WO2012101975A1 - Ｓｎ合金バンプの製造方法 - Google Patents

Ｓｎ合金バンプの製造方法 Download PDF

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Publication number
WO2012101975A1
WO2012101975A1 PCT/JP2012/000217 JP2012000217W WO2012101975A1 WO 2012101975 A1 WO2012101975 A1 WO 2012101975A1 JP 2012000217 W JP2012000217 W JP 2012000217W WO 2012101975 A1 WO2012101975 A1 WO 2012101975A1
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WIPO (PCT)
Prior art keywords
layer
alloy
bump
composition
plating
Prior art date
Application number
PCT/JP2012/000217
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English (en)
French (fr)
Inventor
健志 八田
増田　昭裕
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三菱マテリアル株式会社
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Publication date
Application filed by 三菱マテリアル株式会社 filed Critical 三菱マテリアル株式会社
Priority to EP12739744.6A priority Critical patent/EP2669937B1/en
Priority to CN201280006685.XA priority patent/CN103339718B/zh
Priority to KR1020137018729A priority patent/KR101842738B1/ko
Priority to US13/981,862 priority patent/US8822326B2/en
Publication of WO2012101975A1 publication Critical patent/WO2012101975A1/ja

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    • H01L24/11—Manufacturing methods
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C13/00—Alloys based on tin
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    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/02—Electroplating of selected surface areas
    • C25D5/022—Electroplating of selected surface areas using masking means
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    • C25D5/10—Electroplating with more than one layer of the same or of different metals
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    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
    • H05K3/4007—Surface contacts, e.g. bumps

Definitions

  • the present invention relates to a method of manufacturing an Sn alloy bump suitable for flip chip mounting for mounting an electronic component on a substrate.
  • a solder layer is formed by electrolytic plating on an electrode pad in a resist opening formed on a substrate, and the solder layer is melted by performing reflow after removing the resist. Spherical bumps are formed.
  • Patent Document 1 discloses a method of forming a Sn—Ag—Cu ternary thin film on a substrate, wherein the substrate is immersed in a plating bath containing an Sn compound, an Ag compound, and a Cu compound, A method of forming by electroplating is described.
  • Patent Document 2 proposes a method for forming a Sn—Ag—Cu solder alloy in which Sn—Ag alloy plating is performed, then Sn—Cu alloy plating is performed, and then the obtained multilayer alloy plating layer is reflowed. ing.
  • the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a method of manufacturing an Sn alloy bump that can easily control the composition in the height direction of the Sn alloy bump.
  • the manufacturing method of the Sn alloy bump according to the present invention is a manufacturing method of an Sn alloy bump formed of an alloy of Sn and one or more other metals, and a resist formed on a substrate.
  • an Sn layer is formed on an electrode by electrolytic plating, and an alloy layer of Sn and the other metal (the other kind or two or more metals) is electrolyzed on the Sn layer. Since lamination is performed by plating, the depth of the opening is reduced by the Sn layer formed in advance when the alloy layer is plated, so that it is possible to suppress variations in the composition of other metals in the height direction.
  • the other metal in the alloy layer to be laminated is more than the case of only alloy plating of Sn and other metal depending on the target composition when the Sn layer and the alloy layer are melted to form an Sn alloy bump. By setting the composition high, it is possible to control the composition of the Sn alloy bump.
  • the manufacturing method of the Sn alloy bump according to the present invention includes a step of forming an Sn—Ag layer as the alloy layer on the Sn layer by electrolytic plating, and after removing the resist.
  • the other metal is two kinds of metals, and an alloy layer of Sn and one of the two kinds on the Sn layer and Sn and the two kinds of the two kinds.
  • a step of laminating two of the alloy layers with the other by electroplating, a step of forming Sn alloy bumps by melting the two layers of the alloy layer laminated with the Sn layer after removing the resist, and It is characterized by having. That is, in this Sn alloy bump manufacturing method, an alloy layer of one of the two types and an alloy layer of Sn and the other of the two types are laminated on the Sn layer by electrolytic plating. Since the depth of the opening is reduced by the Sn layer formed in advance when the two layers are plated, it is possible to suppress variation in the composition of the two kinds of metals in the height direction. *
  • one of the two types of metals is Ag and the other metal is Cu, and the Sn—Ag layer and the Sn—Cu layer are formed on the Sn layer.
  • the present invention has the following effects. That is, according to the manufacturing method of the Sn alloy bump according to the present invention, the Sn layer is formed on the electrode by electrolytic plating, and the alloy layer of Sn and another metal is laminated on the Sn layer by electrolytic plating. Variations in the composition of other metals in the height direction can be suppressed, and the composition of bumps formed by melting each layer can be controlled. Therefore, according to the manufacturing method of the Sn alloy bump of the present invention, it is possible to obtain the Sn alloy bump having high composition uniformity corresponding to the high aspect ratio pattern, and to cope with the fine pitch.
  • the manufacturing method of the Sn alloy bump according to the first embodiment is a manufacturing method of an Sn alloy bump formed of an alloy of Sn and Ag or another kind or two or more metals, as shown in FIG.
