TW201304026A - 引線上凸塊之倒裝晶片互連 - Google Patents

引線上凸塊之倒裝晶片互連 Download PDF

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Publication number
TW201304026A
TW201304026A TW101133048A TW101133048A TW201304026A TW 201304026 A TW201304026 A TW 201304026A TW 101133048 A TW101133048 A TW 101133048A TW 101133048 A TW101133048 A TW 101133048A TW 201304026 A TW201304026 A TW 201304026A
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Taiwan
Prior art keywords
interconnect
substrate
bump
die
locations
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TW101133048A
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English (en)
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TWI534915B (zh
Inventor
Rajendra D Pendse
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Chippac Inc
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Publication of TWI534915B publication Critical patent/TWI534915B/zh

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    • H01—ELECTRIC ELEMENTS
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    • H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
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    • H01L21/563—Encapsulation of active face of flip-chip device, e.g. underfilling or underencapsulation of flip-chip, encapsulation preform on chip or mounting substrate
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Abstract

本發明揭示一種倒裝晶片互連，其形成係將互連凸塊直接嚙合至一引線上，而非嚙合至一捕獲焊墊上。還有，一倒裝晶片封裝包括：一晶粒，其在一作用表面中具有黏在互連焊墊上的焊料凸塊；及一基板，其在一晶粒黏著表面中具有導電接線，其中該等凸塊係直接嚙合在該等接線上。該互連的形成並未採用一焊料遮罩。還有，用於形成一引線上凸塊之倒裝晶片互連的方法也免除焊料遮罩的使用。在某些方法中，會將一可固化黏著劑塗在該晶粒的凸塊上或該基板的接線上；該黏著劑可在該嚙合程序期間部分固化，及該部分固化的黏著劑可在一回熔程序期間用來限制熔化的焊料。

Description

引線上凸塊之倒裝晶片互連
本發明有關半導體封裝，尤共有關倒裝晶片互連。
倒裝晶片封裝包括黏在封裝基板上的半導體晶粒，其中晶粒的作用側面對基板。照慣例，藉由黏在晶粒之互連焊墊之陣列上及焊接至基板之互連焊墊(通常稱為「捕獲焊墊」)之對應(互補)陣列的凸塊，即可形成晶粒中電路和基板中電路的互連。
積體電路上電子特徵的面密度已大幅增加，具有較大之電路特徵密度的晶片也具有較大之用於和封裝基板互連之位置的密度。
