The present invention relates to the field of electronics, and more particularly to electronic structures including solder layers and related methods.
Solder layers may be used to provide electrical and mechanical coupling between two electronic substrates, such as in flip-chip bonding. In particular, a solder layer may be provided on a conductive pad of an electronic substrate (such as an input/output pad of an integrated circuit substrate), and the solder layer can be used to bond the electronic substrate to a next level of packaging such as a printed circuit board, a ceramic substrate, and/or another integrated circuit device. Accordingly, the solder layer may provide an electrical interconnection between the electronic substrate and the next level of packaging.
More particularly, a solder bump may be provided on a portion of a conductive pad exposed through a via in an insulating layer. In addition, a relatively thin underbump metallurgy (UBM) layer may promote adhesion, provide a plating electrode, and/or provide a routing conductor. An insulating layer on the electronic structure may include a via therein exposing a portion of the conductive pad on which the solder layer is provided. As current flowing in a conventional structure reaches an edge of a solder bump via, a lower resistance of the bump may cause most of the current to turn the corner at the via edge. A non-uniform current density may result, and a non-uniform current density may reduce reliability.
More particularly, a relatively high current density at the via edge may accelerate local electromigration of the solder layer at the via edge. Solder, for example, may be particularly susceptible to electromigration because of its relatively low melting temperature. Diffusion of metal in the solder layer away from the via edge may result in formation of a void in the solder layer adjacent the via edge. The void may block current flow thus forcing the current to travel farther past the via edge before turning toward the solder. Accordingly, a void may grow laterally along an interface between the solder and the conductive pad.
Solder layers may be relatively sensitive to electromigration as discussed, for example, by W. J. Choi et al. in “Electromigration Of Flip Chip Solder Bump On Cu/Ni(V)/Al Thin Film Under Bump Metallization” (Proceedings of the IEEE Electronic Components Technology Conference, 2002). The disclosure of the Choi et al. reference is hereby incorporated herein in its entirety by reference.
According to some embodiments of the present invention, an integrated circuit device may include a substrate, a conductive pad on a surface of the substrate, and a conductive line on the surface of the substrate. The conductive line may be connected to the conductive pad, and the conductive line may be narrow relative to the conductive pad. An insulating layer may be provided on the substrate, on the conductive line, and on edge portions of the conductive pad, and the insulating layer may have a hole therein exposing a central portion of the conductive pad. In addition, a first segment of a perimeter of the hole may substantially define an arc of a circle around the central portion of the conductive pad, and a second segment of the perimeter of the hole may substantially deviate from the circle around the central portion of the conductive pad. Moreover, the second segment of the perimeter of the hole may be adjacent a connection between the conductive line and the conductive pad.
A conductive bump may be provided on the central portion of the conductive pad and on portions of the insulating layer surrounding the hole so that the insulating layer is between the conductive bump and edge portions of the conductive pad. Moreover, the conductive bump may include a solder bump, and/or the conductive bump may have a substantially circular footprint on the insulating layer. In addition, an underbump metallurgy layer may be provided on the central portion of the conductive pad and on portions of the insulating layer surrounding the hole so that the under bump metallurgy layer is between the conductive bump and portions of the insulating layer surrounding the hole, and the underbump metallurgy layer and the conductive bump may comprise different materials.
An input/output pad may be provided on the substrate, and the conductive line may provide electrical connection between the conductive pad and the input/output pad. In addition, a second conductive line may be connected to the input/output pad, and a second conductive pad may be connected to the second conductive line wherein the insulating layer has a second hole therein exposing a central portion of the second conductive pad. In addition, a first conductive bump may be provided on the central portion of the first conductive pad and on portions of the insulating layer surrounding the first hole, and a second conductive bump may be provided on the central portion of the second conductive pad and on portions of the insulating layer surrounding the second hole.
According to some embodiments of the present invention, the second segment of the perimeter of the hole may substantially define a line, and a length of the second segment may be at least as great as a width of the conductive line. According to other embodiments of the present invention, the second segment of the perimeter of the hole may curve toward the center of the conductive pad.
