Source: https://patents.google.com/patent/KR20140037930A/en
Timestamp: 2020-07-15 01:01:35+00:00
Document Index: 45979706

Matched Legal Cases: ['art 100', 'art 100', 'art 100', 'art 100', 'art 100', 'art 100']

KR20140037930A - Laser and plasma etch wafer dicing using water-soluble die attach film - Google Patents
Laser and plasma etch wafer dicing using water-soluble die attach film Download PDF
KR20140037930A
KR20140037930A KR1020147001007A KR20147001007A KR20140037930A KR 20140037930 A KR20140037930 A KR 20140037930A KR 1020147001007 A KR1020147001007 A KR 1020147001007A KR 20147001007 A KR20147001007 A KR 20147001007A KR 20140037930 A KR20140037930 A KR 20140037930A
KR1020147001007A
KR101910398B1 (en
웨이-솅 레이
매드하바 라오 얄라만칠리
브래드 이튼
사라브지트 싱흐
아제이 쿠마르
2011-06-15 Priority to US13/161,045 priority Critical patent/US8507363B2/en
2011-06-15 Priority to US13/161,045 priority
2012-05-23 Application filed by 어플라이드 머티어리얼스, 인코포레이티드 filed Critical 어플라이드 머티어리얼스, 인코포레이티드
2012-05-23 Priority to PCT/US2012/039209 priority patent/WO2012173760A2/en
2014-03-27 Publication of KR20140037930A publication Critical patent/KR20140037930A/en
2018-10-22 Publication of KR101910398B1 publication Critical patent/KR101910398B1/en
239000010408 films Substances 0.000 title claims abstract description 100
239000004065 semiconductor Substances 0.000 claims abstract description 95
238000000059 patterning Methods 0.000 claims abstract description 31
239000007864 aqueous solution Substances 0.000 claims abstract description 21
239000010410 layers Substances 0.000 claims description 75
229910052710 silicon Inorganic materials 0.000 claims description 29
XUIMIQQOPSSXEZ-UHFFFAOYSA-N silicon Chemical compound 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238000005530 etching Methods 0.000 claims description 17
VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound 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229910001885 silicon dioxide Inorganic materials 0.000 claims description 13
239000000377 silicon dioxide Substances 0.000 claims description 13
239000000243 solutions Substances 0.000 claims description 8
239000003929 acidic solution Substances 0.000 claims description 4
239000008367 deionised water Substances 0.000 claims description 4
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238000005507 spraying Methods 0.000 claims 1
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URQUNWYOBNUYJQ-UHFFFAOYSA-N Diazonaphthoquinone Chemical compound C1=CC=C2C(=O)C(=[N]=[N])C=CC2=C1 URQUNWYOBNUYJQ-UHFFFAOYSA-N 0.000 description 1
WGXGKXTZIQFQFO-CMDGGOBGSA-N ethenyl (E)-3-phenylprop-2-enoate Chemical compound 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C=COC(=O)\C=C\C1=CC=CC=C1 WGXGKXTZIQFQFO-CMDGGOBGSA-N 0.000 description 1
Methods of dicing semiconductor wafers are described, each wafer having a plurality of integrated circuits. The method includes forming a mask over a semiconductor wafer. The semiconductor wafer is disposed on the water soluble die attach film. The mask covers and protects the integrated circuits. The mask is patterned by a laser scribing process to provide a patterned mask with gaps. The patterning exposes areas of the semiconductor wafer between integrated circuits. The semiconductor wafer is then etched through gaps in the patterned mask to form singulated integrated circuits. Thereafter, the water soluble die attach film is patterned by the aqueous solution.
LASER AND PLASMA ETCH WAFER DICING USING WATER-SOLUBLE DIE ATTACH FILM}
Embodiments of the present invention relate to the field of semiconductor processing and, in particular, to methods of dicing semiconductor wafers, each wafer having a plurality of integrated circuits thereon.
In semiconductor wafer processing, integrated circuits are formed on a wafer (also referred to as a substrate) made of silicon or other semiconductor material. Generally, layers of various materials that are semiconducting, conductive or insulating are used to form integrated circuits. Such materials are doped, deposited and etched using various well-known processes to form integrated circuits. Each wafer is processed to form a large number of individual regions, including integrated circuits, known as dice.
After the integrated circuit formation process, the wafers are "diced " to separate individual die from one another for use in packaging or in unpackaged form in larger circuits, ". The two main techniques used for wafer dicing are scribing and sawing. Using scribing, a diamond tipped scribe is moved across the wafer surface along pre-formed scribe lines. These scribe lines extend along the spaces between the dice. These spaces are generally referred to as "streets". Diamond scribes form shallow scratches within the wafer surface along streets. For example, when pressure is applied using a roller, the wafer is separated along the scribe lines. Breaks in the wafer follow the crystal lattice structure of the wafer substrate. Scribing can be used for wafers having a thickness of about 10 mils (one thousandth of an inch) or less. For thicker wafers, sawing is the current preferred method for dicing.