此封裝係藉由封裝及底部電路之間的第二階互連(如接針)而連接至採用此封裝之裝置中的底部電路，如印刷電路板(如「主機板」)。第二階互連具有的間距比倒裝晶片互連大，因此基板上的配線照慣例會「成扇形散開」。重大的技術發展已經可以建構精細的線路及間隔；但在習用的配置中，相鄰焊墊之間的間隔卻會限制接線數而非避免陣列中更多向內的捕獲焊墊，且照慣例會在封裝基板內的多個金屬層上，在晶粒下的捕獲焊墊及封裝的外部接針之間形成成扇形散開的配線。對於複雜的互連陣列，可能需要使用具有多層的基板，才能達成封裝上晶粒焊墊及第二階互連之間的配線。
多層基板很昂貴，且在習用的倒裝晶片構想中，通常光 是基板就佔去封裝成本的一半以上(在一些典型的例子中，約佔60%)。多層基板的高成本一直是限制主流產品之倒裝晶片技術發展的因素。
在習用的倒裝晶片構想中，散逸配線圖案通常會引起額外的電寄生現象，因為配線在信號傳輸路徑的線路層之間包括短程的未屏蔽線路及通道。電寄生現象將明顯限制封裝的效能。
根據本發明，將互連凸塊直接連接至引線，而非連接至焊墊，即可完成倒裝晶片互連。本發明可在基板上提供更有效的接線配線。尤其，可在基板的單一金屬層中整個形成信號配線。這可減少基板中的層數，且在單層中形成信號接線也可以擺脫一些基板必須符合的通道、線路及間隔設計規則。此基板簡化可大幅減少倒裝晶片封裝的總成本。引線上凸塊架構亦有助於消除基板設計如通道及「導孔(stub)」等特徵，及啟用信號傳輸微帶控制的阻抗電環境，藉此大幅提高效能。
在一個一般方面中，本發明具有倒裝晶片互連，該互連在晶粒上具有黏在互連焊墊上的焊料凸塊並在基板上嚙合至對應接線上。
在另一個一般方面，本發明具有一倒裝晶片封裝，其包括：一晶粒，其在一作用表面中具有黏在互連焊墊上的焊料凸塊；及一基板，其在一晶粒黏著表面中具有導電接線，其中該等凸塊係直接嚙合在該等接線上。
一般而言，根據本發明的方法形成引線上凸塊互連，且並未使用在程序中再熔化階段期間會限制熔化焊料的焊料遮罩。免除焊料遮罩的需求可以產生更精細的互連幾何形狀。
在部分具體實施例中，進一步提供該基板一焊料遮罩，該遮罩在引線的互連位置上具有開口。在部分具體實施例中，進一步提供該基板在互連位置之引線上的焊料膏。
在另一個一般方面，本發明具有一種用於形成倒裝晶片互連的方法，其係藉由：提供一基板，該基板具有：在一晶粒黏著表面中形成的接線、及在一作用表面中具有黏在互連焊墊上之凸塊的一晶粒；固定該基板及該晶粒；塗上大量可固化黏著劑於該基板上(覆蓋至少該等接線上的連接位置)或該晶粒之作用側上(覆蓋至少該等凸塊)；放置該晶粒，將該晶粒的作用側朝向該基板的晶粒黏著表面，及對準該晶粒及基板然後將其中一個移向另一個，致使該等凸塊接觸該基板上該等對應的接線(引線)；施力以將該等凸塊壓在該等嚙合接線上，足夠在該凸塊及該嚙合接線之間取代該黏著劑；至少部分固化該黏著劑；熔化然後再重新凝固該焊料，以在該凸塊及該接線之間形成一冶金互連。
在另一個一般方面，本發明具有一種用於形成倒裝晶片互連的方法，其係藉由：提供一基板，該基板具有：在晶粒黏著表面中形成的接線、在該引線之互連位置上具有開口的一焊料遮罩、及在一作用表面中具有黏在互連焊墊上 之凸塊的一晶粒；固定該基板及該晶粒；放置該晶粒，將該晶粒的作用側朝向該基板的晶粒黏著表面，及對準該晶粒及基板然後將其中一個移向另一個，致使該等凸塊接觸該基板上該等對應的接線(引線)；熔化然後再重新凝固以在該凸塊及該接線之間形成一冶金互連。
在部分具體實施例中，該焊料凸塊包括一可壓扁的焊料部分，然後熔化及凝固步驟可熔化該凸塊以在該引線上形成互連。在部分具體實施例中，進一步提供該基板在該引線上的一焊料膏，及將該晶粒及該基板移向彼此的步驟可在該引線上的該等凸塊及該焊料之間形成一接觸，然後熔化及凝固步驟可熔化在該引線上的焊料以形成互連。
在另一個一般方面，本發明具有一種用於形成倒裝晶片互連的方法，其係藉由：提供一基板，該基板具有：在一晶粒黏著表面中形成的接線、在該引線之互連位置上具有開口的一焊料遮罩、在該互連位置之引線上的焊料膏、及在一作用表面中具有黏在互連焊墊上之凸塊的一晶粒；固定該基板及該晶粒；放置該晶粒，將該晶粒的作用側朝向該基板的晶粒黏著表面，及對準該晶粒及基板然後將其中一個移向另一個，致使該等凸塊接觸該基板上該等對應接線(引線)上的焊鍚膏；熔化然後再重新凝固該焊料膏，以在該凸塊及該接線之間形成一冶金互連。
