Abstract:
In one embodiment, the invention provides a method comprising fabricating a die bump on a die, the die bump being shaped and dimensioned to at least reduce the flow of solder material used, to attach the die bump to a package substrate, towards an under bump metallurgy (UBM) layer located below the die bump. Advantageously, the method may comprise performing a substrate reflow operation to attach the package substrate to the die bump, without performing a separate wafer reflow operation to reflow the die bump.

Description:
RELATED APPLICATIONS 
       [0001]    The present divisional application is related to, incorporates by reference, and hereby claims the priority benefit of U.S. patent application Ser. No. 11/087,180, filed Mar. 22, 2005, assigned to the assignee of the present application. 
     
    
     FIELD OF THE INVENTION 
       [0002]    Embodiments of the invention relate to flip chip (FC) technology, and in particular to the under bump metallurgy (UBM) layer of a solder joint formed during flip chip assembly. 
       BACKGROUND 
       [0003]      FIG. 1  of the drawings shows the components of a solder joint  10  formed using FC technology. As will be seen, the solder joint  10  includes a solder bump  12  which is electrically connected to a metal or bond pad  14  of a semiconductor die  16 . The solder joint  10  also includes an under bump metallurgy (UBM) layer  18  which serves as a wetting layer for the solder bump  12 , and as a diffusion barrier to prevent the ingress of metals/solder into the semiconductor die  16 , during various reflow operations including wafer reflow chip join, ball attach and mounting on motherboard 
         [0004]    Wafer reflow involves reflowing the solder bump  12  on the die to remove oxides formed on the solder bump  12  so that the bump can be attached to a substrate solder during substrate reflow. Typically, the solder bump  12  has a high-lead content, e.g., the solder bump  12  may be 90% lead (Pb) and 10% tin (Sn), and reflows at a temperature of around 330° C. During wafer reflow some of the Sn present in the die bump and reacts with the UBM layer  18 . 
         [0005]    During substrate reflow, the solder bump  12  is brought into contact with eutectic solder  20  formed on a substrate  22 . Eutectic solder typically comprises about 63% Sn and 37% Pb and has a melting point of 183° C. During chip join to substrate the eutectic solder is heated to its melting point and beyond, e.g. to 220° C. During chip join reflow some of the eutectic solder  20  flows or wicks around the solder bump  12  and reacts with the UBM layer  18 . More particularly, the tin from the eutectic solder  20  reacts with nickel from the UBM layer  18 , thereby consuming the nickel. This degrades the UBM layer  18 , a problem that is exacerbated when subsequent motherboard reflow steps are performed at temperatures between 220° C. and 270° C. At this temperature, the eutectic solder  20  wicks around the solder bump  12 , in the manner described above, and reacts with the UBM layer  18  thereby consuming more of the tin in the UBM layer  18 . Because the UBM layer  18  has been degraded by the consumption of the tin content therein, as described above, the UBM layer  18  eventually cracks, leading to a failure of the solder joint  10 . 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  shows a schematic drawing of a solder joint; 
           [0007]      FIG. 2  shows the solder joint of  FIG. 1  being attached to a substrate; 
           [0008]      FIG. 3  shows a schematic drawing of a solder bump in accordance with one embodiment of the invention; 
           [0009]      FIG. 4  shows a solder joint formed using the solder bump of  FIG. 3 ; 
           [0010]      FIG. 5  shows a schematic drawing of a solder bump in accordance with another embodiment of the invention; 
           [0011]      FIG. 6  shows a solder joint formed using the solder bump of  FIG. 5 ; and 
           [0012]      FIGS. 7 and 8  illustrate how a solder bump in accordance with the invention may be manufactured. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention. 
         [0014]    Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments. 
         [0015]      FIG. 3  of the drawings illustrates a solder bump  30  which is formed on a die, in accordance with one embodiment of the invention. As will be seen, the solder bump  30  extends through an opening  32  in a passivation layer formed on the die and makes contact with a UBM layer  34 . The solder bump  30  has a distal end  36  which is remote from a near end  38 . As will be seen, the solder bump  30  has a frusto-conical shape with the distal end  36  having a greater or wider cross-sectional area than the near end  38 . Further, it will be seen that the solder bump  30  extends beyond the opening  32  in the passivation layer, which allows the solder bump to act as a barrier to prevent solder material from reaching the UBM layer  34  during substrate reflow. The solder bump  30  also includes a wetting layer  40  formed over the solder bump  30 . The wetting layer  40  is of a material that acts to prevent the oxidation of the die solder bump  30  but also has good adhesion/wetting to the substrate solder. For example, in one embodiment, the wetting layer may comprise gold, cobalt, copper, or nickel, or an alloy of nickel/copper, gold and nickel. 
