Protective layer for protecting TSV tips during thermo-compressive bonding
A method of protecting through substrate via (TSV) die from bonding damage includes providing a substrate including a plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs that include an inner metal core that reaches from the topside to protruding TSV tips that extend out from the bottomside. A protective layer is formed on or applied to the bottomside of the TSV die including between and over the protruding TSV tips. The TSV die is bonded with its topside down onto a workpiece having a workpiece surface and its bottomside up and in contact with a bond head. The protective layer reduces damage from the bonding process including warpage of the TSV die by preventing the bond head from making direct contact to the protruding TSV tips.
1. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips; and
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips, wherein said TSV tips include a metal cap thereon comprising at least one metal layer that includes a metal that is not in said inner metal core.
2. The method of claim 1 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
3. The method of claim 1 , wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
4. The method of claim 1 , wherein said workpiece comprises an organic substrate.
5. The method of claim 1 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
6. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips; and
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips, wherein said workpiece comprises an organic substrate.
7. The method of claim 6 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
8. The method of claim 6 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
9. The method of claim 6 , wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
10. The method of claim 6 , wherein said workpiece is mounted to a carrier wafer during said bonding.
11. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips;
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips;
removing at least a portion of said protective layer to expose said plurality of TSV tips after said bonding; and
bonding a top die having bonding features to said plurality of TSV tips on said TSV die after said expose, wherein said removing comprises a dry etch.
12. The method of claim 11 , wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
13. The method of claim 11 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
14. The method of claim 11 , wherein said workpiece comprises an organic substrate.
15. The method of claim 11 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
16. The method of claim 11 , wherein said workpiece is mounted to a carrier wafer during said bonding.
17. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips; and
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips, wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
18. The method of claim 17 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
19. The method of claim 17 , wherein said workpiece comprises an organic substrate.
20. The method of claim 17 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
21. The method of claim 17 , wherein said workpiece is mounted to a carrier wafer during said bonding.
22. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips; and
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips, wherein said workpiece is mounted to a carrier wafer during said bonding.
23. The method of claim 22 , wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
24. The method of claim 22 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
25. The method of claim 22 , wherein said workpiece comprises an organic substrate.
26. The method of claim 22 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
27. A method of protecting through substrate via (TSV) die from bonding damage, comprising:
providing a substrate comprising a plurality of TSV die, said plurality of TSV die having a topside including active circuitry, a bottomside, and a plurality of TSVs comprising an inner metal core that reaches from said topside to protruding TSV tips that extend out from said bottomside;
forming or applying a protective layer on said bottomside including between and over said protruding TSV tips; and
bonding said TSV die with said topside down onto a workpiece having a workpiece surface and said bottomside up and in contact with a bond head, wherein said protective layer prevents said bond head from making direct contact to said protruding TSV tips, wherein said inner metal core comprises copper and said TSV tips include a metal cap thereon that includes at least one of titanium, nickel, palladium, and gold.
28. The method of claim 27 , wherein said forming said protective layer comprises a spin-on process, and at least one curing process subsequent to said spin-on process.
29. The method of claim 27 , further comprising singulating said substrate into a plurality of said TSV die before said bonding.
30. The method of claim 27 , wherein said workpiece comprises an organic substrate.
31. The method of claim 27 , wherein said protective layer is a blanket layer that substantially planarizes said bottomside of said TSV die.
32. The method of claim 27 , wherein said workpiece is mounted to a carrier wafer during said bonding.