Abstract:
Testing is performed on a semiconductor die ( 50 ) having a plurality of protruding electrical contacts ( 52 ) formed thereon. The test method uses a carrier ( 100 ) having a plurality of wells ( 110 ) formed in a dielectric layer ( 118 ) thereon. At least a portion of the protruding electrical contacts ( 52 ) is inserted into a corresponding portion of the plurality of wells ( 110 ) in order to make electrical connections between the semiconductor die ( 50 ) and the carrier ( 100 ) with minimal damage to the protruding electrical contacts ( 52 ). Testing (e.g. functional testing, burn-in testing, full-speed testing) of the semiconductor die ( 50 ) may then be performed using the electrical connections. Once testing of the semiconductor die ( 50 ) is completed, the semiconductor die ( 50 ) is removed from the carrier ( 100 ) and the carrier ( 100 ) may be reused for testing a different semiconductor die.

Description:
This is based on U.S. patent application Ser. No. 08/987,714 filed Dec. 9, 1997, which is hereby incorporated herein by reference, and priority thereto for common subject matter is hereby claimed. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates in general to semiconductor die, and more particularly to testing of semiconductor die using wells. 
     BACKGROUND OF THE INVENTION 
     Semiconductor manufacturers have the cost saving goal of detecting and screening out defective integrated circuits as early as possible in the manufacturing process. In addition, the requirement of supplying “known good die” to multi-chip module (MCM) manufacturers has increased the importance of this goal. 
     During a typical semiconductor manufacturing process, a plurality of integrated circuits are formed as individual die on a semiconductor wafer. At present, each semiconductor wafer generally has dozens to hundreds of individual die formed thereon. As integration geometries decrease and the size of semiconductor wafers increase, the number of integrated circuit die formed on each wafer will most likely increase. 
     While the die are still in wafer form, each die is probed in order to determine whether each die passes a very basic opens/shorts test (e.g. a test for electrical opens or electrical shorts). In some cases, a full functional test is also performed using the probe equipment. However, no reliability testing is performed because it would be too costly to tie up the probe equipment testing one or a few die at a time for the hours required for reliability testing. 
     The purpose of the wafer level probe test is to determine, as early as possible in the manufacturing process, whether each individual die is defective or not. The earlier a defective die is detected, the less money that is wasted on further processing of defective die. 
     The die are then separated or singulated into individual die using any one of a variety of singulation techniques. In most cases, each die is then packaged in an integrated circuit package. Once the die have been packaged, thorough electrical testing is performed on each of the packaged integrated circuits. The purpose of the thorough electrical testing is to determine whether each packaged integrated circuit properly performs the functionality specified by the semiconductor manufacturer. The tested, packaged integrated circuits are then sold. 
     In some cases, the packaged integrated circuits also undergo a reliability testing procedure called burn-in. Burn-in testing involves the testing of an integrated circuit for an extended period of time while the temperature of the integrated circuit is elevated above room temperature. In some cases, the heat generated by the integrated circuit itself is sufficient to elevate the temperature of the integrated circuit. In other cases, the temperature of the integrated circuit is raised by an apparatus external to the integrated circuit (e.g. a burn-in oven in which the packaged integrated circuits are placed). 
     Alternately, instead of or in addition to burn-in testing, cold temperature reliability testing may be performed. Cold temperature reliability testing involves the testing of an integrated circuit for an extended period of time while the temperature of the integrated circuit is decreased below room temperature. 
     Semiconductor manufacturers spend a significant amount of money packaging defective die which pass the testing performed during probing, but which do not pass the reliability testing after packaging. In addition, the probe testing is redundant in that the same electrical tests are again performed on the individual integrated circuits after packaging. 
     The cost saving goal of detecting and screening out defective die as early as possible in the manufacturing process is especially important in the context of multi-chip modules (MCMs). Multi-chip modules (MCMs) are electronic modules that include a plurality of integrated circuit die which are packaged together as one unit. Multi-chip modules are becoming more widely used. 
