JP2017001193A - 保護テープ、及びこれを用いた半導体装置の製造方法 - Google Patents
保護テープ、及びこれを用いた半導体装置の製造方法 Download PDFInfo
- Publication number
- JP2017001193A JP2017001193A JP2015114338A JP2015114338A JP2017001193A JP 2017001193 A JP2017001193 A JP 2017001193A JP 2015114338 A JP2015114338 A JP 2015114338A JP 2015114338 A JP2015114338 A JP 2015114338A JP 2017001193 A JP2017001193 A JP 2017001193A
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- Prior art keywords
- thermoplastic resin
- protective tape
- resin layer
- layer
- formula
- Prior art date
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- Granted
Links
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Classifications
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Abstract
Description
(1)Ga>Gb
(2)Ta<Tb
(3)(Ga×Ta+Gb×Tb)/(Ta+Tb)≦1.4E+06Pa
(式(1)中、Gaは保護テープを貼付する貼付温度における第1の熱可塑性樹脂層の貯蔵剪断弾性率であり、Gbは保護テープを貼付する貼付温度における第2の熱可塑性樹脂層の貯蔵剪断弾性率である。式(2)中、Taは第1の熱可塑性樹脂層の厚みであり、Tbは第2の熱可塑性樹脂層の厚みである。式(3)中、Ga及びGbは式(1)中のGa及びGbと同義であり、Ta及びTbは式(2)中のTa及びTbと同義である。)
1.保護テープ
2.半導体装置の製造方法
3.実施例
本実施の形態に係る保護テープは、接着剤層と、第1の熱可塑性樹脂層と、第2の熱可塑性樹脂層と、基材フィルム層とをこの順に有し、下記式(1)〜(3)の条件を満たす。
(1)Ga>Gb
(2)Ta<Tb
(3)(Ga×Ta+Gb×Tb)/(Ta+Tb)≦1.4E+06Pa
(式(1)中、Gaは保護テープを貼付する貼付温度における第1の熱可塑性樹脂層の貯蔵剪断弾性率であり、Gbは保護テープを貼付する貼付温度における第2の熱可塑性樹脂層の貯蔵剪断弾性率である。式(2)中、Taは第1の熱可塑性樹脂層の厚みであり、Tbは第2の熱可塑性樹脂層の厚みである。式(3)中、Ga及びGbは式(1)中のGa及びGbと同義であり、Ta及びTbは式(2)中のTa及びTbと同義である。)
(1A)Ga>Gb>Gn
(式(1A)中、Gnは保護テープを貼付する貼付温度における接着剤層の貯蔵剪断弾性率であり、Ga及びGbは式(1)中のGa及びGbと同義である。)
(2A)Tn<Ta<Tb
(式(2A)中、Tnは接着剤層の厚みであり、Ta及びTbは式(2)中のTa及びTbと同義である。)
(4)Gn/Ga≦0.01
接着剤層11の60℃での貯蔵剪断弾性率(Gn)は、1.0E+01Pa〜5.0E+04Paであることが好ましく、1.0E+02Pa〜3.5E+03Paであることがより好ましい。接着剤層11の貯蔵剪断弾性率を1.0E+01Pa以上とすることにより、バンプが接着剤を貫通する間に接着剤層11付着してバンプ先端を接着剤層が覆ってしまうことを抑制することができる。また、保護テープ10をウエハに貼り付けた際に接着剤層11の樹脂が流れてしまうことを抑制することができる。接着剤層11の貯蔵剪断弾性率を5.0E+04Pa以下とすることにより、バンプが接着剤層11をより容易に貫通することができ、導通をより良好にすることができる。
第1の熱可塑性樹脂層12は、例えば、エチレン酢酸ビニル共重合体(EVA:Ethylene Vinyl Acetate)、ポリエチレン、ポリプロピレン、ポリアミド、ポリアセタール、ポリエチレンテレフタレート、ポリブチレンテレフタレート、フッ素樹脂、ポリフェニレンサルファイド、ポリスチレン、ABS樹脂、アクリル系樹脂、ポリカーボネート、ポリウレタン、ポリ塩化ビニル、ポリフェニレンオキサイドなどの樹脂からなる層である。上記樹脂は、1種単独で使用してもよいし、2種以上を併用してもよい。
