JP2012069734A - 半導体装置の製造方法 - Google Patents

半導体装置の製造方法 Download PDF

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Publication number
JP2012069734A
JP2012069734A JP2010213216A JP2010213216A JP2012069734A JP 2012069734 A JP2012069734 A JP 2012069734A JP 2010213216 A JP2010213216 A JP 2010213216A JP 2010213216 A JP2010213216 A JP 2010213216A JP 2012069734 A JP2012069734 A JP 2012069734A
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Prior art keywords
layer
semiconductor device
resin layer
manufacturing
support substrate
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JP2010213216A
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Inventor
Soichi Honma
荘一 本間
Taku Kamoto
拓 加本
Yusuke Takano
勇佑 高野
Masayuki Miura
正幸 三浦
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Toshiba Corp
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Toshiba Corp
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Priority to JP2010213216A priority Critical patent/JP2012069734A/ja
Priority to TW100131342A priority patent/TWI446465B/zh
Priority to US13/235,417 priority patent/US20120077313A1/en
Publication of JP2012069734A publication Critical patent/JP2012069734A/ja
Pending legal-status Critical Current

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Abstract

【課題】配線層の形成時や支持基板の剥離時に、配線層のずれや基板の割れといった不具合が発生しにくい半導体装置の製造方法を提供する。
【解決手段】半導体装置の製造方法は、光の透過が抑制された第1の樹脂層3を支持基板2上に形成し、第1の樹脂層上に熱可塑性樹脂からなる第2の樹脂層4を形成する。第2の樹脂層上に絶縁層5および配線層8を形成し、配線層上に第1の半導体チップ10を実装する。第1の樹脂層にレーザ光を照射して支持基板を剥離し、第2の樹脂層を除去することを特徴とする。
【選択図】図13

Description

本発明の実施形態は半導体装置の製造方法に関する。
半導体装置には、単一の基板の両面に複数の半導体チップが実装される、いわゆる両面実装型の半導体装置や、一方の面に半導体チップが実装され、他方の面に端子が形成された片面実装型の半導体装置がある。上記のような半導体装置において、薄膜基板を用いた半導体装置の製造では、所定の支持基板上に基板や配線層が設けられる。そして、支持基板上の基板の一方の面に半導体チップが実装され、その後、支持基板が基板から剥離される。
特開2000−323613号公報 特開平05−259639号公報 特開2004−200668号公報
このような半導体装置では、配線層の形成時や支持基板の剥離時に、配線層のずれや基板の割れといった不具合が発生しにくい製造方法が望まれている。
