Source: https://patents.google.com/patent/US8169215?oq=6437692
Timestamp: 2018-03-24 12:32:05
Document Index: 700333850

Matched Legal Cases: ['Application No. 2006', 'Application No. 2006', 'Application No. 07740148', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006', 'Application No. 2006']

US8169215B2 - Magnetic sensor and method of manufacturing thereof - Google Patents
Magnetic sensor and method of manufacturing thereof Download PDF
US8169215B2
US8169215B2 US12296770 US29677007A US8169215B2 US 8169215 B2 US8169215 B2 US 8169215B2 US 12296770 US12296770 US 12296770 US 29677007 A US29677007 A US 29677007A US 8169215 B2 US8169215 B2 US 8169215B2
US12296770
US20090309590A1 (en )
The present invention relates to a magnetic sensor with which magnetic characteristics are made extremely stable by consideration of an area of contact of a base layer of a magnetic substance and a semiconductor substrate. On a semiconductor substrate (111) a plurality of Hall elements (112 a, 112 b) are embedded so as to be coplanar to a top surface of the semiconductor substrate while being mutually spaced apart by a predetermined distance, and above the Hall elements and the semiconductor substrate, a base layer (114), having coefficient of thermal expansion differing from that of the Hall elements and partially covers a region of each Hall elements, is formed via a protective layer (113), and a magnetic flux concentrator (115), having an area larger than the base layer and with magnetic amplification, is formed on the base layer. An area of contact of the base layer of the magnetic substance and the semiconductor substrate is made small to lessen the generation of an offset voltage.
This application is a U.S. National Phase of International Application No. PCT/JP2007/056710, filed Mar. 28, 2007, and claims the priority of Japanese Application No. 2006-11100, filed Apr. 13, 2006, the content of both of which is incorporated herein by reference.
The present invention relates to a magnetic sensor, and in particular, relates to a magnetic sensor comprising a plurality of Hall elements and magnetic substance with a magnetic amplification function, which enables detecting a direction of a magnetic field in two or three dimensions. The present invention further relates to a method of manufacturing the magnetic sensor.
Conventionally, a magnetic sensor, combining Hall elements and a magnetic substance (magnetic flux concentrator) with a magnetic amplification function, has been known. For example, Patent Document 1 relates to a magnetic field direction detection sensor, which enables detecting a direction of a magnetic field in three dimensions and comprises a magnetic flux concentrator, having a flat shape, and Hall elements, positioned at end regions of the magnetic flux concentrator.
FIG. 2 is a process diagram for describing a method for manufacturing the magnetic flux concentrator of the conventional magnetic sensor and shows a process of adhering a magnetic tape onto a semiconductor substrate 11. First, an IC (Integrated Circuit)-processed wafer is prepared. Next, using an epoxy adhesive, the magnetic tape (amorphous metal tape) is adhered onto the wafer. A magnetic flux focusing pattern 14 is then formed by photolithography. Etching of the amorphous metal is then performed. The magnetic flux concentrator is thus formed on the semiconductor substrate 11. Here, a central position of a magnetic sensing surface of each Hall element is positioned near a circumferential edge of the magnetic flux concentrator. Also here, the magnetic flux concentrator has a film thickness of no less than 20 μm. The magnetic flux concentrator is prepared by processing a thick magnetic tape by wet etching. In this case, the epoxy adhesive is approximately 2 to 4 μm thick, and a distance from a magnetic sensing surface of each Hall element to a bottom surface of the magnetic flux concentrator is approximately 6 to 8 μm. Also in this case, the magnetic flux concentrator 5 is 15 μm thick. Furthermore, an angle formed by a top surface of the semiconductor substrate 1 and a side surface of the magnetic flux concentrator 5 is substantially 90°.
And with this arrangement, after forming the semiconductor Hall elements, the magnetic flux concentrator is formed by depositing a soft magnetic thin film by electroplating. And a two-layer structure is formed by depositing a Ti thin film, which is a first metal film, to 0.05 μm by sputtering, thereafter using a dry film resist to form a pattern corresponding to a magnetic substance in a form of an opening, and depositing a Ni—Fe alloy thin film, which is a second metal film, to 0.07 μm.
