TW202349517A - Semiconductor substrate structure and manufacturing method thereof - Google Patents
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Abstract
Description
本發明是有關於一種半導體基板結構及其製造方法。The invention relates to a semiconductor substrate structure and a manufacturing method thereof.
在積體電路應用中,重佈線路層(RDL)是由導電材料與介電材料所形成的多層結構,且重佈線路層常會於臨時載體上製作,然而,前述多層結構使用的材料與臨時載體使用的材料會有熱膨脹係數(coefficient of thermal expansion, CTE)失配(mismatch)的情形,因此在臨時載體上連續形成前述多層結構(連續形成至少四層)的過程中容易導致翹曲問題,且層數越多時翹曲問題會更加明顯,如此一來,會對半導體基板結構的良率與電氣性能產生不良影響。In integrated circuit applications, the redistribution line layer (RDL) is a multi-layer structure formed by conductive materials and dielectric materials, and the RDL is often produced on a temporary carrier. However, the materials used in the aforementioned multi-layer structure are not the same as the temporary carrier. The materials used in the carrier will have a coefficient of thermal expansion (CTE) mismatch, so the process of continuously forming the aforementioned multi-layer structure (continuously forming at least four layers) on the temporary carrier can easily lead to warping problems. And the warpage problem will be more obvious as the number of layers increases, which will have a negative impact on the yield and electrical performance of the semiconductor substrate structure.
本發明提供一種半導體基板結構及其製造方法,其可以在具有多層重佈線結構的同時維持較佳的良率與電氣性能。The present invention provides a semiconductor substrate structure and a manufacturing method thereof, which can maintain better yield and electrical performance while having a multi-layer rewiring structure.
本發明的一種半導體基板結構,包括第一組線路結構以及第二組線路結構。第一組線路結構包括多層第一線路層與第一接合層。第二組線路結構包括多層第二線路層與第二接合層。第二組線路結構設置在第一組線路結構上並與第一組線路結構電性連接。第一接合層接合至第二接合層,以構成多層重佈線結構。A semiconductor substrate structure of the present invention includes a first group of circuit structures and a second group of circuit structures. The first group of circuit structures includes a plurality of first circuit layers and first bonding layers. The second set of circuit structures includes multiple layers of second circuit layers and second bonding layers. The second group of circuit structures is disposed on the first group of circuit structures and is electrically connected to the first group of circuit structures. The first bonding layer is bonded to the second bonding layer to form a multi-layer redistribution structure.
本發明的一種半導體基板結構,包括第一組線路結構、第二組線路結構以及第三組線路結構。第一組線路結構包括多層第一線路層與第一接合層。第二組線路結構包括多層第二線路層與第二接合層。第二組線路結構設置在第一組線路結構上並與第一組線路結構電性連接。第一接合層接合至第二接合層。第三組線路結構包括多層第三線路層與第三接合層。第二組線路結構設置在第一組線路結構與第三組線路結構之間且彼此相互電性連接,第二組線路結構具有相對於第一組線路結構的另一接合層,且另一接合層接合至第三接合層,以構成多層重佈線結構。A semiconductor substrate structure of the present invention includes a first group of circuit structures, a second group of circuit structures and a third group of circuit structures. The first set of circuit structures includes a plurality of first circuit layers and first bonding layers. The second set of circuit structures includes multiple layers of second circuit layers and second bonding layers. The second group of circuit structures is disposed on the first group of circuit structures and is electrically connected to the first group of circuit structures. The first bonding layer is bonded to the second bonding layer. The third group of circuit structures includes multiple third circuit layers and third bonding layers. The second group of circuit structures is disposed between the first group of circuit structures and the third group of circuit structures and are electrically connected to each other. The second group of circuit structures has another bonding layer relative to the first group of circuit structures, and the other bonding layer The layer is bonded to a third bonding layer to form a multi-layer redistribution structure.
本發明的一種半導體基板結構的製造方法至少包括以下步驟。形成第一組線路結構於第一臨時載體上,其中第一組線路結構包括多層第一線路層與第一接合層。形成第二組線路結構於第二臨時載體上,其中第二組線路結構包括多層第二線路層與第二接合層。直接接合第一組線路結構與第二組線路結構,以使第一接合層接合至第二接合層。A method for manufacturing a semiconductor substrate structure of the present invention at least includes the following steps. A first group of circuit structures is formed on the first temporary carrier, wherein the first group of circuit structures includes multiple layers of first circuit layers and first bonding layers. A second set of circuit structures is formed on the second temporary carrier, wherein the second set of circuit structures includes multiple layers of second circuit layers and second bonding layers. The first group of circuit structures and the second group of circuit structures are directly bonded, so that the first bonding layer is bonded to the second bonding layer.
本發明的一種半導體基板結構的製造方法至少包括以下步驟。形成第一組線路結構於第一臨時載體上,其中第一組線路結構包括多層第一線路層與第一接合層。形成第二組線路結構於第二臨時載體上,其中第二組線路結構包括多層第二線路層與第二接合層。直接接合第一組線路結構與第二組線路結構,以使第一接合層接合至第二接合層。形成第三組線路結構於所述第二組線路結構上。第三組線路結構包括多層第三線路層與第三接合層。接合第二組線路結構與第三組線路結構。第二組線路結構具有相對於第一組線路結構的另一接合層,且另一接合層接合至第三接合層,以構成多層重佈線結構。A method for manufacturing a semiconductor substrate structure of the present invention at least includes the following steps. A first group of circuit structures is formed on the first temporary carrier, wherein the first group of circuit structures includes multiple layers of first circuit layers and first bonding layers. A second set of circuit structures is formed on the second temporary carrier, wherein the second set of circuit structures includes multiple layers of second circuit layers and second bonding layers. The first group of circuit structures and the second group of circuit structures are directly bonded, so that the first bonding layer is bonded to the second bonding layer. A third group of circuit structures is formed on the second group of circuit structures. The third group of circuit structures includes multiple third circuit layers and third bonding layers. Join the second set of circuit structures to the third set of circuit structures. The second group of circuit structures has another bonding layer relative to the first group of circuit structures, and the other bonding layer is bonded to the third bonding layer to form a multi-layer redistribution structure.
本發明的一種半導體基板結構的製造方法至少包括以下步驟。形成第二組線路結構於第二臨時載體上;形成第三組線路結構於第二組線路結構上;接合第二組線路結構與第三組線路結構;移除第二臨時載體;形成第一組線路結構於第一臨時載體上;直接接合第一組線路結構與第二組線路結構;移除第一臨時載體;形成導電柱與導電蓋於第一組線路結構的表面上,且形成外部端子於第三組線路結構的表面上。A method for manufacturing a semiconductor substrate structure of the present invention at least includes the following steps. forming a second group of line structures on the second temporary carrier; forming a third group of line structures on the second group of line structures; joining the second group of line structures and the third group of line structures; removing the second temporary carrier; forming a first A set of circuit structures is placed on a first temporary carrier; directly joining the first group of circuit structures and a second group of circuit structures; removing the first temporary carrier; forming conductive pillars and conductive covers on the surface of the first group of circuit structures, and forming an external The terminals are on the surface of the third set of circuit structures.
本發明的一種半導體基板結構,包括第一組線路結構以及第二組線路結構,其中第二組線路結構設置在第一組線路結構上並與所述第一組線路結構電性連接,以構成多層重佈線結構,且第一組線路結構中的介電層與第二組線路結構中的介電層是有機薄膜。A semiconductor substrate structure of the present invention includes a first group of circuit structures and a second group of circuit structures, wherein the second group of circuit structures is disposed on the first group of circuit structures and is electrically connected to the first group of circuit structures to form A multi-layer rewiring structure, and the dielectric layer in the first group of circuit structures and the dielectric layer in the second group of circuit structures are organic films.
基於上述,本發明先將多組線路結構分別單獨製作於臨時載體上,再將前述多組線路結構直接接合組裝成多層重佈線結構,如此一來,相較於一次性連續製作的多層重佈線結構而言,可以有效地降低翹曲程度,使半導體基板結構可以在具有多層重佈線結構的同時維持較佳的良率與電氣性能。Based on the above, the present invention first separately manufactures multiple sets of circuit structures on temporary carriers, and then directly joins and assembles the aforementioned multiple sets of circuit structures into a multi-layer rewiring structure. In this way, compared with the multi-layer rewiring structure produced continuously at one time In terms of structure, the degree of warpage can be effectively reduced, allowing the semiconductor substrate structure to maintain better yield and electrical performance while having a multi-layer rewiring structure.
為讓本發明的上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。In order to make the above-mentioned features and advantages of the present invention more obvious and easy to understand, embodiments are given below and described in detail with reference to the accompanying drawings.
