Method and apparatus for flag-less water bonding tool
First Claim
1. A method for forming multi-layered materials, the method comprising:
- providing a first substrate having a first backside surface supported on a first porous chuck, and a first surface region, the first surface region being characterized by a first end and a second end;
providing a second substrate having a second backside surface supported on a second porous chuck, and a second surface region, the second surface region being characterized by a third end and a fourth end;
initiating a physical contact of a first predetermined portion of the first end of the first surface region with a second predetermined portion of the third end of the second surface region, while maintaining utilizing the first and second porous chucks, other portions of the first surface region and the second surface region substantially free from joining the other portions of the first surface region to the second surface region;
causing a bond wave to form by an interface region within a vicinity of the first predetermined portion and the second predetermined portion;
moving, using a controlled process, the bond wave from the first end of the first surface and the third end of the second surface to the second end of the first surface and the fourth end of the second surface while maintaining a determined velocity of the bond wave to form a continuous interface to join the first surface of the first substrate with the second surface of the second surface.
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Abstract
Embodiments in accordance with the present invention relate to methods and apparatuses for bonding together substrates in a manner that suppresses the formation of voids between them. In a specific embodiment, a backside of each substrate is adhered to a front area of flexible, porous chuck having a rear area in pneumatic communication with a vacuum. Application of the vacuum causes the chuck and the associated substrate to slightly bend. Owing to this bending, physical contact between local portions on the front side of the flexed substrates may be initiated, while maintaining other portions on front side of the substrates substantially free from contact with each other. A bond wave is formed and maintained at a determined velocity to form a continuous interface joining the front sides of the substrates, without formation of voids therebetween. In one embodiment, the chucks may comprise porous polyethylene sealed with polyimide except for a portion of the front configured to be in contact with the substrate, and a portion of the backside configured to be in communication with a vacuum source.
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Citations
39 Claims
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1. A method for forming multi-layered materials, the method comprising:
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providing a first substrate having a first backside surface supported on a first porous chuck, and a first surface region, the first surface region being characterized by a first end and a second end; providing a second substrate having a second backside surface supported on a second porous chuck, and a second surface region, the second surface region being characterized by a third end and a fourth end; initiating a physical contact of a first predetermined portion of the first end of the first surface region with a second predetermined portion of the third end of the second surface region, while maintaining utilizing the first and second porous chucks, other portions of the first surface region and the second surface region substantially free from joining the other portions of the first surface region to the second surface region; causing a bond wave to form by an interface region within a vicinity of the first predetermined portion and the second predetermined portion; moving, using a controlled process, the bond wave from the first end of the first surface and the third end of the second surface to the second end of the first surface and the fourth end of the second surface while maintaining a determined velocity of the bond wave to form a continuous interface to join the first surface of the first substrate with the second surface of the second surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. An apparatus comprising:
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a first porous and flexible chuck in pneumatic communication with a vacuum; a second porous and flexible chuck in pneumatic communication with the vacuum; a substrate handing apparatus configured to position a backside of a first wafer in contact with the first chuck, and to position a backside of a second wafer in contact with the second chuck; and an energy source configured to pinch together first ends of the first and second wafers and thereby initiate a bonding wave. - View Dependent Claims (34, 35, 36, 37, 38, 39)
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Specification