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CN102099911A - 使用预模制载体的嵌入式裸片封装及工艺流程 - Google Patents

使用预模制载体的嵌入式裸片封装及工艺流程 Download PDF

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Publication number
CN102099911A
CN102099911A CN2009801277269A CN200980127726A CN102099911A CN 102099911 A CN102099911 A CN 102099911A CN 2009801277269 A CN2009801277269 A CN 2009801277269A CN 200980127726 A CN200980127726 A CN 200980127726A CN 102099911 A CN102099911 A CN 102099911A
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China
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forming
electrical device
metal conductors
solder bumps
dielectric layer
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卢克·英格兰
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Fairchild Semiconductor Corp
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Fairchild Semiconductor Corp
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Abstract

本发明提供一种嵌入式裸片封装,其包括:载体,其具有在所述载体的腔中的电装置;第一电介质层,其覆盖所述电装置的侧及顶部,除所述电装置的选定接合垫上方的导通孔外;多个金属导体,其中的每一者与所述导通孔中的至少一者接触;一个或一个以上额外电介质层,其位于所述金属导体及所述第一电介质层上方,其中所述一个或一个以上电介质层的顶部层具有开口,其中下方的金属化物耦合到所述金属导体中的至少一者;及焊料凸块,其从所述开口中的每一者突出。

