Patent Description:
In semiconductor packaging, methods of bonding to packages to each other by using metal alloys having various melting temperatures have been used. One of these bonding methods is soldering. As a material commonly used for soldering, SnAgCu (SAC)-based solder composed of an alloy of metal materials such as tin (Sn), silver (Ag), and copper (Cu) is a representative example.

In the case of SAC-based solder, the melting point is in the range of about <NUM> to about <NUM>, and when the SAC-based solder is used in the case of a highly integrated and thin semiconductor package, a substrate may be bent or stretched depending on a process temperature range. Damage to a solder joint occurs as forces in opposite directions, that is, tensile stress and compressive stress, are applied to upper and lower portions of the substrate.

<CIT> relates to an electronic device that uses a lead-free solder (solder that contains at most a trace amount of lead) and, more particularly to an electronic device fabricated by solder bonding using a temperature hierarchy that is effective in mounting a module formed of the electronic device.

<CIT> relates to a solder material, solder paste, solder preform, a solder joint and a method of managing the solder material.

Provided are hybrid bonding structures configured to bond at a low temperature.

Provided are semiconductor devices bonded at a low temperature.

Provided are methods of manufacturing a semiconductor device at a low temperature.

According to an aspect of the invention, a hybrid bonding structure is provided in accordance with claim <NUM>.

According to another aspect of the invention, a solder paste composition is provided in accordance with claim <NUM>.

The solder ball may include a first tin (Sn)-silver (Ag)-copper (Cu) alloy.

The core may include a second Sn-Ag-Cu alloy, and the shell may include bismuth (Bi).

The core may include copper (Cu), and the shell may include at least one of indium (In) and silver (Ag).

The melting point of the shell may be in a temperature range of <NUM> to <NUM>.

A re-decomposition temperature of the intermetallic compound may be in a temperature range of about <NUM> to about <NUM>.

A ratio of a thickness of the shell to a diameter of the core may be in a range of <NUM> to <NUM>.

The solder paste may further include a metal particle, and the metal particle may include at least one of tin (Sn), indium (In), silver (Ag), gold (Au), copper (Cu), and nickel (Ni).

The core of the solder paste composition may have a diameter in a range of <NUM> to <NUM>.

A thickness of the shell of the solder paste composition may be in the range of <NUM> to <NUM>.

The solder paste composition may further include an insertion layer between the core and the shell.

The insertion layer may include at least one of Ni, carbon nanotubes (CNT), graphene, and gallium (Ga).

According to an embodiment, a semiconductor device is provided in accordance with claim <NUM>.

According to another aspect of the invention, a method of manufacturing a semiconductor device is provided in accordance with claim <NUM>.

The method may further include manufacturing an electronic device that includes the semiconductor device.

According to some example embodiments, an electronic device may include the semiconductor device.

The shell may completely cover the surface of the core.

Reference will now be made in detail to example embodiments, some of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. In this regard, some example embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein.

It will be understood that elements and/or properties thereof may be recited herein as being "the same" or "equal" as other elements and/or properties thereof, and it will be further understood that elements and/or properties thereof recited herein as being "the same" as or "equal" to other elements and/or properties thereof may be "the same" as or "equal" to or "substantially the same" as or "substantially equal" to the other elements and/or properties thereof. Elements and/or properties thereof that are "substantially the same" as or "substantially equal" to other elements and/or properties thereof will be understood to include elements and/or properties thereof that are the same as or equal to the other elements and/or properties thereof within manufacturing tolerances and/or material tolerances. Elements and/or properties thereof that are the same or substantially the same as other elements and/or properties thereof may be structurally the same or substantially the same, functionally the same or substantially the same, and/or compositionally the same or substantially the same.

It will be understood that elements and/or properties thereof described herein as being the "substantially" the same encompasses elements and/or properties thereof that have a relative difference in magnitude that is equal to or less than <NUM>%. Further, regardless of whether elements and/or properties thereof are modified as "substantially," it will be understood that these elements and/or properties thereof should be construed as including a manufacturing or operational tolerance (e.g., ±<NUM>%) around the stated elements and/or properties thereof.

