TWI821270B - 半導體裝置製造方法 - Google Patents

半導體裝置製造方法 Download PDF

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Publication number
TWI821270B
TWI821270B TW108112460A TW108112460A TWI821270B TW I821270 B TWI821270 B TW I821270B TW 108112460 A TW108112460 A TW 108112460A TW 108112460 A TW108112460 A TW 108112460A TW I821270 B TWI821270 B TW I821270B
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Taiwan
Prior art keywords
sintering
bonding
sintered
semiconductor device
material sheet
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TW108112460A
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English (en)
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TW201945113A (zh
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三田亮太
市川智昭
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日商日東電工股份有限公司
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Publication of TW201945113A publication Critical patent/TW201945113A/zh
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Abstract

本發明提供一種適合於待經歷在加壓條件下進行之半導體晶片之燒結接合步驟的半導體裝置製造方法中，將複數個半導體晶片一次燒結接合於基板之方法。 本半導體裝置製造方法包括準備步驟及燒結接合步驟。於準備步驟中，準備燒結接合工件X，該燒結接合工件X具有包含基板S、待配置且接合於其單面側之複數個半導體晶片C、及分別介存於各半導體晶片C與基板S之間並含有燒結性粒子之複數個燒結接合用材料層11的積層構成。於燒結接合步驟中，於將厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材20及燒結接合工件X重疊並夾持於一對加壓面Pa、Pa之間之狀態下，於該加壓面Pa、Pa間對燒結接合工件X一面沿其積層方向加壓一面使其經歷加熱過程，藉此由各燒結接合用材料層11形成燒結層12。

Description

半導體裝置製造方法
本發明係關於一種製造所謂功率半導體裝置等半導體裝置之方法。
於半導體裝置之製造中，作為用於對引線框架或絕緣電路基板等基板將半導體晶片一面與基板側電性連接一面進行黏晶之方法，已知有於基板與晶片之間形成Au-Si共晶合金層實現接合狀態之方法、或將焊料或含有導電性粒子之樹脂用作接合材之方法。
另一方面，負責電力之供給控制之功率半導體裝置於近年來顯著得到普及。功率半導體裝置因動作時之通電量較大而發熱量較大之情形較多。因此，於功率半導體裝置之製造中，對於將半導體晶片一面與基板側電性連接一面於基板進行黏晶之方法，要求能夠實現即便於高溫動作時可靠性亦較高之接合狀態。對於採用SiC或GaN作為半導體材料而實現高溫動作化之功率半導體裝置，此種要求尤為強烈。於是，為了應對此種要求，作為伴有電性連接之黏晶方法，提出有使用含有燒結性粒子及溶劑等之燒結接合用組合物之技術。
於使用含有燒結性粒子之燒結接合用材料所進行之黏晶中，首先，將半導體晶片經由燒結接合用材料於特定之溫度、負荷條件下載置於基板之晶片接合預定部位。其後，於特定溫度、加壓條件下進行燒結步驟，從而於基板與其上之半導體晶片之間使燒結接合用材料中之溶劑產生揮發等，且於燒結性粒子間進行燒結。藉此，於基板與半導體晶片之間形成燒結層，將半導體晶片電性連接且機械接合於基板。此種技術例如記載於下述專利文獻1、2。 [先前技術文獻] [專利文獻]
[專利文獻1]國際公開第2008/065728號 [專利文獻2]日本專利特開2013-039580號公報
[發明所欲解決之問題]
於藉由燒結接合進行黏晶之半導體裝置製造過程中之該燒結接合步驟中，存在使用具備加熱壓製用之一對平行平板的加熱壓製機之情形。該步驟具體而言係將經由燒結接合用材料層暫時固定之基板與半導體晶片即工件夾持於在基板與半導體晶片之積層方向上打開之一對平行平板之間，於該狀態下，藉由該一對平行平板一面加壓一面加熱。藉由經歷此種過程，由燒結接合用材料層形成燒結層從而將半導體晶片燒結接合於基板。
