TWI764194B - 接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體 - Google Patents

接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體

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TWI764194B
TWI764194B TW109123380A TW109123380A TWI764194B TW I764194 B TWI764194 B TW I764194B TW 109123380 A TW109123380 A TW 109123380A TW 109123380 A TW109123380 A TW 109123380A TW I764194 B TWI764194 B TW I764194B
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Taiwan
Prior art keywords
bonding
fine particles
layer
film
metal fine
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TW109123380A
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English (en)
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TW202111044A (zh
Inventor
新田納澤福
藤原英道
佐藤義浩
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日商古河電氣工業股份有限公司
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Publication of TW202111044A publication Critical patent/TW202111044A/zh
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    • H01L24/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
    • H01L24/28—Structure, shape, material or disposition of the layer connectors prior to the connecting process
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    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
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Abstract

本發明提供連接耐熱性充分且信賴性高，且無關於半導體元件之電極種類，與基板之接合良好，接合步驟簡易之接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體。 一種用以接合導體元件(2)與基板(40)之接合薄膜(13)，其特徵係具有將包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層(13a)，及具有觸黏性且層合於導電性接合層(13a)之觸黏層(13b)，觸黏層(13b)相對於導電性接合層(13a)內之金屬微粒子(P)，含有0.1~1.0質量%之金屬微粒子(M)，前述金屬微粒子(M)之熔點為250℃以下。

Description

接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體
本發明有關接合薄膜及晶圓加工用膠帶，尤其有關用以將半導體元件與電路基板或陶瓷基板等之基板連接之連接薄膜及具備其之晶圓加工用膠帶。
以往，半導體晶片與配線基板等之接著時使用薄膜狀接著劑(晶粒黏附薄膜)。進而，已開發出同時具有將半導體晶圓切斷分離(切晶)為各個晶片之際用以固定半導體晶圓之切晶膠帶、及用以將經切斷之半導體晶片接著於配線基板等之晶粒黏附薄膜(亦稱為晶粒黏合薄膜)的2種功能之切晶・黏合膠帶(例如參考專利文獻1)。
此等切晶・黏合膠帶使用於進行電力控制或供給等之半導體元件(所謂功率半導體元件)與電路基板、陶瓷基板及導線框架等之基板之連接時，有連接耐熱性不充分之問題。
因此，功率半導體元件與基板之連接一般使用焊料。作為此等焊料，主要使用於焊料粉末中添加助焊劑並設成適當黏度之乳狀焊料。然而，若使用助焊劑，則有污染半導體元件表面之可能性，而有必須進行洗淨步驟之問題。且，近幾年來，基於環境上之考量，要求使用不含鉛之無鉛焊料材料。作為可對應於功率半導體之發熱的無鉛焊料材料，有Au-Sn系焊料，但由於昂貴，故不實用。作為比Au-Sn系焊料便宜的焊料材料，有Sn-Ag-Cu系焊料，但有因熱履歷所致之金屬間化合物之成長關連到信賴性降低之問題。
作為不使用焊料之接合構件，有於熱硬化性樹脂中混合具有導電性之微細金屬粒子者成形為膜狀之向異性導電薄膜(Anisotropic Conductive Film：ACF)。然而，ACF為了獲得良好接著狀態，而含有一定比例以上之樹脂，故有金屬粒子間之接觸成為點接觸，無法期待充分之導熱，連接耐熱性不充分之問題點。且ACF由於有熱硬化性樹脂因高熱而劣化之顧慮，故不適於發熱量較大之功率半導體之連接。
作為其他不使用焊料之接合構件，最近有含金屬微粒子之糊膏(以下稱為金屬糊膏)(例如參考專利文獻2)。金屬糊膏係於金屬微粒子中，添加防止保存時或製造步驟中之金屬微粒子彼此凝縮之有機分散劑與於接合時與有機分散劑反應而去除有機分散劑之分散輔助物質，於其中混合溶劑等作成糊膏狀者。金屬微粒子係至少含有粒徑為1~500nm左右之極微細粒子者，表面為活性狀態。
使用金屬糊膏將半導體元件與基板接合時，藉由佈膠器或網版印刷於半導體元件及/或基板之接合面塗佈金屬糊膏，於150~300℃加熱特定時間(1分鐘~1小時左右)。藉此，使有機分散劑與分散輔助材反應而去除有機分散劑，溶劑亦同時揮發去除。有機分散劑或溶劑去除時，處於活性狀態之金屬微粒子彼此結合，成為該金屬成分之單體膜。
使用佈膠器或網版印刷將金屬糊膏塗佈於接合面之情況，必須調節溶劑等之量，某程度降低金屬糊膏之黏度。然而，黏度降低時，將金屬糊膏塗佈於接合面之際，會有金屬糊膏飛散，附著於半導體元件或基板之接合面以外之部分而污染半導體元件或基板之問題。
因此，提案有將金屬糊膏預先作成薄片狀之連接薄片(參考專利文獻3)。然而，如專利文獻3所記載般使用具有將金屬糊膏預先作成薄片狀之接合層之連接薄片使半導體元件與基板接合之情況，由於接合層本身不具有黏著性，故必須使用吸附治具等將接合層載置於基板上，於其上載置半導體元件，使接合層燒結。因此，有步驟變繁雜之問題。
為了解決上述課題，提案有改善了接合層之黏著性問題、接合步驟簡略化之晶圓加工膠帶(參考專利文獻4)。專利文獻4中記載之用以將半導體元件與基板接合之晶圓加工膠帶，其特徵為具有：具有基材薄膜與設於該基材薄膜上之黏著劑層之黏著薄膜、設於該黏著薄膜上之將包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層、與具有觸黏性且層合於該導電性接合層之觸黏層。 [先前技術文獻] [專利文獻]
