Semiconductor apparatus, stacked semiconductor apparatus, encapsulated stacked-semiconductor apparatus, and method for manufacturing the same

Abstract

A semiconductor apparatus includes a semiconductor device, on-semiconductor-device metal pad and metal interconnect each electrically connected to the semiconductor device, a through electrode and a solder bump each electrically connected to the metal interconnect, a first insulating layer on which the semiconductor device is placed, a second insulating layer formed on the semiconductor device, a third insulating layer formed on the second layer. The metal interconnect is electrically connected to the semiconductor device via the on-semiconductor-device metal pad at an upper surface of the second layer, penetrates the second layer from its upper surface, and is electrically connected to the through electrode at an lower surface of the second layer, and an under-semiconductor-device metal interconnect is between the first layer and the semiconductor device, and the under-semiconductor-device metal interconnect is electrically connected to the metal interconnect at the lower surface of the second layer.

Claims

1. A method for manufacturing a semiconductor apparatus, comprising the steps of: (1) applying a temporary adhesive to a supporting substrate and forming a first insulating layer having a thickness of 1 to 20 m on the temporary adhesive, wherein the first insulating layer consists of a photo-curable resin layer composed of a resist composition; (2) patterning the first insulating layer by lithography via a mask to form a hole pattern for forming a through electrode, and then baking the first insulating layer to cure the first insulating layer; (3) forming a seed layer on the first insulting layer by sputtering, then filling the hole pattern for forming the through electrode by plating to form a metal interconnect to be connected to the through electrode, and simultaneously forming an under-semiconductor-device metal interconnect; (4) die bonding a semiconductor device having a height of 20 to 100 m to the cured first insulating layer, on which the under-semiconductor-device metal interconnect is formed, with a die bonding agent, wherein an exposed electrode pad is provided on an upper surface of the semiconductor device; (5) preparing photo-curable dry films comprising a photo-curable resin layer sandwiched between a supporting film and a protective film, wherein the photo-curable resin layer has a thickness of 5 to 100 m and is composed of a resist composition; (6) forming a second insulating layer by laminating the photo-curable resin layer of one of the photo-curable dry film such that the semiconductor device die-bonded on the first insulating layer is covered with the photo-curable resin layer; (7) patterning the second insulating layer by lithography via a mask to simultaneously form an opening on the electrode pad, an opening for forming a metal interconnect that penetrates the second insulating layer on the metal interconnect to be connected to the through electrode, and an opening for forming the through electrode, and then baking the second insulating layer to cure the second insulating layer; (8) after curing, forming a seed layer by sputtering, then filling the opening on the electrode pad, the opening for forming the metal interconnect that penetrates the second insulating layer, and the opening for forming the through electrode by plating to respectively form an on-semiconductor-device metal pad, the metal interconnect that penetrates the second insulating layer, and the through electrode, and connecting the on-semiconductor-device metal pad and the metal interconnect that penetrates the second insulating layer, which are formed by plating, via a metal interconnect formed by plating; (9) after forming the metal interconnects, forming a third insulating layer by laminating the photo-curable resin layer of the other photo-curable dry film or applying the same resist composition as used in the photo-curable dry film by spin coating; (10) patterning the third insulating layer by lithography via a mask to form an opening on the through electrode, and then baking the third insulating layer to cure the third insulating layer; and (11) after curing, forming a solder bump in the opening on the through electrode.

2. The method for manufacturing a semiconductor apparatus according to claim 1, wherein the resist composition constituting the photo-curable resin layer of the photo-curable dry film prepared in the step (5) is a chemically amplified negative resist composition containing: (A) a silicone skeleton-containing polymer compound having a repeating unit shown by the following general formula (1) and having a weight average molecular weight of 3,000 to 500,000 ##STR00016## wherein R.sup.1 to R.sup.4 may be the same or different and represent a monovalent hydrocarbon group having 1 to 8 carbon atoms; m is an integer of 1 to 100; a, b, c, and d are each 0 or a positive number, and a, b, c, and d are not simultaneously 0, provided that a+b+c+d=1; X represents an organic group shown by the following general formula (2); and Y represents an organic group shown by the following general formula (3); ##STR00017## wherein Z represents a divalent organic group selected from any of ##STR00018## n is 0 or 1; R.sup.5 and R.sup.6 each represent an alkyl group or alkoxy group having 1 to 4 carbon atoms and may be the same or different from each other; and k is 0, 1, or 2; ##STR00019## wherein V represents a divalent organic group selected from any of ##STR00020## p is 0 or 1; R.sup.7 and R.sup.8 each represent an alkyl group or alkoxy group having 1 to 4 carbon atoms and may be the same or different from each other; and h is 0, 1, or 2; (B) one or more crosslinking agents selected from an amino condensate modified with formaldehyde or formaldehyde-alcohol and a phenol compound having on average two or more methylol groups or alkoxymethylol groups per molecule; (C) a photo acid generator capable of generating an acid by decomposition with light having a wavelength of 190 to 500 nm; and (D) a solvent.

3. The method for manufacturing a semiconductor apparatus according to claim 1, wherein the step (6) includes mechanically pressing the second insulating layer.

4. The method for manufacturing a semiconductor apparatus according to claim 2, wherein the step (6) includes mechanically pressing the second insulating layer.

5. The method for manufacturing a semiconductor apparatus according to claim 1, wherein the step (11) includes forming an on-through-electrode metal pad in the opening on the through electrode by plating, and forming a solder ball on the on-through-electrode metal pad for the solder bump.

6. The method for manufacturing a semiconductor apparatus according to claim 2, wherein the step (11) includes forming an on-through-electrode metal pad in the opening on the through electrode by plating, and forming a solder ball on the on-through-electrode metal pad for the solder bump.