又，於藉由燒結接合進行黏晶之半導體裝置製造過程中之該燒結接合步驟中，存在將複數個半導體晶片一次燒結接合於基板之情形。然而，於使用上述加熱壓製機進行一次性燒結接合步驟之情形時，有時於所形成之複數個燒結層中，會出現其周緣部未接合於基板或半導體晶片者。認為此種接合不良之起因在於：作用於在燒結接合步驟中夾持於平行平板間之工件之負荷於複數個燒結接合用材料層之間存在不均勻性。工件中之半導體晶片及燒結接合用材料層之厚度較小，為數μm～數百μm左右，於使用具備一對平行平板之加熱壓製機進行之燒結接合步驟中，平行平板自理想平行姿勢之偏離或傾斜容易招致半導體晶片及燒結接合用材料層各自之負荷之差異。認為於平行平板之平行度或姿勢控制之準確度與半導體晶片或燒結接合用材料層之薄度不相稱之情形時，容易產生上述接合不良。
本發明係基於如上情況而構思完成者，其目的在於提供一種適合於待經歷在加壓條件下進行之半導體晶片之燒結接合步驟之半導體裝置製造方法中，將複數個半導體晶片一次燒結接合於基板的方法。 [解決問題之技術手段]
本發明所提供之半導體裝置製造方法包括如下之準備步驟及燒結接合步驟。本方法適合製造具備半導體晶片之燒結接合部位之功率半導體裝置等半導體裝置。
於準備步驟中準備燒結接合工件。燒結接合工件包含具有第1面及與其相反之第2面之基板、待配置且接合於第1面側之複數個半導體晶片、及分別介存於各半導體晶片與基板之間並含有燒結性粒子之複數個燒結接合用材料層。例如，可藉由將附燒結接合用材料層之半導體晶片經由該燒結接合用材料層壓接並暫時固定於基板，從而準備燒結接合工件。作為燒結接合用材料層之供給材，例如可使用同時含有燒結性粒子與熱分解性高分子黏合劑的組合物之片材體(燒結接合用片材)。
於燒結接合步驟中，一面使用緩衝材片材一面將各半導體晶片燒結接合於燒結接合工件中之基板。所使用之緩衝材片材具有5～5000 μm之厚度，且具有2～150 MPa之拉伸彈性模數。於本發明中，所謂緩衝材片材之拉伸彈性模數，係設為如下之值：對寬度10 mm×長度40 mm×厚度100 μm之緩衝材片材試樣片，於初始夾頭間距離10 mm、23℃及拉伸速度50 mm/分鐘之條件下，進行拉伸試驗，將基於該拉伸試驗中之測定所求出之值設為拉伸彈性模數。於燒結接合步驟中，於將此種緩衝材片材與燒結接合工件重疊並夾持於加熱壓製機中之一對加壓面之間的狀態下，於該加壓面間對燒結接合工件一面沿其積層方向加壓一面使其經歷加熱過程，藉此由工件中之各燒結接合用材料層形成燒結層。一對加壓面例如為加熱壓製用之一對平行平板中之一對對向面。對於燒結接合工件，緩衝材片材係重疊於其半導體晶片配設側，或重疊於基板之第2面側。藉由於基板與各半導體晶片之間形成燒結層，將各半導體晶片燒結接合於基板。
於本半導體裝置製造方法中，於其燒結接合步驟中，如上所述，於將厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材與燒結接合工件重疊並夾持於加熱壓製機之加壓面間的狀態下，對燒結接合工件一面加壓一面加熱。此種構成適於使作用於在燒結接合步驟中夾持於平行平板間之燒結接合工件的加壓力及負荷於複數個燒結接合用材料層之間實現較高之均勻性。其原因在於：於燒結接合步驟中，將具有5～5000 μm之厚度且具有2～150 MPa之拉伸彈性模數之緩衝材片材與燒結接合工件重疊，當一對加壓面自理想之平行姿勢產生偏離或傾斜、或基板第1面至半導體晶片頂面之高度在半導體晶片間存在差異時，該緩衝材片材能夠發揮實質性地吸收該差異而將其減少、消除之緩衝功能。
此外，厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材具有充分之形狀保持性，於半導體裝置製造製程中容易處理。此種緩衝材片材於上述燒結接合步驟中容易以高效率且適當之配置重疊於燒結接合工件。
如上，本發明之半導體裝置製造方法適合將複數個半導體晶片一次燒結接合於基板。
上述燒結接合步驟中所使用之緩衝材片材於大氣氛圍下、基準重量溫度25℃、及升溫速度10℃/分鐘之條件下之重量減少測定中，350℃下之重量減少率為0.1%以下。此種構成適於在經歷高溫加熱過程的燒結接合步驟中，使緩衝材片材充分地發揮其緩衝功能等功能。緩衝材片材之重量減少率例如可對約10 mg之緩衝材片材試樣使用示差熱-熱重量同步測定裝置測定。
於上述燒結接合步驟中，較佳為加熱溫度為200℃以上，且加壓力為5 MPa以上。即，於燒結接合步驟中，於一對加壓面間，對燒結接合工件，一面沿其積層方向以較佳為5 MPa以上之壓力加壓一面使其經歷較佳為200℃以上之溫度下之加熱過程，藉此由燒結接合用材料層形成燒結層。此種構成適於在要燒結接合之基板與各半導體晶片之間形成牢固之燒結層。
上述燒結接合用材料層內之燒結性粒子較佳為包含選自由銀粒子、銅粒子、氧化銀粒子、及氧化銅粒子所組成之群中之至少一種。此種構成適於在要燒結接合之基板與半導體晶片之間形成牢固之燒結層。
就實現可靠性較高之燒結接合之觀點而言，燒結接合用材料層中之燒結性粒子之含有比率較佳為60～99質量%，更佳為65～98質量%，更佳為70～97質量%。
圖1至圖4表示本發明之一實施形態之半導體裝置製造方法。本實施形態之半導體裝置製造方法係用於製造具備半導體晶片之燒結接合部位之功率半導體裝置等半導體裝置之方法，至少包括如下之準備步驟及燒結接合步驟。
於準備步驟中，準備要實施燒結接合步驟之如圖1所示之燒結接合工件X。燒結接合工件X具有包含基板S、複數個晶片C、及複數個燒結接合用材料層11之積層構成。
