JP2009531869A - はんだ付け可能なループ接触部を有する半導体デバイス - Google Patents
はんだ付け可能なループ接触部を有する半導体デバイス Download PDFInfo
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- JP2009531869A JP2009531869A JP2009503217A JP2009503217A JP2009531869A JP 2009531869 A JP2009531869 A JP 2009531869A JP 2009503217 A JP2009503217 A JP 2009503217A JP 2009503217 A JP2009503217 A JP 2009503217A JP 2009531869 A JP2009531869 A JP 2009531869A
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Abstract
半導体ダイに信頼性のあるはんだ接触部を容易に製造する方法では、当該はんだ接触部は、金属ワイヤ又はリボン状部材から形成されたループの形状に形成され、当該金属ワイヤ又はリボン状部材は別のはんだ付け可能な金属により被覆されていてもよい。ループ部は半導体ダイに、複数のループ、単一のループ、又は複数のループ及び単一のループで形成され得る。ループ接触部は、著音波熱圧着方式ボンディング又は超音波ボンディングを用いてダイに形成されてもよい。ダイは封止材料によりパッケージ化されてもよく、デバイスのためのはんだ準備接触部として封止材料を経て露出したダイを残している。
Description
本発明は半導体デバイスに関し、特に、はんだ付け可能な表面としてループ接触部を有する半導体デバイスに関し、半導体ダイにはんだ付け可能な接触部を形成する安価且つより効率的な方法を提供する。
本発明のデバイスは、より効率的に且つ安価にはんだ付け可能な接触部を形成する方法により形成された半導体デバイスである。当該デバイスは、単純な構造の故に短い製造時間だけを必要とする。
半導体ダイに形成されたバンプ、はんだバンプ、又はスタッドバンプのようなはんだ付け可能な接触部を有する半導体デバイスが当該技術分野において周知である。バンプを有するデバイス(当該バンプは当該デバイスに形成されている)は本発明のデバイスを製造する方法と比較すると、余分な処置・プロセスを必要とする。ダイにバンプを有するデバイスは、ダイにバンプを形成するため、フラックスを封止する(flux encapsulating)ため、はんだバンプを形成するため、及び最後にリフロプロセスのために銅ワイヤを必要とする。
上記の従来のデバイスに付随した問題は製造プロセスが細かく分けられていることである。また、バンプは、ボードの取付の後に、ひび割れを起こしやすいので、はんだ接触部は信頼性がない。
より効率的且つより複雑でない半導体デバイスを製造する方法が望まれている。
半導体デバイスをボード取付部にはんだ付けするため又は取り付けるための信頼性のある接触部を設けることが望まれている。
本発明の実施例においては、半導体デバイスは、半導体ダイと、ダイのドレイン領域に取り付けられるダイ取付パッドと、ダイのソース領域及びゲート領域に取り付けられるはんだ付け可能なループ接触部とを含んでいる。ループ接触部は、はんだ付け可能な金属ワイヤ又はリボン状部材(リボン)から形成され、当該はんだ付け可能な金属ワイヤ又はリボン状部材は、別のはんだ付け可能な金属により被覆されていてもよい。ループ接触部をダイにボンディングする方法は超音波熱圧着方式ボンディングか超音波方式ボンディングである。
より詳しくは、本発明は、第1実施例において、ループ接触部を有する半導体デバイスを含み、当該ループ接触部は、単一の接触部、複数の接触部、又は単一の接触部及び複数の接触部の両方に超音波熱圧着方式で接合されている。ループ接触部は、金又は銅のようなはんだ付け可能な金属ワイヤから形成され、さらに、当該ワイヤは、銅、ニッケル、パラジウム、又はプラチナにより被覆されていてもよい。当該デバイスは封止材料によりパッケージ化されてもよく、はんだを用いてアプリケーションボードに取り付けられてもよい。
