WO2024177149A1 - 半導体構造体及びその製造方法 - Google Patents
半導体構造体及びその製造方法 Download PDFInfo
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- WO2024177149A1 WO2024177149A1 PCT/JP2024/006620 JP2024006620W WO2024177149A1 WO 2024177149 A1 WO2024177149 A1 WO 2024177149A1 JP 2024006620 W JP2024006620 W JP 2024006620W WO 2024177149 A1 WO2024177149 A1 WO 2024177149A1
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- H01L23/482—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of lead-in layers inseparably applied to the semiconductor body (electrodes)
- H01L23/485—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of lead-in layers inseparably applied to the semiconductor body (electrodes) consisting of layered constructions comprising conductive layers and insulating layers, e.g. planar contacts
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- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
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- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
- H01L23/532—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body characterised by the materials
- H01L23/53204—Conductive materials
- H01L23/53271—Conductive materials containing semiconductor material, e.g. polysilicon
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- H01L24/18—High density interconnect [HDI] connectors; Manufacturing methods related thereto
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- H01L24/18—High density interconnect [HDI] connectors; Manufacturing methods related thereto
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- 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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- H01L25/04—Assemblies consisting of a plurality of semiconductor or other solid state devices all the devices being of a type provided for in a single subclass of subclasses H10B, H10D, H10F, H10H, H10K or H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
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Definitions
- This disclosure relates to a semiconductor structure and a method for manufacturing the same.
- Patent Document 1 discloses a semiconductor structure including a die set provided on a wiring layer, and an inorganic gap fill material including silicon provided on the wiring layer and surrounding the periphery of the die set.
- Patent document 1 U.S. Patent Publication No. 2022/0013504
- hybrid bonding is being developed as a high-density bonding technology to increase data transfer per unit area.
- hybrid bonding refers to a type of bonding in which electrodes are bonded to each other and insulating films are bonded to each other by bringing two exposed surfaces of an electrode and an insulating material into contact with each other.
- the film stress of the inorganic gap fill material may cause warping of the semiconductor structure.
- An object of one aspect of the present disclosure is to provide a semiconductor structure comprising a semiconductor substrate including a semiconductor substrate bonding layer, a composite substrate including a plurality of silicon dies arranged two-dimensionally and a gap fill material filled between the plurality of silicon dies, and an intermediate bonding layer interposed between the composite substrate and the semiconductor substrate bonding layer in the semiconductor substrate, wherein the semiconductor substrate bonding layer and the intermediate bonding layer are hybrid-bonded, and wherein warping is suppressed, and a method for manufacturing the same.
- a semiconductor substrate including a semiconductor substrate bonding layer including an insulating layer and an electrode; A composite substrate including a plurality of silicon dies arranged in a two-dimensional manner and an organic gap fill material filled between the plurality of silicon dies; an intermediate bonding layer including an insulating layer and an electrode and interposed between the semiconductor substrate and the composite substrate; Equipped with The semiconductor substrate bonding layer and the intermediate bonding layer in the semiconductor substrate are hybrid-bonded.
- Semiconductor structure ⁇ 2> The semiconductor structure according to ⁇ 1>, wherein the intermediate bonding layer is disposed across at least two of the plurality of silicon dies.
- a rewiring layer including an insulating layer and a wiring is provided between the composite substrate and the intermediate bonding layer.
- ⁇ 4> The semiconductor structure according to ⁇ 3>, wherein at least two of the plurality of silicon dies are electrically connected via the redistribution layer.
- the insulating layer in the redistribution layer includes at least one selected from the group consisting of a SiO 2 layer, a SiCN layer, a SiN layer, and a resin layer containing a siloxane bond.
- the insulating layer in the semiconductor substrate bonding layer and the insulating layer in the intermediate bonding layer each include at least one selected from the group consisting of a SiO 2 layer, a SiCN layer, a SiN layer, and a resin layer containing a siloxane bond.
- the organic gap fill material is at least one selected from the group consisting of polyimide, polyamide, polyamideimide, maleimide resin, parylene, polyarylene ether polyimide, polybenzoxazole, benzocyclobutene resin, epoxy resin, and resin having a siloxane bond.
- ⁇ 8> A method for producing a semiconductor structure according to any one of ⁇ 1> to ⁇ 7>, a step of forming the composite substrate on a first temporary fixing substrate by two-dimensionally arranging a plurality of silicon dies and temporarily fixing the same on the first temporary fixing substrate, and then filling the gaps between the plurality of silicon dies with the organic gap fill material; a step of temporarily fixing a second temporary fixing substrate on the opposite side of the composite substrate from the side on which the first temporary fixing substrate is disposed, thereby obtaining a laminate X1; removing the first temporary fixing substrate from the stacked body X1 to obtain a stacked body X2 in which the plurality of silicon dies are exposed; providing the semiconductor substrate including the insulating layer and the semiconductor substrate bonding layer including the electrode; forming an intermediate bonding layer including an insulating layer and an electrode on an exposed surface side of the plurality of silicon dies in the stack X2; a step of hybrid-bonding the intermediate bonding layer in the stacked body X2 on which the
- the step of forming the intermediate bonding layer includes: forming a rewiring layer including an insulating layer and wiring on an exposed surface side of the plurality of silicon dies in the stack X2; forming an intermediate bonding layer on the redistribution layer;
- the method for producing a semiconductor structure according to ⁇ 8> comprising:
- the objective of one aspect of the present disclosure is to provide a semiconductor structure that includes a semiconductor substrate including a semiconductor substrate bonding layer, a composite substrate including a plurality of silicon dies arranged two-dimensionally and a gap fill material filled between the plurality of silicon dies, and an intermediate bonding layer interposed between the composite substrate and the semiconductor substrate bonding layer in the semiconductor substrate, in which the semiconductor substrate bonding layer and the intermediate bonding layer are hybrid-bonded, and in which warping is suppressed, and a method for manufacturing the same.
- 1 is a schematic cross-sectional view illustrating an example of a semiconductor structure of the present disclosure.
- 2 is a schematic cross-sectional view illustrating another example of a semiconductor structure of the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to the present disclosure.
- 1 is a schematic flow diagram illustrating an example of a method for manufacturing a semiconductor structure according to 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 semiconductor structure of the present disclosure comprises: a semiconductor substrate including a semiconductor substrate bonding layer including an insulating layer and an electrode; a composite substrate including a plurality of silicon dies arranged in a two-dimensional manner and an organic gap fill material filled between the plurality of silicon dies; an intermediate bonding layer interposed between the composite substrate and the semiconductor substrate bonding layer of the semiconductor substrate, the intermediate bonding layer including an insulating layer and an electrode; Equipped with A semiconductor substrate bonding layer and an intermediate bonding layer in the semiconductor substrate are hybrid-bonded.
- a semiconductor structure including a semiconductor substrate bonding layer including an insulating layer and an electrode
- Patent Document 1 U.S. Patent Publication No. 2022/0013504
- the semiconductor structure of the present disclosure uses an organic gap fill material as the gap fill material, thereby suppressing the problem of the semiconductor structure warping due to the film stress of the inorganic gap fill material, thereby suppressing bonding failure and/or misalignment between the semiconductor substrate and the composite substrate caused by the warping of the semiconductor structure.
- the semiconductor structure of the present disclosure has the advantage that the gap fill material can be formed quickly and easily by a wet process such as spin coating, slit coating, spray coating, screen printing, squeegeeing, or inkjet printing, as compared to forming an inorganic gap fill material by a vapor phase growth method (i.e., a dry process) such as CVD (Chemical Vapor Deposition).
- a wet process such as spin coating, slit coating, spray coating, screen printing, squeegeeing, or inkjet printing
- CVD Chemical Vapor Deposition
- FIG. 1 is a schematic cross-sectional view of an example semiconductor structure 100 of the present disclosure.
- a semiconductor structure 100 includes: A semiconductor substrate 10; A composite substrate 31; an intermediate bonding layer 32 interposed between the semiconductor substrate 10 and the composite substrate 31; Equipped with.
- the semiconductor substrate 10 is A substrate body 12; a semiconductor substrate bonding layer 14 provided on one surface side of the substrate body 12; a through electrode 16 electrically connected to the semiconductor substrate bonding layer 14 and penetrating the substrate body 12; Includes.
- the substrate body 12 in the semiconductor substrate 10 is not particularly limited and may be any commonly used substrate, one example of which is a silicon substrate. Specific examples of the substrate body 12 will be described later.
- An integrated circuit (not shown) is formed inside the substrate body 12 of the semiconductor substrate 10 .
- the semiconductor substrate bonding layer 14 in the semiconductor substrate 10 includes an insulating layer and an electrode (not shown).
- the semiconductor substrate bonding layer 14 preferably includes an insulating layer and an electrode that penetrates the insulating layer.