基板S具有面Sa及與其相反之面Sb。作為基板S，例如可列舉表面設有銅配線等配線之絕緣電路基板、及引線框架。基板S中之晶片搭載部位可為銅配線或引線框架等之生坯表面，亦可為形成於生坯表面上之鍍膜之表面。作為該鍍膜，例如可列舉金鍍膜、銀鍍膜、鎳鍍膜、鈀鍍膜、及鉑鍍膜。
各晶片C係半導體晶片，具有內置有半導體元件之側之元件形成面及與其相反之背面。背面形成有作為外部電極之平面電極(未圖示)。該晶片背面(圖1中為下表面)側經由燒結接合用材料層11暫時固定於基板S之面Sa側。作為用於形成晶片C中之晶片本體之構成材料，例如可列舉碳化矽(SiC)或氮化鎵(GaN)等功率半導體裝置用半導體材料。又，晶片C之厚度例如為20～1000 μm。
各燒結接合用材料層11於本實施形態中係包含含有導電性金屬之燒結性粒子及黏合劑成分的組合物之層，對每一晶片C介存於該晶片C與基板S之間。
如上之積層構成之燒結接合工件X可以如下方式製作。
首先，如圖2(a)所示，準備複數個晶片C及燒結接合用片材10。複數個晶片C之各者已內置有特定之半導體元件，且固定於晶片固定用膠帶T1之黏著面T1a上。於各晶片C中，於貼合燒結接合用片材10之側之表面(圖2中為上表面)已形成有平面電極(未圖示)作為外部電極。於各晶片C之另一面(圖2中為下表面)，視需要形成有其他電極墊等(未圖示)。燒結接合用片材10係至少包含含有導電性金屬之燒結性粒子及黏合劑成分的組合物之片材體，其單面設有剝離襯墊L。
其次，如圖2(b)所示，將燒結接合用片材10貼合於複數個晶片C。具體而言，一面將燒結接合用片材10自其剝離襯墊L之側按壓至晶片C側，一面將燒結接合用片材10貼合於複數個晶片C。作為按壓機構，例如可列舉壓接輥。貼合溫度例如為室溫至200℃之範圍內。貼合用負荷例如為0.01～10 MPa。
其次，如圖2(c)所示，進行剝離襯墊L之剝離。藉此，將燒結接合用片材10之各部位轉印於各晶片C之表面，獲得設有燒結接合用材料層11之晶片C。
其次，如圖2(d)所示，將晶片C暫時固定於上述基板S。具體而言，例如使用晶片貼片機，將附燒結接合用材料層之晶片C經由其燒結接合用材料層11按壓從而暫時固定於基板S。可以如上方式準備燒結接合工件X。
於製作燒結接合工件X時使用之燒結接合用片材10係燒結接合用材料之供給材，且如上所述，係至少包含含有導電性金屬之燒結性粒子及黏合劑成分的組合物之片材體。
燒結接合用片材10中之燒結性粒子係含有導電性金屬元素能夠燒結之粒子。作為導電性金屬元素，例如可列舉金、銀、銅、鈀、錫、及鎳。作為此種燒結性粒子之構成材料，例如可列舉金、銀、銅、鈀、錫、鎳、及選自其等之群中之兩種以上之金屬之合金。作為燒結性粒子之構成材料，可列舉氧化銀、氧化銅、氧化鈀、或氧化錫等金屬氧化物。又，燒結性粒子亦可為具有核殼結構之粒子。例如，燒結性粒子亦可為具有以銅為主成分之核、以金或銀等為主成分且被覆核之殼的核殼結構粒子。於本實施形態中，燒結性粒子較佳為包含選自由銀粒子、銅粒子、氧化銀粒子、及氧化銅粒子所組成之群中之至少一種。就使所形成之燒結層實現高導電性及高導熱性之觀點而言，作為燒結性粒子，較佳為銀粒子及銅粒子。此外，就抗氧化性之觀點而言，銀粒子易於處理，因此較佳。例如，於對附銀鍍膜之銅基板燒結接合半導體晶片時，於使用包含銅粒子作為燒結性粒子之燒結材之情形時，必須在氮氣氛圍下等惰性環境下進行燒結製程，但於使用以銀粒子作為燒結性粒子之燒結材之情形時，即便在空氣氛圍下亦能夠適當地執行燒結製程。
就使燒結性粒子實現低燒結溫度等從而確保良好之燒結性之觀點而言，所使用之燒結性粒子之平均粒徑較佳為2000 nm以下，更佳為800 nm以下，更佳為500 nm以下。就使燒結接合用片材10及用於形成其之組合物中之燒結性粒子實現良好之分散性之觀點而言，燒結性粒子之平均粒徑較佳為1 nm以上，較佳為10 nm以上，更佳為50 nm以上，更佳為100 nm以上。燒結性粒子之平均粒徑可藉由使用掃描式電子顯微鏡(SEM)所進行之觀察進行測量。
就實現可靠性較高之燒結接合之觀點而言，燒結接合用片材10中之燒結性粒子之含有比率較佳為60～99質量%，更佳為65～98質量%，更佳為70～97質量%。
燒結接合用片材10中之黏合劑成分於本實施形態中至少包含熱分解性高分子黏合劑及低沸點黏合劑，亦可進而包含塑化劑等其他成分。熱分解性高分子黏合劑係能夠於燒結接合用高溫加熱過程中熱分解之黏合劑成分，係有助於在該加熱過程前保持燒結接合用片材10之片材形狀之要素。於本實施形態中，就確保片材形狀保持功能之觀點而言，熱分解性高分子黏合劑係於常溫(23℃)下為固體之材料。作為此種熱分解性高分子黏合劑，例如可列舉聚碳酸酯樹脂及丙烯酸樹脂。
作為用作熱分解性高分子黏合劑之聚碳酸酯樹脂，例如可列舉於主鏈之碳酸酯基(-O-CO-O-)間不含苯環等芳香族化合物而包含脂肪族鏈之脂肪族聚碳酸酯、及於主鏈之碳酸酯基(-O-CO-O-)間包含芳香族化合物之芳香族聚碳酸酯。作為脂肪族聚碳酸酯，例如可列舉聚碳酸乙二酯及聚碳酸丙二酯。作為芳香族聚碳酸酯，可列舉於主鏈包含雙酚A結構之聚碳酸酯。
作為用作熱分解性高分子黏合劑之丙烯酸樹脂，例如可列舉具有碳數4～18之直鏈狀或支鏈狀之烷基之丙烯酸酯及/或甲基丙烯酸酯之聚合物。以下以「(甲基)丙烯酸」表示「丙烯酸」及/或「甲基丙烯酸」，以「(甲基)丙烯酸酯」表示「丙烯酸酯」及/或「甲基丙烯酸酯」。作為用於形成用作熱分解性高分子黏合劑之丙烯酸樹脂的(甲基)丙烯酸酯之烷基，例如可列舉甲基、乙基、丙基、異丙基、正丁基、第三丁基、異丁基、戊基、異戊基、己基、庚基、環己基、2-乙基己基、辛基、異辛基、壬基、異壬基、癸基、異癸基、十一烷基、月桂基、十三烷基、十四烷基、硬脂基、及十八烷基。
