`
`1191'
`
`Hsu
`
`[11] Patent Number:
`
`5,627,106
`
`[45] Date of Patent:
`
`May 6, 1997
`
`USOOS627106A
`
`[54] TRENCH METHOD FOR THREE
`DIMENSIONAL CHIP CONNECTING
`DURING IC FABRICATION
`
`Assistant Examiner—C. Everhart
`Attomey, Agent, or Fimz—William H. Wright
`
`[57]
`
`ABSTRACT
`
`A new method of connecting three-dimensional integrated
`circuit chips using trench technology is described. Semicon-
`ductor device structures are provided in and on the top side
`of a semiconductor substrate of a first and a second three—
`
`integrated circuit chip. Deep trenches are
`dimensional
`etched into the first semiconductor substrate. A conductive
`
`material is deposited into the trenches. An insulating mate-
`rial is deposited over the surface of the substrate, polished
`and planarized. The bottom side of the first semiconductor
`substrate is ground, polished, and selectively etched so that
`the deep trenches form protrusions from the bottom surface.
`A passivation layer and a polyirnide layer are deposited on
`the bottom surface of the first semiconductor substrate and
`
`etched away around the protrusions. A pas sivation layer and
`a polyirnide layer are deposited over the top surface of the
`second semiconductor substrate. Connection windows are
`
`etched through the two layers to the top conducting surface
`of the second semiconductor substrate. The first and second
`
`integrated circuits are aligned so that the protrusions on the
`bottom surface of the first integrated circuit chip fit into the
`connection windows in the top surface of the second inte—
`grated circuit chip. The polyirnide layer on the bottom
`surface of the first integrated circuit contacts the polyimide
`layer on the top surface of the second integrated circuit
`completing the connection between the two chips.
`
`[75]
`
`Inventor: Chen-Chung Hsu, Taichung, Taiwan
`
`[73] Assignee: United Microelectronics Corporation,
`Hsin—Chu, Taiwan
`
`[21] Appl. N0.: 239,281
`
`[22] Filed:
`
`May 6, 1994
`
`Int. Cl.6 ..................................................... H01L 21/44
`[51]
`[52] US. Cl.
`.......................... 438/459; 438/152; 438/667;
`438/107
`
`[58] Field of Search ..................................... 437/203, 915.
`437/208, 209; 148/DIG. 164
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`
`156/633
`..
`9/1986 Yasumoto et al.
`4/1989 Rai et al.
`................................ 437/209
`1/1991 Chatterjee.
`3/1991 Hayashi
`............................... 228/1801
`2/1992 Hayashi
`.. ......... ..
`.... ... 437/51
`6/1993 Batchelder et al.
`356/345
`11/1993 Takao ............ ... ..
`....... 437/51
`12/1993 Bertin et a1.
`437/209
`5/1995 Huebner .................................. 156/645
`
`
`
`4,612,083
`4,818,728
`4,982,266
`4,998,665
`5,087,585
`5,220,403
`5,266,511
`5,270,261
`5,419,806
`
`Primary Examiner—George Fourson
`
`33 Claims, 6 Drawing Sheets
`
`
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`SAMSUNG EXHIBIT 1008
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`SAMSUNG EXHIBIT 1008
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`1 Sheet 1 of 6
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`FIG.
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`1
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`FIG. 2
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`Sheet 2 of 6
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`FIG. 3
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`
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`FIG. 4
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`Sheet 3 of 6
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`FIG. 6
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`52
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`4-2
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`52
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`
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`+
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`50
`48
`46
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`45
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`44
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`9
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`Sheet 6 of 6
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`20
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`20
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`1
`TRENCH METHOD FOR THREE
`DIMENSIONAL CHIP CONNECTING
`DURING IC FABRICATION
`
`BACKGROUND OF THE INVENTION
`
`(1) Field of the Invention
`The invention relates to a method of connecting three-
`dimensional integrated circuits chips, and more particularly,
`to a method of connecting integrated circuit chips using a
`trench method.
`
`(2) Description of the Prior Art
`The density and scale of integration of integrated circuit
`chips will continue to increase in the future. High density
`integrated circuits have a limited space available without
`shrinking transistor device sizes. One of the technologies
`which provide a means to break through the space limitation
`is a three—dimensional integrated circuit technology.
