WO2020215738A1 - 一种芯片互连结构及其制备方法 - Google Patents

一种芯片互连结构及其制备方法 Download PDF

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WO2020215738A1
WO2020215738A1 PCT/CN2019/123823 CN2019123823W WO2020215738A1 WO 2020215738 A1 WO2020215738 A1 WO 2020215738A1 CN 2019123823 W CN2019123823 W CN 2019123823W WO 2020215738 A1 WO2020215738 A1 WO 2020215738A1
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chip
metal film
nano metal
layer
nano
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PCT/CN2019/123823
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English (en)
French (fr)
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刘旭
叶怀宇
张卫红
敖日格力
李俊
韩飞
张国旗
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深圳第三代半导体研究院
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Publication of WO2020215738A1 publication Critical patent/WO2020215738A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/054—Nanosized particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
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Definitions

  • the present invention relates to the field of chip package interconnection, and more specifically to the preparation technology of metal film for sintering.
  • nano-silver sintering has gradually become the mainstream of power semiconductor device packaging interconnection, and major packaging application manufacturers at home and abroad have entered practical and large-scale use.
  • nano-silver sintering patents, materials, processes and equipment are mainly controlled by foreign manufacturers, and their development in China is greatly restricted.
  • the nano-silver sintering technology also has shortcomings: 1) The high price of silver material itself limits its wide use. 2) The thermal expansion coefficients of the backside materials of silver and SiC chips are different, and other intermediate metal layers need to be added to improve interconnection performance, thereby increasing process complexity and cost. 3) Electromigration exists in the silver layer, which is not conducive to long-term reliable application of power devices.
  • Nano-copper particles similar to nano-silver can be melted under low temperature conditions, and the melting point after sintering is close to copper elemental material (1083°C), which can construct a stable metal interconnection layer. Its single-component metal characteristics avoid the service reliability problem under the thermal cycling effect of alloy materials, realize copper-copper bonding, solve the problem of thermal expansion coefficient matching between the chip and the substrate, and avoid the reliability problem caused by electromigration. Compared with nano-silver particles, it effectively reduces the material and processing costs of interconnect packaging. More importantly, it can further promote the practical application and industrialization of the "All copper" concept from the field of chip packaging applications, and promote the innovative development of the semiconductor industry.
  • the first prior art is a patent document with the publication number CN103262172A, which discloses a sintered material and a thin layer prepared from the sintered material, and an adhesion method of the material.
  • the thin layer is composed of metal powder, solder paste, adhesive and solvent.
  • the metal powder includes gold, palladium, silver, copper, aluminum, silver-palladium alloy or gold-palladium alloy, and may further include one or more functional additives.
  • the metal powder includes nanoparticles.
  • the metal powder is applied to the substrate, and the material on the substrate is dried to form a thin layer.
  • the substrate material includes polyester fiber.
  • the disadvantage of the prior art is that the nano metal layer on the substrate has a single composition and size, which results in a large porosity after sintering and poor electrical and thermal conductivity.
  • the second prior art is the patent document with publication number CN105492198A, which discloses a composite and multilayer silver film for electrical parts and mechanical parts, in which reinforcing particles or fibers are added to the sinterable silver layer to increase its strength.
  • a reinforced metal foil layer is added to the slightly decomposable silver particle layer. Its composition can be silver, copper, gold or any other metal or any alloy, or it can be a metal polymer or ceramic foil, or it can be composite or Plating structure with different metal and alloy layers.
  • the reinforced metal foil layer can be applied in solid, perforated or grid form.
  • the problem with the prior art is that the addition of the multilayer composite metal film and the reinforced metal foil layer increases the number of interfaces of the connection layer after sintering, thereby possibly reducing the connection strength; in addition, the single-size silver particle layer is sintered.
  • the porosity is large, which reduces thermal conductivity, electrical conductivity and shear stress, thereby reducing reliability.
  • the third prior art is a Chinese patent application with a patent publication number CN106660120A, which discloses a discrete sintered material and a fixing method using it.
  • the material includes metal powder and a substrate.
  • the metal powder includes shell-structured nanoparticles and the substrate includes a polymer.
  • the disadvantage of this method is that on the one hand, a large sintered metal film is used.
  • the gas generated at the center position has no effective channel to remove, which may cause problems such as large porosity of the interconnection layer after sintering; printing or pouring is used directly
  • the method of preparing discrete shapes may cause the shape of the discrete pieces to depend on the design of the printing screen, and it is difficult to change the shape; it also causes problems such as rough edges, uneven thickness, and low resolution.
  • the present invention provides a chip interconnection structure, which includes:
  • N pieces of nano metal film N ⁇ 2
  • the nano metal film chip includes first size nano metal particles and second size nano metal particles,
  • the diameter of the first size nano metal particles is different from that of the second size nano metal particles.
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the larger-size nano-metal particles have a diameter of 1nm ⁇ D ⁇ 10 ⁇ m; the first-size nano-metal particles and the second-size Among the size nano metal particles, the diameter of the smaller size nano metal particles is 0.5nm ⁇ d ⁇ 20nm.
  • the nano metal film chips are located between the chip and the substrate, and the nano metal film chips are arranged at intervals; one or more nano metal film chips are arranged between the chip and the substrate, and different layers of the nano metal film chips are arranged. There is a continuous nano metal film between.
