CN114944442A - Laser projection proximity type MicroLED huge transfer transposition, method and system - Google Patents
Laser projection proximity type MicroLED huge transfer transposition, method and system Download PDFInfo
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Abstract
本发明属于半导体相关技术领域,并公开了一种激光投影接近式巨量转移装置、成形方法及激光投影系统。该装置包括支撑层、动态释放层和粘性层,其中,所述支撑层为基底层,所述动态释放层设置在所述基底层上,所述粘性层设置在所述动态释放层上,用于与待转移MicroLED接触,当激光穿过所述支撑层照射在该动态释放层上时,该动态释放层发生烧蚀或者相变,从而鼓起并使得所述粘性层也产生鼓泡,从而减小与所述待转移MicroLED的接触,实现转移装与待转移MicroLED的剥离。通过本发明,解决MicroLED巨量转移的问题。
The invention belongs to the technical field of semiconductors, and discloses a laser projection proximity type mass transfer device, a forming method and a laser projection system. The device comprises a support layer, a dynamic release layer and an adhesive layer, wherein the support layer is a base layer, the dynamic release layer is arranged on the base layer, the adhesive layer is arranged on the dynamic release layer, and the In contact with the MicroLED to be transferred, when the laser passes through the support layer and irradiates the dynamic release layer, the dynamic release layer undergoes ablation or a phase change, thereby bulging and causing the viscous layer to also bubble, thereby The contact with the to-be-transferred MicroLED is reduced, and the transfer device and the to-be-transferred MicroLED are peeled off. Through the present invention, the problem of mass transfer of MicroLED is solved.
Description
技术领域technical field
本发明属于半导体相关技术领域,更具体地,涉及一种激光投影接近式MicroLED巨量转移转置、方法及系统。The invention belongs to the technical field of semiconductors, and more particularly, relates to a laser projection proximity type MicroLED mass transfer transposition, method and system.
背景技术Background technique
虽然MicroLED优势众多,应用前景也一片光明,但关键难点在于如何将大量微小尺度的MicroLED转移到显示电路基板上。主要原因在于,随着MicroLED尺寸逐渐减少(≤50μm),重力衰减速度比范德华力或静电引力更快,导致机器手和真空吸附的拾取方式没有作用区间(极限尺寸~80μm),转移效率慢(~2.5万/小时),因此难以满足微尺度芯片的转移可靠性、效率的要求,由此巨量转移(Mass Transfer)技术也应运而生。巨量转移技术要求将微米级大小的MicroLED从原生蓝宝石基板上选择性的批量转移到电路基板上,由于MicroLED尺寸非常小,而且巨量转移技术要求非常高的良率(99.9999%)、效率和转移精度(±5μm),因此巨量转移技术也成为MicroLED显示研发过程的最大挑战,阻碍了MicroLED的发展。Although MicroLED has many advantages and bright application prospects, the key difficulty lies in how to transfer a large number of micro-scale MicroLEDs to display circuit substrates. The main reason is that as the size of MicroLED gradually decreases (≤50μm), the decay rate of gravity is faster than that of van der Waals force or electrostatic attraction, resulting in no effective range for the pick-up method of robotic hands and vacuum adsorption (limit size ~ 80μm), and the transfer efficiency is slow ( ~25,000/hour), so it is difficult to meet the transfer reliability and efficiency requirements of micro-scale chips, so Mass Transfer technology also came into being. Mass transfer technology requires selective batch transfer of micron-sized MicroLEDs from native sapphire substrates to circuit substrates. Due to the very small size of MicroLEDs, and mass transfer technology requires very high yield (99.9999%), efficiency and The transfer accuracy (±5μm), so the mass transfer technology has also become the biggest challenge in the MicroLED display research and development process, hindering the development of MicroLED.
转印MicroLED的办法,主要依靠粘性印章方法和转移芯片的直接物理接触,通过控制印章和芯片粘性,完成转移。虽然能够大批量的转移,但不能选择性转移。静电吸附需要在特定的带磁性MicroLED上和印章,才能实现转移工作,具有一定的局限性。激光无接触转移技术是以激光为驱动实现无接触选择性加工,并以图案化激光光斑的方式实现MicroLED阵列化和批量化的转移。由于激光工艺具有快速加工、可选择性、受影响区域局部化等独特优势,因此可以高效率地实现MicroLED阵列化和批量化的转移,有望应用于超大尺寸、高分辨率Micro LED显示制造。The method of transferring MicroLED mainly relies on the sticky stamp method and the direct physical contact of the transfer chip, and the transfer is completed by controlling the stickiness of the stamp and the chip. Although it can be transferred in large quantities, it cannot be selectively transferred. Electrostatic adsorption needs to be stamped on a specific magnetic MicroLED to achieve transfer work, which has certain limitations. Laser non-contact transfer technology is driven by laser to achieve non-contact selective processing, and realizes the array and batch transfer of MicroLEDs in the form of patterned laser spots. Due to the unique advantages of laser processing, such as rapid processing, selectivity, and localization of affected areas, it can efficiently realize the transfer of MicroLED arrays and batches, and is expected to be applied to the manufacture of ultra-large, high-resolution Micro LED displays.
