CN102365713A - 增强光和/或激光烧结的缓冲层 - Google Patents

增强光和/或激光烧结的缓冲层 Download PDF

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CN102365713A
CN102365713A CN2010800158424A CN201080015842A CN102365713A CN 102365713 A CN102365713 A CN 102365713A CN 2010800158424 A CN2010800158424 A CN 2010800158424A CN 201080015842 A CN201080015842 A CN 201080015842A CN 102365713 A CN102365713 A CN 102365713A
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thermal conductivity
sintering
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material layer
polyimides
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CN102365713B (zh
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Z·雅尼弗
M·杨
P·B·莱克斯顿
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Ishihara Chemical Co Ltd
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Abstract

在基板上沉积导线以产生用于在电子元件之间导电的迹线。在基板上形成图案化金属层,并且随后在图案化金属层和基板上涂敷具有低热导率的材料层。穿过具有低热导率的材料层形成通孔,由此露出图案化金属层的多个部分。导电墨膜随后被涂敷在具有低热导率的材料层上并进入通孔以由此涂敷图案化金属层的多个部分,并且随后被烧结。涂敷在图案化金属层的部分上的导电墨膜从烧结吸收的能量不如涂敷在具有低热导率的材料层上的导电墨膜所吸收的多。具有低热导率的材料层可以是聚合物,诸如聚酰亚胺。