         [0016]      FIG. 4  of the drawings shows the solder bump  30  in contact with solder bump  48  during a substrate reflow operation to form a solder joint. The wider cross-section of the distal end  36  of the solder bump  30  acts as a diffusion barrier to at least reduce the flow of the eutectic solder material from the solder bump  48  around the solder bump  30 , thereby to protect the UBM layer  34  from the eutectic solder material. Further, since the near end  38  of the solder bump  30  is wider than the opening  32  in the passivation layer, the chances of the eutectic solder material making contact with the UBM layer  34  and reacting therewith is negligible. 
         [0017]    Referring now to  FIG. 5  of the drawings, reference numeral  42  generally indicates a solder bump in accordance with another embodiment of the invention. In  FIG. 5 , the same reference numerals used in  FIG. 3  have been used to indicate like or similar features between the solder bumps  42  and  30 . One difference between the solder bumps  42  and  30  is that instead of being frusto-conical in shape, the solder bump  42  has a generally T-shaped profile with an enlarged head  44 .  FIG. 6  of the drawings shows the solder bump  42  in contact with solder bump  48  during a substrate reflow operation. As will be seen, the enlarged head  44  serves to act as a barrier to prevent or at least reduce eutectic solder material from the solder bump  48  wicking around the solder bump  42  to reach the UBM layer  34 . 
         [0018]    Although only two examples of solder bumps in accordance with the invention have been shown, it is to be understood that various other shapes of solder bumps are possible. Generally, a solder bump of the present invention includes a distal end which acts as a diffusion barrier in order to prevent or at least reduce solder material wicking around the solder bump and reaching the UBM layer below the solder bump. Further, in other embodiments a near end remote from the distal end may be wider than an opening in a passivation layer within which the UBM layer  34  is formed. 
         [0019]      FIGS. 7A and 7B  of the drawings illustrate process steps, in accordance with one embodiment of the invention, to form the solder bump  30 . Referring to  FIG. 7A , a photoresist material is deposited over a passivation layer formed over a die. The photoresist material  50  is patterned and developed to form an opening  52 . The opening  52  has a shape that matches the shape of the solder bump  30  to be formed.  FIG. 7B  shows how the solder bump  30  may be formed by depositing solder material into the opening  52 . Once the solder material has been deposited, the photoresist material  50  may be removed to reveal the solder bump  30 . 
         [0020]      FIG. 8  of the drawings illustrates how the solder bump  42  may be manufactured in accordance with one embodiment of the invention. In the case of the solder bump  42 , two separate photoresist layers  54 ,  56  are used. The photoresist layer  54  is patterned and developed to match the shape of a body section of solder bump  42 , excluding the enlarged head  44 , whereas the photoresist layer  56  is patterned and developed to match the shape of the enlarged head  44 . Once the material to form the solder bump and wetting layer have been deposited, using conventional techniques, the photoresist layers  54  and  56  are removed to reveal the solder bump  42 . 
         [0021]    Because of the wetting layer  40 , oxidation of the solder bumps  30  and  42  is prevented or at least reduced so that it is not necessary to perform a wafer reflow operation prior to performing the substrate reflow operations described with reference to  FIGS. 4 and 6  of the drawings. Thus, one advantage of the techniques disclosed herein is that the consumption of the tin content of the UBM layer  34  during wafer reflow is avoided. 
         [0022]    It is to be understood that the wetting layer  40  formed on the solder bumps  30  and  42  is merely optional so that in other embodiments there may be no wetting layer. In the case of embodiments that do not have a wetting layer, greater quantities of flux than normally used during substrate reflow is used in order to remove oxidation from the solder bumps  30  and  42 . Thus, even in cases where the solder bumps  30  and  42  do not include a wetting layer  40 , the wafer reflow step is avoided. 
         [0023]    Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that the various modification and changes can be made to these embodiments without departing from the broader spirit of the invention as set forth in the claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than in a restrictive sense.