`Using three-dimensional integrated circuit
`technology,
`high density integrated circuits can be produced which
`consist of one master chip and some subordinate chips. All
`control circuits can be put in the master chip and other
`function block circuits can be arranged in subordinate chips
`with interconnection between the chips. For example, in a
`Read-Only Memory (ROM) or Static Random Access
`Memory (SRAM) circuit, the control circuit can be fabri—
`cated on the master chip and 8 input/output (I/O) blocks can
`be formed in each subordinate chip. The chips can be
`stacked by interconnection through the pad window. The
`interconnection between chips can be fabricated during
`integrated circuit processing. Using this method, we can
`fabricate a high density ROM or SRAM stack memory chip.
`US. Pat. No. 4,818,728 to Rai et al teaches a chip
`interconnection method involving metal studs on a surface
`of one chip and solder deposits on the surface of the second
`chip. The solder deposits are melted and the chips connected
`by fixing the metal studs into the melted solder. US. Pat. No.
`4,998,665 to Hayashi teaches a chip interconnection method
`in which a high melting point conductive material projection
`is plunged into a liquid low melting point conductive
`material and then cooled to complete the connection.
`
`SUMMARY OF THE INVENTION
`
`Aprincipal object of the present invention is to provide an
`etfective and Very manufacturable method of connecting
`three-dimensional integrated circuit chips.
`Another object of the invention is to provide an effective
`and very manufacturable method of connecting three-
`dimensional integrated circuit chips using a trench method.
`In accordance with the objects of this invention, a new
`method of connecting three-dimensional integrated circuit
`chips using trench technology is achieved. Semiconductor
`device structures are provided in and on the top side of a
`semiconductor substrate of a first and a second three-
`
`integrated circuit chip. The first integrated
`dimensional
`circuit chip is prepared for connection as follows. Deep
`trenches are etched into the first semiconductor substrate. An
`
`insulating film is deposited over the entire surface of the first
`semiconductor substrate and within the deep trenches. The
`insulating film is selectively etched away from the bottom of
`the trenches. Afirst conductive material is deposited into the
`trenches. A second conductive material is deposited over the
`surface of the oxide film wherein the second conductive
`material connects to the first conductive material. A passi-
`vation layer is formed over the second conductive layer.
`Contact windows are opened in the passivation layer to the
`
`5,627,106
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`2
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`second conductive layer over the deep trenches. The bottom
`side of the first semiconductor substrate is ground, polished,
`and selectively etched so that the deep trenches form pro-
`trusions from the bottom surface of the first semiconductor
`
`substrate. A bottom passivation layer is deposited on the
`bottom surface of the first semiconductor substrate. The
`
`bottom passivation layer is etched away around the protru-
`sions. A polyimide coating is deposited over the surface of
`the bottom passivation layer and etched away around the
`protrusions completing preparation of the first integrated
`circuit for connection. The second integrated circuit chip is
`prepared for connection as follows. A passivation layer is
`deposited over the top surface of the second semiconductor
`substrate. A polyimide coating is applied over the passiva—
`tion layer. Connection windows are etched through the
`polyimide and passivation layers to the top conducting
`surface of the second semiconductor substrate completing
`preparation of the second integrated circuit for connection.
`The first and second integrated circuits are aligned so that
`the protrusions on the bottom surface of the first integrated
`circuit chip fit into the connection windows in the top
`surface of the second integrated circuit chip. The polyimide
`layer on the bottom surface of the first integrated circuit
`contacts the polyimide layer on the top surface of the second
`integrated circuit completing the connection between the
`two three-dimensional integrated circuit chips.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`In the accompanying drawings forming a material part of
`this description, there is shown:
`FIG. 1 schematically illustrates a simple inverter circuit.
`FIGS. 2 through 8 schematically illustrate in cross-
`sectional representation the preparation of a subordinate
`chip for connection.
`FIG. 9 schematically illustrates in cross-sectional repre-
`sentation the preparation of a master chip for connection.
