Front facing piggyback wafer assembly
View Patent ↗Front facing piggyback wafer assembly. In accordance with an embodiment of the present invention, a plurality of piggyback substrates are attached to a carrier wafer. The plurality of piggyback substrates are dissimilar in composition to the carrier wafer. The plurality of piggyback substrates are processed, while attached to the carrier wafer, to produce a plurality of integrated circuit devices. The plurality of integrated circuit devices are singulated to form individual integrated circuit devices. The carrier wafer may be processed to form integrated circuit structures prior to the attaching.
1. A method comprising:
attaching a plurality of piggyback substrates to a carrier wafer, wherein said plurality of piggyback substrates are dissimilar in composition to said carrier wafer;
forming and processing an active layer on said plurality of piggyback substrates, while attached to said carrier wafer, to produce a plurality of integrated circuit devices included in said active layer ; and
singulating said plurality of integrated circuit devices to form individual integrated circuit devices.
2. The method of claim 1 wherein said forming and processing takes place on manufacturing equipment designed to process wafers larger than said plurality of piggyback substrates.
3. The method of claim 1 wherein said plurality of piggyback substrates comprises a plurality of wafers.
4. The method of claim 1 further comprising processing said carrier wafer, prior to said attaching, to form integrated circuit structures.
5. The method of claim 1 further comprising singulating said plurality of piggyback substrates from a plurality of wafers prior to said attaching.
6. The method of claim 1 further comprising processing said carrier wafer, after said attaching, to form integrated circuit structures.
7. The method of claim 1 wherein said individual integrated circuit devices comprise a portion of said carrier wafer after said singulating said plurality of integrated circuit devices.
8. The method of claim 1 wherein said plurality of integrated circuit devices are of more than one design.
9. A method comprising:
attaching a plurality of piggyback substrates to a carrier wafer, wherein said plurality of piggyback substrates are dissimilar in composition to said carrier wafer;
forming and processing an active layer on said plurality of piggyback substrates, while attached to said carrier wafer, to produce a plurality of integrated circuit devices included in said active layer;
processing said carrier wafer to produce a plurality of integrated circuit structures; and
singulating said plurality of integrated circuit devices to form individual integrated circuit devices.
10. The method of claim 9 wherein said processing said carrier wafer occurs while said plurality of piggyback substrates are attached to said carrier wafer.
11. The method of claim 10 wherein said plurality of integrated circuit structures formed on said carrier wafer are electrically coupled to said plurality of integrated circuit devices formed on said plurality of piggyback substrates.
12. The method of claim 9 wherein said plurality of integrated circuit structures formed on said carrier wafer are formed outside of a vertical projection of said plurality of piggyback substrates.
13. The method of claim 12 wherein said individual integrated circuit devices comprise structures formed outside of the vertical projection of said plurality of piggyback substrates.
14. The method of claim 9 wherein said plurality of integrated circuit structures formed by said processing said carrier wafer comprise structures to couple power from said carrier wafer to said plurality of integrated circuit devices formed on said plurality of piggyback substrates.
15. The method of claim 9 wherein said plurality of integrated circuit structures formed by said processing said carrier wafer comprise power control electronics to couple power from said carrier wafer to said plurality of integrated circuit devices formed on said plurality of piggyback substrates.
16. A method comprising:
attaching a plurality of piggyback substrates to a carrier wafer, wherein said plurality of piggyback substrates are dissimilar in composition to said carrier wafer;
forming and processing an active layer on said plurality of piggyback substrates, while attached to said carrier wafer, to produce a plurality of light emitting diodes included in said active layer;
forming conductive structures through said carrier wafer to electrically couple to contacts of said plurality of light emitting diodes; and
singulating said plurality of light emitting diodes to form individual light emitting diode devices.
17. The method of claim 16 further comprising forming a plurality of package contacts on said carrier wafer to electrically couple to said conductive structures.
18. The method of claim 17 wherein said plurality of package contacts are on a back side of said carrier wafer.
19. The method of claim 16 further comprising forming a plurality of optical layers on top of said plurality of light emitting diodes.
20. The method of claim 19 wherein at least one of said plurality of optical layers comprises a lens.
21. The method of claim 16 wherein said conductive structures extend beyond said carrier wafer to electrically couple active layers of said plurality of light emitting diodes.
22. The method of claim 21 further comprising encapsulating said plurality of light emitting diodes and said conductive structures.