用作熱分解性高分子黏合劑之丙烯酸樹脂亦可為包含來自上述(甲基)丙烯酸酯以外之其他單體之單體單元之聚合物。作為此種其他單體，例如可列舉含有羧基之單體、酸酐單體、含有羥基之單體、含有磺酸基之單體、及含有磷酸基之單體。具體而言，作為含有羧基之單體，例如可列舉丙烯酸、甲基丙烯酸、丙烯酸羧基乙酯、丙烯酸羧基戊酯、伊康酸、馬來酸、富馬酸、及丁烯酸。作為酸酐單體，例如可列舉馬來酸酐或伊康酸酐。作為含有羥基之單體，例如可列舉(甲基)丙烯酸2-羥基乙酯、(甲基)丙烯酸2-羥基丙酯、(甲基)丙烯酸4-羥基丁酯、(甲基)丙烯酸6-羥基己酯、(甲基)丙烯酸8-羥基辛酯、(甲基)丙烯酸10-羥基癸酯、(甲基)丙烯酸12-羥基月桂酯、及(甲基)丙烯酸4-(羥基甲基)環己基甲酯。作為含有磺酸基之單體，例如可列舉苯乙烯磺酸、烯丙基磺酸、2-(甲基)丙烯醯胺-2-甲基丙磺酸、(甲基)丙烯醯胺丙磺酸、(甲基)丙烯酸磺丙酯、及(甲基)丙烯醯氧基萘磺酸。作為含有磷酸基之單體，例如可列舉2-羥基乙丙烯醯基磷酸酯。
熱分解性高分子黏合劑之重量平均分子量較佳為10000以上。熱分解性高分子黏合劑之重量平均分子量設為藉由凝膠滲透層析法(GPC)測定並藉由聚苯乙烯換算所計算出之值。
就適當地發揮上述片材形狀保持功能之觀點而言，燒結接合用片材10中之熱分解性高分子黏合劑之含有比率較佳為0.5～10質量%，更佳為0.8～8質量%，更佳為1～6質量%。
燒結接合用片材10中之低沸點黏合劑設為使用動態黏彈性測定裝置(商品名「HAAKE MARS III」，Thermo Fisher Scientfic公司製造)所測定之23℃下之黏度表現為1×105 Pa･s以下之液狀或半液狀者。於本黏度測定中，使用20 mm之平行平板作為夾具，板間距設為100 μm，旋轉剪切中之剪切速度設為1 s-1 。
作為燒結接合用材料層11所包含之低沸點黏合劑，例如可列舉萜烯醇類、除萜烯醇類以外之醇類、伸烷基二醇烷基醚類、及除伸烷基二醇烷基醚類以外之醚類。作為萜烯醇類，例如可列舉異𦯉基環己醇、香茅醇、香葉草醇、橙花醇、葛縷醇、及α-松油醇。作為除萜烯醇類以外之醇類，例如可列舉戊醇、己醇、庚醇、辛醇、1-癸醇、乙二醇、二乙二醇、丙二醇、丁二醇、及2,4-二甲基-1,5戊二醇。作為伸烷基二醇烷基醚類，例如可列舉乙二醇丁醚、二乙二醇甲醚、二乙二醇***、二乙二醇丁醚、二乙二醇異丁醚、二乙二醇己醚、二乙二醇二甲醚、二乙二醇二***、二乙二醇二丁醚、二乙二醇丁基甲醚、二乙二醇異丙基甲醚、三乙二醇甲醚、三乙二醇二甲醚、三乙二醇丁基甲醚、丙二醇丙醚、二丙二醇甲醚、二丙二醇***、二丙二醇丙醚、二丙二醇丁醚、二丙二醇二甲醚、三丙二醇甲醚、及三丙二醇二甲醚。作為除伸烷基二醇烷基醚類以外之醚類，例如可列舉乙二醇***乙酸酯、乙二醇丁醚乙酸酯、二乙二醇***乙酸酯、二乙二醇丁醚乙酸酯、及二丙二醇甲醚乙酸酯。作為燒結接合用片材10中之成分，可使用一種低沸點黏合劑，亦可使用兩種以上低沸點黏合劑。作為燒結接合用片材10中之低沸點黏合劑，就常溫下之穩定性之觀點而言，較佳為萜烯醇類，更佳為異𦯉基環己醇。
燒結接合用片材10之23℃下之厚度較佳為5 μm以上，更佳為10 μm以上，且較佳為300 μm以下，更佳為200 μm以下，更佳為150 μm以下。又，燒結接合用片材10及形成其之燒結接合用組合物之70℃下之黏度例如為5×103 ～1×107 Pa･s，較佳為1×104 ～1×106 Pa･s。
燒結接合用片材10例如可藉由將上述各成分混合於溶劑中製備清漆，將該清漆塗佈於作為基材之隔離膜之上形成塗膜，並使該塗膜乾燥而製作。作為用於製備清漆之溶劑，可使用有機溶劑或醇溶劑。
於本發明之半導體裝置製造方法中，於上述準備步驟之後，將各晶片C燒結接合於燒結接合工件X中之基板S(燒結接合步驟)。具體如下所述。
首先，如圖3(a)及圖3(b)所示，將燒結接合工件X與緩衝材片材20重疊，夾持於加熱壓製機所具備之加熱壓製用之一對平行平板P、P中之一對加壓面Pa、Pa之間。於圖3(b)中，緩衝材片材20重疊於燒結接合工件X之晶片配設側。作為緩衝材片材20之構成材料，例如可列舉四氟乙烯樹脂(PTFE)等氟樹脂、聚甲基矽氧烷等聚矽氧樹脂、及碳片材。
所使用之緩衝材片材20之厚度為5～5000 μm。就確保緩衝材片材20之剛性及形狀保持性之觀點而言，緩衝材片材20之厚度較佳為10 μm以上，更佳為20 μm以上，更佳為30 μm以上。就抑制與緩衝材片材20相關之成本、乃至半導體裝置之製造成本之觀點而言，緩衝材片材20之厚度較佳為3000 μm以下，更佳為1500 μm以下，更佳為1000 μm以下，更佳為500 μm以下。又，緩衝材片材20之俯視形狀之尺寸可與燒結接合工件X之俯視形狀之尺寸相同，亦可大於燒結接合工件X之俯視形狀之尺寸。
