JP2011071486A - ダイシングシート付き接着フィルム及びその製造方法 - Google Patents
ダイシングシート付き接着フィルム及びその製造方法 Download PDFInfo
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- JP2011071486A JP2011071486A JP2010159905A JP2010159905A JP2011071486A JP 2011071486 A JP2011071486 A JP 2011071486A JP 2010159905 A JP2010159905 A JP 2010159905A JP 2010159905 A JP2010159905 A JP 2010159905A JP 2011071486 A JP2011071486 A JP 2011071486A
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Abstract
【解決手段】 本発明のダイシングシート付き接着フィルムは、基材上に粘着剤層及び接着剤層が順次積層されたダイシングシート付き接着フィルムであって、前記粘着剤層において、前記接着剤層に対する貼り合わせ面の少なくとも一部領域が、Si−Kα線強度で0.01〜100kcpsである。
【選択図】 図1
Description
即ち、本発明のダイシングシート付き接着フィルムによれば、基材上に粘着剤層及び接着剤層が順次積層された構造を有しており、当該粘着剤層の接着剤層との貼り合わせ面に於ける少なくとも一部の領域には、表面改質が施されている。表面改質は、Si−Kα線強度に於いて0.01〜100kcpsとなる様に処理されたものであるので、これにより粘着剤層と接着剤層の間に於ける接着性と剥離性のバランスを良好なものにできる。その結果、例えば、半導体ウェハをダイシングする際の半導体チップのチップ飛びやチッピングの発生を防止すると共に、当該半導体チップをピックアップする際にも糊残りやピックアップ不良の発生を同時に防止することができ、製造上のスループットの向上が図れる。
本実施の形態に係るダイシングシート付き接着フィルムについて、以下に説明する。
前記基材1はダイシングシート付き接着フィルム10、12の強度母体となるものである。例えば、低密度ポリエチレン、直鎖状ポリエチレン、中密度ポリエチレン、高密度ポリエチレン、超低密度ポリエチレン、ランダム共重合ポリプロピレン、ブロック共重合ポリプロピレン、ホモポリプロレン、ポリブテン、ポリメチルペンテン等のポリオレフィン、エチレン−酢酸ビニル共重合体、アイオノマー樹脂、エチレン−(メタ)アクリル酸共重合体、エチレン−(メタ)アクリル酸エステル(ランダム、交互)共重合体、エチレン−ブテン共重合体、エチレン−ヘキセン共重合体、ポリウレタン、ポリエチレンテレフタレート、ポリエチレンナフタレート等のポリエステル、ポリカーボネート、ポリイミド、ポリエーテルエーテルケトン、ポリイミド、ポリエーテルイミド、ポリアミド、全芳香族ポリアミド、ポリフェニルスルフィド、アラミド(紙)、ガラス、ガラスクロス、フッ素樹脂、ポリ塩化ビニル、ポリ塩化ビニリデン、セルロース系樹脂、シリコーン樹脂、金属(箔)、紙等が挙げられる。尚、粘着剤層2が紫外線硬化型である場合、基材1は紫外線透過性を有するものを採用するのが好ましい。
本実施の形態に係るダイシングシート付き接着フィルムの製造方法は、基材1上に粘着剤層2を形成する工程と、粘着剤層2の表面を表面改質する工程と、表面改質後の粘着剤層2上に接着剤層3を形成する工程とを有する。
本発明のダイシングシート付き接着フィルム10、12は、接着剤層3、3’上に任意に設けられたセパレータを適宜に剥離して、次の様に使用される。以下では、図3を参照しながらダイシングシート付き接着フィルム10を用いた場合を例にして説明する。
次に、本発明の他の形態に係る半導体装置の製造方法について、以下に説明する。
