JP2018129475A - 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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JP2018129475A
JP2018129475A JP2017023207A JP2017023207A JP2018129475A JP 2018129475 A JP2018129475 A JP 2018129475A JP 2017023207 A JP2017023207 A JP 2017023207A JP 2017023207 A JP2017023207 A JP 2017023207A JP 2018129475 A JP2018129475 A JP 2018129475A
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Prior art keywords
bump
semiconductor device
protective layer
opening
electrode
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JP2017023207A
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JP6680705B2 (ja
Inventor
拓 加本
Taku Kamoto
拓 加本
達夫 右田
Tatsuo Uda
達夫 右田
渡辺 慎也
Shinya Watanabe
慎也 渡辺
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Kioxia Corp
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Toshiba Memory Corp
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Priority to JP2017023207A priority Critical patent/JP6680705B2/ja
Priority to TW109130967A priority patent/TWI783264B/zh
Priority to TW106124853A priority patent/TWI720233B/zh
Priority to CN201710651125.4A priority patent/CN108417550B/zh
Priority to US15/694,998 priority patent/US10115689B2/en
Publication of JP2018129475A publication Critical patent/JP2018129475A/ja
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Publication of JP6680705B2 publication Critical patent/JP6680705B2/ja
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Abstract

【課題】基板接合の信頼性を高めた半導体装置及びその製造方法を提供する。
【解決手段】実施形態の半導体装置は、第一の配線電極が表面に設けられた第一の半導体基板と、前記半導体基板上に形成され、前記第一の配線電極上に開口部を有する第一の保護層と、前記第一の保護層の開口部に形成された第一のバンプ電極と、前記第一のバンプ電極に接合されたバンプ径が30μm以下のバンプと、を有する。前記開口部に形成された前記第一のバンプ電極の底面の径は前記第一の保護層の膜厚の1.5倍以下である。
【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。
半導体装置の製造において、半導体装置が形成された基板を他の半導体装置や配線が形成された基板にバンプを介してフリップチップ接続する際、一方の基板表面に予め形成された電極に対して他方の基板に設けられたバンプを接続する。このとき電極は基板表面に形成された開口部に埋め込まれて形成されており、電極表面は開口部に沿って凹形状表面となることがある。凹形状表面の電極にバンプを接合する際、凹部において空気等の気体をかみ込むおそれがあり、接合箇所にボイドが発生する場合がある。
特開2007−250561号公報
本実施形態が解決しようとする課題は、基板接合の信頼性を高めた半導体装置及びその製造方法を提供する。
実施形態の半導体装置は、第一の配線電極が表面に設けられた第一の半導体基板と、前記半導体基板上に形成され、前記第一の配線電極上に開口部を有する第一の保護層と、前記第一の保護層の開口部に形成された第一のバンプ電極と、前記第一のバンプ電極に接合されたバンプ径が30μm以下のバンプと、を有する。前記開口部に形成された前記第一のバンプ電極の底面の径は前記第一の保護層の膜厚の1.5倍以下である。
実施形態に係る半導体装置の構成を説明する図。 図1の半導体装置の製造方法を説明する図。 図1の半導体装置の製造方法を説明する図. 実施形態の変形例に係る半導体装置の構成を説明する図。
