Method for producing structure, and structure

Abstract

This method for producing a structure wherein base materials are bonded by atomic diffusion comprises: a step for applying a liquid resin on the base material; a step for smoothing the surface of the liquid resin by surface tension; a step for forming a resin layer by curing; a step for forming a metal thin film on the resin layer; a step for forming a metal thin film on the base material; and a step for bringing the metal thin film of the base material and the metal thin film of the base material into close contact with each other, thereby bonding the metal thin film of the resin layer and the metal thin film of the base material with each other by atomic diffusion.

Claims

1. A manufacturing method of a structure in which a plurality of elements are bonded, the manufacturing method comprising: applying a liquid resin to a surface of at least one of the plurality of elements; smoothing a surface of the liquid resin by surface tension of the applied liquid resin; forming a resin layer by curing the liquid resin, wherein a surface of the resin layer is smoothed; forming a metal thin film on the smoothed surface of the resin layer, wherein the resin layer is sandwiched between the metal thin film and at least one of the plurality of elements; forming another metal thin film on a surface of another element; and superposing the metal thin film of the at least one element and the metal thin film of the other element, and tightly attaching and bonding the metal thin film of the at least one element and the metal thin film of the other element by deformation of the resin layer.

2. The manufacturing method of the structure according to claim 1, wherein the resin layer has elasticity.

3. The manufacturing method of the structure according to claim 2, wherein the plurality of elements are semiconductors.

4. The manufacturing method of the structure according to claim 3, wherein at least one of the semiconductors comprises a plurality of electrodes protruding from a surface of the at least one semiconductor for a predetermined length; and the liquid resin is applied between the plurality of electrodes, and the surface of the liquid resin is smoothed by surface tension of the liquid resin such that distal end surfaces of the plurality of electrodes and the surface of the liquid resin are in the same plane.

5. The manufacturing method of the structure according to claim 3, wherein the plurality of elements are semiconductor chips that form semiconductors, the liquid resin is applied to a front surface and/or a back surface of each of the semiconductor chips, and the applied liquid resin is smoothed to have a surface roughness lower than that of the other element.

6. The manufacturing method of the structure according to claim 1, wherein the plurality of elements are semiconductors.

7. The manufacturing method of the structure according to claim 6, wherein at least one of the semiconductors comprises a plurality of electrodes protruding from a surface of the at least one semiconductor for a predetermined length; and the liquid resin is applied between the plurality of electrodes, and the surface of the liquid resin is smoothed by surface tension of the liquid resin such that distal end surfaces of the plurality of electrodes and the surface of the liquid resin are in the same plane.

8. The manufacturing method of the structure according to claim 6, wherein the plurality of elements are semiconductor chips that form semiconductors, the liquid resin is applied to a front surface and/or a back surface of each of the semiconductor chips, and the applied liquid resin is smoothed to have a surface roughness lower than that of the other element.

9. The manufacturing method of the structure according to claim 1, wherein the metal thin film of the at least one element is bonded to the metal thin film of the other element using atomic diffusion.

10. A manufacturing method of a structure in which a plurality of elements are bonded, the manufacturing method comprising: applying a liquid resin to surfaces of the plurality of elements; smoothing surfaces of the liquid resin using surface tension of the applied liquid resin; foaming resin layers by curing the liquid resin, wherein a surface of each of the resin layers is smoothed; forming a metal thin film on the smoothed surface of each of the resin layers, wherein each of the resin layers is sandwiched between the metal thin film and each of the plurality of elements; and superposing the metal thin films of the plurality of elements to one another, and tightly attaching and bonding the metal thin films to each other by deformation of the resin layer.

11. The manufacturing method of the structure according to claim 10, wherein the resin layers have elasticity.

12. The manufacturing method of the structure according to claim 11, wherein the plurality of elements are semiconductors.

13. The manufacturing method of the structure according to claim 12, wherein at least one of the semiconductors comprises a plurality of electrodes protruding from a surface of the at least one semiconductor for a predetermined length; and the liquid resin is applied between the plurality of electrodes, and the surface of the liquid resin is smoothed by surface tension of the liquid resin such that distal end surfaces of the plurality of electrodes and the surface of the liquid resin are in the same plane.

