IP Library Granted Patent US 11,841,531
Granted Patent B2
US 11,841,531 · App. 17/815,962 · Granted Dec 12, 2023

Wafer scale bonded active photonics interposer

Inventors: Douglas Coolbaugh (Albany, NY); Douglas La Tulipe (Albany, NY); Gerald Leake (Albany, NY)
Assignee: THE RESEARCH FOUNDATION FOR THE STATE UNIVERSITY OF NEW YORK
G02B6/12002G02B6/131G02B6/4232G02B6/43H01L21/187H01L21/486H01L23/49838H01L24/92H01L27/1266H01L31/02002H01L31/02016H01L31/02327G02B6/12G02B6/12004G02B2006/121G02B2006/12038G02B2006/12061G02B2006/12138G02B2006/12147G02B2006/12176G02B2006/12178H01L21/7624H01L21/76224H01L23/49816H01L23/49827H01L24/08H01L24/16H01L24/24H01L24/80H01L24/81H01L24/82H01L25/0657H01L25/18H01L25/50H01L27/1203H01L2224/03002H01L2224/0401H01L2224/05008H01L2224/05025H01L2224/05582H01L2224/08225H01L2224/09181H01L2224/11002H01L2224/16145H01L2224/24105H01L2224/24226H01L2224/73204H01L2224/80896H01L2224/81191H01L2224/8203H01L2224/9202H01L2224/9222H01L2224/94H01L2225/06513H01L2225/06541H01L2924/0002H01L2924/1431
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 11,841,531
App. No.
17/815,962
Granted
Dec 12, 2023
Kind
B2
Abstract

There is set forth herein an optoelectrical device, comprising: a substrate; an interposer dielectric stack formed on the substrate, the interposer dielectric stack including a base interposer dielectric stack, a photonics device dielectric stack, and a bond layer that integrally bonds the photonics device dielectric stack to the base interposer dielectric stack. There is set forth herein a method comprising building an interposer base structure on a first wafer having a first substrate, including fabricating a plurality of through vias in the first substrate and fabricating within an interposer base dielectric stack formed on the first substrate one or more metallization layers; and building a photonics structure on a second wafer having a second substrate, including fabricating one or more photonics devices within a photonics device dielectric stack formed on the second substrate.

Claims (39)

1. An optoelectrical device, comprising:

a substrate;

an interposer dielectric stack formed on the substrate, the interposer dielectric stack including a base interposer dielectric stack, a photonics device dielectric stack, and a bond layer that integrally bonds the photonics device dielectric stack to the base interposer dielectric stack;

one or more through vias at least partially within the substrate;

one or more metallization layers fabricated in the base interposer dielectric stack; and

one or more photonics device fabricated in the photonics device dielectric stack, wherein a through via of the one or more through via is connected to an associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack and the bond layer.

2. The device of claim 1 , wherein the optoelectrical device includes a backside metal redistribution layer formed on the substrate.

3. The device of claim 1 , wherein the optoelectrical device includes backside formations formed on a backside of the substrate, the backside formations facilitating solder bonding of said optoelectrical device to an understructure selected from the group consisting of a ball grid array, a printed circuit board, and an interposer.

4. The device of claim 1 , wherein the connection of the through vias is defined by a conductive path including a redistribution layer connected to the through via at least partially within the substrate.

5. The device of claim 1 , wherein at least one through via of the one or more through via is connected by a bridge connection to the associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack.

6. The device of claim 1 , wherein at least one through via of the one or more through vias is connected by a bridge connection to the associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack, the bridge connection fabricated in the base interposer dielectric stack, and wherein the vertically extending photonics structure through via is 0.5 times the size of the through via or smaller.