The Ti thin film that is the first metal film is adopted for improving close adhesion of a basing insulating layer and the Ni—Fe alloy thin film.
Furthermore, in the case of the magnetic sensor thus manufactured, the metal film with the two-layer structure is stacked between the semiconductor substrate and the magnetic flux concentrator by stacking the Ti thin film, which is the first metal film, to 0.05 μm by sputtering and thereafter depositing the Ni—Fe alloy thin film, which is the second metal film, to 0.07 μm. However, the Ti thin film that is the first metal layer is provided to improve close adhesion of the basing insulating layer and the Ni—Fe alloy thin film and no consideration whatsoever is made in regard to the coefficient of thermal expansions of the two metal films and the magnetic flux concentrator. Therefore, magnetostriction occurs due to the thermal expansion difference between the NiFe in the magnetic flux concentrator 5 and the Ti, W, or TiW alloy in the metal film, and the magnetic characteristics of the magnetic sensor that combines the Hall elements and the magnetic substance are consequently unstable.
As another problem, with the magnetic sensor shown in FIG. 1, because the angle formed by the top surface of the semiconductor substrate 1 and the side surface of the magnetic flux concentrator 5 is substantially 90°, a perpendicular side surface of the magnetic flux concentrator is positioned very close to each Hall element, although the magnetic flux concentrates at the side surface and thereby improves the magnetic detection function. However the magnetic flux concentrates excessively, magnetic saturation occurs and it becomes difficult to secure linearity of sensor output.
Patent Document 1: Japanese Patent Laid-Open No. 2002-71381
Patent Document 2: Japanese Patent Laid-Open No. 2003-142752
To achieve the object above, the present invention provides a magnetic sensor, including: a semiconductor substrate, on which plural Hail elements are disposed; and a magnetic substance, having a magnetic amplification function is disposed above the semiconductor substrate; and with this magnetic sensor, a base layer, serving as a backing of the magnetic substance, is disposed above the semiconductor substrate, the base layer has a coefficient of thermal expansion differing from that of the Hall elements and an area covering a region of each Hall element at least partially, and the magnetic substance has an area larger than the area of the base layer.
In this case, the second metal film preferably has a film thickness of 0.1 to 2 μm. Or, the second metal film preferably has a coefficient of thermal expansion of 15 to 20 ppm/° C.
The magnetic substance is preferably formed of an alloy, containing at least two types of metal selected from the group consisting of Ni, Fe, and Co, and has a coefficient of thermal expansion of 10 to 15 ppm/° C.
Preferably, the taper angle α is such that 90°<α≦120°. Meanwhile, the magnetic substance also preferably has a forward tapered shape, with which the inner taper angle α between the top surface of the semiconductor substrate and the side surface of the magnetic substance is an acute angle.
Preferably in this case, the magnetic substance is formed by photolithography so as to have an inverted tapered shape, with which an inner taper angle α between a top surface of the semiconductor substrate and the side surface of the magnetic substance is an obtuse angle. In particular the taper angle α is preferably such that 90°<α≦120°.
Furthermore, with the present invention, because the distance from the magnetic sensing surface of each Hall element to the bottom surface of the magnetic flux concentrator is set at about 9˜20 μm, although an absolute value of sensitivity may be lowered. Changes of sensitivity with respect to positional shifts along with a plane of magnetic flux concentrator, and changes of distance in a vertical direction between the magnetic flux concentrator and magnetic sensing surface are small. By having an intermediate layer not be thin, thickness adjustment has some allowance and brings an effect of suppressing variations of the sensitivity. In addition, because the intermediate layer is not so thin, an effect of suppressing sensitivity variations due to a void, etc., at the bottom surface side of the magnetic flux concentrator is provided.