Using sawing, a diamond-tipped saw rotating at high revolutions per minute contacts the wafer surface and shoots the wafer along the streets. The wafer is mounted on a support member, such as an adhesive film, stretched over the film frame, and the saw is repeatedly applied to both the vertical and horizontal streets. One problem with scribing or sawing is that chips and gouges can be formed along the cut edges of the die. Cracks can also be formed, propagate from the edges of the die into the substrate, and disable the integrated circuit. Chipping and cracking are particularly problematic for scribing because only one side of a square or rectangular die can be scribed in the <110> direction of the crystal structure. As a result, cleaving the other side of the die results in a jagged separation line. Due to chipping and cracking, additional spacing between dies on the wafer is required to prevent damage to the integrated circuits, e.g., chips and cracks are kept at a distance from the actual integrated circuits. As a result of the spacing requirements, many dies can not be formed on standard size wafers and wasted real estate otherwise could be used for circuitry. The use of saws worsens site waste on semiconductor wafers. The blade of the saw is approximately 15 microns thick. Thus, each die network often has to be separated by 300 to 500 microns in order to ensure that cracks and other damage around the cuts made by the saw do not damage the integrated circuits. Also, after the cutting, each die requires substantial cleaning to remove particles and other contaminants resulting from the sawing process.
Plasma dicing has also been used, but may also have limitations. For example, one limitation to the implementation of plasma dicing may be cost. Standard lithography operations for patterning resist can greatly increase the operating cost. Another limitation that may possibly interfere with the practice of plasma dicing is that plasma processing of metals (e.g., copper) that are commonly encountered in dicing along streets can lead to production problems or throughput, Can create limits.
In one embodiment, a method of dicing a semiconductor wafer having a plurality of integrated circuits includes forming a mask over the semiconductor wafer. The semiconductor wafer is placed on a water-soluble die attach film. The mask covers and protects the integrated circuits. The mask is then patterned with a laser scribing process to expose regions of the semiconductor wafer between the integrated circuits by providing a patterned mask having gaps. The semiconductor wafer is then etched through gaps in the patterned mask to form singulated integrated circuits. The water soluble die attach film is then patterned by aqueous solution.
In another embodiment, a system for dicing a semiconductor wafer includes a factory interface. The laser scribe device is coupled with the factory interface and includes a laser. The plasma etch chamber is also coupled with the factory interface. Wet / dry stations are also coupled with the factory interface. The wet / dry station is configured to pattern the water soluble die attach film.
In another embodiment, a method of dicing a semiconductor wafer having a plurality of integrated circuits includes forming a mask over a silicon substrate. The silicon substrate is disposed on the water soluble die attach film. The mask covers and protects the integrated circuits disposed on the silicon substrate. Integrated circuits consist of a layer of low K material and a layer of silicon dioxide disposed over the layer of copper. The mask, the layer of silicon dioxide, the layer of low K material, and the layer of copper are patterned by a laser scribing process, exposing regions of the silicon substrate between the integrated circuits. The silicon substrate is then etched through the gaps to form singulated integrated circuits. Thereafter, the water soluble die attach film is patterned by the water soluble solution.
1 is a flow diagram illustrating operations in a method of dicing a semiconductor wafer including a plurality of integrated circuits, in accordance with an embodiment of the present invention.
2A illustrates a cross-sectional view of a semiconductor wafer including a plurality of integrated circuits during performing a method of dicing a semiconductor wafer, corresponding to operation 102 of the flowchart of FIG. 1, in accordance with an embodiment of the present invention. do.
FIG. 2B illustrates a cross-sectional view of a semiconductor wafer including a plurality of integrated circuits during performing a method of dicing a semiconductor wafer, corresponding to operation 104 of the flowchart of FIG. 1, in accordance with an embodiment of the present invention. do.
2C is a schematic diagram of a semiconductor wafer including a plurality of integrated circuits during a method of dicing a semiconductor wafer, corresponding to operations 106 and 108 of the flow diagram of FIG. 1, in accordance with an embodiment of the present invention. FIG.
Figure 3 illustrates a cross-sectional view of a stack of materials that may be used in a street region of a semiconductor wafer or substrate, in accordance with an embodiment of the present invention.
4A-4F illustrate cross-sectional views of various operations in a method of dicing a semiconductor wafer, in accordance with an embodiment of the present invention.
Figure 5 shows a block diagram of a tool layout for laser and plasma dicing of wafers or substrates, in accordance with an embodiment of the present invention.
Figure 6 shows a block diagram of an exemplary computer system, in accordance with an embodiment of the invention.
Methods of dicing semiconductor wafers are described, each wafer having a plurality of integrated circuits thereon. In the following description, numerous specific details are set forth, such as water soluble die attach films for laser scribing and plasma etch singulation processes, to provide a thorough understanding of embodiments of the present invention. It will be apparent to those skilled in the art that embodiments of the present invention may be practiced without these specific details. In other instances, well-known aspects, such as integrated circuit fabrication, are not described in detail in order not to unnecessarily obscure embodiments of the present invention. In addition, it should be understood that the various embodiments shown in the drawings are descriptive and are not necessarily drawn to scale.
A hybrid wafer or substrate dicing process, including an initial laser scribe and subsequent plasma etch, may be performed for die singulation. A laser scribe process can be used to cleanly remove mask, organic and inorganic dielectric layers, and device layers. Thereafter, the laser etching process may be terminated upon exposure of the wafer or substrate, or upon partial etching of the wafer or substrate. The plasma etched portion of the dicing process can then be used to etch through the bulk of the wafer or substrate, such as through bulk monocrystalline silicon, to yield die or chip singulation or dicing. Suitable die attach films for use with laser scribe and plasma etching processes may be water soluble die attach films that may be etched or partially dissolved by an aqueous solution.
As part of the singulation process, a device wafer to-be-diced is mounted on a carrier tape or carrier wafer. A die attach film (DAF) is applied between the carrier wafer (or tape) and the device wafer to hold the device wafer during dicing. After completing the dicing process, the die attach film may also be singulated. Singling the die attach film while still attached to the device wafer makes it possible to remove the singulated dies for subsequent packaging and assembly processes. Singulation of the die attach film is typically performed by laser cutting where laser cuts are required to stop at the die attach film / carrier tape interface.