  • the multilayer nano metal chip includes:
  • the first organic medium material layer is the first organic medium material layer
  • the second organic medium material layer is the second organic medium material layer
  • the first organic medium material layer contains first-size nano metal particles
  • the first organic medium material layer contains second-size nano metal particles
  • the first size nano metal particles and the second size nano metal particles have different diameters.
  • the multi-layer nano metal film chip distribution mode is:
  • N N 1 +N 2 +...+N n .
  • a method for connecting a chip interconnection structure includes:
  • Step 1 Prepare a nano metal film, the nano metal film includes first size nano metal particles and second size nano metal particles, the first size nano metal particles and the second size nano metal particles have different diameters;
  • Step 2 Cutting the nano metal film to obtain N nano metal film pieces
  • Step 3 Attach one side of the nano metal film chip to the bottom of the chip
  • Step 4 Attach the substrate and the other side of the nano metal film chip
  • Step 5 Interconnect the chip and the substrate.
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the larger-size nano-metal particles have a diameter of 1nm ⁇ D ⁇ 10 ⁇ m; the first-size nano-metal particles and the second-size Among the size nano metal particles, the diameter of the smaller size nano metal particles is 0.5nm ⁇ d ⁇ 20nm.
  • the nano metal film chips are located between the chip and the substrate, and the nano metal film chips are arranged at intervals; one or more nano metal film chips are arranged between the chip and the substrate, and different layers of the nano metal film chips are arranged. There is a continuous nano metal film between.
  • the distribution mode of the nano metal film pieces of the one layer includes:
  • the nano metal film pieces are attached to the bottom of the chip according to length A and width B.
  • the multi-layer nano metal film chip distribution mode includes:
  • a 31 th the length, total width B 31 the N 1 th metal adhesive film pieces are arranged according to the design of the bottom of the chip, and then dried to obtain a first metal film layer;
  • the metal film pieces of the length A 3n and the width B 3n totaling N n are adhered to the bottom of the n-1th metal film layer according to the designed arrangement, and then dried to obtain the nth metal film layer.
  • the step 3 and step 4 further include drying treatment.
  • the step 4 further includes:
  • Step 5.1 Peel off the supporting substrate
  • Step 5.2 Place the chip with the multilayer metal film on the substrate
  • Step 5.3 Heat the multi-layer metal film chip in the sintering furnace, select whether to have pressure assist, and interconnect the substrate and the multi-layer metal film chip.
  • the metal film is set as a plurality of discontinuous small pieces and arranged between the chip and the substrate according to the pre-designed arrangement.
  • the small piece gaps left by the discrete arrangement can be used as channels for gas exhaust during sintering, which is beneficial to the improvement of compactness after sintering. This improves the thermal conductivity of the interconnection layer; at the same time, as the sintering progresses, due to the limitation of the z-direction, the metal film pieces will deform in the x and y directions, and contact each other to form a dense sintered layer, which is compared with using a single piece
  • the large metal film can effectively reduce the tilt problem in the chip bonding process.
  • FIG. 1 is a schematic diagram of a discontinuous nano-copper sintered film provided by Embodiment 1 of the present invention.
  • FIG. 2 is a schematic diagram of a structure method using a single-layer discontinuous metal film sintered interconnection provided in the second embodiment.
  • FIG 3 is a schematic diagram of a structure method using a multilayer discontinuous metal film sintered interconnection provided in the third embodiment.
  • FIG. 4 is a schematic diagram of a structure method using a multilayer periodic discontinuous metal film sintered interconnection provided by the fourth embodiment.
  • This embodiment provides a chip substrate connection structure and method using a nano metal film, as shown in FIG. 1, including:
  • the metal film includes an organic carrier and nano metal particles
  • the metal film may have a single-layer structure or a multilayer structure
  • the single-layer structure may include first-size nano-metal particles and second-size nano-metal particles mixed together;
  • the multilayer structure includes a layer of nano metal particles of a first size and a layer of nano metal particles of a second size
  • the diameter of the first size nano metal particles is different from that of the second size nano metal particles.
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the larger-size nano-metal particles have a diameter of 1 nm ⁇ D ⁇ 10 ⁇ m.
  • the pre-formed metal film pieces can be formed by forging, shearing or programmable laser cutting to obtain a sequence of discrete structured films in a specific shape.
  • discontinuous means that the metal film at the bottom of the chip is not a complete piece, but multiple pieces with a certain interval. Arranged small metal film structure.
  • the discontinuous metal film sintered interconnection structure is characterized in that the sizes of the N metal film pieces are all the same; or all are different; or a combination of the same and different sizes of multilayer metal films.
  • the discontinuous metal film sintered interconnection structure is characterized in that the positions of the N metal film pieces are arranged in an n ⁇ n square matrix (as shown in FIG. 1); the N metal film pieces The size of is set according to [(1/N)-k] which is the area of the bottom surface of the chip, k is the designed chip pitch, and the range of k is 10 ⁇ m to 2mm.
  • This embodiment provides a chip substrate connection structure and method using a single-layer nano metal film, as shown in FIG. 2.
  • the single-layer structure may include first-size nano-metal particles and second-size nano-metal particles mixed together;
  • the mixing methods include: 1) directly prepare the mixed solution; 2) prepare solutions, pastes, and films of large-size particles, and inject small-size particles by physical impact;
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the larger-size nano-metal particles have a diameter of 1 nm ⁇ D ⁇ 10 ⁇ m.
