US20230005807A1 - Zinc Layer For A Semiconductor Die Pillar - Google Patents
Zinc Layer For A Semiconductor Die Pillar Download PDFInfo
- Publication number
- US20230005807A1 US20230005807A1 US17/931,828 US202217931828A US2023005807A1 US 20230005807 A1 US20230005807 A1 US 20230005807A1 US 202217931828 A US202217931828 A US 202217931828A US 2023005807 A1 US2023005807 A1 US 2023005807A1
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- US
- United States
- Prior art keywords
- layer
- tiw
- semiconductor device
- copper
- semiconductor die
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000004065 semiconductor Substances 0.000 title claims abstract description 106
- 239000011701 zinc Substances 0.000 title claims abstract description 31
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 title claims abstract description 30
- 229910052725 zinc Inorganic materials 0.000 title claims abstract description 11
- 239000010949 copper Substances 0.000 claims abstract description 74
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 70
- 229910052802 copper Inorganic materials 0.000 claims abstract description 70
- MAKDTFFYCIMFQP-UHFFFAOYSA-N titanium tungsten Chemical compound [Ti].[W] MAKDTFFYCIMFQP-UHFFFAOYSA-N 0.000 claims abstract description 5
- 150000001875 compounds Chemical class 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 5
- 239000000758 substrate Substances 0.000 claims 2
- 238000000034 method Methods 0.000 description 49
- 230000008569 process Effects 0.000 description 23
- 229920002120 photoresistant polymer Polymers 0.000 description 20
- VTLYHLREPCPDKX-UHFFFAOYSA-N 1,2-dichloro-3-(2,3-dichlorophenyl)benzene Chemical compound ClC1=CC=CC(C=2C(=C(Cl)C=CC=2)Cl)=C1Cl VTLYHLREPCPDKX-UHFFFAOYSA-N 0.000 description 16
- 238000004519 manufacturing process Methods 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 10
- 239000000463 material Substances 0.000 description 9
- 238000000576 coating method Methods 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 6
- 238000009713 electroplating Methods 0.000 description 6
- 229910000679 solder Inorganic materials 0.000 description 6
- 229910001369 Brass Inorganic materials 0.000 description 4
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 4
- 239000010951 brass Substances 0.000 description 4
- 238000000151 deposition Methods 0.000 description 4
- 238000005530 etching Methods 0.000 description 4
- 238000009792 diffusion process Methods 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 238000004544 sputter deposition Methods 0.000 description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 3
- 239000010937 tungsten Substances 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 229910007637 SnAg Inorganic materials 0.000 description 2
- 239000002318 adhesion promoter Substances 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 239000003990 capacitor Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000005693 optoelectronics Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 1
- 239000005751 Copper oxide Substances 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000004210 cathodic protection Methods 0.000 description 1
- 229910000431 copper oxide Inorganic materials 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
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- H01L2224/16225—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
- H01L2224/16227—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation the bump connector connecting to a bond pad of the item
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- H01L2224/94—Batch processes at wafer-level, i.e. with connecting carried out on a wafer comprising a plurality of undiced individual devices
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- H01L2924/15—Details of package parts other than the semiconductor or other solid state devices to be connected
- H01L2924/151—Die mounting substrate
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- H01L2924/1531—Connection portion the connection portion being formed only on the surface of the substrate opposite to the die mounting surface
- H01L2924/15313—Connection portion the connection portion being formed only on the surface of the substrate opposite to the die mounting surface being a land array, e.g. LGA
Definitions
- This invention relates to the fabrication of a pillar over a via of a semiconductor die.
- FIG. 1 is a cross-sectional view of a packaged semiconductor device in accordance with the present invention.
- FIG. 2 is a method for fabricating the packaged semiconductor device of FIG. 1 .
- FIGS. 3 - 11 are cross-sectional diagrams of selected steps of the method of FIG. 2 .
- FIG. 12 is a cross-sectional view of an alternative packaged semiconductor device in accordance with the present invention.
- FIG. 13 is a method for fabricating the alternative packaged semiconductor device of FIG. 12 .
- FIGS. 14 - 24 are cross-sectional diagrams of selected steps of the alternative method of FIG. 13 .
- FIG. 1 is a cross-sectional view of a packaged semiconductor device 10 in accordance with an example embodiment.
- the packaged semiconductor device 10 contains a semiconductor die 20 that has copper vias 30 connected to electrical circuitry (not shown) within the semiconductor die 20 .
- the copper vias 30 may be formed with a conventional process, such as etching via holes into the surface of the semiconductor die 20 , coating the surface of the semiconductor die 20 with titanium tungsten (TiW), coating the TiW surface with copper, using an electroplating process to fill the via holes with copper, and then polishing the TiW and Cu off the surface of the semiconductor die 20 .
- the vias may be formed by depositing tungsten (W) instead of Cu into the via holes (over the coating of TiW).
- the semiconductor die 20 is electrically and physically attached to a multi-layered solder resist printed circuit board (PCB) 40 .