When the terms "about" or "substantially" are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±<NUM>% around the stated numerical value. When ranges are specified, the range includes all values therebetween such as increments of <NUM>%.

Hereinafter, hybrid bonding structures, solder paste compositions, semiconductor devices including the same, and/or electronic devices including the same according to some example embodiments will be described in detail with reference to the accompanying drawings. The same reference numerals refer to the same elements throughout. In the drawings, the sizes of constituent elements may be exaggerated for clarity. These terms are used only to differentiate an element from another element.

In addition, it will be understood that when a unit is referred to as "comprising" another element, it does not preclude the possibility that one or more other elements may exist or may be added. In addition, thicknesses or sizes of elements in the drawings are exaggerated for convenience and clarity of description. Furthermore, when an element is referred to as being "on" or "above" another element, it may be directly on the other element, or intervening elements (e.g., one or more structures and/or spaces) may also be present such that the element may be indirectly on the other element so as to be isolated from direct contact with the other element. Moreover, the materials constituting each layer in the following embodiments are merely examples, and other materials may be used.

The particular implementations shown and described herein are illustrative examples of the inventive concepts and are not intended to otherwise limit the scope of the inventive concepts in any way. For the sake of brevity, conventional electronics, control systems, software development and other functional aspects of the systems may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device.

The use of the terms "a," "an," and "the" and similar referents is to be construed to cover both the singular and the plural.

Operations constituting a method may be performed in any suitable order unless explicitly stated that they should be performed in the order described. Further, the use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the inventive concepts and does not pose a limitation on the scope of the present disclosure unless otherwise claimed.

<FIG> is a view of a semiconductor device according to some example embodiments.

A semiconductor device <NUM> may include a circuit board <NUM>, a semiconductor chip <NUM>, and a hybrid bonding structure <NUM> for bonding the circuit board <NUM> and the semiconductor chip <NUM>. As shown, the hybrid bonding structure <NUM> is between the circuit board <NUM> and the semiconductor chip <NUM>. The hybrid bonding structure <NUM> may be directly between the circuit board <NUM> and the semiconductor chip <NUM>, such that the hybrid bonding structure <NUM> is in direct contact with each of the circuit board <NUM> and the semiconductor chip <NUM>.

The hybrid bonding structure <NUM> includes a solder ball <NUM> and a solder paste <NUM> bonded to the solder ball <NUM>.

The solder ball <NUM> includes at least one alloy selected from the group consisting of a Sn-Ag-Cu alloy, a Sn-Bi alloy, a Sn-Bi-Ag alloy, and a Sn-Ag-Cu-Ni alloy. The solder ball <NUM> may include, for example, at least one of Sn-Ag(<NUM> to <NUM>)-Cu(<NUM> to <NUM>), Sn-Bi(<NUM> to <NUM>), Sn-Bi(<NUM> to <NUM>)-Ag(<NUM> to <NUM>), and Sn-Ag(<NUM> to <NUM>)-Cu(<NUM> to <NUM>)-Ni(<NUM> to <NUM>). The solder ball <NUM> may include a Sn-Ag-Cu alloy (e.g., SAC alloy). For example, when the solder ball <NUM> is composed of a Sn-Ag-Cu alloy, the solder ball <NUM> may include SAC305 (e.g., Sn-<NUM>. 5Cu) or SAC205 (e.g., Sn-<NUM>.

The solder paste <NUM> includes a solder paste composition and may include a flux. In some example embodiments, the flux may be omitted.

<FIG> schematically show a solder paste composition which is included in the solder paste <NUM> shown in at least <FIG>. The solder paste composition <NUM> includes a core <NUM> and a shell <NUM> provided on (e.g., directly or indirectly on) the surface <NUM> of the core <NUM>. In some example embodiments, the shell <NUM> may completely cover the surface <NUM> (e.g., outer surface) of the core <NUM>. Where the shell <NUM> completely covers the surface <NUM>, the shell <NUM> may isolate the core <NUM> from exposure to an exterior of the solder paste composition <NUM>. In some example embodiments, the shell <NUM> may partially (e.g., imperfectly) cover the surface <NUM> of the core <NUM>, such that at least a portion of the surface <NUM> of the core <NUM> is directly exposed to an exterior of the solder paste composition <NUM>.

