Method of manufacturing a semiconductor device, semiconductor device obtained by means of said method, and device for carrying out such a method
The invention relates to a method of manufacturing a semiconductor device, wherein a semiconductor element is provided on one side with a number of connection regions which are electroconductively attached, by means of a metal connection, to a conductor pattern layer provided on a foil, wherein the foil provided with the conductor pattern layer is brought into contact with the semiconductor element in such a manner that a part of the conductor pattern layer is situated opposite a connection region, and wherein ultrasonic energy is transferred to said part of the conductor pattern layer by means of a bonding tool which is brought into contact with the foil, as a result of which said part of the conductor pattern layer is attached to the connection region, and wherein two or more parts of the conductor pattern layer are simultaneously connected to two or more connection regions by means of a single bonding tool. The invention also relates to a semiconductor device thus obtained and to a device for carrying out such a method.
Such a method is very suitable for the low-cost manufacture of devices comprising a (semi-)discrete silicon module as the semiconductor element. Such a method is disclosed in German patent specification DE 199 22 559, which was published on 31 August 2000. In said document a description is given of the way in which a semiconductor element is attached by its connection region to a conductor pattern layer present on a foil by means of a bonding tool to which ultrasonic energy is supplied. The foil is made of a synthetic resin and is situated on the side of the semiconductor element, said foil having an opening at the location of the connection region of the semiconductor element, enabling the conductor pattern layer to be brought into contact with the connection region of the semiconductor element. To enable a relatively large number of connections to be made simultaneously between a semiconductor element and various (parts of) conductor patterns, the bonding tool is provided with a bonding surface having a number of projecting parts. A drawback of the known method resides in that its flexibility is limited. As a matter of fact, if the locations where the connections are made between the conductor pattern layer and the semiconductor element vary, which is normally the case if another semiconductor element is taken into production, another, suitably adapted bonding tool must
be used. In addition, the bonding tool is comparatively expensive due to its slightly more complex geometry.
Therefore it is an object of the invention to provide a method wherein said drawback is absent or at least reduced; which method can be readily applied also if it is used to manufacture different products, and which employs a simple bonding tool.
To achieve this, a method of the type mentioned in the opening paragraph is characterized in accordance with the invention in that for the foil use is made of a metal foil, a side of the bonding tool facing the foil is embodied so as to be flat, and after the semiconductor element and the conductor pattern layer have been attached to each other, the metal foil is at least partially removed from the conductor pattern layer.
The invention is first of all based on the insight that the use of a metal foil enables a flat bonding tool to simultaneously make various connections between a semiconductor element and the conductor pattern. After all, a metal, unlike a synthetic resin such as the foil in the known method, enables an efficient transfer of ultrasonic energy without the risk of causing damage to the semiconductor element. The invention is further based on the surprising insight that the drawback of a foil which, like the conductor pattern layer, is electroconductive and hence leads to short circuits, can be readily obviated if the foil can be removed from the conductor pattern layer. The complete foil may be removed, but alternatively part of the foil is removed and the non-removed part is used for definition of contacts, and the like. For this purpose of foil removal, the foil should be situated only on a side facing away from the semiconductor element and, for example, be removably attached to the conductor pattern layer, for example by means of an adhesive layer. The step of removing the foil from the conductor pattern layer may be very simple and without an adverse effect on the quality of the conductor pattern layer, as will become apparent hereafter. In addition, the method is hardly made more complex by this additional step because a step of forming an opening in the foil so that the conductor pattern layer can be brought into contact with a connection region of the semiconductor element can be dispensed with.
It will further be apparent from the above that now in particular use can advantageously be made of a flat bonding tool. Said flat bonding tool is suitable for any orientation of the connection regions on the semiconductor element and, in addition to this, it can be readily manufactured. Furthermore, it is still possible, provided the contact surface of the bonding tool is large enough, to form a large number of connections at the same time.
In a preferred embodiment of a method in accordance with the invention, the metal used for the metal foil is selectively etchable with respect to the conductor pattern
layer, and, after the connections have been made, the foil is removed again by means of selective etching. This method is very simple, as is the manufacture of such a foil that is provided with one or more conductor patterns. A particularly suitable material for such a foil is aluminum, in which case the conductor pattern is made of copper. In this case, for example phosphoric acid can be used as the etchant for selectively etching the foil. Such a, flexible, foil may additionally be very thin. What proved to be suitable is, for example, a 30 μm thick aluminum foil which is provided with a copper conductor pattern (layer) having a thickness of 10 μm.