- the PCB 40 contains multiple layers of electrical traces that properly direct electrical signals within the PCB.
- the PCB 40 contains leads 50 that electrically connect the PCB 40 and the semiconductor die 20 to other electrical devices (not shown) within an electrical system.
- the semiconductor die 20 is attached to pads 35 of the PCB through a layer of TiW 60 , a copper pillar 70 , and solder resist 80 . Molding compound 90 encapsulates the semiconductor die 20 and portions of the PCB 40 . Note that the surface of leads 50 is often left unencapsulated to facilitate their electrical interconnection to other electrical devices.
- the copper pillar 70 has a bottom portion 75 that includes interdiffused zinc (the top portion is pure copper). Therefore, the bottom portion 75 of the copper pillar 70 may contain brass (as explained more fully below).
- FIG. 1 it is within the scope of the invention to create a layer of TiW and a copper pillar 70 / 75 that has a perimeter 100 that extends beyond the location of vias 30 .
- This extended perimeter of elements 60 , 70 / 75 may increase the likelihood that the entire surface of each via 30 is in electrical contact with elements 60 , 70 / 75 (which may improve the reliability of the packaged semiconductor device 10 ).
- FIG. 2 shows an example method 200 for fabricating the packaged semiconductor device 10 of FIG. 1 .
- FIGS. 3 - 11 illustrate selected steps of method 200 .
- the example method 200 is exemplary but not restrictive of alternative ways of implementing the principles of the invention. Moreover, features and procedures whose implementations are well known to those skilled in the art are omitted for brevity. For example, the implementation of common fabrication steps lies within the ability of those skilled in the art and accordingly any detailed discussion thereof may be omitted.
- Step 210 is the provision of a fully processed semiconductor wafer 110 , as shown in FIG. 3 .
- the semiconductor wafer 110 contains numerous completed semiconductor dies 20 .
- the semiconductor dies 20 may contain any combination of active and passive electrical circuitry, such as CMOS, BiCMOS and bipolar junction transistors - as well as capacitors, optoelectronic devices, inductors, resistors, and diodes.
- the semiconductor dies 20 include vias 30 that are connected to the electrical circuitry (not shown) within the semiconductor die 20 .
- the vias include copper; however, the vias may contain other suitable materials such as tungsten.
- the semiconductor dies 20 are spaced apart from each other on the semiconductor wafer 110 by zones 120 of unprocessed semiconductor material. These zones 120 of unprocessed semiconductor material are mostly destroyed by a rotating saw blade during the singulation process (as explained below). Therefore, the zones 120 of unprocessed semiconductor material are often called “saw streets” because they form a grid between all of the semiconductor dies 20 on the semiconductor wafer 110 that is largely destroyed by the saw during the dicing process.
- the next step in the fabrication process is the formation of a layer of TiW 60 over the semiconductor wafer 110 .
- a layer of TIW is coated over the semiconductor wafer in step 220 .
- the layer of TiW 60 is formed by sputtering; however, any acceptable method of deposition may be used.
- the thickness of the layer of TiW 60 may range from 100-400 nm. It is within the scope of the invention to use other acceptable materials that are a diffusion barrier and adhesion promoter.
- a layer of Ti or TaN may be used instead of TiW 60 .
- step 230 is the formation of a layer of Zn 130 over the layer of TiW 60 .
- Step 230 is shown in FIG. 5 .
- the thickness of the layer of Zn 130 may range from 100 nm-20 ⁇ m.
- Zn 130 is sputtered over the layer of TiW 60 in step 230 ; however, another acceptable coating method may be used (such as electroplating).
- a patterned photoresist 140 is formed in step 240 .
- the patterned photoresist 140 has openings 150 over the vias 30 . These openings 150 will be used to create the copper pillars 70 in the next step of the fabrication process.
- the openings 150 are large enough to create copper pillars 70 with a perimeter 100 that exceeds the width of vias 30 .
- copper pillars 70 having a perimeter 100 that exceeds the width of vias 30 may improve the reliability of the packaged semiconductor device 10 .
- Step 250 is the formation of copper pillars 70 .
- the copper pillars 70 are formed over vias 30 . More specifically, the copper pillars 70 are formed on the exposed layers of Zn 130 by a standard electroplating process and then the patterned photoresist 140 is removed (using solvent or a plasma etch).
- Method 200 continues with an anneal of the semiconductor wafer 110 .
- the annealing process will cause the layer of Zn 130 to interdiffuse with the adjoining copper pillar 70 .
- the diffusion process is likely to result in the formation of brass (Cu-20 wt % Zn) in the majority of the bottom portion 75 of the copper pillar 70 , as illustrated in FIG. 8 . (The top portion of copper pillar 70 will remain pure cupper.)
- step 270 the remaining layer of zinc 130 is removed, as shown in FIG. 9 .
- the remaining layer of Zn 130 may be removed by any acceptable process such as a wet etch using diluted hydrochloric acid.
