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CN1822339A - 用于将电子部件或类似部件集成至衬底中的方法 - Google Patents

用于将电子部件或类似部件集成至衬底中的方法 Download PDF

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CN1822339A
CN1822339A CN200610008557.5A CN200610008557A CN1822339A CN 1822339 A CN1822339 A CN 1822339A CN 200610008557 A CN200610008557 A CN 200610008557A CN 1822339 A CN1822339 A CN 1822339A
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substrate
dielectric insulation
insulation layer
aforementioned
cavity
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穆杰塔巴·约达基
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Atmel Germany GmbH
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Atmel Germany GmbH
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Abstract

本发明涉及用于将电子部件(8)或类似部件集成至一个衬底(1)上的方法,具有以下方法步骤:在衬底(1)的正面形成一个介电绝缘层(2、3、4);从衬底(1)的背面将衬底(1)的一个区域完全地反向蚀刻以形成一个空腔(6);在衬底(1)的背面上以均匀的厚度形成一个光刻胶层(7);将电子部件(8)设置在在空腔(6)中形成的光刻胶层(7)上,用于将电子部件(8)粘附在该光刻胶层上;去除形成的、在电子部件(8)在空腔(6)的光刻胶层(7)上粘附的区域之外的光刻胶层(7);以及在衬底(1)的背面上形成固定层(9),用于将电子部件(8)固定在衬底(1)的空腔(6)中。

Description

用于将电子部件或类似部件集成至衬底中的方法
技术领域
本发明涉及用于将电子部件或类似部件集成至衬底中的方法。
背景技术
集成在半导体衬底上的部件的元器建模随着增加的工作频率而发挥着越来越大的作用,因为在这种情况下线路特性、在间断处的反射、重叠以及损耗功率都增加。由此在建模中,特别是在高频领域中对于这些效应的考虑一般来说是不可或缺的。特别是在低电阻的衬底中,例如硅衬底中,衬底导电能力和附加的电容的寄生影响是不能忽略的。
虽然可以一般地应用在任意的电子部件上,然而本发明以及以其为基础的问题优选地关于待集成到衬底中的芯片进行详细阐述。
电子部件至半导体衬底中的集成以及单个的封装在很大程度上影响功率、成本、可靠性以及元器件的寿命。一般来说,未布线的子系统由不同部件、例如由高频收发器、数字处理器、MEM或类似部件构成。微波收发器例如不但由集成的电路而且还由具有滤波器和功率元件的无源元器件构成,它们未被集成在半导体衬底中。这些部件基于不同的材料和技术。
在从前,在电子部件的制造和特性中实现了显著的改进,并且一些新的部件被开发出来。化合物半导体,例如砷化镓、磷化铟或类似材料的发展,以及三重(3-fach)化合物半导体的发展实现了建立具有出色的噪音特性和功率特性的微波部件和毫米波部件。在射频领域中的微加工以及MEM’s作为技术表明,它们能够对在射频范围内、例如在传感器特别是雷达传感器中以及在通信领域中的存在的结构产生很大的影响,其方式是它们降低了重量、成本、大小以及损耗功率。为此必需的技术同时可用。
