Wafer packaging and singulation method
First Claim
Patent Images
1. A method comprising:
- providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap;
sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and
forming a spacer between the wafer substrate and the lid substrate, wherein the formed spacer comprises a seal between the lid substrate and the wafer substrate and about each main portion between each main portion and each contact point and wherein the seal comprises a bond ring, wherein the multi-device lid substrate has a flat face opposite the wafer substrate extending across essentially an entirety of the wafer substrate, wherein the spacer includes a portion extending between the contact points and the lid substrate.
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Abstract
A method includes providing a micro device wafer having micro devices supported by a wafer substrate and a multi-device lid substrate coupled to and spaced from the wafer substrate. The method further includes sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate.
34 Citations
32 Claims
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1. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and forming a spacer between the wafer substrate and the lid substrate, wherein the formed spacer comprises a seal between the lid substrate and the wafer substrate and about each main portion between each main portion and each contact point and wherein the seal comprises a bond ring, wherein the multi-device lid substrate has a flat face opposite the wafer substrate extending across essentially an entirety of the wafer substrate, wherein the spacer includes a portion extending between the contact points and the lid substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, each micro device having a main portion and a contact point electrically and physically connected to and projecting from the main portion; coupling a multi-lid substrate to the wafer substrate such that the lid substrate is supported and spaced above the contact point of each device; and sawing through the lid substrate to a depth between the wafer substrate and the lid substrate so as to expose the contact point of each micro device by forming an opening on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening, wherein the lid substrate is spaced from the wafer substrate by a bond ring extending above and next to the contact point and wherein the sawing through the lid substrate includes positioning a saw blade across from and opposite to the bond ring. - View Dependent Claims (22, 23)
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24. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and providing a protective material between the at least one of the contact points and the lid substrate such that the at least one contact point is sandwiched between the protective material and the wafer substrate and such that the protective material is out of contact with the main portions of the micro devices, wherein the sawing through the multi-device lid substrate forms an opening through the multi-device lid substrate and adjacent to the protective material.
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25. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and forming a spacer between the wafer substrate and the lid substrate, wherein the spacer includes a portion extending between the contact points and the lid substrate.
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26. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and forming a spacer between the wafer substrate and the lid substrate, wherein the formed spacer comprises a seal between the lid substrate and the wafer substrate and about each main portion between each main portion and each contact point and wherein the seal comprises a bond ring, wherein the multi-device lid substrate has a flat face opposite the wafer substrate extending across essentially an entirety of the wafer substrate, wherein the opening is adjacent a first contact point of a first micro device and a second contact point of a consecutive second micro device. - View Dependent Claims (27)
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28. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; and forming a spacer between the wafer substrate and the lid substrate, wherein the formed spacer comprises a seal between the lid substrate and the wafer substrate and about each main portion between each main portion and each contact point and wherein the seal comprises a bond ring, wherein the multi-device lid substrate has a flat face opposite the wafer substrate extending across essentially an entirety of the wafer substrate, wherein each micro device has a first contact point electrically and physically connected to and on a first side of the main portion and a second contact point on a second side of the main portion and wherein the saw is configured to form openings adjacent the first contact point and the second contact point such that the first contact point and the second contact point are sandwiched between the wafer substrate and the openings. - View Dependent Claims (29)
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30. A method comprising:
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providing a micro device wafer having micro devices supported by a wafer substrate, wherein each micro device includes a main portion and at least one contact point electrically and physically connected to and projecting from the main portion, and a multi-device lid substrate coupled to and spaced from the wafer substrate, the multi-device lid substrate having portions opposite each main portion and spaced from each opposite main portion by an empty gap; sawing through the multi-device lid substrate to a depth between the wafer substrate and the lid substrate, wherein the sawing forms an opening adjacent to at least one contact point of at least one device on an opposite side of the at least one contact point as the wafer substrate such that the at least one contact point is sandwiched between the wafer substrate and the opening; forming a spacer between the wafer substrate and the lid substrate, wherein the formed spacer comprises a seal between the lid substrate and the wafer substrate and about each main portion between each main portion and each contact point and wherein the seal comprises a bond ring, wherein the multi-device lid substrate has a flat face opposite the wafer substrate extending across essentially an entirety of the wafer substrate; providing a protective material between the at least one of the contact point and the lid substrate such that the at least one contact point is sandwiched between the protective material and the wafer substrate and such that the protective material is out of contact with the main portions of the micro devices, wherein the sawing through the multi-device lid substrate forms an opening through the multi-device lid substrate and adjacent to the protective material; and removing the protective material to expose the contact points. - View Dependent Claims (31, 32)
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Specification