Method of forming a temporary connection to a semiconductor integrated circuit

Abstract: A semiconductor integrated circuit device includes: a base film (1, 20, 30, 40, 50) made of insulating material; a wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54) of a pre-determined shape formed on the base film (1, 20, 30, 40, 50); a semiconductor chip (6, 25, 33) provided on the base film (1, 20, 30, 40, 50), wherein an electrode terminal (6a, 25a, 33a) of the semiconductor chip (6, 25, 33) comes into contact with one end of the wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54); and a flexible protective film (7, 26, 34) having an insulating property, the flexible protective film (7, 26, 34) being adhered onto the base film (1, 20, 30, 40, 50) while it covers the semiconductor chip (6, 25, 33) and said one end of the wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54).

Description: The present invention relates to a method of carrying out an operation test on a bare chip. In general, a bare chip, that is, a semiconductor chip that has been cut out from a wafer, is permanently packaged with a plastic or ceramic film and subjected to a screening test that is an initial inspection test through which defective articles are screened out. Only articles that have passed the test, that is, only articles, with assured quality, are shipped. However, a multi-chip-module (referred to as "MCM" hereinafter) has entered the market recently, and the demand has expanded rapidly. In accordance with the expansion of the demand, it is desired to assure quality of bare semiconductor chips. In this case, MCM is an assembling technique by which the delay of a signal transmission between packages can be avoided when a plurality of semiconductor chips of ICs or LSIs are directly provided on a highly dense wiring board, so that the characteristics of the chips can be fully utilized. Therefore, MCM is a promising technique superior to the prior art, in which the manufacturing characteristics of silicon are better utilized, and system performance can be enhanced. The conventional test on a semiconductor chip is carried out in the following manner: A probe for inspection use is contacted with the electrode terminal of a semiconductor chip. Alternatively, the test can be made after the semiconductor chip has been assembled into a semiconductor package. One example of a conventional semiconductor package is disclosed in EP-A-052710. In this a semiconductor chip is sandwiched between two thin films of plastics material one of which carries a wiring pattern. In this example the films are ultrasonically welded together in a region surrounding the semiconductor chip. In this connection, as described above, in the case of an MCM in which a plurality of semiconductor chips are provided on one base board, the yield of the MCM is directly affected by the quality of each chip. Therefore, it is required to carry out the quality assurance test under the condition of a semiconductor chip, and a quality check test is performed using a socket used exclusively for the semiconductor chip, wherein this socket is temporarily used only for the test. However, the size of the electrode terminal and the interval between the electrode terminals of the semiconductor chip are very minute. Therefore, it is difficult to accurately match the terminal size and interval of the exclusive socket to those of the semiconductor chip. Therefore, the cost of developing the exclusive socket is increased. When the screening test is performed on a semiconductor chip, the semiconductor chip tends to be damaged by external factors such as static electricity when it is conveyed or packaged. For this reason, the reliability of quality assurance deteriorates. According to claim 1 of the present invention, a method of forming a temporary connection to a semiconductor chip to enable it to be tested comprises the steps of: providing a base film made of insulating material having a wiring pattern of a pre-determined shape formed on it; placing a semiconductor chip on the base film, so that electrode terminals of the semiconductor chip come into contact with first ends of the wiring pattern; and temporarily adhering a flexible protective film having an insulating property, to the base film so that it covers the semiconductor chip and said first ends of the wiring pattern but leaves exposed second ends of the wiring pattern to enable them to be used in testing, and separating the protective film from said base film after testing. The semiconductor chip is completely covered with the base film and protective film. Therefore, the semiconductor chip can be protected from damage caused by external factors such as static electricity when it is conveyed or packaged. The terminal size and interval of the exclusive socket for use in the screening test may be made to coincide with the pattern width and the pattern interval on the other side of the wiring pattern. Such a pattern width and pattern interval can be freely designed, so that the exclusive socket can be commonly used for different semiconductor chips. Accordingly, the cost of developing the exclusive socket can be reduced. The wiring pattern may be formed on the same side of the base film as that on which the semiconductor chip is placed, and the protective film may include a ring of perforations in this case the method includes the additional step of removing the protective film outside the ring of