According to additional embodiments of the present invention, an integrated circuit device may include a substrate, a conductive pad on a surface of the substrate, and a conductive line on the surface of the substrate. The conductive line may be connected to the conductive pad, and the conductive line may be narrow relative to the conductive pad. An insulating layer may be provided on the substrate, on the conductive line, and on edge portions of the conductive pad, the insulating layer may have a hole therein exposing a central portion of the conductive pad, and at least a segment of a perimeter of the hole may be non-circular. In addition, a conductive bump may be provided on the central portion of the conductive pad and on portions of the insulating layer surrounding the hole so that the insulating layer is between the conductive bump and edge portions of the conductive pad and so that the conductive bump has a substantially circular footprint on the insulating layer.
More particularly, the conductive bump may include a solder bump. In addition, an underbump metallurgy layer may be provided on the central portion of the conductive pad and on portions of the insulating layer surrounding the hole so that the under bump metallurgy layer is between the conductive bump and portions of the insulating layer surrounding the hole. Moreover, the underbump metallurgy layer and the conductive bump may include different materials.
A first segment of a perimeter of the hole may substantially define an arc of a circle around the central portion of the conductive pad, and a second segment of the perimeter of the hole may substantially deviate from the circle around the central portion of the conductive pad. The second segment of the perimeter of the hole may be adjacent a connection between the conductive line and the conductive pad. According to some embodiments of the present invention, the second segment of the perimeter of the hole may substantially define a line, and a length of the second segment may be at least as great as a width of the conductive line. In other embodiments of the present invention, the second segment of the perimeter of the hole may curve toward the center of the conductive pad. Moreover, an input/output pad may be provided on the substrate wherein the conductive line provides electrical connection between the conductive pad and the input/output pad.
In addition, the integrated circuit device may include a second conductive line connected to the input/output pad, and a second conductive pad connected to the second conductive line wherein the insulating layer has a second hole therein exposing a central portion of the second conductive pad. A first conductive bump may be provided on the central portion of the first conductive pad and on portions of the insulating layer surrounding the first hole, and a second conductive bump may be provided on the central portion of the second conductive pad and on portions of the insulating layer surrounding the second hole.
According to additional embodiments of the present invention, an integrated circuit device may include a substrate, an input/output pad on the substrate, and first and second conductive lines on the substrate with both of the first and second lines being connected to the input/output pad. First and second conductive pads may be provided on the substrate with the first conductive pad being connected to the first conductive line and with the second conductive pad being connected to the second conductive line. An insulating layer may be provided on the first and second conductive lines and on edge portions of the first and second conductive pads, and the insulating layer may have first and second holes therein exposing central portions of the respective first and second conductive pads. In addition, a first conductive bump may be provided on the central portion of the first conductive bump and on portions of the insulating layer surrounding the first hole, and a second conductive bump may be provided on the central portion of the second conductive pad and on portions of the insulating layer surrounding the second hole.
The first and second conductive bumps may include respective first and second solder bumps, and each of the first and second conductive bumps may have a substantially circular footprint on the insulating layer. In addition, a first underbump metallurgy layer may be provided on the central portion of the first conductive pad and on portions of the insulating layer surrounding the first hole so that the first under bump metallurgy layer is between the first conductive bump and portions of the insulating layer surrounding the first hole, and the first underbump metallurgy layer and the first conductive bump may include different materials. A second underbump metallurgy layer may be provided on the central portion of the second conductive pad and on portions of the insulating layer surrounding the second hole so that the second under bump metallurgy layer is between the second conductive bump and portions of the insulating layer surrounding the second hole, and the second underbump metallurgy layer and the second conductive bump may include different materials.
The first conductive line may provide a first electrical resistance between the input/output pad and the first conductive pad, the second conductive line may provide a second electrical resistance between the input/output pad and the second conductive pad, and the first and second electrical resistances may be different. According to some embodiments of the present invention, the first conductive line may have a first length between the input/output pad and the first conductive pad, the second conductive line may have a second length between the input/output pad and the second conductive pad, and the first and second lengths may be different. According to some other embodiments of the present invention, the first conductive line may have a first width, the second conductive line may have a second width, and the first and second widths may be different. According to still other embodiments of the present invention, the first conductive line may have a first thickness, the second conductive line may have a second thickness, and the first and second thicknesses may be different. According to yet other embodiments of the present invention, the first conductive line may include a first material, the second conductive line may include a second material, and the first and second materials may be different.
