This application is based upon and claims the benefit of priority from the prior Japanese Patent Application 2013-191108, filed on Sep. 13, 2013, the entire contents of which are incorporated herein by reference.
Embodiments described herein are generally related to a method of testing a semiconductor device and an apparatus of testing a semiconductor device.
A bonding material is used for a bonding portion between a semiconductor element and a substrate. A material such as Sn-95Pb to Sn-90Pb or SnAg is used for the bonding material. Further, in recent years, diffusion bonding or sinter bonding using metal fine particles such as Ag, Au or Cu is used.
Whether or not bonding portions are good is determined by observing the bonding portions of semiconductor elements one by one using a magnifying glass. Further, a bonding thickness of sinter bonding and diffusion bonding is several tens of micrometers (μm), and is about one tenth compared to that of a solder bonding portion. Therefore, performing an accurate test by way of visual checking is very difficult. Further, the thickness of the bonding portion is thin, and so thermal resistance is also little.
That is, a test which uses thermal resistance causes little resistance change, and is likely to cause an error. It is important to accurately determine whether or not a bonding portion of a semiconductor element which uses a bonding material including metal fine particles is good.
FIGS. 3A1 to 3A8, FIGS. 3B1 to 3B8 and FIGS. 3C1 to 3C8 are views illustrating examples of image data of heat distributions according to the first embodiment.
According to one embodiment, in a method of testing a semiconductor device, the semiconductor device has a semiconductor element and a substrate which are bonded by bonding material including metal fine particles. Image data of a heat distribution in the semiconductor device are temporally acquired while heating the semiconductor device. A time change of a fractal dimension based on the image data is calculated. An inclination of the time change of the fractal dimension is calculated. The inclination and a reference inclination set in advance are compared. Whether or not the semiconductor device is good is determined.
Embodiments will be described below with reference to the drawings. In the drawings, the same reference numerals show the same or similar portions. The same portions in the drawings are denoted by the same numerals and a detailed explanation of the same portions is appropriately omitted, and different portions will be described.
As illustrated in
Upon the preparation of the semiconductor device in step S101, a semiconductor device having a semiconductor element and a substrate bonded by a bonding material including metal fine particles is prepared. The semiconductor device is a target object whose bonding portion is determined to be good or not.
Upon the acquisition of the image data of the heat distribution in step S102, the semiconductor device prepared in step S101 is heated, and the image data of the heat distribution of the semiconductor device is temporally acquired. The image data of the heat distribution is an infrared image obtained by capturing the semiconductor element from above, for example. In step S102, while the semiconductor device is heated, the image data obtained by capturing the semiconductor element from above every time a predetermined time passes is acquired. In step S102, two or more items of image data of heat distributions are acquired as a heating time passes.
Upon the calculation of the fractal dimension in step S103, a time change of the fractal dimension is calculated based on the image data of the heat distribution taken in step S102.
The fractal dimension is calculated in accordance with following equation
N(R)·RD=C (1)
In equation (1), N(R) denotes the number of cubes which are required for covering, R denotes a length of one side of a cube, D denotes the fractal dimension and C denotes a constant (a volume of a target cube).
The fractal dimension is an indicator which represents complexity of a distribution shape. A temperature distribution can be represented by a two or three fractal dimension.
Upon the calculation of the inclination of the fractal dimension in step S104, an inclination of a time change of the fractal dimension is calculated. In step S103, the time change of the fractal dimension is calculated. In step S104, the inclination of the time change of the fractal dimension is calculated by linear approximation, for example.
Upon determination as to whether or not the semiconductor device is good in step S105, the inclination of the time change of the fractal dimension calculated in step S104 and a reference inclination set in advance are compared, and whether or not the semiconductor device is good is determined. That is, there is a correlation between the inclination of the time change of the fractal dimension and a bonding state of the bonding portion (a crack growth rate, for example). The correlation is used to determine whether or not the bonding state of the bonding portion is good depending on whether or not a value of the inclination of the time change of the fractal dimension exceeds a value of the reference inclination.
