JP2015176958A - 半導体装置及びその製造方法 - Google Patents

半導体装置及びその製造方法 Download PDF

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JP2015176958A
JP2015176958A JP2014051238A JP2014051238A JP2015176958A JP 2015176958 A JP2015176958 A JP 2015176958A JP 2014051238 A JP2014051238 A JP 2014051238A JP 2014051238 A JP2014051238 A JP 2014051238A JP 2015176958 A JP2015176958 A JP 2015176958A
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Prior art keywords
chip
wiring layer
circuit surface
electrode
wafer
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JP2014051238A
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English (en)
Inventor
一茂 河崎
Kazushige Kawasaki
一茂 河崎
栗田 洋一郎
Yoichiro Kurita
洋一郎 栗田
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Toshiba Corp
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Toshiba Corp
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Priority to JP2014051238A priority Critical patent/JP2015176958A/ja
Priority to TW103123336A priority patent/TWI550824B/zh
Priority to US14/475,298 priority patent/US9721935B2/en
Priority to CN201410444601.1A priority patent/CN104916619B/zh
Publication of JP2015176958A publication Critical patent/JP2015176958A/ja
Priority to US15/630,496 priority patent/US10128223B2/en
Pending legal-status Critical Current

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Abstract

【課題】貫通電極部分の寄生容量低減が可能な半導体装置及びその製造方法を提供する。【解決手段】第2チップは、第1チップの第1配線層側に積層されている。第2チップは、第1配線層に対向した第2回路面と、第2回路面の反対側の第2裏面とを有する第2半導体層と、第2回路面に設けられ第1チップの第1配線層と接続された第2配線層と、第2半導体層を貫通して設けられ、第2配線層に接続された第2貫通電極と、を有する。第3チップは、第2チップの第2裏面側に積層されている。第3チップは、第3回路面と、第2チップに対向した第3裏面とを有する第3半導体層と、第3回路面に設けられた第3配線層と、第3半導体層を貫通して設けられ、第3配線層に接続されるとともに第2チップの第2貫通電極にバンプ接続された第3貫通電極とを有する。【選択図】図1

Description

本発明の実施形態は、半導体装置及びその製造方法に関する。
TSV(Through-Silicon Via)を使った構造において、チップの積層数が多くなるなどTSVの数が増えると、TSVとシリコン基板との間の寄生容量の増大をまねく。
米国特許第7119428号明細書