The input/output pad may be a ground pad providing a ground connection for the integrated circuit device, or the input/output pad may be a power pad providing a power connection for the integrated circuit device. The first conductive line may be narrow relative to the first conductive pad, a first segment of a perimeter of the first hole may substantially define an arc of a circle around the central portion of the first conductive pad, and a second segment of the perimeter of the first hole may substantially deviate from the circle around the central portion of the conductive pad. Moreover, the second segment of the perimeter of the first hole may be adjacent a connection between the conductive line and the conductive pad. Moreover, at least a segment of a perimeter of the first hole may be non-circular.
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
In the drawings, the thickness of layers and regions are exaggerated for clarity. It will also be understood that when an element such as a layer, region or substrate is referred to as being on another element, it can be directly on the other element or intervening elements may also be present. In contrast, if an element such as a layer, region or substrate is referred to as being directly on another element, then no other intervening elements are present. Similarly, when an element such as a layer, region or substrate is referred to as being coupled or connected to/with another element, it can be directly coupled or connected to/with the other element or intervening elements may also be present. In contrast, if an element such as a layer, region or substrate is referred to as being directly coupled or connected to/with another element, then no other intervening elements are present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. The symbol “/” is also used as a shorthand notation for “and/or”.
Embodiments of the invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle will, typically, have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place. Moreover, a patterned feature (such as a perimeter of a hole) illustrated having sharp transitions may typically have a rounded or curved transition. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the invention.
Furthermore, relative terms, such as beneath, upper, lower, top, and/or bottom may be used herein to describe one element's relationship to another element as illustrated in the figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if the device in one of the figures is turned over, elements described as below other elements would then be oriented above the other elements. The exemplary term below, can therefore, encompasses both an orientation of above and below.
It will be understood that although the terms first and second are used herein to describe various regions, layers and/or sections, these regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one region, layer or section from another region, layer or section. Thus, a first region, layer or section discussed below could be termed a second region, layer or section, and similarly, a second region, layer or section could be termed a first region, layer or section without departing from the teachings of the present invention. Like numbers refer to like elements throughout.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes”, and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Several approaches are discussed to reduce electromigration. According to embodiments of the present invention, effects of electromigration can be reduced by using more power or ground bumps depending on an expected operating temperature of a solder bump interconnection (such as a SnPb solder bump interconnection) because segregation of lead and tin may be a risk at the cathode below 100 degrees C. and at the anode above 100 degrees C. due to the relative diffusivities of the two components.
More particularly, diffusivities of lead and tin in a lead-tin solder may vary over temperature, with lead diffusing faster than tin at temperatures greater than approximately 100 degrees C. and with tin diffusing faster than lead at temperatures less than approximately 100 degrees C. Moreover, a faster diffusing component of the solder metallurgy may tend to segregate toward a positive terminal (i.e., an anode) of the solder bump, and/or a slower diffusing component of the solder metallurgy may tend to segregate toward a negative terminal (i.e., a cathode) of the solder bump. An increased tin concentration may damage an under bump metallurgy layer between a lead-tin solder bump and a contact pad of an integrated circuit device.
As shown in
If operating conditions for an integrated circuit device are generally expected to exceed approximately 100 degrees C., a number of power bumps provided for the integrated circuit device may exceed a number of ground bumps provided for the integrated circuit device. While particular embodiments of the present invention have been discussed with respect to binary solid solution solders such as lead-tin solders, other solid solution solders (including higher order solid solution solders) may be used. Moreover, binary and higher order intermetallic compound solders such as tin-silver and tin-silver-copper solders may also be used according to embodiments of the present invention.
As shown in the top view of
In addition or in an alternative, a plurality of solder bumps may be connected to a respective plurality of Vcc pads. By providing a plurality of power bumps, current can be distributed, and segregation can be reduced. Moreover, failure of a single power bump may not be catastrophic.