本発明の実施の形態は、配線層の形成時や支持基板の剥離時に、配線層のずれや基板の割れといった不具合が発生しにくい半導体装置の製造方法を提供することを目的とする。
実施の形態の半導体装置の製造方法は、光の透過が抑制された第1の樹脂層を支持基板上に形成し、第1の樹脂層上に熱可塑性樹脂からなる第2の樹脂層を形成する。第2の樹脂層上に絶縁層および配線層を形成し、配線層上に第1の半導体チップを実装する。第1の樹脂層にレーザ光を照射して支持基板を剥離し、第2の樹脂層を除去することを特徴とする。
第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明する図である。 第1の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明する図である。 第2の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明する図である。 第3の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。 複数個の半導体チップを積層させてモールド封止させる場合の途中工程を例示する図である。 再配線を行った面にさらに半導体チップをFC実装した半導体装置を例示する図である。
以下に添付図面を参照して、実施の形態にかかる半導体装置の製造方法を詳細に説明する。なお、この実施の形態により本発明が限定されるものではない。
(第1の実施の形態)
図1〜19は、第1の実施の形態にかかる半導体装置の製造方法を説明する図である。図20は、第1の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。なお、以下の説明において、有機絶縁層5のうち、支持基板2側の面を第二面5dとし、その裏側の面を第一面5cとする(図9などを参照)。
まず、支持基板2となる8インチガラスウエハの表面に、光の透過が抑制された光吸収層(第1の樹脂層)3を形成する(ステップS1、図1も参照)。光吸収層3は、光の透過を抑える透過阻害材を合成樹脂に混合したものが用いられる。透過阻害材は、例えばカーボンブラック、グラファイト粉末や鉄、酸化チタンなどの金属酸化物、あるいは染料や顔料である。光吸収層3は、後の工程において、レーザ光の照射によって分解される。
光吸収層3は、0.1μm以上であって5μm以下の厚さで形成されるのが好ましい。例えば、光吸収層3を1.5μmの厚さで形成する。光吸収層3の厚さが0.1μm未満の場合は、レーザ光の照射時に光吸収が効率的に行われず、光吸収層3がうまく分解されない場合がある。また、光吸収層3の厚さが5μmを超えると、一部の光吸収層3が分解されずに、残存してしまう場合がある。
次に、光吸収層3上に熱可塑性樹脂層(第2の樹脂層)4を形成する(ステップS2、図2も参照)。熱可塑性樹脂層4は、1μm以上であって50μm以下の厚さで形成される。例えば、熱可塑性樹脂層4は、15μmの厚さで形成される。熱可塑性樹脂層4の材料としては、ポリスチレン系、メタクリル樹脂系、ポリエチレン系、ポリプロピレン系、セルロース系、ポリアミド系、ポリフェニレンサルファイド(PPS)系、ポリエーテルエーテルケトン(PEEK)系、液晶ポリマー(LCP)系、ポリテトラフロロエチレン(PTFE)系、ポリエーテルイミド(PEI)系、ポリアリレート(PAR)系、ポリサルフォン(PSF)系、ポリエーテルサルフォン(PES)系、ポリアミドイミド(PAI)系などの合成樹脂を使用することができる。なお、光吸収層3として、熱可塑性材料に光の透過を抑える透過阻害材を混合したものを用いれば、光吸収層3上の熱可塑性樹脂層4を省略することも可能である。
熱可塑性樹脂層4の厚さが1μm未満では、光吸収層3にレーザ光が照射された際に、熱の影響でダメージを受ける可能性がある。また、熱可塑性樹脂層4の厚さが50μmを超えると、その上部に形成される有機絶縁層5の開口に歪みが発生する場合がある。
また、熱可塑性樹脂層4の材料としては、ガラス転移温度が150℃以上であって280℃以下のものを使用する。ガラス転移温度が150℃未満の場合は、高温時に軟化し有機絶縁層の開口がゆがむ問題が発生する。また、ガラス転移温度が280℃を超える合成樹脂については合成樹脂の作製そのものが難しくなる。
また、熱可塑性樹脂層4の材料としては、分解温度が200℃以上であって400℃以下のものを使用する。分解温度が200℃未満の場合は、有機絶縁層5のキュア工程において、高温に耐えきれず分解されてしまうおそれがある。また、分解温度が400℃を超える樹脂については合成樹脂の作製そのものが難しくなる。