In a favorable modification, the conductor pattern layer is formed as a conductor pattern on the foil before the semiconductor element is attached thereon. The starting point of the method in accordance with the invention thus is a foil on which one or more conductor patterns have already been formed. This is the most favorable variant in terms of ease of manufacture. If necessary, the conductor pattern layer may alternatively comprise a continuous layer of a conductive material. If so, the desired conductor pattern can be readily formed therein after the foil has been removed from the conductor pattern layer by means of etching or otherwise. To form said conductor pattern in the conductor pattern layer use may be made of photolithography and etching. Preferably this takes place after the encapsulation has been provided, so that the semiconductor element is protected during said process. It will be obvious that, in this patent application, a semiconductor pattern layer is to be taken to mean a - substantially - uniform continuous conductive layer as well as an already-formed conductor pattern.
Preferably, the bonding tool is maintained in a substantially fixed position, the side of the foil facing away from the conductor pattern is brought into contact with the bonding tool, and on the side of the semiconductor element provided with the connection regions the semiconductor element is aligned with respect to the conductor pattern layer by means of a movable holder and is held against or pressed onto said conductor pattern layer. This offers various advantages, such as the fact that the risk of damage to the semiconductor element during bonding is further reduced. In addition, it enables the bonding tools used to be comparatively simple. The holder may be, for example, a movable arm of a robot that picks up the semiconductor elements and takes them to the bonding position. The "hand" of the arm used to grip the element may advantageously be, for example, a vacuum pincette.
In an important embodiment the, preferably strip-shaped, foil is provided with a large number of conductor patterns, and after the connection has been made between one of the conductor patterns and the connection regions of the semiconductor element, the foil is
displaced, in which process the semiconductor element is released by the holder and, together with the foil, transported from the position of the bonding tool, a subsequent (part of the) conductor pattern layer being brought to the position of the bonding tool, and a subsequent semiconductor element being picked up by the movable holder and being attached to the next (part of the) conductor pattern layer. This enables high-speed manufacturing, resulting in an attractive intermediate product in the form of a foil provided with a large number of semiconductor elements that can either be readily and rapidly subjected to further processing or stored.
In particular as regards the previous embodiment, the foil is preferably supported, on either side of the bonding tool, by a supporting tool, and during attaching the semiconductor element to the conductor pattern layer, the foil on either side of the holder is held against or pressed onto the supporting members by means of a movable stamp. This too contributes to an efficient transfer of the ultrasonic energy and to a low risk of damage to the semiconductor elements. One of the stamps will of course exert pressure on the foil via a semiconductor element that has already been placed. This is not objectionable.
In a further favorable modification, after attaching a semiconductor element to the conductor pattern layer and before removing the foil, the semiconductor element is provided with an isolating encapsulation. The foil can be used as a wall, as it were, of a mold that may be used, for example, for providing a synthetic resin encapsulation of an epoxy material by means of injection molding.
The invention also comprises a semiconductor device obtained by means of a method in accordance with the invention.
The invention further comprises a device for carrying out a method in accordance with the invention, which device comprises a bonding tool by means of which ultrasonic energy can be delivered, via a foil provided with a conductor pattern layer, for attaching the connection regions of a semiconductor element to the conductor pattern layer, and by means of which two or more parts of the conductor pattern layer can be simultaneously connected to two or more connection regions, characterized in that a side of the bonding tool facing the foil is embodied so as to be flat. Preferably, the bonding tool is in a substantially fixed position, and the device comprises means for providing the foil, by the side facing away from the conductor pattern layer, on the bonding tool, and a movable holder by means of which the semiconductor element is aligned, on the side provided with the connection regions, with respect to the conductor pattern layer and held against or pressed onto said conductor pattern layer. Such
means may comprise, for example, a system of driven bobbins from which the foil is wound off and onto which the foil is rewound. By virtue thereof, the device is also suited for handling a foil having a (large) number of conductor patterns, and the foil can be moved away from the position of the bonding tool after the connection between one of the conductor patterns and the connection regions of the semiconductor element has been made. The holder is preferably provided with means for picking up semiconductor elements.
