TWI624369B - 保護帶、及使用其之半導體裝置之製造方法、以及半導體裝置 - Google Patents

保護帶、及使用其之半導體裝置之製造方法、以及半導體裝置 Download PDF

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TWI624369B
TWI624369B TW103128014A TW103128014A TWI624369B TW I624369 B TWI624369 B TW I624369B TW 103128014 A TW103128014 A TW 103128014A TW 103128014 A TW103128014 A TW 103128014A TW I624369 B TWI624369 B TW I624369B
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adhesive layer
protective tape
layer
adhesive
tape
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TW201540507A (zh
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森山浩伸
Hironobu Moriyama
出口真吾
Shingo Deguchi
八木秀和
Hidekazu Yagi
石松朋之
Tomoyuki Ishimatsu
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迪睿合股份有限公司
Dexerials Corporation
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/683Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L21/6835Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L21/6836Wafer tapes, e.g. grinding or dicing support tapes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
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    • C09J7/00Adhesives in the form of films or foils
    • C09J7/20Adhesives in the form of films or foils characterised by their carriers
    • C09J7/29Laminated material
    • HELECTRICITY
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    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • 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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    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/28Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
    • H01L23/31Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
    • H01L23/3107Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
    • H01L23/3142Sealing arrangements between parts, e.g. adhesion promotors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2203/00Applications of adhesives in processes or use of adhesives in the form of films or foils