  • the preparation steps include:
  • Step 1 Preparation of a single-layer metal film
  • Step 2 Cut the metal film to obtain N metal film pieces
  • Step 3 Paste the metal film to the bottom of the chip to be interconnected, as shown in FIG. 2, taking a 3x3 chip arrangement as an example;
  • Step 4 Heating the chip with the metal film attached to obtain a chip with the metal film attached
  • Step 5 Interconnect the substrate and the metal film chip.
  • step 1 includes:
  • Step 1.1 configure a mixed solution of nano metal particles with a first size and a nano metal with a second size to prepare a metal paste;
  • Step 1.2 Put the metal paste on the supporting substrate, and dry the supporting substrate to form a metal film;
  • step 5 includes:
  • Step 5.1 Peel off the supporting substrate.
  • Step 5.2 Place the multilayer metal film chip on the substrate
  • Step 5.3 Heat the multi-layer metal film chip in the sintering furnace, select whether to have pressure assist, and interconnect the substrate and the multi-layer metal film chip.
  • the system is optionally sintered at 200-280°C for 10 minutes in a sintering furnace, so that the substrate and the chip are interconnected.
  • test results show that the chip and substrate system interconnected by the discontinuous copper film has a porosity of less than 25% after sintering, effective exhaust of gas, thermal conductivity greater than 100 (W/mK), and shear stress greater than 10MPa.
  • the shear stress is still greater than 8 MPa after 1000 thermal cycles at a temperature of -40 to 150°C.
  • This embodiment provides a chip substrate connection structure and method using a multilayer nano metal film, as shown in FIG. 3.
  • the multi-layer non-continuous metal film includes
  • the first organic medium material layer is the first organic medium material layer
  • the second organic medium material layer is the second organic medium material layer
  • the first organic medium material layer contains first-size nano metal particles
  • the first organic medium material layer contains second-size nano metal particles
  • the first size nano metal particles and the second size nano metal particles have different diameters.
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the preparation steps include
  • Step 1 Preparation of multilayer metal film
  • Step 2 Cut the metal film to obtain N metal film pieces
  • Step 3 Paste the metal film to the bottom of the chip to be interconnected, as shown in Figure 3, taking a 3x3 chip arrangement as an example;
  • Step 4 Heating the chip with the metal film attached to obtain a chip with the metal film attached
  • Step 5 Interconnect the substrate and the metal film chip.
  • step 5 includes:
  • Step 5.1 Peel off the supporting substrate.
  • Step 5.2 Place the multilayer metal film chip on the substrate
  • Step 5.3 Heat the multi-layer metal film chip in the sintering furnace, select whether to have pressure assist, and interconnect the substrate and the multi-layer metal film chip.
  • the system is optionally sintered at 200-280°C for 20 minutes in a sintering furnace, so that the substrate and the chip are interconnected.
  • the test result shows that the porosity after sintering is further increased to less than 20% by using the chip and substrate system interconnected by the discontinuous copper film.
  • This embodiment provides a chip substrate connection structure and method using periodic multilayer nano metal films, as shown in FIG. 4.
  • the multi-layer discontinuous metal film includes:
  • the first organic medium material layer is the first organic medium material layer
  • the second organic medium material layer is the second organic medium material layer
  • the first organic medium material layer contains first-size nano metal particles
  • the first organic medium material layer contains second-size nano metal particles
  • the first size nano metal particles and the second size nano metal particles have different diameters.
  • the first material layer and the second material layer have different length, width and height dimensions
  • the nano metal particle material is copper.
  • the nano metal particle material is gold, palladium, silver, copper, aluminum, silver-palladium alloy, gold-palladium alloy, copper-silver alloy, copper-silver-nickel alloy or copper-aluminum alloy.
  • the method for sintering interconnections using a multilayer discontinuous metal film specifically includes the following steps:
  • Step 1 Preparation of multilayer metal film A, B;
  • Step 2 Cut the metal film to obtain N metal film small pieces b (number 10 in FIG. 4);
  • Step 3 Paste the metal film A on the bottom of the chip to be interconnected and dry
  • Step 4 Paste the N metal film pieces b on the bottom of the metal film A according to the designed arrangement, and dry;
  • Step 5 Paste another metal film A to the bottom of the n metal film pieces b, and dry;
  • Step 6 heating the chip with the metal film attached to obtain a chip with the metal film attached
  • Step 7 Interconnect the substrate and the metal film chip.
  • test results show that using the discontinuous copper film interconnected chip and substrate system, the porosity after sintering is increased to less than 20%, and the gas is effectively discharged.
  • the original continuous metal film is set into a plurality of discontinuous small pieces and arranged in a pre-designed arrangement between the chip and the substrate, discretely arranged
  • the gap between the small pieces of the cloth can be used as a channel for gas exhaust during sintering, which is beneficial to the improvement of the compactness after sintering, thereby improving the thermal conductivity of the interconnection layer; at the same time, as the sintering progresses, the metal film small pieces are If it is restricted, it will deform in the x and y directions and contact each other to form a dense sintered layer.
  • the discontinuous multi-sheet metal film structure adopted by the present invention can effectively reduce the tilt problem in the chip bonding process. Therefore, the structure and process are also suitable for interconnecting power chips of larger sizes in the future.
  • Nano metal particles prepared by chemical methods in the packaging field are difficult to achieve the preparation and subsequent stable retention of nano metal particles with a particle size of less than 20 nm or even less than 1 nm. Although the operation and environment are strictly controlled, the particle size range of the same batch is still There are technical problems of poor distribution concentration and large dispersion, which will affect the performance of the metal film after sintering to varying degrees.