Description

增强光和/或激光烧结的缓冲层
本申请要求美国临时专利申请S/N.61/174,758和61/163,894的优先权。
背景信息
微电子和半导体封装行业已经开始变换到可印刷电子行业。电子电路包括彼此电连接的各种组件。不同组件之间的这些电连接可由能用导电墨印刷在基板上的导电金属迹线制成迹线。墨在基板上沉积之后进行处理并烧结以变得导电。热烧结使用高温(例如,≥250℃)来熔合墨中的纳米颗粒。光子(光)和激光烧结利用极高强度的灯/激光用低温在极短的时间段(例如,微秒)内熔合纳米颗粒而不损坏下面的基板。然而,光/激光烧结工艺具有基板需要低热导率材料的限制,以使纳米颗粒有效地吸收能量并且在热能消散到基板中之前烧结。换言之,可用于这些应用的基板将仅限于低热导率材料。
另一方面,低热导率基板可用于柔性可印刷电子技术。诸如聚乙烯(PE)、聚酯(PET)等低温熔点材料可防止纳米颗粒墨正确地烧结,并且可损坏基板,其结果是电阻率将很高。
附图简述
图1是示出光烧结在四个硅晶片上的铜墨的数字照片。
图2是示出光烧结之前的铜墨的数字照片。
图3是示出光烧结之后的铜墨的数字照片。
图4是示出Kapton基板上的激光烧结线的数字照片。
图5是示出图4的激光烧结线的放大数字照片。
图6示出了显示通过激光来烧结的铜墨的电阻率不仅与激光功率成反比、而且与由聚酰亚胺制成的缓冲层的厚度成反比的曲线图。
图7示出了显示在各个自旋速度下所测量的经固化聚酰亚胺的厚度的曲线图。
图8示出了显示经烧结铜膜的电阻率与聚酰亚胺的厚度成反比的曲线图。
图9示出了显示铜墨膜对聚酰亚胺的粘合性与聚酰亚胺的厚度成正比的曲线图。
图10示出了显示激光写入线宽度与激光功率密度成正比的曲线图。
图11A-11F示出了根据本发明的实施例的工艺。
详细描述
本发明的实施例公开了一种光烧结工艺,用以有效地在聚酰亚胺基板上烧结金属纳米颗粒,由此使膜在体材料附近是极为导电的。另一方面,不能很好地对涂敷在拥有高热导率的基板(诸如,陶瓷和硅晶片)上的纳米颗粒墨执行光烧结工艺。表1示出了各种材料的热导率。
表1
Figure BPA00001445975300021
诸如聚酰亚胺之类的低电导率材料可用作其他高热导率基板(诸如,陶瓷和硅晶片)上的涂敷材料,从而在光烧结工艺期间使散热与纳米颗粒隔离以便更有效地熔合纳米颗粒。散热多快取决于低热导率材料(例如,聚酰亚胺膜)的厚度。
为了示出本发明如何工作进行以下实验。三个晶片分别用1、1.5和2.3微米厚的DuPont PI-2610聚酰亚胺来自旋涂敷,并且在350℃的温度下进行热固化达30分钟。一个裸硅晶片用作基准(晶片#1)。所有四个晶片使用引伸(drawdown)工艺用铜墨来涂敷。在100℃的温度下执行60分钟的干燥工艺之后,每个晶片分成三个区,这三个区分别用三个不同的能级来烧结。用电压表来测量每个区和每个晶片的电阻,其结果在表2中示出,表2示出了在硅晶片上有各种涂敷厚度的聚酰亚胺的情况下光烧结之后的铜膜的电阻。
表2
Figure BPA00001445975300031
其中 能级1=850/1050V、1000μsec的三个烧结射击
能级2=850/1150V、1000μsec的四个烧结射击
能级3=850/1250V、2000μsec的五个烧结射击
除晶片4的区3之外,四个晶片的所有区在光烧结之后电阻不再改变。晶片4的区3在最高能级改变了其金属颜色,如图1所示。这个区域被剧烈吹除。周围区域有留下的铜碎片,这些铜碎片导电。这清楚地证明了聚酰亚胺材料可用作热绝缘体。聚酰亚胺的厚度可大于3微米。聚酰亚胺和硅的热导率分别为0.12和148W/m.K。因为没有聚酰亚胺材料,所以热很快地消散到硅基板(晶片#1)中以至于不能烧结铜纳米颗粒。
晶片1、2和3都有高电阻(大于20兆欧姆)。如图1所示在中心区具有20欧姆电阻的晶片4显现出铜纳米颗粒膜开始熔合、烧结并变成铜色。由此,更厚的低热导率材料可用作不错的热绝缘体。
除以上公开的液态聚酰亚胺之外,还可利用干聚酰亚胺膜。在50微米的聚酰亚胺膜(Kapton)上涂敷铜墨。在硅晶片和carbAL高热导率的散热片上放置样本,如图2所示。硅脂被涂敷在Kapton和硅晶片和carbAL之间以确保良好的热接触。同时在单个射击中光烧结样本。铜被烧结地很好并变成有光泽的铜色,如图3所示。Kapton驻留在什么材料上是没有关系的。至少50微米厚的聚酰亚胺对于光烧结工艺的隔离热能和防止散热而言是足够厚的,尽管小于50微米的厚度可用于导电迹线需要更小电导率的实施例。
