CN102347320B - 装置及其制造方法 - Google Patents
装置及其制造方法 Download PDFInfo
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- CN102347320B CN102347320B CN201110006036.7A CN201110006036A CN102347320B CN 102347320 B CN102347320 B CN 102347320B CN 201110006036 A CN201110006036 A CN 201110006036A CN 102347320 B CN102347320 B CN 102347320B
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- H01L2924/19—Details of hybrid assemblies other than the semiconductor or other solid state devices to be connected
- H01L2924/1901—Structure
- H01L2924/1904—Component type
- H01L2924/19042—Component type being an inductor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/19—Details of hybrid assemblies other than the semiconductor or other solid state devices to be connected
- H01L2924/1901—Structure
- H01L2924/1904—Component type
- H01L2924/19043—Component type being a resistor
Abstract
本发明揭示一种装置及其制造方法,该装置包括:一第一芯片,具有一第一侧及与其相对的一第二侧,第一侧具有一第一区及一第二区,且一第一金属凸块形成于第一芯片的第一区上,具有一第一平面尺寸。一第二芯片通过第一金属凸块而接合至第一芯片的第一侧。一介电层位于第一芯片的第一侧上方且包括直接位于第二芯片上的一第一部、环绕第二芯片的一第二部以及露出第一芯片的第二区的一开口。一第二金属凸块形成于第一芯片的第二区上且延伸进入介电层的开口内,具有大于第一平面尺寸的一第二平面尺寸。一电子部件通过第二金属凸块而接合至第一芯片的第一侧。本发明增加了芯片堆叠的弹性。
Description
技术领域
本发明涉及一种集成电路,特别涉及一种具有转接板(interposer)的三维集成电路(three-dimensional integrated circuit,3DIC)及其制造方法。
背景技术
由于各个电子部件(即,晶体管、二极管、电阻、电容等等)的集积度(integration density)持续的改进,使集成电路持续不断的快速成长发展。主要来说,集积度的改进来自于最小特征尺寸(minimum feature size)不断缩小而容许更多的部件整合至既有的芯片面积内。
集成部件所占的体积实际上位于半导体晶片的表面。尽管微影(lithography)技术的精进为二维(2D)集成电路制作带来相当大的助益,二维空间所能拥有的密度还是有其物理限制。这些限制之一在于制作这些部件所需的最小尺寸。再者,当更多的装置放入一芯片中,需具有更复杂的电路设计。另一限制来自于当装置数量增加时,其间的内连线(interconnection)的数量及长度大幅增加。而当内连线的数量及长度增加时,电路的时间延迟(RC delay)以及电量耗损均会增加。
因此,开始发展出三维集成电路(3DIC),其中芯片的堆叠可通过用于堆叠芯片并将其连接至封装基底的打线接合(wire bonding)、倒装芯片接合(flip-chip bonding)和/或硅通孔电极(through-silicon via,TSV)。在传统的芯片堆叠方法中,当二个芯片接合至另一芯片时便会产生问题,二个芯片可能需要不同的凸块(bump)尺寸,其造成后续接合、焊料凸块回流(reflowing)、底胶填充(underfill filling)及晶片切割的困难度。
发明内容