本發明現在將參考說明本發明替代具體實施例之圖式進一步詳細說明。圖式為概略圖，顯示本發明之特徵及與其 他特徵及結構之關係，其均未按比例繪製。為清楚說明起見，在說明本發明具體實施例的圖式中，對應其他圖式中元件的元件並未全部特別重新標記，不過其在所有圖式中均可迅速識別。
習用的倒裝晶片互連係利用熔化程序形成，以將凸塊(照慣例，焊料凸塊)結合至對應之捕獲焊墊的嚙合表面上，因此，這可稱為「捕獲焊墊上凸塊」(「BOC」)互連。在BOC設計中明顯有兩個特徵：第一，需要使用比較大的捕獲焊墊以配合晶粒上的凸塊；第二，需要使用通常稱為「焊料遮罩」的絕緣材料以在互連程序期間限制焊料的流動。焊料遮罩開口可定義在捕獲焊墊之熔化焊料的輪廓(「焊料遮罩定義的」)，或是無法藉由遮罩開口定義焊料輪廓(「非焊料遮罩定義的」)；後一個情況如圖1的範例，下文將會詳述；焊料遮罩開口可明顯大於捕獲焊墊。 用於定義焊料遮罩開口的技術具有寬廣的公差範圍。因此，對於焊料遮罩定義的凸塊組態，捕獲焊墊必須很大(通常大於遮罩開口的設計尺寸甚多)，以確保遮罩開口可位在焊墊的嚙合表面上；及對於非焊料遮罩定義的凸塊組態，焊料遮罩開口必須大於捕獲焊墊。捕獲焊墊的寬度(圓形焊墊則為直徑)通常約和球(或凸塊)直徑相同，且可以比接線寬度寬二到四倍。這會使頂部基板層損失許多配線間隔。尤其，例如，「散逸配線間距」會大於基板技術能夠提供的最細接線間距甚多。這表示，通常在晶粒的覆蓋區之下，必須藉由短導孔及通道在下方基板層上配線極 大量的焊墊，以從所論焊墊放射。
圖1及2以截面圖顯示習用倒裝晶片封裝的部分10、20；圖1局部的截面圖係沿著圖2直線1-1'截取和封裝基板表面平行的平面；及圖2局部的截面圖係沿著圖1直線2-2'截取和封裝基板表面垂直的平面。特定特徵顯示猶如透明，但圖1中之許多特徵至少部分以覆蓋的特徵顯示成陰影。現在參考圖1及圖2，封裝基板的晶粒黏著表面包括在介電層12上形成的金屬或薄層。將金屬層圖案化可形成引線13及捕獲焊墊14。絕緣層16，通常又稱為「焊料遮罩」，可覆蓋基板的晶粒黏著表面；焊料遮罩通常以光可定義的材料構成及藉由習用的光阻圖案化技術進行圖案化，可曝露捕獲焊墊14的嚙合表面。黏在晶粒18之作用側上之焊墊的互連凸塊15可結合至基板上對應捕獲焊墊14的嚙合表面，以在晶粒上的電路及基板上的引線之間形成適當的電互連。在回熔的焊料冷卻以建立電連接後，會將側填滿材料17引入晶粒18及基板12之間的間隔，以在機械上穩定互連並保護晶粒及基板之間的特徵。
如圖1舉例顯示，基板(引線13)上方金屬層中的信號散逸接線，從其個別捕獲焊墊14引導橫跨晶粒邊緣位置，如虛線11所示，並離開晶粒覆蓋區。在典型的範例中，信號接線可具有散逸間距PE約112 um。30 um/30 um的設計規則通常用於如圖1所示組態中的接線本身；亦即，接線標稱為30 um寬，及其間隔相近30 um。捕獲焊墊通常大於接線寬度三倍，因此，在此範例中，捕獲焊墊具有標稱90 um的寬度(或在此範例中，若約略為圓形，則是直徑)。還有，在此範例中，焊料遮罩中的開口大於焊墊，且具有135 um的標稱寬度(直徑)。
圖1及2顯示非焊料遮罩定義的焊料輪廓。隨著晶粒上凸塊的易熔材料熔化，熔化的焊料傾向於「弄濕」引線及捕獲焊墊的金屬，及焊料傾向於「跑出」任何未遮罩的連續金屬表面上。焊料傾向於沿著連續引線13流動，及在此焊料流動會受到焊料遮罩(如圖1的19)的限制。焊墊上非焊料遮罩定義的焊料輪廓在圖2中清楚可見，其中將凸塊15的材料顯示為在捕獲焊墊14的側面上流動的29並向下到達基板12之介電層的表面。這稱為「非焊料遮罩定義的輪廓」，因為焊料遮罩並不會限制焊料在表面上的流動及向下到達捕獲焊墊的側面，除非焊墊有大量過多的焊料，否則焊料的流動會受到以下事實的限制：基板的介電表面通常不會被熔化的焊料弄濕。在如圖1的習用配置中，除了其他因素之外，捕獲焊墊之密度的下限係由以下因素決定：對遮罩形成技術之能力的限制，以製造可靠的窄遮罩結構；及在相鄰遮罩開口之間提供遮罩結構的需求。除了其他因素之外，散逸密度的下限另外由以下因素決定：將位置更為集中之捕獲焊墊的散逸線路配線在位置更為週邊之捕獲焊墊之間的需求。
