JP4657840B2 - Semiconductor device and manufacturing method thereof - Google Patents

Semiconductor device and manufacturing method thereof Download PDF

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JP4657840B2
JP4657840B2 JP2005205341A JP2005205341A JP4657840B2 JP 4657840 B2 JP4657840 B2 JP 4657840B2 JP 2005205341 A JP2005205341 A JP 2005205341A JP 2005205341 A JP2005205341 A JP 2005205341A JP 4657840 B2 JP4657840 B2 JP 4657840B2
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chip
thermoplastic resin
insulating substrate
semiconductor chip
connection terminal
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JP2007027305A (en
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史典 三橋
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新藤電子工業株式会社
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/10—Bump connectors; Manufacturing methods related thereto
    • H01L2224/15—Structure, shape, material or disposition of the bump connectors after the connecting process
    • H01L2224/16—Structure, shape, material or disposition of the bump connectors after the connecting process of an individual bump connector
    • H01L2224/161—Disposition
    • H01L2224/16151—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/16221—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/16225—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
    • H01L2224/31—Structure, shape, material or disposition of the layer connectors after the connecting process
    • H01L2224/32—Structure, shape, material or disposition of the layer connectors after the connecting process of an individual layer connector
    • H01L2224/321—Disposition
    • H01L2224/32151—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/32221—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/32225—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/73—Means for bonding being of different types provided for in two or more of groups H01L2224/10, H01L2224/18, H01L2224/26, H01L2224/34, H01L2224/42, H01L2224/50, H01L2224/63, H01L2224/71
    • H01L2224/732—Location after the connecting process
    • H01L2224/73201—Location after the connecting process on the same surface
    • H01L2224/73203—Bump and layer connectors
    • H01L2224/73204—Bump and layer connectors the bump connector being embedded into the layer connector
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
    • H01L2224/83—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a layer connector
    • H01L2224/8319—Arrangement of the layer connectors prior to mounting
    • H01L2224/83192—Arrangement of the layer connectors prior to mounting wherein the layer connectors are disposed only on another item or body to be connected to the semiconductor or solid-state body

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Description

この発明は、ＮＣＰやＡＣＰを使用することなく、プリント配線板上に半導体チップを実装する半導体装置およびその製造方法に関する。   The present invention relates to a semiconductor device in which a semiconductor chip is mounted on a printed wiring board without using NCP or ACP, and a manufacturing method thereof.

近年、エレクトロ産業の発展により、フラットパネルディスプレイの需要が高まっており、その駆動用ドライバとして、高密度実装が可能で自由に折り曲げることができるフレキシブルプリント配線板が広く使用され、フレキシブルプリント配線板の一種であるＣＯＦ（chip on film）実装方式などの半導体装置が多く採用されている。   In recent years, with the development of the electro industry, the demand for flat panel displays has increased. As a driver for driving the flexible printed wiring board, high-density mounting that can be bent freely is widely used. Many types of semiconductor devices such as a COF (chip on film) mounting method are employed.

図２（Ａ）ないし（Ｅ）には、そのようなＣＯＦ実装方式を用いる半導体装置の製造工程を示す。   2A to 2E show a manufacturing process of a semiconductor device using such a COF mounting method.

プラスチックフィルム状の絶縁基板の片面に導電体を有する基材を用い、まずその基材の両側縁に金型を用いて一定間隔置きにパーフォレーションを形成し、次に導電体にレジスト塗布、露光、現像、エッチング、レジスト除去などを行い、図２（Ａ）に示すように絶縁基板１の表面に同一の導電パターン２を絶縁基板１の長さ方向に繰り返し形成する。図中符号３は、パーフォレーションである。   Using a base material that has a conductor on one side of a plastic film-like insulating substrate, first form perforations at regular intervals using molds on both side edges of the base material, then apply resist to the conductor, expose, Development, etching, resist removal, and the like are performed, and the same conductive pattern 2 is repeatedly formed in the length direction of the insulating substrate 1 on the surface of the insulating substrate 1 as shown in FIG. Reference numeral 3 in the figure denotes perforation.

その後、図示省略するが、導体パターン２にすずめっきを行い、また必要に応じ導体パターン２をソルダーレジストで覆ってフレキシブルプリント配線板４を得ていた。なお、ここですずめっきとソルダーレジストは、いずれを先に設けてもよい。   Thereafter, although not shown in the figure, the conductive pattern 2 was tin-plated, and the flexible printed wiring board 4 was obtained by covering the conductive pattern 2 with a solder resist as necessary. Here, either tin plating or solder resist may be provided first.

それから、図２（Ｂ）に示すように、フレキシブルプリント配線板４を加熱ステージ５上にセットし、チップ電極に設けられた金属バンプ６と導体パターン２のチップ接続端子２ａとを位置合わせし、ボンディングツール７で熱と圧力を加えてそれらを接合し、フレキシブルプリント配線板４上に半導体チップ８を搭載する。   Then, as shown in FIG. 2 (B), the flexible printed wiring board 4 is set on the heating stage 5, and the metal bumps 6 provided on the chip electrodes and the chip connection terminals 2a of the conductor pattern 2 are aligned, The bonding tool 7 applies heat and pressure to join them, and the semiconductor chip 8 is mounted on the flexible printed wiring board 4.

