TWI437676B - 積體電路結構 - Google Patents

積體電路結構 Download PDF

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Publication number
TWI437676B
TWI437676B TW099108662A TW99108662A TWI437676B TW I437676 B TWI437676 B TW I437676B TW 099108662 A TW099108662 A TW 099108662A TW 99108662 A TW99108662 A TW 99108662A TW I437676 B TWI437676 B TW I437676B
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TW
Taiwan
Prior art keywords
palladium
solder
layer
integrated circuit
circuit structure
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TW099108662A
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English (en)
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TW201115700A (en
Inventor
Ching Wen Hsiao
Jiun Yi Wu
Ru Ying Huang
Chen Shien Chen
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Taiwan Semiconductor Mfg
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Publication of TW201115700A publication Critical patent/TW201115700A/zh
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Publication of TWI437676B publication Critical patent/TWI437676B/zh

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    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
    • H01L23/49816—Spherical bumps on the substrate for external connection, e.g. ball grid arrays [BGA]
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    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49827—Via connections through the substrates, e.g. pins going through the substrate, coaxial cables
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Description

積體電路結構
本發明係有關於一種積體電路，特別是有關於一種覆晶式(filp-chip)接合墊結構及其製造方法。
在半導體晶片製造中，積體電路裝置係先形成於半導體晶片中半導體基底的表面上，例如電晶體。接著內連(interconnect)結構形成於積體電路裝置上方。凸塊(bump)係形成於半導體晶片的表面，而得以應用半導體裝置。
在半導體晶片的封裝(packaging)中，半導體晶片時常利用覆晶接合(flip-chip bonding)而接合至封裝基底。焊料(solder)係使用於連接半導體晶片內的凸塊與封裝基底內的接合墊。傳統上，含鉛(Pb)及錫(Sn)的共晶(eutectic)焊料係作為凸塊接合的材料。舉例而言，一般使用的含鉛共晶焊料含63%的錫與37%的鉛。上述組合使焊料具有適當的熔點及低電阻率。再者，共晶焊料的抗龜裂性佳。
