Abstract:
A pattern forming method comprising the steps of: detecting a position of a base pattern formed on a substrate; forming a photosensitive resin film on the substrate; correcting a pattern data of a pattern to be formed on the substrate, based on a positional information of the base pattern to thereby compute a corrected pattern data; displaying a mask pattern on a liquid crystal panel, based on the corrected pattern data; and exposing the photosensitive resin film with the liquid crystal panel as a mask and developing the same to thereby pattern the photosensitive resin film. Even when a base pattern has rotations, shrinkages, distortions, etc., a prescribed upper layer pattern can be formed in alignment with the lower layer pattern.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
         [0001]    This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-384297, filed in Dec. 18, 2001, the entire contents of which are incorporated herein by reference.  
         BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to a pattern forming method, more specifically to a pattern forming method suitable for forming a multi-level interconnection layer on a substrate with LSI chips embedded in.  
           [0003]    With requirements of higher performance and smaller sizes of electronic equipments, input and output densities of semiconductor devices are on increase. It is proposed to use, as LSI packages, packages, such as CSP (Chip Size Package) and wafer-level CSP, etc., which can be smaller-sized. As substrates for these small-size packages to be mounted on, multi-layered resin substrates formed of plurality of interconnection layers and resin insulating layers alternately laid one on the other are proposed.  
           [0004]    Recently is proposed a method in which a multi-level interconnection layer is formed on a substrate with LSI chips embedded in instead of mounting LSI chips onto a package substrate in the above-described method. The package substrate prepared by this method has advantages of small inductances and decreasing stresses generated by heat. A further advantage is that interconnections can be increased, and various electronic and optical devices, such as logic LSI, memory LSI, RF, MEMS (micro electromechanical systems), etc., can be built in. Furthermore, the package substrate has higher interconnection freedom and good electric power supply performance, and is suitable to incorporate inter-layer dielectric material of low dielectric constant.  
           [0005]    Then, the method for fabricating the conventional package substrate, in which a multi-level interconnection layer is formed on a substrate with LSI chips embedded in will be explained with reference to FIGS.  6 A- 6 C.  
           [0006]    LSI chip  102  is embedded in a mold frame of a core substrate  100  of BT (bismaleimide triazine) resin, etc. (FIG. 6A).  
           [0007]    Next, a sealing resin  104  is filled into the gaps between the core substrate  100  and the LSI chip  102  to thereby secure the LSI chip  102  to the core substrate  100  (FIG. 6B).  
           [0008]    Then, on the core substrate  100  with the LSI chip  100  embedded in, insulating layers  106 ,  110 ,  114 ,  118  and interconnection layers  108 ,  112 ,  116  are alternately laid into a multi-level interconnection layer  120  in the same way as in the method for forming a built-up layer in the conventional packaging technique (FIG. 6C).  
           [0009]    The package substrate with the multi-level interconnection layer  120  connected to the LSI chip  102  can be thus formed on the core substrate  100 .  
           [0010]    However, according to the above-described method for fabricating the conventional package substrate, in which a multi-level interconnection layer is formed on a substrate with LSI chip embedded in, a plurality of LSI chips embedded in a core substrate are often independently disaligned. In such case, patterning of via holes and interconnection layers by using a glass mask or a reticle with a prescribed pattern formed on cannot form the multi-level interconnection layer in accurate alignment with the respective LSI chips.  
           [0011]    This has required very high alignment accuracy in arranging the LSI chips. Higher accuracy for the alignment is required for a larger number of LSI chips, which makes it difficult to control the alignment accuracy.  
           [0012]    Even when LSI chips are secured to a core substrate with high alignment accuracy, the alignment accuracy is often degraded due to a thermal expansion coefficient difference with respect to the sealing resin.  
           [0013]    In forming a multi-level interconnection layer, when pattern distortions and shrinkages take place due to thermal processing, it often makes it difficult to align a pattern of a layer to be formed thereon.  