次いで、図２（Ｃ）に示すように、塗布ノズル９を使用して半導体チップ８の周囲を描画して封止樹脂１０を塗布し、毛細管現象によりフレキシブルプリント配線板４と半導体チップ８との間に浸透して充填する。その後、熱を加えて封止樹脂１０を加熱硬化し、図２（Ｄ）に示すように封止樹脂１０で封止してフレキシブルプリント配線板４上に半導体チップ８を搭載する。   Next, as shown in FIG. 2C, the periphery of the semiconductor chip 8 is drawn using the application nozzle 9 and the sealing resin 10 is applied, and the flexible printed wiring board 4 and the semiconductor chip 8 are separated by a capillary phenomenon. Penetration in between. Thereafter, heat is applied to heat and cure the sealing resin 10, and the semiconductor chip 8 is mounted on the flexible printed wiring board 4 by sealing with the sealing resin 10 as shown in FIG.

これにより、半導体チップ８とフレキシブルプリント配線板４との熱膨張係数の差から、接続信頼性が低下することを防止する。そして、最後に導体パターン２ごとに金型で打ち抜いて、図２（Ｅ）に示すような半導体装置を得ていた。   This prevents the connection reliability from being lowered due to the difference in thermal expansion coefficient between the semiconductor chip 8 and the flexible printed wiring board 4. Finally, each conductor pattern 2 was punched with a die to obtain a semiconductor device as shown in FIG.

しかし、このような従来の製造方法では、封止樹脂１０で樹脂封止する際、封止樹脂１０の浸透速度に合わせて半導体チップ８の周囲を描画し、フレキシブルプリント配線板４と半導体チップ８との間に封止樹脂１０を充填する必要があることから、塗布スピードを早くすることができない欠点があった。   However, in such a conventional manufacturing method, when the resin is sealed with the sealing resin 10, the periphery of the semiconductor chip 8 is drawn according to the penetration speed of the sealing resin 10, and the flexible printed wiring board 4 and the semiconductor chip 8 are drawn. Since the sealing resin 10 needs to be filled in between, the coating speed cannot be increased.

そのような欠点を解消すべく、従来の製造方法の中には、図３（Ａ）ないし（Ｇ）に示すような製造方法もある。   In order to eliminate such drawbacks, among the conventional manufacturing methods, there is a manufacturing method as shown in FIGS.

すなわち、この製造方法では、図３（Ａ）に示すように、パーフォレーション３を形成した絶縁基板１の表面に同一の導電パターン２を絶縁基板１の長さ方向に繰り返し形成し、すずめっきとソルダーレジストを行ってフレキシブルプリント配線板４を形成して後、図３（Ｂ）に示すように塗布ノズル９を使用して、半導体チップ８の搭載領域に図３（Ｃ）に示すように封止樹脂１０を塗布する。   That is, in this manufacturing method, as shown in FIG. 3A, the same conductive pattern 2 is repeatedly formed in the length direction of the insulating substrate 1 on the surface of the insulating substrate 1 on which the perforations 3 are formed. After the resist is formed to form the flexible printed wiring board 4, the coating nozzle 9 is used as shown in FIG. 3B to seal the semiconductor chip 8 mounting area as shown in FIG. Resin 10 is applied.

それから、図３（Ｄ）に示すように、加熱ステージ５とボンディングツール７を用いて、チップ電極に設けられた金属バンプ６と導体パターン２のチップ接続端子２ａとを位置合わせし、図３（Ｅ）に示すようにボンディングツール７で熱と圧力を加えてそれらを接合することにより電気的に接続し、図３（Ｆ）に示すように封止樹脂１０で封止してフレキシブルプリント配線板４上に半導体チップ８を搭載する。最後に、導体パターン２ごとに金型で打ち抜いて、図３（Ｇ）に示すような半導体装置を得ていた。   Then, as shown in FIG. 3 (D), the metal bump 6 provided on the chip electrode and the chip connection terminal 2a of the conductor pattern 2 are aligned using the heating stage 5 and the bonding tool 7, and FIG. E) Applying heat and pressure with the bonding tool 7 as shown in FIG. 3B and joining them together, and sealing with a sealing resin 10 as shown in FIG. A semiconductor chip 8 is mounted on 4. Finally, each conductor pattern 2 was punched with a die to obtain a semiconductor device as shown in FIG.

ところが、図２に示すような製造方法も、図３に示すような製造方法も、塗布ノズル９を用いて封止樹脂１０を塗布する必要があるとともに、半導体チップ８を封止して後、封止樹脂１０を加熱硬化する必要があり、生産性の点で問題がある。また、工程数が多くなり、封止樹脂１０の材料コストも高くなって製造コストがアップする問題があった。   However, both the manufacturing method as shown in FIG. 2 and the manufacturing method as shown in FIG. 3 require that the sealing resin 10 be applied using the application nozzle 9, and after the semiconductor chip 8 is sealed, It is necessary to heat and cure the sealing resin 10, which is problematic in terms of productivity. Further, there are problems that the number of steps increases, the material cost of the sealing resin 10 increases, and the manufacturing cost increases.

このため、従来の半導体装置の製造方法の中には、さらに図４に示すように、塗布ノズル９を使用した封止樹脂１０の塗布を行わないようにしたものもある。   For this reason, some conventional semiconductor device manufacturing methods do not apply the sealing resin 10 using the application nozzle 9 as shown in FIG.