[專利文獻1]日本特開2010-265453號公報 [專利文獻2]日本特開2006-352080號公報 [專利文獻3]日本特開2013-236090號公報 [專利文獻4]國際公開第2018/092671號
[發明欲解決之課題]
然而，上述專利文獻4中記載之晶圓加工膠帶，有因構成導電性接合層之金屬微粒子之種類而可接合之半導體元件之種類受限制之問題。例如使用銅微粒子作為金屬微粒子之情況，限定認為對銅電極或金電極之接合良好之導電性接合層與半導體元件之電極種類，使用銀微粒子作為金屬微粒子之情況，認為對銀電極或金電極之接合良好之導電性接合層與半導體元件之電極種類受到限定。
因此，本發明之目的係提供連接耐熱性充分且信賴性高，且無關於半導體元件之電極種類，與基板之接合良好，接合步驟簡易之接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體。
[用以解決課題之手段]
為了解決以上課題，本發明之接合薄膜係用以接合半導體元件與基板之接合薄膜，其特徵係具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層，及具有觸黏性且層合於前述導電性接合層之觸黏層，前述觸黏層相對於前述導電性接合層內之前述金屬微粒子(P)，含有0.1~1.0質量%的金屬微粒子(M)，前述金屬微粒子(M)之熔點為250℃以下。
上述接合薄膜較佳係前述金屬微粒子(P)之平均一次粒徑為10~500nm。
又，上述接合薄膜較佳係前述導電性糊膏含有有機溶劑(S)。
又，上述接合薄膜較佳係前述金屬微粒子(P)含有銅或銀。
又，上述接合薄膜較佳係前述導電性糊膏含有有機黏合劑(R)。
又，上述接合薄膜較佳係前述觸黏層係由選自聚甘油、甘油脂肪酸酯、聚甘油脂肪酸酯、膦類、磷酸酯類、硫化物類、二硫化物類、三硫化物類及亞碸類中之1種或2種以上所成。
又，上述接合薄膜較佳係前述金屬微粒子(M)之平均一次粒徑亦為1~3μm。
又，上述接合薄膜較佳係前述金屬微粒子(M)含有錫。
又，上述接合薄膜較佳係前述有機溶劑(S)含有由於常壓下之沸點為100℃以上且分子中具有1或2個以上羥基之醇及/或多元醇所成之有機溶劑(SC)。
又，上述接合薄膜較佳係前述有機黏合劑(R)係選自由纖維素樹脂系黏合劑、乙酸酯樹脂系黏合劑、丙烯酸樹脂系黏合劑、胺基甲酸酯樹脂系黏合劑、聚乙烯吡咯啶酮樹脂系黏合劑、聚醯胺樹脂系黏合劑、縮丁醛樹脂系黏合劑及萜烯系黏合劑中之1種或2種以上。
又，為了解決上述課題，本發明之晶圓加工用膠帶之特徵係具有：具有基材薄膜與設於該基材薄膜上之黏著劑層之黏著薄膜，及上述任一者之接合薄膜，於前述黏著劑層上設有前述接合薄膜之導電性接合層。
又，為了解決上述課題，本發明之接合體之製造方法之特徵係具有下述步驟：將具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層與具有觸黏性且包含金屬微粒子(M)、層合於前述導電性接合層之觸黏層之接合薄膜，配置於半導體元件與基板之間並加熱，使前述觸黏層熱分解，使前述金屬微粒子(M)熔融，與前述半導體元件之電極反應後，藉由使前述導電性接合層之前述金屬微粒子(P)燒結，而接合前述半導體元件與前述基板的接合步驟。
又，為了解決上述課題，本發明之半導體與基板之接合體係於基板上具有由金屬多孔質體所成之導電連接構件，於其上具有半導體元件之半導體與基板之接合體，其特徵為使用上述任一者之接合薄膜予以接合，前述金屬多孔質體係上述接合薄膜中所含之金屬微粒子(P)之燒結體，於前述金屬多孔質體與前述半導體元件之電極之界面，形成上述接合薄膜中所含之金屬微粒子(M)與前述電極之合金相或金屬化合物相。
上述半導體與基板之接合體較佳係前述金屬多孔質體之空隙率為1~6體積%，平均空孔徑為10~60nm。
又，為了解決上述課題，本發明之貼合體係貼合有下述之貼合體：具有基材薄膜與設於該基材薄膜上之黏著劑層之黏著薄膜、用以將半導體元件與基板接合之接合薄膜、及半導體晶圓，其特徵係前述接合薄膜具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層與具有觸黏性且層合於前述導電性接合層之觸黏層，前述導電性接合層貼合於前述黏著劑層，前述半導體晶圓貼合於前述觸黏層，前述觸黏層可熱分解，且相對於前述導電性接合層內之前述金屬微粒子(P)，金屬微粒子(M)含有0.1~1.0質量%，藉由接合時之加熱，前述觸黏層被熱分解，金屬微粒子(M)熔融與前述半導體元件之電極反應後，藉由將前述導電性接合層之前述金屬微粒子(P)燒結，而將前述半導體元件與前述基板接合。
依據本發明，可提供連接耐熱性充分且信賴性高，且無關於半導體元件之電極種類，與基板之接合良 好，接合步驟簡易之接合薄膜、晶圓加工用膠帶、接合體之製造方法、接合體及貼合體。
以下，基於圖式說明本發明之實施形態之接著薄膜及晶圓加工用膠帶。基於圖1至圖5說明本發明之一實施形態之晶圓加工用膠帶。圖1係顯示一實施形態之晶圓加工用膠帶10之剖面圖。圖2係顯示於晶圓加工用膠帶10上貼合半導體晶圓1之狀態的圖。且，圖3係用以說明半導體裝置之製造步驟之切晶步驟之圖，圖4係說明擴展步驟之圖，圖5係說明拾取步驟之圖。圖6係示意性顯示使用本發明之實施形態之晶圓加工用膠帶製造之半導體裝置之剖面圖。
如圖1所示，本發明一實施形態之晶圓加工用膠帶10具有由基材薄膜12a與設於其上之黏著劑層12b所成之黏著薄膜12，及層合於該黏著薄膜12上之接合薄膜13。接合薄膜13具有將包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層13a，及具有觸黏性且層合於導電性接合層13a之觸黏層13b，於黏著劑層12b上設置導電性接合層13a。晶圓加工用膠帶10係使用於將半導體晶圓1切斷為半導體元件2(亦稱為晶片或半導體晶片)之切晶步驟，與將經切斷之半導體元件2接合於電路基板、陶瓷基板及導線框架等之基板40(參照圖6)之晶粒黏合步驟之兩步驟中。關於切晶步驟參考圖3將於後述。
又，黏著劑層12b可由一層黏著劑層構成，亦可由兩層以上之黏著劑層層合而成者所構成。又，圖1中，顯示為了保護接合薄膜13，而於晶圓加工用膠帶10上設置脫模薄膜11之狀態。作為脫模薄膜11可使用習知者。
黏著薄膜12及接合薄膜13亦可配合使用步驟或裝置預先形成為特定形狀。
以下針對本實施形態之晶圓加工用膠帶10之各構成要素詳細說明。
(接合薄膜) 接合薄膜13係作為於貼合半導體晶圓1並切晶後，將經單片化之半導體元件2拾取之際，自黏著薄膜12剝離並貼附於半導體元件2並拾取，並將半導體元件2固定於基板40之際的接合材使用者。而且，接合薄膜13具有於拾取步驟中，以附著於經單片化之半導體元件2之狀態，可自黏著薄膜12剝離之黏著性及剝離性，進而，具有將半導體元件2與基板40接合之充分接合信賴性者。關於拾取步驟將參考圖5於後述。
接合薄膜13具有將包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層13a，及具有觸黏性且層合於導電性接合層13a之觸黏層13b。 又，本發明中所謂觸黏性意指接著性，具體意指可將導電性接合層13a保持於半導體晶圓1或半導體元件2的接著性。