A melting point of the shell <NUM> is less than (e.g., lower than) a melting point of the core <NUM>. Restated, a temperature of the melting point of the shell <NUM> is lower than a temperature of the melting point of the core <NUM>. For example, the shell <NUM> may have a melting point in the range (e.g. temperature range) of about <NUM> to <NUM>. For example, the shell <NUM> may have a melting point in the range of <NUM> to <NUM>. For example, the shell <NUM> may have a melting point in the range of <NUM> to about <NUM>. For example, the core <NUM> may have a melting point of about <NUM> or higher (e.g., about <NUM> to about <NUM>).

The core <NUM> may have a composition similar to that of the solder ball <NUM>. The core <NUM> includes at least one alloy selected from the group consisting of a Sn-Ag-Cu alloy, a Sn-Bi alloy, a Sn-Bi-Ag alloy, and a Sn-Ag-Cu-Ni alloy. In some example embodiments, the core <NUM> may include a Sn-Ag-Cu alloy, which may be the same as or different from a Sn-Ag-Cu alloy included in the solder ball <NUM>. The shell <NUM> includes at least one of bismuth (Bi), indium (In), gallium (Ga), and silver (Ag). In some example embodiments, the core <NUM> may include Cu, and the shell <NUM> may include at least one of In and Ag. In the solder paste composition <NUM>, material A included in the core <NUM> and material B included in the shell <NUM> are mixed in a liquid state according to (e.g., in response to) temperature to form (e.g., establish, generate, create, etc.) an intermetallic compound. The core <NUM> and the shell <NUM> may form an intermetallic compound during a reflow process. The core <NUM> and the shell <NUM> form (e.g., may collectively form, may at least partially mix to form, etc.) an intermetallic compound in a temperature range of <NUM> to <NUM>. The core <NUM> and the shell <NUM> may at least partially mix to form the intermetallic compound in response to the solder paste composition at least partially being at a temperature within the temperature range of <NUM> to <NUM>. The intermetallic compound is a compound composed of two or more metals. A typical alloy has a structure of a solid solution in which a structure of one of original metals is maintained, and the other of the original metals is randomly substituted. The typical alloy is called a solid solution alloy. The composition of the solid solution alloy may be made in various ratios within a certain range even if the constituent metals are the same. In some example embodiments, the intermetallic compound is a compound having a crystal structure different from that of the original metals. The composition of the intermetallic compound may at least partially comprise two or more metals with a simple integer ratio. For example, as shown in <FIG>, where the core <NUM> includes material A and the shell <NUM> includes material B, the composition of the intermetallic compound may include AB<NUM> (e.g., a <NUM>:<NUM> ratio of B:A).

In some example embodiments, as shown in at least <FIG>, an insertion layer <NUM> may be further provided between (e.g., directly between) the core <NUM> and the shell <NUM> in the solder paste composition <NUM>. The insertion layer <NUM> may include, for example, at least one of Ni, carbon nanotubes (CNT), graphene, and Ga.

<FIG> show a state in which a solder paste is at least partially melted. The shell <NUM> of the solder paste composition <NUM> may be at least partially melted to form an intermetallic compound 136a by the core <NUM> and the shell <NUM>. In <FIG> the shell <NUM> is completely melted and mixed with at least some material of the core <NUM> to form the intermetallic compound 136a, and in <FIG> the shell <NUM> is partially melted and mixed with at least some material of the core <NUM> to form the intermetallic compound 136a. The shell <NUM> may be at least partially melted to form the intermetallic compound 136a, and the solder ball <NUM> and the solder paste <NUM> may be bonded to each other by the intermetallic compound 136a. The shell <NUM> has a lower melting point than the core <NUM>, and the core <NUM> is configured to include a composition having physical properties similar to those of the solder ball <NUM>, so that bonding force between the solder ball <NUM> and the solder paste <NUM> may be increased, and destruction due to external impact may be reduced. The shell <NUM> may lower a melting temperature, and the core <NUM> may improve mechanical properties at a bonding boundary area between the solder ball <NUM> and the solder paste <NUM>. That is, the core <NUM> may include a material having a composition similar to that of the solder ball <NUM> to reduce a difference in physical properties between the solder ball <NUM> and the solder paste <NUM>, thereby improving mechanical properties at the bonding boundary area. The bonding boundary area may include, for example, a central area of a bonding area between the solder ball <NUM> and the solder paste <NUM>.

