CN1291069C - 微细间距倒装焊凸点电镀制备方法 - Google Patents

微细间距倒装焊凸点电镀制备方法 Download PDF

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CN1291069C
CN1291069C CNB031406564A CN03140656A CN1291069C CN 1291069 C CN1291069 C CN 1291069C CN B031406564 A CNB031406564 A CN B031406564A CN 03140656 A CN03140656 A CN 03140656A CN 1291069 C CN1291069 C CN 1291069C
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course
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salient point
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CN1552951A (zh
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陈正豪
肖国伟
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Hong Kong University of Science and Technology HKUST
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Abstract

本发明提供了一系列新工艺用以通过电镀方法,制备可用于半导体封装,具有微细间距、良好可靠性的焊球。本发明所采用的新工艺技术可适用于不同组分的电镀铅-锡合金焊料、无铅的锡基焊料(如:铜-锡、锡-铜-银、锡-银、锡-铋合金)等。其工艺能够满足焊球边间距50微米以上,焊球直径在50至300微米的需求。在本发明中,通过采用凸点回流控制层,避免了工艺过程中焊料的损失,从而能够制备微细间距和高可靠性焊球。通过对关键工艺和电镀金属层的控制,以调整电镀层微观结构,本发明能够制备用于倒装焊封装的高可靠性焊球。本发明同时应用特殊设计涂覆光胶构件和光刻工艺,以满足微细间距电镀凸点的工艺制备要求。

