This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2015-053842 filed Mar. 17, 2015, the entire contents of which are incorporated herein by reference.
An embodiment described herein relates generally to a semiconductor manufacturing method and a semiconductor manufacturing device.
In the semiconductor manufacturing process, a wafer having been previously processed to form integrated circuits therein and/or thereon is thinned. Thinning is performed while the wafer is bonded (temporary bonding) to a transparent (to light) supporting substrate by a joining layer. Further, in order to make the thinned wafer easily separate from the supporting substrate, a photothermal conversion layer that is converted by the energy of visible light is provided between the wafer and the supporting substrate. Then, after thinning the wafer, by irradiating the photothermal conversion layer with visible light from the supporting substrate side of the stack, the properties of the photo thermal conversion layer are changed, allowing separation of the wafer from the supporting substrate.
In the above method, however, the material of the supporting substrate is limited to a transparent material, such as glass. Therefore, the degree of freedom in selecting the material of the supporting substrate is desired to be increased.
According to an embodiment, there is provided a semiconductor manufacturing method and a semiconductor manufacturing device capable of increasing the degree of freedom for selection of the material of a supporting substrate used during the thinning of a semiconductor substrate.
In general, according to one embodiment, a semiconductor manufacturing method for a stacked body including a semiconductor substrate, a supporting substrate containing silicon, and a joining layer arranged between the semiconductor substrate and the supporting substrate to join the semiconductor substrate and the supporting substrate, in which a surface of the semiconductor substrate opposite to a side of the joining layer is ground is provided, the method including irradiating the stacked body with electromagnetic waves having energy of 0.11 to 0.14 eV from the supporting substrate side of the stack, and thereafter separating the semiconductor substrate from the supporting substrate.
Hereinafter, an embodiment will be described with reference to the drawings. This embodiment does not limit the scope of the invention.
The semiconductor manufacturing method according to the embodiment includes manufacturing a stacked body, thinning a semiconductor substrate, embrittling a joining layer, and separating the semiconductor substrate from the stacked body, in this order. These processes will be hereinafter described together with an apparatus and structures for carrying out the respective processes.
(Stacked Body Manufacturing Process)
According to the semiconductor manufacturing method, at first, a stacked body manufacturing process is performed.
Here, the structure example of a stacked body will be described.
As illustrated in
The semiconductor substrate 13 is, for example, silicon substrate (silicon wafer).
The supporting substrate 11 contains silicon (Si). For example, a single crystal silicon substrate is preferably used as the supporting substrate 11. By using a single crystal silicon substrate as the supporting substrate 11, mechanical characteristics of the supporting substrate 11 are almost with the same as those of the semiconductor substrate 13 (silicon substrate). As a result of the mechanical characteristics of the substrates 11, 13 being nearly identical, warping and cracking of the semiconductor substrate 13 may be avoided and further, handling of the semiconductor substrate 13 may resultantly be improved. Further, a single crystal silicon substrate has higher thermal conductivity than glass. Therefore, by using a single crystal silicon substrate as the supporting substrate 11, the supporting substrate 11 will better cool the entire stacked body 1 heated during the manufacturing process of the stacked body 1 and the embrittlement process of the joining layer 12. As the stacked body 1 is cooled effectively, the semiconductor substrate 13 is also cooled effectively. By effectively cooling the semiconductor substrate 13, changes in characteristics of the device formed on the device surface 13b may be reduced. The supporting substrate 11 may be also a glass (SiO2, SiSe2) substrate.
The joining layer 12 is embrittled by the energy of electromagnetic waves having energy of 0.11 to 0.14 eV. In other words, the joining layer 12 is embrittled (bulk fractured) by the energy of the electromagnetic waves. For example, a thermosetting adhesive (thermosetting resin) is preferably used for the joining layer 12. By using a thermosetting adhesive for the joining layer 12, the joining layer 12 better resists high temperatures of processes, such as the etching of the through silicon vias through the wafer 11 while the wafer and backing wafer 13 are still attached to one another. Since the joining layer 12 better resist the high temperatures of certain processes, the degree of freedom in the carrying out of these processes is increased. A thermoplastic adhesive (cooling and curing adhesive, thermoplastic resin) may be used for the joining layer 12.
Further, the joining layer 12 may have an absorption coefficient of 0.01 μm−1 or more for electromagnetic waves having energy of 0.11 to 0.14 eV. Here, the absorption coefficient means a constant indicating how much the energy of the electromagnetic waves is absorbed by the joining layer 12 when the electromagnetic wave enters the joining layer 12, having a dimension of the inverse of length. When the absorption coefficient is defined as α, the intensity of the electromagnetic waves before entering the joining layer 12 is defined as I0, the intensity of the electromagnetic wave after entering the joining layer 12 is defined as I, and the distance of the electromagnetic wave passing through the joining layer 12 (medium) is defined as x, the absorption coefficient α may satisfy the following formula according to the Lambert-Beer law.