第2の熱可塑性樹脂層13は、第1の熱可塑性樹脂層12と同様の樹脂からなる層である。第2の熱可塑性樹脂層を構成する樹脂は、1種単独で使用してもよいし、2種以上を併用してもよい。
基材フィルム層14としては、ポリエチレンテレフタレート、ポリエチレン、ポリプロピレン、ポリエステルなどのプラスチックフィルムや、紙、布、不織布等からなる多孔質基材を用いることができる。
(1A)Gc>Ga>Gb
(2A)Tc<Ta<Tb
(式(1A)中、Gcは、保護テープを貼付する貼付温度における第3の熱可塑性樹脂層の貯蔵剪断弾性率であり、Ga及びGbは式(1)中のGa及びGbと同義である。式(2A)中、Tcは第3の熱可塑性樹脂層の厚さであり、Ta及びTbは式(2)中のTa及びTbと同義である。)
次に、上述した保護テープを用いた半導体装置の製造方法について説明する。本実施の形態に係る半導体装置の製造方法は、バンプが形成されたウエハ面に接着剤層を有する保護テープを貼付する保護テープ貼付工程と、保護テープ貼付面の反対面をグラインド処理するグラインド処理工程と、接着剤層を残して保護テープを剥離し、他の層を除去する保護テープ剥離工程とを有し、保護テープが、上述した保護テープである。
図2は、保護テープ貼付工程の概略を示す断面図である。保護テープ貼付工程では、バンプ22が形成されたウエハ21面に保護テープ10を貼り付ける。保護テープ10を貼り付ける貼付温度は、ボイドの減少、ウエハ密着性の向上およびウエハ研削後のウエハの反り防止の観点から、25℃〜100℃が好ましく、40℃〜80℃がより好ましい。
図3は、グラインド工程の概略を示す断面図である。グラインド工程では、保護テープ10を貼り付けたウエハ21の反対面、すなわち、バンプ22が形成されている面とは反対面を研削装置に固定して研磨する。研磨は通常、ウエハ21の厚みが50〜600μmになるまで行うが、本実施の形態では、接着剤層11によりバンプ22が補強されるため、50μm以下の厚さまで研磨してもよい。
図4は、粘着テープ貼付工程の概略を示す断面図である。粘着テープ貼付工程では、グラインド処理面に粘着テープ30を貼付する。粘着テープ30は、ダイシングテープ(Dicing Tape)と呼ばれるものであり、ダイシング工程(F)において、ウエハ21を保護、固定し、ピックアップ工程(H)まで保持するためのテープである。
図5は、保護テープ剥離工程の概略を示す断面図である。保護テープ剥離工程では、接着剤層11を残して保護テープ10を剥離し、他の層を除去する。すなわち、第1の熱可塑性樹脂層12、第2の熱可塑性樹脂祖13及び基材フィルム層14が除去され、ウエハ21上には接着剤層11のみが残る。
図6は、硬化工程の概略を示す断面図である。硬化工程では、接着剤層11を硬化させる。硬化方法及び硬化条件としては、熱硬化型の接着剤を硬化させる公知の方法を用いることができる。例えば、硬化条件は、100〜200℃で1時間以上が好ましい。
図7は、ダイシング処理工程の概略を示す断面図である。ダイシング処理工程では、粘着テープ30が貼付されたウエハ21をダイシング処理し、個片の半導体チップを得る。ダイシング方法としては、特に限定されず、例えばダイシングソーでウエハ21を切削して切り出すなどの公知の方法を用いることができる。
図8は、エキスパンド工程の概略を示す断面図である。エキスパンド工程では、例えば分割された複数個の半導体チップが貼着されている粘着テープ30を水平方向に伸長させ、個々の半導体チップの間隔を広げる。
図9は、ピックアップ工程の概略を示す断面図である。ピックアップ工程では、粘着テープ30上に貼着固定された半導体チップを、粘着テープ30の下面より突き上げて剥離させ、この剥離された半導体チップをコレットで吸着する。ピックアップされた半導体チップは、チップトレイに収納されるか、またはフリップチップボンダーのチップ搭載ノズルへと搬送される。
図10は、実装工程の概略を示す断面図である。実装工程では、例えば半導体チップと回路基板とをNCF(Non Conductive Film)などの回路接続材料を用いて接続する。回路基板としては、特に限定されないが、ポリイミド基板、ガラスエポキシ基板などのプラスチック基板、セラミック基板などを用いることができる。また、接続方法としては、加熱ボンダー、リフロー炉などを用いる公知の方法を用いることができる。
接着剤層及び熱可塑性樹脂層の60℃における貯蔵剪断弾性率は、粘弾性測定装置を用いて算出した。測定条件は、測定温度域0〜120℃、昇温速度5℃/分、振動数1Hz、歪み0.1%に設定した。
<熱可塑性樹脂層(フィルム1)の作製>
PET基材(厚み75μm)上に、第1の熱可塑性樹脂層(下記熱可塑性樹脂層A1〜A3のいずれか)、及び/又は、第2の熱可塑性樹脂層(下記熱可塑性樹脂層B1〜B3のいずれか)がこの順に形成されるように、熱可塑性樹脂を押し出し溶融成型した。
