1. Technical Field
The present disclosure relates to a method of fabricating a wiring board formed on a support board and a method of fabricating a semiconductor device constituted by mounting a semiconductor chip on the wiring board.
2. Related Art
In recent years, high density formation and thin-sized formation of a semiconductor chip has been promoted in accordance with high speed formation and high integrated formation of a semiconductor device and high density formation/thin-sized formation are requested similarly to a wiring board connected with the semiconductor chip.
In order to deal with high density formation of a wiring of the wiring board and thin-sized formation thereof, in recent years, the main current is constituted by a method of forming a wiring board by a so-to-speak build up method. When a multilayer wiring board is formed by the build up method, the multilayer wiring board is formed as follows.
First, a build up layer comprising an insulating resin layer is formed on a support board (core board) having a pertinent rigidity, a via hole informed at the build up layer, thereafter, a via plug is formed at the via hole by a plating method and a pattern wiring connected to the via plug is formed. Thereafter, by repeating the steps, a multilayer wiring board can be formed by the build up method.
The build up layer (insulating resin layer) comprises a soft material of, for example, thermosetting epoxy resin or the like and therefore, in order to maintain flatness of the build up layer, there is adopted a method of forming the build up layer on a support board having a pertinent rigidity (For example, See Japanese patent document JP-A-2002-198462).
However, it is requested to further subject the wiring board formed by the build up method to thin-sized formation and therefore, there has been proposed a structure of removing the support board, or a wiring board having a so-to-speak coreless structure.
However, when the wiring board is constituted by the coreless structure, a rigidity of the wiring board is reduced. Therefore, there poses a problem which becomes difficult when after removing the support board or exfoliating the wiring board from the support board, a step of laminating a necessary layer on the wiring board and working the wiring board is provided. An example of the step will be explained as follows.
For example, water absorbing performance of the build up layer is high and in a state of exposing a surface thereof, there is brought about a concern in insulation reliability over a long period of time and it is preferable to cover the surface by a protecting layer of a solder resist layer or the like. However, according to the build up method of the related-art, when the solder resist layer covering the surface of the build up layer formed right above the support board is formed, it is necessary to remove the support board or exfoliate the build up layer from the support board.
In this case, it is necessary to carry the wiring board in the midst of working in which the support board is removed and the rigidity is reduced to pose a problem that a concern of damaging the wiring board is increased. Further, when the solder resist layer is formed at the build up layer after removing the support board, the rigidity is insufficient and therefore, there is a case of posing a problem in flatness of the wiring board.
Therefore, there is a case in which it is difficult to excellently maintain accuracy of working the solder resist layer. The problem of the accuracy of working the solder resist layer becomes significant particularly when a wiring board in correspondence with a high function semiconductor chip in recent years which is subjected to high density/high integrated formation.
The disclosure below describes a method of forming a novel and useful wiring board resolving the above-described problem.
The disclosure describes a method of fabricating a wiring board and a method of fabricating a semiconductor device constituted by mounting the semiconductor device on the wiring board.
In a first aspect, the disclosure describes a method of fabricating a wiring board comprising a first step of forming a first solder resist layer having a first opening portion on a support board, a second step of forming an electrode at the first opening portion, a third step of forming an insulating layer on the electrode and forming a wiring portion connected to the electrode at the insulating layer, a fourth step of forming a second solder resist layer having a second opening portion on the wiring portion, and a fifth step of removing the support board.
According to the method of fabricating the wiring board, there can be provided the method of fabricating the wiring board capable of constituting thin-sized formation and capable of dealing with high density wiring.
Further, when the support board comprises a conductive material and the electrode is formed by an electrolytic plating method, the electrode can be formed by an easy method and with excellent working accuracy.
Further, when the second step includes a step of forming a recess portion by etching the support board and the electrode is formed to correspond to the recess portion, the electrode can be constituted by a structure of being projected from the first solder resist layer.
