CN101937853B - 集成电路结构的形成方法 - Google Patents
集成电路结构的形成方法 Download PDFInfo
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- CN101937853B CN101937853B CN2010102128980A CN201010212898A CN101937853B CN 101937853 B CN101937853 B CN 101937853B CN 2010102128980 A CN2010102128980 A CN 2010102128980A CN 201010212898 A CN201010212898 A CN 201010212898A CN 101937853 B CN101937853 B CN 101937853B
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Abstract
本发明一实施例提供一种集成电路结构的形成方法,包括:提供一半导体晶片,包括一第一刻痕,自该半导体晶片的一边缘延伸进入该半导体晶片;以及将一承载晶片设置于该半导体晶片之上,其中该承载晶片包括一第二刻痕,位于该承载晶片之中,且其中将该承载晶片的设置步骤包括使至少一部分的该第一刻痕与至少一部分的该第二刻痕重叠。本发明通过于承载晶片中形成刻痕,无凸块下金属层会形成于承载晶片的通过半导体晶片中的刻痕所露出的部分。因此,可进行更可靠的对准。由于承载晶片的角落不具有斜面区,可减少凸块下金属层的脱层。再者,由于承载晶片的电阻率被减低,承载晶片可更可靠地固定于静电吸盘上。
Description
技术领域
本发明涉及集成电路结构,且特别涉及穿硅导电插塞(through-siliconvias),且更涉及于晶片的背面上形成内连线结构,并连接至穿硅导电插塞。
背景技术
自从集成电路发明,半导体工业已经历持续的快速成长,这是由于各种电子元件(即,晶体管、二极管、电阻器、电容器等)的整合密度的持续增进。占最大原因地,此整合密度的增进来自于最小特征尺寸(minimum feature size)的一再缩小化,允许了更多元件整合至所给予的芯片面积中。
这些整合增进实际上为实质二维的,其中所整合的元件所占的体积实质于半导体晶片的表面上。虽然,光刻工艺的显著的增进已于二维集成电路制作中造成相当大的进步,但在二维中所能达到的密度有着物理限制。这些限制其中之一为制造这些元件所需的最小尺寸。并且,当更多的元件放进一芯片中时,需要更多复杂的设计。
另一附加限制来自于随着元件数目的增加,元件间内连线的数目与长度随的显著增加。当内连线的长度与数目增加时,电路的RC延迟与功率损耗(power consumption)也增加。
为解决上述限制,常使用的方法包括使用三维集成电路(3DICs)及堆叠裸片(stacked dies)。穿硅导电插塞(through-silicon vias,TSVs)因而用于三维集成电路及堆叠裸片之中。在此情形下,穿硅导电插塞常用以将一裸片上的集成电路连接至该裸片的背面。此外,穿硅导电插塞还用以通过裸片的背面提供集成电路接地的短接地路径(short grounding path),裸片的背面可能覆盖有接地金属薄膜(grounded metallic film)。
背面穿硅导电插塞线路的传统工艺遭遇一些阻碍。请参照图1,其显示制作背面内连线结构的中间阶段的剖面图,硅晶片100包括穿硅导电插塞102。硅晶片100通过胶106设置于承载晶片104之上。凸块下金属层(UBM)108沉积于硅晶片100之上。承载晶片104一般大于硅晶片100,凸块下金属层108因而也沉积于承载晶片之上。既然承载晶片104具有斜面区(beveled areas)110,凸块下金属层108将包括沉积于斜面区110上的部分,而凸块下金属层108的这些部分易于刮伤(scratching)与脱层(peeling)。在工艺中,显示于图1中的结构可通过自动控制装置(robots)而钳紧或转移。当凸块下金属层108位于斜面区110上的部分被钳子或自动控制装置钳紧或接触时,颗粒可能脱离并污染晶片。