また、熱可塑性樹脂層4の材料としては、25℃での弾性率が0.01GPa以上であって10GPa以下であるものを使用する。弾性率が0.01GPa未満の場合は、弾性率が低いため、有機絶縁層5の開口に歪みが発生したり、開口のテーパが広がったりしてしまう場合がある。また、弾性率が10GPaを超える合成樹脂については、合成樹脂にフィラーを入れる必要があり、開口を形成することが困難になる。
また、熱可塑性樹脂層4の熱膨張係数CTE1が有機絶縁層の熱膨張係数CTE2に対して「CTE2×0.7以上であってCTE2×1.3以下」とする。CTE2×0.7未満や、CTE×1.3を超える場合は有機絶縁層5を形成した場合、開口部分が歪む問題が発生しやすくなる。
また、熱可塑性樹脂層4の材料としては、有機絶縁層5に含まれる溶剤に耐性のあるものを選択して使用する必要がある。耐性の無い材料を使用した場合には、有機絶縁層5を形成したときに、有機絶縁層5に含まれる溶剤によって熱可塑性樹脂層4が溶解して有機絶縁層5に混合してしまい、後に残渣となって除去が難しくなる。
次に、熱可塑性樹脂層4の上に有機絶縁層(絶縁層)5としてポリイミドを3μmの厚さで形成する(ステップS3、図3も参照)。次に、露光現像によって、有機絶縁層5に開口5aを形成する(ステップS4、図4も参照)。開口5aは、第二面5dの接続パッドが形成される位置に対応させて形成される。開口5aは、例えば、20μmの径寸法、40μmのピッチで形成される。
次に、有機絶縁層5の表面、開口5aの形成の内側面、および開口5aの形成によって露出された熱可塑性樹脂層4の表面に、めっきのシード層としてTi膜・Cu膜6を形成する(ステップS5、図5も参照)。Ti膜・Cu膜6は、厚さが0.05μmのTi膜と、厚さが0.1μmのCu膜で構成される。
次に、Ti膜・Cu膜6の上にレジスト7を厚さが5μmとなるように塗布し、露光現像によって、第一の配線層(3μm幅)用の開口を形成する(ステップS6、図6も参照)。次に、シード層であるTi膜・Cu膜6を電極として、電解Cuめっきを行い3μmの第一の配線層8を形成する(ステップS7、図7も参照)。
次に、レジスト7を除去し、さらにシード層のCu膜・Ti膜6をエッチングする(ステップS8、図8も参照)。Cu膜・Ti膜6のうち、Cu膜のエッチングには硫酸と過酸化水素水を混合させたものを用い、Ti膜のエッチングにはアンモニア水と過酸化水素水を混合させたものを用いる。
次に、ポリイミドなどを塗布して有機絶縁層5を積層し、第1の半導体チップとして第一面5cに実装される半導体チップ10の金属バンプ10aに対応する箇所に、20μm径(40μmピッチ)で開口5bを形成する(ステップS9、図9も参照)。次に、有機絶縁層5の第一面5c上に、半導体チップ10をフリップチップ実装する(ステップS10、図10も参照)。
半導体チップ10の金属バンプ10aは、SnAgで構成される。なお、開口5bの形成によって露出された第一の配線層8に、Ni/Pd/Au膜を形成した後にSnAgバンプを形成してもよい。
また、金属バンプ10aとしては、SnAgバンプ以外にAu、Sn、Ag、Cu、Bi、In、Ge、Ni、Pd、Pt、Pbなどを使用してもよい。また、これらの金属の合金、混合物でもよい。金属バンプ10aのピッチは40μmピッチで20μm径のバンプである。FC実装は金属バンプ10a上にフラックスを塗布して配線パッド上にフリップチップボンダーで搭載し、リフロー炉に入れて接続を行い、その後、フラックスを洗浄液で除去する。またはフラックスを用いずにSnAgバンプの酸化膜を、プラズマを用いて除去し、フリップチップボンダーを用いてパルスヒートで接続を行ってもよい。有機絶縁層5の第一面5c上には、複数の半導体チップがフリップチップ実装される。
半導体チップ10をフリップチップ実装後、チップ下に樹脂を流し込んでアンダーフィル17を形成し(ステップS11、図11も参照)、さらに第一面5c上を熱硬化性樹脂13でモールド封止する(ステップS12、図12も参照)。