另外,通过如上所述的相同设置在硅晶片上利用激光烧结。激光器是波长为830nm和功率为800mW的固态二极管。聚焦光束尺寸是直径为15微米并且由准直仪和物镜控制,如图4和5所示。
该激光器有足够的功率来烧结和熔合纳米颗粒并使铜墨变成导电。存在分别用各个厚度为1、1.5、2和3的聚酰亚胺来涂敷的四个硅晶片,以及作为基准的裸硅晶片。在图6中绘制了每个晶片的电阻率以及激光功率,图6示出铜膜电导率与聚酰亚胺的厚度成正比,并且激光所产生的热被传送到基板,具有聚酰亚胺的基板的热比没有聚酰亚胺的裸硅晶片的热少。这清楚地证明了任何具有低热导率的材料(诸如,聚酰亚胺材料)可用作热绝缘体并且可增强光和激光烧结工艺。
此外,各个厚度的聚酰亚胺被涂敷在硅晶片上并且在350℃温度下被固化一小时。随后标准铜墨通过引伸来涂敷,在烤箱中干燥,并且被光/激光烧结。电测量被执行并且表征为铜墨样本。
由DuPont制造的三种类型的聚酰亚胺材料用于以1000、2000、3000、4000和5000rpm自旋涂敷在硅晶片上。图7示出了显示在各个自旋速度下所测量的经固化聚酰亚胺的厚度的曲线图。对于每个晶片范围分别为1到20微米。
在准备好样本之后,对铜墨执行光和激光烧结两者。不同类型的烧结就电阻率和粘合性以及用于激光烧结的线宽进行比较。表3示出了在各个厚度的聚酰亚胺的情况下在相同能级下光烧结的样本。表4示出了在各个厚度的聚酰亚胺的情况下在固定能级激光烧结的样本。
表3
Figure BPA00001445975300041
表4
Figure BPA00001445975300051
图8示出了显示经烧结铜膜的电阻率与聚酰亚胺厚度成反比的曲线图。电阻率的饱和点针对光烧结大约在10微米处,而针对激光烧结大约在5微米处。光烧结的功率密度比激光烧结的功率密度小很多,这提供了为什么其电阻率更高的原因。
图9示出了显示铜墨膜对聚酰亚胺的粘合性与聚酰亚胺厚度成正比的曲线图。存在一些噪声点,但是从曲线图来看趋势很清楚。聚酰亚胺越厚,粘合性越好。再次,针对良好粘合性的聚酰亚胺厚度的临界点对于光烧结大约在10微米处,而对于激光烧结大约在5微米处。
图10示出了显示激光写入线宽度与激光功率密度成正比的曲线图。通过给定的激光功率,激光写入线宽也与聚酰亚胺膜厚度成正比,这更加证明了对于这些工艺聚酰亚胺是不错的热绝缘体。沉积在铜墨表面的激光能量和热不能垂直散布到任意深度,但可以在聚酰亚胺厚度增加时横向散布。
参考图11A-11F,示出了用于执行本发明的实施例的工艺。设置在其上要安装电子电路的基板1101。在图11B中,使用公知的制造工艺,在基板1101上以所需图案沉积金属材料1102的迹线。在图11C中,在金属迹线1102和基板1101上涂敷低热导率材料层1103,诸如,聚酰亚胺。为了创建要沉积的导电迹线的其他图案,穿过材料1103形成通孔1104,从而露出金属迹线1102的多个部分。在图11E中,喷墨装置1106在材料1103和通过通孔1104露出的金属迹线1102上沉积导电墨1105,诸如,铜纳米颗粒。在图11F中,对所沉积的导电墨纳米颗粒1105执行光或激光烧结工艺以将它们烧结到导电迹线1107中,如此处所述。在美国专利公开No.2008/0286488 A1中描述了导电墨的沉积和烧结工艺,该专利公开通过引用结合于此。
概述
1.光烧结工艺的有效性不仅取决于金属纳米颗粒的尺寸,而且取决于物质的类型。
2.有效的光烧结通过300nm以下的纳米颗粒来实现。
3.物质的热导率可影响金属墨光烧结。物质的热导率越低,纳米颗粒膜的电导率越好。
4.高热导率物质可通过涂敷诸如聚酰亚胺或聚合物之类的低热导率材料来针对有效的光烧结工艺进行调整和隔离。
5.隔离散热所需的聚酰亚胺的涂敷厚度约为1-50微米。
6.通过激光和光烧结两者,在诸如硅晶片之类的高热导率材料上展示变成导电膜的铜墨。
7.通过涂敷在晶片上的各个厚度的聚酰亚胺来示出高热导率硅晶片上的散热。低热导率材料可用作缓冲层以放慢散热且增强光或激光烧结。
8.铜墨可通过涂敷在硅晶片上的聚酰亚胺来很好地烧结,其电阻率通过光烧结为1x10-5欧姆-cm而通过激光烧结为4x10-6欧姆-cm。
9.聚酰亚胺材料不仅可用作高热导率基板上的热绝缘体并增强铜墨光和激光烧结的有效性,而且可应用于低熔温基板作为用以在烧结工艺期间保护其免受热损坏的热绝缘体。
10.聚酰亚胺层和金属迹线层可被重复若干次作为多层电路。
11.聚酰亚胺层可用作电介质材料并且作为电容器而引入。
12.纳米铜墨可在顶层导体处用作为二维和三维芯片封装应用中的触点金属。