- the layer 60 of TiW located outside the perimeter 100 of the copper pillars 70 is also removed by any acceptable process such as a wet etch using hydrogen peroxide. It is to be noted that there will be minimal undercutting below the outer corners of portion 75 of the copper pillar 70 during the wet etch of the layer of Zn 130 . However, there may be a slight amount of undercutting (less than 3%) under the copper pillar 70 / 75 during the wet etch of the layer of TiW 60 .
- the semiconductor wafer 110 is singulated in step 290 , as shown in FIG. 11 .
- a rotating saw blade 160 is typically used to cut through the saw street zones 120 during the dicing process.
- This singulation process creates individual semiconductor dies 20 that can be further fabricated into a packaged semiconductor die 10 using conventional manufacturing steps.
- the individual semiconductor dies 20 may be connected to the PCB 40 using any acceptable conventional manufacturing process.
- solder resist 80 such as SnAg
- a robotic pick-and-place machine may be used to attach the copper pillars 70 to the pads 35 of the PCB 40 .
- the semiconductor die 20 and portions of the PCB 40 are encapsulated with molding compound to create the packaged semiconductor device 10 shown in FIG. 1 .
- the formation of brass at the interface 75 between the copper pillar 70 and the layer of TiW 60 may provide desired corrosion resistance for the copper pillar 70 .
- the presence of brass at the interface 75 between the copper pillar 70 and the layer of TiW 60 may provide electromigration improvements; thereby increasing the electrical reliability of the packaged semiconductor device 10 .
- FIG. 12 is a cross-sectional view of a packaged semiconductor device 10 in accordance with an alternative embodiment.
- the semiconductor die 20 has copper vias 30 that are connected to electrical circuitry (not shown) within the semiconductor die 20 .
- the copper vias 30 may be formed with a conventional process, such as etching via holes into the surface of the semiconductor die 20 , coating the surface of the semiconductor die 20 with TiW, coating the TiW surface with copper, using an electroplating process to fill the via holes with copper, and then polishing the TiW and Cu off the surface of the semiconductor die 20 .
- the vias may be formed by depositing W instead of Cu into the via holes (over the coating of TiW).
- the semiconductor die 20 of FIG. 12 is electrically and physically attached to a multi-layered solder resist PCB 40 .
- the PCB 40 contains multiple layers of electrical traces that properly direct electrical signals within the PCB.
- the PCB 40 contains leads 50 that electrically connect the circuitry of the PCB 40 and the semiconductor die 20 to other electrical devices (not shown) within an electrical system.
- the semiconductor die 20 is attached to the pads 35 of the PCB 40 through a layer of TiW 60 , a copper pillar 70 , and solder resist 80 .
- Molding compound 90 encapsulates the semiconductor die 20 and portions of the PCB 40 .
- the copper pillar 70 in the alternative embodiment is pure copper throughout (therefore, there is no bottom portion 75 that includes interdiffused zinc).
- the use of both positive tone photoresist and negative tone photoresist during the fabrication process 300 may prevent the formation of a layer of Zn at the interface between the layer of TiW 60 and the copper pillar 70 .
- FIG. 12 it is within the scope of the invention to create a layer of TiW and a copper pillar 70 that has a perimeter 100 that extends beyond the location of vias 30 .
- This extended perimeter of elements 60 , 70 may increase the likelihood that the entire surface of each via 30 is in electrical contact with elements 60 , 70 (which may improve the reliability of the packaged semiconductor device 10 ).
- FIG. 13 shows an alternative method 300 for fabricating the packaged semiconductor device 10 of FIG. 12 .
- FIGS. 14 - 24 illustrate selected steps of method 300 .
- the example method 300 is exemplary but not restrictive of alternative ways of implementing the principles of the invention.
- Step 310 is the provision of a fully processed semiconductor wafer 110 , as shown in FIG. 14 .
- the semiconductor wafer 110 contains numerous completed semiconductor dies 20 .
- the semiconductor dies may contain any combination of active and passive electrical circuitry (not shown), such as CMOS, BiCMOS and bipolar junction transistors - as well as capacitors, optoelectronic devices, inductors, resistors, and diodes.
- the semiconductor dies 20 include vias 30 that are connected to the electrical circuitry within the semiconductor die 20 .
- the vias include copper; however, the vias may contain other suitable materials such as tungsten.
- the semiconductor dies 20 are spaced apart from each other on the semiconductor wafer 110 by zones 120 of unprocessed semiconductor material. These zones 120 of unprocessed semiconductor material are mostly destroyed by a rotating saw blade during the singulation process.
- the next step in the fabrication process is the formation of a layer of TiW 60 over the semiconductor wafer 110 .
- a layer of TIW is coated over the semiconductor wafer in step 320 .
- the layer of TiW 60 is formed by sputtering; however, any acceptable method of deposition may be used.
- the thickness of the layer of TiW 60 may range from 100-400 nm. It is within the scope of the invention to use other acceptable materials that are a diffusion barrier and adhesion promoter.
