invention, heat may be transferred through the receiving substrate  300  and into the bonding layers with one or more heaters  305 . Heat can be applied in a variety of fashions including infra red heat lamps, lasers, and resistive heating elements, amongst others. In an embodiment, receiving substrate  300  is heated to a temperature below (e.g. 1 to 50° C. below) the liquidus or melting temperature of the bonding layer  304 . In an embodiment, the receiving substrate  300  is heated to a temperature below (e.g. 1 to 50° C. below) the bonding temperature. While the particular embodiment illustrated includes both a bonding layer  304  and contact pad  302 , embodiments of the invention are not so limited. For example, a single bonding layer  304  or single contact pad  302  may be present. In another embodiment, multiple bonding layers may be used. For example, a bonding layer matching the composition of bonding layer  110  may be located between bonding layer  304  and contact pad  302 . In an embodiment, a bonding layer matching the composition of bonding layer  110  is formed over bonding layer  304  to protect against oxidation of bonding layer  304 . Alternatively, a single bonding layer or contact pad may be used for bonding multiple micro devices, rather than individual micro devices. 
     Still referring to  FIG. 3D , the receiving substrate  300  may be, but is not limited to, a display substrate, a lighting substrate, a substrate with functional devices such as transistors or ICs, or a substrate with metal redistribution lines. In an embodiment, the substrate is a display substrate including thin film transistors. Depending upon the particular application, substrate  300  may be opaque, transparent, or semi-transparent to the visible wavelength (e.g. 380-750 nm wavelength), and substrate  300  may be rigid or flexible. For example, substrate  300  may be formed of glass or a polymer such as polyethylene terephthalate (PET), polyethelyne naphthalate (PEN), polycarbonate (PC), polyethersulphone (PES), aromatic fluorine-containing polyarylates (PAR), polycyclic olefin (PCO), and polyimide (PI). Depending upon the particular application contact pad  302  may be opaque, transparent, or semi-transparent to the visible wavelength. Exemplary transparent conductive materials include amorphous silicon, transparent conductive oxides (TCO) such as indium-tin-oxide (ITO) and indium-zinc-oxide (IZO), carbon nanotube film, or a transparent conducting polymer such as poly(3,4-ethylenedioxythiophene) (PEDOT), polyaniline, polyacetylene, polypyrrole, and polythiophene. In an embodiment contact pad  302  is approximately 100 nm-200 nm thick ITO. In an embodiment, the contact pad  302  includes nanoparticles such as silver, gold, aluminum, molybdenum, titanium, tungsten, ITO, and IZO. The contact pad  302  or may also be reflective to the visible wavelength. In an embodiment, a contact pad  302  comprises a reflective metallic film such as aluminum, molybdenum, titanium, titanium-tungsten, silver, or gold, or alloys thereof. In an embodiment, contact pad  302  functions as an electrode (e.g. anode or cathode) or electrode line. 
     A receiving substrate bonding layer  304  may optionally be formed over the conductive pad  302  to facilitate bonding of the micro device. Bonding layer  304  may be formed of any of the materials described above with regard to bonding layer  110 . The particular selection of materials for bonding layers  110 ,  304  may dependent upon the particular bonding mechanism such as eutectic alloy bonding, transient liquid phase bonding, or solid state diffusion bonding described in further detail below. 
     Referring now to  FIG. 3E , the receiving substrate  300  is contacted with the array of micro devices  150 . As shown in the close-up illustration of a single micro device  150 , in an embodiment contacting the receiving substrate with the array of micro devices includes contacting a receiving substrate bonding layer  304  with a micro device bonding layer  110  for each respective micro device. In an embodiment, each micro device bonding layer  110  is wider than a corresponding receiving substrate bonding layer  304 . For example, as illustrated, the receiving substrate bonding layers  304  may be in the form of posts onto which the micro devices  150  will be placed. In an embodiment, the receiving substrate bonding layer  304  is approximately 1 μm wide, and is approximately 0.1 μm to 2 μm thick. A post structure may be useful in a variety of bonding operations. In one implementation, by decreasing the width of bonding layer  304  relative to the bonding layer  110 , the pressure realized at the interface may be higher than the pressure applied to the micro devices  150  from the electrostatic transfer heads  204 . In another implementation, where bonding layer  304  is liquefied during the bonding operation, the liquefied bonding layer  304  may act as a cushion and partially compensate for system uneven leveling (e.g nonplanar surfaces) between the array of micro devices  150  and the receiving substrate  300  during bonding, and for variations in height of the micro devices. 
     At operation  1030  energy is transferred from the electrostatic transfer head assembly and through the array of micro devices to bond the array of micro devices to the receiving substrate. Transferring energy from the electrostatic transfer head assembly and through the array of micro devices may facilitate several types of bonding mechanisms such as eutectic alloy bonding, transient liquid phase bonding, and solid state diffusion bonding. In an embodiment thermal energy transferred from the electrostatic transfer head assembly is also accompanied by the application of pressure from the electrostatic transfer head assembly. 
       FIGS. 3H-3J  are cross-sectional side view illustrations of exemplary types of bonding mechanisms that may occur between a micro device and receiving substrate. It is to be appreciated that the material structures illustrated and described with regard to  FIGS. 3H-3J  are exemplary in nature and are intended to convey different bonding mechanisms, and that embodiments of the invention are not limited to the simplified examples illustrated and described. Furthermore, as described above embodiments of the invention include alternative layer configurations, and embodiments are not limited to the specific layers illustrated in  FIGS. 3H-3J . Referring now to  FIG. 3H , in the particular embodiment illustrated a eutectic alloy bonding layer  310  is formed from the micro device bonding layer  110  and receiving substrate bonding layer  304  for each respective micro device. In such an embodiment, the energy transferred from the electrostatic transfer head assembly may liquefy a eutectic alloy bonding layer  310  formed at the interface of bonding layers  110 ,  304  after the formation of an alloy due to diffusion of one or both of the bonding layers. In an embodiment, the bonding layers  110 ,  304  may be completely consumed during the formation of the eutectic alloy bonding layer  310  if their volumes are precisely controlled to reflect the eutectic composition. In other embodiments, one or both of the bonding layers  110 ,  304  are not completely consumed. In an embodiment, eutectic alloy bonding is performed by heating bonding layers  110 ,  304  to a temperature exceeding the eutectic point by 5-30° C., followed by cooling down to a temperature below the eutectic temperature. An exemplary non-limiting list of eutectic bonding alloys and eutectic temperatures is provided below in Table 2. In an embodiment, the electrostatic transfer head assembly applies a low contact pressure (e.g. 0.1 MPa to 1 MPa) during eutectic alloy bonding in order to prevent the liquid phase from excessively squeezing out from between the micro device and receiving substrate. 
     