14. The manufacturing method of the structure according to claim 12, wherein the plurality of elements are semiconductor chips that form semiconductors, the liquid resin is applied to a front surface and/or a back surface of each of the semiconductor chips, and the applied liquid resin is smoothed to have a surface roughness lower than that of the plurality of elements.

15. The manufacturing method of the structure according to claim 10, wherein the plurality of elements are semiconductors.

16. The manufacturing method of the structure according to claim 15, wherein at least one of the semiconductors comprises a plurality of electrodes protruding from a surface of the at least one semiconductor for a predetermined length; and the liquid resin is applied between the plurality of electrodes, and the surface of the liquid resin is smoothed by surface tension of the liquid resin such that distal end surfaces of the plurality of electrodes and the surface of the liquid resin are in the same plane.

17. The manufacturing method of the structure according to claim 15, wherein the plurality of elements are semiconductor chips that form semiconductors, the liquid resin is applied to a front surface and/or a back surface of each of the semiconductor chips, and the applied liquid resin is smoothed to have a surface roughness lower than that of the plurality of elements.

18. The manufacturing method of the structure according to claim 10, wherein the metal thin film of at least one of the plurality of elements is bonded to the metal thin film of another element using atomic diffusion.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic configuration diagram of a structure according to a first embodiment;

(2) FIG. 2 is a manufacturing process diagram of the structure according to the first embodiment;

(3) FIG. 3A is a schematic diagram showing a conventional structure with a rough substrate surface;

(4) FIG. 3B is a schematic diagram of the structure according to the first embodiment with a rough substrate surface;

(5) FIG. 4 is a schematic diagram of a structure according to a second embodiment;

(6) FIG. 5 is a manufacturing process diagram of the structure according to the second embodiment;

(7) FIG. 6A is a schematic diagram showing a conventional structure when a contaminant has entered between metal thin films;

(8) FIG. 6B is a schematic diagram of the structure according to the second embodiment when a contaminant has entered between the metal thin films;

(9) FIG. 7 is a schematic configuration diagram of a variation of the structure according to the second embodiment; and

(10) FIG. 8 is a schematic configuration diagram of a structure according to a third embodiment.

DESCRIPTION OF EMBODIMENTS

(11) Initially, a first embodiment will be described by reference to FIGS. 1 to 3B. As shown in FIG. 1, a structure 1 according to the first embodiment is formed by bonding a pair of elements, base components 10, 20, using an atomic diffusion bonding method. It should be noted that although the structure 1 including a single pair of base components 10, 20 is described below, the number of the pair of base components 10, 20 may also be two or more.

(12) The structure 1 includes the base component 10 on one side, a resin layer 11 disposed on a faying surface of the base component 10; a metal thin film 12 disposed on a surface of the resin layer 11; the base component 20 on the other side; and a metal thin film 21 disposed on a faying surface of the base component 20. The base component 20 is an element to which the base component 10 is bonded.

(13) The faying surface of the base component 10 is a rough surface. As a material for the base components 10, 20, besides various metals and alloys, a semiconductor substrate such as a silicon (Si) substrate, glass, ceramics, and resin can be used. The bonding between base components 10, 20 are not limited to bonding between the same materials such as between metal material components. The bonding may be between different materials, for example, between a metal component and a ceramic component, or between an integrated circuit (IC) chip and an Si substrate. The shapes of the base components 10, 20 are not limited. The base components 10, 20 may have planer shapes or complicated three-dimensional shapes. The base component 10 may be, for example, a semiconductor chip that forms a semiconductor. The base component 20 may be an Si substrate (silicon substrate) or a semiconductor chip, each of which forms a semiconductor.

(14) The resin layer 11 is formed to have a predetermined thickness on the faying surface of the base component 10. The resin layer 11 is formed by spin coating a liquid resin on the faying surface of the base component 10 and curing the liquid resin. The resin layer 11 needs to be selected from resins having characteristics of good bonding compatibility with the metal thin film 12. For example, a resin, such as a silicone resin, a fluorine resin, a polyimide resin, an acrylic resin, or an epoxy resin may be used.

(15) The metal thin film 12 having a film thickness of several nm to several hundred nm is formed on the surface of the resin layer 11 by a sputtering film forming method. The metal thin film 21 having a film thickness of several nm to 10 nm is formed on the surface of the base component 20 by a similar film forming method. Besides the sputtering, a film forming method, such as physical vapor deposition (PVD), chemical vapor deposition (CVD), or vacuum deposition, may be used. As a material for the metal thin films 12, 21, metal, such as gold (Au) and silver (Ag), may be used.