Further, when the second step includes a step of forming an electrode height adjusting layer at the first opening portion and the electrode is formed on the electrode height adjusting layer, the electrode can be constituted by a structure of being recessed from the first solder resist layer.
Further, when in the fifth step, the electrode height adjusting layer is removed along with the support board, the step of removing the electrode height adjusting layer becomes simple, which is preferable.
Further, when the support board and the height adjusting layer comprise Cu or a Cu alloy, the support and the height adjusting layer can be removed by the same etching solution.
Further, when a thickness of the electrode height adjusting layer is equal to or larger than a thickness of the first solder resist layer, the electrode can be constituted by a structure of being embedded in the insulating layer.
Further, when an area of the electrode is larger than an area of the first opening portion, a strength of the electrode is improved.
Further, when there is provided the method of fabricating a wiring board, further comprising a sixth step of pasting the support board together with a separate support board before the first step, a seventh step of forming a third solder resist layer having a third opening portion on the separate support board, an eighth step of forming a separate electrode at the third opening portion, a ninth step of forming a separate insulating layer to cover the separate electrode and forming a separate wiring portion connected to the separate electrode at the separate insulating layer, a tenth step of forming a fourth solder resist layer having a fourth opening portion to cover the separate wiring portion, and an eleventh step of removing the separate support board, the wiring boards can be formed at both of the support board and the separate support board.
Further, in a second aspect of the invention, the disclosure describes a method of fabricating a semiconductor device using the method of fabricating a wiring board, characterized in further comprising a mounting step of mounting a semiconductor chip to be electrically connected to the wiring portion from the second opening portion after the fourth step.
According to the method of fabricating a semiconductor device, there can be provided the method of fabricating a semiconductor device capable of constituting thin-sized formation and capable of dealing with high density wiring.
Further, when the method further comprises a step of etching the support board exposed from the first opening portion and forming an external connecting terminal at the etched support board after the first step, a portion of connecting the semiconductor device and an object to be connected is easily formed.
Further, in a third aspect of the invention, the disclosure describes a method of fabricating a semiconductor device characterized in a method of fabricating a semiconductor device using the method of fabricating the wiring board, further comprising a mounting step of mounting a semiconductor chip to be electrically connected to the wiring portion by way of the electrode after the fifth step.
According to the method of fabricating a semiconductor device, there can be provided the method of fabricating a semiconductor device capable of constituting thin-sized formation and capable of dealing with high density wiring.
Further, when the method further comprises a step of etching the support board exposed from the first opening portion and forming a semiconductor connecting terminal at the etched support board after the first step, wherein the semiconductor chip is mounted on the semiconductor chip connecting terminal, the semiconductor chip is easily mounted.
One or more of the following advantages may be present in some implementations. For example, there can be provided the method of fabricating a wiring board capable of constituting thin-sized formation and capable of dealing with high density wiring and the method of fabricating a semiconductor device constituted by mounting the semiconductor device on the wiring board.
Further, the wiring board which is constituted by a coreless structure, both sides of which are covered by the solder resist layers and which is formed by a build up method can be provided.
Further, the wiring board constituted by the coreless structure and subjected thin-sized formation can be formed, further, the first opening portion is formed in a state in which flatness of the first resist layer is excellent and therefore, accuracy of working the first opening portion becomes excellent. Therefore, the wiring board capable of dealing with a high density wiring, and a semiconductor device constituted by mounting the semiconductor device on the wiring board can be, fabricated.
Other features and advantages may be apparent from the following detailed description, the accompanying drawings and the claims.
Next, embodiments of the invention will be explained in reference to the drawings.
First, at step shown in
Next, ultraviolet ray is irradiated to the solder resist layer 102 by way of a mask pattern (not illustrated) to expose to thereby pattern the solder resist layer 102 and form an opening portion 102A. There is brought about a state of exposing the support board 101 from the opening portion 102A.
