WO2024172044A1 - 基板積層体の製造方法、積層体、及び基板積層体 - Google Patents
基板積層体の製造方法、積層体、及び基板積層体 Download PDFInfo
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- WO2024172044A1 WO2024172044A1 PCT/JP2024/004891 JP2024004891W WO2024172044A1 WO 2024172044 A1 WO2024172044 A1 WO 2024172044A1 JP 2024004891 W JP2024004891 W JP 2024004891W WO 2024172044 A1 WO2024172044 A1 WO 2024172044A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L24/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
- H01L24/27—Manufacturing methods
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L24/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
- H01L24/28—Structure, shape, material or disposition of the layer connectors prior to the connecting process
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L24/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
- H01L24/31—Structure, shape, material or disposition of the layer connectors after the connecting process
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
- H01L24/83—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a layer connector
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
- H01L2224/28—Structure, shape, material or disposition of the layer connectors prior to the connecting process
- H01L2224/29—Structure, shape, material or disposition of the layer connectors prior to the connecting process of an individual layer connector
- H01L2224/29001—Core members of the layer connector
- H01L2224/29099—Material
- H01L2224/291—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron [B], silicon [Si], germanium [Ge], arsenic [As], antimony [Sb], tellurium [Te] and polonium [Po], and alloys thereof
Definitions
- the present disclosure relates to a method for manufacturing a substrate laminate, a laminate, and a substrate laminate.
- Patent Document 1 discloses a method for manufacturing a semiconductor device, which includes the steps of forming a wiring layer on the surface side of a first semiconductor wafer, forming a filling film to fill in a step on the wiring layer formed at the boundary between a peripheral region of the first semiconductor wafer and an inner region located more inward than the peripheral region, the step being formed by forming the surface of the wiring layer in the peripheral region lower than the surface of the wiring layer in the inner region, thereby making the surfaces of the wiring layer in the peripheral region and the inner region approximately flush with each other, and bonding the surface of the wiring layer formed on the first semiconductor wafer face-to-face with a desired surface of a second semiconductor wafer.
- Patent document 1 JP 2012-174937 A
- a technique is required for bonding the substrates together at a low temperature (for example, 140° C. or lower; the same applies below). If substrates could be bonded together at low temperatures, it is expected that the process speed for producing a substrate stack will be improved. For example, if it were possible to permanently bond substrates together at low temperatures, the temperature rise and fall times could be reduced, significantly improving the process speed. Furthermore, even in cases where substrates are temporarily bonded together at low temperatures and then permanently bonded together by heating, if the strength of the temporary bond is improved at low temperatures, it is expected that the total thermal damage inflicted on the substrate stack can be reduced.
- a low temperature for example, 140° C. or lower; the same applies below.
- the concept of "joining substrates together” also includes joining a laminate including a substrate and a layer to another laminate including a substrate and a layer.
- An object of one aspect of the present disclosure is to provide a method for manufacturing a substrate laminate that can improve the bonding strength when substrates are bonded at low temperatures (e.g., 140° C. or lower), a laminate that is suitable as one raw material in the method for manufacturing the substrate laminate, and a substrate laminate having excellent bonding strength between substrates.
- a method for manufacturing a substrate laminate comprising: ⁇ 2> The method for producing a substrate laminate according to ⁇ 1>, wherein the organic substance-containing layer contains Si.
- ⁇ 3> The method for producing a substrate laminate according to ⁇ 1> or ⁇ 2>, wherein, after the step B and before the step C, when the Si content in atomic % is measured at seven points in the organic-substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is maximum.
- ⁇ 4> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 3>, wherein, after the step B and before the step C, when the Si content in atomic % is measured at a total of seven points in the organic-substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is the maximum, and a value obtained by subtracting the minimum value among the measured values at the six points from the measured value at the surface is 3 atomic % to 50 atomic %.
- ⁇ 5> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 4>, wherein, after the step B and before the step C, when the O content in atomic % is measured at seven points in the organic-substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is maximum.
- ⁇ 6> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 5>, wherein, after the step B and before the step C, when the O content in atomic % is measured at seven points in the organic-substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is the maximum, and a value obtained by subtracting the minimum value among the measured values at the six points from the measured value at the surface is 3 atomic % to 70 atomic %.
- ⁇ 7> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 6>, wherein the surface of the organic substance-containing layer after the step B and before the step C has a surface roughness Ra defined in JIS B 0601:1982 of 5 nm or less.
- ⁇ 8> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 7>, wherein, when a content of Si in atomic % is measured at a surface at a depth of 0 nm in the organic substance-containing layer after the step B and before the step C, the measured value at the surface is 5 atomic % to 70 atomic %.
- ⁇ 9> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 8>, wherein, when a content of O in atomic % is measured at a surface at a depth of 0 nm in the organic substance-containing layer after the step B and before the step C, the measured value at the surface is 10 atomic % to 80 atomic %.
- a composite elastic modulus of the organic substance-containing layer after the step B and before the step C is 1 GPa to 20 GPa.
- ⁇ 11> The method for manufacturing a substrate laminate according to any one of ⁇ 1> to ⁇ 10>, wherein a bonding strength between the first laminate and the second laminate in the substrate laminate is 0.2 J/ m2 or more.
- the second bonding layer includes an inorganic material layer, and a surface of the inorganic material layer is exposed,
- the step C includes bonding the surface of the organic substance-containing layer of the first laminate to the surface of the inorganic material layer of the second substrate.
- ⁇ 1> ⁇ 2> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 11>.
- ⁇ 13> The method for manufacturing a substrate stack according to any one of ⁇ 1> to ⁇ 12>, wherein the first substrate and the second substrate have different thermal expansion coefficients.
- ⁇ 14> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 13>, wherein the surface of the organic substance-containing layer after the step B and before the step C contains a silanol group.
- ⁇ 15> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 14>, wherein the organic substance-containing layer contains at least one bond selected from the group consisting of a siloxane bond, an amide bond, and an imide bond.
- ⁇ 16> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 15>, wherein the surface activation treatment is at least one selected from the group consisting of a plasma treatment, fast atom beam irradiation, and an ozone treatment.
- the plasma treatment is at least one selected from the group consisting of an oxygen plasma treatment and a nitrogen plasma treatment.
- a temperature of a joining surface between the first laminate and the second laminate is 140° C. or less.
- the first bonding layer further includes a first electrode, and a surface of the first electrode and a surface of the organic substance-containing layer are exposed.
- the first bonding layer further includes a first electrode, and a surface of the first electrode and a surface of the organic substance-containing layer are exposed
- the second bonding layer includes a second electrode and an insulating layer, and a surface of the second electrode and a surface of the insulating layer are exposed in the second laminate
- the substrate laminate obtained in the step C is a first laminated region in which the first substrate, the organic substance-containing layer, the insulating layer, and the second substrate are arranged in this order; a second stacked region in which the first substrate, the first electrode, the second electrode, and the second substrate are arranged in this order; Including, ⁇ 19> A method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 19>.
- ⁇ 21> The method for producing a substrate laminate according to ⁇ 20>, wherein, in the substrate laminate obtained in the step C, the first laminated region is present in two or more in a stacking direction, and the second laminated region is present in two or more in a stacking direction.
- ⁇ 22> The method for producing a substrate laminate according to any one of ⁇ 1> to ⁇ 21>, wherein at least one of the first substrate and the second substrate is a semiconductor substrate containing at least one element selected from the group consisting of Si, Al, Ti, Zr, Hf, Fe, Ni, Cu, Ag, Au, Ga, Ge, Sn, Pd, As, Pt, Mg, In, Ta, and Nb.
- a semiconductor device comprising a first substrate and a first bonding layer, the first bonding layer including an organic substance-containing layer, and a surface of the organic substance-containing layer being exposed, when the Si content in atomic % is measured at seven points in the organic substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is the maximum; Laminate.
- ⁇ 24> The laminate according to ⁇ 23>, wherein when the Si content in atomic % is measured at a total of seven points in the organic substance-containing layer, including the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is the maximum, and a value obtained by subtracting the minimum value among the measured values at the six points from the measured value at the surface is 3 atomic % to 50 atomic %.
- ⁇ 25> The laminate according to ⁇ 23> or ⁇ 24>, wherein when the O content in atomic % is measured at seven points in the organic substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, the measured value at the surface is the maximum.
- the measured value at the surface is the maximum, and the value obtained by subtracting the minimum value among the measured values at the six points from the measured value at the surface is 3 atomic % to 70 atomic %.
- ⁇ 27> The laminate according to any one of ⁇ 23> to ⁇ 26>, wherein the organic substance-containing layer has a composite elastic modulus of 1 GPa to 20 GPa.
- ⁇ 28> The laminate according to any one of ⁇ 23> to ⁇ 27>, wherein the organic substance-containing layer contains at least one bond selected from the group consisting of a siloxane bond, an amide bond, and an imide bond.
- the first bonding layer further includes a first electrode
- the second bonding layer includes a second electrode and an insulating layer; the organic substance-containing layer and the insulating layer are bonded to each other, and the first electrode and the second electrode are bonded to each other;
- a method for manufacturing a substrate laminate that can improve the bonding strength when substrates are bonded together at low temperatures (e.g., 140°C or less), a laminate suitable as one raw material in the method for manufacturing the substrate laminate, and a substrate laminate having excellent bonding strength between substrates.
- FIG. 2 is a schematic cross-sectional view of step A in a preferred example of the manufacturing method of the present disclosure.
- 3 is a schematic cross-sectional view of a substrate laminate obtained in step C in a preferred example of the manufacturing method of the present disclosure.
- a numerical range expressed using “to” means a range that includes the numerical values before and after "to” as the lower and upper limits.
- the upper or lower limit value described in one numerical range may be replaced with the upper or lower limit value of another numerical range described in stages.
- the upper or lower limit value of the numerical range may be replaced with a value shown in the examples.
- the method for producing a substrate laminate according to the present disclosure includes: A step A of preparing a first laminate including a first substrate and a first bonding layer, the first bonding layer including an organic substance-containing layer, and an exposed surface of the organic substance-containing layer, and a step B of preparing a second laminate including a second substrate and a second bonding layer; A step B of performing a surface activation treatment on the surface of the organic substance-containing layer in the first laminate; A step C of bonding the first laminate having been subjected to the step B and the second laminate in a direction in which the organic substance-containing layer of the first laminate and the second bonding layer of the second substrate are in contact with each other to obtain a substrate laminate; Includes.
- the manufacturing method of the present disclosure may include other steps as necessary.
- bonding strength at low temperature when substrates (i.e., a first laminate and a second laminate) are bonded together at a low temperature (e.g., 140°C or lower). This effect is believed to be due to the surface activation treatment performed on the surface of the organic substance-containing layer, which is the bonding interface between the first laminate and the second laminate.
- bonding strength at low temperatures e.g., 140°C or less
- bonding strength at room temperature 25°C
- the bonding strength between the first laminate and the second laminate in the substrate laminate is, for example, 0.2 J/m 2 or more, preferably 1.0 J/m 2 or more, and more preferably 2.0 J/m 2 or more.
- Step A is A first laminate including a first substrate and a first bonding layer, the first bonding layer including an organic substance-containing layer, and an exposed surface of the organic substance-containing layer is prepared; and A step of preparing a second laminate including a second substrate and a second bonding layer.
- Step A may be a step of producing a first laminate, or may be a step of simply preparing a first laminate that has already been produced.
- step A may be a step of producing a second laminate, or may be a step of simply preparing a second laminate that has already been produced.
- the first laminate includes a first substrate and a first bonding layer, the first bonding layer includes an organic substance-containing layer, and the surface of the organic substance-containing layer is exposed.
- the material of the first substrate is not particularly limited, and may be any material that is commonly used.
- the first substrate preferably contains at least one element selected from the group consisting of Si, Al, Ti, Zr, Hf, Fe, Ni, Cu, Ag, Au, Ga, Ge, Sn, Pd, As, Pt, Mg, In, Ta and Nb, and is preferably a semiconductor substrate containing at least one element selected from the group consisting of Si, Ga, Ge and As.
- the material of the first substrate include: Semiconductors such as Si, InP, GaN, GaAs, InGaAs, InGaAlAs, SiGe, SiC, etc.; oxides, carbides, or nitrides such as borosilicate glass (Pyrex (registered trademark)), quartz glass (SiO 2 ), sapphire (Al 2 O 3 ), ZrO 2 , Si 3 N 4 , AlN, MgAl 2 O 4 , etc.; Piezoelectric or dielectric materials such as BaTiO3 , LiNbO3 , SrTiO3 , LiTaO3 , gadolinium gallium garnet ( Gd3Ga5O12 ), etc .; diamond; Metals such as Al, Ti, Fe, Cu, Ag, Au, Pt, Pd, Ta, and Nb; carbon; Resins such as polydimethylsiloxane (PDMS), epoxy resins, phenolic resins, poly(ethylene
- the main applications of the first substrate including each material include the following.
- Si is used in semiconductor memories, LSIs, CMOS image sensors, MEMS, optical devices, LEDs, etc.
- SiO2 is used in MEMS sealing, microchannels, interposers for 2.5D mounting, displays, etc.
- BaTiO3 , LiNbO3 , SrTiO3 , LiTaO3 , and Gd3Ga5O12 are used in surface acoustic wave devices and the like .
- PDMS is used for microchannels and the like.
- InGaAlAs, InGaAs, and InP are used in optical devices and the like.
- InGaAlAs, GaAs, and GaN are used in LEDs and the like.
- the first bonding layer includes an organic-containing layer.
- the surface of the organic substance-containing layer is exposed. The surface of this organic substance-containing layer becomes the bonding surface with the second laminate.
- the organic substance-containing layer contains at least one organic substance.
- the organic substance-containing layer may contain an inorganic substance such as an inorganic filler.
- the organic matter contained in the organic matter-containing layer is preferably a resin.
- the resin include polyimide, BCB, polymaleimide, siloxane imide, epoxy modified siloxane, and polybenzoxazole.
- examples of the resin include a cured product of composition A described below and a cured product of composition B described below.
- the organic substance-containing layer preferably contains Si. This further improves the bonding strength at low temperatures.
- the surface of the organic-containing layer after step B and before step C preferably contains silanol groups. This further improves the bonding strength at low temperatures.
- the organic substance-containing layer preferably contains at least one bond selected from the group consisting of a siloxane bond, an amide bond, and an imide bond, which further improves the bonding strength at low temperatures.
- An organic substance-containing layer having at least one bond selected from the group consisting of a siloxane bond, an amide bond, and an imide bond can be formed using, for example, composition A described below or composition B described below.
- the content of Si in atomic % is measured at a total of seven points in the organic-containing layer, including the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, after the step B and before the step C, it is preferable that the measured value at the surface is the maximum.
- the value obtained by subtracting the minimum value of the measured values at the six points from the measured value at the surface is preferably 3 atomic % to 50 atomic %, more preferably 5 atomic % to 30 atomic %, even more preferably 10 atomic % to 25 atomic %, and even more preferably 10 atomic % to 18 atomic %.
- the presence of a high Si content on the surface of the organic-substance-containing layer improves the bonding strength at low temperatures, and that the Si content inside the organic-substance-containing layer is lower than the Si content on the surface of the organic-substance-containing layer, thereby increasing the flexibility of the organic-substance-containing layer and making voids less likely to occur.
- a depth of 1 nm or the like means the depth from the surface of the organic-containing layer (i.e., the bonding surface with the second laminate).
- the measured value of the Si content in the above-mentioned atomic percentages on the surface is preferably 5 atomic % to 70 atomic %, more preferably 10 atomic % to 50 atomic %, and even more preferably 15 atomic % to 35 atomic %, from the viewpoint of further improving the bonding strength at low temperatures.
- the measured value at the surface is preferably larger than the measured value at the depth of 7 nm.
- the value obtained by subtracting the measured value at the depth of 7 nm from the measured value at the surface is preferably 3 atomic % to 50 atomic %, more preferably 15 atomic % to 25 atomic %.
- the presence of a high Si content on the surface of the organic-substance-containing layer improves the bonding strength at low temperatures, and that the Si content inside the organic-substance-containing layer is lower than the Si content on the surface of the organic-substance-containing layer, thereby increasing the flexibility of the organic-substance-containing layer and making voids less likely to occur.
- the manufacturing method of the present disclosure preferably, after step B and before step C, measures the O (oxygen) content in atomic % at seven points in the organic-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm, such that the measured value at the surface is the maximum.
- the value obtained by subtracting the minimum value of the measured values at the six points from the measured value at the surface is preferably 3 atomic % to 70 atomic %, and more preferably 35 atomic % to 50 atomic %.
- the measured value of the O content in the above-mentioned atomic percentages on the surface is preferably 10 atomic % to 80 atomic %, more preferably 30 atomic % to 70 atomic %, and even more preferably 50 atomic % to 70 atomic %, from the viewpoint of further improving the bonding strength at low temperatures.
- the measured value at the surface is greater than the measured value at the position at a depth of 7 nm.
- the value obtained by subtracting the measured value at the position at a depth of 7 nm from the measured value at the surface is preferably 3 atomic % to 70 atomic %, and more preferably 35 atomic % to 50 atomic %.
- the surface of the organic-substance-containing layer after step B and before step C has a surface roughness Ra defined in JIS B 0601:1982 of preferably 5 nm or less, more preferably 3 nm or less, and even more preferably 2 nm or less.
- a surface roughness Ra defined in JIS B 0601:1982 of preferably 5 nm or less, more preferably 3 nm or less, and even more preferably 2 nm or less.
- the surface roughness Ra is, for example, 0.01 nm.
- the composite elastic modulus of the organic-containing layer after step B and before step C is not particularly limited, but is, for example, 1 GPa to 20 GPa, preferably 2 GPa to 15 GPa, and more preferably 3 GPa to 10 GPa.
- the first bonding layer further includes a first electrode, and a surface of the first electrode and a surface of the organic substance-containing layer are exposed.
- the first electrode may be an electrode containing Cu, gold, tin, or the like.
- the first electrode may be an electrode that penetrates the organic-containing layer.
- the first laminate may include, in addition to the first electrode, a substrate through-electrode that penetrates the first substrate.
- the second laminate includes a second substrate and a second bonding layer.
- the second substrate may be the same as the first substrate.
- the material of the second substrate may be the same as or different from the material of the first substrate.
- the coefficient of thermal expansion (CTE) of the first substrate and the coefficient of thermal expansion (CTE) of the second substrate may be different.