第2実施例において、ボンディング部分(箇所)はダイに形成されたスタッドバンプである。ダイへボンディングすることとは異なり、ループ接触部をスタッドバンプにボンディングすることは、超音波熱圧着方式ボンディングプロセスのために必要とされる熱による半導体ダイへの損傷を直接防止する。ループ接触部が形成されると、上記デバイスは封止材料を用いて封止され、ループ接触部を当該封止材料を経て露出させたままである。金属ワイヤは銅又は金であり、さらに、当該金属ワイヤは、銅、ニッケル、パラジウム、又はプラチナにより被覆されていてもよい。
第3実施例において、上記デバイスは金属ワイヤ又は金属リボン状部材から形成されたループ接触部を有している。ワイヤ又はリボン状部材は、銅、アルミニウム、又は金のようなはんだ付け可能な金属から形成され、当該ワイヤ又はリボン状部材は、銅、ニッケル、パラジウム、及びプラチナにより被覆されていてもよい。ワイヤ又はリボン状部材は超音波方式ボンディング技法により、ダイに直接接合される。また、ダイは封止材料を用いてパッケージ化されてもよい。
本発明の利点はデバイスを効率的な製造プロセスにより形成できることである。これは、フォトレジスト分配ステップ、現像ステップ、金属メッキステップ、バンプを形成するステップ、及びリフロステップを必要とすることを解消する。ダイがダイ取付パッドに取り付けられた後、ワイヤ又はリボン状部材は中間ステップを必要とせずにダイに直接接合される。以下において詳しく説明するように、超音波熱圧着方式ボンディングプロセスはボンディングツールにワイヤの挿入を必要とし、当該ワイヤは加熱され、その後ダイに取り付けられる。その後、別の接合部が、ボンディングツール内のワイヤをダイに取り付け、ダイすなわち接合面にウェッジ接合部を形成することにより形成されることができる。スタッドバンプ又ははんだバンプを形成する製造プロセスにおけるリフロプロセスのようなループ接触部製造プロセスに少なくとも関係するような更なるステップは必要とされない。
本発明の別の利点は、ループ接触部が耐久性があり且つ信頼性のあるはんだ接触部であることである。スタッドボール又はバンプを有するデバイスのような従来のデバイスはひび割れを起こしやすい。本発明のループ接触部は堅い(中実)金属ワイヤ又はリボン状部材から形成される。これら堅い金属ワイヤ又はリボン状部材は、はんだバンプ又はスタッドバンプよりも強度があり、ループ接触部は、スタッドバンプを有するデバイスと同じようにボードを取り付けた後に容易にはひびが入らない。
一致する参照符号は、幾つかの図面において一致する部分を示す。本明細書において示した例は本発明の一部の実施例であり、いかなるようにも本発明の範囲を限定するとして解釈されるべきではない。
図1は、半導体デバイス100の本発明の第1実施例を示している。当該デバイスは、はんだ付け可能な材料から形成されたループ接触部104、108、109を有するパッケージ化された半導体100であり、当該ループ接触部は半導体ダイ102に接合されている。半導体ダイ102は、ゲート領域、ソース領域、及びドレイン領域を有するフリップチップである。ソース領域及びゲート領域は半導体ダイ102の上面にあり、ドレイン領域は半導体ダイ102の底面にある。ドレイン領域はダイ取付パッド101に取り付けられ、ダイ取付パッドとドレイン接触部を形成する。半導体ダイ102のソース領域及びゲート領域はループ接触部104、108、109を有している。デバイス100はマルチループの接触部104と単一のループ端子接触部108、109とを示している。ループ接触部は、さらに以下において説明される超音波熱圧着方式ボールボンディング方法を用いて半導体ダイ102に接合される。
図1及び図1aを参照すると、デバイス100はワイヤから形成される複数のループ端子接触部を有していてもよく、単一の線のワイヤが、はんだ面を形成するために半導体ダイ102に複数のループ部を形成するのに使用される。この実施例においては、ワイヤはマルチループの接触部104と単一ループの接触部108、109とを形成するのに使用される。
