3D integration by wafer-level aligned wafer bonding

Author(s):  
V. Dragoi ◽  
J. Burggraf ◽  
F. Kurz ◽  
B. Rebhan
2011 ◽  
Vol 2011 (DPC) ◽  
pp. 000836-000858 ◽  
Author(s):  
Sang Hwui Lee ◽  
Michael Khbeis

This paper reports on a successful 3D integration (3DI) of multi-purpose signal processor (MSP) chips with memory chips using die-to-wafer (D2W) and wafer-to-wafer (W2W) bonding technologies. 3D integration enables compact systems of commercial-off-the-shelf (COTS) parts with high functionality using a wafer-level process for better thinning process uniformity and high yield throughput. The3D system is comprised of commercial Flash memory bare die and MSP bare die. The bare die are face-down aligned to a 150mm diameter silicon handle wafer with alignment marks polished silicon surface. Unique features on the commercial die are detected and used for die registration using a flip-chip bonder with vision automation. An adhesive film between the die and silicon handle wafer are used for temporary bonding. After the die-to-wafer population and bonding, the die substrates are thinned at the wafer-level to a target of 60 microns for the memory die and 25 microns for the MSP die, respectively. The thinned memory die set is permanently transferred onto a 150mm diameter silicon carrier wafer using a low temperature silicon covalent wafer bonding. Following bonding, an adhesive film release process is used to separate the memory die set from the temporary handle wafer. The thinned MSP die on a second handle wafer are then aligned to the thinned memory die set using a wafer-to-wafer alignment tool, and bonded with thin-film polyimide in a high-yield, low temperature wafer bonding process, followed by the release process to separate the MSP die set from the handle wafer. Finally, the MSP/memory stack are electrically connected using a via-last through-silicon-via (TSV) process. One of the key considerations for COTS 3DI is to meet the back-end-of-line (BEOL) thermal budgets of 350–400 Celsius. Plasma-assisted preparation facilitates the reduction in thermal budget for silicon covalent bonding and is performed at 150 Celsius, followed by a long-term annealing process at 175 Celsius. Stacking of thinned die relies on low temperature polyimide bonding that is performed at 200 Celsius. Fluorine and oxygen based plasma surface activation process and CTE-matched polyimide bonding play a critical role in enabling the low temperature bonding for this 3D MSP/memory integration. The thinning and bonding processing details that are presented in this paper are essential for COTS 3DI but can also be applied to several low-profile multi-chip module and packaging applications.


2012 ◽  
Vol 18 (7-8) ◽  
pp. 1065-1075 ◽  
Author(s):  
Viorel Dragoi ◽  
Eric Pabo ◽  
Jürgen Burggraf ◽  
Gerald Mittendorfer

2004 ◽  
Vol 816 ◽  
Author(s):  
J.-Q. Lu ◽  
G. Rajagopalan ◽  
M. Gupta ◽  
T.S. Cale ◽  
R.J. Gutmann

AbstractMonolithic wafer-level three-dimensional (3D) ICs based upon bonding of processed wafers and die-to-wafer 3D ICs based upon bonding die to a host wafer require additional planarization considerations compared to conventional planar ICs and wafer-scale packaging. Various planarization issues are described, focusing on the more stringent technology requirements of monolithic wafer-level 3D ICs. The specific 3D IC technology approach considered here consists of wafer bonding with dielectric adhesives, a three-step thinning process of grinding, polishing and etching, and an inter-wafer interconnect process using copper damascene patterning. The use of a bonding adhesive to relax pre-bonding wafer planarization requirements is a key to process compatibility with standard IC processes. Minimizing edge chipping during wafer thinning requires understanding of the relationships between wafer bonding, thinning and pre-bonding IC processes. The advantage of silicon-on-insulator technology in alleviating planarization issues with wafer thinning for 3D ICs is described.


2016 ◽  
Vol 75 (9) ◽  
pp. 345-353 ◽  
Author(s):  
F. Kurz ◽  
T. Plach ◽  
J. Suss ◽  
T. Wagenleitner ◽  
D. Zinner ◽  
...  

2018 ◽  
Vol 86 (5) ◽  
pp. 145-158 ◽  
Author(s):  
Thomas Plach ◽  
Bernhard Rebhan ◽  
Viorel Dragoi ◽  
Thomas Wagenleitner ◽  
Markus Wimplinger ◽  
...  

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