熱可塑性樹脂層A1:エチレン・酢酸ビニル共重合体(VF120T、宇部丸善ポリエチレン(株)社製)、60℃での貯蔵剪断弾性率:3.1E+06Pa
熱可塑性樹脂層A2:(0540F、宇部丸善ポリエチレン(株)社製)、60℃での貯蔵剪断弾性率:7.1E+06Pa
熱可塑性樹脂層A3:エチレン・酢酸ビニル共重合体(V319、宇部丸善ポリエチレン(株)社製)、60℃での貯蔵剪断弾性率:1.1E+06Pa
熱可塑性樹脂層B1:エチレン・酢酸ビニル共重合体(EV40LX、三井・デュポンポリケミカル(株)社製)、60℃での貯蔵剪断弾性率:4.9E+05Pa
熱可塑性樹脂層B2:エチレン・酢酸ビニル共重合体(EV45LX、三井・デュポンポリケミカル(株)社製)、60℃での貯蔵剪断弾性率:4.2E+04Pa
熱可塑性樹脂層B3:エチレン・酢酸ビニル共重合体(EV170、三井・デュポンポリケミカル(株)社製)、60℃での貯蔵剪断弾性率:6.2E+05Pa
表1に示すように、接着剤層No.1〜No.3を作製した。接着剤層No.1は、膜形成樹脂13.0質量部と、エポキシ樹脂54.8質量部と、硬化剤32.4質量部と、硬化助剤0.3質量部とを配合して接着剤組成物を調製し、これを、乾燥後の厚みが30μmとなるように剥離処理されたPET(Polyethylene terephthalate)にバーコーターを用いて塗布し、オーブンで乾燥させて作製した。接着剤層No.1の60℃での貯蔵剪断弾性率は、3.3E+03Paであった。
エポキシ樹脂:ジシクロペンタジエン型エポキシ樹脂(HP7200H、DIC(株)社製)
硬化剤:ノボラック型フェノール樹脂(TD−2093、DIC(株)社製)
硬化助剤:2−エチル−4−メチルイミダゾール(2E4MZ)
フィラー:シリカ(アエロジルRY200、日本アエロジル(株)社製)
上記熱可塑性樹脂層(フィルム1)と、上記接着剤層(フィルム2)とをラミネートし、保護テープを作製した。フィルム1としては、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用いた。フィルム2としては、接着剤層No.1(20μm)を用いた。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A2(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.2(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A3(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.3(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B2(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B3(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(20μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(200μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(300μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(600μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(50μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(100μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(5μm)と熱可塑性樹脂層B1(495μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(50μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.2(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(250μm)と熱可塑性樹脂層B1(450μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層B1(500μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
