TW201642366A - 晶片配置結構及形成接觸連接之方法 - Google Patents

晶片配置結構及形成接觸連接之方法 Download PDF

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TW201642366A
TW201642366A TW105106213A TW105106213A TW201642366A TW 201642366 A TW201642366 A TW 201642366A TW 105106213 A TW105106213 A TW 105106213A TW 105106213 A TW105106213 A TW 105106213A TW 201642366 A TW201642366 A TW 201642366A
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contact
wafer
paste
copper
conductor
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TW105106213A
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TWI625801B (zh
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亨利 路德克
利卡多 蓋爾哈
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派克科技-包裝科技有限公司
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    • H01L24/34Strap connectors, e.g. copper straps for grounding power devices; Manufacturing methods related thereto
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract

本發明是關於一種晶片配置結構(10)以及用於形成晶片(18) , 特別是功率電晶體及其類似物與導體材料軌道(14)之間之接觸連接(11)的方法,導體材料軌道形成在非導電基板上,晶片被設置在基板上或在導體材料軌道(15)上,銀膏(29)或銅膏被塗佈於晶片之晶片接觸表面(25)及導體材料軌道(28)中之每一個上,接觸導體(30)被浸於晶片接觸表面上之銀膏或銅膏中,並被浸於導體材料軌道上之銀膏或銅膏中。銀膏或銅膏中所含之溶劑至少部分透過加熱蒸發並藉由雷射能之方式燒結銀膏或銅膏形成接觸連接。

Description

晶片配置結構及形成接觸連接之方法
本發明是關於一種晶片配置結構,以及用於形成晶片,特別是功率電晶體或其類似物與導體材料軌道之間的接觸連接的方法;導體材料軌道被形成在非導電基板上且晶片被設置在基板上或導體材料軌道上。
本領域中已知的晶片可以具有外殼的以及裸半導體元件來實現。這些晶片被稱為裸晶或裸晶片。這種晶片在沒有殼體下被加工並直接安裝至基板或印刷電路板。這樣做時,可以在晶片的晶片接觸表面及導體材料軌道之間形成直接接觸。晶片之其他晶片接觸表面可以透過接觸導體或所謂的接合線連接到其他導體材料軌道。這種的接觸連接還經常形成在功率電晶體上。在這方面,例如,晶片或功率電晶體之下晶片接觸表面被設置在導體材料軌道上,並且大致上橫跨其整個表面地連接至其。例如,與接觸之下晶片接觸表面相對之晶片之上晶片接觸表面透過接合線,藉由超音波接合或焊接而連接到在晶片旁運行之另一導體材料軌道。晶片配置結構確保足夠大的導體截面可用性供高電流傳輸。此外,這種應用可使用相對厚的鋁製接合線。