緩衝材片材20之拉伸彈性模數為2～150 MPa。所謂緩衝材片材之拉伸彈性模數，係設為如下之值：對寬度10 mm×長度40 mm×厚度100 μm之緩衝材片材試樣片，於初始夾頭間距離10 mm、23℃及拉伸速度50 mm/分鐘之條件下進行拉伸試驗，將基於該拉伸試驗中之測定所求出之值設為拉伸彈性模數。具體而言，可自根據本測定所獲得之應力-應變曲線中之測定初始期間之上升直線部分之斜率求出拉伸彈性模數。此種拉伸試驗例如可使用拉伸試驗機(商品名「Autograph AGS-50NX」，島津製作所股份有限公司製造)實施。就確保緩衝材片材20之剛性及形狀保持性之觀點而言，緩衝材片材20之拉伸彈性模數較佳為5 MPa以上，更佳為15 MPa以上，更佳為30 MPa以上。就使緩衝材片材20實現高緩衝性之觀點而言，緩衝材片材20之拉伸彈性模數較佳為150 MPa以下，更佳為120 MPa以下，更佳為100 MPa以下。
緩衝材片材20於大氣氛圍下、基準重量溫度25℃、及升溫速度10℃/分鐘之條件下之重量減少測定中，350℃下之重量減少率為0.1%以下。緩衝材片材之重量減少率可對約10 mg之緩衝材片材試樣使用示差熱-熱重量同步測定裝置測定。作為該裝置，例如可列舉Rigaku股份有限公司製造之示差熱天平TG-DTA TG8120。
於燒結接合步驟中，其次，藉由經歷特定之高溫加熱過程，如圖3(c)所示，由燒結接合工件X中之各燒結接合用材料層11形成燒結層12。具體而言，於將緩衝材片材20與燒結接合工件X重疊並夾持於一對加壓面Pa、Pa之間之狀態下，於加壓面Pa、Pa間對燒結接合工件X一面沿其厚度方向即積層方向加壓一面使其經歷特定之高溫加熱過程。藉此，於基板S與晶片C之間，使燒結接合用材料層11中之低沸點黏合劑揮發，使熱分解性高分子黏合劑熱分解揮散，從而使燒結性粒子之導電性金屬燒結。於本步驟中，於基板S與各晶片C之間形成燒結層12，將晶片C與基板S側電性連接燒結接合至基板S即其面Sa。
於本步驟中，用於燒結接合之加熱溫度例如為150～400℃，較佳為200～400℃，更佳為250～350℃。用於燒結接合之加壓力較佳為5 MPa以上，例如為60 MPa以下，較佳為40 MPa以下。此種溫度條件及壓力條件適於在燒結接合之基板S與各晶片C之間形成牢固之燒結層12。燒結接合之加壓加熱時間例如為0.3～300分鐘，較佳為0.5～240分鐘。又，就防止參與燒結接合之金屬之氧化之觀點而言，本步驟較佳為於氮氣氛圍下、減壓下、或還原氣體氛圍下進行。
本步驟所形成之燒結層12之平均厚度較佳為5～200 μm，更佳為10～150 μm。此種構成適於緩和燒結層12中因熱應力產生之內部應力而確保充分之熱衝擊可靠性，並且抑制與燒結接合相關之成本、乃至半導體裝置之製造成本。
於本半導體裝置製造方法中，其次，如圖4(a)所示，視需要將晶片C之端子部(未圖示)與基板S所具有之端子部(未圖示)經由接合線W電性連接(打線接合步驟)。晶片C之端子部及基板S之端子部與接合線W之接線例如藉由伴有加熱之超音波焊接實現。作為接合線W，例如可使用金線、鋁線、或銅線。打線接合中之線加熱溫度例如為80～250℃，較佳為80～220℃。又，其加熱時間為數秒～數分鐘。
其次，如圖4(b)所示，形成用於保護基板S上之晶片C及接合線W之密封樹脂R(密封步驟)。於本步驟中，例如藉由使用模具進行之轉注成形技術形成密封樹脂R。作為密封樹脂R之構成材料，例如可使用環氧系樹脂。於本步驟中，用於形成密封樹脂R之加熱溫度例如為165～185℃，加熱時間例如為60秒～數分鐘。於在本密封步驟中密封樹脂R未充分硬化之情形時，於本步驟之後進行用於使密封樹脂R完全硬化之後硬化步驟。
可以如上方式製造具備半導體晶片之燒結接合部位之半導體裝置。
於本半導體裝置製造方法中，於參照圖3於上所述之燒結接合步驟中，於將厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材20與燒結接合工件X重疊並夾持於加熱壓製機之一對平行平板P、P之加壓面Pa、Pa間的狀態下，對燒結接合工件X一面加壓一面加熱。此種構成適合使作用於在燒結接合步驟中夾持於平行平板P、P間之燒結接合工件X的加壓力及負荷於複數個燒結接合用材料層11之間之實現較高之均勻性。其原因在於：於燒結接合步驟中，將具有5～5000 μm之厚度且具有2～150 MPa之拉伸彈性模數之緩衝材片材20與燒結接合工件X重疊，當一對加壓面Pa、Pa自理想之平行姿勢產生偏離或傾斜、或基板S之面Sa至晶片C之頂面之高度在晶片C間存在差異時，該緩衝材片材20能夠發揮實質性地吸收該差異從而將其減少、消除之緩衝功能。
此外，厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材20具有充分之形狀保持性，於半導體裝置製造製程中容易處理。此種緩衝材片材20於上述燒結接合步驟中容易高效地且以適當之配置重疊於燒結接合工件X。又，此種緩衝材片材20於待經歷高溫加壓過程之上述燒結接合步驟中，不易產生過度之壓縮變形或下垂變形。於高溫加壓過程中，若所使用之緩衝材片材產生如包埋基板S上之晶片C般之過度之壓縮變形或下垂變形而於晶片C周圍形成封閉空間(由基板S、晶片C及緩衝材片材所封閉之空間)，則有時自燒結接合用材料層11揮發逸出之成分會沈積於基板S。若產生此種沈積，則另外需要用於淨化沈積部位之洗淨步驟，因而欠佳。於待經歷高溫加壓過程之上述燒結接合步驟中不易產生過度之壓縮變形或下垂變形之上述緩衝材片材20適合避免此類問題。
如上所述，本實施形態之半導體裝置製造方法適合將複數個晶片C一次燒結接合於基板S。
緩衝材片材20於25～350℃之重量減少率如上所述，較佳為0.1%以下。此種構成適於在待經歷高溫加熱過程之燒結接合步驟中使緩衝材片材20充分地發揮其緩衝功能等功能。