- substrate laminates in which two substrates with different CTEs are bonded together tend to warp and crack.
- the substrates can be bonded together at low temperatures (e.g., 140°C or lower), so that warping or cracking of the substrate stack can be suppressed even when the coefficient of thermal expansion (CTE) of the first substrate and the coefficient of thermal expansion (CTE) of the second substrate are different.
- the second bonding layer in the second laminate may include an insulating layer.
- the insulating layer is preferably at least one of an inorganic material layer and an organic substance-containing layer.
- An example of an organic substance-containing layer that can be included in the second bonding layer is the same as the organic substance-containing layer included in the first laminate.
- Examples of inorganic material layers that can be included in the second bonding layer include a SiO2 layer, a SiCN layer, a SiN layer, etc. These inorganic material layers can be formed by, for example, a known vapor phase method.
- the second bonding layer in the second laminate includes an inorganic material layer has the advantage that the internal stress when the base laminate is formed can be further reduced, thereby further suppressing warping and/or cracking of the substrate.
- the aspect in which the second bonding layer in the second laminate prepared in step A includes an inorganic material layer can further reduce internal stress when the substrate laminate is formed, and therefore, when the first electrode and the second electrode are bonded as described below, the bonding stability of the first electrode and the second electrode is also excellent.
- the second bonding layer in the second laminate prepared in step A includes an inorganic material layer, it is preferable that the inorganic material layer is exposed (i.e., serves as a bonding surface with the organic-containing layer in the first laminate).
- the second laminate may include an inorganic material layer as the second bonding layer, which is the outermost layer, and an organic substance-containing layer below the inorganic material layer (i.e., closer to the second substrate). That is, the second laminate may have a laminate structure of inorganic material layer (second bonding layer)/organic substance-containing layer/second substrate.
- the embodiment in which the second bonding layer in the second laminate prepared in step A includes an organic substance-containing layer has the advantage that bonding defects caused when a foreign substance is present in the bonding portion can be suppressed.
- the second laminate may include an organic substance-containing layer as the second bonding layer, which is the outermost layer, and an inorganic material layer below the organic substance-containing layer (i.e., closer to the second substrate). That is, the second laminate may have a laminate structure of organic substance-containing layer (second bonding layer)/inorganic material layer/second substrate.
- the second bonding layer includes a second electrode and an insulating layer, and that a surface of the second electrode and a surface of the insulating layer are exposed in the second laminate.
- the first laminate and the second laminate can be hybrid-bonded. Hybrid junctions will be described later.
- the manufacturing method according to the present disclosure includes a step B of performing a surface activation treatment on the surface of the organic substance-containing layer in the first laminate.
- the surface activation treatment in step B is preferably at least one selected from the group consisting of plasma treatment, fast atom beam irradiation, and ozone treatment. This further improves the bonding strength at low temperatures.
- the plasma treatment is at least one selected from the group consisting of oxygen plasma treatment and nitrogen plasma treatment.
- the gas flow rate of the oxygen gas or nitrogen gas is preferably 5 sccm to 200 sccm, more preferably 10 sccm to 100 sccm, and even more preferably 10 sccm to 60 sccm.
- the treatment pressure is preferably 10 Pa to 100 Pa, more preferably 20 Pa to 80 Pa.
- the RF power is preferably 10W to 200W, more preferably 20W to 150W.
- the processing time is preferably 10 to 200 seconds, more preferably 20 to 100 seconds.
- Step B may include performing a surface activation treatment on the surface of the organic substance-containing layer of the first laminate, followed by washing with water. This further improves the bonding strength at low temperatures.
- Step C is a step of bonding the first laminate that has undergone step B and the second laminate in an orientation in which the organic-containing layer in the first laminate and the second bonding layer in the second substrate are in contact with each other to obtain a substrate laminate.
- step C the temperature of the bonding surface between the first laminate and the second laminate is, for example, 140°C or lower.
- a preferred embodiment of the manufacturing method of the present disclosure includes: In the first laminate prepared in the step A, the first bonding layer further includes a first electrode, and a surface of the first electrode and a surface of the organic substance-containing layer are exposed, In the second laminate prepared in step A, the second bonding layer includes a second electrode and an insulating layer, and a surface of the second electrode and a surface of the insulating layer are exposed in the second laminate.
- the first laminate and the second laminate can be hybrid-bonded. Hybrid junctions are advantageous in that they allow for narrower wiring pitches.
- hybrid bonding refers to a type of bonding in which electrodes are bonded to each other and insulating layers are bonded to each other by contacting two exposed surfaces of an electrode and an insulating layer.
- the first electrode in the first bonding layer and the second electrode in the second bonding layer are bonded, and the organic-containing layer in the first bonding layer and the insulating layer in the second bonding layer are bonded.
- FIG. 1 As a preferred example of the manufacturing method of the present disclosure, an example in which a substrate laminate is obtained by hybrid bonding a first laminate and a second laminate will be described with reference to FIGS. 1 and 2.
- FIG. 1 the manufacturing method of the present disclosure is not limited to the following specific examples.
- substantially identical elements e.g., parts or portions
- duplicate descriptions may be omitted.
- FIG. 1 is a schematic cross-sectional view of step A in a preferred example of the manufacturing method of the present disclosure.
- a first laminate 10 and a second laminate 20 are prepared.
- the first laminate 10 includes a first substrate 11 and a first bonding layer 16 .
- the first bonding layer 16 includes an organic-substance-containing layer 12 and a first electrode 14.
- the surface of the organic-substance-containing layer 12 and the surface of the first electrode 14 are each exposed.
- step B the surface of the organic substance-containing layer 12 is subjected to a surface activation treatment and then washed with water.
- the second laminate 20 includes a second substrate 21 and a second bonding layer 26 .
- the second bonding layer 26 includes an inorganic material layer 22 and a second electrode 24. The surface of the inorganic material layer 22 and the surface of the second electrode 24 are each exposed.
- FIG. 2 is a schematic cross-sectional view of a substrate laminate obtained in step C in a preferred example of the manufacturing method of the present disclosure.
- the first laminate 10 and the second laminate 20 are bonded together in an orientation in which the first bonding layer 16 and the second bonding layer 26 are in contact with each other.
- the first electrode 14 and the second electrode 24 are joined by hybrid joining, and the organic substance-containing layer 12 and the inorganic material layer 22 are joined by hybrid joining.
- step B before bonding the first laminate 10 and the second laminate 20 (i.e., before lamination), a surface activation treatment is performed on the surface of the organic substance-containing layer 12. This results in excellent bonding strength when the first laminate 10 and the second laminate 20 are bonded at a low temperature.
- the substrate laminate obtained in step C is preferably a first laminated region in which the first substrate, the organic substance-containing layer, the insulating layer, and the second substrate are arranged in this order; a second stacked region in which the first substrate, the first electrode, the second electrode, and the second substrate are arranged in this order; Includes.
- the first laminated region and the second laminated region may be formed by hybrid bonding as described above.
- first laminate region or two or more first laminate regions in the substrate laminate obtained in step C There may be only one first laminate region or two or more first laminate regions in the substrate laminate obtained in step C.
- first laminate regions at least one of the first laminate and the second laminate is present in two or more in the laminate direction.
- the number of the second laminated regions may be only one or may be two or more in the substrate laminate obtained in the step C. Even when the number of the second laminated regions is two or more, at least one of the first laminate and the second laminate is present in two or more.
- a first bonding layer is provided on one surface of a substrate
- a second bonding layer is provided on the other surface of the substrate, and three or more of the resulting substrates are stacked to form two or more first and second stacked regions.
- the substrate functions as a first stacked body on the side where the first bonding layer is provided, and functions as a second stacked body on the side where the second bonding layer is provided.
- a laminate according to a first embodiment of the present disclosure includes a first substrate and a first bonding layer, the first bonding layer includes an organic substance-containing layer, and a surface of the organic substance-containing layer is exposed,
- the Si content in atomic % is measured at seven points in the organic-substance-containing layer, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm
- the measured value at the surface is the maximum.
- the value obtained by subtracting the minimum value of the measured values at the six points from the measured value at the surface is preferably 3 atomic % to 50 atomic %.
- the laminate according to the first embodiment of the present disclosure is preferably used as the first laminate in the method for manufacturing a substrate laminate according to the present disclosure.
- the preferred aspects of the laminate according to the first embodiment of the present disclosure are the same as the preferred aspects of the first laminate in the method for manufacturing a substrate laminate according to the present disclosure.
- the O content in atomic % is measured at seven points in the organic-containing layer, namely the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm
- the measured value at the surface is the maximum.
- the value obtained by subtracting the minimum value of the measured values at the six points from the measured value at the surface is preferably 3 atomic % to 70 atomic %.
- the composite elastic modulus of the organic-containing layer is preferably 1 GPa to 20 GPa.
- the organic-containing layer preferably contains at least one bond selected from the group consisting of siloxane bonds, amide bonds, and imide bonds.
- a laminate according to a second embodiment of the present disclosure includes a first substrate and a first bonding layer, the first bonding layer includes an organic-containing layer, the surface of the organic-containing layer is exposed, and when the Si content in atomic % is measured at a surface position at a depth of 0 nm and at a position at a depth of 7 nm in the organic-containing layer, the measured value at the surface is greater than the measured value at the position at a depth of 7 nm.
- the value obtained by subtracting the measured value at the position at a depth of 7 nm from the measured value at the surface is preferably 3 atomic % to 50 atomic %.
- the preferred aspects of the laminate according to the second embodiment of the present disclosure are the same as the preferred aspects of the first laminate in the method for manufacturing a substrate laminate according to the present disclosure.
- a laminate according to a third embodiment of the present disclosure includes a first substrate and a first bonding layer, the first bonding layer includes an organic-containing layer, a surface of the organic-containing layer is exposed, and when the O content in atomic % is measured at a surface at a depth of 0 nm and at a position at a depth of 7 nm in the organic-containing layer, the measured value at the surface is greater than the measured value at the position at a depth of 7 nm.
- the value obtained by subtracting the measured value at the position at a depth of 7 nm from the measured value at the surface is preferably 3 atomic % to 70 atomic %.
- the preferred aspects of the laminate according to the second embodiment of the present disclosure are the same as the preferred aspects of the first laminate in the method for manufacturing a substrate laminate according to the present disclosure.
- the substrate laminate according to the first embodiment of the present disclosure includes: A first laminate which is the laminate of the first embodiment described above; a second laminate including a second substrate and a second bonding layer; Including, The first laminate and the second laminate are bonded in a direction in which the organic substance-containing layer of the first laminate and the second bonding layer of the second substrate are in contact with each other.
- a substrate laminate includes: A first laminate which is the laminate of the first embodiment described above; a second laminate including a second substrate and a second bonding layer; Including, The first laminate and the second laminate are bonded in a direction in which the organic substance-containing layer of the first laminate and the second bonding layer of the second substrate are in contact with each other.
- the bonding strength between the first laminate and the second laminate expressed in terms of surface energy, is preferably 0.2 J/m 2 or more.
- the surface energy can be determined by a blade insertion test described later.
- the ratio of the total area of voids is preferably 30% or less, more preferably 20% or less, and even more preferably 10% or less.
- the void area ratio is a value calculated by dividing the total area of voids by the total area where transmitted light was observable in infrared light transmission observation, and multiplying the result by 100.
- the measurement can be performed in a similar manner using reflected waves from an ultrasonic microscope, transmitted waves from an ultrasonic microscope, or reflected infrared light, preferably using reflected waves from an ultrasonic microscope.
- the first bonding layer further comprises a first electrode;
- the second bonding layer includes a second electrode and an insulating layer; It is preferable that the organic substance-containing layer and the insulating layer are joined, and that the first electrode and the second electrode are joined.
- This embodiment is the hybrid junction embodiment described above. This is therefore advantageous in terms of narrowing the wiring pitch.
- the substrate laminate of the second embodiment of the present disclosure is obtained by changing the laminate of the first embodiment of the substrate laminate of the first embodiment of the present disclosure to a laminate of the second embodiment.
- the substrate laminate of the third embodiment of the present disclosure is obtained by changing the laminate of the first embodiment of the substrate laminate of the first embodiment of the present disclosure to a laminate of the third embodiment.
- composition A and composition B which are specific examples of compositions for forming an organic substance-containing layer in the present disclosure, will be described below.
- composition for forming the organic substance-containing layer for example, known documents such as International Publication No. 2018/199117, International Publication No. 2022/054839, and JP-A-2021-182621 may be referenced.
- X is a hydrogen atom or an alkyl group having 1 to 6 carbon atoms
- composition A contains compound (A) and compound (B), and thus can form an adhesive layer (i.e., an organic substance-containing layer in this disclosure; the same applies below) of uniform thickness, and also has excellent bonding strength between substrates. Furthermore, since the adhesive layer has excellent bonding strength between substrates even when the thickness is thin, this is advantageous when forming a multi-layer three-dimensional structure while achieving miniaturization. In addition, since the adhesive layer can be thin, the solvent can be easily volatilized when manufacturing the substrate laminate, and the occurrence of voids is suppressed. Furthermore, since the occurrence of voids is suppressed, the adhesive area is less likely to become small, and unintended peeling of the substrates can be suppressed.
- an adhesive layer i.e., an organic substance-containing layer in this disclosure; the same applies below
- Compound (A) is a compound having a cationic functional group containing at least one of a primary nitrogen atom and a secondary nitrogen atom, a siloxane bond (Si—O bond), and an amino group, and having a weight average molecular weight of 130 or more and 10,000 or less.
- the cationic functional group is not particularly limited as long as it is a functional group that can bear a positive charge and contains at least one of a primary nitrogen atom and a secondary nitrogen atom.
- compound (A) may contain a tertiary nitrogen atom in addition to the primary and secondary nitrogen atoms.
- a "primary nitrogen atom” refers to a nitrogen atom bonded to only two hydrogen atoms and one atom other than a hydrogen atom (for example, a nitrogen atom contained in a primary amino group ( -NH2 group)), or a nitrogen atom bonded to only three hydrogen atoms and one atom other than a hydrogen atom (cation).
- the term “secondary nitrogen atom” refers to a nitrogen atom bonded to only one hydrogen atom and two atoms other than hydrogen atoms (i.e., a nitrogen atom contained in a functional group represented by the following formula (a)), or a nitrogen atom (cation) bonded to only two hydrogen atoms and two atoms other than hydrogen atoms.
- tertiary nitrogen atom refers to a nitrogen atom bonded to only three atoms other than hydrogen atoms (i.e., a nitrogen atom that is a functional group represented by the following formula (b)), or a nitrogen atom (cation) bonded to one hydrogen atom and only three atoms other than hydrogen atoms.
- the functional group represented by the formula (a) may be a functional group constituting a part of a secondary amino group (-NHR a group; here, R a represents an alkyl group), or may be a divalent linking group contained in the skeleton of a polymer.
- the functional group represented by formula (b) may be a functional group constituting a part of a tertiary amino group (-NR b R c group; here, R b and R c each independently represent an alkyl group), or may be a trivalent linking group contained in the skeleton of a polymer.
- the weight average molecular weight of compound (A) is 130 or more and 10,000 or less, more preferably 130 or more and 5,000 or less, and even more preferably 130 or more and 2,000 or less.
- the weight average molecular weight refers to a weight average molecular weight calculated as polyethylene glycol, measured by GPC (Gel Permeation Chromatography). Specifically, the weight average molecular weight is calculated by detecting the refractive index at a flow rate of 1.0 mL/min using an aqueous solution of sodium nitrate having a concentration of 0.1 mol/L as a developing solvent, a Shodex DET RI-101 analyzer, and two types of analytical columns (TSKgel G6000PWXL-CP and TSKgel G3000PWXL-CP, manufactured by Tosoh Corporation), and using polyethylene glycol/polyethylene oxide as standards with analytical software (Empower3, manufactured by Waters Corporation).
- GPC Gel Permeation Chromatography
- the compound (A) may further have an anionic functional group, a nonionic functional group, or the like, as necessary.
- the nonionic functional group may be a hydrogen bond accepting group or a hydrogen bond donating group.
- Examples of the nonionic functional group include a hydroxyl group, a carbonyl group, and an ether group (-O-).
- the anionic functional group is not particularly limited as long as it is a functional group that can bear a negative charge.
- examples of the anionic functional group include a carboxylic acid group, a sulfonic acid group, and a sulfate group.
- Examples of the compound (A) include siloxane diamines, silane coupling agents having an amino group, and siloxane polymers of silane coupling agents having an amino group.
- An example of the silane coupling agent having an amino group is a compound represented by the following formula (A-3).
- R 1 represents an alkyl group having 1 to 4 carbon atoms which may be substituted.
- R 2 and R 3 each independently represent an alkylene group having 1 to 12 carbon atoms, an ether group, or a carbonyl group which may be substituted (the skeleton may contain a carbonyl group, an ether group, etc.).
- R 4 and R 5 each independently represent an alkylene group having 1 to 4 carbon atoms which may be substituted or a single bond.
- Ar represents a divalent or trivalent aromatic ring.
- X 1 represents hydrogen or an alkyl group having 1 to 5 carbon atoms which may be substituted.
- X 2 represents hydrogen, a cycloalkyl group, a heterocyclic group, an aryl group, or an alkyl group having 1 to 5 carbon atoms which may be substituted (the skeleton may contain a carbonyl group, an ether group, etc.).
- a plurality of R 1 , R 2 , R 3 , R 4 , R 5 , and X 1 may be the same or different.
- Substituents of the alkyl and alkylene groups in R1 , R2 , R3 , R4 , R5 , X1 and X2 each independently include an amino group, a hydroxy group, an alkoxy group, a cyano group, a carboxylic acid group, a sulfonic acid group and halogens.
- Examples of the divalent or trivalent aromatic ring in Ar include a divalent or trivalent benzene ring.
- Examples of the aryl group in X2 include a phenyl group, a methylbenzyl group, and a vinylbenzyl group.
- silane coupling agents represented by formula (A-3) include, for example, N-(2-aminoethyl)-3-aminopropylmethyldiethoxysilane, N-(2-aminoethyl)-3-aminopropyltriethoxysilane, N-(2-aminoethyl)-3-aminoisobutyldimethylmethoxysilane, N-(2-aminoethyl)-3-aminoisobutylmethyldimethoxysilane, N-(2-aminoethyl)-11-aminoundecyltrimethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, N-phenyl-3-aminopropyltrimethoxysilane, (aminoethylaminoethyl)phenyltriethoxysilane, methylbenzylaminoethyla
- silane coupling agents containing an amino group other than those represented by formula (A-3) include N,N-bis[3-(trimethoxysilyl)propyl]ethylenediamine, N,N'-bis[3-(trimethoxysilyl)propyl]ethylenediamine, bis[(3-triethoxysilyl)propyl]amine, piperazinylpropylmethyldimethoxysilane, bis[3-(triethoxysilyl)propyl]urea, bis(methyldiethoxysilylpropyl)amine, 2-methyl-2-phenylpropanedi ...