α=(−1/x)ln(I/I0) (1)
Where ln is the logarithm of a number in base e.
By setting the absorption coefficient as 0.01 μm−1 or more, the joining layer 12 may efficiently convert the electromagnetic energy of the electromagnetic waves entering thereinto into heat and will become embrittled.
As illustrated in
Further, by providing the conversion layer 14 between the supporting substrate 11 and the joining layer 12, heat generated in the conversion layer 14 is somewhat insulated from the semiconductor substrate 13 by the joining layer 12, compared to the case where the conversion layer 14 is located between the joining layer 12 and the semiconductor substrate 13. Accordingly, changes in the electrical characteristics in a device may be further reduced and the quality of the resulting product may be improved. When the elements at or adjacent to the device surface 13b are not heat sensitive, the conversion layer 14 may be located between the joining layer 12 and the semiconductor substrate 13.
The conversion layer 14 uses an adhesive which includes, for example, silica. Silica has a high absorption ratio of electromagnetic waves having energy of 0.11 to 0.14 eV. Therefore, by including silica in the conversion layer 14, the semiconductor substrate 13 may be separated more easily from the stack after the joining layer 13 is treated with electromagnetic waves.
Further, the conversion layer 14 may include carbon black to convert electromagnetic wave energy into heat. In this case, in order to lessen the affect of the conductivity of the carbon black on the device, the upper limit of the content of the carbon black is preferably set at 5%.
As illustrated in
Next, an example of the structure of a device capable of carrying out the manufacturing process of the stacked body will be described.
The manufacturing process to form the stacked body 1 is performed, for example, using a vacuum bonding device 21 that is a portion of the semiconductor manufacturing system 2 in
As illustrated in
The vacuum chamber 211 is connected to a vacuum device, such as a vacuum pump (not illustrated), through the piping 214 and the valve 215.
The first holding unit 212 is positioned at the bottom of the vacuum chamber 211. The first holding unit 212 receives and holds the supporting substrate 11. The first holding unit 212 may receive and hold the semiconductor substrate 13.
The second holding unit 213 includes a shaft 2131, a holding surface 2132, and a clamp 2133. The second holding unit 213 may move (vertically) between a position near the first holding unit 212 and a position spaced further therefrom, according to the position of the shaft 2131 relative to the first holding unit 212. The shaft 2131 is driven by an actuator (not illustrated).
Next, the manufacturing process of the stacked body 1 using the vacuum bonding device 21 will be described.
As illustrated in
Then, the vacuum chamber 211 is evacuated by the vacuum pump to a vacuum state. By providing a vacuum state in the vacuum chamber 211, generation of voids in the adhesive 120 is suppressed. Since the generation of voids is suppressed, the supporting substrate 11 and the semiconductor substrate 13 may be properly adhered to each other through the adhesive 120.
Next, as illustrated in
By curing the adhesive 120 by heating to form the joining layer 12 at the same time, the supporting substrate 11 and the semiconductor substrate 13 are bonded (adhered) to each other by the joining layer 12. The supporting substrate 11 is bonded to the semiconductor substrate 13, and the stacked body is obtained 1 as a result.
(Semiconductor Substrate Thinning Process)
In the semiconductor manufacturing method according to the embodiment, after the manufacturing process of the stacked body 1, the thinning process of the semiconductor substrate 13 is performed on the manufactured stacked body 1. Before and after the process, the stacked body 1 may be automatically transferred using a carrying mechanism not illustrated. In the thinning process of the semiconductor substrate 13, the semiconductor substrate 13 is thinned, for example, by grinding or polishing the surface to be ground 13a of the semiconductor substrate 13 with a grinding or polishing device (not illustrated).
(Joining Layer Embrittlement Process)
In the semiconductor manufacturing method according to the embodiment, after the thinning process of the semiconductor substrate 13, the embrittlement process of the joining layer 12 is performed. Here, another process may be performed between the thinning process and the embrittlement process. The other process includes, for example, a washing process, a drying process, a forming process to form through silicon via(s) (TSV) in the wafer, and an electrode forming process.
Next, an example of the structure of a device capable of carrying out the embrittlement process of the joining layer 12 will be described.