まず図４（Ａ）に示すように、銅箔１１の裏面側に加熱によって接着性を発現する熱硬化性樹脂１２を設けて２層シート１３を形成する。一方、絶縁基板１の両面には、導体パターン２を有する両面フレキシブルプリント配線板４を形成する。そして、図４（Ｂ）に示すように、２層シート１３を、両面フレキシブルプリント配線板４の、半導体チップ８を搭載する側にラミネートする。   First, as shown in FIG. 4A, a thermosetting resin 12 that develops adhesiveness is provided on the back side of the copper foil 11 to form a two-layer sheet 13. On the other hand, a double-sided flexible printed wiring board 4 having a conductor pattern 2 is formed on both sides of the insulating substrate 1. Then, as shown in FIG. 4B, the two-layer sheet 13 is laminated on the side of the double-sided flexible printed wiring board 4 on which the semiconductor chip 8 is mounted.

それから、銅箔１１にレジスト塗布、露光、現像、エッチング、レジスト除去などを行い、図４（Ｃ）に示すように導体端子１４を形成し、次に導体端子１４に表面処理を行うことにより図４（Ｄ）に示すように接続端子部１５を有する半導体搭載用基板１６を形成する。その後、図４（Ｅ）に示すようにその半導体搭載用基板１６を加熱ステージ５上にセットし、ボンディングツール７を用いて半導体チップ８のチップ電極と接続端子部１５とを位置合わせする。   Then, resist coating, exposure, development, etching, resist removal, and the like are performed on the copper foil 11 to form the conductor terminals 14 as shown in FIG. 4C, and then the conductor terminals 14 are subjected to surface treatment. As shown in FIG. 4D, the semiconductor mounting substrate 16 having the connection terminal portions 15 is formed. Thereafter, as shown in FIG. 4E, the semiconductor mounting substrate 16 is set on the heating stage 5, and the chip electrode of the semiconductor chip 8 and the connection terminal portion 15 are aligned using the bonding tool 7.

次いで、図４（Ｆ）に示すようにボンディングツール７で熱と圧力を加えて熱硬化性樹脂１２を加熱軟化しながら半導体チップ８のチップ電極を接続端子部１５に押し当て、接続端子部１５を押し込んで熱硬化性樹脂１２中に埋没し、導体パターン２のチップ接続端子２ａに接続して半導体搭載用基板１６上に半導体チップ８を搭載する。それから、導体パターン２ごとに金型で打ち抜いて、図３（Ｇ）に示すような半導体装置を得ていた。   Next, as shown in FIG. 4 (F), heat and pressure are applied by the bonding tool 7 to heat and soften the thermosetting resin 12, and the chip electrode of the semiconductor chip 8 is pressed against the connection terminal portion 15 to connect the connection terminal portion 15. Is embedded in the thermosetting resin 12 and connected to the chip connection terminal 2 a of the conductor pattern 2 to mount the semiconductor chip 8 on the semiconductor mounting substrate 16. Then, each conductor pattern 2 was punched with a die to obtain a semiconductor device as shown in FIG.

特開２０００−３２３６２０号公報JP 2000-323620 A

ところが、図４（Ａ）および（Ｇ）に示す半導体装置では、銅箔１１の裏面側に加熱によって接着性を発現する熱硬化性樹脂１２を設けて２層シート１３を形成する必要があり、さらにその２層シート１３を両面フレキシブルプリント配線板４の、半導体チップ８を搭載する側にラミネートする必要があり、しかもその両面フレキシブルプリント配線板４を製造するためには、非常に多くの工程を必要とするから、工程数が多くなるとともに、材料も多く必要としてコスト高となる問題があった。   However, in the semiconductor device shown in FIGS. 4A and 4G, it is necessary to form the two-layer sheet 13 by providing the thermosetting resin 12 that exhibits adhesiveness by heating on the back surface side of the copper foil 11, Furthermore, it is necessary to laminate the two-layer sheet 13 on the side of the double-sided flexible printed wiring board 4 on which the semiconductor chip 8 is mounted, and in order to manufacture the double-sided flexible printed wiring board 4, a very large number of steps are required. Since this is necessary, there is a problem that the number of steps is increased and more materials are required, resulting in an increase in cost.

そこで、この発明の目的は、製造工程数が少なく、材料費も少なくて済む半導体装置またその製造方法を提供することにある。   SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a semiconductor device having a small number of manufacturing steps and a low material cost, and a manufacturing method thereof.

かかる目的を達成すべく、この発明の第１の態様は、耐熱性を有するポリイミド等を用いた絶縁基板の表面に、加熱により軟化して接着性を発現する熱可塑性樹脂を設け、
その熱可塑性樹脂の表面に導体パターンを形成するとともに、その導体パターンのチップ接続端子を熱可塑性樹脂中に埋没して絶縁基板に押し当て、
そのチップ接続端子に、金めっき等の金属バンプを介してチップ電極を接続して下部を熱可塑性樹脂中に埋没した状態で半導体チップを絶縁基板上に搭載することを特徴とする、半導体装置である。 In order to achieve such an object, a first aspect of the present invention provides a surface of an insulating substrate using a heat-resistant polyimide or the like with a thermoplastic resin that is softened by heating and exhibits adhesiveness.
A conductor pattern is formed on the surface of the thermoplastic resin, and the chip connection terminal of the conductor pattern is buried in the thermoplastic resin and pressed against the insulating substrate,
A semiconductor device characterized in that a chip electrode is connected to the chip connection terminal via a metal bump such as gold plating and a semiconductor chip is mounted on an insulating substrate in a state where a lower part is buried in a thermoplastic resin. is there.