[導電性接合層] 導電性糊膏除了金屬微粒子(P)以外，較佳包含有機分散介質(D)。
作為導電性糊膏中所含之金屬微粒子(P)(亦稱為「導電性接合層內金屬微粒子」)，可使用選自由銅、鎂、鋁、鋅、鎵、鈦、錳、鍺、銀、金、鎳、鉑及鈀所成之金屬元素群之1種微粒子、選自前述金屬元素群之2種以上混合成之微粒子、由選自前述金屬元素群之2種以上元素之合金所成之微粒子、選自前述金屬元素群之1種微粒子或選自前述金屬元素群之2種以上混合成之微粒子與由選自前述金屬元素群之2種以上元素之合金所成之微粒子混合而成之微粒子、該等之氧化物或該等之氫氧化物等。
考慮導電性、加熱處理之際的燒結性時，金屬微粒子(P)較佳使用(i)銅微粒子(P1)，或(ii)由銅微粒子(P1) 90~100質量%與選自鎂、鋁、鋅、鎵、鈦、錳及鍺之1種或2種以上之第二金屬微粒子(P2) 10~0質量%所成之金屬微粒子。前述銅微粒子(P1)係相對導電性較高之金屬，另一方面，金屬微粒子(P2)係相對熔點較低之金屬。於銅微粒子(P1)中併用第二金屬微粒子(P2)時，較佳金屬微粒子(P2)於金屬微粒子(P)中與銅微粒子(P1)形成合金，或前述金屬微粒子(P2)於金屬微粒子(P)中於銅微粒子(P1)表面形成被覆層。藉由併用前述銅微粒子(P1)及金屬微粒子(P2)，可降低加熱處理溫度，或可使金屬微粒子間之鍵結更容易。
金屬微粒子(P)之加熱處理前之平均一次粒徑較佳為10~500nm，更佳為30~300nm，又更佳為100~150nm。金屬微粒子(P)之平均一次粒徑未達10nm時，有難以藉由加熱處理(燒結)遍及燒結體全體形成均質粒徑與空孔之虞，有熱循環特性降低，並且接合強度亦降低之情況。另一方面，該平均一次粒徑超過500nm時，構成燒結體之金屬微粒子及空孔徑接近微米尺寸，反而使熱循環特性降低。加熱處理前之金屬微粒子(P)之平均一次粒徑可藉由掃描型電子顯微鏡(SEM)測定其直徑。例如二次元形狀為略圓形狀之情況測定其圓直徑，為略橢圓形狀之情況測定其橢圓之短徑，為略正方形狀之情況測定其正方形之邊長，為略長方形狀之情況測定該長方形之短邊長。「平均一次粒徑」係將隨機選擇之10~20個複數粒子之粒徑以上述顯微鏡觀察並測量，藉由算出其平均值而求出。
作為前述金屬微粒子(P)之製造方法並未特別限定，可使用例如濕式化學還原法、霧化法、鍍敷法、電漿CVD法、MOCVD法等之方法。
平均一次粒徑10~500nm之金屬微粒子(P)之製造方法具體可採用日本特開2008-231564號公報中揭示之方法。採用該公報中揭示之製造方法時，可容易獲得平均一次粒徑為10~500nm之金屬微粒子(P)，且該公報中揭示之金屬微粒子之製造方法中，於金屬離子還原反應結束後藉由於還原反應水溶液中添加凝集劑並離心分離等而回收之反應液中之雜質經去除之金屬微粒子中添加有機分散介質(D)並混練，可製造本發明之導電性糊膏。
為了於導電性糊膏中均一分散金屬微粒子(P)，重要的是選擇分散性、加熱處理之際的燒結性優異之特定有機分散介質(D)。有機分散介質(D)可發揮將金屬微粒子(P)分散於導電性糊膏中，調節導電性糊膏之黏度，維持薄膜形狀，且加熱處理之際以液狀及氣體狀作為還原劑之功能。有機分散介質(D)至少含有有機溶劑(S)，進而較佳含有有機黏合劑(R)。
有機溶劑(S)較佳含有由於常壓下之沸點為100℃以上且分子中具有1或2個以上羥基之醇及/或多元醇所成之有機溶劑(SC)。進而有機溶劑(S)較佳選自(i)有機溶劑(S1)及(ii)有機溶劑(S2)中之1種，該有機溶劑(S1)至少含有具有醯胺基之有機溶劑(SA)5~90體積%、常壓下沸點為20~100℃之低沸點有機溶劑(SB)5~45體積%及常壓下沸點為100℃以上且由分子中具有1或2個以上羥基之醇及/或多元醇而成之有機溶劑(SC)5~90體積%，該有機溶劑(S2)至少含有具有醯胺基之有機溶劑(SA)5~95體積%及常壓下沸點為100℃以上且由分子中具有1或2個以上羥基之醇及/或多元醇而成之有機溶劑(SC)5~95體積%。
調配上述以外之其他有機溶劑成分之情況，可使用四氫呋喃、二甘醇二甲醚、碳酸伸乙酯、碳酸伸丙酯、環丁碸、二甲基亞碸等之極性有機溶劑。
有機溶劑(S1)係至少含有具有醯胺基之有機溶劑(SA)5~90體積%、常壓下沸點為20~100℃之低沸點有機溶劑(SB)5~45體積%及常壓下沸點為100℃以上且由分子中具有1或2個以上羥基之醇及/或多元醇而成之有機溶劑(SC)5~90體積%的有機溶劑。於有機溶劑(S1)中含有5~90體積%之有機溶劑(SA)，可提高導電性糊膏中之分散性與保存安定性，進而將前述接合面上之導電性接合層進行加熱處理形成燒結體之際，具有提高接合面之密著性之作用。於有機溶劑(S1)中含有5~45體積%之有機溶劑(SB)，可使導電性糊膏中溶劑分子間之相互作用降低，具有提高所分散之金屬微粒子(P)對於有機溶劑(S1)之親和性之作用。於有機溶劑(S1)中含有5~90體積%之有機溶劑 (SC)，可實現導電性糊膏中之分散性與分散性之更長期安定化。又，於混合有機溶劑中存在有機溶劑(SC)時，將其導電性接合層配置於接合面進行加熱處理時，燒結體之均一性提高，且有機溶劑(SC)具有之氧化被膜之還原促進效果亦發揮作用，可獲得導電性較高之接合構件。所謂「有機溶劑(S1)至少含有有機溶劑(SA)5~90體積%、有機溶劑(SB)5~45體積%及有機溶劑(SC)5~90體積%之有機溶劑」意指有機溶劑(S1)係由有機溶劑(SA)、有機溶劑(SB)及有機溶劑(SC)以前述調配比例調配成100體積%，或亦可於前述調配比例之範圍內，在不損及本發明效果之範圍進而調配其他有機溶劑成分，但該情況下，由有機溶劑(SA)、有機溶劑(SB)及有機溶劑(SC)所成之成分較佳含有90體積%以上，更佳為95體積%以上。前述調配比例較佳為有機溶劑(SA)5~70體積%、有機溶劑(SB)5~30體積%及有機溶劑(SC)10~90體積%
有機溶劑(S2)係至少含有具有醯胺基之有機溶劑(SA)5~95體積%及常壓下沸點為100℃以上且由分子中具有1或2個以上羥基之醇及/或多元醇而成之有機溶劑(SC)5~95體積%之有機溶劑。於有機溶劑(S2)中含有5~95體積%之有機溶劑(SA)，可提高該混合有機溶劑中之分散性與保存安定性，進而於將導電性糊膏進行加熱處理形成金屬多孔質體之際具有提高接合面之密著性之作用。於有機溶劑(S2)中含有5~95體積%之有機溶劑(SC)，可更提高導電性糊膏中之分散性。且於有機溶劑(S2)中存在有機溶劑(SA)及有機溶劑(SC)時，將導電性接合層配置於接合面上後進行加熱處理時，即使以比較低的加熱處理溫度亦可進行燒結。所謂「有機溶劑(S2)至少含有有機溶劑(SA) 5~95體積%及有機溶劑(SC) 5~95體積%之有機溶劑」意指有機溶劑(S2)係由有機溶劑(SA)及有機溶劑(SC)以前述調配比例調配成100體積%，或亦可於前述調配比例之範圍內，在不損及本發明效果之範圍進而調配其他有機溶劑成分，但該情況下，由有機溶劑(SA)及有機溶劑(SC)所成之成分較佳含有90體積%以上，更佳為95體積%以上。前述調配比例較佳為有機溶劑(SA) 5~80體積%及有機溶劑(SC) 10~90體積%
以下顯示上述有機溶劑(SC)、有機溶劑(SA)及有機溶劑(SB)之具體例。
