TWI499030B - 在矽穿孔插入物中形成開放孔穴以包含在晶圓級晶片尺寸模組封裝的半導體晶粒之半導體裝置和方法 - Google Patents

在矽穿孔插入物中形成開放孔穴以包含在晶圓級晶片尺寸模組封裝的半導體晶粒之半導體裝置和方法 Download PDF

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TWI499030B
TWI499030B TW099123391A TW99123391A TWI499030B TW I499030 B TWI499030 B TW I499030B TW 099123391 A TW099123391 A TW 099123391A TW 99123391 A TW99123391 A TW 99123391A TW I499030 B TWI499030 B TW I499030B
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Taiwan
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semiconductor
semiconductor die
conductive
die
wafer
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TW099123391A
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English (en)
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TW201133769A (en
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Heejo Chi
Namju Cho
Hangil Shin
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Stats Chippac Ltd
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    • H01L21/70Manufacture or treatment of devices consisting of a plurality of solid state components formed in or on a common substrate or of parts thereof; Manufacture of integrated circuit devices or of parts thereof
    • H01L21/77Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate
    • H01L21/78Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate with subsequent division of the substrate into plural individual devices
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Description

在矽穿孔插入物中形成開放孔穴以包含在晶圓級晶片尺寸模組封裝的半導體晶粒之半導體裝置和方法
本發明一般有關於半導體裝置,以及更特別是有關於在矽穿孔(TSV)插入物中形成開放孔穴以包含在晶圓級晶片尺寸模組封裝(WLCSMP)中半導體晶粒之半導體裝置和方法。
在現代電子產品中通常可以發現半導體裝置。半導體裝置電性組件之數目與密度可以改變。離散半導體裝置通常包括一種形式電性組件,例如:發光二極體(LED)、小信號電晶體、電阻器、電容器、電感器以及功率金屬氧化物半導體場效應電晶體(MOSFET)。積體半導體裝置典型地包括數百個至數百萬個電性組件。積體半導體裝置之例包括:微控制器、微處理器、電荷耦合裝置(CCD)、太陽能電池以及數位微鏡裝置(DMD)。
半導體裝置實施廣大範圍之功能,例如:高速計算、發射與接收電磁信號、控制電子裝置、將陽光轉變成電力以及產生用於電視顯示之視覺投影。在娛樂、通訊、電力轉換、網路、電腦、以及消費者產品之領域中可以發現半導體裝置。在軍事應用、航空、汽車、工業控制器以及辦公室設備中亦可以發現半導體裝置。
半導體裝置使用半導體材料之電氣性質。此半導體材料之原子結構允許其導電率藉由施加電場或基極電流、或經由掺雜過程而操控。掺雜會將雜質導入於半導體材料中,以操縱且控制半導體裝置之導電率。
半導體裝置包括主動與被動電性結構。主動結構包括雙載子電晶體與場效應電晶體,其控制電流之流動。藉由改變掺雜以及施加電場或基極電流之位準,電晶體可以增強或限制電流之流動。被動結構包括:電阻器、電容器以及電感器,其在實施各種所需電性功能之電壓與電流之間產生關係。將此等被動與主動結構電性連接以形成電路,其使得半導體裝置能夠實施高速計算與其他有用功能。
