JP5191616B1 - はんだバンプの形成方法及び実装基板の製造方法 - Google Patents
はんだバンプの形成方法及び実装基板の製造方法 Download PDFInfo
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- JP5191616B1 JP5191616B1 JP2012518680A JP2012518680A JP5191616B1 JP 5191616 B1 JP5191616 B1 JP 5191616B1 JP 2012518680 A JP2012518680 A JP 2012518680A JP 2012518680 A JP2012518680 A JP 2012518680A JP 5191616 B1 JP5191616 B1 JP 5191616B1
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- solder
- mask
- molten solder
- fatty acid
- thickness
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—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
- H01L24/10—Bump connectors ; Manufacturing methods related thereto
- H01L24/11—Manufacturing methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/06—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for positioning the molten material, e.g. confining it to a desired area
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- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
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Abstract
【解決手段】準備された基板1と準備されたマスク5とを重ねた後に溶融はんだの噴流を吹き付けてマスク5の開口部にマスク5の厚さよりも厚くなるまで溶融はんだ11aを盛る工程と、マスク5の厚さを超える溶融はんだ11aを除去して所定厚さのはんだバンプ11を形成する工程と、マスク5を取り外す工程とを有し、溶融はんだ11aが、錫を主成分とし、ニッケルを副成分として少なくとも含み、さらに銀、銅、ゲルマニウム等を任意に含む溶融鉛フリーはんだであり、マスク5の厚さを超える溶融はんだ11aの除去を、ブレード又はエアーカッターで行う、又は、炭素数12〜20の有機脂肪酸含有溶液18をスプレーして行うことによって上記課題を解決した。
【選択図】図4
Description
本発明に係るはんだバンプ11の形成方法は、銅電極2が形成された基板1を準備する工程と、銅電極2上の必要な箇所にはんだバンプ11を形成するための開口部6が形成されたマスク5を準備する工程と、基板1とマスク5とを重ねた後に、マスク5の表面S1側から溶融はんだの噴流11’を吹き付けてマスク5の開口部6にマスク5の厚さよりも厚くなるまで溶融はんだ11aを盛る工程と、マスク5の厚さを超える溶融はんだ11aを除去して所定厚さのはんだバンプ11を形成する工程と、マスク5を取り外す工程と、を有する。
準備される基板1は、図1に示すように、プリント基板、ウエハー及びフレキシブル基板等の基板である。これらの基板1は、所定の銅電極2が形成されている。銅電極2としては、パターン幅で5μm以上又は10μm以上で、500μm以下の狭ピッチのものを好ましく挙げることができる。銅電極2の厚さは特に限定されないが、通常、5μm以上30μm以下程度である。基板1の大きさや外形形状も特に限定されず、各種のものに対して本発明を適用できる。
準備されるマスク5は、図1に示すように、銅電極2上の必要な箇所にはんだバンプ11を形成するための開口部6が形成されている。マスク5の材質は特に限定されないが、溶融はんだ11aの噴流11’が吹き付けられ、その溶融はんだ11aと一定時間接触するので、耐熱性の材質であればよい。通常、金属製のマスクや耐熱性プラスチック等が用いられる。マスク5に設けられている開口部6は、基板1の銅電極2のうち、はんだバンプ11を設ける必要のある箇所(はんだ接続部)に空けられている。
はんだ盛り工程は、図1及び図2(B)に示すように、基板1とマスク5とを重ねた後に、図2(C)に示すように、マスク5の表面S1側から溶融はんだの噴流11’を吹き付けて、図2(D)に示すように、マスク5の開口部6にマスク5の厚さよりも厚くなるまで溶融はんだ11aを盛る工程である。基板1とマスク5とを重ねるときの位置決めは、それぞれに設けられた位置決めマークや位置決め突起等によって行われ、両者は精度よく位置決めされる。