以下將參考圖式來全面地描述本發明的例示性實施例,但本發明還可按照多種不同形式來實施,且不應解釋為限於本文所述的實施例。在圖式中,為了清楚起見,各區域、部位及層的大小與厚度可不按實際比例繪製。為了方便理解,下述說明中相同的元件將以相同之符號標示來說明。Exemplary embodiments of the present invention will be fully described below with reference to the accompanying drawings, although the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In the drawings, the sizes and thicknesses of various regions, locations and layers are not drawn to actual scale for clarity. To facilitate understanding, the same components in the following description will be labeled with the same symbols.
參照本實施例之圖式以更全面地闡述本發明。然而,本發明亦可以各種不同的形式體現,而不應限於本文中所述之實施例。圖式中的層或區域的厚度、尺寸或大小會為了清楚起見而放大。相同或相似之參考號碼表示相同或相似之元件,以下段落將不再一一贅述。The present invention will be described more fully with reference to the drawings of this embodiment. However, the present invention may also be embodied in various forms and should not be limited to the embodiments described herein. The thickness, size, or dimensions of layers or regions in the drawings may be exaggerated for clarity. The same or similar reference numbers indicate the same or similar components, and will not be repeated one by one in the following paragraphs.
本文所使用之方向用語(例如,上、下、右、左、前、後、頂部、底部)僅作為參看所繪圖式使用且不意欲暗示絕對定向。Directional terms used herein (eg, up, down, right, left, front, back, top, bottom) are used only with reference to the drawings and are not intended to imply absolute orientation.
應當理解,儘管術語”第一”、”第二”、”第三”等在本文中可以用於描述各種元件、部件、區域、層及/或部分,但是這些元件、部件、區域、及/或部分不應受這些術語的限制。這些術語僅用於將一個元件、部件、區域、層或部分與另一個元件、部件、區域、層或部分區分開。It will be understood that, although the terms "first," "second," "third," etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, and/or sections or parts thereof shall not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section.
除非另有定義,本文使用的所有術語(包括技術和科學術語)具有與本發明所屬領域的普通技術人員通常理解的相同的含義。Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
圖1A至圖1I是示出根據本發明的一些實施例的半導體基板結構的製造方法的部分示意性剖視圖。圖1J、圖1K、圖1L是示出圖1D的第一組線路結構的替代性實施例的製造方法的部分示意性剖視圖。圖1M、圖1N、圖1O是示出根據本發明的另一些實施例的半導體基板結構的部分示意性剖視圖。圖1P是示出根據本發明的一些實施例的半導體基板結構接合時的示意圖。圖1Q是示出根據本發明的一些實施例的半導體基板結構接合後的示意圖。圖1R是示出習知技術的半導體基板結構接合後的示意圖。請參考圖1A,於第一臨時載體10上形成多層第一線路層111,其中第一臨時載體10可以由玻璃、塑料、矽、金屬或其他合適的材料製成,只要該材料能夠承受後續製程並同時承載在其上形成的結構即可。1A to 1I are partially schematic cross-sectional views illustrating a method of manufacturing a semiconductor substrate structure according to some embodiments of the present invention. 1J, 1K, and 1L are partially schematic cross-sectional views illustrating a method of manufacturing an alternative embodiment of the first set of circuit structures of FIG. 1D. 1M, 1N, and 1O are partial schematic cross-sectional views showing the structure of a semiconductor substrate according to other embodiments of the present invention. FIG. 1P is a schematic diagram illustrating semiconductor substrate structures when bonded according to some embodiments of the present invention. 1Q is a schematic diagram illustrating a semiconductor substrate structure after bonding according to some embodiments of the invention. FIG. 1R is a schematic diagram showing a conventional semiconductor substrate structure after bonding. Referring to FIG. 1A , multiple first circuit layers 111 are formed on the first
在一些實施例中,可選地可以在第一臨時載體10與第一組線路結構110之間塗敷第一離型層12(例如光熱轉換膜或其他合適的離型層),以增強在後續過程中第一臨時載體10與第一組線路結構110之間的可剝離性且可以改善第一組線路結構110的平面度,但本發明不限於此。In some embodiments, a first release layer 12 (such as a photothermal conversion film or other suitable release layer) may optionally be coated between the first
在本實施例中,可以在第一臨時載體10上形成包括多層第一線路層111(圖1A示意地繪示出六層)與位於第一線路層111上的第一微凸塊12a(後續用於形成如圖1D所示的第一接合件112a),其中每一第一線路層111可以包括第一導電圖案111a、第一介電層111b及/或第一導電通孔111c。在此,第一導電圖案111a與第一導電通孔111c可以是嵌設於第一介電層111b內,且第一微凸塊12a可以是電性連接至第一線路層111,但本發明不限於此。In this embodiment, a multi-layer first circuit layer 111 (six layers are schematically shown in FIG. 1A) and a first micro-bump 12a located on the first circuit layer 111 (followed by For forming the first joint member 112a) as shown in FIG. 1D, each first circuit layer 111 may include a first conductive pattern 111a, a first dielectric layer 111b and/or a first conductive via 111c. Here, the first conductive patterns 111a and the first conductive vias 111c may be embedded in the first dielectric layer 111b, and the first micro-bumps 12a may be electrically connected to the first circuit layer 111. However, the present invention Not limited to this.
在一些實施例中,可使用沉積製程、微影製程和蝕刻製程或其他合適的製程在第一臨時載體10上形成第一導電圖案111a。接下來,可使用例如塗覆製程、微影蝕刻製程或其他合適的製程在第一臨時載體10上形成包括多個開口的第一介電層111b,其中開口暴露出第一導電圖案111a的至少一部分以用於電性連接。然後,可在第一介電層111b的開口內形成導電材料,以使用合適的沉積製程形成第一導電通孔111c。然後,多次執行上述步驟,以形成多層第一線路層111。接著,可以使用合適的沉積製程形成第一微凸塊12a。應當注意的是,圖1A中所示的第一組線路結構110僅為示例性的,可以根據電路設計要求形成更多層或更少層的第一線路層111,只要第一線路層111包括至少二層皆屬於本發明的保護範圍。In some embodiments, a deposition process, a lithography process, an etching process or other suitable processes may be used to form the first conductive pattern 111a on the first
在一些實施例中,第一導電圖案111a、第一導電通孔111c的材料可以包括銅、金、鎳、鋁、鉑、錫、其組合、其合金或其他合適的導電材料,而第一介電層111b的材料可以包括聚酰亞胺(polyimide, PI)、苯並環丁烯(benzocyclobutene, BCB)、聚苯並噁唑(polybenzoxazole, PBO)、無機介電材料(例如氧化矽,氮化矽等)或其他合適的電性絕緣材料,但本發明不限於此。In some embodiments, the materials of the first conductive pattern 111a and the first conductive via 111c may include copper, gold, nickel, aluminum, platinum, tin, combinations thereof, alloys thereof, or other suitable conductive materials, and the first dielectric The material of the electrical layer 111b may include polyimide (PI), benzocyclobutene (BCB), polybenzoxazole (PBO), inorganic dielectric materials (such as silicon oxide, nitride silicon, etc.) or other suitable electrical insulating materials, but the invention is not limited thereto.
請參考圖1B,於第一微凸塊12a上形成第一連接凸塊12b,其中當第一微凸塊12a的材料與第一連接凸塊12b的材料實質相同時,第一微凸塊12a與第一連接凸塊12b可以不具有實質介面,但本發明不限於此,第一微凸塊12a的材料與第一連接凸塊12b的材料也可以不相同。此外,第一微凸塊12a與第一線路層111之間還可以包括其他膜層(如晶種層,未繪示)。Referring to FIG. 1B , a first connection bump 12b is formed on the first micro-bump 12a. When the material of the first micro-bump 12a is substantially the same as the material of the first connection bump 12b, the first micro-bump 12a There may be no substantial interface with the first connection bump 12b, but the present invention is not limited thereto. The material of the first micro-bump 12a and the first connection bump 12b may also be different. In addition, other film layers (such as a seed layer, not shown) may also be included between the first microbump 12a and the first circuit layer 111.