以下、発明を実施するための実施形態について説明する。
(実施形態)
本実施形態に係る半導体装置について図1、図2、及び図3を参照して説明する。なお、以下の図面の記載において、同一部分は同一符号で表している。ただし、図面は厚さと平面寸法との関係、比率等は現実のものとは異なり、模式的なものである。
本実施形態に係る半導体装置の構成について図1を用いて説明する。図1は本実施形態の半導体装置の構成を示す断面図である。
図1に示すように、本実施形態に係る半導体装置1は、第一の半導体装置10と第二の半導体装置30とを有し、第一の半導体装置10と第二の半導体装置30とが導電性のバンプ20により接合され、各々電気的に接続されている。
第一の半導体装置10は、シリコン基板等の第一の半導体基板100、第一の配線電極101、第一の保護層102、第一のバリア膜103、及び第一のバンプ電極104を備えている。
第一の半導体基板100には、それぞれ図示を省略するが半導体素子、素子と電気的に接続されたCu等の導電配線層、及び層間絶縁層が設けられている。第一の半導体基板100の表面には、配線層を介して半導体素子と接続された第一の配線電極101が形成されている。第一の配線電極101は、たとえばAl、Cu、Ni、Au、Ag、またはそれらの合金からなる導電体である。
第一の配線層101上には、絶縁性の第一の保護層102が形成されている。第一の保護層102は、たとえば、シリコン酸化膜、シリコン窒化膜、およびポリイミド等のいずれか単層またはそれらの複数層で構成される。第一の保護層102の膜厚は5μmである。第一の保護層102の膜厚を5μm以上にすることで半導体基板100に形成された半導体素子や配線層等の内部構造を効果的に保護することができる。第一の保護層102には、第一の配線層101上に開口部が形成されている。
第一の保護層102の開口部の底面並びに側面、及び第一の保護層102の開口部近傍の上部には、第一のバリア膜103が形成されている。第一のバリア膜103は、Ti、TiN、Ta、及びTaN等のいずれか単層またはそれらの積層で構成され、均等の膜厚で形成される。なお場合によっては第一のバリア膜103を形成しなくともよい。
第一のバリア膜103上には第一のバンプ電極104が形成され、第一の保護層102の開口部は第一のバンプ電極104により埋められる。第一のバンプ電極104は、Cu、Ni、Au、Ag、Pd、Al及びそれらの合金、のいずれか単層またはそれらの積層で構成され、たとえば、Cuめっきシード層とCuめっき層の積層から構成されるCuピラー層である。
第一のバンプ電極104の膜厚は3μmである。ここで膜厚は、第一の保護層102上に設けられた第一のバンプ電極104の膜厚をいう。複数の半導体基板が積層された半導体装置では、バンプ電極104の膜厚を3μm以下とすることによって、各半導体基板間の距離を抑えることができ半導体装置全体を小型化することができる。
第一の保護層102の開口部の開口径は5μm以下である。第一のバリア膜103が開口部内部に形成されている場合は、第一のバリア膜103が形成された開口部の開口径が5μm以下であれば好ましい。すなわち、開口部に埋め込まれた第一のバンプ電極104底面の径が5μm以下であれば好ましい。ここで開口部に埋め込まれた第一のバンプ電極104底面の径は、特定の方向において5μm以下であればよいが、いずれの方向においても5μm以下であればさらに好ましい。
このように開口径を小さくすることで、第一のバンプ電極104を開口部に埋め込み形成する際に、開口部上部に設けられる第一のバンプ電極104表面の凹み量を抑制できる。ここで第一のバンプ電極104表面の凹み量は、第一のバンプ電極104の上層表面の最上部と最下部の差とする。
バンプを接合する電極表面の凹み量が3〜5μm以上になると、電極とバンプ間またはバンプ内部で空気をかみこみ、ボイドが発生し易い。ボイドが発生すると、バンプ接合における電気抵抗が増加したり、物理的な接合信頼性が悪化したりする。本実施形態では、開口部に埋め込まれた第一のバンプ電極104底面の径を第一の保護層102の膜厚以下にすることで、開口部を第一のバンプ電極104で十分に閉じることができ、第一のバンプ電極104表面の凹み量を1μm以下に抑えることができる。さらに、開口部に埋め込まれた第一のバンプ電極104底面の径を第一の保護層102の膜厚の1.5倍以下としても、第一のバンプ電極104表面の凹み量を1.5μm以下に抑えることができる。
第一のバンプ電極104上には、バンプ20が形成されている。バンプ20の材料は、Cu,Sn、Pb、Au、Ag、Pd、Ni、またはこれらの合金で構成される。バンプ20は、バンプ径が30μm以下のマイクロバンプであり、また第一の半導体装置10の同一表面側に設けられた少なくとも一つの他のバンプとの距離(バンプピッチ)を60μm以下と小さくすることで、半導体装置全体を小型化できる。
一般にバンプ径が、80μm、100μm、150μmもしくはそれ以上の大きさの場合には、バンプとバンプ電極との接合箇所に生じるボイドはバンプの大きさに比べて相対的に小さいため接合信頼性が問題になることは少ない。反対に、バンプ径が30μm以下のマイクロバンプを用いる場合、バンプとバンプ電極との接合箇所に生じるボイドがバンプの大きさに対して相対的に大きくなるため接合信頼性の問題が生じやすい。
