JP5984912B2 - 積層型半導体の製造方法 - Google Patents

積層型半導体の製造方法 Download PDF

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JP5984912B2
JP5984912B2 JP2014506159A JP2014506159A JP5984912B2 JP 5984912 B2 JP5984912 B2 JP 5984912B2 JP 2014506159 A JP2014506159 A JP 2014506159A JP 2014506159 A JP2014506159 A JP 2014506159A JP 5984912 B2 JP5984912 B2 JP 5984912B2
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substrate
wall portion
electrode
electrodes
semiconductor device
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JPWO2013141091A1 (ja
Inventor
良章 竹本
良章 竹本
直裕 高澤
直裕 高澤
菊地 広
広 菊地
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Olympus Corp
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Olympus Corp
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Description

本発明は、積層型半導体の製造方法に関する。
半導体装置においては、その集積度を上げる技術が日夜進歩しており、これまで、主として回路パターンの微細化の促進により集積度が高められてきた。しかしながら、微細化そのものが限界を迎え、それ以上集積度を上げるために、従来の2次元構造から、構成を立体的にした3次元構造へ展開することが一つの解決策として期待されている。
3D−LSIを大きく分類すると、KGD(Known−Good−Die)のみを低精度のダイボンダで積層しワイヤボンドで半導体チップ間を接続する「簡易Chip積層」、バーンイン・テストを行った良品パッケージを積層する「パッケージ型積層」、そして、シリコン製のウェハ(基板)上に素子間の貫通電極やマイクロバンプを設け、ウェハもしくは半導体チップ同士を直接接続して形成する「貫通電極型積層(以下、TSV:Through Si Via積層と称する)」に分類できる。
前2者は既に実用化の域にあり、TSV積層が最終的な形態として期待されている。これは、例えばDRAMの場合、高度な微細化を待たずにメモリセルアレイウェハの単純な積層により、チップサイズや設計線幅の変更なく容量を増大できるためである。
さて、TSV積層を以下の3つの方法に分類する。
(1)Chip−to−Chip(C2C):KGD(Known−Good−Die)同士を積層する簡便な手法である。
(2)Chip−to−Wafer(C2W):ウェハ上にKGDを搭載するもので(1)と類似の系といえる。
(3)Wafer−to−Wafer(W2W):高歩留まりウェハを前提とし、ウェハ同士を直接貼り合わせる方式であり最終的な積層形態といえる。
本発明は、W2W方式の接合技術に関する。その場合のウェハとウェハを接合するウェハ接合装置の概要を図11および図12に示す。なお、ウェハ接合装置全体の概要は、例えば特許文献1に記載されており、公知のものである。このため、図示と説明を省略し、本発明に関係のある部分のみを図示し説明する。
2枚のウェハ151、152には、接続電極(電極)153が形成された電極領域154が設けられている。電極領域154の周囲は、ウェハ151、152以外には何も設けられないブランク領域となっている。電極領域154には、ウェハ151、152上にそれぞれ接続電極153が形成されており、ウェハ151、152上に形成された接続電極153同士を接合することによりウェハ151、152間での電気的接合を図っている。なお、接続電極153の中には、電気的導通には寄与せず、接合の強度を保つためのダミーも含まれている場合がある。
