JP4888666B2 - Semiconductor wafer inspection method and semiconductor chip manufacturing method - Google Patents

Description

  The present invention relates to a method for inspecting a semiconductor wafer by wafer probing and a method for manufacturing a semiconductor chip.

  In a semiconductor chip manufacturing process, an electrical inspection is performed on each semiconductor chip on a semiconductor wafer on which a large number of semiconductor chips are formed, and defective products are screened. As this inspection, there is a probe inspection using probing. In general, after the probe inspection of the wafer, the wafer is diced to form a chip. Therefore, for example, in the subsequent semiconductor chip mounting process, when heat and pressure are applied to the electrodes of the semiconductor chip, a failure may occur in the semiconductor element of the semiconductor chip. However, in the conventional general semiconductor chip manufacturing method, such a failure is detected by, for example, a package inspection after mounting the semiconductor chip, and thus cannot be detected earlier than this.

  An object of the present invention is to provide a semiconductor wafer inspection method capable of screening a failure that may occur in an initial failure period with higher accuracy.

  Another object of the present invention is to provide a method of manufacturing a semiconductor chip using the inspection method of the present invention.

A method for inspecting a semiconductor wafer according to the present invention includes:
Preparing a semiconductor wafer on which a chip region having electrodes is formed;
A first inspection step of inspecting the semiconductor wafer by probing;
Pressing the electrode with a load larger than the load pressing the electrode during mounting; and
A second inspection step of inspecting the semiconductor wafer by probing in this order .
According to the method for inspecting a semiconductor wafer of the present invention, it is possible to detect in advance a failure that is likely to occur at the time of mounting a semiconductor chip at the stage of the semiconductor wafer, so that screening can be performed more reliably. As a result, a failure rate can be reduced and a highly reliable semiconductor chip can be obtained.
In the semiconductor wafer inspection method of the present invention, the electrode can be further heated in the pressing step.
In the semiconductor wafer inspection method of the present invention, in the pressing step, the pressing can be performed using a pressing member having a flat surface.
In the semiconductor wafer inspection method of the present invention, the upper surface of the electrode can be flattened in the pressing step.
In the semiconductor wafer inspection method of the present invention, in the pressing step, the pressing can be performed using a bonding tool.
In the semiconductor wafer inspection method of the present invention, a semiconductor element may be formed below the electrode.
In the semiconductor wafer inspection method of the present invention, the electrode may have a bump, and the semiconductor element may be a transistor.
The semiconductor chip manufacturing method of the present invention can include a semiconductor wafer inspection method.
In the semiconductor wafer inspection method of the present invention, a step of preparing a semiconductor wafer in which a chip region having a semiconductor element and an electrode is formed;
A first inspection step of inspecting the semiconductor wafer by probing;
Pressing the electrode;
A second inspection step of inspecting the semiconductor wafer by probing, in this order,
The second inspection step is a step of detecting a failure of the semiconductor element generated by the pressing step.
In the semiconductor wafer inspection method of the present invention, the electrode can be further heated in the pressing step.
In the semiconductor wafer inspection method of the present invention, in the pressing step, the pressing can be performed using a pressing member having a flat surface.
In the semiconductor wafer inspection method of the present invention, the upper surface of the electrode can be flattened in the pressing step.
In the semiconductor wafer inspection method of the present invention, in the pressing step, the pressing can be performed using a bonding tool.
In the semiconductor wafer inspection method of the present invention,
The semiconductor element may be formed below the electrode.
In the semiconductor wafer inspection method of the present invention, the electrode may have a bump, and the semiconductor element may be a transistor.
The semiconductor chip manufacturing method of the present invention can include an inspection method.

  Hereinafter, an example of an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a diagram for explaining a semiconductor wafer inspection method according to the present embodiment. FIG. 2 is a cross-sectional view schematically showing one step of the semiconductor wafer inspection method. FIG. 3 is a plan view schematically showing a wafer to be inspected. FIG. 4 is a cross-sectional view schematically showing a part of the chip region.