鉛為有毒材料，因而法規及工業規定已要求使用無鉛焊料凸塊。因此，開始研究以無鉛焊料取代含鉛焊料的解決之道。然而，習知無鉛材料過脆而有龜裂的問題，例如SnAg、SnAgCu及其內部的金屬成分。因此，由無鉛焊料所構成的焊料接點時常不牢靠而無法通過可靠度測試，例如熱循環測試。
焊料龜裂通常由應力所造成。應力產生的主要原因之一在於封裝組件中材料之間不匹配的熱膨脹係數(coefficient of thermal expansion,CTE)。舉例而言，矽基底的CTE通常約為3ppm/℃，低介電常數(low-k)材料的CTE通常約為20ppm/℃，而封裝基底的CTE通常約為17ppm/℃。CTE的明顯差異導致在發生熱變化時，於結構內產生應力。凸塊內所使用的銅將使問題更為嚴重。由於銅不易彎曲，高應力會施加於鄰接的銅凸塊，使焊料更容易龜裂。
根據本發明的一型態，一種積體電路結構，包括：一第一工作部件及一第二工作部件。第一工作部件包括一半導體基底以及位於半導體基底上方的一銅凸塊。第二工作部件包括一接合墊。一焊料鄰接於第一工作部件與第二工作部件之間，其中焊料將銅凸塊電性連接至接合墊。焊料包括鈀。
本發明亦揭示其他實施例。
以下說明本發明實施例之製作與使用。然而，可輕易了解本發明實施例提供許多合適的發明概念而可實施於廣泛的各種特定背景。所揭示的特定實施例僅僅用於說明以特定方法製作及使用本發明，並非用以侷限本發明的範圍。
根據一實施例，提供一種新的積體電路製造。以下說明製造一實施例的部分階段，並敘述實施例中的變化。不同的實施例中，相同的部件係使用相同的標號。
請參照第1A圖，提供一工作部件2，其可為包括基底10的半導體晶片2。以下內文中，工作部件2雖以晶片2表示之，然其也可為封裝基底或介層(interposer)基底。在一實施例中，基底10係一半導體基底，例如一矽塊材(bulk silicon)基底，而其可包括其他半導體材料，例如三族、四族、及/或五族元素。半導體裝置14，例如電晶體，可形成於基底10的表面。內連結構12係形成於基底10上方，其包括金屬線及連接窗(via)(未繪示)且連接至半導體裝置14。金屬線及連接窗可由銅或銅合金所構成，且可藉由熟習的鑲嵌(damascene)製程來製作。內連結構12可包括一般習知的內層介電(inter-layer dielectric,ILD)及金屬層間介電(inter-metal dielectric,IMD)。
金屬墊28係形成於內層結構12上方。金屬墊28可包括鋁、銅(Cu)、銀(Ag)、金(Au)、鎳(Ni)、鎢(W)、其合金、及/或其多層金屬。金屬墊28可電性連接至半導體裝置14，例如經由下方的內連結構12。可形成鈍化保護層30以覆蓋金屬墊28的邊緣部分。在一實施例中，鈍化保護層由聚亞醯胺(polyimide)或其他習知介電材料所構成。
凸塊底部金屬化層(under bump metallurgy,UBM)32係形成於金屬墊28上方且與其電性連接。凸塊底部金屬化層32可包括一銅層及一鈦層(未繪示)。銅凸塊34形成於凸塊底部金屬化層32上方。在一實施例中，銅凸塊34係藉由電鍍而成。電鍍製程包括：在凸塊底部金屬化層上形成一罩幕、圖案化罩幕以形成一開口、在開口內電鍍形成銅凸塊34、及去除罩幕以及未被覆蓋的凸塊底部金屬化層部分。銅凸塊34的厚度可大於30微米(μm)或大於45微米。銅凸塊34可由純銅所構成。
阻障層36可接著藉由電鍍而形成於銅凸塊34上方。阻障層36可由鎳所構成，然而也可加入其他的金屬。在一實施例中，一鈀層38係形成於阻障層36上方。在另一實施例中，未形成阻障層36，而鈀層38與銅凸塊34接觸。阻障層36及/或鈀層38的製作可利用相同於電鍍銅凸塊34所使用的罩幕(未繪示)來進行電鍍，因而使阻障層36及/或鈀層38被限制於銅凸塊34的正上方區域，而不會形成於銅凸塊34的側壁。在另一實施例中，在去除電鍍銅凸塊34所使用的罩幕之後才進行阻障層36及/或鈀層38的電鍍。如此一來，阻障層36及/或鈀層38也會形成於銅凸塊34的側壁，如圖中虛線所示。
鈀層38的厚度在0.01微米至0.1微米的範圍。在一實施例中，鈀層38由純鈀所構成。舉例而言，鈀層38中鈀重量百分比大於95%或甚至大於99%或99.9%。上述鈀層38由”純”鈀所構成的範例中，任何所屬技術領域中具有通常知識者可以知道此限制條件在於涵蓋製程中非刻意導入雜質的範圍以及涵蓋製程最佳化所刻意導入雜質的範圍。