Two problems with laser cutting a die attach film are throughput and die contamination. For example, one possible disadvantage of using a laser to cut a die attach film is low throughput. In a laser cut die attach film process, debris from the die attach film may splash on the sidewalls and top surface of the die. The die attach film may also be carbonized. In order to achieve the required yield, subsequent cleaning processes may be required to remove this contamination. Much effort has been made to eliminate the cleaning step after die attach film laser cutting, but little or no success. In addition, cleaning the die attach film on the back side of each die can pose its own set of problems. For example, during laser cutting of a die attach film, the singulated dice are subjected to further exposure of laser radiation, potentially transferring heat damage or debris to the die. According to one embodiment of the invention, a water soluble die attach film is used in the singulation process and is patterned by an aqueous solution instead of a laser.
1 is a flow diagram 100 illustrating operations in a method of dicing a semiconductor wafer including a plurality of integrated circuits, according to one embodiment of the invention. 2A-2C illustrate cross-sectional views of a semiconductor wafer including a plurality of integrated circuits during performing a method of dicing a semiconductor wafer, corresponding to the operations of flowchart 100, in accordance with one embodiment of the present invention. do.
Referring to operation 102 of flowchart 100, and corresponding FIG. 2A, a mask 202 is formed over a semiconductor wafer or substrate 204. The wafer or substrate 204 is disposed on the water soluble die attach film 214. The mask 202 covers and protects the integrated circuits 206 formed on the surface of the semiconductor wafer 204. Mask 202 also covers intervening streets 207 formed between respective integrated circuits 206.
According to one embodiment of the invention, forming the mask 202 includes forming a layer, such as, but not limited to, a photo-resist layer or an I-line patterning layer. For example, the polymer layer, such as a photo-resist layer, may be made of a material otherwise suitable for use in a lithographic process. In one embodiment, the photo-resist layer is formed from a material selected from the group consisting of, but not limited to, 248 nm (nm) resist, 193 nm resist, 157 nm resist, extreme ultra-violet (EUV) and a positive photo-resist material such as a phenolic resin matrix having a diazonaphthoquinone sensitizer. In another embodiment, the photo-resist layer can be formed by a photolithographic process including, but not limited to, forming a negative photoresist layer, such as poly-cis-isoprene and poly-vinyl- cinnamate, Made of resist material.
In one embodiment, the semiconductor wafer or substrate 204 is made of a material that is suitable for withstanding the manufacturing process and where the semiconductor processing layers may be appropriately disposed thereon. For example, in one embodiment, the semiconductor wafer or substrate 204 is comprised of a Group IV-based material, such as, but not limited to, crystalline silicon, germanium, or silicon / germanium. In a specific embodiment, providing the semiconductor wafer 204 includes providing a monocrystalline silicon substrate. In certain embodiments, the single crystal silicon substrate is doped with impurity atoms. In another embodiment, the semiconductor wafer or substrate 204 is comprised of a III-V material, such as, for example, a III-V material substrate used in the fabrication of light emitting diodes (LEDs).
In one embodiment, as part of the integrated circuits 206, an array of semiconductor devices is disposed within or on the semiconductor wafer or substrate 204. Examples of such semiconductor devices include, but are not limited to, memory devices or complementary metal-oxide-semiconductor (CMOS) transistors fabricated in a silicon substrate and encased within a dielectric layer. A plurality of metal interconnects may be formed over the devices or transistors and in the surrounding dielectric layers, and to electrically couple the devices or transistors to form integrated circuits 206. Can be used. Conductive bumps and / or passivation layers may be formed over the wiring layers. The materials that make up the streets 207 may be similar or the same as the materials used to form the integrated circuits 206. For example, the streets 207 may be made of dielectric materials, semiconductor materials, and layers of metallization. In one embodiment, one or more of the streets 207 include test devices similar to the actual devices of the integrated circuits 206.
Referring to operation 104 of flowchart 100 and corresponding Figure 2B, the mask 202 is patterned by a laser scribing process to provide a patterned mask 208 with gaps 210, To expose areas of the semiconductor wafer or substrate 204 between the integrated circuits 206. Thus, a laser scribing process is used to remove the material of the streets 207 originally formed between the integrated circuits 206. In accordance with one embodiment of the present invention, patterning the mask 202 by a laser scribing process may be performed within the regions of the semiconductor wafer 204 between the integrated circuits 206, And partially forming trenches 212.
In one embodiment, patterning the mask 202 by a laser scribing process includes using a laser having a pulse width in the femtosecond range. Specifically, using a laser having wavelengths in the visible spectrum or ultraviolet (UV) or infrared (IR) ranges (totaling broadband optical spectrum), a femtosecond-based laser, ie approximately femtoseconds ( 10-15) Laser having a pulse width of a second) can be provided. In one embodiment, ablation is not wavelength dependent or essentially wavelength dependent, thus allowing complex films, such as films of mask 202, streets 207, and possibly , A portion of the semiconductor wafer or substrate 204.
Successful laser scribing and dicing selection of laser parameters such as pulse width minimizes chipping, microcracks and delamination to achieve clean laser scribe cuts. This can be important in developing a process. The cleaner the laser scribe cut, the smoother the etch process that can be performed for the final die singulation. In semiconductor device wafers, typically, many functional layers of different material types (e.g., conductors, insulators, semiconductors) and thicknesses are disposed on top. Such materials may include, but are not limited to, organic materials such as polymers, metals, or inorganic dielectrics such as silicon dioxide and silicon nitride.