     For multi-chip modules, it is quite costly to replace one or more failed die once the die have been bonded onto a substrate. Therefore, it is desirable to determine whether or not a die is fully functional and is reliable before the die is packaged as part of a multi-chip module. In addition, many manufacturers of multi-chip modules are requiring that semiconductor manufacturers sell them fully tested “known good die” which have passed reliability tests and which are not packaged in an integrated circuit package. 
     As summarized above, testing of “known good die” has become particularly important in modem semiconductor manufacturing. In this regard, various testing procedures have been devised with respect to semiconductor die that have bond pads to which are connected wire bonds, known in the art as a wirebond die. One example of a portion of an apparatus to test and burn-in such wirebond die is shown in FIG.  1 . 
     FIG. 1 illustrates a prior art structure including carrier  10  which is connected to socket  12 , which in turn is connected to testing equipment (not shown) for testing and burn-in of die  50 . As shown, carrier  10  includes a forced delivery mechanism  14  which is connected to lid  16  through a biasing member (e.g. a spring). The force delivery mechanism is placed to overlie die  50  and bias die  50  in a downward direction such that the wirebond pads around the outer periphery of the die are biased against carrier contacts  18 . As shown, the carrier contacts  18  have a “mushroom” shape, and are connected to interconnects  20  which extend over compliant material. The interconnects  20  are in turn connected to electrical contacts (not shown) extending through the socket  12 . 
     While the apparatus shown in FIG. 1 including carrier  10  and socket  12  may be used to test and burn-in wirebond-type die, it is not particularly adapted for testing and burn-in of “bumped” semiconductor die, such as die having bumps formed on an active surface thereof by the known Control Collapsed Chip Connection technology (“C 4 ”). As is known in the art, such bumped die have a relatively large array of solder bumps provided on the active surface of the semiconductor die. The bumped die is configured to be inverted and placed on a plastic or ceramic substrate, and the solder bumps are reflowed to effect mechanical and electrical connection between the bumped die and the substrate. However, the bumps formed on the die are at a relatively fine pitch, and are formed in a relatively large number. For example, a common C 4  bump is on the order of 125 microns in diameter and adjacent bumps are spaced apart from each other by 125 micron spaces. 
     Accordingly, the array is formed at a relatively fine pitch, typically on the order of 250 microns. In current applications, a typical microprocessor semiconductor die can have on the order of one thousand or greater C 4  bumps. 
     Because of the relatively large number, high density and fine feature size associated with bumped die, numerous difficulties exist with testing and burn-in. More particularly, in an attempt to test or burn-in a bumped die, the present inventors attempted to modify the known carrier  10  depicted in FIG. 1 for use with a C 4  bumped die, which brought to light several problems. First, as shown in FIG. 1, the carrier contact  18  has somewhat of a “mushroom” shape, wherein the upper contact surface of the carrier contact  18  is roughened to have a texture which contacts the C 4  bumps. This texture is effective to break a native oxide on wirebond pads, to make ohmic contact to the wirebond pads. However, this same texture has the effect of roughening and pitting the C 4  bumps on the die. As a result of the pitting, it was found that the vision equipment utilized for alignment during the first level packaging operation (i.e., bonding of the bumped die to the substrate) could not properly image and align the bumped die with the substrate. In addition, it was believed that roughening of the contact surfaces of the bumps may cause problems subsequent to reflow, including void formation and perhaps reliability problems. 
     Further, it was found that according to the bumped die in which the bumps are laid out in an array fashion at a relatively small pitch (i.e. high density), the carrier contacts  18  had to be placed at an equally fine pitch, separated by even smaller spacing than the C 4  bumps, due to the flared “mushroom” top of the carrier contacts  18 . In this regard, it was found that the side of the die which is formed subsequent to the sawing operation is not generally formed with the precision required for the die to properly align with the carrier contacts. Accordingly, slight shifts in formation of the side surfaces of the die cause shifting of the die, whereby the bumps straddle adjacent carrier contacts which cause undesirable shorting. This phenomena is due to the fact that the sides of the die are used for alignment purposes within the carrier  10 . 