W2W方式においては、ウェハ151、152同士の対応する接続電極153同士が接するようにウェハ151、152を重ね合わせて接合する。
具体的には、ウェハ151、152の接続電極153が互いに接する様にして加圧板155、156の間に挟み、図示しないプレス装置によって、上下から加圧板155、156を加圧する。ウェハ151、152の接合には、接続電極153を加熱し、加圧して接合する加熱加圧接合が一般的に使用される。
このようなW2W方式の接合方式において、特許文献2では、前述の特許文献1とは異なる接合方法が開示されている。すなわち、特許文献2の接合方法は、図11に示すように複数の接続電極153から形成される電極領域154を外周接続部(壁部)157で囲んだ電極構造とすることで、前記外周接続部157に囲まれた領域を任意の雰囲気とし、仮接合と本接合工程を有した製造工程を用いることによって、接続信頼性を高めている。
なお、ウェハ151、152を接合することで、複数の積層型半導体装置が形成される。
特開2005−251972号公報 特開2009−220151号公報
しかしながら、特許文献1および2の方法で製造された積層型半導体装置は、積層型半導体装置を個片化する工程、所謂ダイシング工程を実施する必要がある。ダイシング工程には、ブレードを用いた方式やレーザーを用いた方式が成されているが、いかなる方式においても、積層型半導体装置に少なからず物理的衝撃が生じる。その衝撃によって、前述の外周接続部157や接続電極153がダメージを受けることで、接続信頼性が低下することが懸念される。
なお、外周接続部157の領域を大きくすることによって接続電極153に与える衝撃を緩和する手段も考えられるが、その場合には接続しなければならない電極部が増加することによってウェハ全面で接続電極153を接合することが困難となる。
本発明はこのような事情に鑑みてなされたもので、個片化した際にも基板の電極同士の接続信頼性を確保することができる積層型半導体の製造方法を提供することを目的とする。
発明の積層型半導体装置の製造方法は、一方の面に複数の第一の電極、およびそれぞれの前記第一の電極を囲うように立設した複数の第一の壁部が設けられた第一の基板と、第一の面に複数の第二の電極、およびそれぞれの前記第二の電極を囲うように立設した複数の第二の壁部が設けられた第二の基板とを、前記一方の面と前記第一の面とを対向させ、それぞれの前記第一の電極と前記第二の電極とを接続させるとともに、それぞれの前記第一の壁部のうち前記第一の壁部が立設する先端部とそれぞれの前記第二の壁部のうち前記第二の壁部が立設する先端部とを前記第一の壁部の全周にわたり接続することで互いに接続する接続工程と、前記第一の基板と前記第二の基板との間であってそれぞれの前記第一の壁部および前記第二の壁部の外側に封止部材を充填する封止工程と、前記第一の基板、前記第二の基板、および前記封止部材を、前記第一の基板の厚さ方向に見たときの隣り合う前記第一の壁部の中間部で切断する切断工程と、を備えることを特徴としている。
本発明の積層型半導体の製造方法によれば、個片化した際にも基板の電極同士の接続信頼性を確保することができる。
本発明の第1実施形態の積層型半導体装置の側面の断面図である。 図1中の切断線A1−A1の断面図である。 分割される前の両基板を対向配置した状態の側面の断面図である。 分割される前の第一の基板の要部の底面図である。 本実施形態の積層型半導体装置の製造方法の接続工程終了時の状態を説明する側面の断面図である。 図5中の切断線A2−A2の断面図である。 本発明の第2実施形態の積層型半導体装置の側面の断面図である。 分割される前の両基板を対向配置した状態の側面の断面図である。 本実施形態の積層型半導体装置の製造方法の接続工程終了時の状態を説明する側面の断面図である。 本発明の変形例の実施形態の積層型半導体装置における要部の断面図である。 従来のウェハ接合装置に用いられるウェハの平面図である。 同ウェハ接合装置でウェハを接合している状態を示す模式図である。