- the electrodes in the semiconductor substrate bonding layer 14 are electrically connected to the integrated circuit in the substrate body 12.
- an "electrode penetrating the insulating layer” means an electrode disposed in the insulating layer and exposed from both sides of the insulating layer.
- the electrode may penetrate the insulating layer in a straight line or in a curved (e.g., serpentine) manner.
- the electrode may be a single member (e.g., a metal member) or a composite member made of multiple members (e.g., metal members).
- the through electrode 16 in the semiconductor substrate 10 may be omitted.
- the composite substrate 31 includes a plurality of silicon dies 20 arranged in a two-dimensional array and an organic gap fill material 30 filled between the plurality of silicon dies 20 .
- An integrated circuit (not shown) is formed inside the silicon die 20 .
- the internal structure of the silicon die 20 is not shown in the drawings because it is a typical structure.
- the semiconductor structure 100 includes an intermediate bonding layer 32 interposed between the semiconductor substrate 10 and the composite substrate 31 .
- the intermediate bonding layer 32 includes an insulating layer and an electrode (not shown).
- the intermediate bonding layer 32 preferably includes an insulating layer and an electrode that penetrates the insulating layer.
- the semiconductor substrate bonding layer 14 in the semiconductor substrate 10 and the intermediate bonding layer 32 are hybrid bonded.
- This hybrid bonding electrically connects the integrated circuits inside the substrate body 12 in the semiconductor substrate 10 and the integrated circuits inside the multiple silicon dies 20 via electrodes in the semiconductor substrate bonding layer 14 in the semiconductor substrate 10 and electrodes in the intermediate bonding layer 32.
- the composite substrate 31 in the semiconductor structure 100 includes the organic gap-fill material 30 as a gap-fill material filled between the multiple silicon dies 20 . Therefore, in the semiconductor structure 100, compared to when the gap fill material is an inorganic gap fill material (for example, the aforementioned Patent Document 1 (U.S. Patent Publication No. 2022/0013504)), the film stress of the gap fill material is reduced, and warping of the entire semiconductor structure is suppressed. This makes it possible to suppress bonding defects and/or misalignment between the semiconductor substrate and the composite substrate caused by warping of the semiconductor structure. Furthermore, as described above, the semiconductor structure 100 allows the gap fill material to be formed quickly and easily.
- the gap fill material is an inorganic gap fill material (for example, the aforementioned Patent Document 1 (U.S. Patent Publication No. 2022/0013504)
- the intermediate bonding layer 32 is disposed across at least two of the multiple silicon dies 20 (see FIG. 1).
- FIG. 2 is a schematic cross-sectional view of another example semiconductor structure 200 of the present disclosure.
- Semiconductor structure 200 is a variation on semiconductor structure 100 described above.
- the semiconductor structure 200 differs from the previously described semiconductor structure 100 in the following respects:
- the semiconductor structure 200 is otherwise similar to the previously described semiconductor structure 100.
- the semiconductor structure 200 includes a redistribution layer 34 between a composite substrate 31 and an intermediate bonding layer 32 .
- the redistribution layer 34 includes an insulating layer and wiring formed in the insulating layer (not shown).
- the semiconductor substrate bonding layer 14 in the semiconductor substrate 10 and the intermediate bonding layer 32 are hybrid-bonded.
- At least two of the multiple silicon dies 20 are preferably electrically connected via the redistribution layer 34 (specifically, the wiring in the redistribution layer 34).
- Method X One embodiment of a method for manufacturing a semiconductor structure (Method X)> There are no particular limitations on the method for fabricating the semiconductor structure of the present disclosure.
- One embodiment of a method for producing a semiconductor structure according to the present disclosure is the following "Production Method X.”
- the manufacturing method X is A step of forming a composite substrate on a first temporary fixing substrate by two-dimensionally arranging and temporarily fixing a plurality of silicon dies on a first temporary fixing substrate, and then filling spaces between the plurality of silicon dies with an organic gap fill material; a step of temporarily fixing a second temporary fixing substrate on the side opposite to the side on which the first temporary fixing substrate is disposed as viewed from the composite substrate to obtain a laminate X1; removing the first temporary fixing substrate from the stacked body X1 to obtain a stacked body X2 in which the plurality of silicon dies are exposed; providing a semiconductor substrate including a semiconductor substrate bonding layer including an insulating layer and an electrode; forming an intermediate bonding layer including an insulating layer and an electrode on the exposed surface side of the plurality of silicon dies in the stack X2; a step of hybrid-bonding the intermediate bonding layer in the stacked body X2 on which the intermediate bonding layer is formed and the semiconductor substrate bonding layer in the semiconductor substrate to obtain a
- 3A to 3H are schematic process diagrams showing an example of manufacturing method X (hereinafter, also referred to as "manufacturing method X1").
- Steps for forming a composite substrate show steps for forming a composite substrate in manufacturing method X1.
- a plurality of silicon dies 20 are two-dimensionally arranged and temporarily fixed on a first temporary fixing substrate 40, and then an organic gap fill material 30 is filled between the plurality of silicon dies 20 to form a composite substrate 31 on the first temporary fixing substrate 40.
- the organic gap fill material 30 between the silicon dies 20 is formed as follows. First, an organic gap fill material 30A is formed on the side of the first temporary fixing substrate 40 on which the multiple silicon dies 20 are temporarily fixed, so that a portion of the organic gap fill material 30A fills the spaces between the multiple silicon dies 20, and the upper surfaces of the multiple silicon dies 20 are covered with a portion of the remaining organic gap fill material 30A ( Figure 3B). Next, the organic gap fill material 30A on the upper surfaces of the multiple silicon dies 20 is removed to expose the upper surfaces of the multiple silicon dies 20. This leaves the organic gap fill material 30A filled between the multiple silicon dies 20. The remaining organic gap fill material 30A becomes the organic gap fill material 30 in FIG. 3C.
- the method of forming the organic gap-fill material 30 is not limited to the above example of forming the organic gap-fill material 30A via the organic gap-fill material 30.
- the organic gap-fill material 30 may be directly formed between the multiple silicon dies 20.
- the first temporary fixing substrate 40 may be, for example, a silicon substrate, a glass substrate, a resin substrate, or the like.
- the multiple silicon dies 20 are temporarily fixed on the first temporary fixing substrate 40 by, for example: Methods using adhesives such as acrylic and epoxy polymers; A method using a heat-resistant resin such as polyimide, polyamideimide, polymaleimide, or siloxane polymer; Direct bonding of SiO2 to SiO2 ; This can be done by, etc.
- the first temporary fixing substrate 40 is to be removed (i.e., peeled off) during the manufacturing method X1. For this reason, a surface treatment may be applied to the surface of the first fixing substrate 40 facing the multiple silicon dies 20 in order to facilitate peeling from the multiple silicon dies 20.
- the organic gap fill material 30A can be formed on the first temporary fixing substrate 40 by a wet process such as spray coating, spin coating, screen printing, squeegeeing, or inkjet printing.
- Removal of the organic gap-fill material 30A on the top surfaces of the multiple silicon dies 20 can be done, for example, by polishing. Polishing can be carried out according to a conventional method such as mechanical polishing, chemical polishing, or chemical mechanical polishing.
- FIG. 3D shows a step of obtaining a laminate X1 in the manufacturing method X1.
- a second temporary fixing substrate 42 is temporarily fixed on the side opposite to the side on which the first temporary fixing substrate 40 is arranged, as viewed from the composite substrate 31, to obtain a laminate X101 as the laminate X1.
- the second temporary fixing substrate 42 can be temporarily fixed using, for example, an adhesive.
- the second temporary fixing substrate 42 is removed (i.e., peeled off) during the manufacturing method X1. For this reason, a surface treatment may be applied to the surface of the second fixing substrate 42 facing the multiple silicon dies 20 and the organic gap fill material 30 to facilitate peeling from the multiple silicon dies 20 and the organic gap fill material 30.
- FIG. 3E shows a step of obtaining a laminate X2 in the manufacturing method X1.
- the first temporary fixing substrate 40 is removed from the stack X101 as the stack X1 to obtain the stack X102 as the stack X2 in which the multiple silicon dies 20 are exposed.
- the first temporary fixing substrate 40 can be removed, for example, by the following method.
- the first temporary fixing substrate 40 can be removed by, for example, thermal foaming, mechanical peeling, thermal sliding, laser peeling, or the like.
- the first temporary fixing substrate 40 is temporarily fixed using a heat-resistant resin such as polyimide, polyamideimide, polymaleimide, or siloxane polymer
- the first temporary fixing substrate 40 can be removed by, for example, laser peeling, mechanical peeling, thermal sliding, or the like.