超音波熱圧着方式ボンディングプロセスは、接合部分において球状部を形成し、ボール接合部106を形成する。通常、ループ接触部に使用されるワイヤは中空のキャピラリに通される。電子フレームオフシステム(electronic-flame-off system)は、ワイヤが通るキャピラリの下においてワイヤを溶かす。上述したように、このワイヤは球状に固められ、ボール接合部を形成する。キャピラリの下において溶かされたワイヤは接合部が形成される材料に十分な力でプレスされ、塑性変形及び原子相互拡散を可能にする。超音波熱圧着方式ボールボンディングプロセスは100℃から280℃の間の温度範囲を使用し、熱は、ワイヤが接合されるべきデバイスが取り付けられる台座に与えられる。銅ワイヤを使用するときには、銅が酸化し易いので、ボンディングプロセスは、不活性の雰囲気において行われ、酸化を防止しなければならない。
第1接合部が形成された後、キャピラリは、ワイヤが第2接合部分(箇所)にプレスされ、超音波エネルギを加えると共に加熱されるまで開放されて持ち上げられ、塑性変形及び原子相互拡散を引き起こす。第2接合部は、ワイヤが送られるキャピラリデバイスの形状の故に、くさび(ウェッジ)形状である。このプロセスは必要な数のループ接触部を形成する前に行われてもよい。最後のループ接触部において、ワイヤクランプは閉ざされ、キャピラリは最後のウェッジ接合部の真上でワイヤを切断する。
図1及び図1aを参照すると、半導体デバイス100は3つのループ接触部104を有し、当該3つのループ接触部104は、ボール接合部106と2つのウェッジ接合部107とを有し、当該2つのウェッジ接合部107は3つのループ接触部104同士の間にある。これらマルチループの接触部104は半導体ダイ102のソース領域に形成され、ソース接触部を形成する。アプリケーションボード114が、はんだ110によりループ接触部104、108、109に取り付けられ、半導体ダイ102は、ダイ取付材料111によりダイ取付パッドにダイボンディングされる。さらに、この第1実施例は、アプリケーションボード114を取り付ける前に、封止材料112によりデバイスを封止することによりパッケージ化されてもよい。
図1及び図1bによれば、図1bは図1のデバイス100の単一ループの接触部108、109の断面図を示している。単一ループの接触部108は半導体ダイ102のソース領域に形成され、ソースループ接触部108となる。図1及び図1bの中央の単一ループの接触部109はダイ102のゲート領域に形成されたゲートループ接触部109である。
ループ接触部104、108、109は、金ワイヤ、銅ワイヤ、又は別の適切な材料のワイヤから形成されてもよい。さらに、当該ワイヤは、ニッケル、パラジウム、銅、プラチナ、又は別のはんだ付け可能な金属により被覆されていてもよい。
図2及び図2aに示した第2実施例を参照すると、図2の半導体デバイス200は、半導体ダイ202のスタッドバンプ214、215に形成されたはんだ付け可能なループ接触部204、208、209を有している。半導体ダイ202は、ダイ202の底面にドレイン領域を有し、上面にソース領域及びゲート領域を有している。図2aを参照すると、半導体ダイ202のドレイン領域はダイ取付パッド201に取り付けられ、ループ接触部204、208がスタッドバンプ214、215に設けられている。ループ接触部204、208、209は、上述したようなプロセスと同様の超音波熱圧着方式ボンディングにより形成される。なお、半導体ダイ202はスタッドバンプ214、215を有している。スタッドバンプは、ボンディングプロセスの間に、半導体ダイ202を保護するのに使用される。上述したように、超音波熱圧着方式ボディングプロセスは、ワイヤ及び当該ワイヤが接合される材料の塑性変形及び原子的な金属間結合(atomic intermetallization)を引き起こすのに熱を必要とする。半導体ダイに熱を直接加えることはダイに損傷を与えるかもしれない。よって、ワイヤをダイ202のスタッドバンプ214、215に接合することは、ダイ202への損傷を防止することができるか、最小化することができる。
図2は、超音波熱圧着方式ボールボンディング技法を用いてワイヤを接合し、ループ接触部204、208,209を形成することにより、マルチループの接触部204及び単一ループの接触部208、209を有する半導体デバイス200を示している。マルチループの接触部204及び単一ループの接触部208はダイ202のソースバンプ214に形成され、中央の単一ループの接触部209は半導体ダイ202のゲートバンプ215に形成される。ループ端子接触部204、208、209を形成するのに使用されるワイヤは、銅、金、又は別の適切な材料の金属ワイヤであってもよく、さらに、銅、ニッケル、パラジウム、又はプラチナのようなはんだ付け可能な金属により被覆されていてもよい。