半導体チップには、熱可塑性樹脂中に埋没するエッジ部分にステップカットを設けるとよい。ステップカットは、半導体チップのエッジ部分に、そのエッジ部分が導体パターンに接触しないように階段状に切り欠いて設ける。   The semiconductor chip may be provided with a step cut at the edge portion buried in the thermoplastic resin. The step cut is provided at the edge portion of the semiconductor chip by stepping out so that the edge portion does not contact the conductor pattern.

この発明の第２の態様は、耐熱性を有するポリイミド等を用いた絶縁基板の表面に、加熱により軟化して接着性を発現する熱可塑性樹脂を設け、
その熱可塑性樹脂の表面に導電体を設けてその導電体をエッチングすることにより導体パターンを形成し、
その導電パターンのチップ接続端子に、半導体チップのチップ電極に設ける、金めっき等の金属バンプを位置合わせし、
その半導体チップに熱と圧力とを加えて熱可塑性樹脂を軟化し、チップ接続端子とともに半導体チップを熱可塑性樹脂中に埋没してチップ接続端子を絶縁基板に押し当て、チップ接続端子に金属バンプを接合して半導体チップを絶縁基板上に搭載する、
ことを特徴とする、半導体装置の製造方法である。 According to a second aspect of the present invention, a thermoplastic resin that is softened by heating and exhibits adhesiveness is provided on the surface of an insulating substrate using polyimide or the like having heat resistance,
A conductor pattern is formed by providing a conductor on the surface of the thermoplastic resin and etching the conductor,
Align metal bumps such as gold plating on the chip electrode of the semiconductor chip to the chip connection terminals of the conductive pattern,
Heat and pressure are applied to the semiconductor chip to soften the thermoplastic resin, the semiconductor chip is buried in the thermoplastic resin together with the chip connection terminal, the chip connection terminal is pressed against the insulating substrate, and metal bumps are applied to the chip connection terminal. Bonding and mounting a semiconductor chip on an insulating substrate,
This is a method for manufacturing a semiconductor device.

導電体は、例えば、熱可塑性樹脂の表面にスパッタ層を形成して後、電解めっきを行って設ける。または、熱可塑性樹脂を介してラミネートして設ける。一方、導体パターンを形成して後、少なくともチップ接続端子の表面には、すずめっき、金めっき、ニッケル下地の金めっき、インジュウムめっきのいずれか１つのめっきを行うとよい。   The conductor is provided, for example, by forming a sputter layer on the surface of a thermoplastic resin and then performing electroplating. Or it laminates and provides through a thermoplastic resin. On the other hand, after forming the conductor pattern, at least the surface of the chip connection terminal may be plated with any one of tin plating, gold plating, gold plating of nickel base, and indium plating.

この発明によれば、絶縁基板の表面に熱可塑性樹脂を設け、その表面に導体パターンを形成し、その導体パターンのチップ接続端子に半導体チップの金属バンプを位置合わせしてから、半導体チップに熱と圧力とを加えて熱可塑性樹脂を軟化し、チップ接続端子とともに半導体チップを熱可塑性樹脂中に埋没してチップ接続端子を絶縁基板に押し当て、チップ接続端子に金属バンプを接合して半導体チップを絶縁基板上に搭載するので、アンダーフィル材を半導体チップと絶縁基板間に充填する必要がなく、従来のような塗布ノズルを用いた封止樹脂の塗布を不要として、製造工程数が少なく、材料費も少なくて済む半導体装置またその製造方法を提供することができる。   According to the present invention, the thermoplastic resin is provided on the surface of the insulating substrate, the conductor pattern is formed on the surface, the metal bumps of the semiconductor chip are aligned with the chip connection terminals of the conductor pattern, and then the semiconductor chip is heated. Apply pressure and pressure to soften the thermoplastic resin, bury the semiconductor chip together with the chip connection terminal in the thermoplastic resin, press the chip connection terminal against the insulating substrate, and join the metal bump to the chip connection terminal to make the semiconductor chip Since it is mounted on an insulating substrate, it is not necessary to fill an underfill material between the semiconductor chip and the insulating substrate, and there is no need to apply a sealing resin using a conventional application nozzle, and the number of manufacturing processes is small. It is possible to provide a semiconductor device that requires less material costs and a method for manufacturing the same.

請求項２に記載の発明によれば、半導体チップには、熱可塑性樹脂中に埋没するエッジ部分にステップカットを設けるので、半導体チップのエッジ部分が導体パターンに接触しないようにすることができる。   According to the second aspect of the present invention, since the step cut is provided in the edge portion embedded in the thermoplastic resin in the semiconductor chip, the edge portion of the semiconductor chip can be prevented from contacting the conductor pattern.