本発明の実施形態は、貫通電極部分の寄生容量低減が可能な半導体装置及びその製造方法を提供する。
実施形態によれば、半導体装置は、第1チップと、第2チップと、第3チップと、を備えている。前記第1チップは、第1回路面と、前記第1回路面の反対側の第1裏面とを有する第1半導体層と、前記第1回路面に設けられた第1配線層と、前記第1半導体層を貫通して設けられ、前記第1配線層に接続された第1貫通電極と、を有する。前記第2チップは、前記第1チップの前記第1配線層側に積層されている。前記第2チップは、前記第1配線層に対向した第2回路面と、前記第2回路面の反対側の第2裏面とを有する第2半導体層と、前記第2回路面に設けられ、前記第1チップの前記第1配線層と接続された第2配線層と、前記第2半導体層を貫通して設けられ、前記第2配線層に接続された第2貫通電極と、を有する。前記第3チップは、前記第2チップの前記第2裏面側に積層されている。前記第3チップは、第3回路面と、前記第3回路面の反対側に位置し、前記第2チップに対向した第3裏面とを有する第3半導体層と、前記第3回路面に設けられた第3配線層と、前記第3半導体層を貫通して設けられ、前記第3配線層に接続されるとともに、バンプを介して前記第2チップの前記第2貫通電極と接続された第3貫通電極と、を有する。
実施形態の半導体装置の模式断面図。 実施形態の半導体装置の模式断面図。 実施形態の半導体装置の模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置の製造方法を示す模式断面図。 実施形態の半導体装置における複数のチップの接続関係を示す模式図。 実施形態の半導体装置の模式断面図。
以下、図面を参照し、実施形態について説明する。なお、各図面中、同じ要素には同じ符号を付している。
図1(a)は、実施形態の半導体装置の模式断面図である。
実施形態の半導体装置は、複数の半導体チップ(以下、単にチップともいう)11の積層体が、実装基板(インターポーザ)51上に実装され、封止樹脂80に覆われている。
図1(a)には、例えば8個のチップ11が積層された構造を例示するが、チップ11の積層数は任意である。複数のチップ11は、厚さ、平面サイズ、厚み方向の層構造および材料などが同じ、例えばメモリチップである。
実施形態によれば、2つのチップ11が回路面12aどうしをフェイストゥフェイスで対向させてボンディングされた構成の2チップ積層体10が複数積層されている。
2チップ積層体10における1対のチップ11は、後述するようにウェーハトゥウェーハボンディングにより接合される。複数の2チップ積層体10どうしは、バンプ接続している。
図1(b)は、図1におけるA部の拡大模式断面図であり、2チップ積層体10の部分断面を表す。
それぞれのチップ11は、半導体層12と、配線層13と、貫通電極18と、接合金属(または中間電極)21とを有する。
半導体層12には、例えばシリコン基板を用いる。あるいは、半導体層12には、SOI(Silicon On Insulator)構造におけるシリコン層を用いる。また、半導体層12には、シリコン以外の例えばSiC、GaNなどの層(基板)を用いてもよい。以下の説明では、半導体層12をシリコン基板として説明する。
シリコン基板12は、回路面12aとその反対側の裏面12bとを有する。ここでの裏面12bとは、回路面12aに対する裏面を表す。
回路面12aには、図示しないトランジスタなどを含む半導体集積回路が形成されている。例えば、メモリチップの場合、回路面12a上に電荷蓄積層、制御電極などが形成されている。
回路面12a上には、半導体集積回路、制御電極と接続された配線層13が設けられている。図には、多層配線を例示するが、配線層13は単層であってもよい。配線層13と回路面12aとの間、配線層13どうしの間、および最上層の配線層13の上には、層間絶縁層14が設けられている。
層間絶縁層14は、例えば、酸化シリコン(SiO)、窒化シリコン(SiN)、酸窒化シリコン(SiON)、炭化窒化シリコン(SiCN)、酸化炭化シリコン(SiOC)の少なくともいずれかを含む。
配線層13は、いわゆるオンチップ配線層であり、樹脂中に設けられた再配線層(RDL:Redistribution Layer)とは異なる。