Next, at a step shown in
Next, at a step shown in
Next, a via plug 105 is formed at the via hole and a pattern wiring 106 connected to the via plug 105 is formed on the insulating layer 104 by, for example, a semiadditive method. In this case, it is preferable to form a seed layer on the insulating layer 104 by electroless plating and thereafter form the via plug 105 on the pattern wiring 106 by electrolytic plating. In this way, a wiring layer comprising the via plug 105 and the pattern wiring 106 is formed.
Next, at a stop shown in
Next, in a step shown in
According to the board 100, the electrode 103 is disposed on a side of being connected to an external connected apparatus of, for example, a mother board or the like (so-to-speak land side) and the pattern wiring 106 exposed from the opening portion 107A is connected with, for example, a semiconductor chip. In this case, the electrode 103 may be formed with, for example, a solder ball or the like. Further, the pattern wiring 106 exposed from the opening portion 107A may be formed with, for example, an electrode comprising Au/Ni, or a solder ball, or a solder layer for reflow or the like.
According to the embodiment, one of characteristics thereof resides in that prior to forming the insulating layer 104, the solder resist layer 102 is formed on the support board 101. Therefore, the wiring board by the build up method which is constituted by the coreless structure and both sides of which are covered by the solder resist layer can be formed.
In this case, there is achieved an effect of capable of protecting the both sides of the insulating layer 104 by the solder resist layers, reducing a difference between stresses applied on the both sides of the insulating layer 104 and restraining the wiring board from being warped.
Further, in the case of the embodiment, the opening portion 107A is formed in a state of supporting the solder resist layer 107 by the support board 101 and therefore, when the opening portion 107A is formed, flatness of the solder resist layer 107 is excellent. Therefore, accuracy of working the opening portion 107A becomes excellent and the opening portion 107A can be formed by a fine shape and a fine pitch.
In a semiconductor chip of the recent years, high integrated formation/high density wiring formation are progressed, also at a portion of connecting a semiconductor chip and a wiring board, fine pitch formation and high density wiring formation are progressed and therefore, particularly, accuracy of positioning the opening portion 107A and working accuracy of a shape thereof are needed. According to the method of fabricating the wiring board according to the embodiment, the wiring board in correspondence with the requests and in correspondence with fine pitch formation/high density wiring formation can be formed.
Further, according to the method of fabricating the wiring board according to the embodiment, a so-to-speak coreless structure is realized by removing the support board and thin-sized formation of the wiring board is realized in correspondence with the high density wiring.
Further, according to the wiring board according to the embodiment, the electrode 103 is disposed on a side of connecting an external apparatus of a mother board or the like (so-to-speak land side). Therefore, an area (opening diameter) of the opening portion 102A becomes larger than an area (opening diameter) of the opening portion 107A. For example, there is a large difference between the opening diameters such that the opening diameter of the opening portion 107A connected with the semiconductor chip is about 80 μm through 100 μm, the opening diameter of the opening portion 102A connected with the mother board or the like is about 0.5 mm through 1 mm.
For example, when the large opening portion is formed, in the case of using laser, a problem of taking time is posed. According to the embodiment, patterning of the opening portion 102A is carried out by sensitizing and the opening portion can be formed more swiftly than in the case of laser.
Further, by repeatedly executing the step shown in
For example, as materials of constituting the solder resist layers 102, 107, epoxy acrylic species resin, epoxy species resin, acrylic species resin can be used. Further, the method of patterning the solder resist layers 102, 107 is not limited to the method by exposure/development described above. For example, a solder resist layer formed (patterned) with an opening portion may be formed by a screen printing method. In this case, a material other than a photosensitive material can be used for the solder resist layer.
Further, although according to the embodiment, thicknesses of the electrode 103 the solder resist layer 102 are substantially the same, the invention is not limited thereto but the electrode 103 can be modified or changed variously as shown below as necessary.
A step shown in
Next, in a step shown in
Next, at a step shown in
Next, at steps shown in
According to the wiring board 101A according to the embodiment, the electrode 103A is constituted by a structure of being projected from the solder resist layer 102. Therefore, when a portion of connecting the electrode 103A and a mother board or the like is connected by the solder ball, a contact area of the solder ball and the electrode 103A is increased and therefore, an effect of improving electric connection reliability is achieved.
