TW201310584A - 半導體裝置與半導體裝置的形成方法 - Google Patents
半導體裝置與半導體裝置的形成方法 Download PDFInfo
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- TW201310584A TW201310584A TW100139546A TW100139546A TW201310584A TW 201310584 A TW201310584 A TW 201310584A TW 100139546 A TW100139546 A TW 100139546A TW 100139546 A TW100139546 A TW 100139546A TW 201310584 A TW201310584 A TW 201310584A
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- Prior art keywords
- layer
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- forming
- package member
- electrical connector
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Classifications
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Abstract
一種半導體裝置包括一金屬墊於一基板上。一鈍化層包括一部份於該金屬墊上。一後鈍化內連線(post-passivation interconnect,PPI)與該金屬墊電性耦接,其中該後鈍化內連線包括一部份於該金屬墊與該鈍化層上。一聚合物層於該後鈍化內連線上。一虛擬凸塊於該聚合物層上,其中該虛擬凸塊與在該聚合物層下方之導電結構電性絕緣。
Description
本發明係關於一種半導體裝置,且特別關於一種封裝結構。
積體電路通常形成於半導體晶片上。為了增加製造生產量與降低製造成本,將積體電路製造於半導體晶圓中,各含有許多相同之半導體晶片。在製造出積體電路之後,於半導體晶片可被使用之前,將半導體晶片從晶圓鋸開並進行封裝。
在一些封裝程中,將半導體晶片(在本技術領域中也意指為晶粒)與封裝基板接合。使用底層填充材料(underfill)來使接合更牢固,底層填充材料一般包括環氧樹脂。可使用倒裝晶片接合(flip-chip bonding)或導線接合(wire bonding)來使半導體晶片接合。在一晶粒至一封裝基板的倒裝晶片接合製程中,執行一回焊(re-flow)以使介於晶粒與封裝基板之間的焊料熔化,以將晶粒連接至封裝基板。
常見的接合製程遭受到缺點。例如,在回焊製程期間,封裝基板的溫度被提高。由於封裝基板易於翹曲(warpage),所以在回焊之後,封裝基板可具有翹曲。隨著封裝基板的翹曲,於晶粒之中心或邊緣的凸塊及/或封裝基板被伸長或壓縮。此引起要傳給在晶粒中之低介電常數介電材料的應力,且分層可發生至低介電常數層。此外,應力可更進一步導致介於晶粒與封裝基板之間的焊料遭受破裂。
本發明提供一種半導體裝置,包括:一基板;一金屬墊於該基板上;一鈍化層,其包括一部份於該金屬墊上;一後鈍化內連線(post-passivation interconnect,PPI)與該金屬墊電性耦接,其中該後鈍化內連線包括一部份於該金屬墊與該鈍化層上;一聚合物層於該後鈍化內連線上;以及一虛擬凸塊於該聚合物層上,其中該虛擬凸塊與在該聚合物層下方之導電結構電性絕緣。
本發明另提供一種半導體裝置,包括:一第一封裝構件,其包括一電性連接器;一第二封裝構件,經由該電性連接器與該第一封裝構件結合;以及一虛擬凸塊,介於該第一封裝構件與該第二封裝構件之間,其中該虛擬凸塊與在該第一封裝構件與該第二封裝構件之至少一個中的導電結構電性絕緣。
