1. Field of the Invention
The present invention relates to a hybridly integrated component that includes at least one ASIC (application-specific integrated circuit) element having a processed front side, a first MEMS (micro-electromechanical systems) element having a micromechanical structure, and a first cap wafer. The micromechanical structure of the first MEMS element extends over the entire thickness of the MEMS substrate and includes at least one deflectable structural element. The first MEMS element is mounted on the processed front side of the ASIC element in such a way that a gap exists between the micromechanical structure and the ASIC element. The first cap wafer is mounted over the micromechanical structure of the first MEMS element. In addition, the present invention relates to a method for producing such a hybridly integrated component.
2. Description of the Related Art
Components having MEMS components have been mass-produced for many years for a wide variety of applications, for example in the area of automotive technology and consumer electronics. The miniaturization of the components has become increasingly important. The miniaturization contributes substantially to reducing the production costs of the components and thus also of the end devices. In addition, in particular in the area of consumer electronics more and more functions—and therefore components—are to be incorporated into an end device, while the end devices themselves become ever smaller. Consequently, less and less space is available on the application circuit boards for the individual components.
In practical use, various miniaturization designs for sensor components are known that provide an integration of the micromechanically realized sensor function and the circuit-based processing and evaluation of the sensor signals in a component. Besides the lateral integration of the MEMS function and the ASIC function on a common chip, there are also designs for so-called vertical hybrid integration, according to which a chip stack is formed of an ASIC, a MEMS, and a cap wafer.
Such a vertically integrated component and a method for its production are described in US Patent Application Publication No. 2011/0049652 A1. The known method provides the bonding of the initial substrate for the MEMS element on an already-processed ASIC substrate. Only after this is a micromechanical structure produced in the MEMS substrate, including at least one deflectable structural element. Independently of this, a cap wafer is structured and is prepared for mounting over the micromechanical structure of the MEMS substrate and on the ASIC substrate. The cap wafer processed in this way is bonded onto the ASIC substrate after the structuring of the MEMS substrate, so that the micromechanical structure between the ASIC substrate and the cap wafer is enclosed so as to be hermetically sealed.
The known component design enables an economical mass production of robust components having a micromechanical function and a signal processing circuit, because here not only are the individual components—MEMS element, cap, and ASIC—produced in the wafer composite, but their assembly to form a component on the wafer level is also realized. The MEMS functions and the ASIC functions can be tested on the wafer level, and even the calibration of the individual components can be carried out before their separation on the wafer level. Moreover, due to the stacked construction the known components require a comparatively small mounting surface, which has an advantageous effect on the production costs of the end devices.
The known component design presupposes a good surface matching between the MEMS element and the ASIC element. Accordingly, the miniaturization effect and the cost advantage connected therewith is particularly large if the micromechanical MEMS function and the circuit-based ASIC function have a comparable surface requirement. Only in this case can both elements be realized without wasting chip surface.
However, in a series of applications known from practical use, the micromechanical structure of the MEMS element takes up significantly larger chip surface than is required for the realization of the associated ASIC function. Examples of this include rotational rate sensors and so-called IMUs (Inertial Measurement Units), where rotational rate sensor elements and acceleration sensor elements are integrated with relatively large micromechanical structures in one component.
The present invention provides measures for realizing hybridly integrated components of the type named above, through which a particularly high integration density and a particularly effective surface usage can be achieved, in particular when the surface requirement for the realization of the MEMS function is significantly greater than that for the realization of the ASIC function.
According to the present invention, this is achieved with the aid of a second MEMS element on the rear side of the ASIC element, whose micromechanical structure extends over the entire thickness of the second MEMS substrate and includes at least one deflectable structural element. This second MEMS element is mounted on the rear side of the ASIC element in such a way that a gap exists between the micromechanical structure of the second MEMS element and the ASIC element. A second cap wafer is then mounted over the micromechanical structure of the second MEMS element.