`FIGS. 10 through 12 schematically illustrate in cross—
`sectional representation the connection of a master chip and
`a subordinate chip.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`The logic diagram of a simple CMOS inverter circuit is
`shown in FIG. 1. Such a circuit will be used as an example
`to describe the stacking chip fabrication by trench connec-
`tion method of the invention. For example,
`the NMOS
`portion of the circuit may reside in the master chip while the
`PMOS portion of the circuit resides in the subordinate chip.
`Referring now more particularly to FIG. 2, the process of
`the present invention will be described. A portion of a
`partially completed integrated circuit subordinate chip is
`illustrated in FIG. 2 consisting of a semiconductor substrate
`10, preferably composed of monocrystalline silicon. Semi-
`conductor device structures have been formed as is conven-
`tional in the art in and on the semiconductor substrate 10.
`
`For example, gate electrode 12 and source/drain regions 14
`are illustrated in FIG. 2. Now the subordinate chip will be
`prepared for interconnection with a master chip.
`First, deep trenches 16 are etched into the silicon substrate
`as by reactive ion etching. The trenches are more than about
`10 microns in depth and are between about 20 to 50 microns
`in width. A silicon dioxide film 18 for insulation is formed
`on the entire surface of the substrate. This film is formed by
`atmospheric pressure chemical vapor deposition (APCVD)
`and has a thickness of between about 2500 to 3000 Ang-
`stroms.
`
`5
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`15
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`Referring now to FIG. 3. the silicon dioxide film 18 is
`selectively etched from the bottom of the trenches 16. A
`mask patterning process is used to accomplish this selective
`plasma etching.
`A conductive material layer 20 is deposited by selective
`tungsten chemical vapor deposition (CVD) techniques. as
`shown in FIG. 4.
`
`Referring now to FIG. 5. an insulation material 22. such
`as silicon dioxide. is deposited over the silicon dioxide film
`18. This layer is polished by Chemical Mechanical Polishing
`(CMP) to planarize the layer. The combined thickness of
`insulation layers 18 and 22 is between about 3000 to 3500
`Angstroms.
`In order to handle a thin wafer more easily. a sacrificial
`wafer is used A layer of thermal oxide 24 is grown to a
`thickness of between about 3000 to 5000 Angstroms on the
`surface of a monocrystalline silicon wafer 25. Using wafer
`oxide to oxide bonding technology. the silicon dioxide layer
`22 bonds with the thermal oxide layer 24 of the sacrificial
`wafer. as shown in FIG. 6.
`
`the bottom surface of the
`Referring now to FIG. 7.
`substrate is ground and polished so that only a thin portion
`of the substrate remains over the tungsten-filled trenches 20.
`Back side selective etching is used to etch away the silicon
`substrate from the bottom leaving the tungsten-filled
`trenches protruding about 5 to 6 microns from the bottom
`surface of the substrate.
`
`Using plasma enhanced chemical vapor deposition
`(PECVD). a silicon dioxide passivation layer 28 is deposited
`on the bottom surface of the substrate. as shown in FIG. 8.
`using a low temperature of less than about 300° C. to a
`thickness of between about 8000 to 12.000 Angstroms.
`Using photoresist and a mask patterning process. the oxide
`layer 22 is etched away around the protrusions 20. as shown
`in FIG. 8. A layer of polyimide 30 is coated on the bottom
`surface of the substrate. Using photoresist and a mask
`patterning process as above. the polyimide layer 30 is etched
`away around the tungsten protrusions 20. The subordinate
`chip has now been prepared for connection.
`Referring now to FIG. 9. the master chip is prepared for
`connection to the subordinate chip. A portion of a partially
`completed integrated circuit master chip is illustrated in
`FIG. 9 consisting of a semiconductor substrate 40. prefer—
`ably composed of monocrystalline silicon. Semiconductor
`device structures have been formed as is conventional in the
`
`art in and on the semiconductor substrate 40. For example,
`gate electrode 42 and source/drain regions 44 are illustrated
`in FIG. 9. Aconductive layer. such as aluminum, 46 has been
`deposited and patterned on the top surface of the substrate.
`Now a passivation layer 48 of silicon dioxide or silicon
`nitride is deposited by CVD over the top of the patterned
`conductive layer 46.
`A polyimide coating 50 is now applied to the top surface
`of the substrate. The polyimide and passivation layers 50
`and 48. respectively. are etched to provide connection win-
`dows 52 contacting conductive layer 46 and in a position
`corresponding to the protrusions of the subordinate chip.
