Enhanced Polymer Passivation Layer for Wafer Level Chip Scale ...

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Acknowledgments An undertaking such as a dissertation is not completed without the support of many people. My first wholehearted gratitude must go to my advisor, Dr. R. Wayne Johnson for his support and academic guidance throughout my pursuit of this degree. His wisdom, rigor and academic achievements in science and technology, and his wonderful, kindly personality have made him a lifetime example for me. Special thanks to my committees, Dr. Robert N Dean, Dr. Stuart M. Wentworth, and Dr. Dong-Joo (Daniel) Kim for their advice on this work. Thanks are also given to my group member and friends, Ping Zheng, Rui Zhang, and Phillip Henson for their cooperative support and assistance. The financial support provided for this work by Lord Corporation is acknowledged. I would like to recognize the help of several key members of the technical staffs and industrial financial support partner. Special thanks are due to Mike Palmer, John Marcell, Charles Ellis, and Russell Stapleton for their assistance throughout the process of this research. Finally, I would like to express my profound gratitude to my parents and my husband Anjen Cheng for their love, understanding, encouragement and support throughout this work. iv
Table of Contents Abstract ......................................................................................................................................... ii Acknowledgments........................................................................................................................ iv List of Tables ............................................................................................................................. viii List of Figures .............................................................................................................................. ix Chapter 1 Introduction ................................................................................................................ 1 1.1 Trends in Integrated Circuit (IC) Package .................................................................. 1 1.2 Chip Scale Package ..................................................................................................... 2 1.3 Wafer Level Chip Scale Package .............................................................................. 4 1.4 Solder Joint Fatigue .................................................................................................. 5 1.5 Photo-definable Epoxy Resin ................................................................................... 6 1.6 Research Objective and Outlines .............................................................................. 8 Chapter 2 Literature Review ..................................................................................................... 13 2.1 Chip Scale Package Technology ............................................................................... 13 2.1.1 Background .................................................................................................... 13 2.1.2 Advantages and Disadvantages ...................................................................... 14 2.2 Wafer Level Chip Scale Packaging Technology ..................................................... 16 2.2.1 Background .................................................................................................... 16 2.2.2 WLCSP Process Flow .................................................................................... 20 2.2.3 Technical Challenges ..................................................................................... 22 v
Page 1 and 2: Enhanced Polymer Passivation Layer
Page 3: SolderBrace coatings were low tempe
Page 7 and 8: 4.4 Failure Analysis ..............
Page 9 and 10: List of Figures Figure 1.1 Trends i
Page 11 and 12: Figure 3.17 SAC305 Reflow profile .
Page 13 and 14: CHAPTER 1 INTRODUCTION In the era o
Page 15 and 16: This effect changes the package to
Page 17 and 18: 1.4 Solder Joint Fatigue Figure 1.2
Page 19 and 20: leading to the solder joint failure
Page 21 and 22: umped wafers. The coating is stenci
Page 23 and 24: 11 Bumped Wafer Print over ball Pre
Page 25 and 26: 2.1 Chip Scale Package Technology C
Page 27 and 28: Mountable with conventional assembl
Page 29 and 30: Figure 2.3 Cross section of a typic
Page 31 and 32: Table 2.1 Comparison between tradit
Page 33 and 34: In-Situ Bumped Wafers Placed Prefor
Page 35 and 36: of solder joint failure, and they o
Page 37 and 38: (a) (b) Figure 2.8(a). Metalized ph
Page 39 and 40: "underfilled" structure distributes
Page 41 and 42: have generally been the modificatio
Page 43 and 44: are “low temperature” wafer lev
Page 45 and 46: 2.3.4 Optimized SolderBrace Materia
Page 47 and 48: CHAPTER 3 WLCSP DIE FABRCIATION In
Page 49 and 50: Table 3.1 Test Die used for Reliabi
Page 51 and 52: Figure 3.4 Fabrication Process Flow
Page 53 and 54: spin coating. A layer of light sens
Page 55 and 56:
layer, is investigated as a potenti
Page 57 and 58:
10. Final cleaning: After the passi
Page 59 and 60:
Cyclopentanone, a colorless liquid
Page 61 and 62:
used to check the basic spin and ph
Page 63 and 64:
Figure 3.7 SolderBrace film thickne
Page 65 and 66:
6. Post-UV exposure bake: This step
Page 67 and 68:
8. Pattern characterization: The su
Page 69 and 70:
offers the optimum flux release cha
Page 71 and 72:
fatigue resistance, lower cost SAC
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Figure 3.12 Solder Ball Placement M
Page 75 and 76:
of solder balls to the holes on the
Page 77 and 78:
of thermal shock. If the temperatur
Page 79 and 80:
Figure 3.17 SAC305 Reflow profile -
Page 81 and 82:
foaming and high performance cleane
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- Polish clean: used the optimized
Page 85 and 86:
Figure 3.22 SolderBrace printed waf
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Voids Figure 3.25 SolderBrace Mater
Page 89 and 90:
cutting speed was set at a low valu
Page 91 and 92:
Figure 4.2 Process Flow of Board As
Page 93 and 94:
pitch, and bump diameter), and subs
Page 95 and 96:
4.2.4 X-Ray Inspection Figure 4.5 R
Page 97 and 98:
Figure 4.6 Air to air thermal cycli
Page 99 and 100:
Figure 4.7 Thermal Cycling Setup 87
Page 101 and 102:
4.4 Failure Analysis The main purpo
Page 103 and 104:
Figure 4.10 Pad cratering failure o
Page 105 and 106:
CHAPTER 5 FINITE ELEMENT ANALYSIS I
Page 107 and 108:
5.1.1 Modeling Approaches Due to th
Page 109 and 110:
are shown in Figure 5.2. However, t
Page 111 and 112:
5.1.2 Material Properties Many pack
Page 113 and 114:
strain rate sensitivity. The evolut
Page 115 and 116:
Morris et a1 [96] used a double pow
Page 117 and 118:
focus on the time-dependent effects
Page 119 and 120:
5.2 Modeling Procedure In this proj
Page 121 and 122:
Figure 5.6 The diagonal symmetry mo
Page 123 and 124:
5.2.3 Meshing Table 5.2 Anand const
Page 125 and 126:
direction, but that the surface is
Page 127 and 128:
PREP7 tref,398 ! set zero strain te
Page 129 and 130:
5.2.7 Thermal Fatigue Life Predicti
Page 131 and 132:
CHAPTER 6 CONCLUSIONS Wafer level c
Page 133 and 134:
References 1. Future Trends in Elec
Page 135 and 136:
23. Electronic Packaging and Interc
Page 137 and 138:
48. Ultra Low Stress and Low Temper
Page 139 and 140:
70. Factors for Successful Wafer-Le
Page 141 and 142:
92. Microstructural Dependendence o
Page 143:
111. Nonlinear Analysis of Full Mat
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