本実施形態に係る半導体装置1では、マイクロバンプを用いて小型化を図りつつ、第一の保護層102の膜厚と第一のバンプ電極104の径を適切な大きさに調整することにより、第一のバンプ電極104表面の凹み量を抑えているため、図1に示したようにバンプとバンプ電極との接合箇所にボイドを発生させない、あるいは接合箇所のボイドの大きさを十分に抑えることができるため、接合信頼性を高めることができる。
バンプ20を介して、第二の半導体装置30が第一の半導体装置10と接合されている。第二の半導体装置30は、シリコン基板等の第二の半導体基板300、第二の配線電極301、第二の保護層302、第二のバリア膜303、及び第二のバンプ電極304を備えている。
第二の半導体基板300には、それぞれ図示を省略するが半導体素子、素子と電気的に接続されたCu等の導電配線層、及び層間絶縁層が設けられている。第二の半導体基板300の表面には、Cu配線層を介して半導体素子と接続された第二の配線電極301が形成されている。第二の配線電極301は、たとえばNi、Au、Cu、Alなどの導電材である。
第二の配線層301上には、絶縁性の第二の保護層302が形成されている。第二の保護層302は、たとえば、シリコン酸化膜、シリコン窒化膜、およびポリイミド等のいずれか単層またはそれらの複数層で構成される。第一の保護層102と同様、第二の保護層302の膜厚を5μm以上にすることで半導体基板上の素子構造を効果的に保護することができる。第二の保護層302には、第二の配線層301上部に開口部が形成されている。
第二の保護層302の開口部の底面並びに側面、及び第二の保護層302の開口部近傍の上部には、第二のバリア膜303が形成されている。第二のバリア膜303は、第一バリア膜103と同様の材料および構造を採用できる。また第二のバリア膜303は必ずしも形成しなくともよい。
第二のバンプ電極304が、第二のバリア膜303上で、第二の保護層302の開口部内に埋められる。第二のバンプ電極304は、第一のバンプ電極104と同様の材料または構造であり、その膜厚は、第一のバンプ電極104と同様、3μm以下とすることにより半導体装置全体を小型化することができる。
第二のバンプ電極304上にはバンプ20が形成されており、バンプ20を介して半導体装置20と半導体装置10は電気的および物理的に接続されている。
続いて、本実施形態に係る半導体装置の製造方法について、図2及び図3を用いて説明する。図2および図3は本実施形態の半導体装置の製造方法を示す工程断面図である。
まず、図2(a)に示すように、第一の半導体装置10の第一の半導体基板100を用意する。第一の半導体基板100には、図示を省略するが、半導体素子、素子と電気的に接続されたCu等の導電配線層、及び層間絶縁層が設けられている。第一の半導体基板100の表面に、配線層を介して半導体素子と電気的に接続する第一の配線電極101を形成する。さらに第一の半導体基板100の表面に、第一の配線電極101を覆うように、CVD法等により膜厚5μmの第一の保護層102を形成する。その後、リソグラフィおよびドライエッチングにより、第一の保護層102に開口径5μm程度の開口部を設け、第一の配線電極101の一部を開口部から露出する。
次に、図2(b)に示すように、スパッタ法等により第一のバリア膜103を、第一の保護層102の上面および開口部の底面および側面に形成する。その後、フォトレジスト105を第一のバリア膜103上に形成した後、リソグラフィによりフォトレジスト105に開口部を設け、第一のバリア膜103の一部を露出させる。
その後、図2(c)に示すように、電気めっき法を用いて、フォトレジスト105の開口部内で露出したバリア膜103上に第一のバンプ電極104を形成することで、第一のバンプ電極104が第一の保護層102の開口部に埋め込まれる。第一のバンプ電極104の材料はCuであり、膜厚は3μmとする。このとき第一の保護層102の開口部上方で、第一のバンプ電極104の表面に微小な凹部が生じるが、凹み量は抑制されている。第一のバンプ電極104を形成した後、フォトレジスト105をアッシングにより除去し、さらに露出した第一のバリア膜103も除去する。以上、図2(a)乃至図2(c)に示したように第一の半導体装置10を製造する。
次に、図3(a)に示すように、第一の半導体装置10と同様の方法により、第二の半導体装置30を製造する。第二の半導体基板300を用意し、第二の配線電極301、第二の保護層302、第二のバリア膜303、フォトレジスト305、及び第二のバンプ電極304をそれぞれ形成する。
続いて、図3(b)に示すように、電気めっきにより、フォトレジスト305の開口部の第二のバンプ電極304上にSn合金等のはんだ層201を形成する。はんだ層201を形成した後、フォトレジスト305およびフォトレジスト305下方の第二のバリア膜303をともに除去する。
次に、図3(c)に示すように、熱処理によりはんだ層201を溶融して、第二の半導体装置30上にバンプ20を形成する。バンプ20は、バンプ径が30μm以下のマイクロバンプである。また図示を省略するが、バンプ20は、第二の半導体基板300の同一表面側に複数同時に形成され、それぞれのバンプ間距離は60μm以下とする。
