1. Field of the Invention
The present invention relates to a manufacturing method of semiconductor devices and a semiconductor device manufactured by the above method. More particularly, it relates to a method of manufacturing semiconductor devices by flip chip bonding using ultrasonic vibration and the so-manufactured semiconductor device.
2. Description of the Related Art
In mounting a semiconductor device on a wiring substrate or a lead frame through flip chip bonding, soldering and conductive adhesive have been used up to this day. Additionally, flip chip bonding using ultrasonic vibration is also known in Japanese Patent Publication Laid-open No. H08-45994.
In the semiconductor device, circuit elements are built in a semiconductor substrate while the circuit elements are electrically connected with each other through conductive silicon forming the semiconductor substrate. Here, it is noted that silicon has a higher electric resistivity than that of metals.
Therefore, in a semiconductor device required with a small electric resistance, as typified by a power transistor, circuit elements are formed in one principle surface of the semiconductor substrate, while a metal layer of smaller electrical resistivity than silicon's is formed on the other principle surface on the opposite side of the former principle surface for the purpose of reducing an electrical resistance for current between the circuit elements.
In order to mount the semiconductor device 100 on the wiring substrate 105 by flip chip bonding using ultrasonic vibration, the wiring substrate 105 is firstly mounted on a work holder (not shown). Then, the semiconductor device 100 is arranged in a manner so that the bumps 104 abut on the wiring substrate 105 while a bonding tool 106 for generating ultrasonic vibration abuts on the metal layer 103. When generating ultrasonic vibration for the semiconductor device 100, the bonding tool 106 is pressed on the device 100 while self-vibrating in the direction of arrow A.
However, the illustrated flip chip bonding for the semiconductor device 100 has a problem as follows.
In the bonding tool 106, its surface in abutment with the metal layer 103 is formed with irregularities 107. Accordingly, when applying ultrasonic vibration to the semiconductor device 100, shavings 108 are produced since the metal layer 103 is shaved by the irregularities 107 of the bonding tool 106. Consequently, the produced shavings 108 stick to the bonding tool 106 so as to fill up with the irregularities 107.
Due to the adhesion of the shavings 108 on the bonding tool 106, depending on the degree of adhesion, the application of ultrasonic vibration from the tool 6 to the semiconductor device 100 varies in terms of the degree of impression. Thus, due to variations in the degree of impression, the mounting state of the semiconductor device 100 on the wiring substrate 105 changes with respect to each device 100, causing so-assembled semiconductor installations to be varied in quality.
In the above-mentioned situation, it is an object of the present invention to suppress a variation in the quality of the assembled semiconductor installations due to the adhesion of shavings to the bonding tool. More specifically, when mounting a semiconductor device having a conductive layer formed on a substrate surface to reduce an electrical resistance between circuit elements in the substrate by means of flip chip bonding using ultrasonic vibration, the object of the present invention is to prevent the conductive layer from being shaved by the bonding tool.
In order to attain the above object, according to a first aspect of the present invention, there is provided a manufacturing method for semiconductor devices, comprising the steps of: forming a conductive layer on one principle surface of a semiconductor wafer having a plurality of circuit elements formed in an other principle surface of the semiconductor wafer; forming a protecting layer on at least a part of the conductive layer, the protecting layer being made from material having hard-to-shave characteristics in comparison with the conductive layer; and cutting the semiconductor wafer into pieces with respect to each of the semiconductor devices.
According to a second aspect of the present invention, there is also provided a manufacturing method for semiconductor devices, comprising the steps of: forming a recess on one principle surface of a semiconductor wafer having a plurality of circuit elements formed in an other principle surface of the semiconductor wafer, with respect to each of the semiconductor devices assuming that the semiconductor wafer is cut into pieces for the semiconductor devices; forming a conductive layer in the recess, the conductive layer having a thickness smaller than a depth of the recess; and cutting the semiconductor wafer into the pieces with respect to each of the semiconductor devices.
Additionally, according to a third aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a plurality of circuit elements formed in one principle surface of the semiconductor substrate; a conductive layer formed on an other principle surface of the semiconductor substrate; and a protecting layer formed on the conductive layer in lamination to have hard-to-shave characteristics in comparison with the conductive layer.
