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面向超高分辨微显示的金属凸点制备工艺研究

Fabrication Technology of Metal Bumps for Ultra-high Resolution Micro-display

  • 摘要: 超高密度微纳显示器件对互连凸点提出了极小间距、高均匀性的严苛要求。本文以电化学沉积为核心工艺,结合紫外激光直写技术制备超细间距铜(Cu)金属凸点阵列。实验优化光刻工艺以获得高分辨率微孔掩模,采用硫酸铜酸性电镀液体系进行生长,探究电流密度、沉积时间等参数对凸点形貌、高度均匀性、内部结构及界面结合性能的影响。最终实现了中心间距2 μm的超高密度凸点的高效制备,阵列尺寸达到5000 × 5000,凸点高度可达2 μm,阵列高度不均匀性低至2.92%。所得铜凸点阵列表面形貌光滑有序、无短路桥连,内部结构致密无孔洞及杂质等缺陷,去除冗余种子层后仍保持稳定结构。基于该工艺,在氮化镓发光二极管(GaN-LED)外延片上制备并成功实现了250 × 250阵列发光,验证了实现12700 PPI像素密度的可行性。本研究或将为超高分辨率微显示器件的互连键合技术与高效发光器件的研发与产业化应用提供参考。

     

    Abstract: Ultra-high density micro-nano display devices impose stringent requirements on interconnect bumps, including ultra-fine pitch and high uniformity. In this work, ultra-fine pitch copper (Cu) bump arrays were fabricated by combining electrochemical deposition, the core process, with ultraviolet laser direct writing technology. The photolithography process was optimized to obtain high-resolution micropore masks, and a copper sulfate-based acidic electroplating solution was adopted for bump growth. The effects of current density, deposition time and other parameters on bump morphology, height uniformity, internal structure and interfacial bonding performance were systematically investigated. Finally, ultra-high density bumps with a pitch of 2 μm were efficiently fabricated. The array scale reached 5000 × 5000, and the bump height was up to 2 μm, with the array height non-uniformity as low as 2.92%. The as-prepared copper bump arrays featured smooth and regular surfaces without short-circuit bridging, as well as dense internal structures free of voids, impurities and other defects. The bump structures remained stable even after the removal of the redundant seed layer. Using the proposed process, 250 × 250 light-emitting arrays were successfully fabricated on gallium nitride light-emitting diode (GaN-LED) epitaxial wafers, which verified the feasibility of achieving a pixel density of 12700 PPI. This study provides a valuable reference for the interconnection and bonding technology of ultra-high resolution micro-display devices, as well as the research, development and industrial application of high-efficiency light-emitting devices.

     

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