通常使用兩個複雜製造過程以製造半導體裝置,即前端製造過程與後端製造過程,其各可能涉及數百個步驟。前端製造過程涉及在半導體晶圓表面上形成複數個晶粒(die)。各晶粒典型地相同且包含藉由將主動與被動組件電性連接所形成之電路。後端製造過程涉及將所完成晶圓單一化成個別晶粒,且將此等晶粒封裝以提供結構支持與環境隔離。
半導體製造之一目標為產生較小半導體裝置。較小裝置典型地消耗較少功率,具有較高性能表現,且可以更有效率地製造。此外,較小半導體裝置具有較小佔用空間(footprint),此對於較小終端產品為令人所欲。可以藉由改善前端製造過程以達成較小晶粒尺寸,以導致具有較小且較高密度主動與被動組件之晶粒。後端製造過程可以藉由改善電性互連與封裝材料,以導致具有較小佔用空間之半導體裝置封裝。
在晶圓級晶片尺寸模組封裝(WLCSMP)典型地包含:在用於較高裝置整合程度之有機基板或插入物之上與之間之堆疊半導體晶粒。此具有上與下堆疊半導體晶粒之WLCSMP之例可以在美國專利案號6921968、5977640以及6906415中找到。此下半導體晶粒較有機基板為薄,因此包含於封膠中。因此,難以將下半導體晶粒所產生之熱適當地驅散。當處理時,此固定有機基板需要小心照顧,以避免對此薄的半導體晶粒造成損害。此外,由於在上與下半導體晶粒以及有機基板之間熱膨脹係數(CTE)匹配不良,會重複產生翹曲的問題。
目前對於具有良好散熱能力且結實堅固可以防止翹曲之較薄之WLCSMP存在一種需求。因此,在一實施例中,本發明為一種製造半導體裝置之方法,其包括以下步驟:將一半導體晶圓安裝至一暫時載體;經由此半導體晶圓形成複數個TSV;經由此半導體晶圓部份地形成一孔穴;將第一半導體晶粒安裝至第二半導體晶粒;將第一與第二半導體晶粒安裝至半導體晶圓,以致於第一半導體晶粒設置在半導體晶圓上且電性連接至TSV,且此第二半導體晶粒設置在此孔穴中;將封膠沉積在半導體晶圓上以及在第一與第二半導體晶粒周圍;將封膠之一部份去除,以曝露此第一半導體晶粒之第一表面;以及將此半導體晶圓之一部份去除,以曝露TSV與此第二半導體晶粒之第一表面。此半導體晶圓之其餘部份操作為用於第一與第二半導體晶粒之TSV插入物。此方法更包括步驟,以形成在TSV插入物上之第一互連結構。
在另一實施例中,本發明為一種製造半導體裝置之方法,其包括以下步驟:提供一半導體晶圓;經由此半導體晶圓形成複數個導電通孔;在此半導體晶圓中形成第一孔穴;將第一半導體晶粒安裝至第二半導體晶粒;將第一與第二半導體晶粒安裝至半導體晶圓,以致於第一半導體晶粒設置在半導體晶圓上且電性連接至導電通孔,且此第二半導體晶粒設置在第一孔穴中;將封膠沉積在半導體晶圓上以及在第一與第二半導體晶粒周圍;以及將半導體晶圓之一部份去除,以曝露此導電通孔與第二半導體晶粒之第一表面。此半導體晶圓之其餘部份操作為用於第一與第二半導體晶粒之插入物。此方法更包括步驟,在插入物上形成第一互連結構。
在另一實施例中,本發明為一種製造半導體裝置之方法,包括以下步驟:提供一半導體晶圓;經由此半導體晶圓形成複數個導電通孔;在此半導體晶圓中形成一孔穴;將第一半導體晶粒安裝至第二半導體晶粒;將第一與第二半導體晶粒安裝至半導體晶圓,以致於第一半導體晶粒設置在半導體晶圓上且電性連接至導電通孔,且此第二半導體晶粒設置在此孔穴中;將封膠沉積在半導體晶圓上以及在第一與第二半導體晶粒上;以及半導體晶圓之一部份去除,以曝露此導電通孔與第二半導體晶粒之第一表面。此半導體晶圓之其餘部份操作為用於第一與第二半導體晶粒之插入物。
在另一實施例中,本發明為一半導體裝置,其包括:一插入物,其具有經由此插入物所形成之複數個導電通孔,與在此插入物中所形成之孔穴;一第一半導體晶粒,安裝至此插入物;一第二半導體晶粒,安裝至此第一半導體晶粒且設置於此孔穴中;一封膠,沉積於此插入物以及第一與第二半導體晶粒上,由此封膠曝露第一半導體晶粒之第一表面,且此封膠曝露第二半導體晶粒之第一表面;以及第一互連結構,形成於此插入物上。
本發明在以下一或更多實施例中參考所附圖式說明,其中,相同號碼代表相同或類似元件。雖然,本發明是以達成本發明目的之最佳模式說明,然而,熟習此技術人士瞭解,其用意為包含各種替代、修正、以及等同,而此等替代、修正、等同是包含於由所附申請專利範圍與其等同物所界定本發明精神與範圍中,且由以下揭示內容與圖式所支持。
通常使用兩個複雜製造過程以製造半導體裝置:前端製造過程與後端製造過程。前端製造過程涉及在半導體晶圓表面上形成複數個晶粒(die)。在晶圓上之各晶粒包含主動與被動電性組件,其電性連接以形成功能性電路。主動電性組件例如為電晶體與二極體,其具有能力以控制電流之流動。被動電性組件例如為電容器、電感器、電阻器以及變壓器,其在實施所須電路功能之電壓與電流之間產生關係。
此等被動與主動組件藉由一系列製程步驟形成於半導體晶圓之表面上。此等步驟包括:掺雜、沉積、微影術、蝕刻以及平坦化。掺雜藉由例如離子植入或熱擴散技術,將雜質導入於半導體材料中。此掺雜過程可以改變在主動元件中之半導體材料之導電率,將半導體材料轉換成絕緣體、導電體,或動態地改變半導體材料導電率,以響應於電場或基極電流。電晶體包括改變型式與掺雜程度之區域,其如同所需地配置,以使得在施加電場或基極電流時,電晶體可以增強或限制電流之流動。