7. The method for manufacturing a semiconductor apparatus according to claim 1, wherein plating to form the through electrode in the step (8) includes plating with SnAg, the step (10) includes patterning to form the opening on the through electrode such that the SnAg plating is uncovered, and the step (11) includes melting the SnAg plating and thereby forming a protruding electrode in the opening on the through electrode for the solder bump.

8. The method for manufacturing a semiconductor apparatus according to claim 1, further comprising the steps of: after the step (11), removing the supporting substrate, which has been temporarily bonded to the first insulating layer in the step (1); and after removing the substrate, dicing the semiconductor apparatus into individual pieces.

9. A method for manufacturing a stacked semiconductor apparatus, comprising stacking a plurality of individual semiconductor apparatuses obtained by dicing in the manufacturing method according to claim 8, while putting an insulting resin layer between the individual semiconductor apparatuses such that the individual semiconductor apparatuses are electrically connected through the solder bump.

10. A method for manufacturing an encapsulated stacked-semiconductor apparatus, comprising the steps of: placing a stacked semiconductor apparatus manufactured by the manufacturing method according to claim 9 on a substrate having an electric circuit; and encapsulating the stacked semiconductor apparatus placed on the substrate with an insulating encapsulating resin layer.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic sectional view showing a semiconductor apparatus according to an embodiment of the present invention;

(2) FIG. 2 is a schematic sectional view showing a stacked semiconductor apparatus according to an embodiment of the present invention;

(3) FIG. 3 is a schematic sectional view showing an encapsulated stacked-semiconductor apparatus according to an embodiment of the present invention;

(4) FIG. 4 is a schematic sectional view showing the step (1) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(5) FIG. 5 is a schematic sectional view showing the step (2) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(6) FIG. 6 is a schematic sectional view showing the step (3) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(7) FIG. 7 is a schematic sectional view showing the step (4) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(8) FIG. 8 is a schematic sectional view showing the step (6) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(9) FIG. 9 is a schematic sectional view showing the step (7) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(10) FIG. 10 is a schematic sectional view showing the step (8) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(11) FIG. 11 is a schematic sectional view showing the step (8) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(12) FIG. 12 is a schematic sectional view showing the step (9) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(13) FIG. 13 is a schematic sectional view showing the step (10) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(14) FIG. 14 is a schematic sectional view showing the step (11) in a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(15) FIG. 15 is a schematic sectional view showing the step (8) in a method for manufacturing a semiconductor apparatus according to another embodiment of the present invention;

(16) FIG. 16 is a schematic sectional view showing the step (11) in a method for manufacturing a semiconductor apparatus according to another embodiment of the present invention;

(17) FIG. 17 is a schematic sectional view showing an individual semiconductor apparatus obtained by a method for manufacturing a semiconductor apparatus according to an embodiment of the present invention;

(18) FIG. 18 is a schematic sectional view showing an individual semiconductor apparatus obtained by a method for manufacturing a semiconductor apparatus according to another embodiment of the present invention;

(19) FIG. 19 is a schematic sectional view showing a method for manufacturing a stacked semiconductor apparatus according to an embodiment of the present invention;

(20) FIG. 20 is a schematic sectional view showing a method for manufacturing a stacked semiconductor apparatus according to another embodiment of the present invention;

(21) FIG. 21 is a schematic sectional view showing a stacked semiconductor apparatus placed on a circuit board according to an embodiment of the present invention;

(22) FIG. 22 is a schematic sectional view showing a stacked semiconductor apparatus placed on a circuit board according to another embodiment of the present invention;

(23) FIG. 23 is a schematic sectional view showing a method for manufacturing an encapsulated stacked-semiconductor apparatus according to an embodiment of the present invention;

(24) FIG. 24 is a schematic sectional view showing a method for manufacturing an encapsulated stacked-semiconductor apparatus according to another embodiment of the present invention;

(25) FIG. 25 is an explanatory view showing a conventional method for manufacturing a semiconductor apparatus;

(26) FIG. 26 is an explanatory view showing a conventional method for manufacturing a semiconductor apparatus;

(27) FIG. 27 is an explanatory view showing a conventional method for manufacturing a semiconductor apparatus; and

(28) FIG. 28 is an explanatory view showing a conventional method for manufacturing a semiconductor apparatus.

DESCRIPTION OF EMBODIMENTS

(29) As previously described, requirements are rapidly increasing for further downsizing, thinning, and higher density in a semiconductor apparatus, and it is desired to develop a semiconductor apparatus and a method for manufacturing the same that can be easily placed on a circuit board and stacked. Moreover, as a multilevel interconnect is required in future to cope with an increase of signals in the semiconductor apparatus, it is desired to develop a semiconductor apparatus and a method for manufacturing the same that can reduce warpage of the semiconductor apparatus itself even with dense metal interconnects, such as a multilevel interconnect.

(30) The present inventors have earnestly investigated to achieve the above object and consequently found that a semiconductor apparatus and stacked semiconductor apparatus that solve the problems can be easily manufactured by the following steps, thereby bringing the present invention to completion.

(31) First, a first insulating layer is formed on a supporting substrate to which a temporary adhesive is applied, with a resist composition. The first insulating layer is then patterned to form a hole pattern for forming a through electrode. After curing by baking, the hole pattern for forming the through electrode is filled by plating to form a metal interconnect to be connected to the through electrode, and a metal interconnect that connects the through electrodes (the metal interconnects to be connected to the through electrodes) in the vicinity thereof is simultaneously formed. A semiconductor device is then die bonded to the first insulating layer, on which the metal interconnects are formed. Then, the periphery of the die-bonded semiconductor device is laminated with a photo-curable dry film having a photo-curable resin layer composed of a resist composition, whereby the periphery of the semiconductor device can be filled with the film without voids (a second insulating layer is formed). The second insulating layer is then patterned by lithography via a mask. This patterning enables simultaneous formation of an opening on the electrode pad, an opening for forming a metal interconnect that penetrates the second insulating layer, and an opening for forming the through electrode, thus enabling easy processing. From these findings, the present invention was brought to completion.