The solder paste composition <NUM> is configured such that the core <NUM> and the shell <NUM> form an intermetallic compound in response to the solder paste composition <NUM> being at least partially at a temperature within the temperature range of <NUM> to <NUM>. <FIG> show that the core <NUM> and the shell <NUM> form the intermetallic compound 136a. A re-decomposition temperature of the intermetallic compound 136a may be about <NUM> or higher. For example, the re-decomposition temperature of the intermetallic compound 136a may be in a temperature range of about <NUM> to about <NUM>.

For example, the solder ball <NUM> may include a SnAgCu alloy (e.g., a first SnAgCu alloy), the core <NUM> may include a SnAgCu alloy (e.g., a second SnAgCu alloy which may be the same as or different from the first SnAgCu alloy), and the shell <NUM> may include Bi.

<FIG> is a view illustrating an example of a solder paste composition of a hybrid bonding structure, according to some example embodiments. <FIG> shows a solder paste composition in which the core <NUM> includes SnAgCu alloy and the shell <NUM> includes Bi. In some example embodiments, the solder ball <NUM> may include a SnAgCu alloy, the core <NUM> may include Cu, and the shell <NUM> may include at least one of In and Ag.

<FIG> is a view illustrating another example of a solder paste composition of a hybrid bonding structure, according to some example embodiments. <FIG> shows a solder paste composition in which the core <NUM> includes Cu and the shell <NUM> includes In-Ag.

<FIG> shows the bonding between solder paste compositions <NUM>. For example, the core <NUM> may include Cu, and the shell <NUM> may include In/Ag. When heat is applied to the solder paste composition <NUM>, the shell <NUM> melts, and an intermetallic compound 136a may be formed between the core <NUM> and the shell <NUM> and/or between the shell <NUM> and an exterior of the solder paste composition <NUM>. The solder paste compositions <NUM> may be locally bonded to each other by the intermetallic compound 136a. In addition, bonding strength between the solder paste compositions <NUM> and a solder paste including a flux may be increased.

In some example embodiments, the solder paste <NUM> may further include a metal particle. The metal particle may include, for example, at least one of Au, Ag, Sn, In, Cu, and Ni.

When the solder paste composition <NUM> is melted by a reflow process, a flux is volatilized and removed, and only metal particles may remain. The flux may include volatile components. The flux may remove an oxide film or improve a solder phase flow. The solder paste <NUM> is composed of a mixture of the solder paste composition <NUM> and the flux. Referring to <FIG>, the core <NUM> of the solder paste composition <NUM> may have a diameter 134d in a range of, for example, <NUM> to <NUM>.

The flux may include organic materials. The flux may include a water-soluble flux or a fat-soluble flux. The flux may include at least one selected from the group consisting of a rosin-based flux, a resin-based flux, and an organic acid-based flux. However, the flux is not limited thereto. The flux may facilitate the fluidity of the solder paste composition <NUM> and a reaction between particles, and may facilitate a printing process.

A hybrid solder structure according to some example embodiments may be soldered by local melting of a shell during reflow. <FIG> conceptually shows local bonding by an In/Ag shell.