While not shown in
As shown in
If operating conditions for an integrated circuit device are generally expected not to exceed approximately 100 degrees C., a number of ground bumps provided for the integrated circuit device may exceed a number of power bumps provided for the integrated circuit device. While particular embodiments of the present invention have been discussed with respect to binary solid solution solders such as lead-tin solders, other solid solution solders (including higher order solid solution solders) may be used. Moreover, binary and higher order intermetallic compound solders such as tin-silver and tin-silver-copper solders may also be used according to embodiments of the present invention.
As shown in the top view of
While not shown in
In addition or in an alternative, a plurality of solder bumps may be connected to a respective plurality of ground pads. By providing a plurality of ground bumps, current can be distributed, and segregation can be reduced. Moreover, failure of a single ground bump may not be catastrophic.
Benefits may also be provided according to embodiments of the present invention by connecting a plurality of solder bumps to input/output pads other than ground and/or Vcc pads. As discussed above with respect to ground and Vcc pads, current can be distributed and segregation can be reduced, and failure of a single bump may not be catastrophic. Provision of multiple bumps may be particularly, beneficial with input/output pads carrying currents sufficient to result in accumulation of vacancies at interfaces between a solder bump and its under bump metallurgy. For example, provision of multiple bumps may be beneficial where relatively large DC currents are provided through a pad (such as a ground and/or Vcc pad). Provision of multiple bumps may also be beneficial where intermittent unidirectional currents are provided through a pad (such as a pad providing a Pulse Width Modulation signal) and/or where bi-directional currents which are predominate in one direction are provided through a pad (such as a pad providing a Pulse-Reverse Plating signal). In addition, provision of multiple bumps may be beneficial wherein sufficiently high AC currents are provided through a pad such that vacancies may accumulate at a solder bump interface during half cycles of the signal.
By providing a plurality of solder bumps connected to a same pad such as a ground pad, a Vcc pad, and/or an input/output pad, a device lifetime may be increased. More particularly, different resistances may be provided between the pad and each of the solder bumps connected to the pad so that, initially, current predominantly flows between the pad and a first solder bump connected through a path of least electrical resistance. Accordingly, vacancies (due to electromigration) may initially accumulate between the first solder bump and the respective under bump metallurgy layer, and vacancies may not substantially accumulate at a second solder bump connected through a path of higher resistance while the first solder bump is operational. The accumulation of vacancies at the first solder bump may eventually result in a void at the first solder bump and then failure of the first solder bump. Because significant current may not flow through the second solder bump until the first solder bump fails (due to the higher electrical resistance between the second solder bump and the pad), vacancies may not begin to significantly accumulate at the second solder bump until after failure of the first solder bump. An initiation of incubation of vacancies and/or voids in the second solder bump may thus be substantially delayed until after failure of the first solder bump. Stated in other words, initiation of a failure mechanism in the second solder bump may be substantially delayed until after failure of the first solder bump.
According to additional embodiments of the present invention, effects of electromigration can be reduced by providing a ‘D’ shaped via with a flat of the D facing the conductive line or trace (i.e. facing the incoming/outgoing current flow). This structure may reduce current crowding at a short path to a nearest point of a conventional circular via. In an alternative, the via can be concave and/or crescent shaped in the direction of the conductive line or trace (i.e. in the direction of the incoming/outgoing current flow.
As shown in the top view of
As shown in
According to some embodiments of the present invention, a first segment 917 of the perimeter of the via hole 918 may substantially define an arc of a circle around central portions of the conductive pad 903. In addition, a second segment 917′ or 917″ of the perimeter of the via hole 918 may substantially deviate from the circle around the central portion of the conductive pad 903. Moreover, the second segment 917′ or 917″ of the perimeter of the via hole 918 may be adjacent a connection between the conductive line 905 and the conductive pad 903. More particularly, the second segment of the perimeter of the via hole 918 may define a line as shown by the segment 917′, and a length of the second segment 917′ may be at least as great as a width of the conductive line. In an alternative, the second segment 917″ of the perimeter of the via hole 918 may curve toward a center of the conductive pad 903. According to some other embodiments of the present invention, at least a segment of the perimeter of the via hole may be non-circular.