請參考圖1C與圖1D,形成第一接合介電材料層12c,以覆蓋第一微凸塊12a與第一連接凸塊12b,亦即第一接合介電材料層12c的高度會高於第一微凸塊12a與第一連接凸塊12b的堆疊高度。接著,進行平坦化製程(例如研磨製程、化學機械拋光製程或其組合),以形成第一接合件112a與第一接合介電層112b,其中第一接合件112a與第一接合介電層112b可以視為第一接合層112。進一步而言,可以藉由研磨輪101進行平坦化製程(研磨與拋光),直到第一連接凸塊12b的頂面露出,並形成頂面共平面(coplanar)的第一接合件112a與第一接合介電層112b。在此,多層第一線路層111與第一接合層112可以視為第一組線路結構110。Referring to FIG. 1C and FIG. 1D, the first bonding dielectric material layer 12c is formed to cover the first micro-bump 12a and the first connection bump 12b. That is, the height of the first bonding dielectric material layer 12c will be higher than that of the first bonding dielectric material layer 12c. The stacking height of a micro-bump 12a and the first connection bump 12b. Then, a planarization process (such as a grinding process, a chemical mechanical polishing process or a combination thereof) is performed to form the first joining member 112a and the first joining dielectric layer 112b, wherein the first joining member 112a and the first joining dielectric layer 112b It can be regarded as the first bonding layer 112 . Furthermore, the grinding wheel 101 can be used to perform a planarization process (grinding and polishing) until the top surface of the first connecting bump 12b is exposed, and a coplanar top surface of the first joint member 112a and the first connecting block 12b are formed. Bonding dielectric layer 112b. Here, the multilayer first circuit layer 111 and the first bonding layer 112 can be regarded as the first group of
在一些實施例中,第一接合件112a可以是由材料例如是鈦/銅(Ti/Cu)的晶種層與材料例如是銅的電鍍層依序堆疊所形成,但本發明不限於此,在另一些實施例中,第一接合件112a可以包括其他合適的導電材料如銀、金、鎳或其合金,舉例而言,可以是Cu、Cu/Ni/Au、Cu/Ti、Cu/Ag或其類似者,且可以在材料例如是銅的第一層上形成材料例如是鈦的第二層,再藉由電鍍、濺鍍或其他合適的沉積方式於第二層上形成材料例如是銀的第三層,其中第二層的厚度可以小於第三層的厚度,但本發明不限於此。此外,第一接合件112a可以是接墊(pad)形式或是導電柱(pillar)形式。In some embodiments, the first joint member 112a may be formed by sequentially stacking a seed layer of material such as titanium/copper (Ti/Cu) and an electroplating layer of material such as copper, but the invention is not limited thereto. In other embodiments, the first joint 112a may include other suitable conductive materials such as silver, gold, nickel or alloys thereof, for example, Cu, Cu/Ni/Au, Cu/Ti, Cu/Ag Or the like, and a second layer of material, such as titanium, can be formed on the first layer of material, such as copper, and then a material, such as silver, can be formed on the second layer by electroplating, sputtering or other suitable deposition methods. The third layer, wherein the thickness of the second layer may be smaller than the thickness of the third layer, but the invention is not limited thereto. In addition, the first connecting member 112a may be in the form of a pad or a conductive pillar.
在一些實施例中,第一接合介電層112b可以為兩階段固化材料(如聚酰亞胺),因此在此階段可以是藉由固化溫度及/或製程參數的控制使前述材料呈現半固化狀態,如此一來,在此階段第一接合介電層112b可以具有一定程度的彈性與柔軟度,但本發明不限於此,也可以直接固化第一接合介電層112b。In some embodiments, the first bonding dielectric layer 112b may be a two-stage curing material (such as polyimide). Therefore, at this stage, the aforementioned material may be semi-cured by controlling the curing temperature and/or process parameters. In this state, the first joining dielectric layer 112b may have a certain degree of elasticity and softness at this stage, but the present invention is not limited thereto, and the first joining dielectric layer 112b may also be directly cured.
在本實施例中,第一組線路結構110包括彼此相對的第一表面110t和第二表面110b,其中第二表面110b靠近第一臨時載體10,且在第二表面110b處的第一導電圖案111a和第一介電層111b可基本上為齊平的。此外,第一導電通孔111c朝向所述多個第一接合層112的方向上逐漸變粗(如寬度或直徑逐漸變粗),換句話說,第一導電通孔111c朝向第一臨時載體10的方向上逐漸變細(如寬度或直徑逐漸變細),但本發明不限於此。In this embodiment, the first group of
在一些實施例中,第一組線路結構110的第二表面110b的第一導電圖案111a的分布密度須足以用於後續安裝半導體晶片(chip),但本發明不限於此。In some embodiments, the distribution density of the first conductive patterns 111a on the second surface 110b of the first group of
請參考圖1E,於第二臨時載體20上形成多層第二線路層121。在本實施例中,可以在第二臨時載體20上形成多層第二線路層121(圖1E示意地繪示出六層)與位於第二線路層121上的第二微凸塊22a(後續用於形成如圖1H所示的第二接合件122a),且每一第二線路層121可以包括第二導電圖案121a、第二介電層121b及/或第二導電通孔121c。在此,第二導電圖案121a與第二導電通孔121c可以是嵌設於第二介電層121b內,且第二微凸塊22a可以是電性連接至第二線路層121,但本發明不限於此。Referring to FIG. 1E , multiple second circuit layers 121 are formed on the second
請參考圖1F,於第二微凸塊22a上形成第二連接凸塊22b,其中第二微凸塊22a與第二線路層121之間還可以包括其他膜層(如晶種層,未繪示)。在此,第二微凸塊22a與第二連接凸塊22b類似於第一微凸塊12a的材料與第一連接凸塊12b,於此不再贅述。Referring to FIG. 1F, a second connection bump 22b is formed on the
請參考圖1G與圖1H,形成第二接合介電材料層22c,以覆蓋第二微凸塊22a與第二連接凸塊22b,亦即第二接合介電材料層22c的高度會高於第二微凸塊22a與第二連接凸塊22b的堆疊高度。接著,進行平坦化製程(例如研磨製程、化學機械拋光製程或其組合),以形成第二接合件122a與第二接合介電層122b,其中第二接合件122a與第二接合介電層122b可以視為第二接合層122。進一步而言,可以藉由研磨輪101進行平坦化製程(研磨與拋光),直到第二連接凸塊22b的頂面露出,並形成頂面共平面的第二接合件122a與第二接合介電層122b。在此,多層第二線路層121與第二接合層122可以視為第二組線路結構120。Referring to FIG. 1G and FIG. 1H, the second bonding dielectric material layer 22c is formed to cover the
在本實施例中,第二組線路結構120包括彼此相對的第三表面120t和第四表面120b,其中第四表面120b靠近第二臨時載體20,且在第四表面120b處的第二導電圖案121a和第二介電層121b可基本上為齊平的。此外,第二導電通孔121c朝向所述多個第二接合層122的方向上逐漸變粗(如寬度或直徑逐漸變粗),換句話說,第二導電通孔121c朝向第二臨時載體20的方向上逐漸變細(如寬度或直徑逐漸變細),但本發明不限於此。In this embodiment, the second group of
在一些實施例中,第二組線路結構120的第四表面120b的第一導電圖案121a可以是用於後續安裝基板(substrate)或外部端子(terminal),但本發明不限於此。In some embodiments, the first
在一些實施例中,第一組線路結構110的介電層(如第一介電層111b與第一接合介電層112b)與第二組線路結構120的介電層(如第二介電層121b與第二接合介電層122b)是有機薄膜,但本發明不限於此。In some embodiments, the dielectric layers of the first group of circuit structures 110 (such as the first dielectric layer 111b and the first bonding dielectric layer 112b) and the dielectric layers of the second group of circuit structures 120 (such as the second dielectric layer The
在一些實施例中,第一組線路結構110的介電層(如第一介電層111b與第一接合介電層112b)的材料與第二組線路結構120的介電層(如第二介電層121b與第二接合介電層122b)的材料相同(例如是介電(材料)熱膨脹係數相同),但本發明不限於此,在另一些實施例中,第一組線路結構110的介電層(如第一介電層111b與第一接合介電層112b)的材料與第二組線路結構120的介電層(如第二介電層121b與第二接合介電層122b)的材料可以不同(例如是介電熱膨脹係數不同),其中不同可以包括相近似但未完全相同。In some embodiments, the material of the dielectric layer of the first set of circuit structures 110 (such as the first dielectric layer 111b and the first bonding dielectric layer 112b) is different from the material of the dielectric layer of the second set of circuit structures 120 (such as the second The
在一些實施例中,第一組線路結構110的介電層(如第一介電層111b與第一接合介電層112b)的介電熱膨脹係數與第二組線路結構120的介電層(如第二介電層121b與第二接合介電層122b)的介電熱膨脹係數之間的差異可以小於10%,但本發明不限於此。In some embodiments, the dielectric thermal expansion coefficient of the dielectric layer of the first set of circuit structures 110 (such as the first dielectric layer 111b and the first bonding dielectric layer 112b) is the same as the dielectric thermal expansion coefficient of the dielectric layer of the second set of circuit structures 120 (such as the first dielectric layer 111b and the first bonding dielectric layer 112b). For example, the difference between the dielectric thermal expansion coefficients of the
應說明的是,形成第二組線路結構120的其他具體細節(如材料、形成方法及第二離型層22的設置)皆類似於形成第一組線路結構110,於此不再贅述。It should be noted that other specific details of forming the second group of circuit structures 120 (such as materials, formation methods, and arrangement of the second release layer 22) are similar to forming the first group of
請參考圖1I,將圖1D所繪示的結構上下翻面(flipped upside down),直接接合第一組線路結構110與第二組線路結構120,以使第一接合層112接合至第二接合層122構成多層重佈線結構RDL。經由上述製作已經大致完成本實施例的半導體基板結構100。本實施例的半導體基板結構100包括第一組線路結構110以及第二組線路結構120。第一組線路結構110包括多層第一線路層111與第一接合層112。第二組線路結構120包括多層第二線路層121與第二接合層122。第二組線路結構120設置在第一組線路結構110上並與第一組線路結構110電性連接。第一接合層112接合至第二接合層122,以構成多層重佈線結構RDL,據此,本實施例先將多組線路結構(第一組線路結構110與第二組線路結構120)分別單獨製作於臨時載體(第一臨時載體10與第二臨時載體20)上,再將多組線路結構直接接合組裝成多層重佈線結構(多層重佈線結構RDL),如此一來,相較於一次性連續製作多層重佈線結構而言,可以有效地降低翹曲程度,使半導體基板結構100可以在具有多層重佈線結構RDL的同時維持較佳的良率與電氣性能。Referring to FIG. 1I , the structure shown in FIG. 1D is flipped upside down, and the first group of
進一步而言,由於製程上的限制,困難度與製作的層數會呈正相關,因此當要製作越多層時,在製造過程中使整個重佈線結構受到損壞的機率就越高,進而無法有效控管良率與成本的問題,而本實施例將多層重佈線結構RDL拆分成多組較少層數的線路結構分別單獨製作,因此可以避免連續堆疊多層無法有效控管良率與成本的問題,但本發明不限於此。Furthermore, due to process limitations, the difficulty is positively correlated with the number of layers to be produced. Therefore, when more layers are produced, the probability of the entire rewiring structure being damaged during the manufacturing process is higher, making it impossible to effectively control To solve the problem of yield and cost, this embodiment splits the multi-layer rewiring structure RDL into multiple groups of circuit structures with a smaller number of layers and fabricates them separately. Therefore, it can avoid the problem of continuously stacking multiple layers and being unable to effectively control the yield and cost. , but the present invention is not limited to this.