     In an attempt to address the deficiencies of the known carrier, the present inventors considered using more sharply pointed carrier contacts. However, it was determined that such carrier contacts would not be practically feasible for a number of reasons. For example, such contacts would cause problems with the vision equipment for alignment, voids in the bumps, etc. 
     Other methods for testing bumped die include a technique wherein a temporary solder joint is formed, between the C 4  bump and a test substrate, and testing equipment connected to the I/O pins or BGA (ball grid array) balls of the substrate. According to this technique, the bumped die is placed on a substrate having relatively small contact pads, and reflow is carried out. However, this technique requires physical separation of the bumped die from the substrate, after reflow and testing, which is laborious and not cost effective. 
     Accordingly, it is quite clear that a need exists in the art for testing bumped semiconductor die utilizing a novel known good die carrier particularly adapted for bumped die. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic view of a prior art known good die carrier and socket used for wirebond-type semiconductor die; 
     FIGS. 2 and 3 are bottom and top plan views, respectively, of a known good die carrier according to one embodiment of the present invention; 
     FIG. 4 is an exploded view of the well array provided along the top surface of the known good die carrier shown in FIG. 3; 
     FIG. 5 is a cross-sectional view of FIG. 4 along sectional line  5 — 5 ′; 
     FIG. 6 is an exploded cross-sectional view of a single well of the well array as shown in FIG. 5, prior to receiving a bumped semiconductor die; 
     FIG. 7 illustrates a view similar to FIG. 6, after receiving the bumped semiconductor die; 
     FIGS. 8-12 illustrate various steps in forming an embodiment of the known good die carrier according to one embodiment of the present invention; and 
     FIG. 13 is a flow diagram representing a method of carrying out a known good die test according to an embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION 
     Turning to FIGS. 2 and 3, an embodiment according to the present invention is disclosed, depicting a known good die (KGD) carrier  100 , having a bottom surface on which a ball grid array (BGA)  104  is formed, having individual BGA balls  102 . On the top surface of the KGD carrier  100 , a well array  110  and a plurality of alignment fiducials  106  are formed. Although not depicted in FIGS. 2 and 3, it is understood that the electrical contacts from individual wells  112  are electrically routed to individual BGA balls  102  for a subsequent connection to appropriate known testing equipment (not shown). That is, KGD carrier  100  fans out the well array  110  to a larger scale array, BGA  104 . It is also noted that the embodiment shown in FIGS. 2 and 3 illustrates a KGD carrier for use with a singulated bumped semiconductor die. However, the KGD carrier  100  may be formed so as to accommodate a plurality of die, such as a 10×10 or 20×20 array of die. Alternatively, the KGD carrier may be configured to test all die formed on a wafer. 
     The details of the well array  110  are more clearly shown in FIGS. 4 and 5. As illustrated, well array  110  includes individual wells  112  that terminate at a bottom surface thereof in the form of contact pads  116 . More particularly, the KGD carrier  100  includes a substrate  114  on which are formed a plurality of the contact pads  116 , each of which is connected to an interconnect  117 . Preferably the substrate is made of a ceramic insulating material, but may also be formed of an organic polymer (i.e. plastic) as is well known in the art. In this embodiment, the contact pad  116  is formed of a thin film of Ti/Cu, with a Cu/Ni plating layer. The wells  112  are defined within a dielectric layer  118  that is formed on the substrate  114 . According to the embodiment shown, the dielectric layer is formed of polyimide, but may be formed of other dielectric materials as well. 