主動與被動組件可以由具有不同電氣性質之材料層所形成。此等層可以藉由各種沉積技術而形成,此技術部份由所沉積材料之型式所決定。例如,薄膜沉積可以涉及:化學氣相沉積(CVD)、物理氣相沉積(PVD)、電解質電鍍以及無電極電鍍過程。通常將各層圖案化以形成:主動組件、被動組件、或組件間電性連接之部份。
可以使用微影術將此等層圖案化,其涉及將光敏感材料例如光阻沉積在被圖案化之層上。使用光線將圖案由光罩移轉至光阻。使用溶劑將受光線照射之光阻圖案之部份去除,以曝露被圖案化下層之部份。將光阻之剩餘部份去除,以留下圖案化層。以替代方式,可以使用例如無電極與電解質電鍍技術,藉由將材料直接沉積於由先前沉積/蝕刻過程所形成區域或洞孔中,將一些型式材料圖案化。
將薄膜材料沉積於現有圖案上,會擴大下面圖案,且產生不均勻之平坦表面。通常需要均勻平坦表面,以生產較小且更密集地封裝之主動與被動組件。可以使用平坦化將材料從晶圓表面去除,以產生均勻平坦表面。平坦化涉及以拋光墊將晶圓表面拋光。在拋光期間,將研磨材料與腐蝕性化學物質加至晶圓表面。此研磨之機械作用與化學物質之腐蝕作用之組合,可以去除任何不規則地形,以導致均勻平坦表面。
後端製造過程是指將所完成晶圓切割或單一化成為個別晶粒,以及然後將此等晶粒封裝用於結構支持與環境隔離。為了將此晶粒單一化,將晶圓沿著稱為鋸道或劃線之晶圓無功能區域劃線且分開。使用雷射切割工具或鋸刀將晶圓單一化。在單一化之後,將個別晶粒安裝至封裝基板,此基板包括接腳或接觸墊,用於與其他系統組件互連。然後,將此半導體晶粒上所形成之接觸墊連接至此封裝中之接觸墊。此電性連接可以焊料突起、柱(stud)突起、導電漿或接線製成。將封膠或其他模製材料沉積在封裝上,以提供實體支持與電性隔離。然後,將此所完成封裝插入於電性系統中,且使得此半導體裝置功能可供其他系統組件使用。
圖1說明具有晶片載體基板或印刷電路板(PCB) 52之電子裝置50,此基板或電路板具有複數個安裝於其表面上之半導體封裝。取決於應用,此電子裝置50可以具有一種型式半導體封裝或多種型式半導體封裝。用於說明目的,圖1中顯示不同型式半導體封裝。
電子裝置50可以為獨立式系統,其使用半導體封裝以實施一或更多個電性功能。以替代方式,電子裝置50可以為一較大系統之次組件。例如,電子裝置50為可以插入於電腦中之圖形卡、網路介面卡或其他信號處理卡。半導體封裝可以包括微處理器、記憶體、特殊用途積體電路(ASIC)、邏輯電路、類比電路、射頻(RF)電路、離散裝置或其他半導體晶粒或電性組件。
在圖1中,PCB 52提供一般基板,用於安裝在於PCB上半導體封裝之機械支持與電性互連。使用蒸鍍、電解質電鍍、無電極電鍍、絲網印刷或其他適當金屬沉積過程,在PCB 52之表面上或層中形成導電信號跡線54。
信號跡線54提供在各半導體封裝、安裝組件、以及其他外部系統組件之間之電性連通。跡線54亦將功率與接地連接提供給各半導體封裝。
在一些實施例中,半導體裝置具有兩個封裝位準。第一位準封裝為一種技術,用於將半導體晶粒機械地與電性地裝附於一中間載體。第二位準封裝是關於將中間載體機械地與電性地裝附於PCB。在其他實施例中,半導體裝置僅具有第一位準封裝,而將晶粒機械地與電性地直接安裝至PCB。
為了說明目的而顯示,在PCB 52上數種型式第一位準封裝,其包括接線封裝56與覆晶58。此外,顯示在PCB 52上數種型式第二位準封裝,其包括:球格柵陣列(BGA)60、突起晶片載體(BCC)62、雙內線封裝(DIP)64、平面格柵陣列(LGA)66、多晶片模組(MCM)68、四方形扁平無接腳封裝(QFN)70以及四方形扁平封裝72。取決於系統需求,可以將半導體封裝之任何組合、以第一與第二位準封裝型式之任何組合而組態,而將其與其他電子組件一起連接至PCB 52。在一些實施例中,電子裝置50包括單一裝附半導體封裝,而其他實施例需要多個互連封裝。藉由將一或更多個半導體封裝組合於單一基板上,製造商可以將預製組件合併於電子裝置與系統中。因為半導體封裝包括複雜功能,可以使用較便宜組件與合理化製程以製造電子裝置。此所產生之裝置較不可能故障且製造較便宜,導致對於消費者較低成本。
圖2a-2c顯示典範半導體封裝。圖2a說明安裝於PCB 52上DIP 64之進一步細節。半導體晶粒74包括:一主動區域,其所包含類比或數位電路執行作為主動元件、被動元件、導電層以及形成於晶粒中之介電層,且根據晶粒之電性設計而電性互連。例如,電路可以包括:一或更多個電晶體、二極體、電感器、電容器、電阻器以及形成於半導體晶粒74主動區域中之其他電路元件。接觸墊76為一或更多層導電材料,例如鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、或銀(Ag),且電性連接至形成於半導體晶粒74中之電路元件。在DIP 64組裝期間,使用金-矽共晶層或黏著材料例如熱環氧樹脂,將半導體晶粒74安裝至一中間載體78。封裝體包括絕緣封裝材料,例如聚合物或陶瓷。導線80與接線82提供半導體晶粒74與PCB 52間之電性互連。封膠84沉積在封裝上,其藉由防止濕氣與粒子進入封裝且污染晶粒74與接線82而作環境保護。