在一些實施例中,由於熱膨脹係數(CTE)之間的差異,會發生翹曲的現象,且在堆疊越多層的情況會愈發嚴重,因此當一次性連續製作多層重佈線結構,翹曲的幅度會累加而越來越大,如圖1R所示的形成在臨時載體1上的多層重佈線結構2,而本實施例藉由將多層重佈線結構RDL拆成多組線路結構(第一組線路結構110與第二組線路結構120)單獨製作後,再將其中一組上下翻面進行接合(後續可藉由上下壓力使接合平面趨於水平),如此一來,藉由上下的翹曲方向不同,可以有效地抵銷應力,進而減緩翹曲的現象,如圖1P與圖1Q所示。應說明的是,在圖1Q中為尚未加壓的情形並簡潔繪示省略第一臨時載體10,且圖1P至圖1R中的翹曲程度僅為示例性說明非用於對本發明的限制,實際翹曲程度需視實際製程狀況而定。In some embodiments, warping will occur due to differences in coefficients of thermal expansion (CTE), and the situation will become more severe as more layers are stacked. Therefore, when a multi-layer rewiring structure is continuously fabricated at one time, warping will occur. The amplitude will accumulate and become larger and larger. As shown in Figure 1R, a
在一些實施例中,可以藉由銅對銅混合接合製程(Cu to Cu hybrid bonding)或銅對銅直接接合製程(Cu to Cu direct bonding)進行直接接合,以使多個第一接合件112a與多個第二接合件122a直接接觸,且第一接合介電層112b與第二接合介電層122b直接接觸,其中第一接合件112a與第二接合件122a可以是一對一的方式接合,且第一接合件112a例如是實質上對準第二接合件122a,但由於製程條件設計,第一接合件112a也可以實質上部分交錯於第二接合件122a。在此,由於第一接合層112與第二接合層122之間沒有使用焊接材料進行接合,因此多層重佈線結構RDL的連接可以視為無焊(solderless)連接。In some embodiments, direct bonding may be performed through a Cu to Cu hybrid bonding process or a Cu to Cu direct bonding process, so that the plurality of first bonding members 112 a and The plurality of second joining members 122a are in direct contact, and the first joining dielectric layer 112b is in direct contact with the second joining dielectric layer 122b, where the first joining members 112a and the second joining members 122a may be joined in a one-to-one manner, For example, the first joining member 112a is substantially aligned with the second joining member 122a. However, due to the design of process conditions, the first joining member 112a may also be substantially partially staggered with the second joining member 122a. Here, since no solder material is used for bonding between the first bonding layer 112 and the second bonding layer 122, the connection of the multi-layer redistribution structure RDL can be regarded as a solderless connection.
在一些實施例中,當線路的線距/間距(L/S)(例如是線寬)越細的時候,製程的要求會更加嚴苛,因此欲形成多層重佈線結構會遭遇到更多困難,而本實施例使用接合組裝多組線路結構的方式製作精細線距/間距結構相較於連續形成的結構在良率與電氣性能上可以具有更大的優勢,舉例而言,第一組線路結構110與第二組線路結構120可以皆具有至少小於10微米的精細線距/間距,因此第一組線路結構110與第二組線路結構120直接接合組裝後可以為精細線距/間距的多層重佈線結構RDL,但本發明不限於此。In some embodiments, when the line length/spacing (L/S) (such as line width) of the lines becomes thinner, the process requirements will be more stringent, so forming a multi-layer heavy wiring structure will encounter more difficulties. , and this embodiment uses the method of joining and assembling multiple sets of circuit structures to produce a fine pitch/spacing structure, which can have greater advantages in yield and electrical performance than a continuously formed structure. For example, the first set of circuits The
在一些實施例中,如圖1I所示,每一第一線路層111包括相鄰的二個第一線路,相鄰的二個第一線路的中心點之間具有第一間距111s,每一第二線路層121包括相鄰的二個第二線路,相鄰的二個第二線路的中心點之間具有第二間距121s,每一第一線路層111的第一間距111s皆小於每一第二線路層121的第二間距121s,且各層間距從第一組線路結構110朝向第二組線路結構120逐漸變大,例如是由第一組線路結構110的第二表面110b朝向第二組線路結構120的第四表面120b的方向且會經過第一組線路結構110的第一表面110t與第二組線路結構120的第三表面120t,其中第一表面110t接合至第三表面120t。在此,第一間距111s與第二間距121s為各層之最小間距,但本發明不限於此,在其他實施例中,第一間距111s與第二間距121s可以為各層之平均間距。In some embodiments, as shown in Figure 1I, each first circuit layer 111 includes two adjacent first circuits, and there is a first spacing 111s between the center points of the two adjacent first circuits. The
圖4A是示出線路結構的間距的部分示意性剖視圖。圖4B是對應圖4A的部分示意性俯視圖。進一步而言,如圖4A與圖4B所示,線路層中可以具有細間距F與粗間距C,且間距可以例如是相鄰的二個線路的中心點之間的距離,如相鄰的二個線路L1的中心點之間的距離為細間距F,相鄰的二個線路L2的中心點之間的距離為粗間距C,或者是相鄰的二個接墊之間的距離,如相鄰的二個接墊P1的中心點之間的距離為細間距F,相鄰的二個接墊P2的中心點之間的距離為粗間距C,因此前述第一間距111s與第二間距121s可以依照實際設計上的需求使用該些設計,本發明不加以限制。4A is a partially schematic cross-sectional view showing the pitch of the line structure. Fig. 4B is a partial schematic top view corresponding to Fig. 4A. Furthermore, as shown in FIGS. 4A and 4B , the line layer may have fine pitch F and coarse pitch C, and the pitch may be, for example, the distance between the center points of two adjacent lines, such as two adjacent lines. The distance between the center points of a line L1 is a fine pitch F, and the distance between the center points of two adjacent lines L2 is a coarse pitch C, or the distance between two adjacent pads, such as The distance between the center points of two adjacent pads P1 is the fine pitch F, and the distance between the center points of the two adjacent pads P2 is the coarse pitch C. Therefore, the aforementioned first pitch 111s and the second pitch 121s These designs can be used according to actual design requirements and are not limited by the present invention.