有機溶劑(SC)係由於常壓下之沸點為100℃以上且分子中具有1或2個以上羥基之醇及/或多元醇所成，具有還原性之有機化合物。又，較佳為碳數為5以上之醇及碳數為2以上之多元醇，較佳於常溫為液狀、比介電率高者，例如較佳為10以上者。平均一次粒徑10~500nm之金屬微粒子(P)由於微粒子表面積較大，故必須考慮氧化的影響，但以下舉例之有機溶劑(SC)由於在加熱處理(燒結)之際為液狀或氣體狀而發揮作為還原劑之功能，故加熱處理之際抑制金屬微粒子(P)之氧化促進燒結。作為有機溶劑(SC)之具體例，可例示乙二醇、二乙二醇、1,2-丙二醇、1,3-丙二醇、1,2-丁二醇、1,3-丁二醇、1,4-丁二醇、2-丁烯-1,4-二醇、2,3-丁二醇、戊二醇、己二醇、辛二醇、甘油、1,1,1-三羥甲基乙烷、2-乙基-2-羥基甲基-1,3-丙二醇、1,2,6-己三醇、1,2,3-己三醇、1,2,4-丁三醇等。
又，作為有機溶劑(SC)之具體例，亦可使用蘇糖醇(D-Threitol)、赤蘚醇(Erythritol)、季戊四醇(Pentaerythritol)、戊糖醇(Pentitol)、己糖醇(Hexitol)等之糖醇類，戊糖醇中包含木醣醇(Xylitol)、核糖醇(Ribitol)、阿糖醇(Arabitol)。前述己糖醇中包含甘露醇(Mannitol)、山梨糖醇(Sorbitol)、半乳糖醇(Dulcitol)等。再者，亦可使用甘油醛(Glyceric aldehyde)、二氧基丙酮(Dioxy-acetone)、蘇糖(Threose)、赤蘚酮糖(Erythrulose)、赤蘚糖(Erythrose)、阿拉伯糖(Arabinose)、核糖(Ribose)、核酮糖(Ribulose)、木糖(Xylose)、木酮糖(Xylulose)、來蘇糖(Lyxose)、葡萄糖(Glucose)、果糖(Fructose)、甘露糖(Mannose)、艾杜糖(Idose)、山梨糖(Sorbose)、古洛糖(Gulose)、塔羅糖(Talose)、塔格糖(Tagatose)、半乳糖(Galactose)、阿洛糖(Allose)、阿卓糖(Altrose)、乳糖(Lactose)、異麥芽糖(Isomaltose)、葡萄-七碳糖(Gluco-heptose)、七碳糖(Heptose)、麥芽三糖(Maltotriose)、乳果糖(Lactulose)、海藻糖(Trehalose)等之糖類，但關於熔點較高者可混合其他熔點較低之有機溶劑(SC)。上述醇類中，更佳為分子中具有2個以上羥基之多元醇，特佳為乙二醇及甘油。
有機溶劑(SA)係具有醯胺基(-CONH-)之化合物，特佳為比介電率較高者。作為有機溶劑(A)，可舉例為N-甲基乙醯胺(在32℃為191.3)、N-甲基甲醯胺(在25℃為182.4)、N-甲基丙醯胺(在25℃為172.2)、甲醯胺(在20℃為111.0)、N,N-二甲基乙醯胺(在25℃為37.78)、1,3-二甲基-2-咪唑啶酮(在25℃為37.6)、N,N-二甲基甲醯胺(在25℃為36.7)、1-甲基-2-吡咯啶酮(在25℃為32.58)、六甲基磷酸醯胺(在20℃為29.0)、2-吡咯啶二酮、ε-己內醯胺、乙醯胺等，但亦可將該等混合使用。又，上述具有醯胺基之化合物名之後括弧中之數字表示各溶劑之測定溫度下之比介電率。該等中，於測定溫度20~32℃之比介電率為100以上之N-甲基乙醯胺、N-甲基甲醯胺、N-丙基甲醯胺及甲醯胺等可較佳地使用。又，測定溫度20~32℃範圍相當於糊膏化、薄膜化加工溫度，藉由使此時之比介電率為100以上，可抑制於薄膜化前之糊膏化步驟中之金屬微粒子(P)之凝集，使薄膜加工性提高，故成為重要之溫度範圍。又，如N-甲基乙醯胺(熔點：26~28℃)之在常溫為固體之情況下，可與其他溶劑混合於處理溫度作為液狀使用。
有機溶劑(SB)係於常壓下沸點為20~100℃範圍，較佳60.0~100℃範圍的有機化合物。常壓下沸點若未達20℃，則包含有機溶劑(SB)之粒子分散液於常溫保持之際，有機溶劑(SB)之成分揮發，有糊膏組成產生變化之虞。且常壓下沸點為100℃以下之情況，使因該溶劑添加所致之溶劑分子間之相互引力降低，可期待有效發揮更提高微粒子分散性之效果。進而，常壓下之沸點為60℃以上之情況，混練之際即使不冷卻亦可穩定地製造，故而較佳。作為有機溶劑(SB)，可例示以通式R1-O-R2(R1、R2分別獨立為烷基，碳原子數為1~4)表示之醚系化合物(SB1)、以通式R3-OH(R3為烷基且碳原子數為1~4)表示之醇(SB2)、以通式R4-C(=O)-R5(R4、R5分別獨立為烷基且碳原子數為1~2)表示之酮系化合物(SB3)，及以通式R6-(N-R7)-R8(R6、R7、R8分別獨立為烷基或氫原子，碳原子數為0~2)表示之胺系化合物(SB4)。
以下雖例示上述有機溶劑(SB)，但化合物名之後括弧內之數字表示常壓下之沸點。作為前述醚系化合物(SB1)，可例示二乙醚(35℃)、甲基丙基醚(31℃)、二丙醚(89℃)、二異丙醚(68℃)、甲基-第三丁基醚(55.3℃)、第三戊基甲基醚(85℃)、二乙烯基醚(28.5℃)、乙基乙烯基醚(36℃)、烯丙基醚(94℃)等。作為前述醇(SB2)可例示甲醇(64.7℃)、乙醇(78.0℃)、1-丙醇(97.15℃)、2-丙醇(82.4℃)、2-丁醇(100℃)、2-甲基2-丙醇(83℃)等。作為前述酮系化合物(SB3)，可例示丙酮(56.5℃)、甲基乙基酮(79.5℃)、二乙基酮(100℃)等。又作為前述胺系化合物(SB4)可例示三乙胺(89.7℃)、二乙胺(55.5℃)等。
有機黏合劑(R)發揮抑制導電性糊膏中之金屬微粒子(P)之凝集、調節導電性糊膏之黏度及維持導電連接構件前驅物之形狀之功能。前述有機黏合劑(R)較佳選自由纖維素樹脂系黏合劑、乙酸酯樹脂系黏合劑、丙烯酸樹脂系黏合劑、胺基甲酸酯樹脂系黏合劑、聚乙烯吡咯啶酮樹脂系黏合劑、聚醯胺樹脂系黏合劑、縮丁醛樹脂系黏合劑及萜烯系黏合劑中之1種或2種以上。具體而言，係選自下述中之1種或2種以上：前述纖維素樹脂系黏合劑係乙醯基纖維素、甲基纖維素、乙基纖維素、丁基纖維素及硝基纖維素；乙酸酯樹脂系黏合劑係甲基二醇乙酸酯、乙基二醇乙酸酯、丁基二醇乙酸酯、乙基雙二醇乙酸酯及丁基雙二醇乙酸酯；丙烯酸樹脂系黏合劑係甲基丙烯酸甲酯、甲基丙烯酸乙酯及甲基丙烯酸丁酯；胺基甲酸酯樹脂系黏合劑係2,4-甲苯二異氰酸酯及對-伸苯基二異氰酸酯；聚乙烯吡咯啶酮樹脂系黏合劑係聚乙烯吡咯啶酮及N-乙烯吡咯啶酮；聚醯胺樹脂系黏合劑係聚醯胺6、聚醯胺66及聚醯胺11；縮丁醛樹脂系黏合劑係聚乙烯縮丁醛；萜烯系黏合劑為蒎烯、桉葉油醇、檸烯及松油醇。
導電性糊膏係包含金屬微粒子(P)與由有機溶劑(S)所成之有機分散介質(D)之導電性糊膏，或前述金屬微粒子(P)與由有機溶劑(S)及有機黏合劑(R)所成之有機分散介質(D)之導電性糊膏。對其進行加熱處理時，達到某溫度時，進行有機溶劑(S)蒸發，或進行有機溶劑(S)蒸發及有機黏合劑(R)之熱分解，顯現出金屬微粒子(P)表面，相互於表面結合(燒結)，利用該原理而作為接合材發揮功能。前述導電性糊膏中之金屬微粒子(P)與有機分散介質(D)之調配比例(P/D)較佳為50~85質量%/50~15質量%(質量%之合計為100質量%)。又，於不損及本發明效果之範圍內，本發明之導電性糊膏亦可調配上述以外之金屬微粒子、有機分散介質等。