The cross sectional view of
The cross sectional view of
Elements of structures illustrated in
Particular embodiments of the present invention including “D” shaped and crescent shaped vias are discussed above with respect to
According to additional embodiments of the present invention, increased solder bump life may be provided by reserving backup bumps that pass little current until a respective primary bump fails. Because nucleation of voids proceeds at a rate slower than void growth, relatively little nucleation may occur in a backup bump until the primary bump fails, and void nucleation in the backup bump may not substantially begin until after failure of the first bump when the backup bump begins carrying significant current. More particularly, separate redistribution lines may be provided from an integrated circuit contact pad to primary and backup solder bumps, and the redistribution line to the backup solder bump may provide a higher resistance than the redistribution line to the primary solder bump so that during normal operation, the backup solder bump carries significantly less current than the primary solder bump. For example, the redistribution line to the backup solder bump may be narrower, thinner, and/or longer than the redistribution line to the primary solder bump. Accordingly, the redistribution line to the backup solder bump may provide a resistance sufficiently greater than that of the redistribution line to the primary solder bump so that the primary solder bump carries significantly more current during normal operations. The resistance of the redistribution line to the backup solder bump, however, is sufficiently low so that performance of the integrated circuit device is not significantly diminished on failure of the primary solder bump. A failure mechanism resulting from void nucleation and growth in the backup solder bump may thus not substantially begin until after failure of the primary solder bump.
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As shown in the top view of
As further shown in
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As shown in the top view of
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As shown in the top view of
As further shown in
Moreover, the different segments 10001a-c of the conductive line may have different properties to provided further increases in resistance between solder bumps more distantly located from the input/output pad 10003. For example, a width of the segment 10001a may be greater than a width of the segment 10001b, and/or a width of the segment 10001b may be greater than a width of the segment 10001c. In addition or in an alternative, a thickness of the segment 10001a may be greater than a thickness of the segment 10001b, and/or a thickness of the segment 10001b may be greater than a thickness of the segment 10001c. Moreover, a length of the segment 10001a may be less than a length of the segment 10001b, and/or a length of the segment 10001b may be less than a length of the segment 10001c.
While not shown in
As used herein, the term under bump metallurgy layer refers to one or more conductive layers provided between a solder bump and a substrate. An under bump metallurgy layer may include an adhesion layer (such as a layer of titanium, tungsten, chrome, and/or combinations thereof), a conduction layer (such as a layer of copper), and/or a barrier layer (such as a layer of nickel, platinum, palladium, and/or combinations thereof). A solder bump may be a bump of one or more different solder materials. For example, a solder bump may include one or more of a single element, binary, ternary, and/or higher order solder; such as a lead-tin solder, a lead-bismuth solder, a lead-indium solder, a lead free solder, a tin-silver solder, a tin-silver-copper solder, an indium-tin solder, an indium-gallium solder, a gallium solder, an indium-bismuth solder, a tin-bismuth solder, an indium-cadmium solder, bismuth-cadmium solder, tin-cadmium, etc. Accordingly, an under bump metallurgy layer may provide a surface that is wettable to a solder bump wherein the solder wettable surface of the under bump metallurgy layer and the solder bump comprise different materials.
While the present invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
The present application claims the benefit of priority as a Continuation-In-Part (CIP) application from U.S. Utility application Ser. No. 11/226,569 filed Sep. 14, 2005 now U.S. Pat. No. 7,297,631, which claims the benefit of priority as a Divisional application from U.S. Utility patent application Ser. No. 10/601,938 filed Jun. 23, 2003, now U.S. Pat. No. 6,960,828, which claims the benefit of priority from U.S. Provisional Application No. 60/391,511 filed Jun. 25, 2002. The present application also claims the benefit of priority from U.S. Provisional Application No. 60/626,802 filed Nov. 10, 2004. The disclosures of each of the above referenced utility and provisional applications are hereby incorporated herein in their entirety by reference.
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Number | Date | Country | |
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Child | 11226569 | US |
Number | Date | Country | |
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Parent | 11226569 | Sep 2005 | US |
Child | 11270366 | US |