在一些實施例中,當第一接合介電層112b與第二接合介電層122b為兩階段固化材料(如聚酰亞胺)時,在前述接合製程中,會對第一接合層112與第二接合層122施加熱及/或力,舉例而言,可以對第一接合層112與第二接合層122的接合介面施加大於第一接合層112與第二接合層122的玻璃轉化溫度(Tg)的溫度,因此第一接合介電層112b與第二接合介電層122b在此階段會從半固化變成固化狀態,因此可以增強第一接合層112與第二接合層122之間的接合力,但本發明不限於此。In some embodiments, when the first bonding dielectric layer 112b and the second bonding dielectric layer 122b are made of a two-stage curing material (such as polyimide), during the foregoing bonding process, the first bonding layer 112 and the second bonding dielectric layer 122b are made of a two-stage curing material. The second bonding layer 122 applies heat and/or force. For example, the bonding interface of the first bonding layer 112 and the second bonding layer 122 can be applied with a glass transition temperature greater than the glass transition temperature of the first bonding layer 112 and the second bonding layer 122 ( Tg), so the first bonding dielectric layer 112b and the second bonding dielectric layer 122b will change from a semi-solidified state to a solidified state at this stage, so the bonding between the first bonding layer 112 and the second bonding layer 122 can be enhanced. force, but the invention is not limited thereto.
在一些實施例中,第一接合介電層112b的材料與第二接合介電層122b的材料可以相同,因此實質上在第一接合介電層112b與第二接合介電層122b之間不會觀察到有介面,但本發明不限於此。In some embodiments, the material of the first bonding dielectric layer 112b and the second bonding dielectric layer 122b may be the same, so there is substantially no gap between the first bonding dielectric layer 112b and the second bonding dielectric layer 122b. It will be observed that there is an interface, but the invention is not limited thereto.
在一些實施例中,第一導電通孔111c朝向第一接合層112的方向上逐漸變粗(如寬度或直徑逐漸變粗),且第二導電通孔112c朝向第二接合層122的方向上逐漸變粗(如寬度或直徑逐漸變粗),換句話說,第一導電通孔111c朝向第一臨時載體10的方向上逐漸變細(如寬度或直徑逐漸變細),且第二導電通孔112c朝向第二臨時載體20的方向上逐漸變細(如寬度或直徑逐漸變細),也就是說,在接合製程之後,第一導電通孔111c逐漸變細的方向與第二導電通孔112c逐漸變細的方向相反。In some embodiments, the first conductive via 111 c gradually becomes thicker (eg, the width or diameter gradually becomes thicker) in the direction toward the first bonding layer 112 , and the second conductive via 112 c becomes gradually thicker in the direction toward the second bonding layer 122 gradually becomes thicker (such as the width or diameter gradually becomes thicker), in other words, the first conductive via hole 111c gradually becomes thinner (such as the width or diameter gradually becomes smaller) toward the first
應說明的是,依照實際應用上的需求,可以可選地移除第一臨時載體10及/或第二臨時載體20,以暴露出第一導電圖案111a及/或第二導電圖案121a並與其他元件進行電性連接。在此,可以藉由在線路結構的底表面和臨時載體之間施加外部能量以剝離離型層。It should be noted that, according to actual application requirements, the first
請參考圖1J至圖1L,在替代實施例中,第一接合層112可以使用其他製作方法。首先,可以於多層第一線路層111上形成第一感光性介電層12d。接著,藉由微影工具(lithographic tool)例如是步進機(stepper)對第一感光性介電層12d進行圖案化並將第一感光性介電層12d固化,以形成暴露出下方的第一線路層111的多個開口12e,如圖1J所示。接著,形成第一晶種層12f,以覆蓋圖案化的第一感光性介電層12d,且部分第一晶種層12f填入多個開口12e中,如圖1K所示。然後,進行電鍍製程,以形成第一金屬層12g,並藉由研磨輪101進行平坦化製程,以形成頂面共平面的第一接合件112a與第一接合介電層112b,如圖1L與圖1D所示。應說明的是,為了簡潔,於此不再繪示,第二接合層122可以使用類似於上述的製造方法所形成,例如是形成第二感光性介電層於多層第二線路層122上,對第二感光性介電層進行圖案化並將第二感光性介電層固化,以形成暴露出下方的第二線路層122的多個開口,形成第二晶種層,以覆蓋圖案化的第二感光性介電層,且部分第二晶種層填入所述多個開口中,進行電鍍製程,以形成第二金屬層,並藉由研磨輪101進行平坦化製程,以形成頂面共平面的第二接合件122a與第二接合介電層122b。Referring to FIGS. 1J to 1L , in alternative embodiments, the first bonding layer 112 may use other manufacturing methods. First, the first photosensitive dielectric layer 12d can be formed on the multi-layer first circuit layer 111. Next, the first photosensitive dielectric layer 12d is patterned using a lithographic tool, such as a stepper, and the first photosensitive dielectric layer 12d is cured to form a third exposed layer below. A plurality of openings 12e of the circuit layer 111 are shown in Figure 1J. Next, a first seed layer 12f is formed to cover the patterned first photosensitive dielectric layer 12d, and part of the first seed layer 12f is filled in the plurality of openings 12e, as shown in FIG. 1K. Then, an electroplating process is performed to form the first metal layer 12g, and a planarization process is performed using the grinding wheel 101 to form the first joining member 112a and the first joining dielectric layer 112b with coplanar top surfaces, as shown in FIG. 1L and As shown in Figure 1D. It should be noted that, for the sake of simplicity, it is not shown here. The second bonding layer 122 can be formed using a manufacturing method similar to the above, for example, forming a second photosensitive dielectric layer on the multi-layer second circuit layer 122. The second photosensitive dielectric layer is patterned and cured to form a plurality of openings exposing the underlying second circuit layer 122, and a second seed layer is formed to cover the patterned The second photosensitive dielectric layer is filled with part of the second seed layer into the plurality of openings, an electroplating process is performed to form a second metal layer, and a planarization process is performed using the grinding wheel 101 to form the top surface. The coplanar second bonding member 122a and the second bonding dielectric layer 122b.
在一些實施例中,第一晶種層12f的材料例如是Ti(厚度例如是0.1微米)/Cu(厚度例如是0.3微米),而第一金屬層12g的材料例如是Cu,但本發明不限於此。In some embodiments, the material of the first seed layer 12f is, for example, Ti (thickness is, for example, 0.1 micron)/Cu (thickness is, for example, 0.3 micron), and the material of the first metal layer 12g is, for example, Cu. However, the present invention does not Limited to this.
在一些實施例中,線路結構的組數也可以不限制於二組,舉例而言,如圖1M所示的半導體基板結構100A的多層重佈線結構RDL1可以更包括第三組線路結構130,其中第三組線路結構130包括多層第三線路層131與第三接合層132。進一步而言,第二組線路結構120設置在第一組線路結構110與第三組線路結構130之間且彼此相互電性連接,第二組線路結構120具有相對於第一組線路結構的另一接合層123,且另一接合層123接合至第三接合層132,但本發明不限於此。此外,第三組線路結構110包括彼此相對的第五表面130t和第六表面130b。In some embodiments, the number of circuit structure groups is not limited to two groups. For example, the multi-layer redistribution structure RDL1 of the semiconductor substrate structure 100A shown in FIG. 1M may further include a third group of circuit structures 130, where The third group of circuit structures 130 includes multiple third circuit layers 131 and third bonding layers 132 . Furthermore, the second group of
此外,半導體基板結構100A可以是接續圖1H,移除第二臨時載體20與第二離型層22,於第二組線路結構110上接合在第三臨時載體30與第三離型層32上的第三組線路結構130,以形成多層重佈線結構RDL1,但本發明不限於此。In addition, the semiconductor substrate structure 100A may continue with FIG. 1H , remove the second
在一些實施例中,第一組線路結構110的第一線路層111的數量(六層結構)與第二組線路結構120的第二線路層121的數量(六層結構)相同,但也可以具有不同實施態樣,舉例而言,如圖1M所示的半導體基板結構100A,第一組線路結構110的第一線路層111的數量與第二組線路結構120的第二線路層121的數量不同於第三組線路結構130的數量(五層結構),而前述數量差可以為一層或兩層,但本發明不限於此。In some embodiments, the number of the first circuit layers 111 of the first group of circuit structures 110 (six-layer structure) is the same as the number of the second circuit layers 121 of the second group of circuit structures 120 (six-layer structure), but they may also be There are different implementation aspects. For example, in the semiconductor substrate structure 100A shown in FIG. 1M, the number of the first circuit layers 111 of the first group of
在一些實施例中,第一組線路結構110的第一線路層111的厚度(六層結構)與第二組線路結構120的第二線路層121的厚度(六層結構)相同,但也可以具有不同實施態樣,舉例而言,如圖1N所示的半導體基板結構100B,第一組線路結構110的第一線路層111的厚度與第二組線路結構120的第二線路層121的厚度不同於第三組線路結構130B的厚度,其中第三組線路結構130B的厚度可以是第一線路層111的厚度或第二組線路結構120的第二線路層121的厚度的二倍,以形成多層重佈線結構RDL2。此外,在本實施例中,第二組線路結構120與第三組線路結構130B之間是使用銅對銅混合接合製程或銅對銅直接接合製程的方式進行接合,然而,本發明不限於此,在其他實施例中,如圖1O所示的半導體基板結構100C,第二組線路結構120與第三組線路結構130B之間可以使用焊料124、134進行接合,以形成多層重佈線結構RDL3,但本發明不限於此。In some embodiments, the thickness of the first circuit layer 111 of the first group of circuit structures 110 (six-layer structure) is the same as the thickness of the
在一些實施例中,如圖1M與圖1N所示,第三組線路結構的每一第三線路層131包括相鄰的二個第三線路,相鄰的二個第三線路的中心點之間具有第三間距131s,第三間距131s大於第一間距111s與第二間距121s,且各層間距從第一組線路結構110朝向第三組線路結構130逐漸變大,例如是由第一組線路結構110的第二表面110b朝向第三組線路結構130的第六表面130b的方向且會經過第一組線路結構110的第一表面110t、第二組線路結構120的第三表面120t、第二組線路結構120的第四表面120b與第三組線路結構130的第五表面130t,其中第四表面120b接合於第五表面130t。此外,第三接合層132的介電熱膨脹係數(CTE)小於第一接合層112的介電熱膨脹係數與第二接合層122的介電熱膨脹係數,但本發明不限於此。In some embodiments, as shown in Figure 1M and Figure 1N, each third circuit layer 131 of the third group of circuit structures includes two adjacent third circuits, and the center point of the two adjacent third circuits is between There is a third spacing 131s between them, the third spacing 131s is larger than the first spacing 111s and the second spacing 121s, and the spacing between each layer gradually becomes larger from the first group of
在此必須說明的是,以下實施例沿用上述實施例的元件標號與部分內容,其中採用相同或近似的標號來表示相同或近似的元件,並且省略了相同技術內容的說明,關於省略部分的說明可參考前述實施例,下述實施例不再重複贅述。It must be noted here that the following embodiments follow the component numbers and part of the content of the above embodiments, where the same or similar numbers are used to represent the same or similar elements, and the description of the same technical content is omitted. Regarding the description of the omitted parts Reference may be made to the foregoing embodiments, and details will not be repeated in the following embodiments.