The streets between the individual integrated circuits disposed on the wafer or substrate may include similar or identical layers to the integrated circuits themselves. For example, FIG. 3 shows a cross-sectional view of a stack of materials that can be used in the street area of a semiconductor wafer or substrate, in accordance with an embodiment of the present invention.
Referring to FIG. 3, the street area 300 is a top portion 302, a first silicon dioxide layer 304, a first etch stop layer 306 of the silicon substrate, with the relative thicknesses shown. A first low k dielectric layer 308, a second etch stop layer 310, a second low k dielectric layer 312 (e.g., having a dielectric constant less than a dielectric constant of 4.0 for silicon dioxide) A third etch stop layer 314, an undoped silica glass (USG) layer 316, a second silicon dioxide layer 318, and a layer 320 of photo-resist. Copper metallization 322 is disposed between the first and third etch stop layers 306 and 314 and through the second etch stop layer 310. In a specific embodiment, the first, second, and third etch stop layers 306, 310, and 314 are made of silicon nitride, while the low K dielectric layers 308 and 312 are made of carbon-doped silicon oxide material. Is done.
Under conventional laser irradiation (eg, nanosecond-based or picosecond-based laser irradiation), the materials of the street 300 behave very differently in terms of optical absorption and ablation mechanisms. . For example, dielectric layers such as silicon dioxide are essentially transparent to all laser wavelengths commercially available under normal conditions. In contrast, metals, organic (e. G., Low K materials) and silicon can very easily couple photons, especially in response to nanosecond-based or picoseco- have. However, in one embodiment, the femtosecond-based laser process may ablate a layer of silicon dioxide, a layer of low K material, and copper by ablating the layer of silicon dioxide prior to ablation of the layer of low K material and the layer of copper. It is used to pattern the layer of. In a specific embodiment, pulses, such as or less than approximately 400 femtoseconds, are used in a femtosecond-based laser irradiation process to remove portions of the mask, street, and silicon substrate.
In accordance with one embodiment of the present invention, suitable femtosecond-based laser processes are characterized by high peak intensity (irradiance) that generally causes non-linear interactions in a variety of materials. In one such embodiment, femtosecond laser sources have a pulse width in the range of approximately 10 femtoseconds to 500 femtoseconds, although a range of 100 femtoseconds to 400 femtoseconds is preferred. In one embodiment, femtosecond laser sources have wavelengths in the range of approximately 1570 nanometers to 200 nanometers, although a range of 540 nanometers to 250 nanometers is preferred. In one embodiment, the laser and the corresponding optical system have a focal spot at a work surface in the range of approximately 3 microns to 15 microns, although a roughly 5 micron to 10 microns range is preferred. to provide.
The spatial beam profile at the work surface may be a single mode (Gaussian), or it may have a shaped top-hat profile. In one embodiment, the laser source has a pulse repetition rate in the range of approximately 200 kHz to 10 MHz, although a range of approximately 500 kHz to 5 MHz is preferred. In one embodiment, the laser source delivers pulse energy in the range of approximately 0.5 [mu] J to 100 [mu] J to the work surface, although a range of approximately 1 [mu] J to 5 [mu] J is preferred. In one embodiment, the laser scribing process is performed at a speed in the range of approximately 500 mm / sec to 5 m / sec, although a range of approximately 600 mm / sec to 2 m / sec is desirable, (work piece) Run along the surface.
The scribing process may operate with only one pass or multiple passes, but in one embodiment, it may preferably operate with 1-2 passes. In one embodiment, the scribing depth in the workpiece is a depth in the range of approximately 5 microns to 50 microns, preferably approximately 10 microns to 20 microns. The laser may be applied as a train of single pulses at a given pulse repetition rate, or as a train of pulse bursts. In one embodiment, the kerf width of the generated laser beam is preferably in the range of approximately 6 microns to 10 microns measured at the device / silicon interface, although in silicon wafer scribing / dicing. However, the range is approximately 2 microns to 15 microns.
Provides a sufficiently high laser intensity to achieve ionization of inorganic dielectrics (e.g., silicon dioxide) and to minimize delamination and chipping caused by underlayer damage prior to direct ablation of inorganic dielectrics Laser parameters with gains and advantages can be selected, such as to. In addition, the parameters can be selected to provide meaningful process throughput for industrial applications using precisely controlled ablation widths (e.g., cuff widths) and depths. As described above, compared to picosecond-based and nanosecond-based laser ablation processes, femtosecond-based lasers are far more suitable for providing such advantages. However, even within the spectrum of femtosecond-based laser ablation, certain wavelengths can provide better performance than other wavelengths. For example, in one embodiment, a femtosecond-based laser process having a wavelength within or near the UV range provides a cleaner ablation process than a femtosecond-based laser process having a wavelength within or nearer the IR range. do. In such specific embodiments, femtosecond-based laser processes suitable for semiconductor wafer or substrate scribing are based on lasers having a wavelength of about or less than about 540 nanometers. In such a specific embodiment, pulses of about 400 femtoseconds or less of a laser having a wavelength equal to or less than about 540 nanometers are used. However, in alternative embodiments, dual laser wavelengths (e.g., a combination of an IR laser and a UV laser) are used.