請求項６に記載の発明によれば、導体パターンを形成して後、少なくともチップ接続端子の表面にすずめっき、金めっき、ニッケル下地の金めっき、インジュウムめっきのいずれか１つのめっきを行うので、チップ接続端子の防錆を行い、チップ接続端子と金属バンプとの電気的な接続をより確実なものとすることができる。すずめっきの場合には、Ａｕ−Ｓｎ共晶接合を行うことを可能として、チップ接続端子と金属バンプとの接続のさらなる信頼性の向上を図ることができる。   According to the invention described in claim 6, after the conductor pattern is formed, at least the surface of the chip connection terminal is subjected to any one of tin plating, gold plating, gold plating of nickel base, and indium plating. It is possible to prevent the chip connection terminals from being rusted and to secure the electrical connection between the chip connection terminals and the metal bumps. In the case of tin plating, Au—Sn eutectic bonding can be performed, and the reliability of the connection between the chip connection terminal and the metal bump can be further improved.

以下、図面を参照しつつ、この発明の実施の最良形態について説明する。
図１（Ａ）ないし（Ｆ）には、半導体装置の製造工程を示す。 The best mode for carrying out the present invention will be described below with reference to the drawings.
1A to 1F show a manufacturing process of a semiconductor device.

図中符号２０は、可撓性とともに耐熱性を有する長尺プラスチックフィルム製の絶縁基板であり、厚さが１２．５〜５０μｍのポリイミドなどを使用する。例えば、宇部興産（株）製の商品名「ユーピレックス」や、東レ・デュポン（株）製の商品名「カプトン」などを用いる。   Reference numeral 20 in the drawing is an insulating substrate made of a long plastic film having flexibility and heat resistance, and polyimide having a thickness of 12.5 to 50 μm is used. For example, the product name “UPILEX” manufactured by Ube Industries, Ltd., or the product name “Kapton” manufactured by Toray DuPont Co., Ltd. is used.

耐熱性を有する絶縁基板２０の表面には、加熱により軟化して接着性を発現する熱可塑性樹脂２１を設ける。熱可塑性樹脂２１は、厚さが２５〜５０μｍ、好適には３０〜４０μｍで、ガラス転移温度または熱変形温度３００℃以下の熱可塑性ポリイミド接着フィルムを使用する。例えば三井東圧化学株式会社製の「ＬＡＲＣ−ＴＰＩフィルム」などを用い、熱と圧力とを加えて絶縁基板２０の表面にラミネートして形成する。   On the surface of the insulating substrate 20 having heat resistance, a thermoplastic resin 21 that is softened by heating and exhibits adhesiveness is provided. The thermoplastic resin 21 has a thickness of 25 to 50 μm, preferably 30 to 40 μm, and uses a thermoplastic polyimide adhesive film having a glass transition temperature or a heat distortion temperature of 300 ° C. or less. For example, “LARC-TPI film” manufactured by Mitsui Toatsu Chemical Co., Ltd. is used, and heat and pressure are applied and laminated on the surface of the insulating substrate 20.

熱可塑性樹脂２１の表面には、Ｎｉ−Ｃｒ合金のスパッタ層を形成して後、電解めっきを行って図１（Ａ）に示すように導電体２２を設け、基材２３を形成する。または、熱可塑性樹脂２１を介してラミネートして導電体２２を設け、基材２３を形成する。導電体２２は、銅めっきにより例えば厚さ５〜１２μｍとし、好適には７〜９μｍとする。それから、基材２３の両側縁に、金型を用いて長さ方向に一定間隔置きに打ち抜いてパーフォレーション２４をあける。   A sputter layer of Ni—Cr alloy is formed on the surface of the thermoplastic resin 21, and then electroplating is performed to provide a conductor 22 as shown in FIG. Alternatively, the conductive material 22 is provided by laminating via the thermoplastic resin 21 to form the base material 23. The conductor 22 is, for example, 5 to 12 μm thick, preferably 7 to 9 μm, by copper plating. Then, perforations 24 are formed by punching the both sides of the base material 23 at regular intervals in the length direction using a mold.

その後、導電体２２の表面にフォトレジストを塗布して後、パーフォレーション２４を用いて基材２３を搬送位置決めしながら露光、現像を行ってから、エッチングし、そしてレジストを除去することにより、図１（Ｂ）に示すように導電体２２で、チップ接続端子２５ａを有する導体パターン２５を形成する。   Thereafter, after applying a photoresist to the surface of the conductor 22, exposure and development are performed while transporting and positioning the base material 23 using the perforation 24, and then etching is performed, and then the resist is removed. As shown in (B), the conductor pattern 25 having the chip connection terminals 25a is formed by the conductor 22.

次いで、導体パターン２５の表面に、すずめっき、金めっき、ニッケル下地の金めっき、インジュウムめっきなどを行い、半導体チップとの電気的接続を良好とし、また防錆効果を高める。また必要に応じ、導体パターン２５にチップ接続端子２５ａおよびその他の接続端子部分を除いて、印刷により、可撓性に優れたソルダーレジストを設け、導体パターン２５を保護してフレキシブルプリント配線板２７を形成する。このフレキシブルプリント配線板２７のソルダーレジストを設ける工程は、めっき工程の前でも後でもよい。   Next, the surface of the conductor pattern 25 is subjected to tin plating, gold plating, nickel base gold plating, indium plating, or the like to improve the electrical connection with the semiconductor chip and enhance the rust prevention effect. Further, if necessary, a solder resist having excellent flexibility is provided by printing except for the chip connection terminals 25a and other connection terminal portions on the conductor pattern 25, and the flexible printed wiring board 27 is protected by protecting the conductor pattern 25. Form. The step of providing the solder resist for the flexible printed wiring board 27 may be before or after the plating step.