(32) After the second insulating layer is cured by baking, the opening on the electrode pad, the opening for forming the metal interconnect that penetrates the second insulating layer, and the opening for forming the through electrode are filled by plating to form an on-semiconductor-device metal pad, the metal interconnect that penetrates the second insulating layer, and the through electrode. The on-semiconductor-device metal pad and the metal interconnect that penetrates the second insulating layer, which are formed by plating, are connected via a metal interconnect formed by plating. Then, a third insulating layer is formed thereon, and the third insulating layer is patterned to form an opening on the through electrode. After curing the third insulating layer, a solder bump is formed in this opening. Furthermore, the supporting substrate bonded with the temporary adhesive may be removed, and the semiconductor apparatus may be diced into individual pieces. This method can manufacture a semiconductor apparatus much rationally and achieve the object of the present invention.

(33) Moreover, the inventors found that the semiconductor apparatus manufactured by the above method, in which metal interconnects are formed on both sides of the second insulating layer such that the semiconductor device is interposed, can reduce warpage of the semiconductor apparatus itself even with dense interconnects.

(34) Furthermore, the semiconductor apparatus obtained by the above manufacturing method has the protruding solder bump on the upper portion and the through electrode, which can be easily uncovered by removing the supporting substrate, on the lower portion. Thus, a plurality of the semiconductor apparatuses can be easily electrically connected and stacked by using the protruding solder bump and the uncovered electrode. This stacked semiconductor apparatus can be easily placed on a circuit board. From these findings, the present invention was brought to completion.

(35) That is, the present invention is a semiconductor apparatus including: a semiconductor device; an on-semiconductor-device metal pad electrically connected to the semiconductor device; a metal interconnect electrically connected to the semiconductor device; a through electrode electrically connected to the metal interconnect; a solder bump electrically connected to the metal interconnect; a first insulating layer on which the semiconductor device is placed; a second insulating layer formed on the semiconductor device; a third insulating layer formed on the second insulating layer, wherein

(36) the metal interconnect is electrically connected to the semiconductor device via the on-semiconductor-device metal pad at an upper surface of the second insulating layer, and the metal interconnect penetrates the second insulating layer from the upper surface of the second insulating layer and is electrically connected to the through electrode at an lower surface of the second insulating layer, and

(37) an under-semiconductor-device metal interconnect is disposed between the first insulating layer and the semiconductor device, and the under-semiconductor-device metal interconnect is electrically connected to the metal interconnect at the lower surface of the second insulating layer.

(38) Hereinafter, the present invention will be described with reference to drawings in detail, but the present invention is not limited thereto.

(39) As shown in FIG. 1, the inventive semiconductor apparatus 1 includes a semiconductor device 2, an on-semiconductor-device metal pad 3 and a metal interconnect 4 each electrically connected to the semiconductor device 2, a through electrode 5 and a solder bump 6 each electrically connected to the metal interconnect 4, a first insulating layer 7 on which the semiconductor device 2 is placed, a second insulating layer 8 formed on the semiconductor device 2, a third insulating layer 9 formed on the second insulating layer 8. The metal interconnect 4 is electrically connected to the semiconductor device 2 via the on-semiconductor-device metal pad 3 at an upper surface of the second insulating layer 8, penetrates the second insulating layer 8 from the upper surface of the second insulating layer 8, and is electrically connected to the through electrode 5 at an lower surface of the second insulating layer 8. An under-semiconductor-device metal interconnect 25 is disposed between the first insulating layer 7 and the semiconductor device 2, and the under-semiconductor-device metal interconnect 25 is electrically connected to the metal interconnect 4 (the lower metal interconnect 4b) at the lower surface of the second insulating layer 8.

(40) The metal interconnect 4 is composed of a metal interconnect (an upper metal interconnect) 4a connected to the on-semiconductor-device metal pad 3 at the upper surface of the second insulating layer 8, a metal interconnect (a lower metal interconnect) 4b connected to the through electrode 5 at the lower surface of the second insulating layer 8, and a metal interconnect (a through metal interconnect) 4c that penetrates the second insulating layer 8 and connects the upper metal interconnect 4a and the lower metal interconnect 4b.

(41) In the semiconductor apparatus 1 of FIG. 1, the semiconductor device 2 is die bonded to the first insulating layer 7 with a die bonding agent 10.

(42) Such a semiconductor apparatus can be easily placed on a circuit board and stacked by forming the fine electrode on the semiconductor device and providing the through electrode outside the semiconductor device. In addition, this semiconductor apparatus, in which the metal interconnect is formed on both surfaces of the second insulating layer such that the semiconductor device is interposed, can reduce its warpage even with dense metal interconnects.

(43) It is preferred that the first insulating layer 7 be formed by a photo-curable dry film or a photo-curable resist coating film, the second insulating layer 8 be formed by the photo-curable dry film, and the third insulating layer 9 be formed by the photo-curable dry film or a photo-curable resist coating film. Such a semiconductor apparatus allows the semiconductor device to be embedded without voids at the periphery even when the semiconductor device 2 has a height of several tens of m.

(44) Additionally, it is preferred that the semiconductor device 2 have a height of 20 to 100 m, the first insulating film 7 have a thickness of 1 to 20 m, the second insulating film 8 have a thickness of 5 to 100 m, the third insulating film 9 have a thickness of 5 to 100 m, and the semiconductor apparatus 1 have a thickness of 50 to 300 m. Such a semiconductor apparatus is thin and allows the semiconductor device to be embedded without voids at the periphery.