另一问题是寻找刻痕(notch)上的困难。图2A显示图1所示结构的俯视图。刻痕112是为了对准的目的而形成于硅晶片100中。图2B显示图2A所示结构的剖面图,其中剖面图显示沿着图2A中的切线2B-2B的切面。可发现凸块下金属层108也沉积于承载晶片104通过刻痕112而露出的部分上。既然凸块下金属层108非透明的,例如是光学步进机(photo steppers)的仪器常无法找到刻痕112,因而无法进行后续工艺所需的对准。
为了形成背面穿硅导电插塞连接(backside TSV connection),显示于图1的结构需放置于反应室中,并由静电吸盘(electrostatic chuck,ESC或E-chuck)固定。然而,承载晶片104一般由玻璃制成而无法稳固地固定于静电吸盘之上。这部分是因为玻璃中的可移动离子不充足。因此,业界亟需能克服或减轻上述问题的背面内连线结构及制造方法。
发明内容
为克服现有技术的缺陷,本发明一实施例提供一种集成电路结构的形成方法,包括:提供一半导体晶片,包括一第一刻痕,自该半导体晶片的一边缘延伸进入该半导体晶片;以及将一承载晶片设置于该半导体晶片之上,其中该承载晶片包括一第二刻痕,位于该承载晶片之中,且其中将该承载晶片的设置步骤包括使至少一部分的该第一刻痕与至少一部分的该第二刻痕重叠。
本发明一实施例提供一种集成电路结构的形成方法,包括:提供一半导体晶片;以及将一承载晶片设置于该半导体晶片之上,其中该承载晶片面对该半导体晶片的一侧面与该承载晶片的一边缘形成一锐角。
本发明一实施例提供一种集成电路结构的形成方法,包括:提供一半导体晶片;以及将一承载晶片设置于该半导体晶片之上,其中该承载晶片具有一电阻率,小于约1×108Ohm-cm。
也讨论其他实施例。
本发明实施例具有许多优点。通过于承载晶片中形成刻痕,无凸块下金属层会形成于承载晶片的通过半导体晶片中的刻痕所露出的部分。因此,可进行更可靠的对准。由于承载晶片的角落不具有斜面区,可减少凸块下金属层的脱层。再者,由于承载晶片的电阻率被减低,承载晶片可更可靠地固定于静电吸盘上。
附图说明
图1显示制作穿硅导电插塞背面连接时的中间工艺阶段的剖面图,其中承载晶片的斜面区上沉积有凸块下金属层。
图2A显示设置于承载晶片上的硅晶片的俯视图,其中硅晶片中形成有刻痕。
图2B显示图2A所示的结构的剖面图。
图3A-图12显示根据一实施例制作内连线结构的工艺俯视图及剖面图。
其中,附图标记说明如下:
2~晶片;
4~集成电路元件
10~基底;
12~内连线结构;
14~接垫;
15、17~刻痕;
16~承载晶片;
18~粘着层;
20~穿硅导电插塞;
22、24~绝缘层;
26~籽晶层(或凸块下金属层);
46~掩模;
50、58、65~开口;
52~重布线路;
521~重布线路条;
522~垫;
56~保护层;
60、63~光致抗蚀剂;
64、86~铜柱;
66、84~缓冲层;
68~焊料;
80~芯片/晶片;
90~底胶;
100~硅晶片;
102~穿硅导电插塞;
104~承载晶片;
106~胶;
108~凸块下金属层;
110~斜面区;
112~刻痕;
C1、C2~中心;
D1、D2~直径;
R1~半径;
S1、S2~距离;
W~翘曲。
具体实施方式
以下,将详细讨论本发明实施例的形成与使用方式。然应注意的是,实施例提供许多可应用于广泛应用面的发明特点。所讨论的特定实施例仅为举例说明制作与使用本发明实施例的特定方式,不可用以限制本发明实施例的范围。再者,当述及一第一材料层位于一第二材料层上或之上时,包括第一材料层与第二材料层直接接触或间隔有一或更多其他材料层的情形。
本发明实施例提供用以形成一新颖的连接至穿硅导电插塞(TSV,或可为穿半导体导电插塞(through-semiconductor vias))背面内连线结构的方法。将说明一实施例的制作流程,并讨论实施例的变化。在各附图及实施例的说明中,相似的标号将用以标示相似的元件。