Claims (25)

1.一种用于在基板上沉积导线的方法,包括:
在所述基板上以图案沉积金属层;
在图案化金属层和所述基板上涂敷具有低热导率的材料层;
在具有所述低热导率的材料层上沉积导电墨膜;以及
烧结所述导电墨膜。
2.如权利要求1所述的方法,其特征在于,还包括:
穿过具有所述低热导率的材料层形成通孔,由此露出所述图案化金属层的一部分,其中沉积所述导电墨膜包括将所述导电墨膜沉积到所述通孔中以由此用所述导电墨膜来涂敷所述图案化金属层的部分,其中涂敷所述图案化金属层的部分的导电墨膜还被烧结。
3.如权利要求2所述的方法,其特征在于,涂敷在所述图案化金属层的部分上的导电墨膜从烧结耗散的能量不如涂敷在具有所述低热导率的材料层上的导电墨膜多。
4.如权利要求3所述的方法,其特征在于,具有所述低热导率的材料层包括聚合物。
5.如权利要求3所述的方法,其特征在于,具有所述低热导率的材料层包括聚酰亚胺。
6.如权利要求5所述的方法,其特征在于,所述聚酰亚胺的厚度为至少50微米。
7.如权利要求5所述的方法,其特征在于,所述烧结用光烧结装置来执行。
8.如权利要求5所述的方法,其特征在于,所述烧结用激光烧结装置来执行。
9.如权利要求8所述的方法,其特征在于,所述激光烧结装置包括波长为830nm和功率为800mW的固态二极管。
10.如权利要求9所述的方法,其特征在于,所述固态二极管的聚焦光束尺寸是直径为15微米。
11.如权利要求5所述的方法,其特征在于,所述聚酰亚胺的厚度为至少5微米。
12.如权利要求5所述的方法,其特征在于,所述聚酰亚胺的厚度为至少2.3微米。
13.如权利要求5所述的方法,其特征在于,所述基板包括硅。
14.如权利要求5所述的方法,其特征在于,所述基板包括陶瓷。
15.如权利要求1所述的方法,其特征在于,所述基板的热导率大于具有所述低热导率的材料层的热导率。
16.如权利要求5所述的方法,其特征在于,所述导电墨膜包括铜纳米颗粒。
17.一种电子电路,包括:
基板;
沉积在所述基板上的金属迹线图案;
涂敷在所述基板和金属迹线图案上的低热导率材料层,所述金属迹线图案沉积在所述基板上,其中穿过所述低热导率材料层在所述金属迹线图案的部分上形成通孔;以及
涂敷在所述低热导率材料层上的经烧结导电墨膜,所述低热导率材料层涂敷在所述基板上,其中在所述金属迹线图案的部分上、在穿过所述低热导率材料层形成的通孔内涂敷所述经烧结导电墨膜。
18.如权利要求17所述的电子电路,其特征在于,所述基板的热导率大于具有所述低热导率的材料层的热导率。
19.如权利要求18所述的电子电路,其特征在于,所述低热导率材料层包括聚酰亚胺。
20.如权利要求19所述的电子电路,其特征在于,所述聚酰亚胺的厚度为至少50微米。
21.如权利要求19所述的电子电路,其特征在于,所述经烧结导电墨包括用光烧结装置来烧结的经烧结铜纳米颗粒。
22.如权利要求19所述的电子电路,其特征在于,所述经烧结导电墨包括用激光烧结装置来烧结的经烧结铜纳米颗粒。
23.如权利要求19所述的电子电路,其特征在于,所述聚酰亚胺的厚度为至少5微米。
24.如权利要求19所述的电子电路,其特征在于,所述聚酰亚胺的厚度为至少2.3微米。
25.如权利要求19所述的电子电路,其特征在于,所述基板包括硅。
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US8647979B2 (en) 2014-02-11
WO2010111581A1 (en) 2010-09-30
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JP2012522383A (ja) 2012-09-20
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