  • a step of forming an Sn layer 4a on the electrode pad 3 in the opening 2a of the resist 2 formed on the substrate 1 by electrolytic plating, and an alloy layer of Sn and the other metal on the Sn layer 4a A step of laminating 4b by electroplating, and a step of melting Sn layer 4a and laminated alloy layer 4b after removing resist 2 to form Sn alloy bumps 5 by reflow treatment.
  • an Sn layer is first formed on the electrode pad 3 in the opening 2a of the resist 2 formed on the substrate 1.
  • 4a is formed by electrolytic plating. This Sn layer 4a is formed up to, for example, half the depth of the opening 2a.
  • the substrate 1 is a semiconductor wafer, a printed substrate, a heat sink substrate, or the like, and a resist 2 is patterned on the surface, and a bump opening 2a is provided with a high aspect ratio pattern of 1.0 or more.
  • the electrode pad 3 is a metal film in which a Cu plating film 3a and a Ni plating film 3b are laminated, for example.
  • the opening 2a is, for example, a depth: 120 ⁇ m, an opening diameter: 70 ⁇ m, and a high aspect ratio pattern with an aspect ratio of 1.7.
  • the bump pitch can be a fine pitch of 100 tens of ⁇ m. *
  • an alloy layer 4b which is a Sn—Ag layer is formed on the Sn layer 4a by electrolytic plating.
  • the alloy layer 4b which is this Sn—Ag layer, is formed to fill the remaining half of the opening 2a at the same height as the Sn layer 4a. That is, the alloy layer 4b (Sn—Ag layer) is formed so as to fill the opening 2a which is raised by the Sn layer 4a and has a substantially reduced aspect ratio.
  • the other metal in the alloy layer 4b to be laminated is only alloy plating of Sn and another metal according to the target composition when the Sn layer 4a and the alloy layer 4b are melted to form an Sn alloy bump.
  • the composition control of the Sn alloy bump can be performed. That is, in the first embodiment, the alloy layer 4b which is the Sn—Ag layer forms the Sn alloy bump only by Sn—Ag plating, corresponding to the Ag composition of the Sn layer 4a and the molten Sn alloy bump after the reflow process.
  • the Ag composition is set higher than in the case. For example, when the target Ag composition of the Sn alloy bump is 2.5 wt%, the Ag composition is set to 5 wt% in the Sn—Ag layer (alloy layer 4 b) having the same height as the Sn layer 4 a. *
  • the resist 2 is removed, and as shown in FIG. 1C, the Sn layer 4a and the alloy layer 4b (Sn—Ag layer) are melted by a reflow process to form a substantially spherical Sn alloy bump 5.
  • Sn-Ag bumps are formed.
  • a hot air type reflow furnace is used, and heat is applied in a nitrogen atmosphere with a flux applied to the bump surface for the purpose of removing an oxide film.
  • the Sn layer 4a is formed on the electrode pad 3 by electrolytic plating, and the Sn and other metal alloy layer 4b is electrolytically plated on the Sn layer 4a. Since the depth of the opening 2a is reduced by the Sn layer 4a formed in advance when the alloy layer 4b is plated, it is possible to suppress the composition variation of the other metal in the height direction. . Therefore, the composition control of the Sn alloy bump 5 after the reflow process becomes easy.
  • the alloy layer 4b which is a Sn—Ag layer, is formed on the Sn layer 4a by electrolytic plating, and the Sn layer 4a and the alloy layer 4b (Sn—Ag layer) are melted.
  • the variation of the Ag composition in the height direction due to the above can be reduced, and an Sn—Ag alloy bump in which the Ag composition is controlled can be formed.
  • the difference between the second embodiment and the first embodiment is that, in the first embodiment, an alloy layer 4b of Sn and a kind of metal (Ag) is formed on the Sn layer 4a, and Sn alloy bumps are formed by reflow processing.
  • the other metal is two kinds of metals, and a manufacturing method of an Sn alloy bump formed of an alloy of Sn and two kinds of metals, 2, two layers of Sn and the first alloy layer 24b of one of the two kinds and Sn and the second alloy layer 24c of the other of the two kinds are stacked on the Sn layer 4a by electrolytic plating.
  • this is the point of reflow processing.
  • a case where one of the two metals is Ag and the other metal is Cu will be described.
  • An Sn layer 4a is formed on the electrode pad 3 in the opening 2a of the formed resist 2 by electrolytic plating.
  • two layers of a first alloy layer 24b which is a Sn—Cu layer and a second alloy layer 24c which is a Sn—Ag layer are formed on the Sn layer 4a by electrolytic plating. It is formed by stacking.
  • the first alloy layer 24b which is the Sn—Cu layer
  • the second alloy layer 24c which is the Sn—Ag layer
  • the two kinds of metals in the first alloy layer 24b and the second alloy layer 24c are used when the Sn layer 4a, the first alloy layer 24b, and the second alloy layer 24c are melted to form the Sn alloy bump 25.
  • the composition of the Sn alloy bumps can be controlled by setting the composition higher than the case of only the alloy plating of Sn and the two kinds of metals.
  • the first alloy layer 24b (Sn—Cu layer) and the second alloy layer 24c (Sn—Ag layer) correspond to the Ag composition and Cu composition of the Sn alloy bumps melted after the reflow process.
  • the Ag composition and the Cu composition are set higher than in the case where the Sn alloy bump is formed only by the Sn—Ag—Cu plating.