请参照图3A,提供晶片2,其包括基底10。适合的基底10可为半导体基底,例如块材硅基底(bulk silicon substrate),然而基底10可包括其他的半导体材料,例如三族、四族、及/或五族的元素。例如是晶体管的集成电路元件(以方块4显示)可形成在基底10的前表面(即,图3A中朝上的表面)。内连线结构(interconnect structure)12形成于基底10之上,且可连接至集成电路元件,其中内连线结构12包括形成于其中的金属线路及插塞(未显示)。金属线路及插塞可由铜或铜合金制成,且可使用所周知的镶嵌工艺形成。内连线结构12可包括一般常见的层间介电层(ILDs)及金属间介电层(IMDs)。
穿硅导电插塞20形成于基底10之中,并自基底10的前表面(图3A中朝上的表面)延伸进入基底10之中。在一第一实施例中,如图3A所示,穿硅导电插塞20是使用先插塞方法(via-first approach)而形成,且于底部金属化层(bottom metallization layer,即所知的M1)形成之前形成。因此,穿硅导电插塞20穿过基底10及内连线结构12。绝缘层22形成于穿硅导电插塞20的侧壁上,且电性隔离穿硅导电插塞20与基底10。绝缘层22可由常用的介电材料形成,例如氮化硅、氧化硅(例如,TEOS氧化物)、及其相似物。
图3B显示晶片2的俯视图,其显示形成于晶片2中的刻痕15。刻痕15可自晶片2的一表面朝相反的表面延伸(两表面皆为平坦表面)。并且,刻痕15自晶片2的一边缘延伸进入晶片2。在一实施例中,刻痕15在俯视图中具有一三角形。在其他实施例中,刻痕15在俯视图中可具有其他的形状,例如是矩形。
图4A显示承载晶片16(有时也称之为承载基底)的俯视图。承载晶片16可由玻璃、硅、陶瓷玻璃、或其相似物形成。在一实施例中,承载晶片16具有低于约1×108Ohm-cm的电阻率。电阻率也可低于约1×106Ohm-cm,或甚至低于约1×103Ohm-cm。这点可例如通过于制造承载晶片16时掺杂更为可移动的离子至适当的浓度而达到,例如可掺杂Na、K、Al、或其相似物。借着减低承载晶片16的电阻率,承载晶片16在后续工艺中可更为可靠地固定于静电吸盘上。
承载晶片16也包括刻痕17,其也自承载晶片16的一表面朝相反表面延伸(两表面皆为平坦表面)。在一实施例中,承载晶片16的直径D2大于晶片2的直径D1。再者,自承载晶片16的中心C2至刻痕17的距离S2小于晶片2的半径R1(参照图3B)。距离S2也可大于、等于、或小于自晶片2的中心C1到刻痕15的最接近点的距离S1。
图4B显示承载晶片16的剖面图。优选地,顶角落19(在面向后续将接合的晶片2一侧上,其以虚线显示)具有尖锐的轮廓而不具斜面区。换言之,承载晶片16的侧面与承载晶片16的边缘形成一尖锐角(例如,90度)。
请参照图5A,接垫14形成在晶片2的前表面(图5A中朝上的表面)上,且接垫14凸出于前表面。接着,通过粘着层18将晶片2设置于承载晶片16上。在接合之后,所结合的包含晶片2与承载晶片16的结构的翘曲(warpage)W(见图5E及图5F)优选小于约20μm,或甚至小于约1μm。图5E显示翘曲W的第一例子。可了解的是翘曲W也可能为相反的方向,如图5F所示。翘曲W的缩减可通过玻璃平坦度或胶的控制而达到。
图5B显示图5A所示的结构的俯视图。在一实施例中,如图5B所示,部分的刻痕17与整个刻痕15重叠,且可延伸于晶片2之下。在另一实施例中,如图5C所示,刻痕17的边缘与刻痕15的边缘对准。在又一实施例中,如图5D所示,刻痕17的整体仅与部分的刻痕15重叠。
在图6中,进行背面研磨(backside grinding)以移除基底10的多余的部分。对晶片2的背面进行化学机械研磨(CMP)而使穿硅导电插塞20露出。形成背面绝缘层24以覆盖基底10的背面。在一实施例中,背面绝缘层24的形成包括对基底10的背面进行回蚀刻、毯覆式形成背面绝缘层24、以及进行轻微的化学机械研磨以移除背面绝缘层24的直接位于穿硅导电插塞20上的部分。因此,穿硅导电插塞20通过在背面绝缘层24中的开口而露出。在另一实施例中,背面绝缘层24中的开口(穿硅导电插塞20通过该开口而露出)通过蚀刻而形成。由于晶片2可包括多个穿硅导电插塞(TSVs),翘曲的减少可造成晶片2中的穿硅导电插塞均匀露出,而不是部分的穿硅导电插塞未露出,但另一部分的穿硅导电插塞露出。