Further,
First, a step shown in
Next, at a step shown in
Next, at a step shown in
Next, at steps shown in
In the case of embodiment, at the step shown in
In the case of the embodiment, the wiring board can be formed similar to exemplary, non-limiting Embodiment 1 other than the method of forming the electrode 103C and an effect similar that in the case of exemplary, non-limiting Embodiment 1 is achieved.
According to the wiring board 100B according to the embodiment, the electrode 103C is constituted by a structure of being recessed from a face on an outer side of the third resist layer 102.
Therefore, an effect of improving a mechanical strength of the electrode 103C is achieved. Further, when the electrode 103C and a connecting terminal or the like are connected by soldering, an effect of restraining a contiguous electrode from being short circuited by making a solder flow out. Further, when a solder ball is bonded to the electrode 103C, an effect of preferably mounting the solder ball is achieved.
Further, the structure of recessing the electrode from the solder resist layer shown in the embodiment can be modified into a structure shown in exemplary, non-limiting Embodiment 4 as follows.
First, a step shown in
Next, at a step shown in
Next, at steps shown in
Next, at steps shown in
In the case of embodiment, when the support board 101 is removed by wet etching, the electrode height adjusting layer 103D is similarly removed similar to the step shown in
In the case of the embodiment, the wiring board can be formed similar to exemplary, non-limiting Embodiment 3 other than the method of forming the electrode 103E and an effect similar that in the case of exemplary, non-limiting Embodiment 3 is achieved.
According to the wiring board 100C according to the embodiment, the electrode 103E is constituted by a structure of being recessed from the face on the outer side of the solder resist layer 102 and the electrode 103E is constituted by a structure of being substantially embedded in the insulating layer 104. That is, a total of a side wall face of the electrode 103E is formed to be brought into contact with the insulating layer 104. Therefore, in addition to achieving the effect in the case of exemplary, non-limiting Embodiment 3, there is achieved an effect of further improving the mechanical strength of the electrode 103C in comparison with that in the case of exemplary, non-limiting Embodiment 3.
Further, an area of the electrode 103E becomes larger than the area of the opening portion 102A. This is because when the electrode 103E is formed by electrolytic plating, the electrode 103E grows substantially isotropically and therefore, the electrode grows in a lateral direction. Therefore, there is constituted a structure of covering a peripheral edge portion of the electrode 103E by the solder resist layer 102 to achieve an effect of improving a strength of the electrode 103E.
Further, although according to the embodiment, an explanation has been given by taking an example of a case in which the thickness of the electrode height adjusting layer is substantially the same as the thickness of the solder resist layer 102, when the thickness of the electrode height adjusting layer is equal to or larger than the thickness of the solder resist layer 102, an effect similar to that in the above-described case is achieved.
Further, for example, in the cases of exemplary, non-limiting Embodiment 1 through exemplary, non-limiting Embodiment 4, it is also possible to use a structure of pasting two sheets of the support boards 101 together to form wiring boards at the respective support boards and in that case, an efficiency of forming the wiring board can be improved.
The solder resist layer 101a, the electrode 103a, the insulating layer 104a, the via plug 105a, the pattern wiring 106a, the solder resist layer 107a, an opening portion 107b respectively correspond to the solder resist layer 101, the electrode 103, the insulating layer 104, the via plug 105, the pattern wiring 106, the solder resist layer 107, and the opening portion 107A and can be formed similar to the case of exemplary, non-limiting Embodiment 1.
