Methods to reduce debonding forces on flexible semiconductor films disposed on vapor-releasing adhesives

1. A method, comprising:

providing a handle substrate having a front surface and a back surface;

providing a layer of flexible semiconductor material having a front surface and a back surface and an at least partially sacrificial backing layer stack on the back surface of the layer of flexible semiconductor material;

disposing a metal adhesion layer on the front surface of the layer of flexible semiconductor material;

bonding the front surface of the layer of flexible semiconductor material with the metal adhesion layer to the front surface of the handle substrate such that the front surface of the layer of flexible semiconductor material is bonded to the front surface of the handle substrate via the metal adhesion layer;

removing at least a portion of the at least partially sacrificial backing layer stack from the back surface of the layer of flexible semiconductor material;

opening outgassing paths through the layer of flexible semiconductor material; and

processing the layer of flexible semiconductor material.

2. The method of claim 1 , further comprising opening the outgassing paths through the metal adhesion layer.

3. The method of claim 1 , wherein the layer of flexible semiconductor material comprises silicon and the metal adhesion layer is a thermally evaporated metal layer.

4. The method of claim 1 , wherein bonding the front surface of the layer of flexible semiconductor material with the metal adhesion layer to the front surface of the handle substrate comprises applying an epoxy adhesive to at least a portion of the front surface of the handle substrate.

5. The method of claim 4 , further comprising applying pressure to distribute the epoxy adhesive between the metal adhesion layer and the front surface of the handle substrate.

6. The method of claim 1 , wherein bonding the front surface of the layer of flexible semiconductor material with the metal adhesion layer to the front surface of the handle substrate comprises applying an epoxy adhesive to at least a portion of the metal adhesion layer.

7. The method of claim 1 , wherein the layer of flexible semiconductor material comprises material selected from the group consisting of silicon, germanium, SiGe, bulk III-V materials, epitaxially grown semiconductor layers, any of the foregoing materials having doped layers, any of the foregoing materials having metallic layers, any of the foregoing materials having passivating layers, and combinations of the foregoing materials.

8. The method of claim 1 , wherein the at least partially sacrificial backing layer stack comprises an adhesion layer disposed on the back surface of the layer of flexible semiconductor material, a seed layer disposed on the adhesion layer, a stressor layer disposed on the seed layer, and a transfer tape disposed on the stressor layer.

9. The method of claim 1 , wherein processing the layer of flexible semiconductor material comprises at least one of patterning, thermally treating, and depositing a film on the layer of flexible semiconductor material.

10. A method, comprising:

providing an at least partially sacrificial backing layer stack on a back surface of a semiconductor layer;

disposing a metal adhesion layer on a front surface of the semiconductor layer;

bonding the metal adhesion layer to a front surface of a substrate;

removing at least a portion of the at least partially sacrificial backing layer stack from the back surface of the semiconductor layer;

opening outgassing paths through the semiconductor layer; and

processing the semiconductor layer;

wherein the at least partially sacrificial backing layer stack comprises an adhesion layer disposed on the back surface of the layer of the semiconductor layer, a seed layer disposed on the metal adhesion layer, a stressor layer disposed on the seed layer, and a transfer tape disposed on the stressor layer.

11. The method of claim 10 , wherein bonding the metal adhesion layer to the front surface of the substrate comprises applying an epoxy adhesive to at least a portion of the front surface of the substrate and causing the epoxy adhesive to engage the metal adhesion layer.

12. The method of claim 11 , further comprising applying pressure to distribute the epoxy adhesive between the front surface of the substrate and the metal adhesion layer.

13. The method of claim 10 , wherein bonding the metal adhesion layer to the front surface of the substrate comprises applying an epoxy adhesive to at least a portion of the metal adhesion layer and causing the epoxy adhesive to engage the front surface of the substrate.

14. The method of claim 10 , wherein the semiconductor layer comprises material selected from the group consisting of silicon, germanium, SiGe, bulk III-V materials, epitaxially grown semiconductor layers, any of the foregoing materials having doped layers, any of the foregoing materials having metallic layers, any of the foregoing materials having passivating layers, and combinations of the foregoing materials.

15. The method of claim 10 , wherein the semiconductor layer comprises silicon and the metal adhesion layer is a thermally evaporated metal layer.

16. A method, comprising:

providing an at least partially sacrificial backing layer stack on a back surface of a semiconductor layer;

disposing a metal adhesion layer on a front surface of the semiconductor layer;

bonding the metal adhesion layer to a front surface of a substrate;

removing at least a portion of the at least partially sacrificial backing layer stack from the back surface of the semiconductor layer;

opening outgassing paths through the semiconductor layer; and

processing the semiconductor layer;

wherein processing the semiconductor layer comprises at least one of patterning, thermally treating, and depositing a film on the semiconductor layer.

17. The method of claim 16 , wherein bonding the metal adhesion layer to the front surface of the substrate comprises applying an epoxy adhesive to at least a portion of the metal adhesion layer and causing the epoxy adhesive to engage the front surface of the substrate.

18. The method of claim 17 , further comprising applying pressure to distribute the epoxy adhesive between the front surface of the substrate and the metal adhesion layer.

19. The method of claim 16 , wherein the semiconductor layer comprises material selected from the group consisting of silicon, germanium, SiGe, bulk III-V materials, epitaxially grown semiconductor layers, any of the foregoing materials having doped layers, any of the foregoing materials having metallic layers, any of the foregoing materials having passivating layers, and combinations of the foregoing materials.

20. The method of claim 16 , wherein the semiconductor layer comprises silicon and the metal adhesion layer is a thermally evaporated metal layer.