`The master chip is now prepared for interconnection to the
`subordinate chip.
`Using infrared microscopy, the subordinate chip and the
`master chip are aligned and put together at between about
`380° to 420° C.. and preferably 400° C. so that the protru-
`sions 20 of the subordinate chip fit into the connection
`windows 52 of the master chip as shown in FIG. 10. The
`tungsten protrusions 20 will adhere to the metal layer 48
`within the contact windows 52 and the two polyimide layers
`
`10
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`15
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`30 and 50 will adhere to complete the connection of the two
`integrated circuit chips.
`the combination chip is
`Referring now to FIG. 11.
`reversed 180°. The sacrificial silicon surface 25 and the
`thermal oxide 24 are ground and polished using CMP to the
`edge of the silicon dioxide 22 layer.
`Referring now to FIG. 12. a metal layer 26 is deposited on
`the surface of the subordinate chip and patterned. A silicon
`dioxide layer 27 is deposited over the metal layer 26. The top
`surface of the subordinate chip can now be prepared to be
`connected to other subordinate chips. This combination chip
`will now act as the master chip to be connected to another
`subordinate chip. following the process of the invention
`described in detail above.
`
`While the invention has been particularly shown and
`described with reference to the preferred embodiments
`thereof. it will be understood by those skilled in the art that
`various changes in form and details may be made without
`departing from the spirit and scope of the invention.
`What is claimed is:
`1. The method of connecting two three-dimensional inte-
`grated circuit chips comprising:
`providing semiconductor device structures in and on the
`top side of a semiconductor substrate of a first and a
`second three-dimensional integrated circuit chip;
`preparing said first integrated circuit chip for connection
`as follows:
`
`etching deep trenches into said first semiconductor
`substrate;
`depositing an insulating film over the entire surface of
`said first semiconductor substrate and within said
`
`deep trenches;
`selectively etching away said insulating film from the
`bottom of said trenches;
`depositing a conductive material into said trenches;
`depositing an isolation material over the surface of said
`insulating film and polishing and planarizing said
`isolation material;
`grinding, polishing, and selectively etching the bottom
`side of said first semiconductor substrate wherein
`
`said deep trenches form protrusions from said bot—
`tom surface of said first semiconductor substrate;
`depositing a bottom passivation layer on said bottom
`surface of said first semiconductor substrate;
`etching away said bottom passivation layer around said
`protrusions;
`depositing a polyimide coating over the surface of said
`bottom passivation layer; and
`etching away said polyimide coating around said pro-
`trusions completing preparation of said first inte-
`grated circuit for connection;
`preparing said second integrated circuit chip for connec-
`tion as follows:
`
`depositing a passivation layer over the top surface of
`said second semiconductor substrate;
`depositing a polyimide coating over said passivation
`layer; and
`etching through said polyimide and said passivation
`layers to said top conducting surface of said second
`semiconductor substrate to provide connection win-
`dows for said connection completing preparation of
`said second integrated circuit for connection;
`aligning said first and second integrated circuits wherein
`said protrusions on said bottom surface of said first
`integrated circuit chip fit into said connection windows
`in said top surface of said second integrated circuit chip
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`and wherein said polyimide layer on said bottom sur-
`face of said first integrated circuit contacts said poly-
`imide layer on said top surface of said second inte-
`grated circuit; and
`completing said connection between said two three-
`dimensional integrated circuit chips.
`2. The method of claim 1 wherein said first integrated
`circuit chip is a subordinate chip and wherein said second
`integrated circuit chip is a master chip.
`3. The method of claim 1 wherein said semiconductor
`device structures include gate electrodes and source and
`drain regions.
`4. The method of claim 1 wherein said deep trenches
`extend greater than 10 microns into the surface of said first
`semiconductor substrate.
`5. The method of claim 1 wherein said deep trenches have
`a width of between about 20 to 50 microns.
`6. The method of claim 1 wherein said insulating film is
`composed of silicon dioxide and is deposited by atmospheric
`pressure chemical vapor deposition (APCVD) to a thickness
`of between about 2500 to 3000 Angstroms.
`7. The method of claim 1 wherein said conductive mate-
`rial is tungsten.