     Wells  112  include a conductive layer  120  which covers the side surface of the wells, and which defines peripheral side surfaces  122 . In this particular embodiment, the peripheral side surfaces  122  are inclined, at an angle preferably on the order of 105-115 degrees, such as 110 degrees, with respect to the plane of the contact pads  116 . As described in more detail below, the inclined nature of the peripheral side surfaces  122  is particularly important to induce a scrubbing action between the bumps on the semiconductor die and the conductive layer  120 . In addition the inclined nature of the peripheral side surfaces  122  increases interfacial area between the bump and the well to improve electrical contact, and also provides a self-aligning feature for the bumped semiconductor die. These features are more clearly illustrated with respect to FIGS. 6 and 7 discussed below. 
     As shown, the well array  110  of the KGD carrier  100  has a perimeter portion and an interior portion. As is clear to one of ordinary skill, the bumps on the die have a configuration that corresponds to that of the well array  110 . As used herein, the perimeter portion includes about half of the total surface area of the die, and the interior portion includes the balance (i.e., the other half). Note that in alternate embodiments of the present invention, the well array  110  may range from a totally random pattern to a completely symmetrical and regular pattern, with any range of non-regularity in between. 
     For clarity, FIGS. 6 and 7 illustrate a single well/bump interface according to a particular embodiment of the present invention. As disclosed, semiconductor die  50  includes a bump  52 , which is mated to a well  112  of the well array  110  of the KGD carrier  100 . In this particular embodiment, the bump is formed by the known C 4  process, and is comprised of a high lead solder, particularly, 97/3 (97% Pb/3% Sn) solder which has relatively high melting point. However, the bump, more generally, the protruding electrical contact, may be formed by techniques other than C 4 . The bump may be formed by screen printing and reflow, using a vacuum stencil to apply solder balls, or any other technique. In addition, other conductive materials such as sputtered gold may be used. The arcuate or rounded shape of the bump  52  is provided by reflow of the lead and tin materials after deposition on bump sites on the semiconductor die  50 . 
     As shown in more detail in FIGS. 6 and 7, the conductive layer  120  includes an adhesion film  120   a  and a plating film  120   b  which together define the peripheral side surface  122  of the well  112 . The adhesion film  120   a  is formed of a thin film of Cr/Ti/Cu, and has a Ni plating thereon. The plating film  120   b  is formed of a relatively hard metal, approximately 5 microns of Pd/Ni. It is noted that the adhesion film  120   a  is incorporated to promote adhesion between the plating film  120   b  and the polyimide material of the dielectric layer  118 . The particular composition of the conductive film  120  can be altered based upon the ultimate needs of the user. For example, should a dielectric layer formed of a material other than polyimide be employed, alternative conductive materials may be utilized. 
     As shown in FIG. 7, when the semiconductor die  50  is dropped completely down and onto the KGD carrier  100 , the dielectric layer  118  provides a stand-off, between the bottom (active) surface of the semiconductor die  50  and the bottom surface of the bump  52 . By provision of the dielectric layer  118  at a particular thickness, the bump  52  is prevented from being crushed or “pancaked”. Note that the depth of well  112  may be a function of the height of bump  52 . Preferably, the depth of well  112  is on the order of the height of the bump  52 , and more preferably, slightly less than the height of the bump  52 . Accordingly, the bump  52  may be slightly deformed due to the pressure exerted on the semiconductor die  50 , at least in the vertical Y direction. 
     According to the particular embodiment shown, the peripheral side surface  122  of the well  112  contacts and scrubs against the corresponding peripheral side surface of the bump  52 . This scrubbing action is ensured by configuring the precise diameter of the well for the particular size of the bump  52 . That is, the well  52  has a diameter which is slightly larger at the top and smaller at the bottom than a corresponding diameter or profile of the bump, so that the bump is “squeezed” or compressed in the horizontal X direction during downward movement of the bump into the well  112 . Accordingly, by appropriately choosing the thickness of the dielectric layer  118  relative to the height of the bump, and the diameter of the well  112  relative to a corresponding diameter of the bump  52 , electrical contact is ensured through scrubbing action along the peripheral side surfaces of the well  112  and the bump  52 , as well as the contact pad  116  and an opposing bottom surface of the bump  52 . 