金屬微粒子(P)之調配比例若超過前述85質量%，則糊膏變高黏度，於加熱處理中有產生金屬微粒子(P)表面間之結合不足使導電性降低之虞。另一方面，金屬微粒子(P)之調配比例若未達前述50質量%，則糊膏黏度降低，薄膜形狀維持變困難，且加熱處理之際有產生收縮之缺陷之虞，進而，亦有於加熱處理之際伴有有機分散介質(D)之蒸發速度變慢之缺陷之虞。基於該觀點，前述金屬微粒子(P)與有機分散介質(D)之調配比例(P/D)更佳為55~80質量%/45~20質量%。又，該有機分散介質(D)中之有機溶劑(S)與有機黏合劑(R)之調配比例(S/R)較佳為80~100質量%/20~0質量%(質量%之合計均為100質量%)，更佳為85~95質量%/15~5質量%。
有機分散介質(D)中之有機黏合劑(R)之調配比例若超過20質量%，則加熱處理導電性接合層13a之際有機黏合劑(R)熱分解且飛散之速度變慢，且導電連接構件中殘留碳量增加時，阻礙燒結，而有龜裂、剝離等問題產生之可能性。藉由選擇有機溶劑(S)，於僅以該溶劑使金屬微粒子(P)均一分散，可發揮導電性糊膏之黏度調節及可維持薄膜形狀之功能之情況，亦可使用僅由有機溶劑(S)所成之成分作為有機分散介質(D)。導電性糊膏中，根據需要可於前述成分中添加消泡劑、分散劑、可塑劑、界面活性劑、增黏劑等之習知添加物。製造導電性糊膏之際，可混合各成分之後使用球磨機等進行混練。
[觸黏層] 觸黏層13b係用以將半導體晶圓1或半導體元件2保持於導電性接合層13a者，具有觸黏性。且，觸黏層13b藉由將半導體元件2與基板40接合之際的加熱而熱分解。觸黏層13b若係具有此等性質者，則可無特別限制地由任意者構成。
由於導電性接合層13a不具有觸黏性，故觸黏層13b係用以改善半導體晶圓1或半導體元件2與導電性接合層13a之接著性之層。若無觸黏層13b，則由於半導體晶圓1或半導體元件2與導電性接合層13a之接著力較弱，故半導體晶圓1之切晶時或半導體元件2之拾取時，半導體晶圓1或半導體元件2與導電性接合層13a之間會剝離。且，觸黏層13b亦為用以提高導電性接合層13a對半導體晶圓1或半導體元件2之密著力之層。藉由提高密著力，亦可提高介隔導電性接合層13a將半導體元件2與基板40接合時之接合強度。
本發明中，重要的是觸黏層13b藉由將半導體元件2與基板40接合之際的加熱而熱分解，將半導體元件2與基板40介隔導電性接合層13a機械性接合。因此，觸黏層13b於接合時之加熱溫度下，於空氣環境下、升溫速度5℃/分鐘之熱重量測定中之重量減少較佳為70重量%以上，更佳為85重量%以上，又更佳為95重量%以上。
又，觸黏層13b由於接合時與半導體元件2直接接觸，故亦可期待使半導體元件2之電極表面活化之效果。此認為係因為觸黏層13b中所含之物質於加熱時分解之際，與金屬的電極表面之氧化層反應並清潔金屬面之故。如此藉由半導體元件2之電極表面活性化，可提高半導體元件2之電極與導電性接合層13a之密著力。
作為構成觸黏層13b之材料，較佳使用於極性或非極性溶劑中，於室溫不溶，但加熱至熔點則容易溶解者。此等材料加熱至熔點於溶劑中溶解，塗佈於導電性接合層13a等之上後，冷卻至室溫，使溶劑蒸發，藉此可形成具有觸黏性之膜狀體。作為溶劑，可適當使用習知溶劑，但為了使成膜時容易蒸發，較佳使用低沸點之溶劑。作為低沸點之溶劑亦可使用有機溶劑(SB)。
再者，觸黏層13b更佳係以將導電性糊膏中之金屬微粒子(P)加熱燒結之際，使金屬微粒子(P)還原之物質構成。由於以多段反應引起觸黏層13b之分解反應之物質的反應溫度區域廣，金屬微粒子(P)被還原，故金屬微粒子(P)燒結後電阻率降低，而提高導電性。
觸黏層13b較佳係例如選自下述中之1種或2種以上：聚甘油(熔點：23℃)；甘油單癸酸酯(熔點：46℃)、甘油單月桂酸酯(熔點：57℃)、甘油單硬脂酸酯(熔點：70℃)、甘油單山萮酸酯(熔點：85℃)等之甘油脂肪酸酯；二甘油硬脂酸酯(熔點：61℃)、二甘油月桂酸酯(熔點：34℃)等之聚甘油脂肪酸酯；苯乙烯對苯乙烯二苯基膦(熔點：75℃)、三苯膦(熔點：81℃)、三-正辛基膦(熔點：30℃)等之膦類；亞磷酸酯類；雙(4-甲基丙烯醯氧基硫苯基)硫醚(熔點：64℃)、苯基對-三硫醚(熔點：23℃)、糠基硫醚(熔點：32℃)等之硫醚類；二苯基二硫醚(熔點：61℃)、苄基二硫醚(熔點：72℃)、四乙基秋蘭姆二硫醚(熔點：70℃)等之二硫醚類；三硫醚類；及亞碸類。
又，於不阻礙觸黏性及熱分解性，於對半導體元件2或基板40之污染或發生突沸氣體之方面不產生問題之範圍內，觸黏層13b可根據需要添加消泡劑、分散劑、可塑劑、界面活性劑、增黏劑等之習知添加物。
相對於導電性接合層13a內之金屬微粒子(P)，觸黏層13b含有0.1~1.0質量%之金屬微粒子(M)(亦稱為「觸黏層內金屬微粒子」)。金屬微粒子(M)熔點為250℃以下。金屬微粒子(M)較佳為錫或其合金微粒子，例如可使用Sn焊料粉末、SnNiCu、SnNiCu(Ge)、SnAgCu或SnAu之粉末等。觸黏層13b中，藉由以相對於導電性接合層13a內之金屬微粒子(P)為0.1~1.0質量%添加金屬微粒子(M)，藉由接合時之熱使觸黏層13b熱分解，金屬微粒子(M)熔融並與半導體元件之電極擴散反應形成合金化相或金屬化合物相(以下亦稱為擴散層)，故導電性接合層13a與半導體元件2之電極的接合性便良好，無關於構成導電性接合層13a之金屬微粒子(P)之種類或電極之種類，均可良好接合。
金屬微粒子(M)較佳平均一次粒徑為1~3μm，為使形成之擴散相厚度更薄，更佳為1~2μm。金屬微粒子(M)之平均一次粒徑未達1μm時，因尺寸效果而自低溫開始燒結，自燒結初期階段粒徑開始增大或產生粒徑偏差，而有與電極之擴散反應變差或會產生擴散相之偏差之虞。且，該平均一次粒徑超過3μm時，擴散反應所致之擴散相較厚，而有阻礙接合體之導電性及散熱性之虞。金屬微粒子(M)之平均一次粒徑可藉由掃描型電子顯微鏡(SEM)測定其直徑。例如二次元形狀為略圓形狀之情況為其圓的直徑，為略橢圓形狀之情況為其橢圓之短徑，為略正方形狀之情況為其正方形之邊的長度，為略長方形狀之情況為其長方形短邊之長度。「平均一次粒徑」係將隨機選擇之10~20個複數粒子之粒徑以上述顯微鏡觀察並測量，藉由算出其平均值而求出。
其次，針對製造接合薄膜13之方法加以說明。首先，於載置台上，載置脫模薄膜，於脫模薄膜上配置間隔物。間隔物例如為SUS等之金屬製的板，於中央部具有圓形開口部。於間隔物之開口部且脫模薄膜上，配置上述導電性糊膏，使用橡皮輥進行網版印刷，將導電性糊膏均一擴展，而將導電性糊膏成形為圓形之薄膜狀。隨後，去除脫模薄膜及間隔物。接著，藉由使經成形為圓形薄膜狀之導電性糊膏預乾燥，形成導電性接合層13a。預乾燥時間係依據印刷厚度而定，但可設定為例如5~20分鐘。
隨後，將上述觸黏層13b之構成成分的材料加熱並於溶劑中混練，使用橡膠輥法或噴霧塗佈法等塗佈於導電性接合層13a上並冷卻。隨後，使加熱乾燥並使溶劑蒸發，形成觸黏層13b。
又，本實施形態中，本發明之接合薄膜13係設於黏著薄膜12上，全體構成晶圓加工用膠帶10，但作為製造晶圓加工用膠帶10之材料亦可由接合薄膜13單體更換，該情況下，接合薄膜13較佳於兩面由保護薄膜予以保護。作為保護薄膜可使用聚乙烯系、聚苯乙烯系、聚對苯二甲酸乙二酯(PET)系、以及經脫模處理之薄膜等之習知者，但基於具有保持接合薄膜13之適當硬度之觀點，較佳使用聚乙烯薄膜或聚苯乙烯薄膜。保護薄膜之厚度並未特別限定，可適當設定，但較佳為10~300μm。
(黏著薄膜) 黏著薄膜12具有於將半導體晶圓1切晶之際以使保持於接合薄膜13之半導體晶圓1不剝離之充分黏著力，於切晶後拾取經單片化之半導體元件2之際可容易自接合薄膜13剝離般的低黏著力者。本實施形態中，黏著薄膜12如圖1所示，係例示於基材薄膜12a設置黏著劑層12b者，但不限定於此，可使用作為切晶膠帶使用之習知黏著薄膜。