A hybrid solder structure according to some example embodiments may be used as a low-temperature bonding material applied to, for example, a data server, a laptop computer, a mobile phone, a home appliance such as a TV, a computer, and a mobile product, all of which may be examples of an electronic device <NUM> according to any of the example embodiments. As a substrate becomes thinner and a semiconductor device becomes smaller, the semiconductor device may be affected by temperature. Accordingly, a structure capable of being bonded at a low temperature may be employed as a bonding structure for bonding a semiconductor device to have as little influence on the semiconductor device as possible. However, for example, Sn58Bi is a low-temperature bonding material, but a Bi component is brittle and may be easily damaged by drop impact and thermal deformation.

A hybrid bonding structure according to some example embodiments may be bonded at a low temperature and may have strong properties against brittleness. The solder paste <NUM> includes the solder paste composition <NUM> to alleviate brittleness, and the content of the solder paste composition <NUM>, the thickness of a shell, and the content of a shell may be adjusted. For example, referring to <FIG>, a core <NUM> may have a diameter 134d ranging from <NUM> to <NUM>, and a shell <NUM> may have a thickness 136t ranging from <NUM> to <NUM>. Referring to <FIG>, for example, a ratio (shell thickness/core diameter) of the shell <NUM> thickness 136t to the core <NUM> diameter 134d may be in a range of <NUM> to <NUM>. Where the core <NUM> diameter 134d is outside the above-noted range, where the shell <NUM> thickness 136t is outside the above-noted range, and/or where the ratio (shell thickness/core diameter) of the shell <NUM> thickness 136t to the core <NUM> diameter 134d is outside the above-noted range, the adhesion of the shell <NUM> to the core <NUM> may decrease, intermetallic compound 136a formation may be at least partially inhibited, and/or damage to the solder paste composition <NUM> may occur.

<FIG> are enlarged photographs of a solder paste according to a bismuth (Bi) content of a solder paste, according to some example embodiments. <FIG> show images for each Bi content of a solder paste composition including a SAC core and a Bi shell. <FIG> shows a case of Bi <NUM> wt%, and <FIG> shows a case of Bi <NUM> wt%. When the Bi content increases, a shell surface tends to change to a dark color. For example, when the Bi content increases from about <NUM> % to about <NUM> %, the surface of the solder paste composition may become rough. When the surface of the solder paste composition becomes rough, uniformity of a plating thickness of a shell decreases, and bonding strength with a core may decrease. For example, the Bi content may range from about <NUM> % to about <NUM> %.

<FIG>, <FIG> are photographs according to PH during plating of a solder paste composition included in a solder paste, according to some example embodiments. The solder paste composition may be produced by plating. When plating the shell on the core, the shell may be coated on the core while adjusting the pH of a plating solution. <FIG> shows a cross-sectional image of a solder paste composition when the PH is <NUM>, <FIG> shows a cross-sectional image of a solder paste composition when the PH is <NUM>, <FIG> shows a cross-sectional image of a solder paste composition when the PH is <NUM>, and <FIG> shows a cross-sectional image of a solder paste composition when the PH is <NUM>. For example, when the PH is greater than <NUM>, the Bi shell tends to separate. For example, when plating the shell of the solder paste composition, the shell may be plated with a plating solution having a PH in the range of about <NUM> to about <NUM>.

<FIG> shows a cross-sectional image of a solder paste composition for each plating time of a shell.

When the solder paste composition is produced by a plating method, the thickness of the shell increases as the plating time increases. For example, the thickness of the shell may be about <NUM> when plating <NUM> minute (min), the thickness of the shell may be about <NUM> when plating <NUM> minutes, and the thickness of the shell may be about <NUM> to about <NUM> when plating <NUM> minutes. As the thickness of the shell increases, the adhesion to a core may decrease. For example, when the plating time is increased up to <NUM> minutes, damage to the solder paste composition is observed. Plating process factors largely include temperature, time, PH, and rotation speed (rpm). The solder paste composition may be plated by appropriately controlling the plating time, the temperature, and the PH.

