OXIDATION AND CORROSION PREVENTION IN SEMICONDUCTOR DEVICES AND SEMICONDUCTOR DEVICE ASSEMBLIES
20240387425 · 2024-11-21
Assignee
Inventors
Cpc classification
H01L2224/0401
ELECTRICITY
H01L2224/131
ELECTRICITY
H01L2224/04042
ELECTRICITY
H01L2224/131
ELECTRICITY
H01L2224/13101
ELECTRICITY
H01L2224/035
ELECTRICITY
H01L2224/13101
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/04034
ELECTRICITY
H01L2224/48465
ELECTRICITY
International classification
Abstract
In some aspects, the techniques described herein relate to an electronic device including: a substrate; a metallization layer, the metallization layer having: a first surface disposed on the substrate; a second surface opposite the first surface; and a corrosion-prevention implant layer disposed in the metallization layer, the corrosion-prevention implant layer extending from the second surface to a depth from the second surface in the metallization layer, the depth being less than a thickness of the metallization layer; and an electrical connector coupled with the second surface.
Claims
1. A semiconductor device comprising: a semiconductor substrate; an active circuit disposed on a surface of the semiconductor substrate; a first metallization layer disposed on the active circuit, the first metallization layer including a first through hole; a first non-conducting layer disposed on the first metallization layer and in the first through hole, the first non-conducting layer including a second through hole; a second metallization layer disposed on the first non-conducting layer and in the second through hole, the second metallization layer including a third through hole separating the second metallization layer into a first portion and second portion; a corrosion prevention implant disposed in an upper surface of the second metallization layer; and a second non-conducting layer disposed on the second metallization layer and in the third through hole, the second non-conducting layer including a fourth through hole above the second portion of the second metallization layer, the fourth through hole exposing at least a portion of the upper surface of the second metallization layer.
2. The semiconductor device of claim 1, wherein the active circuit includes at least one electrical contact.
3. The semiconductor device of claim 1, wherein the first portion of the second metallization layer is electrically coupled with the semiconductor substrate via an electrical contact.
4. The semiconductor device of claim 1, wherein at least one of the first through hole, the second through hole, the third through hole and the fourth through hole includes tapered side walls.
5. The semiconductor device of claim 1, further comprising a connector electrically coupled to the upper surface of the second metallization layer.
6. A silicon carbide semiconductor device comprising: a silicon carbide substrate; an active circuit disposed on a surface of the silicon carbide substrate; a first metallization layer disposed on the active circuit, the first metallization layer including a first through hole; a first non-conducting layer disposed on the first metallization layer and in the first through hole, the first non-conducting layer including a second through hole; a second metallization layer disposed on the first non-conducting layer and in the second through hole, the second metallization layer including a third through hole separating the second metallization layer into a first portion and a second portion; a corrosion prevention implant disposed in an upper surface of the second metallization layer; and a second non-conducting layer disposed on the second metallization layer and in the third through hole, the second non-conducting layer including a fourth through hole above the second portion of the second metallization layer, the fourth through hole exposing at least a portion of the upper surface of the second metallization layer.
7. The silicon carbide semiconductor device of claim 6, wherein the active circuit includes at least one electrical contact.
8. The silicon carbide semiconductor device of claim 6, wherein the first portion of the second metallization layer is electrically coupled with the silicon carbide substrate via an electrical contact.
9. The silicon carbide semiconductor device of claim 6, wherein at least one of the first through hole, the second through hole, the third through hole and the fourth through hole includes tapered side walls.
10. A method for producing a semiconductor device, the method comprising: forming an active circuit on a surface of a semiconductor substrate; forming a first metallization layer on the active circuit, the first metallization layer including a first through hole; forming a first non-conducting layer on the first metallization layer and in the first through hole, the first non-conducting layer including a second through hole; forming a second metallization layer on the first non-conducting layer and in the second through hole, the second metallization layer including a third through hole separating the second metallization layer into a first portion and second portion; forming a corrosion prevention implant in an upper surface of the second metallization layer; and forming a second non-conducting layer on the second metallization layer and in the third through hole, the second non-conducting layer including a fourth through hole above the second portion of the second metallization layer, the fourth through hole exposing at least a portion of the upper surface of the second metallization layer.
