A wafer-scale assembly apparatus for integrated circuits and method for
forming the wafer-scale assembly. A semiconductor wafer including a
plurality of circuits is provided with a plurality of metal contact pads
as electrical entry and exit ports. A first wafer-scale patterned polymer
film carrying solder balls for each of the contact pads on the wafer is
positioned opposite the wafer, and the wafer and the film are aligned. The
film is brought into contact with the wafer. Radiant energy in the near
infrared spectrum is applied to the backside of the wafer, heating the
wafer uniformly and rapidly without moving the semiconductor wafer.
Thermal energy is transferred through the wafer to the surface of the
wafer and into the solder balls, which reflow onto the contact pads, while
the thermal stretching of the polymer film is mechanically compensated.
The uniformity of the height of the liquid solder balls is controlled
either by mechanical stoppers or by the precision linear motion of motors.
After cooling, the solder balls solidify and the first polymer film is
removed.