圖2b說明安裝在PCB 52上BCC 62之進一步細節。使用底部填料或環氧樹脂黏著材料92,將半導體晶粒88安裝在載體90上。接線94提供接觸墊96與98間之第一位準封裝互連。將模製複合物或封膠100沉積在半導體晶粒88與接線94上,以提供用於此裝置之實體支持與電性隔離。使用適當金屬沉積過程例如電解質電鍍或無電極電鍍過程以防止氧化,將接觸墊102形成於PCB 52之表面上。將接觸墊102電性連接至PCB 52中一或更多個導電信號跡線54。在BCC 62之接觸墊98與PCB 52之接觸墊102之間形成突起104。
在圖2c中,將半導體晶粒58面向下、以覆晶型式第一位準封裝安裝至中間載體106。半導體晶粒58之主動區域108包括類比或數位電路,其執行作為根據晶粒電性設計所形成之主動元件、被動元件、導電層、以及介電層。例如,電路可以包括一或更多個電晶體、二極體、電感器、電容器、電阻器以及在主動區域108中之其他電路元件。半導體晶粒58經由突起110而電性地與機械地連接至載體106。
使用突起112,將BGA 60以BGA型式第二位準封裝電性地且機械地連接至PCB 52。經由突起110、信號線114以及突起112,將半導體晶粒58電性連接至在PCB 52中之導電信號跡線54。將模製複合物或封膠116沉積在半導體晶粒58與載體106上,以提供用於此裝置之實體支持與電性隔離。此覆晶半導體裝置提供從在半導體晶粒58上主動元件至在PCB 52上導電軌之短的導電路徑,以便縮短信號傳送距離、降低電容以及改善整個電路之性能表現。在另一實施例中,可以使用覆晶型式第一位準封裝而無需中間載體106,將半導體晶粒58電性地且機械地直接連接至PCB 52。
圖3a-3i說明有關於圖1與圖2a-2c之過程,以形成一WLCSMP,其所具有開放孔穴用於容納半導體晶粒,且經由TSV插入物而互連。圖3a顯示一半導體晶圓118,其包含基礎基板材料,例如:矽、鍺、砷化鎵、磷化銦或碳化矽,而用於結構支持。基板或載體120包含暫時或犧牲基礎材料,例如用於結構支持之:矽、聚合物、聚合複合物、金屬、陶瓷、玻璃、玻璃環氧樹脂、氧化鈹或其他適當低成本、堅硬材料、或塊半導體材料。在載體120上塗佈介面層或帶121作為暫時黏著接合薄膜或蝕刻停止層。將半導體晶圓118安裝至載體帶121,而以其表面123背向此帶。
在圖3b中,使用雷射鑽孔或蝕刻過程、例如深反應性離子蝕刻(DRIE),部份地經由半導體晶圓118在表面123形成複數個通孔。使用物理氣相沉積(PVD)、化學氣相沉積(CVD)、電解質電鍍、無電極電鍍或其他適當金屬沉積過程,將通孔填以鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)、鈦(Ti)、鎢(W)、多晶矽或其他合適導電材料,以形成導電矽穿孔(TSV) 122。在TSV 122周圍形成選擇性絕緣層。在半導體晶圓118之表面123上形成電路層124。電路層124包括由絕緣層126所分開之導電層125。絕緣層126可以為由以下材料所構成之一或更多層:二氧化矽(SiO2 )、氮化矽(Si3 N4 )、氮氧化矽(SiON)、過氧化鉭(Ta2 O5 )、三氧化二鋁(Al2 O3 )、光阻或具有類似絕緣與結構性質之其他材料。使用物理氣相沉積(PVD)、化學氣相沉積(CVD)、印刷、旋轉塗佈、噴灑覆蓋、燒結或熱氧化以形成絕緣層126。藉由蝕刻過程以去除絕緣層126之一部份。使用具有物理氣相沉積(PVD)、化學氣相沉積(CVD)、濺鍍、電解質電鍍、無電極電鍍或其他適當金屬沉積過程之圖案化,在絕緣層126被去除部份中形成導電層125。導電層125可以為以下所形成之一或更多層:鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)或其他合適導電材料。導電層125之一部份電性連接至TSV 122。取決於半導體裝置之設計與功能,導電層125之其他部份可以為電性連接或電性隔離。可以在電路層124中形成一或更多個(IPD),例如:電感器、電容器以及電阻器,用於射頻(RF)信號處理。
溝渠128是從表面123部份地經由半導體晶圓118而形成,其具有足夠的寬度與深度以容納一半導體晶粒。可以鋸刀、雷射鑽孔或RDIE形成溝渠128。在一實施例中,溝渠128之寬度大於半導體晶粒134之x/y軸長度,且其深度大於半導體晶粒134之厚度。選擇性溝渠130是從表面123部份地經由半導體晶圓118而形成,用於切割鋸開空間。溝渠130允許半導體晶圓118之側面(稍後稱為TSV插入物)在單一化之後由封膠覆蓋。
圖3c顯示半導體晶粒或組件132,其所具有主動表面133包含類比或數位電路,其可以執行作為主動元件、被動元件、導電層,以及形成於晶粒中之介電層,且根據晶粒之電性設計與功能而電性地互連。例如,此電路可以包括:一或更多個電晶體、二極體、以及形成於主動表面133中之其他電路元件,以執行類比電路或數位電路,例如:數位信號處理器(DSP)、特殊用途積體電路(ASIC)、記憶體或其他信號處理電路。半導體晶粒132亦包含整合式被動元件(IPD),例如:電感器、電容器以及電阻器,用於射頻(RF)信號處理。