(16) Next, a manufacturing method of the structure 1 will be described by reference to FIG. 2. First, in step S1 in FIG. 2, the base component 10 is prepared. The faying surface of the base component 10 is rough. Although a polishing process to smooth the rough surface is required when the faying surface is rough, as in this case, no polishing process is performed in the first embodiment and the surface in a rough state is used.

(17) In step S2, a liquid resin 11a is applied on the rough surface of the base component 10. The applied liquid resin 11a fills the rough surface and the surface of the liquid resin 11a is smoothed by surface tension of the liquid resin 11a. Specifically, immediately after the application, the surface tension acts on the liquid resin 11a to smooth the surface of the liquid resin 11a. After it is confirmed that the surface of the liquid resin 11a is smoothed, the base component 10 and the liquid resin 11a are heated and the liquid resin 11a is cured to form the resin layer 11.

(18) In step S3, the base component 10 with the resin layer 11 formed thereon is disposed inside a vacuum enclosure. The metal thin film 12 is formed by sputtering on the surface of the resin layer 11.

(19) Meanwhile, in step S4, the base component 20 is prepared. In step S5, the base component 20 is disposed inside a vacuum enclosure. The metal thin film 21 is formed by sputtering on the surface of the base component 20. Because no smoothing of the surface is required for the surface of the base component 20 that is not a rough surface like that of the base component 10, a liquid resin application, like the one for the base component 10, is not performed.

(20) In step S6, the base components 10, 20 are respectively taken out of the vacuum enclosures. The base component 10 is turned over to direct the surface with the metal thin film 12 downwards, and the metal thin film 12 is superposed on the metal thin film 21 of the base component 20. In such a superposed state, a load is applied to the base component 10 so that the metal thin film 12 of the base component 10 and the metal thin film 21 of the base component 20 are tightly attached together. This tight attachment bonds the metal thin films 12, 21 together by atomic diffusion. The metal thin films 12, 21 are tightly bonded by the atomic diffusion bonding in which the metal thin films 12, 21 are in metal bonding or are intermolecularly bonded at an atomic level. The structure 1 is formed by the tight bonding of the metal thin films 12, 21.

(21) In comparing a surface Ra (the arithmetic average of the roughness) of the base component 10 with a surface Ra of the resin layer 11, the surface Ra of the resin layer 11 is lower than the surface Ra of the base component 10. In other words, because the surface of the resin layer 11 is smoothed, the surface Ra is low, whereas because the surface is rough, the surface Ra of the base component 10 is high. This results in a relationship of the surface Ra of the resin layer 11<the surface Ra of the base component 10. Smoothing of the resin layer 11 makes the surface Ra of the resin layer 11 lower than the surface Ra of the base component 20 that has a smooth surface and does not require the smoothing of the surface.

(22) With reference to FIGS. 3A, 3B, advantages of the structure 1 will be described. FIGS. 3A, 3B are schematic diagrams in which base components with a rough faying surface are bonded using the atomic diffusion. FIG. 3A shows a conventional structure 100, whereas FIG. 3B shows the structure 1 according to the first embodiment.

(23) With reference to FIG. 3A, the configuration of the conventional structure 100 will be briefly described. The structure 100 includes a base component 110 that has a rough faying surface; a metal thin film 111 formed on the rough faying surface of the base component 110; a base component 120, and a metal thin film 121 formed on a surface of the base component 120. The structure 100 is formed by superposing and bonding the metal thin films 111, 121 using atomic diffusion.

(24) In the structure 100, because of the low smoothness of the rough surface of the base component 110, the surface of the metal thin film 111 formed on this rough surface also has a low smoothness. Accordingly, it becomes difficult to tightly attach and bond the metal thin films 111, 121 using atomic diffusion. This may cause a bonding failure.

(25) In contrast, as shown in FIG. 3B, because the structure 1 has the resin layer 11 that fills the rough surface of the base component 10 and the surface of the resin layer 11 is a smooth surface, the surface of the metal thin film 12 is also smooth. Thus, the metal thin films 12, 21 can be tightly attached and bonded together using atomic diffusing.