特別是在功率電晶體的情況下,例如在15至150千瓦的功率範圍 ,MOSFET、IGBT及用於電源模組二極體,會產生高熱及電應力。這些壓力很容易導致接觸連接及晶片配置結構的元件故障。此外,舉例而言,使用在車輛或風力發電廠的晶片配置結構,可能因為高溫波動而進一步降低晶片配置結構的使用壽命。例如,接觸連接可能會因為這些應力斷裂或被斷開。此外,在不使接觸連接永久損壞下,接觸導體及導體材料軌道或晶片接觸表面之間的焊料(solder)連接最高只能被加熱到175℃。此外,這種類型的晶片配置結構的生產因為需要將複數個接觸導體設置在晶片接觸表面及導體材料軌道之間以傳輸大電流而相對地昂貴。
因此,本發明旨在提出具有接觸連接的晶片配置結構以及用於形成接觸連接的方法,其中接觸連接具有改良之耐久性及簡化之生產。
本發明的一實施例係關於一種用於形成於晶片,特別是功率電晶體及其類似物與導體材料軌道之間之接觸連接之方法,其中導體材料軌道被形成在非導電基板上,晶片被設置在非導電基板上或導體材料軌道上,且銀膏或銅膏被塗佈於該晶片之晶片接觸表面及導體材料軌道的每一個,接觸導體被浸入在晶片接觸表面上之銀膏或銅膏中,以及導電材料軌道上之銀膏或銅膏中,包含在銀膏或銅膏中之溶劑至少部分藉由加熱蒸發且接觸連接係藉由雷射能之方式燒結銀膏或銅膏來形成。
本發明的另一實施例係關於一種晶片配置結構,特別係用於功率電晶體或其類似物的一種晶片配置結構,其包括晶片、具有導體材料軌道形成於其上之非導電基板、及接觸導體,晶片被設置在非導電基板上或在導體材料軌道上,其中銀膏或銅膏被塗佈至晶片之晶片接觸表面及導體材料軌道的每一個,接觸導體被浸入在晶片接觸表面上之銀膏或銅膏中以及導體材料軌道上之銀膏或銅膏中,包含在銀膏或銅膏中之溶劑藉由加熱而蒸發,且接觸連接係藉由雷射能之方式燒結銀膏或銅膏來形成。
本發明是透過一種具有申請專利範圍第1項特徵之形成接觸連接之方法以及透過具有根據申請專利範圍第14項特徵之晶片配置結構來實現。
根據本發明的一種用於形成晶片,特別是功率電晶體或其類似物與導體材料軌道之間的接觸連接的方法,其中導體材料軌道被形成在非導電基板上,晶片被設置在基板上或在導體材料軌道上,銀膏及銅膏被塗佈到晶片的晶片接觸表面及導體材料軌道之每一個,接觸導體被浸入晶片接觸表面上的銀膏及銅膏中及導體材料軌道上的銀膏及銅膏中,包含在銀膏或銅膏的溶劑至少部分透過加熱蒸發並藉由雷射能之方式燒結銀膏或銅膏以形成接觸連接。
基板可以由塑料材料或陶瓷材料製成,先形成用於連接電子元件或半導體元件之第一導體材料軌道於基板上。這可以透過在本領域現有技術中以已被完整理解的方法進行。晶片隨後被直接設置在非導電基板上或導體材料軌道上。如果晶片被配置在導體材料軌道上,其被電氣連接到後者。在背對基板或導體材料軌道晶片的上側上,形成至少一上晶片接觸表面以用於形成與晶片的接點。藉由形成接觸連接,晶片接觸表面現在將透過接觸導體連接到相對於晶片毗鄰之導體材料軌道或另一導體材料軌道。為此,液體或糊狀的銀膏及銅膏被塗佈到相對於晶片毗鄰之導體材料軌道。膏狀物或金屬膏也被塗佈到上晶片接觸表面。膏狀物可以由塗佈器的方式自動地塗佈。其後,將接觸導體浸入晶片接觸表面上的膏狀物及導體材料軌道上的膏狀物,以使接觸導體在各種情況下至少部分地被膏狀物包圍。銀膏或銅膏含有溶劑,其至少部分透過加熱蒸發,其可使塗佈之膏狀物的體積減少。根據加熱的程度,溶劑可以透過蒸發或沸騰汽化。接觸連接的最終形成是藉由雷射能或雷射燒結的方式,燒結銀膏或銅膏而產生,其中雷射光束直接或間接地瞄準所述接觸連接的區域。銀膏中所含的銀粉末或銀顆粒將至少部分地熔化或燒結在一起,從而在接觸導體及晶片接觸表面之間與接觸導體及導體材料軌道之間形成電氣連接。銅膏是以相同的方式燒結。銀膏或銅膏於晶片接觸表面、導體材料軌道以及,如果適用的話,接觸導體的塗佈及隨後的燒結可以同時或依序發生,然而與晶片接觸表面或導體材料軌道是否先提供有膏狀物或燒結相比,這是不重要的。另外,也可以先完成形成在晶片接觸表面或導體材料軌道上的接點,並隨後塗佈並燒結用於形成第二接點之膏狀物。關於方法步驟的順序,接觸導體也可以在塗佈膏狀物前先將晶片設置在接觸表面或導體材料軌道上。然後,膏狀物被塗佈在具有接觸導體之晶片接觸表面或導體材料軌道上,使得接觸導體同時浸漬在膏狀物中。