<FIG> shows ball shear test (BST) strength according to the amount of solder paste composition as a proportion in wt% of the total solder paste. The BST strength may represent shear stress strength. When the content of the solder paste composition to the total solder paste is <NUM> wt% and <NUM> wt%, for example, each exhibits BST strength greater than <NUM> gf. While a Sn58Bi solder exhibits BST strength of about <NUM> gf under the same experimental conditions, in some example embodiments, it may have BST strength of <NUM> gf or more. For example, the solder paste composition may have a content of <NUM> wt% or less. Thereby, the BST strength may be increased. However, the content of the solder paste compositions is not limited thereto.

Referring to <FIG>, the solder paste composition may have a content of greater than about <NUM> wt% and less than about <NUM> wt%. For example, the solder paste composition includes a SAC core and a Bi shell, and may have a content of about <NUM> wt% to about <NUM> wt%. When the content of the solder paste composition is <NUM> wt%, the shear stress strength increases, and when the content of the solder paste composition is <NUM> wt%, the shear stress strength decreases. In <FIG>, the dashed line shows a comparative example in which a solder paste includes Sn57Bi1Ag, and in the case of a solder paste including a solder paste composition (e.g., having a SAC/Bi core shell structure) having a content of greater than about <NUM> wt% and less than about <NUM> wt%, the shear stress strength is higher than that of the comparative example.

<FIG> shows images of a cross section of a solder paste and a fracture surface of solder paste bonding when the content of a solder paste composition is about <NUM> wt% and about <NUM> wt%. A fracture location is observed through the analysis of solder fracture section. Solder fracture generally occurs near the boundary between a solder ball and a low temperature solder paste. When the solder paste composition has a content of <NUM> wt%, ductile fracture occurs in a solder ball area.

<FIG> shows a microstructure of a bonding cross-section of a solder paste including a solder paste composition formed of SAC/Bi, and <FIG> shows a result of analyzing components of the solder paste composition.

<FIG> shows a result of evaluating the deformation of a joint of a hybrid bonding structure. <FIG> shows joint shift test (JST) strain according to the number (e.g., quantity) of thermal cycles (T/C). A glass chip for evaluation is prepared and the deformation of a joint during T/C evaluation is observed.

A comparative example shows a case where a solder paste includes Sn57.6Bi0.4Ag. In addition, a solder paste according to some example embodiments includes a solder paste composition having a SAC/Bi core shell structure, and some example embodiments show a result of evaluating the deformation of a joint when about <NUM> wt% of the solder paste composition is included. Compared to the comparative example, in the case of including the solder paste composition according to some example embodiments, the strain is relatively small.

The following shows the number (e.g., quantity) of joints with deformation according to the number (e.g., quantity) of thermal cycles.

A hybrid bonding structure according to some example embodiments may be bonded at a low temperature and may reduce a defect rate of a joint caused by thermal deformation. In addition, compared to a Sn58Bi-based solder paste of the comparative example, mechanical properties, for example, toughness may be improved. When the Sn58Bi-based solder paste is applied to the hybrid bonding structure, a joint failure occurs in less than about <NUM> cycles when evaluating thermal shock. The joint failure includes, for example, a ball shift, a crack, and the like, and the joint failure may lead to a final overall package failure. Therefore, it is necessary to secure toughness equal to or greater than that of the existing SAC305 solder while lowering a melting point of a solder.

Since the solder paste of the hybrid bonding structure according to the invention includes a solder paste composition having a core-shell structure, a defect rate due to poor application and wettability of the solder paste may be reduced.

<FIG>, <FIG>, and <FIG> are views illustrating a method of manufacturing a semiconductor device, according to some example embodiments. <FIG> is a flowchart illustrating a method of manufacturing a semiconductor device, according to some example embodiments.

Referring to <FIG>, at S2410 a semiconductor chip <NUM> is formed. The semiconductor chip <NUM> may be formed via various operations, including, without limitation, deposition of materials on a substrate or other devices, for example via physical vapor deposition (PVD), chemical vapor deposition (CVD), electrochemical deposition (ECD), molecular beam epitaxy (MBE), atomic layer deposition (ALD), or the like. The semiconductor chip <NUM> may be formed via various operations, including etching, patterning, or the like of one or more layers of deposited material. The semiconductor chip <NUM> may be formed via various operations, including front-end-of-line (FEOL) processing, back-end-of-line (BEOL) processing.