  • the above-mentioned metal particle size design adopted in the present invention achieves the effects of improving the compactness of the metal layer and reducing the porosity after sintering, which cannot be achieved by the combination of nano metal particles of other diameter sizes.
  • the present invention preferably uses nano-copper instead of nano-silver materials, thereby effectively reducing the material and processing of interconnect packaging cost.
  • the sintering nano-copper film made of nano-copper powder and paste has the excellent characteristics of copper materials, but also has the portability and easy formability of metal sintered films. It is the first choice for the next generation of electrical interconnection.
  • the discontinuous nano metal sintered film for chip solidification and the method provided by the present invention solve the problems of high porosity, low thermal conductivity and chip tilt of the original metal sintered film, which is beneficial to the improvement of compactness after sintering and improves
  • the thermal conductivity of the interconnection layer is improved, and it is the first choice for the next generation of electrical interconnection.

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Abstract

一种芯片互连结构及其制备方法，结构包括：芯片（2），N个纳米金属膜小片（6，10），N≥2，基板（3），所述纳米金属膜小片（6，10）包括第一尺寸纳米金属颗粒及第二尺寸纳米金属颗粒，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同。解决了原有金属烧结膜高孔隙率、低热导率、芯片倾斜的问题，有利于烧结后致密性的提高，提升了互连层的热导率。

Description

一种芯片互连结构及其制备方法 技术领域
本发明涉及芯片封装互连领域，更具体地涉及烧结用金属膜的制备技术。
背景技术
在功率半导体封装领域，寻求低温工艺、高温服役、热膨胀系数相匹配、高导热导电、低成本的互连材料成为现在急需解决的问题。以焊接及引线键合的传统材料工艺存在熔点低、高温蠕变失效、引线缠绕、寄生参数等无法解决的问题，新型互连材料正从焊接向烧结技术发展。通过减小烧结颗粒的尺寸，降低烧结温度，纳米金属颗粒烧结技术已经成为功率半导体器件新型互连材料中最有前景的技术。
目前以纳米银烧结为代表的先进工艺已逐渐成为功率半导体器件封装互连的主流，国内外主要封装应用厂商已进入实用化和规模化使用中。然而纳米银烧结专利、材料、工艺及设备主要由国外厂商控制，在国内的发展受到较大限制。同时纳米银烧结技术也存在不足：1)银材料本身价格较高，限制其不能被广泛使用。2)银和SiC芯片背面材料热膨胀系数的不同，需要添加其它中间金属层提高互连性能，从而增加了工艺复杂性和成本。3)银层存在电迁移现象，不利于功率器件长期可靠应用。与纳米银近似的纳米铜颗粒可以在低温条件下熔融，烧结后熔点接近铜单质材料(1083℃)，可构筑稳定的金属互连层。其单组分金属的特性，避免了合金材料热循环效应下的服役可靠性问题，实现铜铜键合，解决芯片和基板之间热膨胀系数匹配的问题，同时避免电迁移现象导致可靠性问题。对比纳米银颗粒，有效降低互连封装的材料和加工成本。更重要的是能够从芯片封装应用领域，进一步推进“全铜化”(All copper)理念的实际应用和产业化，推动半导体产业的创新发展。
现有技术一为公开号为CN103262172A的专利文献，公开了一种烧结材料和烧结材料制备的薄层，以及该材料的附着方法。薄层是由金属粉末、焊膏、粘合剂和溶剂组成。其中金属粉末包括金、钯、银、铜、铝、银钯合金或者金钯合金，可进一步包括一种或更多的功能性添加物。金属粉末包括纳米颗粒。金属粉末被适用到基片上，对基片上的材料进行干燥形成薄层。基片材料包括聚酯纤维，该现有技术的缺点在于 基片上的纳米金属层成分、尺寸单一，由此造成烧结后孔隙率较大，导电导热效果差等后果。