FIG. 1 is an arrangement diagram for describing a conventional magnetic sensor;
Next, as shown in FIG. 4C, the magnetic flux concentrator 115 is formed above the pattern by electroplating. That is, the magnetic flux concentrator 115, formed of NiFe and having the magnetic amplification function, is formed by electroplating in the opening 116 a above the base layer 114 (magnetic substance plating process). The magnetic flux concentrator 115 is formed by preparing an Fe—Ni based alloy by electroplating and preferably comprises a permalloy or super-permalloy (Fe—Ni based alloy) and more preferably comprises such an alloy with Co added because magnetic hysteresis is then reduced. Furthermore, the magnetic flux concentrator 115 preferably comprises permendur (Fe—Co based alloy) or sendust (Fe—Si—Al based alloy).
In a case where one magnetic flux concentrator has a diameter of 230 μm and another magnetic flux concentrator has a diameter of 200 μm, a ratio of the areas of contact of the base layers of the magnetic flux concentrators of different diameters with the semiconductor substrate is (230×230)/(200×200)=1:0.75. In this case, the Hall element offset voltage ratio is 1:0.6 (measured value). This signifies that when the diameter of the magnetic flux concentrator 115 is made small to make the area of contact with the semiconductor substrate 111 small, the offset voltage becomes small. This is clear from the graph shown in FIG. 6.
Supposing that absolute values of the sensitivity ratio (X/Z or Y/Z) are set to no less than 1, in the example of the present numerical analysis, the absolute value of the sensitivity ratio becomes 1 when the distance between the magnetic sensing surface of each of the Hall elements and the bottom surface of the magnetic flux concentrator=20 μm, and when the diameter of the magnetic flux concentrator=240 μm, and when the thickness of the magnetic flux concentrator=16 μm. If a balance of sensitivity among the X-axis·Y-axis and the Z-axis is not required as 1, a diameter may be set in a radius of 200 μm or beyond 200 μm, and the distance may be set in the range of 9 to 20 μm or beyond.
With the present invention, a distance between central positions of magnetic detecting surfaces of Hall elements and radial edges of the magnetic flux concentrator is set so that the central positions of the magnetic detecting surfaces of the Hall elements 112 a and 112 b are positioned in a region of approximately 60% to approximately 90% of a radial distance from a central position of the magnetic flux concentrator 115. Or, the radial distance at a central position of the magnetic detecting surfaces from the center of the magnetic substance (geometrical center of the disk-like magnetic flux concentrator) is in a region of approximately 0.6 to approximately 0.9 times. For example, when the radius of the magnetic flux concentrator is 115 μm, the central position of the magnetic detecting surface of each Hall element is positioned in a region of 115×0.6 to 115×0.9=69 to 103.5 μm. That is, the central position of the magnetic detecting surface is positioned in a region that is located 11.5 to 46 μm inward from the edge of the magnetic flux concentrator.
For example, in a case where the radius of the magnetic flux concentrator is 135 μm, the central position of the magnetic detecting surface of each of the Hall elements is formed in a region of 135×0.6 to 135×0.9=81 to 121 μm. That is, the central position of each magnetic detecting surface is positioned in a region 14 to 57 μm inward from the edge of the magnetic flux concentrator.
concentrator radius [μm] Minimum radius [μm] Maximum radius [μm]
Radial Central position of Central position of Central position of
Case distance magnetic detecting magnetic detecting magnetic detecting
No. [μm] surface [ratio] surface [ratio] surface [ratio]
1 89.27 100.00 97.50 102.50
0.8927 0.9156 0.8709
2 89.27 115.00 112.50 117.50
0.7763 0.7935 0.7597
3 89.27 140.00 137.50 142.50
0.6376 0.6492 0.6265
4 89.27 150.00 147.50 152.50
0.5951 0.6052 0.5854
Taking into consideration the slight differences of conditions, a “region of 0.55 to 0.95 times in the radius” is used as a guideline.