Referring to <FIG> and <FIG>, at S2420 a metal pad <NUM> may be formed on a semiconductor chip <NUM>. In some example embodiments, the formation of the metal pad <NUM> on the semiconductor chip at S2420 may be considered to be part of the formation of the semiconductor chip <NUM> at S2410. Still referring to <FIG> and <FIG>, at S2430 solder balls <NUM> may be arranged on (e.g., indirectly on or directly on) the metal pad <NUM>. The solder balls <NUM> may be arranged on the metal pad <NUM> such that the solder balls <NUM> are spaced apart from each other as shown in <FIG>. The semiconductor chip <NUM> may include, for example, a memory chip or an LED chip. The semiconductor chip <NUM> may include, for example, dynamic random access memory (DRAM) or phase-change RAM (PRAM). Reference numeral <NUM> denotes a protective film.

Referring to <FIG> and <FIG>, at S2440 a solder ball <NUM> may be attached to the metal pad <NUM>. The solder ball <NUM> includes at least one alloy selected from the group consisting of a Sn-Ag-Cu alloy, a Sn-Bi alloy, a Sn-Bi-Ag alloy, and a Sn-Ag-Cu-Ni alloy. In some example embodiments, the attaching of the solder ball <NUM> to the metal pad <NUM> at S2440 may be considered to be part of the arranging of the solder balls <NUM> on the semiconductor chip <NUM> at S2430.

Referring to <FIG> and <FIG>, at S2450 a solder paste <NUM> is applied to a circuit board <NUM>, for example by using a mask <NUM>. As a method of applying the solder paste <NUM>, for example, a stencil printing method may be used. The circuit board <NUM> may include an electrode <NUM> along with a wire or a thin-film transistor (TFT) required to supply power. The electrode <NUM> may be a part of a metal wire formed on the circuit board <NUM> or a metal pad connected to the wire. Because the solder paste <NUM> is substantially the same as that described with reference to <FIG> (e.g., the solder paste <NUM> may include a flux and a solder paste composition, the solder paste composition including a core and a shell as described herein with regard to any of the example embodiments), a detailed description thereof will not be given herein.

Referring to <FIG> and <FIG>, at S2460 the solder ball <NUM> of <FIG> is positioned to face the solder paste <NUM> and at S2470 may be brought into contact with the solder paste <NUM>. In some example embodiments, the bringing the solder ball <NUM> into contact with the solder paste <NUM> at S2470 may be considered to be part of the positioning of the solder ball <NUM> to face the solder paste <NUM> at S2460.

Further, referring to <FIG> and <FIG>, the solder paste <NUM> may be melted through a reflow process at S2480 to bond the solder ball <NUM> and the electrode <NUM> to thereby form the hybrid bonding structure <NUM> that bonds the semiconductor chip <NUM> to the circuit board <NUM> at S2490, thereby forming a semiconductor device according to some example embodiments. A melting point of a shell of a solder paste composition of the solder paste <NUM> may be in a temperature range of, for example, about <NUM> to about <NUM>. For example, the melting point of the shell of the solder paste composition of the solder paste <NUM> may be in a temperature range of about <NUM> to about <NUM>. In a reflow process, an intermetallic compound may be formed between the shell and a core of the solder paste composition of the solder paste <NUM>. The core and the shell form an intermetallic compound in a temperature range of <NUM> to <NUM>. For example, the melting at S2480 may include melting the shell at <NUM> to <NUM> to form an intermetallic compound between the shell and the core.

A hybrid bonding structure may be cured during a cooling period in the reflow process.

According to a method of manufacturing a semiconductor device according to some example embodiments, a melting temperature may be lowered and mechanical properties of a solder joint may be improved by using a solder paste including a solder paste composition having a core-shell structure.

The semiconductor device according to some example embodiments may include an active device or a passive device. The semiconductor device may be highly integrated on one substrate. At this time, a low-temperature bonding material is required to reduce defects and performance degradation due to thermal damage of the semiconductor device. Such a low-temperature bonding material may be applied to semiconductor devices according to some example embodiments. For example, the semiconductor device may include a memory semiconductor package or a module used in a data server, a mobile, or Laptop computer.