- the first temporary fixing substrate 40 is temporarily fixed by direct bonding between SiO 2 films
- the first temporary fixing substrate 40 can be removed by, for example, laser peeling using infrared rays or the like.
- the exposed surfaces of the multiple silicon dies 20 exposed by removing the first temporary fixing substrate 40 may be cleaned.
- the cleaning method is not particularly limited, and examples thereof include plasma cleaning, cleaning with a cleaning solution, polishing, and the like.
- Step of Preparing Semiconductor Substrate In the step of preparing a semiconductor substrate in manufacturing method X1, a semiconductor substrate 10 (see FIG. 3G described later) including a semiconductor substrate bonding layer 14 including an insulating layer and an electrode is prepared.
- FIG. 3F shows one embodiment of a step of forming an intermediate bonding layer in manufacturing method X1.
- an intermediate bonding layer 32 including an insulating layer and an electrode is formed on the exposed surface side of the multiple silicon dies 20 in the stack X102.
- FIG. 3G shows a step of obtaining a laminate X3 in the manufacturing method X1.
- the intermediate bonding layer 32 in the laminate X102 on which the intermediate bonding layer 32 is formed is hybrid-bonded to the semiconductor substrate bonding layer 14 in the semiconductor substrate 10 to obtain the laminate X102 as the laminate X3.
- FIG. 3H shows a step in process X1 for obtaining a semiconductor structure.
- the second temporary fixing substrate 42 is removed from the stacked body X103 in FIG. 3G, thereby obtaining the semiconductor structure 100.
- the second temporary fixing substrate 42 can be removed by the same method as that for removing the first temporary fixing substrate.
- the manufacturing method X can also be used to manufacture a semiconductor structure including the redistribution layer described above (for example, the semiconductor structure 200 including the redistribution layer 34 shown in FIG. 2).
- the step of forming the intermediate bonding layer for example, the step shown in FIG.
- a rewiring layer (e.g., rewiring layer 34) including an insulating layer and wiring on an exposed surface side of a plurality of silicon dies (e.g., silicon die 20) in a stacked body X2 (e.g., stacked body X102); forming an intermediate bonding layer (e.g., intermediate bonding layer 32) on a redistribution layer (e.g., redistribution layer 34); Includes.
- a semiconductor structure of the present disclosure includes a semiconductor substrate (eg, semiconductor substrate 10).
- the semiconductor substrate may include a substrate body and a semiconductor substrate bonding layer provided on one surface of the substrate body.
- the semiconductor substrate bonding layer may be disposed on both surfaces of the substrate body.
- the material of the substrate body is not particularly limited, and may be any material that is commonly used as a semiconductor substrate.
- the substrate body 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.
- the material of the substrate body is, for example: Semiconductors (e.g., Si, InP, GaN, GaAs, InGaAs, InGaAlAs, SiC, etc.); oxides, carbides, or nitrides (e.g., borosilicate glass (Pyrex), quartz glass ( SiO2 ), sapphire, ZrO2 , Si3N4 , AlN, etc.); Piezoelectric or dielectric materials (e.g.
- Semiconductors e.g., Si, InP, GaN, GaAs, InGaAs, InGaAlAs, SiC, etc.
- oxides, carbides, or nitrides e.g., borosilicate glass (Pyrex), quartz glass ( SiO2 ), sapphire, ZrO2 , Si3N4 , AlN, etc.
- Piezoelectric or dielectric materials e.g.
- the substrate body may contain only one of these materials, or may contain two or more of them.
- the substrate body is preferably a silicon substrate, a GaAs substrate, a SiC substrate, a diamond substrate, a glass substrate, or a resin substrate, and is typically a silicon substrate.
- the substrate body may have a multi-layer structure.
- the semiconductor substrate bonding layer includes an insulating layer and an electrode.
- the semiconductor substrate bonding layer preferably includes an insulating layer and an electrode (eg, a Cu electrode) penetrating the insulating layer.
- the electrodes penetrating the insulating layer are as described above.
- Examples of materials for the electrodes in the semiconductor substrate bonding layer include Cu, Sn, Au, Ag, Al, solder, and the like.
- the electrode in the semiconductor substrate bonding layer preferably contains Cu.
- the electrodes in the semiconductor substrate bonding layer can be formed by a known manufacturing method such as a damascene process or a semi-additive process.
- the insulating layer in the semiconductor substrate bonding layer preferably includes at least one selected from the group consisting of a SiO 2 layer, a SiCN layer, a SiN layer, and a resin layer containing a siloxane bond.
- the SiO 2 layer, the SiCN layer, and the SiN layer serving as the insulating layer can be formed by a vapor phase growth method such as sputtering, chemical vapor deposition (CVD), or atomic layer deposition (ALD).
- a vapor phase growth method such as sputtering, chemical vapor deposition (CVD), or atomic layer deposition (ALD).
- Examples of the material of the resin layer containing siloxane bonds as the insulating layer include the same materials as the "resin containing siloxane bonds" as the "organic gap fill material” described later.
- examples of the method of forming the resin layer containing siloxane bonds as the insulating layer examples of the method of forming the "organic gap-fill material” described later can be appropriately referred to.
- the semiconductor substrate may include a through electrode that penetrates a substrate body.
- the through electrode is not particularly limited, and any known through electrode can be used.
- the through electrodes provide electrical connection between the integrated circuit in the semiconductor substrate and an electronic device or the like disposed outside the semiconductor structure.
- the semiconductor structures of the present disclosure include a composite substrate (eg, composite substrate 31).
- the composite substrate includes multiple silicon dies (eg, silicon die 20) and an organic gap-fill material (eg, organic gap-fill material 30) disposed between the multiple silicon dies.
- a composite substrate (eg, composite substrate 31) includes multiple silicon dies (eg, silicon die 20) arranged in a two-dimensional manner.
- silicon die e.g, silicon die 20
- a normal silicon die can be used, which is obtained by forming an integrated circuit on a silicon substrate (for example, a silicon wafer) and cutting it into chips.
- the spacing between the multiple silicon dies is preferably 0.1 ⁇ m to 100,000 ⁇ m, more preferably 1 ⁇ m to 10,000 ⁇ m, and even more preferably 50 ⁇ m to 1,000 ⁇ m.
- the thickness of the silicon die is preferably 5 ⁇ m to 700 ⁇ m, more preferably 10 ⁇ m to 300 ⁇ m, and even more preferably 15 ⁇ m to 100 ⁇ m.
- the composite substrate (eg, composite substrate 31) includes an organic gap fill material (eg, organic gap fill material 30) filled between a plurality of silicon dies (eg, silicon die 20) arranged in a two-dimensional manner.
- organic gap fill material eg, organic gap fill material 30
- the organic gap fill material contains at least one organic material (preferably a resin, more preferably a heat-resistant resin).
- the glass transition temperature of the organic material in the organic gap fill material is preferably 110°C or higher and 400°C or lower, more preferably 120°C or higher and 350°C or lower, and more preferably 150°C or higher and 300°C or lower.
- the glass transition temperature can be measured by the following method. That is, a test piece of an organic material having a width of 4 mm and a length of 20 mm is prepared.
- the glass transition temperature of this test piece is measured by TMA using a thermal analyzer (TMA-50) manufactured by Shimadzu Corporation under the measurement conditions of a temperature range of 25 to 350°C, a heating rate of 5°C/min, a load of 14 g/ mm2 , and a tensile mode, and the glass transition temperature (Tg) can be determined from the inflection point of the obtained temperature-test piece elongation curve.
- TMA-50 thermal analyzer manufactured by Shimadzu Corporation under the measurement conditions of a temperature range of 25 to 350°C, a heating rate of 5°C/min, a load of 14 g/ mm2 , and a tensile mode
- resins in organic gap fill materials include polyimide, polyamide, polyamideimide, maleimide resin, parylene, polyarylene ether, polybenzoxazole, benzocyclobutene resin, epoxy resin, resin containing siloxane bonds, etc.
- resins containing siloxane bonds include polybenzoxazole, divinylsiloxane benzocyclobutene polymer, siloxane imide polymer, and epoxy-modified siloxane polymer.
- the resin containing a siloxane bond may contain a structure represented by the following formulas (1) to (3).
- the group bonded to Si may be substituted with an alkylene group, a phenylene group, or the like.
- a structure having (—O—) x (R 1 ) y Si-(R 2 )-Si(R 1 ) y (—O—) x or the like R 1 represents a methyl group or the like, R 2 represents an alkylene group, a phenylene group, or the like, x and y are each independently an integer of 0 or more, and x+y is 3).
- Examples of materials for forming Si—O bonds include compounds represented by the following formulas (4) and (5).
- the structures represented by formulae (1) and (2) can be produced, for example, by heating and reacting the compounds represented by formulae (4) and (5).
- the resin-containing organic gap fill material can be formed by, for example, spin coating, slit coating, spray coating, screen printing, squeegeeing, inkjet printing, etc.