7. A method of fabricating an optoelectrical device, comprising:

building an interposer base structure on a first wafer having a first substrate, including fabricating a plurality of through vias in the first substrate and fabricating within an interposer base dielectric stack formed on the first substrate one or more metallization layers;

building a photonics structure on a second wafer having a second substrate, including fabricating one or more photonics devices within a photonics device dielectric stack formed on the second substrate; and

bonding the photonics structure to the interposer base structure to define an interposer having the interposer base structure and one or more photonics devices fabricated within the photonics device dielectric stack, wherein the bonding defines a bond layer between the base interposer dielectric stack and the photonics device dielectric stack such that at least one through via of the plurality of through vias is connected to an associated vertically extending photonics structure through via, and such that the vertically extending photonics structure through via extends substantially through the photonics device dielectric stack and the bond layer.

8. The method of claim 7 , wherein the bonding uses a low temperature oxide bond process.

9. The method of claim 7 , wherein the bonding uses a low temperature oxide fusion bond process that includes a polishing stage, an activation stage and an annealing stage.

10. The method of claim 7 , wherein the second wafer is a silicon on insulator (SOI) wafer.

11. The method of claim 7 , wherein the method includes, subsequent to the bonding, removing material from the first substrate to reveal through vias of the plurality of through vias such that the through vias extend entirely through the first substrate.

12. The method of claim 7 , wherein fabricating a plurality of through vias in the first substrate is fabricating such that the plurality of through vias extend to such depth within the first substrate that the through vias extend entirely through the first substrate at performing removal of material of the first substrate to reveal the plurality of through vias.

13. The method of claim 7 , further including forming a plurality of photonics structures through vias within the photonics device dielectric stack.

14. The method of claim 7 , further including:

forming a plurality of photonics structure through vias through the photonics device dielectric stack, and

connecting photonics structure through vias of the plurality of photonics structure through vias to through vias of the plurality of through vias using respective bridge connections, the respective bridge connections having features defined within the interposer base dielectric stack.

15. An optoelectrical device, comprising:

a substrate;

an interposer dielectric stack formed on the substrate, the interposer dielectric stack including a base interposer dielectric stack, a photonics device dielectric stack, and a bond layer that integrally bonds the photonics device dielectric stack to the base interposer dielectric stack;

one or more connective means formed at least partially within the substrate, the connective means selectively communicating signals therethrough;

one or more metallization layers fabricated in the base interposer dielectric stack; and

one or more photonics devices fabricated in the photonics device dielectric stack, wherein at least one connective means is connected to an associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack and the bond layer.

16. The device of claim 15 , wherein at least one connective means includes a conductive path including a redistribution layer connected to the at least one connective means at least partially within the substrate.

17. The device of claim 15 , wherein at least one connective means is connected by a bridge connection to the associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack.

18. The device of claim 15 , wherein at least one at least one connective means is connected by a bridge connection to the associated vertically extending photonics structure through via, the vertically extending photonics structure through via extending through the photonics device dielectric stack, the bridge connection fabricated in the base interposer dielectric stack, and wherein the vertically extending photonics structure through via is 0.5 times the size of a through via or smaller.

19. The device of claim 15 , further including a connection defined by a conductive path including a redistribution layer connected to the one or more connective means.

20. The device of claim 19 , wherein:

the substrate further including a frontside and backside thereof;

the one or more connective means is connected to the associated vertically extending photonics structure through via;

the base interposer dielectric stack is formed on the frontside of the substrate; and

the redistribution layer is formed on the backside of the substrate.

Assignments (2)
CONFIRMATORY LICENSE Recorded Sep 4, 2025
From: THE RESEARCH FOUNDATION FOR THE STATE UNIVERSITY OF NEW YORK
To: GOVERNMENT OF THE UNITED STATES AS REPRESENTED BY THE SECRETARY OF THE AIR FORCE
Reel/Frame 072853/0304 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 29, 2022
From: COOLBAUGH, DOUGLAS; LA TULIPE, DOUGLAS; LEAKE, GERALD
To: THE RESEARCH FOUNDATION FOR THE STATE UNIVERSITY OF NEW YORK
Reel/Frame 060665/0427 →
Continuity (4)
Continuation 16909557 · Jun 23, 2020
Continuation 15891847 · Feb 8, 2018
Provisional Application 62490665 · Apr 27, 2017
Related Publication 20220381974A1 · Dec 1, 2022