於本半導體裝置製造方法中之燒結接合步驟中，亦可對複數個燒結接合工件X一次性地進行燒結接合。具體而言，亦可如圖5所示，於將分別設有複數個晶片C之複數個燒結接合工件X與緩衝材片材20重疊並夾持於一對加壓面Pa、Pa之間的狀態下，於加壓面Pa、Pa間對複數個燒結接合工件X一面沿其厚度方向即積層方向加壓一面使其經歷特定之高溫加熱過程。於燒結接合步驟中與緩衝材片材20重疊之複數個燒結接合工件X亦可為排列成複數列且複數行者，例如可如圖6所示，排列成3列×3行。於此種燒結接合步驟中，將具有5～5000 μm之厚度且具有2～150 MPa之拉伸彈性模數之緩衝材片材20與複數個燒結接合工件X重疊，於當包含基板S之厚度在內之燒結接合工件X之厚度在燒結接合工件X間存在差異之情形時，該緩衝材片材20能夠發揮實質性地吸收該差異從而將其減少、消除之緩衝功能。藉由發揮此種緩衝功能，可使作用於在該燒結接合步驟中夾持於平行平板P、P間之複數個燒結接合工件X的加壓力及負荷於複數個燒結接合用材料層11之間實現均勻化。
於本半導體裝置製造方法中之燒結接合步驟中，亦可如圖7(a)及圖7(b)所示，將緩衝材片材20對燒結接合工件X重疊於基板S之面Sb側。利用此種構成，亦可藉由發揮緩衝材片材20之緩衝功能，使作用於夾持於平行平板P、P間之燒結接合工件X的加壓力及負荷於複數個燒結接合用材料層11之間實現均勻化。
於本半導體裝置製造方法中之燒結接合步驟中，亦可如圖8所示，對採用晶片配設側朝向下方之配向之燒結接合工件X將緩衝材片材20重疊於其晶片配設側。利用此種構成，亦可藉由發揮緩衝材片材20之緩衝功能，使作用於夾持於平行平板P、P間之燒結接合工件X的加壓力及負荷於複數個燒結接合用材料層11之間實現均勻化。此外，此種構成還適於避免因來自燒結接合用材料層11之成分沈積於基板S導致形成上述封閉空間。
又，亦可於本半導體裝置製造方法所使用之上述緩衝材片材20形成將其向厚度方向貫通之複數個貫通孔。此種構成適於避免因來自燒結接合用材料層11之成分沈積於基板S導致形成上述封閉空間。 [實施例]
[燒結接合用片之製作] 將作為燒結性粒子之第1銀粒子(平均粒徑60 nm，DOWA Electronics股份有限公司製造)35.86質量份、作為燒結性粒子之第2銀粒子(平均粒徑1100 nm，三井金屬礦業股份有限公司製造)23.90質量份、作為熱分解性高分子黏合劑之聚碳酸酯(商品名「QPAC40」，重量平均分子量150000，於常溫下為固體，Empower Materials公司製造)0.87質量份、作為低沸點黏合劑之異𦯉基環己醇(商品名「Terusolve MTPH」，於常溫下為液體，Nippon Terpene化學工業股份有限公司製造)3.47質量份、及作為溶劑之甲基乙基酮35.91質量份使用混合攪拌機(商品名「HM-500」，KEYENCE股份有限公司製造)於其攪拌模式下混合，製備清漆。攪拌時間設為3分鐘。然後，將所得之清漆塗佈於離型處理膜(商品名「MRA50」，三菱樹脂股份有限公司製造)後乾燥，形成燒結接合用組合物之厚度40 μm之片材體。乾燥溫度設為110℃，乾燥時間設為3分鐘。以如上方式，製作包含燒結性粒子、熱分解性高分子黏合劑、及低沸點黏合劑之燒結接合用片材。
[實施例1] 如下，製作附燒結接合用材料層之矽晶片，藉由將該晶片暫時固定於銅基板，進行燒結接合工件之製作，並且進行該工件之一次性燒結接合。然後，對燒結接合部位進行觀察。
[附燒結接合用材料層之矽晶片之製作] 首先，準備於一面具有平面電極(5 mm見方)之矽晶片(5 mm見方，厚度350 μm)。平面電極具有矽晶片表面上之Ti層(厚度50 nm)與其上之Au層(厚度100 nm)之積層構造。其次，使用具備壓接輥之貼合機將燒結接合用片材貼合於矽晶片之平面電極。貼合溫度為70℃，貼合用負荷(壓接輥之壓力)為0.3 MPa，壓接輥之速度為10 mm/秒。貼合之後，將燒結接合用片材中已壓接於矽晶片之平面電極之部分保留於電極上，去除該片材之其他部分，獲得於單面設有5 mm見方之燒結接合用材料層之矽晶片。以此種方式，製作所需數量之附燒結接合用材料層之矽晶片。
[燒結接合工件之製作] 將兩個附燒結接合用材料層之矽晶片以其燒結接合用材料層側壓接並暫時固定於整體被Ag膜(厚度5 μm)覆蓋之銅板(厚度3 mm)，獲得燒結接合工件。以此種方式，製作兩個燒結接合工件。
[一次性燒結接合] 使用具備加熱壓製用之一對平行平板之燒結裝置(商品名「HTM-3000」，伯東股份有限公司製造)，對複數個燒結接合工件進行一次性燒結接合。具體而言，於將複數個燒結接合工件(分別暫時固定有兩個附燒結接合用材料層之半導體晶片)與重疊於其上之厚度30 μm之第1緩衝材片材(商品名「900UL」，日東電工股份有限公司製造)夾持於一對平行平板中之一對加壓面之間的狀態下，於該加壓面間對燒結接合工件一面沿其積層方向加壓一面使其經歷加熱過程，由各燒結接合工件中之各燒結接合用材料層形成燒結層。於此種燒結接合步驟中，加壓力設為10 MPa。於加熱過程中，以升溫速度1.5℃/秒自80℃升溫至300℃，於300℃保持2.5分鐘。其後，藉由空冷降溫至170℃，然後藉由水冷降溫至80℃。水冷係利用設於平行平板內之水冷機構進行。
[燒結接合部位之觀察] 使用超音波影像裝置(商品名「FineSAT FS200」，Hitachi Power Solutions股份有限公司製造)，觀察燒結接合工件中之各燒結接合部位。於各燒結接合工件中，在形成於兩個矽晶片之各者與銅基板之間之各燒結層未見接合不良(燒結層之周緣部未接合於基板或半導體晶片之狀態)。將其結果記載於表1。