Description

微细间距倒装焊凸点电镀制备方法
技术领域
本发明与电子封装有关,是一种使用于半导体工艺过程中,在晶片或芯片上制备倒装焊凸点焊球的技术(electroplated solder bumpingtechnology for flip-chip)。
本发明与电子封装有关,是一种使用于半导体工艺过程中,在晶片或芯片上制备倒装焊凸点焊球的技术。
背景技术
随着集成电路技术的不断发展,电子产品越来越向小型化、智能化、高性能、高可靠性方向发展。而集成电路封装不仅直接影响着集成电路、电子模块乃至整机的性能,而且还制约着整个电子***的小型化、低成本和可靠性。在集成电路芯片尺寸逐步缩小,集成度不断提高的情况下,电子工业对集成电路封装技术的提出了越来越高的要求。
倒装焊技术是通过在芯片表面形成的焊球,使芯片翻转与底板形成连接,从而减小封装尺寸,满足电子产品的高性能(如高速、高频、更小的引脚)、小外形的要求,使产品具有很好的电学性能和传热性能。在60年代IBM公司首先开发了倒装焊技术和可控塌陷凸点(C4)技术,其中凸点制备技术是利用金属掩膜蒸发工艺完成的,由于成本很高、工艺复杂,这一技术的应用受到很大的限制。在凸点倒装焊技术中,凸点是焊料通过一定工艺沉积在芯片互连金属层上,经过一定温度回流形成的金属焊球。在焊球下有防塌陷金属层,以保证焊料在回流时不会流动塌陷在芯片表面。
目前焊球的制备技术有许多种,包括金属掩膜蒸发、电镀凸点技术、激光植球技术、模板印刷技术等。倒装焊凸点主要结构如图1所示。其中,晶片1在凸点制备工艺前,以完成互连金属层3和钝化层2工艺。电镀凸点技术一般使用蒸发或溅射工艺,首先在晶片1表面沉积一金属层6,作为电镀时导电层和凸点下金属层。然后,使用光刻胶工艺形成电镀掩膜和电镀图形,在焊料电镀液中通过电镀工艺完成金属层5和焊料的沉积。最后,去除光刻胶和金属层,在一定温度下焊料回流形成焊球4。
在电镀凸点技术中,焊球下防塌陷金属层、光刻工艺、电镀工艺和金属层刻蚀是决定凸点焊球质量的关键。光刻胶的厚度和显影后图形的质量会影响焊球的均匀性和可靠性,差的光刻工艺会导致焊球之间的搭桥现象,使焊点短路和器件失效。在电镀完成后,金属层刻蚀及焊球下防塌陷层形成时,化学刻蚀工艺通常会影响焊料,导致焊料流失,影响焊球均匀性和质量。同时,刻蚀中经常出现的残余金属,会导致焊料在回流中塌陷,影响焊球形状很均匀性,当焊点间距微小时,造成焊点短路。
发明内容
本发明采取了一系列新工艺方法,使晶片上焊球制备工艺易于完成,提高焊球均匀性,减小焊球间距,降低焊球中孔洞率,提高工艺成品率和焊球的可靠性。本发明采用的新工艺技术适用于不同组分的电镀铅-锡合金焊料、无铅的锡基焊料(如:铜-锡、锡-铜-银、锡-银、锡-铋合金)等。
本发明是在晶片集成电路半导体前工序加工工艺后,在钝化开孔处金属层上,完成可用于倒装焊技术的焊球制备的系列工艺。本发明适用于并能够实现焊球边间距50微米以上,焊球直径在50微米至300微米的工艺需求。
即本发明提出一种可用于半导体封装的、制备在晶片上钝化层开孔处互连金属层上的焊球的方法,包括以下步骤:
a)在晶片表面沉积作为凸点下金属层;
b)在凸点下金属层上涂覆凸点回流控制层;
c)运用半导体光刻技术或浮脱工艺,形成凸点回流控制层上的图形,以在金属互连层上形成用于露出凸点下金属层的开孔;
d)在凸点回流控制层上制备一个绕开孔周围覆盖的电镀掩膜用厚光胶;
e)在开孔处进行电镀,形成凸点下金属层上的电镀铜层;
f)在电镀铜层进行焊料形成的电镀工艺:
g)除去电镀掩膜用厚光胶,根据焊料成分决定回流温度曲线和时间,进行回流工艺,从而焊料能够形成焊球;
h)除去凸点回流控制层;
i)刻蚀去除部分凸点下金属层。
当凸点回流控制层为有机薄膜时,采用半导体光刻技术以形成凸点回流控制层上的图形;而当凸点回流控制层为金属薄层时,采用浮脱工艺形成凸点回流控制层上的图形。
本发明所采用的主要技术、方法和设计包括有:
1.通过溅射或者蒸发工艺,在晶片表面形成金属层,金属材料为钛、钛-钨合金、铜、镍等。然后,在金属层上制备一层薄膜,其材料选择上,必须使焊料不能在其表面粘附,如有机薄膜或不粘焊料的其他金属(钛、钨、钛-钨、铝、铝合金)。本发明称该薄膜层为凸点回流控制层(Bump-Reflow-Control Layer)。在其厚度以不影响后续工艺为准,一般在100纳米至1500纳米之间。运用半导体光刻工艺,在需要制备焊球的位置开出合适尺寸孔洞,使金属层露出。
2.当在晶片上旋转涂覆光刻胶时,采用一个特殊设计的构件,如图2所示,其加载在晶片1上的密封盖结构7,在光胶涂覆过程中,保证构件腔体8密闭,使涂覆的光刻胶达到焊料电镀工艺需要的高度。光胶厚度在50微米至175微米之间。
3.在光刻胶涂覆、显影和曝光过程,采用一系列特殊工艺过程,在使用不同光刻胶时,以满足焊料电镀工艺对光胶的要求。同时,保证工艺能够满足焊球中心间距在100微米至400微米的要求。
4.在电镀工艺中,通过控制有关工艺参数,使电镀铜层的晶粒尺寸尽可能减小在2微米内,表面均匀性控制在500纳米以内。这样能够通过工艺,减小形成较厚金属间化合物,影响焊球的可靠性。
5.在焊料电镀工艺完成后,去除光刻胶,但保留前面形成的有机薄膜。然后,根据焊料特性在一定温度曲线下,直接进行回流形成焊球。由于凸点回流控制层存在,焊料回流时不会塌陷在晶片表面,能够形成设计所需的球形。
6.回流后去除有机薄膜,然后刻蚀去金属层至原来晶片的钝化层完全露出。由于焊球已经过回流,上述工艺不会造成焊料损失,影响焊球均匀性和可靠性。
7.在上述工艺过程开始时,根据晶片集成电路互连金属线路情况,按照工艺过程需要,设计相应的光刻工艺掩膜版。掩膜版的设计参数要与相关工艺要求、焊球尺寸相匹配。
针对本发明所采用的技术、方法和设计,现使用有关材料举一实施例并结合附图,详细说明工艺过程。所使用附图不是按照为正常比例绘制。
附图简要说明:
图1为倒装焊凸点截面示意图。
图2为密封晶片涂胶器件结构示意图。