perforations after the protective film has been adhered to the base film to expose the second ends of the wiring pattern. Alternatively the wiring pattern may be formed on a side of the base film opposite to the side on which a semiconductor chip is provided, in which case the first ends of the wiring pattern penetrate through the base film so as to be exposed onto the surface of the base film on which the semiconductor chip is placed. The electrode terminals of the semiconductor chip come into contact with said first ends of the wiring pattern. In this case the wiring pattern is provided on a reverse side of the base film, that is, the wiring pattern is provided on the side opposite to the side onto which the protective film is adhered. Therefore, no exposing process for exposing the wiring pattern to make it come into contact with the terminals of the exclusive socket for use in the screening test is necessary, that is, the peeling work for partially peeling off the protective film so as to expose the wiring pattern from the protective film is not necessary. Therefore, it is possible to reduce the cost. Particular embodiments of a semiconductor integrated circuit device obtained by the method in accordance with this invention will now be described with reference to the accompanying drawings, in which:- Figures 1(a) and 1(b) are cross sectional and plan views of a semiconductor integrated circuit obtained by the method of the first embodiment of the present invention; Figures 2(a) through 2(d) show a manufacturing process of the first embodiment shown in Figures 1(a) and 1(b); Figure 3 is a perspective plan view of a semiconductor integrated circuit obtained by the method of the first embodiment; Figures 4(a) and 4(b) are cross sectional and plan views of a semiconductor integrated circuit obtained by the method of the second embodiment of the present invention; Figure 5 is a perspective plan view of a semiconductor integrated circuit obtained by the method of the third embodiment; Figure 6 is a cross sectional view of a semiconductor integrated circuit obtained by the method of the fourth embodiment; and Figures 7 and 8 are plan views of a semiconductor integrated circuit obtained by the method of the fifth and sixth embodiments of this invention. Figs 1(a) and 1(b), 2(a) through 2(d), and 3 are views showing a first example of the semiconductor integrated circuit device obtained by the method of the present invention. First, the construction of this example will be described. In Figs. 1(a) and 1(b) numeral 1 is a base film. For example, insulating materials such as polyester, polypropylene or polyimide are used for the base film 1. On the base film 1, wiring patterns 2 to 5 are formed from copper foil by means of etching, electrically conductive paste (made of Au, Ag, Cu and Ni, or solder), plating, vapor-depositing or spattering. Concerning the configuration of the pattern, as a typical example is shown by the wiring pattern 2, the pattern is designed in the following manner: The pattern width and pattern interval on one side 2a are made to coincide with the size and interval of the electrode terminals 6a, preferably "bumps" of the conductor chip 6. Further, the pattern width and pattern interval on the other side 2b are made to be as large as possible. Furthermore, the pattern width and pattern interval on the other side 2b are made to coincide with the terminal size and terminal interval of an exclusive socket used for the screening test. A protective film 7 is adhered onto the base film 1 so that the protective film 7 covers the overall semiconductor chip 6 and also covers the portions of the wiring patterns 2 to 5 on one side, that is, the other portions of the wiring patterns 2 to 5 are exposed. For example, insulating and flexible materials such as polyester, polypropylene or PET (polyethylene terephthalate) are used for the protective film 7. Next, the manufacturing process of this example will be explained. As illustrated in Fig. 2(a), the tape-shaped base film 1 wound around a drum is fed to a predetermined position. In this case, the wiring patterns are formed on the base film 1 at regular intervals. Then, a surface on which the electrode terminals 6a of the semiconductor chip 6 are formed is opposed to a surface of the base film 1 on which the wiring patterns 2 to 5 are formed. After that, the semiconductor chip 6 is placed on the base film 1 while the electrode terminals of the semiconductor chip 6 are positioned onto one ends of the wiring patterns 2 to 5. Such an operation can be carried out by means of a robot hand (not shown). Next, as illustrated in Fig. 2(b), the tape-shaped protective film 7 wound around a drum is fed by a predetermined length and set along the surface on which the semiconductor chip is provided. After that, the protective film 7 is adhered onto the surface by means of vacuum adsorption. In this case, perforations 7a are previously formed on the protective film 7 at regular intervals, and an area enclosed by the perforations 7a is the same as the final size of the protective film 7. As a means of vacuum adsorption, it is possible to suck air which exists between the base film 1 and the protective film 7. However, it is preferable that the entire work is carried out in a vacuum chamber because the work can be simplified. After the adhesion process of the base film 1 and the protective film 7 has been completed, as illustrated in Fig. 2(c), both the base film 