`8. The method of claim 1 wherein said isolation material
`is sflicon dioxide and wherein said isolation material is
`polished using Chemical Mechanical Polishing.
`9. The method of claim 1 wherein after said isolation
`material has been planarized, a sacrificial semiconductor
`chip composed of a thermal oxide layer grown on the surface
`of a silicon substrate is bonded to said first integrated circuit
`chip wherein said thermal oxide layer of said sacrificial
`semiconductor chip bonds to said isolation material of said
`first
`integrated circuit chip and wherein said sacrificial
`integrated circuit chip allows for ease of handling of said
`first integrated circuit chip.
`10. The method of claim 9 wherein after said two three-
`dimensional integrated circuit chips have been connected,
`said silicon substrate and said thermal oxide layer of said
`sacrificial semiconductor chip are ground and polished away
`leaving said isolation material as the top layer of said first
`integrated circuit chip.
`11. The method of claim 1 wherein said protrusions
`protrude from the bottom side of said first semiconductor
`substrate by between about 5 to 6 microns.
`12. The method of claim 1 wherein said bottom passiva-
`tion layer is composed of silicon dioxide and is deposited by
`plasma enhanced chemical vapor deposition (PECVD) to a
`thickness of between about 8000 to 12,000 Angstroms.
`13. The method of claim 1 wherein said polyimide layer
`is coated to a thickness of between about 15,000 to 20,000
`Angstroms.
`14. The method of claim 1 wherein said passivation layer
`deposited on top surface of said second semiconductor
`substrate is composed of phosphosilicate glass and is depos-
`ited to a thickness of between about 8000 to 12.000 Ang-
`stroms.
`
`15. The method of claim 1 wherein said passivation layer
`deposited on top surface of said second semiconductor
`substrate is composed of silicon nitride and is deposited to
`a thickness of between about 8000 to 12,000 Angstroms.
`16. The method of claim 1 wherein said polyimide layer
`is deposited on said top surface of said second semiconduc-
`tor substrate to a thickness of between about 15,000 to
`20,000 Angstroms.
`17. The method of claim 1 wherein said first and second
`integrated circuits are aligned using infrared microscopy.
`18. The method of claim 1 wherein said first and second
`integrated circuits are connected by thermal compression of
`about 190 kg/cm2 and heating said integrated circuits to
`400° C.
`
`6
`19. The method of claim 1 wherein after said first and
`second integrated circuit chips have been connected, a metal
`layer is deposited over the surface of said first integrated
`circuit chip and wherein said connected integrated circuit
`chip can be prepared to be connected to a third integrated
`circuit chip wherein said connected integrated circuit chip
`will be prepared f0r connection as was said second inte-
`grated circuit chip described hereabove.
`20. The method of claim 19 wherein said metal layer is
`composed of aluminum deposited to a thiclmess of between
`about 8000 to 10.000 Angstroms.
`21. The method of connecting two-three dimensional
`integrated circuit chips comprising:
`providing semiconductor device structures in and on the
`top side of a semiconductor substrate of a first and a
`second three-dimensional
`integrated circuit chip
`wherein said semiconductor device structures include
`
`gate electrodes and source and drain regions;
`forming protrusions of a conductive material protruding
`from the bottom surface of said first integrated circuit
`chip wherein said bottom surface between said protru—
`sions is covered with a passivation layer covered with
`polyimide coating, said protrusion formed by:
`etching deep trenches into said first semiconductor
`substrate,
`depositing an insulating film over the entire surface of
`said first semiconductor substrate and within said
`
`deep trenches.
`selectively etching away said insulating film from the
`bottom of said trenches,
`depositing a conductive material into said trenches,
`depositing an isolation material over the surface of said
`insulating film and planarizing said isolation
`material, and
`removing a portion of said first semiconductor substrate
`so that said deep trenches form said protrusions;
`covering the top conductive surface of said second inte-
`grated circuit chip with a polyimide layer wherein said
`polyimide layer is deposited over a passivation layer;
`opening connection windows through said polyimide and
`said passivation layers to said top conductive surface of
`said second integrated circuit chip wherein said con-
`nection windows of said second integrated circuit chip
`correspond to said protrusions on said first integrated
`circuit chip; and
`aligning said first and second integrated circuit chips
`wherein said protrusions on said bottom surface of said
`first integrated circuit chip fit into said connection
`windows and contact said conductive surface of said
`second integrated circuit chip and wherein said poly—
`imide layer on said bottom surface of said first inte-
`grated circuit contacts said polyimide layer on said top
`surface of said second integrated circuit.