図2aは、太線で示したソーススタッドバンプ214を有するマルチループの接触部204の断面図である。しかし、マルチループの接触部204は半導体ダイ202に1つの接合部206を直接取り付けられている。超音波熱圧着方式ボールボンディングプロセスにおいて説明したような最初のボール接合部206が半導体ダイ202に直接形成される。また、半導体デバイス202は、ループ接触部204、208、209を封止材料を経て露出させたままでパッケージ化されてもよい。露出したループ接触部204、208、209はゲート接続部及びソース接続部として使用される。
図3、図3a、及び図3bを参照すると、本発明の第3実施例は、リボン状部材(リボン)から形成されたループ接触部304、308、309を有する半導体デバイス300を示している。なお、ワイヤがリボン状部材の代わりに使用されてもよい。さらに、リボン状部材は、超音波方式ウェッジボンディング(ultrasonic wedge bonding)技法を用いて半導体ダイ302に直接接合される。半導体ダイ302はドレイン領域を一方の表面に有し、反対側の表面にソース領域及びゲート領域を有している(収容している)。ダイ302のドレイン領域は、はんだ310によりダイ取付パッド301に取り付けられる。デバイス300は、ダイ302に直接接合された単一ループの接触部308、309とマルチループの接触部304とを有している。
図3aは、図3におけるデバイス300のマルチループの接触部の断面図である。マルチループの接触部304は、超音波方式ボンディング方法を用いてダイ302に直接接合されている。超音波方式ボンディングは、所定の角度でリボン状部材又はワイヤをボンディングツールに送ることによりウェッジ接合部306を形成する。ワイヤは半導体ダイ302に保持され、超音波エネルギが、ワイヤとダイ302との間に接合部306を形成するために加えられる。このプロセスは、超音波熱圧着方式ボールボンディングプロセスに用いられる高い温度を必要としない。すなわち超音波方式ボンディングは約25℃を必要とする。当該プロセスは、所望の数のループ接触部を形成するために繰り返される。ワイヤは、ボンディングツールと共に取り付けられたワイヤカッタにより切断されるか、クランプにより切断される。クランプにより切断される場合には、クランプを所定の位置に維持し、ボンディングツールを上昇させ、ボンディングツールが上昇される間に、ワイヤを引きちぎることにより、ワイヤが切断される。
図3aは、半導体ダイ302に接合されたマルチループの接触部304を示し、デバイス300はループ接触部304を封止材料312から露出させたまま封止されている。
図3bは、ソース領域及びゲート領域において半導体ダイ302に接合されて、単一のソースループ接触部308及び単一のゲートループ接触部309を形成する単一ループの接触部308、309の断面図である。また、デバイス300は、別の表面にはんだ付けするために、露出したループ接触部308、309の部分を残して半導体ダイ302を覆う封止材料312によりパッケージ化される。図3はリボン状部材ループ接触部304、308、309を示しているが、上述したように、ワイヤが、この実施例におけるリボン状部材の代わりに用いられてもよい。ワイヤ若しくはリボン状部材は、アルミニウム、銅、若しくは金のような適切なはんだ付け可能な金属であってもよく、さらに銅、ニッケル、パラジウム、若しくはプラチナにより被覆されていてもよい。