(45) The photo-curable dry film to be used for forming the first insulating layer 7, the second insulating layer 8, and the third insulating layer 9 preferably has a photo-curable resin layer composed of a chemically amplified negative resist composition containing the following components (A) to (D), for such a photo-curable dry film prevents warpage, reduces residual stress, and improves reliability and processing properties.

(46) Of course, any other photo-curable resin may be used.

(47) The component (A) is a silicone skeleton-containing polymer compound having a repeating unit shown by the following general formula (1) and having a weight average molecular weight of 3,000 to 500,000

(48) ##STR00011##
wherein R.sup.1 to R.sup.4 may be the same or different and represent a monovalent hydrocarbon group having 1 to 8 carbon atoms; m is an integer of 1 to 100; a, b, c, and d are each 0 or a positive number, and a, b, c, and d are not simultaneously 0, provided that a+b+c+d=1; X represents an organic group shown by the following general formula (2); and Y represents an organic group shown by the following general formula (3);

(49) ##STR00012##
wherein Z represents a divalent organic group selected from any of

(50) ##STR00013##
n is 0 or 1; R.sup.5 and R.sup.6 each represent an alkyl group or alkoxy group having 1 to 4 carbon atoms and may be the same or different from each other; and k is 0, 1, or 2;

(51) ##STR00014##
wherein V represents a divalent organic group selected from any of

(52) ##STR00015##
p is 0 or 1; R.sup.7 and R.sup.8 each represent an alkyl group or alkoxy group having 1 to 4 carbon atoms and may be the same or different from each other; and h is 0, 1, or 2.

(53) The component (B) is one or more crosslinking agents selected from an amino condensate modified with formaldehyde or formaldehyde-alcohol and a phenol compound having on average two or more methylol groups or alkoxymethylol groups per molecule.

(54) The component (C) is a photo acid generator capable of generating an acid by decomposition with light having a wavelength of 190 to 500 nm.

(55) The component (D) is a solvent.

(56) The component (B) may be any known crosslinking agent that is one or more compounds selected from an amino condensate modified with formaldehyde or formaldehyde-alcohol and a phenol compound having on average two or more methylol groups or alkoxymethylol groups per molecule.

(57) Examples of the amino condensate modified with formaldehyde or formaldehyde-alcohol include melamine condensates modified with formaldehyde or formaldehyde-alcohol and urea condensates modified with formaldehyde or formaldehyde-alcohol.

(58) These modified melamine condensates and modified urea condensates may be used alone or in combination of two or more kinds.

(59) Examples of the phenol compound having on average two or more methylol groups or alkoxymethylol groups per molecule include (2-hydroxy-5-methyl)-1,3-benzenedimethanol, 2,2,6,6-tetramethoxymethyl bisphenol A.

(60) These phenol compounds may be used alone or in combination of two or more kinds.

(61) The component (C) may be any compound capable of generating an acid by exposure to light having a wavelength of 190 to 500 nm, which serves as a curing catalyst.

(62) Examples of such a photo acid generator include onium salts, diazomethane derivatives, glyoxime derivatives, -ketosulfone derivatives, disulfone derivatives, nitrobenzylsulfonate derivatives, sulfonate ester derivatives, imide-yl-sulfonate derivatives, oximesulfonate derivatives, iminosulfonate derivatives, and triazine derivatives.

(63) The component (D) may be any solvent capable of dissolving (A) the silicone skeleton-containing polymer compound, (B) the crosslinking agents, and (C) the photo acid generator.

(64) Examples of the solvent include ketones such as cyclohexanone, cyclopentanone, and methyl-2-n-amylketone; alcohols such as 3-methoxybutanol, 3-methyl-3-methoxybutanol, 1-methoxy-2-propanol, and 1-ethoxy-2-propanol; ethers such as propylene glycol monomethyl ether, ethylene glycol monomethyl ether, propylene glycol monoethyl ether, ethylene glycol monoethyl ether, propylene glycol dimethyl ether, and diethylene glycol dimethyl ether; and esters such as propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl lactate, ethyl pyruvate, butyl acetate, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, tert-butyl acetate, tert-butyl propionate, propylene glycol mono-tert-butyl ether acetate, and -butyrolactone.

(65) The first insulating layer 7 and the third insulating layer 9 may be a photo-curable resist coating film formed by applying the chemically amplified negative resist composition containing the components (A) to (D) by spin coating or, of course, may be a photo-curable resist coating film formed by applying other photo-curable resin by spin coating.

(66) Furthermore, the present invention provides a stacked semiconductor apparatus including a plurality of the semiconductor apparatuses that are stacked by flip chip.

(67) The inventive stacked semiconductor apparatus 11 includes, as shown in FIG. 2, a plurality of the semiconductor apparatuses 1 electrically connected through the through electrodes 5 and the solder bumps 6 and stacked by flip chip, and may further include insulating resin layers 12 inserted between the semiconductor apparatuses.

(68) Furthermore, the present invention provides an encapsulated stacked-semiconductor apparatus that includes the stacked semiconductor apparatus placed on a substrate having an electric circuit and encapsulated with an insulating encapsulating resin layer.

(69) The inventive encapsulated stacked-semiconductor apparatus 13 includes, as shown in FIG. 3, the stacked semiconductor apparatus 11 that is placed, through the solder bump 6, on a substrate (a circuit board 14) having an electric circuit, and encapsulated with an insulating encapsulating resin layer 15.