  In this embodiment, first, a wafer to be inspected is prepared. As shown in FIGS. 2 and 3, the wafer is formed with a plurality of chip regions 12 which are later cut into semiconductor chips on a semiconductor substrate 10. The chip area 12 is provided with an integrated circuit (not shown). The configuration of the integrated circuit is not particularly limited, and can include, for example, active elements such as transistors and passive elements such as resistors, coils, and capacitors.

  The chip region 12 has a connection electrode 14. The electrode 14 can be electrically connected to the inside of the chip region 12. In addition, an electrode that is not electrically connected to the chip region 12 may be referred to as an electrode 14. As shown in FIG. 4, the electrode 14 may include a pad 16 and a bump 18 formed on the pad 16. At this time, the bump 18 may have a structure in which, for example, a gold bump or a nickel bump is plated with gold.

The wafer is inspected according to the procedure shown in FIG.
(A) First, the wafer is subjected to a first probe inspection (S1) by probing using a probe apparatus. Probe inspection is not particularly limited, and a known method can be employed. For example, in the probe inspection, as shown in FIG. 3, the probe needle of the probe card is brought into contact with the electrode 14 formed on the chip area 12 of the semiconductor wafer, a predetermined voltage is applied from the probe needle, and each chip area is detected by a tester. Conduct electrical inspection such as 12 continuity tests. The probe inspection is performed by bringing a probe needle into contact with the electrode 14 for each one chip region 12 or a plurality of tip regions 12, and the tip regions 12 can be sequentially inspected, for example, as indicated by arrows in FIG. .
(B) Next, the electrode 14 of the wafer is pressed by the pressure member (S2). In this step, as shown in FIG. 2, the pressure member 20 having the flat surface 22 is lowered with the flat surface 22 facing down, and the flat surface 22 is brought into contact with the upper surface of the electrode 14. Then, the pressure member 20 is lowered and the electrode 14 is pressed so that a predetermined pressure is applied to the electrode 14. Furthermore, when it is desired to examine the influence of heating of the electrode 14, this pressing operation can be performed while the pressure member 20 is heated.

  For example, when a semiconductor chip is mounted on a mounting substrate, the electrode 14 is usually pressed against the wiring portion of the mounting substrate while heating the electrode 14 with a bonding tool. When it is desired to inspect the influence at this time, the influence can be more reliably inspected by pressurizing and heating the electrode 14 under conditions stricter than the mounting conditions in this step (b).

  For example, for reference, an example of conditions for COG (Chip On Glass) mounting and conditions in this step (b) will be described below. It should be noted that both the lowering speed of the pressure member 20 and the time of the pressing operation can be the same.

COG step (b)
Load applied to the electrode 14 30 MPa 45 MPa
Temperature of electrode 14 300 ° C. or lower 300 to 350 ° C.
The pressing / heating operation in this step (b) can be performed for each chip region 12 or for each of the plurality of chip regions 12. In this step (b), the upper surface of the bump 18 of the electrode 14 is flattened.

The pressure member 20 is not particularly limited as long as at least pressure adjustment, preferably pressure and heating can be adjusted. For example, the pressure member 20 is used to collectively connect wiring portions of a mounting substrate and electrodes of a semiconductor chip. Can also be used as a bonding tool.
(C) Next, similarly to the first probe inspection, a second probe inspection for inspecting the wafer by probing is performed (S3). By this probe inspection, it is possible to detect a failure that has occurred in the pressurizing step in the step (b) or the pressurizing / heating step.

  The inspection method of the present embodiment can be applied to a semiconductor wafer having a general semiconductor chip, but is also useful for an inspection method of a semiconductor wafer having a semiconductor device of the type described below.

