This study focuses on alternative technologies for fine pitch 3D interconnect. These technologies are: µ-inserts (insertion of a nickel cylinder in Aluminium pad), µ-tubes (insertion of a hard tube in Aluminium pad), Transient Liquid Phase (TLP) bonding (whole solder reacts to form intermetallic compound) and copper direct bonding. In the first part the process flow is described. Then electrical performances are presented, including a comparison of the Kelvin resistance for each technology. The next part presents reliability considerations, where the failure modes and the weaknesses of each interconnect technologies are described. The mechanical impact of insertion technologies is also studied.
IntroductionOne of the most promising features of 3D Integration is the large communication bandwidth between chips. This can only be achieved through high density TSVs and interconnects. In face to back (F2B) stacking, the interconnect pitch is limited by TSV, but in face to face (F2F) stacking, there is no such limitation. Aggressive pitch is therefore one the top requirement for 3D interconnects. In this study, we will assess and compare different 3D interconnect technologies for sub-20µm pitch. These technologies are: µ-inserts (insertion of a nickel cylinder in Aluminium pad), µ-tubes (insertion of a hard tube in Aluminium pad), Transient Liquid Phase (TLP) bonding (whole solder reacts to form intermetallic compound) and Copper direct bonding. These interconnects have been developed for different application domains, with process temperatures ranging from room temperature to 400°C. In the first part the process flow and the assembly technology used for each type of interconnect are described. The second part focuses on electrical performances. The classical solder bonding technology using µ-bump is also presented as a reference. The Kelvin resistance is used to compare the electrical performance of each interconnect technology. In the last part, reliability considerations are presented. The failure modes and the weaknesses of each interconnect technologies are described. The mechanical impact of insertion technologies is also studied with finite element modeling.