In an important embodiment of a device in accordance with the invention, a supporting tool for the foil is situated on either side of the bonding tool, and on either side of the movable holder there is a movable stamp by means of which the foil, which may or may not be provided with a semiconductor element, is held against or pressed onto the supporting members. The stamps may be synchronous or not and are provided, in any case, with a drive operating in accordance with a suitable rhythm. Also the pressure exerted by the stamps may be adjustable. The supporting members are preferably in a fixed position and, like the stamps, may be embodied so as to be in one piece or two separate pieces. The movable holder is preferably embodied so as to be a vacuum pincette. The simplest and most reliable way of operating the device is achieved if the bonding tool is situated below the foil to be placed and the holder is situated above said foil.
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiment(s) described hereinafter.
In the drawings:
Figs. 1 through 4 are diagrammatic cross-sectional views at right angles to the thickness direction, of a semiconductor device in successive stages of the manufacture by means of an embodiment of a method in accordance with the invention, and
Figs. 5 through 11 are diagrammatic perspective views of a device in accordance with the invention for applying the method in accordance with the invention in successive stages of the implementation of the method.
The Figures are not drawn to scale and some dimensions, such as the dimensions in the thickness direction, are exaggerated for clarity. Corresponding areas or parts bear the same reference numerals whenever possible.
Figs. 1 through 4 are diagrammatic cross-sectional views at right angles to the thickness direction, of a semiconductor device in successive stages of the manufacture by means of an embodiment of a method in accordance with the invention. The finished
semiconductor device 10 (see Fig. 4) comprises a semiconductor body 1 provided with connection regions 2, which in this case take the form of so -termed bumps 2, in this case of gold, which are provided on electroconductive regions of the body 1. The semiconductor body 1 is surrounded by a synthetic resin encapsulation 11 of an epoxy material. The lower side of the device 10 accommodates a conductor pattern 4 which is connected to the bumps 2 and which renders the device 10 suitable for surface mounting. The dimensions of the semiconductor body 1 are, in this example, 400 μm x 500 μm and the thickness is 300 μm. In an important stage of a method in accordance with the invention for the manufacture of the device 10, (see Fig. 1) the semiconductor body 1 is attached by its bumps 2 onto a conductor pattern 4 by means of ultrasonic bonding. The conductor pattern 4, having a thickness in this case of 10 μm, which is covered with 2 μm nickel and 1 μm gold, is formed on a (flexible) foil 3, in this case a 30 μm thick aluminum foil. The body 1 is brought to the foil 3 by means of a holder 6 and held against/pressed onto said foil. The foil 3 is supported by a sonotrode 5 by means of which ultrasonic energy is released via the metal foil 3 and the copper pattern 4 provided thereon, resulting in the formation of a metal connection between the bumps 2 and the pattern 4. In this process, a number of bumps 2 are simultaneously connected to the pattern 4. This is possible by virtue of the fact that the sonotrode 5 is flat and its surface is sufficiently large, and by virtue of the fact that the ultrasonic energy is transferred exclusively via metals. This energy transfer can thus take place in a sufficiently efficient manner and without causing damage to the body 1. In this example, the pressure of the holder 6, in this case a vacuum pincette, on the semiconductor body 1 is approximately 500 grams. The sonotrode 5 is operated at a frequency of 40 kHz and an amplitude of 5 μm. The processing time is 50 msec. Fig. 1 also diagrammatically shows other semiconductor bodies 1', 1" which, respectively, are already attached to a conductor pattern 4 or will, in a next phase of the process, be attached to a subsequent conductor pattern 4. Therefore, the foil 3 is strip-shaped and comprises a large number of juxtaposed conductor patterns 4.
In a next stage of the manufacture (see Fig. 2), the foil 3 provided with the semiconductor bodies 1, 1', 1" is introduced into a mold Ml, M2, and the semiconductor bodies 1, 1', 1" are encapsulated by a synthetic resin encapsulation by introducing an epoxy material 11 into the mold by injection molding. In a variant, for the part Ml of the mold use is made of a metal foil which is attached to the - upper side of - the semiconductor bodies 1 and will be part of the devices 10 to be formed. After the provision of the encapsulation 11, the devices 10 to be formed are removed from the mold Ml, M2.