`22. The method of claim 21 wherein said first integrated
`circuit chip is a subordinate chip and wherein said second
`integrated circuit chip is a master chip.
`23. The method of claim 21 wherein said deep trenches
`extend greater than 10 microns into the surface of said first
`semiconductor substrate.
`
`10
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`15
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`20
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`25
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`30
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`35
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`4o
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`45
`
`50
`
`55
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`24. The method of claim 21 wherein said deep trenches
`have a width of between about 20 to 50 Angstroms.
`25. The method of claim 21 wherein said insulating film
`is composed of silicon dioxide and is deposited to a thick-
`ness of between about 2500 to 3000 Angstroms.
`26. The method of claim 21 wherein said conductive
`material is tungsten.
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`27. The method of claim 21 wherein said isolation mate-
`rial is silicon dioxide and wherein said isolation material is
`polished using Chemical Mechanical Polishing.
`28. The method of claim 21 wherein said protrusions
`protrude from the bottom side of said first semiconductor
`substrate by between about 5 to 6 microns.
`29. The method of claim 21 wherein said polyirnide layer
`on said bottom surface of said first integrated circuit is
`coated to a thickness of between about 8000 to 12.000
`Angstroms.
`30. The method of claim 21 wherein said polyirnide layer
`deposited on top surface of said second integrated is coated
`to a thickness of between about 8000 to 12,000 Angstroms.
`31. The method of claim 21 wherein said first and second
`
`integrated circuits are aligned using infrared microscopy.
`32. The method of claim 21 wherein said first and second
`integrated circuits are connected by thermal compression of
`about 190 kg/cm2 and heating said integrated circuits to
`400° C.
`33. The method of connecting two three-dimensional
`integrated circuit chips comprising:
`providing semiconductor device structures in and on the
`top side of a semiconductor substrate of a first and a
`second three-dimensional
`integrated circuit chip
`wherein said semiconductor device structures include
`gate electrodes and source and drain regions;
`forming protrusions of a conductive material protruding
`from the bottom surface of said first integrated circuit
`chip comprising the steps of:
`etching deep trenches into said first semiconductor
`substrate;
`depositing an insulating film over the entire surface of
`said first semiconductor substrate and within said
`deep trenches;
`selectively etching away said insulating film from the
`bottom of said trenches;
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`8
`depositing a conductive material into said trenches;
`depositing an isolation material over the surface of said
`insulating film and polishing and planarizing said
`isolation material; and
`grinding, polishing. and selectively etching the bottom
`side of said first semiconductor substrate wherein
`
`said deep trenches form said protrusions from said
`bottom surface of said first semiconductor substrate;
`
`covering said bottom surface between said protrusions
`with a passivation layer COVered with a polyirnide
`coating;
`covering the top conductive surface of said second inte-
`grated circuit chip with a polyirnide layer wherein said
`polyimide layer is deposited over a passivation layer;
`opening connection windows through said polyirnide and
`said passivation layers to said top conductive surface of
`said second integrated circuit chip wherein said con-
`nection windows of said second integrated circuit chip
`correspond to said protrusions on said first integrated
`circuit chip;
`aligning said first and second integrated circuit chips
`wherein said protrusions on said bottom surface of said
`first integrated circuit chip fit into said connection
`windows and contact said conductive surface of said
`
`second integrated circuit chip and wherein said poly-
`imide layer on said bottom surface of said first inte-
`grated circuit contacts said polyimide layer on said top
`surface of said second integrated circuit; and
`completing said connection between said two three-
`dimensional integrated circuit chips by thermal com-
`pression of about 190 kgcm2 and heating said inte-
`grated circuit chips to 400° C.
`*
`*
`*
`*
`
`*
`
`SAMSUNG EXHIBIT 1008
`Page 11 of 11
`
`
`
`SAMSUNG EXHIBIT 1008
`
`Page 11 of 11
`
`