    • C09J2203/326Applications of adhesives in processes or use of adhesives in the form of films or foils for bonding electronic components such as wafers, chips or semiconductors
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00Additional features of adhesives in the form of films or foils
    • C09J2301/10Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet
    • C09J2301/12Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the arrangement of layers
    • C09J2301/122Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the arrangement of layers the adhesive layer being present only on one side of the carrier, e.g. single-sided adhesive tape
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00Additional features of adhesives in the form of films or foils
    • C09J2301/30Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
    • C09J2301/312Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier parameters being the characterizing feature
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
    • H01L21/18Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic System or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/302Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
    • H01L21/304Mechanical treatment, e.g. grinding, polishing, cutting
    • HELECTRICITY
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    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68318Auxiliary support including means facilitating the separation of a device or wafer from the auxiliary support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/68327Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used during dicing or grinding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2221/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof covered by H01L21/00
    • H01L2221/67Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere
    • H01L2221/683Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L2221/68304Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support
    • H01L2221/6834Apparatus for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components; Apparatus not specifically provided for elsewhere for supporting or gripping using temporarily an auxiliary support used to protect an active side of a device or wafer
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/10Bump connectors; Manufacturing methods related thereto
    • H01L2224/12Structure, shape, material or disposition of the bump connectors prior to the connecting process
    • H01L2224/13Structure, shape, material or disposition of the bump connectors prior to the connecting process of an individual bump connector
    • HELECTRICITY
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    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
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  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Treatment Of Semiconductor (AREA)
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  • Adhesive Tapes (AREA)
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  • Laminated Bodies (AREA)

Abstract

本發明提供一種可獲得優異之連接性之保護帶、及使用其之半導體裝置之製造方法。
本發明之保護帶依序具有接著劑層11、熱塑性樹脂層12、及基材膜層13,且於貼附保護帶之貼附溫度,接著劑層11之儲存剪切彈性模數與熱塑性樹脂層12之儲存剪切彈性模數之彈性模數比為0.01以下。藉此,凸塊上之樹脂殘留得到抑制,故而可獲得優異之連接性。

Description

保護帶、及使用其之半導體裝置之製造方法、以及半導體裝置
本發明係關於一種半導體裝置之製造中所使用之保護帶、及使用其之半導體裝置之製造方法。
先前,倒裝晶片構裝用之半導體製造程序之後續步驟係以如下方式進行。首先,於形成有複數個突起電極之晶圓之突起電極形成面貼合被稱為背面研磨帶之黏著片或黏著帶,並於該狀態下將突起電極形成面之相反面研削至特定厚度。研削結束後,將背面研磨帶剝離,將晶圓切晶(dicing)而製成單個半導體晶片。繼而,將半導體晶片倒裝晶片構裝於另一半導體晶片或基板上。又,使先供給型或後供給型之底膠硬化而對半導體晶片進行補強。
近年來,研究有使用積層有熱硬化性樹脂層與熱塑性樹脂層者作為背面研磨帶,於晶圓僅殘留熱硬化性樹脂層而將其他層去除之方法(例如參照專利文獻1)。
然而,關於上述背面研磨帶,於在晶圓僅殘留熱硬化性樹脂層而將其他層去除時,於凸塊上殘留樹脂,例如於回焊時,有阻礙焊接而降低連接性之情況。
[專利文獻1]日本特開2005-28734號公報
本發明係鑒於上述先前之實際情況而提出者,提供一種可獲得優異之連接性之保護帶、及使用其之半導體裝置之製造方法。
為了解決上述課題,本發明之保護帶之特徵在於:依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於貼附該保護帶之貼附溫度,上述接著劑層之儲存剪切彈性模數與上述熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下。
又,本發明之半導體裝置之製造方法之特徵在於具有:保護帶貼附步驟,其係於形成有突起電極之晶圓面貼附具有接著劑層之保護帶;研磨處理步驟,其係對上述保護帶貼附面之相反面進行研磨處理;及剝離步驟,其係殘留上述接著劑層而將上述保護帶剝離,將其他層去除;且上述保護帶依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於貼附該保護帶之貼附溫度,上述接著劑層之儲存剪切彈性模數與上述熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下。