         SUMMARY OF THE INVENTION  
         [0014]    An object of the present invention is to provide a pattern forming method which, in forming a multi-level interconnection layer on a substrate with LSI chips embedded in, enables a prescribed pattern of an upper layer to be formed even when disalignments, rotations, shrinkages, distortions, etc. take place in a lower layer.  
           [0015]    According to one aspect of the present invention, there is provided a pattern forming method comprising the steps of: detecting a position of a base pattern formed on a substrate; forming a photosensitive resin film on the substrate; correcting a pattern data of a pattern to be formed on the substrate, based on a positional information of the base pattern to thereby compute a corrected pattern data; displaying a mask pattern on a liquid crystal panel, based on the corrected pattern data; and exposing the photosensitive resin film with the liquid crystal panel as a mask and developing the same to thereby pattern the photosensitive resin film.  
           [0016]    According to another aspect of the present invention, there is provided a pattern forming method comprising the steps of: securing an LSI chip to a core substrate; detecting a position of the LSI chip with respect to the core substrate; forming a photosensitive resin film on the core substrate with the LSI chip secured to; correcting a pattern data of a pattern to be formed on the core substrate, based on a detected positional information of the LSI chip to thereby compute a corrected pattern data; displaying a mask pattern on a liquid crystal panel, based on the corrected pattern data; and exposing the photosensitive resin film with the liquid crystal panel as a mask and developing the same to thereby pattern the photosensitive resin film.  
           [0017]    According to the present invention, positions of the LSI chips with respect to the core substrate are detected, the pattern data for a pattern to be formed on the core substrate is corrected based on positional information of the LSI chips, a mask pattern based on the corrected pattern data is displayed on a liquid crystal panel, and the pattern is formed by lithography with the liquid crystal panel as a mask, whereby even when the LSI chips are disaligned with the core substrate, the multi-level interconnection layer can be formed on the core substrate accurately in alignment with the LSI chips. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    FIGS.  1 A- 1 E and  2 A- 2 E are sectional views of a package substrate in the steps of the pattern forming method according to one embodiment of the present invention, which explain the method.  
         [0019]    [0019]FIGS. 3A and 3B are plan views showing the pattern forming method according to the embodiment of the present invention.  
         [0020]    [0020]FIG. 4 is a plan view showing one example of disalignment of LSI chips.  
         [0021]    [0021]FIGS. 5A and 5B are plan views of one example of a basic mask pattern of an interconnection layer and the mask pattern as corrected.  
         [0022]    FIGS.  6 A- 6 C are sectional views of the conventional package substrate in the steps of the method for fabricating the same, which explain the method. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    The pattern forming method according to one embodiment of the present invention will be explained with reference to FIGS.  1 A- 1 E,  2 A- 2 E,  3 A- 3 B,  4  and  5 A- 5 B.  
         [0024]    FIGS.  1 A- 1 E and  2 A- 2 E are sectional views of a package substrate in the steps of the pattern forming method according to the present embodiment, which explain the method. FIGS. 3A and 3B are plan views showing the pattern forming method according to the present embodiment. FIG. 4 is a plan view showing one example of disalignment of LSI chips. FIGS. 5A and 5B are plan views of one example of a basic mask pattern and the mask pattern as corrected.  
         [0025]    Grooves  12  for a plurality of LSI chips to be embedded in are formed in a core substrate  10  to be the base (FIG. 1A, FIG. 3A). In place of forming the grooves  12 , a core substrate with mold frames for the LSI chips to be embedded in may be used.  
         [0026]    Then, LSI chips  14  are fit in the grooves  12  formed in the core substrate  12  and secured with a resin (FIG. 1B). The LSI chips are embedded with the circuit surfaces thereof faced upward. Preferably, the resin is set by pressing the surfaces of the LSI chips  14  with a parallel plate, so that the circuit surfaces of the LSI chips  14  can be flush with the level of a height of the core substrate  10 .  