- the organic gap fill material can be formed, for example, using a solution for forming an organic gap fill material.
- the organic gap fill material forming solution may be, for example, a solution containing a resin material.
- Compound (A)- Compound (A) is a compound having a cationic functional group containing at least one of a primary nitrogen atom and a secondary nitrogen atom, and having a weight average molecular weight of 90 to 400,000.
- 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 that is bonded to only two hydrogen atoms and one atom other than a hydrogen atom (e.g., a nitrogen atom contained in a primary amino group ( -NH2 group)), or a nitrogen atom that is bonded to only three hydrogen atoms and one atom other than a hydrogen atom (cation).
- 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 90 or more and 400,000 or less.
- Examples of compound (A) include aliphatic amines, compounds having a siloxane bond (Si-O bond) and an amino group, and amine compounds having a ring structure without an Si-O bond in the molecule.
- the weight average molecular weight is preferably 10,000 or more and 200,000 or less.
- the weight average molecular weight is preferably 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 is preferably 90 or more and 600 or less.
- the weight average molecular weight refers to the weight average molecular weight in terms of polyethylene glycol, measured by GPC (Gel Permeation Chromatography) for a substance other than the monomer. 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 compound (A) include aliphatic amines, and more specifically, polyalkyleneimines, which are polymers of alkyleneimines such as ethyleneimine, propyleneimine, butyleneimine, pentyleneimine, hexyleneimine, heptyleneimine, octyleneimine, trimethyleneimine, tetramethyleneimine, pentamethyleneimine, hexamethyleneimine, and octamethyleneimine; polyallylamine; and polyacrylamide.
- polyalkyleneimines which are polymers of alkyleneimines such as ethyleneimine, propyleneimine, butyleneimine, pentyleneimine, hexyleneimine, heptyleneimine, octyleneimine, trimethyleneimine, tetramethyleneimine, pentamethyleneimine, hexamethyleneimine, and octamethyleneimine
- polyallylamine and polyacrylamide.
- Polyethyleneimine can be produced by known methods such as those described in JP-B-43-8828, JP-B-49-33120, JP-A-2001-213958, and WO 2010/137711.
- Polyalkyleneimines other than polyethyleneimine can also be produced by the same methods as polyethyleneimine.
- Compound (A) is also preferably a derivative of the above-mentioned polyalkyleneimine (polyalkyleneimine derivative; particularly preferably a polyethyleneimine derivative).
- the polyalkyleneimine derivative is not particularly limited as long as it is a compound that can be produced using the above-mentioned polyalkyleneimine.
- examples of the polyalkyleneimine derivative include polyalkyleneimine derivatives obtained by introducing an alkyl group (preferably an alkyl group having 1 to 10 carbon atoms), an aryl group, or the like into a polyalkyleneimine, and polyalkyleneimine derivatives obtained by introducing a crosslinkable group such as a hydroxyl group into a polyalkyleneimine.
- These polyalkyleneimine derivatives can be produced by a method generally used using the above-mentioned polyalkyleneimines, specifically, for example, the method described in JP-A-6-016809.
- polyalkyleneimine derivative a highly branched polyalkyleneimine obtained by reacting a polyalkyleneimine with a monomer containing a cationic functional group to increase the branching degree of the polyalkyleneimine is also preferred.
- Examples of methods for obtaining a highly branched polyalkyleneimine include a method of reacting a polyalkyleneimine having a plurality of secondary nitrogen atoms in the skeleton with a cationic functional group-containing monomer to replace at least one of the plurality of secondary nitrogen atoms with the cationic functional group-containing monomer, and a method of reacting a polyalkyleneimine having a plurality of primary nitrogen atoms at its terminals with a cationic functional group-containing monomer to replace at least one of the plurality of primary nitrogen atoms with the cationic functional group-containing monomer.
- Examples of the cationic functional group introduced to improve the degree of branching include an aminoethyl group, an aminopropyl group, a diaminopropyl group, an aminobutyl group, a diaminobutyl group, and a triaminobutyl group. From the viewpoints of decreasing the cationic functional group equivalent and increasing the cationic functional group density, the aminoethyl group is preferred.
- polyethyleneimine and its derivatives may be commercially available.
- polyethyleneimine and its derivatives may be appropriately selected and used from those commercially available from Nippon Shokubai Co., Ltd., BASF, MP-Biomedicals, etc.
- Examples of the compound (A) include the above-mentioned aliphatic amines as well as compounds having a Si--O bond and an amino group.
- the compound (A) having an Si—O bond and an amino group is suitable as a material for a resin containing a siloxane bond.
- Examples of compounds having an Si--O bond and an amino group include siloxane diamines, silane coupling agents having an amino group, and siloxane polymers of silane coupling agents having an amino group.
- 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) also includes an amine compound having a ring structure.
- amine compounds having a ring structure and a weight average molecular weight of 90 to 600 are preferred.
- examples of amine compounds having a ring structure and a weight average molecular weight of 90 to 600 include alicyclic amines, aromatic ring amines, and heterocyclic (heterocyclic) amines.
- a plurality of ring structures may be present in the molecule, and the plurality of ring structures may be the same or different.
- a compound having an aromatic ring is more preferred because it is easy to obtain a thermally more stable compound.
- a compound having a primary amino group is preferred, since it is easy to form a thermal crosslinked structure such as amide, amideimide, imide, etc. together with the crosslinking agent (B) and can enhance heat resistance.
- a diamine compound having two primary amino groups, a triamine compound having three primary amino groups, etc. are preferred, since it is easy to increase the number of thermal crosslinked structures such as amide, amideimide, imide, etc. together with the crosslinking agent (B) and can further enhance heat resistance.
- Examples of the alicyclic amine include cyclohexylamine and dimethylaminocyclohexane.
- aromatic ring amines include diaminodiphenyl ether, xylylene diamine (preferably paraxylylene diamine), diaminobenzene, diaminotoluene, methylene dianiline, 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, tris(4-aminophenyl)amine,
- heterocycle of the heterocyclic amine examples include a heterocycle containing a sulfur atom as a heteroatom (e.g., a thiophene ring), and a heterocycle containing a nitrogen atom as a heteroatom (e.g., a 5-membered ring such as a pyrrole ring, a pyrrolidine ring, a pyrazole ring, an imidazole ring, or a triazole ring; a 6-membered ring such as an isocyanuric ring, a pyridine ring, a pyridazine ring, a pyrimidine ring, a pyrazine ring, a piperidine ring, a piperazine ring, or a triazine ring; and a condensed ring such as an indole ring, an indoline ring, a quinoline ring, an acridine ring, a naphthy
- 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.
- 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 a polar solvent (D) described below.
- a polar solvent (D) By using the compound (A) that is easily dissolved in a polar solvent (D), 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 joint portion for hybrid bonding can be reduced.
- 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 joint 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 joint, 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.
- the crosslinking agent (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.
- the crosslinking agent (B) preferably has a ring structure in the molecule.
- the ring structure include an alicyclic structure and an aromatic ring structure.
- the crosslinking agent (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 the crosslinking agent (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 joint, at least one of a benzene ring and a naphthalene ring is more preferable.
- the crosslinking agent (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.
- the crosslinking agent (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.
- the crosslinking agent (B) may have a fluoroalkyl group in the molecule, and specifically, may have a trifluoroalkyl group or a hexafluoroisopropyl group.
- examples of the crosslinking agent (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.
- the crosslinking agent (B) as a carboxylic acid ester compound, aggregation due to association between the compound (A) and the crosslinking agent (B) is suppressed, the number of aggregates and pits is reduced, and the film thickness can be easily adjusted.
- 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 crosslinking agent (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'-(ethyne-1,2-diyl)diphthalic acid acid), 4,4'-(1,4-phenylenebis(oxy))diphthalic acid, 4,4'-([1,1'-biphenyl]-4,4'-diylbis(
- 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-5).
- R is each independently an alkyl group having 1 to 6 carbon atoms. Among them, a methyl group, an ethyl group, a propyl group, and a butyl group are preferable, and an ethyl group and a propyl group are more preferable.
- Y is a single bond, O, C ⁇ O, or C(CF 3 ) 2 , and is preferably O.
- 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 joint preferably has a crosslinked structure such as amide, amide-imide, or imide, and has excellent heat resistance.
- compound (A) has uncrosslinked cationic functional groups, if compound (A) is included as a component of the joint without crosslinking agent (B), the crosslink density is low and heat resistance is likely to be insufficient.
- the cationic functional groups of compound (A) react with the carboxyl groups of crosslinking agent (B) to form covalent bonds, resulting in a high crosslink density and high heat resistance.