Depending on signal processing algorithms, like an integrated circuit, executed by subsequent sequences after the magnetic flux concentrator and the Hall elements, the ratio of the sensitivities of the X-axis and Y-axis on magnetic detecting surfaces of the Hall elements and the sensitivity of the Z-axis on magnetic detecting surfaces of the Hall elements may be set to a value other than approximately 1. And, in this case, the position of the center of the magnetic detecting surface of each Hall element is not restricted to being within the above-mentioned “region of 0.55 to 0.95 times in the radius.”
As seen, (in the case where the ratio of the sensitivities of the X-axis and Y-axis to the sensitivity for the Z-axis on magnetic detecting surfaces of the Hall elements is approximately 2), it can thus be understood that there is a useful region where the sensitivity variation is small and the crosstalk is low. In terms of process, this is realized by suppressing the positional shift of the magnetic flux concentrator to within approximately ±2 to ±3 μm.
flux concentrator [μm] Minimum radius [μm] Maximum radius [μm]
Radial (ratio of) center (ratio of) center (ratio of) center
Case distance position of magnetic position of magnetic position ofmagnetic
No. [μm] detecting surface detecting surface detecting surface
1 151.33 155.00 152.50 157.50
0.9763 0.9923 0.9608
2 161.25 165.00 162.50 167.50
0.9772 0.9923 0.9627
3 171.17 175.00 172.50 2.50
0.9781 0.9923 0.9644
The range of “0.55 to 0.95” is described as being useful in the above table. The range of “0.95 to 1” is also useful as can be seen in the above table; in summary, the range of “0.55 to 1” is one of the most useful range ranges.
Next, as shown in FIG. 19E, the magnetic alloy film (magnetic flux concentrator) 312, having the film thickness of 5 to 30 μm and having the magnetic amplification function, is formed by electroplating in the opening 318 a above the second metal film 316 b (magnetic substance plating process). The magnetic alloy film 312 is formed by preparing an Fe—Ni based alloy by electroplating and preferably comprises a permalloy or super-permalloy (Fe—Ni based alloy) and more preferably comprises such an alloy with Co added because magnetic hysteresis is then reduced. Furthermore, the magnetic alloy film 312 preferably comprises permendur (Fe—Co based alloy) or sendust (Fe—Si—Al based alloy).
Next as shown in FIG. 19F, the resist pattern 318 is removed (resist pattern removal). As a result, the magnetic alloy film 312 is left on the second metal film 316 b.
Although not illustrated, Cu etching is then performed using NiFe as a mask. In this case, NiFe is not etched and just Cu is etched selectively. The etching solution may be either an alkali-based solution or an acid-based solution (Cu etching). Also, Ti etching is performed using NiFe as a mask. In this case, NiFe is not etched and just Ti is etched selectively. The etching solution may be either an alkali-based solution or an acid-based solution (Ti etching).
The buffer coat layer 415 is stacked on the semiconductor circuit 411 so as to be positioned above the Hall elements 414 a and 414 b, the first metal film 416 a is stacked above the buffer coat film 415 and the second metal film 416 b is stacked further above. The magnetic flux concentrator 412, having the magnetic amplification function, is stacked above the second metal film 416 b.
Although not illustrated in FIG. 21, in actuality, an IC layer is placed between the semiconductor circuit 411 and the buffer coat layer 415 (the IC layer is illustrated in FIG. 22A onward for describing a manufacturing method).
The magnetic flux concentrator 412 is formed of an alloy containing at least two types of metal selected from the group consisting of Ni, Fe, and Co, preferably has a coefficient of thermal expansion of 10 to 15 ppm/° C., and in particular, the coefficient of thermal expansion is optimally 12 ppm/° C. The magnetic flux concentrator 412 preferably has a film thickness of 5 to 30 μm.
The metal film has a two-layer structure, which comprises the first metal film 416 a and the second metal film 416 b, and the first metal film 416 a of the first layer is formed of Ti, W, or a TiW alloy, preferably has a coefficient of thermal expansion of 4 to 10 ppm/° C., and in particular, the coefficient of thermal expansion of Ti is optimally 8 ppm/° C. and the coefficient of thermal expansion of W is optimally 4 ppm/° C. The first metal film 416 a of the first layer has a film thickness of preferably 0.01 to 1 μm.