フィルム1として、PET基材(75μm)と熱可塑性樹脂層A1(500μm)とからなるものを用い、フィルム2として、接着剤層No.1(20μm)を用いたこと以外は、実施例1と同様に保護テープを作製した。
保護テープの接着剤層面を、はんだバンプ(φ=250μm、H=200μm、ピッチ=250μm)が形成されたウエハ(サイズ:5cm×5cm×700μmt)に貼り付け、真空式ラミネータを用いて60℃の温度でラミネートした。
基板の金電極上にフラックスを塗布し、最大260℃のリフロー温度ではんだ接合した際に、バンプサイズの面積を100%として、はんだが濡れ広がった面積を計測した。はんだが濡れ広がった面積が、バンプサイズの面積に対して40%以上の場合をはんだ接合性が良好と評価し、40%未満の場合をはんだ接合性が良好でないと評価した。実施例及び比較例の結果を下記表2及び表3に示す。
保護テープの接着剤層面を、8インチのウエハ(厚み725μm)に貼り合わせ、ウエハ厚みを300μmまでバックグラインド処理した際のウエハの反り量を測定した。反り量が5mm以下の場合をウエハの反り量が小さいと評価し、5mmを超える場合をウエハの反り量が大きいと評価した。実施例及び比較例の結果を下記表2及び表3に示す。
Claims (10)
- 接着剤層と、第1の熱可塑性樹脂層と、第2の熱可塑性樹脂層と、基材フィルム層とをこの順に有し、
下記式(1)〜(3)の条件を満たす、保護テープ。
(1)Ga>Gb
(2)Ta<Tb
(3)(Ga×Ta+Gb×Tb)/(Ta+Tb)≦1.4E+06Pa
(式(1)中、Gaは当該保護テープを貼付する貼付温度における第1の熱可塑性樹脂層の貯蔵剪断弾性率であり、Gbは当該保護テープを貼付する貼付温度における第2の熱可塑性樹脂層の貯蔵剪断弾性率である。式(2)中、Taは第1の熱可塑性樹脂層の厚みであり、Tbは第2の熱可塑性樹脂層の厚みである。式(3)中、Ga及びGbは式(1)中のGa及びGbと同義であり、Ta及びTbは式(2)中のTa及びTbと同義である。) - 下記式(4)の条件をさらに満たす、請求項1記載の保護テープ。
(4)Gn/Ga≦0.01
(式(4)中、Gnは当該保護テープを貼付する貼付温度における上記接着剤層の貯蔵剪断弾性率であり、Gaは上記式(1)中のGaと同義である。) - 上記貼付温度が、40〜80℃である請求項1記載の保護テープ。
- 上記第1の熱可塑性樹脂層の60℃での貯蔵剪断弾性率が、1.0E+06Pa〜1.0E+09Paであり、
上記第2の熱可塑性樹脂層の60℃での貯蔵剪断弾性率が、1.0E+04Pa〜2.0E+06Paである請求項1乃至3のいずれか1項に記載の保護テープ。 - 上記接着剤層の60℃での貯蔵剪断弾性率が、1.0E+01Pa〜5.0E+04Paである請求項1乃至4のいずれか1項に記載の保護テープ。
- バンプが形成されたウエハ面に上記接着剤層が貼付されるものであり、
上記接着剤層の厚さと、上記第1の熱可塑性樹脂層の厚さと、上記第2の熱可塑性樹脂層の厚さとの合計が、上記バンプの高さ以上である、請求項1乃至5のいずれか1項に記載の保護テープ。 - 上記接着剤層の厚みが、上記バンプの高さの10〜80%である請求項6記載の保護テープ。
- バンプが形成されたウエハ面に接着剤層を有する保護テープを貼付する保護テープ貼付工程と、
上記保護テープを貼付けたウエハの反対面をグラインド処理するグラインド処理工程と、
上記接着剤層を残して上記保護テープを剥離し、他の層を除去する保護テープ剥離工程とを有し、
上記保護テープが、接着剤層と、第1の熱可塑性樹脂層と、第2の熱可塑性樹脂層と、基材フィルム層とをこの順に有し、下記式(1)〜(3)の条件を満たす、半導体装置の製造方法。
(1)Ga>Gb
(2)Ta<Tb
(3)(Ga×Ta+Gb×Tb)/(Ta+Tb)≦1.4E+06Pa
(式(1)中、Gaは上記保護テープを貼付する貼付温度における第1の熱可塑性樹脂層の貯蔵剪断弾性率であり、Gbは上記保護テープを貼付する貼付温度における第2の熱可塑性樹脂層の貯蔵剪断弾性率である。式(2)中、Taは第1の熱可塑性樹脂層の厚みであり、Tbは第2の熱可塑性樹脂層の厚みである。式(3)中、Ga及びGbは式(1)中のGa及びGbと同義であり、Ta及びTbは式(2)中のTa及びTbと同義である。) - グラインド処理面に粘着テープを貼付する粘着テープ貼付工程と、
上記粘着テープが貼付されたウエハをダイシング処理し、個片の半導体チップを得るダイシング処理工程と、
上記接着剤層を硬化させる硬化工程とを有し、
上記硬化工程が、上記ダイシング処理工程前に行われる請求項8記載の半導体装置の製造方法。 - 請求項8又は9記載の半導体装置の製造方法によって得られる半導体装置。
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