Back side exposure of variable size through silicon vias

Abstract

The formation of microscale vertical interconnects enables three-dimensional interconnects for chip stacking applications. These vertical interconnects, or metal filled through silicon vias, are formed by a series of processing steps that include silicon etch, insulation/barrier/seed deposition, electroplated Cu to fill via, wafer grinding and thinning, and back side processing for contacts. Variable diameter size vias residing in the same wafer allow flexibility in integration for many applications. Producing variable size through silicon vias (VTSVs) on a single wafer is challenging. This article presents details regarding the exposure of VTSV using a unique wafer back side processing technique. Via diameters are in the range of 10–30μm and etch depth varies with via diameter due to the commonly observed reactive ion etch lag. In this approach, the finished wafers are thicker than that produced in a previous project which reduces the risk of wafer breakage during the debonding process.