次に、支持基板2側から光吸収層3に向けてレーザ光を印加する(ステップS13、図13も参照)。レーザ光は支持基板2を透過して光吸収層3に到達する。光吸収層3は、光の透過が抑制されているので、印加されたレーザ光を吸収して温度が上昇する。これにより、光吸収層3が分解されるので、光吸収層3の部分で支持基板2を剥離する(ステップS14、図14も参照)。光吸収層3が分解されるので、支持基板2の剥離を円滑に行いやすくなり、有機絶縁層5に亀裂が入るなどの不具合の発生を抑えることができる。
印加するレーザ光としては、例えば、YAGレーザ、ルビーレーザ、エキシマレーザ、COレーザ、He−Neレーザ、Arイオンレーザ、半導体レーザなどを用いることができる。レーザ光の波長は、10.6μm、1064nmの赤外線や、694nm、633nm、532nm、514nm、488nmの可視光や、355nm、351nm、308nm、248nmなどの紫外線など、種々の波長を使用することが可能である。また、レーザは連続波、パルス波ともに使用することができる。
支持基板2を剥離した後に、光吸収層3、および熱可塑性樹脂層4をアセトンなどの溶剤で除去する(ステップS15、図15も参照)。ここで、熱可塑性樹脂層4は溶剤に溶解することが必要である。残渣が残っている場合はさらにプラズマを印加して除去してもよい。
光吸収層3、および熱可塑性樹脂層4を除去したあとに、有機絶縁層5の開口5aから露出しているTi膜・Cu膜6をエッチングにより除去する(ステップS16、図16も参照)。Cu膜のエッチングには硫酸と過酸化水素水を混合させたものを用い、Ti膜のエッチングにはアンモニア水と過酸化水素水を混合させたものを用いる。
裏面に接続パッドとなるCuが露出するので、そのCu面へ無電解めっきにより、Ni・Pd・Au膜14を形成する(ステップS17、図17も参照)。Ni・Pd・Au膜14は、Niを3μm、Pdを0.05μm、Auを0.5μmの厚さで形成することで構成される。
次に、有機絶縁層5の第一面5cと同様に、第2の半導体チップとしての半導体チップ10を第二面5d上にフリップチップ実装する(ステップS18、図18も参照)。以上の工程により、半導体装置の中間体15が製造される。その後、プリント基板16にマウントペーストを用いて中間体15を搭載し、Auワイヤー29を用いてプリント基板16上にワイヤーボンディングする。さらに樹脂モールドを行い、裏面にボールを搭載することで(ステップS19、図19も参照)、半導体装置が完成する。
上述の工程に従って、半導体装置を製造し、温度サイクル試験に供して、その信頼性を調べた。なお温度サイクル試験は−55℃(30min)〜25℃(5min)〜125℃(30min)を1サイクルとして行った。その結果3000サイクル後でも第一面5cおよび第二面のフリップチップ接続箇所には破断の発生はほとんど認められなかった。
なお、有機絶縁層5としては、ポリイミドの他にも、PBO(ポリベンゾオキサゾール)、フェノール系樹脂、アクリル系樹脂などを使用してもよい。第一の配線層8の材料にはCuを例示したが、Al、Ag、Auなども使用できる。また、ガラスを支持基板2として配線層を形成したが、シリコン、サファイヤなどを使用してもよい。すなわち、支持基板2には、レーザ光が透過する材料であれば種々のものを使用することができる。
また、本実施の形態では、第一の配線層8のみの1層の構成を例示しているが、配線層を多層構成にしてもよい。配線層を多層構成にする場合には、ステップS8の工程を実施した後に、ステップS3〜ステップS8までの工程を繰り返して、第二の配線層、第三の配線層などを形成する。例えば、ステップS8に相当する工程の次に、ポリイミドをさらに塗布して有機絶縁層を積層するとともに、露光現像によりVia層を形成する。レジストを5μm塗布し、露光現像によって、第二の配線層(3μm幅)の開口を形成する。シード層を電極として電解Cuめっきを行い3μmの第一の配線層を形成する。レジストを除去し、さらにシード層のCu膜とTi膜をエッチングする。Cu膜は硫酸と過酸化水素水を混合させたものを用い、Ti膜はアンモニア水と過酸化水素水を混合させたものを用いる。
また、本実施の形態では、両面実装型の半導体装置を例示して説明したがこれに限られない。例えば、一方の面に半導体チップが実装され、他方の面に端子が形成された片面実装型の半導体装置の製造において、本実施の形態の製造方法を適用してもよい。
(第2の実施の形態)
図21〜28は、第2の実施の形態にかかる半導体装置の製造方法を説明する図である。図29は、第2の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。実施の形態1と同様の構成については同様の符号を付して、詳細な説明を省略する。