圖2A至圖2D是示出根據本發明的又一些實施例的半導體結構的製造方法的部分示意性剖視圖。圖2E是示出根據本發明的一些實施例的半導體結構的部分製造流程圖。圖2F是示出根據本發明的一些實施例的半導體結構的部分示意性剖視圖。請參考圖2A與圖2E,接續圖1E的組裝第一組線路結構與第二組線路結構(步驟S110),藉由第一離型層移除第一臨時載體(步驟S120),舉例而言,半導體基板結構的製造方法可以進一步移除第一離型層12與第一臨時載體10(例如是藉由雷射製程移除,且可以藉由電漿(plasma)製程清除剩餘的第一離型層12),以暴露出第一組線路結構110的第二表面110b的第一導電圖案111a與第一介電層111b(可以視為多層重佈線結構RDL的晶片端)。接著,在移除第一臨時載體10後,於第一組線路結構上形成多個導電連接件(步驟S130),舉例而言,可以於第一組線路結構110的第二表面110b的第一導電圖案111a上形成多個導電連接件240,其中導電連接件240包括導電柱(pillar)241以及形成於其上的導電蓋(cap)242。在此,導電柱241可以由銅所製成,而導電蓋242可以由焊料所製成,但本發明不限於此,導電柱241與導電蓋242也可以是使用其他合適的材料所製成,舉例而言,導電蓋242可以是Sn/Ag無鉛焊錫(lead-free solder)。經由上述製作可完成另一用於半導體晶片與外部端子電性連接的半導體基板結構,但本發明不限於此。2A to 2D are partially schematic cross-sectional views illustrating a method of manufacturing a semiconductor structure according to further embodiments of the present invention. Figure 2E is a partial fabrication flow diagram illustrating a semiconductor structure in accordance with some embodiments of the invention. 2F is a partially schematic cross-sectional view illustrating a semiconductor structure in accordance with some embodiments of the invention. Please refer to Figure 2A and Figure 2E. Following the assembly of the first set of circuit structures and the second set of circuit structures in Figure 1E (step S110), the first temporary carrier is removed through the first release layer (step S120), for example The manufacturing method of the semiconductor substrate structure can further remove the first release layer 12 and the first temporary carrier 10 (for example, by a laser process), and can remove the remaining first release layer 12 by a plasma process. layer 12) to expose the first conductive pattern 111a and the first dielectric layer 111b on the second surface 110b of the first set of circuit structures 110 (which can be regarded as the chip end of the multi-layer redistribution structure RDL). Next, after the first
在一些實施例中,相鄰的導電連接件240可以具有精細間距(pitch),以對應於隨後要安裝的晶片,但本發明不限於此。In some embodiments, adjacent conductive connections 240 may have a fine pitch to correspond to the wafer to be subsequently mounted, but the invention is not limited thereto.
請參考圖2B與圖2E,接合半導體晶片於半導體基板結構上(步驟S140),舉例而言,半導體晶片301可使用例如覆晶接合以連接到第一組線路結構110的第二表面110b。舉例來說,半導體晶片301的導電凸塊302(可進一步包括焊料)可以接合到導電連接件240的導電蓋242上,換句話說,半導體晶片301的導電凸塊302可以與導電連接件240的導電蓋242直接接觸,以形成異質整合模組(heterogeneous integration module)或系統。進一步而言,半導體晶片301可以藉由熱壓接合製程(thermal compression bonding)接合在第二組線路結構120上。Referring to FIGS. 2B and 2E , the semiconductor chip is bonded to the semiconductor substrate structure (step S140 ). For example, the semiconductor chip 301 may be connected to the second surface 110 b of the first set of
在一些實施例中,半導體晶片301例如是邏輯晶片(logic chip)、記憶體晶片(memory chip)、三維積體電路(3DIC)晶片(如高頻寬記憶體晶片(high bandwidth memory chip))及/或其類似者,其中3DIC晶片包括相互堆疊的多個層,且形成有矽穿孔(TSVs)以提供各層之間的垂直電性連接,但本發明不限於此。In some embodiments, the semiconductor chip 301 is, for example, a logic chip, a memory chip, a three-dimensional integrated circuit (3DIC) chip (such as a high bandwidth memory chip), and/or Similarly, the 3DIC chip includes multiple layers stacked on each other, and through-silicon vias (TSVs) are formed to provide vertical electrical connections between the layers, but the invention is not limited thereto.
在一些實施例中,導電凸塊302的高度302h可以大於對應的導電連接件240的高度240h,但本發明不限於此,導電凸塊302的高度302h與導電連接件240的高度240h可以依照實際設計上的需求而定。In some embodiments, the height 302h of the conductive bump 302 may be greater than the height 240h of the corresponding conductive connector 240, but the invention is not limited thereto. The height 302h of the conductive bump 302 and the height 240h of the conductive connector 240 may be determined according to actual conditions. Depends on design needs.
在一些實施例中,形成底膠於半導體基板結構上(步驟S150),舉例而言,底膠(underfill)40可形成在第一組線路結構110的第二表面110b上,以填充第二表面110b和半導體晶片301之間的間隙,從而增強覆晶接合的可靠性。在一些實施例中,可以在第一組線路結構110上設置多於一個執行相同或不同功能的半導體晶片301。在這種情況下,多個半導體晶片301可以與第一組線路結構110電性連接且藉由第一組線路結構110彼此電性連接。設置在第一組線路結構110上的半導體晶片301的數量不構成本公開的限制。In some embodiments, an underfill is formed on the semiconductor substrate structure (step S150). For example, an underfill 40 can be formed on the second surface 110b of the first group of
請參考圖2C與圖2E,包封半導體基板結構與半導體晶片(步驟S160),舉例而言,於第一組線路結構110的第二表面110b上形成密封體250,以包封半導體晶片301與底膠40,其中密封體250可以是藉由模塑製程(molding process)所形成的模塑化合物(molding compound)。在此,密封體250例如可以由環氧樹脂或其他適宜的樹脂等絕緣材料所形成的,但本發明不限於此。Please refer to FIG. 2C and FIG. 2E to encapsulate the semiconductor substrate structure and the semiconductor chip (step S160). For example, a sealing body 250 is formed on the second surface 110b of the first group of
請參考圖2D與圖2E,移除第二離型層與第二臨時載體(步驟S170),舉例而言,移除第二離型層22與第二臨時載體20,以暴露出第二組線路結構120的第四表面120b的第二導電圖案121a與第二介電層121b(可以視為多層重佈線結構RDL的端子端)。然後,形成外部端子於第二組線路結構上(步驟S180),舉例而言,可以於第二導電圖案121a上金屬化形成底部連接焊墊,並在底部連接焊墊上形成焊料,以於多層重佈線結構RDL的端子端上形成多個外部端子260,其中第二組線路結構120設置於外部端子260與第一組線路結構110之間,且外部端子260與第二組線路結構120電性連接。經由上述製作已經大致完成本實施例的半導體結構200。Referring to FIG. 2D and FIG. 2E, the second release layer and the second temporary carrier are removed (step S170). For example, the second release layer 22 and the second
在一些實施例中,如圖2F所示,移除第二離型層22與第二臨時載體20之後還可以進一步形成第三組線路結構130,接著再形成外部端子於第三組線路結構130上,完成半導體結構200A,其中第三組線路結構130的材料細節與形成方法類似於圖1M與圖2D所述,於此不再贅述。In some embodiments, as shown in FIG. 2F , after removing the second release layer 22 and the second
在一些實施例中,外部端子260可以是焊球,並可使用植球製程形成以放置在第二組線路結構120的第二導電圖案121a上,且可選擇性地執行焊接製程和回焊(reflow)製程,以增強外部端子260與第二導電圖案121a之間的黏附,但本發明不限於此。In some embodiments, the external terminal 260 may be a solder ball and may be formed using a ball placement process to be placed on the second
在未繪示的實施例中,可以進一步將半導體結構200設置在電路載體(例如印刷電路板(PCB)、系統板、母板等)、封裝體及/或其他元件上,以形成電子裝置。舉例來說,外部端子260設置在電路載體上,且半導體晶片301藉由多層重佈線結構RDL電性連接到電路載體上或電路載體中的其他元件,但本發明不限於此。In embodiments not shown, the semiconductor structure 200 may be further disposed on a circuit carrier (such as a printed circuit board (PCB), a system board, a motherboard, etc.), a package, and/or other components to form an electronic device. For example, the external terminal 260 is provided on the circuit carrier, and the semiconductor chip 301 is electrically connected to the circuit carrier or other components in the circuit carrier through the multi-layer redistribution structure RDL, but the invention is not limited thereto.