(70) The above-described semiconductor apparatus can be manufactured by the inventive method for manufacturing a semiconductor apparatus shown below. The inventive method for manufacturing a semiconductor apparatus includes the steps of:

(71) (1) applying a temporary adhesive to a supporting substrate and forming a first insulating layer having a thickness of 1 to 20 m on the temporary adhesive, wherein the first insulating layer consists of a photo-curable resin layer composed of a resist composition;
(2) patterning the first insulating layer by lithography via a mask to form a hole pattern for forming a through electrode, and then baking the first insulating layer to cure the first insulating layer;
(3) forming a seed layer on the first insulting layer by sputtering, then filling the hole pattern for forming the through electrode by plating to form a metal interconnect to be connected to the through electrode, and simultaneously forming an under-semiconductor-device metal interconnect;
(4) die bonding a semiconductor device having a height of 20 to 100 m to the cured first insulating layer, on which the under-semiconductor-device metal interconnect is formed, with a die bonding agent, wherein an exposed electrode pad is provided on an upper surface of the semiconductor device;
(5) preparing photo-curable dry films comprising a photo-curable resin layer sandwiched between a supporting film and a protective film, wherein the photo-curable resin layer has a thickness of 5 to 100 m and is composed of a resist composition;
(6) forming a second insulating layer by laminating the photo-curable resin layer of one of the photo-curable dry film such that the semiconductor device die-bonded on the first insulating layer is covered with the photo-curable resin layer;
(7) patterning the second insulating layer by lithography via a mask to simultaneously form an opening on the electrode pad, an opening for forming a metal interconnect that penetrates the second insulating layer on the metal interconnect to be connected to the through electrode, and an opening for forming the through electrode, and then baking the second insulating layer to cure the second insulating layer;
(8) after curing, forming a seed layer by sputtering, then filling the opening on the electrode pad, the opening for forming the metal interconnect that penetrates the second insulating layer, and the opening for forming the through electrode by plating to respectively form an on-semiconductor-device metal pad, the metal interconnect that penetrates the second insulating layer, and the through electrode, and connecting the on-semiconductor-device metal pad and the metal interconnect that penetrates the second insulating layer, which are formed by plating, via a metal interconnect formed by plating;
(9) after forming the metal interconnects, forming a third insulating layer by laminating the photo-curable resin layer of the other photo-curable dry film or applying the same resist composition as used in the photo-curable dry film by spin coating;
(10) patterning the third insulating layer by lithography via a mask to form an opening on the through electrode, and then baking the third insulating layer to cure the third insulating layer; and
(11) after curing, forming a solder bump in the opening on the through electrode.

(72) In the following, each step will be described in detail.

(73) In the step (1), as shown in FIG. 4, a temporary adhesive 17 is first applied to a supporting substrate 16, and a first insulating layer 7, which consists of a photo-curable resin layer composed of a resist composition, having a thickness of 1 to 20 m is formed on the temporary adhesive 17.

(74) The supporting substrate 16 is not particularly limited and, for example, a silicon wafer or a glass substrate may be used.

(75) The temporary adhesive 17 may be for example, but is not particularly limited to, a thermoplastic resin, including an olefin type thermoplastic elastomer, a polybutadiene type thermoplastic elastomer, a styrene type thermoplastic elastomer, a styrene/butadiene type thermoplastic elastomer, and a styrene/polyolefin type thermoplastic elastomer. In particular, a hydrogenated polystyrene type elastomer excellent in heat resistance is preferable. Illustrative examples thereof include Tuftec (available from Asahi Kasei Chemicals Corporation), ESPOLEX SB series (available from Sumitomo Chemical Co., Ltd.), RABALON (available from Mitsubishi Chemical Corporation), SEPTON (available from Kuraray Co., Ltd.), DYNARON (available from JSR). In addition, there may be mentioned a cycloolefin polymer represented by ZEONEX (available from ZEON Corporation) and a cyclic olefin copolymer represented by TOPAS (available from Nippon Polyplastics Co., Ltd.). A silicone type thermoplastic resin may also be used. For examples, dimethyl silicone, phenyl silicone, alkyl-modified silicone, or silicone resin is preferably used. Illustrative examples thereof include KF96, KF54, and X-40-9800 (all available from Shin-Etsu Chemical Co., Ltd.).

(76) As described above, the first insulating layer 7 may be formed by, for example, laminating a photo-curable dry film having a photo-curable resin layer composed of a chemically amplified negative resist composition containing the components (A) to (D), or applying the resist composition by spin coating. Of course, other photo-curable resin may be used.

(77) The first insulating layer has a thickness of 1 to 20 m, preferably 5 to 10 m. This thickness allows a thin semiconductor apparatus to be manufactured.

(78) Then, in the step (2), the first insulating layer 7 is patterned by lithography via a mask to form a hole pattern A for forming a through electrode, as shown in FIG. 5. The first insulating layer 7 is then cured by baking.

(79) In this patterning, after the first insulating layer 7 is formed, the layer is exposed to light, subjected to post exposure baking (PEB), developed, and optionally post-cured to form a pattern. In other words, a known lithography technique can be used for patterning.

(80) To effectively carry out photo-curing reaction of the first insulating layer, to improve adhesion between the first insulating layer 7 and the supporting substrate 16, or to improve planarity of the adhering first insulating layer 7, pre-baking may be performed, if necessary. The pre-baking may be performed, for example, at 40 to 140 C. for 1 minute to 1 hour.

(81) The layer is exposed to light having a wavelength of 190 to 500 nm via a photomask, and then cured. The photomask may be obtained by engraving a prescribed pattern. The photomask is preferably made of a material that can block the light having a wavelength of 190 to 500 nm. For example, a material such as chromium is preferably used, but it is not limited thereto.

(82) Examples of the light having a wavelength of 190 to 500 nm include light having various wavelengths generated from, for example, a radiation-generating apparatus, including ultraviolet rays such as g-line and i-line and far ultraviolet rays (248 nm and 193 nm). The wavelength preferably ranges from 248 to 436 nm. The exposure dose preferably ranges from 10 to 3,000 mJ/cm.sup.2. Such exposure causes an exposed part to crosslink, thereby forming a pattern that is insoluble in a developer.