[實施例2] 於燒結接合步驟中，使用厚度100 μm之第2緩衝材片材(商品名「900UL」，日東電工股份有限公司製造)代替厚度30 μm之第1緩衝材片材，除此以外，以與實施例1同樣之方式進行附燒結接合用材料層之矽晶片之製作至一次性燒結接合，且進行燒結接合部位之觀察。於各燒結接合工件中，在形成於兩個矽晶片之各者與銅基板之間之各燒結層未見接合不良(燒結層之周緣部未接合於基板或半導體晶片之狀態)。將其結果記載於表1。
[實施例3] 於燒結接合步驟中，使用厚度30 μm之第3緩衝材片材(商品名「920UL」，日東電工股份有限公司製造)代替厚度30 μm之第1緩衝材片材，除此以外，以與實施例1同樣之方式進行附燒結接合用材料層之矽晶片之製作至一次性燒結接合，且進行燒結接合部位之觀察。於各燒結接合工件中，在形成於兩個矽晶片之各者與銅基板之間之各燒結層未見接合不良(燒結層之周緣部未接合於基板或半導體晶片之狀態)。將其結果記載於表1。
[比較例1] 於燒結接合步驟中未使用緩衝材片材，除此以外，以與實施例1同樣之方式進行附燒結接合用材料層之矽晶片之製作至一次性燒結接合，且進行燒結接合部位之觀察。存在於燒結接合工件中在燒結層產生接合不良(燒結層之周緣部未接合於基板或半導體晶片的狀態)者。將其結果記載於表1。
[比較例2] 於燒結接合步驟中，使用厚度30 μm之第4緩衝材片材代替厚度30 μm之第1緩衝材片材，除此以外，以與實施例1同樣之方式，進行附燒結接合用材料層之矽晶片之製作至一次性燒結接合，且進行燒結接合部位之觀察。第4緩衝材片材以如下方式製作。
首先，將於兩末端具有矽烷醇基之特定聚二甲基矽氧烷(數量平均分子量11500)2031 g、乙烯基三甲氧基矽烷15.71 g、及(3-縮水甘油氧基丙基)三甲氧基矽烷2.80 g攪拌，獲得混合物。其次，向該混合物加入作為縮合觸媒之氫氧化四甲基銨之甲醇溶液0.97 mL(濃度10質量%、觸媒含量0.88毫莫耳)後，於40℃下攪拌1小時(縮合反應)。其次，將以此方式所得之組合物於40℃之減壓下(10 mmHg)攪拌1小時。藉此，去除該組合物中之甲醇等揮發成分。其次，於常壓下，向該組合物加入有機氫矽氧烷(信越化學工業股份有限公司製造，二甲基聚矽氧烷-共聚-甲基氫聚矽氧烷，平均分子量2000)44.5 g，於40℃下攪拌1小時後，加入作為加成觸媒之鉑-羰基錯合物之矽氧烷溶液(鉑濃度2質量%)0.13 g，於40℃攪拌10分鐘(加成反應)。藉此，獲得熱硬化型聚矽氧樹脂組合物。其次，對熱硬化型聚矽氧樹脂組合物調配(調配量為20質量%)聚甲基倍半矽氧烷微粒子(商品名「Tospearl 2000B」，平均粒徑6.0 μm，Momentive Performance Materials Japan公司製造)，將該組合物於室溫(25℃)攪拌10分鐘。攪拌後，對該組合物使用真空乾燥機於室溫下進行30分鐘以上消泡。將以此種方式製備之緩衝材片材形成用之樹脂組合物塗佈於作為離型片材之聚酯膜(商品名「SS4C」，厚度50 μm，Nippa股份有限公司製造)上後，於135℃加熱9分鐘。藉此，於離型片材上形成厚度30 μm之半硬化狀態之聚矽氧樹脂片。比較例2中所使用之第4緩衝材片材係以如上方式製作者。
[比較例3] 於燒結接合步驟中，使用厚度30 μm之第5緩衝材片材(商品名「9700UL」，日東電工股份有限公司製造)代替厚度30 μm之第1緩衝材片材，除此以外，以與實施例1同樣之方式進行附燒結接合用材料層之矽晶片之製作至一次性燒結接合，且進行燒結接合部位之觀察。存在於燒結接合工件中在燒結層產生接合不良(燒結層之周緣部未接合於基板或半導體晶片之狀態)者。將其結果記載於表1。
[緩衝材片材之拉伸彈性模數] 對實施例1～3及比較例1～3中所使用之各緩衝材片材調查拉伸彈性模數。具體而言，對同一組成之緩衝材片材試樣片(寬度10 mm×長度40 mm×厚度100 μm)，使用拉伸試驗機(商品名「Autograph AGS-50NX」，島津製作所股份有限公司製造)，於初始夾頭間距離10 mm、23℃及拉伸速度50 mm/分鐘之條件下，進行拉伸試驗。並且，根據藉由同試驗之測定所得之應力-應變曲線中之測定初始期間之上升直線部分之斜率求出拉伸彈性模數(MPa)。將其結果記載於表1。
[緩衝材片材之耐熱性] 對實施例1～3及比較例1～3中所使用之各緩衝材片材調查耐熱性。將其結果記載於表1。具體而言，自緩衝材片材切取約10 mg之試樣，對該試樣，使用示差熱-熱重量同步測定裝置(商品名「示差熱天平TG-DTA TG8120」，Rigaku股份有限公司製造)，測定升溫過程中之重量減少。本測定於大氣氛圍下以升溫速度10℃/分鐘自基準重量溫度之25℃升溫至500℃。將試樣自25℃下之重量(基準重量)至350℃下之重量之減少率(%)記載於表1。
[一次性燒結接合中之作業性] 比較例2中所使用之第4緩衝材片材於進行燒結接合步驟時，過於柔軟而難以重疊於燒結接合工件上。與此相對，其他緩衝材片材中未發生此種問題。將其結果記載於表1。
[晶片損傷之觀察] 於比較例1、3中，存在於經歷一次性燒結後之燒結接合工件產生裂紋或缺口之矽晶片。於實施例1～3及比較例2中，未產生此種裂紋或缺口。將其結果記載於表1。
[表1]