層間絶縁層14の表面上には、樹脂層15が設けられている。樹脂層15には、例えばベンゾシクロブテン(BCB)樹脂を用いる。あるいは、樹脂層15には、ポリイミド樹脂、またはエポキシ樹脂を用いる。
シリコン基板12には貫通電極18が設けられている。また、シリコン基板12の裏面12bには、裏面電極19が設けられている。貫通電極18は、裏面電極19が形成された位置でシリコン基板12を貫通し、裏面電極19と配線層13とを接続している。貫通電極18は、例えば、銅を主成分として含む金属を用いる。
貫通電極18とシリコン基板12との間には、貫通電極18とシリコン基板12との直接的な導通を防ぐ絶縁膜17が設けられている。絶縁膜17には、例えば、シリコン酸化膜、シリコン窒化膜、またはシリコン酸窒化膜を用いる。
樹脂層15には、接合金属(または中間電極)21が埋め込まれている。接合金属21は、樹脂層15、および層間絶縁層14の一部を貫通して、配線層13に接続している。接合金属21には、例えば銅を主成分として含む金属を用いる。
以上説明した構造を有するチップ11どうしが回路面12a(配線層13)側を対向させて接合され、2チップ積層体10が形成されている。
互いのチップ11の接合金属21どうしが接合され、且つ樹脂層15どうしが接合(接着)されている。
図1(a)において、例えば最下層の2チップ積層体10における上側のチップ11の裏面電極19と、その上の2チップ積層体10における下側のチップ11の裏面電極19との間にはバンプ31が設けられている。バンプ31は、例えば、はんだボール、または金属バンプであり、上下のチップ11の裏面電極19どうしを接続している。すなわち、複数の2チップ積層体10どうしはバンプ接続されている。
図1(a)において、最下層の2チップ積層体10における下側のチップ11の裏面12bには、再配線層41が設けられている。最下層のチップ11の裏面電極19は、再配線層41と接続されている。再配線層41は、樹脂中に設けられ、チップ11の配線層(オンチップ配線層)13と、実装基板51の配線層との接続を担う。
再配線層41の下面にはバンプ(例えば、はんだボール、金属バンプ)32が設けられ、そのバンプ32を介して複数のチップ11を含む積層体は、実装基板51上にマウントされている。実装基板51の裏面には、外部端子(例えば、はんだボール、金属バンプ)52が設けられている。
実装基板51上の積層体は、封止樹脂80で覆われている。また、樹脂85が、2チップ積層体10と2チップ積層体10との間に充填されている。すなわち、バンプ31の接合部は樹脂85で覆われ保護されている。
2チップ積層体10における回路面12aどうしを対向させて接合された2つのチップ11間の樹脂層15のフィラー含有量は、バンプ31を介して接続された2つのチップ11間の樹脂85のフィラー含有量よりも少ない。あるいは、樹脂層15はフィラーを含まない。ウェーハ同士の接合では、バンプを介した接合に比較してチップ間の距離が短く、樹脂の熱膨張による信頼性への影響が小さいため、熱膨張を抑制するフィラー量は樹脂85よりも少なくてもよい(あるいはフィラーが無くてもよい)。
複数のチップ11のそれぞれの半導体集積回路(メモリ素子も含む)は、配線層13、接合金属21、貫通電極18、裏面電極19、バンプ31、再配線層41、およびバンプ32を介して、実装基板51の配線層と電気的に接続されている。そして、実装基板51の配線層は、外部端子52を介して、外部回路と接続される。
複数のチップ11は、メモリチップであり、図10に示すように、共通のデータ入出力端子90に対して並列接続(バス接続)される。
すなわち、貫通電極18、接合金属21およびバンプ31によってチップ積層方向に形成される共通のデータバス91に対して、複数のチップ11のデータ入出力線が並列接続している。
図11は、図1(a)に示す半導体装置から、複数のチップ11(複数の2チップ積層体10)の積層体を抽出した模式断面図である。
図11に示すように、互いの回路面12aどうしを対向させて積層された2つのチップ11の回路面間ピッチをa、互いの裏面どうしを対向させて積層された2つのチップ11の回路面間ピッチをbとすると、a<bであり、また、ピッチaとピッチbが複数チップの積層方向に交互に周期的に繰り返されている。