本發明還提供一種半導體裝置的形成方法,包括:形成一第一封裝構件,其中該形成之步驟包括下列步驟:形成一鈍化層,其包括一部份於一金屬墊上;形成一後鈍化內連線,其與該金屬墊電性耦接,其中該後鈍化內連線包括一部份於該金屬墊與該鈍化層上;形成一聚合物層於該後鈍化內連線上;形成一電性連接器於該後鈍化內連線上且與其電性耦接,其中該電性連接器包括一部份於該聚合物層之一上表面上;以及形成一虛擬凸塊於該聚合物層上,其中該虛擬凸塊與在該聚合物層下方之所有導電結構絕緣。
為了讓本發明之上述和其他目的、特徵、和優點能更明顯易懂,下文特舉較佳實施例,並配合所附圖示,作詳細說明如下:
依照一實施例提供一封裝結構,此封裝結構包括虛擬凸塊與其形成方法。圖解說明製造各種實施例的中間階段。之後討論實施例的變化。遍及各種圖式與說明之實施例,相同的參考標號被使用來代表相同的元件。
參見第1圖,提供晶圓10,其包括半導體基板20。在一實施例中,晶圓10為一裝置晶圓,其可包括主動裝置,例如電晶體於其中。因此,半導體基板20可為一塊狀矽(bulk silicon)基板或一絕緣層上矽(silicon-on-insulator)基板。也可使用其他半導體材料,包括III族、IV族與V族元素。在替代實施例中,晶圓10可為不包括主動裝置於其中之其他封裝構件的晶圓,且例如可為一中介層晶圓(interposer wafer)。在此實施例中,晶圓10不包括主動裝置,晶圓10可包括被動裝置,例如電阻器或電容器,或無被動裝置。此外,在晶圓10不包括主動裝置於其中的實施例中,基板20可為一介電基板,例如一玻璃基板、一陶瓷基板、一有機基板或其類似物。
當晶圓10為一裝置晶圓時,於半導體基板20的表面形成積體電路裝置,例如電晶體(概要性地繪示為21)。晶圓10可更包括層間介電層(inter-layer dielectric,ILD)22於半導體基板20上,與金屬層24於層間介電層22上。於介電層25中形成金屬層24,其包括金屬線26,其中更進一步藉由接觸插塞(via)28來將金屬線26內連結。在一實施例中,介電層25係由低介電常數介電材料所形成。低介電常數介電材料的介電常數(k值)可為,例如小於約2.8,或小於約2.5。金屬線26與接觸插塞28可由銅或銅合金來形成,然而,它們也可由其他材料來形成。
金屬墊30被形成於金屬層24上,且與金屬線26與接觸插塞28電性連接。金屬墊30可為鋁墊或鋁合金墊,且因此於此之後二擇一地意指為鋁墊30,然而也可使用其他金屬材料。於金屬層24上形成鈍化層32。鈍化層32的一部份可覆蓋鋁墊30的邊緣部分。經由在鈍化層32中的開口露出鋁墊30的中央部分。鈍化層32可為一單一層或一複合層,且可由一非多孔材料所形成。在一實施例中,鈍化層32係由一複合層所形成,複合層包括一氧化矽層(未顯示)與一氮化矽層(未顯示)於氧化矽層上。鈍化層32也可由無摻雜矽玻璃(un-doped silicate glass,USG)、氮氧化矽及/或其類似物所形成。
於鈍化層32上形成聚合物層36。聚合物層36可由一聚合物,例如環氧樹脂、聚亞醯胺、苯並環丁烯(benzocyclobutene,BCB)、聚苯並噁唑(polybenzoxazole,PBO)與其類似物所形成。形成方法包括旋塗(spin coating)或其他方法。將聚合物層圖案化以形成一開口,經由此開口露出鋁墊30。聚合物層36的圖案化可包括光微影蝕刻技術。之後可執行一硬化以硬化聚合物層36。形成後鈍化內連線(post-passivation interconnect,PPI)38以經由在聚合物層36中的開口與鋁墊30電性耦接。後鈍化內連線38被以此命名,是由於後鈍化內連線38的形成係在於鈍化層32的形成之後。後鈍化內連線38可由純銅、實質上純銅、一銅合金或其他金屬或金屬合金所形成。後鈍化內連線38可更包括一含鎳層。形成方法包括電鍍、無電電鍍(electroless plating)、濺鍍、化學氣相沈積方法與其類似方法。