最後に、図3(d)に示すように、熱圧着により、第二の半導体装置30上に形成されたバンプ20を第一の半導体装置10の第一のバンプ電極104に押し付け、その後冷却することにより第一の半導体装置10と第一の半導体装置30をバンプ20で接合する。第一のバンプ電極104表面には凹部が形成されているものの、凹部の凹み量が小さいため、バンプ20を第一のバンプ電極104に圧着する過程で空気がかみ込まれる恐れがなく、ボイドが生じないため接合信頼性を高めることができる。
なお、他のバンプ接合技術として、バンプを第一の半導体装置上にも予め設けておき、第一の半導体装置上のバンプと第二の半導体装置上のバンプを接合する技術も知られている。これに対し、本実施形態の半導体装置の製造方法では、第二の半導体装置上にのみバンプを形成して第一の半導体装置に接合しているため、はんだ使用量を低減することができる。
図4は、本実施形態の半導体装置の構成の変形例を示す図である。図4に示すとおり、本変形例に係る半導体装置は、図1で示した半導体装置の第二の半導体装置30上にバンプ40を介してさらに第三の半導体装置50を積層した構成を有する。
第二の半導体装置30は、第二の半導体基板300内に基板貫通方向に伸びる導電性のビア306が形成されている。ビア306はCuなどの導体材料で構成され、第一の半導体装置10側の端部で第二の配線電極301と電気的に接続されている。またビア306は、反対側の端部においても第二の配線電極307と電気的に接続されている。
第二の配線電極307上には、第一の半導体装置10における第一の保護層102、第一のバリア膜103、及び第一のバンプ電極104と同様の構成、材料、サイズ、配置で、第二の保護層308、第二のバリア膜309、及び第二のバンプ電極310が設けられている。ここで、第二のバンプ電極310表面の凹み量は、第一のバンプ電極104表面の凹み量と同様、十分に抑えられている。
第二のバンプ電極310上には導電性バンプ40が接合され、さらにバンプ40上には第三の半導体装置50が接合されている。第三の半導体装置50の構成は、第二の半導体装置30の構成、材料、サイズ、配置と同様であり、シリコン基板等の第三の半導体基板500、第三の配線電極501、第三の保護層502、第三のバリア膜503、及び第三のバンプ電極504を備えている。バンプ40は、第二のバンプ電極310と第三のバンプ電極504間を接合して、第二の半導体装置30と第三の半導体装置50との電気的接続を確立する。
以上説明した本変形例に係る半導体装置では、半導体基板の貫通方向に伸びるビアを設けることにより、積層された3以上の半導体装置をコンパクトに保ちつつ各々の電気的接続を図ることができる。また、バンプ接合におけるボイドの発生を抑えられるため、接合信頼性を高めることができる。
以上、本発明の実施形態を説明したが、本実施形態は、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。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。
1 半導体装置
10 第一の半導体装置
20、40 バンプ
30 第二の半導体装置
50 第三の半導体装置
100 第一の半導体基板
101 第一の配線電極
102 第一の保護層
103 第一のバリア膜
104 第一のバンプ電極
300 第二の半導体基板
301、307 第二の配線電極
302、308 第二の保護層
303、309 第二のバリア膜
304、310 第二のバンプ電極
306 ビア
500 第三の半導体基板
501 第三の配線電極
502 第三の保護層
503 第三のバリア膜
504 第三のバンプ電極

Claims (5)

  1. 第一の配線電極が表面に設けられた第一の半導体基板と、
    前記半導体基板上に形成され、前記第一の配線電極上に開口部を有する第一の保護層と、
    前記第一の保護層の開口部に形成された第一のバンプ電極と、
    前記第一のバンプ電極に接合されたバンプ径が30μm以下のバンプと、
    を有し、
    前記開口部に形成された前記第一のバンプ電極の底面の径が、前記第一の保護層の膜厚の1.5倍以下であることを特徴とする半導体装置。
  2. 前記開口部に形成された前記第一のバンプ電極の底面の径が、前記第一の保護層の膜厚以下であることを特徴とする請求項1記載の半導体装置。
  3. 前記第一のバンプ電極は前記第一の保護層上にも形成され、前記第一の保護層上の前記第一のバンプ電極の膜厚は3μm以下であることを特徴とする請求項1または2記載の半導体装置。
  4. 前記バンプと、前記第一の半導体基板の同一表面側に設けられた他のバンプとの距離が60μm以下であることを特徴とする請求項1乃至3のいずれか一項記載の半導体装置。
  5. 開口部を有する第一の保護層と前記開口部に形成された第一のバンプ電極とを表面に備えた半導体基板を用意し、
    前記第一のバンプ電極にバンプ径が30μm以下のバンプを接合する半導体装置の製造方法であって、
    前記開口部に形成された前記第一のバンプ電極の底面の径が、前記第一の保護層の膜厚の1.5倍以下であることを特徴とする半導体装置の製造方法。
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