但现阶段激光无接触转移技术仍然存在一定的局限性。如气体冲击-激光前向转移技术,需要烧蚀印章中牺牲层,并产生冲击波,从而实现芯片转移,但由于:1)芯片的剥离并非完全对称,影响芯片飞行轨迹;2)往往该种冲击波传播速度比芯片掉落速度快,因此会产生冲击波反弹到接收基底上,影响芯片落点的稳定性。以上两个原因直接影响芯片的转移精度。鼓泡-激光前向转移技术由于其较好的尺寸兼容性和工艺可行性受到了广泛关注,该种工艺主要通过激光与动力释放层相互作用,汽化动力释放层,并形成鼓泡推动芯片转移。该种工艺下,由于冲击波被DRL层包围,因此大大的减少了冲击波对芯片转移的影响,但该种转移过程中,激光光斑形状、激光能量不均匀、光斑分辨率、芯片与接收基底的间距仍然影响着转移精度。如转移670×670×50μm芯片,在195μm的转移间距下,仍然存在偏移,其平均值、中位数和标准差分别为61.2μm、50.0μm和46.3μm,另外,现有技术中利用磁场转移其采用磁场将激光诱导掉落的芯片磁化,并牵引滑移至目标位置实现自主定位。虽然该方法可以进一步提高精度,但无法轻易实现MicroLED在接收基板上较紧密的阵列化排布,且芯片需要一层磁化层,因此具有一定的局限性。However, the current laser non-contact transfer technology still has certain limitations. For example, the gas shock-laser forward transfer technology needs to ablate the sacrificial layer in the seal and generate shock waves to achieve chip transfer, but because: 1) the peeling of the chip is not completely symmetrical, which affects the flight trajectory of the chip; 2) this kind of shock wave often The propagation speed is faster than the drop speed of the chip, so a shock wave will be generated to bounce back to the receiving substrate, affecting the stability of the chip drop point. The above two reasons directly affect the transfer accuracy of the chip. Bubble-laser forward transfer technology has received extensive attention due to its good dimensional compatibility and process feasibility. This process mainly uses the laser to interact with the power release layer, vaporize the power release layer, and form bubbles to promote chip transfer. . In this process, since the shock wave is surrounded by the DRL layer, the impact of the shock wave on the transfer of the chip is greatly reduced. still affects the transfer accuracy. For example, when transferring a 670×670×50μm chip, under the transfer pitch of 195μm, there is still an offset, and the mean, median and standard deviation are 61.2μm, 50.0μm and 46.3μm, respectively. In addition, the magnetic field is used in the prior art. It uses a magnetic field to magnetize the laser-induced falling chip, and pulls it to the target position to achieve autonomous positioning. Although this method can further improve the accuracy, it cannot easily achieve a tighter array arrangement of MicroLEDs on the receiving substrate, and the chip requires a magnetization layer, so it has certain limitations.
发明内容SUMMARY OF THE INVENTION
针对现有技术的以上缺陷或改进需求,本发明提供了一种激光投影接近式MicroLED巨量转移转置、方法及系统,解决MicroLED巨量转移中精度低的问题。In view of the above defects or improvement needs of the prior art, the present invention provides a laser projection proximity MicroLED mass transfer transposition, method and system to solve the problem of low precision in MicroLED mass transfer.
为实现上述目的,按照本发明的一个方面,提供了一种激光投影接近式巨量转移装置,该装置包括支撑层、动态释放层和粘性层,其中,In order to achieve the above object, according to one aspect of the present invention, a laser projection proximity mass transfer device is provided, the device includes a support layer, a dynamic release layer and an adhesive layer, wherein,
所述支撑层为基底层,所述动态释放层设置在所述基底层上,所述粘性层设置在所述动态释放层上,用于与待转移MicroLED接触,当激光穿过所述支撑层照射在该动态释放层上时,该动态释放层发生烧蚀或者相变,从而鼓起并使得所述粘性层也产生鼓泡,从而减小与所述待转移MicroLED的接触,实现转移装与待转移MicroLED的剥离。The support layer is a base layer, the dynamic release layer is disposed on the base layer, and the adhesive layer is disposed on the dynamic release layer for contact with the MicroLED to be transferred. When the laser passes through the support layer When irradiated on the dynamic release layer, the dynamic release layer undergoes ablation or a phase change, so as to bulge and make the viscous layer also bubble, thereby reducing the contact with the MicroLED to be transferred and realizing the transfer and Stripping of the MicroLED to be transferred.
