Patent Application
20100044853
The present invention relates to a system-in package and to a method for a fabricating a system-in-package.
US 2002/0084513 A1 describes an assembly of a wafer and an external substrate in the form of a chip or a printed circuit board. The wafer comprises transistors. The external substrate is contacted using a contact structure. For fabricating the contact structure, a trench is fabricated in the wafer by reactive ion etching (RIE) and filled with an insulation layer of BPSG or silicon dioxide, with an electrically conductive layer that allows a later soldering to an external substrate, and, adjacent to the electrically conductive layer, a tungsten core. Subsequently, the wafer is thinned from its backside such that the filling of the hole protrudes from the wafer backside considerably, in a manner that allows using the contact structure as a bump. The insulation layer is therefore partly removed in this step to allow establishing an electrical contact between a contact element of the external substrate and the contact structure.
According to a first aspect of the invention, a system-in-package is provided, comprising:
an integration substrate with a thickness of less than 100 micrometer and including a first plurality of through-substrate vias, which have an electrically conductive via core and an aspect ratio larger than 5, and which are configured to electrically connect a first conductive element on the first integration-substrate side with a second conductive element on the second integration-substrate side;
a support, which is attached to the integration substrate on its first integration-substrate side and which is suitable for mechanically supporting the integration substrate; and
a first chip, which is attached and electrically connected to the integration substrate either on its first integration-substrate side, where it is either arranged between the integration substrate and the support or where it forms the support, or
a second chip, which is attached and electrically connected to the integration substrate on its second integration-substrate side.
The system-in-package of the present invention has through-substrate vias in an integration substrate, which has a thickness of 100 micrometer or less. This implies that there is no lateral region, where the integration substrate as such has a thickness of more than 100 micrometer. For the purpose of definition of the thickness of the integration substrate, only the substrate material or wafer material of the integration substrate is considered, and not additional layers or structures deposited on this material on either of the integration-substrate sides. For a through-substrate via typically connects at least one first electrically conductive element on a first integration-substrate side with at least one second electrically conductive element on a second integration-substrate side. Where the conductive elements are formed of layers deposited on the integration substrate, such as metallization layers, their thickness shall not count under the present definition. Nor does the thickness include an extension of solder balls or bumps that can be present on one of the integration-substrate sides, for the purpose of the present definition.
In the system-in-package of the present invention, the through-substrate vias have an aspect ratio larger than five. The aspect ratio of a through-substrate via is the quotient of a depth extension of the through-substrate via between its ends on the first and second integration-substrate sides, and of a lateral extension of the trench that is formed to fabricate the through-substrate in the integration substrate. The lateral extension generally refers to a distance between opposite via-substrate interfaces. The via-substrate interface corresponds to the walls of the original trench. In this context, the via insulation layer is considered a part of the through-substrate via. Therefore, in some embodiments via-substrate interface is formed by the interface between the insulation layer and integration substrate. The lateral trench extension can be derived from the finished integration substrate of the system-in-package, even after filling of the trench during further processing. Suitable analytic techniques are for instance known microscopic methods, like for instance optical microscopy or electron microscopy on a cross section of the integration substrate.
The lateral trench extension of a single trench may vary in the depth direction. For the purpose of definition, in such an embodiment the lateral trench extension shall be considered to be the mean value of the lateral trench extension over along the extension in depth direction.
The system-in-package therefore has through-substrate vias in the integration substrate, which in comparison with the vias of the cited prior art document are particularly short and, due to their high aspect ratio, at the same time have a particularly small lateral extension. In synergy, this combination of features provides a system-in-package that allows combining a very high integration density on the integration substrate with very low parasitic lead inductances of the vias. Both requirements are important for advanced high-frequency applications, like devices for radio-frequency (RF) applications. Both requirements can therefore now be met at the same time.
The inductance of the through-substrate vias scales in a superlinear manner with the length of the through-substrate vias, i.e., their extension in the depth direction, while its dependence on the aspect ratio is only sublinear. Therefore, even though a high integration density is achieved with relatively high aspect ratios of the through-substrate vias, which tends to increase the parasitic lead inductance for a given thickness of the integration substrate, the parasitic lead inductances of the through-substrate vias are at particularly low values. This synergy is achieved by the fabrication technology described herein, which allows providing the integration-substrate with a thickness below 100 micrometer. The low thickness of the integration substrate corresponds with the length of the through-substrate vias.
Integration substrates with a thickness below 100 micrometer bear a very high risk of breakage by the required processing during fabrication, especially during wafer-scale processing, or during dicing, or handling after fabrication, or operation. The present invention overcomes this problem and allows finally achieving the aforementioned advantages by providing a support, which is attached to the integration substrate on its first integration-substrate side and which is suitable for mechanically supporting the integration substrate. The term “suitable” with reference to the support implies a mechanical stability that withstands mechanical stress in an amount that would damage or break an integration substrate of less than 100 micrometer thickness during processing in fabrication, especially during wafer-scale processing, and during handling after fabrication, and during normal operation. The system-in-package of the present invention can thus be produced on wafer scale with good yield and lifetime according to industry standards.