       
         
           
               
               
               
               
             
               
                 TABLE 2 
               
               
                   
               
               
                 Eutectic alloy 
                 Eutectic 
                 Bonding layer 
                 Bonding layer 
               
               
                 (wt %) 
                 temperature (° C.) 
                 110 material 
                 304 material 
               
               
                   
               
             
            
               
                 Au:Sn (20/80) 
                 280 
                 Au 
                 Sn 
               
               
                 Au:Ge (28/72) 
                 361 
                 Au 
                 Ge 
               
               
                 Al:Ge (49/51) 
                 419 
                 Al 
                 Ge 
               
               
                 Ag:In (3/97) 
                 143 
                 Ag 
                 In 
               
               
                   
               
            
           
         
       
     
     As described above, the substrate  200  supporting the array of electrostatic transfer heads  204  and the receiving substrate  300  may be heated. In an embodiment, the substrate  200  is heated to a temperature below the liquidus temperature of bonding layer  110 , and the receiving substrate  300  is heated to a temperature below the liquidus temperature of bonding layer  304 . In certain embodiments, the transfer of heat from the electrostatic transfer head assembly  206  though the array of micro devices is sufficient form the eutectic alloy. For example, the electrostatic transfer head assembly may be held at a temperature of 5-30° C. above the eutectic temperature, while bonding layer  110  is formed of a eutectic alloy component with a liquidus temperature above the eutectic temperature. In a specific embodiment, the substrate  200  supporting the array of electrostatic transfer heads  204  is held at 150° C., bonding layer  110  is formed of Ag, and bonding layer  304  is formed of In. The temperatures of the substrates  200 ,  300  may be maintained throughout the process, or ramped up during bonding. Upon completion of eutectic alloy bonding, the temperature of one of the substrate  200  or  300  may be reduced to solidify the eutectic alloy. 
     Referring to  FIG. 3I , in the particular embodiment illustrated transient liquid phase bonding includes liquefying the receiving substrate bonding layer  304  to interdiffuse the receiving substrate bonding layer  304  with the micro device bonding layer  110  and form an inter-metallic compound layer  312  having an ambient melting temperature higher than an ambient melting temperature of the receiving substrate bonding layer  304 . In an embodiment, the bonding layers  110 ,  304  may be completely consumed during the formation of the inter-metallic compound layer  312 . In other embodiments the one or both of bonding layers  110 ,  304  are not completely consumed. Transient liquid phase bonding may be accomplished at or above the lowest liquidus temperature of the bonding layers. In an embodiment, the micro device bonding layer  110  includes the higher melting temperature material and the receiving substrate bonding layer  304  includes the lower melting temperature material. In an embodiment, the micro device bonding layer  110  may have a liquidus temperature above 250° C. such as bismuth (271.4° C.), or a liquidus temperature above 350° C. such as gold (1064° C.), copper (1084° C.), silver (962° C.), aluminum (660° C.), zinc (419.5° C.), or nickel (1453° C.). In an embodiment, the receiving substrate bonding layer  304  has a liquidus temperature below the liquidus temperature of bonding layer  110 . For example, the receiving substrate bonding layer  304  may be any of the low temperature solders listed in Table 1 above. In an embodiment, the receiving substrate bonding layer  304  includes tin (232° C.) or indium (156.7° C.). A list of exemplary materials system for transient liquid phase bonding is provided below in Table 3 along with melting temperatures of some exemplary inter-metallic compounds that may be formed. 
     
       
         
           
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                 Bonding layer 
                 Bonding layer 
                 Inter-metallic compound 
               
               
                 110 material 
                 304 material 
                 melting temperature (° C.) 
               
               
                   
               
             
            
               
                 Cu 
                 Sn 
                 415 
               
               
                 Ag 
                 Sn 
                 600 
               
               
                 Ag 
                 In 
                 880 
               
               
                 Au 
                 Sn 
                 278 
               
               
                 Au 
                 In 
                 495 
               
               
                 Ni 
                 Sn 
                 400 
               
               
                   
               
            
           
         
       
     