图3为晶片上金属溅射沉积钛-钨合金和铜金属层工艺截面示意图。
图4为使用有机薄膜制备凸点回流控制层(Bump-Reflow-ControlLayer)的工艺过程截面示意图,图4(a)为有机薄膜沉积后截面示意图,图4(b)为有机薄膜刻蚀后截面示意图。
图5为另一种采用金属层和浮脱工艺(Lift-off process)制备凸点回流控制层截面示意图,图5(a)为光胶工艺后截面示意图,图5(b)为凸点回流控制层沉积后截面示意图。图5(c)为浮脱工艺后截面示意图。
图6为光胶曝光、显影、烘干后截面图。
图7为电镀工艺过程截面示意图,图7(a)为厚光胶工艺完成后截面示意图,图7(b)为焊料沉积后截面示意图。
图8为电镀铜时电流密度和镀层表面均匀性的关系曲线。
图9为焊料经过回流工艺后形成焊球的截面图,图9(a)为去除厚光胶后截面示意图,图9(b)为回流工艺形成焊球的截面示意图。
图10为去除凸点回流控制层及金属层的工艺过程截面图,图10(a)为去除凸点回流控制层后截面示意图,图10(b)为去除电镀导电金属层后截面示意图。
图中:
1-晶片                          2-钝化层
3-互连金属层(铝或铜)            4-凸点焊球
5-电镀铜层                      6-凸点下金属层
7-涂覆光胶密封盖                8-密封空间
9-凸点回流控制层(有机层)        10-凸点回流控制层开孔处
11-钝化层开孔处                 12-浮脱工艺中光胶
13-凸点回流控制层(金属)         14-电镀掩膜用厚光胶
15-电镀焊料(未回流)
具体实施方式
如图2所示,当在晶片上旋转涂覆光刻胶时,采用一个特殊设计的构件,其加载在晶片1上的密封盖结构7,在光胶涂覆过程中,保证构件腔体8密闭,使涂覆的光刻胶达到焊料电镀工艺需要的高度。光胶厚度在50微米至175微米之间。
如图3所示,在晶片1上已完成了的互连金属化3(铝引线)和钝化层2。通过溅射工艺,钛-钨合金首先沉积在晶片1表面,其厚度在50纳米至120纳米之间。然后,铜金属层溅射沉积在钛-钨合金上,其厚度为200纳米至600纳米之间,形成电镀导电层和凸点下金属层6。为保证金属层6中的钛-钨合金与铜金属层之间良好的粘合性和电学性能,两种金属溅射需要在同一稳定真空环境下溅射完成。
图4描述了采用有机薄膜制备凸点回流控制层9(Bump-Reflow-Control Layer)的工艺过程。在晶片1上使用旋转涂覆的方法,把一种可感光的聚酰亚胺材料沉积下来,形成150纳米以下的薄膜层9。运用半导体光刻技术,在金属互连层开孔11上,刻蚀去聚酰亚胺薄膜层9,露出凸点下金属层6。其刻蚀开孔10直径要大于钝化层开孔11直径的10%~35%。需注意的是该有机薄膜9材料的选择,需能够承受焊料回流时的温度,保证在焊料回流工艺后,该薄膜层9能够刻蚀除去。如图4(b)所示,钝化层开孔11直径为80微米,聚酰亚胺薄膜层开孔10直径为110微米。光刻需要的掩膜版按照上述参数设计完成。
图5是另一种替代图4的方法,采用金属层和浮脱工艺(Lift-offprocess)制备凸点回流控制层6的过程。首先,按照薄膜层开孔图形和尺寸,在晶片1的上完成光刻胶12工艺,如图5(a)所示。光刻掩膜版按照有关参数制作。通过溅射工艺沉积30纳米至50纳米钛-钨合金层13在晶片1上(如图5(b))。使用浮脱工艺形成所需图形(如图5(c))。其中,该钛-钨金属层(13)开孔直径为110微米。
在凸点回流控制层制备完成后,即图4(b)或图5(c)之后,需要进行电镀中使用的光胶制备过程。为获得设计的焊球高度,光刻胶需要达到一定厚度要求。本发明在光刻胶旋转涂覆过程中,使用了图2所示设计器件。该设计使用密闭构件7,能够确保在旋转涂覆光刻胶过程中,晶片1和光刻胶处于一个封闭空间8中。当晶片旋转时,构件和其密闭空间的空气等速旋转,使光刻胶中成分不会大量挥发,从而获得足够厚度的胶层。
图6显示了光胶14曝光、显影、烘干后的图形结构。在此过程中,为保证光胶14图形质量和厚度,本发明采用了如下特殊工艺:
1)光胶涂覆后,在曝光前预烘工艺中,使用平板电炉在45~60摄氏度进行前预烘,时间一般为4~10分钟;2
)在20~25摄氏度环境放置30~60分钟;
3)按照正常预烘工艺,在110摄氏度进行预烘;
4)进行曝光和显影;
5)显影完成后,在50~60摄氏度平板电炉上烘干20~45分钟。
这里采用的是正胶材料。如需要增加胶层厚度,可以重复上述工艺。在光胶掩膜版设计中,光胶开孔处直径需小于凸点回流控制层开孔直径,以保证工艺质量,一般为5%左右。如图6中,光胶开孔处直径是100微米。
图7描述了电镀工艺过程。通过控制有关工艺参数,使电镀铜层5的晶粒尺寸尽可能减小在2微米内,表面均匀性控制在500纳米以内,消除电镀层中孔洞的形成。这样在使用过程中,能够减小焊球中形成较厚金属间化合物,增强焊球机械强度,提高焊球的可靠性。电镀铜层5厚度在5~25微米之间,以使焊球获得良好机械强度。铜层电镀完成后,进行焊料15的电镀工艺。
图8显示了电镀铜时电流密度和镀层表面均匀性的关系。其表面均匀性用算术平均值和均方根值描述。当使用饱和硫酸铜电镀液,在20~25摄氏度下,镀层表面均匀性会随着电镀电流密度增加而增加。
当焊料15电镀完成后,将光胶除去,如图9(a)所示。如图9(b)所示,根据焊料成分决定回流温度曲线和时间,进行回流工艺,由于凸点回流控制层13/9的存在,焊料能够形成焊球4,而不会塌陷在晶片1表面。
图10描述了回流完成后,去除凸点回流控制层13/9(聚酰亚胺薄膜或钛-钨层),如图10(a)所示。然后,刻蚀去除溅射铜薄膜和底部的钛-钨薄膜6,如图10(b)所示。由于凸点回流控制层13/9的存在,电镀焊料15已经完成回流工艺形成焊球4,这样就避免了在焊料回流之前刻蚀这些凸点下金属膜层6,所导致的焊料损失和腐蚀,影响焊球质量和可靠性。至此,在晶片1上制备焊球的工艺过程完成。