又,本發明之半導體裝置之特徵在於:其係藉由上述半導體裝置之製造方法而獲得。
本發明係藉由使於貼附溫度之接著劑層之儲存剪切彈性模數與熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下,而於殘留接著劑層而將其他層去除時,凸塊上之樹脂殘留得到抑制,故而可獲得優異之連接性。
10‧‧‧保護帶
11‧‧‧接著劑層
12‧‧‧熱塑性樹脂層
13‧‧‧基材膜層
21‧‧‧晶圓
22‧‧‧突起電極
30‧‧‧黏著帶
31‧‧‧黏著劑層
32‧‧‧基材膜層
圖1係表示保護帶之概略之剖面圖。
圖2係表示保護帶貼附步驟之概略之剖面圖。
圖3係表示研磨步驟之概略之剖面圖。
圖4係表示黏著帶貼附步驟之概略之剖面圖。
圖5係表示保護帶剝離步驟之概略之剖面圖。
圖6係表示硬化步驟之概略之剖面圖。
圖7係表示切晶處理步驟之概略之剖面圖。
圖8係表示延伸步驟之概略之剖面圖。
圖9係表示拾取步驟之概略之剖面圖。
圖10係表示構裝步驟之概略之剖面圖。
以下,按照下述順序對於本發明之實施形態詳細地進行說明。
1.保護帶
2.半導體裝置之製造方法
3.實施例
<1.保護帶>
本實施形態之保護帶依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於貼附保護帶之貼附溫度,接著劑層之儲存剪切彈性模數與熱塑性樹脂 層之儲存剪切彈性模數之彈性模數比為0.01以下,較佳為0.00001以上且0.005以下。藉此,於殘留接著劑層而將其他層去除時,凸塊上之樹脂殘留得到抑制,故而可獲得優異之連接性。可認為其原因在於,接著劑層與熱塑性樹脂層相比,變形或流動極其良好,故而於貼附保護帶時,接著劑向凸塊上之附著得到抑制。
圖1係表示保護帶之概略之剖面圖。保護帶10係被稱為背面研磨帶(Back Grind Tape)者,且於研磨步驟中,保護晶圓免受刮傷、破裂、污染等。如圖1所示,保護帶10係將接著劑層11、熱塑性樹脂層12、及基材膜層13依序積層。
接著劑層11之於60℃之儲存剪切彈性模數較佳為1.0E+01 Pa以上且1.0E+05 Pa以下。若接著劑層11之儲存剪切彈性模數過小,則於貼附於晶圓時樹脂流動,若儲存剪切彈性模數過大,則無法使凸塊貫通。
又,接著劑層11之厚度為形成於晶圓之突起電極之高度之10%以上且80%以下,較佳為30%以上且60%以下。若接著劑層11之厚度過小,則無法獲得補強突起電極之效果,若厚度過大,則有突起電極未貫通之情況。
作為接著劑層11之樹脂組成,並無特別限定,例如可使用熱陰離子硬化型、熱陽離子硬化型、熱自由基硬化型等熱硬化型,光陽離子硬化型、光自由基硬化型等光硬化型,或將該等併用而大致同樣地使用之熱/光硬化型者。
此處,作為接著劑層11,對含有膜形成樹脂、環氧樹脂、硬化劑、及硬化助劑之熱硬化型之接著劑組成物進行說明。
作為膜形成樹脂,可使用苯氧基樹脂、環氧樹脂、改質環氧樹脂、胺酯樹脂(urethane resin)等各種樹脂。該等膜形成樹脂可單獨使用1種,亦可將2種以上組合而使用。該等中,就膜形成狀態、連接可靠性等觀點而言,可較佳地使用苯氧基樹脂。
作為環氧樹脂,例如可列舉:二環戊二烯型環氧樹脂、環氧丙醚型環氧樹脂、環氧丙胺型環氧樹脂、雙酚A型環氧樹脂、雙酚F型環氧樹脂、雙酚S型環氧樹脂、螺環型環氧樹脂、萘型環氧樹脂、聯苯型環氧樹脂、萜烯型環氧樹脂、四溴雙酚A型環氧樹脂、甲酚酚醛清漆型環氧樹脂、苯酚酚醛清漆型環氧樹脂、α-萘酚酚醛清漆型環氧樹脂、溴化苯酚酚醛清漆型環氧樹脂等。該等環氧樹脂可單獨使用1種,亦可將2種以上組合而使用。該等中,就高接著性、耐熱性之方面而言,可較佳地使用二環戊二烯型環氧樹脂。
作為硬化劑,例如可列舉:酚醛清漆型酚樹脂、脂肪族胺、芳香族胺、酸酐等,該等硬化劑可單獨使用1種,亦可將2種以上組合而使用。該等中,就硬化物之交聯密度之觀點而言,可較佳地使用酚醛清漆型酚樹脂。
作為硬化促進劑,可列舉:2-甲基咪唑、2-乙基咪唑、2-乙基-4-甲基咪唑等咪唑類,1,8-二氮雙環(5,4,0)十一烯-7鹽(DBU鹽)、2-(二甲胺基甲基)苯酚等三級胺類、三苯基膦等膦類、辛酸亞錫等金屬化合物等。
又,於接著劑組成物中,作為其他成分,亦可根據目的適當調配無機填料、矽烷偶合劑、丙烯酸橡膠等彈性體、碳黑等顏料。
作為熱塑性樹脂層12,可列舉:乙烯-乙酸乙烯酯共聚物 (EVA:Ethylene Vinyl Acetate)、聚乙烯、聚丙烯、聚醯胺、聚縮醛、聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯、氟樹脂、聚苯硫醚、聚苯乙烯、ABS樹脂、丙烯酸系樹脂、聚碳酸酯、聚胺酯、聚氯乙烯、聚苯醚等,該等可單獨使用1種,亦可併用2種以上。
