This application is based upon and claims priority to Japanese Patent Application No. 2023-144376, filed on Sep. 6, 2023, the entire contents of which are incorporated herein by reference.
A certain aspect of the embodiment discussed herein is related to wiring substrates and semiconductor devices.
As semiconductor elements are becoming increasingly more functional, the pitch of electrodes in semiconductor elements is becoming narrower, so that the pitch of protruding electrodes to connect to semiconductor elements is required to be narrower in wiring substrates on which semiconductor elements are mountable (see, for example, Japanese Patent No. 6, 608,108).
According to an aspect, a wiring substrate includes an insulating layer and a protruding electrode. The insulating layer has a recess formed in the upper surface of the insulating layer. The protruding electrode is partly buried in the insulating layer to protrude in the recess. The width of the protruding electrode is constant in a sectional view of the protruding electrode. The upper surface of the protruding electrode is positioned lower than the upper surface of the insulating layer.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and not restrictive of the invention, as claimed.
As the pitch of protruding electrodes becomes narrower, adjacent protruding electrodes are more likely to be short-circuited when the protruding electrodes are connected to semiconductor elements.
According to an embodiment, a wiring substrate in which adjacent protruding electrodes are less likely to be short-circuited is provided.
One or more embodiments of the present invention are explained below with reference to the accompanying drawings. In the following, the same elements or configurations are referred to using the same reference numerals, and description thereof may be omitted.
According to this embodiment, for convenience of description, the insulating layer 17 side of the wiring substrate 1 is referred to “upper side”, and the insulating layer 11 side of the wiring substrate 1 is referred to as “lower side.” Furthermore, with respect to each part or element of the wiring substrate 1, a surface on the insulating layer 17 side is referred to as “upper surface” and a surface on the insulating layer 11 side is referred to as “lower surface.” The wiring substrate 1, however, may be used in an inverted position or oriented at any angle. Furthermore, a plan view refers to a view of an object taken in a direction normal to the upper surface of the insulating layer 17, and a planar shape refers to the shape of an object as viewed in a direction normal to the upper surface of the insulating layer 17.
The insulating layer 11 is, for example, an insulating layer that may be formed, using a build-up process, as an interlayer insulating layer for multilayer wiring. Accordingly, other wiring layers and other insulating layers may be stacked as underlayers of the insulating layer 11. In this case, via holes may be suitably provided in the insulating layer 11 and other insulating layers, and wiring layers may be connected via the via holes.
Examples of materials that may be used for the insulating layer 11 include non-photosensitive (thermosetting) epoxy insulating resins and polyimide insulating resins. Examples of materials that may be used for the insulating layer 11 may further include photosensitive epoxy resins and acrylic insulating resins. The thickness of the insulating layer 11 may be, for example, approximately 20 μm to approximately 40 μm. The insulating layer 11 may also include filler such as silica (SiO2).
The wiring layer 12 is formed on the insulating layer 11. The wiring layer 12 may have a structure in which an electroplating layer 12b is stacked on a seed layer 12a, for example. The seed layer 12a is, for example, a copper (Cu) layer of approximately 100 nm to approximately 350 nm in thickness. As the seed layer 12a, a laminate film in which a copper layer of approximately 100 nm to approximately 300 nm in thickness is stacked on a titanium layer of approximately 20 nm to approximately 50 nm in thickness may also be used. The electroplating layer 12b is, for example, a copper layer of approximately 10 μm to approximately 20 μm in thickness. Because the seed layer 12a is extremely thin, the thickness of the electroplating layer 12b may be regarded as the thickness of the entirety of the wiring layer 12.