In the following, embodiments of the system-in-package of the first aspect of the invention will be explained. Unless stated otherwise explicitly, the embodiments can be combined with each other.
First, different embodiments will be described that concern arrangements of the first and second chips.
In different alternative embodiments, the system-in-package has either only the first chip, or only the second chip, or both the first and the second chip.
The first chip is in one embodiment attached and electrically connected to the integration substrate on its first integration-substrate side, where it is arranged between the integration substrate and the support substrate. If the second chip is additionally attached and electrically connected to the integration substrate on its second integration-substrate side, a further increased integration density of electronic components contained in the system-in-package can be achieved. An electrical connection between the first and second chips or between components or conductive elements on either integration-substrate side and the chip on the other integration-substrate side can be provided by the through-substrate vias, where required for an application embodiment.
In the following, different embodiments will now be described that further elucidate the combination of integration-substrate thickness and aspect ratio of the through-wafer vias.
The aspect ratio of the through-substrate vias is in some embodiments between 5 and 25, and preferably between 15 and 25. These embodiments are particularly suitable for achieving a high integration density of components on the integration substrate.
Naturally, the depth extension of a through-substrate via is equal or approximately equal to the thickness of the integration substrate. For instance, in one embodiment the integration substrate of the finished system-in-package has a thickness of 40 micrometer, which approximately equals the extension of the through-substrate via in the depth direction. Small difference may result from the presence of additional layers on either the first or the second integration-substrate side.
The lateral extension of the through-substrate via is in some embodiments equal to that of the trench that is formed to fabricate the through-substrate via. In the given example, where the integration substrate has a thickness of 40 micrometer, the lateral extension of the through-substrate via has a value lower than 8 micrometer in any lateral direction, for instance between 8 and 2 micrometer, corresponding to an aspect ratio between 5 and 20.
Speaking of a thickness of 100 micrometer or less obviously does not mean to include the case that the integration substrate is removed completely, i.e., to zero thickness. A lower boundary for the thickness of the integration substrates depends on the particular requirements of an application of the system-in-package. In some embodiments, the thickness is between 10 and 80 micrometer. In some embodiments, the integration substrate has a thickness that just allows accommodating components, such as passive components like trench capacitors or inductors, which are integrated in it. Taking the example of an integration substrate with trench capacitors of 25 to 30 micrometer depth extension, a thickness of the integration substrate of 30 to 40 micrometer forms a lower thickness boundary for the case of this illustrative example. Thus, such embodiments have a thickness of the integration substrate between 30 and 100, 30 and 80, or 30 and 60 micrometer, depending, among other factors, on the depth of the trench capacitors used. In other embodiments, where no trench capacitors are present in the integration substrate, a thickness of only 15 or even less can be suitable. The integration substrate has in some embodiments a thickness between 15 and 40 Micrometer.
As will be described later in more detail when turning to the method aspects of the invention, the through-substrate vias are processed as trench structures in the integration substrate. The term trench structure, as used herein, refers to any suitable shape of recess that is formed in the integration substrate on its first integration-substrate side. A suitable trench structure for a through-substrate via, which is also referred to as a via trench or via trench structure herein, extends through the integration substrate after the processing of the method of the invention. The term trench structure or via trench is in other contexts also used to denote the respective structure after filling, as will be clear from the respective context of usage of the term.
The processing of the trench structures can be differentiated at some point during the processing according to their specific purpose in a desired application in advantageous processing embodiments of the method of the second aspect of the invention. This differentiation is reflected in the claim language by defining different pluralities of trench structures or through-substrate vias.
In one embodiment, a second plurality of trench structures is contained in the integrated substrate, which in comparison with the first plurality of through-substrate vias have smaller depth extensions. The second plurality of trench structures can for instance form trench capacitors.
In one embodiment, the trench capacitors are formed as pillar capacitors. Here, the trench structures have a ring shape, and an alternating layer sequence of conductive and insulating layers is deposited on a pillar or column defined by the trench. A combination of trench capacitors and pillar capacitors is also possible.
In a further embodiment, the system-in-package comprises at least one trench structure in the integration substrate, which has the same depth extension as the through-substrate vias. The at least one trench structure can be used for different functions in application devices, which will be explained by way of different examples in the following.
Such trench structures can for instance be used as electrically floating structures, which serve to electrically isolate components on the integration substrate. Thus, in one embodiment, a subset of the trench structures is formed of fully electrically isolated filled trench structures, and the integration substrate comprises at least one electrical component between a respective pair of neighboring fully electrically isolated filled trench structures. Also, such trench structures can be used to achieve an optical isolation of devices in different areas of the integration substrate.
In one embodiment, the trench structure or the plurality of trench structures forms a section of a cavity in the integration substrate. The cavity can for instance form a part of a micro-electro-mechanical system (MEMS) device on the first integration-substrate side and contain a resonating beam. During the fabrication of a free-standing MEMS device, the trench structure or trench structures can be used as a release trench or access channel for a cavity and/or structural elements of the MEMS device to be created or released by removal of a sacrificial layer through said access channel.