可以使用蒸鍍、電解質電鍍、無電極電鍍、球滴或絲網印刷過程,將導電突起材料沉積在主動表面133上。此突起材料可以為鋁(Al)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)、鉛(Pb)、鉍(Bi)、銅(Cu)、焊料以及其組合,而具有選擇性的助焊劑溶液。例如,此突起材料可以為共晶Sn/Pb、高鉛焊料或無鉛焊料。藉由將材料加熱至其熔點以上而使得突起材料回焊,以形成球體或突起136。突起136代表可以形成於主動表面133上之一種形式互連結構。此互連結構亦可使用柱突起、微突起、導電柱、導電漿或其他電性互連。
可以使用突起136安裝半導體晶粒或組件134,且電性連接至半導體晶粒132。半導體晶粒134具有主動表面135,其包含類比或數位電路,而可以執行作為主動元件、被動元件、導電層,以及形成於晶粒中之介電層,且根據晶粒之電性設計與功能而電性互連。例如,此電路可以包括形成於主動表面135中之一或更多個電晶體、二極體以及其他電路元件,以執行類比電路或數位電路,例如:數位信號處理器(DSP)、特殊用途積體電路(ASIC)、記憶體或其他信號處理電路。半導體晶粒134亦包含整合式被動元件(IPD),例如:電感器、電容器以及電阻器,用於射頻(RF)信號處理。
此經組合半導體晶粒132-134可以設置在半導體晶圓118上,且將其對準而將半導體晶粒134設置在溝渠128上。然後,藉由將突起136回焊,將經組合半導體晶粒132-134安裝至半導體晶圓118,而將主動表面133冶金地且電性地連接至導電層125,如同於圖3d中顯示。半導體晶粒134包含於溝渠128中,以降低封裝高度。
在圖3e中,使用漿料印刷、壓擠模製、移轉模製、液體封膠模製、真空堆疊、旋轉塗佈或其他適當塗佈劑,將封膠或模製複合物140沉積在半導體晶圓118上以及半導體晶粒132與134周圍。封膠140可以為聚合物複合材料,例如:具有填料之環氧樹脂、具有填料之環氧樹脂丙烯酸脂或具有適當填料之聚合物。封膠140為不導電,且可以對半導體裝置提供環境保護,以防止外部元件與污染物之進入。
在圖3f中,藉由磨輪142去除封膠140之一部份,以曝露半導體晶粒132之後表面143,且降低封裝之高度。在另一實施例中,例如在圖9中說明,磨輪142可以留下封膠140之一部份,以覆蓋半導體晶粒132之表面143。
在圖3g中,基板或載體144包含暫時或犧牲基礎材料而用於結構支持,例如:矽、聚合物、聚合複合物、金屬、陶瓷、玻璃、玻璃環氧樹脂、氧化鈹或其他適當低成本、堅硬材料或塊(bulk)半導體材料。可以將介面層或帶146塗佈於載體144上,作為暫時黏著接合薄膜或蝕刻停止層。將在圖3a-3f中所說明組裝反轉,且安裝至載體帶146。藉由化學蝕刻、機械剝離、化學機械拋光(CMP)、機械研磨、熱烘焙、雷射掃瞄或濕性剝除,以去除載體120與帶121。
在圖3h中,藉由磨輪142,將面對表面123之半導體晶圓118之表面147之一部份去除,以曝露TSV 122與半導體晶粒134之後表面148,且降低此封裝之高度。半導體晶圓118之其餘部份構成插入物149,其具有用於電性互連之TSV 122。
在圖3i中,在插入件149之表面151上形成互連結構150。互連結構150包括形成於表面151上之絕緣層或鈍化層152,其使用物理氣相沉積(PVD)、化學氣相沉積(CVD)、印刷、旋轉塗佈、噴灑覆蓋、燒結或熱氧化而形成。絕緣層152為由以下材料所形成之一或更多層:二氧化矽(SiO2 )、氮化矽(Si3 N4 )、氮氧化矽(SiON)、過氧化鉭(Ta2 O5 )、三氧化二鋁(Al2 O3 )以及具有類似絕緣與結構性質之其他材料。藉由蝕刻過程以去除絕緣層152之一部份,以曝露TSV 122。
使用圖案化與沉積過程例如:物理氣相沉積(PVD)、化學氣相沉積(CVD)、濺鍍、電解質電鍍以及無電極電鍍,在TSV 122與絕緣層152被去除部份上形成導電層154。導電層154可以為以下材料所形成之一或更多層:鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)或其他合適導電材料。可以在導電層154上形成一下突起金屬化(UBM)層。可以將導電層154之一部份電性連接至TSV 122與電路層124。取決於半導體裝置之設計與功能,導電層154之其他部份可以為電性連接或電性隔離。
使用蒸鍍、電解質電鍍、無電極電鍍、球滴或絲網印刷過程,將導電突起材料沉積在建立式互連結構150上,且電性連接至導電層154。此突起材料可以為鋁(Al)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)、鉛(Pb)、鉍(Bi)、銅(Cu)、焊料以及其組合,而具有選擇性的助焊劑溶液。例如,此突起材料可以為共晶Sn/Pb、高鉛焊料或無鉛焊料。使用適當裝附或接合過程,將突起材料接合至導電層154。在一實施例中,藉由將材料加熱至其熔點以上而使得突起材料回焊,以形成球體或突起156。在一些應用中,此突起156第二次回焊,以改善至導電層154之電性接觸。突起亦可以被壓擠接合至導電層154。突起156代表可以形成於導電層154上之一種形式互連結構。此互連結構亦可使用柱突起、微突起、導電柱、導電漿或其他電性互連。