1 and the protective film 7 are cut by a predetermined length. Finally, as illustrated in Fig. 2(d), an unnecessary portion 7b of the protective film 7 is removed along the perforations 7a formed on the protective film 7. In this way, the construction illustrated in Fig. 1 is completed. According to the semiconductor integrated circuit having the structure described above, as illustrated in Fig. 3, the semiconductor chip 6 is interposed between the base film 1 and the protective film 7. To be more accurate, the semiconductor chip 6 is interposed between the base film 1 and the protective film 7 enclosed by the perforations 7a. Accordingly, the entire semiconductor chip 6 is completely covered while the outside air is shut off. Therefore, for example, in the processes of screening test, conveyance and packaging, the semiconductor chip 6 is not damaged by external factors such as static electricity. It is possible to arbitrarily design the pattern width and the pattern interval of the wiring patterns 2 to 5 on the other side. Accordingly, when these values are appropriately designed, it is possible to realize an exclusive socket used for the screening test that can be commonly used with respect to various sizes. When the other side of the wiring patterns 2 to 5 is made to be common irrespective of the type of the semiconductor chip, it is possible to apply one type of exclusive socket to various types of semiconductor chips. Since the base film 1 and the protective film 7 are only closely contacted to each other by means of vacuum-adsorption, when air is introduced between the base film 1 and the protective film 7 by inserting a finger nail or similar object into a gap between the base film 1 and the protective film 7, both films 1 and 7 are easily separated from each other, and the semiconductor chip can be easily picked up. Figs. 4(a) and 4(b) are views showing a second example of the semiconductor circuit device obtained by the method of the present invention. In addition to the structure of the first example described above, the second example is constructed in such a manner that the base film 1 and the protective film 7 are partially adhered to each other by an adhesive agent. In this case, the adhesive agent loses its adhesive force when it is subjected to the after-treatment. In this connection, like reference characters are used to indicate like parts in the first and second examples. In this example, numeral 10 denotes a thermal separation type adhesive agent, which is a polyurethane type adhesive agent, the adhesive force of which is lost when it is heated. Also, numeral 10 denotes a UV hardening type adhesive agent, the adhesive force of which is lost when it is exposed to ultraviolet rays, for example, a base material made of polyester, polyurethane or epoxy, and a photosensitive group such as an acryloyl group or a diazo group is contained therein. The adhesive agent 10 is coated along a line surrounding the semiconductor chip 6, and the width of the coated zone is very minute. The coated zone is a hatched portion in the drawing. Due to the foregoing, the base film 1 and the protective film 7 are positively adhered to each other over a long period of time. Especially when the semiconductor chip is stored over a long period of time, the semiconductor chip 6 is not affected by the moisture contained in the outside air, so that the deterioration of the semiconductor chip can be avoided. In the case where the semiconductor chip 6 is picked up, after heat has been applied to the adhesive portion and ultraviolet rays have been irradiated upon it, the base film 1 and the protective film 7 may be separated from each other with a finger nail. Instead of applying the adhesive agent, the base film 1 and the protective film 7 may be thermally adhered with pressure along a line to be adhered, that is, thermo-compression adhesion may be applied. When the adhesive agent is used, or when the base film 1 and the protective film 7 are subjected to thermo-compression adhesion, the vacuum adsorption method is not necessarily used. In the case where the vacuum adsorption method is not used, an inert gas such as N 2 gas may be enclosed between the base film 1 and the protective film 7. Fig. 5 is a view showing a third example of the semiconductor circuit device obtained by the method of the present invention. In this example, it is not necessary to provide perforations on the protective film, and it is not necessary either to provide a process in which the extra portion of the protective film is removed. The process in which an extra portion of the protective film is removed is illustrated in Fig. 2(d). In Fig. 5, numeral 20 is a base film, and wiring patterns 21 to 24 are formed on the base film 20. The patterns are designed in the following manner: The width and interval of the pattern on one side, which is represented by reference numeral 21a in Fig. 5, are made to coincide with the size and interval of electrode terminals (reference numeral 6a in Fig. 1) of the semiconductor chip 25. At the same time, the width and interval of the pattern on the other side are made to be as wide as possible, or alternatively the width and interval of the pattern on the other side are made to be the same as those of the exclusive socket used for the screening test not illustrated in the drawing. Further, all the terminals on the other side 21b are arranged at an end of the base film 20 in the lateral direction. Numeral 