With reference to operation 106 of flowchart 100 and corresponding Figure 2C, a semiconductor wafer 204 (not shown) is fabricated through gaps 210 in a patterned mask 208 to form singulated integrated circuits 206 Is etched. According to one embodiment of the present invention, etching the semiconductor wafer 204 completely etches the semiconductor wafer 204 by etching the trenches 212 formed by the laser scribing process, as shown in FIG. 2C. Finally etching through.
In one embodiment, etching the semiconductor wafer 204 includes using a plasma etching process. In one embodiment, a through-silicon via type etching process is used. For example, in a specific embodiment, the etch rate of the material of the semiconductor wafer 204 is greater than 25 microns per minute. An ultra-high-density plasma source may be used for the plasma etch portion of the die singulation process. Examples of suitable process chambers for performing such plasma etching processes are Applied Centura, available from Applied Materials, Sunnyvale, California.
Silvia TM There is an Etch system. Applied centura
Silvia TM The Etch system combines capacitive and inductive RF coupling, which is much more independent of ion density and ion energy than was possible with only capacitive coupling, just as with the improvements provided by magnetic enhancement. Provide control. This combination allows for effective decoupling of ion density from ion energy, thereby achieving relatively high density plasmas even at very low pressures, without high, potentially damaging DC bias levels. To be. This results in an exceptionally wide process window. However, any plasma etch chamber capable of etching silicon can be used. In an exemplary embodiment, a deep silicon etch is used to provide an etch rate greater than about 40% of typical silicon etch rates while maintaining intrinsically accurate profile control and substantially scallop-free sidewalls The single crystal silicon substrate or the wafer 204 is etched. In a specific embodiment, a silicon-through via type etch process is used. The etching process is based on a plasma generated from a reactive gas, which is generally a fluorine-based gas such as SF 6 , C 4 F 8 , CHF 3 , XeF 2 , or a relatively fast etch. Any other reactant gas capable of etching silicon at a rate.
Referring back to operation 108 of flow chart 100, and corresponding FIG. 2C, to provide die attach film portions 216 on respective singulated integrated circuits 206, a water soluble die attach film. 214 is patterned. In one embodiment, the water soluble die attach film 214 is patterned by wet etching in aqueous solution. In one embodiment, the water soluble die attach film 214 is patterned in a sequence following the laser scribe and plasma etch portions of the singulation process, as shown in FIG. 2C. In one embodiment, as shown in FIG. 2C, after the laser scribe and plasma etch portions of the singulation process, the patterned mask 208 is removed. As described in more detail below with respect to FIGS. 4A-4F, the patterned mask 208 may be removed prior to, during, or after patterning of the water soluble die attach film 214.
Thus, referring back to the flowchart 100 and Figs. 2A-2C, wafer dicing can be performed through the mask layer, through the wafer streets (including metallization), and partly into the silicon substrate, . The laser pulse width can be selected in the femtosecond range. Then, by subsequent through-silocon deep plasma etching, the dicing can be completed. In addition, dissolution of the exposed portions of the water soluble die attach film is performed to provide singulated integrated circuits, each of which has a portion of the die attach film on top. In addition, the mask layer may be removed during or after the process. According to one embodiment of the invention, a specific example of a stack of materials for dicing is described below with respect to FIGS. 4A-4D.
Referring to FIG. 4A, a stack of materials for hybrid laser ablation and plasma etch dicing includes a mask layer 402, a device layer 404, and a substrate 406. The mask layer, device layer, and substrate are disposed over a die attach film 408 that is attached to a backing tape 410. In one embodiment, mask layer 402 is a photo-resist layer, such as the photo-resist layers described above with respect to mask 202. The device layer 404 is an inorganic dielectric layer (eg, silicon dioxide) disposed on one or more metal layers (eg, copper layers) and one or more low K dielectric layers (eg, carbon— Doped oxide layers). The device layer 404 also includes streets arranged between integrated circuits, which streets include the same or similar layers as the integrated circuits. In one embodiment, the substrate 406 is a bulk single crystal silicon substrate.
In one embodiment, the water soluble die attach film 408 is a die attach film that is readily soluble in aqueous media. For example, in one embodiment, the aqueous die attach film 408 is made of a material that is soluble in one or two or more of an alkaline solution, an acidic solution, or in deionized water. The water soluble die attach film 408 may be suitable for bonding a thinned or thin wafer or substrate to the backing tape 410. In one embodiment, the water soluble die attach film 408 has a thickness in the range of approximately 5-60 microns. In a specific embodiment, the water soluble die attach film 408 has a thickness of approximately 20 microns.
In one embodiment, the water soluble die attach film 408 maintains its water solubility during the heating process, such as, for example, heating in the range of approximately 50-160 ° C. For example, in one embodiment, the water soluble die attach film 408 is soluble in aqueous solutions after exposure to chamber conditions used in laser and plasma etch singulation processes. In one embodiment, the water soluble die attach film 408 is, but is not limited to, such as polyvinyl alcohol, polyacrylic acid, dextran, polymethacrylic acid, polyethylene imine, or polyethylene oxide. Made of materials. In a specific embodiment, the water soluble die attach film 408 has an etch rate in the aqueous solution range of approximately 1-15 microns per minute, more specifically approximately 1.3 microns per minute. In another specific embodiment, the aqueous die attach film 408 is formed over the device layer 404 by spin-on techniques.
In one embodiment, the bulk monocrystalline silicon substrate 406 is thinned from the backside before attaching to the die attach film 408. In one such embodiment, the thinning is performed after forming or placing the mask 402 over the device layer 404. However, in such other embodiments, thinning is performed prior to forming or placing the mask 402 over the device layer 404. Thinning can be performed by a backside grind process. In one embodiment, the bulk monocrystalline silicon substrate 406 is thinned to a thickness in the range of approximately 50-100 microns. In one embodiment, it is important to note that this thinning is performed prior to the laser ablation and plasma etch dicing process. In one embodiment, device layer 404 has a thickness in the range of approximately 2-3 microns.