先ず、ダイシングシート付き接着フィルムの接着フィルム上に任意に設けられたセパレータを適宜に剥離し、当該接着フィルム上に半導体ウエハを貼着して、これを接着保持させ固定する(マウント工程)。このとき前記接着フィルムは未硬化状態(半硬化状態を含む)にある。また、ダイシングシート付き接着フィルムは、半導体ウエハの裏面に貼着される。半導体ウエハの裏面とは、回路面とは反対側の面(非回路面、非電極形成面などとも称される)を意味する。貼着方法は特に限定されないが、圧着による方法が好ましい。圧着は、通常、圧着ロール等の押圧手段により押圧しながら行われる。
次に、半導体ウエハのダイシングを行う。これにより、半導体ウエハを所定のサイズに切断して個片化(小片化)し、半導体チップを製造する。ダイシングは、例えば、半導体ウエハの回路面側から常法に従い行われる。また、本工程では、例えば、ダイシングシート付き接着フィルムまで切込みを行うフルカットと呼ばれる切断方式等を採用できる。本工程で用いるダイシング装置としては特に限定されず、従来公知のものを用いることができる。また、半導体ウエハは、接着フィルムを有するダイシングシート付き接着フィルムにより優れた密着性で接着固定されているので、チップ欠けやチップ飛びを抑制できると共に、半導体ウエハの破損も抑制できる。なお、接着フィルムがエポキシ樹脂を含む樹脂組成物により形成されていると、ダイシングにより切断されても、その切断面において接着フィルムの接着剤層の糊はみ出しが生じるのを抑制又は防止することができる。その結果、切断面同士が再付着(ブロッキング)することを抑制又は防止することができ、後述のピックアップを一層良好に行うことができる。
ダイシングシート付き接着フィルムに接着固定された半導体チップを回収する為に、半導体チップのピックアップを行って、半導体チップを接着フィルムとともにダイシングテープより剥離させる。ピックアップの方法としては特に限定されず、従来公知の種々の方法を採用できる。例えば、個々の半導体チップをダイシングシート付き接着フィルムの基材側からニードルによって突き上げ、突き上げられた半導体チップをピックアップ装置によってピックアップする方法等が挙げられる。なお、ピックアップされた半導体チップは、その裏面が接着フィルムにより保護されている。
ピックアップした半導体チップは、基板等の被着体に、フリップチップボンディング方式(フリップチップ実装方式)により固定させる。具体的には、半導体チップを、半導体チップの回路面(表面、回路パターン形成面、電極形成面などとも称される)が被着体と対向する形態で、被着体に常法に従い固定させる。例えば、半導体チップの回路面側に形成されているバンプを、被着体の接続パッドに被着された接合用の導電材(半田など)に接触させて押圧しながら導電材を溶融させることにより、半導体チップと被着体との電気的導通を確保し、半導体チップを被着体に固定させることができる(フリップチップボンディング工程)。このとき、半導体チップと被着体との間には空隙が形成されており、その空隙間距離は、一般的に30μm〜300μm程度である。尚、半導体チップを被着体上にフリップチップボンディング(フリップチップ接続)した後は、半導体チップと被着体との対向面や間隙を洗浄し、該間隙に封止材(封止樹脂など)を充填させて封止することが重要である。
<粘着剤層の形成>
冷却管、窒素導入管、温度計および撹拌装置を備えた反応容器に、アクリル酸2−エチルヘキシル(以下、「2EHA」という。)95部、アクリル酸−2−ヒドロキシエチル(以下、「HEA」という。)5部、及びトルエン65部を入れ、窒素気流中で61℃にて6時間重合処理をし、アクリル系ポリマーAを得た。
エポキシ樹脂(日本化薬(株)製、商品名;EPPN501HY)50部、フェノール樹脂(明和化成(株)製、商品名;MEH7851)50部、アクリル共重合体(ノガワケミカル(株)製、商品名;レビタルAR31)100部、及びフィラーとしての球状シリカ(アドマテックス(株)製、商品名;S0−25R、平均粒径0.5μm)70部をメチルエチルケトンに溶解させ、濃度23.6重量%の接着剤組成物溶液を得た。