Further, after the step shown in the drawing, the support board 101 and the support board 101a are separated, a step in correspondence with the step shown in
It is apparent that the structure, the material or the like explained in the embodiments can pertinently be modified or changed. For example, the material constituting the electrodes 103, 103A, 103C, 103E, 103a or the like is not limited to Au/Ni, for example, Au/Ni/Cu, Au/Pd/Ni, Au/Pd/Ni/Cu, Au/Pd/Ni/Pd, Au/Pd/Ni/Pd/Cu, Sn—Pb/Ni, Sn—Pb/Ni/Cu, Sn—Ag/Ni, Su—Ag/Ni/Cu, or the like can be used. Further, the above-described materials are described successively from the metal layer constituting the surface (outer side) when the wiring board is finished.
Further, there may be constituted a structure of increasing a rigidity of the wiring board by providing, for example, a reinforcement plate at a peripheral edge portion of the wiring board.
Next, an explanation will be given of an example of fabricating a semiconductor device by mounting a semiconductor chip to the above-described wiring board in reference to
According to a method of fabricating a semiconductor device according to the embodiment, first the steps shown in
Next, at a step shown in
Next, at a step shown in
Next, insulation and reliability of a mounted portion are ensured by permeating and curing an underfill 203 between the semiconductor chip 201 and the solder resist layer 107.
Next, at a step shown in
Next, at a step shown in
For example, according to a semiconductor device having a PGA (Pin Grid Array) structure is formed with a pin as an external connecting terminal. Further, there may be constituted an LGA (Land Grid Array) structure using an electrode per se of a wiring board (semiconductor device) as an external connecting terminal by omitting to form the external connecting terminal.
Next, at a step shown in
According to the method of fabricating the semiconductor device according to the embodiment, there can be fabricated the semiconductor device achieving an effect similar to the effect described in exemplary, non-limiting Embodiment 1, capable of constituting thin-sized formation and capable of dealing with high density wiring.
Further, the method of mounting the semiconductor chip is not limited to the case described in exemplary, non-limiting Embodiment 6.
According to the method of fabricating the semiconductor device according to the embodiment, first, the steps up to
Next, at a step shown in
After the step of
Further, in exemplary, non-limiting Embodiment 6 or exemplary, non-limiting Embodiment 7, a method of forming the external connecting terminal (solder ball) 109 may be changed.
According to the method of fabricating a semiconductor chip according to the embodiment, first, the step shown in
Next, in a step shown in
Next, at a step shown in
In the following steps, steps similar to those of exemplary, non-limiting Embodiment 7 or exemplary, non-limiting Embodiment 8 may be carried out. That is, the steps shown in
Further, although according to exemplary, non-limiting Embodiment 6 through exemplary, non-limiting Embodiment 8, the semiconductor chip is mounted to a side of the solder resist layer 107, a method of fabricating the semiconductor device according to the invention is not limited thereto. For example, as explained below, the semiconductor chip may be mounted to be connected to the electrode exposed by removing the support board.
According to the method of fabricating the semiconductor chip according to the embodiment, first, steps in correspondence with the step shown in
Next, at a step shown in
Further, in the case of the embodiment, the semiconductor chip is mounted on an electrode 103F (in correspondence with the electrode 103 in cases of exemplary, non-limiting Embodiments 6 through 8) and therefore, an area of the electrode 103F becomes smaller than that of the electrode 103 of exemplary, non-limiting Embodiments 6 through 8. Further, an external connecting terminal (for example, a solder ball or the like) is formed on the electrode 108F (in correspondence with the electrode 108 in cases of exemplary, non-limiting Embodiments 6 through 8) in later steps and therefore, an area of the electrode 108F becomes larger than that of the electrode 108 of exemplary, non-limiting Embodiments 6 through 8. Steps up to the step are made to be similar to those in cases of exemplary, non-limiting Embodiments 6 through 8 other than shapes of electrodes (opening portions of solder resist in correspondence with the electrodes).
Next, at a step shown in
Next, at a step shown in
Next, insulation and reliability of a mounted portion are ensured by permeating and curing an underfill 203F between the semiconductor chip 201F and the solder resist layer 102.