  • the target composition of the Sn alloy bump 25 is Sn-3Ag-0.5Cu (mass%)
  • the Cu composition of the first alloy layer 24b (Sn—Cu layer) is set to 2.5 wt%.
  • the Ag composition of the second alloy layer 24c (Sn—Ag layer) is set to 5 wt%.
  • the resist 2 is removed, and as shown in FIG. 2C, the Sn layer 4a and the first alloy layer 24b and the second alloy layer 24c are melted by a reflow process to form a substantially spherical Sn alloy bump 25.
  • Sn—Ag—Cu bumps are formed.
  • the first alloy layer 24b (Sn—Cu layer) and the second alloy layer 24c (Sn—Ag layer) are stacked in this order on the Sn layer 4a, but conversely the second alloy layer 24c (Sn—Ag layer). Layer) and the first alloy layer 24b (Sn—Cu layer) may be laminated in this order. *
  • the first alloy layer 24b of Sn and one of the two types and the second alloy of Sn and the other of the two types are formed on the Sn layer 4a. Since two layers of the layer 24c are laminated by electrolytic plating, the depth of the opening 2a is reduced by the Sn layer 4a formed in advance when the first alloy layer 24b is plated, and when the second alloy layer 24c is further plated. In addition, since the depth of the opening 2a is further reduced by the first alloy layer 24b, variation in the composition of the two kinds of metals in the height direction can be suppressed.
  • two layers of the first alloy layer 24b of the Sn—Ag layer and the second alloy layer 24c of the Sn—Cu layer are formed on the Sn layer 4a by electrolytic plating, and the Sn layer 4a and the second alloy layer 24c are formed. Since the first alloy layer 24b and the second alloy layer 24c are melted, the variation in the composition of Ag and Cu in the height direction due to precipitation of Ag and Cu is reduced, and the Sn composition and the Cu composition are controlled. Alloy bumps can be formed.
  • Example 1 As a substrate, a wafer having a diameter of 12 inches (30.48 cm) was used, and a resist having a thickness of 120 ⁇ m, in which openings of a high aspect ratio pattern having an opening diameter of 80 ⁇ m were formed on the surface at a pitch of 200 ⁇ m, was patterned.
  • electrolytic plating was performed under the following conditions using a new solution of Sn plating solution and Sn-Ag plating solution. *
  • two-layer plating was performed with a Sn plating thickness of 60 ⁇ m and a Sn—Ag plating thickness of 60 ⁇ m, and a Sn layer and an alloy layer (Sn—Ag layer) were laminated.
  • the electrolytic plating was performed by setting conditions such that the Ag composition in the Sn alloy bump after reflowing was 2.5 wt%. That is, the Ag concentration in the plating solution was adjusted to double that in the case of forming an Sn alloy bump only by Sn—Ag plating.
  • a reflow process was performed after removing the resist to form the Sn alloy bump of Example 1.
  • the reflow process at this time is carried out in a hot air type reflow furnace, a flux is applied to the bump surface for the purpose of removing the oxide film on the bump surface, and the reflow profile shown in FIG. 3 under a nitrogen atmosphere (oxygen concentration of 100 ppm or less). Conducted under conditions.
  • a nitrogen atmosphere oxygen concentration of 100 ppm or less
  • Example 1 a Sn-Ag single layer having a thickness of 120 ⁇ m was formed in an opening having a high aspect ratio pattern similar to that in Example 1 by using only Sn—Ag plating, and the same reflow as in Example 1 was performed. Sn alloy bumps were formed by the treatment. At this time, the electrolytic plating was performed by setting conditions such that the Ag composition in the Sn alloy bump after reflowing was 2.5 wt%. Furthermore, as Example 2 and Comparative Example 2, electrolytic plating was performed under the same conditions as in Example 1 and Comparative Example 1 with Sn-Ag plating solution after plating on about 1000 wafers. The Sn alloy bumps were formed by the same reflow process as described above. The Ag concentration in these liquids was set to a concentration equal to the conditions of Example 1 and Comparative Example 1. *
  • the Ag composition was measured by XRF (fluorescence X-ray analysis). As a result, the average bump composition was Example 1: 2.5 wt%, Comparative Example They were 1: 2.5 wt%, Example 2: 2.4 wt%, and Comparative Example 2: 2.0 wt%. As described above, in Example 1 and Comparative Example 1 using the new plating solution, the target Ag composition was obtained, but the corresponding plating solution was used after 1000 wafers were plated. In the case of Comparative Example 2, the Ag composition is lower than the target composition, whereas in Example 1, the target Ag composition is substantially maintained. *
  • Example 3 electrolytic plating was performed using a new solution of Sn plating solution, Sn—Cu plating solution and Sn—Ag plating solution under the following conditions. That is, using the same wafer as in Example 1, Sn plating was 24 ⁇ m in thickness, and the Cu composition in the film was 2.5 wt%. The Sn—Cu plating was 24 ⁇ m in thickness and the Ag composition in the film was 5 wt%. Under these conditions, Sn—Ag plating was performed with a thickness of 72 ⁇ m, and three-layer plating was performed, and electrolytic plating was performed so that the composition of the Sn alloy bump after reflow treatment was Sn-3Ag-0.5Cu. Further, a reflow process was performed after removing the resist to form the Sn alloy bump of Example 2. *
  • two layers of the first alloy layer 24b (Sn—Cu layer) and the second alloy layer 24c (Sn—Ag layer) are stacked on the Sn layer, and these are subjected to reflow treatment. It is preferable to form a Sn—Ag—Cu ternary bump by melting with, but a Sn—Ag—Cu layer is laminated on the Sn layer as an alloy layer of Sn and two kinds of metals Ag and Cu. These may be melted by a reflow process to form a Sn—Ag—Cu ternary bump.