作為黏著薄膜12之基材薄膜12a，若為以往習知者則可無特別限定地使用，但如後述，本實施形態中，作為黏著劑層12b，由於使用能量硬化性之材料中之放射線硬化性材料，故係使用具有放射線透過性者。
例如，作為基材薄膜12a之材料，可列舉聚乙烯、聚丙烯、乙烯丙烯共聚物、聚丁烯-1、聚-4-甲基戊烯-1、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸酯共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸共聚物、離子聚合物等之α-烯烴之均聚物或共聚物或該等之混合物、聚胺基甲酸酯、苯乙烯-乙烯-丁烯共聚物或戊烯系共聚物、聚醯胺-多元醇共聚物等之熱塑性彈性體及該等之混合物。且，基材薄膜12a亦可為選自該等之群之2種以上材料混合而成者，該等可為單層或經複數層化者。基材薄膜12a之厚度並未特別限定，可適當設定，但較佳為50~200μm。
本實施形態中，為了藉由對黏著薄膜12照射紫外線等之放射線，使黏著劑層12b硬化，而容易自接合薄膜13剝離黏著劑層12b，故黏著劑層12b之樹脂較佳於黏著劑中使用之習知氯化聚丙烯樹脂、丙烯酸樹脂、聚酯樹脂、聚胺基甲酸酯樹脂、環氧樹脂、加成反應型有機聚矽氧烷系樹脂、聚矽氧丙烯酸酯樹脂、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸酯共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸共聚物、聚異戊二烯或苯乙烯・丁二烯共聚物或其氫化物等之各種彈性體等或其混合物中，適當調配放射線聚合性化合物，而調製黏著劑。且，亦可添加各種界面活性劑或表面平滑劑。黏著劑層12b之厚度並未特別限定，而可適當設定，但較佳為5~30μm。
作為放射線聚合性化合物，使用例如藉由光照射而三位元網狀化之分子內具有至少2個以上光聚合性碳-碳雙鍵之低分子量化合物，或於取代基中具有光聚合性碳-碳雙鍵之聚合物或寡聚物。具體而言，可適用三羥甲基丙烷三丙烯酸酯、季戊四醇三丙烯酸酯、季戊四醇四丙烯酸酯、二季戊四醇單羥基五丙烯酸酯、二季戊四醇六丙烯酸酯、1,4-丁二醇二丙烯酸酯、1,6-己二醇二丙烯酸酯、聚乙二醇二丙烯酸酯或寡聚酯丙烯酸酯等、聚矽氧丙烯酸酯等、丙烯酸或各種丙烯酸酯類之共聚物等。
又，除上述之丙烯酸酯系化合物以外，亦可使用胺基甲酸酯丙烯酸酯系寡聚物。胺基甲酸酯丙烯酸酯系寡聚物係使聚酯型或聚醚型等之多元醇化合物與多元異氰酸酯化合物(例如2,4-甲苯二異氰酸酯、2,6-甲苯二異氰酸酯、1,3-二甲苯二異氰酸酯、1,4-二甲苯二異氰酸酯、二苯基甲烷4,4-二異氰酸酯等)反應而得之末端異氰酸酯胺基甲酸酯預聚物，與具有羥基之丙烯酸酯或甲基丙烯酸酯(例如丙烯酸2-羥基乙酯、甲基丙烯酸2-羥基乙酯、丙烯酸2-羥基丙酯、甲基丙烯酸2-羥基丙酯、聚乙二醇丙烯酸酯、聚乙二醇甲基丙烯酸酯等)反應而得。又，黏著劑層12b亦可為選自上述樹脂之2種以上混合而成者。
又，作為黏著劑層12b之組成物，除了藉由照射放射線而硬化之放射線聚合性化合物以外，亦可使用適當調配有丙烯酸系黏著劑、光聚合起始劑、硬化劑等之組成物。
使用光聚合起始劑時，可使用例如異丙基苯偶因醚、異丁基苯偶因醚、二苯甲酮、米氏酮、氯噻噸酮、十二烷基噻噸酮、二甲基噻噸酮、二乙基噻噸酮、苄基二甲基縮醛、α-羥基環己基苯基酮、2-羥基甲基苯基丙烷等。該等光聚合起始劑之調配量相對於丙烯酸系共聚物100質量份，較佳為0.01~5質量份。
黏著薄膜12可藉由作為切晶膠帶之製造方法而過去習知之方法製造。晶圓加工用膠帶10可藉由於黏著薄膜12之黏著劑層12b上貼合上述導電性接合層13之導電性接合層13a而製造。
(晶圓加工用膠帶之使用方法) 半導體裝置100(參考圖6)之製造步驟中，晶圓加工用膠帶10如以下般使用。圖2中，顯示於晶圓加工用膠帶10貼合半導體晶圓1與環框20之狀況。 首先，如圖2所示，黏著薄膜12之黏著劑層12b貼附於環框20，將半導體晶圓1貼合於接合薄膜13之觸黏層13b。該等貼合順序並未限制，亦可將半導體晶圓1貼合於接合薄膜13後，將黏著薄膜12之黏著劑層12b貼附於環框20。又，亦可同時進行將黏著薄膜12貼附於環框20，及將半導體晶圓1貼合於接合薄膜13。
因此，如圖3所示，實施半導體晶圓1之切晶步驟，其次，實施對黏著薄膜12照射能量線例如紫外線之步驟。具體而言，首先，為了藉由切晶刀21將半導體晶圓1與接合薄膜13予以切晶，而藉由吸附台22，自黏著薄膜12面側吸附支撐晶圓加工用膠帶10。接著，藉由切晶刀21將半導體晶圓1與接合薄膜13切斷成半導體元件2單位予以單片化，隨後，自黏著薄膜12之下面側照射能量線。藉由該能量線照射，使黏著劑層12b硬化，使其黏著力降低。又，亦可替代能量線之照射，而藉由加熱等之外部刺激使黏著薄膜12之黏著劑層12b之黏著力降低。黏著劑層12b由兩層以上之黏著劑層層合而構成之情況，亦可將各黏著劑層內之一層或全部層藉由能量線照射而硬化，使各黏著劑層內之一層或全部層之黏著力降低。
之後，如圖4所示，實施將保持有經切晶之半導體元件2及接合薄膜13之黏著薄膜12於環框20之周向拉伸之擴展步驟。具體而言，對保持有經切晶之複數半導體元件2及接合薄膜13之狀態之黏著薄膜12，自黏著薄膜12之下面側使中空圓柱形狀之頂起構件30上升，將黏著薄膜12於環框20之周向拉伸。
實施擴展步驟後，如圖5所示，以將黏著薄膜12擴展之狀態，實施拾取半導體元件2之拾取步驟。具體而言，自黏著薄膜12之下面側藉由銷31將半導體元件2頂起，並且自黏著薄膜12之上面側以吸附治具32吸附半導體元件2，將經單片化之半導體元件2與接合薄膜13一起拾取。
接著，實施拾取步驟後，實施接合步驟。具體而言，於拾取步驟與半導體元件2一起被拾取之接合薄膜13之導電性接合層13a側配置於導線框架或封裝基板等之基板40的接合位置。隨後，於250~350℃之溫度加熱處理接合薄膜13。此時，觸黏層13b熱分解並且導電性接合層13a中之有機分散介質(D)被去除，金屬微粒子(M)熔融並與半導體元件之電極進行擴散反應而形成合金化相或金屬化合物相。又，金屬微粒子(P)藉由其表面之能量於比塊體狀態之金屬的熔點更低溫下凝集，進行金屬微粒子表面間之結合(燒結)，形成由金屬多孔質體所成之導電連接構件50。加熱處理之際若於有機溶劑(S)中含有有機溶劑(SC)，則該溶劑以液狀及氣體狀發揮還原功能，故抑制金屬微粒子(P)之氧化並促進燒結。又，含有比較低沸點之有機溶劑(S)作為導電性接合層13a中之有機分散介質(D)之情況，於加熱處理之前，設置預先乾燥步驟，可事先將有機溶劑(S)之至少一部分蒸發、去除。如此藉由加熱處理，將半導體元件2與基板40機械接合。又，接合步驟可於無加壓下進行，亦可於加壓下進行。經加壓之情況，導電性糊膏與導線框架或封裝基板等之密著性提高。
導電連接構件50係金屬微粒子(P)彼此面接觸並結合(燒結)而形成之金屬多孔質體，故具有適度彈力性與柔軟性，且亦不損及導電性。金屬多孔質體之空隙率為1~9體積%，較佳為1~6體積%之範圍，平均空孔徑為10~120nm，較佳10~60nm之範圍。又，導電連接構件50之空隙率、金屬微粒子之平均一次粒徑及平均空孔徑之測定方法如下。