圖3以和圖2相同的截面圖顯示習用之焊料遮罩定義的焊料輪廓。所示的晶粒38係藉由凸塊35附加到捕獲焊墊34的嚙合表面上；藉由圖案化在基板32之介電層之晶粒黏著側 上的金屬層，即可和接線(引線33)一起形成捕獲焊墊34。在回熔的焊料冷卻以建立電連接後，會將側填滿材料37引入晶粒38及基板32之間的間隔，以在機械上穩定互連並保護晶粒及基板之間的特徵。此處的捕獲焊墊34比圖1及2中的範例寬，且焊料遮罩開口小於捕獲焊墊，因此焊料遮罩材料可覆蓋各捕獲焊墊之嚙合表面的側面及部分(如39所示)及引線33。在使凸塊35和個別捕獲焊墊34之嚙合表面接觸，然後再加以熔化後，焊料遮罩材料39可限制熔化之焊料的流動，因此焊料輪廓的形狀可以藉由捕獲焊墊34上之遮罩開口的形狀及尺寸來定義。
圖4及6各根據本發明的一項具體實施例，分別以沿著圖5及7中直線4-4'及6-6'截取自和基板表面平行之平面的局部截面圖，顯示倒裝晶片互連之引線上凸塊(「BOL」的部分)。特定特徵顯示猶如透明。根據本發明，將凸塊直接嚙合至基板上個別的窄引線或接線上，即可達到互連，因此，這在此又稱為「引線上凸塊」(「BOL」)互連。焊料遮罩材料通常在這麼精細的幾何形狀無法解決，而根據本發明的這些具體實施例，並不用焊料遮罩。裝配程序的過程中不用焊料遮罩即可完成限制熔化之焊料流動的功能(說明如下)。圖5顯示圖4之封裝的局部截面圖，其係沿著圖4直線5-5'截取自和封裝基板表面之平面垂直的平面；及圖7顯示圖6之封裝的局部截面圖，其係沿著圖6直線7-7'截取自和封裝基板表面之平面垂直的平面。
圖4及6根據本發明，舉例顯示用於引線上凸塊 (「BOL」)基板的散逸配線圖案：在圖4中，配置用於其上互連球之晶粒黏著焊墊在接近晶粒周圍排成一列的晶粒，會在接近晶粒覆蓋區邊緣排成一列的散逸接線43上，將凸塊45嚙合至對應的互連位置，如虛線41所示；在圖6中，配置用於其上晶粒黏著焊墊在接近晶粒周圍為平行列之陣列的晶粒，會在接近晶粒覆蓋區邊緣之互補陣列的散逸接線63上，將凸塊65嚙合至對應的互連位置，如虛線61所示。
如圖4及6顯示，利用根據本發明之引線上凸塊互連可達到的配線密度能夠等於基板技術所提供之最精細的接線間距。在所示的特定情況中，這可構成比習用之捕獲焊墊上凸塊配置所達到的配線密度高約90%。在BOL之周圍列具體實施例(如圖4)中，係按照精細的間距放置凸塊，該間距等於基板之最精細的接線間距。此配置對裝配程序將形成挑戰，因為凸塊形成及焊接的間距必須非常精細。在BOL的周圍陣列形式(如圖6)中，會將凸塊配置在區域陣列上，以對更大的凸塊形成及焊接間距提供更大的間隔，因而能夠因應裝配程序的技術挑戰。即使在陣列具體實施例中，基板上的配線接線和周圍列配置一樣係按照相同的有效間距，因此圖6的配置不用犧牲精細散逸配線間距的好處，即可因應精細間距凸塊形成及焊接的重責。
現在尤其請參考圖4及5，會在基板介電層42的晶粒黏著表面上，藉由圖案化金屬層以形成引線43。根據本發明，將晶粒上的凸塊45直接結合至引線43上，即可形成晶粒48 的電互連。根據本發明，並不需要使用捕獲焊墊，及在如圖4及5的具體實施例中，也不需要使用焊料遮罩；此程序詳細說明如下。
習用的捕獲焊墊的寬度(直徑)通常和凸塊的相同，且通常是接線或引線寬度的二至四倍寬。正如所瞭解的，預期引線的寬度會有一些變化。如本文所用，多達標稱120%的接線寬度或接線設計規則寬度的接線寬度變化無法構成捕獲焊墊，及根據本發明的引線上凸塊互連包括在引線如此較寬部分上形成的凸塊。
同樣地，參考圖6及7，藉由在基板介電層62的晶粒黏著表面上圖案化金屬層，即可形成引線63。信號散逸接線會引導橫跨晶粒邊緣位置，如虛線61所示，並離開晶粒覆蓋區。根據本發明，將晶粒上的凸塊65直接結合至引線63上，即可形成晶粒68的電互連。從成列的互連位置引導橫跨晶粒邊緣位置到達晶粒覆蓋區之內部的特定散逸接線，如66，會在互連位置之較外圍列的凸塊65之間通過。根據本發明，並不需要使用捕獲焊墊，及在如圖6及7的具體實施例中，也不需要使用焊料遮罩；此程序詳細說明如下。
如圖4及6所示，根據本發明的引線上凸塊互連能夠提供明顯較高的信號接線散逸配線密度。還有，如圖4及6所示，根據本發明此方面的BOL互連並不需要使用焊料遮罩以定義互連位置的焊料輪廓。