Other functions, for which the at least one trench structure can be used, comprise heat dissipation, grounding, lateral enclosure of a first portion of the integration substrate.
In some embodiments the through-substrate vias have a via-insulation layer, which is arranged to prevent a direct electrical connection between the via core and the integration substrate. This is useful where the integration substrate must be isolated from the via core for proper functioning of an application.
In some embodiments the through-substrate via has the shape of a “hollow” cylinder. This corresponds to a ring shape in a top view. Similar embodiments have a rectangular, quadratic, elliptical or oval ring shape in a top view. Note that the comparison with a “hollow” cylinder is not meant to necessarily imply that there is no material inside the cylinder walls in the present embodiment. In fact, the through-substrate vias are filled in some forms of this embodiment, for instance with the material of the integration substrate, or an insulator material, but with a material different from that of the walls of the “hollow” cylinder.
In fact, a ring-shaped through-substrate via can be used to electrically or optically isolate active or passive circuit elements or devices in the region of the integration substrate, which is arranged inside the ring. The ring-shaped through-substrate vias thus function as an isolation trench in some embodiments.
The fabrication of this useful structure is made possible by the presence of the support. For in the absence of a support, the integration-substrate region surrounded by this isolation trench could detach from the rest of the integration-substrate.
For the purpose of clarity of definition, in this embodiment the term lateral extension does not refer to the distance between outer walls of the hollow cylinder, i.e., the outer diameter of the hollow cylinder, but to the thickness of the wall of the hollow cylinder, i.e., the distance between an inner and an outer wall of the hollow cylinder in a radial direction.
In a further embodiment, a subset of the first plurality of through-substrate vias is electrically connected to a single contact element on the second integration substrate side. The contact element on the second integration-substrate side can for instance be a solder bump. Additionally, an under-bump metallization scheme can be present in some embodiments. Providing a subset of through-substrate vias for connection with the solder bump reduces the electrical resistance and also helps decreasing parasitic lead inductances. This can also be achieved by a through-substrate via that forms a hollow cylinder or a similar shape mentioned before as alternatives for the shape of the through-substrate vias.
Some embodiments comprise an opening in the integration substrate. The opening is open on the second integration substrate side. The opening can for instance be used under strip-lines or an inductor arranged on the first integration-substrate side, to improve the quality of the inductor. An alternative is the use of the opening for a filling with high-resistivity silicon. The opening is in one embodiment used to arrange a third chip therein. This further increases the integration density and variability of the system-in-package.
A second aspect of the invention is formed by a system-in-package that comprises:
an integration substrate with a thickness of less than 100 micrometer and including through-substrate vias that have an electrically conductive via core, of which through-substrate vias a first number are configured to electrically connect a first conductive element on the first integration-substrate side with a second conductive element on the second integration-substrate side, and of which through-substrate vias at least one second through-substrate via is configured to constitute a lateral enclosure for a first portion of the integration substrate;
a support, which is attached to the integration substrate on its first integration-substrate side and which is suitable for mechanically supporting the integration substrate; and
a first chip, which is attached and electrically connected to the integration substrate either on its first integration-substrate side, where it is either arranged between the integration substrate and the support or where it forms the support, or a second chip, which is attached and electrically connected to the integration substrate on its second integration-substrate side.
The system-in-package of the second aspect of the invention shares many of the advantages of the system-in-package of the first aspect of the invention. It has through-substrate vias that serve different functions. In particular, the at least one second through-substrate via is configured to constitute a lateral enclosure for a first portion of the integration substrate. An example of a suitable configuration of the at least one second through-substrate via is a ring-shaped through-substrate via. It can be used to electrically or optically isolate active or passive circuit elements or devices in the region of the integration substrate, which is arranged inside the ring. The ring-shaped through-substrate vias thus function as an isolation trench in some embodiments.
The fabrication of this useful structure is made possible by the presence of the support. For in the absence of a support, the integration-substrate region surrounded by this isolation trench could detach from the rest of the integration-substrate.
In one embodiment of the system-in-package the through-substrate vias are provided with an electrically insulating side wall, and the lateral enclosure is configured to electrically isolate the first portion of the integration substrate. In particular, the lateral enclosure can form at least a part of an electrical shield for a component in or on the first portion of the integration substrate.
Further embodiments of the system-in-package of the second aspect of the invention have additional features, which have been described for embodiments of the system-in-package of the first aspect of the invention.
According to a third aspect of the invention, a system-in-package is provided that comprises:
an integration substrate with a thickness of less than 100 micrometer and including a first plurality of through-substrate vias, that have an electrically conductive via core, of which vias a first plurality are configured to electrically connect a first conductive element on the first integration-substrate side with a second conductive element on the second integration-substrate side;
at least one access channel to a cavity that is defined at and/or on the first integration-substrate side, said access channel extending from the second integration-substrate side parallel to said through-substrate vias;
a support, which is attached to the integration substrate on its first integration-substrate side and which is suitable for mechanically supporting the integration substrate; and
a first chip, which is attached and electrically connected to the integration substrate on its first integration-substrate side, where it is either arranged between the integration substrate and the support or where it forms the support, or a second chip, which is attached and electrically connected to the integration substrate on its second integration-substrate side.