余剰はんだの除去工程は、図3(A)(B)に示すように、マスク5の表面から厚さ方向にはみ出る(マスク5の厚さを超えるとも言うことができる。)溶融はんだ11aを除去して所定厚さのはんだバンプ11を形成する工程である。マスク5の厚さを超える溶融はんだ11aの除去は、ブレード15又はエアーカッター等の除去手段で行う、又は、炭素数12〜20の有機脂肪酸含有溶液18をスプレーする除去手段で行う。こうすることで、マスク5の表面から厚さ方向にはみ出るはんだ11を除去することができる。
最後に、図3(C)に示すように、マスク5を取り外す。マスク5を取り外すことにより、所定厚さのはんだバンプ11を形成することができる。溶融はんだ11aからはんだバンプ11への冷却は、マスク5を取り外す前であってもよいし、マスク5を取り外した後であってもよい。冷却は、放冷であっても強制冷却であってもよい。強制冷却の場合は、空気又は不活性ガス(窒素ガス又はアルゴンガス等)を吹き付けて冷却することができる。
本発明に係る実装基板の製造方法は、電子部品を実装する銅電極2の接合部に、上記した本発明に係るはんだバンプの形成方法ではんだバンプ11を形成し、形成されたはんだバンプ11に電子部品をはんだ付けして実装することに特徴がある。こうすることで、実装基板の銅ランド等の銅電極2の信頼性を確保でき、電子部品を実装基板にはんだ付けする際に、従来のはんだ付け時に起こる銅溶食を抑制できる。また、微細な銅電極2を有する実装基板に所望の一定厚さのはんだバンプ11を容易に且つ寸法精度よく形成することができる。こうした本発明によれば、従来のような高コストの工程が不要になるので、電子部品をはんだバンプにはんだ接合した接合部の信頼性と歩留まりを高めることができ、低コストな実装基板を製造することができる。
一例として、幅が例えば200μmで厚さが例えば10μmの銅配線パターンが形成された基板1を準備した。この基板1は、銅配線パターンのうち、電子部品の実装部分となる幅が例えば200μmで長さが例えば50μmの接続部のみが露出し、他の銅電極2は絶縁層で覆われている。こうした接続部上にはんだバンプ11を形成するための開口部6を持つマスク5を準備した。基板1上で銅電極2が露出した接続部と、マスク5の開口部6とを位置合わせして重ねた後、Ni:0.05質量%、Ge:0.005質量%、Ag:3質量%、Cu:0.5質量%、残部がSnからなる5元系鉛フリーはんだを用い、250℃に加熱して溶融はんだ11aとし、その溶融はんだの噴流11’を開口部6に向けて噴射した。溶融はんだの噴流11’は、ノズル12を例えば45°に傾けた状態で、250℃の溶融はんだ11aの温度が冷えないように雰囲気温度も250℃前後にして噴射装置を利用して行った。溶融はんだの噴流11’を噴射した後の開口部6の形態は、溶融はんだ11aが表面張力で盛り上がった状態であった。この溶融はんだ11aは、蒸気雰囲気温度によって溶融状態を保持させた。
実施例1において、はんだ材料として、Ni:0.03質量%、Ge:0.005質量%、Ag:3質量%、Cu:0.5質量%、残部がSnからなる5元系鉛フリーはんだを用いた他は、実施例1と同様にして、実施例2に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、やや凹凸があるものの、1μmの厚さで形成されていた。
実施例1において、はんだ材料として、Ni:0.07質量%、Ge:0.005質量%、Ag:3質量%、Cu:0.5質量%、残部がSnからなる5元系鉛フリーはんだを用いた他は、実施例1と同様にして、実施例3に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、2μmの厚さで均一に形成されていた。
実施例1において、有機脂肪酸含有溶液中のパルミチン酸含有量を7質量%とした他は、実施例1と同様にして、実施例4に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、1.5μmの厚さで均一に形成されていた。
実施例1において、有機脂肪酸含有溶液中のパルミチン酸含有量を12質量%とした他は、実施例1と同様にして、実施例5に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、1.5μmの厚さで均一に形成されていた。
実施例1において、はんだ材料として、Ag:3質量%、Cu:0.5質量%、残部がSnからなる3元系鉛フリーはんだを用いた他は、実施例1と同様にして、比較例1に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層は存在せず(図6(A)を参照。)、銅電極2上には、CuSn金属間化合物層13bが形成されていた。
実施例1において、はんだ材料として、Ni:0.005質量%、Ge:0.005質量%、Ag:3質量%、Cu:0.5質量%、残部がSnからなる5元系鉛フリーはんだを用いた他は、実施例1と同様にして、比較例2に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、凹凸が激しく、膜として連続していなかった。