藉由化學蝕刻、機械剝離、化學機械拋光(CMP)、機械研磨、熱烘焙、雷射掃瞄或濕性剝除,以去除載體144與帶146。可以鋸刀或雷射切割裝置160將半導體晶粒132與134單一化成個別WLCSMP。圖4顯示在單一化後之WLCSMP 162。將被動組件164例如:電阻器、電容器、電感器,或主動組件安裝至插入物149。半導體晶粒134經由突起136電性連接至半導體晶粒132。半導體晶粒132經由電路層124與包含TSV 122之插入物149而電性連接至互連結構150。WLCSMP 162具有一開放孔穴,用於容納半導體晶粒134,以降低封裝高度。此研磨過程亦降低WLCSMP 162之高度。在一實施例中,由於此由溝渠130所提供額外切割空間,此插入物149之側被封膠140覆蓋。以替代方式,並不設置溝渠130,可以曝露插入物149之側。半導體晶粒132之曝露表面143與半導體晶粒134之曝露表面148提供良好熱驅散。半導體晶粒132與134以及插入物149之類似基礎材料例如矽,提供熱應力解除,且使得WLCSMP 162結實堅固,以防止封裝組件之間熱膨脹係數(CTE)中任何匹配不良。因此,可以減少WLCSMP 162翹曲之發生。
在圖3h之後,在以上過程之變化中,如同於圖5中顯示可以在插入物149之表面151上形成互連結構170。互連結構170包括聚合物絕緣層172,其使用旋轉塗佈、薄膜堆疊、模製、或其他適當沉積過程,而形成於表面151上。聚合物絕緣層172可以為以下材料所形成之一或更多層:聚亞醯胺、苯環丁烯(BCB)、聚醚醯亞胺(PBO)或其他具有類似絕緣與結構性質之材料。藉由蝕刻過程以去除聚合物絕緣層172之一部份,以曝露TSV 122。
使用圖案化與沉積過程,例如物理氣相沉積(PVD)、化學氣相沉積(CVD)、濺鍍,電解質電鍍、無電極電鍍,在TSV 122上與聚合物絕緣層172被去除部份上形成導電層174。導電層174可以為以下材料所形成之一或更多層:鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)或其他合適導電材料。導電層174之一部份電性連接至TSV 122與電路層124。取決於半導體裝置之設計與功能,導電層174之其他部份可以為電性連接或電性隔離。
使用蒸鍍、電解質電鍍、無電極電鍍、球滴或絲網印刷過程,將導電突起材料沉積在建立式互連結構170上,且電性連接至導電層174。此突起材料可以為鋁(Al)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)、鉛(Pb)、鉍(Bi)、銅(Cu)、焊料以及其組合,而具有選擇性的助焊劑溶液。例如,此突起材料可以為共晶Sn/Pb、高鉛焊料、或無鉛焊料。使用適當裝附或接合過程,將突起材料接合至導電層174。在一實施例中,藉由將材料加熱至其熔點以上而使得突起材料回焊,以形成球體或突起176。在一些應用中,此突起176第二次回焊,以改善至導電層174之電性接觸。突起亦可以被壓擠接合至導電層174。突起176代表可以形成於導電層174上之一種形式互連結構。此互連結構亦可使用柱突起、微突起、導電柱、導電漿或其他電性互連。
圖6顯示WLCSMP 178,其包括在圖3a-3i與4中所說明特徵,且將金屬板180安裝至:半導體晶粒132之表面143、以及具有導熱黏著劑之封膠140。金屬板180亦可以藉由無電極電鍍或電解質電鍍過程形成。金屬板180亦可以操作為散熱器,將來自WLCSMP 178之熱能驅散。金屬板180可以為
鋁(Al)、銅(Cu)或具有高熱導率之另外材料。選擇性晶粒裝附黏著劑或熱介面層(TIM)182,將金屬板180牢固至半導體晶粒132與封膠140。金屬板180可以增加WLCSMP 178之硬度。
圖7顯示WLCSMP 190,其包括在圖3a-3i與4中所說明特徵,且將金屬板192安裝至:半導體晶粒132之表面143、以及具有黏著劑之封膠140。金屬板192亦可以藉由無電極電鍍或電解質電鍍過程形成。金屬板192亦可以操作為電磁干擾(EMI)屏蔽層或射頻干擾(RFI)屏蔽層。金屬板192可以由以下材料所製成:銅;鋁;肥粒鐵或羰基鐵;不銹鋼;鎳銀;低碳鋼;矽鐵鋼;錫箔;環氧樹脂;導電樹脂;以及其他金屬與複合物,其能夠阻擋或吸收電磁干擾(EMI)、射頻干擾(RFI)以及其他裝置間干擾。屏蔽層亦可以為非金屬材料,例如:碳烟粉或鋁片,以減少EMI或RFI效應。金屬板192可以經由導電柱(pillar)或柱(stud)194、電路層124、在插入物149中TSV 122、以及互連結構150而接地。導電柱194可以為金柱、或銅柱或焊料。金屬板192亦可以操作為散熱器,將來自WLCSMP 190之熱能驅散。
圖8顯示WLCSMP 196,其包括在圖3a-3i與4中所說明特徵,以及在封膠140中形成導電柱或柱198。導電柱198可以藉由以下方式形成:在封膠140中雷射鑽孔或蝕刻通孔,且將通孔以導電材料例如銅、金、或焊料填滿而形成。導電柱198提供用於堆疊半導體封裝之額外互連能力。