(第1実施形態)
以下、本発明に係る積層型半導体装置(以下、「半導体装置」と略称する。)の第1実施形態を、図1から図6を参照しながら説明する。
図1および図2に示すように、本半導体装置1は、一方の面10aに複数の第一の電極11、およびこれら複数の第一の電極11を囲うように立設した壁部12が設けられた第一の基板10と、第一の面20aに複数の第二の電極21が設けられた第二の基板20とを備えている。
なお、後述する素子14、24、および配線15、25は、説明の便宜上、図1および後述する図7のみに示している。
第一の基板10は、シリコンなどの材料で、第一の基板10の厚さ方向Xに見たときに矩形となる平板状に形成されている。第一の基板10には、トランジスタなどの素子14が内蔵されている。素子14に設けられた不図示の接点は、ビアなどの配線15を介して第一の電極11に接続されている。
複数の第一の電極11は、一方の面10aにおいて格子状に配置され、複数の第一の電極11が全体として第一の電極領域R11を構成している。厚さ方向Xに見た平面視において、例えば、それぞれの第一の電極11は直径が数μm程度に形成され、第一の電極領域R11は数mm角程度に形成されている。
壁部12は、厚さ方向Xに見て、第一の電極領域R11の外形を外側に拡大するとともに、第一の基板10を内側に縮小した矩形状(矩形の輪郭状)に形成されている。壁部12が一方の面10aから立設する立設方向は、厚さ方向Xの一方側X1となる。厚さ方向Xの長さは、第一の電極11および第二の電極21の和と、壁部12とがほぼ等しくなるように設定されている。
この例では、壁部12は、第一の電極11と同一の金属、例えば銅や金などで形成されている。
第二の基板20は、シリコンなどの材料で、厚さ方向Xに見たときに第一の基板10と同一の形状となる平板状に形成されている。第二の基板20には、素子14と同様の素子24が内蔵されている。素子24に設けられた不図示の接点は、配線25を介して第二の電極21に接続されている。
複数の第二の電極21は、第一の面20aにおいて、複数の第一の電極11と同様の格子状に配置され、複数の第二の電極21が全体として第二の電極領域R12を構成している。
第一の基板10と第二の基板20とは、一方の面10aと第一の面20aとを対向させ、対応する第一の電極11と第二の電極21とを接続させるとともに、壁部12のうち一方側X1の先端部を第一の面20aに全周にわたり接続した状態に配置されている。第一の電極11と第二の電極21とは、両電極11、21を加熱した状態で押圧することで電気的に接続されている。第二の基板20と壁部12とも、同様に接続されている。
第一の基板10と第二の基板20との間であって壁部12の外側には、壁部12の全周にわたりエポキシ樹脂(封止部材)30が充填されている。第二の基板20と壁部12とを接続することと、エポキシ樹脂30を充填することで、第一の基板10と第二の基板20との間であって壁部12の内側となる内部空間R20は、外部から気密に封止されている。
この例では、内部空間R20は真空となるように減圧されている。ここで言う真空とは、大気圧よりも低い圧力のことを意味し、絶対圧力で、0Pa以上1Pa以下であることが好ましい。これにより、電極11、21の周囲は、真空雰囲気となっている。
第一の電極領域R11と第二の電極領域R12とで、電極領域R10が構成される。以下では、各図において電極領域R10に同一のハッチングを付して示すことにする。
半導体装置1は、配線15、25、および電極11、21を介して電気的に接続された素子14、24が、互いに信号を送受信しながら所定の処理を行うように構成されている。
次に、以上のように構成された半導体装置1を製造する、本実施形態の半導体装置1の製造方法について説明する。
本製造方法は、第一の基板10と第二の基板20とを接続する接続工程と、第一の基板10と第二の基板20との間にエポキシ樹脂30を充填する封止工程と、基板10、20を切断する切断工程とを備えている。