         [0027]    Next, a resin  16  is filled in the gaps between the LSI chips  14  without adhering the resin  16  to the circuit surfaces of the LSI chips  14  to thereby make the surface flat (FIG. 1C, FIG. 3B). At this time, there is a risk that the respective LSI chips  14  may be disaligned due to alignment accuracy when the LSI chips  14  are secured to the core substrate  10  and stresses produced when the resin  16  is dried. The disalignment will include x-axial disalignment, y-axial disalignment, rotations, etc.  
         [0028]    [0028]FIG. 4 shows an image in which the LSI chip  14 A has a disalignment containing rotation, and the LSI chip  14 B and the LSI chip  14 C have y-axial disalignments. In FIG. 4, the dotted lines indicate the basic positions of the LSI chips  14 , and the solid lines indicate positions where the LSI chips  14  have been actually located.  
         [0029]    Then, a photosensitive dielectric resin  18  is applied to the core substrate  10  with the LSI chips  14  embedded in, and dried (FIG. 1D).  
         [0030]    Thus, a base pattern formed by the LSI chips  14  is formed on the core substrate  10 . The base pattern is a pattern including a tetragonal shape, a polygonal shape, etc. which is formed over the core substrate  10 . At least one interconnection layer is to be formed on the base pattern. In the present embodiment, outline shapes of the LSI chips  14  correspond to the base pattern.  
         [0031]    Next, relative positions of the respective LSI chips  14  with respect to the core substrate  10  are detected by optical means. The positions of the LSI chips  14  may be detected by detecting the edges of the LSI chips  14  or alignment marks on the LSI chips  14 .  
         [0032]    Then, based on the detected positional information of the LSI chips  14 , positions of the electrodes (not shown) formed on the LSI chips  14  are computed. For the computation, positional relationships between the edges of the LSI chips  14  and the electrodes or positional relationships between the alignment marks and the electrodes are beforehand in storage means, so that positions of the electrodes of the LSI chips  14  are computed, based on the stored information.  
         [0033]    Next, based on the computed positional information of the electrodes of the respective LSI chips, basic pattern data of via holes, which has been in advance stored in the storage means is corrected to compute corrected pattern data. The basic pattern data is pattern data of idealistic locations of the LSI chips  14  without disalignments. The corrected pattern data is a pattern data of the basic pattern which has been corrected so that positions of the respective via holes are above the electrodes of the actual LSI chips.  
         [0034]    For example, in a case that the basic pattern data of the via holes is based on coordinate origins of the respective vial holes, the coordinate origins of the respective via holes are shifted by amounts corresponding to disalignment amounts of the LSI chips to thereby produce the corrected pattern data.  
         [0035]    Then, based on the thus-computed corrected pattern data of the via holes, a mask pattern is produced and displayed on a liquid crystal panel.  
         [0036]    Next, with the liquid crystal panel displaying the mask pattern as a mask, the photosensitive dielectric resin  18  is exposed and developed. The liquid crystal panel is thus used as a mask to thereby prepare mask patterns corrected suitably corresponding to disalignments of the LSI chips  14 .  
         [0037]    Thus, via holes  20  are formed in the photosensitive dielectric resin  18  in alignment with the positions of the electrodes of the respective LSI chips  14  (FIG. 1E). The photosensitive dielectric resin  18  is to be an inter-layer insulating film for insulating the interconnection layers.  
         [0038]    Then, a titanium nitride film, for example, is deposited on the entire surface to form a barrier metal layer  22  of the titanium nitride film (FIG. 2A).  
         [0039]    Next, a photoresist film  24  is applied to the barrier metal layer  22  and dried.  
         [0040]    Then, based on the computed positional information of the electrodes of the LSI chips  14 , basic pattern data of an interconnection layer, which has been beforehand stored in the storage means is corrected to compute corrected pattern data. Here, the basic pattern data is idealistic pattern data of the LSI chips  14  without disalignments. The corrected pattern data is a pattern data of the basic pattern which has been corrected so that contact positions of the respective interconnections are above the via holes  20  formed in the photosensitive dielectric resin  18 .  
         [0041]    For example, in a case that the basic pattern of the interconnection layer is based on coordinate origins of the respective via holes  20 , the corrected pattern data can be produced, based on coordinate origins of the via holes  20 , which have been corrected in consideration of the positional information of the LSI chips.  