Referring to FIG. 4B, a portion of mask 402, device layer 404, and substrate 406 is patterned by laser scribing process 412 to form trenches 414 in substrate 406. . In one embodiment, the laser scribing process 412 is a femtosecond-based laser scribing process 412. In one embodiment, the mask 402 is cut by the laser scribing process 412 to function to carry debris generated by the laser scribing process 412.
Referring to FIG. 4C, using the silicon-penetrating deep plasma etching process 416, the trench 414 extends down to the die attach film 408 to expose the top portion of the die attach film 408 and The silicon substrate 406 is singulated. The device layer 404 is protected by the mask 402 during the silicon-penetrating deep plasma etching process 416.
Referring to FIG. 4D, the singulation process may further include patterning the die attach film 408. In one embodiment, the water soluble die attach film 408 is patterned by at least partial dissolution in an aqueous mesh. For example, in one embodiment, the water soluble die attach film 408 is at least partially dissolved in a solution such as, but not limited to, alkaline solution, acidic solution, or deionized water. Patterning exposes the upper portion of backing tape 410 and singulates the water soluble die attach film 408 to provide die attach film portions 418.
Thus, according to one embodiment of the invention, a water soluble die attach film is applied to the device wafer for singulation. The water soluble die attach film is applied on a carrier taper or carrier wafer. After laser scribing and subsequent silicon etching processes, the dies are singulated while the portions of the die attach films are exposed along the wafer streets. Then, in one embodiment, the singulated device wafer is dipping or sprayed by a water-based solution to pattern the die attach film along wafer streets.
The patterning of the water soluble die attach film may comprise dissolving the exposed portions of the water soluble die attach film through its entire thickness, while maintaining most of the die attach film under the singulated die. In a specific embodiment, the open or exposed areas of the die attach film have a width in the range of approximately 10-60 microns, and the die attach film has a thickness in the range of approximately only 5-50 microns. On the other hand, the die size is in the range of approximately 7 millimeters by 7 millimeters or larger. Thus, in one embodiment, most of the die attach film below each die is retained. For example, FIG. 4E shows an ideal result, where portions 418 of the water soluble die attach film retained after patterning are flush with the edges of the individualized die 406. In another example, FIG. 4F shows the resulting aqueous solution patterning where portions 418 of the water soluble die attach film maintained after patterning slightly undercut the edges of the individualized die 406.
Additional embodiments may subsequently include removing singulated portions of the substrate 406 from the backing tape 410 (eg, as individual integrated circuits). In one embodiment, portions 418 of singulated die attach film 408 are retained on the backsides of singulated portions of substrate 406. In one embodiment, singulated integrated circuits are removed from the backing tape 410 for packaging. In one such embodiment, portions 418 of die attach film 408 are retained on the backside of each integrated circuit and are included in the final packaging. However, in another embodiment, portions 418 of die attach film 408 are removed during or after the singulation process, such as by an extended aqueous solution treatment.
Further embodiments may include removal of the remaining portions of the mask 402. The mask 402 may be removed before patterning, during patterning, or after patterning of the water soluble die attach film 408. In one embodiment, the mask 402 is also made of a water soluble material, and the mask 402 is removed during the patterning of the water soluble die attach film 408.
Referring again to FIGS. 2A-2C, the plurality of integrated circuits 206 may be separated by streets 207 having a width of approximately 10 microns or less. The use of a femtosecond-based laser scribing approach may enable such compaction in the layout of integrated circuits, at least in part due to the tight profile control of the laser. However, it should be understood that it is not always desirable to reduce the street width to less than 10 microns, although this is possible by a femtosecond-based laser scribing process. For example, some applications may require a street width of at least 40 microns to fabricate dummy or test devices in streets that separate integrated circuits. In one embodiment, the plurality of integrated circuits 206 may be arranged on the semiconductor wafer or substrate 204 in a non-restricted or freeform layout.
A single process tool can be configured to perform many or all operations in a hybrid laser ablation and plasma etch singulation process involving the use of a water soluble die attach film. For example, FIG. 5 shows a block diagram of a tool layout for laser and plasma dicing of wafers or substrates, in accordance with an embodiment of the present invention.
Referring to FIG. 5, the process tool 500 includes a factory interface (FI) 502, to which a plurality of load locks 504 are coupled. . Cluster tool 506 is coupled with factory interface 502. The cluster tool 506 includes a plasma etch chamber 508. The laser scribe device 510 is also coupled to the factory interface 502. The overall footprint of the process tool 500 may, in one embodiment, be approximately 3500 millimeters (3.5 meters) x approximately 3800 millimeters (3.8 meters), as shown in FIG. 5.
In one embodiment, the laser scribe device 510 houses a laser. In one such embodiment, the laser is a femtosecond-based laser. The laser is suitable for performing laser ablation portions of hybrid laser and etch singulation processes, including the use of a mask, such as the laser ablation processes described above. In one embodiment, a movable stage is also included in the laser scribe device 500, which is configured to move the wafer or substrate (or its carrier) relative to the laser. In a specific embodiment, the laser is also movable. The overall footprint of the laser scribe device 1210, in one embodiment, may be approximately 2240 millimeters by approximately 1270 millimeters, as shown in FIG.