在从前已完成了许多高功率部件,它们可以集成到半导体衬底中并且可以没有功率减小地被封装。在此,整个组件可以由多个单个的部件构成,它们逐渐地互相包封(ineinander verkapselt),其中这种被包封的系统被称为SOP(System On a Package)系统。在SOP系统中的主要任务在于,将单个的元器件或芯片集成到一包封的作为准第一级的一承载衬底中。
在现有技术中,存在多种方法用于将由不同材料制成的单个芯片集成在衬底中或集成至其中。常见的方法是作为键合工艺或倒装芯片工艺(Flip-Chip-Technologie)而公开。
键合被理解为例如将芯片安装在芯片载体上,其中单个的芯片例如在芯片粘合器中借助环氧粘合剂(Epoxydklebers)粘贴至芯片载体上。大多数情况下铝线或金线用于将芯片的接触区域(粘结焊点)与衬底的所配置的接触轨电连接。
在楔型键合(Wedge-Bonden)中,焊线水平地保持在键合表面上并且由楔型的工具轧断一其中过剩的线被拉走。
在球点键合(Ball-Point-Bonden)中,在焊线的末端借助例如氢焰或电火花形成球体。所使用的线具有大约10至25um的直径。这些非常细的线在更高的频率下具有高的电感。此外其线长和其弯曲的形状的改变不利地导致与多个模块相关的不同功率。
此外根据现有技术公开了倒装芯片工艺。在倒装芯片工艺中,如图2所示的那样,芯片8方向向下地安装在衬底1上。焊堆(Lothügel)14以及例如以导电粉填充的粘结连接在此用作连接手段,由此保证了良好的电连接。热径(thermische Pfad)直接延伸到衬底1上。
然而在根据现有技术的这种方式中,证实有这种事实是不利的,即例如对于高功率砷化镓-MMIC的情况,该热径作为通常的方式被证实对于可靠的工作是不足够的,这样必须设计附加的热排出通道。此外在该方式中不利的是,各个被使用的材料的热膨胀系数被不同地构造,由此降低了组件的寿命。
此外企业还如下地做到了:开发新的方法用于将基于不同材料的芯片可靠地集成到硅衬底上或集成至其中。在图3中示出了在衬底1中集成的电子部件8的示意性横截图。衬底1被从正面蚀刻,并且芯片8在被蚀刻的空腔(Kavitt)中借助能导热的粘合剂固定。
此外,在衬底1的正面离心涂覆一个有机介电层,以便将整个晶圆的表面平坦地构造。如在图3中此外还显然能见到的那样,在有机的介电层16上设置了合适的金属化结构18,用于芯片8的电接触。
然而在根据现有技术的这种方式中,证实有这种事实是不利的,即难以实现对在衬底1中的垂直被蚀刻的空腔深度的准确控制。大多数按照标准的半导体制造方法要求在芯片表面和晶圆表面之间的最大高度差为2μm。虽然使用了被离心涂覆的有机介电层16,还可以建立至芯片8的电连接,然而平坦的结构仍是值得期望的。
该现有技术的一种另外的固有的缺点在于,具有不同结构高度的不同芯片要求不同的空腔深度,这样必须使用复杂和昂贵的蚀刻方法。
此外在根据图3的结构的高热阻中还存在一个缺点。虽然通常在该方法中使用热传导的粘合剂或环氧化物,然而这些材料相比硅或例如金或铜这些金属具有显然更低的热传导能力。在芯片8和衬底1之间出现空气缝17时,如在图3中所示,整个结构的热阻甚至可表现更高的值。
因为热导的粘合剂以及环氧化物具有高的热膨胀系数,所以在图3中所示的结构中具有大的热-机械应力,它不利地显著降低了整个器件的寿命。
根据另外的现有技术公开了所谓的“增强的准单片集成工艺(QMIT)”,它可以被视为有机地淀积的多芯片模块(MCM-D)。这种工艺使用整个的并且被构造为薄膜的化合物用于包封或封装的第一级。因为这种工艺还处于其开始阶段,所以目前做了许多努力将这种工艺进一步改进。
发明内容
由此本发明的任务在于,实现一种方法用于将电子部件集成至衬底中,它没有上面提及的缺点并且与常见的方法相比保证了电子部件至衬底中的、更简单和廉价的集成以及保证了改善的热传导。