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Abstract

Ｓｎ合金バンプの組成コントロールが容易なＳｎ合金バンプの製造方法を提供する。Ｓｎと他の一種または二種以上の金属との合金で形成されたＳｎ合金バンプの製造方法であって、基板１の上に形成されているレジスト開口部２ａ内の電極パッド３上にＳｎ層４ａを電解めっきにより形成する工程と、Ｓｎ層４ａ上にＳｎと合金層４ｂを電解めっきにより積層する工程と、レジスト２を除去した後にＳｎ層４ａと積層された合金層４ｂとを溶融してＳｎ合金バンプ５を形成する工程とを有する。

Description

Ｓｎ合金バンプの製造方法
本発明は、電子部品を基板に実装するフリップチップ実装等の際に好適なＳｎ合金バンプの製造方法に関するものである。
現在、電子部品をプリント基板等に実装する場合に、バンプを使用したフリップチップ実装により表面実装する方法が多く採用されている。上記バンプを形成する方法としては、例えば基板の上に形成したレジスト開口部内の電極パッド上に、ハンダ層を電解めっきにより形成し、レジスト除去後にリフローを行うことで、ハンダ層を溶融させて略球状のバンプを形成している。　
近年、鉛（Ｐｂ）を含有するハンダ材料が環境の面から好ましくないため、電子部品の接合に用いるハンダは、鉛フリー化が進められており、バンプの材料についてもＳｎを主成分とするＳｎ－Ａｇ或いはＳｎ－Ｃｕ二元系ハンダやＳｎ－Ａｇ－Ｃｕ三元系ハンダ等が検討されている。　例えば、特許文献１には、基材上にＳｎ－Ａｇ－Ｃｕ三元系薄膜を形成する方法であって、基材をＳｎ化合物とＡｇ化合物とＣｕ化合物とを含んだめっき浴に浸漬し、電気めっきにより形成する方法が記載されている。　また、特許文献２には、Ｓｎ－Ａｇ合金めっきを行い、次いでＳｎ－Ｃｕ合金めっきを行った後、得られた多層合金めっき層をリフローさせるＳｎ－Ａｇ－Ｃｕハンダ合金の形成方法が提案されている。
特開２００６－２９１３２３号公報 特開２００３－３４２７８４号公報
上記従来の技術には、以下の課題が残されている。　すなわち、近年の微細化によりファインピッチ化されて高アスペクト比パターンとなったレジストの開口部（ビア）に合金めっきを形成する場合、Ｓｎ－Ａｇ－Ｃｕ合金めっき液を使用する場合或いはＳｎ－ＡｇとＳｎ－Ｃｕとのめっき液による二層めっきを行う場合では、開口部の底部においてＡｇやＣｕの析出が抑制されるため、底部ほどＡｇやＣｕが少なくなってＳｎが多く析出してしまう不都合があった。このため、開口部の高さ方向で組成のばらつきが生じ、結果としてＳｎ合金バンプの組成コントロールが困難であるという問題があった。特に、何度も電解めっきを繰り返すとめっき液中の酸濃度が高くなって粘度が上がり、より一層Ａｇが底部に析出し難くなるため、リフロー後に安定した組成を得ることが困難であった。　
本発明は、前述の課題に鑑みてなされたもので、Ｓｎ合金バンプの高さ方向における組成コントロールが容易にできるＳｎ合金バンプの製造方法を提供することを目的とする。
本発明は、前記課題を解決するために以下の構成を採用した。すなわち、本発明のＳｎ合金バンプの製造方法は、Ｓｎと他の一種または二種以上の金属との合金で形成されたＳｎ合金バンプの製造方法であって、基板の上に形成されているレジスト開口部内の電極上にＳｎ層を電解めっきにより形成する工程と、前記Ｓｎ層上にＳｎと前記他の金属との合金層を電解めっきにより積層する工程と、前記レジストを除去した後に前記Ｓｎ層と前記合金層とを溶融してＳｎ合金バンプを形成する工程とを有することを特徴とする。　
このＳｎ合金バンプの製造方法では、電極上にＳｎ層を電解めっきにより形成し、該Ｓｎ層上にＳｎと前記他の金属（前記他の一種または二種以上の金属）との合金層を電解めっきにより積層するので、合金層をめっきする際に予め形成したＳｎ層によって開口部の深さが軽減されることから、高さ方向の他の金属の組成ばらつきを抑制することができる。なお、積層する合金層における他の金属は、Ｓｎ層と合金層とが溶融してＳｎ合金バンプとする際の目的の組成に応じて、Ｓｎと他の金属との合金めっきのみの場合よりも組成を高く設定することで、Ｓｎ合金バンプの組成コントロールを行うことができる。　