进一步优选地,所述动态释放层采用的材料为聚酰亚胺、GaN薄膜、三氮烯聚合物和金、钛中的一种。Further preferably, the material used for the dynamic release layer is one of polyimide, GaN film, triazene polymer, gold and titanium.
进一步优选地,所述动态释放层的厚度为5μm~15μm。Further preferably, the thickness of the dynamic release layer is 5 μm˜15 μm.
进一步优选地,所述粘性层为粘弹性材料,为聚二甲基硅氧烷或环氧树脂。Further preferably, the adhesive layer is a viscoelastic material, such as polydimethylsiloxane or epoxy resin.
进一步优选地,所述粘性层的厚度为30μm~40μm。Further preferably, the thickness of the adhesive layer is 30 μm˜40 μm.
进一步优选地,所述支撑层的材料为蓝宝石或者石英。Further preferably, the material of the support layer is sapphire or quartz.
进一步优选地,所述支撑层的厚度为500μm~1000μm。Further preferably, the thickness of the support layer is 500 μm˜1000 μm.
按照本发明的另一个方面,提供了一种上述所述的激光投影接近式巨量转移方法,该方法包括下列步骤:According to another aspect of the present invention, there is provided a laser projection proximity mass transfer method described above, the method comprising the following steps:
S1将巨量转移装置设置在待转移MicroLED上方,并一一对应;S1 sets the mass transfer device above the MicroLED to be transferred, and corresponds one by one;
S2采用激光照射所述巨量转移装置,激光穿过所述支撑层照射在所述动态释放层,使得动态释放层烧蚀或发生相变鼓泡,巨量转移装置的粘性层和待转移MicroLED界面接触面积减少;S2 uses a laser to irradiate the mass transfer device, and the laser passes through the support layer and irradiates the dynamic release layer, so that the dynamic release layer is ablated or phase-change bubbling occurs, and the adhesive layer of the mass transfer device and the MicroLED to be transferred are The interface contact area is reduced;
S3巨量转移装置鼓泡产生回弹,使得MicroLED完全从印章上剥离,并成功转移到接收基底上。The S3 mass transfer device bubbling to produce a rebound, allowing the MicroLED to be completely peeled from the stamp and successfully transferred to the receiving substrate.
按照本发明的又一个方面,提供了一种上述所述的激光投影接近式巨量转移装置进行激光投影的系统,其特征在于,该系统包括光源、衰减器、望远单元、匀光器、光斑投影单元和运动平台,其中:According to another aspect of the present invention, there is provided a system for laser projection by the above-mentioned laser projection proximity mass transfer device, characterized in that the system includes a light source, an attenuator, a telephoto unit, a light homogenizer, Spot projection unit and motion platform, where:
所述衰减器设置在所述光源的前方,用于调节所述光源发出的激光的输出能量;所述望远单元设置在所述衰减器后方,用于将来自所述衰减器的光斑进行扩束和整形;所述匀光器设置在所述望远单元后方,用于从来自所述望远单元的光中截取一段波长稳定的光束;所述光斑投影单元设置在所述匀光器的后方,用于将来自所述匀光器的光进行图案化和聚焦,所述运动平台设置在所述光斑投影单元的下方,用于放置上述所述的激光投影接近式巨量转移装置。The attenuator is arranged in front of the light source to adjust the output energy of the laser light emitted by the light source; the telephoto unit is arranged behind the attenuator to expand the light spot from the attenuator. beam and shaping; the light homogenizer is arranged behind the telephoto unit, and is used to intercept a section of light beam with stable wavelength from the light from the telephoto unit; the spot projection unit is arranged at the back of the light homogenizer The rear is used for patterning and focusing the light from the homogenizer, and the moving platform is arranged below the spot projection unit for placing the above-mentioned laser projection proximity mass transfer device.
进一步优选地,所述系统中还包括反射镜,所述衰减器和望远单元之间,所述匀光器与所述光斑投影单元之间均设置有反射镜,用于改变光路的方向。Further preferably, the system further includes a reflecting mirror, and between the attenuator and the telephoto unit, and between the light homogenizer and the light spot projection unit, a reflecting mirror is arranged for changing the direction of the light path.