それから、図１（Ｃ）に示すように、フレキシブルプリント配線板２７を、所定の温度に設定した加熱ステージ２８上にセットし、同じく所定の温度に設定したボンディングツール３０で半導体チップ３２を保持して、そのチップ電極に設けられた、金めっき等の金属バンプ３３を導体パターン２５のチップ接続端子２５ａに位置合わせし、ボンディングツール３０を下降して半導体チップ３２を介して熱と圧力を加え、金属バンプ３３とチップ接続端子２５ａとを接続する。   Then, as shown in FIG. 1C, the flexible printed wiring board 27 is set on the heating stage 28 set to a predetermined temperature, and the semiconductor chip 32 is held by the bonding tool 30 also set to the predetermined temperature. Then, the metal bump 33 such as gold plating provided on the chip electrode is aligned with the chip connection terminal 25a of the conductor pattern 25, the bonding tool 30 is lowered, and heat and pressure are applied via the semiconductor chip 32, The metal bump 33 and the chip connection terminal 25a are connected.

その後、時間の経過とともに、ボンディングツール３０の熱は、半導体チップ３２から金属バンプ３３およびチップ接続端子２５ａを介して熱可塑性樹脂２１に伝わる。また、加熱ステージ２８の熱は、絶縁基板２０を介して熱可塑性樹脂２１に伝わる。これにより、絶縁基板２０は耐熱性のポリイミドを用いることから熱により軟化しないし、圧力により変形もしないが、熱可塑性樹脂２１は軟化し、図１（Ｄ）に示すようにチップ接続端子２５ａとともに半導体チップ３２の下部を熱可塑性樹脂２１中に埋没してチップ接続端子２５ａを絶縁基板２０に押し当て、チップ接続端子２５ａに金属バンプ３３を確実に接合して電気的に確実に接続し、半導体チップ３２を絶縁基板２０上に搭載してフレキシブルプリント配線板２７に実装する。   Thereafter, as time passes, the heat of the bonding tool 30 is transferred from the semiconductor chip 32 to the thermoplastic resin 21 via the metal bumps 33 and the chip connection terminals 25a. Further, the heat of the heating stage 28 is transmitted to the thermoplastic resin 21 through the insulating substrate 20. As a result, the insulating substrate 20 is made of heat-resistant polyimide, so that it is not softened by heat and is not deformed by pressure, but the thermoplastic resin 21 is softened, together with the chip connection terminals 25a as shown in FIG. The lower part of the semiconductor chip 32 is buried in the thermoplastic resin 21, the chip connection terminal 25a is pressed against the insulating substrate 20, the metal bump 33 is securely bonded to the chip connection terminal 25a, and the semiconductor is securely connected electrically. The chip 32 is mounted on the insulating substrate 20 and mounted on the flexible printed wiring board 27.

この後、ボンディングツール３０を上昇してフレキシブルプリント配線板２７を搬送し、図１（Ｅ）に示すように半導体チップ搭載領域を加熱ステージ２８から離し、熱可塑性樹脂２１の温度を下げる。そして、熱可塑性樹脂２１を硬化するとともに、その線膨張係数に従って収縮する。これにより、チップ接続端子２５ａと金属バンプ３３との接合部には、絶えずそれらを圧接する力が働くようになっており、常に高い信頼性を確保することができる。   Thereafter, the bonding tool 30 is raised to convey the flexible printed wiring board 27, and the semiconductor chip mounting area is separated from the heating stage 28 as shown in FIG. 1E, and the temperature of the thermoplastic resin 21 is lowered. And while hardening the thermoplastic resin 21, it shrink | contracts according to the linear expansion coefficient. Thereby, a force that constantly presses the chip connecting terminals 25a and the metal bumps 33 is applied to the joints, so that high reliability can always be ensured.

ところで、熱可塑性樹脂２１の材料は、ガラス転移温度が２５０℃程度の熱可塑性ポリイミド材を用いた場合、加熱ステージ２８の温度は３００〜５００℃、ボンディングツール３０の温度も同じく３００〜５００℃程度が好ましい。例えば、加熱ステージ２８の温度を３２０℃、ボンディングツール３０の温度を３４０℃とする。   By the way, as the material of the thermoplastic resin 21, when a thermoplastic polyimide material having a glass transition temperature of about 250 ° C. is used, the temperature of the heating stage 28 is 300 to 500 ° C., and the temperature of the bonding tool 30 is also about 300 to 500 ° C. Is preferred. For example, the temperature of the heating stage 28 is 320 ° C., and the temperature of the bonding tool 30 is 340 ° C.

また、チップ接続端子２５ａに施すめっきをすずめっきに限定した場合、加熱ステージ２８の温度を３００〜５００℃、ボンディングツール３０の温度を４００〜５００℃程度にすることで、金属バンプ３３と、すずめっきされたチップ接続端子２５ａとの接合をＡｕ−Ｓｎ共晶接合にすることができる。   When the plating applied to the chip connection terminal 25a is limited to tin plating, the temperature of the heating stage 28 is set to 300 to 500 ° C., and the temperature of the bonding tool 30 is set to about 400 to 500 ° C. The bonding with the plated chip connection terminal 25a can be an Au—Sn eutectic bonding.