- polar solvent (D)- Specific examples of the polar solvent (D) include: Protic inorganic compounds 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 cyclohexane; Acid derivatives such as acetic anhydride, ethyl acetate, butyl acetate, ethylene carbonate, propylene carbonate, formaldehyde, N-methylformamide, N,N-di
- the content of the polar solvent (D) in the solution is not particularly limited, and is, for example, from 1.0 mass % to 99.99896 mass %, preferably from 40 mass % to 99.99896 mass %, based on the total mass of the solution.
- the boiling point of the polar solvent (D) is preferably 150° C. or lower, and more preferably 120° C. or lower.
- the solution containing the resin material may contain an additive (C).
- the additive (C) include an acid (C-1) having a carboxy group and a weight average molecular weight of 46 to 195, and a base (C-2) having a nitrogen atom and no ring structure and a weight average molecular weight of 17 to 120.
- the acid (C-1) is an acid having a carboxy group and a weight average molecular weight of 46 to 195. It is presumed that by including the acid (C-1) as the additive (C), the amino group in the compound (A) and the carboxy group in the acid (C-1) form an ionic bond, thereby suppressing aggregation due to association between the compound (A) and the crosslinking agent (B).
- the acid (C-1) is not particularly limited as long as it has a carboxy group and has a weight average molecular weight of 46 to 195, and examples of the acid (C-1) include monocarboxylic acid compounds, dicarboxylic acid compounds, and oxydicarboxylic acid compounds. More specifically, examples of the acid (C-1) include formic acid, acetic acid, malonic acid, oxalic acid, citric 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.
- the content of acid (C-1) in the solution containing the resin material is not particularly limited, and for example, the ratio (COOH/N) of the number of carboxy groups in acid (C-1) to the total number of nitrogen atoms in compound (A) is preferably 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 base (C-2) is a base having a nitrogen atom and a weight average molecular weight of 17 to 120. It is presumed that the solution containing the resin material contains the base (C-2) as an additive (C), and thus the carboxy group in the crosslinking agent (B) and the amino group in the base (C-2) form an ionic bond, suppressing aggregation due to association between the compound (A) and the crosslinking agent (B).
- the base (C-2) is not particularly limited as long as it has a nitrogen atom and does not have a ring structure with a weight average molecular weight of 17 to 120, and examples of the base include monoamine compounds and diamine compounds. More specifically, examples of the base (C-2) include ammonia, ethylamine, ethanolamine, diethylamine, triethylamine, ethylenediamine, N-acetylethylenediamine, N-(2-aminoethyl)ethanolamine, and N-(2-aminoethyl)glycine.
- the content of the base (C-2) in the solution containing a resin material is not particularly limited, and for example, the ratio (N/COOH) of the number of nitrogen atoms in the base (C-2) to the number of carboxy groups in the crosslinking agent (B) is preferably 0.5 or more and 5 or less, and more preferably 0.9 or more and 3 or less.
- the solution containing the resin material may be mixed with 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, or 1,3,5-trimethyl-1,3,5-trimethyl-1,3,5-triethoxy-1,3,5-trisilacyclohexane.
- methyltriethoxysilane, dimethyldiethoxysilane, trimethylethoxysilane, etc. may be mixed in. These compounds may be mixed in order to control the etch selectivity.
- the solution containing the resin material may contain a solvent other than the polar solvent (D), such as normal hexane.
- the solution containing the resin material may contain phthalic acid, benzoic acid, or a derivative thereof, for example, to improve electrical characteristics.
- the solution containing the resin material may also contain benzotriazole or a derivative thereof, for example to inhibit corrosion of copper.
- the pH of the solution containing the resin material is not particularly limited, but is preferably 2.0 or more and 12.0 or less.
- acid (C-1) is used as additive (C)
- a base (C-2) is used as the additive (C)
- a semiconductor structure (e.g., semiconductor structure 100) of the present disclosure includes an intermediate bonding layer (e.g., intermediate bonding layer 32) interposed between a semiconductor substrate bonding layer (e.g., semiconductor substrate bonding layer 14) in a semiconductor substrate (e.g., semiconductor substrate 10) and a composite substrate (e.g., composite substrate 31).
- a semiconductor substrate bonding layer in a semiconductor substrate and an intermediate bonding layer are hybrid-bonded.
- a known hybrid joint can be applied.
- the intermediate bonding layer includes an insulating layer and an electrode.
- the intermediate bonding layer preferably includes an insulating layer and an electrode that penetrates the insulating layer.
- the electrodes penetrating the insulating layer are as described above.