     As described above, the substrate  200  supporting the array of electrostatic transfer heads  204  and the receiving substrate  300  may be heated. In an embodiment, the substrate  200  is heated to a temperature below the liquidus temperature of bonding layer  110 , and the receiving substrate  300  is heated to a temperature below the liquidus temperature of bonding layer  304 . In certain embodiments, the transfer of heat from the electrostatic transfer head assembly though the array of micro devices is sufficient to form the transient liquid state of bonding layer  304  with subsequent isothermal solidification as an inter-metallic compound. While in the liquid phase, the lower melting temperature material both spreads out over the surface and diffuses into a solid solution of the higher melting temperature material or dissolves the higher melting temperature material and solidifies as an inter-metallic compound. For example, the substrate  200  supporting the array of electrostatic transfer heads  204  may be held at a temperature of 10-70° C., or more particularly 10-30° C., above the liquidus temperature of the receiving substrate bonding layer  304 , while bonding layer  110  is formed of a component with a liquidus temperature above the liquidus temperature of bonding layer  304 . In a specific embodiment, the substrate  200  supporting the array of electrostatic transfer heads  204  is held at 180° C., bonding layer  110  is formed of Au, and bonding layer  304  is formed of In. In an embodiment, the electrostatic transfer head assembly applies a low contact pressure during initial contact at operation  1020  for transient liquid phase bonding in order to prevent the liquid phase from excessively squeezing out from between the micro device and receiving substrate. In accordance with embodiments of the invention, pressure may be related to the strength of bonding layers. For example, indium has a tensile strength of 1.6 MPa at room temperature. In an embodiment, the applied pressure is below the tensile strength of a metal bonding layer material at room temperature. For example, where bonding layer  304  is indium, the applied pressure may be below 1 MPa. 
     In accordance with some embodiments of the invention, eutectic alloy bonding and transient liquid phase bonding can both provide an additional degree of freedom for system component leveling, such as planarity of the array of micro devices with the receiving substrate, and for variations in height of the micro devices due to the change in height of the liquefied bonding layers as they spread out over the surface. 
     Referring to  FIG. 3J , in the particular embodiment illustrated solid state diffusion bonding occurs between the receiving substrate bonding layer  304  and micro device bonding layer  110  to form a metal bond  314 . In such an embodiment, solid state diffusion occurs at a temperature below the ambient melting temperature of the bonding layers  304 ,  110 . Where the bonding mechanism includes solid state diffusion, application of heat at pressure may aid in diffusion. For example, thermocompression bonding (TCB) may be used. During solid state diffusion a metal bond is established between two metal surface pressed together. By heating the two surfaces, the amount of pressure applied for the bonding process can be reduced due to metal softening. Non-limiting examples of materials for layers  110 ,  304  may include Au—Au, Cu—Cu, Al—Al, though dissimilar metals may also be used. As described above, the substrate  200  supporting the array of electrostatic transfer heads  204  and the receiving substrate  300  may be heated. In an embodiment, the substrate  200  and receiving substrate  300  are both heated to temperatures below the liquidus temperatures of the bonding layers  110 ,  304 . In an embodiment, TCB is performed at a temperature range of 200° C. -500° C. Furthermore, pressure may be higher than pressures used for eutectic alloy bonding and transient liquid phase bonding. For example, pressures for TCB may be from above 1 MPa to 20 MPa. 