このＡｕ−Ｓｎ共晶接合にした場合にも、ボンディングツール３０と加熱ステージ２８を引き離すことにより熱可塑性樹脂２１の温度が下がり、線膨張係数に従って収縮することから、同様にチップ接続端子２５ａと金属バンプ３３との接合部には、絶えずそれらを圧接する力が働くようになっており、常に高い信頼性を確保することができる。   Even in this Au—Sn eutectic bonding, the bonding tool 30 and the heating stage 28 are separated to lower the temperature of the thermoplastic resin 21 and shrink according to the linear expansion coefficient. A force that constantly presses the bumps 33 is applied to the joints with the bumps 33, so that high reliability can always be ensured.

さて、以上のような構成とすると、半導体チップ３２のエッジ部分が導体パターン２５に接触するおそれがある。このため、図示例では、半導体チップ３２の、熱可塑性樹脂２１中に埋没するエッジ部分に、ステップカット３５を設ける。ステップカット３５は、半導体ウエハを切断して半導体チップ３２にする段階で、エッジ部分が導体パターンに接触しないようにエッジ部分を階段状に切り欠いて形成する。   With the above configuration, the edge portion of the semiconductor chip 32 may come into contact with the conductor pattern 25. For this reason, in the illustrated example, the step cut 35 is provided at the edge portion of the semiconductor chip 32 embedded in the thermoplastic resin 21. The step cut 35 is formed by cutting the edge portion stepwise so that the edge portion does not contact the conductor pattern at the stage of cutting the semiconductor wafer into the semiconductor chip 32.

上述したとおり、図１に示す製造方法によれば、絶縁基板２０の表面に熱可塑性樹脂２１を設け、その表面に導体パターン２５を形成し、その導体パターン２５のチップ接続端子２５ａに半導体チップ３２の金属バンプ３３を位置合わせしてから、半導体チップ３２に熱と圧力とを加えて熱可塑性樹脂２１を軟化し、チップ接続端子２５ａとともに半導体チップ３２を熱可塑性樹脂２１中に埋没してチップ接続端子２５ａを絶縁基板２０に押し当て、チップ接続端子２５ａに金属バンプ３３を接合して半導体チップ３２を絶縁基板２０上に搭載する。そこで、アンダーフィル材を半導体チップ３２と絶縁基板２０間に充填する必要がなく、従来のような塗布ノズルを用いた封止樹脂の塗布を不要として、製造工程数が少なく、材料費も少なくて済む。   As described above, according to the manufacturing method shown in FIG. 1, the thermoplastic resin 21 is provided on the surface of the insulating substrate 20, the conductor pattern 25 is formed on the surface, and the semiconductor chip 32 is connected to the chip connection terminal 25 a of the conductor pattern 25. After the metal bumps 33 are aligned, heat and pressure are applied to the semiconductor chip 32 to soften the thermoplastic resin 21, and the semiconductor chip 32 is embedded in the thermoplastic resin 21 together with the chip connection terminals 25a to connect the chip. The terminal 25a is pressed against the insulating substrate 20, the metal bump 33 is bonded to the chip connecting terminal 25a, and the semiconductor chip 32 is mounted on the insulating substrate 20. Therefore, it is not necessary to fill the underfill material between the semiconductor chip 32 and the insulating substrate 20, and it is not necessary to apply a sealing resin using a conventional application nozzle, so that the number of manufacturing processes is small and the material cost is low. That's it.

そして、半導体チップ３２を実装したフレキシブルプリント配線板２７は、最後に単位ごとに金型などで打ち抜いて、図１（Ｆ）に示すような半導体装置を得る。   Then, the flexible printed wiring board 27 on which the semiconductor chip 32 is mounted is finally punched for each unit with a die or the like to obtain a semiconductor device as shown in FIG.

よって、図１（Ｆ）に示す半導体装置は、耐熱性を有する絶縁基板２０の表面に、加熱により軟化して接着性を発現する熱可塑性樹脂２１を設け、その熱可塑性樹脂２１の表面に導体パターン２５を形成するとともに、その導体パターン２５のチップ接続端子２５ａを熱可塑性樹脂２１中に埋没して絶縁基板２０に押し当て、そのチップ接続端子２５ａに金属バンプ３３を介してチップ電極を接続して下部を熱可塑性樹脂２１中に埋没した状態で半導体チップ３２を絶縁基板２０上に搭載する。   Therefore, in the semiconductor device illustrated in FIG. 1F, the thermoplastic resin 21 that is softened by heating and exhibits adhesiveness is provided on the surface of the insulating substrate 20 having heat resistance, and a conductor is provided on the surface of the thermoplastic resin 21. The pattern 25 is formed, the chip connection terminal 25a of the conductor pattern 25 is buried in the thermoplastic resin 21 and pressed against the insulating substrate 20, and the chip electrode is connected to the chip connection terminal 25a via the metal bump 33. Then, the semiconductor chip 32 is mounted on the insulating substrate 20 with the lower part buried in the thermoplastic resin 21.