次に、図4〜図9を参照して、2チップ積層体10の製造方法について説明する。図4〜図9に示す工程はウェーハ状態で進められ、図4〜図9にはウェーハW1、W2の一部断面を示している。
まず、ウェーハプロセスで、シリコン基板12上に、前述した要素を形成する。そして、2枚のウェーハW1、W2を回路面12a側を対向させて貼り合わせる。
図4には、貼り合わせ前の第1ウェーハW1と第2ウェーハW2を示す。第1ウェーハW1と第2ウェーハW2は、構造は同じで、貼り合わせ面を挟んで各要素が鏡像対称になっている。
第1ウェーハW1と第2ウェーハW2は、互いの対応する接合金属21の位置を合わせて、図5に示すように貼り合わされる。加圧及び加熱下で2枚のウェーハW1、W2は貼り合わされ、接合金属21どうしが接合されるとともに、樹脂層15どうしが接着(ウェーハボンディング)される。
ウェーハボンディング後、図6に示すように、第1ウェーハW1のシリコン基板12を裏面12b側から研削して薄化する。第1ウェーハW1のシリコン基板12が薄くなっても、第2ウェーハW2のシリコン基板12が支持体となる。あるいは、第1ウェーハW1のシリコン基板12を支持体にして、先に第2ウェーハW2のシリコン基板12を研削して薄化してもよい。
研削前のシリコン基板12は例えば700μm以上であり、研削により、シリコン基板12は、貫通電極を形成する場合は例えば30〜50μm程度に、貫通電極を形成しない場合は例えば100〜500μm程度に薄化される。
第1ウェーハW1のシリコン基板12を薄化した後、図6に示すように、シリコン基板12を貫通して第1ウェーハW1の配線層13に達するビア16を形成する。例えば、RIE(Reactive Ion Etching)などのエッチングによりビア16が形成される。
図7に示すように、ビア16の内壁、およびビア16周囲のシリコン基板12の裏面12bには絶縁膜17が形成される。そして、絶縁膜17を介してビア16内に貫通電極18が埋め込まれる。また、シリコン基板12の裏面12bには貫通電極18と接続した裏面電極19が形成される。裏面電極19とシリコン基板12の裏面12bとの間にも絶縁膜17が介在される。
次に、図8に示すように、貫通電極18が形成された第1ウェーハW1のシリコン基板12の裏面12b側に支持体100を貼り付ける。図8において、図7と上下を逆にして第1ウェーハW1及び第2ウェーハW2を示している。
支持体100は、例えばガラス基板などの剛体である。支持体100は接着層101を介して第1ウェーハW1のシリコン基板12に貼り付けられる。
支持体100によって第1ウェーハW1および第2ウェーハW2が支持された状態で、第2ウェーハW2のシリコン基板12を裏面12b側から研削して薄化する。
第2ウェーハW2のシリコン基板12を薄化した後、第1ウェーハW1に対するプロセスと同様に、シリコン基板12を貫通して第2ウェーハW2の配線層13に達するビアを形成する。
そして、図9に示すように、第2ウェーハW2のビア16の内壁、およびビア16周囲のシリコン基板12の裏面12bに絶縁膜17が形成される。そして、絶縁膜17を介してビア16内に貫通電極18が埋め込まれる。また、シリコン基板12の裏面12bには貫通電極18と接続した裏面電極19が形成される。裏面電極19とシリコン基板12の裏面12bとの間にも絶縁膜17が介在される。また、必要に応じて、裏面電極19上にバンプ31が形成される。
その後、第1ウェーハW1および第2ウェーハW2の接合体をダイシングし、支持体100を除去(剥離)することで、個片化された2チップ積層体10が得られる。
例えば、支持体100がダイシングテープに貼り付けられた状態で、第2ウェーハW2および第1ウェーハW1がダイシングされる。あるいは、支持体100を剥離してから第1ウェーハW1および第2ウェーハW2をダイシングしてもよい。
実施形態の2チップ積層体10は、個片化した2チップのチップトゥチップボンディングではなく、ウェーハトゥウェーハボンディングの後のダイシングにより得られる。したがって、2チップ積層体10は、連続した側面を有する直方体形状に形成される。
個片化された複数の2チップ積層体10は、図1(a)に示すように、実装基板51上に積層され、複数の2チップ積層体10どうしの間には樹脂85が充填される。あるいは、複数の2チップ積層体10を、樹脂フィルムを介して貼り合わせて積層してもよい。