The second metal film 416 b of the second layer contains Cu, has a coefficient of thermal expansion of preferably 15 to 20 ppm/° C., and has a film thickness of preferably 0.1 to 2 μm.
Next, as shown in FIG. 22B, the first metal film 416 a, which comprises Ti, W, or the TiW alloy and has a film thickness of 0.01 to 1 μm, is formed by sputtering or vacuum vapor deposition on the buffer coat layer 415 (forming of a base layer). As mentioned above, the first metal film 416 a preferably has a coefficient of thermal expansion of 4 to 10 ppm/° C., and in particular, the coefficient of thermal expansion of Ti is optimally 8 ppm/° C. and the coefficient of thermal expansion of W is optimally 4 ppm/° C.
Next, as shown in FIG. 22C, the second metal film 416 b, containing Cu and having the film thickness of 0.1 to 2 μm, is formed by sputtering or vacuum vapor deposition on the first metal film 416 a (forming of an intermediate layer). As mentioned above, the second metal film 416 b preferably has a coefficient of thermal expansion of 15 to 20 ppm/° C.
Next, as shown in FIG. 22E, the magnetic alloy film (magnetic flux concentrator) 412, having a film thickness of 5 to 30 μm and having the magnetic amplification function, is formed by electroplating in the opening 418 a above the second metal film 416 b (magnetic substance plating process). The magnetic alloy film 412 is formed by preparing an Fe—Ni based alloy by electroplating and preferably comprises a permalloy or super-permalloy (Fe—Ni based alloy) and more preferably comprises such an alloy with Co added because magnetic hysteresis is then reduced. Furthermore, the magnetic alloy film 412 preferably comprises permendur (Fe—Co based alloy) or sendust (Fe—Si—Al based alloy).
Next as shown in FIG. 22F, the resist pattern 418 is removed (resist pattern removal). As a result, the magnetic alloy film 412 is left on the second metal film 416 b.
Although not illustrated, Cu etching is then performed using NiFe as a mask. In this case, NiFe is not etched, but Cu is etched selectively. The etching solution may be either an alkali-based solution or an acid-based solution (Cu etching). Also, Ti etching is performed using NiFe as a mask. In this case, NiFe is not etched, but Ti is etched selectively. The etching solution may be either an alkali-based solution or an acid-based solution (Ti etching).
FIG. 23 is a table of relationships of magnetic strain and coefficient of thermal expansion of the magnetic alloy film. FIG. 23 shows the coefficient of thermal expansions and Hall element magnetic characteristics when the alloy ratio of TiW is varied from 100% to 0% (with 100% being a state of pure W and 0% being a state of pure Ti). From FIG. 23, it can be understood that there is no magnetic strain when the coefficient of thermal expansion of the magnetic alloy film is 10 to 15 ppm/° C.
That is, as shown in FIG. 24A, the magnetic flux concentrator 515 has the forward tapered shape, with which an inner taper angle α between a top surface of the semiconductor substrate 511 and the side surface of the magnetic flux concentrator 515 is an acute angle. Or, as shown in FIG. 24B, the magnetic flux concentrator 515 has the inverted tapered shape, with which the inner taper angle α between the top surface of the semiconductor substrate 511 and the side surface of the magnetic flux concentrator 515 is an obtuse angle. The inverted taper angle α is preferably such that 90°<α≦120°.