为克服上述现有技术的缺陷,在本发明一实施例中,一种装置,包括:一第一芯片,具有一第一侧及与其相对的一第二侧,第一侧具有一第一区及一第二区;一第一金属凸块,形成于第一芯片的第一侧的第一区上,具有一第一平面尺寸;一第二芯片,通过第一金属凸块而接合至第一芯片的该第一侧;一介电层,位于第一芯片的第一侧上方,且包括直接位于第二芯片上的一第一部、环绕第二芯片的一第二部以及露出第一芯片的第一侧的第二区的一开口;一第二金属凸块,形成于第一芯片的第一侧的该第二区上且延伸进入介电层的开口内,具有一第二平面尺寸,第二平面尺寸大于第一平面尺寸;以及一电子部件,通过第二金属凸块而接合至第一芯片的第一侧;以及一底胶材料,形成于该第一电子部件与该介电层之间的空间内。
本发明另一实施例中,一种装置,包括:一第一芯片,包括一基底,其具有一第一侧及与其相对的一第二侧;一第一基底通孔电极及一第二基底通孔电极,形成于基底内;一第一凸块下方金属层及一第二凸块下方金属层,形成于基底的第一侧上,且分别电性耦接至第一基底通孔电极及第二基底通孔电极;一介电层,位于第一凸块下方金属层及第二凸块下方金属层上方,且具有露出至少一部分的第一凸块下方金属层的一第一开口以及露出至少一部分的第二凸块下方金属层的一第二开口,其中第一开口具有一第一平面尺寸且小于第二开口具有的一第二平面尺寸;一第一金属凸块,具有一第一高度且形成于露出的第一凸块下方金属层上并延伸进入介电层的第一开口内;一第二金属凸块,具有一第二高度且形成于露出的第二凸块下方金属层上并延伸进入介电层的第二开口内,其中第一高度低于第二高度;以及一第二芯片,通过第一金属凸块而接合至第一芯片。
本发明又一实施例中,一种装置的制造方法,包括:提供一晶片;在晶片上方形成一第一凸块下方金属层及一第二凸块下方金属层;在第一凸块下方金属层上形成一第一金属凸块并与其电性耦接;将一第一芯片接合至第一金属凸块;形成一防焊涂布层,以覆盖第一芯片及晶片;在防焊涂布层内形成一开口,以露出至少一部分的第二凸块下方金属层;以及在开口内形成一第二金属凸块,且电性耦接至第二凸块下方金属层,其中第二金属凸块大于第一金属凸块。
本发明增加了芯片堆叠的弹性。
附图说明
图1至图8示出根据一实施例的具有堆叠芯片的三维集成电路制造方法中各个阶段的剖面示意图,其中具有不同尺寸的金属凸块形成于同一芯片/晶片上。
其中,附图标记说明如下:
10~基底;
10a~第一侧;
10b~第二侧;
12~集成电路;
16~基底通孔电极;
18、22~内连结构;
20~金属凸块;
24、32、44~介电层;
26~金属线/重布局层;
28~金属介层窗/重布局层;
30、30A、30B~凸块下方金属层;
34A、34B~凸块下方金属层开口;
35~承载板;
36~小金属凸块;
38、100’~芯片;
40、52~底胶;
46~开口;
48~大金属凸块;
50、56~电子部件/芯片;
58~成形材料;
100~晶片;
H~高度;
L1、L2、L3、L4~平面尺寸;
T~厚度。
具体实施方式
以下说明本发明实施例的制作与使用。然而,可轻易了解本发明实施例提供许多合适的发明概念而可实施于广泛的各种特定背景。所揭示的特定实施例仅仅用于说明以特定方法制作及使用本发明,并非用以局限本发明的范围。
以下提供一种新的三维集成电路(3DIC)及其制造方法并说明一实施例的制造方法中各个阶段。在各个附图及实施例中,相同的部件使用相同的标号。
请参照图1,提供一晶片100,其内包括一基底10。基底10可由半导体材料所构成,例如硅、锗化硅、碳化硅、砷化锗或其它习用半导体材料。在一实施例中,晶片100为一装置晶片,包括集成电路12,其可包括互补式金属-氧化物-半导体(complementary metal-oxide-semiconductor,CMOS)晶体管、电阻、电感、和/或电容等等。在另一实施例中,晶片100为一中介晶片(interposer wafer),其实质上不具有有源(active)装置,例如晶体管。再者,中介晶片100可具有或不具有无源装置,例如电容、电阻和/或电感等等。因此,基底10可由介电材料所构成,例如氧化硅。
在基底10内形成基底通孔电极(through-substrate via,TSV)16,且可通过绝缘层(未示出)而与基底10电性绝缘。基底通孔电极16自基底的一侧贯穿至一相对侧。在一实施例中,晶片100为一装置晶片,且基底10具有一第一侧10a及与第一侧10a相对的一第二侧10b。在集成电路工艺中,第二侧10b称为基底10的前侧,而第一侧10a则称为基底10的背侧。在基底10的第二侧10b上形成一内连结构18,其内包括金属线及金属介层窗(via)(未示出)且电性耦接至集成电路12。金属线及金属介层窗可由铜或铜合金所构成且可通过公知镶嵌工艺而形成。内连结构18可包括一公知内层介电(inter-layer dielectric,ILD)层及金属层间介电(inter-metal dielectric,IMD)层,其可为具有低介电常数(例如,低于2.5,甚至低于2.0)的低介电常数介电层。在另一实施例中,晶片100面向上的一侧为装置晶片100的前侧,而面向下的一侧则为背侧。金属凸块20形成于晶片100的一表面,其可为焊料凸块且电性耦接至集成电路12。