In the embodiment, it is possible to precisely determine using a fractal dimension whether or not the bonding portion is good, the bonding portion being hardly determined to be good or not only by referring to an image of a heat distribution corresponding to a heating time of a semiconductor device. Particularly when a bonding material includes metal fine particles including at least one of Ag, Au and Cu selected from a group including Ag, Au and Cu, it is difficult to precisely determine whether or not a bonding portion is good, from an image of a heat distribution. As in the embodiment, whether or not a bonding portion is good is precisely determined without destruction based on the inclination of the time change of the fractal dimension.
The semiconductor element includes one of SiC and GaN, for example. The semiconductor element including SiC or GaN can operate at a higher temperature than that of a semiconductor element including Si. The semiconductor element including SiC or GaN, for example, can operate at 200° C. or more. When the semiconductor element and the substrate are bonded through the bonding material, the bonding material needs to be sufficiently robust against process or an operation at a high temperature. In the embodiment, whether or not the semiconductor device is good is precisely determined based on characteristics of the inclination of the time change of the fractal dimension in the semiconductor device whose semiconductor element including SiC or GaN and the substrate are bonded.
Upon the calculation of the inclination of the time change of the fractal dimension in step S104, an inclination within 100 seconds from start of heating of the semiconductor device may be calculated. A size of the semiconductor element including SiC or GaN, for example, is smaller than a size of the semiconductor element including Si. The characteristics of the inclination of the time change of the fractal dimension appear in the semiconductor element including SiC or GaN at a comparatively early stage from start of heating. Consequently, precision to determine whether or not the semiconductor device is good is improved by calculating the inclination within 100 seconds from start of heating. The precision to determine whether or not the semiconductor device is good is improved particularly by calculating an inclination within 70 seconds from start of heating.
Next, a specific example will be described.
As illustrated in
The semiconductor element 20 is cut as a chip from a wafer. The semiconductor element 20 includes one of SiC and GaN. In the specific example, the semiconductor element 20 includes SiC. The semiconductor element 20 is a power transistor (IGBT as Insulated Gate Bipolar Transistor, for example) or a power diode (FRD as Fast Recovery Diode, for example).
The bonding material 30 includes metal fine particles 30a. The metal fine particles 30a include at least one selected from the group including Ag, Au and Cu. In the specific example, Ag is used for the metal fine particles 30a. The diameter of the metal fine particles 30a is several tens of nanometers (nm) or more and several hundreds of nm or less, for example. When the bonding material 30 including Ag fine particles is used, a melting point of the bonding material 30 becomes equal to the melting point of Ag (960° C.). The semiconductor element 20 is sinter-bonded on the first surface 10a of the substrate 10 through the bonding material 30. In the description, metal includes not only pure metal but also an intermetallic compound (alloy).
In the specific example, while the semiconductor device S is heated, image data of a heat distribution is acquired.
FIGS. 3A1 to 3A8, FIGS. 3B1 to 3B8 and FIGS. 3C1 to 3C8 are views illustrating examples of image data of heat distributions.
FIGS. 3A1 to 3A8 illustrate image data of heat distributions in a first semiconductor device S1. FIGS. 3A1 to 3A7 illustrate image data per ten seconds from start of heating to 70 seconds, and FIG. 3A8 illustrates image data after 240 seconds from start of heating.
FIGS. 3B1 to 3B8 illustrate image data of heat distributions in a second semiconductor device S2. FIGS. 3B1 to 3B7 illustrate image data per 10 seconds from start of heating to 70 seconds, and FIG. 3B8 illustrates image data after 240 seconds from start of heating.
FIGS. 3C1 to 3C8 illustrate image data of heat distributions in a third semiconductor device S3. FIGS. 3C1 to 3C7 illustrate image data per 10 seconds from start of heating to 70 seconds, and FIG. 3C8 illustrates image data after 240 seconds from start of heating.