请参照图7A,于背面绝缘层24及穿硅导电插塞20上形成薄籽晶层26(也为凸块下金属层,UBM)。凸块下金属层26可借着溅镀或其他可应用方法而形成。凸块下金属层26的可用材料包括铜或铜合金。然而,也可包括其他金属,例如银、金、铝、或前述的组合。
图7B显示图7A所示的结构的边缘部分。为了简化,仅显示凸块下金属层26、晶片2、粘着层18、及承载晶片16,其他元件则不显示。可发现由于承载晶片16中的刻痕17形成在晶片2中的刻痕15之下,没有凸块下金属层26会沉积于承载晶片16之上而通过刻痕15露出。因此,用以进行后续工艺步骤的仪器(例如,光学步进机)可轻易地找到刻痕15,导致更为可靠的工艺。
图7A还显示掩模(mask)46的形成。在一实施例中,掩模46为一光致抗蚀剂。或者,掩模46由干膜(dry film)制成,其可包括有机材料,例如是日本Ajinomoto公司所供应的增层膜(Ajinimoto buildup film,ABF)。接着,将掩模46图案化以于掩模46中形成开口50,其中穿硅导电插塞20(及凸块下金属层26的覆盖部分)通过开口50而露出。既然承载晶片16刻有刻痕,可在掩模46的图案化中进行更为准确的对准。
在图8中,如图7A所示的开口50被选择性填充以金属材料,而于开口50中形成重布线路(redistribution line,RDL)52。在优选实施例中,填充材料包括铜或铜合金,然而也可使用其他金属,例如铝、银、金、或前述的组合。形成方法可包括电化学电镀(ECP)、无电镀(electroless plating)、或其他常用的沉积方法,例如溅镀、印刷(printing)、及化学气相沉积(CVD)。接着,移除掩模46。因此,露出了凸块下金属层26位于掩模46下的部分。
请参照图9,通过快速蚀刻(flash etching)移除凸块下金属层26的露出部分。所留下的重布线路52可包括重布线路条(RDL strip)521(也称之为redistribution trace),其包括直接位于穿硅导电插塞20之上且与之连接的部分,以及重布线路52可选择性包括与重布线路条521连结的垫(pad)522。在图9及后续的附图中,将不显示凸块下金属层26,这是由于凸块下金属层26一般由与重布线路52相似的材质形成,因而与重布线路52合并显示。由于快速蚀刻,也移除重布线路52的一薄层。然而,重布线路52所移除的部分与其整体厚度相比是可忽略的。
接着,如图10所示,毯覆式形成保护层(passivation layer)56,并将之图案化以形成开口58。保护层56可由氮化物、氧化物、聚酰亚胺(polyimide)、或其相似物所形成。涂布光致抗蚀剂60并将之显影以定义出开口58的图案。部分的垫522通过保护层56中的开口58而露出。开口58可占据垫522的中心部分。重布线路条521可继续被保护层56覆盖。
接着,如图11所示,移除光致抗蚀剂60,并形成接垫(bonding pad),其包括铜柱(copper pillar)64及缓冲层(barrier layer)66。在一实施例中,形成光致抗蚀剂63。光致抗蚀剂63优选厚于光致抗蚀剂60。在一实施例中,光致抗蚀剂63厚了约20μm或甚至厚了约60μm。将光致抗蚀剂63图案化以形成开口65,通过开口65露出了垫522。接着,借着电镀自开口65开始形成铜柱64。铜柱64可包括铜及/或其他金属,例如银、金、钨、铝、或前述的组合。可于铜柱64上形成缓冲层66,其例如由镍所形成,且可于缓冲层66上形成焊料(solder)68。
请参照图12,移除光致抗蚀剂63。承载晶片16可接着自晶片2取下。显示于图10的结构可接合至其他芯片或晶片,例如芯片/晶片80。在一实施例中,芯片/晶片80在其前表面上具有铜柱(copper post)86及缓冲层84,其中可回焊(reflow)焊料68以接合晶片2与芯片/晶片80。可于晶片2与芯片/晶片80之间填充底胶(underfill)90。在另一实施例中,在接合至其他芯片/晶片之前,可将晶片2分切成多个芯片。在另一实施例中,承载晶片16的取下可在晶片2接合至芯片/晶片80之后才进行。