- silane coupling agents having an amino group may be used alone or in combination of two or more.
- a silane coupling agent having an amino group may also be used in combination with a silane coupling agent not having an amino group.
- a silane coupling agent having a mercapto group may be used to improve adhesion to metals.
- polymers (siloxane polymers) formed from these silane coupling agents via siloxane bonds may be used.
- siloxane polymers formed from these silane coupling agents via siloxane bonds
- Si-O-Si siloxane bonds
- a polymer having a linear siloxane structure a polymer having a branched siloxane structure, a polymer having a cyclic siloxane structure, a polymer having a cage siloxane structure, etc.
- the cage siloxane structure is represented, for example, by the following formula (A-1).
- siloxane diamines examples include compounds represented by the following formula (A-2).
- i is an integer from 0 to 4
- j is an integer from 1 to 3
- Me is a methyl group.
- compound (A) Since compound (A) has a primary or secondary amino group, it can strongly bond the substrates to each other by electrostatic interaction with functional groups such as hydroxyl groups, epoxy groups, carboxy groups, amino groups, and mercapto groups that may be present on the surfaces of the first substrate and the second substrate, or by forming a close covalent bond with the functional groups.
- the compound (A) since the compound (A) has a primary or secondary amino group, it is easily dissolved in the polar solvent (D) described below.
- the affinity with the hydrophilic surface of a substrate such as a silicon substrate is increased, so that a smooth film is easily formed and the thickness of the adhesive layer can be reduced.
- compound (A) a compound having a Si-O bond and a primary amino group is preferred from the viewpoint of forming a thermally crosslinked structure such as an amide, amide-imide, or imide to further improve heat resistance.
- the ratio of the total number of primary and secondary nitrogen atoms to the number of silicon atoms in compound (A) is 0.2 or more and 5 or less.
- compound (A) has a molar ratio of Si element to non-crosslinkable group such as methyl group bonded to Si element that satisfies the relationship (non-crosslinkable group)/Si ⁇ 2.
- compound (A) has a cationic functional group containing at least one of a primary nitrogen atom and a secondary nitrogen atom.
- the proportion of primary nitrogen atoms in the total nitrogen atoms in compound (A) is preferably 20 mol% or more, more preferably 25 mol% or more, and even more preferably 30 mol% or more.
- Compound (A) may also have a cationic functional group that contains a primary nitrogen atom and does not contain any nitrogen atoms other than the primary nitrogen atom (e.g., secondary nitrogen atom, tertiary nitrogen atom).
- the ratio of secondary nitrogen atoms to the total nitrogen atoms in compound (A) is preferably 5 mol % or more and 50 mol % or less, and more preferably 10 mol % or more and 45 mol % or less.
- compound (A) may contain a tertiary nitrogen atom in addition to a primary nitrogen atom and a secondary nitrogen atom.
- the ratio of the tertiary nitrogen atoms to the total nitrogen atoms in compound (A) is preferably 20 mol % or more and 50 mol % or less, and more preferably 25 mol % or more and 45 mol % or less.
- the content of the component derived from compound (A) in the adhesive layer is not particularly limited, and can be, for example, 1% by mass or more and 82% by mass or less with respect to the entire adhesive layer, preferably 5% by mass or more and 82% by mass or less, and more preferably 13% by mass or more and 82% by mass or less.
- X is a hydrogen atom or an alkyl group having 1 to 6 carbon atoms
- Compound (B) is a compound having a weight average molecular weight of 200 or more and 600 or less. Preferably, it is a compound having a weight average molecular weight of 200 or more and 400 or less.
- Compound (B) preferably has a ring structure in the molecule.
- the ring structure include an alicyclic structure and an aromatic ring structure.
- Compound (B) may also have multiple ring structures in the molecule, and the multiple ring structures may be the same or different.
- Examples of the alicyclic structure include alicyclic structures having 3 to 8 carbon atoms, preferably alicyclic structures having 4 to 6 carbon atoms, and the ring structure may be saturated or unsaturated. More specifically, examples of the alicyclic structure include saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a cycloheptane ring, and a cyclooctane ring; and unsaturated alicyclic structures such as a cyclopropene ring, a cyclobutene ring, a cyclopentene ring, a cyclohexene ring, a cycloheptene ring, and a cyclooctene ring.
- saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring
- the aromatic ring structure is not particularly limited as long as it is a ring structure that exhibits aromaticity, and examples thereof include benzene-based aromatic rings such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring, aromatic heterocycles such as a pyridine ring and a thiophene ring, and non-benzene-based aromatic rings such as an indene ring and an azulene ring.
- benzene-based aromatic rings such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring
- aromatic heterocycles such as a pyridine ring and a thiophene ring
- non-benzene-based aromatic rings such as an indene ring and an azulene ring.
- the ring structure that compound (B) has in the molecule is, for example, preferably at least one selected from the group consisting of a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a benzene ring, and a naphthalene ring, and from the viewpoint of further increasing the heat resistance of the adhesive layer, at least one of a benzene ring and a naphthalene ring is more preferable.
- compound (B) may have multiple ring structures in the molecule, and when the ring structure is benzene, it may have a biphenyl structure, a benzophenone structure, a diphenyl ether structure, etc.
- Compound (B) preferably has a fluorine atom in the molecule, more preferably has 1 to 6 fluorine atoms in the molecule, and even more preferably has 3 to 6 fluorine atoms in the molecule.
- compound (B) may have a fluoroalkyl group in the molecule, and specifically, may have a trifluoroalkyl group or a hexafluoroisopropyl group.
- examples of compound (B) include carboxylic acid compounds such as alicyclic carboxylic acid, benzene carboxylic acid, naphthalene carboxylic acid, diphthalic acid, and fluorinated aromatic ring carboxylic acid; and carboxylic acid ester compounds such as alicyclic carboxylic acid ester, benzene carboxylic acid ester, naphthalene carboxylic acid ester, diphthalic acid ester, and fluorinated aromatic ring carboxylic acid ester.
- carboxylic acid compounds such as alicyclic carboxylic acid, benzene carboxylic acid, naphthalene carboxylic acid, diphthalic acid ester, and fluorinated aromatic ring carboxylic acid ester.
- compound (B) is a carboxylic acid ester compound, aggregation due to association between compound (A) and compound (B) is suppressed, aggregates and pits are reduced, and adjustment of the film thickness is made easier.
- X is preferably a methyl group, an ethyl group, a propyl group, a butyl group, etc., but is preferably an ethyl group or a propyl group from the viewpoint of further suppressing aggregation due to association between compound (A) and compound (B).
- carboxylic acid compound examples include, but are not limited to, alicyclic carboxylic acids such as 1,2,3,4-cyclobutane tetracarboxylic acid, 1,2,3,4-cyclopentane tetracarboxylic acid, 1,3,5-cyclohexane tricarboxylic acid, 1,2,4-cyclohexane tricarboxylic acid, 1,2,4,5-cyclohexane tetracarboxylic acid, and 1,2,3,4,5,6-cyclohexane hexacarboxylic acid; benzene carboxylic acids such as 1,2,4-benzene tricarboxylic acid, 1,3,5-benzene tricarboxylic acid, pyromellitic acid, benzene pentacarboxylic acid, and mellitic acid; and 1,4,5,8-naphthalene tetracarboxylic acid.
- alicyclic carboxylic acids such as 1,2,3,4-cyclobutan
- naphthalene carboxylic acids such as 2,3,6,7-naphthalene tetracarboxylic acid; 3,3',5,5'-tetracarboxydiphenylmethane, biphenyl-3,3',5,5'-tetracarboxylic acid, biphenyl-3,4',5-tricarboxylic acid, biphenyl-3,3',4,4'-tetracarboxylic acid, benzophenone-3,3',4,4'-tetracarboxylic acid, 4,4'-oxydiphthalic acid, 3,4'-oxydiphthalic acid, 1,3-bis(phthalic acid)tetramethyldisiloxane, 4,4'-(ethyn-1,2-diyl)diphthalic acid acid), 4,4'-(1,4-phenylenebis(oxy))diphthalic acid, 4,4'-([1,1'-biphenyl]-4,4'-diylbis(oxy
- carboxylic acid ester compound examples include compounds in which at least one carboxy group in the specific examples of the carboxylic acid compound described above has been replaced with an ester group.
- carboxylic acid ester compound examples include half-esterified compounds represented by the following general formulas (B-1) to (B-6).
- R is each independently an alkyl group having 1 to 6 carbon atoms, of which methyl, ethyl, propyl, and butyl are preferred, and ethyl and propyl are more preferred.
- a half-esterified compound can be produced, for example, by mixing a carboxylic acid anhydride, which is the anhydride of the aforementioned carboxylic acid compound, with an alcohol solvent and opening the ring of the carboxylic acid anhydride.
- Y represents an imide-bridged or amide-bridged nitrogen atom, OH, or an ester group.
- the adhesive layer preferably has a thermally crosslinked structure such as amide, amide-imide, or imide, and has excellent heat resistance.
- compound (A) has an uncrosslinked cationic functional group
- the adhesive layer contains compound (A) but not compound (B)
- the crosslink density is low and the heat resistance is insufficient.
- the cationic functional group of compound (A) reacts with the carboxyl group of compound (B) to form a covalent bond, resulting in a high crosslink density and high heat resistance.
- Composition A may further contain the following compound (C).
- Compound (C) is a compound having a ring structure and one or more primary nitrogen atoms directly bonded to the ring structure.
- the compound (C) reacts with the compound (A) and the compound (B) to form a cured product.
- Compound (C) has a ring structure and one or more primary nitrogen atoms directly bonded to the ring structure. It is believed that the introduction of this structure into a cured product increases the rigidity of the cured product and reduces the thermal expansion coefficient.
- the compound (C) may be used alone or in combination of two or more kinds.
- a "primary nitrogen atom directly bonded to a ring structure” refers to a primary nitrogen atom (-NH 2 ) that is bonded to a ring structure via a single bond (ie, not via a carbon atom or the like).
- the number of primary nitrogen atoms directly bonded to the ring structure in the molecule of compound (C) is not particularly limited as long as it is one or more. From the viewpoint of increasing the crosslink density, it is preferable that there are two or more, and a diamine compound having two primary amino groups or a triamine compound having three primary amino groups is more preferable.
- Compound (C) may have one ring structure or multiple ring structures in the molecule. When compound (C) has multiple ring structures in the molecule, it may have a cationic functional group containing a primary nitrogen atom directly bonded to each ring structure, or may have a cationic functional group containing a primary nitrogen atom directly bonded to only one of the ring structures.
- the multiple ring structures may be the same or different and may form a condensed ring.
- the multiple ring structures may be bonded by a single bond or may be bonded via a linking group such as an ether group, a carbonyl group, a sulfonyl group, or a methylene group.
- Examples of the ring structure contained in the compound (C) include an alicyclic structure, an aromatic ring (including a heterocyclic ring) structure, and a condensed ring structure thereof.
- the alicyclic structure may be an alicyclic structure having 3 to 8 carbon atoms, preferably 4 to 6 carbon atoms.
- the ring structure may be saturated or unsaturated.
- examples of the alicyclic structure include saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a cycloheptane ring, and a cyclooctane ring; and unsaturated alicyclic structures such as a cyclopropene ring, a cyclobutene ring, a cyclopentene ring, a cyclohexene ring, a cycloheptene ring, and a cyclooctene ring.
- aromatic ring structures include aromatic ring structures having 6 to 20 carbon atoms, preferably 6 to 10 carbon atoms.
- Specific examples include benzene-based aromatic ring structures such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring, and non-benzene-based aromatic ring structures such as a pyridine ring, a thiophene ring, an indene ring, and an azulene ring.
- the heterocyclic structure may be a 3- to 10-membered, preferably a 5- or 6-membered heterocyclic structure.
- heteroatoms contained in the heterocyclic ring include a sulfur atom, a nitrogen atom, and an oxygen atom, and may be one or more of these.
- heterocyclic structure examples include an oxazole ring, a thiophene ring, a pyrrole ring, a pyrrolidine ring, a pyrazole ring, an imidazole ring, a triazole ring, an isocyanuric ring, a pyridine ring, a pyridazine ring, a pyrimidine ring, a pyrazine ring, a piperidine ring, a piperazine ring, a triazine ring, an indole ring, an indoline ring, a quinoline ring, an acridine ring, a naphthyridine ring, a quinazoline ring, a purine ring, and a quinoxaline ring.
- the ring structure that compound (C) has in the molecule is preferably a benzene ring, a cyclohexane ring, or a benzoxazole ring.
- the ring structure that compound (C) has in its molecule may have a substituent other than a primary nitrogen atom.
- it may have an alkyl group having 1 to 6 carbon atoms, an alkyl group substituted with a halogen atom, etc.
- the weight average molecular weight of compound (C) is not particularly limited. For example, it may be 80 or more and 600 or less, 90 or more and 500 or less, or 100 or more and 450 or less.
- Examples of the compound (C) include alicyclic amines, aromatic ring amines, heterocyclic amines having a nitrogen-containing heterocycle, and amine compounds having both a heterocycle and an aromatic ring.
- Specific examples of the alicyclic amine include cyclohexylamine and dimethylaminocyclohexane.
- aromatic ring amines include diaminodiphenyl ether, xylylenediamine (preferably paraxylylenediamine), diaminobenzene, diaminotoluene, methylenedianiline, dimethyldiaminobiphenyl, bis(trifluoromethyl)diaminobiphenyl, diaminobenzophenone, diaminobenzanilide, bis(aminophenyl)fluorene, bis(aminophenoxy)benzene, bis(aminophenoxy)biphenyl, dicarboxydiaminodiphenylmethane, diaminoresorcin, dihydroxybenzidine, diaminobenzidine, 1,3,5-triaminophenoxybenzene, 2,2'-dimethylbenzidine, and tris(4-aminophenyl)amine.
- diaminodiphenyl ether xylylenediamine (preferably paraxylylenediamine),
- heterocyclic amines having a nitrogen-containing heterocycle include melamine, ammeline, melam, melem, and tris(4-aminophenyl)amine.
- Specific examples of the amine compound having both a heterocycle and an aromatic ring include N2,N4,N6-tris(4-aminophenyl)-1,3,5-triazine-2,4,6-triamine and 2-(4-aminophenyl)benzoxazole-5-amine.
- the content of compound (C) in composition A is not particularly limited, so long as the proportion of the primary nitrogen atoms contained in compound (A) to the total of the primary nitrogen atoms and secondary nitrogen atoms contained in compound (A) and the primary nitrogen atoms contained in compound (C) is 3 mol % to 95 mol %. From the viewpoint of the balance between the thermal expansion coefficient and the bonding strength, the above ratio is preferably 5 mol % to 75 mol %, more preferably 10 mol % to 50 mol %, and even more preferably 10 mol % to 30 mol %.
- composition A may contain a polar solvent.
- polar solvent refers to a solvent having a relative dielectric constant of 5 or more at room temperature (25° C.).
- the polar solvent may be used alone or in combination of two or more kinds.
- polar solvents include protic solvents such as water and heavy water; alcohols such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, isobutyl alcohol, isopentyl alcohol, cyclohexanol, ethylene glycol, propylene glycol, 2-methoxyethanol, 2-ethoxyethanol, benzyl alcohol, diethylene glycol, triethylene glycol, and glycerin; ethers such as tetrahydrofuran and dimethoxyethane; aldehydes and ketones such as furfural, acetone, ethyl methyl ketone, and cyclohexanone; acid derivatives such as acetic anhydride, ethyl acetate, butyl acetate, ethylene carbonate, propylene carbonate, formaldehyde, N-methylformamide, N,N-dimethylformamide, N-methylacetamide, N,N-
- composition A contains a polar solvent
- its content is not particularly limited, and may be, for example, 1.0% by mass or more and 99.99896% by mass or less, or 40% by mass or more and 99.99896% by mass or less, relative to the entire composition A.
- Composition A may contain additives as necessary.
- the additives include an acid having a carboxy group and a weight average molecular weight of 46 to 195, and a base having a nitrogen atom and no ring structure and a weight average molecular weight of 17 to 120.
- composition A contains an acid having a weight average molecular weight of 46 to 195 and having a carboxy group, the primary or secondary nitrogen atoms of compounds (A) and (C) form ionic bonds with the carboxy group in the acid, thereby suppressing aggregation due to association of compounds (A) and (C) with compound (B).
- the type of acid having a carboxy group and a weight average molecular weight of 46 to 195 is not particularly limited, and examples include monocarboxylic acid compounds, dicarboxylic acid compounds, and oxydicarboxylic acid compounds. More specifically, examples include formic acid, acetic acid, malonic acid, oxalic acid, benzoic acid, lactic acid, glycolic acid, glyceric acid, butyric acid, methoxyacetic acid, ethoxyacetic acid, phthalic acid, terephthalic acid, picolinic acid, salicylic acid, and 3,4,5-trihydroxybenzoic acid (excluding those that fall under compound (B)).
- composition A contains an acid having a weight average molecular weight of 46 or more and 195 or less
- its content is not particularly limited, but for example, the content is preferably such that the ratio (COOH/N) of the number of carboxy groups of the acid to the total number of primary and secondary nitrogen atoms of compound (A) and compound (C) is 0.01 or more and 10 or less, more preferably 0.02 or more and 6 or less, and even more preferably 0.5 or more and 3 or less.
- the carboxy group of compound (B) forms an ionic bond with the amino group of the base, thereby suppressing aggregation due to association of compound (A) and compound (C) with compound (B). More specifically, it is speculated that aggregation is suppressed because the interaction between the carboxylate ion derived from the carboxy group in compound (B) and the ammonium ion derived from the amino group in the base is stronger than the interaction between the ammonium ion derived from compound (A) and compound (C) and the carboxylate ion derived from the carboxy group in compound (B). Note that the present invention is in no way limited by the above speculation.