如圖4、5、6及7舉例所示之具體實施例的BOL互連結構可以根據本發明數個方法中任何一項來產生，並不需要使 用焊料遮罩。一般而言，互連凸塊(通常為焊料凸塊)係附加在晶粒之作用側的互連焊墊上。基板的晶粒黏著表面(稱為「上方」表面)具有圖案化的上方金屬層，以在特定晶粒上視需要提供和凸塊配置互連的接線。由於不需要使用捕獲焊墊，圖案化的接線(引線)只需要透過晶粒上和互補於凸塊配置之圖案對應的位置來配線。在本發明的較佳方法中，會採用封裝樹脂黏著劑以限制焊料在互連程序之熔化階段期間的流動。
圖8及9根據本發明的另一項具體實施例，顯示引線上凸塊之倒裝晶片互連之部分的兩個範例，其係為截取自和基板表面平行之平面的截面圖。特定特徵顯示猶如透明。根據本發明的此方面，會提供一焊料遮罩，其具有介於約80 um至90 um的標稱遮罩開口直徑。在此間距可解決焊料遮罩材料，尤其，可以比較便宜的方式製造具有含90 um開口及對準公差加減25 um之焊料遮罩的基板。在部分具體實施例中，可以使用根據標準設計規則所製造的層板基板(如4個金屬層層板)。例如，在圖8及9的具體實施例中，接線的間距可以是~90 um及互連位置的區域陣列可以是270 um，以提供橫跨晶粒覆蓋區的邊緣(如虛線81所示)之有效的散逸間距~90 um。
在如圖8及9的具體實施例中，不需要使用非流動的側填滿；可以採用習用的毛細管側填滿。
在如圖8的具體實施例中，在基板82之晶粒黏著表面的介電層上圖案化的窄引線或接線83上，將凸塊直接嚙合在 互連位置84上，即可達到互連；其中並沒有焊墊，及焊料遮罩86可用來限制焊料在遮罩開口88之界限內的流動，以防止焊料沿著焊料可濕性引線流動離開互連位置。此焊料遮罩另外可限制熔化的焊料在引線之間流動，或是這可在裝配程序的過程中完成。
在圖9的具體實施例中，如圖8，根據本發明，其中並沒有互連焊墊。在基板92的晶粒黏著表面上，會圖案化介電層上的窄引線或接線93。焊料膏係提供於引線93上的互連位置94，以提供用於互連的易熔媒介。焊料遮罩96中的開口98可用來定義焊料膏。焊料膏可藉由如標準印刷程序塗上，然後回熔，然後視需要再加以鑄造，以提供配合球的均勻表面。如上述參考圖8，可在利用基板的裝配過程中塗上焊料膏；或可在裝配之前提供具有適當圖案化之焊料膏的基板。其他將焊料選擇性塗上互連位置的方法可用於本發明之具體實施例的引線上焊料，包括無電電鍍及電鍍技術。引線上焊料組態可提供額外用於互連的焊料量，因此能提供較高的產品良率，及也能提供較高的晶粒凸出物。
因此，在部分具體實施例中，根據本發明的引線上焊料組態可用於具有高熔化溫度焊料凸塊(如高鉛焊料，照慣例用於和陶瓷基板的互連)之晶粒和有機基板的互連。可以選擇具有熔化溫度夠低致使有機基板在回熔期間不會損壞的焊料膏。為了在此種具體實施例中形成互連，會將高熔化互連凸塊和引線上焊料位置接觸，且再熔化可將引線 上焊料熔接至凸塊。和引線上焊料程序一起使用不可壓扁的凸塊時，不需要事先塗上黏著劑，因為各互連只有少量焊料的事實可限制焊料的取代或流動，因而不可壓扁的凸塊可防止裝配件跨掉。
在其他具體實施例中，根據本發明的引線上焊料組態可用於具有共熔焊料凸塊之晶粒的互連。
形成引線上凸塊互連之較佳方法的一項具體實施例如圖10A至10C所示。
參考圖式，會提供具有至少一介電層及在晶粒黏著表面113上具有金屬層的基板112，可將金屬層圖案化以提供電路，尤其接線或引線114在晶粒黏著表面上具有用於互連的位置。基板112係固定於載體或平台116上，其中基板表面對置面對固定體的晶粒黏著表面113。會將大量封裝樹脂122塗在基板的晶粒黏著表面113上，以覆蓋至少引線114上的互連位置。會在作用側103上，提供具有黏在晶粒焊墊上(圖中未顯示)之凸塊104的晶粒102。此凸塊包括可接觸引線之嚙合表面的易熔材料。取放工具108包括夾頭106，其可將夾頭106和晶粒的背面101接觸而拾取晶粒。利用拾取工具，可將晶粒放置面對基板，其中晶粒的作用側對著基板的晶粒黏著表面，如圖10A所示；及會將晶粒與基板彼此對準移動(箭頭M)，致使凸塊104接觸基板之接線(引線)114上的對應互連位置。然後會施力(箭頭F)，將凸塊105壓在引線115上互連位置的嚙合表面134上，如圖10B所示。該力必須足夠，至少可取代引線114上互連位置 之凸塊及嚙合表面間的黏著劑122。凸塊會因此力而變形，使得凸塊之接觸表面及/或引線的嚙合表面上的氧化膜破裂。凸塊的變形會使凸塊的易熔材料壓在引線的頂部及其邊緣上。如藉由加熱至選定的溫度，可使黏著劑固化至少部分，如132所示。在此階段，黏著劑只需要部分固化，亦即，只要到達以下程度即可：實質上足以防止熔化的焊料沿著黏著劑及導電接線之間的介面流動。