第1B圖係繪示出工作部件100。在一實施例中，工作部件100為一封裝基底(且以下以封裝基底100表示之)，然其也可為一半導體晶片或一介層基底等等。封裝基底100可包括一接合墊110，其經由金屬內連線112而電性連接至接合墊114。接合墊114及110矽位於封裝基底100的相對側。金屬內連線112可形成於介電基底116內。
接合墊110包括金屬墊122，其可為由銅(例如純銅或大抵為純銅)、鋁、銀及其合金所構成的接合墊。阻障層124接著藉由無電(electroless)電鍍或電鍍而形成於金屬墊122上方。阻障層124可由鎳所構成，然而也可加入其他金屬。在一實施例中，接合墊110更包括一鈀層126，位於阻障層124上方。在另一實施例中，未形成阻障層124，因而鈀層126與金屬墊122直接接觸。鈀層126的厚度及材料實質上相同於前述的鈀層38(第1A圖)。
焊球130裝貼於鈀層126上方。在一實施例中，焊球130由含SnAg、SnAgCu等等無鉛焊料所構成，然而焊球130也可由含鉛(Pb)及錫(Sn)的共晶(eutectic)焊料所構成。
工作部件2及100可經由覆晶接合進行接合，如第2圖所示。焊球130將工作部件2及100連結在一起。進行一回流(reflow)製程，以熔化焊球130。在一實施例中，回流溫度可在220℃至280℃的範圍。回流溫度及持續時間可進行調整，以對鈀層38及/或126中鈀的擴散進行最佳化，使焊球130回流之後更具抗龜裂能力。
在進行回流之後，由於鈀層38及/或126中鈀擴散進入焊球130，焊球130內包括重量百分比小於0.3%的鈀。在一實施例中，焊球130內包括平均重量百分比在0.15%至0.3%範圍的鈀。然而，鈀可能會聚集而形成富含鈀的晶粒(grain)，如圖中所示的晶粒132。此處晶粒132也可表示為金屬間化合物132，其包括銅、鎳、錫、鈀及/或其他金屬，且鈀的重量百分比在5%至10%的範圍，大於金屬間化合物132外側鈀的重量百分比。此處晶粒132也可表示為富含鈀的晶粒132。再者，在焊球130與原鈀層38及126之間的界面處，會留有或未留下每個鈀層38及126的剩餘部。若留有鈀層38及126的剩餘部，其可能為銅、鈀、鎳及/或焊球130內焊料的合金，且取決於膜層34、36、38、130、126、124及122的組成(參見第1A及1B圖)。再者，焊球130內具有一區域，其中鈀的重量百分比自靠近銅凸塊34(或金屬墊122)的一側往焊球130中心處逐漸下降。
鈀可從晶片2側及封裝基底100側加入於焊球130內。因此，儘管需形成鈀層38及鈀層126中至少一者或兩者，但鈀層38及鈀層126的其中一者是非必需的。對應的鈀層38及/或126的厚度可由焊球130內所需的鈀重量百分比以及焊球130總量而定且可由實驗得知。
鈀層及焊料可以任何組合方式形成於晶片2或是封裝基底100上方，只要鈀層能靠近於焊料，而使鈀能擴散入內。第3A及3B圖係繪示出另一實施例，其中一焊料層40形成於晶片2側，而焊球130可選擇性地形成於封裝基底100上。在本實施例中，焊料層40相對較薄，舉例而言，其厚度小於40微米，且可利用相同於電鍍銅凸塊34、阻障層36及鈀層38所使用的罩幕(未繪示)來進行電鍍。因此，焊料層40的邊緣會垂直對準於銅凸塊34所對應的邊緣。換句話說，焊料層40會被限制於銅凸塊34正上方的區域。
第4A及4B圖係繪示出又另一實施例，其中銅凸塊34、阻障層36及鈀層38形成於封裝基底100側，而阻障層124、鈀層126及焊球130形成於半導體晶片2側。在形成第3A/3B圖或第4A/4B圖的結構之後，可進行半導體晶片2與封裝基底100的接合，而任何所屬技術領域中具有通常知識者可經由上述章節所教示而得知其最終結構。
從可靠度測試中可觀察到由於鈀擴散進入焊料內，焊料的可靠度有明顯的改善。上述可靠度測試是進行熱循環，以對相似於第2圖的結構(具有或不具有鈀層38及126)施加應力。可觀察到未形成鈀層38及126的第一複數樣品在熱循環之後產生長度大於70微米至80微米的裂縫，同時具有鈀層38及126的第二複數樣品則裂縫長度有明顯縮短，其中大部分的樣品的裂縫長度小於20微米，且某些樣品的裂縫長度約為6微米。第二複數樣品的裂縫長度通常為第一複數樣品的裂縫長度的10%至20%之間。
