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

1. A method, comprising:

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

controllably spelling the semiconductor layer by separating the semiconductor layer at a plane extending through the semiconductor layer parallel to the at least partially sacrificial backing layer stack;

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

bonding the metal adhesion layer to a front surface of a substrate by applying an epoxy adhesive to at least one of the metal adhesion layer and the front surface of the substrate;

applying pressure to distribute the epoxy adhesive between the front surface of the substrate and the metal adhesion layer;

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.

2. The method of claim 1 , 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.

3. 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 semiconductor layer, 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.

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

5. The method of claim 1 , wherein controllably spalling the semiconductor layer comprises mechanically guiding a portion of the sacrificial backing layer stack to induce and sustain a spalling mode fracture.

6. A method, comprising:

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

controllably spalling the semiconductor layer by separating the semiconductor layer at a plane extending through the semiconductor layer parallel to the at least partially sacrificial backing layer stack;

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 semiconductor layer comprises silicon and the metal adhesion layer is a thermally evaporated metal layer.

7. The method of claim 6 , wherein the semiconductor layer further comprises material selected from the group consisting of 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 6 , wherein the at least partially sacrificial backing layer stack comprises an adhesion layer disposed on the back surface of the semiconductor layer, 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 6 , wherein controllably spalling the semiconductor layer comprises mechanically guiding a portion of the sacrificial backing layer stack to induce and sustain a spalling mode fracture.

10. A method, comprising:

providing a stressor layer stack on a back surface of a semiconductor substrate;

controllably spalling the semiconductor substrate by separating the semiconductor substrate at a plane extending through the semiconductor substrate parallel to the stressor layer stack;

forming a metal adhesion layer on a front surface of the semiconductor substrate;

adhesively bonding the front surface of the semiconductor substrate to the handle substrate via the metal adhesion layer;

removing at least a portion of the stressor layer stack from the back surface of the semiconductor substrate;

applying a hardmask to the back surface of the semiconductor substrate exposed by removing the at least a portion of the stressor layer stack;

forming semiconductor cells in the semiconductor substrate under the hardmask such that the formed semiconductor cells are spaced apart from each other; and

allowing the epoxy adhesive to outgas from the spaces defined between the semiconductor cells.

11. The method of claim 10 , further comprising allowing the epoxy adhesive to outgas through the metal adhesion layer.

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

13. The method of claim 12 , wherein the thermally evaporated metal layer is aluminum.

14. The method of claim 10 , wherein the semiconductor substrate 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 stressor layer stack comprises an adhesion layer disposed on the back surface of the semiconductor substrate, 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.

16. The method of claim 10 , wherein controllably spalling the semiconductor layer comprises mechanically guiding a portion of the stressor layer stack using a transfer tape.

17. The method of claim 16 , wherein mechanically guiding a portion of the stressor layer stack comprises inducing and sustaining a spalling mode fracture at the plane extending through the semiconductor substrate parallel to the stressor layer stack.