The system-in-package of the third aspect of the invention provides a platform for the fabrication of MEMS devices with cavities integrated into the integration substrate. Embodiments of the system-in-package of the third aspect of the invention have additional features, which have been described for embodiments of the system-in-package of the first aspect of the invention.
A fourth aspect of the invention is formed by a method for fabricating a system-in-package. The method comprises:
providing an integration substrate of a thickness, the integration substrate having a first integration-substrate side and a second integration-substrate side and trench structures, such that in the integration substrate of the finished system-in-package an aspect ratio of the through-substrate vias fabricated from the trench structures is larger than 5, a first plurality of which trench structures is provided with an electrically conductive via core;
attaching a support, which is suitable for mechanically supporting the integration substrate at a reduced integration-substrate thickness of less than 100 micrometer, to the integration substrate on its first integration substrate side;
reducing the thickness of the integration substrate from its second integration-substrate side to a thickness below 100 micrometer, such that only a bottom face of the via cores of the trench structures is exposed;
electrically connecting and attaching a first chip to the integration substrate on its first integration-substrate side, such that the first chip is arranged between the integration substrate and the support, or electrically connecting and attaching a second chip to the integration substrate on its second integration-substrate side.
The processing of the method of the invention comprises a thinning of the integration substrate to a thickness of less than 100 micrometer. Experience shows that thinning the integration substrate down to this range strongly increases the risk of substrate breakage during thinning, later processing or handling of the integration substrate.
This problem is not considered at all in US 2002/0084513 and limits the applicability of the method known from this document to an integration-substrate thickness well above 100 micrometer. In this thickness range, however, it is impossible with the processing techniques described in US 2002/0084513, namely, reactive ion etching, to fabricate through-substrate vias with an aspect ratio larger than 5.
This problem is overcome by the method of the present aspect of the invention by attaching a support to the integration substrate on its first integration substrate side. The support is suitable for mechanically supporting the integration substrate at a reduced integration-substrate thickness of less than 100 Micrometer. That means, it provides the mechanical stability required to avoid breakage during thinning, later processing, and handling of the integration substrate. Another advantage of the support is that it helps dealing with high thermo-mechanical stress in the field operation on the surface of an ultra thin substrate (lower than 100 μm), possibly inducing cracks in the substrate die.
This processing turns away from the concept of fabricating a single through-substrate via to function also as a solder bump. Instead, during processing, only a bottom face of the via cores via trench structures is exposed. This processing relaxes the requirements of mechanical stability against lateral stress applied to the through-substrate via and allows fabricating the through-substrate vias with a reduced lateral extension. This in turn allows increasing the integration density on the integration substrate, including a fabrication of a larger number of through-substrate vias without increasing area consumption on the integration substrate.
Therefore, not only can the integration density be driven to very high values, but also can parasitic lead inductances of the through-substrate vias be made very low.
In one embodiment, this is made possible without having to use though-wafer via holes with a conductive copper core. Instead, tungsten is used for the via core in this embodiment. Being able to avoid the use of copper is a great advantage in the present context. The use of copper would require the provision of a copper diffusion barrier in the via holes. From a processing point of view, this is undesirable. For at the moment, this can only be achieved using atomic layer deposition (ALD) equipment and therefore involves an extremely low deposition rate. This increases processing costs. Furthermore, copper processing and the processing of copper-containing integration substrates, such as silicon wafers, is usually also undesirable due to possible contaminations introduced by the presence of copper. Additionally, fully copper-filled via holes could pose a reliability risk due to differences in thermal-expansion coefficients in comparison with surrounding material, such as silicon. In contrast, being able to stay with established processing technology allows using for instance tungsten as a via core material. Tungsten can be deposited fast, for instance by chemical vapor deposition (CVD) or plasma-enhanced (PE)CVD.
Note that the above considerations shall not be understood as restricting the scope of the invention via plugs with materials other than copper in the via core. Copper does have advantages, for instance a high conductance. The extra cost of an introduction of Cu may well be outweighed by its advantages for a particular application in other embodiments.
The support is suitably an insulating substrate, such as a glass or silicon substrate, that is attached to the integration substrate prior to its thinning. Alternatively, the support may be an over-moulded encapsulation, for instance on the basis of an epoxy material, such as usually applied in packaging.
Another embodiment comprises the provision of the integration substrate with a temporary support on its second integration side. Thus, in one embodiment, providing the integration substrate comprises providing an integration-substrate assembly with the integration substrate having an integration-substrate thickness below 100 micrometer and a temporary support attached thereto. In this embodiment, the integration substrate has already been provided with the vias and has been thinned to a suitable thickness. This temporary support may be removed after the assembly of the chip on the first integration side and the provision of the support. Thus, reducing the thickness of the integration substrate from its second integration-substrate side to a thickness below 100 micrometer comprises removing the temporary support. The advantage hereof is that one need not perform etching and deposition steps after assembly. This reduces risks and is more in line with the usual division between front end and back end processing.