上記デバイスを製造する方法は、バンプ若しくはボール部を有する従来の半導体デバイス、又ははんだ付け可能な金属被覆部を有する半導体デバイスに優る顕著な利点を生ずる。第1実施例によれば、当該製造方法は半導体ダイのドレイン領域をダイ取付パッドに取り付けるステップを必要とする。その後、ワイヤが、上述したような超音波熱圧着方式ボールボンディング技法を用いて、半導体ダイのソース領域に接合される。ワイヤボンディングプロセスが、ダイに単一ループの接触部又はマルチループの接触部を形成するのに使用され得る。第1実施例に示したように、半導体ダイには単一ループの接触部及びマルチループの接触部が存在する。ループ端子接触部のための材料は、はんだ付け可能な金属であってもよく、当該はんだ付け可能な金属は別のはんだ付け可能な金属により被覆されていてもよい。例えば、ワイヤは銅又は金であってもよく、銅、ニッケル、パラジウム、又はプラチナにより被覆されていてもよい。ループ接触部がダイに接合された後、ダイは、封止材料により覆われてもよく、ループ接触部を封止材料を経て露出した状態で残すように覆われている。その後、ループ接触部ははんだによりアプリケーションボードに取り付けられる。
第2実施例のデバイスを製造する方法は、スタッドバンプ若しくはボール部を有する半導体ダイを使用する必要があり、当該スタッドバンプ若しくはボール部には、最初のボール接合部が半導体ダイに形成された後に、ステッチ接合部若しくはウェッジ接合部が形成される。ダイのドレイン領域はダイ取付パッドに取り付けられる。その後、超音波熱圧着方式ボンディング技法を使用することにより、ワイヤは半導体ダイにボール形状で接合され、別の接合部が半導体ダイのスタッドバンプ上に形成される。また、この実施例において使用されるワイヤは銅又は金のようなはんだ付け可能な金属ワイヤであり、当該ワイヤは、銅、ニッケル、パラジウム、若しくはプラチナのようなはんだ付け可能な金属により被覆されていてもよい。その後、半導体デバイスは、適切な封止材料を用いて封止され、ループ接触部を当該材料を経て露出させるように封止されてもよい。
第3実施例によれば、半導体デバイスは、第1実施例のように、半導体ダイに接合されたはんだ付け可能なループ接触部を有している。しかし、ダイはダイ取付パッドにまず取り付けられる。その後、ループ接触部が超音波方式ボンディング技法を用いてダイに形成される。この実施例におけるループ接触部は、銅、金、又はアルミニウムのようなはんだ付け可能な金属から形成されたワイヤ又はリボン状部材により形成されてもよい。また、ワイヤ又はリボン状部材は、銅、ニッケル、パラジウム、又はプラチナのような別のはんだ付け可能な金属により被覆されていてもよい。リボン状部材又はワイヤは超音波エネルギを用いることによりダイに直接接合され、ウェッジ接合部を形成する。ループ接合部は、ダイに単一のループ、複数のループ、又は単一のループと複数のループとを組み合わせた形状で形成されてもよい。第3実施例は、ダイのソース領域にマルチループの接触部と単一ループの接触部とを有し、単一のゲートループ接触部を有している。当該デバイスは封止材料により、ループ接触部を当該封止材料を経て露出させるように封止されてもよい。
本発明はMOSFETデバイスの実施例と共に説明されたが、本発明は、ダイオード、IGBT、サイリスタ、及びバイポーラ接合トランジスタのような別の半導体ダイと共に使用されてもよいことは当業者により理解されるであろう。
本発明は好ましい実施例を参照して説明されたが、様々な変更・変形がなされてもよく、均等物が本発明の範囲から離れることなく特定の状況に合うように本発明の要素の代わりに用いられてもよいことが、当業者により理解されるであろう。よって、本発明は、本発明を実施するための最良の形態として説明した特定の実施例に限定されず、添付した特許請求の範囲の範囲及び精神内の全ての実施例を含むことを意図している。
Claims (24)
- 半導体デバイスであって、
a)1つ以上の端子を有する第1表面及び少なくとも1つの端子を有する第2表面を備えた半導体ダイと、
b)リード線を有するダイ取付パッドと、
c)少なくとも1つのはんだ付け可能なループ接触部と、
を含み、前記少なくとも1つのはんだ付け可能なループ接触部は前記半導体ダイの前記第1表面における前記端子の1つに接触されることを特徴とする半導体デバイス。 - 前記はんだ付け可能なループ接触部は金属ワイヤから形成されることを特徴とする請求項1に記載のデバイス。
- 前記ワイヤは、銅、アルミニウム、及び金からなる群から選択される金属であることを特徴とする請求項2に記載のデバイス。
- 前記ワイヤははんだ付け可能な材料により被覆されていることを特徴とする請求項3に記載のデバイス。
- 前記はんだ付け可能な材料は、銅、ニッケル、パラジウム、及びプラチナからなる群から選択される金属であることを特徴とする請求項4に記載のデバイス。