- the preferred aspects of the intermediate bonding layer eg, the preferred aspects of the insulating layer, the electrodes, and the formation method
- the semiconductor structure of the present disclosure may further include a redistribution layer (e.g., redistribution layer 34) between the composite substrate (e.g., composite substrate 31) and the intermediate bonding layer (e.g., intermediate bonding layer 32).
- redistribution layer 34 e.g., redistribution layer 34
- the semiconductor substrate bonding layer in the semiconductor substrate and the intermediate bonding layer are hybrid-bonded.
- the redistribution layer includes an insulating layer and wiring.
- the preferred aspects of the insulating layer in the redistribution layer are the same as the preferred aspects of the insulating layer in the semiconductor substrate bonding layer.
- the wiring in the redistribution layer is a metal member formed in an insulating layer in the redistribution layer and extending in the surface direction of the redistribution layer (i.e., in a direction perpendicular to the thickness direction of the redistribution layer).
- Examples of the material for the wiring include Cu, Sn, Au, Ag, Al, solder, and the like.
- the wiring in the semiconductor substrate bonding layer preferably contains Cu.
- the wiring in the semiconductor substrate bonding layer can be formed by a known manufacturing method such as a damascene process or a semi-additive process.
- at least two of the multiple silicon dies e.g., silicon die 20
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Abstract
Description
例えば、特許文献1には、配線層上に設けられたダイセットと、配線層上に設けられ、ダイセットの周囲を取り囲む、シリコンを含む無機ギャップフィル材と、を含む半導体構造体が開示されている。
本開示の一態様の課題は、半導体基板接合層を含む半導体基板と、二次元配置された複数のシリコンダイと複数のシリコンダイの間に充填されたギャップフィル材とを含む複合基板と、複合基板と半導体基板における半導体基板接合層との間に介在する中間接合層と、を備え、半導体基板接合層と中間接合層とがハイブリッド接合されている半導体構造体であって、反りが抑制された半導体構造体及びその製造方法を提供することである。
<1> 絶縁層及び電極を含む半導体基板接合層を含む半導体基板と、
二次元配置された複数のシリコンダイと、前記複数のシリコンダイの間に充填された有機ギャップフィル材と、を含む複合基板と、
絶縁層及び電極を含み、前記半導体基板と前記複合基板との間に介在する中間接合層と、
を備え、
前記半導体基板における前記半導体基板接合層と、前記中間接合層と、がハイブリッド接合されている、
半導体構造体。
<2> 前記中間接合層が、前記複数のシリコンダイのうちの少なくとも2つに跨って配置されている、<1>に記載の半導体構造体。
<3> 更に、前記複合基板と前記中間接合層との間に、絶縁層及び配線を含む再配線層を備える、
<1>又は<2>に記載の半導体構造体。
<4> 前記複数のシリコンダイのうちの少なくとも2つが、前記再配線層を介して電気的に接続されている、<3>に記載の半導体構造体。
<5> 前記再配線層における前記絶縁層が、SiO2層、SiCN層、SiN層、及び、シロキサン結合を含む樹脂層からなる群から選択される少なくとも1つを含む、<3>又は<4>に記載の半導体構造体。
<6> 前記半導体基板接合層における前記絶縁層、及び、前記中間接合層における前記絶縁層における前記絶縁層の各々が、SiO2層、SiCN層、SiN層、及び、シロキサン結合を含む樹脂層からなる群から選択される少なくとも1つを含む、<1>~<5>のいずれか1つに記載の半導体構造体。
<7> 前記有機ギャップフィル材が、ポリイミド、ポリアミド、ポリアミドイミド、マレイミド樹脂、パリレン、ポリアリレンエーテルポリイミド、ポリベンゾオキサゾール、ベンゾシクロブテン樹脂、エポキシ樹脂、及び、シロキサン結合を有する樹脂からなる群から選択される少なくとも1種を含む、<1>~<6>のいずれか1つに記載の半導体構造体。
<8> <1>~<7>のいずれか1つに記載の半導体構造体を製造する方法であって、
第1仮固定基板上に、複数のシリコンダイを二次元配置して仮固定し、次いで、前記複数のシリコンダイの間に前記有機ギャップフィル材を充填することにより、前記第1仮固定基板上に前記複合基板を形成する工程と、
前記複合基板から見て前記第1仮固定基板が配置されている側とは反対側に、第2仮固定基板を仮固定して積層体X1を得る工程と、
前記積層体X1から前記第1仮固定基板を除去することにより、前記複数のシリコンダイが露出している積層体X2を得る工程と、
前記絶縁層及び前記電極を含む前記半導体基板接合層を含む前記半導体基板を準備する工程と、
前記積層体X2における前記複数のシリコンダイの露出面側に、絶縁層及び電極を含む中間接合層を形成する工程と、
前記中間接合層が形成された前記積層体X2における前記中間接合層と、前記半導体基板における前記半導体基板接合層と、をハイブリッド接合させて積層体X3を得る工程と、
前記積層体X3から前記第2仮固定基板を除去することにより、前記半導体構造体を得る工程と、
を含む、
半導体構造体の製造方法。
<9> 前記中間接合層を形成する工程は、
前記積層体X2における前記複数のシリコンダイの露出面側に、絶縁層及び配線を含む再配線層を形成することと、
前記再配線層上に、中間接合層を形成することと、
を含む、<8>に記載の半導体構造体の製造方法。
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。
本開示の半導体構造体は、
絶縁層及び電極を含む半導体基板接合層を含む半導体基板と、
二次元配置された複数のシリコンダイ、及び、複数のシリコンダイの間に充填された有機ギャップフィル材を含む複合基板と、
複合基板と半導体基板における半導体基板接合層との間に介在し、絶縁層及び電極を含む中間接合層と、
を備え、
半導体基板における半導体基板接合層と、中間接合層と、がハイブリッド接合されている、
半導体構造体である。
これに対し、本開示の半導体構造体は、ギャップフィル材を、有機ギャップフィル材とすることにより、無機ギャップフィル材の膜応力によって半導体構造体が反る問題が抑制される。これにより、半導体構造体の反りに起因する、接合不良、及び/又は、半導体基板と複合基板との位置ずれを抑制できる。
以下、本開示の半導体構造体の一例(半導体構造体100)を、図面を参照しながら説明する。
但し、本開示の半導体構造体は、以下の一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、半導体構造体100は、
半導体基板10と、
複合基板31と、
半導体基板10と複合基板31との間に介在する中間接合層32と、
を備える。
基板本体12と、
基板本体12の一方の面側に設けられた半導体基板接合層14と、
半導体基板接合層14に対して電気的に接続され、基板本体12を貫通する貫通電極16と、
を含む。
半導体基板10における基板本体12の内部には、集積回路が形成されている(不図示)。
半導体基板10における半導体基板接合層14は、絶縁層及び電極を含む(不図示)。
半導体基板接合層14は、好ましくは、絶縁層と、絶縁層を貫通する電極と、を含む。
半導体基板接合層14中の電極は、基板本体12における集積回路に対し、電気的に接続されている。これらの構造は、一般的な構造であるため、図示を省略している。
シリコンダイ20の内部には、集積回路が形成されている(不図示)。
シリコンダイ20の内部の構造は、一般的な構造であるため、図示を省略している。
中間接合層32は、絶縁層及び電極を含む(不図示)。
中間接合層32は、好ましくは、絶縁層と、絶縁層を貫通する電極と、を含む。
このハイブリッド接合により、半導体基板10における基板本体12の内部の集積回路と、複数のシリコンダイ20の内部の集積回路と、が、半導体基板10における半導体基板接合層14における電極及び中間接合層32における電極を介して、電気的に接続される。
このため、半導体構造体100では、ギャップフィル材が無機ギャップフィル材である場合(例えば、前述の特許文献1(米国特許公開第2022/0013504号明細書))と比較して、ギャップフィル材の膜応力が低減されるので、半導体構造体全体の反りが抑制される。これにより、半導体構造体の反りに起因する、接合不良、及び/又は、半導体基板と複合基板との位置ずれを抑制できる。
また、前述のとおり、半導体構造体100では、ギャップフィル材を、短時間かつ簡易に形成できる。
図2は、本開示の半導体構造体の別の一例である半導体構造体200を示す概略断面図である。
半導体構造体200は、前述の半導体構造体100に対する変形例である。
半導体構造体200は、以下の点で、前述の半導体構造体100と異なる。以下の点以外は、半導体構造体200は前述の半導体構造体100と同様である。
図2に示されるように、半導体構造体200は、複合基板31と、中間接合層32と、の間に、再配線層34を備えている。
再配線層34は、絶縁層と、絶縁層中に形成された配線と、を含む(不図示)。
半導体構造体200においても、半導体基板10における半導体基板接合層14と、中間接合層32と、がハイブリッド接合されている。
複数のシリコンダイ20のうちの少なくとも2つは、再配線層34(詳細には、再配線層34中の配線)を介して電気的に接続されていることが好ましい。
本開示の半導体構造体を製造する方法には特に制限はない。
本開示の半導体構造体を製造する方法の一実施形態として、以下の「製法X」が挙げられる。
第1仮固定基板上に、複数のシリコンダイを二次元配置して仮固定し、次いで、複数のシリコンダイの間に有機ギャップフィル材を充填することにより、第1仮固定基板上に複合基板を形成する工程と、