- the type of compound having a nitrogen atom and a weight average molecular weight of 17 to 120 is not particularly limited, and examples include monoamine compounds and diamine compounds (excluding compounds (A) and (C)). More specifically, examples include ammonia, ethylamine, ethanolamine, diethylamine, triethylamine, ethylenediamine, N-acetylethylenediamine, N-(2-aminoethyl)ethanolamine, and N-(2-aminoethyl)glycine.
- composition A contains a base having a weight-average molecular weight of 17 to 120
- the content is not particularly limited, but for example, the ratio of the number of nitrogen atoms in the base to the number of carboxy groups in compound (B) (N/COOH) is preferably 0.5 to 5, and more preferably 0.9 to 3.
- composition A may contain a metal alkoxide represented by the following general formula (I).
- R1 n M(OR2) m ⁇ n ...(I) (In the formula, R1 is a non-hydrolyzable group, R2 is an alkyl group having 1 to 6 carbon atoms, M is at least one metal atom selected from the group consisting of Ti, Al, Zr, Sr, Ba, Zn, B, Ga, Y, Ge, Pb, P, Sb, V, Ta, W, La, Nd, and In, m is the valence of the metal atom M and is 3 or 4, n is an integer of 0 to 2 when m is 4, and is 0 or 1 when m is 3, when there are multiple R1s, each R1 may be the same as or different from each other, and when there are multiple OR2s, each OR2 may
- a silane compound (excluding those corresponding to compound (A)) may be contained in order to improve the insulating properties or mechanical strength.
- silane compound examples include tetraethoxysilane, tetramethoxysilane, bistriethoxysilylethane, bistriethoxysilylmethane, bis(methyldiethoxysilyl)ethane, 1,1,3,3,5,5-hexaethoxy-1,3,5-trisilacyclohexane, 1,3,5,7-tetramethyl-1,3,5,7-tetrahydroxylcyclosiloxane, 1,1,4,4-tetramethyl-1,4-diethoxydisilethylene, 1,3,5-trimethyl-1,3,5-trimethyl-1,3,5-triethoxy-1,3,5-trisilacyclohexane, and silane coupling agents having a functional group other than an amino group (such as an epoxy group or a mercapto group).
- silane coupling agents having a functional group other than an amino group (such as an epoxy group or a mercapto group).
- Composition A may contain a solvent other than a polar solvent.
- solvent other than a polar solvent include normal hexane.
- Composition A may contain benzotriazole or a derivative thereof, for example to inhibit copper corrosion.
- the pH of composition A is not particularly limited, but is preferably from 2.0 to 12.0. When the pH of composition A is 2.0 or more and 12.0 or less, damage to the substrate caused by composition A is suppressed.
- the sodium and potassium contents of Composition A are preferably 10 ppb by mass or less on an elemental basis, respectively. If the sodium or potassium contents are 10 ppb by mass or less on an elemental basis, respectively, the occurrence of problems in the electrical characteristics of the semiconductor device, such as transistor malfunctions, can be suppressed.
- non-volatile components refers to components other than components (solvent, etc.) that are removed when composition A becomes a cured product.
- Composition B contains at least one of a compound (X1) having a structure represented by the following general formula (1) and a molecular weight of 400 to 5,000, and a compound (X2) having a structure represented by the following general formula (2) and a molecular weight of 400 to 5,000:
- R1 and R3 each independently represent an organic group having 6 or less carbon atoms
- R2 represents a methylene group, an ethylene group, a propylene group, or a phenylene group
- a represents 2 or 3
- b represents the number 3-a
- X1 represents a structure derived from a carboxylic dianhydride.
- R1 and R3 each independently represent an organic group having 6 or less carbon atoms
- R2 represents a methylene group, an ethylene group, a propylene group, or a phenylene group
- a represents 2 or 3
- b represents the number 3-a
- X1 represents a structure derived from a carboxylic acid dianhydride
- X2 represents a structure derived from an amine compound
- n represents a positive number.
- Comparative composition B can form a resin layer with less residual stress than composition B containing unreacted precursors of compound (X1) or compound (X2), such as a silane coupling agent, a carboxylic acid dianhydride, or an amine compound.
- precursors of compound (X1) or compound (X2) such as a silane coupling agent, a carboxylic acid dianhydride, or an amine compound.
- X1 is a structure derived from a carboxylic dianhydride, and preferably contains a ring structure.
- the amide group and the carboxy group bonded to X1 react with each other on the substrate to form an imide bond. Therefore, the resulting resin layer exhibits excellent heat resistance.
- a is preferably 2.
- examples of the organic group having 6 or less carbon atoms represented by R1 and R3 include alkyl groups having 6 or less carbon atoms, preferably 3 or less carbon atoms, and more preferably 2 or less carbon atoms.
- X1 and X2 are structures derived from a carboxylic dianhydride and an amine compound, respectively, and preferably contain a ring structure.
- the amide group and the carboxyl group bonded to X1 react with each other on the substrate to form an imide bond. Therefore, the resulting resin layer exhibits excellent heat resistance.
- a is preferably 2.
- examples of the organic group having 6 or less carbon atoms represented by R1 and R3 include alkyl groups having 6 or less carbon atoms, preferably 3 or less carbon atoms, and more preferably 2 or less carbon atoms.
- n is not particularly limited as long as it is a positive number, and may be, for example, within the range of 1 or more and 6 or less.
- the compound (X2) represented by the general formula (2) may be in a state in which a structure derived from a carboxylic acid dianhydride and a structure derived from an amine compound are arranged alternately (polyamic acid).
- the compound (X1) contained in the composition B may be a compound having a structure obtained by reacting a silane coupling agent (A) with a carboxylic acid dianhydride (B) having a molecular weight of 200 to 600 and a ring structure.
- the compound (X2) contained in the above composition B may be a compound having a structure obtained by reacting a silane coupling agent (A) with a carboxylic acid dianhydride (B) having a molecular weight of 200 to 600 and a ring structure, and a structure obtained by reacting an amine compound (C) having a ring structure, having a molecular weight of 90 to 600, no Si—O bond, and with a carboxylic acid dianhydride (B) having a ring structure and a molecular weight of 200 to 600.
- the carboxylic acid dianhydride (B) having a molecular weight of 200 to 600 and a ring structure, and the amine compound (C) having a molecular weight of 90 to 600 and a ring structure without a Si-O bond may be referred to simply as the carboxylic acid dianhydride (B) and the amine compound (C), respectively.
- the silane coupling agent (A) is a compound having one or more Si—O bonds in the molecule and reacting with a carboxylic dianhydride to produce the compound (X1) or the compound (X2).
- the Si—O bonds in the silane coupling agent (A) contribute to improving the bonding strength between the resin layer formed by using the composition B and the substrate.
- the silane coupling agent (A) is not particularly limited as long as it has a functional group capable of reacting with the anhydride group of the carboxylic acid dianhydride (B).
- functional groups include amino groups, epoxy groups, and isocyanate groups.
- the silane coupling agent (A) has an amino group, and from the viewpoint of forming an imide structure in the resin layer to improve heat resistance, a compound having a primary amino group (-NH2) is more preferable.
- the silane coupling agent (A) may be used alone or in combination of two or more.
- the molecular weight of the silane coupling agent (A) is not particularly limited. For example, it may be 130 or more and 10,000 or less, 130 or more and 5,000 or less, or 130 or more and 2,000 or less.
- silane coupling agent (A) having an amino group is a compound represented by the following formula (A-3).
- R 1 represents an alkyl group having 1 to 4 carbon atoms which may be substituted.
- R 2 and R 3 each independently represent an alkylene group having 1 to 12 carbon atoms, an ether group, or a carbonyl group which may be substituted (the skeleton may contain a carbonyl group, an ether group, etc.).
- R 4 and R 5 each independently represent an alkylene group having 1 to 4 carbon atoms which may be substituted or a single bond.
- Ar represents a divalent or trivalent aromatic ring.
- X1 represents hydrogen or an alkyl group having 1 to 5 carbon atoms which may be substituted.
- X2 represents hydrogen, a cycloalkyl group, a heterocyclic group, an aryl group, or an alkyl group having 1 to 5 carbon atoms which may be substituted (the skeleton may contain a carbonyl group, an ether group, etc.).
- Multiple R 1 , R 2 , R 3 , R 4 , R 5 , and X 1 may be the same or different.
- Substituents of the alkyl and alkylene groups in R1 , R2 , R3 , R4 , R5 , X1 and X2 each independently include an amino group, a hydroxy group, an alkoxy group, a cyano group, a carboxylic acid group, a sulfonic acid group and halogens.
- Examples of the divalent or trivalent aromatic ring in Ar include a divalent or trivalent benzene ring.
- Examples of the aryl group in X2 include a phenyl group, a methylbenzyl group, and a vinylbenzyl group.
- silane coupling agent represented by formula (A-3) include, for example, N-(2-aminoethyl)-3-aminopropylmethyldiethoxysilane, N-(2-aminoethyl)-3-aminopropyltriethoxysilane, N-(2-aminoethyl)-3-aminoisobutyldimethylmethoxysilane, N-(2-aminoethyl)-3-aminoisobutylmethyldimethoxysilane, N-(2-aminoethyl)-11-aminoundecyltrimethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, N-phenyl-3-aminopropyltrimethoxysilane, (aminoethylaminoethyl)phenyltriethoxysilane, methylbenzylaminoethy
- silane coupling agents containing an amino group other than those represented by formula (A-3) include N,N-bis[3-(trimethoxysilyl)propyl]ethylenediamine, N,N'-bis[3-(trimethoxysilyl)propyl]ethylenediamine, bis[(3-triethoxysilyl)propyl]amine, piperazinylpropylmethyldimethoxysilane, bis[3-(triethoxysilyl)propyl]urea, bis(methyldiethoxysilylpropyl)amine, 2-methyl-2-phenylpropanedi ...
- the silane coupling agent (A) having an amino group may be used alone or in combination of two or more.
- the carboxylic acid dianhydride (B) is a compound having one or more ring structures and two anhydride groups in the molecule and having a molecular weight of 200 or more and 600 or less.
- the molecular weight of the carboxylic acid dianhydride (B) may be 200 or more and 400 or less.
- the carboxylic acid dianhydride (B) may be used alone or in combination of two or more kinds.
- the ring structure that the carboxylic acid dianhydride (B) has in the molecule may be an alicyclic structure, an aromatic ring (including a heterocyclic ring), or the like.
- the carboxylic acid dianhydride (B) may have one ring structure or multiple ring structures in the molecule.
- Examples of the alicyclic structure include alicyclic structures having 3 to 8 carbon atoms, preferably alicyclic structures having 4 to 6 carbon atoms, and the ring structure may be saturated or unsaturated. More specifically, examples of the alicyclic structure include saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a cycloheptane ring, and a cyclooctane ring; and unsaturated alicyclic structures such as a cyclopropene ring, a cyclobutene ring, a cyclopentene ring, a cyclohexene ring, a cycloheptene ring, and a cyclooctene ring.
- saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring
- the aromatic ring structure is not particularly limited as long as it is a ring structure that exhibits aromaticity, and examples thereof include benzene-based aromatic rings such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring, aromatic heterocycles such as a pyridine ring and a thiophene ring, and non-benzene-based aromatic rings such as an indene ring and an azulene ring.
- benzene-based aromatic rings such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring
- aromatic heterocycles such as a pyridine ring and a thiophene ring
- non-benzene-based aromatic rings such as an indene ring and an azulene ring.
- the ring structure that the carboxylic acid dianhydride (B) has in its molecule is preferably at least one selected from the group consisting of a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a benzene ring, and a naphthalene ring, and from the viewpoint of further increasing the heat resistance of the resin layer, at least one of a benzene ring and a naphthalene ring is more preferable. Furthermore, from the viewpoint of suppressing the occurrence of voids in the resin layer when a resin layer is formed between multiple substrates using composition B, it is preferable that the resin layer contains two or more benzene rings.
- the multiple ring structures may be the same or different and may form a condensed ring.
- the multiple ring structures may be bonded by a single bond or may be bonded via a linking group such as an ether group, a carbonyl group, a sulfonyl group, or a methylene group.
- Carboxylic acid dianhydride (B) may have a fluorine atom in the molecule. For example, it may have 1 to 6 fluorine atoms in the molecule, or may have 3 to 6 fluorine atoms in the molecule.
- carboxylic acid dianhydride (B) may have a fluoroalkyl group in the molecule, specifically, it may have a trifluoroalkyl group or a hexafluoroisopropyl group.
- Examples of the carboxylic acid dianhydride (B) include dianhydrides of compounds having a ring structure in the molecule and four carboxy groups capable of forming an anhydride group.
- anhydrides of alicyclic tetracarboxylic acids such as 1,2,3,4-cyclobutanetetracarboxylic acid, 1,2,3,4-cyclopentanetetracarboxylic acid, 1,2,4,5-cyclohexanetetracarboxylic acid, and 1,2,3,4,5,6-cyclohexanehexacarboxylic acid
- Dianhydrides of benzenetetracarboxylic acids such as pyromellitic acid
- Dianhydrides of naphthalenetetracarboxylic acids such as 1,4,5,8-naphthalenetetracarboxylic acid and 2,3,6,7-naphthalenetetracarboxylic acid
- dianhydrides of biphenyltetracarboxylic acids such as 3,3',4,4
- the content of carboxylic dianhydride (B) in composition B is, for example, an amount such that the ratio (A/B) of the functional group equivalent number A of the silane coupling agent (A) capable of reacting with the anhydride group of the carboxylic dianhydride (B) to the anhydride group equivalent number B of the carboxylic dianhydride (B) is 0.9 or more and 1.1 or less, more preferably 0.95 or more and 1.05 or less, and even more preferably 0.98 or more and 1.02 or less.
- composition B further contains a compound capable of reacting with the anhydride group of the carboxylic dianhydride (B), such as compound (C) described below
- the ratio (A'/B') of the functional group equivalent number A' of all compounds capable of reacting with the anhydride group of the carboxylic dianhydride (B) to the anhydride group equivalent number B' of the carboxylic dianhydride (B) is preferably an amount that is 0.9 or more and 1.1 or less, more preferably an amount that is 0.95 or more and 1.05 or less, and even more preferably an amount that is 0.98 or more and 1.02 or less.
- the amine compound (C) is a compound having one or more ring structures and one or more amino groups in the molecule, a molecular weight of 90 to 600, and no Si—O bond.
- the amine compound (C) may be used alone or in combination of two or more kinds.
- the number of amino groups in the molecule of the amine compound (C) may be one or more, but from the viewpoint of reducing the thermal expansion coefficient of the resin layer, it is preferable that there are more than one, and more preferably two (diamine) or three (triamine). From the viewpoint of forming an imide structure in the resin layer to improve heat resistance, it is more preferable that there is a primary amino group (-NH2).
- the amine compound (C) has one or more amino groups directly bonded to the ring structure. If the molecular structure of the compound (X2) contains a structure derived from an amino group directly bonded to the ring structure, it is believed that the rigidity of the molecular structure increases, further reducing the thermal expansion coefficient.
- an amino group directly bonded to a ring structure means an amino group that is bonded to a ring structure via a single bond (i.e., not via a carbon atom, etc.).
- the amine compound (C) may have one ring structure or multiple ring structures in the molecule.
- the multiple ring structures may be the same or different and may form a condensed ring.
- the multiple ring structures may be bonded by a single bond or may be bonded via a linking group such as an ether group, a carbonyl group, a sulfonyl group, or a methylene group.
- Examples of the ring structure contained in the amine compound (C) include an alicyclic structure, an aromatic ring (including a heterocyclic ring) structure, and a condensed ring structure thereof.
- the alicyclic structure may be an alicyclic structure having 3 to 8 carbon atoms, preferably 4 to 6 carbon atoms.
- the ring structure may be saturated or unsaturated.
- examples of the alicyclic structure include saturated alicyclic structures such as a cyclopropane ring, a cyclobutane ring, a cyclopentane ring, a cyclohexane ring, a cycloheptane ring, and a cyclooctane ring; and unsaturated alicyclic structures such as a cyclopropene ring, a cyclobutene ring, a cyclopentene ring, a cyclohexene ring, a cycloheptene ring, and a cyclooctene ring.
- aromatic ring structures include aromatic ring structures having 6 to 20 carbon atoms, preferably 6 to 10 carbon atoms.
- Specific examples include benzene-based aromatic ring structures such as a benzene ring, a naphthalene ring, an anthracene ring, and a perylene ring, and non-benzene-based aromatic ring structures such as a pyridine ring, a thiophene ring, an indene ring, and an azulene ring.
- the heterocyclic structure may be a 3- to 10-membered, preferably a 5- or 6-membered heterocyclic structure.
- heteroatoms contained in the heterocyclic ring include a sulfur atom, a nitrogen atom, and an oxygen atom, and may be one or more of these.
- heterocyclic structure examples include an oxazole ring, a thiophene ring, a pyrrole ring, a pyrrolidine ring, a pyrazole ring, an imidazole ring, a triazole ring, an isocyanuric ring, a pyridine ring, a pyridazine ring, a pyrimidine ring, a pyrazine ring, a piperidine ring, a piperazine ring, a triazine ring, an indole ring, an indoline ring, a quinoline ring, an acridine ring, a naphthyridine ring, a quinazoline ring, a purine ring, and a quinoxaline ring.
- the ring structure that the amine compound (C) has in its molecule is preferably a benzene ring, a cyclohexane ring, or a benzoxazole ring.
- the ring structure that the amine compound (C) has in its molecule may have a substituent other than an amino group.
- it may have an alkyl group having 1 to 6 carbon atoms, an alkyl group substituted with a halogen atom, etc.
- amine compound (C) examples include the following compounds.
- alicyclic amine examples include cyclohexylamine and dimethylaminocyclohexane.
- aromatic ring amines include diaminodiphenyl ether, xylylene diamine (preferably paraxylylene diamine), diaminobenzene, diaminotoluene, methylene dianiline, dimethyldiaminobiphenyl, bis(trifluoromethyl)diaminobiphenyl (TFDB), diaminobenzophenone, diaminobenzanilide, bis(aminophenyl)fluorene, bis(aminophenoxy)benzene, bis(aminophenoxy)biphenyl, dicarboxydiaminodiphenylmethane, diaminoresorcin, dihydroxybenzidine, diaminobenzidine, 1,3,5-triaminophenoxybenzene, 2,2'-dimethyl
- heterocyclic amines having a nitrogen-containing heterocycle include melamine, ammeline, melam, melem, and tris(4-aminophenyl)amine.