26 is a protective film adhered onto the base film 20 in such a manner that at least all the semiconductor chip 25 is covered with the protective film 26. The width L 26 of the protective film 26 in the lateral direction is determined to be shorter than the width L 20 of the base film 20 in the lateral direction. Preferable materials used for each component of this example are the same as those having the same names in the first example. In this example, the base film 20 and the protective film 26 are adhered to each other by the vacuum adsorption method, the adhesion method or the thermo-compression adhesion method. These methods may be singly applied, or alternatively they may be combined with each other. According to the above structure, at a point of time when the base film 20 and the protective film 26 are adhered to each other, all the terminals of the wiring patterns 21 to 24 on the other side 21b are exposed. Therefore, unlike the first example, it is not necessary to provide perforations on the protective film and to peel off an extra portion of the protective film. Accordingly, the cost can be further reduced. Fig. 6 is a view showing a fourth example of the semiconductor circuit device obtained by the method of the present invention. In this example, the wiring pattern is formed on a reverse side of the base film. In Fig. 6, numeral 30 is a base film. On the bottom side (reverse side) of the base film 30, wiring patterns 31, 32 are provided. The patterns are designed in the following manner: The width and interval of the pattern on one side 31a, 32a are made to coincide with the size and interval of electrode terminals 33a of the semiconductor chip 33. At the same time, the width and interval of the pattern on the other side 31b, 32b are made to be as wide as possible, or alternatively the width and interval of the pattern on the other side are made to be the same as those of the exclusive socket used for the screening test not illustrated in the drawing. Terminals on one side 31a, 32a penetrate through the base film 30 and are exposed onto an upper surface of the base film 30 (a surface on which the semiconductor chip 30 is placed) through a via 30a. Numeral 34 is a protective film adhered onto the base film 30 in such a manner that the entire semiconductor chip 33 is covered with the protective film. Preferable materials used for the components of this example are the same as those having the same names in the first example. In this example, the base film 30 and the protective film 34 are adhered to each other by the vacuum adsorption method, the adhesion method or the thermo-compression adhesion method. These methods may be singly applied, or alternatively they may be combined with each other. According to the above structure, the wiring patterns 31, 32 are formed on a reverse surface (a surface opposite to the surface on which the semiconductor chip 33 is placed). Therefore, unlike the first example, it is not necessary to provide perforations on the protective film and to peel off an extra portion of the protective film in this example. Further, unlike the third example, it is not necessary to give consideration to the widths (L 26 , L 20 ) of the base film and the protective film. Accordingly, the cost can be further reduced. In this connection, in all examples described above, it is preferable that the semiconductor chip and the base film are temporarily fastened to each other with an adhesive agent when the semiconductor chip is assembled onto the base film. In this case, the adhesive agent loses its adhesive force in the after-treatment. In this case, the thermal separation type adhesive agent and the UV hardening type adhesive agent, which are used in the second example, may be also used. Due to the foregoing, positioning accuracy of the semiconductor can be enhanced, and further, it is possible to avoid the deviation of the position of the semiconductor chip while the semiconductor chip is not covered with the protective film. Figs. 7 and 8 are views showing fifth and sixth examples of the base film providing with wiring patterns in a semiconductor circuit device obtained by the method of the present invention. These examples can be advantageously used if the plurality of electrode terminals of the semiconductor chip (not shown in Figs. 7 and 8) are arranged in a land grid array. In Fig. 7, numeral 40 is a base film, and wiring patterns 41 and 42 are formed on the base film 40. Each of the wiring patterns 41 and 42 is provided at the inner end thereof with a conductive land portion 43. The land portion 43 are also arranged in a land grid array to coincide with the respective electrode terminals of the semiconductor chip. The width and interval of the patterns 41 and 42 on the other side are made to be the same as those of the exclusive socket used for the screening test (not illustrated in the drawing), in the same manner as the embodiment shown in Fig. 5. In Fig. 8, numeral 50 is a base film, and wiring patterns 51 to 54 are formed on the base film 50. In the same manner as the embodiment of Fig. 7, each of the wiring patterns 51 to 54 is provided at the inner end thereof with a conductive land portion 55. The land portions 55 are also arranged in a land grid array to coincide with the respective electrode terminals of the semiconductor chip. The width and interval of the patterns 51 to 54 on the other side are made to be the same as the embodiment shown in Fig. 3.