(26) As described above, because no polishing process is required to smooth the rough surface of the base component 10, cost can be reduced by omitting polishing procedures. Further, because the atomic diffusion bonding is possible even with a rough surface of the base component 10, the applicable range of the bondable materials by atomic diffusion can be extended.

(27) When the surface of the base component 20 on which the metal thin film 21 is to be formed is rough, the resin layer 11 may be formed between the base component 20 and the metal thin film 21. In this case, in FIG. 2, a step similar to step S2 is performed between steps S4 and S5.

(28) Next, a second embodiment will be described by reference to FIGS. 4 to 6B. In the second embodiment, a faying surface of a base component 30 of a structure 2 is smooth. A resin layer 31 has characteristics that differ from those of the resin layer 11. Other configurations are identical to those of the structure 1 in the first embodiment. In FIG. 4, elements that are similar to those in FIG. 1 are assigned the same reference numerals and their descriptions are omitted.

(29) The resin layer 31 of a predetermined thickness is formed on the faying surface (smooth surface) of the base component 30. The resin layer 31 is formed by spin coating a liquid resin on the faying surface of the base component 30 and curing the liquid resin. The resin layer 31 needs to be selected from resins having characteristics of good bonding compatibility with the metal thin film 12 and elasticity after curing. As an example of such a resin, a silicone resin, a fluorine resin, a polyimide resin, acrylic resin, and an epoxy resin may be used.

(30) With reference to FIG. 5, manufacturing of the structure 2 will be described. In step S11 in FIG. 5, the base component 30 is prepared.

(31) In step S12, a liquid resin 31a is applied on a faying surface of the base component 30. As the material for the liquid resin 31a, a resin material having elasticity after curing is used. The surface of the applied liquid resin 31a becomes smooth because of surface tension of the liquid resin 31a. After the surface of the liquid resin 31a has been smoothed, the base component 30 and the liquid resin 31a are heated, and the liquid resin 31a is cured to form the resin layer 31. The resin layer 31 has elasticity after curing.

(32) In step S13, the base component 30 with the resin layer 31 formed thereon is disposed inside a vacuum enclosure. The metal thin film 12 is formed by sputtering on the surface of the resin layer 31.

(33) In steps S14, S15, the metal thin film 21 is formed on the base component 20, similarly to as in steps S4, S5. Subsequently, in S16, the base component 30 is turned over to direct the surface with the metal thin film 12 downwards, and the metal thin film 12 is superposed on the metal thin film 21 of the base component 20. In such a superposed state, a load is applied to the base component 30 so that the metal thin film 12 of the base component 30 and the metal thin film 21 of the base component 20 are tightly attached together. This tight attachment bonds the metal thin films 12, 21 together by atomic diffusion. The metal thin films 12, 21 are tightly bonded by the atomic diffusion in which the metal thin films 12, 21 are in metal bonding, or are bonded at an atomic or intermolecular level. The structure 2 is formed by the tight bonding of the metal thin films 12, 21.

(34) Advantages of the structure 2 will be described with reference to FIGS. 6A, 6B. FIGS. 6A, 6B are schematic diagrams which are used to describe cases where a contaminant D has entered between the metal thin films. FIG. 6A shows a conventional structure 200, while FIG. 6B shows the structure 2 according to the second embodiment.

(35) In FIG. 6A, the conventional structure 200 includes a base component 210, a metal thin film 211 formed on a surface of the base component 210, a base component 220, and a metal thin film 221 formed on a surface of the base component 220. The structure 200 is formed by superposing and bonding the metal thin films 211, 221 using atomic diffusion.

(36) In the structure 200, when the contaminant D has entered between the metal thin films 211, 221 while superposing the metal thin films 211, 221, it becomes difficult to tightly superpose and attach the metal thin films 211, 221 because of the contaminant D acting as an obstacle. It therefore becomes difficult to bond the metal thin films 211, 221 using atomic diffusion. This may cause a bonding failure.

(37) In contrast, as shown in FIG. 6B, in the structure 2 according to the second embodiment, the resin layer 31 elastically deforms in accordance with the shape of the contaminant D when the metal thin films 12, 21 are superposed together with the contaminant D having entered there between. With the contaminant D being enclosed, the metal thin films 12, 21 are tightly attached together. Specifically, the metal thin films 12, 21 are tightly attached together except for the area with the contaminant D.