Meanwhile, in FIG. 25B, the magnetic flux concentrator is formed by electroplating above the Hall elements formed by the semiconductor process and photolithography conditions are adjusted to prepare the magnetic flux concentrator 515 with the inverted tapered shape. A taper is formed at a side surface of the resist 516 by adjusting the photolithography conditions so that a portion above the Hall elements becomes an opening 516 a with an inverted tapered shape and thereafter, the magnetic flux concentrator 515, having the magnetic amplification function, is formed by electroplating in the opening 516 a and the resist 516 is then removed. The inverted tapered shape is thus formed at the side surface of the magnetic flux concentrator 515. In this case, the inner taper angle α between the surface of the semiconductor substrate and the side surface of the magnetic flux concentrator is preferably such that 90°<α≦120°. That is, as shown in FIG. 26B, with the inverted tapered shape, by making the taper angle an obtuse angle, the concentrating of the magnetic flux is relaxed to make magnetic saturation less likely to occur and the linearity can thus be improved without lowering the sensitivity.
By thus providing a forward tapered shape or an inverted tapered shape at the side surface of the magnetic flux concentrator 515, distinct characteristics are provided respectively in comparison to conventional arrangements with perpendicular shapes. By providing the forward tapered shape, the magnetic flux becomes readily concentrated at end portions of the magnetic flux concentrator and consequently, the sensitivity improves. As another effect, when a buffer coat layer of polyimide is formed above the magnetic flux concentrator to relax package stress, by providing a forward tapered shape, improvement can be anticipated in regard to inadequate coverage at the acute angle portion. In this case, a degree of acuteness such that magnetic saturation does not occur within a range of use of the sensor is required. Meanwhile, when an inverted tapered shape is provided, because concentrating of the magnetic flux can be relaxed, the effect of improved linearity is provided. Selection can thus be made as suited according to the purpose of use and the usage method of the magnetic sensor is improved significantly. Conventionally, the angle between the side surface of the magnetic flux concentrator and the surface of the semiconductor substrate is substantially 90°, and there are no ideas of providing a tapered shape as in the present invention. The high usage value of the magnetic flux concentrator according to the present invention can be understood from this point as well.
The magnetic focusing film 515 is formed by preparing an Fe—Ni based alloy by electroplating and preferably comprises a permalloy or super-permalloy (Fe—Ni based alloy) and more preferably comprises such an alloy with Co added because magnetic hysteresis is then reduced. Furthermore, the magnetic focusing film 515 preferably comprises permendur (Fe—Co based alloy) or sendust (Fe—Si—Al based alloy).
The present invention relates to a magnetic sensor including a plurality of Hall elements and a magnetic substance having a magnetic amplification function, which is enabled to detect magnetism in two-dimensional or three-dimensional directions, and a method for manufacturing the magnetic sensor. In particular, the present invention provides a magnetic sensor with extremely stable magnetic characteristics and low offset voltage by consideration of the contact area between the base layer of the magnetic substance and the semiconductor substrate, and a method for manufacturing such a magnetic sensor. Also, the magnetic flux concentrator is formed above a polyimide layer, and does not use a conventionally epoxy adhesive. Therefore, the warp of the wafer due to the epoxy adhesive is out of consideration during processing.
13. The magnetic sensor according to claim 11, wherein the second metal layer has coefficient of thermal expansion of 15 to 20 ppm/° C.
14. The magnetic sensor according to claim 11, wherein the magnetic substance is composed of an alloy containing at least two types of metal selected from the group consisting of Ni, Fe, and Co, and has coefficient of thermal expansion of 10 to 15 ppm/° C.
21. The magnetic sensor according to claim 20, wherein the taper angle α is 90°<α≦120°.
35. The magnetic sensor manufacturing method according to claim 34, wherein the taper angle α is 90°<α≦120°.
US12296770 2006-04-13 2007-03-28 Magnetic sensor and method of manufacturing thereof Active 2028-12-01 US8169215B2 (en)
JP2006-111100 2006-04-13
JP2006111100 2006-04-13
PCT/JP2007/056710 WO2007119569A1 (en) 2006-04-13 2007-03-28 Magnetic sensor and method for fabricating the same
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US8169215B2 true US8169215B2 (en) 2012-05-01
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US12296770 Active 2028-12-01 US8169215B2 (en) 2006-04-13 2007-03-28 Magnetic sensor and method of manufacturing thereof
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KR (1) KR101057249B1 (en)
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