複合基板から見て第1仮固定基板が配置されている側とは反対側に、第2仮固定基板を仮固定して積層体X1を得る工程と、
前記積層体X1から前記第1仮固定基板を除去することにより、前記複数のシリコンダイが露出している積層体X2を得る工程と、
絶縁層及び電極を含む半導体基板接合層を含む半導体基板を準備する工程と、
積層体X2における複数のシリコンダイの露出面側に、絶縁層及び電極を含む中間接合層を形成する工程と、
前記中間接合層が形成された前記積層体X2における前記中間接合層と、前記半導体基板における前記半導体基板接合層と、をハイブリッド接合させて積層体X3を得る工程と、
積層体X3から第2仮固定基板を除去することにより、半導体構造体を得る工程と、
を含む。
製法Xは、必要に応じ、その他の工程を含んでいてもよい。
図3A~図3Hは、製法Xの一例(以下、「製法X1」ともいう)を示す概略工程図である。
図3A~図3Cは、製法X1における複合基板を形成する工程を示している。
図3A~図3Cに示されるように、製法X1における複合基板を形成する工程では、第1仮固定基板40上に、複数のシリコンダイ20を二次元配置して仮固定し、次いで、複数のシリコンダイ20の間に有機ギャップフィル材30を充填することにより、第1仮固定基板40上に複合基板31を形成する。
まず、第1仮固定基板40上の、複数のシリコンダイ20が仮固定された側に有機ギャップフィル材30Aを形成することにより、有機ギャップフィル材30Aの一部を複数のシリコンダイ20の間に充填し、かつ、有機ギャップフィル材30Aの残部の一部により、複数のシリコンダイ20の上面を被覆する(図3B)。
次いで、複数のシリコンダイ20の上面上の有機ギャップフィル材30Aを除去し、複数のシリコンダイ20の上面を露出させる。これにより、複数のシリコンダイ20の間に充填された有機ギャップフィル材30Aが残る。残った有機ギャップフィル材30Aが、図3Cにおける有機ギャップフィル材30となる。
有機ギャップフィル材30の形成方法は、有機ギャップフィル材30Aを経由して形成する上記一例には限定されない。有機ギャップフィル材30は、複数のシリコンダイ20の間に直接形成されてもよい。
第1仮固定基板40上への複数のシリコンダイ20の仮固定は、例えば;
アクリル、エポキシポリマーなど粘着剤を用いた方法;
ポリイミド、ポリアミドイミド、ポリマレイミド、シロキサンポリマーなどの耐熱性樹脂を用いた方法;
SiO2同士の直接接合;
等によって行うことができる。
第1仮固定基板40は、製法X1の途中で除去(即ち、剥離)されるものである。このため、第1固定基板40の複数のシリコンダイ20との対向面には、複数のシリコンダイ20からの剥離を容易にするための表面処理が施されていてもよい。
研磨は、機械研磨、化学研磨、化学機械研磨等、常法に従って行うことができる。
図3Dは、製法X1における、積層体X1を得る工程を示している。
図3Dに示されるように、製法X1における本工程では、複合基板31から見て第1仮固定基板40が配置されている側とは反対側に、第2仮固定基板42を仮固定して、積層体X1としての積層体X101を得る。
第2仮固定基板42の仮固定は、例えば粘着剤を用いて行うことができる。
第2仮固定基板42は、製法X1の途中で除去(即ち、剥離)されるものである。このため、第2固定基板42における、複数のシリコンダイ20及び有機ギャップフィル材30との対向面には、複数のシリコンダイ20及び有機ギャップフィル材30からの剥離を容易にするための表面処理が施されていてもよい。
図3Eは、製法X1における、積層体X2を得る工程を示している。
図3Eに示されるように、製法X1における本工程では、積層体X1としての積層体X101から第1仮固定基板40を除去することにより、複数のシリコンダイ20が露出している、積層体X2としての積層体X102を得る。
第1仮固定基板40の仮固定を、アクリル粘着剤又はエポキシ粘着剤によって行った場合、第1仮固定基板40の除去は、例えば、熱発泡、機械剥離、熱スライド、レーザー剥離等によって行うことができる。
第1仮固定基板40の仮固定を、ポリイミド、ポリアミドイミド、ポリマレイミド、シロキサンポリマー等の耐熱性樹脂を用いて行った場合、第1仮固定基板40の除去は、例えば、レーザー剥離、機械剥離、熱スライド等によって行うことができる。
第1仮固定基板40の仮固定を、SiO2同士の直接接合によって行った場合、第1仮固定基板40の除去は、例えば、赤外線等を用いたレーザー剥離等によって行うことができる。
クリーニングの方法としては特に制限はなく、例えば、プラズマクリーニング、洗浄液によるクリーニング、研磨、等が挙げられる。
製法X1における半導体基板を準備する工程では、絶縁層及び電極を含む半導体基板接合層14を含む半導体基板10(後述の図3G参照)を準備する。
図3Fは、製法X1における、中間接合層を形成する工程の一態様を示している。
図3Fに示されるように、この一態様では、積層体X102における複数のシリコンダイ20の露出面側に、絶縁層及び電極を含む中間接合層32を形成する。
図3Gは、製法X1における、積層体X3を得る工程を示している。
図3Gに示されるように、本工程では、中間接合層32が形成された積層体X102における中間接合層32と、半導体基板10における半導体基板接合層14と、をハイブリッド接合させて、積層体X3としての積層体X102を得る。
図3Hは、製法X1における、半導体構造体を得る工程を示している。
図3Hに示されるように、本工程では、図3Gにおける積層体X103から第2仮固定基板42を除去することにより、半導体構造体100を得る。
第2仮固定基板42の除去は、第1仮固定基板の除去と同様の方法によって行うことができる。
この場合の製法Xでは、中間接合層を形成する工程(例えば図3Fに示す工程)が、
積層体X2(例えば積層体X102)における複数のシリコンダイ(例えばシリコンダイ20)の露出面側に、絶縁層及び配線を含む再配線層(例えば再配線層34)を形成することと、
再配線層(例えば再配線層34)上に、中間接合層(例えば、中間接合層32)を形成することと、
を含む。
本開示の半導体構造体(例えば半導体構造体100)は、半導体基板(例えば半導体基板10)を含む。
半導体基板は、基板本体と、基板本体の一方の面側に設けられた半導体基板接合層と、を含み得る。半導体基板接合層は、基板本体の両面に配置されていてもよい。
基板本体の材質は、特に限定されず、半導体基板として通常使用されるものであればよい。
基板本体は、Si、Al、Ti、Zr、Hf、Fe、Ni、Cu、Ag、Au、Ga、Ge、Sn、Pd、As、Pt、Mg、In、Ta及びNbからなる群から選ばれる少なくとも1種の元素を含むことが好ましい。
基板本体の材質として、より具体的には、例えば;
半導体(例えば、Si、InP、GaN、GaAs、InGaAs、InGaAlAs、SiC等);
酸化物、炭化物、又は窒化物(例えば、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、ZrO2、Si3N4、AlN等);
圧電体又は誘電体(例えば、BaTiO3、LiNbO3、SrTiO3、ダイヤモンド等);
金属(例えば、Al、Ti、Fe、Cu、Ag、Au、Pt、Pd、Ta、Nb等);
樹脂(例えば、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);
などが挙げられる。
基板本体は、これらの材質を1種のみ含んでいてもよいし、2種以上含んでいてもよい。
基板本体として、好ましくは、シリコン基板、GaAs基板、SiC基板、ダイヤモンド基板、ガラス基板、又は樹脂基板であり、典型的にはシリコン基板である。
基板本体は、多層構造を有していてもよい。
半導体基板接合層は、絶縁層及び電極を含む。
半導体基板接合層は、好ましくは、絶縁層と、絶縁層を貫通する電極(例えばCu電極)と、を含む。
絶縁層を貫通する電極については前述のとおりである。
半導体基板接合層における電極は、Cuを含むことが好ましい。
半導体基板接合層における電極は、例えば、ダマシンプロセス、セミアディティブプロセス等の公知の製造方法によって形成され得る。
絶縁層としての、シロキサン結合を含む樹脂層の形成方法についても、後述する「有機ギャップフィル材」の形成方法の例を適宜参照できる。
半導体基板は、基板本体を貫通する貫通電極を含み得る。
貫通電極としては特に制限はなく、公知の貫通電極が適用され得る。
この貫通電極により、半導体基板中の集積回路と、半導体構造体の外部に配置される電子デバイス等と、の電気的な接続がなされる。
本開示の半導体構造体(例えば半導体構造体100)は、複合基板(例えば、複合基板31)を含む。
複合基板は、複数のシリコンダイ(例えば、シリコンダイ20)と複数のシリコンダイの間に充填された有機ギャップフィル材(例えば、有機ギャップフィル材30)とを含む。
複合基板(例えば、複合基板31)は、二次元配置された複数のシリコンダイ(例えばシリコンダイ20)を含む。
シリコンダイとしては、シリコン基板(例えばシリコンウェハ)に集積回路が形成され、かつ、チップ状に切り出されて得られる、通常のシリコンダイを用いることができる。
シリコンダイの厚さは、好ましくは5μm~700μm、より好ましくは10μm~300μm、更に好ましくは15μm~100μmである。
本複合基板(例えば、複合基板31)は、二次元配置された複数のシリコンダイ(例えばシリコンダイ20)の間に充填された有機ギャップフィル材(例えば有機ギャップフィル材30)を含む。
ガラス転移温度は、以下の方法で測定することができる。
即ち、幅4mm、長さ20mmの有機材料の試験片を準備する。この試験片のガラス転移温度を、島津製作所社製の熱分析装置(TMA-50)を用いて、25~350℃の温度範囲で、昇温速度5℃/分、荷重14g/mm2、引張りモードの測定条件で、TMA測定し、得られた温度-試験片伸び曲線の変曲点から、ガラス転移温度(Tg)を特定することができる。
シロキサン結合を含む樹脂は、以下に示す式(1)~式(3)で表される構造を含んでもよい。
また、式(1)及び式(2)で表される構造は、例えば、式(4)及び式(5)で表される化合物を加熱して反応させることで生成できる。
有機ギャップフィル材は、例えば、有機ギャップフィル材形成用溶液を用いて形成できる。
有機ギャップフィル材形成用溶液としては、例えば、樹脂材料を含む溶液が挙げられる。
樹脂材料を含む溶液は、
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を有し、重量平均分子量が90以上40万以下である化合物(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以下である架橋剤(B)と、
極性溶媒(D)と、
を含むことが好ましい。
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を有し、重量平均分子量が90以上40万以下である化合物である。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。
均分子量を指す。
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。
これらのポリアルキレンイミン誘導体は、上記ポリアルキレンイミンを用いて通常行われる方法により製造することができる。具体的には例えば、特開平6―016809号公報等に記載の方法に準拠して製造することができる。