Description

使用预模制载体的嵌入式裸片封装及工艺流程
相关申请案交叉参考
本申请案请求对2008年7月17日提出申请的第12/175,171号美国专利申请案的优先权。
技术领域
本发明涉及用于所模制电装置或多个电装置的封装。
背景技术
在过去的电装置中,通常通过首先将装置安装于引线框上且然后制作到外部引线的连接且然后囊封来封装(例如)半导体裸片。然而,随着电装置的小型化已发展,已开发且仍正在开发新封装技术,用于通过例如将多个裸片放到一封装中且使用具有薄模制覆盖物的焊料凸块互连的方法来缩小经封装半导体装置。
尽管焊料凸块及薄模制提供小封装,但半导体裸片脆弱且通常必须以充足刚性来封装以保护裸片并密封裸片。另一限制为封装方法,为对于商业市场在经济上可行,其需要具有通用性,以使得其可与不同装置大小及几何形状一同使用且仍提供具有匹配行业中的实际标准的占地面积的封装。
发明内容
在其一个形式上,本发明包含一种形成嵌入式封装的方法。所述方法包含以下步骤:形成具有第一多个腔的载体;将电装置置于所述第一多个腔中的每一者中;在所述电装置中的每一者周围及上方且在所述载体的上部表面上方形成第一电介质层;形成穿过所述电介质层到达所述电装置中的每一者上的选定接合垫的导通孔;及形成第二多个金属导体,其中的每一者与所述导通孔中的一者接触且远离那些导通孔延伸一距离。所述方法还包括:在所述第二多个金属导体中的每一者及所述第一电介质层的暴露部分上方形成一个或一个以上额外电介质层;在金属导体上方于所述一个或一个以上额外电介质层中的一者中形成开口;形成第三多个焊料凸块,其中的每一者耦合到所述第二多个金属导体中的一者;及将所述第一多个腔单个化。
在另一形式上,本发明包含一种嵌入式裸片封装,其包括:预模制载体,其具有在所述载体的第一腔中的第一电装置;第一电介质层,其覆盖所述第一电装置的侧及顶部,除所述电装置的选定接合垫上方的导通孔外;第一多个金属导体,其中的每一者与所述导通孔中的至少一者接触;一个或一个以上额外电介质层,其位于所述金属导体及所述第一电介质层上方,其中所述一个或一个以上电介质层的顶部层在所述金属导体中的每一者的一部分上方具有开口;及第二多个焊料凸块,其从所述开口中的每一者突出。
在又一形式上,本发明包含一种除所述预模制载体为扁平水平表面而非具有腔的预模制载体外的以以上形式描述的嵌入式裸片封装。
附图说明
通过结合附图阅读以下更详细说明,将更好地理解前述及其它特征、特性、优点及本发明大体内容,附图中:
图1A是根据本发明的实施例的预模制载体的图表式横截面图;
图1B是图1A中所示的预模制载体在两个半导体裸片已被裸片附接于所述预模制载体的两个腔中之后的图表式横截面图;
图1C是图1B中所示的预模制载体在第一电介质层已形成之后的图表式横截面图;
图1D是图1C中所示的预模制载体在金属互连件已形成之后的图表式横截面图;
图1E是图1D中所示的预模制载体在第二电介质层已形成之后的图表式横截面图;
图1F是图1E中所示的预模制载体在焊料凸块已形成之后的图表式横截面图;
图2A及2B显示根据本发明的实施例的经封装半导体裸片的相应俯视透视图及仰视透视图;
图3A、3B、3C、3D、3E及3F显示根据本发明的实施例的在形成嵌入式裸片封装时的各个阶段;及
图4、5及6是显示可实践本发明的实施例中的一些实施例的图表式横截面图。
应了解,出于清晰的目的且在认为适当时,已在图中重复参考编号以指示对应的特征。此外,在某些情况下,已使图式中各种物体的相对大小偏离现实以更清楚地显示本发明。
具体实施方式
图1A是从囊封材料(例如,环氧树脂模制化合物)形成的预模制载体20的图表式横截面图。图1中所示的载体20具有两个腔22及24,腔22、24具有用于腔22的外部侧壁26及用于腔24的外部侧壁28。较厚中心壁30将两个腔22、24分离,腔22、24表示预模制载体上的两个邻近封装地点。腔22、24具有基底32。
图1B显示在两个半导体裸片34及36已分别裸片附接于腔22及24中之后的预模制载体20。在图1B中,半导体裸片34及36在预模制载体20的侧壁26、28及中心壁30上面延伸。半导体裸片34及36中的每一者具有接合垫38。可用标准裸片附接方法(例如但不限于环氧树脂或裸片附接膜40)来进行裸片附接。在图1C中,电介质材料42填充半导体裸片34及36、侧壁26、28及中心壁30之间的空隙,且在上面及半导体裸片34及36的顶部延伸。已穿过电介质材料42制作到接合垫38的导通孔44。