第2の実施の形態にかかる半導体装置の製造方法は、図29に示すように、ステップS9までは実施の形態1で説明したものと同様の手順になっている。
そして、ステップS9の工程の後で、ポリイミドなどの有機膜を塗布して有機絶縁層5を積層するとともに、第一面5cの接続パッドに対応する部分に、短辺70μm長辺100umの開口を100μmピッチで形成する(ステップS21、図21も参照)。配線層は1層の例を説明したが、もちろん2層の構成や、それ以上の層で構成されてもよい。
次に、開口した接続パッド上にNi・Pd・Au膜24を形成する(ステップS22、図22も参照)。Ni・Pd・Au膜24は、無電解めっきによりNiを3μm、Pdを0.05μm、Auを0.5μmの厚さで形成する。
半導体チップ20を有機絶縁層5上にマウント材25を用いてマウントする(ステップS23、図23も参照)。マウント材25には、例えば樹脂を用いる。また、マウント材25に用いる樹脂は、エポキシ系、アクリル系、ポリイミド系などの液状樹脂やフィルム状の樹脂を用いる。なお、本実施の形態2で用いる半導体チップ20には、金属バンプ10aは設けられておらず、表面にAlパッド20aが形成されている。そのため、半導体チップ20は、有機絶縁層5に対してフリップチップ実装ではなく、マウント材25を用いたマウントがなされる。
有機絶縁層5上にマウントする半導体チップ20は1個でもよいし、2個以上積層して多段にチップを形成してもよい。次に、マウントした半導体チップ20のAlパッド20aを、Auワイヤー29を用いたワイヤーボンディングによってNi・Pd・Au膜24と電気的に接続する(ステップS24、図24も参照)。
次に、有機絶縁層5の第一面5c上を熱硬化性樹脂13でモールド封止する(ステップS25、図25も参照)。そして、実施の形態1で説明した手順と同様に、ステップS13〜ステップS17の工程を経て、樹脂体27が製造される(図26,27も参照)。
そして、この樹脂体をダイシングにより個片化し、個片化したパッケージをさらに基板28上に樹脂を使用してマウントする(ステップS26)。図28に示すように個片化されたパッケージを積層してもよい。積層されたパッケージに対して、さらにワイヤーボンディングを行う(ステップS27)。次に、全体をモールド樹脂で覆い、基板28の裏面にボール搭載を行うことで(ステップS28)、半導体装置が完成する。
上述の工程に従って、半導体装置を製造し、温度サイクル試験に供して、その信頼性を調べた。なお温度サイクル試験は−55℃(30min)〜25℃(5min)〜125℃(30min)を1サイクルとして行った。その結果3000サイクル後でもワイヤーボンディング部分の破断の発生はほとんど認められなかった。配線層に形成した電極パッドが剥離層に向かって小さくなっていることと、配線層の外周にモールド樹脂があることにより、配線層の伸び縮みが抑えられ、電極パッドにかかる応力が小さくなり、リフローや、TCT(Thermal Cycling Test)時の電極パッドと配線の破断が発生しにくくなっている。
なお、有機絶縁層5としては、ポリイミドの他にも、PBO(ポリベンゾオキサゾール)、フェノール系樹脂、アクリル系樹脂などを使用してもよい。第一の配線層8の材料にはCuを例示したが、Al、Ag、Auなども使用できる。また、ガラスを支持基板2として配線層を形成したが、シリコン、サファイヤなどを使用してもよい。すなわち、支持基板2には、レーザ光が透過する材料であれば種々のものを使用することができる。
(第3の実施の形態)
図30〜39は、第3の実施の形態にかかる半導体装置の製造方法を説明する図である。図40は、第3の実施の形態にかかる半導体装置の製造方法を説明するフローチャートである。上記実施の形態と同様の構成については同様の符号を付して、詳細な説明を省略する。
まず、支持基板2となる8インチガラスウエハの表面に、光の透過が抑制された光吸収層(第1の樹脂層)3を形成する(ステップS31)。光吸収層3は、光の透過を抑える透過阻害材を合成樹脂に混合したものが用いられる。透過阻害材は、例えばカーボンブラック、グラファイト粉末や鉄、酸化チタンなどの金属酸化物、あるいは染料や顔料である。光吸収層3は、後の工程において、レーザ光の照射によって分解される。