11. The method of claim 10, wherein forming the active circuit includes forming at least one electrical contact of the active circuit.
12. The method of claim 10, further comprising forming an electrical contact electrically coupling the first portion of the second metallization layer to the semiconductor substrate.
13. The method of claim 10, wherein at least one of the first through hole, the second through hole, the third through hole and the fourth through hole includes tapered side walls.
14. The method of claim 10, comprising electrically coupling a connector to the upper surface of the second metallization layer.
15. A semiconductor device assembly having an active circuit embedded in the semiconductor device assembly comprising: a semiconductor substrate including an active circuit; a first metallization layer disposed on the active circuit of the semiconductor substrate; a first non-conducting layer disposed on the first metallization layer; a second metallization layer disposed on the first non-conducting layer; a corrosion prevention implant disposed in an upper surface of the second metallization layer; and a second non-conducting layer disposed on the second metallization layer, the second non-conducting layer including a through hole exposing at least a portion of the upper surface of the second metallization layer.
16. The semiconductor device assembly of claim 15, further comprising an external electrical connector that is electrically coupled with the active circuit via the first metallization layer and the second metallization layer.
17. The semiconductor device assembly of claim 15, wherein the active circuit includes at least one electrical contact.
18. The semiconductor device assembly of claim 15, wherein the second metallization layer is electrically coupled with the semiconductor substrate via an electrical contact.
19. The semiconductor device assembly of claim 15, wherein the through hole includes tapered side walls.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032] In the drawings, which are not necessarily drawn to scale, like reference symbols may indicate like and/or similar components (elements, structures, etc.) in different views. The drawings illustrate generally, by way of example, but not by way of limitation, various implementations discussed in the present disclosure. Reference symbols show in one drawing may not be repeated for the same, and/or similar elements in related views. Reference symbols that are repeated in multiple drawings may not be specifically discussed with respect to each of those drawings, but are provided for context between related views. Also, not all like elements in the drawings are specifically referenced with a reference symbol when multiple instances of that element are illustrated.
DETAILED DESCRIPTION
[0033] This disclosure is directed to approaches preventing corrosion (oxidation, etc.) of metallization, e.g., exposed metallization, in semiconductor devices and/or semiconductor device assemblies, where such corrosion can cause poor electrical interconnection quality, such as due to poor wire bond or conductive clip adhesion. Thus, the approaches described herein facilitate producing electric interconnections for semiconductor devices and/or semiconductor device assemblies with good adhesion quality, and good conductivity (low resistance). The approaches described herein can also overcome at least some of the drawbacks of current approaches. For instance, the disclosed approaches can be less complex, can be easily integrated with existing manufacturing processes, may be lower cost than the current approaches, and can prevent cross-contamination.
[0034] In the approaches described herein, a corrosion-prevention implant process can be performed in an upper portion of metallization layers to inhibit corrosion of, or portions, of those metallization layers prior to forming electrical connections using, e.g., wire bonds and/or conductive clips. In some implementations, by way of example, aluminum (Al), magnesium (Mg) and/or nitrogen (N) (e.g., Al, Mg and/or N ions) can be implanted in an upper portions of a metallization layer, such as copper (Cu) metallization, aluminum-copper (AlCu) metallization, titanium-nickel-copper (TiNiCu) metallization, or titanium-nickel-silver (TiNiAg) metallization.
[0035] While generally described with respective to semiconductor devices, and semiconductor wafer fabrication, the approaches described herein can also be applied in conjunction with other components of semiconductor device assemblies, such as metallization layers included on a substrate, such a direct-bonded metal (DBM) substrate. In some implementations, metallization layers described herein can be referred to as top metallization layers, where additional metallization layers can be included with the top metallization layers in a stack, with dielectric layers and/or passivation layers being disposed between different layers of metallization, such as in a semiconductor device produced with a process that includes forming multiple layers of interconnected patterned metallization.