（Ａ）ないし（Ｆ）は、この発明による半導体装置の製造工程図である。(A) thru | or (F) is a manufacturing-process figure of the semiconductor device by this invention. （Ａ）ないし（Ｅ）は、ＣＯＦ実装方式を用いる、従来の半導体装置の製造工程図である。(A) thru | or (E) is a manufacturing-process figure of the conventional semiconductor device using a COF mounting system. （Ａ）ないし（Ｇ）は、従来の別の半導体装置の製造工程図である。(A) thru | or (G) is a manufacturing-process figure of another conventional semiconductor device. （Ａ）ないし（Ｇ）は、従来のさらに別の半導体装置の製造工程図である。(A) thru | or (G) is a manufacturing-process figure of another conventional semiconductor device.

符号の説明Explanation of symbols

２０ 絶縁基板
２１ 熱可塑性樹脂
２２ 導電体
２３ 基材
２５ 導体パターン
２５ａ チップ接続端子
２７ フレキシブルプリント配線板
２８ 加熱ステージ
３０ ボンディングツール
３２ 半導体チップ
３３ 金属バンプ
３５ ステップカット

20 Insulating substrate 21 Thermoplastic resin 22 Conductor 23 Base material 25 Conductive pattern 25a Chip connection terminal 27 Flexible printed wiring board 28 Heating stage 30 Bonding tool 32 Semiconductor chip 33 Metal bump 35 Step cut

Claims (6)

耐熱性を有する絶縁基板の表面に、加熱により軟化して接着性を発現する熱可塑性樹脂を設け、
その熱可塑性樹脂の表面に導体パターンを形成するとともに、その導体パターンのチップ接続端子を前記熱可塑性樹脂中に埋没して前記絶縁基板に押し当て、
そのチップ接続端子に金属バンプを介してチップ電極を接続して下部を前記熱可塑性樹脂中に埋没した状態で半導体チップを前記絶縁基板上に搭載する、
ことを特徴とする、半導体装置。 The surface of the insulating substrate having heat resistance is provided with a thermoplastic resin that is softened by heating and exhibits adhesiveness.
While forming a conductor pattern on the surface of the thermoplastic resin, the chip connection terminal of the conductor pattern is buried in the thermoplastic resin and pressed against the insulating substrate,
A chip electrode is connected to the chip connection terminal via a metal bump, and a semiconductor chip is mounted on the insulating substrate in a state where a lower part is buried in the thermoplastic resin.
A semiconductor device. 前記半導体チップの、前記熱可塑性樹脂中に埋没するエッジ部分にステップカットを設けることを特徴とする、請求項１に記載の半導体装置。   The semiconductor device according to claim 1, wherein a step cut is provided at an edge portion of the semiconductor chip that is buried in the thermoplastic resin. 耐熱性を有する絶縁基板の表面に、加熱により軟化して接着性を発現する熱可塑性樹脂を設け、
その熱可塑性樹脂の表面に導電体を設けてその導電体をエッチングすることにより導体パターンを形成し、
その導電パターンのチップ接続端子に、半導体チップのチップ電極に設ける金属バンプを位置合わせし、
その半導体チップに熱と圧力とを加えて前記熱可塑性樹脂を軟化し、前記チップ接続端子とともに前記半導体チップを熱可塑性樹脂中に埋没して前記チップ接続端子を前記絶縁基板に押し当て、前記チップ接続端子に前記金属バンプを接合して前記半導体チップを前記絶縁基板上に搭載する、
ことを特徴とする、半導体装置の製造方法。 The surface of the insulating substrate having heat resistance is provided with a thermoplastic resin that is softened by heating and exhibits adhesiveness.
A conductor pattern is formed by providing a conductor on the surface of the thermoplastic resin and etching the conductor,
The metal bumps provided on the chip electrodes of the semiconductor chip are aligned with the chip connection terminals of the conductive pattern,
Heat and pressure are applied to the semiconductor chip to soften the thermoplastic resin, the semiconductor chip is buried in the thermoplastic resin together with the chip connection terminal, and the chip connection terminal is pressed against the insulating substrate, and the chip The semiconductor chip is mounted on the insulating substrate by bonding the metal bumps to connection terminals.
A method for manufacturing a semiconductor device. 前記熱可塑性樹脂の表面にスパッタ層を形成して後、電解めっきを行って前記導電体を設けることを特徴とする、請求項３に記載の半導体装置の製造方法。   The method of manufacturing a semiconductor device according to claim 3, wherein after forming a sputter layer on the surface of the thermoplastic resin, electrolytic plating is performed to provide the conductor. 前記熱可塑性樹脂を介してラミネートして前記導電体を設けることを特徴とする、請求項３に記載の半導体装置の製造方法。   The method of manufacturing a semiconductor device according to claim 3, wherein the conductor is provided by laminating via the thermoplastic resin. 前記導体パターンを形成して後、少なくとも前記チップ接続端子の表面にすずめっき、金めっき、ニッケル下地の金めっき、インジュウムめっきのいずれか１つのめっきを行うことを特徴とする、請求項３ないし５のいずれかに記載の半導体装置の製造方法。
6. After forming the conductor pattern, at least the surface of the chip connection terminal is subjected to any one of tin plating, gold plating, gold plating of nickel base, and indium plating. A method for manufacturing a semiconductor device according to any one of the above.
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