第2圖繪示聚合物層39的形成與圖案化。聚合物層39可包括一聚合物,其可為聚亞醯胺或其類似物,且可使用與圖案化聚合物36相同之方法來將聚合物層39圖案化。在聚合物層39的圖案化之後,後鈍化內連線38的一部份經由開口40被露出。在其中後鈍化內連線38係由一含銅材料所形成的一實施例中,含銅材料之表面可經由在聚合物層39中的開口40被露出。
參見第3圖,凸塊下冶金(undr-bump-metallurgy,UBM)層45被形成。在一實施例中,凸塊下冶金層45包括阻擋層42與晶種層44於阻擋層42上。阻擋層42延伸進入開口40且與後鈍化內連線38電性耦接,且可與後鈍化內連線38物理性接觸。阻擋層42可為一鈦層、一氮化鈦層、一鉭層、一氮化鉭層或由鈦合金或鉭合金所形成的一層。晶種層44的材料可包括銅或銅合金,且因此於此之後可將晶種層44二擇一地意指為一銅晶種層。然而,也可包括其他材料,例如銀、金、鋁、鈀、鎳、鎳合金、鎢合金、鉻、鉻合金與其組合。在一實施例中,使用物理氣相沈積或其他合適的方法來形成阻擋層42與晶種層44。阻擋層42可具有一厚度介於約500 與約2,000 之間。晶種層44可具有一厚度介於約1,000 與10,000 之間,然而,也可使用不同的厚度。
第4圖繪示罩幕46的形成,其可由,例如一光阻或經層壓(laminated)的一乾燥薄膜形成於凸塊下冶金層45上。將罩幕46圖案化,並經由在罩幕46中之開口47與48露出凸塊下冶金層45的部份,而凸塊下冶金層45的一些部份則由罩幕46所覆蓋。開口46係直接於後鈍化內連線38的一金屬墊上。另一方面,將開口48形成於聚合物層39的一部份上,但可不具有一下方的後鈍化內連線墊(PPI pad)。因此,經由開口46所露出之露出部分凸塊下冶金層45A可具有下表面45A1,其接觸後鈍化內連線38,而經由開口48所露出之露出部分凸塊下冶金層45B可具有一下表面45B1,其不與任何後鈍化內連線墊接觸。作為替代地,下表面45B1與一下方之介電材料接觸,而介電材料在一些實施例中可為聚合物層39。
接著,也如於第5圖中所示,形成金屬凸塊50與52。在一實施例中,將晶圓10置入一電鍍溶液中(未顯示),並執行一鍍覆(plating)步驟以於凸塊下冶金層45上及於開口47與48中分別形成金屬凸塊50與52。鍍覆可為一電鍍、一無電解電鍍、一浸鍍(immersion plating)或其類似方法。在一示範實施例中,金屬凸塊50與52的各個包含一非可回焊(non-reflowable)部分,其在隨後的回焊製程中不熔化。非可回焊(non-reflowable)部分被指示為銅凸塊50A與52A。視需要而定,金屬凸塊50與52可包括蓋層,其擇自由一鎳層、一鎳合金、一鈀層、一金層、一銀層與其多層所組成的群組,形成於銅凸塊50A與52A上。金屬凸塊50與52可更分別包括焊料蓋50B與52B,其可由一Sn-Ag合金、一Sn-Cu合金、一Sn-Ag-Cu合金或其類似物所形成,且可為無鉛或含鉛。
參見第6圖,在形成金屬凸塊50之後,移除罩幕46,且露出先前由罩幕46所覆蓋之凸塊下冶金層45的部分。之後執行一蝕刻以移除不被金屬凸塊(例如,金屬凸塊50與52)所覆蓋之凸塊下冶金層45的部分。在所產生的結構中,凸塊下冶金部分45A與上方之金屬凸塊50結合意指為電性連接器60,而凸塊下冶金部分45B與上方之金屬凸塊52結合意指為虛擬凸塊62。電性連接器60與金屬墊30電性耦接。虛擬凸塊62直接位於聚合物層39上,且可與其物理性接觸。因此虛擬凸塊62不具有與在晶圓10中之結構電性連接的功能,且不與任何後鈍化內連線電性耦接。