         [0042]    Then, based on the thus computed corrected pattern data of the interconnection layer, the mask pattern is produced and displayed on a liquid crystal panel. At this time, when the photoresist film  24  is provided by a positive resist, the mask pattern is formed on the liquid crystal panel so that a region for the interconnection layer to be formed in is a transmitting region. FIG. 5A shows one example of the mask pattern formed based on the basic pattern data, and FIG. 5B shows one example of the mask pattern formed based on the corrected pattern data.  
         [0043]    When the basic pattern of the interconnection layer is corrected, it is preferable to suitably adjust a width of the interconnection so as not to change the width of the interconnection. Especially, there is a risk that the breakage of the equipment or obstruction of the normal circuit operation is occurred because of exceeding the upper limit of the current density when the width of the interconnection narrows, so that it is effective to suitably adjust the width of the interconnection.  
         [0044]    Then, with the liquid crystal panel displaying the mask pattern as a mask, the photoresist film  24  is exposed and developed. Thus, the photoresist film  24  in the region for the interconnection layer to be formed in is selectively removed (FIG. 2B).  
         [0045]    Next, with the photoresist film  24  formed, copper, for example, is deposited by plating with the barrier metal layer  22  as a seed layer to form a copper film  26  selectively in the region for the interconnection layer to be formed in (FIG. 2C).  
         [0046]    Then, after the photoresist film  24  has been removed, with the copper film  26  as a mask, the barrier metal layer  22  is etched off to form the interconnection layer  28 , etc. of the barrier metal layer  22  and the copper layer  26  laid the one on the other (FIG. 2D).  
         [0047]    Next, in the same way as in the steps of, e.g., FIGS. 1D to  2 D, on the photosensitive dielectric resin with the interconnection layer formed on, photosensitive dielectric resins  30 ,  34 ,  38 , etc. and interconnection layers  32 ,  36 , etc. are repeated formed to thereby form a multi-level interconnection layer  40  on the core substrate  10  (FIG. 2E)  
         [0048]    As described above, according to the present embodiment, positions of the LSI chips with respect to the core substrate are detected, the pattern data for a pattern to be formed on the core substrate is corrected based on positional information of the LSI chips, a mask pattern based on the corrected pattern data is displayed on a liquid crystal panel, and the pattern is formed by lithography with the liquid crystal panel as a mask, whereby even when the LSI chips are disaligned with the core substrate, the multi-level interconnection layer can be formed on the core substrate accurately in alignment with the LSI chips.  
         [0049]    In the present embodiment, the patterning is performed in the process of forming the multi-level interconnection layer  40  by using information of positions of the electrodes of the LSI chips  14 . However, it is possible that positions of the via holes or the interconnection layer formed on the core substrate  10  are detected to obtain new positional information, and based on the positional information, the patterning of the upper layers is performed. In the latter, the multi-level interconnection layer  40  can be formed while not only disalignments of the LSI chips  14 , but also distortions and shrinkages of patterns taking place in processes, as of thermal processing, etc., are corrected.  
         [0050]    In the present embodiment, positions of the LSI chips are detected after the photosensitive dielectric resin  18  has been applied to, but the positional detection of the LCI chips may be performed before the application of the photosensitive dielectric resin  18 . When positions of the LSI chips are detected, the entire surface region of the core substrate is divided in a plurality of units, and the positional detection of the LSI chips may be performed for the respective units.  
         [0051]    In the present embodiment, the present invention has been explained by means of the example that the multi-level interconnection layer is formed on the core substrate with the LSI chips embedded in. However, the present invention is not limited to the process of fabricating package substrates and is applicable widely to the formation of patterns by photolithography. The present invention is advantageously applicable especially to cases where different factors for disalignment are present in one and the same plane and where distortion and shrinkage take place due to build-up, etc.  
         [0052]    The base pattern is not limited to a pattern formed on the core substrate  10 . As described above, a pattern formed by the interconnection layer formed on the core substrate  10 , etc. may be also included in the base pattern.