The protruding electrodes 13, which may be hereinafter collectively referred to as “protruding electrode 13” where no distinction is made between the protruding electrodes 13, are formed in part of the upper surface of the wiring layer 12. The protruding electrode 13 may include a first metal layer 14, a second metal layer 15, and a third metal layer 16. The first metal layer 14 is stacked on the upper surface of the wiring layer 12. The second metal layer 15 is stacked on the upper surface of the first metal layer 14 without extending onto a side surface 14s of the first metal layer 14. That is, while the upper surface of the first metal layer 14 is covered with the second metal layer 15, the side surface 14s of the first metal layer 14 is not covered by and is exposed from the second metal layer 15. The third metal layer 16 is stacked on the upper surface of the second metal layer 15 without extending onto a side surface 15s of the second metal layer 15. That is, while the upper surface of the second metal layer 15 is covered with the third metal layer 16, the side surface 15s of the second metal layer 15 is not covered by and is exposed from the third metal layer 16.
The protruding electrode 13 may be formed of only the first metal layer 14 or may be formed of only the first metal layer 14 and the second metal layer 15.
The first metal layer 14 is, for example, a copper layer. The thickness of the first metal layer 14 is, for example, approximately 5 μm to approximately 10 μm. The second metal layer 15 is, for example, a nickel layer. The thickness of the second metal layer 15 is, for example, approximately 0.1 μm to approximately 3 μm. The third metal layer 16 includes, for example, a gold (Au) layer. The third metal layer 16 may be formed of only a gold layer or may be formed of a gold layer and a palladium (Pd) layer stacked on the gold layer. The thickness of the third metal layer 16 is, for example, approximately 0.01 μm to approximately 0.1 μm.
The insulating layer 17 is stacked on the upper surface of the insulating layer 11 to cover the upper surface and the side surface of the wiring layer 12 and part of the side surface of the protruding electrode 13. Recesses 17x, which may be hereinafter collectively referred to as “recess 17x” where no distinction is made between the recesses 17x, are formed in an upper surface 17u of the insulating layer 17 to have respective openings at the upper surface 17u of the insulating layer 17. In a sectional view, the joint of the side and the bottom of the recess 17x may be curved or rounded as illustrated in
The protruding electrode 13 includes a part buried in the insulating layer 17 and the part protruding into the recess 17x. According to this embodiment, a lower part of the first metal layer 14 of the protruding electrode 13 is buried in the insulating layer 17, and an upper part of the first metal layer 14, the second metal layer 15, and the third metal layer 16 protrude into the recess 17x.
The protruding electrode 13 is, for example, cylindrical. In a sectional view of the protruding electrode 13 (for example, taken along a plane perpendicular to the upper surface 17u of the insulating layer 17), a width W1 of the part protruding in the recess 17x is equal to a width W2 of the part buried in the insulating layer 17. Here, being equal means that the larger is less than or equal to 1.1 times the smaller of the width W1 and the width W2. An upper surface 13u of the protruding electrode 13 is positioned lower than the upper surface 17u of the insulating layer 17. That is, the upper surface 13u of the protruding electrode 13 is closer to the bottom of the recess 17x than is the upper surface 17u of the insulating layer 17. According to this embodiment, the upper surface 13u of the protruding electrode 13 is the upper surface of the third metal layer 16. An interval L1 between the adjacent protruding electrodes 13 may be, for example, approximately 5 μm to approximately 30 μm.
Next, a method of manufacturing a wiring substrate according to this embodiment is described.
First, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
The recesses 17x may be, for example, circular in a plan view. Part of the protruding electrode 13 is exposed in each recess 17x. Specifically, a lower part of the first metal layer 14 is buried in the insulating layer 17, and an upper part of the first metal layer 14, the second metal layer 15, and the third metal layer 16 protrude in the recesses 17x. The insulating layer 17 is thinner than in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
Next, in the process illustrated in
According to the wiring substrate of the comparative example, with respect to each protruding electrode 13A, the part protruding in the corresponding recess 17x is wider than the part buried in the insulating layer 17 in a sectional view. According to the wiring substrate of the comparative example, with respect to the protruding electrodes 13A, while the interval between their respective parts covered with the insulating layer 17 is L2, the interval between their respective parts protruding in the recesses 17x is L3. That is, while the interval between the protruding electrodes 13A by design is L2, the actual interval between the protruding electrodes 13A is L3, which is smaller than the design value. Therefore, the adjacent protruding electrodes 13A may be short-circuited when a semiconductor element is connected to the protruding electrodes 13A. This is explained in detail below.