电介质材料42可以若干已知方法中的任一种形成,所述方法包括:使用用例如味之素累积膜(ABF)等材料的真空膜层压工艺后接对导通孔44的激光钻孔。还可通过旋涂或喷涂聚酰亚胺或光致抗蚀剂随后进行光刻来形成导通孔44。
沉积、图案化并蚀刻金属化物以形成从接合垫38到不直接在半导体裸片22及24上方的位置的金属互连件48,如图1D中所示。在本发明的一个实施例中,通过首先经由无电极Cu镀敷或Cu喷溅沉积用薄金属种子层涂覆电介质层42的表面及暴露的接合垫38、放下经图案化光致抗蚀剂层且在所述薄金属层的暴露区域中电镀额外金属来形成金属化物。然后移除所述光致抗蚀剂且使用酸性蚀刻移除所述金属种子层。在本发明的另一实施例中,通过A1喷溅沉积来将所述金属互连件形成为所需最终互连件厚度。然后沉积光致抗蚀剂层且将其图案化以匹配互连布线。蚀刻掉所述Al金属,随后进行光致抗蚀剂移除,此留下最终的互连图案。
参照图1E,在形成金属互连件48之后,接着在第一层级电介质材料42及金属互连件48上方施加并图案化第二电介质层52。此电介质层52施加工艺可匹配第一电介质层42施加工艺。
在图1F中,已使用若干已知工艺中的一种形成了焊料凸块56,所述工艺例如但不限于模板印刷或球滴(ball drop)后接回流循环。依据互连金属成分,可需要可软焊的凸块下金属化物(UBM)层。此可通过无电极镀敷方法实现。通过两个封装的单个化来完成嵌入式裸片封装58的形成。
图2A及2B显示根据本发明的实施例的经封装半导体裸片64的相应俯视透视图60及仰视透视图62。这些图中所示的封装具有预模制载体66,第二电介质层68具有突出穿过的焊料凸块56。
图3A到3F显示根据本发明的实施例的形成嵌入式裸片封装70中的各个阶段。图3A显示预模制载体72,其具有九个腔74的矩阵。半导体裸片76被置于六个腔74中的每一者中,如图3B中所示。
图3C显示在第一电介质层80已形成于裸片76上方、导通孔已形成于第一电介质层80中且金属导体82已形成于接合垫78及将放置焊料凸块56的地点84中的每一者之间之后的嵌入式裸片封装。然后,在第一电介质层80及金属导体82上方形成第二电介质层86,且在第二电介质层86中制作开口88以暴露用于焊料凸块56的地点84,如图3D中所示。
图3E显示焊料凸块56位于地点84上,且图3F显示在单个化工艺之后的个别裸片封装70。
图4、5及6显示可实践本发明的实施例中的一些实施例。在图4中,半导体裸片34在腔22中,腔22邻近含有无源电元件92(例如,电感器、电阻器或电容器)的深得多的腔90。半导体裸片34可具有约20μm的高度且电元件92可具有1mm的高度,但每一者的高度可随应用要求而变换。另外,半导体裸片34与电元件92的宽度可不同,如图4中所示。因此,预模制载体94经形成以适应半导体裸片34及电元件92的高度及宽度。
图5是根据本发明的另一实施例的预模制载体的图表式横截面图,其中在两个半导体裸片34与36之间制作有互连金属化物。可使用一般PC板或重分布层技术在不同垂直层级处制作互连件。在图5中,金属互连件96位于第一电介质层42与可比图1E中所示的第二电介质层52厚的第二电介质层94之间。金属互连件96将作为嵌入式裸片封装98(其为多芯片封装)的部分的半导体裸片34及36的接合垫38连接在一起。金属互连件100形成从接合垫102到位于第二电介质层94上的金属互连件104的连接,金属互连件104延伸到金属互连件96。另一金属互连件106形成从接合垫108到位于第二电介质层94上的第二金属互连件110的连接。第三电介质层112覆盖金属互连件104及110以及第二电介质层94的暴露区。图5中还显示,焊料凸块56延伸穿过第三电介质层112中的开口,到达金属互连件104及110。
在图6中,预模制载体114不具有侧壁26、28或中心壁30,而是具有扁平水平表面。上文关于图1A到1F所描述的工艺仍适用于形成图6中所示的实施例。在不使用接合垫38的应用中,嵌入式裸片封装中可不存在到接合垫的金属互连件,其实例显示于图6中。
尽管已参考特定实施例描述了本发明,但所属领域的技术人员应理解,可在不背离本发明范围的情况下做出各种改变且可用等效物代替元件。另外,为适应特定情况或材料可在不背离本发明的范围的情况下对本发明的教示做出许多修改。
因此,本文并非打算将本发明限于所揭示的作为实施本发明的最好设想模式的特定实施例,而是本发明将包括属于所附权利要求书的范围及精神内的所有实施例。