The embrittlement process of the joining layer 12 is performed, for example, using the irradiation device 22 in
As illustrated in
Next, the embrittlement process of the joining layer 12 using the irradiation device 22 will be described.
As illustrated in
Then, as illustrated in
Further, as illustrated in
The electromagnetic waves EW having energy of 0.11 to 0.14 eV have the property that they are difficult to scatter, as compared with to visible light. Therefore, even when the supporting substrate 11 is a substrate that does not transmit the visible light (for example, single crystal silicon substrate), the electromagnetic waves EW may be transmitted through the supporting substrate 11 and reach the joining layer 12.
The electromagnetic waves EW that reach the joining layer 12 embrittle the joining layer 12 by heating the joining layer 12. For example, the electromagnetic waves EW generate defects such as voids or cracks (resolution, bulk fracture) in the joining layer 12. By the embrittlement of the joining layer 12, the semiconductor substrate 13 is easily separated from the supporting substrate 11. Therefore, the semiconductor substrate 13 may be separated more easily from the supporting substrate 11 in the separating process of the semiconductor substrate 13.
(Semiconductor Substrate Separating Process)
In the semiconductor manufacturing method according to the embodiment, after the embrittlement process of the joining layer 12, the separating process of the semiconductor substrate 13 is performed.
Here, an example of the structure of a device capable of carrying out the separating process of the semiconductor substrate 13 will be described.
The separating process of the semiconductor substrate 13 may be performed, for example, by the separating device 23 that is a portion of the semiconductor manufacturing system 2 in
As illustrated in
The separating process of the semiconductor substrate 13 using the separating device 23 will be described.
As illustrated in
Next, the suction unit 231 is moved by the moving device 234 to a position to come into contact with the stacked body 1, while providing suction to the interior of the suction unit 231 using the vacuum device 233. According to this, the supporting substrate 11 in the uppermost layer of the stacked body 1 is vacuum chucked by the suction unit 231.
While the supporting substrate 11 is vacuum chucked, the suction unit 231 is moved away from the stacked body 1 by the moving device 234. Here, the joining layer 12 between the supporting substrate 11 and the semiconductor substrate 13 was embrittled during the above-described embrittlement process. In other words, the coupling between the supporting substrate 11 and the semiconductor substrate 13 by the joining layer 12 is weaker than the vacuum coupling between the suction unit 231 and the supporting substrate 11. Accordingly, as illustrated in
The joining layer 12 is removed from the separated semiconductor substrate 13 using mechanical polishing or wet etching, and after dicing the substrate into individual pieces, the individual pieces of the semiconductor substrate 13 may be packaged. Further, the individual pieces of the semiconductor substrate 13 may be three-dimensionally mounted into 2.5 or three dimensional stacked packages using the TSV(s).
According to the embodiment, by irradiating the joining layer 12 with electromagnetic waves having energy of 0.11 to 0.14 eV, the joining layer 12 is embrittled even if the material of the supporting substrate 11 is opaque. For example, even when the supporting substrate 11 is a substrate such as single crystal silicon that does not transmit visible light, electromagnetic waves having energy of 0.11 to 0.14 eV will embrittle the joining layer 12 by heating the joining layer 12. Therefore, according to the embodiment, the degree of freedom in selecting the material of the supporting substrate may be increased.
Further, if the supporting substrate 11 is formed of single crystal silicon, the generation of warping or cracks in the semiconductor substrate 13 is suppressed, and the handling properties the semiconductor substrate 13 are improved. That is, the yield and the ease of manufacture of the semiconductor device are improved.
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.
For example, although the embodiment has been described in the case of using the silica for the conversion layer 14, a metal layer (for example, Ti, Ta, Ni, Cu, Al, or alloy or multi-layered film thereof) may be used for the conversion layer 14. When a metal film is used for the conversion layer 14, the conversion layer 14 itself is not embrittled; however, the joining layer 12 may be embrittled by transmitting heat from the conversion layer 14 to the joint layer 12.
The semiconductor manufacturing method in which the pulse width of the electromagnetic wave is 50 ns or less.
The semiconductor manufacturing method in which the absorption coefficient of the electromagnetic wave in the joining layer is 0.01 μm−1 or more.
The semiconductor manufacturing method in which the supporting substrate is a glass substrate.
The semiconductor manufacturing method in which the stacked body includes a conversion layer for converting the electromagnetic wave to heat between the joining layer and the semiconductor substrate, the method including embrittling the conversion layer by irradiating the stacked body with electromagnetic waves from the supporting substrate side thereof.
The semiconductor manufacturing method in which the conversion layer contains Ti, Ta, Ni, Cu, and Al.
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