[0036]
[0037] In this example, the metallization layer 120 can be a top level metallization layer that is patterned, e.g., using photolithography, where such patterning is appropriate for a given implementation. The metallization layer 120 can have a surface 121, which can be fully exposed, or can be partially exposed, such as through a passivation layer (not shown). In some implementations, the metallization layer 120 can include one or more of Cu, AlCu, TiNiCu, or TiNiAg, though other metals can be used.
[0038] In some implementations, the substrate 110 can be a ceramic substrate, such as included in a DBM substrate. For instance, the substrate 110 can include aluminum-oxide, or aluminum-nitride, though other materials can be used. In this example, the metallization layer 120 can be a patterned metallization layer (e.g., Cu layer) that is direct-bonded, e.g., using a sintering process, and can be used for electrical connection to a corresponding semiconductor device, e.g., using the electrical connector 130.
[0039] As further shown in
[0040] The corrosion-prevention implant 122 can be formed using an ion beam with an energy and ion dose that is appropriate for the particular implementation. For example, the implantation energy and dose can depend on the composition of the metallization layer 120 and/or on a process used to produce the metallization layer 120, e.g., sputtering, plating, etc. As one example, a Cu metallization layer that is formed using sputtering can be implanted with Al ions using an energy in a range of 10 of kiloelectron volts (keV) and 60 keV, and an implant dose in a range of 1?10.sup.15 cm-2 to 6?10.sup.15 cm.sup.?2.
[0041] In this example, the corrosion-prevention implant 122 is only formed in a portion of the metallization layer 120 along the surface 121, while other portions of the metallization layer 120 along the surface 121 exclude the corrosion-prevention implant 122. Such an approach could be used for bond pads of a semiconductor device, where the portions of the metallization layer 120 that exclude the corrosion-prevention implant 122 may be covered by passivation that blocks the corrosion-prevention implant 122 during its formation. In other implementations, the corrosion-prevention implant 122 can be formed over the entirety of the surface 121 of the metallization layer 120, such as for metallization of a redistribution layer for a chip-scale package, or for metallization included in a DBM substrate. Such an approach can be referred to as a blanket implant.
[0042] As illustrated in
[0043] In the apparatus 100, the electrical connector 130 is disposed on, and electrically coupled with the surface 121 corresponding with the portion of the metallization layer 120 including the corrosion-prevention implant 122. Depending on the particular implementation, the electrical connector 130 can be a wire bond, a conductive clip, a solder ball, and so forth, where the electrical connector 130 can facilitate electrical connection with the metallization layer 120 and/or the substrate 110. In such an arrangement, the corrosion-prevention implant 122, by preventing corrosion (oxidation, or otherwise) of the metallization layer 120, can facilitate a low resistance and mechanically robust connection between the metallization layer 120 and the electrical connector 130, while avoiding drawbacks of current approaches.
[0044]
[0045] As compared with the corrosion-prevention implant 122 of the apparatus 100, the metallization layer 220 includes a corrosion-prevention implant 222 that is disposed (e.g., using a blanket implant) in the metallization layer 220 along an entirety of a surface 221 (e.g., using a blanket implant). In this example, the corrosion-prevention implant 222 is formed through the surface 221 of the metallization layer 220. As with the corrosion-prevention implant 122, in implementations, the corrosion-prevention implant 222 includes one or more materials that inhibit corrosion of the metallic layer 220. The particular materials included in the corrosion-prevention implant 222 can depend, at least in part, on the composition of the metallization layer 220. For instance, in some implementations, the metallization layer 220 can include one or more of Cu, AlCu, TiNiCu, or TiNiAg, though other metals can be used. In some implementations, the corrosion-prevention implant 222 can include Al, Mg and/or N, e.g., implanted as ions. In some implementations, the corrosion-prevention implant 222 can include other substances.