Claims (8)

1.一种可用于半导体封装的、制备在晶片上钝化层(2)开孔处互连金属层(3)上的焊球的方法,包括以下步骤:
a)在晶片(1)表面沉积作为凸点下金属层(6);
b)在凸点下金属层(6)上涂覆凸点回流控制层(9,13);
c)运用半导体光刻技术或浮脱工艺,形成凸点回流控制层(9,13)上的图形,以在金属互连层(3)上形成用于露出凸点下金属层(6)的开孔(10);
d)在凸点回流控制层(9,13)上制备一个绕开孔(10)周围覆盖的电镀掩膜用厚光胶(14);
e)在开孔(10)处进行电镀,形成凸点下金属层(6)上的电镀铜层(5);
f)在电镀铜层(5)进行焊料(15)形成的电镀工艺;
g)除去电镀掩膜用厚光胶(14),根据焊料成分决定回流温度曲线和时间,进行回流工艺,从而焊料能够形成焊球(4);
h)除去凸点回流控制层(9,13);
i)刻蚀去除部分凸点下金属层(6)。
2.根据权利要求1所述的方法,其特征在于,凸点回流控制层(9,13)是一有机薄膜或金属薄膜,其材料与焊料在回流过程中不相粘附。
3.根据权利要求2所述的方法,其特征在于,凸点回流控制层(9,13)是在凸点下金属层沉积之后制备,凸点回流控制层厚度为100纳米至1500纳米之间。
4.根据权利要求1所述的方法,其特征在于,光刻工艺的掩膜版设计中,凸点回流控制层开孔尺寸大于钝化层开孔尺寸的10%~35%。
5.根据权利要求1所述的方法,其特征在于,当凸点回流控制层(9)为有机薄膜时,采用半导体光刻技术以形成凸点回流控制层上的图形;而当凸点回流控制层(13)为金属薄层时,采用浮脱工艺形成凸点回流控制层上的图形。
6.根据权利要求1所述的方法,其特征在于,电镀用厚光胶开孔(10)尺寸需小于凸点回流控制层开孔直径3~7%。
7.根据权利要求1所述的方法,其特征在于,当涂覆光刻胶时,使用一个密封构件(7),使晶片和光刻胶处于一个封闭空间中,晶片旋转时,密封构件和所封闭空气与晶片等速旋转。
8.根据权利要求1所述的方法,其特征在于,一厚光胶工艺被采用,以获得厚度在50~175微米光胶层,其工艺步骤是:
a)在高温预烘前,使用平板电炉在低温下进行前预烘,温度为45~60摄氏度,时间为4~10分钟;
b)在20~25摄氏度环境放置30~60分钟;
c)在110摄氏度进行预烘,然后曝光和显影;
d)在50~60摄氏度平板电炉上烘干20~45分钟。
CNB031406564A 2003-05-31 2003-05-31 微细间距倒装焊凸点电镀制备方法 Expired - Lifetime CN1291069C (zh)

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US10/854,174 US7199036B2 (en) 2003-05-31 2004-05-27 Under-bump metallization layers and electroplated solder bumping technology for flip-chip
HK05103510A HK1070927A1 (en) 2003-05-31 2005-04-25 Method of preparing fine-pitch electroplated solder bumpoing for flip-chip

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