在一些實施例中,半導體結構200為晶圓級半導體封裝結構(wafer level semiconductor packaging structure),但本發明不限於此。In some embodiments, the semiconductor structure 200 is a wafer level semiconductor packaging structure, but the invention is not limited thereto.
圖3A是示出根據本發明的再一些實施例的半導體結構的部分示意性剖視圖。圖3B與圖3C是示出圖3A的連接層的一些具體實施態樣的部分示意性剖視圖。請參考圖3A,相較於圖2D的半導體結構200而言,本實施例的半導體結構300在多層重佈線結構RDL與外部端子260之間更包括連接層370與基板380,其中多層重佈線結構RDL藉由連接層370耦合至基板380(多層重佈線結構RDL與基板380可以統稱為2.2D積體基板),且基板380可以是陶瓷基板、層壓有機基板、封裝基板、積體基板或其類似者。3A is a partially schematic cross-sectional view illustrating a semiconductor structure according to further embodiments of the present invention. 3B and 3C are partial schematic cross-sectional views showing some specific implementation aspects of the connection layer of FIG. 3A. Please refer to FIG. 3A. Compared with the semiconductor structure 200 of FIG. 2D, the semiconductor structure 300 of this embodiment further includes a connection layer 370 and a substrate 380 between the multi-layer redistribution structure RDL and the external terminal 260. The multi-layer redistribution structure RDL The RDL is coupled to the substrate 380 through the connection layer 370 (the multilayer redistribution structure RDL and the substrate 380 may be collectively referred to as a 2.2D integrated substrate), and the substrate 380 may be a ceramic substrate, a laminated organic substrate, a packaging substrate, an integrated substrate, or other Similar.
在一些實施例中,連接層370可以使用焊料與其他元件進行連接,舉例而言,如圖3B所示,連接層370可以包括與多層重佈線結構RDL直接接觸的銅接墊371(也可以是銅柱)、與基板380直接接觸的銅接墊372以及設置於銅接墊371與銅接墊372之間的焊料373,其中銅接墊372的表面可以由Cu/Ni/Au所組成且還可以被防焊油墨374所圍繞,以提升電性表現,但本發明不限於此,連接層370與其他元件之間亦可以使用無焊連接,舉例而言,如圖3C所示,連接層370的連接方式例如是混合接合製程或銅對銅直接接合製程,連接層370可以包括與多層重佈線結構RDL直接接觸的銅接墊371以及與基板380直接接觸的銅接墊372,且銅接墊371與銅接墊372可以直接接觸且接合在一起,但本發明不限於此。In some embodiments, the connection layer 370 may be connected to other components using solder. For example, as shown in FIG. 3B , the connection layer 370 may include copper pads 371 (which may also be in direct contact with the multi-layer redistribution structure RDL). copper pillars), copper pads 372 in direct contact with the substrate 380, and solder 373 disposed between the copper pads 371 and 372, where the surface of the copper pads 372 may be composed of Cu/Ni/Au and also It can be surrounded by solder mask ink 374 to improve electrical performance, but the invention is not limited thereto. Solderless connections can also be used between the connection layer 370 and other components. For example, as shown in FIG. 3C , the connection layer 370 The connection method is, for example, a hybrid bonding process or a copper-to-copper direct bonding process. The connection layer 370 may include a copper pad 371 in direct contact with the multi-layer redistribution structure RDL and a copper pad 372 in direct contact with the substrate 380, and the copper pads 371 and the copper pad 372 may be in direct contact and joined together, but the invention is not limited thereto.
在一些實施例中,基板380包括核心層(core layer)381、增層結構382與多個穿孔381a,其中增層結構382分別形成在增層結構382的二側,且多個穿孔381a貫穿核心層381以電性連接兩側的增層結構382,其中增層結構382包括嵌設於介電層中的導電圖案382a,但本發明不限於此,在未繪示的實施例中,基板380也可以不具有核心層381。In some embodiments, the substrate 380 includes a core layer 381, a build-up structure 382 and a plurality of through holes 381a, wherein the build-up structures 382 are respectively formed on two sides of the build-up structure 382, and the plurality of through holes 381a penetrate the core. The layer 381 is electrically connected to the build-up structures 382 on both sides. The build-up structure 382 includes a conductive pattern 382a embedded in the dielectric layer. However, the present invention is not limited thereto. In an embodiment not shown, the substrate 380 The core layer 381 may not be provided.
圖5A是示出根據本發明的一些實施例的半導體基板結構的部分製造流程圖。圖5B是示出根據本發明的一些實施例的半導體基板結構的部分示意性剖視圖。請參考圖2A、圖2F、圖5A與圖5B,本實施例的半導體基板結構100D可以具有不同的製造方法,其中步驟包括:提供設置於第二臨時載體上的第二組線路結構,且接合第三組線路結構與第二組線路結構(步驟S210);移除第二臨時載體(步驟S220);將設置於第一臨時載體上的第一組線路結構接合至第二組線路結構(步驟S230);移除第一臨時載體(步驟S240);形成導電柱與導電蓋於第一組線路結構的表面上,且形成外部端子於第三組線路結構的表面上(步驟250)。經由上述製作已經大致完成本實施例的半導體結構100D。Figure 5A is a partial manufacturing flow diagram illustrating a semiconductor substrate structure in accordance with some embodiments of the invention. Figure 5B is a partially schematic cross-sectional view illustrating a semiconductor substrate structure according to some embodiments of the present invention. Please refer to Figure 2A, Figure 2F, Figure 5A and Figure 5B. The semiconductor substrate structure 100D of this embodiment can have different manufacturing methods. The steps include: providing a second group of circuit structures disposed on a second temporary carrier, and bonding The third group of circuit structures and the second group of circuit structures (step S210); remove the second temporary carrier (step S220); join the first group of circuit structures provided on the first temporary carrier to the second group of circuit structures (step S220); S230); remove the first temporary carrier (step S240); form conductive pillars and conductive covers on the surface of the first group of circuit structures, and form external terminals on the surface of the third group of circuit structures (step 250). Through the above fabrication, the semiconductor structure 100D of this embodiment has been substantially completed.
在本實施例中,半導體結構100D的製造方法亦可以對應至下述步驟:形成第二組線路結構於第二臨時載體上;形成第三組線路結構於第二組線路結構上;接合第二組線路結構與第三組線路結構;移除第二臨時載體;形成第一組線路結構於第一臨時載體上;直接接合第一組線路結構與第二組線路結構;移除第一臨時載體;形成導電柱與導電蓋於第一組線路結構的表面上,且形成外部端子於第三組線路結構的表面上。In this embodiment, the manufacturing method of the semiconductor structure 100D can also correspond to the following steps: forming a second group of circuit structures on the second temporary carrier; forming a third group of circuit structures on the second group of circuit structures; bonding the second group of circuit structures. A set of line structures and a third set of line structures; removing the second temporary carrier; forming the first set of line structures on the first temporary carrier; directly joining the first set of line structures and the second set of line structures; removing the first temporary carrier ; Form conductive pillars and conductive covers on the surface of the first group of circuit structures, and form external terminals on the surface of the third group of circuit structures.