Meanwhile, in order to simulate flaws, the first semiconductor device S1 and the third semiconductor device S3 are subjected to thermal cycles hundred times, and the second semiconductor device S2 is subjected to thermal cycles 500 times. In one thermal cycle, 200° C. and −50° C. are maintained for 30 minutes.
In the following description, the first semiconductor device S1, the second semiconductor device S2 and the third semiconductor device S3 are collectively referred to as the semiconductor device S.
The semiconductor device S is heated by a heat source such as a high frequency oscillator or a lamp. Image data of a heat distribution is acquired using temperature measuring equipment such as a thermography. The temperature measuring equipment takes in data of a temperature distribution on a surface of the semiconductor element captured from above of the semiconductor device S. The image data of the heat distribution is displayed on a monitor, for example, as an image by color-coding data of a temperature distribution per predetermined temperature range.
FIGS. 3A1 to 3A8, FIGS. 3B1 to 3B8 and FIGS. 3C1 to 3C8 illustrate examples of image data of heat distributions taken in as described above. It is difficult to determine whether or not the bonding portion between the semiconductor element 20 and the substrate 10 is good only by referring to the image data.
A horizontal axis in
In
The fractal dimension changes between 2 and 3 until 240 seconds from start of heating on each of the lines L11, L12 and L13. The fractal dimension immediately after start of heating is a value close to 2, and, when the heating time increases, the fractal dimension becomes close to 3. The time change of the fractal dimension within 100 seconds from immediately after heating is greater than the time change of the fractal dimension after 100 seconds to 240 seconds.
Each of the horizontal axes in
The lines L211, L221, L231, L212, L222 and L232 linearly approximate the time changes of the fractal dimensions. When the horizontal axes in
An equation of linear approximation of each of the lines L211, L221, L231, L212, L222 and L232 is as follows.
Line L211 . . . y=0.2262×log(x)+1.8871
Line L221 . . . y=0.2561×log(x)+1.7467
Line L231 . . . y=0.2298×log(x)+1.869
Line L212 . . . y=0.07×log(x)+2.57
Line L222 . . . y=0.08×log(x)+2.53
Line L232 . . . y=0.08×log(x)+2.56
As is clear from
Meanwhile, as is clear from
A horizontal axis in
As illustrated in
In the specific example, whether or not the bonding portion (bonding material 30) between the semiconductor element 20 and the substrate 10 is good, that is, whether or not the semiconductor device is good is determined using the correlation between the crack growth rate and the inclination of the time change of the fractal dimension.
An inclination corresponding to a crack growth rate 50% is used as a reference inclination Th, for example, and the calculated inclination of the time change of the fractal dimension and the reference inclination Th are compared. The semiconductor device is determined to be “good” when the calculated inclination of the time change of the fractal dimension is not more than the reference inclination Th. Meanwhile, the semiconductor device is determined to be “poor” when the calculated inclination of the time change of the fractal dimension is greater than the reference inclination Th. In addition, the reference inclination Th is an example, and may be another inclination.
As illustrated in
It is difficult to determine whether or not the semiconductor device is good from the image data of the heat distributions illustrated in FIGS. 3A1 to 3A8, FIGS. 3B1 to 3B8 and FIGS. 3C1 to 3C8. However, in the specific example, it is possible to precisely determine whether or not the semiconductor device is good based on the calculated inclination of the time change of the fractal dimension of the semiconductor device using the correlation between the crack growth rate and the inclination of the time change of the fractal dimension.
Further, in the specific example, the crack growth rate may be predicted from the calculated inclination of the time change of the fractal dimension using the correlation between the crack growth rate and the inclination of the time change of the fractal dimension illustrated in
Thus, in accordance with the specific example, it is possible to precisely determine whether or not the bonding portion between the semiconductor element 20 and the substrate 10 is good from the calculated inclination of the time change of the fractal dimension of the semiconductor device. Further, it is also possible to predict a crack growth rate from the calculated inclination of the time change of the fractal dimension.