总体而言,通过本发明所构思的以上技术方案与现有技术相比,具备下列有益效果:In general, compared with the prior art, the above technical solutions conceived by the present invention have the following beneficial effects:
1.本发明提供的激光巨量转移装置,其不仅仅可以通过激光快速调控转移装置的鼓泡高度和芯片和转移装置界面粘性,同时匹配MicroLED与接受基板的微间距,使得MicroLED芯片与接收基底从原先的无接触转成微弱接触,实现高精度、高可靠式转移,避免激光冲击波、芯片飞行、不对称剥离、芯片在接收基板上回弹、芯片偏转等因素对转移精度的影响,显著提高了MicroLED转移精度和效率;1. The laser mass transfer device provided by the present invention can not only rapidly adjust the bubbling height of the transfer device and the interface viscosity between the chip and the transfer device through the laser, but also match the micro-spacing between the MicroLED and the receiving substrate, so that the MicroLED chip and the receiving substrate can be adjusted. From the original non-contact to weak contact, high-precision and high-reliability transfer is realized, avoiding the influence of laser shock wave, chip flying, asymmetric peeling, chip rebounding on the receiving substrate, chip deflection and other factors on the transfer accuracy, which is significantly improved. improved MicroLED transfer accuracy and efficiency;
2.本发明的接近式激光巨量转移降低了对转移装置的平面度和接收基底尺度要求,由于在释放过程中,转移装置不需要与接收基板完全接触,所以平面度的误差对转移成功率的影响大大降低,从而保证转移精度,同时在后期的无接触转成微弱接触,由于此时转移装置呈现半球形或鼓泡形状,其共形性往往比平面转移装置要好,因此大大减低了对接收基底尺度要求;2. The proximity laser mass transfer of the present invention reduces the flatness requirements of the transfer device and the size of the receiving substrate. Since the transfer device does not need to be in complete contact with the receiving substrate during the release process, the error of the flatness affects the transfer success rate. The influence of the transfer device is greatly reduced, so as to ensure the transfer accuracy, and at the same time, the non-contact is turned into a weak contact in the later stage. Since the transfer device presents a hemispherical or bubbling shape at this time, its conformality is often better than that of the plane transfer device, so it greatly reduces the impact on the transfer device. Receive base size requirements;
3.本发明采用激光投影式系统,可以将激光光束通过掩模板投影阵列为多个单束激光,从而实现并行转移,同时采用投影的方式,使得掩模孔加工时比所需光斑尺寸同比放大m倍,大幅度降低了掩模板的加工难度,提高了光斑分辨率,进一步减少激光衍射效应,并可以进一步均匀化光斑形状,减少不均匀光斑能量和形状对转移精度的影响,从而大大提高巨量转移精度;3. The present invention adopts a laser projection system, which can project the laser beam into a plurality of single-beam lasers through the mask plate to realize parallel transfer. At the same time, the projection method is adopted to make the mask hole processing larger than the required spot size year-on-year. m times, greatly reduces the processing difficulty of the mask, improves the spot resolution, further reduces the laser diffraction effect, and can further homogenize the spot shape, reduce the influence of uneven spot energy and shape on the transfer accuracy, thereby greatly improving the giant Volume transfer accuracy;
4.本发明制备的转移装置工艺简单,不需要额外的光刻、二次倒模、键合等复杂的工艺手段,大大减少巨量转移操作复杂程度,提高了转移速率。4. The transfer device prepared by the present invention has a simple process, does not require additional complex process means such as photolithography, secondary mold injection, bonding, etc., which greatly reduces the complexity of the massive transfer operation and improves the transfer rate.
附图说明Description of drawings
图1是按照本发明的优选实施例所构建的激光投影接近式巨量转移装置的结构示意图;1 is a schematic structural diagram of a laser projection proximity mass transfer device constructed according to a preferred embodiment of the present invention;
图2是按照本发明的优选实施例所构建的动态释放层与鼓泡高度的关系图;Fig. 2 is the relation diagram of the dynamic release layer constructed according to the preferred embodiment of the present invention and bubbling height;
图3是按照本发明的优选实施例所构建的转移装置与接收基底之间不同间距的示意图,其中,(a)是间距过小的示意图;(b)是间距过大的示意图;3 is a schematic diagram of different distances between a transfer device constructed according to a preferred embodiment of the present invention and a receiving substrate, wherein (a) is a schematic diagram of an excessively small distance; (b) is a schematic diagram of an excessively large distance;
图4是按照本发明的优选实施例所构建的转移装置工作原理流程示意图;4 is a schematic flow chart of the working principle of the transfer device constructed according to the preferred embodiment of the present invention;
图5是按照本发明的优选实施例所构建的激光投影系统结构示意图;5 is a schematic structural diagram of a laser projection system constructed according to a preferred embodiment of the present invention;
图6是按照本发明的优选实施例所构建的激光投影系统的简化原理图;6 is a simplified schematic diagram of a laser projection system constructed in accordance with a preferred embodiment of the present invention;
图7是按照本发明的优选实施例所构建的激光投影系统的阵列化缩小尺寸原理图;FIG. 7 is a schematic diagram of an array reduced size of a laser projection system constructed according to a preferred embodiment of the present invention;
图8是按照本发明的优选实施例所构建的阵列光斑在转移装置上的示意图;8 is a schematic diagram of an array light spot constructed according to a preferred embodiment of the present invention on a transfer device;
图9是按照本发明的优选实施例所构建的MicroLED实现转移的整体工艺流程图。FIG. 9 is an overall process flow diagram of transferring the MicroLED constructed according to the preferred embodiment of the present invention.