在基底10的第一侧10a上的内连结构22。内连结构22包括一或多个介电层24以及位于介电层24内的金属线24及金属介层窗28。以下金属线24及金属介层窗28称为重布局线(redistribution line,RDL)。介电层24可由高分子材料、氮化硅、有机介电材料、或低介电常数材料等等所构成。重布局线26及28可由铜或铜合金所构成,然而也可使用其他习用金属材料,例如铝及钨等等。
形成凸块下方金属层(under-bump-metallurgy,UBM)30(包括30A及30B)且电性耦接至重布局线26及28。凸块下方金属层(UBM)30可由铝铜合金、铝或铜等等所构成,且每一凸块下方金属层30也可包括位于含铜层上方的镍层。形成介电层32以覆盖凸块下方金属层30的边缘部分,并通过凸块下方金属层开口34A及34B而露出凸块下方金属层30的中心部分。凸块下方金属层开口34A称为大凸块下方金属层开口,而凸块下方金属层开口34B称为小凸块下方金属层开口,然而其可同时形成。在一实施例中,凸块下方金属层开口34A的平面尺寸(可为长度或宽度)L1大于凸块下方金属层开口34B的平面尺寸L2,而比率(L1/L2)的大于5或甚至大于10。承载板35可为一玻璃晶片,且可接合至晶片100的一侧。
接下来,请参照图2,形成小金属凸块36,其中每一小金属凸块36的一部分位于小凸块下方金属层开口34B的其中一个内。小金属凸块36电性耦接至重布局线26及28,且可电性耦接至基底通孔电极16。在一实施例中,小金属凸块36为焊料凸块,例如共晶(eutectic)焊料凸块。在另一实施例中,小金属凸块36为铜凸块或其他金属凸块,其由金、银、镍、钨、铝和/或其合金所构成。当由铜所构成时,每一小金属凸块36可覆盖一镍层和/或位于镍层上的一焊料上盖层(未示出)。
请参照图3,芯片38接合至小金属凸块36。芯片38可为一装置芯片,其包括集成电路装置形成于内,例如晶体管、电容、电感及电阻(未示出)等等,且可为一逻辑芯片或一记忆体芯片。取决于小金属凸块36的结构,芯片38与小金属凸块36之间的接合可为焊料接合(solder bonding)或直接金属对金属(例如,铜对铜)接合。在将芯片38接合至小金属凸块36之后,在芯片38与晶片100之间的间隙内形成底胶40,并接着进行固化。
请参照图4,在晶片100及芯片38上涂覆一介电层44。介电层44可为一防焊涂布层(solder resist coating),其可由光致抗蚀剂、高分子材料或类高分子材料所构成。另外,介电层44可由硅胶、旋涂玻璃(spin-on glass,SOG)或防焊材料等所构成。介电层44可包括直接位于芯片38上的一部分及环绕芯片38、小金属凸块36及底胶40的一部分。因此,介电层44保护小金属凸块36以及芯片38与晶片100之间的接合。介电层44可利用旋转涂布(spincoating)、喷雾式涂布(spray coating)或喷墨印刷(ink jet print)并接着进行固化步骤而形成。接着在介电层44内形成开口46,而露出凸块下方金属层30A,例如使用蚀刻。
接下来,请参照图5,在开口46内形成大金属凸块48且可与介电层44接触。在一实施例中,大金属凸块48为焊料凸块,其可由共晶焊料或无铅焊料等所构成。在另一实施例中,大金属凸块48为铜凸块且具有镍层和/或焊料上盖层形成于其上。
接下来,请参照图6,将电子部件50接合至大金属凸块48。在一实施例中,电子部件50为装置芯片,其内包括集成电路,例如晶体管。在另一实施例中,电子部件50为封装基板。在大金属凸块48为铜凸块的实施例中,可进行回流(re-flow)工艺,以结合电子部件50与大金属凸块48。在进行接合之后,电子部件50的底表面可高于介电层44的上表面。在电子部件50与晶片100之间的间隙内以及大金属凸块48之间填入底胶52。可以理解的是虽然附图中仅有一芯片38及一芯片(电子部件)50,然而可具有多个芯片38及芯片50接合至晶片100。此时可进行芯片切割(die saw),以将晶片100切割成多个芯片,每一芯片100’(请参照图7)包括晶片100的一部分、其中一个芯片38以极其中一个芯片50。
在将电子部件50接合至晶片100之后,大金属凸块48的平面尺寸(其为长度或宽度)L3大于小金属凸块的平面尺寸L4,而比率(L3/L4)的大于5或甚至大于15。再者,大金属凸块48的高度H大于介电层44的厚度。
请参照图7,将承载板35卸离(de-bonded),并将电子部件56(可为装置芯片或封装基板)接合至晶片100,其中电子部件56及芯片38位于晶片100(或芯片100’)的相对侧。如第8图所示,当电子部件56为装置芯片,可形成成形材料(molding compound)58,以覆盖电子部件56。若尚未进行芯片切割,可接着进行芯片切割,以将晶片100分割成多个芯片。