また、本発明のＳｎ合金バンプの製造方法は、前記他の金属がＡｇであり、前記Ｓｎ層上に前記合金層としてＳｎ－Ａｇ層を電解めっきにより形成する工程と、前記レジストを除去した後に前記Ｓｎ層と前記Ｓｎ－Ａｇ層とを溶融して前記Ｓｎ合金バンプとしてＳｎ－Ａｇバンプを形成する工程とを有することを特徴とする。　すなわち、このＳｎ合金バンプの製造方法では、Ｓｎ層上にＳｎ－Ａｇ層を電解めっきにより形成し、Ｓｎ層とＳｎ－Ａｇ層とを溶融させるので、Ａｇ析出による高さ方向のＡｇ組成のばらつきを低減したＳｎ－Ａｇ合金バンプを形成することができる。　
また、本発明のＳｎ合金バンプの製造方法は、前記他の金属が、二種の金属であり、前記Ｓｎ層上にＳｎと前記二種のうち一方との合金層およびＳｎと前記二種のうち他方との合金層の二層を電解めっきにより積層する工程と、前記レジストを除去した後に前記Ｓｎ層と積層された前記合金層の二層とを溶融してＳｎ合金バンプを形成する工程とを有することを特徴とする。　すなわち、このＳｎ合金バンプの製造方法では、Ｓｎ層上に前記二種のうち一方との合金層およびＳｎと前記二種のうち他方との合金層の二層を電解めっきにより積層するので、合金層の二層をめっきする際に予め形成したＳｎ層によって開口部の深さが軽減されることから、高さ方向の二種の金属の組成ばらつきを抑制することができる。　
さらに、本発明のＳｎ合金バンプの製造方法は、前記二種のうち一方の金属がＡｇであると共に他方の金属がＣｕであり、前記Ｓｎ層上にＳｎ－Ａｇ層とＳｎ－Ｃｕ層との二層を電解めっきにより形成する工程と、前記レジストを除去した後に前記Ｓｎ層と前記Ｓｎ－Ａｇ層と前記Ｓｎ－Ｃｕ層とを溶融して前記Ｓｎ合金バンプとしてＳｎ－Ａｇ－Ｃｕバンプを形成する工程とを有することを特徴とする。　すなわち、このＳｎ合金バンプの製造方法では、Ｓｎ層上にＳｎ－Ａｇ層とＳｎ－Ｃｕ層との二層を電解めっきにより形成し、Ｓｎ層とＳｎ－Ａｇ層とＳｎ－Ｃｕ層とを溶融させるので、ＡｇやＣｕの析出による高さ方向のＡｇやＣｕの組成のばらつきを低減したＳｎ－Ａｇ－Ｃｕ合金バンプを形成することができる。
本発明によれば、以下の効果を奏する。　すなわち、本発明に係るＳｎ合金バンプの製造方法によれば、電極上にＳｎ層を電解めっきにより形成し、該Ｓｎ層上にＳｎと他の金属との合金層を電解めっきにより積層するので、高さ方向の他の金属の組成ばらつきを抑制することができ、各層を溶融して形成するバンプの組成を制御することができる。　したがって、本発明のＳｎ合金バンプの製造方法によれば、高アスペクト比パターンに対応した組成均一性の高いＳｎ合金バンプを得ることができ、ファインピッチ化に対応することが可能になる。
本発明に係るＳｎ合金バンプの製造方法の第１実施形態において、製造工程を工程順に示す概略的な要部断面図である。 本発明に係るＳｎ合金バンプの製造方法の第２実施形態において、製造工程を工程順に示す概略的な要部断面図である。 本発明に係るＳｎ合金バンプの製造方法の実施例において、リフロープロファイルを示すグラフである。
以下、本発明に係るＳｎ合金バンプの製造方法の第１実施形態について、図１を参照して説明する。　
第１実施形態におけるＳｎ合金バンプの製造方法は、ＳｎとＡｇ等の他の一種または二種以上の金属との合金で形成されたＳｎ合金バンプの製造方法であって、図１に示すように、基板１の上に形成されているレジスト２の開口部２ａ内の電極パッド３上にＳｎ層４ａを電解めっきにより形成する工程と、Ｓｎ層４ａ上にＳｎと前記他の金属との合金層４ｂを電解めっきにより積層する工程と、レジスト２を除去した後にＳｎ層４ａと積層された合金層４ｂとをリフロー処理により溶融してＳｎ合金バンプ５を形成する工程とを有している。　
例えば、前記他の金属がＡｇの場合について説明すると、図１の（ａ）に示すように、まず基板１の上に形成されているレジスト２の開口部２ａ内の電極パッド３上にＳｎ層４ａを電解めっきにより形成する。このＳｎ層４ａは、例えば開口部２ａの深さの半分まで形成される。　上記基板１は、半導体ウエハ、プリント基板またはヒートシンク基板などであり、表面にレジスト２がパターニングされて、１．０以上の高アスペクト比パターンでバンプ用の開口部２ａが設けられている。　