- a layer of Ti or TaN may be used instead of TiW 60 .
- step 330 is the formation of a first patterned photoresist 170 over the vias 30 .
- negative tone photoresist 170 is formed over the vias 30 of the semiconductor wafer 110 .
- negative tone photoresist 170 becomes crosslinked (polymerized) when exposed to light. Therefore, negative tone photoresist 170 more difficult to dissolve in photoresist developer.
- step 335 the semiconductor wafer 110 is coated with a layer of Zn 130 .
- the thickness of the layer of Zn 130 may range from 100 nm-20 ⁇ m.
- the layer of Zn 130 is sputtered over the layer of TiW 60 in step 335 ; however, another acceptable coating method may be used (such as electroplating).
- step 340 is the removal of the first patterned photoresist 170 (using solvent or a plasma etch).
- the next step 350 is the formation of a second patterned photoresist 180 over the layer of Zn 130 .
- the second patterned photoresist 180 is positive tone photoresist.
- the portion of positive tone photoresist that is exposed to light becomes soluble to the photoresist developer.
- the unexposed portion of the positive tone photoresist remains insoluble to the photoresist developer. Therefore, a single mask (reticle) can be used for steps 330 and 350 , which may reduce the cost of manufacturing the packaged semiconductor device 10 .
- Step 355 is the formation of copper pillars 70 .
- the copper pillars 70 are formed over vias 30 . More specifically, the copper pillars 70 are formed on the exposed layers of TiW 60 by a standard electroplating process and then the patterned photoresist 140 is removed (using solvent or a plasma etch) in step 360 , as shown in FIG. 21 .
- the next step 365 in the alternative method 300 is the removal of the layer of Zn 130 , as shown in FIG. 22 .
- the layer of Zn 130 may be removed by any acceptable process such as a wet etch using diluted hydrochloric acid. Because the layer of Zn 130 is in contact with the copper pillar 70 , the layer of Zn 130 will act as a cathodic protection component. As a result, the copper pillar 70 will not dissolve before the complete dissolution of the layer of Zn 130 . Therefore, the layer of Zn 130 is a sacrificial layer that may prevent any corrosion of the copper pillar 70 . Moreover, the use of the layer of Zn 130 instead of the copper seed layer that is currently used during the fabrication of copper pillars 70 results in minimal undercutting below the outer corners of the copper pillar 70 during the wet etch of the layer of Zn 130 .
- the layer 60 of TiW located outside the perimeter 100 of the copper pillars 70 is removed in step 370 by any acceptable process such as a wet etch using hydrogen peroxide. It is to be noted that there may be a slight amount of undercutting (less than 3%) under the outer corners of the copper pillar 70 during the wet etch of the layer of TiW 60 .
- the semiconductor wafer 110 is singulated in step 380 , as shown in FIG. 24 .
- a rotating saw blade 160 is typically used to cut through the saw street zones 120 during the dicing process.
- This singulation process creates individual semiconductor dies 20 that can be further fabricated into a packaged semiconductor die 10 using conventional manufacturing steps.
- the individual semiconductor dies 20 may be connected to the PCB 40 using any acceptable conventional manufacturing process.
- solder resist 80 such as SnAg
- a robotic pick-and-place machine may be used to attach the copper pillars 70 to the pads 35 of the PCB 40 .
- the semiconductor die 20 and portions of the PCB 40 are encapsulated with molding compound to create the packaged semiconductor device 10 , as shown in FIG. 12 .
- the semiconductor wafer 110 may be desirable to clean the semiconductor wafer 110 after the copper leads 30 have been exposed in while patterning the photoresist layer 140 .
- the wafer clean may be used to remove any copper oxide that may have formed on the copper leads 30 before the sputtering the copper pillars 70 .
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- Engineering & Computer Science (AREA)
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Abstract
A device includes a semiconductor die including a via, a layer of titanium tungsten (TiW) in contact with the via, and a copper pillar including a top portion and a bottom portion. The bottom portion is in contact with the layer of TiW. The copper pillar includes interdiffused zinc within the bottom portion.
Description
- This application is a division of patent application Ser. No. 15/909,679, filed Mar. 1, 2018 (now U.S. Pat. No. 11,443,996), which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 62/568,484, filed Oct. 5, 2017, Attorney Docket No. TI-78926PS, the content of which is incorporated by reference.
- This invention relates to the fabrication of a pillar over a via of a semiconductor die.
-
FIG. 1 is a cross-sectional view of a packaged semiconductor device in accordance with the present invention. -
FIG. 2 is a method for fabricating the packaged semiconductor device ofFIG. 1 . -
FIGS. 3-11 are cross-sectional diagrams of selected steps of the method ofFIG. 2 . -
FIG. 12 is a cross-sectional view of an alternative packaged semiconductor device in accordance with the present invention. -
FIG. 13 is a method for fabricating the alternative packaged semiconductor device ofFIG. 12 . -
FIGS. 14-24 are cross-sectional diagrams of selected steps of the alternative method ofFIG. 13 . - The present invention is described with reference to the attached figures, wherein like reference numerals are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale and they are provided merely to illustrate the invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the invention. One skilled in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well known structures or operations are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention.
