The disclosure relates to a substrate structure and a manufacturing method thereof.
In substrate technology, vertical conductive connectors (such as plating through holes (PTH)) are often formed so that lines can be interconnected with each other in a thickness direction. However, due to the differences in material properties between the vertical conductive connectors and other components, it can cause problems such as low adhesion strength. Therefore, it is a challenge to improve the adhesion strength of the vertical conductive connectors in the substrate to enhance product reliability.
The disclosure provides a substrate structure and a manufacturing method thereof, which can effectively improve product reliability.
A substrate structure of the disclosure includes a substrate and a vertical conductive connector. The substrate includes a material with a heat resistance temperature of 300° C. or greater.
The vertical conductive connector penetrates through the substrate. The vertical conductive connector has a bonding structure extending toward the substrate.
A manufacturing method of a substrate structure of the disclosure at least includes the following steps. A substrate with a plurality of through holes and a conductive layer are provided.
The substrate is bonded to the conductive layer. An electro-plating process is performed to respectively form a vertical conductive connector in the plurality of through holes. An annealing process is performed to diffuse a plurality of first atoms in the vertical conductive connector toward the substrate to form a bonding structure.
Based on the above, the disclosure introduces the annealing process to diffuse the atoms in the vertical conductive connector to form the bonding structure extending toward the substrate. In this way, the adhesion strength between the vertical conductive connector and the adjacent components can be enhanced, thereby effectively improving product reliability.
In order to make the above-mentioned features and advantages of the disclosure clearer and easier to understand, the following embodiments are given and described in details with accompanying drawings as follows.
In the following detailed description, for the purpose of explanation and not limitation, exemplary embodiments revealing specific details are set forth to provide a thorough understanding of the various principles of the disclosure. However, it will be clear to those skilled in the art that, thanks to the disclosure, the disclosure can be implemented in other embodiments that depart from the specific details disclosed herein. In addition, descriptions of commonly known devices, methods, and materials may be omitted so as to clearly describe the various principles of the disclosure.
The disclosure is more fully described with reference to the drawings of the embodiments. However, the disclosure may be embodied in various forms and should not be construed as being limited to the embodiments described herein. The thickness, dimensions or size of layer or region in the drawings may be exaggerated for clarity. The same or similar reference numbers are used to denote the same or similar elements, and will not be repeatedly described in the following paragraphs.
The aforementioned and other technical contents, features and effects of the disclosure will be clearly presented in the following detailed description of each embodiment with reference to the drawings. Directional terms mentioned in the following embodiments, such as “up”, “down”, “front”, “back”, “left”, “right”, merely refer to directions in the accompanying drawings. Accordingly, the directional terms are used to illustrate rather than to limit the disclosure.
Unless expressly stated otherwise, any method described herein should not be construed as requiring to perform the steps in a particular order.
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For example, a material of the substrate 110 includes glass, ceramic, liquid crystal polymer (LPC) or a combination thereof, but the disclosure is not limited thereto. The material of the substrate 110 can also be made of other suitable heat-resistant inorganic compounds and/or organic compounds.
In some embodiments, a thickness 110T of the substrate 110 is between 0.05 millimeters (mm) and 10 mm, but the disclosure is not limited thereto. The thickness 110T of the substrate 110 can be selected according to actual design requirements.
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In some embodiments, a diameter 111D of the through hole 111 is between 0.05 mm and 0.5 mm, but the disclosure is not limited thereto. The diameter 111D of the through hole 111 can be determined according to actual design requirements.
In the embodiment, a seed layer composed of titanium, copper, palladium or similar metal materials is not formed on the through holes 111, the upper surface 110a of the substrate 110, and the lower surface 110b of the substrate 110.
In some embodiments, when the material of the substrate 110 is glass, since the surface roughness of the glass is low (for example, Ra<1 nanometer (nm)), it is difficult for the seed layer to be deposited thereon (whether using sputtered titanium/copper formed by a dry process or nanopalladium formed by a wet process, etc.), thus resulting in uneven deposition of the seed layer, such that the tensile force of the seed layer is reduced (such as the tensile force of sputtered titanium/copper is <0.3 (kg/cm)), and the adhesion strength cannot be effectively improved between the subsequent vertical conductive connector and the adjacent components thereof. Based on this, the formation of such a film layer can be omitted in the embodiment, and when such a film layer is omitted, the technical effect of improving the adhesion strength between the vertical conductive connector and the adjacent components thereof can still be achieved, but the disclosure is not limited thereto.
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In some embodiments, a thickness 121T of the conductive layer 121 is between 2 microns and 100 microns (such as 3 microns), and therefore can be regarded as a thin metal layer. At this thickness, defects (such as holes) are more likely to occur during use, so the conductive layer 121 can be further bonded to a carrier layer 122. A thickness 122T of the carrier layer 122 is between 1 micron and 25 microns (such as 18 microns). Therefore, the carrier layer 122 can reduce the probability of defects in the conductive layer 121 during the manufacturing process, but the disclosure is not limited thereto. Here, the conductive layer 121 and the carrier layer 122 can be bonded together through a release layer (not shown) to reduce the difficulty of subsequent removal of the carrier layer 122.
In some embodiments, a material of the conductive layer 121 includes copper or the like, a material of the carrier layer 122 includes copper or the like, and the adhesive layer 130 includes polyimide or the like, but the disclosure is not limited thereto.