According to the present invention, a five-fold wafer stack is accordingly produced that includes two MEMS elements and one ASIC element. Through this feature alone, the component produced by the present invention is equipped with a very high functionality per mounting surface. Advantageously, the MEMS elements and the ASIC element form a functional unit, for example in the form of two micromechanical sensor elements that supplement one another in their sensor function, whose signal processing and evaluation circuit is integrated on the ASIC element. The micromechanical structures of the two MEMS elements of a component can be identical or similar if these elements are intended to fulfill comparable functions. In the context of a component according to the present invention, however, MEMS elements may be combined that have completely different sensor or actuator functions, and accordingly also have completely different micromechanical structures.
The design according to the present invention is suitable in particular for the realization of contactlessly operating sensors, such as acceleration sensors, rotational rate sensors, and other inertial sensors. In the case of an inertial sensor, the micromechanical sensor structure includes at least one elastically suspended seismic mass that is deflected on the basis of accelerations. These accelerations can also be caused by centrifugal forces or rotational movements. The deflections of the seismic mass are acquired and evaluated.
Because according to the present invention the micromechanical structures of both MEMS elements each extend over the entire thickness of the corresponding MEMS substrate, here relatively large seismic masses can be realized on a comparatively small chip surface, which has a positive effect on the measurement sensitivity of such sensor elements.
The component design according to the present invention moreover provides a cap of the micromechanical structures of both MEMS elements in that both MEMS elements are situated in sandwiched fashion between the respective cap wafer and the ASIC element situated centrically in the wafer stack. In this way, the sensor structures are protected against contamination, moisture, and particles. In addition, environmental influences on the measurement signals are minimized. In this way, moreover, defined pressure conditions can be created for the sensor structures that substantially contribute to determining the damping behavior of the sensor elements.
As already mentioned, preferably circuit functions are integrated on the ASIC element that support and supplement the micromechanical functions of the MEMS elements. In the case of micromechanical sensor elements, these can be parts of an evaluation circuit, while the ASIC element of an actuator component will preferably include circuit means for controlling the micromechanical structure. In this context, it turns out to be advantageous if through-contacts, so-called TSVs (Through Silicon Vias), are fashioned in the ASIC element that extends from the rear side up to the processed front side, where the circuit functions of the ASIC element are integrated. With the aid of such ASIC through-contacts, a particularly protected and stable electrical connection is easily produced between the rear-side MEMS element and the ASIC element.
The production method according to the present invention can be varied in many ways, in particular relating to the mechanical and electrical connection between the individual components of the five-fold wafer stack and the external electrical contacting of the resulting component. Here, the function, intended use, and location of installation of the component to be produced must be taken into account.
In any case, the production method according to the present invention provides a pre-processing of the ASIC substrate in which the circuit functions are realized and ASIC through-contacts are also already made. In a further method step, the ASIC substrate can be thinned on the rear side in order to reduce the overall component height. This method step can be carried out either in the context of the pre-processing, i.e. before the mounting of the first MEMS substrate on the processed front side of the ASIC substrate, or not until after the mounting of the first MEMS substrate, at the latest before the mounting of the second MEMS substrate on the then thinned rear side of the ASIC substrate.
Moreover, in the context of the processing of the ASIC substrate, a structuring of the mounting surfaces for the two MEMS substrates can be carried out. For example, recesses can be produced in the ASIC surface in order to ensure the movability of structural elements of the adjoining MEMS substrate. In a particularly advantageous specific embodiment of the present invention, on the processed front side of the ASIC substrate a base structure is produced for the mounting of the first MEMS substrate, so that a gap exists between the ASIC substrate and the mounted first MEMS substrate. Such a standoff structure can also be produced on the rear side of the ASIC substrate for the mounting of the second MEMS substrate.