Still further, according to a fourth aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a plurality of circuit elements formed in one principle surface of the semiconductor substrate; a recess formed on an other principle surface of the semiconductor substrate; and a protecting layer formed in the recess to have a thickness smaller than a depth of the recess.
Embodiments of the present invention will be described with reference to attached drawings.
According to the first embodiment, a semiconductor device 1 has a semiconductor substrate 3 in which two circuit elements 2, such as FET, are formed, as shown in
The semiconductor device 1 is provided by cutting a semiconductor wafer 10 (see
For material for the conductive layer 4, there is available any one of gold (Au), silver (Ag), copper (Cu) and aluminum (Al). Alternatively, alloy composed of two or more of these metals may be available for the conductive layer 4.
Taking account of contact with a boding tool (see
In order to fit the semiconductor device 1 onto the wiring substrate 8 by flip chip bonding using ultrasonic vibration, as shown in
The manufacturing process of the semiconductor device 1 will be described with reference to
As shown in
Next, at step S2, it is performed to turn over the semiconductor wafer 10 formed with the circuit elements 2 and the bumps 6 and attach one wafer's surface on the side of the elements 2 and the bumps 6 onto a protecting sheet 11, as shown in
After attaching the semiconductor wafer 10 onto the protecting sheet 11, the conductive layer 4 is formed on the other wafer's surface on the opposite side of the circuit elements 2 and the bumps 6, as shown
After forming the conductive layer 4, it is performed at step S4 to lay a mask 12 on the conductive layer 4 and further apply a protecting resist material 13 on the mask 12. Consequently, the applied protecting resist material 13 enters into openings formed in the mask 12, as shown in
After the protecting resist material 13 gets dry and rigid, it is performed at step S5 to remove the mask 12 from the conductive layer 4. As a result of removing the mask 12, there is remained the protecting resist material (portions) 13 on the conductive layer 4, as shown in
At next step S6, it is performed to dip the semiconductor wafer 10 having the hardened protecting resist material 13 remained on the conductive layer 4 into etching liquid (not shown). Consequently, the conductive layer 4 but its portions beneath the protecting resist material 13 is removed from the semiconductor wafer 10 as shown in
After completing the etching process of leaving the conductive layer 4 in required portions, it is performed at step S7 to remove the protecting resist material 13 with chemicals, causing the conductive layer 4 to be exposed in the required portions, as shown in
After exposing the conductive layer 4 in the required portions, it is performed to form the protecting layer 5 on the conductive layer 4. As for the formation of the protecting layer 5, there are two forming methods depending on the material of the protecting layer 5, i.e. metal or nonmetal. Therefore, at step S8, it is executed to judge whether the protecting layer 5 should be made from metal or not.
If it is required to make the protecting layer 5 from metal (Yes at step S8), it is performed at step S9 to form the protecting layer 5 against the semiconductor wafer 10 of
If it is required to make the protecting layer 5 from nonmetal (No at step S8), it is performed at step S10 to lay a mask 14 having openings formed in respective positions corresponding to the conductive layer (portions) 4 on the semiconductor wafer 10 of
After completing the application of the material 5a, it is performed at step S11 to wait for the hardening of the material 5a with its drying out and subsequently remove the mask 14 from the semiconductor wafer 10, as shown in
In the first embodiment, as shown in
When mounting the semiconductor device 1 formed with the conductive layer 4 and the protecting layer 5 on the wiring substrate 8 by flip chip bonding using ultrasonic vibration in the above constitution, the bonding tool 7 for ultrasonic vibration is brought into contact with the protecting layer 5 as shown in
Therefore, it is possible to prevent the occurrence of the shavings 108 at contacts between the bonding tool 7 and the protecting layer 5 at flip chip bonding and also possible to prevent the degree of applying ultrasonic vibration from the bonding tool 7 onto the semiconductor device 1 from being varied due to adhesion of the shavings to the tool 7. Consequently, it is possible to maintain the application of ultrasonic vibration from the bonding tool 7 onto the individual semiconductor devices 1 uniformly and also possible to suppress a variation in the assembled state of the semiconductor devices 1 on the wiring substrates 8. That is, according to the first embodiment of the invention, it is possible to maintain the quality of the semiconductor installations obtained by mounting the semiconductor devices 1 on the wiring substrates 8, providing the semiconductor installations stabilized in quality.