光吸収層3は、0.1μm以上であって5μm以下の厚さで形成されるのが好ましい。例えば、光吸収層3を1.5μmの厚さで形成する。光吸収層3の厚さが0.1μm未満の場合は、レーザ光の照射時に光吸収が効率的に行われず、光吸収層3がうまく分解されない場合がある。また、光吸収層3の厚さが5μmを超えると、一部の光吸収層3が分解されずに、残存してしまう場合がある。
次に、光吸収層3上に熱可塑性樹脂層(第2の樹脂層)4を形成する(ステップS32、図30も参照)。熱可塑性樹脂層4は、1μm以上であって50μm以下の厚さで形成される。例えば、熱可塑性樹脂層4は、15μmの厚さで形成される。熱可塑性樹脂層4の材料としては、ポリスチレン系、メタクリル樹脂系、ポリエチレン系、ポリプロピレン系、セルロース系などの合成樹脂を使用することができる。
熱可塑性樹脂層4の厚さが1μm未満では、光吸収層3にレーザ光が照射された際に、熱の影響でダメージを受ける可能性がある。また、熱可塑性樹脂層4の厚さが50μmを超えると、その上部へマウントする半導体チップ20の位置ずれが発生しやすくなる。
また、熱可塑性樹脂層4の材料としては、ガラス転移温度が150℃以上であって280℃以下のものを使用する。ガラス転移温度が150℃未満の場合は、高温時に軟化してしまい、その上部へマウントする半導体チップ20の位置ずれが発生しやすくなる。また、ガラス転移温度が280℃を超える合成樹脂については合成樹脂の作製そのものが難しくなる。熱可塑性樹脂層4には、接着性の性質を有しているものが用いられる。
次に、熱可塑性樹脂層4上に第1の半導体チップとして半導体チップ20を位置合わせしてマウントする(ステップS33、図31も参照)。次に、半導体チップ20がマウントされた熱可塑性樹脂層4の第一面4a上を熱硬化性樹脂13でモールド封止する(ステップS34、図32も参照)。
次に、支持基板2側から光吸収層3に向けてレーザ光を印加する(ステップS35、図33も参照)。レーザ光は支持基板2を透過して光吸収層3に到達する。光吸収層3は、光の透過が抑制されているので、印加されたレーザ光を吸収して温度が上昇する。これにより、光吸収層3が分解されるので、光吸収層3の部分で支持基板2を剥離する(ステップS36、図34も参照)。光吸収層3が分解されるので、支持基板2の剥離を円滑に行いやすくなる。
印加するレーザ光としては、例えば、YAGレーザ、ルビーレーザ、エキシマレーザ、COレーザ、He−Neレーザ、Arイオンレーザ、半導体レーザなどを用いることができる。レーザ光の波長は、10.6μm、1064nmの赤外線や、694nm、633nm、532nm、514nm、488nmの可視光や、355nm、351nm、308nm、248nmなどの紫外線など、種々の波長を使用することが可能である。また、レーザは連続波、パルス波ともに使用することができる。
支持基板2を剥離した後に、光吸収層3、および熱可塑性樹脂層4をアセトンなどの溶剤で除去する(ステップS37、図35も参照)。ここで、熱可塑性樹脂層4は溶剤に溶解することが必要である。残渣が残っている場合はさらにプラズマを印加して除去してもよい。
ステップS36,S37の工程を経ることで、半導体チップ20のパッドが露出するため、この面に再配線を形成する(ステップS38)。再配線を形成する工程は、例えば、まず有機絶縁層5を形成する(図36も参照)。そして、有機絶縁層5に開口を形成する。この開口は、半導体チップ20のパッドと一致する位置に形成される。次に、Ti/Cuなどの膜をスパッタし、再配線を形成するためのレジストを形成し、配線用の開口を形成する。そして、レジストの開口部にCuめっきを行い、レジストを除去し、スパッタした膜をエッチングすることで再配線31を形成する(図37も参照)。
このように、再配線を形成した後、有機絶縁層5を積層し、開口を形成する(ステップS39、図38も参照)。次に、開口を行った部分にはんだボール30を形成する(ステップS40、図39も参照)。さらにダイシングを行う(ステップS41)ことでFanoutタイプのCSPを形成することができる。
上述の工程に従って、半導体装置を製造し、温度サイクル試験に供して、その信頼性を調べた。なお温度サイクル試験は−55℃(30min)〜25℃(5min)〜125℃(30min)を1サイクルとして行った。その結果3000サイクル後でも再配線を行った箇所の配線の破断の発生はほとんど認められなかった。