Next (see Fig. 3), the aluminum foil is removed by means of etching. This process is carried out selectively with respect to the copper conductor pattern layer 4 and, in this case, use is made of a sodium hydroxide (NaOH) solution in water as the etchant. Individual devices 10, as shown in Fig. 4, are then obtained by a separation process, such as sawing, in two mutually perpendicular directions one of which lies in the plane of the drawing and the other is indicated by means of R in the drawing. In this case, the separation technique used is sawing. After that, the device 10 is ready for final assembly.
Figs. 5 through 11 are diagrammatic, perspective views of a device in accordance with the invention for applying the method in accordance with the invention in successive stages of the implementation of the method. The device 100 (see Fig. 5) comprises, in addition to a sonotrode 5 which is in a fixed position, two supporting bodies 7 which are in a fixed position on either side of the sonotrode and on which the foil 3 provided with conductor patterns 4 rests. In this case, the device 100 is shown in a stage where a body 1' is already attached to the foil and a next body 1 with bumps 2 is transferred by a holder, not shown in Fig. 4, to the foil 3 above the sonotrode 5. To the left of the body 1, a stamp 8 is shown which, like the body 1, is moved towards the foil 3. In a subsequent stage (see Fig. 6), this descent is shown and the holder 6 becomes visible as well as a second stamp 9 which, to the right of the body 1, will press the part of the foil 3 that is already provided with the body 1' onto the supporting member 7 to the right of the sonotrode 5. This stage is visible in Fig. 7. Next (see Fig. 8), the sonotrode 5 is slightly raised and by means of ultrasonic vibration thereof the connection between the body 1 and the conductor pattern 4 is made. Subsequently (see Fig. 9) the sonotrode 5 moves slightly downward and the stamps 8, 9 and the (empty) holder 6 move away from the foil 3. The holder 6 (see Fig. 10) is no longer visible and picks up a new semiconductor element 1, for example, from a stretched synthetic resin membrane on which a matrix of individual bodies 1 is present, corresponding to a substrate that is sawn through in two mutually perpendicular directions. This picking up process is not shown in the drawing.
During picking up a next semiconductor body 1 by the holder 6 (see Fig. 11), the foil 3 is moved to the right, for example by means of two bobbins, which are not shown in the drawing. The first bobbin thus contains the "empty" foil 3 which is subsequently unwound from said bobbin. The foil 3 provided with semiconductor bodies 1 is wound on the second bobbin. Subsequently the device is again in a stage like that shown in Fig. 5, and the attaching cycle can be repeated. The wound-up foil 3 provided with semiconductor bodies 1 can then be subjected to further treatments, as indicated hereinabove in the discussion of
Figs. 2 through 4. To provide the foil with bodies 1 in two mutually perpendicular directions, the bobbins may be provided with a translation mechanism in a direction parallel to the axis of the bobbins.
The invention is not limited to a method as described in the exemplary embodiment, and within the scope of the invention many variations and modifications are possible to those skilled in the art. For example, it is possible to manufacture devices having a different geometry and/or different dimensions. It is also possible to use different materials for, in particular, the plates. It is further noted that small adaptations enable also an improved heat dissipation to be obtained. It is expressly noted that, in addition to sawing, also cutting or breaking can be used as the mechanical separation technique for shaping the individual semiconductor device. Unlike sawing, where a saw cut-width of material is lost, in the other two techniques in principle hardly any material loss occurs. The loss of material in the case of sawing is comparatively substantial if very small devices are manufactured as is intended in the present invention.
It is further noted that a thin foil may also be applied to the rear side of a number of semiconductor elements. This foil may serve as the other wall of a mold during the provision of the encapsulation.
It is finally noted that although the examples given herein only refer to a discrete semiconductor element, the invention can also be used, and is particularly suited, for the manufacture of more integrated semiconductor products. For example, by jointly mounting a number of, discrete or semi-discrete, semiconductor components such as diodes or transistors or even an IC (= integrated circuit) and/or other passive electronic components such as so-termed jumpers on a conductor pattern, devices can be formed within a single encapsulation which comprise, as it were, a system. For example a system for controlling a voltage. These devices may have, and will have, larger dimensions, of course, particularly in the lateral directions as compared to the semiconductor elements in the examples discussed hereinabove.