本製造方法には、図3および図4に示すように、厚さ方向Xに見たときに略円形となる基板10、20が用いられる。そして、後述するように切断工程で基板10、20をスクライブライン(分割線)Sで切断して平面視で矩形状の個片領域Tに分割することで、個々の半導体装置1に分割(個片化)する。
このように、略円形となる基板10、20において、個片領域Tは略格子状に複数配置されている。
予め、第一の基板10の個片領域Tごとに、素子14および配線15を形成するとともに、第一の基板10の一方の面10aにそれぞれの配線15に接続された第一の電極11を設け、第一の電極領域R11を構成しておく。そして、個片領域Tごとに第一の電極領域R11を囲うように壁部12を形成する。なお、この例では、第一の電極11および壁部12を一方の面10aに金属で形成しているため、第一の電極11および壁部12を同一の半導体製造プロセスで形成することができる。
同様に、第二の基板20の個片領域Tごとに、素子24および配線25を形成するとともに、第二の基板20の第一の面20aにそれぞれの配線25に接続された第二の電極21を設け、第二の電極領域R12を構成しておく。
まず、接続工程において、不図示の真空チャンパ内で以下の工程を行う。図5および図6に示すように、第一の基板10と第二の基板20とを、一方の面10aと第一の面20aとを対向させ、第一の電極領域R11の第一の電極11と第二の電極領域R12の第二の電極21とを接続させるとともに、それぞれの壁部12のうち一方側X1の先端部を第一の面20aに全周にわたり接続する。これにより、第一の基板10と第二の基板20とを互いに接続する。
具体的には、図示はしないが、公知の加圧装置の一対の加圧板の間に基板10、20を配置し、互いに接触させた第一の電極11と第二の電極21、壁部12と第二の基板20を不図示の加熱装置によりそれぞれ加熱した状態で一対の加圧板により基板10、20を厚さ方向Xに押圧することで、第一の電極11と第二の電極21、壁部12と第二の基板20をそれぞれ接合する。
次に、封止工程において、互いに接続された第一の基板10と第二の基板20との間であってそれぞれの壁部12の外側に、加熱して流動性を高めたエポキシ樹脂30を流し込む。壁部12と第二の基板20とは全周にわたり接続されているため、内部空間R20内にエポキシ樹脂30が流れ込むことはない。また、真空雰囲気においてエポキシ樹脂30を流し込むため、エポキシ樹脂30内に気体が混入するのを抑制し、基板10、20間にエポキシ樹脂30を容易に充填させることができる。
この後で、加熱したエポキシ樹脂30を冷却して、固化させる。
続いて、切断工程において、第一の基板10、第二の基板20、およびエポキシ樹脂30を、図5および図6に示すスクライブラインSでダイシングなどにより切断する。このスクライブラインSは、厚さ方向Xに見たときの隣り合う壁部12の中間部に設定される。すなわち、第一の基板10の切断面と第二の基板20の切断面との間に、全周にわたりエポキシ樹脂30が配されるように切断する。
第一の基板10と第二の基板20との間はエポキシ樹脂30が充填されているため、基板10、20を切断するときに作用する荷重をエポキシ樹脂30で支持することができ、第一の電極11と第二の電極21との接合部、壁部12と第二の基板20との接合部に過大な荷重(衝撃)が作用するのが防止される。
スクライブラインSで切断することで個片化され、半導体装置1が得られる。
これまで説明した接続工程から切断工程までの工程により、半導体装置1が製造される。
以上説明したように、本実施形態の半導体装置1、および半導体装置1の製造方法によれば、第二の基板20と壁部12とを壁部12の全周にわたり接続させることと、エポキシ樹脂30を充填させることで、壁部12の内側となる内部空間R20を気密に保持し、両電極11、21の接続状態を安定させることができる。
第一の基板10と第二の基板20との間であって壁部12の外側にはエポキシ樹脂30が充填されているため、基板10、20を切断するときに作用する荷重をエポキシ樹脂30が支持する。したがって、基板10、20を個片化して半導体装置1を製造する際に、壁部12と第二の基板20との接続部に過大な荷重が作用するのが防止され、電極11、21同士の接続を確保することができる。