在本實施例中,半導體結構100D包括由第一組線路結構110、第二組線路結構120、第三組線路結構130所組成的多層重佈線結構RDL1,且第一組線路結構110的第二表面110b上形成有導電柱241與導電蓋242,第三組線路結構130的第六表面130b上形成有外部端子260,其中第三組線路結構130在製造過程中不設置於臨時載體上,為具有支撐性的板狀結構,但本發明不限於此。在此,採用相同或近似的標號來表示相同或近似的元件,因此細節請參照上述的實施例,於此不再贅述。In this embodiment, the semiconductor structure 100D includes a multi-layer redistribution structure RDL1 composed of a first group of
應說明的是,上述各種態樣的實施例可以使用不同的組合方式,且也非為本案的限制,只要先將多組線路結構分別單獨製作再接合組裝成多層重佈線結構皆屬於本發明的保護範圍。此外,臨時載體(如第一臨時載體、第二臨時載體、第三臨時載體或在製程中有使用到的其他臨時載體)不會成為最終結構的一部分。It should be noted that the above various embodiments can be combined in different ways, and this is not a limitation of this case. As long as multiple sets of circuit structures are separately produced separately and then joined and assembled into a multi-layer rewiring structure, they all belong to the present invention. scope of protection. In addition, the temporary carrier (such as the first temporary carrier, the second temporary carrier, the third temporary carrier or other temporary carriers used in the manufacturing process) will not become part of the final structure.
綜上所述,本發明先將多組線路結構分別單獨製作於臨時載體上,再將前述多組線路結構接合組裝成多層重佈線結構,如此一來,相較於一次性連續製作的多層重佈線結構而言,可以有效地降低翹曲程度,使半導體基板結構可以在具有多層重佈線結構的同時維持較佳的良率與電氣性能。To sum up, the present invention first manufactures multiple sets of circuit structures separately on temporary carriers, and then joins and assembles the aforementioned multiple sets of circuit structures into a multi-layer rewiring structure. In this way, compared with the multi-layer rewiring structure produced continuously at one time, As for the wiring structure, the degree of warpage can be effectively reduced, so that the semiconductor substrate structure can maintain better yield and electrical performance while having a multi-layer rewiring structure.
雖然本發明已以實施例揭露如上,然其並非用以限定本發明,任何所屬技術領域中具有通常知識者,在不脫離本發明的精神和範圍內,當可作些許的更動與潤飾,故本發明的保護範圍當視後附的申請專利範圍所界定者為準。Although the present invention has been disclosed above through embodiments, they are not intended to limit the present invention. Anyone with ordinary knowledge in the technical field may make some modifications and modifications without departing from the spirit and scope of the present invention. Therefore, The protection scope of the present invention shall be determined by the appended patent application scope.
1、10、20、30:臨時載體
12、22:離型層
12a、22a:微凸塊
12b、22b:連接凸塊
12c、22c:接合介電材料層
12d:感光性介電層
12e:開口
12f:晶種層
12g:金屬層
302h、240h:高度
40:底膠
100、100A、100B、100C、100D:半導體基板結構
101:研磨輪
110、120、120A、130:線路結構
110t、120t、130t、110b、120b、130b:表面
111、121、131:線路層
111a、121a、382a:導電圖案
111b、121b:介電層
111c、121c:導電通孔
111s、121s、131s、F、C:間距
112、122、132、113:接合層
112a、122a:接合件
112b、122b:接合介電層
200、200A、300:半導體結構
240:導電連接件
241:導電柱
242:導電蓋
250:密封體
260:外部端子
301:半導體晶片
302:導電凸塊
370:連接層
371、372:銅接墊
124、134、373:焊料
374:防焊油墨
380:基板
381:核心層
381a:穿孔
382:增層結構
L1、L2:線路
P1、P2:接墊
2、RDL、RDL1、RDL2、RDL3:多層重佈線結構
S110、S120、S130、S140、S150、S160、S170、S180、S190:步驟
1, 10, 20, 30: temporary carrier
12, 22:
圖1A至圖1I是示出根據本發明的一些實施例的半導體基板結構的製造方法的部分示意性剖視圖。 圖1J、圖1K、圖1L是示出圖1D的第一組線路結構的替代性實施例的製造方法的部分示意性剖視圖。 圖1M、圖1N、圖1O是示出根據本發明的另一些實施例的半導體基板結構的部分示意性剖視圖。 圖1P是示出根據本發明的一些實施例的半導體基板結構接合時的示意圖。 圖1Q是示出根據本發明的一些實施例的半導體基板結構接合後的示意圖。 圖1R是示出習知技術的半導體基板結構接合後的示意圖。 圖2A至圖2D是示出根據本發明的又一些實施例的半導體結構的製造方法的部分示意性剖視圖。 圖2E是示出根據本發明的一些實施例的半導體結構的部分製造流程圖。 圖2F是示出根據本發明的一些實施例的半導體結構的部分示意性剖視圖。 圖3A是示出根據本發明的再一些實施例的半導體結構的部分示意性剖視圖。 圖3B與圖3C是示出圖3A的連接層的一些具體實施態樣的部分示意性剖視圖。 圖4A是示出線路結構的間距的部分示意性剖視圖。 圖4B是對應圖4A的部分示意性俯視圖。 圖5A是示出根據本發明的一些實施例的半導體基板結構的部分製造流程圖。 圖5B是示出根據本發明的一些實施例的半導體基板結構的部分示意性剖視圖。 應說明的是,圖3B與圖3C可以是圖3A的虛線框所放大出來的部分。 1A to 1I are partially schematic cross-sectional views illustrating a method of manufacturing a semiconductor substrate structure according to some embodiments of the present invention. 1J, 1K, and 1L are partially schematic cross-sectional views illustrating a method of manufacturing an alternative embodiment of the first set of circuit structures of FIG. 1D. 1M, 1N, and 1O are partial schematic cross-sectional views showing the structure of a semiconductor substrate according to other embodiments of the present invention. FIG. 1P is a schematic diagram illustrating semiconductor substrate structures when bonded according to some embodiments of the present invention. 1Q is a schematic diagram illustrating a semiconductor substrate structure after bonding according to some embodiments of the invention. FIG. 1R is a schematic diagram showing a conventional semiconductor substrate structure after bonding. 2A to 2D are partially schematic cross-sectional views illustrating a method of manufacturing a semiconductor structure according to further embodiments of the present invention. Figure 2E is a partial fabrication flow diagram illustrating a semiconductor structure in accordance with some embodiments of the invention. 2F is a partially schematic cross-sectional view illustrating a semiconductor structure in accordance with some embodiments of the invention. 3A is a partially schematic cross-sectional view illustrating a semiconductor structure according to further embodiments of the present invention. 3B and 3C are partial schematic cross-sectional views showing some specific implementation aspects of the connection layer of FIG. 3A. 4A is a partially schematic cross-sectional view showing the pitch of the line structure. Fig. 4B is a partial schematic top view corresponding to Fig. 4A. Figure 5A is a partial manufacturing flow diagram illustrating a semiconductor substrate structure in accordance with some embodiments of the invention. Figure 5B is a partially schematic cross-sectional view illustrating a semiconductor substrate structure according to some embodiments of the present invention. It should be noted that FIG. 3B and FIG. 3C may be the enlarged portion of the dotted frame in FIG. 3A .
10、20:臨時載體 10, 20: Temporary carrier
12、22:離型層 12, 22: Release layer
100:半導體基板結構 100:Semiconductor substrate structure
110、120:線路結構 110, 120: Line structure
110b、120b:表面 110b, 120b: surface
112、122:接合層 112, 122: joint layer
112a、122a:接合件 112a, 122a: joints
112b、122b:接合介電層 112b, 122b: bonding dielectric layer
111s、121s:間距 111s, 121s: spacing
RDL:多層重佈線結構 RDL: multi-layer rewiring structure
Claims (48)
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US10177090B2 (en) * | 2015-07-28 | 2019-01-08 | Bridge Semiconductor Corporation | Package-on-package semiconductor assembly having bottom device confined by dielectric recess |
US9899342B2 (en) * | 2016-03-15 | 2018-02-20 | Taiwan Semiconductor Manufacturing Co., Ltd. | Integrated fan-out package, redistribution circuit structure, and method of fabricating the same |
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US10727083B1 (en) * | 2019-02-25 | 2020-07-28 | Applied Materials, Inc. | Method for via formation in flowable epoxy materials by micro-imprint |
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US11088125B2 (en) * | 2019-09-17 | 2021-08-10 | Taiwan Semiconductor Manufacturing Company, Ltd. | IPD modules with flexible connection scheme in packaging |
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US11452246B2 (en) * | 2020-03-25 | 2022-09-20 | Qualcomm Incorporated | Patch substrate configured as a shield located over a cavity of a board |
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