第8圖繪示,在電性連接器60與虛擬凸塊62形成後之晶圓10之一部分的上視圖。於此之後,所繪示的部分意指為封裝構件100。當晶圓10為一裝置晶圓時,封裝構件100可為一裝置晶粒。或者,封裝構件100可為一中介層(intrposer)。封裝構件100具有邊緣102。可於封裝構件100之表面形成複數個電性連接器60與虛擬凸塊62。在一實施例中,將虛擬凸塊分佈至在封裝構件100中的複數個部分,而此複數個部分在將封裝構件與其他封裝構件接合之後,遭受高度的應力,又其他封裝構件,例如為一封裝基板。例如,可將虛擬凸塊分佈置封裝構件100之中央與四個角落,封裝構件100的這些部分相較於其他部分具有較高的應力。在封裝構件100的其他部分中,配置電性連接器60,其與封裝構件100內之結構電性連接。在所繪示之實施例中,將四個虛擬凸塊62配置於封裝構件100的中央,並將兩個虛擬凸塊62配置於封裝構件100的各角落,然而可將較多或較少之虛擬凸塊62配置於各位置。剩餘之凸塊可為電性連接器60。
在形成電性連接器60與虛擬凸塊62之後,可將晶圓10鋸成晶粒,其中這些晶粒的一個,如第8圖中之封裝構件100所示。之後將封裝構件100與封裝構件200接合,如於第7圖中所示。或者,可在晶圓10的晶粒鋸之前來執行封裝構件100至封裝構件200的接合,且因此個別之接合為一晶圓至晶圓接合(wafer to wafer bonding)。封裝構件200可為一裝置晶粒,其包括主動裝置,例如電晶體於其中,或可為其他封裝構件,具有非主動裝置於其中,例如一封裝基板、一中介層或其類似物。封裝構件200也可為一封裝體,其包括一或多個裝置晶粒、中介層及/或封裝基板於任何結合形式中。電性連接器60可與電性連接器202接合,其可為一金屬結構。電性連接器202可與結構206電性耦接,而結構206相較於電性連接器202在封裝構件200的相對側上。在一實施例中,結構206為一焊料凸塊,且經由金屬線與接觸插塞204與電性連接器202耦接。
虛擬凸塊60可與介電層210物理性接觸,介電層210為在封裝構件200的表面。因此虛擬凸塊62可與在封裝構件200中的所有金屬結構絕緣,且可為電性飄移。或者,虛擬凸塊62可與在封裝構件200中之接合墊212接合,而使用虛線來標示接合墊212。然而,接合墊不與在封裝構件200之相對側上的任何其他導電結構電性耦接,且不與在封裝構件200內的任何其他導電結構電性耦接。
第7圖繪示一凸塊導線直接(bump on trace,BOT)結構,其中金屬結構202為一金屬導線,且電性連接器60與金屬導線202接合,此接合結構包括焊料220,其也與金屬導線202之側壁接合。焊料220可包括於第6圖中之焊料蓋50B,且可視需要而定包括預焊料(pre-solder),其被預先提供至金屬結構202上。在替代實施例中,如於第9圖中所示,電性連接器60可與在封裝構件200表面的接合墊214接合,而虛擬凸塊62仍為電性飄移,且可與在封裝構件200中的所有導電結構絕緣。在如第7與9圖中所示之封裝構件100與200的接合之後,將一底層填充材料(underfill)230填入介於封裝構件100與200之間的空間中。底層填充材料230可與電性連接器60與虛擬凸塊62物理性接觸。
在這些實施例中,虛擬凸塊62(第7與第9圖)可不與在封裝結構100中的任何後鈍化內連線連接。在用來接合封裝構件100與封裝構件200的回焊製程之後,封裝構件100與200可具有翹曲。當應力由於翹曲而產生時,虛擬凸塊62可將應力傳給相對地軟的聚合物層39而不是傳送至後鈍化內連線38與封裝構件100內的結構,以使應力可藉由聚合物層39來吸收。因此可改善封裝構件100的可靠度。相似地,在封裝構件200的那側,藉由介電層210將應力部分吸收,來取代直接提供至在封裝構件200中的金屬墊、金屬線與接觸插塞。