また、上記電極パッド３は、例えばＣｕめっき膜３ａとＮｉめっき膜３ｂとを積層した金属膜である。　上記開口部２ａは、例えば深さ：１２０μｍ、開口径：７０μｍとされ、アスペクト比が１．７の高アスペクト比パターンとされる。なお、バンプピッチは、１００数十μｍのファインピッチも可能である。　
次に、図１の（ｂ）に示すように、Ｓｎ層４ａ上にＳｎ－Ａｇ層である合金層４ｂを電解めっきにより形成する。このＳｎ－Ａｇ層である合金層４ｂは、Ｓｎ層４ａと同じ高さで開口部２ａの残り半分を埋めるように形成される。すなわち、Ｓｎ層４ａによって底上げされ実質的なアスペクト比が小さくなった開口部２ａを埋め込むように合金層４ｂ（Ｓｎ－Ａｇ層）が形成される。　
なお、積層する合金層４ｂにおける前記他の金属は、Ｓｎ層４ａと合金層４ｂとが溶融してＳｎ合金バンプとする際の目的の組成に応じて、Ｓｎと他の金属との合金めっきのみの場合よりも組成を高く設定することで、Ｓｎ合金バンプの組成コントロールを行うことができる。　すなわち、第１実施形態において、Ｓｎ－Ａｇ層である合金層４ｂは、リフロー処理後にＳｎ層４ａと溶融したＳｎ合金バンプのＡｇ組成に対応させ、Ｓｎ－ＡｇめっきのみでＳｎ合金バンプを形成する場合に比べてＡｇ組成を高く設定している。例えば、Ｓｎ合金バンプの目標とするＡｇ組成が２．５ｗｔ％である場合、Ｓｎ層４ａと同じ高さのＳｎ－Ａｇ層（合金層４ｂ）では、Ａｇ組成を５ｗｔ％に設定する。　
次に、上記レジスト２を除去し、図１の（ｃ）に示すように、Ｓｎ層４ａと合金層４ｂ（Ｓｎ－Ａｇ層）とをリフロー処理により溶融して略球状のＳｎ合金バンプ５としてＳｎ－Ａｇバンプを形成する。なお、リフロー処理としては、例えば熱風式のリフロー炉を用い、バンプ表面に酸化膜除去を目的としてフラックスを塗布した状態で、窒素雰囲気下で加熱する。　
このように第１実施形態のＳｎ合金バンプの製造方法では、電極パッド３上にＳｎ層４ａを電解めっきにより形成し、該Ｓｎ層４ａ上にＳｎと他の金属との合金層４ｂを電解めっきにより積層するので、合金層４ｂをめっきする際に予め形成したＳｎ層４ａによって開口部２ａの深さが軽減されることから、高さ方向の前記他の金属の組成ばらつきを抑制することができる。したがって、リフロー処理後のＳｎ合金バンプ５の組成コントロールが容易になる。　
特に、第１実施形態では、Ｓｎ層４ａ上にＳｎ－Ａｇ層である合金層４ｂを電解めっきにより形成し、Ｓｎ層４ａと合金層４ｂ（Ｓｎ－Ａｇ層）とを溶融させるので、Ａｇ析出による高さ方向のＡｇ組成のばらつきを低減し、Ａｇ組成をコントロールしたＳｎ－Ａｇ合金バンプを形成することができる。　
次に、本発明に係るＳｎ合金バンプの製造方法の第２実施形態について、図２を参照して説明する。なお、以下の実施形態の説明において、上記実施形態において説明した同一の構成要素には同一の符号を付し、その説明は省略する。　
第２実施形態と第１実施形態との異なる点は、第１実施形態では、Ｓｎ層４ａ上にＳｎと一種の金属（Ａｇ）との合金層４ｂを形成してリフロー処理によってＳｎ合金バンプを形成しているのに対し、第２実施形態では、前記他の金属が二種の金属であり、Ｓｎと二種の金属との合金で形成されたＳｎ合金バンプの製造方法であって、図２に示すように、Ｓｎ層４ａ上にＳｎと前記二種のうち一方との第１合金層２４ｂおよびＳｎと前記二種の
うち他方との第２合金層２４ｃの二層を電解めっきにより積層し、これをリフロー処理する点である。　
例えば、第２実施形態として、前記二種のうち一方の金属がＡｇであると共に他方の金属がＣｕである場合について説明すると、図２の（ａ）に示すように、まず基板１の上に形成されているレジスト２の開口部２ａ内の電極パッド３上にＳｎ層４ａを電解めっきにより形成する。　次に、図１の（ｂ）に示すように、Ｓｎ層４ａ上にＳｎ－Ｃｕ層である第１合金層２４ｂとＳｎ－Ａｇ層である第２合金層２４ｃとの二層を電解めっきにより積層して形成する。　
これらのＳｎ－Ｃｕ層である第１合金層２４ｂおよびＳｎ－Ａｇ層である第２合金層２４ｃは、開口部２ａの残り半分を埋めるように形成される。　例えば、上記各層の厚さは、Ｓｎ層４ａ：第１合金層２４ｂ（Ｓｎ－Ｃｕ層）：第２合金層２４ｃ（Ｓｎ－Ａｇ層）＝１：１：３の比率で形成する。　