(83) Further, PEB is performed to enhance the development sensitivity. The PEB is preferably performed at 40 to 140 C. for 0.5 to 10 minutes.

(84) The layer is then developed with a developer. Preferable examples of the developer include organic solvents such as isopropyl alcohol (IPA) and propylene glycol monomethyl ether acetate (PGMEA). Preferable examples of an alkali aqueous solution used for the developer include a 2.38% tetramethyl ammonium hydroxide (TMAH) aqueous solution. In the inventive method for manufacturing a semiconductor apparatus, an organic solvent is preferably used as the developer.

(85) The development can be carried out by a usual method, for example, by soaking the substrate having a formed pattern into a developer. Then, if necessary, washing, rinsing, drying, and so forth may be performed to obtain a film of the photo-curable resin layer (the first insulating layer) having an intended pattern.

(86) The first insulating layer, in which the pattern is thus formed, is baked with an oven or a hot plate preferably at 100 to 250 C., more preferably 150 to 220 C., much more preferably 170 to 190 C. to cure the layer (post-curing). When the post-curing temperature ranges from 100 to 250 C., the crosslinking density of the first insulating layer increases, and remaining volatile components can be removed. Thus, this temperature range is preferable in view of adhesiveness to a substrate, heat resistance, strength, and electronic characteristics. The time for post-curing can range from 10 minutes to 10 hours.

(87) Then, in the step (3), a seed layer is formed on the first insulting layer 7 by sputtering, the hole pattern A for forming the through electrode is filled by plating to form a metal interconnect (a lower metal interconnect) 4b to be connected to the through electrode, and an under-semiconductor-device metal interconnect 25 is simultaneously formed, as shown in FIG. 6.

(88) The plating is performed as follows, for example. A seed layer is formed on the first insulating layer 7 by sputtering, and the plating resist is patterned. Then, electrolytic plating or the like is performed to fill the hole pattern A for forming the through electrode with metal plating and form the lower metal interconnect 4b and the under-semiconductor-device metal interconnect 25 connected thereto. After these metal interconnects are formed, the seed layer is removed by etching to uncover the first insulating layer 7.

(89) The lower metal interconnect 4b and the under-semiconductor-device metal interconnect 25 are appropriately adjusted so as to have a desired interconnect width. In particular, these metal interconnects are each preferably formed with a thickness of 0.1 to 10 m on the first insulating layer.

(90) Then, in the step (4), as shown in FIG. 7, a semiconductor device 2 having a height of 20 to 100 m, provided with an exposed electrode pad on its upper surface, is die bonded to the cured first insulating layer 7, on which the under-semiconductor-device metal interconnect 25 is formed, with a die bonding agent 10.

(91) The die bonding agent 10 may be any known adhesive.

(92) When the thickness of the semiconductor device 2 ranges from 20 to 100 m, a thin semiconductor apparatus can be manufactured.

(93) Then, in the step (5), photo-curable dry films including a photo-curable resin layer, which has a thickness of 5 to 100 m and is composed of a resist composition, sandwiched between a supporting film and a protective film are prepared.

(94) The photo-curable dry film used in the present invention and a method for producing the same will be now described in detail.

(95) In the inventive method for manufacturing a semiconductor apparatus, the photo-curable dry film used for forming the second insulating layer includes a photo-curable resin layer sandwiched between a supporting film and a protective film. This photo-curable resin layer has a thickness of 5 to 100 m and is composed of a resist composition.

(96) In the inventive method for manufacturing a semiconductor apparatus, the photo-curable resin layer of the photo-curable dry film used for forming the second insulating layer has a thickness of 5 to 100 m. This thickness allows a thin semiconductor apparatus to be manufactured.

(97) When the photo-curable dry film is likewise used to form the first insulating layer and the third insulating layer, a film that includes a photo-curable resin layer having a prescribed thickness may be prepared and used.

(98) In the photo-curable dry film used in the present invention, the resist composition constituting the photo-curable resin layer can be prepared by stirring and mixing components of the photo-curable composition and then filtering the mixture through a filter or the like.

(99) The resist composition is preferably a chemically amplified negative resist composition containing the components (A) to (D) mentioned above.

(100) Of course, any other photo-curable resin may be used.

(101) The supporting film of the photo-curable dry film used in the present invention may be a monolayer or a multilayer film having multiple polymer films that are laminated. The dry film is sandwiched between the supporting film and the protective film.

(102) The material of the supporting film may be a synthetic resin film such as polyethylene, polypropylene, polycarbonate, and polyethylene terephthalate. Among them, polyethylene terephthalate, which has appropriate flexibility, mechanical strength, and heat resistance, is preferable. These films may be subjected to various treatments such as corona treatment and coating treatment with a releasing agent. The film may be a commercially available product. Examples thereof include Cerapeel WZ (RX), Cerapeel BX8 (R) (both are available from Toray Advanced Film Co., Ltd.), E7302, E7304 (both are available from Toyobo Co., Ltd.), Purex G31, Purex G71T1 (both are available from Teijin DuPont Films Japan Ltd.), PET381-A3, PET381-V8, and PET381-X08 (all available from Nippa Co., Ltd.).

(103) The protective film of the photo-curable dry film used in the present invention may be the same film as the supporting film mentioned above, and polyethylene terephthalate and polyethylene, which have appropriate flexibility, are preferable. The film may be a commercially available product, and examples thereof include, besides the polyethylene terephthalates already exemplified, polyethylene such as GF-8 (available from Tamapoly Co., Ltd.) and PE Film 0-Type (available from Nippa Co., Ltd.).

(104) The thicknesses of the supporting film and the protective film are preferably 5 to 100 m each, in view of stable production of the photo-curable dry film and prevention of the rolling habit around a roll axis, so-called curl.