本发明的基本思想在于,用于将电子部件或类似部件集成至衬底中的方法具有以下工艺步骤:在衬底的正面形成一个介电绝缘层;从衬底的背面将衬底的一个范围完全反向蚀刻以形成一个空腔;在衬底的空腔内形成一个光刻胶(photoresistiven)层;将电子部件设置在在空腔中形成的光刻胶层上,用于将电子部件粘附在光刻胶层上;去除所形成的、在该电子部件在该空腔的光刻胶层上粘附的区域之外的光刻胶层;以及在衬底的背面形成固定层,用于将电子部件固定在衬底的空腔中。
由此本发明相对于现有技术具有的优点是,电子部件或类似部件通过简单并且成本低的方法可以被集成至传统的硅衬底中,其中电子部件通过电气绝缘层被覆盖并且被固定层支持。
此外本发明的方法完成了具有小尺寸以及具有低重量、具有出色的寿命和可靠性的结构。
此外还实现了MCM’s的集成可能性,其中有源的、基于不同材料的部件可以被集成。
此外由于在简化的制造步骤中的紧凑的集成而保证成本低的方法,该方法与通常的用于形成模拟或数字电路的半导体工艺、例如Si-MOS工艺、SiGe-HBT工艺以及III-V复合半导体工艺是兼容的。
在下面的内容中有在上面说明的方法的另外的、有利的构型和改进。
根据一种优选的进一步构型,衬底被构造为硅半导体衬底、砷化镓半导体衬底或类似物。自然可以使用可以被各向异性地蚀刻的任意合适的半导体材料。
根据另一种优选的进一步构型,在衬底的正面形成的介电绝缘层由一个第一、一个第二以及一个第三介电绝缘层构成。此外优选地在衬底的背面形成一个第四介电绝缘层。除了第二介电绝缘层,所有介电绝缘层优选地分别由无机的绝缘材料例如硅氧化物、特别是二氧化硅、氮化硅或类似材料制造。这些介电材料特别适合于各向异性的湿法蚀刻方法。
根据另一种优选的实施例,第二介电绝缘层由有机的绝缘材料例如特别是苯环丁烯(Benzozyclobuthen)(BCB)、聚酰亚胺、SU-8或者类似材料制造。这些有机绝缘材料可以有利地以简单的方式必要时再去除。
优选的是衬底的一个区域的完全地反向蚀刻借助一种各向异性的方法,例如借助各向异性的湿法蚀刻方法通过第四介电绝缘层的、以前的结构化来实施。
根据另一种优选的进一步构型,第三和第四介电绝缘层以及第一介电绝缘层的位于空腔底部的区域借助一种合适的方法在光刻胶层形成之前被去除。由此,在其上应该沉积光刻胶层的衬底区域被露出。光刻胶层例如可以通过离心涂覆方法、溅射方法或类似方法以均匀厚度形成。
根据另一种优选的实施例,电子部件被构成为芯片、晶体管、电路、MEMS或者类似部件。对于专业人士显然的是,通过根据本发明的方法可以将任意电子部件有利地集成在半导体衬底中。
该电子部件优选地借助精密置放机(Fine-Placer-Maschine)设置在衬底的空腔中的光刻胶层上。有利的是,在电子部件设置其上之后,光刻胶层借助热处理方法被硬化。在电子部件之外的区域中的光刻胶层的去除优选地借助干法蚀刻方法实施。
根据另一种优选的进一步构型,用于将电子部件固定在衬底的空腔中的固定层以均匀厚度并且由一种介电材料、特别是一种无定形的硅材料或者由一种金属材料、特别是由铬或铂制造。这些材料以非常好的粘附性特别适合铜或金电镀方法。
根据另一种优选的实施例,在形成固定层之后,第二介电绝缘层以及光刻胶层的剩余区域借助合适的方法被去除。之后,优选地在衬底的正面上形成第五介电绝缘层,特别是由一种有机绝缘材料、例如苯环丁烯(BCB)、聚酰亚胺、SU-8或者类似材料制成。
为了芯片或电子部件与另外的电路或类似部件的连接,第五介电绝缘层被结构化。借助该结构化可以接着形成任意的金属化结构。
根据另一种优选的实施例,在集成方法的最后,在衬底中的空腔的空出的区域通过一种填充材料填充。以金刚石粉末填充的聚酰亚胺例如可以作为填充材料使用。这种材料具有特别有利的热传导能力,即高的热传导系数,这样来自结构的热被良好地排向环境中。
附图说明