- 前記デバイスはアプリケーションボードをさらに含むことを特徴とする請求項5に記載のデバイス。
- 前記はんだ付け可能なループ接触部は超音波熱圧着方式ボールボンディングにより形成されることを特徴とする請求項3に記載のデバイス。
- 前記はんだ付け可能なループ接触部は超音波方式ウェッジボンディングにより形成されることを特徴とする請求項3に記載のデバイス。
- 前記はんだ付け可能なループ接触部は超音波熱圧着方式ボールボンディングにより形成されることを特徴とする請求項4に記載のデバイス。
- 前記はんだ付け可能なループ接触部は超音波方式ウェッジボンディングにより形成されることを特徴とする請求項4に記載のデバイス。
- 前記はんだ付け可能なループ接触部はリボン状部材から形成されることを特徴とする請求項1に記載のデバイス。
- 前記リボン状部材は、銅、アルミニウム、及び金からなる群から選択される金属であることを特徴とする請求項11に記載のデバイス。
- 前記リボン状部材ははんだ付け可能な材料により被覆されていることを特徴とする請求項12に記載のデバイス。
- 前記はんだ付け可能な材料は、銅、ニッケル、パラジウム、及びプラチナからなる群から選択される金属であることを特徴とする請求項13に記載のデバイス。
- 前記はんだ付け可能なループ接触部は超音波方式ボンディングにより形成されることを特徴とする請求項14に記載のデバイス。
- 前記デバイスは、パッケージ化材料をさらに含んでいることを特徴とする請求項1に記載のデバイス。
- 前記半導体ダイは、ダイオード、MOSFET、IGBT、サイリスタ、及びバイポーラ接合トランジスタからなる群の1つであることを特徴とする請求項1に記載のデバイス。
- ループ端子接触部を有する半導体デバイスを製造する方法であって、
a)半導体ダイ、リード線を有するダイ取付パッド、及びワイヤ若しくはリボン状部材の形態のはんだ付け可能なループ接触材料を設けるステップと、
b)前記ダイを前記ダイ取付パッドに取り付けるステップと、
c)前記ダイに前記ループ端子接触材料をループ状にボンディングするステップと、
を含むことを特徴とする方法。 - 前記ボンディングするステップは超音波熱圧着方式ボンディングであり、前記ループ接触部ははんだ付け可能なループ接触材料であり、前記はんだ付け可能なループ接触材料は、銅、金、及びアルミニウムの群から選択される金属ワイヤであることを特徴とする請求項18に記載の方法。
- 前記ワイヤは、銅、ニッケル、パラジウム、及びプラチナからなる群から選択されるはんだ付け可能な金属により被覆されていることを特徴とする請求項19に記載の方法。
- 前記超音波熱圧着方式ボンディングは、複数のステッチの形でボール部上の接合ステッチ(a bond stitch over ball under multi stitch)からなることを特徴とする請求項20に記載の方法。
- 前記ボンディングするステップは超音波方式ボンディングであり、前記ループ端子接触部は、アルミニウム、銅、及び金からなる群から選択される金属ワイヤ又は金属リボン状部材であることを特徴とする請求項18に記載の方法。
- 前記ワイヤ又はリボン状部材は、銅、ニッケル、パラジウム、及びプラチナからなる群から選択されるはんだ付け可能な金属により被覆されていることを特徴とする請求項22に記載の方法。
- 前記半導体ダイは、ダイオード、MOSFET、IGBT、サイリスタ、及びバイポーラ接合トランジスタからなる群の1つであることを特徴とする請求項18に記載のデバイス。
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US78613906P | 2006-03-27 | 2006-03-27 | |
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PCT/US2007/065025 WO2007112393A2 (en) | 2006-03-27 | 2007-03-27 | Semiconductor device with solderable loop contacts |
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