Method for thermo-compression diffusion bonding a structured copper strain buffer to each side of a substrateless semiconductor device wafer

Claim 1

A method for thermo-compression diffusion bonding first and second structured copper strain buffers to a substrateless semiconductor device wafer including first and second major opposed surfaces of unequal lateral extents and a beveled outer edge surface, said first and second structured copper strain buffers each including a bundle of substantially parallel closely packed strands of copper of substantially equal length having one common end thereof thermo-compression diffusion bonded to a metallic sheet, respectively, said method comprising: applying first and second metallic layers on said first and second major opposed surfaces, respectively; applying first and second metallizations on said first and second metallic layers, respectively; coating said beveled surface with a passivation material; sandwiching said semiconductor device wafer between and in axial alignment with said first and second structured copper strain buffers, each of said structured copper strain buffers having a lateral extent equal to or less than the lateral extent of the respective major surface of said semiconductor device wafer in contact therewith such that said beveled edge remains uncovered by either of said structured copper strain buffers, the common end of the copper strands of each of said first and second structured copper strain buffers opposite the respective metallic sheet thereof being positioned facing said semiconductor device wafers; surrounding with an inert atmosphere said semiconductor device wafer and structured copper strain buffers when sandwiched together; applying a loading force to selected portions of said first and second structured copper strain buffers to squeeze said first and second structured copper strain buffers and said semiconductor device wafer together at high pressure, the selected portion of said first structured copper strain buffer being substantially of identical geometrical size and shape as, and substantially rotationally and axially aligned with, the selected portion of said second structured copper strain buffer; and heating said semiconductor device wafer and structured copper strain buffers at a temperature within the range of 300° C. to 400° C. while said loading force is being applied.

Claim 2

A method for thermo-compression diffusion bonding first and second structured copper strain buffers to a substrateless semiconductor device wafer including first and second major opposed surfaces of unequal lateral extents and a beveled outer edge surface, said first and second structured copper strain buffers each including a bundle of substantially parallel closely packed strands of copper of substantially equal length having one common end thereof thermo-compression diffusion bonded to a metallic sheet, respectively, said method comprising: applying first and second metallic layers on said first and second major opposed surfaces, respectively; applying first and second metallizations on said first and second metallic layers, respectively; coating said beveled surface with a passivation material; sandwiching said semiconductor device wafer between and in axial alignment with said first and second structured copper strain buffers, each of said structured copper strain buffers having a lateral extent equal to or less than the lateral extent of the respective major surface of said semiconductor device wafer in contact therewith such that said beveled edge remains uncovered by either of said structured copper strain buffers, the common end of the copper strands of each of said first and second structured copper strain buffers opposite the respective metallic sheet thereof being positioned facing said semiconductor device wafers; surrounding with an inert atmosphere said semiconductor device wafer and structured copper strain buffers when sandwiched together; applying a loading force to selected portions of said first and second structured copper strain buffers to squeeze said first and second structured copper strain buffers and said semiconductor device wafer together at high pressure, the selected portion of said first structured copper strain buffer being substantially of identical geometrical size and shape as, and substantially rotationally and axially aligned with, the selected portion of said second structured copper strain buffer; and heating said semiconductor device wafer and structured copper strain buffers at a temperature within the range of 300° C. to 400° C. while said loading force is being applied.

Claim 6

The method of claims 1, 2 or 4 including the step of situating first and second layers of nonreactive compactible material in contact with the metallic sheets of said first and second structured copper strain buffers, respectively, prior to surrounding said semiconductor device wafer and structured copper strain buffers with an inert atmosphere.

Claim 7

A method for thermo-compression diffusion bonding first and second structured copper strain buffers to a substrateless semiconductor device wafer having first and second major opposed surfaces and a beveled outer edge surface, said first major surface being smaller than said second major surface, said first and second structured copper strain buffers each including a bundle of substantially parallel closely packed strands of copper of substantially equal length having one common end thereof thermo-compression diffusion bonded to a metallic sheet, respectively, said method comprising: applying first and second metallic layers on said first and second major opposed surfaces, respectively; applying first and second metallizations on said first and second metallic layers, respectively; sandwiching said semiconductor device wafer between and in axial alignment with said first and second structured copper strain buffers, said first structured copper strain buffer being situtated on said first surface and having a lateral extent no greater than the lateral extent of said first major surface, said second structured copper strain buffer having a lateral extent at least equal to the lateral extent of said second surface, the common ends of the copper strands of said structured copper strain buffers opposite the respective metallic sheets thereof being positioned so as to face and abut said semiconductor device wafer; surrounding with an inert atmosphere said semiconductor device wafer and structured copper strain buffers when sandwiched together; applying a loading force to selected portions of said first and second structured copper strain buffers to squeeze said first and second structured copper strain buffers and said semiconductor device wafer together at high pressure, the selected portion of said first structured copper strain buffer being substantially of identical geometrical size and shape as, and substantially rotationally and axially aligned with, the selected portion of said second structured copper strain buffer; heating said semiconductor device wafer and structured copper strain buffers at a temperature within the range of 300° C. to 400° C. while said loading force is being applied; and finally coating said beveled surface with a passivation material.

Claim 8

A method for thermo-compression diffusion bonding first and second structured copper strain buffers to a substrateless semiconductor device wafer having first and second major opposed surfaces and a beveled outer edge surface, said first major surface being smaller than said second major surface, said first and second structured copper strain buffers each including a bundle of substantially parallel closely packed strands of copper of substantially equal length having one common end thereof thermo-compression diffusion bonded to a metallic sheet, respectively, said method comprising: applying first and second metallic layers on said first and second major opposed surfaces, respectively; applying first and second metallizations on said first and second metallic layers, respectively; sandwiching said semiconductor device wafer between and in axial alignment with said first and second structured copper strain buffers, said first structured copper strain buffer being situtated on said first surface and having a lateral extent no greater than the lateral extent of said first major surface, said second structured copper strain buffer having a lateral extent at least equal to the lateral extent of said second surface, the common ends of the copper strands of said structured copper strain buffers opposite the respective metallic sheets thereof being positioned so as to face and abut said semiconductor device wafer; surrounding with an inert atmosphere said semiconductor device wafer and structured copper strain buffers when sandwiched together; applying a loading force to selected portions of said first and second structured copper strain buffers to squeeze said first and second structured copper strain buffers and said semiconductor device wafer together at high pressure, the selected portion of said first structured copper strain buffer being substantially of identical geometrical size and shape as, and substantially rotationally and axially aligned with, the selected portion of said second structured copper strain buffer; heating said semiconductor device wafer and structured copper strain buffers at a temperature within the range of 300° C. to 400° C. while said loading force is being applied; and finally coating said beveled surface with a passivation material.

Claim 12

The method of claims 6, 7, 8 or 9 wherein said high pressure is within the range of approximately 20,000 to 50,000 psi.

Claim 13

The method of claims 6, 7 or 8 including the step of smoothing said first and second major opposed surfaces prior to applying said first and second metallic layers thereon, respectively.