又,熱塑性樹脂層12之於60℃之儲存剪切彈性模數較佳為1.0E+07 Pa以下。藉由使熱塑性樹脂層12之於60℃之儲存剪切彈性模數為1.0E+07 Pa以下,可提高接著劑層11對凸塊之埋入性。
作為基材膜層13,可使用聚對苯二甲酸乙二酯、聚乙烯、聚丙烯、聚酯等塑膠膜、或由紙、布、不織布等構成之多孔質基材。
再者,保護帶並不限於上述構成,亦可於各層之表面或鄰接之層間形成其他層。
根據此種保護帶,於向晶圓貼附時,可抑制接著劑向凸塊上之附著,故而可獲得優異之連接性。又,接著劑層以良好之狀態埋入凸塊間,故而可藉由接著劑層之硬化而對突起電極進行補強。
<2.半導體裝置之製造方法>
繼而,對使用上述保護帶之半導體裝置之製造方法進行說明。本實施形態之半導體裝置之製造方法具有:保護帶貼附步驟,其係於形成有突起電極之晶圓面貼附具有接著劑層之保護帶;研磨處理步驟,其係對保護帶貼附面之相反面進行研磨處理;及剝離步驟,其係殘留接著劑層而將保護帶剝離,將其他層去除;且保護帶依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於貼附保護帶之貼附溫度,接著劑層之儲存剪切彈性模數與上述熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下。此處, 使接著層硬化之硬化步驟只要於研磨處理步驟、黏著帶貼附步驟、或切晶處理步驟中之任一步驟前進行即可。
以下,對具體之半導體裝置之製造方法進行說明。作為具體例所示之半導體裝置之製造方法如下,即使用上述保護帶,且於黏著帶貼附步驟與切晶處理步驟之間進行硬化步驟。即,作為具體例所示之半導體裝置之製造方法具有:保護帶貼附步驟(A),其係貼附具有接著劑層之保護帶;研磨步驟(B);黏著帶貼附步驟(C);保護帶剝離步驟(D);硬化步驟(E),其係使接著劑層硬化;切晶處理步驟(F);延伸(expanded)步驟(G);拾取步驟(H);及構裝步驟(I)。
[(A)保護帶貼附步驟]
圖2係表示保護帶貼附步驟之概略之剖面圖。於保護帶貼附步驟中,於形成有突起電極22之晶圓21面貼附保護帶10。就減少空隙、提高晶圓密接性及防止晶圓研削後之翹曲之觀點而言,貼附保護帶10之貼附溫度為25℃以上且100℃以下,較佳為40℃以上且80℃以下。
晶圓21具有形成於矽等之半導體表面之積體電路、及被稱為凸塊之連接用之突起電極22。晶圓21之厚度並無特別限定,較佳為200μm以上且1000μm以下。
作為突起電極22,並無特別限定,例如可列舉:藉由焊料獲得之低熔點凸塊或高熔點凸塊、錫凸塊、銀-錫凸塊、銀-錫-銅凸塊、金凸塊、銅凸塊等。又,突起電極22之高度並無特別限制,較佳為10μm以上且200μm以下。
保護帶10係於使突起電極22之形成面與接著劑層11接觸 之狀態下進行貼合。保護帶10之接著劑層11之厚度為突起電極22之高度之10%以上且80%以下,故而突起電極22穿透接著劑層11而埋入至熱塑性樹脂層12。
[(B)研磨步驟]
圖3係表示研磨步驟之概略之剖面圖。於研磨步驟中,對保護帶10貼附面之相反面進行研磨處理。將貼附有保護帶10之晶圓21之相反面固定於研削裝置而進行研磨。研磨通常係進行至晶圓21之厚度成為50μm以上且600μm以下,但於本實施形態中,由於藉由接著劑層11而補強突起電極22,故而亦可研磨至50μm以下之厚度。
[(C)黏著帶貼附步驟]
圖4係表示黏著帶貼附步驟之概略之剖面圖。於黏著帶貼附步驟中,於研磨處理面貼附黏著帶30。黏著帶30係被稱為切晶帶(Dicing Tape)者,係於切晶步驟(F)中,用以保護、固定晶圓21,並保持至拾取步驟(H)之帶。
作為黏著帶30,並無特別限定,可使用公知者。通常,黏著帶30具有黏著劑層31、及基材膜層32。作為黏著劑層31,例如可列舉:聚乙烯系、丙烯酸系、橡膠系、胺酯系等之黏著劑。又,作為基材膜層32,可使用聚對苯二甲酸乙二酯、聚乙烯、聚丙烯、聚酯等塑膠膜、或由紙、布、不織布等構成之多孔質基材。又,作為黏著帶之貼附裝置及條件,並無特別限定,可使用公知之裝置及條件。
[(D)保護帶剝離步驟]
圖5係表示保護帶剝離步驟之概略之剖面圖。於保護帶剝離步驟中, 殘留接著劑層11而將保護帶10剝離,將其他層去除。即,將熱塑性樹脂層12及基材膜層13去除,於晶圓21上僅殘留接著劑層11。
[(E)硬化步驟]
圖6係表示硬化步驟之概略之剖面圖。於硬化步驟中,使接著劑層11硬化。作為硬化方法及硬化條件,可使用使熱硬化型接著劑硬化之公知之方法。
[(F)切晶處理步驟]
圖7係表示切晶處理步驟之概略之剖面圖。於切晶處理步驟中,對貼附有黏著帶30之晶圓21進行切晶處理而獲得單片之半導體晶片。作為切晶方法,並無特別限定,例如可使用利用晶圓切割機對晶圓21進行切削而將其切出等公知之方法。
[(G)延伸步驟]
圖8係表示延伸步驟之概略之剖面圖。於延伸步驟中,例如將貼合有經分割之複數個半導體晶片之黏著帶30於放射方向上延伸,而擴大每個半導體晶片之間隔。
[(H)拾取步驟]
圖9係表示拾取步驟之概略之剖面圖。於拾取步驟中,自黏著帶30之下表面將貼合固定於黏著帶30上之半導體晶片頂出並剝離,利用筒夾(collet)吸附該經剝離之半導體晶片。所拾取之半導體晶片被收納於晶片托盤,或搬送至倒裝晶片接合機之晶片搭載噴嘴。
[(I)構裝步驟]
圖10係表示構裝步驟之概略之剖面圖。於構裝步驟中,例如使用NCF (Non Conductive Film,非導電性膜)等電路連接材料將半導體晶片與電路基板進行連接。作為電路基板,並無特別限定,可使用聚醯亞胺基板、環氧玻璃基板等塑膠基板、陶瓷基板等。又,作為連接方法,可利用使用加熱接合機、回焊爐等之公知之方法。
根據此種半導體裝置之製造方法,於切晶處理步驟前使形成有突起電極之晶圓面之接著劑層硬化而對突起電極進行補強,故而於切晶、拾取、構裝等後續步驟中,可減少突起電極之破損。又,可良率良好地獲得具有優異之連接可靠性之半導體裝置。又,所獲得之半導體裝置具備:半導體晶片,其具有突起電極與形成於突起電極形成面之接著劑層;及電路基板,其具有與突起電極對向之電極,於半導體晶片之突起電極形成面形成有接著劑層11,故而可獲得優異之連接可靠性。
[實施例]
<3.實施例>
以下,對本發明之實施例進行說明。於本實施例中,製作積層有接著劑層及熱塑性樹脂層之保護帶。使用保護帶,依序進行保護帶貼附步驟(A)、研磨步驟(B)、黏著帶貼附步驟(C)、保護帶剝離步驟(D)、硬化步驟(E)、切晶處理步驟(F)、延伸步驟(G)、拾取步驟(H)、及構裝步驟(I),製作半導體裝置。並且,對半導體裝置之焊接性、及凸塊埋入性進行評價。再者,本發明並不限定於該等實施例。
[保護帶之製作]
如表1所示,製作接著劑層A1~A3。接著劑層A1係調配膜形成樹脂13.0質量份、環氧樹脂54.8質量份、硬化劑32.4質量份、及硬化助劑0.3 質量份而製備接著劑組成物,使用棒式塗佈機將其以乾燥後之厚度成為30μm之方式塗佈於經剝離處理之PET(Polyethylene terephthalate),利用烘箱使其乾燥而製作。接著劑層A1之於60℃之儲存剪切彈性模數為3.3E+03 Pa。
接著劑層A2係調配膜形成樹脂13.0質量份、環氧樹脂54.8質量份、硬化劑32.4質量份、硬化助劑0.3質量份、及填料25.0質量份而製備接著劑組成物,使用棒式塗佈機將其以乾燥後之厚度成為30μm之方式塗佈於經剝離處理之PET(Polyethylene terephthalate),利用烘箱使其乾燥而製作。接著劑層A2之於60℃之儲存剪切彈性模數為3.4E+04 Pa。
接著劑層A3係調配膜形成樹脂2.0質量份、環氧樹脂54.8質量份、硬化劑32.4質量份、及硬化助劑0.3質量份而製備接著劑組成物,使用棒式塗佈機將其以乾燥後之厚度成為30μm之方式塗佈於經剝離處理之PET(Polyethylene terephthalate),利用烘箱使其乾燥而製作。接著劑層A3之於60℃之儲存剪切彈性模數為3.6E+01 Pa。
膜形成樹脂:苯氧基樹脂(PKHH,Union Carbide(股))
環氧樹脂:二環戊二烯型環氧樹脂(HP7200H,DIC(股))
硬化劑:酚醛清漆型酚樹脂(TD-2093,DIC(股))
硬化助劑:2-乙基-4-甲基咪唑(2E4MZ)
填料:二氧化矽(Aerosil RY200,日本Aerosil(股))
又,以如下之方式製作熱塑性樹脂層B1~B3。將下述熱塑性樹脂以乾燥後之厚度成為500μm之方式於PET基材(厚度75μm)擠出熔融成形。熱塑性樹脂層B1之於60℃之儲存剪切彈性模數為1.2E+06 Pa,熱塑性樹脂層B2之於60℃之儲存剪切彈性模數為1.4E+05 Pa,熱塑性樹脂層B3之於60℃之儲存剪切彈性模數為1.7E+07 Pa。
熱塑性樹脂層B1:丙烯-烯烴共聚物樹脂(Notio PN0040,三井化學(股))
熱塑性樹脂層B2:α-烯烴共聚物(TAFMER P0275,三井化學(股))
熱塑性樹脂層B3:直鏈狀低密度聚乙烯(NOVATEC UF943,Japan Polyethylene(股))
然後,分別選擇接著劑層A1~A3與熱塑性樹脂層B1~B3進行層疊,製作保護帶。
於60℃之儲存剪切彈性模數G'係使用黏彈性測定裝置而算 出。測定條件係設定為測定溫度區域0~120℃、升溫速度5℃/分鐘、振動數1Hz、應變0.1%。
[半導體裝置之製作]