现有技术二为公开号为CN105492198A专利文献，公开了一种用于电气部件和机械部件的复合和多层银膜，其中在可烧结银层中加入了增强颗粒或纤维，以提高其强度。进一步在可稍解的银颗粒层上外加了增强金属箔层，其成分可以是银、铜、金或任何其他金属或任何合金，也可以是金属聚合物或陶瓷箔，还可以是复合的或具有不同金属和合金层的镀层结构。增强金属箔层可以固体的、穿孔或网格等形式施加。然而该现有技术的问题在于该多层复合金属膜、增强金属箔层的加入，增加了烧结后连接层的界面数，从而可能降低连接强度；此外，单一尺寸的银颗粒层，在烧结后孔隙率很大，会降低热导率、电导率和剪切应力，从而降低可靠性。
现有技术三为专利公开号为CN106660120A的中国专利申请，其公开了一种离散的烧结材料和使用其的固定方法。材料包括金属粉末和基材，金属粉末包括壳结构的纳米颗粒，基材包括聚合物。在聚合物基材上通过印刷或浇筑金属粉末膜，并使用特定方法使该材料形成离散形状的阵列。该方法的缺点在于一方面使用的是大片烧结金属膜，烧结过程中，居中位置产生的气体没有有效的通道排除，由此可能造成烧结后互连层孔隙率大等问题；直接使用印刷或浇筑方式制备离散形状可能导致离散小片的形状依赖印刷丝网的设计，变换形状困难；同时也会导致边缘粗糙、厚度不均、解析度低等问题。
发明内容
为克服现有技术的不足，避免原有金属烧结膜膜高孔隙率、低热导率、芯片倾斜的问题，本发明提供了一种芯片互连结构，包括：
芯片，
N个纳米金属膜小片，N≥2，
基板，
所述纳米金属膜小片包括第一尺寸纳米金属颗及第二尺寸纳米金属颗粒，
所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同。
优选的，所述纳米金属颗粒材料为铜。
优选的，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
优选的，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm；所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
优选的，所述纳米金属膜小片位于芯片和基板之间，纳米金属膜小片之间间隔排列；芯片和基板之间排列有一层或多层纳米金属膜小片并且多层纳米金属膜小片的不同层之间具有连续的纳米金属膜。
优选的，所述N个单层纳米金属小片按照长A 1个，宽B 1个排列，N＝A 1*B 1。
优选的，所述N个多层纳米金属小片按照长A 2个，宽B 2个排列，N＝A 2*B 2。
优选的，所述多层纳米金属小片包括：
第一有机介质材料层，
第二有机介质材料层；
所述第一有机介质材料层中包含第一尺寸纳米金属颗粒，
所述第一有机介质材料层中包含第二尺寸纳米金属颗粒；
所述第一尺寸纳米金属颗粒与第二尺寸纳米金属颗粒直径不同。
优选的，所述多层的纳米金属膜小片分布方式为：
第一金属膜层，所述第一金属膜层包括长A 31个，宽B 31个排列的单层纳米金属膜小片或多层纳米金属膜小片，N 1＝A 31*B 31；
第二金属膜层，所述第二金属膜层包括长A 32个，宽B 32个排列的单层纳米金属膜小片或多层纳米金属膜小片，N 2＝A 32*B 32；
……
第n金属膜层，所述第n金属膜层包括长A 3n个，宽B 3n个排列的单层纳米金属膜小片或多层纳米金属膜小片，N n＝A 3n*B 3n；
N＝N 1+N 2+…+N n。
一种芯片互连结构连接方法，包括：
步骤1：制备纳米金属膜，所述纳米金属膜包括第一尺寸纳米金属颗及第二尺寸纳米金属颗粒，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同；
步骤2：切割所述纳米金属膜，获得N个纳米金属膜小片；
步骤3：将所述纳米金属膜小片一面和芯片底部贴合；
步骤4：将基板和纳米金属膜小片的另一面贴合；
步骤5：将芯片和基板互连。
优选的，所述纳米金属颗粒材料为铜。
优选的，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
优选的，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm；所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
优选的，所述纳米金属膜小片位于芯片和基板之间，纳米金属膜小片之间间隔排列；芯片和基板之间排列有一层或多层纳米金属膜小片并且多层纳米金属膜小片的不同层之间具有连续的纳米金属膜。
优选的，所述一层的纳米金属膜小片分布方式包括：
将所述纳米金属膜小片按照长A个，宽B个贴至芯片底部。
优选的，所述多层的纳米金属膜小片分布方式包括：
将所述长A 31个，宽B 31个共N 1个金属膜小片按照设计排列黏贴至所述芯片底部，然后进行干燥处理，获得第一金属膜层；
将所述长A 32个，宽B 32个共N 2个金属膜小片按照设计排列黏贴至所述第一金属膜层底部，然后进行干燥处理，获得第二金属膜层；
……
将所述长A 3n个，宽B 3n个共N n个金属膜小片按照设计排列黏贴至所述第n-1金属膜层底部，然后进行干燥处理，获得第n金属膜层。
优选的，所述步骤3、步骤4还包括干燥处理。
优选的，所述步骤4还包括：
步骤5.1：剥离支撑基材；
步骤5.2：将所述贴好多层金属膜的芯片置于基板上；
步骤5.3：在烧结炉中对多层金属膜芯片进行加热，选择有无压力辅助，互连基板与多层金属膜芯片。
金属膜设置为多个非连续小片并按照预先设计排列置于芯片与基板之间，离散排布留出的小片间隙可以作为在烧结时气体排出的通道，有利于烧结后致密性的提高，由此提升互连层的热导率；同时，随着烧结进行，金属膜小片由于z方向的限制，会产生x、y方向的变形，并相互接触，形成致密烧结层，相比于使用单片大金属膜，可以有效减少芯片固晶过程中的倾斜问题。
附图说明