Note that the step of providing an integration substrate with a first electrically conductive element is in one embodiment to be understood as comprising a single step, in which an integration substrate is provided, which has a prefabricated first electrically conductive elements. However, the step of providing an integration substrate with a first electrically conductive element is in another embodiment to be understood as comprising a processing, in which the first electrically conductive element that is provided on the first integration-substrate side is fabricated during later processing, after any of the further steps comprised by the method of the first aspect of the invention. As an example for this latter processing, the first electrically conductive element can be fabricated after the formation of the trench structures. However, it must be fabricated before the step of attaching the support.
In one embodiment, fabricating the first plurality of trench structures is performed employing reactive ion etching (RIE). RIE has proven very useful in fabricating trench structures with lateral extensions, which are substantially reduced in comparison with standard through-substrate via holes as known from prior-art processing techniques. The disadvantage of these prior-art processing techniques is that the use of RIE makes the fabrication of through-substrate via holes with larger depth and lateral extensions a relatively slow and expensive process. The use of RIE in the context of the processing of the method of the first aspect of the invention, however, enables reducing the etching time as much as possible. For the depth and the lateral extensions of the trench structures are significantly reduced due to the decreased thickness of the integration substrate in the finished system-in-package, and due to the large aspect ratio of the through-substrate vias.
In some embodiments, trench structures for through-substrate vias and other trench structures, such as trench capacitors or isolation trenches, are fabricated in a single step, which typically is an RIE etching step. One particular embodiment comprises a fabrication of a second plurality of trench structures in the integration substrate with smaller depth extensions in comparison with the first plurality of trench structures, by reactive ion etching. The first and second plurality of trench structures are etched concurrently, and etching comprises forcing smaller lateral extensions for the second plurality of trench structures than for the first plurality of trench structures.
This embodiment makes use of the finding that RIE tends to etch wider trenches faster than narrower trenches. Therefore, this effect can be employed to create two depth levels of trenches in one etching step by forcing two different lateral extensions for the first and second pluralities of trench structures. The different lateral extensions can be forced for instance by providing suitable lateral extensions of mask openings for the etching step.
The second plurality of trench structures can for instance be used for fabricating trench capacitors in later processing steps. This is a particularly simple processing for such different structures. However, it should be noted that there is no requirement to fabricate trench structures for different purposes.
In a further embodiment, the thinning of the integration substrate comprises:
mechanically grinding the integration substrate from the second integration-substrate side to a thickness that just avoids exposure of the first plurality of trenches;
spin-etching the integration substrate using a first etching agent that leaves the via insulation layer intact;
removing a part of the via insulation layer by etching, using a second etching agent that leaves the via core intact.
This processing allows a very precise control of the material removal on the second integration-substrate side.
A particularly high integration density is achieved in the method of the invention by attaching a first chip on the first integration-substrate side of the integration substrate. The first chip on the first integration-substrate side is in the processing of the present invention preferably thinned before attaching the support. The thinning of the first chip makes adhesive bonding of a support substrate easier. A suitable thickness of the first chip after this thinning step is for instance 20 to 30 Micrometer. This thickness can for instance be achieved by grinding after attaching the first chip to the integration substrate. Attaching the first chip typically involves solder bumping of the first chip and an underfilling step.
In a further embodiment, attaching the support comprises:
depositing an adhesive layer that can be cured by irradiation with ultraviolet light on the first integration-substrate side;
positioning a support substrate on the adhesive layer;
irradiating the adhesive layer with ultraviolet light.
The use of an adhesive layer, which can be cured in UV light, avoids heating steps required for other adhesive materials, which could negatively affect the system-in-package. In this context, the use of glass as a support substrate is advantageous, because suitable glass materials can be chosen that are transparent to the UV irradiation used for curing the adhesive layer. An alternative to glass is wafer-level compression molding of epoxy resin.
In a further embodiment, a step of fabricating an opening in the integration substrate is performed. The opening is open on the second integration substrate side. The opening can for instance be used under an inductor or strip-lines to improve the quality of the inductor. An alternative is the use of the opening for a filling with high-resistivity silicon.
The opening can be fabricated by reactive ion etching. Preferably, the etching of the opening is performed at the end of the processing of the system-in-package, in order to keep the integration substrate planar as long as possible and to thus facilitate the processing.
The opening created this way may serve other purposes, such as for positioning a second chip within the opening. This way, a chip stacking on three levels is made possible.