The connection between the first or second MEMS substrate and the ASIC substrate is preferably produced in a bonding process, because in this way it is possible to realize both a hermetically sealed mechanical connection and also reliable electrical connections between the MEMS element and the ASIC element. A number of known process variants that have been proven in practice are available for this, such as plasma-activated direct bonding or eutectic bonding.
The micromechanical structures of the two MEMS elements are each defined and exposed in a structuring process that extends over the entire thickness of the corresponding MEMS substrate. Advantageously, the two MEMS substrates are therefore first thinned before the structuring, down to a structural height suitable for the realization of the respective MEMS function.
The structuring of the MEMS substrates preferably takes place in a trench process, because this method enables the production of trench structures having a particularly high aspect ratio.
With regard to a component design that is as compact as possible and a reliable internal electrical contacting between the individual components of the overall component, it turns out to be advantageous if MEMS through-contacts are also produced in the first and/or in the second MEMS substrate as an electrical connection to the ASIC substrate.
Differing from the MEMS substrates, which are not structured until after mounting on the ASIC substrate, the cap wafers of the component according to the present invention are pre-structured. If warranted, in this pre-processing, cap through-contacts are also produced for the external electrical contacting of the overall component. As in the mounting of the MEMS substrates on the ASIC substrate, the mounting of the pre-processed cap wafers also preferably takes place using a bonding process, because in this way it is easy to produce reliable and long-lasting mechanical and electrical connections.
The external electrical contacting of a component according to the present invention can be carried out using wire bonds, if corresponding exposed connection pads are fashioned on the ASIC element. In this case, as a rule the component is also provided with an outer packaging, for example in the form of a molded housing.
In a particularly advantageous variant of the present invention, the external electrical contacting of the component takes place via cap through-contacts in one of the two cap wafers. In this case, the component can be mounted directly over the corresponding cap wafer on a circuit board, and in addition to the mechanical fixing of the component an electrical connection to the printed conductors on the circuit board is also produced. An outer packaging of the five-fold wafer stack is not required here. Because the mounting takes place via a cap wafer, both the two MEMS elements and also the ASIC element of the component are mechanically decoupled relatively well from the circuit board, so that a bending of the circuit board will not have a significant effect on the functionality of the component.
The method according to the present invention for producing a hybridly integrated component in the form of a five-fold wafer stack having two MEMS elements and one ASIC element begins with a pre-processed ASIC substrate. Advantageously, the ASIC substrate is equipped, during the pre-processing, with a signal processing circuit and with an evaluation or control circuit for the two MEMS elements. In addition, however, MEMS-independent circuit functions can also be realized.
Here it is to be noted that metallized blind holes 13 for the ASIC through-contacts can also be produced before the semiconductor functionality 12, or may be produced in ASIC substrate 11, provided with the layer construction, only subsequently. In other respects, the pre-processing of ASIC substrate 10 is not described here in detail, because, except for the making of the ASIC through-contacts, it is not specified in more detail by the present invention.
In a subsequent method step, nitride passivation 16 is structured in order to enable an electrical contacting of uppermost circuit level 141 of ASIC substrate 10. An oxide layer 171 is then deposited on the surface of ASIC substrate 10 and is structured in order to create a standoff structure 171 for the mounting of a first MEMS substrate.
Structured oxide layer 171 forms the mounting surface for an unstructured first MEMS substrate 20. The connection between first MEMS substrate 20 and ASIC substrate 10 is produced here in a plasma-activated direct bonding method, and is hermetically sealed. Relatively thick MEMS substrate 20 is now thinned, for example using a grinding process, until its thickness corresponds approximately to the sought structural height of the first MEMS element. This is typically in a range between 10 μm and 150 μm.
First MEMS substrate 20 is structured only in combination with ASIC substrate 10. In the present exemplary embodiment, this structuring takes place in two steps.