本実施例に於いては、粘着剤層表面を表面改質する際のシリコーンスプレーによる散布量をSi−Kα線強度で100kcpsとなる様に行ったこと以外は、前記実施例1と同様にして、本実施例に係るダイシングシート付き接着フィルムを作製した。
本実施例に於いては、粘着剤層表面を表面改質する際、シリコーン樹脂塗布フィルム(三菱樹脂(株)製、商品名;ダイヤホイル MRA38)を用いて、粘着剤層表面にシリコーン樹脂を転写させた(粘着剤層表面のSi-Kα線強度:0.9kcps)こと以外は、前記実施例1と同様にして、本実施例の係るダイシングシート付き接着フィルムを作製した。
本実施例に於いては、粘着剤層表面を表面改質する際、シリコーン樹脂塗布フィルム(三菱樹脂(株)製、商品名;ダイヤホイル MRF38)を用いて、粘着剤層表面にシリコーン樹脂を転写させた(粘着剤層表面のSi-Kα線強度:1.2kcps)こと以外は、前記実施例1と同様にして、本実施例の係るダイシングシート付き接着フィルムを作製した。
本実施例に於いては、粘着剤層表面を表面改質する際、粘着剤層表面にシリコーンディパージョン(東レダウコーニング(株)製、商品名;SD7226)を塗工し、70℃で5分間乾燥させて、粘着剤層を表面改質させた(粘着剤層表面のSi-Kα線強度:85kcps)こと以外は、前記実施例1と同様にして、本実施例の係るダイシングシート付き接着フィルムを作製した。
本比較例に於いては、粘着剤層表面を表面改質する際のシリコーンスプレーによる散布量をSi−Kα線強度で0.001kcpsとなる様に行ったこと以外は、前記実施例1と同様にして、本比較例に係るダイシングシート付き接着フィルムを作製した。
本比較例に於いては、粘着剤層表面を表面改質する際のシリコーンスプレーによる散布量をSi−Kα線強度で0.005kcpsとなる様に行ったこと以外は、前記実施例1と同様にして、本比較例に係るダイシングシート付き接着フィルムを作製した。
本比較例に於いては、粘着剤層表面を表面改質する際のシリコーンスプレーによる散布量をSi−Kα線強度で200kcpsとなる様に行ったこと以外は、前記実施例1と同様にして、本比較例に係るダイシングシート付き接着フィルムを作製した。
本比較例に於いては、粘着剤層表面を表面改質する際のシリコーンスプレーによる散布量をSi−Kα線強度で500kcpsとなる様に行ったこと以外は、前記実施例1と同様にして、本比較例に係るダイシングシート付き接着フィルムを作製した。
実施例及び比較例で得られたダイシングシート付き接着フィルムを、20mmテープ幅で短冊状に切断し、接着剤層にテープ(商品名:BT−315(日東電工(株)製、20mm幅))を貼り合わせた。その後、温度25℃、相対湿度55%Rhの環境下で3分間静置した。
各実施例及び比較例のそれぞれダイシングシート付き接着フィルムを用いて、以下の要領で、実際に半導体ウェハのダイシングを行い、各ダイシングシート付き接着フィルムの性能を評価した。
研削装置:ディスコ社製 DFG−8560
半導体ウェハ:8インチ径(厚さ0.6mmから0.025mmに裏面研削)
貼り付け装置:日東精機製、MA−3000II
貼り付け速度計:10mm/min
貼り付け圧力:0.15MPa
貼り付け時のステージ温度:40℃
ダイシング装置:ディスコ社製、DFD−6361
ダイシングリング:2−8−1(ディスコ社製)
ダイシング速度:30mm/sec
ダイシングブレード:ディスコ社製NBC−ZH226J27HAAA
ダイシングブレード回転数:40,000rpm
ブレード高さ:0.085mm
カット方式:シングルステップカット
ウェハチップサイズ:10.0mm角
各実施例及び比較例のそれぞれダイシングシート付き接着フィルムを用いて、以下の要領で、実際に半導体ウェハのダイシングを行った後にピックアップを行い、各ダイシングシート付き接着フィルムの性能を評価した。
研削装置:ディスコ社製 DFG−8560