以下,本发明的优选实施例通过参照附图来进一步阐述。图中示出了:
图1a-1k根据本发明的一种优选实施例的、用于将芯片集成至衬底中的一种方法的不同工艺状态的横截图,用于示出单个的工艺步骤;
图2根据现有技术的倒装芯片方法的示意性示图;以及
图3根据现有技术的在衬底中集成的芯片的横截图。
在图中,只要没有与之相反地说明,则相同的参考标号表示相同的或功能相同的组件。
在这里要指出的是,在图中,在衬底上的另外的电路或部件出于清楚起见没有被一同示出。
具体实施方式
图1a-1k示出了根据本发明的一种优选的实施例、在将电子部件8集成至衬底1中的制造方法期间单个工艺状态的横截图。
这里要指出的是,在图1a、1i和1k中的结构的方向被这样选择,使得衬底1的正面对着向上的方向。另一方面,图1b-1g的示图这样选择,使得衬底1的背面对着向上的方向。这些示图相应于衬底1关于单个工艺步骤的有利的定向地选择,其中借助合适的衬底承载设备可以为不同的工艺步骤而实现衬底1的旋转。
例如使用低电阻的硅半导体衬底、砷化镓衬底或任意另外的可以被各向异性蚀刻的半导体衬底作为承载衬底1。
如在图1a中可以看出的那样,在衬底1的正面首先形成三个介电绝缘层2、3和4。第一和第三介电绝缘层2和4例如可以被构造为氮化硅层或作为二氧化硅层。对于在硅的各向异性湿法蚀刻中的掩蔽(Maskierung),这些材料是有利的材料。
第二介电层3优选地被构造为由一种有机电介质构成的辅助层3。第二介电绝缘层3优选地由这种材料以及这样地在第一介电绝缘层2上被形成,使得它可以借助合适的方法被去除。此外第二介电绝缘层3用作对可能被放入的电子部件的承载膜,这样其用于承载被放入的电子部件的层厚应该被构造得足够厚,以避免第二介电绝缘层3的断裂。第二介电绝缘层3例如由一种有机聚合物材料,特别是苯环丁烯(BCB)、一种SU-8材料或者类似材料构成,并且可以以例如10μm至20μm的厚度被构造,用于暂时承载芯片。
如在图1a中此外还示出的那样,在衬底1的背面施加了一个第四介电绝缘层5,它与第一和第三介电绝缘层2和4类似优选地由无机的绝缘材料、例如二氧化硅、氮化硅或类似材料制造。
接着,如在图1b中示出的那样,从衬底1的背面开始向衬底1内蚀刻出空腔6。蚀刻过程例如可以以常规的方式借助按照标准的KOH湿法蚀刻方法实施。对于衬底1的反向蚀刻,第四介电绝缘层5事先以已知并且合适的方法在衬底1的背面上结构化。蚀刻过程被有利地这样实施,使得在衬底1的正面上的介电绝缘层2、3和4在上面提及的湿法蚀刻方法中保持不受损坏。由此得到在图1b中所示的、在衬底1中的空腔6。
之后参照图1c,在衬底1的背面上的第四介电绝缘层5和第三介电绝缘层4以及第一介电绝缘层2的从空腔6的开口可达到的区域被去除。这例如可以借助各向同性的干法蚀刻方法完成。由此形成在图1c中示出的结构,其中第二介电绝缘层3从衬底1的正面覆盖衬底1的被反向蚀刻的空腔6。
接下来,如在图1d中示出的那样,在衬底1的背面上淀积一个光刻胶层7。例如一种正性的光致抗蚀剂7借助按照标准的离心涂覆方法或者溅射方法被施加在衬底1的背面上。对于专业人士显然的是,替代正性光致抗蚀剂也可以以相应地配置的工艺步骤使用负性光致抗蚀剂。
光刻胶层7优选地以均匀的厚度淀积在衬底1的背面上,如在1d中所示。
在接下来的工艺步骤中,根据图1e,待集成的电子部件、当前例如芯片8从衬底1的背面这样地被置入空腔6中,使得它在空腔6的底部位于光刻胶层7上并且粘附于其上。
替代芯片,电子部件8也可以被构造为电路部分、晶体管、MEM或类似部件。对于专业人士显然的是,任意类似的部件、例如无源或有源的部件都可以通过本发明思想被集成至衬底中。而在以下继续通过使用芯片8来阐述本发明的实施例。
芯片8例如可以通过使用精密置放机或一种另外的合适的工具准确地被装在空腔6中的所期望的位置上。这种精密置放机对于专业人士充分地被公开了并且不被详细描述。
