Method of fabricating and transferring a micro device and an array of micro devices utilizing an intermediate electrically conductive bonding layer
First Claim
Patent Images
1. A method of fabricating a micro device comprising:
- bonding a first substrate stack to a second substrate stack with an intermediate electrically conductive bonding layer having a liquidus temperature of 350°
C. or lower;
patterning an active device layer of the first substrate stack to form a plurality of micro devices;
heating a region of the intermediate electrically conductive bonding layer to the liquidus temperature or higher;
picking up one of the plurality of the micro devices and a portion of the intermediate electrically conductive bonding layer with a transfer head;
placing the micro device and the portion of the intermediate electrically conductive bonding layer on an electrically conductive receiving bonding layer on a receiving substrate; and
bonding the intermediate electrically conductive bonding layer to the electrically conductive receiving bonding layer to form a permanent alloy bonding layer having a liquidus temperature above 150°
C.
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Abstract
A method of fabricating and transferring a micro device and an array of micro devices to a receiving substrate are described. In an embodiment, an electrically insulating layer is utilized as an etch stop layer during etching of a p-n diode layer to form a plurality of micro p-n diodes. In an embodiment, an electrically conductive intermediate bonding layer is utilized during the formation and transfer of the micro devices to the receiving substrate.
212 Citations
19 Claims
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1. A method of fabricating a micro device comprising:
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bonding a first substrate stack to a second substrate stack with an intermediate electrically conductive bonding layer having a liquidus temperature of 350°
C. or lower;patterning an active device layer of the first substrate stack to form a plurality of micro devices; heating a region of the intermediate electrically conductive bonding layer to the liquidus temperature or higher; picking up one of the plurality of the micro devices and a portion of the intermediate electrically conductive bonding layer with a transfer head; placing the micro device and the portion of the intermediate electrically conductive bonding layer on an electrically conductive receiving bonding layer on a receiving substrate; and bonding the intermediate electrically conductive bonding layer to the electrically conductive receiving bonding layer to form a permanent alloy bonding layer having a liquidus temperature above 150°
C. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification