TWI662633B - Bumping process and flip chip structure - Google Patents
Bumping process and flip chip structure Download PDFInfo
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- TWI662633B TWI662633B TW106122272A TW106122272A TWI662633B TW I662633 B TWI662633 B TW I662633B TW 106122272 A TW106122272 A TW 106122272A TW 106122272 A TW106122272 A TW 106122272A TW I662633 B TWI662633 B TW I662633B
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- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means 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
- H01L24/10—Bump connectors ; Manufacturing methods related thereto
- H01L24/11—Manufacturing methods
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- H01L24/10—Bump connectors ; Manufacturing methods related thereto
- H01L24/12—Structure, shape, material or disposition of the bump connectors prior to the connecting process
- H01L24/14—Structure, shape, material or disposition of the bump connectors prior to the connecting process of a plurality of bump connectors
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- H01L2224/10—Bump connectors; Manufacturing methods related thereto
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- H01L2224/114—Manufacturing methods by blanket deposition of the material of the bump connector
- H01L2224/1146—Plating
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- H01L2224/10—Bump connectors; Manufacturing methods related thereto
- H01L2224/12—Structure, shape, material or disposition of the bump connectors prior to the connecting process
- H01L2224/12105—Bump connectors formed on an encapsulation of the semiconductor or solid-state body, e.g. bumps on chip-scale packages
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- H01L2224/01—Means 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
- H01L2224/10—Bump connectors; Manufacturing methods related thereto
- H01L2224/12—Structure, shape, material or disposition of the bump connectors prior to the connecting process
- H01L2224/14—Structure, shape, material or disposition of the bump connectors prior to the connecting process of a plurality of bump connectors
- H01L2224/1401—Structure
- H01L2224/1403—Bump connectors having different sizes, e.g. different diameters, heights or widths
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- H—ELECTRICITY
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- H01L2224/01—Means 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
- H01L2224/10—Bump connectors; Manufacturing methods related thereto
- H01L2224/12—Structure, shape, material or disposition of the bump connectors prior to the connecting process
- H01L2224/14—Structure, shape, material or disposition of the bump connectors prior to the connecting process of a plurality of bump connectors
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Abstract
本發明提供凸塊製程與覆晶結構。凸塊製程包括下列步驟。於晶圓上形成光阻層。晶圓的每一晶片區具有多個接墊,且包括第一區與第二區。圖案化光阻層,以於每一晶片區中形成暴露出多個接墊的多個第一開口,且於至少一晶片區中形成至少一第二開口。第一區具有多個第一開口。經圖案化的光阻層在第一區中所佔的面積比例小於其在第二區中所佔的面積比例。第二開口位於第一區與第二區之間。各第一開口的面積小於第二開口的面積。於多個第一開口中形成多個導電凸塊,且於第二開口中形成擬凸塊。移除經圖案化的光阻層。The invention provides a bump process and a flip-chip structure. The bump process includes the following steps. A photoresist layer is formed on the wafer. Each wafer region of the wafer has a plurality of pads, and includes a first region and a second region. The photoresist layer is patterned to form a plurality of first openings exposing a plurality of pads in each wafer region, and to form at least one second opening in at least one wafer region. The first region has a plurality of first openings. The area ratio of the patterned photoresist layer in the first region is smaller than the area ratio of the patterned photoresist layer in the second region. The second opening is located between the first region and the second region. The area of each first opening is smaller than the area of the second opening. A plurality of conductive bumps are formed in the plurality of first openings, and a pseudo bump is formed in the second opening. The patterned photoresist layer is removed.
Description
本發明是有關於一種凸塊製程與一種覆晶結構,且特別是有關於一種包括形成擬凸塊的凸塊製程與一種具有擬凸塊的覆晶結構。The invention relates to a bump manufacturing process and a flip-chip structure, and in particular to a bump manufacturing process including forming a pseudo-bump and a flip-chip structure having a pseudo-bump.
在晶圓上形成凸塊的製程包括在晶圓上形成圖案化光阻層,其具有暴露出晶圓表面上的多個接墊的多個開口。接著,在多個開口中形成多個導電凸塊。最後,單分晶圓以形成多個覆晶結構。The process of forming bumps on a wafer includes forming a patterned photoresist layer on the wafer, which has a plurality of openings exposing a plurality of pads on the wafer surface. Next, a plurality of conductive bumps are formed in the plurality of openings. Finally, the wafer is singulated to form a plurality of flip-chip structures.
在上述製程中,包括烘烤固化圖案化光阻層及形成導電凸塊的過程皆會放出熱能,而使光阻層受熱膨脹。而晶圓中的各晶片區上的圖案化光阻層可依據開口所佔的面積比例分為開口密集區與開口稀疏區。圖案化光阻層在開口稀疏區所佔的面積比例較大,故其在開口稀疏區中的膨脹量也較大。如此一來,會擠壓開口密集區中的圖案化光阻層,使得該區中的開口扭曲並產生形變,也可能造成開口密集區中的圖案化光阻層剝離而與下方結構之間產生空隙。如此一來,開口密集區中相鄰的開口之間的間距可能縮短,且形成導電凸塊的鍍液可能滲入空隙中而造成滲鍍,進而導致相鄰的導電凸塊之間的間距縮短或相鄰的導電凸塊短路的問題。In the above process, the processes including baking and curing the patterned photoresist layer and forming the conductive bumps will all release heat energy, and cause the photoresist layer to expand due to heat. The patterned photoresist layer on each wafer area in the wafer can be divided into dense opening areas and sparse opening areas according to the area ratio occupied by the openings. The area ratio of the patterned photoresist layer in the sparse area of the opening is relatively large, so its expansion amount in the sparse area of the opening is also large. In this way, the patterned photoresist layer in the dense area of the opening will be squeezed, so that the opening in the dense area will be distorted and deformed, and the patterned photoresist layer in the dense area of the opening may be peeled off and generated between the structure and the underlying structure. Void. In this way, the distance between adjacent openings in the dense area of the opening may be shortened, and the plating solution forming the conductive bumps may penetrate into the gap and cause the plating, thereby causing the distance between adjacent conductive bumps to be shortened or The problem of short circuit between adjacent conductive bumps.
本發明提供一種凸塊製程及一種覆晶結構,可避免相鄰的導電凸塊之間的間距縮短或相鄰的導電凸塊短路的問題。The invention provides a bump manufacturing process and a flip-chip structure, which can avoid the problems of shortening the distance between adjacent conductive bumps or shorting the adjacent conductive bumps.
本發明的凸塊製程包括下列步驟。於晶圓上形成光阻層。晶圓包括多個晶片區。每一晶片區具有多個接墊,且每一晶片區包括彼此相鄰的至少一第一區與至少一第二區。圖案化光阻層,以於每一晶片區中形成暴露出多個接墊的多個第一開口,以及於至少一晶片區中形成至少一第二開口。每一晶片區的至少一第一區中具有沿著一第一方向排列的多個第一開口。經圖案化的光阻層在至少一第一區中所佔的面積比例小於經圖案化的光阻層在相鄰的至少一第二區中所佔的面積比例。至少一第二開口位於至少一第一區與至少一第二區之間,且相鄰於至少一第一區中沿著第一方向排列的多個第一開口而延伸。至少一第一區中的每一第一開口的面積小於至少一第二開口的面積。於多個第一開口中形成多個導電凸塊,且於至少一第二開口中形成至少一擬凸塊。移除經圖案化的光阻層。The bump process of the present invention includes the following steps. A photoresist layer is formed on the wafer. The wafer includes a plurality of wafer regions. Each wafer region has a plurality of pads, and each wafer region includes at least a first region and at least a second region adjacent to each other. The photoresist layer is patterned to form a plurality of first openings exposing a plurality of pads in each wafer region, and to form at least one second opening in at least one wafer region. At least one first region of each wafer region has a plurality of first openings arranged along a first direction. The area ratio of the patterned photoresist layer in the at least one first region is smaller than the area ratio of the patterned photoresist layer in the adjacent at least one second region. The at least one second opening is located between the at least one first area and the at least one second area, and extends adjacent to the plurality of first openings arranged along the first direction in the at least one first area. The area of each first opening in the at least one first region is smaller than the area of at least one second opening. A plurality of conductive bumps are formed in the plurality of first openings, and at least one pseudo-bump is formed in the at least one second opening. The patterned photoresist layer is removed.
本發明的覆晶結構包括晶片、多個導電凸塊以及至少一擬凸塊。晶片具有多個接墊。晶片上包括彼此相鄰的至少一第一區與至少一第二區。多個導電凸塊設置於多個接墊上。至少一第一區中具有沿著一第一方向排列的多個導電凸塊。未被多個導電凸塊覆蓋的區域在至少一第一區中所佔的面積比例小於在相鄰的至少一第二區中所佔的面積比例。至少一擬凸塊設置於晶片上,且位於至少一第一區與至少一第二區之間。至少一擬凸塊相鄰於至少一第一區中沿著第一方向排列的多個導電凸塊而延伸。至少一第一區中的每一導電凸塊的面積小於至少一擬凸塊的面積。The flip-chip structure of the present invention includes a wafer, a plurality of conductive bumps, and at least one pseudo-bump. The wafer has a plurality of pads. The wafer includes at least a first region and at least a second region adjacent to each other. The plurality of conductive bumps are disposed on the plurality of pads. The at least one first region has a plurality of conductive bumps arranged along a first direction. The area ratio occupied by the regions not covered by the plurality of conductive bumps in at least one first region is smaller than the area ratio occupied by adjacent at least one second region. At least one pseudo bump is disposed on the wafer and is located between at least a first region and at least a second region. The at least one pseudo-bump extends adjacent to the plurality of conductive bumps arranged along the first direction in the at least one first region. An area of each of the conductive bumps in the at least one first region is smaller than an area of at least one quasi-bump.
基於上述,藉由在光阻層所佔面積比例較小的第一區與光阻層所佔面積比例較大的第二區之間設置第二開口,可使第二開口在光阻層烘烤固化及形成導電凸塊與擬凸塊的過程中吸收光阻層受熱而產生自第二區朝向第一區的推擠。且由於第二開口的面積大於各第一開口的面積,故第二開口可承受較大的形變量。因此,可減少在第一區中的第一開口受到推擠而產生的形變,也可降低第一區中的光阻層剝離而與下方結構之間產生空隙的機率。如此一來,可避免鍍液滲鍍導致相鄰的導電凸塊之間的間距縮短或相鄰的導電凸塊短路的問題。Based on the above, by providing a second opening between the first area having a smaller area ratio of the photoresist layer and the second area having a larger area ratio of the photoresist layer, the second opening can be dried in the photoresist layer. During the curing process and the formation of the conductive bumps and pseudo-bumps, the absorption of the photoresist layer is heated, and the pushing from the second region toward the first region occurs. And because the area of the second opening is larger than the area of each first opening, the second opening can withstand a larger amount of deformation. Therefore, the deformation of the first opening in the first region due to being pushed can be reduced, and the probability that the photoresist layer in the first region is peeled off to generate a gap with the underlying structure can be reduced. In this way, the problems of shortening the distance between adjacent conductive bumps or short-circuiting the adjacent conductive bumps caused by the plating solution plating can be avoided.
為讓本發明的上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。In order to make the above features and advantages of the present invention more comprehensible, embodiments are hereinafter described in detail with reference to the accompanying drawings.
圖1A至圖1D是依照本發明的一實施例的一種形成覆晶結構的凸塊製程的立體示意圖。圖1E是圖1D的覆晶結構的上視示意圖。本實施例的凸塊製程包括下列步驟。FIG. 1A to FIG. 1D are schematic perspective views of a bump forming process for forming a flip-chip structure according to an embodiment of the present invention. FIG. 1E is a schematic top view of the flip-chip structure of FIG. 1D. The bump manufacturing process of this embodiment includes the following steps.
請參照圖1A,晶圓W包括多個晶片區C,每一晶片區C具有多個接墊P。詳細而言,晶圓W內的多層金屬導線結構匯合至最上層而於晶圓W的表面形成多個接墊P。一般而言,晶圓W上會以鈍化層(圖未繪示)覆蓋,鈍化層具有多個開孔暴露出接墊P。此外,晶圓W例如是半導體晶圓或絕緣體上覆矽(silicon on insulator;SOI)晶圓。半導體晶圓的材料可包括矽、鍺、砷化鎵、碳化矽、砷化銦、磷化銦或其他半導體材料。請同時參照圖1B,每一晶片區C包括彼此相鄰的第一區102與第二區104。特別來說,多個接墊P位於第一區102中。第二區104中可不具有接墊P,或第二區104中的接墊P的數量小於第一區102中的接墊P的數量。以簡潔起見,圖1A至圖1D僅繪示多個晶片區C中的一者。在本實施例中,晶片區C包括多個第一區102以及一第二區104。在其他實施例中,每一晶片區C亦可具有單數個第一區102以及多個第二區104,本發明並不以第一區102及第二區104的數量為限。在本實施例中,可選擇性地在晶圓W上形成晶種層100。晶種層100的材料可包括金屬、合金或金屬化合物。舉例而言,金屬可包括金、銀或銅。形成晶種層100的方法可包括物理氣相沉積(physical vapor deposition;PVD)法,例如是濺鍍(Sputtering)。Referring to FIG. 1A, the wafer W includes a plurality of wafer regions C, and each wafer region C has a plurality of pads P. In detail, the multilayer metal wire structure in the wafer W is merged to the uppermost layer to form a plurality of pads P on the surface of the wafer W. Generally, the wafer W is covered with a passivation layer (not shown), and the passivation layer has a plurality of openings to expose the pads P. In addition, the wafer W is, for example, a semiconductor wafer or a silicon on insulator (SOI) wafer. The material of the semiconductor wafer may include silicon, germanium, gallium arsenide, silicon carbide, indium arsenide, indium phosphide, or other semiconductor materials. Referring to FIG. 1B at the same time, each chip region C includes a first region 102 and a second region 104 adjacent to each other. In particular, a plurality of pads P are located in the first region 102. The second region 104 may not have pads P, or the number of pads P in the second region 104 is smaller than the number of pads P in the first region 102. For brevity, only one of the plurality of wafer regions C is shown in FIGS. 1A to 1D. In this embodiment, the wafer region C includes a plurality of first regions 102 and a second region 104. In other embodiments, each chip region C may have a single number of first regions 102 and a plurality of second regions 104. The present invention is not limited to the number of the first regions 102 and the second regions 104. In this embodiment, the seed layer 100 can be selectively formed on the wafer W. The material of the seed layer 100 may include a metal, an alloy, or a metal compound. For example, the metal may include gold, silver, or copper. The method for forming the seed layer 100 may include a physical vapor deposition (PVD) method, such as sputtering.
接著,於晶圓W上形成光阻層106。隨後圖案化光阻層106,以於每一晶片區C中形成多個第一開口108,且於多個晶片區C中的至少一者中形成至少一第二開口110。多個第一開口108分別暴露出多個接墊P。圖案化光阻層106的方法例如是使用包括曝光、顯影等步驟的光微影製程。需注意的是,本文所述的“第一開口108暴露出接墊P”所代表的意思為第一開口108是暴露出接墊P所在的位置,更詳細而言,第一開口108在晶圓W上的正投影與接墊P在晶圓W上的正投影重疊。在本實施例中,第一開口108是暴露出接墊P上的晶種層100。此外,晶片區C的第一區102中具有沿著第一方向D1排列的多個第一開口108。經圖案化的光阻層106a在第一區102中所佔的面積比例小於其在相鄰的第二區104中所佔的面積比例。換言之,經圖案化的光阻層106a在第一區102中單位面積上所佔的面積小於其在第二區104中單位面積上所佔的面積。詳細而言,在本實施例中,第二區104中不具有第一開口108,而第一區102中則具有密集排列的第一開口108。因此,以0.1 x 0.1mm2 的單位面積來看,經圖案化的光阻層106a在第二區104中單位面積上所佔的面積即為0.1 x 0.1mm2 ,而其在第一區102中單位面積上所佔的面積則是0.1 x 0.1mm2 扣除第一開口108的面積後所剩的面積。Next, a photoresist layer 106 is formed on the wafer W. The photoresist layer 106 is then patterned to form a plurality of first openings 108 in each wafer region C, and at least one second opening 110 is formed in at least one of the plurality of wafer regions C. The plurality of first openings 108 respectively expose a plurality of pads P. A method of patterning the photoresist layer 106 is, for example, a photolithography process using steps including exposure, development, and the like. It should be noted that the “first opening 108 exposes the pad P” described herein means that the first opening 108 is the position where the pad P is exposed. More specifically, the first opening 108 is in the crystal. The orthographic projection on the circle W and the orthographic projection of the pad P on the wafer W overlap. In this embodiment, the first opening 108 is to expose the seed layer 100 on the pad P. In addition, the first region 102 of the wafer region C has a plurality of first openings 108 arranged along the first direction D1. The area ratio of the patterned photoresist layer 106 a in the first region 102 is smaller than the area ratio of the patterned photo resist layer 106 a in the adjacent second region 104. In other words, the area of the patterned photoresist layer 106 a on the unit area in the first region 102 is smaller than the area on the unit area in the second region 104. In detail, in this embodiment, the second region 104 does not have the first openings 108, and the first region 102 has the densely arranged first openings 108. Therefore, 0.1 x 0.1mm 2 per unit area of view, the patterned photoresist layer 106a on the second area 104 occupied by the unit area is the area of 0.1 x 0.1mm 2, in which the first region 102 and The area occupied by the medium unit area is 0.1 x 0.1 mm 2 after subtracting the area of the first opening 108.
第二開口110位於第一區102與第二區104之間。第二開口110相鄰於第一區102中沿著第一方向D1排列的多個第一開口108而延伸。此外,第一區102中的每一第一開口108的面積小於第二開口110的面積。在本實施例中,第一區102包含第一區102a與第一區102b,分別鄰近晶片區C的兩個相對長邊。第二區104位於第一區102a與第一區102b之間,第二開口110a位於第一區102a與第二區104之間,第二開口110b位於第一區102b與第二區104之間。第二開口110a與第二開口110b分別相鄰於第一區102a與第一區102b中沿著第一方向D1排列的多個第一開口108而延伸。在本實施例中,第二開口110a與第二開口110b可分別具有一些間隔G1與間隔G2,使第二開口110a與第二開口110b分別形成間斷的多條線段。藉由間隔G1與間隔G2分別斷開連續的第二開口110a與第二開口110b,可避免形成過長的第二開口110。過長的第二開口110會使第二開口110與相鄰的第一開口108之間的經圖案化的光阻層106a的長度與寬度差異過大,猶如形成一連續的長光阻,由於長光阻的膨脹效應較大,極易導致該處的經圖案化的光阻層106a變形或產生中央塌陷的問題。除此之外,間隔G1與間隔G2的設置位置可呈錯位排列,也就是間隔G1與間隔G2在垂直晶片區C長邊方向的投影不會重疊。當間隔G1與間隔G2位置相互對應時,經圖案化的光阻層106a在間隔G1、第二區104及間隔G2形成了垂直晶片區C長邊方向的長光阻。因此,使間隔G1與間隔G2錯位排列可避免產生膨脹效應較大的長光阻,進而降低經圖案化的光阻層106a於該處產生變形的機率。The second opening 110 is located between the first region 102 and the second region 104. The second opening 110 extends adjacent to the plurality of first openings 108 arranged in the first region 102 along the first direction D1. In addition, an area of each of the first openings 108 in the first region 102 is smaller than an area of the second openings 110. In this embodiment, the first region 102 includes a first region 102a and a first region 102b, which are respectively adjacent to two relatively long sides of the wafer region C. The second region 104 is located between the first region 102a and the first region 102b, the second opening 110a is located between the first region 102a and the second region 104, and the second opening 110b is located between the first region 102b and the second region 104 . The second opening 110a and the second opening 110b extend adjacent to the first openings 108 arranged in the first region 102a and the first region 102b along the first direction D1, respectively. In this embodiment, the second opening 110a and the second opening 110b may have some intervals G1 and G2, respectively, so that the second opening 110a and the second opening 110b respectively form intermittent multiple line segments. By disconnecting the continuous second openings 110a and the second openings 110b respectively at the intervals G1 and G2, it is possible to avoid the formation of the excessively long second openings 110. The excessively long second opening 110 may cause the patterned photoresist layer 106a between the second opening 110 and the adjacent first opening 108 to have a large difference in length and width, as if forming a continuous long photoresist. The expansion effect of the photoresist is large, and it is easy to cause the patterned photoresist layer 106a to deform or generate a central collapse problem. In addition, the positions of the interval G1 and the interval G2 may be arranged in an offset manner, that is, the projections of the interval G1 and the interval G2 in the longitudinal direction of the vertical wafer region C will not overlap. When the positions of the interval G1 and the interval G2 correspond to each other, the patterned photoresist layer 106a forms a long photoresistor in the direction of the long side of the wafer region C in the interval G1, the second region 104, and the interval G2. Therefore, displacing the gap G1 and the gap G2 can avoid the generation of a long photoresist with a large swelling effect, thereby reducing the probability of the patterned photoresist layer 106a being deformed there.
請參照圖1C,於多個第一開口108中形成多個導電凸塊112,且在第二開口110中形成擬凸塊114。之後,移除經圖案化的光阻層106a。在一些實施例中,可同時形成導電凸塊112與擬凸塊114。換言之,導電凸塊112的材料及形成方法可分別與擬凸塊114的材料及形成方法相同。舉例而言,導電凸塊112與擬凸塊114的材料可包括金屬、合金或金屬化合物。金屬可包括金、銀或銅。此外,導電凸塊112與擬凸塊114的形成方法可包括電解電鍍法、化學電鍍法等。在其他實施例中,可在不同的步驟中形成導電凸塊112與擬凸塊114。換言之,導電凸塊112的材料及形成方法可分別相異於與擬凸塊114的材料及形成方法。Referring to FIG. 1C, a plurality of conductive bumps 112 are formed in the plurality of first openings 108, and a pseudo bump 114 is formed in the second opening 110. After that, the patterned photoresist layer 106a is removed. In some embodiments, the conductive bump 112 and the pseudo-bump 114 may be formed at the same time. In other words, the material and the formation method of the conductive bump 112 may be the same as the material and the formation method of the pseudo bump 114, respectively. For example, the materials of the conductive bumps 112 and the pseudo-bumps 114 may include metals, alloys, or metal compounds. The metal may include gold, silver or copper. In addition, a method for forming the conductive bumps 112 and the pseudo-bumps 114 may include an electrolytic plating method, a chemical plating method, and the like. In other embodiments, the conductive bumps 112 and the pseudo-bumps 114 may be formed in different steps. In other words, the materials and forming methods of the conductive bumps 112 may be different from those of the pseudo bumps 114 and the forming methods, respectively.
然而,在烘烤固化經圖案化的光阻層106a及形成導電凸塊112與擬凸塊114的過程中所產生的熱能,會使經圖案化的光阻層106a受熱膨脹。由於經圖案化的光阻層106a在第二區104中所佔的面積比例大於其在第一區102中所佔的面積比例,故第二區104中經圖案化的光阻層106a的膨脹量大於其在第一區102中的膨脹量。如此一來,第二區104中經圖案化的光阻層106a受熱後會由第二區104朝向第一區102推擠。然而,第一區102中密集排列的第一開口108使得經圖案化的光阻層106a於第一區102中的結構猶如許多薄薄的光阻牆,當經圖案化的光阻層106a受熱後由第二區104朝向第一區102推擠時,這些光阻牆極易產生扭曲變形,進而導致光阻牆剝離而與下方的晶種層100之間產生空隙。藉由在第一區102與第二區104之間設置第二開口110,在經圖案化的光阻層106a受熱膨脹時,第二開口110可吸收經圖案化的光阻層106a從第二區104而來的推擠,避免第一區102中的光阻牆被推擠而扭曲變形。此外,由於第二開口110的面積大於第一開口108的面積,故第二開口110可承受較大的形變量。因此,可減少第一開口108在經圖案化的光阻層106a受熱膨脹時受到推擠而產生的形變。再者,由於在第一區102中經圖案化的光阻層106a的形變量降低,故晶種層100與經圖案化的光阻層106a之間因膨脹速率不同而產生的相對位移量也可降低。因此,可避免在晶種層100與經圖案化的光阻層106a之間產生空隙。如此一來,可避免鍍液滲鍍導致導電凸塊112延伸到此空隙中,而造成相鄰的導電凸塊112之間的間距縮短或相鄰的導電凸塊112短路的問題。此外,由於在形成導電凸塊112與擬凸塊114的過程中,第二開口110吸收第二區104中經圖案化的光阻層106a的推擠,故可能使第二開口110的輪廓受到扭曲,或使第二開口110呈現非平滑的輪廓。因此,後續形成在第二開口110中的擬凸塊114可具有扭曲或非平滑的輪廓(並未繪示)。However, the thermal energy generated during the curing of the patterned photoresist layer 106a and the formation of the conductive bumps 112 and the pseudo-bumps 114 will cause the patterned photoresist layer 106a to expand thermally. Since the area proportion of the patterned photoresist layer 106a in the second region 104 is larger than the area proportion thereof in the first region 102, the expansion of the patterned photoresist layer 106a in the second region 104 The amount is greater than the amount of its expansion in the first zone 102. In this way, the patterned photoresist layer 106 a in the second region 104 is pushed from the second region 104 toward the first region 102 after being heated. However, the densely arranged first openings 108 in the first region 102 make the structure of the patterned photoresist layer 106a in the first region 102 like many thin photoresist walls. When the patterned photoresist layer 106a is heated, When pushed from the second region 104 toward the first region 102 later, these photoresist walls are extremely prone to distortion, which in turn causes the photoresist wall to peel off and create a gap with the seed layer 100 below. By providing a second opening 110 between the first region 102 and the second region 104, when the patterned photoresist layer 106a is thermally expanded, the second opening 110 can absorb the patterned photoresist layer 106a from the second The pushing from the area 104 prevents the photoresist wall in the first area 102 from being pushed and distorted. In addition, since the area of the second opening 110 is larger than the area of the first opening 108, the second opening 110 can withstand a large amount of deformation. Therefore, deformation of the first opening 108 caused by being pushed when the patterned photoresist layer 106a is thermally expanded can be reduced. Furthermore, since the amount of deformation of the patterned photoresist layer 106a in the first region 102 is reduced, the amount of relative displacement between the seed layer 100 and the patterned photoresist layer 106a due to different expansion rates is also reduced. Can be lowered. Therefore, a gap can be prevented from being generated between the seed layer 100 and the patterned photoresist layer 106a. In this way, the problems that the conductive bumps 112 extend into the gap caused by the plating solution penetration can be avoided, and the problems of shortening the distance between adjacent conductive bumps 112 or shorting the adjacent conductive bumps 112 can be avoided. In addition, since the second opening 110 absorbs the pushing of the patterned photoresist layer 106a in the second region 104 during the formation of the conductive bump 112 and the pseudo-bump 114, the outline of the second opening 110 may be affected. Distort, or make the second opening 110 non-smooth outline. Therefore, the quasi-bump 114 formed in the second opening 110 may have a distorted or non-smooth outline (not shown).
請參照圖1D,在一些實施例中,更可在移除經圖案化的光阻層106a之後移除被導電凸塊112與擬凸塊114所暴露出的晶種層100。移除部分晶種層100的方法可包括等向性蝕刻,例如是濕式蝕刻。至此,已形成本實施例的覆晶結構10。Referring to FIG. 1D, in some embodiments, the seed layer 100 exposed by the conductive bumps 112 and the pseudo bumps 114 can be removed after the patterned photoresist layer 106 a is removed. A method of removing a portion of the seed layer 100 may include isotropic etching, such as wet etching. So far, the flip-chip structure 10 of this embodiment has been formed.
接下來,以圖1D及圖1E來說明本實施例的覆晶結構10。覆晶結構10包括晶片(晶片區C)、多個導電凸塊112以及至少一擬凸塊114。Next, FIG. 1D and FIG. 1E are used to explain the flip-chip structure 10 of this embodiment. The flip-chip structure 10 includes a wafer (wafer region C), a plurality of conductive bumps 112, and at least one pseudo bump 114.
晶片(晶片區C)具有多個接墊P(請參考圖1A),且包括彼此相鄰的至少一第一區102與至少一第二區104。多個導電凸塊112設置於多個接墊P上。至少一第一區102中具有沿著第一方向D1排列的多個導電凸塊112。未被多個導電凸塊112覆蓋的區域在至少一第一區102中所佔的面積比例小於在至少一第二區104中所佔的面積比例。換言之,未被多個導電凸塊112覆蓋的區域在第一區102中單位面積上所佔的面積小於其在第二區104中單位面積上所佔的面積。至少一擬凸塊114設置於晶片(晶片區C)上,且位於至少一第一區102與至少一第二區104之間。至少一擬凸塊114相鄰於至少一第一區102中沿著第一方向D1排列的多個導電凸塊112而延伸。至少一第一區102中的每一導電凸塊112的面積小於至少一擬凸塊114的面積。在本實施例中,相鄰於至少一第一區102中沿著第一方向D1排列的多個導電凸塊112而延伸的至少一擬凸塊114為間斷的多條線段。The wafer (wafer region C) has a plurality of pads P (refer to FIG. 1A), and includes at least one first region 102 and at least one second region 104 adjacent to each other. The plurality of conductive bumps 112 are disposed on the plurality of pads P. The at least one first region 102 has a plurality of conductive bumps 112 arranged along the first direction D1. The area ratio occupied by the regions not covered by the plurality of conductive bumps 112 in the at least one first region 102 is smaller than the area ratio occupied in the at least one second region 104. In other words, the area that is not covered by the plurality of conductive bumps 112 in the first area 102 per unit area is smaller than the area that it occupies in the second area 104. At least one pseudo bump 114 is disposed on the wafer (wafer region C) and is located between at least one first region 102 and at least one second region 104. The at least one pseudo bump 114 extends adjacent to the plurality of conductive bumps 112 arranged along the first direction D1 in the at least one first region 102. The area of each of the conductive bumps 112 in the at least one first region 102 is smaller than the area of the at least one quasi-bump 114. In this embodiment, at least one quasi-bump 114 extending adjacent to the plurality of conductive bumps 112 arranged along the first direction D1 in the at least one first region 102 is a plurality of intermittent line segments.
基於上述,在經圖案化的光阻層106a受熱膨脹時,第二開口110可吸收經圖案化的光阻層106a從至少一第二區104而來的推擠,進而避免至少一第一區102中的經圖案化的光阻層106a被推擠而扭曲變形。此外,由於第二開口110的面積大於各個第一開口108的面積,故第二開口110可承受較大的形變量。因此,可減少第一開口108受到推擠而產生的形變。如此一來,可避免相鄰的導電凸塊112間距縮短或是相鄰的導電凸塊112短路的問題。此外,更可降低晶種層100與經圖案化的光阻層106a之間因膨脹速率不同而產生的相對位移量,而避免在晶種層100與經圖案化的光阻層106a之間產生空隙。如此一來,可避免鍍液滲鍍導致導電凸塊112延伸到此空隙中,而造成相鄰的導電凸塊112之間的間距縮短或相鄰的導電凸塊112短路的問題。Based on the above, when the patterned photoresist layer 106a is thermally expanded, the second opening 110 can absorb the pushing of the patterned photoresist layer 106a from at least one second region 104, thereby avoiding at least one first region The patterned photoresist layer 106a in 102 is pushed and distorted. In addition, since the area of the second openings 110 is larger than the area of each of the first openings 108, the second openings 110 can withstand a large amount of deformation. Therefore, the deformation caused by the first opening 108 being pushed can be reduced. In this way, the problems of shortening the distance between adjacent conductive bumps 112 or shorting the adjacent conductive bumps 112 can be avoided. In addition, the amount of relative displacement between the seed layer 100 and the patterned photoresist layer 106a due to different expansion rates can be reduced, and generation between the seed layer 100 and the patterned photoresist layer 106a can be avoided. Void. In this way, the problems that the conductive bumps 112 extend into the gap caused by the plating solution penetration can be avoided, and the problems of shortening the distance between adjacent conductive bumps 112 or shorting the adjacent conductive bumps 112 can be avoided.
圖2A至圖2B是依照本發明的另一實施例的一種形成覆晶結構的凸塊製程的立體示意圖。圖2C是圖2B的覆晶結構的上視示意圖。本實施例的覆晶結構20以及形成覆晶結構20的凸塊製程分別與圖1A至圖1E所示的覆晶結構10及形成覆晶結構10的凸塊製程相似。以下僅就差異處進行說明,相同或相似處則不再贅述。此外,相同的元件標號代表相同或相似的構件。FIG. 2A to FIG. 2B are three-dimensional schematic diagrams of a bump manufacturing process for forming a flip-chip structure according to another embodiment of the present invention. FIG. 2C is a schematic top view of the flip-chip structure of FIG. 2B. The flip-chip structure 20 and the bump forming process of the present embodiment are similar to the flip-chip structure 10 and the bump-forming process of forming the flip-chip structure 10 shown in FIGS. 1A to 1E, respectively. Only the differences will be described below, and the same or similar points will not be described again. In addition, the same element numbers represent the same or similar components.