由於使用銀膏或銅膏代替焊料以產生接觸連接這一事實,接觸連接持續實質上較久。燒結之膏狀物實質上更能承受高溫波動及高工作溫度。例如,利用燒結之銀膏可以實現高達300℃的晶片的工作溫度。而且,不再需要為了能夠傳遞高電流而形成大量的接觸連接於晶片終端表面及導體材料軌道之間。根據本發明之方法很大程度上獨立於接觸導體之橫截面,從而能夠實質上地減少接觸導體及接觸連接的數量,使得晶片配置結構的生產整體上更符合成本效益。
可以用絞合線(stranded wire),較佳地為扁形李茲線(litz wire),更佳地為由銅或銅合金製成之絞合線或扁形李茲線作為接觸導體。絞合線具體為可撓的,這意味著與固體導線形式的接觸導體相比,晶片接觸表面上或導體材料軌道上之各接點上不會發生由於大溫差所致之潛在的剪力或拉伸應力。相對於導線或接合線,扁形李茲線具有相對大的橫截面,這就是為什麼其能夠傳輸高電流。
此外,絞合線可以至少部分地被銀膏或銅膏滲透。藉由浸漬絞合線於膏狀物中,膏狀物,即銀粒子或銅粒子,能夠滲入絞合線從而能在燒結過程中形成銀粒子或銅粒子及絞合線之間特別緊密的連接。膏狀物也可透過毛細作用被絞合線吸收,使得絞合線在晶片接觸表面及導體材料軌道之區域中填充有銀粒子或銅粒子。
此外,可以設想在每個晶片接觸表面上只使用一個絞合線。此由於絞合線或扁形李茲線可以具有近似於晶片接觸表面的尺寸之相對較大寬度之事實而成為可能。在這種情況下,不再需要使用複數個接觸導體。如果只使用一個絞合線來連接晶片接觸表面及導體材料軌道,該方法可以特別快以及因此符合成本效益的方式來實現。
可透過設置基板上在加熱元件上或加熱元件的頂部來實現加熱銀膏或銅膏。基板且因此導體材料軌道以及晶片接觸表面可以接著被加熱到膏狀物的溶劑蒸發。因此,可完全省略使用烘箱或類似裝置進行膏狀物的外部加熱。
此外,可以設想在加熱過程中基板藉由夾持裝置之方式支撐。一方面,基板可以因此精確地定位,而在另一方面,夾持裝置可具有加熱元件或形成加熱元件本身。以這種方式,甚至使加熱銀膏或銅膏以蒸發溶劑進一步簡化。
在本方法的過程中,銀膏或銅膏可以在溶劑完全蒸發之前燒結。因此,可以防止銀膏或銅膏可在其燒結之前完全乾燥。完全無溶劑或乾燥的膏狀物很容易由於乾燥過程或移動而產生斷裂,這可能使接觸連接容易失敗。
接觸導體可藉由按壓裝置在燒結過程中壓至晶片接觸表面及/或導體材料表面上。以此種方式,可形成接觸導體與晶片接觸表面或導體材料軌道之間特別緊密之接點。此外,可避免在燒結之銀膏或銅膏的冷卻過程中不希望出現的裂紋形成。
在本方法的另一個實施方案中,接觸導體可於燒結後切斷。例如,接觸導體可以儲存在線圈或捲軸上,且可以自動裝置被饋送至晶片接觸表面及與導體材料軌道。在這樣做時,首先接觸導體的端部可以被放置在晶片接觸表面上。接觸導體的一部分可以佈置在導體材料軌道上,反之亦然。在銀膏或銅膏的燒結以及接觸連接的形成之後,接觸導體可以在該部分被切斷或者切割,以使接觸導體的自由端可再次用於形成另一接觸連接。
晶片接觸表面可以藉由將銅運用於晶片表面上來形成。在這種情況下,晶片表面可以由例如矽之半導體材料製成。透過運用銅條,晶片表面之鍍金屬是特別簡單的。銅條還可以促進與接觸導體之電氣連接的形成。
此外,接點鍍金屬可以運用至導體材料軌道及/或至晶片接觸表面。接點鍍金屬可較薄,以及實質上提高具有銀膏或銅膏或熔化之銀膏或銅膏之晶片接觸表面及導體材料軌道之潤濕性。
接點鍍金屬可透過物理氣相沉積(PVD)、濺鍍沉積、電鍍(galvanization plating)或無電電鍍來形成。
接點鍍金屬可以由銀、鎳、銅、金、鈀、鋁或上述金屬中之其一的其他合金製成。例如,由銀製成之接點鍍金屬,可以形成為相對地薄,以及允許相對更好的電流密度分佈且特別有利於熱能的熱散逸,如用於冷卻晶片。另外,在燒結過程中銀膏或銅膏可以與接點鍍金屬之銀融合的特別好。
