Foundry TSV integration and manufacturing challenges

Foundry integration and manufacturing challenges for 2.5D TSV technology are discussed, with focus on in-line defectivity and warpage control. The major defect types and yield correlation are scrutinized. The results show that Cu out-diffusion from TSV due to oxide liner isolation defects has a bigger impact on yield compared to open TSV. The model suggests that one redundant TSV is enough to mitigate open and leakage risks. Interposer warpage behavior is also discussed. It can be influenced by related TSV process modules and optimization can be achieved to minimize the stress induced failures at wafer and die assembly levels. In-line defectivity, wafer warpage and electrical monitoring are essential for yield projection and manufacturing consistency.