Method for forming a semiconductor device having a mechanically robust pad interface
First Claim
1. A method of forming a semiconductor device, comprising:
- forming a first interconnect level over a semiconductor substrate;
forming an uppermost interconnect level that includes an interconnect portion and a bond pad over the first interconnect level, wherein;
the interconnect portion contacts the first interconnect level by way of vias through an interlevel dielectric layer, and wherein all vias interconnecting the interconect portion and the first interconnect level are positioned outside regions directly below the bond pad;
forming a passivation layer over the uppermost interconnect level;
removing portions of the passivation layer, wherein removing portions of the passivation layer exposes portions of the bond pad and forms a plurality of support structures overlying the uppermost surface of the bond pad; and
forming a conductive capping layer overlying the plurality of support structures, wherein the conductive capping layer electrically contacts the bond pad;
wherein the plurality of support structures are interconnected with unremoved portions of the passivation layer.
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Accused Products
Abstract
A composite bond pad that is resistant to external forces that may be applied during probing or packaging operations is presented. The composite bond pad includes a non-self-passivating conductive bond pad (134) that is formed over a semiconductor substrate (100). A dielectric layer (136) is then formed over the conductive bond pad (134). Portions of the dielectric layer (136) are removed such that the dielectric layer (136) becomes perforated and a portion of the conductive bond pad (134) is exposed. Remaining portions of the dielectric layer (136) form support structures (138) that overlie that bond pad. A self-passivating conductive capping layer (204) is then formed overlying the bond pad structure, where the perforations in the dielectric layer (136) allow for electrical contact between the capping layer (204) and the exposed portions of the underlying bond pad (134). The support structures (138) provide a mechanical barrier that protects the interface between the capping layer (204) and the bond pad (134). Additional mechanical robustness is achieved when the support structures (138) remain coupled to the unremoved portion of the dielectric layer (136), as forces buffered by the support structures (138) are distributed across the dielectric layer (136) and not concentrated at the bond pad location.
77 Citations
16 Claims
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1. A method of forming a semiconductor device, comprising:
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forming a first interconnect level over a semiconductor substrate;
forming an uppermost interconnect level that includes an interconnect portion and a bond pad over the first interconnect level, wherein;
the interconnect portion contacts the first interconnect level by way of vias through an interlevel dielectric layer, and wherein all vias interconnecting the interconect portion and the first interconnect level are positioned outside regions directly below the bond pad;
forming a passivation layer over the uppermost interconnect level;
removing portions of the passivation layer, wherein removing portions of the passivation layer exposes portions of the bond pad and forms a plurality of support structures overlying the uppermost surface of the bond pad; and
forming a conductive capping layer overlying the plurality of support structures, wherein the conductive capping layer electrically contacts the bond pad;
wherein the plurality of support structures are interconnected with unremoved portions of the passivation layer. - View Dependent Claims (2)
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3. A method of forming a semiconductor device, comprising:
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forming a first interconnect level over a semiconductor substrate;
forming an uppermost interconnect level that includes an interconnect portion and a bond pad over the first interconnect level, wherein;
the interconnect portion contacts the first interconnect level by way of vias through an interlevel dielectric layer, and wherein all vias interconnecting the interconnect portion and the first interconnect level are positioned outside regions directly below the bond pad;
forming a passivation layer over the uppermost interconnect level;
removing portions of the passivation layer, wherein removing portions of the passivation layer exposes portions of the bond pad and forms a plurality of support structures overlying the uppermost surface of the bond pad; and
forming a conductive capping layer overlying the plurality of support structures, wherein the conductive capping layer electrically contacts the bond pad;
forming a barrier layer between the capping layer and the bond pad, wherein the barrier layer overlies the support structures and abuts exposed portions of the bond pad. - View Dependent Claims (4, 9, 10, 11, 12, 13)
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5. A method of forming a semiconductor device, comprising:
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depositing a dielectric layer over a semiconductor substrate;
patterning and etching a trench opening within the dielectric layer;
depositing a copper layer over the dielectric layer and within the trench opening;
removing portions of the copper layer not contained within the trench opening to define an unpermost interconnect level comprising a copper bond pad and an interconnect portion, wherein the interconnect portion physically couples to an underlying intereconnect level by way of vias, wherein the vias are positioned beyond regions directly below the copper bond pad;
forming a passivation layer over the uppermost copper bond pad;
pattering and etching the passivation layer to define openings and support structures overlying the uppermost copper bond pad;
depositing a conductive layer over the support structures and within the openings, wherein the conductive layer electrically contacts the uppermost copper bond pad;
patterning and etching the conductive layer to define a capping film over the support structures and the openings;
forming a barrier layer overlying the support structures and within the openings prior to forming the conductive layer, wherein the barrier layer electrically contacts the uppermost copper bond pad. - View Dependent Claims (6, 7, 8, 14, 15, 16)
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Specification