- examples of amine compounds having both a heterocycle and an aromatic ring include N2,N4,N6-tris(4-aminophenyl)-1,3,5-triazine-2,4,6-triamine and 2-(4-aminophenyl)benzoxazol-5-amine (AAPD).
- Method for obtaining compound (X1) As a method for obtaining the compound (X1) by reacting the silane coupling agent (A) with the carboxylic dianhydride (B), for example, a method in which the silane coupling agent (A) is gradually added dropwise to the carboxylic dianhydride (B) while adding the carboxylic dianhydride (B) to a solvent and stirring the mixture, to obtain the compound (X1), can be mentioned.
- Method for obtaining compound (X2) As a method for obtaining the compound (X2) by reacting the silane coupling agent (A), the carboxylic dianhydride (B) and the amine compound (C), for example, a method can be mentioned in which a solvent is added to the amine compound (C) and the mixture is stirred while the carboxylic dianhydride (B) is added, the mixture is stirred until the viscosity of the obtained reaction product (polymer) becomes constant, and then the silane coupling agent (A) is gradually added dropwise to obtain the compound (X2).
- composition B may further contain a compound other than compound (X1) and compound (X2).
- a precursor of resin (D) having a CTE of 90 ppm/K or less between 50° C. and 150° C.
- composition B contains a precursor of resin (D)
- the thermal expansion coefficient of the resulting resin layer tends to be further reduced.
- the resin (D) having a CTE of 90 ppm/K or less between 50° C. and 150° C. include at least one selected from the group consisting of polyimide and polybenzoxazole.
- the CTE of the resin (D) can be measured in the same manner as the CTE of the resin layer.
- composition B contains resin (D)
- the proportion of resin (D) contained in composition B is preferably 99% to 30% by mass of the total non-volatile content of composition B, from the viewpoint of the balance between the thermal expansion coefficient and bonding strength of the resulting resin layer.
- non-volatile content refers to components other than components (solvent, etc.) that are removed when composition B becomes a cured product.
- Organic solvent Composition B may contain an organic solvent.
- the organic solvent is not particularly limited as long as it can dissolve compound (X).
- examples of the organic solvent include aprotic solvents, phenol-based solvents, ether-based solvents, and glycol-based solvents.
- the organic solvent may be used alone or in combination of two or more kinds.
- aprotic solvents include amide-based solvents such as N,N-dimethylformamide (DMF), N,N-dimethylacetamide (DMAc), N-methyl-2-pyrrolidone (NMP), N-methylcaprolactam, 1,3-dimethylimidazolidinone, and tetramethylurea; lactone-based solvents such as ⁇ -butyrolactone and ⁇ -valerolactone; phosphorus-containing amide-based solvents such as hexamethylphosphoric amide and hexamethylphosphine triamide; sulfur-containing solvents such as dimethyl sulfone, dimethyl sulfoxide, and sulfolane; ketone-based solvents such as cyclohexanone and methylcyclohexanone; tertiary amine-based solvents such as picoline and pyridine; and ester-based solvents such as 2-methoxy-1-methylethyl acetate.
- phenol-based solvent examples include phenol, o-cresol, m-cresol, p-cresol, 2,3-xylenol, 2,4-xylenol, 2,5-xylenol, 2,6-xylenol, 3,4-xylenol, and 3,5-xylenol.
- ether-based solvents and glycol-based solvents include 1,2-dimethoxyethane, bis(2-methoxyethyl)ether, 1,2-bis(2-methoxyethoxy)ethane, bis[2-(2-methoxyethoxy)ethyl]ether, tetrahydrofuran, and 1,4-dioxane.
- the boiling point of the organic solvent at normal pressure is preferably 60°C to 300°C, more preferably 140°C to 280°C, and even more preferably 170°C to 270°C. If the boiling point of the solvent is 300°C or lower, the organic solvent can be easily volatilized and removed in the resin layer formation process. If the boiling point of the solvent is 60°C or higher, a resin layer with a uniform surface condition can be obtained.
- composition B contains an organic solvent
- its content is not particularly limited, and may be, for example, 1.0% by mass or more and 99.99896% by mass or less, or 40% by mass or more and 99.99896% by mass or less, based on the total amount of composition B.
- composition B may contain components other than those described above, if necessary.
- the composition B may contain a metal alkoxide represented by the following general formula (I).
- R1nM(OR2)m ⁇ n...(I) (In the formula, R1 is a non-hydrolyzable group, R2 is an alkyl group having 1 to 6 carbon atoms, M is at least one metal atom selected from the group consisting of Ti, Al, Zr, Sr, Ba, Zn, B, Ga, Y, Ge, Pb, P, Sb, V, Ta, W, La, Nd, and In, m is the valence of the metal atom M and is 3 or 4, n is an integer of 0 to 2 when m is 4, and is 0 or 1 when m is 3, when there are multiple R1s, each R1 may be the same as or different from another, and when there are multiple OR2s, each OR2 may be the same as or different from another.)
- a silane compound (excluding those corresponding to the silane coupling agent (A)) may be contained in order to improve the insulation properties or mechanical strength.
- silane compound examples include tetraethoxysilane, tetramethoxysilane, bistriethoxysilylethane, bistriethoxysilylmethane, bis(methyldiethoxysilyl)ethane, 1,1,3,3,5,5-hexaethoxy-1,3,5-trisilacyclohexane, 1,3,5,7-tetramethyl-1,3,5,7-tetrahydroxylcyclosiloxane, 1,1,4,4-tetramethyl-1,4-diethoxydisilethylene, and 1,3,5-trimethyl-1,3,5-trimethyl-1,3,5-triethoxy-1,3,5-trisilacyclohexane.
- Composition B may contain benzotriazole or a derivative thereof, for example to inhibit copper corrosion.
- composition B is not particularly limited, but is preferably from 2.0 to 12.0.
- the sodium and potassium contents of Composition B are preferably 10 ppb by mass or less on an elemental basis, respectively. If the sodium or potassium contents are 10 ppb by mass or less on an elemental basis, respectively, the occurrence of problems in the electrical characteristics of the semiconductor device, such as transistor malfunctions, can be suppressed.
- the content of inorganic or resin fillers having a maximum diameter of 0.3 ⁇ m or more is preferably 30 mass % or less of the total nonvolatile content, more preferably 10 mass % or less, and even more preferably 0 mass %.
- the content of the filler contained in composition B is within the above range, poor bonding of the laminate can be suppressed even when the thickness of the resin layer formed using composition B is reduced.
- alignment may be performed by mechanically recognizing alignment marks formed on each substrate, and when the content of the filler is within the above range, the transparency of the resin film is improved, enabling more accurate alignment.
- Example 1 Preparation of solution containing organic substance-containing layer forming material> A solution containing a material for forming an organic substance-containing layer was prepared. The details are as follows: As a material for forming an organic substance-containing layer, 50% by mass of 3-aminopropyldiethoxymethylsilane (3APDES) and 50% by mass of water were mixed to obtain a solution A containing a hydrolysate of 3APDES. A solution B containing 70% by mass of oxydiphthalic acid half ester (Y in formula (B-2) is O and R is an ethyl group) and 30% by mass of ethanol was obtained. 24 g of solution A, 18 g of solution B, 20 g of 1-propanol, and 38 g of water were mixed together to prepare a solution containing an organic substance-containing layer forming material.
- 3APDES 3-aminopropyldiethoxymethylsilane
- a silicon wafer as a first substrate was placed on a spin coater, and 2.0 mL of the solution containing the organic substance-containing layer-forming material was dropped onto the silicon wafer at a constant speed for 10 seconds, and after holding for 23 seconds, the wafer was rotated at 2000 rpm (rpm is the rotation speed per minute) for 1 second, at 600 rpm for 30 seconds, and then rotated at 2000 rpm for 10 seconds to dry the wafer.
- the first substrate to which the organic substance-containing layer-forming material was applied was heated for 1 hour at 200° C. in a nitrogen atmosphere.
- a resin layer (thickness: 1 ⁇ m) containing a siloxane bond and an imide bond was formed as an organic substance-containing layer serving as a first bonding layer on the first substrate, and a first laminate was obtained.
- the resin layer contains the following structure including a siloxane bond and an imide bond.
- a silicon wafer (second substrate) having a SiO 2 layer (second bonding layer) with a thickness of 0.1 nm to 10 nm formed on its surface was prepared.
- the organic substance-containing layer in the first laminate obtained above was subjected to O2 plasma treatment as a surface activation treatment using a plasma treatment device (SUSS PL12).
- the first laminate was fixed to a metal holder and set in a load lock chamber of a plasma processing apparatus.
- the load lock chamber was evacuated to a vacuum level of 1.0 ⁇ 10 ⁇ 3 Pa or less.
- the first laminate was transferred from the load lock chamber to a plasma processing chamber.
- the plasma processing chamber was evacuated to a vacuum level of 2.0 ⁇ 10 ⁇ 4 Pa or less.
- Oxygen gas was introduced into the plasma processing chamber to adjust the pressure in the plasma processing chamber.
- O2 plasma oxygen gas plasma
- the plasma processing chamber was evacuated to a vacuum, and the first laminate after the plasma processing was carried out into a load lock chamber.
- the load lock chamber was vented with oxygen gas, and opened to the atmosphere, and the first laminate after the plasma processing was taken out from the load lock chamber.
- the Si content (atomic %) in the organic-substance-containing layer in the first laminate was measured at a total of seven points, namely, the surface at a depth of 0 nm and six points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm.
- the Si content at each measurement point was measured using X-ray photoelectron spectroscopy (XPS, ESCA) under the following conditions.
- the Si content was derived from the ratio (%) of the integrated intensity of the peak components from 95 eV to 110 eV, which are peak components derived from silicon atoms, to the integrated intensity of all peak components from 95 eV to 540 eV in the spectral range from 0 eV to 13,000 eV. Measurements at points other than the surface were performed while sputtering and etching the organic substance-containing layer.
- Quantera II manufactured by PHI
- X-ray source monochromatic Al (1486.6 eV)
- Detection area 200 ⁇ m ⁇
- Sputtering conditions Ar, +1.0 kV Sputtering rate: 2 nm/min ( SiO2 equivalent value)
- Measurement locations a total of seven locations: before sputtering (i.e., the surface), and six locations at 0.5 min after sputtering, 1.5 min after sputtering, 3 min after sputtering, 6 min after sputtering, 11 min after sputtering, and 15 min after sputtering.
- the amount of O segregation in the organic-containing layer (value at surface - minimum value among 6 points) was measured in the same manner as in the measurement of the amount of Si segregation in the organic-containing layer, except that the O content (atomic %) was calculated based on the integrated intensity of 525 to 540 eV, which is a peak component derived from oxygen (O) atoms.
- the amount of Si segregation in organic substance-containing layer (value at surface - value at one point at a depth of 7 nm) was determined in the same manner as the amount of Si segregation in the organic-containing layer (value at the surface ⁇ minimum value among the six points), except that the six measurement points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm were changed to one measurement point at a depth of 7 nm, and the value obtained by subtracting the value at the depth of 7 nm from the measurement value at the surface was used as the amount of Si segregation (atomic %).
- Table 1 The results are shown in Table 1.
- the amount of O segregation in the organic-containing layer (value at surface - value at one point at a depth of 7 nm) was determined in the same manner as the amount of O segregation in the organic-containing layer (value at the surface ⁇ minimum value among six points), except that the six measurement points at depths of 1 nm, 3 nm, 6 nm, 12 nm, 22 nm, and 30 nm were changed to one measurement point at a depth of 7 nm, and the value obtained by subtracting the value at the depth of 7 nm from the measurement value at the surface was used as the amount of O segregation (atomic %).
- Table 1 The results are shown in Table 1.
- the composite elastic modulus is defined by the following formula (1):
- Er represents the composite elastic modulus
- Ei represents the Young's modulus of the indenter and is 1140 GPa
- ⁇ i represents the Poisson's ratio of the indenter and is 0.07
- Es and ⁇ s represent the Young's modulus and Poisson's ratio of the sample, respectively.
- the bonding strength between the first laminate and the second laminate at room temperature 25° C.
- the bonding strength at room temperature 25° C.
- the results are shown in Table 1.
- the bonding strength at room temperature was determined by a blade insertion test according to the method of MP Maszara, G. Goetz, A. Cavigila, and J. B. McKitterick, Journal of Applied Physics, 64 (1988) 4943-4950.
- a blade having a thickness of 0.1 mm to 0.3 mm was inserted at room temperature ( 25° C.) into the bonding interface between the first laminate and the second laminate in the substrate laminate (i.e., the bonding interface between the organic substance-containing layer in the first laminate and the SiO 2 layer in the second laminate), and the distance from the blade tip to the position where the first laminate and the second laminate peeled off was measured using an infrared light source and an infrared camera, and the surface energy was calculated based on the obtained distance according to the following formula. The obtained surface energy was determined as the bonding strength.
- ⁇ 3 ⁇ 109 ⁇ tb2 ⁇ E2 ⁇ t6 /(32 ⁇ L4 ⁇ E ⁇ t3 )
- ⁇ represents the surface energy (J/ m2 )
- tb represents the blade thickness (m)
- E represents the Young's modulus (GPa) of the silicon substrate contained in the first laminate and the second laminate
- t represents the thickness (m) of the first laminate and the second laminate
- L represents the distance from the blade tip to the position where the first laminate and the second laminate are peeled off.
- Example 2 The same operation as in Example 1 was performed, except that the O2 gas used in the surface activation treatment was changed to N2 gas instead of O2 plasma treatment, thereby changing the surface activation treatment to N2 plasma treatment.
- the results are shown in Table 1.
- Comparative Example 1 The same procedure as in Example 1 was carried out, except that the surface activation treatment was not carried out. The results are shown in Table 1.
- Examples 1 and 2 in which the surface activation treatment was performed on the organic-containing layer, had superior bonding strength at room temperature between the first laminate and the second laminate, compared to Comparative Example 1, in which the surface activation treatment was not performed on the organic-containing layer.
- Example 1 and Comparative Example 1 In Comparative Examples 2 and 3, the same operations as in Example 1 and Comparative Example 1 were carried out, respectively, except for the following points. The results are shown in Table 2. --Changes to Example 1 and Comparative Example 1-- As the first laminate, instead of the silicon wafer with an organic substance-containing layer in Example 1 and Comparative Example 1, a silicon wafer with a SiO 2 layer similar to the second laminate was used. The SiO2 layer in the first laminate was subjected to a surface activation treatment. The SiO2 layer of the first laminate after the surface activation treatment was washed with water at 25° C. for 30 seconds.
- the first laminate (i.e., silicon wafer with SiO2 layer) and the second laminate (i.e., silicon wafer with SiO2 layer) after the water washing were bonded at room temperature (25°C) in such a manner that the SiO2 layer of the first laminate and the SiO2 layer of the second substrate were in contact with each other to obtain a substrate laminate.
- the bonding conditions were in the atmosphere, at room temperature, and pressure of 0.2 MPa for 1 second.