In some embodiments, in order to improve the adhesion between the adhesive layer 130, the conductive layer 121, and the carrier layer 122, a lamination process may optionally be further used.
In some embodiments, a thickness 130T of the adhesive layer 130 is between 1 nanometer and 50 microns, but the disclosure is not limited thereto. The thickness 130T of the adhesive layer 130 can be determined according to actual design requirements.
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In the embodiment, since no seed layer is formed in the through hole 111, the vertical conductive connector 140 is physically connected to the substrate 110. In other words, the vertical conductive connector 140 can be in direct contact with the substrate 110.
In some embodiments, when the vertical conductive connector is formed through the seed layer, a larger thickness (for example, a thickness greater than 60 micrometers (μm)) is required to fully plate the metal in the through hole, and in this case it is difficult for substrate wirings to achieve thin lines with a line width/line spacing (L/S) less than 16/16 μm. However, through the method provided in the embodiment, the aforementioned problems can be overcome, and it is easier to meet the requirements of thin lines.
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In some embodiments, a maximum extension distance of the bonding structure 141 is between 0.1 nm and 100 nm, but the disclosure is not limited thereto. The extension distance of the bonding structure 141 will correspond to the process temperature and execution time of the annealing process.
In some embodiments, the annealing process is performed in nitrogen (N2) or other suitable ovens. The execution time is 30 minutes or greater (for example, between 30 minutes and 90 minutes), and the process temperature is 300° C. or greater (for example, between 300° C. min. and 600° C. min.), so that the first atoms can be diffused out reliably. However, the disclosure is not limited thereto. The parameter setting of the annealing process can be determined according to actual design requirements.
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After the above process, the production of the substrate structure 100 provided by the embodiment can be substantially completed. In the embodiment, the substrate structure 100 includes the substrate 110 and the vertical conductive connector 140 penetrating through the substrate 110. The vertical conductive connector 140 has the bonding structure 141 (formed by the annealing process) extending toward the substrate 110. In this way, the adhesion strength between the vertical conductive connector 140 and the adjacent substrate 110 can be enhanced, thereby effectively improving product reliability.
It must be noted here that the reference numerals and a part of the contents in the previous embodiment are applicable to the following embodiments, in which identical or similar reference numerals indicate identical or similar elements, and repeated descriptions of the same technical contents are omitted. For the detailed descriptions of the omitted parts, reference can be found in the previous embodiments, and no repeated description is contained in the following embodiments.
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In some embodiments, a material of the buffer layer 270 includes metal oxide (such as titanium oxide, zinc oxide, aluminum oxide, silicon oxide, or the like), metal (such as titanium), or a combination thereof, but the disclosure is not limited thereto.
In some embodiments, the buffer layer 270 may surround an outer surface of the substrate 110, so that no surface of the substrate 110 is exposed, but the disclosure is not limited thereto.
In an embodiment not shown, the buffer layer may have a multi-layer structure. For example, a titanium oxide layer may be formed first and then a titanium layer, but the disclosure is not limited thereto.
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For example, in the embodiment, the annealing process is introduced so that the first atoms of the vertical conductive connector 140 and the second atoms in the buffer layer 270 produce an atomic diffusion phenomenon toward the substrate 110. That is, as shown in the enlarged portion of
In some embodiments, the annealing process is performed in nitrogen or other suitable ovens. The execution time is 30 minutes or greater (for example, between 30 minutes and 90 minutes), and the process temperature is 300° C. or greater (for example, between 300° C. min. and 600° C. min.), so that the first atoms and the second atoms can be diffused out reliably.
In some embodiments, a maximum extension distance of the bonding structure 271 is between 0.1 nm and 100 nm, but the disclosure is not limited thereto. The extension distance of the bonding structure 271 will correspond to the process temperature and execution time of the annealing process.
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For example, the insulating layer 380 can fully cover and directly contact the upper surface 110a and the lower surface 110b of the substrate 110 and the top surface 140a and the bottom surface 140b of the vertical conductive connector 140, but the disclosure is not limited thereto.
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In some embodiments, the bottom of the opening of the insulating layer 380 may be further cleaned, such as through a de-smear process or a plasma process, so that the vertical conductive connector 140 is more reliably exposed, but the disclosure is not limited thereto.
In the embodiment, the circuit layer 160 formed on the insulating layer 380 can penetrate through the insulating layer 380 to be in direct contact with and electrically connected to the vertical conductive connector 140. That is, the insulating layer 380 is located between the circuit layer 160 and the substrate 110, and the circuit layer 160 is only in direct contact with the vertical conductive connector 140, so that the circuit layer 160 is not in direct contact with the substrate 110.
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To sum up, the disclosure introduces the annealing process to diffuse the atoms in the vertical conductive connector to form the bonding structure extending toward the substrate. In this way, the adhesion strength between the vertical conductive connector and the adjacent components can be enhanced, which can effectively improve product reliability.
Although the disclosure has been described with reference to the embodiments above, the embodiments are not intended to limit the disclosure. Any person skilled in the art can make some changes and modifications without departing from the spirit and scope of the disclosure. Therefore, the scope of the disclosure will be defined in the appended claims.
Number | Date | Country | Kind |
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113112493 | Apr 2024 | TW | national |
This application claims the priority benefit of U.S. provisional application Ser. No. 63/609,882, filed on Dec. 14, 2023, and Taiwan application serial no. 113112493, filed on Apr. 2, 2024. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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63609882 | Dec 2023 | US |