内部空間R20は真空となるように減圧されているため、電極11、21が雰囲気により酸化などの影響を受けるのを抑制し、電極11、21同士の接続信頼性を確保することができる。
加熱して流動性を高めたときのエポキシ樹脂30の粘度は、他の樹脂の粘度に比べて比較的低いため、第一の基板10と第二の基板20との間に容易にエポキシ樹脂30を充填させることができる。
(第2実施形態)
次に、本発明の第2実施形態について図7から図9を参照しながら説明するが、前記実施形態と同一の部位には同一の符号を付してその説明は省略し、異なる点についてのみ説明する。
第1実施形態の半導体装置1は、壁部を第一の基板10の一方の面10aのみに形成したが、図7に示す本実施形態の半導体装置2は、この壁部を第一の基板10の一方の面10aおよび第二の基板20の第一の面20aのそれぞれに形成したものとなっている。すなわち、本半導体装置2は、半導体装置1の壁部12に代えて、第一の基板10の一方の面10aに複数の第一の電極11を囲うように立設した第一の壁部17が設けられるとともに、第二の基板20の第一の面20aに複数の第二の電極21を囲うように立設した第二の壁部27が設けられている。
第一の壁部17は、第1実施形態の壁部12とは厚さ(厚さ方向Xの長さ。)のみが異なるものである。第一の壁部17の厚さは、各第一の電極11の厚さに等しい。また、第一の壁部17は、第一の電極11と同一の金属で形成されている。このように構成することで、各第一の電極11と第一の壁部17とを、同一の半導体製造プロセスでより容易に形成することができる。
同様に、第二の壁部27の厚さは各第二の電極21の厚さに等しい。第一の壁部17と第二の壁部27とは、厚さ方向Xに見たときに重なるように(同一の形状に)形成されている。
第一の基板10と第二の基板20とは、一方の面10aと第一の面20aとを対向させ、対応する第一の電極11と第二の電極21とを接続させるとともに、第一の壁部17のうち第一の壁部17が立設する先端部と第二の壁部27のうち第二の壁部27が立設する先端部とを第一の壁部17の全周にわたり接続した状態に配置されている。第一の壁部17と第二の壁部27とは、両壁部17、27を加熱した状態で押圧することで接続されている。
この例では、前述のエポキシ樹脂30は、第一の基板10と第二の基板20との間であって第一の壁部17および第二の壁部27の外側に、第一の壁部17の全周にわたり充填されている。
次に、以上のように構成された半導体装置2を製造する、本実施形態の半導体装置2の製造方法について説明する。
本実施形態の製造方法も、第1実施形態の製造方法と同様に接続工程、封止工程および切断工程を備えている。
予め、図8に示すように、第一の基板10の個片領域Tごとに、複数の第一の電極11からなる第一の電極領域R11、および第一の電極領域R11を囲うように第一の壁部17を形成する。複数の第一の電極11および第一の壁部17の厚さおよび材質が前述のようになっているため、複数の第一の電極11と第一の壁部17とを、同一の半導体製造プロセスでより容易に形成することができる。
同様に、第二の基板20の個片領域Tごとに、複数の第二の電極21からなる第二の電極領域R12、および第二の電極領域R12を囲うように第二の壁部27を形成する。
まず、接続工程において、図9に示すように、第一の基板10と第二の基板20とを、一方の面10aと第一の面20aとを対向させ、第一の電極領域R11の第一の電極11と第二の電極領域R12の第二の電極21とを接続させるとともに、それぞれの第一の壁部17のうち第一の壁部17が立設する先端部とそれぞれの第二の壁部27のうち第二の壁部27が立設する先端部とを第一の壁部17の全周にわたり接続する。これにより、第一の基板10と第二の基板20とを互いに接続する。
次に、封止工程において、第一の基板10と第二の基板10との間であってそれぞれの第一の壁部17および第二の壁部27の外側にエポキシ樹脂30を充填する。
続いて、切断工程において、第一の基板10、第二の基板20、およびエポキシ樹脂30を、図9に示すスクライブラインSで切断する。このスクライブラインSは、厚さ方向Xに見たときの隣り合う第一の壁部17の中間部に設定される。