Again, it is noted that the conductive layer 4 is not formed on the whole surface of the semiconductor wafer 10 but formed with respect to each area of the respective semiconductor devices 1 separately, as shown in
The second embodiment of the present invention will be described with reference to
In the second embodiment, a semiconductor device 20 has a semiconductor substrate 21 in which two circuit elements 2, such as FET, and two bumps 6 are formed, as shown in
In order to fit the semiconductor device 20 onto the wiring substrate 8 by flip chip bonding using ultrasonic vibration, as shown in
The manufacturing process of the semiconductor device 20 will be described with reference to
As shown in
Next, at step S22, it is performed to turn over the semiconductor wafer 10 formed with the circuit elements 2 and the bumps 6 and attach one wafer's surface on the side of the elements 2 and the bumps 6 onto the protecting sheet 11, as shown in
After attaching the semiconductor wafer 10 onto the protecting sheet 11, it is performed at step S23 to form a plurality of recesses 22 in a wafer's surface on the opposite side of the protecting sheet 11 with the use of inert gas and etching liquid, as shown
After forming the recesses 22, a conductive layer 23 is formed on the whole area of the wafer's surface on the side of the recesses 22, as shown
After forming the conductive layer 23, it is performed at step S25 to lay a mask 24 on the conductive layer 23 and further apply a protecting resist material 25 on the mask 24. The mask 24 is formed with openings in positions opposing the recesses 22. Consequently, the applied protecting resist material 25 enters into these openings, as shown in
After the protecting resist material 25 gets dry and rigid, it is performed at step S26 to remove the mask 24 from the conductive layer 23. As a result of removing the mask 24, there is remained the hardened protecting resist material (portions) 25 on the conductive layer 23, as shown in
At next step S27, it is performed to dip the semiconductor wafer 10, which has the hardened protecting resist material 25 remained on the conductive layer 22 in the recesses 22, into etching liquid (not shown). Consequently, the conductive layer 23 but its portions beneath the protecting resist material 25 is removed from the semiconductor wafer 10 as shown in
After completing the etching process of leaving the conductive layer 23 in required portions, it is performed at step S28 to remove the protecting resist material 25 with chemicals, causing the conductive layer 23 to be exposed in the required portions, as shown in
In the above constitution, when mounting the semiconductor device 20 formed with the recess 22 and the conductive layer 23 in the recess 22 on the wiring substrate 8 by flip chip bonding using ultrasonic vibration, the bonding tool 7 for ultrasonic vibration is brought into contact with a surface of the semiconductor substrate 21 on the side of the recess 22 and non-contact with the conductive layer 23 owing to the provision of the recess 22 as shown in
Therefore, it is possible to prevent the occurrence of the shavings at contacts between the bonding tool 7 and the conductive layer 23 at flip chip bonding and also possible to prevent the degree of applying ultrasonic vibration from the bonding tool 7 onto the semiconductor device 20 from being varied due to adhesion of the shavings to the tool 7. Consequently, it is possible to maintain the application of ultrasonic vibration from the bonding tool 7 onto the individual semiconductor devices 20 uniformly and also possible to suppress a variation in the assembled state of the semiconductor devices 20 on the wiring substrates 8. That is, according to the second embodiment of the invention, it is possible to maintain the quality of the semiconductor installations obtained by mounting the semiconductor devices 20 on the wiring substrates 8, providing the semiconductor installations stabilized in quality.
Again, it is noted that the conductive layer 23 is not formed on the whole surface of the semiconductor wafer 10 but formed in each recess 22 of the respective semiconductor devices 20 separately, as shown in
Although the present invention has been described above by reference to two embodiments of the invention, this invention is not limited to these embodiments and modifications will occur to those skilled in the art, in light of the teachings. The scope of the invention is defined with reference to the following claims.
This application is based upon the Japanese Patent Applications No. 2007-015179, filed on Jan. 25, 2007, the entire content of which is incorporated by reference herein.
Number | Date | Country | Kind |
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2007-015179 | Jan 2007 | JP | national |