以上所讨论的实施例中,穿硅导电插塞的背面内连线结构用作解释本发明实施例的例子。应注意的是,本发明实施例也可用于其他涉及承载晶片的工艺,例如晶片-晶片接合工艺(wafer-to-wafer bonding processes)。
本发明实施例具有许多优点。通过于承载晶片中形成刻痕,无凸块下金属层会形成于承载晶片的通过半导体晶片中的刻痕所露出的部分。因此,可进行更可靠的对准。由于承载晶片的角落不具有斜面区,可减少凸块下金属层的脱层。再者,由于承载晶片的电阻率被减低,承载晶片可更可靠地固定于静电吸盘上。
虽然本发明已以数个优选实施例公开如上,然其并非用以限定本发明,任何所属技术领域中的普通技术人员,在不脱离本发明的精神和范围内,当可作任意的更动与润饰,因此本发明的保护范围当视随附的权利要求所界定的保护范围为准。
Claims (9)
1.一种集成电路结构的形成方法,包括:
提供一半导体晶片,包括一第一刻痕,自该半导体晶片的一边缘延伸进入该半导体晶片;以及
将一承载晶片设置于该半导体晶片之上,其中该承载晶片包括一第二刻痕,位于该承载晶片之中,且其中将该承载晶片的设置步骤包括使至少一部分的该第一刻痕与至少一部分的该第二刻痕重叠,
其中该半导体晶片包括一穿半导体导电插塞,延伸进入该半导体晶片,且其中该方法还包括:
在设置该承载晶片的步骤之后,研磨该半导体晶片的一背面以露出该穿半导体导电插塞;以及
于该半导体晶片的该背面上沉积一导电层,该导电层电性连接该穿半导体导电插塞,
其中该第二刻痕自该承载晶片的一边缘延伸进入该承载晶片。
2.如权利要求1所述的集成电路结构的形成方法,其中设置该承载晶片的步骤包括使该第二刻痕的边缘对准该第一刻痕的边缘。
3.如权利要求1所述的集成电路结构的形成方法,其中该第二刻痕的一部分与该第一刻痕的整体重叠。
4.如权利要求1所述的集成电路结构的形成方法,其中该第一刻痕的一部分与该第二刻痕的整体重叠。
5.一种集成电路结构的形成方法,包括:
提供一半导体晶片;以及
将一承载晶片设置于该半导体晶片之上,其中该承载晶片面对该半导体晶片的一侧面与该承载晶片的一边缘形成一锐角,其中该半导体晶片包括一穿半导体导电插塞,延伸进入该半导体晶片,且其中该方法还包括:
在设置该承载晶片的步骤之后,研磨该半导体晶片的一背面以露出该穿半导体导电插塞;以及
于该半导体晶片的该背面上沉积一导电层,该导电层电性连接该穿半导体导电插塞,
其中该半导体晶片包括一第一刻痕,自该半导体晶片的一边缘延伸进入该半导体晶片,且该承载晶片包括一第二刻痕,其中设置该承载晶片的步骤包括对准该第二刻痕而使该第二刻痕与至少一部分的该第一刻痕重叠,
其中该第二刻痕自该承载晶片的一边缘延伸进入该承载晶片。
6.如权利要求5所述的集成电路结构的形成方法,其中该半导体晶片包括一半导体基底以及一穿半导体导电插塞,延伸进入该半导体基底,且其中该方法还包括:
在沉积该导电层的步骤之后,将该承载晶片自该半导体晶片取下。
7.如权利要求5所述的集成电路结构的形成方法,其中包括该承载晶片与该半导体晶片的一联合结构具有一翘曲,小于20μm。
8.一种集成电路结构的形成方法,包括:
提供一半导体晶片;以及
将一承载晶片设置于该半导体晶片之上,其中该承载晶片具有一电阻率,小于1x108Ohm-cm,其中该半导体晶片包括一穿半导体导电插塞,延伸进入该半导体晶片,且其中该方法还包括:
在设置该承载晶片的步骤之后,研磨该半导体晶片的一背面以露出该穿半导体导电插塞;以及
于该半导体晶片的该背面上沉积一导电层,该导电层电性连接该穿半导体导电插塞,
其中该半导体晶片包括一第一刻痕,自该半导体晶片的一边缘延伸进入该半导体晶片,且该承载晶片包括一第二刻痕,其中设置该承载晶片的步骤包括对准该第二刻痕而使该第二刻痕与至少一部分的该第一刻痕重叠,
其中该第二刻痕自该承载晶片的一边缘延伸进入该承载晶片。
9.如权利要求8所述的集成电路结构的形成方法,其中该承载晶片面对该半导体晶片的一侧面上的所有的顶角落具有一尖锐的轮廓,该轮廓具有一90度角。
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