在所有附图中,相同的附图标记用来表示相同的元件或结构,其中:Throughout the drawings, the same reference numbers are used to refer to the same elements or structures, wherein:
10-转移装置,11-支撑层,12-动态释放层,13-粘性层,20-MicroLED,30-接收基底,40-激光,41-光源,42-衰减器,43-望远单元,44-匀光器,45-光斑投影单元,451-光斑图案化模块,452-光斑缩放和聚焦模块,453-掩膜版,50-剥离力,60-中间载体基板,70-原生基板,80-紫外激光,90-运动平台。10-transfer device, 11-support layer, 12-dynamic release layer, 13-adhesive layer, 20-MicroLED, 30-receiving substrate, 40-laser, 41-light source, 42-attenuator, 43-telephoto unit, 44 -Diffuser, 45-Spot Projection Unit, 451-Spot Patterning Module, 452-Spot Scaling and Focusing Module, 453-Reticle, 50-Peel Force, 60-Intermediate Carrier Substrate, 70-Native Substrate, 80- UV laser, 90-motion platform.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。此外,下面所描述的本发明各个实施方式涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, but not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.
如图1所示,该激光投影接近式巨量转移装置包括支撑层11、动态释放层12和粘性层13,其中,所述支撑层为基底层,所述动态释放层设置在所述基底层上,所述粘性层设置在所述动态释放层上,用于与待转移MicroLED接触,当激光穿过所述支撑层照射在该动态释放层上时,该动态释放层发生烧蚀或者相变,从而鼓起并使得所述粘性层也产生鼓泡,从而减小与所述待转移MicroLED的接触,实现转移装与待转移MicroLED的剥离。As shown in FIG. 1, the laser projection proximity mass transfer device includes a
进一步优选地,所述动态释放层采用的材料为聚酰亚胺、GaN薄膜、三氮烯聚合物和金、钛中的一种。上述材料容易和激光产生光热反应(~800℃),并烧蚀产生co和co2等气体,从而鼓起并使得所述粘性层也产生鼓泡。Further preferably, the material used for the dynamic release layer is one of polyimide, GaN thin film, triazene polymer, gold and titanium. The above-mentioned materials are easily photothermally reacted with the laser (~800°C), and ablation generates gases such as co and co 2 , which inflate and make the viscous layer also bubbling.
进一步优选地,所述动态释放层的厚度为5μm~15μm。在0-4μm薄膜太薄,在该动态释放层发生烧蚀或者相变时,容易造成薄膜损伤和断裂,而在>15μm,动态释放层太厚,导致弯曲刚度过大,从而不容易产生鼓泡。Further preferably, the thickness of the dynamic release layer is 5 μm˜15 μm. When the film is too thin at 0-4μm, when the dynamic release layer undergoes ablation or phase transition, it is easy to cause film damage and fracture, while at >15μm, the dynamic release layer is too thick, resulting in excessive bending stiffness, so it is not easy to produce bulging Bubble.
进一步优选地,所述粘性层为粘弹性材料,为聚二甲基硅氧烷或环氧树脂。上述材料容易制备,同时可以提供0-50kPa的粘附强度。Further preferably, the adhesive layer is a viscoelastic material, such as polydimethylsiloxane or epoxy resin. The above materials are easy to prepare and can provide adhesion strengths of 0-50 kPa at the same time.
进一步优选地,所述粘性层的厚度为30μm~40μm。进一步优选地,所述支撑层的材料为蓝宝石或者石英。蓝宝石或者石英一般对激光不吸收,可以使得激光穿透,从而使得激光直接作用在动态释放层上。Further preferably, the thickness of the adhesive layer is 30 μm˜40 μm. Further preferably, the material of the support layer is sapphire or quartz. Sapphire or quartz generally does not absorb laser light, so that the laser light can penetrate, so that the laser light directly acts on the dynamic release layer.