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Abstract
Description
例えば特許文献1には、第1の半導体ウエハの表面側に配線層を形成する工程と、第1の半導体ウエハの周縁領域と、該周縁領域よりも内側の内側領域との境に形成された前記配線層上の段差であって、前記周縁領域における配線層上の表面が前記内側領域における配線層上の表面よりも低く形成されることによって形成された段差を埋め込むように埋め込み膜を形成し、周縁領域と内側領域における配線層上の表面をほぼ面一とする工程と、前記第1の半導体ウエハに形成された配線層上の表面と第2の半導体ウエハの所望の面とを向かい合わせて貼り合わせる工程と、を有する半導体装置の製造方法が開示されている。
基板同士を低温で接合することができれば、基板積層体を製造する際のプロセススピードが向上することが期待される。
例えば、基板同士を低温で永久接合することが可能となれば、昇温・降温を少なくでき、プロセススピードが大幅に向上する。
また、低温で基板同士を仮接合し、その後、加熱によって基板同士を永久接合する場合においても、低温で仮接合の強度が向上すれば、基板積層体に加わるトータルでの熱ダメージを低減できることが期待される。
本開示の一態様の課題は、基板同士を低温(例えば140℃以下)で接合する際の接合強度を向上させることができる基板積層体の製造方法、上記基板積層体の製造方法における一原料として好適な積層体、及び、基板同士の接合強度に優れる基板積層体を提供することである。
<1> 第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出している第1の積層体を準備し、かつ、第2の基板及び第2の接合層を含む第2の積層体を準備する工程Aと、
前記第1の積層体における前記有機物含有層の表面に、表面活性化処理を施す工程Bと、
前記工程Bを経た前記第1の積層体と、前記第2の積層体と、を、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合させて基板積層体を得る工程Cと、
を含む、基板積層体の製造方法。
<2> 前記有機物含有層が、Siを含む、<1>に記載の基板積層体の製造方法。
<3> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大である、<1>又は<2>に記載の基板積層体の製造方法。
<4> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~50原子%である、<1>~<3>のいずれか1つに記載の基板積層体の製造方法。
<5> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大である、<1>~<4>のいずれか1つに記載の基板積層体の製造方法。
<6> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~70原子%である、<1>~<5>のいずれか1つに記載の基板積層体の製造方法。
<7> 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の前記表面は、JIS B 0601:1982で規定される表面粗さRaが、5nm以下である、<1>~<6>のいずれか1つに記載の基板積層体の製造方法。
<8> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面において、原子%でのSiの含有率を測定した場合に、前記表面での測定値が、5原子%~70原子%である、<1>~<7>のいずれか1つに記載の基板積層体の製造方法。
<9> 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面において、原子%でのOの含有率を測定した場合に、前記表面での測定値が、10原子%~80原子%である、<1>~<8>のいずれか1つに記載の基板積層体の製造方法。
<10> 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の複合弾性率が、1GPa~20GPaである、<1>~<9>のいずれか1つに記載の基板積層体の製造方法。
<11> 前記基板積層体における、前記第1の積層体と前記第2の積層体との接合強度が、0.2J/m2以上である、<1>~<10>のいずれか1つに記載の基板積層体の製造方法。
<12> 前記第2の接合層は、無機材料層を含み、前記無機材料層の表面が露出しており、
前記工程Cは、前記第1の積層体における前記有機物含有層の前記表面と、前記第2の基板における前記無機材料層の前記表面と、を接合させる、
<1>~<11>のいずれか1つに記載の基板積層体の製造方法。
<13> 前記第1の基板の熱膨張率と前記第2の基板の熱膨張率とが異なる、<1>~<12>のいずれか1つに記載の基板積層体の製造方法。
<14> 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の前記表面が、シラノール基を含む、<1>~<13>のいずれか1つに記載の基板積層体の製造方法。
<15> 前記有機物含有層が、シロキサン結合、アミド結合、及びイミド結合からなる群より選択される少なくとも1種を含む、<1>~<14>のいずれか1つに記載の基板積層体の製造方法。
<16> 前記表面活性化処理が、プラズマ処理、高速原子線照射、及びオゾン処理からなる群より選択される少なくとも1種である、<1>~<15>のいずれか1つに記載の基板積層体の製造方法。
<17> 前記プラズマ処理が、酸素プラズマ処理及び窒素プラズマ処理からなる群より選択される少なくとも1種である、<16>に記載の基板積層体の製造方法。
<18> 前記工程Cにおける、前記第1の積層体と前記第2の積層体との接合面の温度が、140℃以下である、<1>~<17>のいずれか1つに記載の基板積層体の製造方法。
<19> 前記工程Aで準備される前記第1の積層体において、前記第1の接合層が第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出している、<1>~<18>のいずれか1つに記載の基板積層体の製造方法。
<20> 前記工程Aで準備される前記第1の積層体において、前記第1の接合層が第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出しており、
前記工程Aで準備される前記第2の積層体において、前記第2の接合層が、第2の電極と絶縁層とを含み、前記第2の積層体において、前記第2の電極の表面と前記絶縁層の表面とが露出しており、
前記工程Cで得られる前記基板積層体は、
前記第1の基板と、前記有機物含有層と、前記絶縁層と、前記第2の基板と、がこの順序で配置されている第1の積層領域と、
前記第1の基板と、前記第1の電極と、前記第2の電極と、前記第2の基板と、がこの順序で配置されている第2の積層領域と、
を含む、
<1>~<19>のいずれか1つに記載の基板積層体の製造方法。
<21> 前記工程Cで得られる前記基板積層体において、前記第1の積層領域が、積層方向に2つ以上存在し、かつ、前記第2の積層領域が、積層方向に2つ以上存在する、<20>に記載の基板積層体の製造方法。
<22> 前記第1の基板及び前記第2の基板の少なくとも一方は、Si、Al、Ti、Zr、Hf、Fe、Ni、Cu、Ag、Au、Ga、Ge、Sn、Pd、As、Pt、Mg、In、Ta、及びNbからなる群より選択される少なくとも1種の元素を含む半導体基板である、<1>~<21>のいずれか1つに記載の基板積層体の製造方法。
<23> 第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出しており、
前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大である、
積層体。
<24> 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~50原子%である、<23>に記載の積層体。
<25> 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大である、<23>又は<24>に記載の積層体。
<26> 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~70原子%である、
<23>~<25>のいずれか1つに記載の積層体。
<27> 前記有機物含有層の複合弾性率が、1GPa~20GPaである、<23>~<26>のいずれか1つに記載の積層体。
<28> 前記有機物含有層が、シロキサン結合、アミド結合、及びイミド結合からなる群から選択される少なくとも1種を含む、<23>~<27>のいずれか1つに記載の積層体。
<29> <23>~<28>のいずれか1つに記載の積層体である第1の積層体と、
第2の基板及び第2の接合層を含む第2の積層体と、
を含み、
前記第1の積層体及び前記第2の積層体は、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合されている、
基板積層体。
<30> 表面エネルギーで表した、前記第1の積層体と前記第2の積層体との接合強度が、0.2J/m2以上である、<29>に記載の基板積層体。
<31> 前記第1の接合層が、第1の電極を更に含み、
前記第2の接合層が、第2の電極と絶縁層とを含み、
前記有機物含有層と前記絶縁層とが接合され、かつ、前記第1の電極と前記第2の電極とが接合されている、
<29>又は<30>に記載の基板積層体。
本開示中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本開示中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本開示の基板積層体の製造方法(以下、「本開示の製造方法」ともいう)は、
第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出している第1の積層体を準備し、かつ、第2の基板及び第2の接合層を含む第2の積層体を準備する工程Aと、
前記第1の積層体における前記有機物含有層の表面に、表面活性化処理を施す工程Bと、
前記工程Bを経た前記第1の積層体と、前記第2の積層体と、を、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合させて基板積層体を得る工程Cと、
を含む。
本開示の製造方法は、必要に応じ、その他の工程を含んでいてもよい。
かかる効果は、第1の積層体における第2の積層体との接合界面である有機物含有層の表面に、表面活性化処理を施すことによる効果と考えられる。
本開示の製造方法は、工程Aを含む。
工程Aは、
第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出している第1の積層体を準備し、かつ、
第2の基板及び第2の接合層を含む第2の積層体を準備する
工程である。
同様に、工程Aは、第2の積層体を製造する工程であってもよいし、すでに製造されている第2の積層体を単に準備するだけの工程であってもよい。
第1の積層体は、第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出している積層体である。
第1の基板の材質は、特に限定されず、通常使用されるものであればよい。
Si、InP、GaN、GaAs、InGaAs、InGaAlAs、SiGe、SiC等の半導体;ホウ素珪酸ガラス(パイレックス(登録商標))、石英ガラス(SiO2)、サファイア(Al2O3)、ZrO2、Si3N4、AlN、MgAl2O4、等の酸化物、炭化物、又は窒化物;
BaTiO3、LiNbO3、SrTiO3、LiTaO3、ガドリウムガリウムガーネット(Gd3Ga5O12)、等の圧電体又は誘電体;
ダイヤモンド;
Al、Ti、Fe、Cu、Ag、Au、Pt、Pd、Ta、Nb等の金属;
カーボン;
ポリジメチルシロキサン(PDMS)、エポキシ樹脂、フェノール樹脂、ポリイミド、ベンゾシクロブテン樹脂、ポリベンゾオキサゾール等の樹脂;
などが挙げられる。
Siは、半導体メモリー、LSI、CMOSイメージセンサー、MEMS、光学デバイス、LEDなどに使用される。
SiO2は、MEMS封止、マイクロ流路、2.5D実装用インターポーザー、ディスプレイなどに使用される。
BaTiO3、LiNbO3,SrTiO3、LiTaO3、Gd3Ga5O12は、表面弾性波デバイスなどに使用される。
PDMSは、マイクロ流路などに使用される。
InGaAlAs、InGaAs、InPは、光学デバイスなどに使用される。
InGaAlAs、GaAs、GaNは、LEDなどに使用される。
--有機物含有層--
第1の接合層は有機物含有層を含む。
第1の積層体において、有機物含有層の表面が露出している。
この有機物含有層の表面が、第2の積層体との接合面となる。
有機物含有層は、無機フィラー等の無機物を含有してもよい。
樹脂としては、ポリイミド、BCB、ポリマレイミド、シロキサンイミド、エポキシ変性シロキサン、ポリベンゾオキサゾールなどが挙げられる。
また、樹脂としては、後述する組成物Aの硬化物又は後述する組成物Bの硬化物も挙げられる。
これにより、低温での接合強度がより向上する。
シロキサン結合、アミド結合、及びイミド結合からなる群より選択される少なくとも1種を含む態様の有機物含有層は、例えば、後述する組成物A又は後述する組成物Bを用いて形成され得る。
上述の構成とした場合、以下の効果が得られると考えられる。
即ち、有機物含有層の表面にSiの含有率が多く存在することで、低温での接合強度がより向上し、かつ、有機物含有層の内部でのSiの含有率が、有機物含有層の表面でのSiの含有率に比べて少ないことにより、有機物含有層の柔軟性を高めることができ、ボイドを生じにくくすることができると考えられる。
上述の構成とした場合、以下の効果が得られると考えられる。
即ち、有機物含有層の表面にSiの含有率が多く存在することで、低温での接合強度がより向上し、かつ、有機物含有層の内部でのSiの含有率が、有機物含有層の表面でのSiの含有率に比べて少ないことにより、有機物含有層の柔軟性を高めることができ、ボイドを生じにくくすることができると考えられる。
上記表面粗さRaの下限は特に制限はないが、例えば0.01nmである。
前記工程Aで準備される前記第1の積層体において、前記第1の接合層は、第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出していることが好ましい。
第1の電極としては、Cu、金、スズ等を含む電極が挙げられる。
第1の電極としては、有機物含有層を貫通する電極が挙げられる。
第2の積層体は、第2の基板及び第2の接合層を含む。
第2の基板としては、第1の基板と同様のものが挙げられる。
第2の基板の材質は、第1の基板の材質と同種であってもよいし、異なっていてもよい。
一般的には、CTEが異なる2つの基板を接合させた基板積層体では、反りや割れが生じやすい傾向となる。
しかし本開示の製造方法では、前述のとおり、基板同士を低温(例えば140℃以下)で接合することができるので、第1の基板の熱膨張率(CTE)と第2の基板の熱膨張率(CTE)とが異なる場合においても、基板積層体の反りや割れを抑制できる。
第2の積層体における第2の接合層は、絶縁層を含み得る。
絶縁層としては、無機材料層及び有機物含有層の少なくとも一方が好ましい。
第2の接合層に含まれ得る有機物含有層としては、第1の積層体に含まれる有機物含有層と同様のものが挙げられる。
第2の接合層に含まれ得る無機材料層としては、SiO2層、SiCN層、又はSiN層等が挙げられる。これらの無機材料層は、例えば、公知の気相法によって形成され得る。
また、工程Aで準備する第2の積層体における第2の接合層が無機材料層を含む態様は、基材積層体を形成した時の内部応力をより低減できるので、後述する第1の電極及び第2の電極の接合が行われる場合には、第1の電極及び第2の電極の接合の安定性にも優れる。
工程Aで準備する第2の積層体における第2の接合層が無機材料層を含む場合、無機材料層が露出していること(即ち、第1の積層体における有機物含有層との接合面となること)が好ましい。
この場合、第2の積層体は、最表層である第2の接合層として無機材料層を含み、かつ、その下層側に(即ち、第2の基板に近い側に)有機物含有層を含んでいてもよい。即ち、第2の積層体は、無機材料層(第2の接合層)/有機物含有層/第2の基板の積層構造を有していてもよい。
この場合の第2の積層体は、最表層である第2の接合層として有機物含有層を含み、かつ、その下層側に(即ち、第2の基板に近い側に)無機材料層を含んでいてもよい。即ち、第2の積層体は、有機物含有層(第2の接合層)/無機材料層/第2の基板の積層構造を有していてもよい。
この態様によれば、第1の積層体と第2の積層体とをハイブリッド接合させ得る。
ハイブリッド接合については後述する。
本開示の製造方法は、前記第1の積層体における前記有機物含有層の表面に、表面活性化処理を施す工程Bを含む。
これにより、低温での接合強度がより向上する。
これにより、低温での接合強度がより向上する。
本開示の製造方法は、工程Cを含む。
工程Cは、前記工程Bを経た前記第1の積層体と、前記第2の積層体と、を、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合させて基板積層体を得る工程である。
前記工程Aで準備される前記第1の積層体において、前記第1の接合層が第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出しており、
前記工程Aで準備される前記第2の積層体において、前記第2の接合層が、第2の電極と絶縁層とを含み、前記第2の積層体において、前記第2の電極の表面と前記絶縁層の表面とが露出している態様である。
この態様によれば、第1の積層体と第2の積層体とをハイブリッド接合させ得る。
ハイブリッド接合は、配線間隔の狭ピッチ化の点で有利である。
但し、本開示の製造方法は、以下の具体例には限定されない。
以下の説明において、実質的に同一の要素(例えば部品又は部分)については、同一の符号を付し、重複した説明を省略する場合がある。
図1に示されるように、本一例では、第1の積層体10及び第2の積層体20をそれぞれ準備する。
第1の積層体10は、第1の基板11と、第1の接合層16と、を含む。
第1の接合層16は、有機物含有層12と、第1の電極14と、を含む。有機物含有層12の表面、及び、第1の電極14の表面は、それぞれ露出している。
工程Bでは、この有機物含有層12の表面に、表面活性化処理が施され、次いで水洗浄が施される。
第2の接合層26は、無機材料層22と、第2の電極24と、を含む。無機材料層22の表面、及び、第2の電極24の表面は、それぞれ露出している。
図2に示されるように、基板積層体100は、第1の積層体10と第2の積層体20とが、第1の接合層16及び第2の接合層26が接する向きに接合される。
この際、ハイブリッド接合により、第1の電極14と第2の電極24とが接合され、かつ、有機物含有層12と、無機材料層22と、が接合される。
工程Cで得られる前記基板積層体は、好ましくは、
前記第1の基板と、前記有機物含有層と、前記絶縁層と、前記第2の基板と、がこの順序で配置されている第1の積層領域と、
前記第1の基板と、前記第1の電極と、前記第2の電極と、前記第2の基板と、がこの順序で配置されている第2の積層領域と、
を含む。
第1の積層領域及び第2の積層領域は、前述したハイブリッド接合によって形成され得る。
前記工程Cで得られる前記基板積層体において、第2の積層領域は、1つのみ存在していてもよいし、2つ以上存在していてもよい。第2の積層領域が2つ以上存在する場合も、第1の積層体及び第2の積層体の少なくとも一方が、2つ以上存在する。
例えば、図示は省略するが、基板の一方の面上に第1の接合層を設け、かつ、基板の他方の面上に第2の接合層を設け、得られた基板を、3つ以上積層させることにより、第1の積層領域及び第2の積層領域を2つ以上存在させることができる。この場合の基板は、第1の接合層が設けられている側では第1の積層体として機能し、第2の接合層が設けられている側では第2の積層体として機能する。
<第1実施形態>
本開示の第1実施形態に係る積層体は、第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出しており、
前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大である積層体である。前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値は、好ましくは3原子%~50原子%である。
本開示の第2実施形態に係る積層体は、第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出しており、前記有機物含有層における、深さ0nmである表面と、深さ7nmの位置と、において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が前記深さ7nmの位置での測定値よりも大きい積層体である。前記表面での測定値から前記深さ7nmの位置での測定値を差し引いた値は、好ましくは3原子%~50原子%である。