また、図2(a)、図2(b)、図3(a)に示すように、2チップ積層体10に対して、1つのチップ11がバンプ31を介して積層された構造でもよい。
TSV(Through-Silicon Via)構造において、基板を薄くすれば貫通電極の表面積が小さくなり、絶縁膜を挟んで対向する貫通電極と基板との間の寄生容量を低減できる。しかしながら、基板が薄くなると、チップどうしのボンディング、チップと実装基板とのボンディングなどの組み立てプロセスにおいてハンドリングが困難になる問題が生じる。
そこで、以上説明した実施形態によれば、2枚のウェーハW1、W2を回路面12a側を対向させてウェーハトゥウェーハボンディングした後、一方のウェーハW2のシリコン基板12を支持体として、他方のウェーハW1のシリコン基板12を薄化して貫通電極18を形成する。その後、一方のウェーハW1のシリコン基板12側に支持体(剛体)100を貼り付けた後、他方のウェーハW2のシリコン基板12を薄化して、ウェーハW2にも貫通電極18を形成する。
そのため、ハンドリングの困難性をきたすことなく、2チップ積層体10のそれぞれの基板12を薄化した上でTSV構造を形成することができる。参照例として、チップトゥチップで2チップを積層した構造に比べて、実施形態の2チップ積層体10によれば基板12の厚さを約1/2にすることができる。
したがって、絶縁膜17を挟んでシリコン基板12に対向する貫通電極18の表面積を参照例に比べて約1/2にすることが可能となり、貫通電極18と基板12間の寄生容量を約1/2に低減することができる。
特に、記憶容量の大容量化にともないチップ11の積層数が増大すると、TSVの数も増え、その寄生容量の影響も大きくなる傾向にあるが、実施形態によれば、基板12の薄化によりTSVの寄生容量を低減することで、結果として消費電力の低減を図れる。
また、2チップ積層体10は、接合面を挟んで断面構造が鏡像対称にある同じチップ11どうしがボンディングされた構造であるため、それぞれのチップ11に発生する反りが相殺されて、2チップ積層体10としては反りの小さいものが得られる。
図1(a)には、例えば、4組の2チップ積層体10の積層構造を例示したが、2組または3組の2チップ積層体10の積層構造でもよく、また、5組以上の2チップ積層体10を積層させてもよい。
また、図2(a)に示すように、再配線層41を上に向けて複数チップ11の積層体を実装基板51にボンディングし、最上層の再配線層41と、実装基板51とをワイヤ61によってボンディングしてもよい。
また、図2(b)に示すように、実装基板51を用いずに、複数のチップ11の積層体を再配線層41を介して直接外部端子52に接続させてもよい。
また、図3(a)に示すように、最下層のチップ11の下の再配線層41の下にロジックチップ71を搭載してもよい。ロジックチップ71はバンプ(例えば、はんだボール、金属バンプ)72を介して再配線層41に接合している。ロジックチップ71は、再配線層41を介して、例えば最下層のチップ11(貫通電極、配線層)に電気的に接続している。
ロジックチップ71は、各メモリチップ11を制御するIF(interface)/コントローラチップである。
また、図3(b)に示すように、貫通電極18がないチップ11と、貫通電極18を持つチップ11とが接合金属21及び樹脂層15を介して接合された2チップ積層体10’が含まれていてもよい。
本発明のいくつかの実施形態を説明したが、これらの実施形態は、例として提示したものであり、発明の範囲を限定することは意図していない。これら新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。これら実施形態やその変形は、発明の範囲や要旨に含まれるとともに、特許請求の範囲に記載された発明とその均等の範囲に含まれる。
10…2チップ積層体、11…チップ、12…シリコン基板、12a…回路面、12b…裏面、13…配線層、15…樹脂層、16…ビア、17…絶縁膜、18…貫通電極、19…裏面電極、21…接合金属、31…バンプ、51…実装基板、71…ロジックチップ、80…樹脂、100…支持体

Claims (8)