A fifth aspect of the invention is formed by a method for manufacturing a system-in-package. The method comprises the following steps:
providing an integration substrate having a first integration-substrate side and a second integration-substrate side and a thickness and comprising a first plurality of trench structures and a second set of at least one trench structure, all of which trench structures are provided with an electrically conductive via core, of which the first plurality of trench structures is configured for a signal transmission function and of the which second set of trench structures is configured for another function, which is one of a heat dissipation, grounding, lateral enclosure of a first portion of the integration substrate, and constituting at least one access channel for a cavity to be created by removal of a sacrificial layer through said access channel;
attaching a support, which is suitable for mechanically supporting the integration substrate at a reduced integration-substrate thickness of less than 100 micrometer, to the integration substrate on its first integration substrate side;
reducing the thickness of the integration substrate from its second side to a thickness below 100 micrometer, such that only a bottom face of the via cores of the second plurality of trench structures is exposed; and
electrically connecting and attaching a first chip to the integration substrate on its first integration-substrate side, such that the first chip is arranged between the integration substrate and the support, or electrically connecting and attaching a second chip to the integration substrate on its second integration-substrate side.
The method forms a platform for integrating trench structures for many different application purposes in a unified processing scheme.
A seventh aspect of the invention is formed by an integration substrate including trenches that have an electrically conductive trench core, of which trenches a first plurality are electrically connected with a first conductive element on the first integration-substrate, and of which trenches at least one second trench is configured to constitute a lateral enclosure for a first portion of the integration substrate.
the integration substrate of this aspect of the invention forms an intermediate product of the processing of one of the method aspects of the invention.
Embodiments of the method of the fifth aspect of the invention comprise additional features of embodiments that have been described on the basis of the method of the fourth aspect of the invention.
Further preferred embodiments of the invention are defined in the dependent claims. It shall be understood that the method of the first aspect of the invention and the system-in-package of the second aspect of the invention have similar and/or identical preferred embodiments, as defined herein and in the dependent claims.
The invention will now be explained in more detail with reference to the drawings in which:
On the first integration-substrate side 104, a number of trenches has been fabricated at the processing stage shown in
In the capacitor area 118, three capacitor trenches 128, 130, and 132 have been formed. The number of capacitor trenches is of purely exemplary nature. Of course, also the lateral extension of the capacitor area is chosen here only for the purposes of graphical representation. It is understood that the lateral extension of the capacitor area 118 and the number of capacitor trenches is to be chosen according to the needs of a particular application. The fabrication method described here does not impose limits on the lateral extension or the number of capacitor trenches.
The through-wafer via array 124 is shown to have four via trenches 134, 136, 138, and 140. The number of via trenches and the lateral extension of the through-wafer via array are of purely exemplary nature.
In the present embodiment, the integration substrate 102 is formed by a silicon wafer. However, this is not a necessary requirement. Other substrate materials can be used as well for the integration substrate 102. Suitable examples are for instance InP, GaN, AlN, Glass, GaAs, etc. In one embodiment of a processing method, all trenches provided at the present processing stage have been fabricated in one reactive ion etching (RIE) process. This processing makes use of the fact that in a RIE process like the Bosch process wider trenches tend to be etched faster than narrower trenches. It is thus achieved that two different depths d1 and d2 of trenches can be fabricated in one etching step by using two different trench widths. For instance, suitable etching conditions can be found to achieve a trench depth d2 of 27 μm with a trench width of 1.5 μm, while a trench width of 5.0 μm can be used to achieve a trench depth d1 of 47 μm. However, the trenches may in an alternative embodiment be etched separately, for instance in view of process control requirements. As a further alternative, the trenches may be etched partially simultaneously, for instance by etching the isolation trenches 108, 110, 116, and 122, as well as the via trenches 134 to 140 to a certain depth in a first step, using an auxiliary masking layer. In a second step, the etching of the isolation trenches and the via trenches is continued and at the same time the capacitor trenches 128 to 132 are etched, after removing the auxiliary masking layer.
In a subsequent processing stage, which is shown in
Subsequently, as shown in
The silicon nitride layer 146 is used as a mask during a subsequent thermal oxidation step, in which the exposed polysilicon-layer regions, which are not covered by the silicon nitride layer 146, are oxidized outside the capacitor area 118. In this “LOCOS style” oxidation step, an oxide layer 148 of approximately 1 to 1.5 μm thickness is formed, cf.
Subsequently, as shown in
In a subsequent processing step, the result of which is shown in
The patterning of the dielectric layer 166 allows contacting the capacitor trenches 128 to 132 and the via trenches 134 to 140 with an electrically conductive contact structure 168 and 170, respectively. Note that in an embodiment not shown here, some of the tungsten via cores 134 to 140 may be kept floating. Such trenches can be used to electrically isolate the different components in the process.
Subsequently, after the deposition of the first metal layer comprising the contacts 168 and 170, the fabrication of an interconnect stack 172 proceeds in a well-known manner. The interconnect stack 172 is schematically represented in
Subsequently, as is shown in
The thickness h of the chip 179 is reduced by grinding to approximately 20 to 30 μm before attaching it to the substrate. Providing an underfilling of the chip 179 makes it easier to attach a support substrate in a subsequent step. The chip may form or contain a passive device, a sensor, an actuator, an optoelectronic device, a microlens, or integrated circuitry, in which case it is referred to as an active die. The chip 179 may be made from silicon or other substrate materials, as mentioned before for the integration substrate, i.e. InP, GaN, AlN, Glass, GaAs, to name examples.