(1)金屬微粒子之平均一次粒徑之測定方法 金屬微粒子藉由掃描型電子顯微鏡(SEM)，觀察隨機選擇10個之粒子的剖面，測定對於其剖面之二次元形狀之最大內切圓的直徑，求出其平均值。又，電子顯微鏡之剖面照片中，二次元形狀為略圓形狀之情況測定其圓的直徑，為略橢圓形狀之情況測定其橢圓之短徑，為略正方形狀之情況測定其正方形之邊的長度，為略長方形狀之情況測定其長方形短邊之長度。 (2)平均空孔徑之測定方法 「平均空孔徑」係使用掃描型電子顯微鏡(SEM)觀察隨機選擇之10~20個之空孔徑之剖面形狀並測量，取其平均值。 (3)空隙率之測定方法 空隙率之測定係藉由透過型電子顯微鏡(TEM)，拍攝電子顯微鏡照片，藉由其剖面圖像之解析而決定。又，空孔尺寸小於100nm之情況的空隙率藉由超微切片法而薄片化，以透過型電子顯微鏡(TEM)觀察而測定。
隨後，如圖6所示，進行將基板40之端子部(未圖示)之前端與半導體元件2上之電極墊(未圖示)以黏合線60電性連接之線黏合步驟。作為黏合線60係使用例如金線、鋁線或銅線等。進行線黏合之際的溫度較佳為80℃以上，更佳為120℃以上，該溫度較佳為250℃以下，更佳為175℃以下。又，其加熱時間係進行數秒~數分鐘(例如1秒~1分鐘)。連結線以加熱至如前述溫度範圍內般之狀態，藉由併用超音波之振動能量與施加加壓之壓著能量而進行。
接著，進行利用密封樹脂70密封半導體元件2之密封步驟。本步驟係為了保護搭載於基板40之半導體元件2或黏合線60而進行。本步驟藉由以模具將密封用樹脂成型而進行。作為密封樹脂70係使用例如環氧系樹脂。樹脂密封之際的加熱溫度較佳為165℃以上，更佳為170℃以上，加熱溫度較佳為185℃以下，更佳為180℃以下。
根據需要，密封物亦可進而加熱(後硬化步驟)。藉此，於密封步驟中硬化不足之密封樹脂70可完全硬化。加熱溫度可適當設定。藉此，製造半導體裝置100。
又，上述之例中，接合薄膜使用於將半導體元件2之未形成電路之背面與基板40接合之情況，但不限定於此，亦可使用於將半導體元件2之形成電路之表面與基板40接合(所謂覆晶安裝)之情況。
其次，針對本發明之實施例加以說明，但本發明並非限定於該等。
[導電性接合層之製作] (導電性接合層A) 於水溶液中藉由自銅離子之無電解還原而調製之平均一次粒徑150nm之銅微粒子(相當於金屬微粒子(P)) 70質量%與作為有機溶劑之由甘油40體積%、N-甲基乙醯胺55體積%及三乙胺5體積%所成之混合溶劑(相當於有機溶劑(S1))95質量%與作為有機黏合劑之乙基纖維素(平均分子量1000,000)5質量%所成之有機分散介質30質量%予以混練，調製導電性糊膏。
於載置台上配置脫模薄膜(50μm之聚對苯二甲酸乙二酯)，於其上配置350μm厚且於中央部具有6吋圓形開口之SUS製之間隔物，自間隔物之開口部面向之脫模薄膜上，載置5.0g之上述導電性糊膏，使用橡膠輥進行網版印刷，擴展導電性糊膏，成形為圓形之薄片形狀。接著，去除間隔物後，於惰性環境中進行預乾燥5分鐘，製作導電性接合層A。
(導電性接合層B) 除了替代銅微粒子，使用平均一次粒徑100nm之銀微粒子(日本Sigma Aldrich股份有限公司製，型號：730777) 70質量%以外，與導電性接合層A同樣，製作導電性接合層B。
[觸黏層之製作] (觸黏層組成物A) 又，於聚甘油10質量%中混合甲醇90質量%，稀釋聚甘油，對聚甘油稀釋液以重量%計成為0.1重量%之方式使用超音波分散機分散作為金屬微粒子(M)之平均一次粒徑1.5μm之錫微粒子(三井金屬礦業股份有限公司製)，調製觸黏層組成物。金屬微粒子(M)對於金屬微粒子(P)之比例為0.1重量%。
(觸黏層組成物B) 除了錫微粒子對於聚甘油稀釋液以重量%計成為0.5重量%以外，與觸黏層A同樣製作觸黏層B。金屬微粒子(M)對於金屬微粒子(P)之比例為0.5重量%。
(觸黏層組成物C) 除了錫微粒子對於聚甘油稀釋液以重量%計成為1重量%以外，與觸黏層A同樣製作觸黏層C。金屬微粒子(M)對於金屬微粒子(P)之比例為1重量%。
(觸黏層組成物D) 除了替代錫微粒子，使用平均一次粒徑1.75μm之錫鎳銅合金微粒子(三井金屬礦業股份有限公司製)以外，與觸黏層A同樣製作觸黏層D。金屬微粒子(M)對於金屬微粒子(P)之比例為0.1重量%。
(觸黏層組成物E) 除了錫鎳銅合金微粒子對於聚甘油稀釋液以重量%計成為1重量%以外，與觸黏層D同樣製作觸黏層E。金屬微粒子(M)對於金屬微粒子(P)之比例為1重量%。
(觸黏層組成物F) 除了平均一次粒徑2.0μm之鉍合金微粒子(福田金屬箔粉工業股份有限公司製)對於聚甘油稀釋液以重量%計成為0.5重量%以外，與觸黏層A同樣製作觸黏層F。金屬微粒子(M)對於金屬微粒子(P)之比例為0.5重量%。
(觸黏層組成物G) 除了錫微粒子對於聚甘油稀釋液以重量%計成為0.01重量%以外，與觸黏層A同樣製作觸黏層G。金屬微粒子(M)對於金屬微粒子(P)之比例為0.01重量%。
(觸黏層組成物H) 除了錫微粒子對於聚甘油稀釋液以重量%計成為2重量%以外，與觸黏層A同樣製作觸黏層H。金屬微粒子(M)對於金屬微粒子(P)之比例為2重量%。
(觸黏層組成物I) 除了不含金屬微粒子以外，與觸黏層A同樣製作觸黏層I。
[實施例1] 接著，於加溫至50℃之加熱板上，於導電性接合層A上以噴霧塗佈法以乾燥後膜厚成為2μm之方式塗佈上述觸黏層組成物A，於50℃乾燥180秒，形成觸黏層。如此，獲得實施例1之接合薄膜。
[實施例2~6、比較例1~5] 同樣，以表1及表2所示之導電性接合層與觸黏層之組合，獲得實施例2~6、比較例1~5之接合薄膜。
[晶圓加工用膠帶之製作] 另一方面，如下般製作黏著薄膜。使丙烯酸丁酯65重量份、丙烯酸2-羥基乙酯25重量份、丙烯酸10重量份進行自由基聚合，滴加甲基丙烯酸2-異氰酸酯基乙酯進行反應而合成之重量平均分子量80萬之丙烯酸共聚物中，添加作為硬化劑之聚異氰酸酯3重量份、作為光聚合起始劑之1-羥基-環己基-苯基酮1重量份並混合，作成黏著劑層組成物。所製作之黏著劑層組成物以乾燥膜厚成為10μm之方式塗佈於薄膜(基材薄膜以外之塗佈用薄膜)，於120℃乾燥3分鐘。隨後，塗佈於該薄膜之黏著劑層組成物轉印於基材薄膜的厚100μm之聚丙烯-彈性體(PP：HSBR=80：20之彈性體)樹脂薄膜上，製作黏著薄膜。 又，聚丙烯(PP)使用日本Polychem股份有限公司製之NOVATEC FG4，氫化苯乙烯丁二烯(HSBR)使用JSR股份有限公司製之DYNARON 1320P。又，塗佈用薄膜使用經聚矽氧脫模處理之PET薄膜(帝人：HUPIREX S-314，厚25μm)。
隨後，於上述黏著薄膜之黏著劑層上貼合上述接合薄膜之導電性接合層，獲得晶圓加工用膠帶。
[樣品之製作] 準備厚230μm之半導體晶圓表面上形成Ti/Au、Ti/Ag、Ti/Cu、Ti/Ni之各種晶片電極層者作為半導體晶圓。各種晶片厚度為100nm。又，準備厚1.2mm之調質為半硬質無氧銅板作為基板。上述實施例及比較例之接合薄膜載置於經加熱至50℃之加熱板上並加熱，以提高觸黏層之觸黏性之狀態於觸黏層上貼附表1及表2所示種類之電極的半導體晶圓表面(半導體元件電極層側之面)，隨後恢復至室溫，以使觸黏層冷卻硬化之狀態使用切晶裝置(DISCO公司製，DAD340(商品名))，與接合薄膜一起被切晶成7mm×7mm之半導體晶片。隨後，使用高壓水銀燈之紫外線照射機，自黏著薄膜之基材薄膜面側以照射量成為200mJ/cm2 之方式進行紫外線照射。接著，使用黏晶機(CANON MACHINERY股份有限公司製，CPS-6820(商品名))將黏著薄膜擴展，以該狀態將半導體晶片連同接合薄膜一起拾取，將接合薄膜之導電性接合層側載置於基板上。