光刻胶层7接着例如在60℃至90℃的温度下被烘烤更长的时间,例如超过20分钟。在这种情况下光刻胶层7对于接下来的步骤足够干燥并且可以以后如在下面描述的那样以简单的方法再去除。
接下来,如在图1f中所示的那样,光刻胶层7例如借助干法蚀刻方法从衬底1的背面被去除。仅仅而且只是在芯片8在光刻胶层7上被置于其中并且粘附于其上的区域内,光刻胶层7未被反向蚀刻。在此,得到在图1f中所示的结构。
在图1g中示出了接下来被实施的工艺步骤。在此,一个固定层9从衬底1的背面被施加在衬底1上。固定层9用于将部件8固定在衬底1的空腔6中。固定层9优选地以均匀厚度被构造,如在图1g中可以看出的那样。固定层9优选地由一种介电材料、特别是一种无定形的硅材料构成,或者由一种金属材料制成。固定层9的厚度优选地这样选择,即保证芯片8在空腔6中可靠并且稳定的固定。此外固定层9优选地还具有高的热传导系数,以便能够将损耗热有利地从该布置向环境中导出。
对于金属层的情况,例如由铬及/或铂构成的薄层分别优选地以小于50nm的厚度通过使用蒸镀方法淀积在衬底1的背面上,其中衬底1优选地在金属流(Metallflusses)方向上倾斜,并且可以借助前面已经阐述过的衬底承载设备借助电动马达或类似装置旋转到合适的位置。
接着该由铬及/或铂构成的薄层可以通过电镀方法按照为了在空腔6中固定部件8而需要的厚度被增厚。铬层具有对于硅衬底1良好的粘附特性,并且铂层对于用铜或金电镀是出色的金属,具有良好的粘附特性。固定层9的这种制造方法特别适合高功率应用,然而也可以想象其它的用于制造合适的固定层的方法。
接下来,如在图1h中所示的那样,在芯片8被固定在空腔6中之后,第二介电绝缘层3和光刻胶层7的剩余部分借助合适的方法从衬底1的正面去除。
接下来,如同样在图1h中示出的那样,第五介电绝缘层10被淀积在衬底1的正面上,以保证在整个衬底1上的平坦表面。第五介电绝缘层10例如由有机绝缘材料、例如有机聚合物材料、特别是苯环丁烯(BCB)、聚酰亚胺或类似材料构成。
如在图1i中示出的那样,为了芯片8至所属的电路或类似部分的电气连接,第五介电绝缘层10被这样地结构化,使得可以形成合适的金属化结构11,用于保证与所属部件的合适的电接触。对于微波应用以及毫米波应用,优选地使用一种具有更大厚度的有机介电绝缘层10,以降低可能的衬底损耗。
接下来,如在图1k中所示的那样,一种具有高的热传导能力的电介体12可以被填充到空腔6的空出的区域内。例如可以使用以金刚石粉填充的、具有高热传导系数的聚酰亚胺作为介电层12。对于专业人士显然的是,也可以在可能的情况下放弃附加的介电绝缘层10。
虽然本发明借助优选的实施例突出地被描述,然而它并不局限于此,而是可以以多种方式变换。
例如用上面描述的布置在使用厚的无定形硅层作为介电固定层情况下实现共面线以及在使用金属层作为固定层的情况下实现微带线。然而这只是示例性的复述,这样对于专业人士显然的是,任意用于实现本发明思想的合适的材料和构型都是可能的。
例如由第一、第二和第三介电绝缘层构成的介电整体层根据待集成在衬底中的部件可以以更小或更大的厚度被构造。厚度和材料优选地被这样选择,使得保证部件8在衬底的空腔中可靠和稳定的固定。
此外对于专业人士显然的是,可以使用与所说明不同的材料、层厚和部件,而没有离开本发明思想。
             参考标号表
1    衬底
2    第一介电绝缘层
3    第二介电绝缘层
4    第三介电绝缘层
5    第四介电绝缘层
6    空腔
7    光刻胶层
8    电子部件
9    固定层
10   有机介电绝缘层
11   金属化结构
12   聚酰亚胺层
13
14   焊接堆
15   传导粘合剂
16   有机介电层
17   空气间隙
18   金属化结构

Claims (18)

1.用于将电子部件(8)或类似部件集成至一个衬底(1)中的方法,具有以下方法步骤:
-在衬底(1)的正面形成一个介电绝缘层(2,3,4);