なお、第１合金層２４ｂおよび第２合金層２４ｃにおける前記二種の金属は、Ｓｎ層４ａと第１合金層２４ｂと第２合金層２４ｃとが溶融してＳｎ合金バンプ２５とする際の目的の組成に応じて、Ｓｎと前記二種の金属との合金めっきのみの場合よりも組成を高く設定することで、Ｓｎ合金バンプの組成コントロールを行うことができる。　
すなわち、第２実施形態において、第１合金層２４ｂ（Ｓｎ－Ｃｕ層）および第２合金層２４ｃ（Ｓｎ－Ａｇ層）は、リフロー処理後に溶融したＳｎ合金バンプのＡｇ組成およびＣｕ組成に対応させ、Ｓｎ－Ａｇ－ＣｕめっきのみでＳｎ合金バンプを形成する場合に比べてＡｇ組成およびＣｕ組成を高く設定している。例えば、Ｓｎ合金バンプ２５の目標とする組成が、Ｓｎ－３Ａｇ－０．５Ｃｕ（質量％）である場合、第１合金層２４ｂ（Ｓｎ－Ｃｕ層）のＣｕ組成を２．５ｗｔ％に設定し、第２合金層２４ｃ（Ｓｎ－Ａｇ層）のＡｇ組成を５ｗｔ％に設定する。　
次に、上記レジスト２を除去し、図２の（ｃ）に示すように、Ｓｎ層４ａと第１合金層２４ｂ第２合金層２４ｃとをリフロー処理により溶融して略球状のＳｎ合金バンプ２５としてＳｎ－Ａｇ－Ｃｕバンプを形成する。　なお、Ｓｎ層４ａ上に、第１合金層２４ｂ（Ｓｎ－Ｃｕ層）、第２合金層２４ｃ（Ｓｎ－Ａｇ層）の順に積層しているが、逆に第２合金層２４ｃ（Ｓｎ－Ａｇ層）、第１合金層２４ｂ（Ｓｎ－Ｃｕ層）の順に積層しても構わない。　
このように第２実施形態のＳｎ合金バンプの製造方法では、Ｓｎ層４ａ上にＳｎと前記二種のうち一方との第１合金層２４ｂおよびＳｎと前記二種のうち他方との第２合金層２４ｃの二層を電解めっきにより積層するので、第１合金層２４ｂをめっきする際に予め形成したＳｎ層４ａによって開口部２ａの深さが軽減され、さらに第２合金層２４ｃをめっきする際に第１合金層２４ｂによって開口部２ａの深さがより軽減されることから、高さ方向の前記二種の金属の組成ばらつきを抑制することができる。　
特に、第２実施形態では、Ｓｎ層４ａ上にＳｎ－Ａｇ層の第１合金層２４ｂとＳｎ－Ｃｕ層の第２合金層２４ｃとの二層を電解めっきにより形成し、Ｓｎ層４ａと第１合金層２４ｂと第２合金層２４ｃとを溶融させるので、ＡｇやＣｕの析出による高さ方向のＡｇやＣｕの組成のばらつきを低減し、Ａｇ組成およびＣｕ組成をコントロールしたＳｎ－Ａｇ－Ｃｕ合金バンプを形成することができる。
次に、本発明に係るＳｎ合金バンプの製造方法について、上記実施形態に基づき作製した実施例により評価した結果を説明する。　
基板としては、直径１２インチ（３０．４８ｃｍ）のウエハを用い、その表面に開口径８０μｍの高アスペクト比パターンの開口部を２００μｍピッチで形成した厚さ：１２０μｍのレジストをパターン形成した。　まず、第１実施形態に対応した実施例１として、Ｓｎめっき液及びＳｎ－Ａｇめっき液の新液を用いて、以下の条件にて電解めっきを行った。　
すなわち、Ｓｎめっきを厚さ：６０μｍ、Ｓｎ－Ａｇめっきを厚さ：６０μｍで二層めっきを行い、Ｓｎ層と合金層（Ｓｎ－Ａｇ層）とを積層した。この際、リフロー後のＳｎ合金バンプにおけるＡｇ組成が２．５ｗｔ％となるように条件を設定して電解めっきを行った。すなわち、めっき液中のＡｇ濃度をＳｎ－ＡｇめっきのみでＳｎ合金バンプを形成する場合の倍に調整した。　
さらに、レジスト除去後にリフロー処理を行い、実施例１のＳｎ合金バンプを形成した。この際のリフロー処理は、熱風式のリフロー炉で実施し、バンプ表面の酸化膜除去を目的としてバンプ表面にフラックスを塗布し、窒素雰囲気下（酸素濃度１００ｐｐｍ以下）にて図３に示すリフロープロファイル条件で実施した。　
また、比較例１として、Ｓｎ－Ａｇめっきのみで実施例１と同様の高アスペクト比パターンの開口部に厚さ：１２０μｍでＳｎ－Ａｇ層の単層を形成し、実施例１と同様のリフロー処理でＳｎ合金バンプを形成した。この際、リフロー後のＳｎ合金バンプにおけるＡｇ組成が２．５ｗｔ％となるように条件を設定して電解めっきを行った。　さらに、実施例２および比較例２として、約１０００枚のウエハにめっき処理を行った後のＳｎ－Ａｇめっき液にて、実施例１および比較例１とそれぞれ同条件にて電解めっきを実施し、上記と同様のリフロー処理でＳｎ合金バンプを形成した。なお、これらの液中のＡｇ濃度は、実施例１および比較例１の条件と等しい濃度に設定した。　