然後會熔化凸塊105的易熔材料，然後再重新凝固，以在凸塊105及引線115之間形成冶金互連，因而完成黏著劑固化，以完成晶粒黏著及穩固嚙合表面(現為互連介面)144的電互連，如圖10C的140概括所示。在圖10C所示截面圖的平面中，在特定引線155上，在特定凸塊145及對應的互連位置之間會形成互連，如圖6的組態所示。其他引線156係在其他位置互連，該等位置可見於其他截面圖中。所示為比較高的接線密度。黏著劑的固化可在熔化焊料之前、同時或之後完成。通常，黏著劑為可熱固化黏著劑，及藉由調整溫度，即可在程序中控制任何階段的固化程度。例如，藉由升高取放工具上之夾頭的溫度或基板固定體的溫度，即可加熱及固化成分。
此程序將在圖11A至11D中進一步詳細顯示。在圖11A中，會在晶粒黏著表面上提供具有導電(金屬)接線214的基板212，及會以黏著劑222覆蓋接線上的互連位置。晶粒202的位置和基板212的關係致使晶粒的作用側面對基板的晶粒黏著側，及其對準(箭頭A)致使晶粒上的凸塊204和接 線214上對應的嚙合表面對準。晶粒及基板會移向彼此，致使凸塊接觸接線上的個別嚙合表面。然後，如圖11B所示，會施力以使凸塊205及接線215移向彼此，以取代圖11B之232所示的黏著劑，然後使凸塊在嚙合表面234及接線的邊緣上變形。接線上凸塊的變形會使凸塊之接觸表面及接線之嚙合表面上的氧化膜斷裂，以建立良好的電連接，及接線邊緣上凸塊的變形有助於建立良好的暫時機械連接。如圖10A至10C中的範例，特定接線216的互連位置會脫離圖11B的平面。會加熱以部分固化黏著劑，如圖11C的236所示。然後會加熱以升高凸塊的溫度，以足夠使凸塊的易熔材料熔化，如圖11D所示。這實質上(但不一定完全)可完成黏著劑246的固化，及在引線215的互連位置，完成凸塊245冶金互連至嚙合表面244上。已固化的黏著劑可穩定晶粒黏著。
在較佳方法的替代具體實施例中，可預先將黏著劑塗在晶粒表面上，或至少塗在晶粒表面的凸塊上，而非塗在基板上。例如，可將黏著劑裝在貯存器中，然後將晶粒的作用側浸入黏著劑再取出，致使凸塊上載有大量的黏著劑；然後，利用拾取工具將晶粒放置面對固定的基板，其中晶粒的作用側對著基板的晶粒黏著表面，然後對準晶粒及基板並使其移向彼此，致使凸塊接觸基板上對應的接線(引線)。此種方法說明於2004年8月24日的美國專利第6,780,682號，其內容在此以引用的方式併入本文中。然後如上述執行施力、固化、及熔化。
根據本發明之程序的力及溫度排程如圖12舉例所示。在此圖中，時間在水平軸上從左向右進展；力的輪廓310係顯示為粗線，及溫度輪廓320係顯示為虛線。溫度輪廓始於介於約80℃至約90℃的溫度。力的輪廓實質上始於零力。從初始時間ti開始，力迅速(幾乎馬上)從Fi升高312為取代/變形力Fd並保持314在該力一段時間，如下文所述。Fd是大到足以取代凸塊及引線嚙合表面間之黏著劑的力；及較佳，足以使凸塊的易熔(引線接觸)部分在嚙合表面上變形，使氧化膜斷裂及形成良好的金屬對金屬(冶金)接觸，以及，在部分具體實施例中，足以在引線的邊緣上建立凸塊及引線的機械連鎖(「扭曲」變形)。所需要的總力量取決於凸塊材料及尺寸，及取決於凸塊的數量，且不用過度實驗即可決定。隨著力的升高，溫度也會從初始的溫度Ti迅速升高322至凝膠溫度Tg。凝膠溫度Tg是足以部分固化黏著劑(成為「凝膠」)的溫度。力及溫度斜面的設定較佳致使達到Fd之後及達到Tg之前的滯後時間tdef很短，至少長到足以在黏著劑的局部固化開始之前，允許升高的力取代黏著劑及使凸塊變形。此裝配件會保持314、324在取代/變形壓力Fd及凝膠溫度Tg一段時間tgel，以足夠實現黏著劑的局部固化。黏著劑應該變得夠穩固，使其在焊料重新熔化階段期間實質上維持良好的凸塊輪廓，亦即，夠穩固以免不必要地取代凸塊之熔化的易熔材料，或防止熔化的易熔材料沿著引線流動。在黏著劑部分固化至足夠的程度後，壓力會迅速下降318至實質上沒有任何力(成分的重 量)。然後溫度會進一步升高323至溫度Tm，以足夠重新熔化凸塊的易熔部分(焊料)，將裝配件保持325於重新熔化的溫度Tm一段時間tmelt/cure，至少足以在接線上完全形成焊料重新熔化，及較佳足以實質上(但不一定完全)固化黏著劑。然後，溫度會下降328至初始溫度Ti，最後降至室溫。圖12所示程序執行其過程的時間週期為5-10秒。
