FIELD OF THE DISCLOSURE

[0001] This disclosure relates to wafer- level methods of manufacturing. SUMMARY

[0002] This disclosure describes wafer-level methods for manufacturing one or more uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. In one aspect, for example, the methods include assembling a wafer assembly, where the wafer assembly includes a chuck, a tool wafer, and a module wafer. The module wafer includes the plurality of optoelectronic modules. The method further includes injecting a formable material into the wafer assembly such that one or more surfaces of the plurality of optoelectronic module are coated with a formable material layer. The method further includes ejecting excess formable material from the wafer assembly, and further includes hardening the formable material layer.

[0003] In some implementations, the wafer-level method includes a wafer assembly with a plurality of quick-release foils, a plurality of quick-release protrusions, a quick-release substrate, transmissive portions, or any combination of the aforementioned.

[0004] In some implementations, injecting a formable material into the wafer assembly further includes applying a vacuum to the wafer assembly and/or rotating the wafer assembly.

[0005] In some implementations, ejecting excess formable material from the wafer assembly includes applying a vacuum and/or pressurized gas to the wafer assembly and/or rotating the wafer assembly.

[0006] In some implementations, hardening the formable material layer includes hardening the formable material with reactive pressurized gas, hot pressurized gas, reactive and hot pressurized gas, radiation, or any combination of the aforementioned. [0007] Other aspects, features, and advantages will be apparent from the following detailed description, the accompanying drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 depicts a wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules.

[0009] FIGS. 2A-2E depict an example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules.

[0010] FIGS. 3A-3F depict another example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules.

[0011] FIGS. 4A-4D depict still another example wafer- level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules.

[0012] FIGS. 5A-5J depict yet another example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules.

DETAILED DESCRIPTION

[0013] FIG. 1 depicts a wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. At 1000, a wafer assembly 102 is assembled. The wafer assembly 102 can include a module wafer 104, a tool wafer 108, and a chuck 110. The module wafer 104 can include a plurality of optoelectronic modules 106. In some instances, the optoelectronic modules 106 can be modules that include a plurality of components (e.g., proximity sensors, digital cameras). In some instances, the optoelectronic modules 106 can be modules that include a few components or a single component (e.g., photodiode, laser diode, optical element, prism, lens stack, light-pipe).

[0014] The tool wafer 108, chuck 110, and module wafer 104 are configured to make a gas- tight seal around the plurality of optoelectronic modules 106, and to form gas-tight cavities 136 within the wafer assembly 102. Consequently, the tool wafer 108 and/or chuck 110 can further include a gas-tight mounting frame 112 and gaskets 114 (e.g., composed of rubber or silicone). Further, the tool wafer 108 and/or the chuck 110 can include one or more ports 134 through which a formable material 124 (or 156, 158), such as liquid epoxy in an

uncured/unhardened state, can pass and further conduct into the plurality of cavities 136. Further, the one or more ports 134 can be configured to conduct a pressurized gas 130, and/or hot/reactive pressurized gas 132. Further the one or more ports 134 can be configured to apply a vacuum 126 to the wafer assembly 102.

[0015] The tool wafer 108 can be composed of polydimethylsiloxane (PDMS), glass, cured epoxy, stainless steel, or any other suitable material. In some instances, the tool wafer 108 can include a plurality of quick-release foils 116 (i.e., perforated layers of low-adhesion material, such as Teflon, PDMS, Mylar, or low-adhesion nano-structured materials), or a quick-release substrate 120 (i.e., a contiguous layer of low-adhesion material, such as Teflon, PDMS, Mylar, or low-adhesion nano-structured materials). In some instances, the tool wafer 108 can include a plurality of quick-release protrusions 118 formed into the tool wafer 108. In some instances, the tool wafer 108 can include transmissive portions 122 and non- transmissive portions 138 as further illustrated in FIG. 4A - FIG. 4D.

[0016] Similarly, the chuck 110 and be composed of polydimethylsiloxane (PDMS), glass, cured epoxy, stainless steel, or any other suitable material. In some instances, the chuck 110 can include a plurality of quick-release foils 116 (i.e., perforated layers of low-adhesion material, such as Teflon, PDMS, Mylar, or low-adhesion nano-structured materials), or a quick-release substrate 120 (i.e., a contiguous layer of low-adhesion material, such as Teflon, PDMS, Mylar, or low-adhesion nano-structured materials).