Meanwhile, although a case has been described herein where the metal fine particles 30a are pure metal fine particles such as Ag, Au and Cu, the metal fine particles 30a may be intermetallic compound fine particles. The intermetallic compound is CuSn alloy (Cu3Sn and Cu6Sn5) and AgSn alloy (Ag3Sn), for example. The CuSn alloy has a lower melting point than that of Cu, and the AgSn alloy has a lower melting point than that of Ag. The melting point of Ag3Sn is approximately 480° C., for example, and is lower than the melting point of Ag (960° C.).
When the metal fine particles 30a are intermetallic compound fine particles, there is an advantage of adequately adjusting the melting point of the bonding material 30 according to a purpose. As well as the metal fine particles 30a being pure metal fine particles, even when the metal fine particles 30a are intermetallic compound fine particles, it is possible to precisely determine whether or not the bonding portion between the semiconductor element 20 and the substrate 10 is good, from the inclination of the time change of the fractal dimension.
Next, an apparatus of testing a semiconductor device in accordance with the second embodiment will be described.
As illustrated in
The heating unit 201 has a heat source (a high frequency oscillator or a lamp, for example) which heats a semiconductor device S. The heat source is desirably configured to intensely heat the semiconductor device S. It is desirable that a size of a heated region is desirably substantially equal to a size of the semiconductor device S, for example. By intensely heating the semiconductor device S, a heat distribution of the semiconductor device S is hardly influenced by heating of other portions.
As illustrated in
The image acquiring unit 202 has an infrared camera which outputs an electric signal in accordance with the amount of a received infrared ray, for example. The image acquiring unit 202 temporally acquires image data of a heat distribution of the semiconductor device S while the heating unit 201 heats the semiconductor device S.
The determining unit 203 calculates a time change of fractal dimension based on the image data acquired by the image acquiring unit 202. Further, the determining unit 203 calculates the inclination of the time change of the fractal dimension. Furthermore, the determining unit 203 compares the calculated inclination and a reference inclination Th set in advance to determine whether or not the semiconductor device is good.
The determining unit 203 may calculate an inclination of a time change of a fractal dimension within 100 seconds from start of heating of the semiconductor device. Further, the determining unit 203 may predict a growth rate of a crack produced between the semiconductor element 20 and the substrate 10 from a value of the inclination of the time change of the fractal dimension.
The apparatus 210 of testing the semiconductor device further has a control unit 204. The control unit 204 controls the heating unit 201, the image acquiring unit 202 and the determining unit 203.
At least one of the control unit 204 and the determining unit 203 may be configured by a computer. At least one of the control unit 204 and the determining unit 203 may be connected with another configuration through a network.
At least one of the control unit 204 and the determining unit 203 may be realized by program processing (a semiconductor element bonding portion testing program) to be executed by the computer.
The semiconductor element bonding portion testing program may be recorded in a predetermined medium. Further, the semiconductor element bonding portion testing program may be distributed through the network.
The apparatus 210 of testing the semiconductor device of the embodiment can precisely determine whether or not the bonding portion between the semiconductor element 20 and the substrate 10 is good, from a calculated inclination of a time change of a fractal dimension of a semiconductor device. Further, it is also possible to predict a crack growth rate from the calculated inclination of the time change of the fractal dimension.
As described above, the method of testing the semiconductor device and the apparatus of testing the semiconductor device of the embodiments can accurately determine whether or not a semiconductor device is good.
In addition, although the embodiments have been described, the invention is by no means limited to the embodiments. Addition, removal or design change of components adequately made by one of ordinary skill in art on the above-described embodiments and adequate combinations of features of each embodiment are incorporated in the scope of the invention as long as the spirit of the invention is kept.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
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2013-191108 | Sep 2013 | JP | national |