In one embodiment, the plasma etch chamber 508 is configured to etch the wafer or substrate through gaps in the patterned mask to singulate a plurality of integrated circuits. In one such embodiment, the plasma etch chamber 508 is configured to perform a deep silicon etch process. In a specific embodiment, the plasma etch chamber 508 is an Applied Centura available from Applied Materials, Sunnyvale, California.
Silvia TM Etch system. The plasma etch chamber 508 may be specifically designed for deep silicon etching used to produce singulated silicon substrates or singulated integrated circuits housed on or within wafers. In one embodiment, a high density plasma source is included in the plasma etch chamber 508 to promote high silicon etch rates. In one embodiment, more than one etching chamber is included within the cluster tool 506 portion of the process tool 500 to enable high manufacturing throughput of the singulation or dicing process.
The factory interface 502 may be a suitable atmospheric port for the interface between the cluster tool 506 and an external manufacturing facility having the laser scribe device 510. The factory interface 502 provides wafers (or their) from storage units (eg, front opening unified pods) to cluster tool 506 or laser scribe device 510, or both. Robots with arms or blades for transporting carriers).
The cluster tool 506 may include other chambers suitable for performing the functions of the singulation method. For example, in one embodiment, instead of an additional etch chamber, a deposition chamber 512 is included. The deposition chamber 512 may be configured for mask deposition on or above the device layer of the wafer or substrate prior to laser scribing of the wafer or substrate. In one such embodiment, the deposition chamber 512 is suitable for depositing a photo-resist layer.
In one embodiment, a wet / dry station 514 is included to pattern or remove all of the water soluble die attach film together. The wet / dry station may also be suitable for cleaning or removing masks and residues and fragments following a laser scribe and plasma etch singulation process of the substrate or wafer. In one embodiment, a metrology station is also included as a component of the process tool 500.
Embodiments of the present invention may be implemented in a machine-readable medium having instructions stored thereon, which can be used to program a computer system (or other electronic devices) to perform a process according to embodiments of the present invention. A computer program product, or software, which may include, for example, In one embodiment, the computer system is coupled with the process tool 1200 described with respect to FIG. 5. The machine-readable medium includes any mechanism for storing or conveying information in a form readable by a machine (e.g., a computer). For example, a machine-readable (eg, computer-readable) medium may be a machine (eg, computer) readable storage medium (eg, read only memory (“ROM”), random access memory). (E.g., a computer) readable transmission medium (including, but not limited to, electrical, optical, acoustical or other forms of propagated Signals (e.g., infrared signals, digital signals, etc.)), and the like.
6 shows a schematic representation of a machine in an exemplary form of computer system 600, within which the machine may perform any one or two or more of the methodologies described herein. A set of instructions may be executed. In alternate embodiments, the machine may be connected (e.g., networked) to other machines via a local area network (LAN), an intranet, an extranet, or the Internet. The machine may operate as a server or client machine in a client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The machine may be taken by a personal computer (PC), a tablet PC, a set top box (STB), a personal digital assistant (PDA), a cellular telephone, a web appliance, a server, a network router, a switch or a bridge, May be any machine capable of executing (in a sequential or other manner) a set of instructions specifying the actions. Additionally, although only one machine is illustrated, the term "machine" also refers to a set of instructions (or sets of instructions) individually or collectively to perform any one or more of the methodologies described herein. (E. G., Computers) that execute the &lt; / RTI &gt;
Exemplary computer system 600 includes a processor 602, a main memory 604 (e.g., read only memory (ROM), flash memory, dynamic random access memory (DRAM) ), Static memory 606 (e.g., flash memory, static random access memory (SRAM), etc.), and secondary memory (e.g., (E. G., A data storage device).
Processor 602 represents one or more general purpose processing devices, such as a microprocessor, central processing unit, or the like. More specifically, the processor 602 may be a multiple instruction set computing (CISC) microprocessor, a reduced instruction set computing (RISC) microprocessor, a very long instruction (VLIW) microprocessor, a processor implementing other instruction sets, May be processors that implement the combination. The processor 602 may also be one or more special purpose processing devices, such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), a network processor, or the like. Processor 602 is configured to execute processing logic 626 to perform the operations described herein.
The computer system 600 may further include a network interface device 608. The computer system 600 also includes a video display unit 610 (e.g., a liquid crystal display (LCD), a light emitting diode display (LED), or a cathode ray tube (CRT)), an alphanumeric input device 612 (E.g., a keyboard), a cursor control device 614 (e.g., a mouse), and a signal generating device 616 (e.g., a speaker).
The secondary memory 618 is a machine in which one or more sets of instructions (eg, software 622) are stored that implement any one or two or more of the methodologies or functions described herein. -Accessible storage medium (or, more specifically, computer-readable storage medium) 631. The software 622 may also reside entirely or at least partially within the processor 602 and / or within the main memory 604 during execution of the software by the computer system 600 and may be stored in the main memory 604 and / The processor 602 also constitutes machine-readable storage media. The software 622 may also be transmitted or received via the network 620 by the network interface device 608. [
Although machine-accessible storage medium 631 is shown as being a single medium in an exemplary embodiment, the term "machine-readable storage medium" refers to a single medium or multiple media that stores one or more sets of instructions. It is to be taken as including a central or distributed database, and / or associated caches and servers. The term "machine-readable storage medium" can also be used to store or encode a set of instructions for execution by a machine, and to enable the machine to perform any one or more of the methodologies of the present invention It should be taken to include any medium. Accordingly, the term "machine-readable storage medium" should be taken to include, but is not limited to, solid state memories and optical and magnetic media.
