Conductive interconnect structures and formation methods using supercritical fluids
First Claim
1. A method for processing a substrate, comprising:
- forming a via in a substrate having a first surface and a second surface opposite the first surface, the substrate including a bond site at least proximate to the first surface, the via having an opening proximate to the bond site of the substrate, the opening having a width, a bottom portion in the substrate, and a sidewall with a length generally transverse to the width, the length being approximately 100 microns or more;
contacting the sidewall of the via with a precursor of a conductive material in a supercritical fluid;
precipitating the conductive material from the precursor in the supercritical fluid onto the sidewall of the via;
maintaining a generally uniform concentration of the precursor in the supercritical fluid throughout the via as the conductive material is precipitated from the precursor;
forming a conformal layer of the conductive material on the sidewall of the via from the precipitated conductive material while the via is exposed to the supercritical fluid, the layer of the conductive material having a generally uniform thickness over substantially the entire length of the via in a direction transverse to the width of the via;
after forming the conformal layer, forming a vent hole in the substrate extending from the bottom portion of the via to the second surface of the substrate;
filling the via with a fill material adjacent to the conformal layer of the conductive material after forming the vent hole, the fill material having a first end proximate to the first surface;
exposing a second end of the fill material opposite the first end by removing material from the second surface of the substrate; and
attaching a solder ball to the exposed second end of the fill material, the solder ball being in electrical communication with the bond site of the substrate via the fill material in the via.
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Accused Products
Abstract
Conductive interconnect structures and formation methods using supercritical fluids are disclosed. A method in accordance with one embodiment of the invention includes forming a via in a substrate, with the via having a width and a length generally transverse to the width, and with a length being approximately 100 microns or more. The method can further include disposing a conductive material in the via while the via is exposed to a supercritical fluid. For example, copper can be disposed in the via by introducing a copper-containing precursor into the supercritical fluid and precipitating the copper from the supercritical fluid. Interconnect structures can be formed using this technique in a single generally continuous process, and can produce conductive structures having a generally uniform grain structure across the width of the via.
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Citations
40 Claims
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1. A method for processing a substrate, comprising:
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forming a via in a substrate having a first surface and a second surface opposite the first surface, the substrate including a bond site at least proximate to the first surface, the via having an opening proximate to the bond site of the substrate, the opening having a width, a bottom portion in the substrate, and a sidewall with a length generally transverse to the width, the length being approximately 100 microns or more; contacting the sidewall of the via with a precursor of a conductive material in a supercritical fluid; precipitating the conductive material from the precursor in the supercritical fluid onto the sidewall of the via; maintaining a generally uniform concentration of the precursor in the supercritical fluid throughout the via as the conductive material is precipitated from the precursor; forming a conformal layer of the conductive material on the sidewall of the via from the precipitated conductive material while the via is exposed to the supercritical fluid, the layer of the conductive material having a generally uniform thickness over substantially the entire length of the via in a direction transverse to the width of the via; after forming the conformal layer, forming a vent hole in the substrate extending from the bottom portion of the via to the second surface of the substrate; filling the via with a fill material adjacent to the conformal layer of the conductive material after forming the vent hole, the fill material having a first end proximate to the first surface; exposing a second end of the fill material opposite the first end by removing material from the second surface of the substrate; and attaching a solder ball to the exposed second end of the fill material, the solder ball being in electrical communication with the bond site of the substrate via the fill material in the via. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for processing a substrate, comprising:
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forming a via in a substrate having a first surface and a second surface opposite the first surface, the substrate having a bond site proximate to the first surface, the via having an opening with a width, a bottom portion in the substrate, and a sidewall with a length generally transverse to the width, the length being approximately 100 microns or more; and exposing the sidewall of the via to supercritical carbon dioxide; introducing a conductive material precursor into the supercritical carbon dioxide; reducing the conductive material precursor by introducing an additional chemical specie, or elevating a temperature of the supercritical carbon dioxide, or both; causing the conductive material to precipitate from the supercritical carbon dioxide to form a conformal layer of the conductive material on the sidewall of the via; and maintaining a generally uniform concentration of the precursor in the supercritical fluid through out the via as the conductive material is precipitated from the precursor; after forming the conformal layer, forming a vent hole in the substrate extending from the bottom portion of the via to the second surface of the substrate; filling the via with a fill material adjacent to the conformal layer of the conductive material after forming the vent hole, the fill material having a first end proximate to the first surface; exposing a second end of the fill material opposite the first end by removing material from the second surface of the substrate; and attaching a solder ball to the exposed second end of the fill material, the solder ball being in electrical communication with the bond site of the substrate via the fill material in the via. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28)
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29. A method for processing a substrate, comprising:
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forming a via in a substrate having a first surface and a second surface opposite the first surface, the substrate including a bond site proximate to the first surface, the via having an opening with a width, a bottom portion in the substrate, and a sidewall with a length generally transverse to the width; disposing an organic material on a surface of the substrate and on a sidewall of the via; contacting the sidewall of the via with a precursor of a conductive material in a supercritical fluid; precipitating the conductive material from the precursor in the supercritical fluid onto the sidewall of the via while the supercritical fluid removes at least a portion of the organic material; maintaining a generally uniform concentration of the precursor in the supercritical fluid through out the via as the conductive material is precipitated from the precursor; and forming a conformal layer of the conductive material on the sidewall of the via from the precipitated conductive material while the via is exposed to the supercritical fluid, the layer of the conductive material having a generally uniform thickness over substantially the entire length of the via in a direction transverse to the width of the via; after forming the conformal layer, forming a vent hole in the substrate extending from the bottom portion of the via to the second surface of the substrate; filling the via with a fill material adjacent to the conformal layer of the conductive material, after forming the vent hole, the fill material having a first end proximate to the first surface; exposing a second end of the fill material opposite the first end by removing material from the second surface of the substrate; and attaching a solder ball to the exposed second end of the fill material, the solder ball being in electrical communication with the bond site of the substrate via the fill material in the via. - View Dependent Claims (30, 31, 32, 33)
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34. A method for processing a substrate, comprising:
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forming a via in a substrate having a first surface and a second surface opposite the first surface, the via having an opening proximate to the first surface of the substrate, the opening having a width, a bottom portion in the substrate, and a sidewall with generally transverse to the width; contacting the sidewall of the via with a precursor of a conductive material in a supercritical fluid; precipitating the conductive material from the precursor in the supercritical fluid onto the sidewall of the via, thereby forming a conformal layer of the conductive material on the sidewall of the via; after forming the conformal layer, forming a vent hole in the substrate extending from the bottom portion of the via to the second surface of the substrate; and filling the via with a fill material adjacent to the conformal layer of the conductive material after forming the vent hole. - View Dependent Claims (35, 36, 37, 38, 39, 40)
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Specification