根據實施例,一種裝置包括一金屬墊於一基板上。鈍化層包括一部份於金屬墊上。一後鈍化內連線與金屬墊電性耦接,其中後鈍化內連線包括一部份於金屬墊與鈍化層上。一聚合物層於後鈍化內連線上。一虛擬凸塊於聚合物層上,其中虛擬凸塊與在聚合物層下方之導電結構電性絕緣。
根據其他實施例,一種裝置包括一第一封裝構件,其具有一電性連接器,與包括一第二封裝構件,其經由第一電性連接器與第一封裝結構接合。一虛擬凸塊位於第一封裝構件與第二封裝構件之間。虛擬凸塊與在第一封裝構件與第二封裝構件之至少一個中的導電結構電性絕緣。
根據又其他實施例,一種形成一封裝構件的方法,包括形成一鈍化層,其具有一部份於一金屬墊上,與形成一後鈍化內連線,其與金屬墊電性耦合。後鈍化內連線具有一部份於金屬墊與鈍化層上。於後鈍化內連線上形成一聚合物層。形成一電性連接器,且其與後鈍化內連線電性耦接,其中電性連接器包括一部份於聚合物層之上表面上。於聚合物層上形成一虛擬凸塊,其中虛擬凸塊與在聚合物層下方的所有導電結構絕緣。
雖然本發明已以較佳實施例揭露如上,然其並非用以限定本發明,任何熟習此技藝者,在不脫離本發明之精神和範圍內,當可作些許之更動與潤飾,因此本發明之保護範圍當視後附之申請專利範圍所界定者為準。
10...晶圓
20...半導體基板
21...電晶體
22...層間介電層
24...金屬層
25...介電層
26...金屬線
28、204...接觸插塞
30...金屬墊
32...鈍化層
36、39...聚合物層
38...後鈍化內連線(post-passivation interconnect,PPI)
40、47、48...開口
42...阻擋層
44...晶種層
45...凸塊下冶金(undr-bump-metallurgy,UBM)層
46...罩幕
45A...經由開口46所露出之露出部分凸塊下冶金層
45A1...部分凸塊下冶金層45A的下表面
45B...經由開口48所露出之露出部分凸塊下冶金層
45B1...部分凸塊下冶金層45B的下表面
50、52...金屬凸塊
50A、52A...銅凸塊
50B、52B...焊料蓋
60、202...電性連接器
62...虛擬凸塊
100、200...封裝構件
102...封裝晶粒的邊緣
206...結構(焊料凸塊)
210...介電層
212...接合墊
214...接合墊
220...焊料
230...底層填充材料(underfill)
第1圖至第7圖為根據各種實施例在一封裝體之製造中的中間階段的剖面圖;
第8圖繪示一晶片的上視圖,其中虛擬凸塊被分佈至晶片之高應力區域;以及
第9圖繪示根據替代實施例之一封裝體。
10...晶圓
20...半導體基板
21...電晶體
22...層間介電層
24...金屬層
25...介電層
30...金屬墊
32...鈍化層
36、39...聚合物層
38...後鈍化內連線(post-passivation interconnect,PPI)
45A...經由開口46所露出之露出部分凸塊下冶金層
45B...經由開口48所露出之露出部分凸塊下冶金層
50、52...金屬凸塊
50A、52A...銅凸塊
50B、52B...焊料蓋
60...電性連接器
62...虛擬凸塊
Claims (11)
- 一種半導體裝置,包括:一基板;一金屬墊於該基板上;一鈍化層,其包括一部份於該金屬墊上;一後鈍化內連線(post-passivation interconnect,PPI)與該金屬墊電性耦接,其中該後鈍化內連線包括一部份於該金屬墊與該鈍化層上;一聚合物層於該後鈍化內連線上;以及一虛擬凸塊於該聚合物層上,其中該虛擬凸塊與在該聚合物層下方之導電結構電性絕緣。
- 如申請專利範圍第1項所述之裝置,其中該虛擬凸塊與該聚合物層物理性接觸。
- 如申請專利範圍第1項所述之裝置,其中該虛擬凸塊包括一非可回焊凸塊與一焊料蓋於該非可回焊凸塊上。