- Referring to the drawings,
FIG. 1 is a cross-sectional view of a packagedsemiconductor device 10 in accordance with an example embodiment. In this example, the packagedsemiconductor device 10 contains asemiconductor die 20 that hascopper vias 30 connected to electrical circuitry (not shown) within thesemiconductor die 20. Thecopper vias 30 may be formed with a conventional process, such as etching via holes into the surface of the semiconductor die 20, coating the surface of thesemiconductor die 20 with titanium tungsten (TiW), coating the TiW surface with copper, using an electroplating process to fill the via holes with copper, and then polishing the TiW and Cu off the surface of thesemiconductor die 20. Alternatively, the vias may be formed by depositing tungsten (W) instead of Cu into the via holes (over the coating of TiW). - The
semiconductor die 20 is electrically and physically attached to a multi-layered solder resist printed circuit board (PCB) 40. ThePCB 40 contains multiple layers of electrical traces that properly direct electrical signals within the PCB. In addition, the PCB 40 contains leads 50 that electrically connect thePCB 40 and the semiconductor die 20 to other electrical devices (not shown) within an electrical system. Thesemiconductor die 20 is attached topads 35 of the PCB through a layer ofTiW 60, acopper pillar 70, and solder resist 80.Molding compound 90 encapsulates the semiconductor die 20 and portions of thePCB 40. Note that the surface ofleads 50 is often left unencapsulated to facilitate their electrical interconnection to other electrical devices. - In accordance with the example embodiment, the
copper pillar 70 has abottom portion 75 that includes interdiffused zinc (the top portion is pure copper). Therefore, thebottom portion 75 of thecopper pillar 70 may contain brass (as explained more fully below). - As shown in
FIG. 1 , it is within the scope of the invention to create a layer of TiW and acopper pillar 70/75 that has aperimeter 100 that extends beyond the location ofvias 30. This extended perimeter ofelements elements -
FIG. 2 shows anexample method 200 for fabricating the packagedsemiconductor device 10 ofFIG. 1 .FIGS. 3-11 illustrate selected steps ofmethod 200. Theexample method 200 is exemplary but not restrictive of alternative ways of implementing the principles of the invention. Moreover, features and procedures whose implementations are well known to those skilled in the art are omitted for brevity. For example, the implementation of common fabrication steps lies within the ability of those skilled in the art and accordingly any detailed discussion thereof may be omitted. -
Step 210 is the provision of a fully processedsemiconductor wafer 110, as shown inFIG. 3 . Thesemiconductor wafer 110 contains numerous completed semiconductor dies 20. The semiconductor dies 20 may contain any combination of active and passive electrical circuitry, such as CMOS, BiCMOS and bipolar junction transistors - as well as capacitors, optoelectronic devices, inductors, resistors, and diodes. In addition, the semiconductor dies 20 includevias 30 that are connected to the electrical circuitry (not shown) within thesemiconductor die 20. Inmethod 200 the vias include copper; however, the vias may contain other suitable materials such as tungsten. - The semiconductor dies 20 are spaced apart from each other on the
semiconductor wafer 110 byzones 120 of unprocessed semiconductor material. Thesezones 120 of unprocessed semiconductor material are mostly destroyed by a rotating saw blade during the singulation process (as explained below). Therefore, thezones 120 of unprocessed semiconductor material are often called “saw streets” because they form a grid between all of the semiconductor dies 20 on thesemiconductor wafer 110 that is largely destroyed by the saw during the dicing process. - The next step in the fabrication process is the formation of a layer of
TiW 60 over thesemiconductor wafer 110. As shown inFIG. 4 , a layer of TIW is coated over the semiconductor wafer instep 220. In theexample method 200, the layer of TiW 60 is formed by sputtering; however, any acceptable method of deposition may be used. The thickness of the layer of TiW 60 may range from 100-400 nm. It is within the scope of the invention to use other acceptable materials that are a diffusion barrier and adhesion promoter. For example, a layer of Ti or TaN may be used instead of TiW 60. - In accordance with the
example method 200,step 230 is the formation of a layer ofZn 130 over the layer ofTiW 60.Step 230 is shown inFIG. 5 . The thickness of the layer ofZn 130 may range from 100 nm-20 μm. Zn 130 is sputtered over the layer of TiW 60 instep 230; however, another acceptable coating method may be used (such as electroplating). - Next, a patterned
photoresist 140 is formed instep 240. As shown inFIG. 6 , the patternedphotoresist 140 has openings 150 over thevias 30. Theseopenings 150 will be used to create thecopper pillars 70 in the next step of the fabrication process. In theexample method 200, theopenings 150 are large enough to createcopper pillars 70 with aperimeter 100 that exceeds the width ofvias 30. As stated previously,copper pillars 70 having aperimeter 100 that exceeds the width ofvias 30 may improve the reliability of the packagedsemiconductor device 10. - Step 250 is the formation of
copper pillars 70. As shown inFIG. 7 , thecopper pillars 70 are formed overvias 30. More specifically, thecopper pillars 70 are formed on the exposed layers ofZn 130 by a standard electroplating process and then the patternedphotoresist 140 is removed (using solvent or a plasma etch). -