これまで説明した接続工程から切断工程までの工程により、半導体装置2が製造される。
以上説明したように、本実施形態の半導体装置2、および半導体装置2の製造方法によれば、個片化した際にも基板10、20の電極11、21同士の接続信頼性を確保することができる。
本実施形態では、第一の壁部17の厚さが各第一の電極11の厚さに等しくなく、かつ、第二の壁部27の厚さが各第二の電極21の厚さに等しくないように構成してもよい。第一の壁部17の厚さと第二の壁部27の厚さとの和と、第一の電極11の厚さと第二の電極21の厚さとの和がほぼ等しければ、第一の基板10と第二の基板20とを良好に接続できるからである。
以上、本発明の第1実施形態および第2実施形態について図面を参照して詳述したが、具体的な構成はこの実施形態に限られるものではなく、本発明の要旨を逸脱しない範囲の構成の変更なども含まれる。
たとえば、前記第1実施形態および第2実施形態では、封止部材としてエポキシ樹脂を用いたが、封止部材はこれに限定されず、他にも熱可塑性樹脂や熱硬化性樹脂、有機材料などを適宜選択して用いることができる。ただし、封止部材は、加熱して流動性を有したときに粘度が低くなるものが好ましい。第一の基板10と第二の基板20との間に、隙間なく封止部材を充填できるからである。
壁部12、17、27は、厚さ方向Xに見て矩形状に形成されているとした。しかし、壁部の形状はこれに限定されることなく、図10に示す半導体装置3のように、壁部42は、6角形などの矩形以外の多角形状に形成されていてもよいし、円形や楕円形に形成されていてもよい。
複数の第一の電極11により構成される第一の電極領域R11の形状も、円形や楕円形に形成されていてもよいし、多角形状に形成されていてもよい。第二の電極領域R12についても同様である。
前記第1実施形態および第2実施形態では、内部空間R20は、真空となるように減圧されているとしたが、窒素ガスまたは希ガスが充填されているように構成してもよい。ここで言う希ガスとは、ヘリウムガス、ネオンガス、アルゴンガス、クリプトンガス、キセノンガス、およびラドンガスのことを意味する。このように構成することでも、電極11、21が雰囲気により酸化などの影響を受けるのを抑制し、電極11、21同士の接続信頼性を確保することができる。
壁部12、17、27は第一の電極11と同一の金属で形成されているとしたが、壁部12、17、27は樹脂などで形成されていてもよい。
また、複数の第一の電極11を囲うように壁部12を形成したが、壁部12が囲う第一の電極11の数に制限は無く、1つ以上であればいくつでもよい。壁部17、27についても同様である。
1、2、3 半導体装置(積層型半導体装置)
10 第一の基板
10a 一方の面
11 第一の電極
12、42 壁部
17 第一の壁部
20 第二の基板
20a 第一の面
21 第二の電極
27 第二の壁部
30 エポキシ樹脂(封止部材)
X 厚さ方向

Claims (1)

  1. 一方の面に複数の第一の電極、およびそれぞれの前記第一の電極を囲うように立設した複数の第一の壁部が設けられた第一の基板と、第一の面に複数の第二の電極、およびそれぞれの前記第二の電極を囲うように立設した複数の第二の壁部が設けられた第二の基板とを、前記一方の面と前記第一の面とを対向させ、それぞれの前記第一の電極と前記第二の電極とを接続させるとともに、それぞれの前記第一の壁部のうち前記第一の壁部が立設する先端部とそれぞれの前記第二の壁部のうち前記第二の壁部が立設する先端部とを前記第一の壁部の全周にわたり接続することで互いに接続する接続工程と、
    前記第一の基板と前記第二の基板との間であってそれぞれの前記第一の壁部および前記第二の壁部の外側に封止部材を充填する封止工程と、
    前記第一の基板、前記第二の基板、および前記封止部材を、前記第一の基板の厚さ方向に見たときの隣り合う前記第一の壁部の中間部で切断する切断工程と、
    を備えることを特徴とする積層型半導体装置の製造方法。
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