(105) The method for producing the photo-curable dry film used in the present invention will be now described. As to an apparatus for producing the photo-curable dry film, a film coater for producing an adhesive product may be generally used. Illustrative examples of the film coater include a comma coater, a comma reverse coater, a multi coater, a die coater, a lip coater, a lip reverse coater, a direct gravure coater, an offset gravure coater, a 3-roll bottom reverse coater, and a 4-roll bottom reverse coater.

(106) The dry film can be produced as follows. A supporting film is rolled-out from a roll-out axis of a film coater, and the resist composition is applied onto the supporting film with a prescribed thickness to form a photo-curable resin layer while the film passes through a coater head of the film coater. This film then passes through a hot-air circulating oven at a prescribed temperature for a prescribed period. The supporting film with the photo-curable resin layer thus dried thereon passes through a laminate roll together with a protective film rolled-out from another roll-out axis of the film coater under a prescribed pressure to bond the protective film to the photo-curable resin layer on the supporting film, and then is rolled-up by a roll-up axis of the film coater. In this operation, the temperature of the hot-air circulating oven preferably ranges from 25 to 150 C., the period for passing through preferably ranges from 1 to 100 minutes, and the laminate roll pressure preferably ranges from 0.01 to 5 MPa.

(107) The photo-curable dry film can be produced by the above method. Use of such a photo-curable dry film allows the semiconductor device placed on the first insulating layer on the supporting substrate to be excellently embedded and reduces stress caused when the supporting substrate is removed after producing the semiconductor apparatus or when the semiconductor apparatus is diced into individual pieces. Thus, an intended semiconductor apparatus is prevented from warping, and the semiconductor apparatus can be suitably stacked and placed on a circuit board.

(108) Then, in the step (6), the protective film is removed from the photo-curable dry film prepared above, and as shown in FIG. 8(a), a second insulating layer 8 is formed by laminating the photo-curable resin layer of the photo-curable dry film such that the semiconductor device 2 die-bonded on the first insulating layer 7 is covered with the photo-curable resin layer.

(109) An apparatus for bonding the photo-curable dry film is preferably a vacuum laminator. The photo-curable-dry film is attached to the apparatus, the protective film is removed from the photo-curable dry film, and the photo-curable resin layer thereby exposed is bonded to the substrate on a table at a prescribed temperature by an adhering roll under a prescribed pressure in a vacuum chamber with a prescribed degree of vacuum. The temperature is preferably 60 to 120 C. The pressure is preferably 0 to 5.0 MPa. The degree of vacuum is preferably 50 to 500 Pa. Such vacuum lamination prevents voids from occurring on the periphery of the semiconductor device, and thus is preferable.

(110) When the second insulating layer 8 is formed on the semiconductor device 2 by laminating the photo-curable dry film, the second insulating layer 8 on the semiconductor device 2 can be thick, or the portion farther from the semiconductor device 2 can be thinner, as shown in FIG. 8 (b). Thus, the method preferably includes mechanically pressing the film to flatten this variation in thickness and thin the film on the semiconductor device, as shown in FIG. 8 (a).

(111) Then, in the step (7), as shown in FIG. 9, the second insulating layer 8 is patterned by lithography via a mask to simultaneously form an opening B on the electrode pad, an opening C for forming a metal interconnect (a through metal interconnect) that penetrates the second insulating layer on the metal interconnect (the lower metal interconnect) 4b to be connected to the through electrode, and an opening D for forming the through electrode, and then the second insulating layer 8 is cured by baking.

(112) In this patterning, after the second insulating layer 8 is formed, the layer is exposed to light, subjected to post exposure baking (PEB), developed, and optionally post-cured to form a pattern. In other words, a known lithography technique can be used for patterning as in patterning of the first insulating layer.

(113) In the inventive method for manufacturing a semiconductor apparatus, the opening B on the electrode pad, the opening C for forming the through metal interconnect, and the opening D for forming the through electrode are simultaneously formed by one-shot exposure. Thus, it is rational.

(114) Then, in the step (8), as shown in FIG. 10, after the second insulating layer 8 is cured, a seed layer is formed by sputtering. Then, the opening B on the electrode pad, the opening C for forming the metal interconnect (the through metal interconnect) that penetrates the second insulating layer, and the opening D for forming the through electrode are filled by plating to respectively form an on-semiconductor-device metal pad 3, the metal interconnect (the through metal interconnect) 4c that penetrates the second insulating layer, and the through electrode 5. The on-semiconductor-device metal pad 3 and the metal interconnect (the through metal interconnect) 4c that penetrates the second insulating layer, which are formed by plating, are connected via a metal interconnect (an upper metal interconnect) 4a formed by plating.

(115) The plating is performed as in the step (3). For example, a seed layer is formed by sputtering, and the plating resist is patterned. Then, electrolytic plating or the like is performed to form the on-semiconductor-device metal pad 3, the through metal interconnect 4c, the through electrode 5, and the upper metal interconnect 4a that connects the on-semiconductor-device metal pad 3 and the through metal interconnect 4c.

(116) The upper metal interconnect 4a is appropriately adjusted so as to have a desired interconnect width. In particular, the upper metal interconnect is preferably formed with a thickness of 0.1 to 10 m on the second insulating layer.

(117) The through electrode 5 may be further plated by additional electrolytic plating to add plating of the through electrode 5 and fill the through electrode 5 with a metal plating 18, as shown in FIG. 11.

(118) Additionally, the through metal interconnect 4c may be further plated by additional electrolytic plating to add plating of the through metal interconnect 4c.

(119) Then, in the step (9), after the metal interconnects are formed, a third insulating layer 9 is formed by laminating the photo-curable resin layer of the photo-curable dry film or applying the resist composition used in the photo-curable dry film by spin coating, as shown in FIG. 12.