[0017] At 2000, the formable material 124 (or 156, 158) is injected into the plurality of cavities 136 within the wafer assembly 102 via the one or more ports 134. In some instances, the formable material 125 (or 156, 158) can be injected while applying a vacuum 126 to the wafer assembly 102, wherein the vacuum 126 can draw the formable material 124 (or 156, 158) into the plurality of cavities 136 such that gaps or air-pockets are not formed. In some instances, the formable material 124 (or 156, 158) can be injected while rotating 128 the wafer assembly 102 (e.g., at 1000 - 3000 revolutions / minute) such that the centripetal force applied to the formable material 124 (or 156, 158) draws the formable material into the plurality of cavities 136. In some instances, the formable material 124 (or 156, 158) can be injected while applying the vacuum 126 to the wafer assembly and rotating 128 the wafer assembly 102.

[0018] At 3000, excess formable material 124 (or 156, 158) is ejected from the wafer assembly 102. The formable material that remains in the wafer assembly 102 is a formable material layer 142 (or 162, 182). The formable material layer 142 (or 162, 182) can extend over one or more surfaces of the plurality of optoelectronic modules 106, and can further extend over surfaces of the chuck 110 and tool wafer 108. In some instances, the excess formable material 124 (or 156, 158) can be ejected while applying a vacuum 126 to the wafer assembly 102. In some instances, the excess formable material 124 (or 156, 158) can be ejected while rotating the wafer assembly 102 (e.g., at 1000 - 3000 revolutions / minute) such that the centripetal force applied to the excess formable material 124 (or 156, 158) draws the excess formable material out from the plurality of cavities 136. In some instances, the excess formable material can be ejected while applying pressurized gas 130 to the wafer assembly 102. In some instances, the excess formable material can be ejected while applying a vacuum 126 and/or pressurized gas 130 to the wafer assembly 102, and/or while rotating 128 the wafer assembly 102.

[0019] At 4000, the formable material layer 142 (or 162, 182) on the plurality of

optoelectronic modules 106 is hardened/cured. In some instances, the formable material layer 142 (or 162, 182) on the plurality of optoelectronic modules 106 is hardened by applying a reactive pressurized gas (e.g., oxygen), a hot pressurized gas (e.g., 100 - 100°C), and/or a hot and reactive pressurized gas to the module wafer. For example, in some instances, the formable material 124 (or 156, 158) can be hardened or cured in the presence of oxygen. In such instances, pressurized oxygen (i.e., the reactive pressurized gas) can be injected into the wafer assembly 102. The formable material remaining in the wafer assembly 102 (i.e. the formable material layer) can be partially or fully hardened or cured. In another example, the formable material can be hardened or cured when heated to a particular temperature. In such instances, hot inert pressurized gas can be injected into the wafer assembly. The formable material layer can be partially or fully hardened or cured.

[0020] In some instances, the formable material can be hardened or cured with radiation (e.g., infrared, or ultraviolet), and the plurality of optoelectronic modules can be transmissive to the radiation as further illustrated in FIG. 4 A - FIG. 4D.

[0021] In some instances, the module wafer, including the formable material can be transferred to a hardening station where the formable material can be fully hardened or cured with radiation (e.g., infrared, or ultraviolet) as further illustrated in FIG. 2A - FIG. 2E. [0022] At 5000, modules wafer with partially cured formable material can be transferred to a hardening station where the formable material can be fully hardened or cured with radiation (e.g., infrared, or ultraviolet) as further illustrated in FIG. 3 - FIG. 5.

[0023] At 6000, the aforementioned steps can be repeated. In some instances, for example, multiple layers of formable material may be desired. This step is further illustrated in FIG. 5A - FIG. 5J.