本開示の第3実施形態に係る積層体は、第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出しており、前記有機物含有層における、深さ0nmである表面と、深さ7nmの位置と、において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が前記深さ7nmの位置での測定値よりも大きい積層体である。前記表面での測定値から前記深さ7nmの位置での測定値を差し引いた値は、好ましくは3原子%~70原子%である。
<第1実施形態>
本開示の第1実施形態の基板積層体は、
前述した第1実施形態の積層体である第1の積層体と、
第2の基板及び第2の接合層を含む第2の積層体と、
を含み、
前記第1の積層体及び前記第2の積層体は、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合されている、
基板積層体である。
ボイド面積率は、赤外光透過観察において、ボイドの面積の合計を、透過光を観測できた面積の合計で除し、かつ100を乗じて算出した値である。
赤外光透過観察が困難な場合は、超音波顕微鏡の反射波、超音波顕微鏡の透過波、又は赤外光反射光を用いて、好ましくは超音波顕微鏡の反射波を用いて同様の手法で求めることができる。
前記第1の接合層が、第1の電極を更に含み、
前記第2の接合層が、第2の電極と絶縁層とを含み、
前記有機物含有層と前記絶縁層とが接合され、かつ、前記第1の電極と前記第2の電極とが接合されていることが好ましい。
この態様は、前述したハイブリッド接合の態様である。
従って、配線間隔の狭ピッチ化の点で有利である。
本開示の第2実施形態の基板積層体は、本開示の第1実施形態の基板積層体における第1実施形態の積層体を、第2実施形態の積層体に変更したものである。
本開示の第3実施形態の基板積層体は、本開示の第1実施形態の基板積層体における第1実施形態の積層体を、第3実施形態の積層体に変更したものである。
以下、本開示における有機物含有層を形成するための組成物の具体例である組成物A及び組成物Bについて説明する。
有機物含有層を形成するための組成物については、例えば、国際公開2018/199117号、国際公開第2022/054839号、特開2021-182621号公報等の公知文献を参照してもよい。
組成物Aは、
1級窒素原子及び2級窒素原子の少なくとも1つを含むカチオン性官能基と、シロキサン結合(Si-O結合)と、アミノ基と、を有する、重量平均分子量130以上10000以下の化合物(A)と、
分子内に-C(=O)OX基(Xは、水素原子又は炭素数1以上6以下のアルキル基である)を3つ以上有し、3つ以上の-C(=O)OX基のうち、1つ以上6つ以下が-C(=O)OH基であり、重量平均分子量が200以上600以下である化合物(B)と、を含む、組成物である。
化合物(A)は、1級窒素原子及び2級窒素原子の少なくとも1つを含むカチオン性官能基と、シロキサン結合(Si-O結合)と、アミノ基と、を有する、重量平均分子量130以上10000以下の化合物である。
カチオン性官能基としては、正電荷を帯びることができ、かつ1級窒素原子及び2級窒素原子の少なくとも1つを含む官能基であれば特に限定されない。
また、「2級窒素原子」とは、水素原子1つ及び水素原子以外の原子2つのみに結合している窒素原子(即ち、下記式(a)で表される官能基に含まれる窒素原子)、又は、水素原子2つ及び水素原子以外の原子2つのみに結合している窒素原子(カチオン)を指す。
また、「3級窒素原子」とは、水素原子以外の原子3つのみに結合している窒素原子(即ち、下記式(b)で表される官能基である窒素原子)、又は、水素原子1つ及び水素原子以外の原子3つのみに結合している窒素原子(カチオン)を指す。
ここで、前記式(a)で表される官能基は、2級アミノ基(-NHRa基;ここで、Raはアルキル基を表す)の一部を構成する官能基であってもよいし、ポリマーの骨格中に含まれる2価の連結基であってもよい。
また、前記式(b)で表される官能基(即ち、3級窒素原子)は、3級アミノ基(-NRbRc基;ここで、Rb及びRcは、それぞれ独立に、アルキル基を表す)の一部を構成する官能基であってもよいし、ポリマーの骨格中に含まれる3価の連結基であってもよい。
具体的には、重量平均分子量は、展開溶媒として硝酸ナトリウム濃度0.1mol/Lの水溶液を用い、分析装置Shodex DET RI-101及び2種類の分析カラム(東ソー製 TSKgel G6000PWXL-CP及びTSKgel G3000PWXL-CP)を用いて流速1.0mL/minで屈折率を
検出し、ポリエチレングリコール/ポリエチレンオキサイドを標準品として解析ソフト(Waters製 Empower3)にて算出される。
前記ノニオン性官能基は、水素結合受容基であっても、水素結合供与基であってもよい。前記ノニオン性官能基としては、例えば、ヒドロキシ基、カルボニル基、エーテル基(-O-)、等を挙げることができる。
前記アニオン性官能基は、負電荷を帯びることができる官能基であれば特に制限はない。前記アニオン性官能基としては、例えば、カルボン酸基、スルホン酸基、硫酸基等を挙げることができる。
アミノ基を有するシランカップリング剤としては、例えば下記式(A-3)で表される化合物が挙げられる。
R1、R2、R3、R4、R5、X1、X2におけるアルキル基及びアルキレン基の置換基としては、それぞれ独立に、アミノ基、ヒドロキシ基、アルコキシ基、シアノ基、カルボン酸基、スルホン酸基、ハロゲン等が挙げられる。
Arにおける2価又は3価の芳香環としては、例えば、2価又は3価のベンゼン環が挙げられる。X2におけるアリール基としては、例えば、フェニル基、メチルベンジル基、ビニルベンジル基等が挙げられる。
,2-ジメトキシー1,6-ジアザ―2-シラシクロオクタン、3,5-ジアミノ-N-(4-(メトキシジメチルシリル)フェニル)ベンズアミド、3,5-ジアミノ-N-(4-(トリエトキシシリル)フェニル)ベンズアミド、5-(エトキシジメチルシリル)ベンゼン-1,3-ジアミン、及びこれらの加水分解物が挙げられる。
また、化合物(A)は、一級又は二級のアミノ基を有するため、後述の極性溶媒(D)に容易に溶解する。極性溶媒(D)に容易に溶解する化合物(A)を用いることで、シリコン基板などの基板の親水性表面との親和性が高くなるため、平滑な膜を形成しやすく、接着層の厚さを薄くすることができる。
化合物(B)は、分子内に-C(=O)OX基(Xは、水素原子又は炭素数1以上6以下のアルキル基である)を3つ以上有し、3つ以上の-C(=O)OX基(以下、「COOX」とも称する。)のうち、1つ以上6つ以下が-C(=O)OH基(以下、「COOH」とも称する。)であり、重量平均分子量が200以上600以下である化合物である。
(4,4'-(1,4-phenylenebis(oxy))diphthalic acid)、4,4’-([1,1’-ビフェニル]-4,4’-ジルビス(オキシ))ジフタル酸(4,4'-([1,1'-biphenyl]-4,4'-diylbis(oxy))diphthalic acid)、4,4’-((オキシビス(4,1-フェニレン))ビス(オキシ))ジフタル酸(4,4'-((oxybis(4,1-phenylene))bis(oxy))diphthalic acid)等
のジフタル酸;ペリレン-3,4,9,10-テトラカルボン酸等のペリレンカルボン酸;アントラセン-2,3,6,7-テトラカルボン酸等のアントラセンカルボン酸;4,4’-(ヘキサフルオロイソプロピリデン)ジフタル酸、9,9-ビス(トリフルオロメチル)-9H-キサンテン-2,3,6,7-テトラカルボン酸、1,4-ジトリフルオロメチルピロメリット酸等のフッ化芳香環カルボン酸が挙げられる。
組成物Aは、下記の化合物(C)をさらに含有していてもよい。
化合物(C)は、環構造及び前記環構造に直接結合した1つ以上の1級窒素原子を有する化合物である。
化合物(C)は、化合物(A)とともに化合物(B)と反応して硬化物を形成する。
化合物(C)は、環構造と、前記環構造に直接結合した1つ以上の1級窒素原子を有している。この構造が硬化物中に導入されることで、硬化物の剛直性が増して熱膨張率が低下すると考えられる。
化合物(C)は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
脂環構造としては、炭素数3以上8以下、好ましくは炭素数4以上6以下の脂環構造が挙げられる。環構造内は飽和であっても不飽和であってもよい。より具体的には、シクロプロパン環、シクロブタン環、シクロペンタン環、シクロヘキサン環、シクロヘプタン環、シクロオクタン環などの飽和脂環構造;シクロプロペン環、シクロブテン環、シクロペンテン環、シクロヘキセン環、シクロヘプテン環、シクロオクテン環などの不飽和脂環構造が挙げられる。
複素環構造として具体的には、オキサゾール環、チオフェン環、ピロール環、ピロリジン環、ピラゾール環、イミダゾール環、トリアゾール環、イソシアヌル環、ピリジン環、ピリダジン環、ピリミジン環、ピラジン環、ピペリジン環、ピペラジン環、トリアジン環、インドール環、インドリン環、キノリン環、アクリジン環、ナフチリジン環、キナゾリン環、プリン環、キノキサリン環等が挙げられる。
脂環式アミンとして具体的には、シクロヘキシルアミン、ジメチルアミノシクロヘキサンなどが挙げられる。
芳香環アミンとして具体的には、ジアミノジフェニルエーテル、キシレンジアミン(好ましくはパラキシレンジアミン)、ジアミノベンゼン、ジアミノトルエン、メチレンジアニリン、ジメチルジアミノビフェニル、ビス(トリフルオロメチル)ジアミノビフェニル、ジアミノベンゾフェノン、ジアミノベンズアニリド、ビス(アミノフェニル)フルオレン、ビス(アミノフェノキシ)ベンゼン、ビス(アミノフェノキシ)ビフェニル、ジカルボキシジアミノジフェニルメタン、ジアミノレゾルシン、ジヒドロキシベンジジン、ジアミノベンジジン、1,3,5-トリアミノフェノキシベンゼン、2,2’-ジメチルベンジジン、トリス(4-アミノフェニル)アミンなどが挙げられる。
窒素を含有する複素環を有する複素環アミンとして具体的には、メラミン、アンメリン、メラム、メレム、トリス(4-アミノフェニル)アミンなどが挙げられる。
複素環と芳香環の両方を有するアミン化合物として具体的には、N2,N4,N6-トリス(4-アミノフェニル)-1,3,5-トリアジン-2,4,6-トリアミン、2-(4-アミノフェニル)ベンゾオキサゾール-5-アミンなどが挙げられる。
熱膨張率と接合強度とのバランスの観点からは、上記割合は5モル%~75モル%であることが好ましく、10モル%~50モル%であることがより好ましく、10モル%~30モル%であることがさらに好ましい。
組成物Aは、極性溶媒を含んでもよい。本開示において「極性溶媒」とは、室温(25℃)における比誘電率が5以上である溶媒を指す。
組成物Aが極性溶媒を含んでいると、組成物A中の各成分の溶解性が向上する。
極性溶媒は、1種のみを単独で用いても、2種以上を組み合わせてもよい。
極性溶媒としては、プロトン性溶媒を含むことが好ましく、水を含むことがより好ましく、超純水を含むことがさらに好ましい。
組成物Aは、必要に応じて添加剤を含んでいてもよい。添加剤としては、カルボキシ基を有する重量平均分子量46以上195以下の酸、及び窒素原子を有する重量平均分子量17以上120以下の環構造を有しない塩基が挙げられる。
組成物Aに対し、プラズマエッチング耐性の選択性が求められる場合(例えばギャップフィル材料や埋め込み絶縁膜として用いる場合)、下記一般式(I)で表される金属アルコキシドを含んでもよい。
R1nM(OR2)m-n・・・(I)
(式中、R1は非加水分解性基であり、R2は炭素数1~6のアルキル基であり、MはTi、Al、Zr、Sr、Ba、Zn、B、Ga、Y、Ge、Pb、P、Sb、V、Ta、W、La、Nd及びInの金属原子群から選ばれる少なくとも1種の金属原子を示し、mは金属原子Mの価数で、3又は4であり、nは、mが4の場合は0~2の整数、mが3の場合は0又は1であり、R1が複数ある場合、各R1は互いに同一であっても異なっていてもよく、OR2が複数ある場合、各OR2は互いに同一であっても異なっていてもよい。)
シラン化合物として具体的には、テトラエトキシシラン、テトラメトキシシラン、ビストリエトキシシリルエタン、ビストリエトキシシリルメタン、ビス(メチルジエトキシシリル)エタン、1,1,3,3,5,5-ヘキサエトキシ-1,3,5-トリシラシクロヘキサン、1,3,5,7-テトラメチル―1,3,5,7-テトラヒドロキシルシクロシロキサン、1,1,4,4-テトラメチル-1,4-ジエトキシジシルエチレン、1,3,5-トリメチル-1,3,5-トリメチル-1,3,5-トリエトキシ-1,3,5-トリシラシクロヘキサン、アミノ基以外の官能基(エポキシ基、メルカプト基等)を有するシランカップリング剤等が挙げられる。
組成物AのpHが2.0以上12.0以下であると、組成物Aによる基板へのダメージが抑制される。
組成物Aは、ナトリウム及びカリウムの含有量がそれぞれ元素基準で10質量ppb以下であることが好ましい。ナトリウム又はカリウムの含有量がそれぞれ元素基準で10質量ppb以下であれば、トランジスタの動作不良など半導体装置の電気特性に不都合が発
生することを抑制できる。
組成物Bは、下記一般式(1)で表される構造を有し、分子量が400~5000である化合物(X1)、及び一般式(2)で表される構造を有し、分子量が400~5000である化合物(X2)の少なくともいずれかを含む。
一般式(1)において、R1及びR3で表される炭素数6以下の有機基としては炭素数6以下、好ましくは炭素数3以下、より好ましくは炭素数2以下のアルキル基が挙げられる。
一般式(2)において、R1及びR3で表される炭素数6以下の有機基としては炭素数6以下、好ましくは炭素数3以下、より好ましくは炭素数2以下のアルキル基が挙げられる。
一般式(2)におけるnは正の数であれば特に制限されないが、例えば、1以上6以下の範囲内であってもよい。
一般式(2)で表される化合物(X2)は、カルボン酸二無水物に由来する構造とアミン化合物に由来する構造とが交互に配列した状態(ポリアミド酸)であってもよい。
上記組成物Bに含まれる化合物(X2)は、シランカップリング剤(A)と分子量が200~600であり環構造を有するカルボン酸二無水物(B)とが反応して得られる構造と、分子量が90~600であり、Si-O結合を有さず、環構造を有するアミン化合物(C)と分子量が200~600の環構造を有するカルボン酸二無水物(B)とが反応して得られる構造と、を有する化合物であってもよい。
シランカップリング剤(A)は、1つ以上のSi-O結合を分子中に有し、カルボン酸二無水物と反応して化合物(X1)又は化合物(X2)を生成する化合物である。シランカップリング剤(A)が有するSi-O結合は、組成物Bを用いて形成される樹脂層と基板との接合強度の向上に寄与する。
R1、R2、R3、R4、R5、X1、X2におけるアルキル基及びアルキレン基の置換基としては、それぞれ独立に、アミノ基、ヒドロキシ基、アルコキシ基、シアノ基、カルボン酸基、スルホン酸基、ハロゲン等が挙げられる。
Arにおける2価又は3価の芳香環としては、例えば、2価又は3価のベンゼン環が挙げられる。X2におけるアリール基としては、例えば、フェニル基、メチルベンジル基、ビニルベンジル基等が挙げられる。
エトキシシラン、メチルアミノメチルメチルジエトキシシラン、p-アミノフェニルトリメトキシシラン、N-メチルアミノプロピルトリエトキシシラン、N-メチルアミノプロピルメチルジエトキシシラン、(フェニルアミノメチル)メチルジエトキシシラン、アセトアミドプロピルトリメトキシシランなどが挙げられる。
,2-ジメトキシ-1,6-ジアザ-2-シラシクロオクタン、3,5-ジアミノ-N-(4-(メトキシジメチルシリル)フェニル)ベンズアミド、3,5-ジアミノ-N-(4-(トリエトキシシリル)フェニル)ベンズアミド、5-(エトキシジメチルシリル)ベンゼン-1,3-ジアミンなどが挙げられる。
カルボン酸二無水物(B)は、分子中に1つ以上の環構造と2つの無水物基を有し、分子量が200以上600以下である化合物である。
カルボン酸二無水物(B)の分子量は、200以上400以下であってもよい。
カルボン酸二無水物(B)は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
例えば、1,2,3,4-シクロブタンテトラカルボン酸、1,2,3,4-シクロペンタンテトラカルボン酸、1,2,4,5-シクロヘキサンテトラカルボン酸、1,2,3,4,5,6-シクロヘキサンヘキサカルボン酸等の脂環テトラカルボン酸の無水物;
ピロメリット酸等のベンゼンテトラカルボン酸の二無水物;
1,4,5,8-ナフタレンテトラカルボン酸、2,3,6,7-ナフタレンテトラカルボン酸等のナフタレンテトラカルボン酸の二無水物;
3,3’,4,4’-ビフェニルテトラカルボン酸等のビフェニルテトラカルボン酸の二無水物;
ベンゾフェノン-3,3’,4,4’-テトラカルボン酸等のベンゾフェノンテトラカルボン酸の二無水物
4,4’-オキシジフタル酸(ODPA)、3,4’-オキシジフタル酸、1,3-ビス(フタル酸)テトラメチルジシロキサン、4,4’-(エチン-1,2-ジイル)ジフタル酸、4,4’-(1,4-フェニレンビス(オキシ))ジフタル酸、4,4’-([1,1’-ビフェニル]-4,4’-ジイルビス(オキシ))ジフタル酸、4,4’-((オキシビス(4,1-フェニレン))ビス(オキシ))ジフタル酸等のジフタル酸の二無水物;
ペリレン-3,4,9,10-テトラカルボン酸等のペリレンカルボン酸の二無水物;
アントラセン-2,3,6,7-テトラカルボン酸等のアントラセンカルボン酸の二無水物;
4,4’-(ヘキサフルオロイソプロピリデン)ジフタル酸、9,9-ビス(トリフルオロメチル)-9H-キサンテン-2,3,6,7-テトラカルボン酸、1,4-ジトリフルオロメチルピロメリット酸等のフッ化芳香環カルボン酸の二無水物;
ビス(1,3-ジオキソ-1,3-ジヒドロイソベンゾフラン-5-カルボン酸)1,4-フェニレンの二無水物;
4,4’-(4,4’-イソプロピルイデンジフェノキシ)ジフタル酸(IPBDA)の二無水物;
ビス(1,3-ジオキソ-1,3-ジヒドロイソベンゾフラン-5-カルボン酸)1,4-フェニレン(TAHQ)の二無水物などが挙げられる。
アミン化合物(C)は、分子中に1つ以上の環構造と1つ以上のアミノ基とを有し、分子量が90~600であり、Si-O結合を有さない化合物である。
アミン化合物(C)は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
脂環構造としては、炭素数3以上8以下、好ましくは炭素数4以上6以下の脂環構造が挙げられる。環構造内は飽和であっても不飽和であってもよい。より具体的には、シクロプロパン環、シクロブタン環、シクロペンタン環、シクロヘキサン環、シクロヘプタン環、シクロオクタン環などの飽和脂環構造;シクロプロペン環、シクロブテン環、シクロペンテン環、シクロヘキセン環、シクロヘプテン環、シクロオクテン環などの不飽和脂環構造が挙げられる。
複素環構造として具体的には、オキサゾール環、チオフェン環、ピロール環、ピロリジン環、ピラゾール環、イミダゾール環、トリアゾール環、イソシアヌル環、ピリジン環、ピリダジン環、ピリミジン環、ピラジン環、ピペリジン環、ピペラジン環、トリアジン環、インドール環、インドリン環、キノリン環、アクリジン環、ナフチリジン環、キナゾリン環、プリン環、キノキサリン環などが挙げられる。
脂環式アミンとしては、例えば、シクロヘキシルアミン、ジメチルアミノシクロヘキサンなどが挙げられる。
芳香環アミンとしては、例えば、ジアミノジフェニルエーテル、キシレンジアミン(好ましくはパラキシレンジアミン)、ジアミノベンゼン、ジアミノトルエン、メチレンジアニリン、ジメチルジアミノビフェニル、ビス(トリフルオロメチル)ジアミノビフェニル(TFDB)、ジアミノベンゾフェノン、ジアミノベンズアニリド、ビス(アミノフェニル)フルオレン、ビス(アミノフェノキシ)ベンゼン、ビス(アミノフェノキシ)ビフェニル、ジカルボキシジアミノジフェニルメタン、ジアミノレゾルシン、ジヒドロキシベンジジン、ジアミノベンジジン、1,3,5-トリアミノフェノキシベンゼン、2,2’-ジメチルベンジジン、トリス(4-アミノフェニル)アミンなどが挙げられる。
例えば、窒素を含有する複素環を有する複素環アミンとしては、メラミン、アンメリン、メラム、メレム、トリス(4-アミノフェニル)アミンなどが挙げられる。
さらに、複素環と芳香環の両方を有するアミン化合物としては、N2,N4,N6-トリス(4-アミノフェニル)-1,3,5-トリアジン-2,4,6-トリアミン、2-(4-アミノフェニル)ベンゾオキサゾール-5-アミン(AAPD)などが挙げられる。
シランカップリング剤(A)とカルボン酸二無水物(B)を反応させて化合物(X1)を得る方法としては、例えば、カルボン酸二無水物(B)に溶媒に加えて攪拌しつつ、シランカップリング剤(A)を徐々に滴下することで、化合物(X1)を得る方法が挙げられる。
シランカップリング剤(A)、カルボン酸二無水物(B)及びアミン化合物(C)を反応させて化合物(X2)を得る方法としては、例えば、アミン化合物(C)に溶媒を加えて攪拌しつつ、カルボン酸二無水物(B)を加え、得られる反応物(重合体)の粘度が一定になるまで攪拌を行い、続いて、シランカップリング剤(A)を徐々に滴下することで、化合物(X2)を得る方法が挙げられる。