圖9顯示WLCSMP 200,其包括在圖3a-3i與4中所說明特徵,其所例外不同者為在圖3f中所說明之研磨操作留下封膠140,以覆蓋半導體晶粒132之表面143。導電柱或柱202可以藉由以下方式形成:在封膠140中雷射鑽孔或蝕刻通孔,且將通孔填滿導電材料例如銅、金、或焊料而形成。在封膠140中形成導電層204。導電柱202與導電層204提供用於輸入(fan-in)堆疊半導體封裝之額外互連能力。
圖10顯示WLCSMP 210,其包括在圖3a-3i與4中所說明特徵。此外,導電柱或柱212可以藉由以下方式形成:在封膠140中雷射鑽孔或蝕刻通孔,且將通孔填滿導電材料例如銅、金、或焊料而形成。半導體晶粒132之表面143、以及在封膠140上形成互連結構214。互連結構214包括絕緣或鈍化層216,其藉由使用使用物理氣相沉積(PVD)、化學氣相沉積(CVD)、印刷、旋轉塗佈、噴灑覆蓋、燒結或熱氧化而形成。絕緣層216可以為由以下材料所構成之一或更多層:二氧化矽(SiO2 )、氮化矽(Si3 N4 )、氮氧化矽(SiON)、過氧化鉭(Ta2 O5 )、三氧化二鋁(Al2 O3 )、以及具有類似絕緣與結構性質之其他材料。使用圖案化與沉積過程例如:物理氣相沉積(PVD)、化學氣相沉積(CVD)、濺鍍、電解質電鍍以及無電極電鍍,在絕緣層216中形成導電層218。導電層218可以為以下所形成之一或更多層:鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)或其他合適導電材料。導電層218之一部份電性連接至導電柱212。取決於半導體裝置之設計與功能,導電層218之其他部份可以為電性連接或電性隔離。導電柱212與互連結構214提供用於輸入(fan-in)堆疊半導體封裝之額外互連能力。
圖11顯示WLCSMP 220,其包括在圖3a-3i與4中所說明特徵。此外,導電柱222可以藉由以下方式形成:在半導體晶粒132中雷射鑽孔或蝕刻通孔,且將通孔填滿導電材料例如銅或金而形成。半導體晶粒132之表面143上形成互連結構224。互連結構224包括絕緣或鈍化層226,其藉由使用物理氣相沉積(PVD)、化學氣相沉積(CVD)、印刷、旋轉塗佈、噴灑覆蓋、燒結或熱氧化以形成。絕緣層226可以為由以下材料所構成之一或更多層:二氧化矽(SiO2 )、氮化矽(Si3 N4 )、氮氧化矽(SiON)、過氧化鉭(Ta2 O5 )、三氧化二鋁(Al2 O3 )以及具有類似絕緣與結構性質之其他材料。藉由蝕刻過程以去除絕緣層226之一部份。使用圖案化與沉積過程例如:物理氣相沉積(PVD)、化學氣相沉積(CVD)、濺鍍、電解質電鍍以及無電極電鍍,在絕緣層226被去除部份中形成導電層228。導電層228可以為以下所形成之一或更多層:鋁(Al)、銅(Cu)、錫(Sn)、鎳(Ni)、金(Au)、銀(Ag)或其他合適導電材料。導電柱222與導電層226提供用於堆疊半導體封裝之額外互連能力。
圖12顯示WLCSMP 230,其包括在圖3a-3i與4中所說明特徵。此外,導電柱232可以藉由以下方式形成:在半導體晶粒134中雷射鑽孔或蝕刻通孔,且將通孔填滿導電材料例如銅或金而形成。互連結構150在半導體晶粒134之表面148上延伸。在半導體晶粒134之表面158上之導電柱232與互連結構150,提供用於堆疊半導體封裝之額外互連能力。
以上已經詳細說明本發明之一或更多個實施例,熟習此技術人士瞭解,可以對於此等實施例作修正與調整,而不會偏離以下申請專利範圍中所設定本發明之範圍。
50...電性裝置
52...印刷電路板(PCB)
54...信號跡線
56...接線封裝
58...覆晶
60...球格柵陣列(BGA)
62...突起晶片載體(BCC)
64...雙內線封裝(DIP)
66...平面格柵陣列(LGA)
68...多晶片模組(MCM)
70...四方形扁平無接腳封裝(QFN)
72...四方形扁平封裝
76...接觸墊
78...中間載體
80...導線
82...接線
84...封膠
88...半導體晶粒
90...載體
92...底部填料
94...接線
96...接觸墊
98...接觸墊
100...模製複合物
102...接觸墊
104...突起
106...中間載體
108...主動區域
110...突起
112...突起
114...信號線
116...模製複合物
118...半導體晶圓
120...載體
121...帶
122...矽穿孔
123...表面
124...電路層
125...導電層
126...絕緣層
128...溝渠
130...溝渠
132...半導體晶粒
133...主動表面
134...半導體晶粒
135...主動表面
136...突起
140...模製複合物
142...磨輪
143...表面
144...基板
146...介面層
147...表面
148...後表面
149...插入物
150...互連結構
151...表面
152...絕緣層
154...導電層
156...球體
160...雷射切割裝置
162...晶圓級晶片尺寸模組封裝(WLCSMP)
164...被動組件
170...互連結構
172...聚合物絕緣層
174...導電層
176...球體
178...晶圓級晶片尺寸模組封裝
180...金屬板
182...熱介面層
190...晶圓級晶片尺寸模組封裝
192...金屬板