將保護帶之接著劑層面貼附於形成有焊料凸塊(=250μm,H=200μm,間距=250μm)之晶圓(尺寸:5cm×5cm×725μmt),使用真空式 貼合機於60℃之溫度進行層疊。
繼而,利用DISCO製造之DFG8560進行背面研磨處理直至使晶圓之厚度成為300μm。其後,殘留接著劑層而將保護帶剝離,將其他層去除,將晶圓上之接著劑層於130℃之烘箱內硬化2小時。然後,將晶圓切晶,單片化為晶片後,利用貼片機搭載於基板(附助焊劑之金電極)上,利用最大260℃之回焊爐將晶片與基板焊接。
[焊接性之評價]
於基板之金電極上塗佈助焊劑,並在最大260℃之回焊溫度進行焊接時,測量焊料潤濕擴散之面積,將凸塊尺寸之面積設為100%而算出。
[凸塊埋入性之評價]
利用顯微鏡(100倍)進行觀察,將於接著劑層之凸塊間無空隙者評價為「○」,將有空隙者評價為「△」。再者,凸塊埋入性之評價係僅對焊料連接性之評價為80%以上之樣品進行。
<實施例1>
如表2所示般將接著劑層A1與熱塑性樹脂層B1進行層疊,製作接著劑層與熱塑性樹脂層之彈性模數比為2.8E-03之保護帶。使用該保護帶,利用上述方法製作半導體裝置,結果焊接性為105%,凸塊埋入性之評價為○。
<實施例2>
如表2所示般將接著劑層A2與熱塑性樹脂層B3進行層疊,製作接著劑層與熱塑性樹脂層之彈性模數比為2.1E-03之保護帶。使用該保護帶,利用上述方法製作半導體裝置,結果焊接性之評價為85%,凸塊埋入性之 評價為△。
<實施例3>
如表2所示般將接著劑層A3與熱塑性樹脂層B1進行層疊,製作接著劑層與熱塑性樹脂層之彈性模數比為3.0E-05之保護帶。使用該保護帶,利用上述方法製作半導體裝置,結果焊接性之評價為110%,凸塊埋入性之評價為○。
<比較例1>
如表2所示般將接著劑層A1與熱塑性樹脂層B2進行層疊,製作接著劑層與熱塑性樹脂層之彈性模數比為2.4E-02之保護帶。使用該保護帶,利用上述方法製作半導體裝置,結果焊接性之評價為12%。
<比較例2>
如表2所示般將接著劑層A2與熱塑性樹脂層B1進行層疊,製作接著劑層與熱塑性樹脂層之彈性模數比為3.0E-02之保護帶。使用該保護帶,利用上述方法製作半導體裝置,結果焊接性之評價為3%。
如比較例1、2般,於60℃之彈性模數比(A/B)超過0.01之情形時,未能獲得良好之焊接性。另一方面,如實施例1~3般,於60 ℃之彈性模數比(A/B)為0.01以下之情形時,獲得了良好之焊接性。又,可知藉由如實施例1、3般將熱塑性樹脂層之於60℃之儲存剪切彈性模數設為1.0E+07 Pa以下,可獲得良好之凸塊之埋入性。

Claims (8)

  1. 一種保護帶,其依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於60℃之該接著劑層之儲存剪切彈性模數與該熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下,且該儲存剪切彈性模數係於測定溫度區域0~120℃、升溫速度5℃/分鐘、振動數1Hz、應變0.1%之條件下進行測定者。
  2. 如申請專利範圍第1項之保護帶,其中,該熱塑性樹脂層之於60℃之儲存剪切彈性模數為1.0E+07Pa以下。
  3. 如申請專利範圍第1項之保護帶,其中,該接著劑層之於60℃之儲存剪切彈性模數為1.0E+01Pa以上且1.0E+05Pa以下。
  4. 如申請專利範圍第2項之保護帶,其中,該接著劑層之於60℃之儲存剪切彈性模數為1.0E+01Pa以上且1.0E+05Pa以下。
  5. 如申請專利範圍第1至4項中任一項之保護帶,其係於形成有突起電極之晶圓面貼附該接著劑層者,且該接著劑層之厚度為該突起電極之高度之10%以上且80%以下。
  6. 一種半導體裝置之製造方法,其具有:保護帶貼附步驟,其係於形成有突起電極之晶圓面貼附具有接著劑層之保護帶;研磨處理步驟,其係對該保護帶貼附面之相反面進行研磨處理;及剝離步驟,其係殘留該接著劑層而將該保護帶剝離,將其他層去除;且該保護帶依序具有接著劑層、熱塑性樹脂層、及基材膜層,且於60℃之該接著劑層之儲存剪切彈性模數與該熱塑性樹脂層之儲存剪切彈性模數之彈性模數比為0.01以下,且該儲存剪切彈性模數係於測定溫度區域0~120℃、升溫速度5℃/分鐘、振動數1Hz、應變0.1%之條件下進行測定者。
  7. 如申請專利範圍第6項之半導體裝置之製造方法,其具有:黏著帶貼附步驟,其係於研磨處理面貼附黏著帶;切晶處理步驟,其係對貼附有該黏著帶之晶圓進行切晶處理而獲得單片半導體晶片;及熱硬化步驟,其係使該接著劑層熱硬化;且該熱硬化步驟係於該切晶處理步驟前進行。
  8. 一種半導體裝置,其係藉由申請專利範圍第6或7項之半導體裝置之製造方法而獲得。
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