根據本發明之晶片配置結構,特別是用於功率電晶體或類似物,包括晶片,在其上形成有導體材料軌道及接觸導體之非導電基板,晶片被設置在基板上或導電材料軌道上,其中銀膏或銅膏被塗佈至晶片之晶片接觸表面及導體材料軌道的每一個上,接觸導體被浸入晶片接觸表面上的銀膏或銅膏以及導體軌道上的銀膏或銅膏中,包含於銀膏或銅膏中之溶劑被加熱蒸發而接觸連接藉由以雷射能之方式燒結銀膏或銅膏而形成。
關於根據本發明之晶片配置結構之有益效果,參考本發明之方法之優點的描述。其它晶片配置結構之較佳實施例將從依附於申請專利範圍第1項之附屬項而變得顯而易見。
在下面的描述中,本發明的較佳實施例將參照附圖進行更詳細的說明。
第1圖係繪示接觸連接11的生產過程中晶片配置結構10的剖面示意圖。晶片配置結構10包括非導電基板12,在非導電基板的表面13上形成相異之複數個導體材料軌道14及15。導體材料軌道14及15透過隔離間距16彼此隔開,並因此彼此電氣隔離。由銀或銀合金製成之接點鍍金屬17形成或應用於導體材料軌道14及15的每一個上。或者,接點鍍金屬17也可以由鎳、銅、金、鈀、鋁或上述金屬中之其一之其他合金製成。由半導體材料製成的晶片18,形成在導體材料軌道15上。由銀或銀合金製成之接點鍍金屬23,被應用於背向導體材料軌道15之晶片18之晶片後側19,而接觸凸塊21被應用於面向導體材料軌道15之晶片18之晶片前側20。接觸凸塊21將晶片18連接至導體材料軌道15。因此,在晶片18上形成背晶片接觸表面25及前晶片接觸表面26。晶片18之晶片接觸表面26與導電材料軌道15之導體表面27接觸,即與導電材料軌道15之導體表面27電氣連接。定量之銀膏29被塗佈至導體材料軌道14之導體表面28及晶片18之晶片接觸表面25的每一個。接觸導體30以由銅製成並以其兩端部32及33浸入銀膏29之扁形李茲線31實現,銀膏29實質上圍繞端部32及33。
如第2圖中可得知,銀膏29在包含於其中之溶劑被大致蒸發後燒結。燒結在將雷射能引入至銀膏29及各端部32及33時發生。如此,接觸連接11之第一接點34是以在導體表面28上之銀膏29及端部32形成,而接觸連接11之第二接點35是以晶片接觸表面25上之銀膏29及端部33形成。銀膏29之銀粒子(未繪示)滲入端部32及33且被燒結或透過燒結而部分熔化在一起,分別以扁形李茲線31之線絲(未繪示)與導體表面28及晶片接觸表面25形成特別緊密的連接。因此,燒結之銀膏29在接觸區域36及37固化。
第3圖係繪示晶片配置結構38之第二實施例,其與第2圖中所示之晶片配置結構之不同之處於,其包括僅在銀膏29燒結後被分割之扁形李茲線39。扁形李茲線39之端部40因而從接觸區域41突出,扁形李茲線39之線段42被分割以形成與晶片18接觸之接點43。
第4圖係繪示晶片配置結構44之第三實施例,其與第2圖中所示之晶片配置結構之不同之處於,其包括其間設置有晶片47之導體材料軌道45及46。晶片47在晶片47之前側50上形成兩個前晶片接觸表面48及49,晶片47之背側51被直接設置在基板52上。各晶片接觸表面48及49經由分別以扁形李茲線55及56實現之接觸導體53及54分別連接至導體材料軌道45及46之導體表面57及58。
在上述實施例的實例中,銀膏也可以用銅膏代替。
10、38、44‧‧‧晶片配置結構
11‧‧‧接觸連接
12‧‧‧非導電基板
13‧‧‧表面
14、15、45、46‧‧‧導體材料軌道
16‧‧‧隔離間距
17‧‧‧接觸金屬
18、47‧‧‧晶片
19、51‧‧‧背側
20、50‧‧‧前側
21‧‧‧接觸凸塊
23‧‧‧接觸金屬
25、26、48、49‧‧‧晶片接觸表面
27、28、57、58‧‧‧導體表面
29‧‧‧銀膏
30、53、54‧‧‧接觸導體
31、39、55、56‧‧‧扁形李茲線
32、33、40‧‧‧端部
34‧‧‧第一接點
35‧‧‧第二接點
36、37、41‧‧‧接觸區域
42‧‧‧線段
43‧‧‧接點
52‧‧‧基板
在附圖中:
第1圖係繪示在方法步驟期間晶片配置結構的第一實施例之剖面示意圖。