組成物Bは、化合物(X1)及び化合物(X2)以外の化合物をさらに含んでもよい。例えば、50℃~150℃の間におけるCTEが90ppm/K以下である樹脂(D)の前駆体をさらに含んでもよい。組成物Bが樹脂(D)の前駆体を含むことで、得られる樹脂層の熱膨張率がより低減する傾向にある。
樹脂(D)のCTEは、樹脂層のCTEと同様にして測定できる。
組成物Bは、有機溶媒を含んでもよい。有機溶媒は、化合物(X)を溶解しうるものであれば特に制限されない。例えば、非プロトン性溶媒、フェノ-ル系溶媒、エーテル系溶媒及びグリコ-ル系溶媒が挙げられる。
有機溶媒は、1種のみを単独で用いても、2種以上を組み合わせてもよい。
フェノ-ル系溶媒として具体的には、フェノ-ル、O-クレゾ-ル、m-クレゾ-ル、p-クレゾ-ル、2,3-キシレノ-ル、2,4-キシレノ-ル、2,5-キシレノ-ル、2,6-キシレノ-ル、3,4-キシレノ-ル、3,5-キシレノ-ル等が挙げられる。
エ-テル系溶媒及びグリコ-ル系溶媒として具体的には、1,2-ジメトキシエタン、ビス(2-メトキシエチル)エ-テル、1,2-ビス(2-メトキシエトキシ)エタン、ビス[2-(2-メトキシエトキシ)エチル]エ-テル、テトラヒドロフラン、1,4-ジオキサン等が挙げられる。
組成物Bは、必要に応じて上述した成分以外の成分を含んでもよい。
例えば、組成物Bに対し、プラズマエッチング耐性の選択性が求められる場合(例えばギャップフィル材料や埋め込み絶縁膜として用いる場合)、下記一般式(I)で表される金属アルコキシドを含んでもよい。
R1nM(OR2)m-n・・・(I)
(式中、R1は非加水分解性基、R2は炭素数1~6のアルキル基であり、MはTi、Al、Zr、Sr、Ba、Zn、B、Ga、Y、Ge、Pb、P、Sb、V、Ta、W、La、Nd及びInの金属原子群から選ばれる少なくとも1種の金属原子を示し、mは金属原子Mの価数で、3又は4であり、nは、mが4の場合は0~2の整数、mが3の場合は0又は1であり、R1が複数ある場合、各R1は互いに同一であっても異なっていてもよく、OR2が複数ある場合、各OR2は互いに同一であっても異なっていてもよい。)
シラン化合物として具体的には、テトラエトキシシラン、テトラメトキシシラン、ビストリエトキシシリルエタン、ビストリエトキシシリルメタン、ビス(メチルジエトキシシリル)エタン、1,1,3,3,5,5-ヘキサエトキシ-1,3,5-トリシラシクロヘキサン、1,3,5,7-テトラメチル-1,3,5,7-テトラヒドロキシルシクロシロキサン、1,1,4,4-テトラメチル-1,4-ジエトキシジシルエチレン、1,3,5-トリメチル-1,3,5-トリメチル-1,3,5-トリエトキシ-1,3,5-トリシラシクロヘキサン等が挙げられる。
組成物Bは、ナトリウム及びカリウムの含有量がそれぞれ元素基準で10質量ppb以下であることが好ましい。ナトリウム又はカリウムの含有量がそれぞれ元素基準で10質量ppb以下であれば、トランジスタの動作不良など半導体装置の電気特性に不都合が発生することを抑制できる。
組成物Bに含まれるフィラーの含有量が上記範囲であると、組成物Bを用いて形成される樹脂層の厚みを薄くした場合でも、積層体の接合不良を抑制することが出来る。また、樹脂層が形成された第1の基板を、第2の基板に積層する際、各基板に形成されたアラインメントマークを機械で認識し、位置合わせを行う場合があるが、フィラーの含有量が上記範囲であると樹脂膜の透明性が向上し、より正確な位置合わせが可能となる。
以下において、「水」としては、超純水(Millipore社製Milli-Q水、抵抗18MΩ・cm(25℃)以下)を使用した。
<有機物含有層形成用材料を含む溶液の調製>
有機物含有層形成用材料を含む溶液を調製した。
詳細は以下に示すとおりである。
有機物含有層形成用材料として、3-アミノプロピルジエトキシメチルシラン(3APDES)50質量%と、水50質量%と、を配合し、3APDESの加水分解物を含む溶液Aを得た。
オキシジフタル酸ハーフエステル(式(B-2)におけるYがOでRがエチル基)70質量%とエタノール30質量%とを含む溶液Bを得た。
溶液A24gと、溶液B18gと、1-プロパノール20gと、水38gと、を配合し、有機物含有層形成用材料を含む溶液を調製した。
第1の基板としてのシリコンウェハをスピンコーターの上にのせ、このシリコンウェハ上に、上記有機物含有層形成用材料を含む溶液2.0mLを10秒間一定速度で滴下し、23秒間保持した後、2000rpm(rpmは1分当たりの回転速度)で1秒間、600rpmで30秒間回転させた後、2000rpmで10秒間回転させて乾燥させた。これにより、第1の基板上に有機物含有層形成用材料を付与した。
有機物含有層形成用材料が付与された第1の基板を窒素雰囲気下、200℃で1時間加熱した。これにより、第1の基板上に、第1の接合層としての有機物含有層として、シロキサン結合及びイミド結合を含む樹脂層(厚さ1μm)を形成し、第1の積層体を得た。
ここで、樹脂層は、シロキサン結合及びイミド結合を含む下記構造を含む。
第2の積層体として、表面に、厚さ0.1nm~10nmのSiO2層(第2の接合層)が形成されているシリコンウエハ(第2の基板)を準備した。
上記で得られた第1の積層体における有機物含有層に対し、プラズマ処理装置(SUSS社のPL12)を用い、表面活性化処理としてのO2プラズマ処理を施した。
詳細には、第1の積層体を金属製ホルダーに固定して、プラズマ処理装置のロードロック室にセットした。ロードロック室内の真空引きを行い、ロードロック室内の真空度を1.0×10-3Pa以下にした。第1の積層体をロードロック室内からプラズマ処理室内に搬送した。プラズマ処理室内の真空引きを行い、プラズマ処理室内の真空度を2.0×10-4Pa以下にした。プラズマ処理室内に酸素ガスを導入し、プラズマ処理室内の圧力を調整した。
次に、RF電力を印加して、下記の処理条件で、第1の積層体における有機物含有層の表面を酸素ガスのプラズマ(即ち、O2プラズマ)に曝し、表面活性化処理としてのO2プラズマ処理を施した。
次に、プラズマ処理室内を真空排気し、プラズマ処理後の第1の積層体をロードロック室に搬出した。ロードロック室内の酸素ガスでベント操作を行い、大気に開放し、ロードロック室内からプラズマ処理後の第1の積層体を取り出した。
・材料ガス:O2
・ガス流量:35sccm
・処理圧力:46.7Pa
・RF電力:100W(逆スパッタモード:サンプルホルダーに印加。)
・処理時間:60秒
表面活性化処理後の第1の積層体における有機物含有層に対し、25℃、30秒の水洗浄を施した。
次に、第1の積層体と、第2の積層体(即ち、前述した、SiO2層付きのシリコンウェハ)と、を、第1の積層体における有機物含有層と、第2の基板における第2の接合層(即ち、SiO2層)と、が接する向きに、室温(25℃)で貼り合わせて基板積層体を得た。貼り合わせの条件は、大気中、室温にて、0.2MPaで1秒間加圧とした。
上記基板積層体を得る過程で、以下の測定及び評価を実施した。
有機物含有層の水洗後であって貼り合わせ前において、第1の積層体中の有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率(原子%)を測定した。
各測定点でのSiの含有率の測定は、X線光電子分光法(XPS,ESCA)を用いて下記条件で行った。
Siの含有率(原子%)は、0eV~13000eVのスペクトル範囲において、95eV~540eVの全成分のピーク成分の積分強度に対するシリコン原子に由来するピーク成分である95eV~110eVの積分強度の割合(%)から導出した。
表面以外の測定点については、有機物含有層をスパッタしてエッチングしながら測定した。
・装置:Quantera II(PHI社製)
・X線源:単色化Al(1486.6eV)
・検出領域:200μmφ
・スパッタ条件:Ar、+1.0kV
・スパッタ速度:2nm/min(SiO2換算値)
・測定箇所:スパッタ前(即ち、表面)と、スパッタ0.5min経過時、スパッタ1.5min経過時、スパッタ3min経過時、スパッタ6min経過時、スパッタ11min経過時、及びスパッタ15min経過時の6点と、の合計7点。
次に、表面での測定値から上記6点での測定値の中の最小値を差し引いた値を求め、得られた値をSi偏析量(原子%)とした。
表1に、Si偏析量(原子%)、及び、Si含有率(原子%)(最大=表面での測定値)を示す。
酸素(O)原子に由来するピーク成分である525~540eVの積分強度を元にO含有率(原子%)を算出したこと以外は、有機物含有層におけるSi偏析量の測定と同様にして、有機物含有層におけるO偏析量(表面での値-6点中の最小値)を測定した。
表1に、O偏析量(原子%)、及び、O含有率(原子%)(最大=表面での測定値)を示す。
深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点の測定点を、深さ7nmの1点の測定点に変更し、表面での測定値から深さ7nmの1点を差し引いた値をSi偏析量(原子%)としたこと以外は、有機物含有層におけるSi偏析量(表面での値-6点中の最小値)と同様にして、有機物含有層におけるSi偏析量(表面での値-深さ7nmの1点での値)を求めた。
結果を表1に示す。
深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点の測定点を、深さ7nmの1点の測定点に変更し、表面での測定値から深さ7nmの1点を差し引いた値をO偏析量(原子%)としたこと以外は、有機物含有層におけるO偏析量(表面での値-6点中の最小値)と同様にして、有機物含有層におけるO偏析量(表面での値-深さ7nmの1点での値)を求めた。
結果を表1に示す。
有機物含有層の水洗後であって貼り合わせ前において、第1の積層体中の有機物含有層の表面の表面粗さRaを測定した。
表面粗さRaは、走査型プローブ顕微鏡(SPM)であるSPA400(日立ハイテクノロジーズ製)を用い、ダイナミックフォースマイクロスコープモードにて、3μm×3μm角領域で測定した。
結果を表1に示す。
各実施例及び各比較例で準備した測定サンプルについて、ナノインデンテーター(商品名TI-950 Tribo Indenter、Hysitron社製、Berkovich型圧子)を用い、試験深さ20nmの条件にて23℃における除荷-変位曲線を測定し、参考文献(Handbook of Micro/nano Tribology (second Edition)、Bharat Bhushan編、CRCプレス社)の計算手法に従い、最大負荷及び最大変位から、23℃における複合弾性率を計算により求めた。
結果を表1に示す。
なお、ここで、複合弾性率は下記式(1)により定義される。式(1)中、Erは複合弾性率を表し、Eiは圧子のヤング率を表し、1140GPaであり、νiは圧子のポアソン比を表し、0.07であり、Es及びνsはそれぞれ試料のヤング率及びポアソン比を表す。
上記で得られた基板積層体について、第1の積層体と、第2の積層体と、の室温(25℃)での接合強度を求めた。
室温(25℃)での接合強度は、本開示における低温での接合強度の一例である。
結果を表1に示す。
ここで、室温での接合強度は、M.P.Maszara, G.Goetz, A.Cavigila, and J.B.Mckitterick, Journal of Applied Physics, 64 (1988) 4943-4950. の手法に従って、ブレード挿入試験で求めた。
具体的には、基板積層体における第1の積層体と第2の積層体との接合界面(即ち、第1の積層体における有機物含有層と第2の積層体におけるSiO2層との接合界面)に、室温(25℃)にて、厚さ0.1mm~0.3mmのブレードを挿入し、赤外線光源及び赤外線カメラにて、ブレード刃先から第1の積層体と第2の積層体とが剥離した位置までの距離の測定を行い、得られた距離に基づき、以下に式に従い、表面エネルギーを求めた
。
得られた表面エネルギーを、接合強度とした。
γ=3×109×tb 2×E2×t6/(32×L4×E×t3)
ここで、γは、表面エネルギー(J/m2)、tbは、ブレード厚さ(m)、Eは、第1の積層体及び第2の積層体に含まれるシリコン基板のヤング率(GPa)、tは、第1の積層体及び第2の積層体の厚さ(m)、Lは、ブレード刃先からの第1の積層体と第2の積層体とが剥離した位置までの距離を表す。
表面活性化処理に使用したO2ガスをN2ガスに変更することにより、表面活性化処理をO2プラズマ処理からN2プラズマ処理に変更したこと以外は実施例1と同様の操作を行った。
結果を表1に示す。
表面活性化処理を行わなかったこと以外は実施例1と同様の操作を行った。
結果を表1に示す。
比較例2及び3では、それぞれ、以下の点以外は、実施例1及び比較例1と同様の操作を行った。
結果を表2に示す。
-実施例1及び比較例1に対する変更点-
・第1の積層体として、実施例1及び比較例1における有機物含有層付きシリコンウエハに代えて、第2の積層体と同様の、SiO2層付きシリコンウエハを用いた。
・第1の積層体におけるSiO2層に表面活性化処理を施した。
・表面活性化処理後の第1の積層体におけるSiO2層に対し、25℃、30秒の水洗浄を施した。
・上記水洗浄後の第1の積層体(即ち、SiO2層付きのシリコンウェハ)と、第2の積層体(即ち、SiO2層付きのシリコンウェハ)と、を、第1の積層体におけるSiO2層と、第2の基板におけるSiO2層と、が接する向きに、室温(25℃)で貼り合わせて基板積層体を得た。貼り合わせの条件は、大気中、室温にて、0.2MPaで1秒間加圧とした。
本明細書に記載された全ての文献、特許出願、及び技術規格は、個々の文献、特許出願、及び技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (31)
- 第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出している第1の積層体を準備し、かつ、第2の基板及び第2の接合層を含む第2の積層体を準備する工程Aと、
前記第1の積層体における前記有機物含有層の表面に、表面活性化処理を施す工程Bと、
前記工程Bを経た前記第1の積層体と、前記第2の積層体と、を、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合させて基板積層体を得る工程Cと、
を含む、基板積層体の製造方法。 - 前記有機物含有層が、Siを含む、請求項1に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~50原子%である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~70原子%である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の前記表面は、JIS B 0601:1982で規定される表面粗さRaが、5nm以下である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面において、原子%でのSiの含有率を測定した場合に、前記表面での測定値が、5原子%~70原子%である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前に、前記有機物含有層における、深さ0nmである前記表面において、原子%でのOの含有率を測定した場合に、前記表面での測定値が、10原子%~80原子%である、請求項2に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の複合弾性率が、1GPa~20GPaである、請求項2に記載の基板積層体の製造方法。
- 前記基板積層体における、前記第1の積層体と前記第2の積層体との接合強度が、0.2J/m2以上である、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記第2の接合層は、無機材料層を含み、前記無機材料層の表面が露出しており、
前記工程Cは、前記第1の積層体における前記有機物含有層の前記表面と、前記第2の基板における前記無機材料層の前記表面と、を接合させる、
請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。 - 前記第1の基板の熱膨張率と前記第2の基板の熱膨張率とが異なる、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記工程Bよりも後であって前記工程Cよりも前における前記有機物含有層の前記表面が、シラノール基を含む、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記有機物含有層が、シロキサン結合、アミド結合、及びイミド結合からなる群より選択される少なくとも1種を含む、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記表面活性化処理が、プラズマ処理、高速原子線照射、及びオゾン処理からなる群より選択される少なくとも1種である、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記プラズマ処理が、酸素プラズマ処理及び窒素プラズマ処理からなる群より選択される少なくとも1種である、請求項16に記載の基板積層体の製造方法。
- 前記工程Cにおける、前記第1の積層体と前記第2の積層体との接合面の温度が、140℃以下である、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 前記工程Aで準備される前記第1の積層体において、前記第1の接合層が第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出している、
請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。 - 前記工程Aで準備される前記第1の積層体において、前記第1の接合層が第1の電極を更に含み、前記第1の電極の表面と前記有機物含有層の表面とが露出しており、
前記工程Aで準備される前記第2の積層体において、前記第2の接合層が、第2の電極と絶縁層とを含み、前記第2の積層体において、前記第2の電極の表面と前記絶縁層の表面とが露出しており、
前記工程Cで得られる前記基板積層体は、
前記第1の基板と、前記有機物含有層と、前記絶縁層と、前記第2の基板と、がこの順序で配置されている第1の積層領域と、
前記第1の基板と、前記第1の電極と、前記第2の電極と、前記第2の基板と、がこの順序で配置されている第2の積層領域と、
を含む、
請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。 - 前記工程Cで得られる前記基板積層体において、前記第1の積層領域が、積層方向に2つ以上存在し、かつ、前記第2の積層領域が、積層方向に2つ以上存在する、請求項20に記載の基板積層体の製造方法。
- 前記第1の基板及び前記第2の基板の少なくとも一方は、Si、Al、Ti、Zr、Hf、Fe、Ni、Cu、Ag、Au、Ga、Ge、Sn、Pd、As、Pt、Mg、In、Ta、及びNbからなる群より選択される少なくとも1種の元素を含む半導体基板である、請求項1~請求項10のいずれか1項に記載の基板積層体の製造方法。
- 第1の基板及び第1の接合層を含み、前記第1の接合層が有機物含有層を含み、前記有機物含有層の表面が露出しており、
前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大である、
積層体。 - 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのSiの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~50原子%である、請求項23に記載の積層体。
- 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大である、請求項23に記載の積層体。
- 前記有機物含有層における、深さ0nmである表面と、深さ1nm、深さ3nm、深さ6nm、深さ12nm、深さ22nm、及び深さ30nmの6点と、の合計7点において、それぞれ、原子%でのOの含有率を測定した場合に、前記表面での測定値が最大であり、かつ、前記表面での測定値から前記6点での測定値の中の最小値を差し引いた値が、3原子%~70原子%である、請求項23に記載の積層体。
- 前記有機物含有層の複合弾性率が、1GPa~20GPaである、請求項23に記載の積層体。
- 前記有機物含有層が、シロキサン結合、アミド結合、及びイミド結合からなる群から選択される少なくとも1種を含む、請求項23に記載の積層体。
- 請求項23~請求項28のいずれか1項に記載の積層体である第1の積層体と、
第2の基板及び第2の接合層を含む第2の積層体と、
を含み、
前記第1の積層体及び前記第2の積層体は、前記第1の積層体における前記有機物含有層と、前記第2の基板における第2の接合層と、が接する向きに接合されている、
基板積層体。 - 表面エネルギーで表した、前記第1の積層体と前記第2の積層体との接合強度が、0.2J/m2以上である、請求項29に記載の基板積層体。
- 前記第1の接合層が、第1の電極を更に含み、
前記第2の接合層が、第2の電極と絶縁層とを含み、
前記有機物含有層と前記絶縁層とが接合され、かつ、前記第1の電極と前記第2の電極とが接合されている、
請求項29に記載の基板積層体。
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