进一步优选地,所述支撑层的厚度为500μm~1000μm。支撑层厚度在此厚度下不能受动态释放层发生烧蚀或者相变而产生变形影响。Further preferably, the thickness of the support layer is 500 μm˜1000 μm. The thickness of the support layer cannot be affected by the deformation of the dynamic release layer due to ablation or phase change.
激光诱导转移装置产生的鼓泡高度可以通过控制激光能量和辐射次数进行控制。The bubble height produced by the laser-induced transfer device can be controlled by controlling the laser energy and the number of irradiations.
图1中带有MicroLED 20的转移装置10,在激光40作用下,使得转移装置10中的动态释放层12烧蚀汽化,形成鼓泡,鼓泡最终平衡下的最高的高度为h1(8~3000μm)。如图2所示,在激光40作用下,转移装置10鼓泡变化数据说明图,其根据不同的动态释放层12,鼓泡最终高度不一样,但都存在高度回弹区域和后区鼓泡高度逐渐平稳的平稳区域。In the
激光通过光学掩膜版投影形成的图案化激光阵列光斑,精确作用于转移装置并产生“鼓泡”;在未转移之前,粘附在转移装置上的MicroLED与接收基底间隔一个微小距离(例如8~500μm),鼓泡高度接近MicroLED与基板之间的间距(例如10~500μm),从而使得芯片与接收基底从原先的无接触转成微弱接触,实现高精度、高可靠转移。LaserPPT具有显著的优势:1)可以根据激光与转移装置的作用原理选择不同的激光,具有非常高的灵活性;2)采用激光投影式光路系统,即采用光学系统将高斯分布的激光均匀化为平顶光束,并为了实现阵列化,通过光学投影的方式将掩模板上的图案缩小m倍(m一般取5~10),聚焦并与转移装置上待转移芯片对准,辐射在动态释放层上,这种光学投影式方法可以有效的提高激光辐射的分辨率,减少衍射效应、高斯光斑不均匀等影响,并且很大程度地降低了掩模板的加工难度;3)可以兼顾转移装置接触式转印的高精度优势和激光前向转移高效率的优点,避免激光冲击波、芯片飞行、不对称剥离、芯片在接收基板上回弹等因素对转移精度的影响,显著提高了MicroLED转移精度和效率。The patterned laser array spot formed by the laser projection through the optical mask precisely acts on the transfer device and produces "bubble"; before the transfer, the MicroLED adhered to the transfer device is separated from the receiving substrate by a small distance (for example, 8 ~500μm), the bubbling height is close to the distance between the MicroLED and the substrate (for example, 10-500μm), so that the chip and the receiving substrate can be transferred from the original non-contact to weak contact, achieving high-precision and high-reliability transfer. LaserPPT has significant advantages: 1) Different lasers can be selected according to the working principle of the laser and the transfer device, which has very high flexibility; 2) The laser projection type optical path system is used, that is, the optical system is used to homogenize the Gaussian distributed laser into Flat-top beam, and in order to realize array formation, the pattern on the mask plate is reduced by m times (m is generally 5-10) by optical projection, focused and aligned with the chip to be transferred on the transfer device, and radiated on the dynamic release layer. On the other hand, this optical projection method can effectively improve the resolution of laser radiation, reduce the influence of diffraction effect, Gaussian spot unevenness, etc., and greatly reduce the processing difficulty of the mask plate; 3) It can take into account the contact type of the transfer device. The high-precision advantage of transfer printing and the high efficiency of laser forward transfer avoid the influence of factors such as laser shock wave, chip flying, asymmetric peeling, chip rebound on the receiving substrate, etc. on the transfer accuracy, which significantly improves the transfer accuracy and efficiency of MicroLED .