  In such a semiconductor device, as shown in FIG. 4, a semiconductor element such as a MIS (Metal Insulator Semiconductor) transistor 30 is also formed below the electrode 14. Specifically, in this semiconductor device, an element isolation insulating layer 20 is provided on a semiconductor substrate 10. The element isolation insulating layer 20 can be formed by an STI method, a LOCOS method, and a semi-recessed LOCOS method. FIG. 4 shows the element isolation insulating layer 20 formed by the STI method. A MIS transistor 30 is provided in a region 10A below the electrode 14. Also, in the region 10B outside the lower side of the electrode 14, the MIS transistor 40 is provided as in the region 10A. The MIS transistor 30 includes a gate insulating layer 32, a gate electrode 34 provided on the gate insulating layer 32, and an impurity region 36 provided on the semiconductor layer 10. The impurity region 36 becomes a source region or a drain region. The MIS transistor 40 has the same structure as the MIS transistor 30 and includes a gate insulating layer 42, a gate electrode 44, and an impurity region 46. The gate electrodes 34 and 44 are composed of, for example, a polysilicon layer or a polycide layer. Although not shown in FIG. 4, the MIS transistors 30 and 40 can have sidewall insulating layers. In FIG. 4, reference numeral 14 indicates a wiring layer.

  Above the MIS transistors 30 and 40, an interlayer insulating layer 50 and an interlayer insulating layer 60 provided so as to cover the MIS transistors 30 and 40 are sequentially provided. For the interlayer insulating layer 50 and the interlayer insulating layer 60, a known general material can be used. A wiring layer 52 having a predetermined pattern is provided on the interlayer insulating layer 50, and the wiring layer 52 and the impurity region 36 of the MIS transistor 30 are electrically connected by a contact layer 54.

A pad 16 is provided on the interlayer insulating layer 60. The pad 16 can be electrically connected by the wiring layer 52 and the contact layer 64. The pad 16 can be formed of a metal such as aluminum or copper. The semiconductor device can further include a passivation layer 70. In the passivation layer 70, an opening 72 that exposes at least a part of the pad 16 is formed. The opening 72 may be formed so as to expose only the central region of the pad 16. That is, the passivation layer 70 can be formed so as to cover the peripheral edge of the pad 16. The passivation layer can be formed of, for example, SiO ₂ , SiN, polyimide resin, or the like.

  Bumps 18 are provided in the openings 72. That is, the bump 18 is provided on the exposed surface of the pad 16. In this semiconductor device, the bump 18 is formed to reach the passivation layer 70. The bump 18 is formed of one layer or a plurality of layers, and can be formed of a metal such as gold, nickel, or copper. The outer shape of the bump 18 is not particularly limited, but may be a rectangle (including a square and a rectangle) or a circle. Further, the outer shape of the bump 18 may be smaller than the pad 16. At this time, the bump 18 may be formed only in a region overlapping with the pad 16.

  Although not shown, a barrier layer may be provided in the lowermost layer of the bump 18. The barrier layer is for preventing diffusion of the material of both the pad 16 and the bump 18. The barrier layer can be formed of one layer or a plurality of layers. The barrier layer may be formed by sputtering. Further, the barrier layer may further have a function of improving the adhesion between the pad 16 and the bump 18. The barrier layer may have a titanium tungsten (TiW) layer. When the barrier layer is composed of a plurality of layers, the outermost surface of the barrier layer may be an electroplating power supply metal layer (for example, an Au layer) on which the bumps 18 are deposited.

  In the semiconductor device as shown in FIG. 4, since the MIS transistor 30 is formed below the electrode 14, when pressure and heat are applied to the electrode 14 when the electrode 14 is connected to another member, The influence is also given below the electrode 14. Therefore, the device is more likely to fail than the case where the device such as the MIS transistor is not formed below the electrode 14. However, according to the inspection method of the present embodiment, by having the steps (b) and (c), it is possible to detect a failure that is likely to occur due to the influence before mounting the semiconductor chip. This is of course the same when no MIS transistor is formed below the electrode 14.

  After the above inspection method is performed, a semiconductor chip can be formed by cutting the wafer using a known dicing method or the like.

  The present embodiment has the following operational effects.