194...導電柱
196...晶圓級晶片尺寸模組封裝
198...導電柱
200...晶圓級晶片尺寸模組封裝
202...導電柱
204...導電層
210...晶圓級晶片尺寸模組封裝
212...導電柱
214...互連結構
216...絕緣層
218...導電層
220...晶圓級晶片尺寸模組封裝
222...導電柱
224...互連結構
226...絕緣層
228...導電層
230...晶圓級晶片尺寸模組封裝
232...導電柱
圖1說明一種印刷電路板(PCB),其具有安裝至其表面之不同形式封裝;
圖2a-2c說明安裝至PCB之典範半導體封裝之進一步細節;
圖3a-3i說明形成WLCSMP之過程,其具有一開放孔穴用於包含半導體晶粒且經由一TSV插入物而互連;
圖4說明WLCSMP,其具有一開放孔穴用於包含半導體晶粒,且經由一TSV插入物而互連;
圖5說明具有一聚合物絕緣層之TSV插入物;
圖6說明WLCSMP,其具有一散熱器與形成於上半導體晶粒上之TIM層;
圖7說明WLCSMP,其具有形成於上半導體晶粒上之EMI與RFI屏蔽層;
圖8說明WLCSMP,其具有經由封膠所形成之導電柱;
圖9說明WLCSMP,其具有經由封膠所形成之導電柱、以及形成於封膠上之導電層;
圖10說明WLCSMP,其具有經由封膠所形成之導電柱、以及形成於上半導體晶粒上之互連結構;
圖11說明WLCSMP,其具有經由上半導體晶粒所形成之TSV、以及形成於上半導體晶粒上之互連結構;以及
圖12說明WLCSMP,其具有經由下半導體晶粒所形成之TSV、以及形成於下半導體晶粒上之互連結構。
122‧‧‧矽穿孔
124‧‧‧電路層
125‧‧‧導電層
126‧‧‧絕緣層
132‧‧‧半導體晶粒
133‧‧‧主動表面
134‧‧‧半導體晶粒
135‧‧‧主動表面
136‧‧‧突起
143‧‧‧表面
148‧‧‧後表面
149‧‧‧插入物
150‧‧‧互連結構
152‧‧‧絕緣層
154‧‧‧導電層
156‧‧‧球體
162‧‧‧晶圓級晶片尺寸模組封裝(WLCSMP)
164‧‧‧被動組件

Claims (15)

  1. 一種製造半導體裝置之方法,其包括:提供一半導體晶圓,其包含複數第一導電通孔;經由該半導體晶圓部份地形成一第一孔穴;將一第一半導體晶粒安裝至一第二半導體晶粒;將該第一半導體晶粒與該第二半導體晶粒安裝至該半導體晶圓,以致於該第一半導體晶粒設置在該半導體晶圓上,且電性連接至該第一導電通孔,以及該第二半導體晶粒設置於該第一孔穴中;將封膠沉積在該半導體晶圓上,以及在該第一半導體晶粒與該第二半導體晶粒周圍;自該第一半導體晶粒上將該封膠之一部份去除;將該半導體晶圓之一部份去除,以曝露該導電通孔與該第二半導體晶粒之一第一表面,以致於該半導體晶圓之其餘部份操作為用於該第一半導體晶粒與該第二半導體晶粒之一插入物;以及在該插入物上形成一第一互連結構。
  2. 如申請專利範圍第1項之方法,更包括在該半導體晶圓中形成一第二孔穴,以曝露在單一化之後的該插入物之側上的該封膠。
  3. 如申請專利範圍第1項之方法,更包括在該第一半導體晶粒上形成一第二互連結構。
  4. 如申請專利範圍第1項之方法,更包括經由該第一半導體晶粒或該第二半導體晶粒形成複數個第二導電通 孔。
  5. 如申請專利範圍第1項之方法,更包括在該第一半導體晶粒上形成一金屬板。
  6. 一種製造半導體裝置之方法,其包括:提供一半導體晶圓,其包含複數個導電通孔;在該半導體晶圓中形成一孔穴;將一第一半導體晶粒安裝至該半導體晶圓;將一第二半導體晶粒安裝至該孔穴中;將封膠沉積在該半導體晶圓以及在該第一半導體晶粒與該第二半導體晶粒上;將該半導體晶圓之一部份去除,以曝露該導電通孔與該第二半導體晶粒之一第一表面。
  7. 如申請專利範圍第6項之方法,更包括在該導電通孔上形成一互連結構。
  8. 如申請專利範圍第6項之方法,更包括將該封膠之一部份去除,以曝露該第一半導體晶粒之一第一表面。
  9. 如申請專利範圍第6項之方法,更包括經由該第一半導體晶粒周圍之該封膠形成複數個導電柱。
  10. 如申請專利範圍第6項之方法,更包括在該第一半導體晶粒之一表面上形成一互連結構。
  11. 一種半導體裝置,包括:一插入物,其具有經由該插入物的一表面所形成之複數個導電通孔以及經由該插入物所部份形成之孔穴;一半導體構件,其設置於該孔穴中; 一第一半導體晶粒,其安裝至該半導體構件和該插入物且電性連接至該導電通孔;以及一封膠,其沉積在該插入物以及該第一半導體晶粒上,並且該封膠覆蓋該插入物之外邊。
  12. 如申請專利範圍第11項之半導體裝置,更包括一互連結構,其形成在面對該第一半導體晶粒之該插入物上且電性連接至該導電通孔。
  13. 如申請專利範圍第11項之半導體裝置,更包括一互連結構,其形成在該第一半導體晶粒和該封膠上。
  14. 如申請專利範圍第11項之半導體裝置,其中該第一半導體晶粒和該半導體構件及該插入物包含類似基礎材料以提供熱應力解除。
  15. 如申請專利範圍第11項之半導體裝置,其中該半導體構件包括一第二半導體晶粒。
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