图3是本激光投影接近式巨量转移过程中初始带有芯片的转移装置与接收基底间距取得不合适时候可能出现的转移结果例子示意图,其中,图3中(a)所示,由于间距过小,同时处于激光作用剧烈时候,可能会存在MicroLED 20碰撞问题。图3中(b)是由于间距过大,可能会存在MicroLED20未接触接收基底30情况。也有可能间距过小时,由于回弹速度过快,带来的粘弹性效果。保持间距可以为8~3000μm,具体需要保证间距处于动态释放层中烧蚀气体使得鼓泡高度逐渐趋于平衡阶段的高度和趋于平衡阶段的最高鼓泡高度之间,以免前期烧蚀气体在激光作用强烈鼓泡变化,带来速度冲击以及和接收基板之间的粘弹性效应。Figure 3 is a schematic diagram of an example of the transfer result that may occur when the initial distance between the transfer device with the chip and the receiving substrate is not appropriate in the laser projection proximity mass transfer process. Small, and when the laser action is intense, there may be a collision problem with the
图4为本发明提出的激光投影接近式巨量转移方法的工作流程图。首先,带有MicroLED 20的激转移装置10与接收基底30保持一个微小距离间隔h2,h2间距需要处于动态释放层中烧蚀气体使得鼓泡高度逐渐趋于平衡阶段的高度和平衡阶段的最高鼓泡高度h1之间;其次,转移装置10在激光40照射下,转移装置10中的动态释放层12烧蚀汽化,形成鼓泡,转移装置10和MicroLED 20界面接触面积减少,粘附急剧减弱,同时由于转移装置10的鼓泡h2高度可以达到h1,使得MicroLED 20与接收基底30产生微弱接触;接着,在支撑层上缓慢施加剥离力50,升起转移装置;最后,使得MicroLED 20与转移装置10逐渐分层,并最终成功转移。FIG. 4 is a working flow chart of the laser projection proximity mass transfer method proposed by the present invention. First, the
图5是激光投影系统的结构示意图。该系统包括光源、衰减器42、望远单元43、匀光器44、光斑投影单元45和运动平台90,其中:所述衰减器设置在所述光源的前方,用于调节所述光源发出的激光的输出能量;所述望远单元43设置在所述衰减器后方,用于将来自所述衰减器的光斑进行扩束和整形;所述匀光器设置在所述望远单元43后方,用于从来自所述望远单元的光中截取一段波长稳定的光束;所述光斑投影单元45设置在所述匀光器44的后方,用于将来自所述匀光器的光进行图案化和聚焦,所述运动平台90设置在所述光斑投影单元45的下方,用于放置上述所述的激光投影接近式巨量转移装置。FIG. 5 is a schematic structural diagram of a laser projection system. The system includes a light source, an
所述系统中还包括反射镜,所述衰减器42和望远单元43之间,所述匀光器44与所述光斑投影单元45之间均设置有反射镜,用于改变光路的方向。The system also includes a reflector, and between the
图6是激光投影系统的简化原理。激光光源41发射光源,并通过匀光器44来使得能量不均匀的光斑匀化化处理,进一步通过光斑图案化模块451系统,使得部分光斑图案化传播到光斑缩放和聚焦模块452,使原先掩模版453上的图像缩小4或5倍,聚焦并与转移装置上需要转移位置对准后,阵列光斑作用到转移装置10上。Figure 6 is a simplified schematic of a laser projection system. The
图7中是阵列化光斑缩小4或5倍的尺寸说明示意图。均匀化的激光光源41经过掩膜版453形成阵列或者图案化光斑,此时图案尺寸为5倍,其经过光斑缩放和聚焦模块452,其尺寸缩小到1倍在转移装置10的支撑层11上。FIG. 7 is a schematic diagram illustrating the size of the arrayed light spot reduced by 4 or 5 times. The uniformized
图8是阵列化光斑作用在转移装置上的三维示意图。以四束激光光束为例子,四束激光分别辐射到相应的转移装置10位置上,并使得动态释放层12汽化,起鼓泡。FIG. 8 is a three-dimensional schematic diagram of an arrayed light spot acting on a transfer device. Taking four laser beams as an example, the four laser beams are respectively irradiated to the corresponding positions of the
图7是将MicroLED从蓝宝石基板上转移到中间载体基板60上的过程示意图,该方法的实现通常需要包括如下步骤:FIG. 7 is a schematic diagram of the process of transferring the MicroLED from the sapphire substrate to the
步骤一:将MicroLED 20按压至中间载体基板60上。并利用紫外激光80透过原生基板70,照射于MicroLED 20与原生基板70的界面处。由于MicroLED 20的基底由氮化镓材料构成,氮化镓可以吸收紫外激光,发生热分解,形成液态镓和氮气。因此,被激光照射后MicroLED 20与原生基板70界面的粘附强度显著降低,可以将MicroLED 20与原生基板70分离。Step 1: Press the
步骤二:完成MicroLED 20整体转移至接收基底30上。Step 2: Complete the transfer of the
步骤三:将本发明提出的转移装置10按压在MicroLED 20的临时接收基底60上,并严格一一对应。由于临时接收基底60是起临时过渡作用,因此MicroLED 20与临时接收基底60(如热释放胶基底或UV释放层胶层)之间的界面粘附力可以在一定作用下降低直至消失,实现对MicroLED阵列20的释放。该种方法包括加热融化胶层降低粘性或者通过紫外照射胶层降低粘性等,在此不做赘,由于临时接收基底60与临时接收基底60界面粘性减少,此时转移装置10可以整体剥离走MicroLED 20。Step 3: Press the
步骤四:将带有制备MicroLED阵列20的转移装置10移动到激光驱动平台上。Step 4: Move the
步骤五:打开转移过程中的激光器产生激光40,并驱动转移装置10里面的动态释放层12汽化,并产生鼓泡,推动MicroLED 20与接收基底30接触。Step 5: Turn on the laser during the transfer process to generate
步骤六:缓慢施加剥离力50,升起转移装置,使得MicroLED20与转移装置10逐渐分层Step 6: Slowly apply the peeling