(38) The structure 2 can be obtained even when the contaminant D has entered, because the area excluding the contaminant D has a sufficient overlapping area to enable bonding of the metal thin films 12, 21 using the atomic diffusion.

(39) Further, even when the surfaces of the metal thin films 12, 21 have a low smoothness, the metal thin films 12, 21 can be bonded using the atomic diffusion because the resin layer 31 can elastically deform to enable tight attachment of the metal thin films 12, 21.

(40) Next, variations of the second embodiment will described by reference to FIG. 7. As shown in FIG. 7, in a structure 3 that shows a variation of the second embodiment, a resin layer 22 is formed on the other base component 20. Specifically, the resin layer 22 is formed on a faying surface of the base component 20. As a material for the resin layer 22, a material that has elasticity after curing is used, similarly as for the resin layer 31.

(41) As described above, by forming the resin layers 31, 22 on both of the base components 30, 20, the resin layers 31, 22 elastically deform in accordance with the shape of the contaminant D when the contaminant D has entered between the metal thin films 12, 21. Similarly to the second embodiment, the metal thin films 12, 21 can be bonded using the atomic diffusion because the metal thin films 12, 21 are tightly attached together even with the contaminant D sandwiched therebetween.

(42) Further, because the elastically deformable amount is increased by the resin layers 31, 22, it becomes possible to accommodate a larger contaminant D and improve correspondence between the surfaces of the metal thin films 12, 21, enhancing the tight attachment between the metal thin films 12, 21.

(43) Next, a third embodiment will be described with reference to FIG. 8. In the third embodiment, the structure is a semiconductor assembly 4. As shown in FIG. 8, the semiconductor assembly 4 includes a base component 40, a chip component 50, a resin layer 52 which is provided between electrodes 51 of the chip component 50, and metal thin films 42, 53 that bond the base component 40 and the chip component 50 together. The chip component 50 is, for example, a semiconductor chip that forms a semiconductor.

(44) The base component 40 is a silicone (Si) substrate. Multiple electrodes 41 are embedded in the base component 40. Multiple electrodes 51 are disposed on the lower surface of the chip component 50 and protrude from the lower surface for a predetermined length. The multiple electrodes 51 are arranged to correspond to the respective electrodes 41 disposed on the base component 40.

(45) A liquid resin similar to the liquid resin 11a in the first embodiment is applied between the electrodes 51 such that the distal surfaces of the electrodes 51 and the surface of the liquid resin are in the same plane. By applying the liquid resin between the electrodes 51 of the chip component 50, the surface of the liquid resin becomes smooth as a result of surface tension of the liquid resin. This smooth surface is in the same plane as the distal surfaces of the electrodes 51. The resin layer 52 is formed by curing the liquid resin in this state.

(46) The metal thin film 53 similar to the metal thin film 12 in the first embodiment is formed on the distal surfaces of the electrodes 51 of the chip component 50 and the surface of the resin layer 52. Similarly, a metal thin film 42 similar to the metal thin film 12 in the first embodiment is fonned on the surface of the substrate base component 40. The chip component 50 and the substrate base component 40 are bonded and the semiconductor assembly 4 is fonned by placing the electrodes 51 of the chip component 50 and the electrodes 41 of the substrate base component 40 to oppose each other, and bonding the metal thin films 42, 53 using the atomic diffusion.

(47) As described above, the area where the metal thin film 53 is formed is enlarged by forming the resin layer 52 between the electrodes 51 of the chip component 50 so that the chip component 50 and the base component 40 can be more tightly bonded using the atomic diffusion.

(48) Although two base components are bonded using the atomic diffusion in the above respective embodiments, the present disclosure is not limited to these embodiments. For example, a structure may be formed by stacking multiple semiconductor chips (intermediate chip components, and outermost chip components sandwiching the intermediate chip components), and bonding the chip components using atomic diffusion. Each intermediate chip component may be formed by applying a liquid resin to both the front and back surfaces of a semiconductor chip, curing the liquid resin to form resin layers on both surfaces, and forming metal thin films on the resin layers. Each of the outermost chip components may be formed by applying a liquid resin to a front or back surface of a semiconductor chip and curing the liquid resin to form a resin layer on one of the surfaces, and forming a metal thin layer thereon.