图1为本发明实施例一提供的非连续纳米铜烧结膜示意图。
图2为实施例二提供的利用单层非连续的金属膜烧结互连的结构方法示意图。
图3为实施例三提供的利用多层非连续的金属膜烧结互连的结构方法示意图。
图4为实施例四提供的利用多层周期性非连续的金属膜烧结互连的结构方法示意图。
离散布置的纳米铜膜(烧结前)1，芯片(为便于观察，设置为可透视)2，基板3离散布置纳米铜膜(烧结中)4，完整互连层(烧结后)5，单层复合纳米铜膜小片6，大尺寸纳米铜颗粒7，小尺寸纳米铜颗粒8，第一材料层9，第二材料层10
具体实施方式
下面详细说明本发明的具体实施，有必要在此指出的是，以下实施只是用于本发明的进一步说明，不能理解为对本发明保护范围的限制，该领域技术熟练人员根据上述本发明内容对本发明做出的一些非本质的改进和调整，仍然属于本发明的保护范围。
实施例一
本实施例提供一种利用纳米金属膜的芯片基板连接结构及方法，如图1所示，包括：
芯片，
N个与预成型金属膜小片，N≥2，N＝n^2,n为自然数，(例如N＝4、9、16…)
基板，
所述金属膜包括有机载体和纳米金属颗粒；
所述金属膜可以是单层结构，也可以是多层结构；
所述单层结构内可包含第一尺寸纳米金属颗及第二尺寸纳米金属颗粒混合在一起；
所述多层结构包括第一尺寸纳米金属颗的层及第二尺寸纳米金属颗粒的层，
所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同。
所述纳米金属颗粒材料为铜。
所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm。如权利要求1所述的非连续的金属膜烧结互连的结构，其特征在于，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
所述预成型金属膜小片可通过锻压、剪切或可编程激光切割获得特定形状的离散结构膜片序列。
连续是指传统固晶工艺中，往往是用一整片固晶材料金属膜固定在芯片底部；非连续是指，在芯片底部的金属膜不是完整一片，而是多片有一定间隔，按照一定排列的小金属膜结构。所述的非连续的金属膜烧结互连的结构，其特征在于，所述N个金属膜小片的尺寸均相同；或均不同；或相同及不同尺寸多层金属膜的组合。
所述的非连续的金属膜烧结互连的结构，其特征在于，所述N个金属膜小片的位置按照n×n的方阵排列(如图1所示)；所述N个金属膜小片的尺寸按照为芯片底面面积的[(1/N)-k]设置，k为设计的小片间距，k的范围在10μm至2mm。
本发明与现有技术获得的纳米金属膜的相关性能对比如下：
表1
Figure PCTCN2019123823-appb-000001
实施例二
本实施例提供一种利用单层纳米金属膜的芯片基板连接结构及方法，如图2所示。
所述单层结构内可包含第一尺寸纳米金属颗及第二尺寸纳米金属颗粒混合在一起；
混合方式包括：1)直接配置混合溶液；2)制备大尺寸颗粒的溶液和膏体、膜，物理冲击法打入小尺寸颗粒；
所述纳米金属颗粒材料为铜。
所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm。如权利要求1所述的非连续的金属膜烧结互连的结构，其特征在于，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
制备步骤包括：
步骤1：制备单层金属膜；
步骤2：剪裁所述金属膜，获得N个金属膜小片；
步骤3：将所述金属膜粘贴至待互连芯片底部，如图2所示，3x3的小片排列为例；
步骤4：对所述贴好金属膜的芯片进行加热，获得黏有金属膜的芯片；
步骤5：互连基板与金属膜芯片。
所述的一种利用单层非连续的金属膜烧结互连的方法，其特征在于，所述步骤1包括：
步骤1.1：配置具有第一尺寸的纳米金属颗粒和第二尺寸纳米金属混合溶液，制备金属膏；
步骤1.2：将所述金属膏置于支撑基材上，干燥支撑基材，形成金属膜；
其特征在于，步骤5包括：
步骤5.1：剥离支撑基材。
步骤5.2：将所述多层金属膜芯片置于基板上；
步骤5.3：在烧结炉中对多层金属膜芯片进行加热，选择有无压力辅助，互连基板与多层金属膜芯片。
具体参数如下：
使用10mmx10mmIGBT dummy芯片，50mmx50mm氧化铝DBC基板，单层的大小尺寸纳米铜颗粒混合金属膜A，小尺寸铜颗粒具有从0.5nm<d<20nm的平均最长尺寸，大尺寸纳米铜颗粒具有从1nm<D<10um的平均最长尺寸；
一、将单层铜膜切出2.5mmx2.5mm小片若干；
二、将所述单层金属小片金属膜粘贴到待互连芯片底部；排列方式为三行三列，金属膜小片之间的两两间距设置为1mm，最外侧金属膜与芯片边缘0.5mm；
三、剥离支撑基材；对芯片和铜膜体系可选的进行100～130℃预加热10min；
四、将该芯片/铜膜体系置于基板上；
五、在烧结炉中对该体系可选的进行200～280℃烧结10分钟，使得基板与芯片形成互连。
测试结果表明，利用所述非连续铜膜互连的芯片和基板体系，烧接后孔隙率小于25％，气体得到了有效排出，导热率大于100(W/mK)，剪切应力大于10MPa。在至少某些测试结果中，在-40到150℃的温度条件下，在1000次的热循环之后，剪切应力仍然大于8MPa。
实施例三
本实施例提供一种利用多层纳米金属膜的芯片基板连接结构及方法，如图3所示。
所述多层非连续的金属膜，包括
第一有机介质材料层，
第二有机介质材料层；
所述第一有机介质材料层中包含第一尺寸纳米金属颗粒，
所述第一有机介质材料层中包含第二尺寸纳米金属颗粒；
所述第一尺寸纳米金属颗粒与第二尺寸纳米金属颗粒直径不同。
优选的，所述纳米金属颗粒材料为铜。
优选的，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
制备步骤包括