Next, at a step shown in
Next, a semiconductor device 200A shown in
According to the method of fabricating the semiconductor device according to the embodiment, there can be fabricated the semiconductor device achieving an effect similar to the effect described in exemplary, non-limiting Embodiment 6, capable of constituting thin-sized formation and capable of dealing with high density wiring. Further, the semiconductor chip may be mounted by wire bonding and resin sealing as shown by exemplary, non-limiting Embodiment 7.
Further, in exemplary, non-limiting Embodiment 9, a semiconductor chip connecting terminal (for example, solder ball) for mounting the semiconductor chip may be provided on a side of the board as explained below.
According to the method of fabricating the semiconductor device according to the embodiment; first, a step in correspondence with the step shown in
Next, at a step shown in
Next, at a step shown in
Next, at a step shown in
Next, at a step shown in
Next, similar to the step of
Next, at a step shown in
Next, at a step shown in
Further, insulation and reliability of the mounted portion are ensured by permeating and curing the underfill 203G between the semiconductor chip 201G and the solder resist layer 102.
At a step of
In this way, the semiconductor chip connecting terminal (for example, solder ball) for connecting the semiconductor chip and the board can also be formed on the side of the board.
Further, although in the method of fabricating the semiconductor device shown in exemplary, non-limiting Embodiment 6 through exemplary, non-limiting Embodiment 10, an explanation has been given by taking an example of a case in which the wiring portion is constituted by a single layer, the invention is not limited thereto. For example, it is apparent that the invention is applicable to a case of fabricating a semiconductor device (wiring board) having a multilayer wiring structure formed by laminating wiring portions comprising the via plugs 105 and the pattern wirings 106 in multilayers.
In a semiconductor chip of the recent years, at a portion of connecting a semiconductor chip and a wiring board, fine pitch formation and high density wiring formation are progressed. Therefore, according to the method of fabricating the wiring board according to the embodiment, the semiconductor connecting terminal in correspondence with fine pitch formation can be formed.
Although according to exemplary, non-limiting Embodiment 1 through exemplary, non-limiting Embodiment 10, the solder resist layer 102 is formed on the support board 101 before removing the support board, a method of forming the solder resist layer according to the invention is not limited thereto. For example, as explained below, the solder resist layer may be formed on the insulating layer after removing the support board.
A step shown in
Next, in a step shown in
At steps shown in
Next, in a step shown in
In the case of the embodiment, the wiring board can be formed similar to exemplary, non-limiting Embodiment 1 other than removing the plating resist layer 302 before applying the insulating layer 104 and forming the second solder resist layer 308 on the insulating layer 104 after removing the support layer 101 and an effect similar to that in the case of exemplary, non-limiting Embodiment 1 is achieved.
Further, a semiconductor device can be fabricated by the method of mounting a semiconductor chip to the wiring board as shown in Embodiments 6 to 10.
Although an explanation has been given of the invention with regard to preferable embodiments, the invention is not limited to the specific embodiments but can variously be modified or changed within the gist described in the scope of claims.
According to the foregoing arrangement, various advantages shown below may be achieved in some implementations. For example, there can be provided the method of fabricating the wiring board capable of constituting thin-sized formation and capable of dealing with high density wiring and the method of fabricating the semiconductor device constituted by mounting the semiconductor device on the wiring board.
Number | Date | Country | Kind |
---|---|---|---|
2005-159993 | May 2005 | JP | national |
2006-014199 | Jan 2006 | JP | national |
The present application claims foreign priority based on Japanese Patent Application No. 2005-159993, filed May 31, 2005 and Japanese Patent Application No. 2006-014199, filed Jan. 23, 2006, the contents of which are incorporated herein by reference. The present application is also a continuation of parent U.S. application Ser. No. 11/419,887, filed May 23, 2006.
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Japanese Office Action and English Translation drafted Jan. 16, 2013, 9 pages. |
Number | Date | Country | |
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20110286189 A1 | Nov 2011 | US |
Number | Date | Country | |
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Parent | 11419887 | May 2006 | US |
Child | 13196129 | US |