步骤七:完成转移,并抬起转移装置10。Step 7: The transfer is completed, and the
该巨量转移方法在拾起芯片之前,粘附在印章上的MicroLED与接收基底间隔一个微小距离,并利用激光产生鼓泡高度接近MicroLED与基板之间的间距,从而使得芯片与接收基底从原先的无接触转成微弱接触,同时利用激光在鼓泡里面产生气体,因为冷却,从而产生回弹力,进而芯片转移在电路基板上。In this mass transfer method, before picking up the chip, the MicroLED adhered on the stamp is separated from the receiving substrate by a small distance, and the laser is used to generate a bubble height close to the distance between the MicroLED and the substrate, so that the chip and the receiving substrate are separated from the original. The non-contact is turned into a weak contact, and at the same time, the laser is used to generate gas in the bubble, and due to cooling, a rebound force is generated, and the chip is transferred on the circuit substrate.
进一步优选地,所述粘附在印章上的MicroLED与接收基底间隔一个微小距离可以为10~500μm。Further preferably, a tiny distance between the MicroLEDs adhered on the stamp and the receiving substrate may be 10-500 μm.
进一步优选地,激光作用到印章,产生鼓泡的高度一般为10~500μm。Further preferably, when the laser acts on the seal, the height of the bubbles generated is generally 10-500 μm.
进一步优选地,所述回弹力需要满足A是MicroLED芯片和电路基板的接触面积,C是动态释放层的刚度,Gcrit是电路基板的粘附能量,vcrit是电路基板的临界剥离速率,v是鼓泡的回弹速度。Further preferably, the resilience needs to satisfy A is the contact area between the MicroLED chip and the circuit substrate, C is the stiffness of the dynamic release layer, G crit is the adhesion energy of the circuit substrate, v crit is the critical peeling rate of the circuit substrate, and v is the rebound speed of the bubbling.
所述动态释放层12可以为聚酰亚胺(PI)、金属薄膜(如金、铝)、GaN薄膜、三氮烯聚合物等。The
所粘性层13可以是聚二甲基硅氧烷(PDMS)、环氧树脂等粘弹性材料。The
所述动态释放层12和粘性层13厚度可以通过旋涂参数需要严格控制,以使后期激光作用下的,转移装置的鼓泡能够充分变形。The thickness of the
利用激光剥离技术中的激光可以采用308nm/248nm/266nm准分子激光器、355nm飞秒激光器等。The laser in the laser lift-off technology can be 308nm/248nm/266nm excimer laser, 355nm femtosecond laser, etc.
激光器可以为:①当动态释放层为聚酰亚胺(PI)时,其可以选308nm、248nm、355nm激光器;②当动态释放层为金属薄膜时,此时激光器可以选择1064nm、808nm等红外激光器;③当动态释放层为GaN时,此时激光器可以为533nm,248nm,266nm等激光器。The laser can be: ①When the dynamic release layer is polyimide (PI), it can choose 308nm, 248nm, 355nm laser; ②When the dynamic release layer is a metal film, the laser can choose 1064nm, 808nm and other infrared lasers ; ③ When the dynamic release layer is GaN, the laser can be 533nm, 248nm, 266nm and other lasers at this time.
本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。Those skilled in the art can easily understand that the above are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, etc., All should be included within the protection scope of the present invention.
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CN109926583A (en) * | 2018-12-29 | 2019-06-25 | 苏州德龙激光股份有限公司 | To the processing unit (plant) and method of transfer and sintering production ag paste electrode before induced with laser |
CN111477650A (en) * | 2020-04-16 | 2020-07-31 | 广东工业大学 | A kind of Micro-LED mass transfer method and transfer device |
CN112768572A (en) * | 2021-01-07 | 2021-05-07 | 武汉理工大学 | Micro LED bulk transfer method and device based on high-speed scanning laser transfer printing |
CN113399822A (en) * | 2021-07-20 | 2021-09-17 | 清华大学 | Laser-assisted in-situ mass transfer method and system |
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