如圖12之具體實施例的黏著劑可稱為「非流動側填滿」。在一些倒裝晶片互連的方法中，會先形成冶金互連，然後再讓側填滿材料流入晶粒及基板間的間隔。根據本發明的「非流動側填滿」可在將晶粒及基板接合一起前塗上，及藉由引線上凸塊的方法，及藉由晶粒及基板的對置表面，即可取代非流動側填滿。根據本發明之非流動側填滿黏著劑的黏著劑較佳為快速膠化黏著劑，亦即，在凝膠溫度持續1-2秒等級的時間週期膠化足夠的材料。非流動側填滿黏著劑的較佳材料包括如所謂的「非導電焊料膏」，如Toshiba Chemicals及Loktite-Henkel所銷售的黏著劑。
在根據本發明的引線上凸塊互連中也可以採用替代的凸塊結構。尤其，例如，可以使用所謂的「合成焊料凸塊」。合成焊料凸塊具有至少兩個凸塊部分(以不同的凸塊材料製成)，其包括在回熔條件下可壓扁的部分，及在回熔條件下實質上不可壓扁的部分。不可壓扁的部分係黏在晶粒的互連位置上；用於不可壓扁部分的典型習用材料包括各種具有高鉛(Pb)內容的焊料。可將可壓扁的部分和不 可壓扁的部分相結合，及可壓扁的部分可形成和根據本發明之引線的連接。合成凸塊之可壓扁部分的典型習用材料包括如共熔焊料。
引線上凸塊互連的範例係採用如圖13之截面圖所示的合成凸塊。現在參考圖13，在晶粒之作用側中晶粒焊墊上所提供的晶粒302具有包括不可壓扁的部分345及可壓扁的部分347的合成凸塊。可壓扁的部分如共熔焊料或相對的低溫熔化的焊料。可壓扁的部分可接觸引線的嚙合表面，在此，需要引線上凸塊之易熔部分的變形，凸塊的可壓扁的部分在施力的條件下會變形。不可壓扁的部分如具有高鉛(Pb)內容的焊料。不可壓扁的部分在晶粒於處理期間受壓移向基板時不會變形，且在程序的回熔階段期間不會熔化。因此，不可壓扁的部分具有的尺寸可在晶粒之作用表面及基板之晶粒黏著表面之間提供凸出物距離。
應明白，如圖4、5、6及7所示具體實施例的凸塊不一定要是完全可壓扁的凸塊。在這些圖式中顯示的結構可另外利用合成凸塊來製造，或利用如所說明的引線上焊料方法來製造。
其他具體實施例屬於以下申請專利範圍內。
10,20,30‧‧‧習用倒裝晶片封裝的部分
11‧‧‧晶粒邊絕位置
12‧‧‧介電層/基板
12‧‧‧基板
13‧‧‧引線
14‧‧‧捕獲焊墊
15‧‧‧互連凸塊
16‧‧‧絕緣層
17‧‧‧側填滿材料
18‧‧‧晶粒
19‧‧‧焊料遮罩
29‧‧‧流動的凸塊材料
32‧‧‧基板
33‧‧‧引線
34‧‧‧捕獲焊墊
35‧‧‧凸塊
37‧‧‧側填滿材料
38‧‧‧晶粒
39‧‧‧焊料遮罩材料
40‧‧‧本發明之倒裝晶片封裝的部分
41‧‧‧互連位置
42‧‧‧基板介電層
43‧‧‧引線/散逸接線
45‧‧‧凸塊
48‧‧‧晶粒
61‧‧‧互連位置/信號散逸接線
62‧‧‧基板介電層
63‧‧‧引線/散逸接線
65‧‧‧凸塊
66‧‧‧散逸接線
68‧‧‧晶粒
81‧‧‧晶粒覆蓋區邊緣
82‧‧‧基板
83‧‧‧引線/接線
84‧‧‧互連位置
86‧‧‧焊料遮罩
88‧‧‧遮罩開口
92‧‧‧基板
93‧‧‧引線/接線
94‧‧‧互連位置
96‧‧‧焊料遮罩
98‧‧‧開口
101‧‧‧晶粒背面
102‧‧‧晶粒
103‧‧‧作用側
104‧‧‧凸塊
105‧‧‧凸塊
106‧‧‧夾頭
108‧‧‧取放工具
112‧‧‧基板
113‧‧‧晶粒黏著表面
114‧‧‧引線/接線
115‧‧‧引線
116‧‧‧載體或平台
122‧‧‧黏著劑
132‧‧‧黏著劑固化部分
134‧‧‧嚙合表面
140‧‧‧完成的倒裝晶片互連
144‧‧‧嚙合表面
145‧‧‧凸塊
155‧‧‧引線
156‧‧‧引線
202‧‧‧晶粒
204‧‧‧凸塊
205‧‧‧凸塊
212‧‧‧基板
214‧‧‧導電(金屬)接線
215‧‧‧引線/接線
216‧‧‧接線
222‧‧‧黏著劑
232‧‧‧黏著劑
234‧‧‧嚙合表面
236‧‧‧黏著劑固化部分
244‧‧‧嚙合表面
245‧‧‧凸塊
246‧‧‧黏著劑
302‧‧‧晶粒
310‧‧‧力的輪廓
312‧‧‧力的輪廓之升高
314‧‧‧力的輪廓之保持
318‧‧‧力的輪廓之下降
320‧‧‧溫度輪廓
322‧‧‧溫度輪廓之升高
323‧‧‧溫度輪廓之升高
324‧‧‧溫度輪廓之保持
325‧‧‧溫度輪廓之保持
328‧‧‧溫度輪廓之下降
345‧‧‧不可壓扁的部分
347‧‧‧可壓扁的部分