In the context of the attachment of the chip 179 on the integration substrate 102, use can be made of a self-aligning action of solder bumps. When the solder becomes liquid, surface tensions will cause an exact adjustment of a chip over the apposing contacts (bond pads). This effect becomes stronger if the number of bond pads increases. In principal, Micrometer-accurate alignment is possible this way.
Subsequently, as shown in
An alternative suitable support can be provided in the form of an over-mould, for instances an epoxy over-mould. It should be noted that the reduced thickness of the chip 179 makes it easier to attach the support substrate 184 in an adhesive waver bonding process.
Subsequently, the integration substrate 102 is thinned, for instance by mechanical grinding to a thickness, at which the deepest trenches, which are the isolation trenches 108, 110, 116 and 122 and the via trenches 134, 136, 138, und 140 are not exposed on the backside 106 of the integration substrate 102. Note that the cross-sectional view of the present Figs. leaves some ambiguity with respect to the lateral structure of the isolation trenches, which in fact reflects different embodiments. Reference labels 108, 110 refer in one embodiment to separate isolation trenches. In another embodiment with the same cross-sectional view, reference labels 108 and point to different sides of a single, coherent, ring-shaped or, in other words, annular isolation trench. The same holds for the reference labels 110 and 116, which in one embodiment can be configured in annular shape, as seen in a top view. Of course, the shape can also have a rectangular outline, which would make it possible to combine two closed isolation trenches shown under reference labels 108, 110, and 116, which share the section 110.
It is suitable to leave a distance y of approximately 20 micrometer between the bottom of the deeper trenches and the backside surface 106 of the integration substrate.
Subsequently, as shown in
In a subsequent processing step, the result of which is shown in
Subsequently, as shown in
In a subsequent step, a recess 196 is formed in the integration substrate 102 underneath the inductor area 112. The recess 196 can for instances be formed by removing some integration-substrate material in a deep RIE process, for instance using a Bosch process. Note that in comparison with known processing techniques, the etching step has been postponed to the end of the processing. This allows keeping the integration substrate 102 planar as long as possible and facilitates the processing.
Instead of forming the recess 196, an alternative choice is to use a high-resistivity silicon integration substrate 102. However, high-resistivity silicon substrates are expensive.
After stripping a resist layer 197 used during the RIE process, a backside chip 198 is attached to the integration substrate 102 by solder bumping to the solder bumps 194. Furthermore, solder bumps 199 are placed on the backside 106 of the integration substrate 102, thus enabling an electrical contact between circuit elements on the front side 104 of the integration substrate, circuit elements on the chip 179 on the front side of the integration substrate, circuit elements on the backside chip 200, and an external substrate, such as for instances a printed circuit board.
The described processing has the advantages that no through-substrate hole etching is required. The through-wafer via holes and the trench capacitors are etched in a single etching step. The use of copper as a trench filling or via core material can be avoided. This is due to the fact that the vias can be formed by a deep RIE process with subsequent filling of the substrate. Therefore, a standard tungsten filling can be used. The system in package of
Note that in the process described a glass substrate is used as a support substrate. In many aspects, glass is convenient for this application. It is cheap, available with wafer size, isolating, and transparent, thus also allowing a UV curing. However, glass is not the only suitable support substrate. Other support substrates may be used such as silicon wafers, GaAs-wafers, ceramic or polymer substrates. Additionally, a molding technique may be used to form the support. Epoxy moulds are widely used in the integrated circuits industry, and silicon filling, a thermal expansion approaching that of silicon may be realized. The support substrate is in some embodiments removed, for instances by using thermal or UV releasing adhesives or tapes.
The present embodiment serves to illustrate the suitability of the processing of the invention for the fabrication of a MEMS device. In principle, the processing is applicable to any free standing MEMS device. For the purpose of illustration, the present embodiment uses a simple resonating-beam device, in order to keep the structural detail in the figures as simple as possible.
The processing of the system-in-package 200 starts with the fabrication of an integration substrate 202 in a manner, which is similar to that described in the context of the
An array 206 of trenches contains trenches 206.1 to 206.4, which shall serve as through-substrate vias. Note, for simplicity, the through-substrate vias will be given the same reference labels as the trenches of the present processing stage.
Furthermore, the integration substrate 202 contains a release-trench array 208 with release trenches 208.1 to 208.4.