[0024] FIG. 2 depicts an example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. FIG. 2A depicts formable material 124 being injected into the wafer assembly 102 via the port 134. A vacuum 126 is applied to the wafer assembly 102 via another port 134. Further, the wafer assembly 102 is rotated as depicted by the arrow 128. The wafer assembly 102 is further rotated as depicted in FIG. 2B such that the formable material 124 within the wafer assembly 102 is uniformly distributed within the wafer assembly 102. In addition, a vacuum 126 is applied to the ports 134 in this example, to de-gas the formable material 124. The wafer assembly 102 is further rotated as depicted in FIG. 2D. Moreover, a pressurized gas 130 is injected into the wafer assembly 102 via the port 134. Excess formable material 124 is ejected from another port 134 leaving a formable material layer 142 on one or more surfaces of the pluralities of optoelectronic modules 106 (i.e., formable material layer on module 144) and the surfaces of the tool wafer 108 and the chuck 110 (i.e., formable material layer tails 146). The tool wafer 108 and chuck 110 are separated from the module wafer 104 as depicted in FIG. 2D. Moreover, the quick-release foils 116 and the quick-release protrusions 118 permit the formable material layer 142 to be separated into the formable material layer on module 144 and formable material layer tails 146. The module wafer 104 is mounted to a hardening station substrate 140 (i.e., the hardening station assembly 196) and then the hardening station assembly 196 is brought to a hardening station and subjected to radiation 160 (e.g., UV, IR) as depicted in FIG. 2E such that the formable material layer on modules 144 is fully hardened/cured to the fully hardened material on modules 148.

[0025] FIG. 3 depicts another example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. FIG. 3 A and FIG. 3B depict steps in an example process as described above and illustrated in FIG. 2A and FIG. 2B, respectively; however, the tool wafer 108 includes a quick-release substrate 120. FIG. 3C depicts a step in the example process as described above and illustrated in FIG. 2C. Following ejection of excess material 124, a hot, reactive, or hot and reactive pressurized gas 132 is injected via the port 134 into the module wafer 102. Moreover, a vacuum 126 is applied to another port 134 in this example. The hot, reactive, or hot and reactive pressurized gas 132 causes the formable material later 142 to partially harden, as depicted in FIG. 3D, into a partially hardened formable material layer on module 152 and a partially hardened formable material layer tails 154. The module wafer 104 is separated from the tool wafer 108 and the chuck 110, as depicted in FIG. 3E, and mounted to to the hardening station substrate 140 (i.e., the hardening station assembly 196). The hardening station assembly 196 is then brought to a hardening station and subjected to radiation 160 as described above.

[0026] FIG. 4 depicts still another example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. FIG. 4A depicts a step in an example process as described above and illustrated in FIG. 2A and FIG. 3A; however, the modules 106 are transmissive to radiation used to harden/cure the formable material 124 and the tool wafer 108 further includes transmissive portions 122 and non- transmissive portions 138. The transmissive portions 122 are also transmissive to the radiation used to harden/cure the formable material 124. FIG. 4B depicts another step in the example process as described above and illustrated in FIG. 2B and FIG. 3B; however, radiation is directed to the transmissive portions 122 of the tool wafer 108. The radiation is transmitted through the modules 106 to the formable material 124 such that the formable material 124 is partially hardened to the partially hardened formable material layer 152. FIG. 4C depicts another step in the example process. As above, excess formable material 124 is ejected from the wafer assembly 102 by pressurized gas 130. Moreover, the wafer assembly 102 is rotated such that, together with the pressurized gas 130, excess formable material 124 is ejected from the wafer assembly 102. The module wafer 104 is separated from the tool wafer 108 and the chuck 110 as depicted in FIG. 4D.

[0027] FIG. 5 depicts yet another example wafer-level method for manufacturing uniform layers of material on one or more surfaces of a plurality of optoelectronic modules. FIG. 5 A - FIG. 5D depict steps in an example process as described above and illustrated in FIG. 3A - FIG. 3D, respectively. In another step, a second formable material 158 is injected into the wafer assembly 102 via the port 134 and a vacuum 126 is applied to the wafer assembly 102 via another port 134 as depicted in FIG. 5E. In another step, a vacuum 126 is applied to the ports 134 to de-gas the second formable material 158. In another step, pressurized gas 130 is injected into the wafer assembly 102 to eject excess second formable material as depicted in FIG. 5F. In another step, hot, reactive, or hot and reactive pressurized gas is injected into the wafer assembly 102 via the port 134. The hot, reactive, or hot and reactive pressurized gas partially hardens the second formable material 158 into a partially hardened second formable material layer 190. In another step, the module wafer is separated from the tool wafer 108 and the chuck 110 and mounted to a hardening station substrate 140 as depicted in FIG. 51 and FIG. 5J. The hardening station assembly 196 is then subjected to radiation as depicted din FIG. 5J as described above.

[0028] Other modifications may be made to the foregoing implementations, and features described above in different implementations may be combined in the same implementation. Thus, other implementations are within the scope of the claims.