高分岐型のポリアルキレンイミンを得る方法としては、例えば、骨格中に複数の2級窒素原子を有するポリアルキレンイミンに対してカチオン性官能基含有モノマーを反応させ、前記複数の2級窒素原子のうちの少なくとも1つをカチオン性官能基含有モノマーによって置換する方法、末端に複数の1級窒素原子を有するポリアルキレンイミンに対してカチオン性官能基含有モノマーを反応させ、前記複数の1級窒素原子のうちの少なくとも1つをカチオン性官能基含有モノマーによって置換する方法等、が挙げられる。
分岐度を向上するために導入されるカチオン性官能基としては、アミノエチル基、アミノプロピル基、ジアミノプロピル基、アミノブチル基、ジアミノブチル基、トリアミノブチル基等を挙げることができるが、カチオン性官能基当量を小さくしカチオン性官能基密度を大きくする点から、アミノエチル基が好ましい。
化合物(A)としての、Si-O結合とアミノ基とを有する化合物は、シロキサン結合を含む樹脂の材料として好適である。
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-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。
中でも、環構造を有する重量平均分子量90以上600以下のアミン化合物が好ましい。環構造を有する重量平均分子量90以上600以下のアミン化合物としては、脂環式アミン、芳香環アミン、複素環(ヘテロ環)アミン等が挙げられる。分子内に複数の環構造を有していてもよく、複数の環構造は、同じであっても異なっていてもよい。環構造を有するアミン化合物としては、熱的に、より安定な化合物が得られ易いため、芳香環を有する化合物がより好ましい。
また、環構造を有する重量平均分子量90以上600以下のアミン化合物としては、架橋剤(B)とともにアミド、アミドイミド、イミドなどの熱架橋構造を形成し易く、耐熱性を高めることができる点から、1級アミノ基を有する化合物が好ましい。更に、前述のアミン化合物としては、架橋剤(B)とともにアミド、アミドイミド、イミドなどの熱架橋構造の数を多くし易く、耐熱性をより高めることができる点から、1級アミノ基を2つ有するジアミン化合物、1級アミノ基を3つ有するトリアミン化合物等が好ましい。
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、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、2,7-ジアミノフルオレン、1,9-ジアミノフルオレン、ジベンジルアミンなどが挙げられる。
複素環アミンの複素環としては、ヘテロ原子として硫黄原子を含む複素環(例えば、チオフェン環)、又は、ヘテロ原子として窒素原子を含む複素環(例えば、ピロール環、ピロリジン環、ピラゾール環、イミダゾール環、トリアゾール環等の5員環;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、トリアジン環等の6員環;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、キノキサリン環等の縮合環等)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。
更に、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-トリアミンなどが挙げられる。
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、ハイブリッド接合する接合部の厚さを薄くすることができる。
架橋剤(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’-ジイルビス(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。
一般式(B-2)におけるYは、単結合、O、C=O、又はC(CF3)2であり、Oであることが好ましい。
極性溶媒(D)としては、具体的には;
水、重水などのプロトン性無機化合物;
メタノール、エタノール、1-プロパノール、2-プロパノール、1-ブタノール、2-ブタノール、イソブチルアルコール、イソペンチルアルコール、シクロヘキサノール、エチレングリコール、プロピレングリコール、2-メトキシエタノール、2-エトキシエタノール、ベンジルアルコール、ジエチレングリコール、トリエチレングリコール、グリセリンなどのアルコール類;
テトラヒドロフラン、ジメトキシエタンなどのエーテル類;
フルフラール、アセトン、エチルメチルケトン、シクロヘキサンなどのアルデヒド・ケトン類;
無水酢酸、酢酸エチル、酢酸ブチル、炭酸エチレン、炭酸プロピレン、ホルムアルデヒド、N-メチルホルムアミド、N,N-ジメチルホルムアミド、N-メチルアセトアミド、N,N-ジメチルアセトアミド、N-メチル-2-ピロリドン、ヘキサメチルリン酸アミドなどの酸誘導体;
アセトニトリル、プロピオニトリルなどのニトリル類;ニトロメタン、ニトロベンゼンなどのニトロ化合物;
ジメチルスルホキシドなどの硫黄化合物;
が挙げられる。
極性溶媒(D)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更に好ましい。
溶液中における極性溶媒(D)の含有量は、特に限定されず、例えば、溶液全体に対して1.0質量%以上99.99896質量%以下であり、40質量%以上99.99896質量%以下であることが好ましい。
有機ギャップフィル材を形成する際の加熱により極性溶媒(D)を揮発させ、有機ギャップフィル材中の残溶媒の量を少なくするという観点から、極性溶媒(D)の沸点は、150℃以下が好ましく、120℃以下がより好ましい。
樹脂材料を含む溶液は、添加剤(C)を含んでいてもよい。
添加剤(C)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(C-1)、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(C-2)が挙げられる。
に制限されず、例えば、架橋剤(B)中のカルボキシ基の数に対する塩基(C-2)中の窒素原子の数の比率(N/COOH)が、0.5以上5以下であることが好ましく、0.9以上3以下であることがより好ましい。
更に、有機ギャップフィル材の疎水性改善のために、メチルトリエトキシシラン、ジメチルジエトキシシラン、トリメチルエトキシシラン等を混合させてもよい。これらの化合物はエッチング選択性の制御の為に混合させてもよい。
また、樹脂材料を含む溶液は、例えば銅の腐食を抑制するため、ベンゾトリアゾール又はその誘導体を含有していてもよい。
本開示の半導体構造体(例えば半導体構造体100)は、半導体基板(例えば半導体基板10)における半導体基板接合層(例えば半導体基板接合層14)と、複合基板(例えば、複合基板31)と、の間に介在する中間接合層(例えば、中間接合層32)を備える。
本開示における半導体構造体では、半導体基板における半導体基板接合層と、中間接合層と、がハイブリッド接合されている。
ハイブリッド接合としては、公知のハイブリッド接合を適用できる。
中間接合層は、好ましくは、絶縁層と、絶縁層を貫通する電極と、を含む。
絶縁層を貫通する電極については前述のとおりである。
中間接合層の好ましい態様(例えば、絶縁層、電極、形成方法の好ましい態様)は、前述した半導体基板接合層の好ましい態様と同様である。
本開示の半導体構造体(例えば半導体構造体200)は、更に、複合基板(例えば、複合基板31)と、中間接合層(例えば、中間接合層32)と、の間に、再配線層(例えば、再配線層34)を備えてもよい。
この態様の半導体構造体においても、半導体基板における半導体基板接合層と、中間接合層と、がハイブリッド接合されている。
配線の材質としては、Cu、Sn、Au、Ag、Al、はんだ、等が挙げられる。
半導体基板接合層における配線は、Cuを含むことが好ましい。
半導体基板接合層における配線は、例えば、ダマシンプロセス、セミアディティブプロセス等の公知の製造方法によって形成され得る。
本開示の半導体構造体(例えば半導体構造体200)において、複数のシリコンダイ(例えば、シリコンダイ20)のうちの少なくとも2つは、再配線層(詳細には、再配線層中の配線)を介して電気的に接続されていることが好ましい。
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 (9)
- 絶縁層及び電極を含む半導体基板接合層を含む半導体基板と、
二次元配置された複数のシリコンダイ、及び、前記複数のシリコンダイの間に充填された有機ギャップフィル材を含む複合基板と、
前記半導体基板における前記半導体基板接合層と、前記複合基板と、の間に介在し、絶縁層及び電極を含む中間接合層と、
を備え、
前記半導体基板における前記半導体基板接合層と、前記中間接合層と、がハイブリッド接合されている、
半導体構造体。 - 前記中間接合層が、前記複数のシリコンダイのうちの少なくとも2つに跨って配置されている、請求項1に記載の半導体構造体。
- 更に、前記複合基板と前記中間接合層との間に、絶縁層及び配線を含む再配線層を備える、
請求項1に記載の半導体構造体。 - 前記複数のシリコンダイのうちの少なくとも2つが、前記再配線層を介して電気的に接続されている、請求項3に記載の半導体構造体。
- 前記再配線層における前記絶縁層が、SiO2層、SiCN層、SiN層、及び、シロキサン結合を含む樹脂層からなる群から選択される少なくとも1つを含む、請求項3に記載の半導体構造体。
- 前記半導体基板接合層における前記絶縁層、及び、前記中間接合層における前記絶縁層における前記絶縁層の各々が、SiO2層、SiCN層、SiN層、及び、シロキサン結合を含む樹脂層からなる群から選択される少なくとも1つを含む、請求項1に記載の半導体構造体。
- 前記有機ギャップフィル材が、ポリイミド、ポリアミド、ポリアミドイミド、マレイミド樹脂、パリレン、ポリアリレンエーテルポリイミド、ポリベンゾオキサゾール、ベンゾシクロブテン樹脂、エポキシ樹脂、及び、シロキサン結合を有する樹脂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1~請求項6のいずれか1項に記載の半導体構造体。
- 請求項1又は請求項2に記載の半導体構造体を製造する方法であって、
第1仮固定基板上に、複数のシリコンダイを二次元配置して仮固定し、次いで、前記複数のシリコンダイの間に前記有機ギャップフィル材を充填することにより、前記第1仮固定基板上に前記複合基板を形成する工程と、
前記複合基板から見て前記第1仮固定基板が配置されている側とは反対側に、第2仮固定基板を仮固定して積層体X1を得る工程と、
前記積層体X1から前記第1仮固定基板を除去することにより、前記複数のシリコンダイが露出している積層体X2を得る工程と、
前記絶縁層及び前記電極を含む前記半導体基板接合層を含む前記半導体基板を準備する工程と、
前記積層体X2における前記複数のシリコンダイの露出面側に、絶縁層及び電極を含む中間接合層を形成する工程と、
前記中間接合層が形成された前記積層体X2における前記中間接合層と、前記半導体基板における前記半導体基板接合層と、をハイブリッド接合させて積層体X3を得る工程と、
前記積層体X3から前記第2仮固定基板を除去することにより、前記半導体構造体を得る工程と、
を含む、
半導体構造体の製造方法。 - 前記中間接合層を形成する工程は、
前記積層体X2における前記複数のシリコンダイの露出面側に、絶縁層及び配線を含む再配線層を形成することと、
前記再配線層上に、中間接合層を形成することと、
を含む、請求項8に記載の半導体構造体の製造方法。
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