As can be seen in
Subsequently, in-situ doped poly-silicone was deposited in the trenches and on a first integration substrate side 210, followed by a LPCVD deposition of Si3N4 and patterning by wet etching. A subsequent “LOCOS”-type oxidation of the poly-silicon and a wet etching of the Si3N4 layer resulted in a trench isolation layer 212 of thermal silicon dioxide, which extends in all trenches and on sections of the first integration-substrate side 210, as can be seen in
The trenches were then filled with tungsten by CVD, followed by a tungsten back-etch resulting in tungsten trench fillings present in all trenches shown in
The dielectric layer 216 and the underlying oxide layer 212 were then patterned in preparation of the particular structure required by a specific MEMS structure 218, which in the present example is a resonating-beam device. Then, poly-silicon was deposited and patterned to form a resonating beam 220. Then, an upper release isolation layer 222 was deposited and structured. The upper release isolation layer 222 is in one embodiment a second TEOS layer. Then, an etch-stop layer 224 was deposited and structured. The etch-stop layer 224 is in one embodiment made of silicon nitride and deposited using low-pressure (LP)CVD. A galvanic contact 226 and a capacitor contact 228 were then formed. The galvanic contact 226 is in direct contact with the resonating beam 220, while the capacitive contact 228 is separated from the resonating beam by the upper release isolation layer 222 at the processing stage shown in
The device structure of the MEMS device 218 was finished by standard backend processing, which is not described herein further detail. At the processing stage shown in
The further processing of the device will in the following be described with reference to
A first chip 240 comprising integrated circuits useful for the operation of the device is attached and electrically connected to the integration substrate 202 on its first integration-substrate side 210 by means of solder bumps 242 to 246, and an underfill 248. The active die 240 is thinned to a thickness of 20 to 30 μm.
After thinning of the first chip 240, a glass support substrate 250 is attached to the integration substrate 202. The glass substrate 250 can be glued to the integration substrate 202 by means of an adhesive layer 252. Suitably, a top-side-down gluing method is performed as an alternative to this support structure an epoxy over-mold can be applied on the first integration-substrate side. Note that the processing has been performed on a wafer level, and not on the individual chips.
In a next step, the integration substrate 202 is thinned from its second integration substrate side 254. The details of the thinning step have been described in the context of the previous embodiment with reference to
Turning now to
Precise alignment of the release trenches 208.1 to 208.4 is a critical issue at this step. As can be seen from
Returning to the processing stage of
After this, as can be seen in
The structure is then dried, for instance by critical-point drying, and the access and release trenches are sealed on the second integration substrate side 254 with a resist plug 258 (
As has been described in the context of the first embodiment, the exposed bottom sections of the trench isolation layers are then removed by wet etching, as can be seen in
The processing described allows the fabrication of systems-in-package on a wafer scale. The systems-in-package contain vacuum-sealed cavities, namely, the release trenches 208. The processing allows using front-end processing steps. Regarding the release etch performed in the described processing, it should be considered that a release etch from the second integration-substrate side, which was also referred to as the backside of the wafer herein above, should be left intact and that only the access trenches 256.1 and 256.4 are used for the release etch.
In a subsequent processing step, a support substrate 334 is attached to the integration substrate 302 on its first integration-substrate side by means of an adhesive layer 336. As before, a molding forms an alternative embodiment. The substrate is subsequently thinned on its second integration-substrate side 338 by the two-step processing described earlier. In the processing stage shown in
In a subsequent processing step, the result of which is shown in
A deep reactive ion etching of integration-substrate material is then performed in the opening 344 of the resist layer 342 to fabricate an integration-substrate opening 346. The deep RIE process stops on the trench isolation layer 312, which is typically a silicon dioxide layer, and on the contacts 322 and 324, which may for instance be made from aluminum. The resist layer 342 is then removed to reach the intermediate processing stage shown in
After that, an under-bump metallization 348 is applied to the backside metallization contacts and to the contacts 322 and 324. Here, a suitable electrodeless process can be used.
In a subsequent processing step, a second chip 350 is arranged and attached to the integration substrate in the opening 346. The second chip is connected with the integration substrate electrically by means of the contacts 322 and 324. An underfill 352 is provided between the second chip 350 and the sidewalls of the opening 346 of the integration substrate 302. Finally, a third chip 354 is attached and electrically connected to the integration substrate 302. In the present embodiment, the second chip is arranged to cover the opening 346 that contains the second chip 350. Note that instead of the third chip 354, an optical element such an active optical element like a light-emitting diode, or a passive optical element, such as a lens may be arranged on the second integration-substrate side 338.
In addition, solder balls 356 and 358 are fabricated, finishing the processing of the present embodiment.
The system-in-package 300 of
Furthermore, the present embodiment allows a very high level of integration of integrated circuits by enabling the provision of chips, which are connected with the integration substrate 302, on three different levels.
In case it is not desired that the dry etch should end on the metal contacts 322 and 324, additional layers may be used to device an alternative self-aligned procedure, which was earlier described in U.S. Pat. No. 5,504,036.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.
For instance, the combination of the aspect ratio of the through-substrate vias and of the thickness of the integration substrate is in some embodiments optimized according to the requirements of the specific application with regard to integration density and lead inductance. Increasing the integration density on the integration substrate includes the possibility of providing a larger number of through-substrate vias at different positions, without increasing area consumption on the integration substrate. Having through-substrate vias distributed over the integration substrate allows reducing the length of conductive lines leading to and from the through-substrate vias. Where a particularly low resistance of a through-substrate via is required, several individual through-substrate vias can be electrically connected and used in parallel.
Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.
In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.
Any reference signs in the claims should not be construed as limiting the scope.
| Number | Date | Country | Kind |
|---|---|---|---|
| 07100658.9 | Jan 2007 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB2008/050115 | 1/14/2008 | WO | 00 | 7/14/2009 |