(120) The third insulating layer 9 may be formed by, for example, laminating a photo-curable dry film having a photo-curable resin layer composed of a chemically amplified negative resist composition containing the components (A) to (D), or applying the resist composition by spin coating, in the same manner as the first insulating layer is formed. Of course, other photo-curable resin may be used.

(121) The third insulating layer preferably has a thickness of 5 to 100 m. This thickness allows a thin semiconductor apparatus to be manufactured.

(122) Then, in the step (10), as shown in FIG. 13, the third insulating layer 9 is patterned by lithography via a mask to form an opening E on the through electrode 5, and then the third insulating layer 9 is cured by baking.

(123) In this patterning, after the third insulating layer 9 is formed, the layer is exposed to light, subjected to post exposure baking (PEB), developed, and optionally post-cured to form a pattern. In other words, a known lithography technique can be used for patterning as in patterning of the first insulating layer.

(124) Then, in the step (11), a solder bump is formed in the opening E on the through electrode after the third insulating layer is cured.

(125) The solder bump may be formed by, for example, plating the opening E on the through electrode to form an on-through-electrode metal pad 19, and then forming a solder ball 20 on the on-through-electrode metal pad 19 as the solder bump, as shown in FIG. 14.

(126) Alternatively, the solder bump may be formed as follows. In the step (8), the through electrode 5 is further plated with SnAg to add plating and form an SnAg plating 21, as shown in FIG. 15. In the subsequent step (9), the third insulating layer 9 is formed as mentioned above. In the step (10), the third insulating layer is patterned to form the opening E on the through electrode such that the SnAg plating 21 is uncovered, and then cured by baking. In the step (11), the SnAg plating 21 is melted and brought to protrude toward the opening E on the through electrode so as to form a protruding SnAg electrode 22 as the solder bump, as shown in FIG. 16.

(127) Moreover, after the step (11), the supporting substrate 16, which has been temporarily bonded to the first insulating layer 7 in the step (1), may be removed to uncover a side of the through electrode 5 (the lower metal interconnect 4b) opposite to the solder ball 20, and the uncovered seed layer may be removed by etching to expose the metal plating portion, as shown in FIG. 17. This allows the upper portion and the lower portion of the through electrode 5 to electrically continue. Thereafter, the semiconductor apparatus may be diced into individual pieces, whereby individual semiconductor apparatus 23 can be obtained.

(128) In the case that the protruding SnAg electrode 22 is formed as the solder bump, the supporting substrate 16 may be likewise removed to uncover a side of the through electrode 5 (the lower metal interconnect 4b) opposite to the protruding SnAg electrode 22, and the uncovered seed layer may be removed by etching to expose the metal plating portion, as shown in FIG. 18. This allows the upper portion and the lower portion of the through electrode 5 to electrically continue. Thereafter, the semiconductor apparatus may be diced into individual pieces, whereby individual semiconductor apparatus 24 can be obtained.

(129) The inventive manufacturing method is especially suited for downsizing and thinning and enables production of a thin and compact semiconductor apparatus with a thickness of 50 to 300 m, more preferably 70 to 150 m.

(130) The individual semiconductor apparatuses 23 or the individual semiconductor apparatuses 24 can be stacked while inserting insulting resin layers 12 such that the individual semiconductor apparatuses are electrically connected through the solder bump to obtain a stacked semiconductor apparatus, as shown in FIG. 19 and FIG. 20. The stacked semiconductor apparatus can be placed on a substrate (circuit board 14) having an electric circuit, as shown in FIG. 21 and FIG. 22. FIGS. 19, 20, 21, and 22 each show an example in which the individual semiconductor apparatuses 23 or 24 are flip-chip bonded.

(131) In addition, the stacked semiconductor apparatus thus manufactured can be placed on a circuit board 14 and encapsulated with an insulating encapsulating resin layer 15 to manufacture an encapsulated stacked-semiconductor apparatus, as shown in FIG. 23 and FIG. 24.

(132) A resin used in the insulting resin layer 12 or the insulating encapsulating resin layer 15 may be any materials commonly used for this use. Examples thereof include epoxy resins, silicone resins, and hybrid resins thereof.

(133) The inventive semiconductor apparatus, stacked semiconductor apparatus, and encapsulated stacked-semiconductor apparatus manufactured as described above can be suitably used for fan-out wiring formed in a semiconductor chip and wafer level chip size package (WCSP).

(134) As previously described, the inventive semiconductor apparatus can be easily placed on a circuit board and stacked by forming the fine electrode on the semiconductor device and providing the through electrode outside the semiconductor device. In addition, this semiconductor apparatus allows the semiconductor device to be embedded without voids at the periphery even when the semiconductor device has a height of several tens of m, and warpage of the semiconductor apparatus can be reduced even with dense metal interconnects.

(135) Moreover, the inventive method for manufacturing a semiconductor apparatus facilitates placing the semiconductor apparatus on a circuit board and stacking the semiconductor apparatuses by forming the fine electrode on the semiconductor device and forming the through electrode outside the semiconductor device. This method also facilitates processing the openings of the electrode pad portion, the through electrode, and the like.

(136) Moreover, the inventive semiconductor apparatus thus obtained can be easily placed on a circuit board and stacked, and thus can be used for a stacked semiconductor apparatus including the semiconductor apparatuses that are stacked and for an encapsulated stacked-semiconductor apparatus including the stacked semiconductor apparatus placed on a circuit board and then encapsulated.

(137) It is to be noted that the present invention is not limited to the foregoing embodiment. The embodiment is just an exemplification, and any examples that have substantially the same feature and demonstrate the same functions and effects as those in the technical concept described in claims of the present invention are included in the technical scope of the present invention.