- 如申請專利範圍第1項所述之裝置,更包括一非可回焊電性連接器形成於該聚合物層中,其中該電性連接器與該後鈍化內連線電性耦接。
- 如申請專利範圍第4項所述之裝置,更包括一封裝構件,其中該封裝構件包括:一額外之電性連接器與該非可回焊電性連接器接合;以及一介電層在該封裝構件的一表面,其中該虛擬凸塊與該介電層接觸,且藉由該介電層與該封裝構件中之導電結構電性絕緣。
- 如申請專利範圍第1項所述之裝置,其中該聚合層為一聚亞醯胺層,且其中該虛擬凸塊包括一含銅材料。
- 一種半導體裝置,包括:一第一封裝構件,其包括一電性連接器;一第二封裝構件,經由該電性連接器與該第一封裝構件接合;以及一虛擬凸塊,介於該第一封裝構件與該第二封裝構件之間,其中該虛擬凸塊與在該第一封裝構件與該第二封裝構件之至少一個中的導電結構電性絕緣。
- 一種半導體裝置的形成方法,包括:形成一第一封裝構件,其中該形成之步驟包括下列步驟:形成一鈍化層,其包括一部份於一金屬墊上;形成一後鈍化內連線,其與該金屬墊電性耦接,其中該後鈍化內連線包括一部份於該金屬墊與該鈍化層上;形成一聚合物層於該後鈍化內連線上;形成一電性連接器於該後鈍化內連線上且與其電性耦接,其中該電性連接器包括一部份於該聚合物層之一上表面上;以及形成一虛擬凸塊於該聚合物層上,其中該虛擬凸塊與在該聚合物層下方之所有導電結構絕緣。
- 如申請專利範圍第8項所述之方法,其中形成該電性連接器與該虛擬凸塊的該些步驟,包括:形成一開口於該聚合物層中;形成一凸塊下冶金(undr-bump-metallurgy,UBM)層延伸進入該開口;形成一罩幕於該凸塊下冶金層上;圖案化該罩幕以形成一第一開口與一第二開口,其中該第一開口的一部份為在該後鈍化內連線之一部分上且與其重直對齊,且該第二開口之全部為在於該聚合物層之一部分上且與其垂直對齊;形成一第一凸塊於該第一開口中;形成一第二凸塊於該第二開口中;移除該罩幕;以及移除該凸塊下冶金層由該罩幕所覆蓋的部分,其中該第一凸塊與該凸塊下冶金層之一第一部份直接於該第一凸塊下方形成該電性連接器,且其中該第二凸塊與該凸塊下冶金層之一第二部分直接於該第二凸塊下方形成該虛擬凸塊。
- 如申請專利範圍第9項所述之方法,其中該凸塊下冶金層之該第二部份具有一底部與該聚合物層物理性接觸,而不與在該第一封裝構件中的任何後鈍化內連線電性耦接。
- 如申請專利範圍第8項所述之方法,其中該電性連接器與該虛擬凸塊為同時形成。
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US8912649B2 (en) | 2014-12-16 |
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US20130043583A1 (en) | 2013-02-21 |
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US20190259724A1 (en) | 2019-08-22 |
KR101449789B1 (ko) | 2014-10-13 |
US20160181220A1 (en) | 2016-06-23 |
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US10290600B2 (en) | 2019-05-14 |
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US9287234B2 (en) | 2016-03-15 |
US10734347B2 (en) | 2020-08-04 |
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