隨後，分別將上述半導體晶片、接合薄膜、基板之層合體，以銅微粒子糊膏形成有導電性接合層者，於300℃加熱60分鐘，以銀微粒子糊膏形成有導電性接合層者，於250℃加熱60分鐘，使導電性接合層燒結，製作20個安裝樣品。
針對安裝樣品，進行將-55℃30分鐘與200℃30分鐘設為1循環之溫度循環試驗(TCT)。每100次取出樣品，目視檢查是否有龜裂、剝離。隨後，使用超音波顯微鏡(日立建機股份有限公司製，Mi-Scope(商品名))與碳針(型式「PQ2-13」，50MHz)，自半導體晶片側照射超音波，以反射法進行剝離測定。剝離面積超過10%者判定為故障。使用本實施例及比較例之接合薄膜安裝之樣品直至判定為故障之TCT次數為2500~3000次者設為優良品並以A判定，為1000~2000次者設為良品並以B判定，為1000次以下者設為不良品並以Cde判定。而且，與所有種類之電極之接合中包含A判定之B判定以上之接合薄膜作為優良品並以◎評價，與所有種類之電極之接合中為B判定者作為良品並以○評價，與任一種類之電極之接合中為C判定者作為不良品並以×評價。其結果示於表1、2。
Figure 109123380-A0305-02-0041-2
Figure 109123380-A0305-02-0042-3
如表1所示，實施例1~6由於觸黏層含有對於導電性接合層內之金屬微粒子(P)為0.1~1.0質量%之金屬微粒子(M)，故無關於半導體元件之電極種類，與基板之接合良好，溫度循環試驗評價中亦為良好結果。
相對於此，如表2所示，比較例1、2由於觸黏層中不含金屬微粒子(M)，故根據半導體元件之電極種類，與基板之接合並非良好，溫度循環試驗評價中為較差之結果。比較例3中，由於金屬微粒子(M)的熔點超過250℃，故不形成與電極之合金相，故接合狀態並非良好，溫度循環試驗評價中為較差之結果。比較例4中，由於金屬微粒子(M)之含有比例，相對於金屬微粒子(P)為0.01重量%而較少，故接合後金屬多孔質體與半導體元件之電極之界面無法充分形成金屬微粒子(M)與電極之合金相，根據半導體元件之電極種類，與基板之接合並非良好，溫度循環試驗評價中為較差之結果。比較例5中，由於金屬微粒子(M)之含有比例，相對於金屬微粒子(P)為2重量%而較多，故接合後金屬多孔質體與半導體元件之電極之界面過厚地形成金屬微粒子(M)與電極之合金相，根據半導體元件之電極種類，與基板之接合並非良好，溫度循環試驗評價中為較差之結果。
1:半導體晶圓 2:半導體元件 10:晶圓加工用膠帶 11:脫模薄膜 12:黏著薄膜 12a:基材薄膜 12b:黏著劑層 13:接合薄膜 13a:導電性接合層 13b:觸黏層 20:環框 21:切晶刀 22:吸附台 30:頂起構件 31:銷 32:吸附治具 40:基板 50:導電連接構件 60:黏合線 70:密封樹脂 100:半導體裝置
[圖1]係示意性顯示本發明之實施形態之晶圓加工用膠帶之剖面圖。
[圖2]係於晶圓加工用膠帶上貼合半導體晶圓之圖。
[圖3]係用以說明切晶步驟之圖。
[圖4]係說明擴展步驟之圖。
[圖5]係說明拾取步驟之圖。
[圖6]係示意性顯示使用本發明之實施形態之晶圓加工用膠帶製造之半導體裝置之剖面圖。
1:半導體晶圓
10:晶圓加工用膠帶
12:黏著薄膜
12a:基材薄膜
12b:黏著劑層
13:接合薄膜
13a:導電性接合層
13b:觸黏層
20:環框

Claims (15)

  1. 一種接合薄膜，其係用以接合半導體元件與基板之接合薄膜，其特徵係具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層，及具有觸黏性且層合於前述導電性接合層之觸黏層，前述觸黏層相對於前述導電性接合層內之前述金屬微粒子(P)，含有0.1~1.0質量%的金屬微粒子(M)，前述金屬微粒子(M)之熔點為250℃以下。
  2. 如請求項1之接合薄膜，其中前述金屬微粒子(P)之平均一次粒徑為10~500nm。
  3. 如請求項1之接合薄膜，其中前述導電性糊膏含有有機溶劑(S)。
  4. 如請求項1至3中任一項之接合薄膜，其中前述金屬微粒子(P)含有銅或銀。
  5. 如請求項1至3中任一項之接合薄膜，其中前述導電性糊膏含有有機黏合劑(R)。
  6. 如請求項1至3中任一項之接合薄膜，其中前述觸黏層係由選自聚甘油、甘油脂肪酸酯、聚甘油脂肪酸酯、膦類、磷酸酯類、硫化物類、二硫化物類、三硫化物類及亞碸類中之1種或2種以上所成。
  7. 如請求項1至3中任一項之接合薄膜，其中前述金屬微粒子(M)之平均一次粒徑為1~3μm。
  8. 如請求項1至3中任一項之接合薄膜，其 中前述金屬微粒子(M)含有錫。
  9. 如請求項3之接合薄膜，其中前述有機溶劑(S)含有由於常壓下之沸點為100℃以上且分子中具有1或2個以上羥基之醇及/或多元醇所成之有機溶劑(SC)。
  10. 如請求項5之接合薄膜，其中前述有機黏合劑(R)係選自由纖維素樹脂系黏合劑、乙酸酯樹脂系黏合劑、丙烯酸樹脂系黏合劑、胺基甲酸酯樹脂系黏合劑、聚乙烯吡咯啶酮樹脂系黏合劑、聚醯胺樹脂系黏合劑、縮丁醛樹脂系黏合劑及萜烯系黏合劑中之1種或2種以上。
  11. 一種晶圓加工用膠帶，其特徵係具有：具有基材薄膜與設於該基材薄膜上之黏著劑層之黏著薄膜，及如請求項1至10中任一項之接合薄膜，於前述黏著劑層上設有前述接合薄膜之導電性接合層。
  12. 一種接合體之製造方法，其特徵係具有下述步驟：將具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層與具有觸黏性且包含金屬微粒子(M)、層合於前述導電性接合層之觸黏層之接合薄膜，配置於半導體元件與基板之間並加熱，使前述觸黏層熱分解，使前述金屬微粒子(M)熔融，與前述半導體元件之電極反應後，藉由使前述導電性接合層之前述金屬微粒子(P)燒 結，而接合前述半導體元件與前述基板的接合步驟。
  13. 一種半導體與基板之接合體，其係於基板上具有由金屬多孔質體所成之導電連接構件，於其上具有半導體元件之半導體與基板之接合體，其特徵為使用如請求項1至10中任一項之接合薄膜予以接合，前述金屬多孔質體係如請求項1至10中任一項之接合薄膜中所含之金屬微粒子(P)之燒結體，於前述金屬多孔質體與前述半導體元件之電極之界面，形成如請求項1至10中任一項之接合薄膜中所含之金屬微粒子(M)與前述電極之合金相或金屬化合物相。
  14. 如請求項13之半導體與基板之接合體，其中前述金屬多孔質體之空隙率為1~6體積%，平均空孔徑為10~60nm。
  15. 一種貼合體，其係貼合有下述之貼合體，具有基材薄膜與設於該基材薄膜上之黏著劑層之黏著薄膜，用以將半導體元件與基板接合之接合薄膜，及半導體晶圓，其特徵係前述接合薄膜具有包含金屬微粒子(P)之導電性糊膏成形為薄膜狀之導電性接合層與具有觸黏性且層合於前述導電性接合層之觸黏層，前述導電性接合層貼合於前述黏著劑層，前述半導體晶圓貼合於前述觸黏層， 前述觸黏層可熱分解，且相對於前述導電性接合層內之前述金屬微粒子(P)，金屬微粒子(M)含有0.1~1.0質量%，藉由接合時之加熱，前述觸黏層被熱分解，金屬微粒子(M)熔融與前述半導體元件之電極反應後，藉由將前述導電性接合層之前述金屬微粒子(P)燒結，而將前述半導體元件與前述基板接合。
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