実施例1において、はんだ材料として、Ni:1質量%、Ge:0.005質量%、Ag:3質量%、Cu:0.5質量%、残部がSnからなる5元系鉛フリーはんだを用いた他は、実施例1と同様にして、比較例3に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、5μmの厚さで形成されて、亀裂が発生しているのが確認された。
実施例1において、有機脂肪酸含有溶液中のパルミチン酸含有量を1質量%とした他は、実施例1と同様にして、比較例4に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、1.5μmの厚さで均一に形成されていたが、その表面は酸化していると思われる変色が生じていた。
実施例1において、有機脂肪酸含有溶液中のパルミチン酸含有量を30質量%とした他は、実施例1と同様にして、比較例5に係るはんだバンプ11を形成した。実施例1と同様に、断面の走査型電子顕微鏡写真から、CuNiSn金属間化合物層13aは、1.5μmの厚さで均一に形成されていた。
(ボイド発生についての評価)
CuNiSn金属間化合物層13aの厚さは、断面の走査型電子顕微鏡写真から測定した。また、銅電極2とはんだバンプ11との接合界面付近のボイドの有無は、150℃で240時間エージングした後の断面の走査型電子顕微鏡写真から評価した。図10(A)(B)は比較例1の結果であり、図10(C)(D)は実施例1の結果である。図10に示すように、比較例1のはんだバンプ11は、銅電極2との界面にボイドが発生したのに対し、実施例1のはんだバンプ11は、銅電極2との界面にボイドが発生しなかった。
図11は、実施例1のはんだバンプ11と銅電極2との接合界面付近の走査型電子顕微鏡での断面写真とX線マイクロアナライザー(EPMA)の元素マッピングである。図11に示すように、銅電極2の上にニッケル元素が分布しているのが確認でき、CuNiSn金属間化合物層13aが形成されていることがわかる。
図7は、有機脂肪酸含有溶液で清浄化処理された溶融はんだの濡れ性試験(メニスコグラフ)結果であり、図8は、未処理の溶融はんだの濡れ性試験(メニスコグラフ)結果である。図7と図8のはんだ濡れ性試験(メニスコグラフ)の結果からもわかるように、図7に示す精製された溶融はんだ11aのゼロクロスタイムは0.4秒であったが、図8に示す未精製の溶融はんだのゼロクロスタイムは5秒であった。このことから、有機脂肪酸含有溶液で精製された溶融はんだ11aは、有機脂肪酸含有溶液で精製されていない溶融はんだに比べて、濡れ性が良好であった。
2 銅電極
5,5A,5B マスク
6 開口部
11 はんだバンプ
11a 溶融はんだ
11’ 溶融はんだの噴流
12 噴流ノズル
13a CuNiSn金属間化合物層
13b CuSn金属間化合物層
15 スキージ
17 噴射ノズル
18 有機脂肪酸含有溶液
19 コーティング膜
S1 表面
S2 傾斜面
Claims (4)
- 銅電極が形成された基板を準備する工程と、
前記銅電極上の必要な箇所にはんだバンプを形成するための開口部が形成されたマスクを準備する工程と、
前記基板と前記マスクとを重ねた後に、前記マスクの表面側から精製処理された150℃以上300℃以下の溶融はんだの噴流を吹き付けて前記マスクの開口部に該マスクの厚さよりも厚くなるまで溶融はんだを盛る工程と、
前記マスクの厚さを超える溶融はんだを除去して所定厚さのはんだバンプを形成する工程と、
前記マスクを取り外す工程と、を有し、
前記精製処理が、180℃以上350℃以下に加熱された炭素数12〜20の有機脂肪酸を5質量%以上25質量%以下含有する溶液と接触させて撹拌混合する処理であり、
前記溶融はんだが、錫を主成分とし、ニッケルを副成分として少なくとも含み、さらに銀、銅、亜鉛、ビスマス、アンチモン及びゲルマニウムから選ばれる1種又は2種以上を任意の副成分として含む溶融鉛フリーはんだであり、
前記マスクの厚さを超える溶融はんだの除去を、ブレード又はエアーカッター等の除去手段で行う、又は、炭素数12〜20の有機脂肪酸含有溶液をスプレーする除去手段で行う、ことを特徴とするはんだバンプの形成方法。 - 前記マスクの厚さを超える溶融はんだの除去を、炭素数12〜20の有機脂肪酸含有溶液をスプレーする除去手段で行い、
前記はんだバンプ上に、前記有機脂肪酸含有溶液に含まれる有機脂肪酸のコーティング膜が形成されている、請求項1に記載のはんだバンプの形成方法。 - 前記有機脂肪酸含有溶液が、炭素数16のパルミチン酸を含有する溶液である、請求項1又は2に記載のはんだバンプの形成方法。
- 電子部品を実装する銅電極に、請求項1〜3のいずれか1項に記載のバンプの形成方法ではんだバンプを形成し、形成された前記はんだバンプに電子部品をはんだ付けして実装することを特徴とする実装基板の製造方法。
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JPWO2013157075A1 (ja) | 2015-12-21 |
EP2840596A4 (en) | 2016-04-27 |
EP2840596A1 (en) | 2015-02-25 |
KR20140147103A (ko) | 2014-12-29 |
TW201344820A (zh) | 2013-11-01 |
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