半導体ウェハ:8インチ径(厚さ0.6mmから0.025mmに裏面研削)
貼り付け装置:日東精機製、MA−3000II
貼り付け速度計:10mm/min
貼り付け圧力:0.15MPa
貼り付け時のステージ温度:40℃
ダイシング装置:ディスコ社製、DFD−6361
ダイシングリング:2−8−1(ディスコ社製)
ダイシング速度:30mm/sec
ダイシングブレード:ディスコ社製NBC−ZH226J27HAAA
ダイシングブレード回転数:30,000rpm
ブレード高さ:0.085mm
カット方式:シングルステップカット
ウェハチップサイズ:10.0mm角
ダイボンダー:新川(株)製、装置名:SPA−300
内リングに対する外リングの引落し量:3mm
ダイボンド装置:新川(株)製
ニードル本数:9本
ニードル突き上げ量:300μm
ニードル突き上げ速度:5mm/秒
コレット保持時間:1秒
下記表1から明らかな通り、比較例1及び2では、粘着剤層の接着剤層に対する接着性が良好であったことから、半導体ウェハのダイシングの際のチップ飛びが防止できている。しかしながら、粘着剤層の粘着力が強すぎた結果、半導体チップのピックアップの際にピックアップ不良が発生した。また、比較例3及び4では、粘着剤層の接着剤層に対する剥離性が良好であったことから、半導体チップのピックアップの際に全ての半導体チップが良好にピックアップすることができた。しかしながら、粘着剤層の粘着力が弱すぎた結果、半導体ウェハのダイシングの際にチップ飛びが発生した。これに対し、実施例1及び2においては、粘着剤層の接着剤層との貼り合わせ面における接着性及び剥離性のバランスが良好な状態にあるため、ダイシングの際のチップ飛びを防止すると共に、ピックアップ性も良好であった。
2 粘着剤層
3、13、21 接着剤層
4 半導体ウェハ
5、15 半導体チップ
6 被着体
7 ボンディングワイヤー
8 封止樹脂
9 スペーサ
10、11 ダイシングシート付き接着フィルム
Claims (8)
- 基材上に粘着剤層及び接着剤層が順次積層されたダイシングシート付き接着フィルムであって、
前記粘着剤層において、前記接着剤層に対する貼り合わせ面の少なくとも一部領域が、Si−Kα線強度で0.01〜100kcpsであるダイシングシート付き接着フィルム。 - 前記領域の引き剥がし粘着力は、温度25℃、相対湿度55%、引張速度300mm/min、剥離角度180°で引き剥がしを行ったときに、前記接着剤層に対し、0.01〜0.2N/20mmである請求項1に記載のダイシングシート付き接着フィルム。
- 前記領域が、前記接着剤層のワーク貼り合わせ領域に対応するものである請求項1又は2に記載のダイシングシート付き接着フィルム。
- 基材上に粘着剤層及び接着剤層が順次積層されたダイシングシート付き接着フィルムの製造方法であって、
前記基材上に粘着剤層を形成する工程と、
前記粘着剤層の表面の少なくとも一部領域を、Si−Kα線強度0.01〜100kcpsとなるように表面改質する工程と、
前記粘着剤層に於ける表面改質がなされた表面上に、前記接着剤層を形成する工程とを有するダイシングシート付き接着フィルムの製造方法。 - 前記粘着剤層の前記貼り合わせ面に於ける表面改質は、少なくともシリコーン樹脂を含む溶液を霧状に散布させて行う請求項4に記載のダイシングシート付き接着フィルムの製造方法。
- 前記粘着剤層の前記貼り合わせ面に於ける表面改質は、別フィルム上にシリコーン樹脂を塗布したものを転写させて行う請求項4に記載のダイシングシート付き接着フィルムの製造方法。
- 前記粘着剤層の前記貼り合わせ面に於ける表面改質は、粘着剤層表面にシリコーンディスパージョンを塗布・乾燥させて行う請求項4に記載のダイシングシート付き接着フィルムの製造方法。
- 請求項1〜3の何れか1項に記載のダイシングシート付き接着フィルムにより製造された半導体装置。
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