  First, according to the inspection method of the present embodiment, it is possible to detect in advance a failure that is likely to occur, for example, at the time of mounting at the stage of a semiconductor wafer. As a result, the failure rate of the semiconductor chip to be used can be reduced, and a highly reliable semiconductor chip can be obtained. This feature is particularly advantageous in the case of a semiconductor wafer in which an element such as a MIS transistor is formed below the electrode.

  Further, according to the inspection method of the present embodiment, in step (b), the upper surface of the bumps 18 of the electrode 14 can be flattened by pressing, preferably pressing and heating the upper surface of the electrode 14. As a result, it is possible to obtain a semiconductor chip having the electrodes 14 with good flatness of the bumps 18 and high connection reliability.

  In addition, this invention is not limited to embodiment mentioned above, A various deformation | transformation is possible. For example, the present invention includes configurations that are substantially the same as the configurations described in the embodiments (for example, configurations that have the same functions, methods, and results, or configurations that have the same objects and effects). In addition, the invention includes a configuration in which a non-essential part of the configuration described in the embodiment is replaced. In addition, the invention includes a configuration that achieves the same effect as the configuration described in the embodiment or a configuration that can achieve the same object. Further, the invention includes a configuration in which a known technique is added to the configuration described in the embodiment.

The figure which shows the process order of embodiment concerning this invention. The figure which shows the process of embodiment concerning this invention. The figure which shows the process of embodiment concerning this invention. The figure which shows the one part structure in the semiconductor wafer of embodiment concerning this invention.

Explanation of symbols

10 semiconductor substrate, 14 electrodes, 16 pads, 18 bumps, 20 pressure members, 22 flat surface, 30, 40 MIS transistors.

Claims (15)

Preparing a semiconductor wafer on which a chip region having electrodes is formed;
A first inspection step of inspecting the semiconductor wafer by probing;
Pressing the electrode with a load larger than the load pressing the electrode during mounting; and
A semiconductor wafer inspection method comprising: a second inspection step for inspecting the semiconductor wafer by probing in this order. In claim 1,
A method for inspecting a semiconductor wafer, wherein the electrode is further heated in the pressing step. In claim 1 or 2,
In the pressing step, the pressing is performed using a pressing member having a flat surface. In any one of Claims 1 thru | or 3,
A method for inspecting a semiconductor wafer, wherein the upper surface of the electrode is planarized in the pressing step. In any one of Claims 1 thru | or 4,
In the pressing step, the pressing is performed using a bonding tool. In any one of Claims 1 thru | or 5,
A method for inspecting a semiconductor wafer, wherein a semiconductor element is formed below the electrode. In claim 6,
The electrode has a bump;
The method for inspecting a semiconductor wafer, wherein the semiconductor element is a transistor.   A method for manufacturing a semiconductor chip, comprising the method for inspecting a semiconductor wafer according to claim 1. Preparing a semiconductor wafer on which a chip region having a semiconductor element and an electrode is formed;
A first inspection step of inspecting the semiconductor wafer by probing;
Pressing the electrode;
A second inspection step of inspecting the semiconductor wafer by probing, in this order,
The second inspection process, Ri step der to detect a failure of the semiconductor device generated by said step of pressing,
In the pressing step, the pressing is performed using a pressing member having a flat surface . In claim 9,
A method for inspecting a semiconductor wafer, wherein the electrode is further heated in the pressing step. In claim 9 or 10,
A method for inspecting a semiconductor wafer, wherein the upper surface of the electrode is planarized in the pressing step. In any one of claims 9 to 11,
In the pressing step, the pressing is performed by using a bonding tool. In any one of claims 9 to 12,
A method for inspecting a semiconductor wafer, wherein the semiconductor element is formed below the electrode. In claim 13,
The electrode has a bump;
The method for inspecting a semiconductor wafer, wherein the semiconductor element is a transistor.   A method for manufacturing a semiconductor chip, comprising the inspection method according to claim 9.

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