Claims (20)

1.一种形成嵌入式封装的方法,其包含以下步骤:
a)形成具有第一多个腔的载体;
b)将电装置置于所述第一多个腔中的每一者中;
c)在所述电装置中的每一者周围及上方且在所述载体的上部表面上方形成第一电介质层;
d)形成穿过所述电介质层到达所述电装置中的每一者上的选定接合垫的导通孔;
e)形成第二多个金属导体,其中的每一者与所述导通孔中的一者接触且远离所述导通孔中的所述一者延伸一距离;
f)在所述第二多个金属导体中的每一者及所述第一电介质层的暴露部分上方形成一个或一个以上额外电介质层;
g)在金属导体上方于所述一个或一个以上额外电介质层中的一者中形成开口;
h)形成第三多个焊料凸块,其中的每一者耦合到所述第二多个金属导体中的一者;及
i)将所述第一多个腔单个化。
2.根据权利要求1所述的方法,其中通过模制工艺形成所述载体。
3.根据权利要求1所述的方法,其包括将所述电装置附接到所述载体的额外步骤。
4.根据权利要求1所述的方法,其中将所述焊料凸块中的至少一者置于在所述电装置的横向周界外部的位置中。
5.根据权利要求1所述的方法,其中将所述焊料凸块中的至少一者置于在所述电装置的所述横向周界内部的位置中。
6.根据权利要求1所述的方法,其中所述单个化步骤产生含有两个或两个以上腔的嵌入式封装,所述两个或两个以上腔中的每一者含有电装置。
7.根据权利要求1所述的方法,其中穿过所述开口中的至少一者形成所述焊料凸块中的至少一者,从而形成到所述第二多个金属导体中的一者的电连接。
8.一种形成嵌入式封装的方法,其包含以下步骤:
a)形成具有第一多个腔的预模制载体;
b)将电装置置于所述第一多个腔中的每一者中;
c)在所述电装置中的每一者周围及上方且在所述载体的上部表面上方形成第一电介质层;
d)形成穿过所述电介质层到达所述电装置中的每一者上的选定接合垫的导通孔;
e)形成第二多个金属导体,其中的每一者与所述导通孔中的一者接触且远离所述导通孔中的所述一者延伸一距离;
f)在所述第二多个金属导体中的每一者及所述第一电介质层的暴露部分上方形成一个或一个以上额外电介质层;
g)在金属导体上方于所述一个或一个以上额外电介质层中的一者中形成开口;
h)形成第三多个焊料凸块,其中的每一者耦合到所述第二多个金属导体中的一者;及
i)将所述第一多个腔单个化;
j)其中将所述焊料凸块中的至少一者置于在所述电装置的横向周界内部的位置中,且穿过所述开口中的至少一者形成所述焊料凸块中的至少一者,从而形成到所述第二多个金属导体中的一者的电连接。
9.根据权利要求1或权利要求8所述的方法,其中所述电装置为无源装置。
10.根据权利要求1或权利要求8所述的方法,其中通过层压工艺形成所述第一电介质层。
11.根据权利要求1或权利要求10所述的方法,其中通过激光钻孔形成所述导通孔。
12.根据权利要求1或权利要求10所述的方法,其中通过光刻形成所述导通孔。
13.一种嵌入式裸片封装,其包含:
a)预模制载体,其具有在所述载体的第一腔中的第一电装置;
b)第一电介质层,其覆盖所述第一电装置的侧及顶部,除所述电装置的选定接合垫上方的导通孔外;
c)第一多个金属导体,其中的每一者与所述导通孔中的至少一者接触;
d)一个或一个以上额外电介质层,其位于所述金属导体及所述第一电介质层上方,其中所述一个或一个以上电介质层的顶部层具有开口,其中下方的金属化物耦合到所述第一多个金属导体中的至少一者;及
e)第二多个焊料凸块,其从所述开口中的每一者突出。
14.根据权利要求13所述的封装,其中所述焊料凸块中的至少一者置于在所述电装置的横向周界外部的位置中。
15.根据权利要求13所述的封装,其中所述焊料凸块中的至少一者置于在所述电装置的所述横向周界内部的位置中。
16.根据权利要求13所述的封装,其中单个化步骤产生含有两个或两个以上腔的嵌入式封装,所述两个或两个以上腔中的每一者含有电装置。
17.根据权利要求13所述的封装,其进一步包括形成第四多个金属导体的步骤,所述第四多个金属导体中的每一者耦合到所述第二多个金属导体中的至少一者。
18.根据权利要求13所述的封装,其中所述焊料凸块中的至少一者经形成而穿过所述开口中的至少一者,从而形成到所述第一多个金属导体中的一者的电连接。
19.一种嵌入式裸片封装,其包含:
a)预模制载体,其具有在所述载体的第一腔中的第一电装置;
b)第一电介质层,其覆盖所述第一电装置的侧及顶部,除所述电装置的选定接合垫上方的导通孔外;
c)第一多个金属导体,其中的每一者与所述导通孔中的至少一者接触;
d)一个或一个以上额外电介质层,其位于所述第一多个金属导体及所述第一电介质层上方,其中所述一个或一个以上电介质层的顶部层具有开口,其中下方的金属化物耦合到所述第一多个金属导体中的至少一者;及
e)第二多个焊料凸块,其从所述开口中的每一者突出;
f)其中所述焊料凸块中的至少一者位于所述电装置的横向周界的内部,且所述焊料凸块中的至少一者形成到所述第二多个金属导体中的一者的直接电连接。
20.根据权利要求13或权利要求19所述的封装,其中所述电装置为无源装置。
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