Method 200 continues with an anneal of thesemiconductor wafer 110. Instep 260, the annealing process will cause the layer ofZn 130 to interdiffuse with the adjoiningcopper pillar 70. The diffusion process is likely to result in the formation of brass (Cu-20 wt % Zn) in the majority of thebottom portion 75 of thecopper pillar 70, as illustrated inFIG. 8 . (The top portion ofcopper pillar 70 will remain pure cupper.) - In
step 270 the remaining layer ofzinc 130 is removed, as shown inFIG. 9 . The remaining layer ofZn 130 may be removed by any acceptable process such as a wet etch using diluted hydrochloric acid. As shown inFIG. 10 , thelayer 60 of TiW located outside theperimeter 100 of thecopper pillars 70 is also removed by any acceptable process such as a wet etch using hydrogen peroxide. It is to be noted that there will be minimal undercutting below the outer corners ofportion 75 of thecopper pillar 70 during the wet etch of the layer ofZn 130. However, there may be a slight amount of undercutting (less than 3%) under thecopper pillar 70/75 during the wet etch of the layer ofTiW 60. - The
semiconductor wafer 110 is singulated instep 290, as shown inFIG. 11 . A rotatingsaw blade 160 is typically used to cut through thesaw street zones 120 during the dicing process. This singulation process creates individual semiconductor dies 20 that can be further fabricated into a packaged semiconductor die 10 using conventional manufacturing steps. For example, the individual semiconductor dies 20 may be connected to thePCB 40 using any acceptable conventional manufacturing process. In theexample step 295, solder resist 80 (such as SnAg) is placed on the exposed top portion of thecopper pillar 70 and then a robotic pick-and-place machine may be used to attach thecopper pillars 70 to thepads 35 of thePCB 40. Later, the semiconductor die 20 and portions of thePCB 40 are encapsulated with molding compound to create the packagedsemiconductor device 10 shown inFIG. 1 . - The formation of brass at the
interface 75 between thecopper pillar 70 and the layer of TiW 60 (that is located above the vias 30) may provide desired corrosion resistance for thecopper pillar 70. In addition, the presence of brass at theinterface 75 between thecopper pillar 70 and the layer ofTiW 60 may provide electromigration improvements; thereby increasing the electrical reliability of the packagedsemiconductor device 10. - Referring again to the drawings,
FIG. 12 is a cross-sectional view of a packagedsemiconductor device 10 in accordance with an alternative embodiment. As noted above, like reference numerals are used throughout the figures to designate similar or equivalent elements. As with the embodiment shown inFIG. 1 , the semiconductor die 20 hascopper vias 30 that are connected to electrical circuitry (not shown) within the semiconductor die 20. The copper vias 30 may be formed with a conventional process, such as etching via holes into the surface of the semiconductor die 20, coating the surface of the semiconductor die 20 with TiW, coating the TiW surface with copper, using an electroplating process to fill the via holes with copper, and then polishing the TiW and Cu off the surface of the semiconductor die 20. Alternatively, the vias may be formed by depositing W instead of Cu into the via holes (over the coating of TiW). - Also similar to the embodiment shown in
FIG. 1 , the semiconductor die 20 ofFIG. 12 is electrically and physically attached to a multi-layered solder resistPCB 40. ThePCB 40 contains multiple layers of electrical traces that properly direct electrical signals within the PCB. In addition, thePCB 40 contains leads 50 that electrically connect the circuitry of thePCB 40 and the semiconductor die 20 to other electrical devices (not shown) within an electrical system. - In accordance with the alternative embodiment shown in
FIG. 12 , the semiconductor die 20 is attached to thepads 35 of thePCB 40 through a layer ofTiW 60, acopper pillar 70, and solder resist 80.Molding compound 90 encapsulates the semiconductor die 20 and portions of thePCB 40. - The
copper pillar 70 in the alternative embodiment is pure copper throughout (therefore, there is nobottom portion 75 that includes interdiffused zinc). The use of both positive tone photoresist and negative tone photoresist during the fabrication process 300 (described more fully below) may prevent the formation of a layer of Zn at the interface between the layer ofTiW 60 and thecopper pillar 70. - As shown in
FIG. 12 , it is within the scope of the invention to create a layer of TiW and acopper pillar 70 that has aperimeter 100 that extends beyond the location ofvias 30. This extended perimeter ofelements elements 60, 70 (which may improve the reliability of the packaged semiconductor device 10). -
FIG. 13 shows analternative method 300 for fabricating the packagedsemiconductor device 10 ofFIG. 12 .FIGS. 14-24 illustrate selected steps ofmethod 300. Theexample method 300 is exemplary but not restrictive of alternative ways of implementing the principles of the invention. - Step 310 is the provision of a fully processed
semiconductor wafer 110, as shown inFIG. 14 . Thesemiconductor wafer 110 contains numerous completed semiconductor dies 20. The semiconductor dies may contain any combination of active and passive electrical circuitry (not shown), such as CMOS, BiCMOS and bipolar junction transistors - as well as capacitors, optoelectronic devices, inductors, resistors, and diodes. In addition, the semiconductor dies 20 includevias 30 that are connected to the electrical circuitry within the semiconductor die 20. Inmethod 300 the vias include copper; however, the vias may contain other suitable materials such as tungsten. - The semiconductor dies 20 are spaced apart from each other on the