     Following the transfer of energy to bond the array of micro devices to the receiving substrate, the array of micro devices are released onto the receiving substrate at operation  1040  and illustrated in  FIG. 3G . Where the transfer heads  204  include bipolar electrodes, an alternating voltage may be applied across the pair of electrodes in each transfer head  204  so that at a particular point in time when a negative voltage is applied to one electrode, a positive voltage is applied to the other electrode in the pair, and vice versa to create the pickup pressure. Releasing the array of micro device from the transfer heads  204  may be accomplished with a variety of methods including turning off the voltage sources, lowering the voltage across the electrostatic transfer head electrodes, changing a waveform of an AC voltage, and grounding the voltage sources. Other electrode configurations may be used in accordance with embodiments of the invention. For example, monopolar electrode configurations may be used. In some embodiments the receiving substrate is further annealed after releasing the array of micro devices onto the receiving substrate to strengthen the bonds. 
     A variety of operations can be performed for transferring energy when contacting micro devices on a carrier substrate, picking up the micro devices, transferring the micro devices, contacting the receiving substrate with the micro devices, bonding the micro devices to the receiving substrate, and releasing the micro devices. For example, as described above, heaters  105 ,  205 ,  305  may be used to transfer energy to the bonding layers when contacting micro devices on a carrier substrate, picking up the micro devices, transferring the micro devices, contacting the receiving substrate with the micro devices, bonding the micro devices to the receiving substrate, and releasing the micro devices. In some embodiments the substrate  200  supporting the array of electrostatic transfer heads  204  can be maintained at a uniform elevated temperature during the operations illustrated and described with regard to  FIGS. 3A-3G . For example, in the specific embodiments describing an Au:In bonding layer system, the substrate  200  supporting the array of electrostatic transfer heads  204  is maintained at 180° C. during the operations illustrated and described with regard to  FIGS. 3A-3G . In other embodiments the substrate  200  supporting the array of electrostatic transfer heads  204  is subjected to a thermal cycle, for example ramped up above a liquidus temperature of the bonding layer  110  to pick up the array of micro devices from the carrier substrate, ramped up above a eutectic alloy bonding temperature, ramped up above a liquidus temperature of the bonding layer  304 , or ramped up for TCB. In other embodiments, the temperature of the substrate  200  supporting the array of electrostatic transfer heads  204  may be lowered after initial melting to complete bonding. For example, the temperature of the substrate  200  supporting the array of electrostatic transfer heads  204  may be lowered below a eutectic alloy temperature, or liquidus temperature of a receiving substrate bonding layer. Furthermore, the electrostatic transfer head assembly can be used to transfer a specific contact pressure to the bonding layers when contacting the micro devices on the carrier substrate or receiving substrate, and during bonding the micro devices to the receiving substrate. 
     In utilizing the various aspects of this invention, it would become apparent to one skilled in the art that combinations or variations of the above embodiments are possible when transferring and bonding an array of micro devices to a receiving substrate. Although the present invention has been described in language specific to structural features and/or methodological acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. The specific features and acts disclosed are instead to be understood as particularly graceful implementations of the claimed invention useful for illustrating the present invention.

Metadata:
Filing Date: 20130124
Publication Date: 20170926
Grant Date: 20170926
Priority Date: 20120209
Inventors: BIBL ANDREAS
HIGGINSON JOHN A.
HU HSIN-HUA
LAW HUNG-FAI STEPHEN
Assignee: APPLE INC
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Family ID: 48945903