在上述实施例中,大金属凸块与小金属凸块形成于同一三维集成电路(3DIC)内。由于小金属凸块受到介电材料保护,因此可形成大金属凸块,且可在形成及接合小金属凸块之后,将另一芯片接合至大金属凸块,且在接合大金属凸块期间不会损及小金属凸块。此增加了芯片堆叠的弹性。
虽然本发明已以优选实施例揭示如上,然而其并非用以限定本发明,任何本领域技术人员,在不脱离本发明的精神和范围内,当可作更动、替代与润饰。再者,本发明的保护范围并未局限于说明书内所述特定实施例中的工艺、机器、制造、物质组成、装置、方法及步骤,任何本领域技术人员可从本发明揭示内容中理解现行或未来所发展出的工艺、机器、制造、物质组成、装置、方法及步骤,只要可以在此处所述实施例中实施大体相同功能或获得大体相同结果皆可使用于本发明中。因此,本发明的保护范围包括上述工艺、机器、制造、物质组成、装置、方法及步骤。另外,每一权利要求构成个别的实施例,且本发明的保护范围也包括各个权利要求及实施例的组合。
Claims (8)
1.一种三维集成电路,包括:
一第一芯片,具有一第一侧及与其相对的一第二侧,该第一侧具有一第一区及一第二区;
一第一金属凸块,形成于该第一芯片的该第一侧的该第一区上,具有一第一平面尺寸;
一第二芯片,通过接合至该第一金属凸块而接合至该第一芯片的该第一侧;
一介电层,位于该第一芯片的该第一侧上方,且包括直接位于该第二芯片上的一第一部、环绕该第二芯片的一第二部以及露出该第一芯片的该第一侧的该第二区的一开口;
一第二金属凸块,形成于该第一芯片的该第一侧的该第二区上且延伸进入该介电层的该开口内,具有一第二平面尺寸,该第二平面尺寸大于该第一平面尺寸,其中该第二金属凸块的高度大于该第一金属凸块的高度;
一第一电子部件,通过接合至该第二金属凸块而接合至该第一芯片的该第一侧,且该第一电子部件的底表面高于该介电层的上表面;以及
一底胶材料,形成于该第一电子部件与该介电层之间的空间内。
2.如权利要求1所述的三维集成电路,其中该介电层包括防焊材料、光致抗蚀剂、高分子材料及硅胶中的至少一种。
3.如权利要求1所述的三维集成电路,其中该第二平面尺寸与该第一平面尺寸的比率大于5。
4.如权利要求1所述的三维集成电路,其中该第一芯片包括形成于该第一芯片内且电性耦接至该第一金属凸块的一第一基底通孔电极,以及形成于该第一芯片内且电性耦接至该第二金属凸块的一第二基底通孔电极。
5.如权利要求4所述的三维集成电路,还包括一第二电子部件,接合至该第一芯片的该第二侧,且通过该第二基底通孔电极而电性耦接至该第一电子部件。
6.如权利要求4所述的三维集成电路,还包括:
一第三芯片,通过接合至该第二金属凸块而接合至该第一芯片;以及
一电子部件,接合至该第一芯片的该第二侧,且通过该第二基底通孔电极而电性耦接至该第三芯片。
7.一种三维集成电路制造方法,包括:
提供一晶片;
在该晶片上方形成一第一凸块下方金属层及一第二凸块下方金属层;
在该第一凸块下方金属层上形成一第一金属凸块并与其电性耦接;
将一第一芯片接合至该第一金属凸块;
形成一防焊涂布层,以覆盖该第一芯片及该晶片;
在该防焊涂布层内形成一开口,以露出至少一部分的该第二凸块下方金属层;
在该开口内形成一第二金属凸块,且电性耦接至该第二凸块下方金属层,其中该第二金属凸块大于该第一金属凸块,且该第二金属凸块的高度大于该第一金属凸块的高度;
将一第一电子部件接合至该第二金属凸块,且该第一电子部件的底表面高于该防焊涂布层的上表面;以及
将一底胶材料形成于该第一电子部件与该防焊涂布层之间的空间内。
8.如权利要求7所述的三维集成电路制造方法,还包括:
在该晶片内形成复数个基底通孔电极;以及
将该第一电子部件接合至该第二金属凸块,该第一电子部件择自于由装置芯片及封装基板所组成的群族,该第二金属凸块的平面尺寸与该第一金属凸块的平面尺寸的比率大于5。
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CN102347320A (zh) | 2012-02-08 |
US8669174B2 (en) | 2014-03-11 |
US20130122700A1 (en) | 2013-05-16 |
US20120018876A1 (en) | 2012-01-26 |
TWI413233B (zh) | 2013-10-21 |
US8581418B2 (en) | 2013-11-12 |
TW201205769A (en) | 2012-02-01 |
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