-从该衬底(1)的背面将该衬底(1)的一个区域完全地反向蚀刻以形成一个空腔(6);
-在该衬底(1)的该空腔(6)中形成一个光刻胶层(7);
-将电子部件(8)设置在在该空腔(6)中形成的该光刻胶层(7)上,用于将该电子部件(8)粘附在该光刻胶层上;
-去除所形成的、在该电子部件(8)在该空腔(6)的光刻胶层(7)上粘附的区域之外的光刻胶层(7);以及
-在该衬底(1)的背面上形成一个固定层(9),用于将该电子部件(8)固定在该衬底(1)的该空腔(6)中。
2.根据权利要求1的方法,其特征在于,该衬底(1)被构造为硅半导体衬底、砷化镓半导体衬底或类似物。
3.根据前述权利要求之一的方法,其特征在于,在该衬底(1)的正面上形成的介电绝缘层由一个第一介电绝缘层(2)、一个第二介电绝缘层(3)以及一个第三介电绝缘层(4)构造。
4.根据前述权利要求之一的方法,其特征在于,在该衬底(1)的背面上形成一个第四介电绝缘层(5)。
5.根据前述权利要求之一的方法,其特征在于,除了该第二介电绝缘层(3)此外,这些介电绝缘层(2,4,5)分别由无机的绝缘材料、例如硅氧化物、特别是二氧化硅、氮化硅或类似材料制造。
6.根据前述权利要求之一的方法,其特征在于,该第二介电绝缘层(3)由有机的绝缘材料、特别是苯环丁烯(BCB)、聚酰亚胺、SU-8或者类似材料制造。
7.根据权利要求4的方法,其特征在于,该衬底(1)的一个区域的所述完全的反向蚀刻借助一种各向异性的蚀刻方法、例如借助各向异性的湿法蚀刻方法通过该第四介电绝缘层(5)的结构化来实施。
8.根据前述权利要求之一的方法,其特征在于,该第三介电绝缘层(4)和该第四介电绝缘层(5)以及该第一介电绝缘层(2)的位于该空腔(6)底部上的区域借助一种合适的方法在该光刻胶层(7)形成之前被去除。
9.根据前述权利要求之一的方法,其特征在于,通过一种离心涂覆方法、一种溅射方法或类似方法以均匀厚度形成该光刻胶层(7)。
10.根据前述权利要求之一的方法,其特征在于,所述电子部件(8)被构成芯片、晶体管、电路、MEMS或者类似部件。
11.根据前述权利要求之一的方法,其特征在于,所述电子部件(8)借助精密置放机设置在该衬底(1)的空腔(6)的光刻胶层(7)上。
12.根据前述权利要求之一的方法,其特征在于,在将该电子部件(8)设置该光刻胶层上之后,借助热处理方法处理该光刻胶层(7)。
13.根据前述权利要求之一的方法,其特征在于,借助干法蚀刻方法实施该光刻胶层(7)的去除。
14.根据前述权利要求之一的方法,其特征在于,该具有均匀厚度的固定层(9)由一种介电材料、特别是一种无定形的硅材料或者由一种金属材料、特别是由铬和/或铂制造。
15.根据前述权利要求之一的方法,其特征在于,在形成该固定层(9)之后,借助合适的方法去除该第二介电绝缘层(3)以及该光刻胶层(7)的、以前未被反向蚀刻的区域。
16.根据权利要求15的方法,其特征在于,在所述去除该第二介电绝缘层(3)以及该光刻胶层(7)的、以前未被反向蚀刻的区域之后,在该衬底(1)的正面上形成一个第五介电绝缘层(10),该第五介电绝缘层特别是由一种有机绝缘材料、例如苯环丁烯(BCB)、聚酰亚胺、SU-8或者类似材料构成。
17.根据前述权利要求之一的方法,其特征在于,该第五介电绝缘层(10)被合适地结构化,并且相应于所形成的结构化地形成一个金属化结构。
18.根据前述权利要求之一的方法,其特征在于,在该集成方法的最后,在该衬底(1)中的该空腔(6)的空出的区域被一种具有高的热传导系数的填充材料(12)填充,例如被以金刚石粉填充的聚酰亚胺填充。
CN200610008557.5A 2005-02-18 2006-02-17 用于将电子部件或类似部件集成至衬底中的方法 Pending CN1822339A (zh)

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