     FIGS. 8-12 depict various process steps according to one method for forming the KGD carrier  100  according to the present invention. FIG. 8 illustrates providing a dielectric layer  118  on substrate  114 . As noted above, the dielectric layer  118  is formed of polyimide and is spun-on according to conventional techniques. Thereafter, as shown in FIG. 9, a mask layer  150  is formed and patterned so as to provide an opening overlying the contact pad  116 . The mask  150  is formed by depositing copper on the dielectric layer  118 . The copper is etched according to conventional techniques to form the opening. Then, as shown in FIG. 10, the dielectric layer  118  is etched by utilizing the known technique of reactive ion etching (RIE). As is known in the art, this etching technique combines physical and chemical etching processes. Thus, by relying upon a physical component (ions) and a chemical component the wells  112  may be formed. In one embodiment, RF (radio frequency) power, reduced pressure (i.e. less than atmospheric), and gas flow rate are used to determine the slope of the peripheral side surfaces  122  of wells  112 . 
     After formation of the well opening  111  (FIG.  10 ), adhesion film  120   a  and plating film  120   b  of the conductive layer  120  are deposited by sputtering. As shown, layers  120   a  and  120   b  are conformal, that is, extend along the entire exposed area of the KGD carrier  100 . Following deposition of the conductive layer  120 , the structure is ground along grind plane  154  to form a planar surface, and to remove all portions of the conductive layer  120  that do not extend into respective wells  112 . Accordingly, the wells  112  are electrically isolated from each other, and the conductive film  120  of each well extends to and is in electrical contact with a respective contact pad  116 . 
     Turning to FIG. 13, a process flow diagram is illustrated for testing a bumped semiconductor die according to one embodiment of the present invention. As shown, oval  200  indicates the start of the process, and oval  201  indicates the end of the process. A process flow is initiated with step  210  wherein a dielectric layer  118  is formed and completed, having an array of conductive wells  110 . Step  211  is continued from step  210 , wherein the contact side of the die, (i.e., the bumped surface of the die) is aligned with the array of conductive wells  110 . Step  212  continues from step  211 , wherein physical force is applied to the die in order to achieve electrical contact between the bumps of the semiconductor die and respective conductive wells  112 . Step  213  is continued from step  212 , wherein the semiconductor die is secured within the KGD carrier  100  (e.g. via a lid attached to the KGD carrier  100 , by using continuous force applied to the contactless side of the semiconductor die  50  to ensure electrical contact, or by using vacuum applied to the contact side of the semiconductor die  50  to ensure electrical contact). 
     Step  214  continues from step  213 , wherein the die assembly including KGD carrier  100  and semiconductor die  50 , is placed in a test apparatus. Step  215  continues from step  214 , wherein a plurality of die assemblies are tested in parallel or in series. Step  216  continues from step  215 , wherein each die is evaluated to determine whether the die passes or fails a test or tests executed by the test apparatus. Step  217  continues from step  216 , wherein the die assemblies are removed from the test apparatus. Step  218  continues from step  217 , wherein the die is unsecured from the KGD carrier  100 , such as by opening a lid. Step  219  continues from step  218 , wherein physical force is applied to remove the die from the KGD carrier  100  (e.g. by applying vacuum to the inactive surface opposite the bumped, active surface of the die  50 ). Note that further processing such as bump restoration or bump reflow is not necessary because the bumps have not been deformed beyond viable use. Thereafter, step  220  continues from step  219 , wherein each die is placed in a test category (pass/fail), based on the results of the test or tests for that die. Step  221  continues from step  220 , wherein “known good die” is placed into final packaged form and sold. Then, as stated above, the process flow ends with oval  209 . 
     It is to be understood, therefore, that this invention is not limited to the particular forms illustrated and that the appended claims cover all modifications that do not depart from the spirit and scope of this invention.