The first structuring step is used to produce through-contacts, so-called vias 22. Here, through-openings having substantially circular cross-section are produced in MEMS substrate 20, and open into openings in standoff structure 171 at the locations where passivation layer 16 was opened for the electrical contacting of ASIC substrate 10. The through-openings typically have an aspect ratio of from 5:1 to 20:1, and extend over the entire thickness of MEMS substrate 20. Standardly, the walls of these through-openings are coated with a conductive diffusion barrier such as titanium nitride or titanium-tungsten before being filled with an electrically conductive material 22, such as copper or tungsten, in a deposition process.
In the second structuring step, micromechanical structure 21 of first MEMS element 20 is produced. It extends over the entire thickness of MEMS substrate 20, as is shown in
In the present case, the first MEMS element is a z acceleration sensor having a rocker design. Micromechanical sensor structure 21 includes a rocker structure 23, centrically spring-mounted, as a seismic mass that is defined and exposed by trenches 24 in first MEMS substrate 20.
After the structuring of first MEMS substrate 20, a first pre-structured cap wafer 30 is mounted over sensor structure 21, in order to enclose sensor structure 21 in a hermetically sealed fashion under defined pressure conditions in hollow space 25 between ASIC substrate 10 and first cap wafer 30. According to
ASIC substrate 10 is now thinned on its rear side. During this, ASIC through-contacts 13 are ground. In order to produce rear-side connecting pads 18, as shown in
In a following method step, on the rear side of ASIC substrate 10 processed in this way a further oxide layer 172 is deposited and structured in order to create a standoff structure 172 for the mounting of a second MEMS substrate.
As in the case of first standoff structure 171, rear-side standoff structure 172 also forms the mounting surface for a MEMS substrate 40. The connection between this second MEMS substrate 40 and ASIC substrate 10 is here likewise produced in a plasma-activated direct bonding process, and is hermetically sealed. Second MEMS substrate 40 is then also thinned down to the sought structural height of the second MEMS element.
Second MEMS substrate 40 is also first structured and processed together with ASIC substrate 10. Here, again, first through-contacts 42 are produced, for which purpose second MEMS substrate 40 can be processed in exactly the same way as first MEMS substrate 20.
In a second structuring step, micromechanical structure 41 of second MEMS element 40 is then produced, which also extends over the entire thickness of MEMS substrate 40. Here, the layout of this micromechanical structure 41 is completely independent of the layout of micromechanical structure 21 of first MEMS element 20.
After the structuring of second MEMS substrate 40, finally a second pre-structured cap wafer 50 is mounted over second MEMS element 40 on the rear side of ASIC substrate 10, so that MEMS element 40 is completely situated in hollow space 45 between ASIC substrate 10 and cap wafer 50. This is shown in
Here, first cap wafer 30 can be sawed in order to expose connecting pads 140 on the front side of ASIC substrate 10. These connecting pads 140 are used, in component 100 shown in
Another possibility for the external electrical contacting of a five-fold wafer stack according to the present invention is shown in
Component 200 is particularly well-suited for direct mounting on circuit boards, because the electrical signals of component 200 are led outward via ASIC through-contacts 13 and cap through-contacts 52. Both the mechanical fixing of component 200 on a circuit board and the electrical contacting can here be produced easily using solder bumps 54.
In conclusion, it is again expressly to be indicated that the MEMS surfaces of a component according to the present invention can be used very flexibly. Thus, for example in the first MEMS element the sensor structure of an acceleration sensor can be realized, while the second MEMS element can be equipped with the sensor structure of a rotational rate sensor. The first MEMS element could also include the sensor structures of an acceleration sensor and a one-axis rotational rate sensor, while the sensor structure of a two-axis rotational rate sensor is fashioned in the second MEMS element.
The two MEMS elements of a component according to the present invention can however also be equipped with a quite similar functionality, and correspondingly can also have an identical or very similar micromechanical structure, as is the case for example in component 300 shown in
Number | Date | Country | Kind |
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10 2012 208 031.7 | May 2012 | DE | national |