步骤1：制备多层金属膜；
步骤2：剪裁所述金属膜，获得N个金属膜小片；
步骤3：将所述金属膜粘贴至待互连芯片底部，如图3所示，3x3的小片排列为例；
步骤4：对所述贴好金属膜的芯片进行加热，获得黏有金属膜的芯片；
步骤5：互连基板与金属膜芯片。
其特征在于，步骤5包括：
步骤5.1：剥离支撑基材。
步骤5.2：将所述多层金属膜芯片置于基板上；
步骤5.3：在烧结炉中对多层金属膜芯片进行加热，选择有无压力辅助，互连基板与多层金属膜芯片。
具体参数如下：
使用10mmx10mmIGBT dummy芯片，50mmx50mm氧化铝DBC基板,3层铜膜，小尺寸铜颗粒膜B在中间，小尺寸铜颗粒具有从0.5nm<d<20nm的平均最长尺寸，大尺寸铜颗粒膜C夹在上下两端，大尺寸纳米铜颗粒具有从1nm<D<10um的平均最长尺寸；
一、将多层铜膜切出2.5mmx2.5mm小片若干；
二、将所述小片金属膜粘贴到待互连芯片底部；排列方式为三行三列，金属膜小片之间的两两间距设置为1mm，最外侧金属膜与芯片边缘0.5mm；
三、剥离支撑基材；对芯片和铜膜体系可选的进行100～130℃预加热20min；
四、将该芯片/铜膜体系置于基板上；
五、在烧结炉中对该体系可选的进行200～280℃烧结20分钟，使得基板与芯片形成互连。
测试结果表明，利用所述非连续铜膜互连的芯片和基板体系，烧接后孔隙率进一步提升到小于20％。
实施例四
本实施例提供一种利用周期性多层纳米金属膜的芯片基板连接结构及方法，如图4所示。
所述多层非连续的金属膜，包括：
第一有机介质材料层，
第二有机介质材料层；
所述第一有机介质材料层中包含第一尺寸纳米金属颗粒，
所述第一有机介质材料层中包含第二尺寸纳米金属颗粒；
所述第一尺寸纳米金属颗粒与第二尺寸纳米金属颗粒直径不同。
所述第一材料层与第二材料层有不同的长宽高尺寸
优选的，所述纳米金属颗粒材料为铜。
优选的，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
利用多层非连续的金属膜烧结互连的方法，具体包括以下步骤：
步骤1：制备多层金属膜A，B；
步骤2：剪裁所述金属膜，获得N个金属膜小片b(如图4中序号10)；
步骤3：将所述金属膜A粘贴至待互连芯片底部，干燥；
步骤4：将所述N个金属膜小片b按照设计排列黏贴至所述金属膜A底部，干燥；
步骤5：将另一张金属膜A黏贴至所述n个金属膜小片b底部，干燥；
步骤6：对所述贴好金属膜的芯片进行加热，获得黏有金属膜的芯片；
步骤7：互连基板与金属膜芯片。
具体参数如下：
使用10mmx10mmIGBT dummy芯片，小尺寸铜颗粒膜B,小尺寸铜颗粒具有从0.5nm<d<20nm的平均最长尺寸，大尺寸铜颗粒膜C，大尺寸纳米铜颗粒具有从1nm<D<10um的平均最长尺寸；
一、将单层铜膜B切出2.5mmx2.5mm小片若干；将铜膜C切出10mmx10mm大片2片；
二、将所述铜膜C切出的大片粘贴到待互连芯片底部；
三、将所述铜膜B切出的小片粘贴到上述大片铜膜底部，排列方式为三行三列，金属膜小片之间的两两间距设置为1mm，最外侧金属膜与大片边缘0.5mm；
四、将另一块铜膜C切除的大片黏贴到上述小片底面，与第一块大片对齐；
五、对芯片和铜膜体系可选的进行100～130℃预加热20min；
测试结果表明，利用所述非连续铜膜互连的芯片和基板体系，烧接后孔隙率提高到小于20％，气体得到了有效排出。
本发明的金属膜小片具备如下优势：
1)本发明提供的用于芯片固晶的非连续纳米金属烧结膜及其方法，将原连续金属膜被设置为多个非连续小片并按照预先设计排列置于芯片与基板之间，离散排布留出的小片间隙可以作为在烧结时气体排出的通道，有利于烧结后致密性的提高，由此提升互连层的热导率；同时，随着烧结进行，金属膜小片由于z方向的限制，会产生x、y方向的变形，并相互接触，形成致密烧结层。相比于使用单片大金属膜，本发明采用的非连续的多片金属膜小片结构，按照一定排列的单层，或多层的设计，可有效减少芯片固晶过程中的倾斜问题，由此，该结构和工艺也适用于互连未来更大尺寸的功率芯片。
2)封装领域通过化学方法制备的纳米金属颗粒难以实现20nm以下甚至1nm以下粒径的纳米金属颗粒制备及后续的稳定留存，尽管对操作及环境严格控制，其同批次制备的粒径范围依然存在分布集中性差，离散程度大的技术问题，这将不同程度的影响金属膜的烧结后性能。本发明采用的上述金属颗粒尺寸的设计达到在烧结后提升金属层致密性、降低孔隙率的效果，是其他直径尺寸的纳米金属颗粒组合所不能达到的。
3)为了避免原有银膜高成本、与Si或SiC基芯片热失配、高电迁移率等问题，本发明优选的使用纳米铜代替纳米银材料，从而有效降低互连封装的材料和加工成本。由纳米铜粉体、膏体制成的烧结用纳米铜膜，在具备铜材料的优良特性同时，也同时具备金属烧结膜的便携性、易成型性等特点，是下一代电气互连首选方案。
本发明提供的用于芯片固晶的非连续纳米金属烧结膜及其方法，解决了原有金属烧结膜高孔隙率、低热导率、芯片倾斜的问题，有利于烧结后致密性的提高，提升了互连层的热导率，是下一代电气互连首选方案。
尽管为了说明的目的，已描述了本发明的示例性实施方式，但是本领域的技术人员将理解，不脱离所附权利要求中公开的发明的范围和精神的情况下，可以在形式和细节上进行各种修改、添加和替换等的改变，而所有这些改变都应属于本发明所附权利要求的保护范围，并且本发明要求保护的产品各个部门和方法中的各个步骤，可以以任意组合的形式组合在一起。因此，对本发明中所公开的实施方式的描述并非为了限制本发明的范围，而是用于描述本发明。相应地，本发明的范围不受以上实施方式的限制，而是由权利要求或其等同物进行限定。

Claims (18)

  1. 一种芯片互连结构，其特征在于，包括：
    芯片，
    N个纳米金属膜小片，N≥2，
