This paper describes yield, contact resistance, and preliminary reliability test results on micro-bump C4 interconnects in modules containing Si-chips and Si-carriers. Modules containing eutectic PbSn or SnCu bump solders were fabricated with high yield, with similar interconnect contact resistances for both solders. The contact resistance and reliability test results to date suggest that reliable, highcurrent, high-density bump interconnections can be achieved for Si-carrier technology.
IntroductionSilicon-carrier System-on-Package (SOP) technology offers much promise for a number of electronic packaging applications [1,2]. Several key technology components are required to enable this technology, including Si through-vias, high-density wiring, and high-density, controlled-collapse chip-connection (C4) interconnects between the silicon chip and silicon carrier (micro-bumps). Micro-bump flip-chip interconnections allow high wiring density in the Si-carrier, as compared to organic or ceramic substrates, and also enable high-performance signal and power connections. Although small C4 bumps were first fabricated in the 1960's, the packaging industry is only now moving toward bump arrays smaller than standard 100 µm diameter on 200 µm pitch (4-on-8). When combined with high-density wiring in the Sicarrier, high-density interconnections allow increased signal bandwidth between multiple chipsets, with little or no reduction in signal quality. Of equal importance, a high density array of power and ground interconnections allows improvements in power distribution design, especially for applications involving power cycling. Questions remain concerning the viability of fine-pitch bump arrays, particularly for package components with different thermal expansion coefficients (CTE). For Sn-based solders, there is strong formation of brittle intermetallic compounds (IMCs) over time. As the bump size decreases, the ratio of volume to surface area decreases, so the IMCs will constitute a larger portion of the bump.