[0046] Also, as with the corrosion-prevention implant 122, the corrosion-prevention implant 222 can be formed using an ion beam with an energy and ion dose that is appropriate for the particular implementation. For example, the implantation energy and dose can depend on the composition of the metallization layer 220 and/or on a process used to produce the metallization layer 220, e.g., sputtering, plating, etc. In some implementations, the metallization layer 220 can have a thickness consistent with the ranges described with respect to the metallization layer 120, and the corrosion-prevention implant 222 can have a depth consistent with ranges described above with respect to the corrosion-prevention implant 122.
[0047]
[0048] The metallization layer 320 includes a corrosion-prevention implant 322 that is disposed in the metallization layer 320 along only a portion of a surface 321 and is excluded from other portions of the metallization layer 320, such as with the corrosion-prevention implant 122 in the metallization layer 120 of
[0049] Also, as with the corrosion-prevention implant 122 and the corrosion-prevention implant 222, the corrosion-prevention implant 322 can be formed using an ion beam with an energy and ion dose that is appropriate for the particular implementation. For example, the implantation energy and dose can depend on the composition of the metallization layer 320 and/or on a process used to produce the metallization layer 320, e.g., sputtering, plating, etc. In some implementations, the metallization layer 320 can have a thickness consistent with the ranges described with respect to the metallization layer 120, and the corrosion-prevention implant 322 can have a depth consistent with ranges described above with respect to the corrosion-prevention implant 122.
[0050]
[0051] As shown in
[0052] As with the corrosion-prevention implants of
[0053] Also, as with the corrosion-prevention implants of
[0054]
[0055] Referring to
[0056] At block 530, the method 500 includes performing a corrosion-prevention implant on the metallization layer of block 520, which can be a blanket implant, such as described herein. At block 540, the method 500 includes forming a passivation layer, such as the passivation layer 450 of
[0057] Referring to
[0058] At block 650, the method 600 includes performing a corrosion-prevention implant on the metallization layer of block 640. At block 660, the method includes performing a back grind and back metal process, such as described with respect to
[0059] It will be understood that, in the foregoing description, when an element, such as a layer, a region, or a substrate, is referred to as being on, connected to, electrically connected to, coupled to, or electrically coupled to another element, it may be directly on, connected or coupled to the other element, or one or more intervening elements may be present. In contrast, when an element is referred to as being directly on, directly connected to or directly coupled to another element or layer, there are no intervening elements or layers present. Although the terms directly on, directly connected to, or directly coupled to may not be used throughout the detailed description, elements that are shown as being directly on, directly connected or directly coupled can be referred to as such. The claims of the application may be amended to recite exemplary relationships described in the specification or shown in the figures.
[0060] As used in this specification, a singular form may, unless definitely indicating a particular case in terms of the context, include a plural form. Spatially relative terms (e.g., over, above, upper, under, beneath, below, lower, top, bottom, and so forth) are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. In some implementations, the relative terms above and below can, respectively, include vertically above and vertically below. In some implementations, the term adjacent can include laterally adjacent to or horizontally adjacent to.
[0061] Some implementations may be implemented using various semiconductor processing and/or packaging techniques. Some implementations may be implemented using various types of semiconductor processing techniques associated with semiconductor substrates including, but not limited to, for example, Silicon (Si), Silicon Carbide (SiC), Gallium Arsenide (GaAs), Gallium Nitride (GaN), and/or so forth. Some implementations may be implemented using various types of semiconductor assemblies, such as assemblies include substrates including, but not limited to, direct-bonded metal (DBM) substrates.
[0062] While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the scope of the implementations. It should be understood that they have been presented by way of example only, not limitation, and various changes in form and details may be made. Any portion of the apparatus and/or methods described herein may be combined in any combination, except mutually exclusive combinations. The implementations described herein can include various combinations and/or sub-combinations of the functions, components and/or features of the different implementations described.