これら実施例１，２および比較例１，２のＳｎ合金バンプについて、Ａｇ組成をＸＲＦ（蛍光Ｘ線分析）にて測定した結果、平均バンプ組成が、実施例１：２．５ｗｔ％、比較例１：２．５ｗｔ％、実施例２：２．４ｗｔ％、比較例２：２．０ｗｔ％であった。このように、新液のめっき液を用いた実施例１および比較例１では、目標とするＡｇ組成が得られているのに対し、１０００枚のウエハのめっき処理後に相当するめっき液を用いた場合、比較例２では、Ａｇ組成が目標とする組成よりも低くなっているのに対し、実施例１では、目的とするＡｇ組成がほぼ維持されている。　
次に、第２実施形態に対応した実施例３として、Ｓｎめっき液、Ｓｎ－Ｃｕめっき液及びＳｎ－Ａｇめっき液の新液を用いて、以下の条件にて電解めっきを行った。　すなわち、実施例１と同様のウエハを用い、Ｓｎめっきを厚さ：２４μｍ、膜中Ｃｕ組成が２．５ｗｔ％になる条件にてＳｎ－Ｃｕめっきを厚さ２４μｍ、膜中Ａｇ組成が５ｗｔ％になる条件にてＳｎ－Ａｇめっきを厚さ：７２μｍで三層めっきを行い、リフロー処理後のＳｎ合金バンプの組成がＳｎ－３Ａｇ－０．５Ｃｕとなるように電解めっきを実施した。さらに、レジスト除去後にリフロー処理を行い、実施例２のＳｎ合金バンプを形成した。　
さらに、約１０００枚のウエハめっき処理後に相当する電解を掛けた後、同条件にて上記めっき処理を実施した。それらのリフロー処理後のＳｎ合金バンプにおけるＡｇ組成をＸＲＦにて測定したところ、平均バンプ組成は電解による影響を受けず、一定であった。　
なお、本発明の技術範囲は上記実施形態及び上記実施例に限定されるものではなく、本発明の趣旨を逸脱しない範囲において種々の変更を加えることが可能である。　
例えば、上記第２実施形態のように、Ｓｎ層上に第１合金層２４ｂ（Ｓｎ－Ｃｕ層）と第２合金層２４ｃ（Ｓｎ－Ａｇ層）との二層を積層し、これらをリフロー処理で溶融してＳｎ－Ａｇ－Ｃｕ三元系のバンプを形成することが好ましいが、Ｓｎ層上にＳｎと二種の金属であるＡｇおよびＣｕとの合金層としてＳｎ－Ａｇ－Ｃｕ層を積層し、これらをリフロー処理で溶融してＳｎ－Ａｇ－Ｃｕ三元系のバンプを形成しても構わない。
１…基板、２…レジスト、２ａ…開口部、３…電極パッド（電極）、４ａ…Ｓｎ層、４ｂ…合金層、５，２５…Ｓｎ合金バンプ、２４ｂ…第１合金層、２４ｃ…第２合金層

Claims (4)

  1. Ｓｎと他の一種または二種以上の金属との合金で形成されたＳｎ合金バンプの製造方法であって、　基板の上に形成されているレジスト開口部内の電極上にＳｎ層を電解めっきにより形成する工程と、　前記Ｓｎ層上にＳｎと前記他の金属との合金層を電解めっきにより積層する工程と、　前記レジストを除去した後に前記Ｓｎ層と前記合金層とを溶融してＳｎ合金バンプを形成する工程とを有することを特徴とするＳｎ合金バンプの製造方法。
  2. 請求項１に記載のＳｎ合金バンプの製造方法において、　前記他の金属がＡｇであり、　前記Ｓｎ層上に前記合金層としてＳｎ－Ａｇ層を電解めっきにより形成する工程と、　前記レジストを除去した後に前記Ｓｎ層と前記Ｓｎ－Ａｇ層とを溶融して前記Ｓｎ合金バンプとしてＳｎ－Ａｇバンプを形成する工程とを有することを特徴とするＳｎ合金バンプの製造方法。
  3. 請求項１に記載のＳｎ合金バンプの製造方法において、　前記他の金属が、二種の金属であり、　前記Ｓｎ層上にＳｎと前記二種のうち一方との合金層およびＳｎと前記二種のうち他方との合金層の二層を電解めっきにより積層する工程と、　前記レジストを除去した後に前記Ｓｎ層と積層された前記合金層の二層とを溶融してＳｎ合金バンプを形成する工程とを有することを特徴とするＳｎ合金バンプの製造方法。
  4. 請求項３に記載のＳｎ合金バンプの製造方法において、　前記二種のうち一方の金属がＡｇであると共に他方の金属がＣｕであり、　前記Ｓｎ層上にＳｎ－Ａｇ層とＳｎ－Ｃｕ層との二層を電解めっきにより形成する工程と、　前記レジストを除去した後に前記Ｓｎ層と前記Ｓｎ－Ａｇ層と前記Ｓｎ－Ｃｕ層とを溶融して前記Ｓｎ合金バンプとしてＳｎ－Ａｇ－Ｃｕバンプを形成する工程とを有することを特徴とするＳｎ合金バンプの製造方法。
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