第2圖係繪示接觸連接完成後第1圖之晶片配置結構之剖面示意圖;
第3圖係繪示晶片配置結構的第二實施例之剖面示意圖;以及
第4圖係繪示晶片配置結構的第三實施例之剖面示意圖。
10‧‧‧晶片配置結構
11‧‧‧接觸連接
12‧‧‧非導電基板
14、15‧‧‧導體材料軌道
18‧‧‧晶片
30‧‧‧接觸導體
34‧‧‧第一接點
35‧‧‧第二接點
36、37‧‧‧接觸區域

Claims (14)

  1. 一種用於形成於一晶片(18、47),特別是一功率電晶體及其類似物與一導體材料軌道(14、45、46)之間之一接觸連接(11)之方法,該導體材料軌道被形成在一非導電基板(12、52)上,該晶片被設置在該非導電基板上或一導體材料軌道(15)上,其中 一銀膏(29)或一銅膏被塗佈至該晶片之一晶片接觸表面(25、48、49)及該導體材料軌道(14、45、46)的每一個,一接觸導體(30、53、54)被浸入在該晶片接觸表面上之該銀膏或該銅膏中,以及該導電材料軌道上之該銀膏或該銅膏中,包含在該銀膏或該銅膏中之一溶劑至少部分藉由加熱蒸發且該接觸連接係藉由雷射能之方式燒結該銀膏或該銅膏來形成。
  2. 如申請專利範圍第1項所述之方法,其中一絞合線,較佳地為一扁形李茲線(31、55、56),更佳地為由銅或銅合金製成之一絞合線或一扁形李茲線,被用作為該接觸導體(30、53、54)。
  3. 如申請專利範圍第2項所述之方法,其中該絞合線至少部分地被該銀膏或該銅膏滲透。
  4. 如申請專利範圍第2項或第3項所述之方法,其中在每一該晶片接觸表面上只使用一個該絞合線。
  5. 如前述申請專利範圍中之任一項所述之方法,其中該銀膏或該銅膏之加熱係藉由將該非導電基板(12、52)設置在一加熱元件上或一加熱元件之頂部上來實施。
  6. 如前述申請專利範圍中之任一項所述之方法,其中該非導電基板(12、52)在加熱過程中係由一夾持裝置之方式支撐。
  7. 如前述申請專利範圍中之任一項所述之方法,其中該銀膏(29)或該銅膏在該溶劑完全蒸發之前燒結。
  8. 如前述申請專利範圍中之任一項所述之方法,其中在燒結過程中,該接觸導體(30、53、54)係藉由一推壓裝置之方式推壓在該晶片接觸表面(25、48、49)及/或該導體材料軌道(14、45、46)上。
  9. 如前述申請專利範圍中之任一項所述之方法,其中該接觸導體(30、53、54)在燒結後被分割。
  10. 如前述申請專利範圍中之任一項所述之方法,其中該晶片接觸表面(25、26、48、49)係藉由在一晶片表面上應用一銅條而形成。
  11. 如前述申請專利範圍中之任一項所述之方法,其中一接點鍍金屬(17、23)被應用至該導體材料軌道(14、45、46)及/或該晶片接觸表面(25、26、48、49)。
  12. 如申請專利範圍第11項所述之方法,其中該接點鍍金屬(17、23)係透過物理氣相沉積 (PVD)、濺鍍沉積、電鍍或無電電鍍形成。
  13. 如申請專利範圍第11項或第12項所述之方法,其中該接點鍍金屬(17、23)係由銀、鎳、銅、金、鈀、鋁或上述金屬中之其一之合金製成。
  14. 一種晶片配置結構(10、38、44),特別係用於一功率電晶體或其類似物,包括一晶片(18、47)、具有一導體材料軌道(14、45、46) 形成於其上之一非導電基板(12、52)、及一接觸導體(30、53、54),該晶片被設置在該非導電基板上或在該導體材料軌道(15)上,其中 一銀膏(29)或一銅膏被塗佈至該晶片之一晶片接觸表面(25、48、49)及該導體材料軌道(14、45、46)的每一個,該接觸導體被浸入在該晶片接觸表面上之該銀膏或該銅膏中以及該導體材料軌道上之該銀膏或該銅膏中,包含在該銀膏或該銅膏中之一溶劑藉由加熱而蒸發,且一接觸連接(11)係藉由雷射能之方式燒結該銀膏或該銅膏來形成。
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