請參照圖2A與圖2B,本實施例的第一區102可包括第一區102a、第一區102b、第一區102c以及第一區102d。第二區104可包括第二區104a、第二區104b、第二區104c以及第二區104d。以第一區102a為例,經圖案化的光阻層106a在第一區102a中形成沿著第一方向D1排列的多個第一開口108,此外,第一開口108更沿著第二方向D2排列成三排。而第一方向D1與第二方向D2間的夾角θ大於0度且小於等於90度。在本實施例中,第二區104a、第二區104b以及第二區104c分別相鄰於第一區102a的三側。經圖案化的光阻層106a在第二區104a中不形成第一開口108,而在第二區104b及第二區104c中則分別形成一些第一開口108。在第一區102a中、第二區104b及第二區104c中的第一開口108暴露出接墊P所在位置。然而,第二區104b及第二區104c中第一開口108的數量遠小於第一區102a中第一開口108的數量。更詳細而言,在形成第一開口108之後,經圖案化的光阻層106a在第一區102a中所佔的面積比例小於其在第二區104a、第二區104b或第二區104c中所佔的面積比例。換言之,經圖案化的光阻層106a在第一區102a中所佔的面積比例小於其在第二區104a、第二區104b或第二區104c中所佔的面積比例。對應地,第二開口110可包括第二開口110a、第二開口110b與第二開口110c。第二開口110a位於第一區102a與不具有第一開口108的第二區104a之間,且第二開口110b及第二開口110c分別位於第一區102a與具有一些第一開口108的第二區104b及第二區104c之間。第二開口110a相鄰於第一區102a中沿著第一方向D1排列的第一開口108而延伸,而第二開口110b及第二開口110c則相鄰於沿著第二方向D2排列的第一開口108而延伸。此外,在本實施例中,第一區102a與晶片(晶片區C)邊緣之間也可形成第二開口110a。換言之,兩個第二開口110a、第二開口110b及第二開口110c環繞第一區102a的四周。如此一來,可在多個方向上降低第一區102a中的經圖案化的光阻層106a受到從相鄰的第二區104中的經圖案化的光阻層106a而來的推擠,進而避免第一區102a中的經圖案化的光阻層106a扭曲變形。Referring to FIG. 2A and FIG. 2B, the first region 102 in this embodiment may include a first region 102a, a first region 102b, a first region 102c, and a first region 102d. The second region 104 may include a second region 104a, a second region 104b, a second region 104c, and a second region 104d. Taking the first region 102a as an example, the patterned photoresist layer 106a forms a plurality of first openings 108 arranged along the first direction D1 in the first region 102a. In addition, the first openings 108 are further along the second direction D2 is arranged in three rows. The angle θ between the first direction D1 and the second direction D2 is greater than 0 degrees and less than or equal to 90 degrees. In this embodiment, the second region 104a, the second region 104b, and the second region 104c are adjacent to three sides of the first region 102a, respectively. The patterned photoresist layer 106a does not form the first openings 108 in the second region 104a, and forms some first openings 108 in the second region 104b and the second region 104c, respectively. The first openings 108 in the first region 102a, the second region 104b, and the second region 104c expose the positions of the pads P. However, the number of the first openings 108 in the second region 104b and the second region 104c is much smaller than the number of the first openings 108 in the first region 102a. In more detail, after the first opening 108 is formed, the area ratio of the patterned photoresist layer 106a in the first region 102a is smaller than that in the second region 104a, the second region 104b, or the second region 104c. The proportion of area occupied. In other words, the area proportion of the patterned photoresist layer 106a in the first region 102a is smaller than the area proportion thereof in the second region 104a, the second region 104b, or the second region 104c. Correspondingly, the second opening 110 may include a second opening 110a, a second opening 110b, and a second opening 110c. The second opening 110a is located between the first area 102a and the second area 104a without the first opening 108, and the second opening 110b and the second opening 110c are located respectively in the first area 102a and the second area having some first openings 108 Between the region 104b and the second region 104c. The second opening 110a extends adjacent to the first opening 108 arranged in the first direction 102 along the first direction D1, and the second opening 110b and the second opening 110c are adjacent to the first opening arranged along the second direction D2 An opening 108 extends. In addition, in this embodiment, a second opening 110a may be formed between the first region 102a and the edge of the wafer (wafer region C). In other words, the two second openings 110a, 110b, and 110c surround the periphery of the first region 102a. In this way, the patterned photoresist layer 106a in the first region 102a can be reduced in multiple directions by being pushed from the patterned photoresist layer 106a in the adjacent second region 104. Furthermore, the patterned photoresist layer 106a in the first region 102a is prevented from being distorted.
繼續以第一區102a為例,後續所形成的擬凸塊114包括擬凸塊114a、擬凸塊114b與擬凸塊114c。擬凸塊114a形成於第二開口110a內,擬凸塊114b形成於第二開口110b內,且擬凸塊114c形成於第二開口110c內。相應地,擬凸塊114a、擬凸塊114b及擬凸塊114c環繞第一區102a的四周。如此一來,可在多個方向上降低第一區102a中相鄰的導電凸塊112之間的間距縮短或是相鄰的導電凸塊112短路的問題。Taking the first region 102a as an example, the pseudo-bumps 114 formed later include pseudo-bumps 114a, 114-b and 114c. A pseudo bump 114a is formed in the second opening 110a, a pseudo bump 114b is formed in the second opening 110b, and a pseudo bump 114c is formed in the second opening 110c. Accordingly, the pseudo-bumps 114a, 114b, and 114c surround the first region 102a. In this way, the problems of shortening the distance between adjacent conductive bumps 112 or shorting the adjacent conductive bumps 112 in the first region 102a can be reduced in multiple directions.