なお、再配線を形成するときに、熱硬化性樹脂4の剛性が足りない場合、熱可塑性樹脂層4に対して、ガラスや金属板を貼り付けて、剛性を上げた状態で、再配線の工程を行ってもよい。
また、有機絶縁層5としてはポリイミドの他にも、PBO(ポリベンゾオキサゾール)、フェノール系樹脂、アクリル系樹脂などを使用してもよい。再配線の配線材料にはCuを例示したが、Al、Ag、Auなども使用できる。また、ガラスを支持基板2として配線層を形成したが、シリコン、サファイヤなどを使用してもよい。すなわち、支持基板2には、レーザ光が透過する材料であれば種々のものを使用することができる。
図41は、複数個の半導体チップ20を積層させてモールド封止させる場合の途中工程を例示する図である。図41に示すように、チップを支持基板2(熱可塑性樹脂層4)上にマウントする半導体チップ20は、複数個であってもよい。すなわち、最下層の第1の半導体チップ上に第3の半導体チップとしてさらに半導体チップ20を積層してもよい。なお、複数個の半導体チップ20は、例えば、予めTSVで積層させた積層体をマウントしてもよい。また、TSV用のチップを支持基板2(熱可塑性樹脂層4)上に1個ずつ積み上げながらFC実装して積層させてもよい。
このように、支持基板2上で半導体チップ20を予め積層すれば、最下層の半導体チップ20、すなわち、支持基板2(熱可塑性樹脂層4)に直接マウントされる半導体チップ20を、略平坦な支持基板2にマウントすることができる。したがって、最下層の半導体チップ20に反りが発生しにくくなる。半導体チップ20に反りがあると、半導体チップ20同士の接続を確保しにくくなる。特に、半導体チップ20に設けられるバンプのピッチが微細である場合に、半導体チップ20に反りがあると、互いの接続を確保しにくくなる。一方、本実施の形態では、マウントされる半導体チップ20の反りを抑えることができるので、半導体チップ20同士を確実に接続させやすくなる。
図42は、再配線を行った面にさらに半導体チップ20をFC実装した半導体装置を例示する図である。図42に示すように、ステップS38の再配線の工程の後に、再配線を行った面にさらに第4の半導体チップとして半導体チップ20をFC実装して半導体装置を構成してもよい。
なお、上記実施形態は例示であり、発明の範囲はそれらに限定されない。
2 支持基板、3 光吸収層(第1の樹脂層)、4 熱可塑性樹脂層(第2の樹脂層)、5 有機絶縁層、5a,5b 開口、5c 第一面、5d 第二面、6 Ti膜・Cu膜、7 レジスト、8 第一の配線層、10 半導体チップ、10a 金属バンプ、13 熱硬化性樹脂、14 Ni・Pd・Au膜、15 中間体、16 プリント基板、17 アンダーフィル、20 半導体チップ、20a Alパッド、24 Ni・Pd・Au膜、25 マウント材、27 樹脂体、28 基板。

Claims (5)

  1. 光の透過が抑制された第1の樹脂層を支持基板上に形成し、
    前記第1の樹脂層上に熱可塑性樹脂からなる第2の樹脂層を形成し、
    前記第2の樹脂層上に絶縁層および配線層を形成し、
    前記配線層上に第1の半導体チップを実装し、
    前記第1の樹脂層にレーザ光を照射して前記支持基板を剥離し、
    前記第2の樹脂層を除去する半導体装置の製造方法。
  2. 前記絶縁層内で前記配線層により電気的に導通された層間接続体を形成し、
    前記層間接続体に電気的に接続するように、前記第2の樹脂層の除去により露出された面に対し第2の半導体チップを実装する請求項1に記載の半導体装置の製造方法。
  3. 光の透過が抑制された第1の樹脂層を支持基板上に形成し、
    前記第1の樹脂層上に熱可塑性樹脂からなる第2の樹脂層を形成し、
    前記第2の樹脂層上に第1の半導体チップを実装し、
    前記第1の樹脂層にレーザ光を照射して前記支持基板を剥離し、
    前記第2の樹脂層を除去する半導体装置の製造方法。
  4. 前記支持基板は、透光性の材料で構成され、
    前記レーザ光は、前記支持基板を通して前記第1の樹脂層に照射される請求項1から3のいずれか1項に記載の半導体装置の製造方法。
  5. 前記第1の樹脂層は、光の透過を抑える透過阻害材を合成樹脂に混入させて構成される請求項1から4のいずれか1項に記載の半導体装置の製造方法。
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