作為以上之總結，以下將本發明之構成及其變化列舉為附記。
[附記1] 一種半導體裝置製造方法，其包括：準備具有積層構成之燒結接合工件之步驟，該積層構成包含具有第1面及與其相反之第2面之基板、待配置且接合於上述第1面側之複數個半導體晶片、及分別介存於各半導體晶片與上述基板之間並含有燒結性粒子之複數個燒結接合用材料層；以及 燒結接合步驟，其係於將厚度5～5000 μm且拉伸彈性模數2～150 MPa之緩衝材片材與上述燒結接合工件重疊並夾持於一對加壓面之間的狀態下，於該一對加壓面間對上述燒結接合工件一面沿其積層方向加壓一面使其經歷加熱過程，藉此由上述燒結接合用材料層形成燒結層。 [附記2] 如附記1所記載之半導體裝置製造方法，其中上述緩衝材片材之上述厚度為10 μm以上，較佳為20 μm以上，更佳為30 μm以上。 [附記3] 如附記1或2所記載之半導體裝置製造方法，其中上述緩衝材片材之上述厚度為3000 μm以下，較佳為1500 μm以下，更佳為1000 μm以下，更佳為500 μm以下。 [附記4] 如附記1至3中任一項所記載之半導體裝置製造方法，其中上述緩衝材片材之上述拉伸彈性模數為5 MPa以上，較佳為15 MPa以上，更佳為30 MPa以上。 [附記5] 如附記1至4中任一項所記載之半導體裝置製造方法，其中上述緩衝材片材之上述拉伸彈性模數為120 MPa以下，較佳為100 MPa以下。 [附記6] 如附記1至5中任一項所記載之半導體裝置製造方法，其中上述緩衝材片材於大氣氛圍下、基準重量溫度25℃、及升溫速度10℃/分鐘之條件下之重量減少測定中，350℃下之重量減少率為0.1%以下。 [附記7] 如附記1至6中任一項所記載之半導體裝置製造方法，其中上述燒結接合步驟中之加熱溫度為200℃以上且加壓力為5 MPa以上。 [附記8] 如附記1至7中任一項所記載之半導體裝置製造方法，其中上述燒結性粒子包含選自由銀粒子、銅粒子、氧化銀粒子、及氧化銅粒子所組成之群中之至少一種。 [附記9] 如附記1至8中任一項所記載之半導體裝置製造方法，其中上述燒結接合用材料層中之上述燒結性粒子之含有比率為60～99質量%，較佳為65～98質量%，更佳為70～97質量%。 [附記10] 如附記1至9中任一項所記載之半導體裝置製造方法，其中上述燒結層之厚度為5～200 μm，較佳為10～150 μm。
10‧‧‧燒結接合用片材 11‧‧‧燒結接合用材料層 12‧‧‧燒結層 20‧‧‧緩衝材片材 C‧‧‧晶片(半導體晶片) L‧‧‧剝離襯墊 P‧‧‧平行平板 Pa‧‧‧加壓面 R‧‧‧密封樹脂 S‧‧‧基板 Sa‧‧‧面 Sb‧‧‧面 T1‧‧‧膠帶 T1a‧‧‧黏著面 W‧‧‧接合線 X‧‧‧燒結接合工件
圖1表示本發明之一實施形態之半導體裝置製造方法中之一部分步驟。 圖2(a)～(d)表示燒結接合工件之製作方法之一例。 圖3(a)～(c)表示圖1所示之步驟之後的步驟。 圖4(a)、(b)表示圖3所示之步驟之後的步驟。 圖5表示燒結接合步驟中之緩衝材片材之使用態樣之變化。 圖6表示燒結接合步驟中之緩衝材片材之使用態樣之變化。 圖7(a)、(b)表示燒結接合步驟中之緩衝材片材之使用態樣之變化。 圖8表示燒結接合步驟中之緩衝材片材之使用態樣之變化。
11‧‧‧燒結接合用材料層
12‧‧‧燒結層
20‧‧‧緩衝材片材
C‧‧‧晶片(半導體晶片)
P‧‧‧平行平板
Pa‧‧‧加壓面
S‧‧‧基板
Sa‧‧‧面
X‧‧‧燒結接合工件

Claims (9)

  1. 一種半導體裝置製造方法，其包括：準備具有積層構成之燒結接合工件之步驟，該積層構成包含具有第1面及與其相反之第2面之基板、待配置且接合於上述第1面側之複數個半導體晶片、及分別介存於各半導體晶片與上述基板之間並含有燒結性粒子之複數個燒結接合用材料層；以及燒結接合步驟，其係於將厚度5~5000μm且拉伸彈性模數2~150MPa之緩衝材片材及上述燒結接合工件重疊並夾持於一對加壓面之間的狀態下，於該一對加壓面間對上述燒結接合工件沿其積層方向，以上述緩衝材片材於上述半導體晶片周圍不形成封閉空間之方式一面加壓一面使其經歷加熱過程，藉此由上述燒結接合用材料層形成燒結層。
  2. 如請求項1之半導體裝置製造方法，其中上述緩衝材片材於大氣氛圍下、基準重量溫度25℃、及升溫速度10℃/分鐘之條件下之重量減少測定中，350℃下之重量減少率為0.1%以下。
  3. 如請求項1或2之半導體裝置製造方法，其中上述燒結接合步驟中之加熱溫度為200℃以上且加壓力為5MPa以上。
  4. 如請求項1或2之半導體裝置製造方法，其中上述燒結性粒子包含選自由銀粒子、銅粒子、氧化銀粒子、及氧化銅粒子所組成之群中之至少一種。
  5. 如請求項1或2之半導體裝置製造方法，其中上述燒結接合用材料層中之上述燒結性粒子之含有比率為60~99質量%。
  6. 如請求項1或2之半導體裝置製造方法，其中上述燒結接合用材料層含有熱分解性高分子黏合劑。
  7. 如請求項6之半導體裝置製造方法，其中上述熱分解性高分子黏合劑選自聚碳酸酯樹脂及丙烯酸樹脂中之至少一種。
  8. 如請求項6之半導體裝置製造方法，其中上述燒結接合用材料層中之上述熱分解性高分子黏合劑之含有比率為0.5~10質量%。
  9. 如請求項1或2之半導體裝置製造方法，其中上述燒結層之厚度為5~200μm。
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