此外,第二開口110a在第一方向D1上的延伸長度可大於相鄰的多個第一開口108在相同方向上分布的長度。換言之,第二開口110a的端部可延伸超過第一區102a中沿著第一方向D1排列的多個第一開口108(的最外側一個)。相同地,第二開口110b或第二開口110c在第二方向D2上的延伸長度也可大於相鄰的多個第一開口108在相同方向上分布的長度。也就是說,第二開口110b或第二開口110c的端部也可延伸超過第一區102a中沿著第二方向D2排列的多個第一開口108(的最外側一個)。如此一來,擬凸塊114a在第一方向D1上的延伸長度可大於相鄰的多個導電凸塊112在相同方向上分布的長度。擬凸塊114b或擬凸塊114c在第二方向D2上的延伸長度可大於相鄰的多個導電凸塊112在相同方向上分布的長度。再者,第二開口110a可為間斷的多條線段,避免形成過長的第二開口110a。過長的第二開口110a會使第二開口110a與相鄰的第一開口108之間的經圖案化的光阻層106a的長度與寬度差異過大,即形成一連續的長光阻,長光阻的膨脹效應較大,因此易導致該處的經圖案化的光阻層106a變形或產生中央塌陷的問題。除此之外,第二開口110中的至少一者(例如是第二開口110b)可選擇性地與其相鄰的至少一第一開口108連接。對應地,後續所形成的擬凸塊114中的至少一者(例如是擬凸塊114b)可與其相鄰的至少一導電凸塊112連接。因此,第二開口110b與相鄰的第一開口108之間的經圖案化的光阻層106a藉由兩者間的連接區段而切分為兩段,同樣可避免該處形成膨脹效應較大的長光阻,進而降低經圖案化的光阻層106a變形或中央塌陷的問題發生。In addition, the extension length of the second opening 110a in the first direction D1 may be greater than the length of the adjacent first openings 108 distributed in the same direction. In other words, the end of the second opening 110a may extend beyond the plurality of first openings 108 (the outermost one) arranged in the first region 102a along the first direction D1. Similarly, the extension length of the second opening 110b or the second opening 110c in the second direction D2 may be greater than the length of the adjacent first openings 108 distributed in the same direction. That is, the end of the second opening 110b or the second opening 110c may also extend beyond the plurality of first openings 108 (the outermost one) arranged along the second direction D2 in the first region 102a. In this way, the extension length of the pseudo bump 114a in the first direction D1 may be greater than the length of the adjacent multiple conductive bumps 112 distributed in the same direction. The extension length of the pseudo-bump 114b or the pseudo-bump 114c in the second direction D2 may be greater than the length of the adjacent multiple conductive bumps 112 distributed in the same direction. Moreover, the second opening 110a may be a plurality of intermittent line segments, so as to avoid the formation of the excessively long second opening 110a. The excessively long second opening 110a will cause the patterned photoresist layer 106a between the second opening 110a and the adjacent first opening 108 to have a large difference in length and width, that is, a continuous long photoresistor will be formed. The expansion effect of the resist is large, so it is easy to cause the patterned photoresist layer 106a to be deformed or cause a central collapse problem. In addition, at least one of the second openings 110 (for example, the second opening 110b) may be selectively connected to at least one first opening 108 adjacent thereto. Correspondingly, at least one of the quasi-bumps 114 (for example, quasi-bump 114 b) formed subsequently may be connected to at least one conductive bump 112 adjacent to the quasi-bump 114 b. Therefore, the patterned photoresist layer 106a between the second opening 110b and the adjacent first opening 108 is divided into two sections by the connection section therebetween, which can also prevent the formation of an expansion effect there. Large long photoresist, which reduces the problem of deformation or central collapse of the patterned photoresist layer 106a.
綜上所述,藉由在光阻層所佔面積比例較小的第一區與光阻層所佔面積比例較大的第二區之間設置第二開口,可使第二開口在光阻層烘烤固化及形成導電凸塊與擬凸塊的過程中吸收光阻層受熱而產生自第二區朝向第一區的推擠。且由於第二開口的面積大於各第一開口的面積,故第二開口可承受較大的形變量。因此,可減少在第一區中的第一開口受到推擠而產生的形變,也可降低第一區中的光阻層剝離而與下方結構之間產生空隙的機率。如此一來,可避免鍍液滲鍍導致相鄰的導電凸塊之間的間距縮短或相鄰的導電凸塊短路的問題。In summary, by providing a second opening between the first area with a small area ratio of the photoresist layer and the second area with a large area ratio of the photoresist layer, the second opening can be made in the photoresist During the process of baking and curing the layer and forming the conductive bumps and pseudo-bumps, the absorption of the photoresist layer is heated, and the pushing from the second region toward the first region occurs. And because the area of the second opening is larger than the area of each first opening, the second opening can withstand a larger amount of deformation. Therefore, the deformation of the first opening in the first region due to being pushed can be reduced, and the probability that the photoresist layer in the first region is peeled off to generate a gap with the underlying structure can be reduced. In this way, the problems of shortening the distance between adjacent conductive bumps or short-circuiting the adjacent conductive bumps caused by the plating solution plating can be avoided.
雖然本發明已以實施例揭露如上,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,在不脫離本發明的精神和範圍內,當可作些許的更動與潤飾,故本發明的保護範圍當視後附的申請專利範圍所界定者為準。Although the present invention has been disclosed as above with the examples, it is not intended to limit the present invention. Any person with ordinary knowledge in the technical field can make some modifications and retouching without departing from the spirit and scope of the present invention. The protection scope of the present invention shall be determined by the scope of the attached patent application.
10、20‧‧‧覆晶結構10, 20‧‧‧ flip-chip structure
100‧‧‧晶種層100‧‧‧ seed layer
102、102a、102b、102c、102d‧‧‧第一區102, 102a, 102b, 102c, 102d ‧‧‧ District 1
104、104a、104b、104c、104d‧‧‧第二區104, 104a, 104b, 104c, 104d ‧‧‧ District 2
106‧‧‧光阻層106‧‧‧Photoresist layer
106a‧‧‧經圖案化的光阻層106a‧‧‧ patterned photoresist layer
108‧‧‧第一開口108‧‧‧ first opening
110、110a、110b、110c‧‧‧第二開口110, 110a, 110b, 110c‧‧‧Second opening
112‧‧‧導電凸塊112‧‧‧Conductive bump
114、114a、114b、114c‧‧‧擬凸塊114, 114a, 114b, 114c
C‧‧‧晶片區C‧‧‧Chip Area
D1‧‧‧第一方向D1‧‧‧ first direction
D2‧‧‧第二方向D2‧‧‧ Second direction
G1、G2‧‧‧間隔G1, G2‧‧‧ interval
P‧‧‧接墊P‧‧‧ pad
W‧‧‧晶圓W‧‧‧ Wafer
θ‧‧‧夾角θ‧‧‧ angle
圖1A至圖1D是依照本發明的一實施例的一種形成覆晶結構的凸塊製程的立體示意圖。 圖1E是圖1D的覆晶結構的上視示意圖。 圖2A至圖2B是依照本發明的另一實施例的一種形成覆晶結構的凸塊製程的立體示意圖。 圖2C是圖2B的覆晶結構的上視示意圖。FIG. 1A to FIG. 1D are schematic perspective views of a bump forming process for forming a flip-chip structure according to an embodiment of the present invention. FIG. 1E is a schematic top view of the flip-chip structure of FIG. 1D. FIG. 2A to FIG. 2B are three-dimensional schematic diagrams of a bump manufacturing process for forming a flip-chip structure according to another embodiment of the present invention. FIG. 2C is a schematic top view of the flip-chip structure of FIG. 2B.
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