  1. 第1回路面と、前記第1回路面の反対側の第1裏面とを有する第1半導体層と、前記第1回路面に設けられた第1配線層と、前記第1半導体層を貫通して設けられ、前記第1配線層に接続された第1貫通電極と、を有する第1チップと、
    前記第1チップの前記第1配線層側に積層された第2チップであって、前記第1配線層に対向した第2回路面と、前記第2回路面の反対側の第2裏面とを有する第2半導体層と、前記第2回路面に設けられ、前記第1チップの前記第1配線層と接続された第2配線層と、前記第2半導体層を貫通して設けられ、前記第2配線層に接続された第2貫通電極と、を有する第2チップと、
    前記第2チップの前記第2裏面側に積層された第3チップであって、第3回路面と、前記第3回路面の反対側に位置し、前記第2チップに対向した第3裏面とを有する第3半導体層と、前記第3回路面に設けられた第3配線層と、前記第3半導体層を貫通して設けられ、前記第3配線層に接続されるとともに、バンプを介して前記第2チップの前記第2貫通電極と接続された第3貫通電極と、を有する第3チップと、
    を備えた半導体装置。
  2. 前記第1チップ、前記第2チップおよび前記第3チップのデータ入出力線は、共通のデータ入出力端子に対して並列接続されるメモリチップである請求項1記載の半導体装置。
  3. 前記第1チップの前記第1裏面側に設けられ、前記第1貫通電極に接続され、前記第1チップ、前記第2チップおよび前記第3チップを制御するロジックチップをさらに備えた請求項1または2に記載の半導体装置。
  4. 前記第1チップと前記第2チップとの積層体は、連続した側面を有する直方体形状である請求項1〜3のいずれか1つに記載の半導体装置。
  5. 前記第3チップの前記第3配線層側に積層された第4チップであって、前記第3配線層に対向した第4回路面を有する第4半導体層と、前記第4回路面に設けられ、前記第3配線層と接続された第4配線層と、を有する第4チップをさらに備えた請求項1〜4のいずれか1つに記載の半導体装置。
  6. 前記第4チップは、前記第4半導体層を貫通して設けられ、前記第4配線層と接続された第4貫通電極をさらに有し、
    前記第3チップと前記第4チップとの積層体は、連続した側面を有する直方体形状である請求項5記載の半導体装置。
  7. 前記第1チップと前記第2チップとの間に設けられた樹脂層と、
    前記第2チップと前記第3チップとの間に設けられた封止樹脂と、をさらに備え、
    前記第1チップと前記第2チップとの間の前記樹脂層のフィラー含有量は、前記第2チップと前記第3チップとの間の前記封止樹脂のフィラー含有量よりも少ない請求項1〜6のいずれか1つに記載の半導体装置。
  8. 第1回路面と前記第1回路面の反対側の第1裏面とを有する第1基板と、前記第1回路面に設けられた第1配線層と、前記第1配線層上に設けられ、前記第1配線層と接続された第1接合金属と、を有する第1ウェーハの前記第1回路面と、
    第2回路面と前記第2回路面の反対側の第2裏面とを有する第2基板と、前記第2回路面に設けられた第2配線層と、前記第2配線層上に設けられ、前記第2配線層と接続された第2接合金属と、を有する第2ウェーハの前記第2回路面と、
    を対向させ、前記第1接合金属と前記第2接合金属とを接合させて、前記第1ウェーハと前記第2ウェーハとを貼り合わせ、
    前記第1ウェーハと前記第2ウェーハとが貼り合わされた状態で、前記第1基板を前記第1裏面側から研削し、
    前記研削により薄化された前記第1基板に、前記第1基板を貫通して前記第1配線層に達する第1貫通電極を形成し、
    前記第1貫通電極が形成された前記第1基板の前記第1裏面側に支持体を貼り付けた状態で、前記第2基板を前記第2裏面側から研削し、
    前記研削により薄化された前記第2基板に、前記第2基板を貫通して前記第2配線層に達する第2貫通電極を形成し、
    前記第2貫通電極を形成した後、前記支持体を除去、および前記第1ウェーハと前記第2ウェーハとの接合体を複数のチップに個片化し、
    個片化された複数のチップを積層する
    半導体装置の製造方法。
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