According to one embodiment of the present invention, a machine-accessible storage medium has instructions stored thereon that cause the data processing system to perform a method of dicing a semiconductor wafer having a plurality of integrated circuits . The method includes forming a mask on a semiconductor wafer. The semiconductor wafer is disposed on the water soluble die attach film. The mask covers and protects the integrated circuits. The mask is then patterned by a laser scribing process to provide a patterned mask having gaps. Regions of the semiconductor wafer are exposed between integrated circuits. The semiconductor wafer is then etched through the gaps in the patterned mask to form singulated integrated circuits. Thereafter, the water soluble die attach film is patterned by the aqueous solution.
As such, methods of dicing semiconductor wafers have been disclosed, each wafer having a plurality of integrated circuits. According to one embodiment of the invention, a method of dicing a semiconductor wafer having a plurality of integrated circuits includes forming a mask over the semiconductor wafer. The semiconductor wafer is disposed on a die attach film. The mask covers and protects the integrated circuits. The method also includes patterning the mask by a laser scribing process to provide a patterned mask having gaps, thereby exposing regions of the semiconductor wafer between the integrated circuits. The method also etches the semiconductor wafer through gaps in the patterned mask to form singulated integrated circuits. The method also includes patterning the water soluble die attach film with an aqueous solution. In one embodiment, patterning the water soluble die attach film with an aqueous solution comprises singulating the water soluble die attach film with an etching rate in the range of approximately 1-15 microns per minute. In one embodiment, forming the mask over the semiconductor wafer includes forming a water soluble mask, and patterning the water soluble die attach film with an aqueous solution further includes removing the water soluble mask.
A method of dicing a semiconductor wafer including a plurality of integrated circuits, the method comprising:
Forming a mask over the semiconductor wafer disposed on a water-soluble die attach film, the mask covering and protecting the integrated circuits;
Patterning the mask by a laser scribing process to provide a patterned mask having gaps to expose regions of the semiconductor wafer between the integrated circuits;
Etching the semiconductor wafer through the gaps in the patterned mask to form singulated integrated circuits; And
Patterning the water soluble die attach film with an aqueous solution,
A method of dicing a semiconductor wafer.
The step of patterning the water-soluble die attach film with an aqueous solution,
Singulating the water soluble die attach film at an etch rate in the range of approximately 1-15 microns per minute,
Forming a mask on the semiconductor wafer disposed on the water soluble die attach film,
The mask on the semiconductor wafer disposed on a film comprising a material selected from the group consisting of polyvinyl alcohol, polyacrylic acid, dextran, polymethacrylic acid, polyethylene imine, or polyethylene oxide Forming a step,
The thickness of the film is in the range of approximately 5-60 microns,
Using a solution selected from the group consisting of an alkaline solution, an acidic solution, and deionized water,
Forming a mask on the semiconductor wafer comprises forming a water soluble mask,
Patterning the water soluble die attach film with an aqueous solution further comprises removing the water soluble mask,
Patterning the mask by a laser scribing process includes patterning by a femtosecond-based laser scribing process,
Etching the semiconductor wafer through the gaps in the patterned mask comprises using a high density plasma etching process,
A system for dicing a semiconductor wafer comprising a plurality of integrated circuits,
Factory interface;
A laser scribe device coupled with the factory interface;
A plasma etch chamber coupled with the factory interface; And
A wet / dry station coupled with the factory interface, wherein the wet / dry station is configured to pattern a water soluble die attach film;
A system for dicing a semiconductor wafer.
The wet / dry station is configured to deliver an aqueous solution selected from the group consisting of alkaline solution, acidic solution, and deionized water,
The wet / dry station is configured to deliver the aqueous solution by filling a holding tank or by spraying,
The plasma etch chamber and the wet / dry station are housed on a cluster tool coupled with the factory interface,
The cluster tool further includes a deposition chamber configured to form a water soluble mask,
The wet / dry station is configured to remove the water soluble mask while patterning the water soluble die attach film.
A method of dicing a semiconductor wafer comprising a plurality of integrated circuits, the method comprising:
Forming a mask over a silicon substrate disposed on the water soluble die attach film, the mask covering and protecting the integrated circuits disposed on the silicon substrate, the integrated circuits being made of a layer of low K material and copper; A layer of silicon dioxide disposed over the layer;
Patterning the mask, the layer of silicon dioxide, the layer of low K material, and the layer of copper by a laser scribing process to expose regions of the silicon substrate between the integrated circuits;
Etching the silicon substrate through the exposed regions to form singulated integrated circuits; And
Forming the mask on the semiconductor wafer disposed on a film comprising a material selected from the group consisting of polyvinyl alcohol, polyacrylic acid, dextran, polymethacrylic acid, polyethylene imine, or polyethylene oxide,
KR1020147001007A 2011-06-15 2012-05-23 Laser and plasma etch wafer dicing using water-soluble die attach film KR101910398B1 (en)
US13/161,045 US8507363B2 (en) 2011-06-15 2011-06-15 Laser and plasma etch wafer dicing using water-soluble die attach film
US13/161,045 2011-06-15
PCT/US2012/039209 WO2012173760A2 (en) 2011-06-15 2012-05-23 Laser and plasma etch wafer dicing using water-soluble die attach film
KR20140037930A true KR20140037930A (en) 2014-03-27
KR101910398B1 KR101910398B1 (en) 2018-10-22
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KR1020147001007A KR101910398B1 (en) 2011-06-15 2012-05-23 Laser and plasma etch wafer dicing using water-soluble die attach film
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