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，任何所屬技術領域中具有通常知識者，在不脫離本發明之精神和範圍內，當可作更動與潤飾。再者，本發明之保護範圍並未侷限於說明書內所述特定實施例中的製程、機器、製造、物質組成、裝置、方法及步驟，任何所屬技術領域中具有通常知識者可從本發明揭示內容中理解現行或未來所發展出的製程、機器、製造、物質組成、裝置、方法及步驟，只要可以在此處所述實施例中實施大體相同功能或獲得大體相同結果皆可使用於本發明中。因此，本發明之保護範圍包括上述製程、機器、製造、物質組成、裝置、方法及步驟。另外，每一申請專利範圍構成個別的實施例，且本發明之保護範圍也包括各個申請專利範圍及實施例的組合。
2．．．工作部件/(半導體)晶片
10．．．基底
12．．．內連結構
14．．．半導體裝置
28、122．．．金屬墊
30．．．鈍化保護層
32．．．凸塊底部金屬化層
34．．．銅凸塊
36、124．．．阻障層
38、126．．．鈀層
40．．．焊料層
100．．．工作部件/封裝基底
110、114．．．接合墊
112．．．金屬內連線
116．．．介電基底
130．．．焊球
132．．．金屬間化合物/(富含鈀的)晶粒
第1A圖係繪示出一半導體晶片，其包括銅凸塊及位於銅凸塊上方的鈀層。
第1B圖係繪示出一封裝基底，其包括接合墊及位於接合墊上方的焊球。
第2圖係繪示出第1A及1B圖中結構的接合；
第3A圖係繪示出一半導體晶片，其包括銅凸塊、位於銅凸塊上方的鈀層及位於鈀層上方的焊料層；
第3B圖係繪示出一封裝基底，其包括接合墊，其中焊料可選擇性形成於接合墊上；
第4A圖係繪示出一半導體晶片，其包括接合墊及位於接合墊上方的焊球；及
第4B圖係繪示出一封裝基底，其包括銅凸塊、位於銅凸塊上方的鈀層及位於鈀層上方的焊料層。
2．．．工作部件/(半導體)晶片
10．．．基底
12．．．內連結構
14．．．半導體裝置
28、122．．．金屬墊
30．．．鈍化保護層
34．．．銅凸塊
36、124．．．阻障層
38、126．．．鈀層
100．．．工作部件/封裝基底
110、114．．．接合墊
112．．．金屬內連線
116．．．介電基底
130．．．焊球
132．．．金屬間化合物/(富含鈀的)晶粒

Claims (10)

  1. 一種積體電路結構，包括：一第一工作部件，包括：一半導體基底；以及一銅凸塊，位於該半導體基底上方；一第二工作部件，其包括一接合墊；以及一焊料，鄰接於該第一工作部件與該第二工作部件之間，其中該焊料將該銅凸塊電性連接至該接合墊，且其中該焊料包括鈀，其中該焊料內更包括一金屬間化合物，且該金屬間化合物包括銅、焊錫及鈀，該金屬間化合物中鈀重量百分比在5%至10%的範圍。
  2. 如申請專利範圍第1項所述之積體電路結構，其中該第一工作部件係包括積體電路的一半導體晶片，而該第二工作部件係一封裝基底。
  3. 如申請專利範圍第1項所述之積體電路結構，其中該第一工作部件係一封裝基底，而該第二工作部件係包括積體電路的一半導體晶片。
  4. 如申請專利範圍第1項所述之積體電路結構，其中該焊料內平均鈀重量百分比在0.15%至0.3%的範圍。
  5. 如申請專利範圍第1項所述之積體電路結構，其中該金屬間化合物係一界面層，位於該焊料與該銅凸塊之間。
  6. 如申請專利範圍第5項所述之積體電路結構，更包括一含鎳阻障層，位於該界面層與該銅凸塊之間。
  7. 如申請專利範圍第1項所述之積體電路結構，其中 該第二工作部件包括：一鈀層，位於該接合墊與該焊料之間；以及一阻障層，位於該接合墊與該鈀層之間。
  8. 一種積體電路結構，包括：一半導體基底；一金屬墊，位於該半導體基底上方；一銅凸塊，位於該金屬墊上方且與其電性連接；一含鎳阻障層，位於該銅凸塊上方；一鈀層，位於該含鎳阻障層上方；以及一焊料，位於該鈀層上方，其中該焊料內更包括一金屬間化合物，且該金屬間化合物包括銅、焊錫及鈀，該金屬間化合物中鈀重量百分比在5%至10%的範圍。
  9. 如申請專利範圍第8項所述之積體電路結構，其中該鈀層的鈀重量百分比大於99%。
  10. 如申請專利範圍第8項所述之積體電路結構，其中該銅凸塊包括上表面及側壁，且該含鎳阻障層位於該銅凸塊的上表面或側壁。
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