In some example embodiments, the semiconductor devices according to some example embodiments may be applied to a display device, including a flexible display, a wearable display, a foldable display, a stretchable display, and the like.

<FIG> is a schematic diagram of an electronic device according to some example embodiments.

Referring to <FIG>, the electronic device <NUM> may include a processor <NUM>, a memory <NUM>, and a display device <NUM> which are electrically connected to each other through a bus <NUM>. The processor <NUM>, the memory <NUM>, and/or the display device <NUM> may include any one of the semiconductor devices according to any of the example embodiments herein. In some example embodiments the display device <NUM> may be a flexible display, a wearable display, a foldable display, a stretchable display, and the like according to any of the example embodiments. The memory <NUM>, which is a non-transitory computer-readable medium, may store an instruction program. The processor <NUM> may execute a stored instruction program to perform one or more functions. The processor <NUM> may generate output (e.g., an image to be displayed on the display device <NUM>) based on such processing.

The memory <NUM> may be a non-transitory computer readable medium and may store a program of instructions. The memory <NUM> may be a nonvolatile memory, such as a flash memory, a phase-change random access memory (PRAM), a magneto-resistive RAM (MRAM), a resistive RAM (ReRAM), or a ferro-electric RAM (FRAM), or a volatile memory, such as a static RAM (SRAM), a dynamic RAM (DRAM), or a synchronous DRAM (SDRAM). The processor <NUM> may execute the stored program of instructions to perform one or more functions. The processor <NUM> may include processing circuitry such as hardware including logic circuits; a hardware/software combination such as a processor executing software; or a combination thereof. For example, the processing circuitry more specifically may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, application-specific integrated circuit (ASIC), etc. The processor <NUM> may be configured to generate an output (e.g., an electrical signal) based on such processing.

Referring to <FIG> and <FIG>, at S2499 an electronic device <NUM> that includes the semiconductor device formed at S2490 may manufactured. For example, the semiconductor device may be incorporated (e.g., applied) into one or more elements of the electronic device <NUM> to complete manufacturing of the electronic device <NUM>. Said one or more elements may include, for example, a display device <NUM>, a memory <NUM>, or a processor <NUM>. Said incorporation may include, as part of the manufacturing of the electronic device <NUM>, adhesion of the semiconductor device to one or more other components of the one or more elements via an adhesive, soldering of electrical connections between the semiconductor device and one or more other components of the one or more elements, or the like, in order to at least partially complete assembly of said one or more elements and/or assembly of said electronic device <NUM>.

Provided are hybrid bonding structures capable of bonding at a low temperature. By bonding a circuit board and a semiconductor chip at a low temperature by using a solder paste including a solder paste composition, it is possible to reduce the deformation of a semiconductor package due to a high temperature. In addition, the hybrid bonding structure according to some example embodiments may reduce package defects of a semiconductor device by improving brittleness.

Claim 1:
A hybrid bonding structure, comprising:
a solder ball; and
a solder paste bonded to the solder ball,
wherein the solder paste includes a solder paste composition,
wherein the solder paste composition includes a core and a shell on a surface of the core,
wherein a melting point of the shell is lower than a melting point of the core,
wherein the core and the shell are configured to form an intermetallic compound in response to the solder paste composition at least partially being at a temperature that is within a temperature range of <NUM> to <NUM>,
wherein the core includes at least one alloy of a Sn-Ag-Cu alloy, a Sn-Bi alloy, a Sn-Bi-Ag alloy, and a Sn-Ag-Cu-Ni alloy,
wherein the shell includes at least one of bismuth (Bi), indium (In), gallium (Ga), and silver (Ag), and
wherein the solder ball includes at least one alloy of a Sn-Ag-Cu alloy, a Sn-Bi alloy, a Sn-Bi-Ag alloy, and a Sn-Ag-Cu-Ni alloy.