semiconductor wafer 110 byzones 120 of unprocessed semiconductor material. Thesezones 120 of unprocessed semiconductor material are mostly destroyed by a rotating saw blade during the singulation process. - The next step in the fabrication process is the formation of a layer of
TiW 60 over thesemiconductor wafer 110. As shown inFIG. 15 , a layer of TIW is coated over the semiconductor wafer instep 320. In theexample method 300, the layer ofTiW 60 is formed by sputtering; however, any acceptable method of deposition may be used. The thickness of the layer ofTiW 60 may range from 100-400 nm. It is within the scope of the invention to use other acceptable materials that are a diffusion barrier and adhesion promoter. For example, a layer of Ti or TaN may be used instead ofTiW 60. - In accordance with the
alternative method 300,step 330 is the formation of a firstpatterned photoresist 170 over thevias 30. As shown inFIG. 16 ,negative tone photoresist 170 is formed over thevias 30 of thesemiconductor wafer 110. As known in the art,negative tone photoresist 170 becomes crosslinked (polymerized) when exposed to light. Therefore,negative tone photoresist 170 more difficult to dissolve in photoresist developer. - In
step 335, shown inFIG. 17 , thesemiconductor wafer 110 is coated with a layer ofZn 130. The thickness of the layer ofZn 130 may range from 100 nm-20 μm. The layer ofZn 130 is sputtered over the layer ofTiW 60 instep 335; however, another acceptable coating method may be used (such as electroplating). As shown inFIG. 18 ,step 340 is the removal of the first patterned photoresist 170 (using solvent or a plasma etch). - The
next step 350, shown inFIG. 19 , is the formation of a secondpatterned photoresist 180 over the layer ofZn 130. In accordance with thealternative method 300, the secondpatterned photoresist 180 is positive tone photoresist. As known in the art, the portion of positive tone photoresist that is exposed to light becomes soluble to the photoresist developer. (The unexposed portion of the positive tone photoresist remains insoluble to the photoresist developer). Therefore, a single mask (reticle) can be used forsteps semiconductor device 10. - Step 355 is the formation of
copper pillars 70. As shown inFIG. 20 , thecopper pillars 70 are formed overvias 30. More specifically, thecopper pillars 70 are formed on the exposed layers ofTiW 60 by a standard electroplating process and then the patternedphotoresist 140 is removed (using solvent or a plasma etch) instep 360, as shown inFIG. 21 . - The
next step 365 in thealternative method 300 is the removal of the layer ofZn 130, as shown inFIG. 22 . The layer ofZn 130 may be removed by any acceptable process such as a wet etch using diluted hydrochloric acid. Because the layer ofZn 130 is in contact with thecopper pillar 70, the layer ofZn 130 will act as a cathodic protection component. As a result, thecopper pillar 70 will not dissolve before the complete dissolution of the layer ofZn 130. Therefore, the layer ofZn 130 is a sacrificial layer that may prevent any corrosion of thecopper pillar 70. Moreover, the use of the layer ofZn 130 instead of the copper seed layer that is currently used during the fabrication ofcopper pillars 70 results in minimal undercutting below the outer corners of thecopper pillar 70 during the wet etch of the layer ofZn 130. - As shown in
FIG. 23 , thelayer 60 of TiW located outside theperimeter 100 of thecopper pillars 70 is removed instep 370 by any acceptable process such as a wet etch using hydrogen peroxide. It is to be noted that there may be a slight amount of undercutting (less than 3%) under the outer corners of thecopper pillar 70 during the wet etch of the layer ofTiW 60. - The
semiconductor wafer 110 is singulated instep 380, as shown inFIG. 24 . A rotatingsaw blade 160 is typically used to cut through thesaw street zones 120 during the dicing process. This singulation process creates individual semiconductor dies 20 that can be further fabricated into a packaged semiconductor die 10 using conventional manufacturing steps. The individual semiconductor dies 20 may be connected to thePCB 40 using any acceptable conventional manufacturing process. In theexample step 390, solder resist 80 (such as SnAg) is placed on the exposed top portion of thecopper pillar 70 and then a robotic pick-and-place machine may be used to attach thecopper pillars 70 to thepads 35 of thePCB 40. Later, the semiconductor die 20 and portions of thePCB 40 are encapsulated with molding compound to create the packagedsemiconductor device 10, as shown inFIG. 12 . - Various additional modifications to the invention as described above are within the scope of the claimed invention. As an example, it may be desirable to clean the
semiconductor wafer 110 after the copper leads 30 have been exposed in while patterning thephotoresist layer 140. The wafer clean may be used to remove any copper oxide that may have formed on the copper leads 30 before the sputtering thecopper pillars 70. Similarly, it may be desirable to clean thesemiconductor wafer 110 following the etching steps 270, 280 to remove any unwanted debris created by those etching processes. - While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.