    基板，
    所述纳米金属膜小片包括第一尺寸纳米金属颗及第二尺寸纳米金属颗粒，
    所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同。
  2. 如权利要求1所述利用纳米金属膜的芯片基板连接结构，其特征在于，所述纳米金属颗粒材料为铜。
  3. 如权利要求1所述芯片互连结构，其特征在于，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
  4. 如权利要求1所述芯片互连结构，其特征在于，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm；所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
  5. 如权利要求1所述芯片互连结构，其特征在于，所述纳米金属膜小片位于芯片和基板之间，纳米金属膜小片之间间隔排列；芯片和基板之间排列有一层或多层纳米金属膜小片并且多层纳米金属膜小片的不同层之间具有连续的纳米金属膜。
  6. 如权利要求5所述芯片互连结构，其特征在于，所述N个单层纳米金属小片按照长A 1个，宽B 1个排列，N＝A 1*B 1。
  7. 如权利要求5所述芯片互连结构，其特征在于，所述N个多层纳米金属小片按照长A 2个，宽B 2个排列，N＝A 2*B 2。
  8. 如权利要求7所述芯片互连结构，其特征在于，所述多层纳米金属小片包括：
    第一有机介质材料层，
    第二有机介质材料层；
    所述第一有机介质材料层中包含第一尺寸纳米金属颗粒，
    所述第一有机介质材料层中包含第二尺寸纳米金属颗粒；
    所述第一尺寸纳米金属颗粒与第二尺寸纳米金属颗粒直径不同。
  9. 如权利要求5所述芯片互连结构，其特征在于，所述多层的纳米金属膜小片分布方式为：
    第一金属膜层，所述第一金属膜层包括长A 31个，宽B 31个排列的单层纳米金属膜小片或多层纳米金属膜小片，N 1＝A 31*B 31；
    第二金属膜层，所述第二金属膜层包括长A 32个，宽B 32个排列的单层纳米金属膜小片或多层纳米金属膜小片，N 2＝A 32*B 32；
    ……
    第n金属膜层，所述第n金属膜层包括长A 3n个，宽B 3n个排列的单层纳米金属膜小片或多层纳米金属膜小片，N n＝A 3n*B 3n；
    N＝N 1+N 2+…+N n。
  10. 一种芯片互连结构连接方法，其特征在于，包括：
    步骤1：制备纳米金属膜，所述纳米金属膜包括第一尺寸纳米金属颗及第二尺寸纳米金属颗粒，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒直径不同；
    步骤2：切割所述纳米金属膜，获得N个纳米金属膜小片；
    步骤3：将所述纳米金属膜小片一面和芯片底部贴合；
    步骤4：将基板和纳米金属膜小片的另一面贴合；
    步骤5:将芯片和基板互连。
  11. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述纳米金属颗粒材料为铜。
  12. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述纳米金属颗粒材料为金、钯、银、铜、铝、银钯合金、金钯合金、铜银合金、铜银镍合金或铜铝合金。
  13. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较大尺寸的纳米金属颗粒直径为1nm<D<10μm；所述第一尺寸纳米金属颗粒与所述第二尺寸纳米金属颗粒中，较小尺寸的纳米金属颗粒直径为0.5nm<d<20nm。
  14. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述纳米金属膜小片位于芯片和基板之间，纳米金属膜小片之间间隔排列；芯片和基板之间排列有一层或多层纳米金属膜小片并且多层纳米金属膜小片的不同层之间具有连续的纳米金属膜。
  15. 如权利要求14所述芯片互连结构连接方法，其特征在于，所述一层的纳米金属膜小片分布方式包括：
    将所述纳米金属膜小片按照长A个，宽B个贴至芯片底部。
  16. 如权利要求14所述芯片互连结构连接方法，其特征在于，
    所述多层的纳米金属膜小片分布方式包括：
    将所述长A 31个，宽B 31个共N 1个金属膜小片按照设计排列黏贴至所述芯片底部，然后进行干燥处理，获得第一金属膜层；
    将所述长A 32个，宽B 32个共N 2个金属膜小片按照设计排列黏贴至所述第一金属膜层底部，然后进行干燥处理，获得第二金属膜层；
    ……
    将所述长A 3n个，宽B 3n个共N n个金属膜小片按照设计排列黏贴至所述第n-1金属膜层底部，然后进行干燥处理，获得第n金属膜层。
  17. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述步骤3、步骤4还包括干燥处理。
  18. 如权利要求10所述芯片互连结构连接方法，其特征在于，所述步骤5还包括：
    步骤5.1：剥离支撑基材；
    步骤5.2：将所述贴好多层金属膜的芯片置于基板上；
    步骤5.3：在烧结炉中对多层金属膜芯片进行加热，选择有无压力辅助，互连基板与多层金属膜芯片。
PCT/CN2019/123823 2019-04-24 2019-12-06 一种芯片互连结构及其制备方法 WO2020215738A1 (zh)

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