Claims: A method of forming a temporary connection to a semiconductor chip to enable it to be tested comprising the steps of: providing a base film (1, 20, 30, 40, 50) made of insulating material having a wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54) of a pre-determined shape formed on it; placing a semiconductor chip (6, 25, 33) on the base film (1, 20, 30, 40, 50), so that electrode terminals (6a, 33a) of the semiconductor chip (6, 25, 33) come into contact with first ends of the wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54); and temporarily adhering a flexible protective film (7, 26, 34) having an insulating property, onto the base film (1, 20, 30, 40, 50) so that it covers the semiconductor chip (6, 25, 33) and said first ends of the wiring pattern (2-5, 21-24, 31, 32, 41, 42, 51-54) but leaves exposed second ends of the wiring pattern to enable them to be used in testing and, separating the protective film from said base film after testing. A method according to claim 1, wherein the flexible protective film (7, 26, 34) is temporarily and removably adhered to the base film (1, 20, 30, 40, 50) by establishing a vacuum between them. A method according to claim 1 or 2, wherein the protective film (7, 26, 34) is temporarily and removably adhered to the base film (1, 20, 30, 40, 50) by means of a layer of adhesive (10) surrounding the periphery of the semiconductor chip (6, 25, 33) the adhesive (10) being one which looses its adhesive force when subjected to an after treatment. A method according to claim 1 or 2, wherein the protective film (7, 26, 34) and base film (1, 20, 30, 40, 50) are adhered to each other by means of a thermo-compression adhesion outside the periphery of the semiconductor chip (6, 25, 33). A method according to any one of the preceding claims, wherein the wiring pattern (31, 32) is formed on a side of the base film (30) opposite to the side on which the semiconductor chip (33) is provided, and said first ends (31a, 32a) of the wiring pattern (31, 32) penetrate through the base film (30) so as to be exposed onto the surface of the base film (30) on which the semiconductor chip (33) is provided. A method according to any one of claims 1 to 4, wherein the wiring pattern (2-5) is formed on the same side of the base film (1, 20, 40, 50) as that on which the semiconductor chip (6,25) is placed, and wherein the protective film (7,26) includes a ring of perforations (7a); the method including the additional step of removing the protective film (7,26) outside the ring of perforations after the protective film (7,26) has been adhered to the base film (1, 20, 40, 50) to expose the second ends of the writing pattern. A method according to any one of claims 1 to 4, wherein the wiring pattern (2-5) is formed on the same side of the base film (1, 20, 40, 50) as that on which the semiconductor chip (6,25) is placed, and wherein the protective film (7,26) is of a smaller dimension than the base film so that after the protective film (26) is adhered to the base film (20) the second ends (21b) of the wiring pattern are exposed. A method for testing a semiconductor chip comprising the method steps of any of the preceding claims, further comprising the steps of: testing the semiconductor; loosening the base film from the protective film; separating the protective film from the base film;and, removing the semiconductor chip. A method according to claim 8, wherein the semiconductor chip is temporarily adhered to the base film prior to adhering the flexible protective film.

Inventors: MURAMATSU SHIGETSUGU, MURAMATSU, SHIGETSUGU
Applicants: SHINKO ELECTRIC IND CO, SHINKO ELECTRIC INDUSTRIES CO. LTD.
Application year: 1995
Main classification: H01L23
IPC codes: H01L23, H01L21