Claims (18)
1. A semiconductor device, comprising:
a semiconductor die including a via;
a layer of titanium tungsten (TiW) in contact with the via; and
a copper pillar including a top portion and a bottom portion, the bottom portion in contact with the layer of TiW, the copper pillar including zinc within the bottom portion.
2. The semiconductor device of claim 1 , wherein the layer of TiW contacts portions of the semiconductor die.
3. The semiconductor device of claim 1 , wherein the via includes copper.
4. The semiconductor device of claim 1 , wherein a lateral width of the layer of TiW is more than a lateral width of the via.
5. The semiconductor device of claim 1 further including mold compound in contact with the semiconductor die, the layer of TiW, and the copper pillar.
6. The semiconductor device of claim 1 , wherein the via includes copper.
7. A packaged semiconductor device, comprising:
a semiconductor die including a via;
a layer of titanium tungsten (TiW) coupled to the via;
a copper pillar including a top portion and a bottom portion, the bottom portion in contact with the layer of TiW;
a substrate coupled to the copper pillar; and
molding compound covering portions of the semiconductor die, the copper pillar, the layer of TiW, and the substrate.
8. The packaged semiconductor device of claim 7 , wherein the layer of TiW contacts portions of the semiconductor die.
9. The packaged semiconductor device of claim 7 , wherein the via includes copper.
10. The packaged semiconductor device of claim 7 , wherein the copper pillar includes interdiffused zinc within the bottom portion.
11. A semiconductor device, comprising:
a semiconductor die including a via;
a layer of titanium tungsten (TiW) in contact with the via; and
a copper pillar including a top portion and a bottom portion, the bottom portion in contact with the layer of TiW.
12. The semiconductor device of claim 11 , wherein the layer of TiW contacts portions of the semiconductor die.
13. The semiconductor device of claim 11 , wherein the via includes copper.
14. The semiconductor device of claim 11 , wherein a lateral width of the layer of TiW is more than a lateral width of the via.
15. The semiconductor device of claim 11 further including mold compound in contact with the semiconductor die, the layer of TiW, and the copper pillar.
16. The semiconductor device of claim 11 , wherein the via includes copper.
17. The packaged semiconductor device of claim 11 , wherein the copper pillar includes zinc within the bottom portion.
18. The packaged semiconductor device of claim 17 , wherein the zinc is interdiffused zinc.
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US15/909,679 US11443996B2 (en) | 2017-10-05 | 2018-03-01 | Zinc layer for a semiconductor die pillar |
US17/931,828 US20230005807A1 (en) | 2017-10-05 | 2022-09-13 | Zinc Layer For A Semiconductor Die Pillar |
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US20120032340A1 (en) * | 2010-08-06 | 2012-02-09 | Stats Chippac, Ltd. | Semiconductor Die and Method of Forming FO-WLCSP Vertical Interconnect Using TSV and TMV |
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US7427557B2 (en) * | 2004-03-10 | 2008-09-23 | Unitive International Limited | Methods of forming bumps using barrier layers as etch masks |
US20090197114A1 (en) * | 2007-01-30 | 2009-08-06 | Da-Yuan Shih | Modification of pb-free solder alloy compositions to improve interlayer dielectric delamination in silicon devices and electromigration resistance in solder joints |
US10410988B2 (en) * | 2016-08-09 | 2019-09-10 | Semtech Corporation | Single-shot encapsulation |
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US20120032340A1 (en) * | 2010-08-06 | 2012-02-09 | Stats Chippac, Ltd. | Semiconductor Die and Method of Forming FO-WLCSP Vertical Interconnect Using TSV and TMV |
US20140264843A1 (en) * | 2013-03-14 | 2014-09-18 | Taiwan Semiconductor Manufacturing Company, Ltd. | Integrated Circuit Structure Having Dies with Connectors |
US20160379947A1 (en) * | 2015-06-29 | 2016-12-29 | Infineon Technologies Ag | Semiconductor Device with Metal Structure Electrically Connected to a Conductive Structure |
US20180130759A1 (en) * | 2016-11-10 | 2018-05-10 | Advanced Semiconductor Engineering, Inc. | Semiconductor package and semiconductor manufacturing process |
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