A process of connecting a semiconductor element to protruding electrodes is, for example, as illustrated in
Next, in the process illustrated in
In contrast, according to the wiring substrate 1, as illustrated in, for example,
That is, according to the wiring substrate 1, the interval L1 between the adjacent protruding electrodes 13 is never smaller than the design value. Therefore, in the case of joining the protruding electrodes 13 and the electrodes 32 of the semiconductor element 30 together in the same manner as illustrated in
As described above, according to the wiring substrate 1, each protruding electrode 13 has a constant width and includes no part that would reduce the interval between the adjacent protruding electrodes 13. Therefore, the joining parts 20 are unlikely to overflow to short-circuit the adjacent protruding electrodes 13.
Furthermore, the second metal layer 15 and the third metal layer 16, which have good solder wettability, are formed only on the upper surface and not on the side surface 14s of the first metal layer 14. Therefore, the joining parts 20 are more likely to be formed on the second metal layer 15 and the third metal layer 16 with good solder wettability and are less likely to be formed on the side surface 14s of the first metal layer 14. Therefore, the joining parts 20 are less likely to laterally extend. In particular, when the side surface 14s of the first metal layer 14 is oxidized, the joining parts 20 are less likely to be formed. Because it is possible to prevent the joining parts 20 from flowing into the recesses 17x, the joining parts 20 are more likely to be kept constant in height.
Furthermore, the recesses 17x are formed to be so deep as to expose part of the side surface 14s of the first metal layer 14. Therefore, even if the amount of the joining parts 20 becomes excessive for some reason so that the joining parts 20 flow onto the side surface 14s of the first metal layer 14, on which solder is less likely to be wet, the presence of an area where an excess of the joining part 20 is stored at the bottom of each recess 17x can prevent the joining parts 20 from flowing toward the upper surface 17u of the insulating layer 17.
The joining parts 20 are preferably positioned lower than the upper surface 17u of the insulating layer 17. This can further reduce the possibility that the joining parts 20 flow toward the upper surface 17u of the insulating layer 17.
Next, a variation of the embodiment is described. The variation is different from the embodiment in the thickness of metal layers of the protruding electrode. In the following description of the variation, description of the same elements or configurations as those of the above-described embodiment may be omitted.
According to the wiring substrate 1A, in the protruding electrodes 13, a lower portion of the second metal layer 15 and the first metal layer 14 are buried in the insulating layer 17 and an upper portion of the second metal layer 15 and the third metal layer 16 protrude in the recesses 17x. In the wiring substrate 1A, the thickness of the entirety of each protruding electrode 13 and the interval L1 between the protruding electrodes 13 are the same as those in the wiring substrate 1, and the upper surface 13u of each protruding electrode 13 is positioned lower than the upper surface 17u of the insulating layer 17. In each protruding electrode 13, the width W1 of the part protruding in the recess 17x is equal to the width W2 of the part buried in the insulating layer 17 in a sectional view.
Thus, in the protruding electrodes 13, the first metal layer 14 does not necessarily have to protrude in the recesses 17x and the second metal layer 15 and the third metal layer 16 may protrude in the recesses 17x. In this case as well, the same effects as in the above-described embodiment are achieved.
All examples and conditional language provided herein are intended for pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventors to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority or inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
Various aspects of the subject-matter described herein may be set out non-exhaustively in the following numbered clauses:
1. A method of manufacturing a wiring substrate, the method including:
2. The method of clause 1, wherein the recess is formed by isotropic plasma etching.
Number | Date | Country | Kind |
---|---|---|---|
2023-144376 | Sep 2023 | JP | national |