圖1為習用之捕獲焊墊上凸塊之倒裝晶片互連之部分的示意圖，其係為和封裝基板表面平面平行的截面圖，如圖2中的箭頭1-1'所示。
圖2為顯示習用之捕獲焊墊上凸塊之倒裝晶片互連之部 分的示意圖，其係為和封裝基板表面平面垂直的截面圖，如圖1中的箭頭2-2'所示。
圖3為顯示另一個習用之捕獲焊墊上凸塊之倒裝晶片互連之部分的示意圖，其係為和封裝基板表面平面垂直的截面圖。
圖4為根據本發明之引線上凸塊之倒裝晶片互連之一項具體實施例之部分的示意圖，其係為和封裝基板表面平面平行的截面圖。
圖5為根據如圖4的本發明顯示引線上凸塊之倒裝晶片互連之一項具體實施例之部分的示意圖，其係為和封裝基板表面平面垂直的截面圖，如圖4中的箭頭5-5'所示。
圖6為根據本發明之引線上凸塊之倒裝晶片互連之另一項具體實施例之部分的示意圖，其係為和封裝基板表面平面平行的截面圖。
圖7為根據如圖6的本發明顯示引線上凸塊之倒裝晶片互連之一項具體實施例之部分的示意圖，其係為和封裝基板表面平面垂直的截面圖，如圖6中的箭頭7-7'所示。
圖8及9為根據本發明之引線上凸塊之倒裝晶片互連之另一項具體實施例之各部分的示意圖，其係為和封裝基板表面平面平行的截面圖。
圖10A至10C以截面圖顯示用於形成根據本發明之倒裝晶片互連之程序步驟的示意圖。
圖11A至11D以截面圖顯示用於形成根據本發明之倒裝晶片互連之程序步驟的示意圖。
圖12為顯示用於形成根據本發明之倒裝晶片互連之程序之力及溫度排程的示意圖。
圖13以截面圖顯示具有合成凸塊之根據本發明之引線上凸塊之倒裝晶片互連的示意圖。
40‧‧‧本發明之倒裝晶片封裝的部分
41‧‧‧互連位置
42‧‧‧基板介電層
43‧‧‧引線
45‧‧‧凸塊

Claims (15)

  1. 一種製造一封裝基板之方法，其包含：於該封裝基板之一晶粒黏著側形成複數個接線(trace)，該等接線包括互連位置，該等互連位置之平行邊緣定義一小於貼合至該互連位置之一凸塊之一寬度之互連位置寬度，其中每一互連位置寬度小於該接線離開該互連位置之寬度的1.2倍，該等互連位置係於接近一半導體晶粒接腳(foot print)區域之一邊緣處配置為列之陣列。
  2. 如請求項1之方法，其進一步包含於該等互連位置上沉積一可熔導電介質層。
  3. 如請求項1之方法，其進一步包含於該基板上沉積一黏著劑以覆蓋相對於該基板之該等互連位置之一表面。
  4. 如請求項1之方法，其進一步包含將該凸塊貼合至該互連位置，該凸塊包含一可壓扁材質與一不可壓扁材質。
  5. 如請求項1之方法，其中該互連位置寬度大約小於貼合至該互連位置之該凸塊之寬度之一半。
  6. 一種製造一封裝基板之方法，其包含：於該封裝基板之一晶粒黏著側形成複數個接線，該等接線之每一者具有一用於貼合至一互連結構之互連位置，每一互連位置之一寬度小於該接線之該寬度的1.2倍；及於該封裝基板上沉積一黏著劑以覆蓋相對於該基板之該等互連位置之一表面。
  7. 如請求項6之方法，其中該等互連位置係於接近一半導 體晶粒接腳區域之一邊緣處配置為列之陣列。
  8. 如請求項6之方法，其進一步包含於該等互連位置上沉積一可熔導電介質層。
  9. 如請求項6之方法，其進一步包含將一凸塊貼合至該互連位置，該凸塊包含一可壓扁材質與一不可壓扁材質。
  10. 如請求項6之方法，其中該互連位置寬度大約小於貼合至該互連位置之該凸塊之寬度之一半。
  11. 一種封裝基板，其包含：形成於該封裝基板之一晶粒黏著側之複數個接線，該等接線之每一者包含一互連位置，該等互連位置之平行邊緣定義一小於貼合至該互連位置之一凸塊之一寬度之互連位置寬度，其中該互連位置寬度小於該接線之該寬度的1.2倍；及一沉積於該封裝基板上以覆蓋相對於該基板之該等互連位置之一表面之黏著劑。
  12. 如請求項11之封裝基板，其中該等互連位置係於接近一半導體晶粒接腳區域之一邊緣處配置為列之陣列。
  13. 如請求項11之封裝基板，其進一步包含一沉積於該等互連位置上之可熔導電介質層。
  14. 如請求項11之封裝基板，其進一步包含將該凸塊貼合至該互連位置，且該凸塊包含一可壓扁材質與一不可壓扁材質。
  15. 如請求項11之封裝基板，其中該互連位置寬度大約小於貼合至該互連位置之該凸塊之寬度之一半。
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