CN106548998A - 封装基材的制作方法 - Google Patents
封装基材的制作方法 Download PDFInfo
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- CN106548998A CN106548998A CN201610602076.0A CN201610602076A CN106548998A CN 106548998 A CN106548998 A CN 106548998A CN 201610602076 A CN201610602076 A CN 201610602076A CN 106548998 A CN106548998 A CN 106548998A
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- 239000000463 material Substances 0.000 title claims abstract description 61
- 238000000034 method Methods 0.000 title claims abstract description 56
- 238000005538 encapsulation Methods 0.000 title claims abstract description 42
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 38
- 239000002184 metal Substances 0.000 claims abstract description 139
- 229910052751 metal Inorganic materials 0.000 claims abstract description 139
- 239000011265 semifinished product Substances 0.000 claims abstract description 21
- 239000000945 filler Substances 0.000 claims abstract description 10
- 238000005520 cutting process Methods 0.000 claims abstract description 9
- 238000012856 packing Methods 0.000 claims description 20
- 239000000084 colloidal system Substances 0.000 claims description 16
- 229910000679 solder Inorganic materials 0.000 claims description 16
- 238000004806 packaging method and process Methods 0.000 claims description 8
- 238000012545 processing Methods 0.000 abstract description 22
- 239000010409 thin film Substances 0.000 abstract description 4
- 230000037303 wrinkles Effects 0.000 abstract description 3
- 238000009826 distribution Methods 0.000 description 38
- 239000000758 substrate Substances 0.000 description 6
- 238000003780 insertion Methods 0.000 description 5
- 230000037431 insertion Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 229910001374 Invar Inorganic materials 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 239000010408 film Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 230000001052 transient effect Effects 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- -1 borehole Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 239000003989 dielectric material Substances 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
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Abstract
本发明公开了一种封装基材的制作方法,其步骤至少包括:准备核心基材;制作下层重新分配电路于核心基材的下表面;其中,下层重新分配电路埋设于下层介电层中,包含有复数个第一上层金属垫以及复数个第一下层金属垫;从核心基材的上层磨薄核心基材;从核心基材的上方制作复数个孔;每个孔的底部裸露出对应的第一上层金属垫的上表面;在每个孔的内部填充金属,形成复数个贯穿核心基材的金属柱;以及切割,获得复数个半成品。本发明能有效减少或是消除薄膜封装基材在制程中或是封装程序中产生皱褶(wrinkle)或是板翘(warpage)。
Description
技术领域
本发明涉及一种封装基材的制作方法,特别是一种减少或是消除薄膜封装基材(thin film package substrate)在制程中或是封装程序中可能产生皱褶(wrinkle)或是板翘(warpage)的一种封装基材的制作方法。
背景技术
随着技术的进步,半导体封装基材愈做愈薄,在制程中,基于各种不同材料的热膨胀系数(coefficient of thermal expansion;CTE)的不同,薄膜基材遭遇到的问题之一,便是皱褶或是板翘的问题,若是未能解决皱褶或是板翘的问题,在后续的电路「对位(registration)便会发生很大的困扰,所以,如何消除或是避免薄型电路产生皱褶或是板翘,是高密度薄膜封装基材必须解决的一大课题。
图1A~1E显示美国专利公开号US20150135527A1所揭露的一个先前技艺,其揭露一个封装基材的制程,包含下述步骤:
图1A显示:准备核心基材(core substrate)10;
图1B显示:由核心基材10的上方,制作复数个孔11,孔11的深度不大于基材10的厚度,孔10的底部并未贯通核心基材10;
图1C显示:填充金属于孔11中,制成复数条金属柱12;
图1D显示:制作电路重新分配层RDL于核心基材10上方;电路重新分配层RDL电性耦合于金属柱12。电路重新分配层RDL具有埋设于介电层13中的重新分配电路14;复数个上层焊垫141设置于重新分配电路14的上层;复数个下层焊垫142设置于重新分配电路14的下层;每一个下层焊垫142分别电性耦合至对应的金属柱12的上端。
图1E显示:由核心基材10的下方磨薄核心基材10,使得金属柱12的下端裸露出来,制成金属柱12贯通核心基材10的结构。
之后,再进行后面的制程,后面的制程包含在金属柱12下方制作下层电路重新分配层…等结构;本说明书在此省略后续制程的描述。此一先前技艺,先制作金属柱12的前段制程,然后制作电路重新分配层RDL于金属柱12上方;然后从下方开始磨薄核心基材10,使金属柱12呈现贯通核心基材10的状态。
此一先前技艺的缺点是:在含有金属柱12的核心基材10上方制作薄膜电路重新分配层RDL,因为有金属柱12与核心基材10混合材料做基础,混合材料的CTE相对较大,故制作薄膜电路重新分配层RDL的时候,基于CTE匹配问题,使得薄膜电路重新分配层RDL尺寸稳定度较差,后续制程在对位上,会有偏差可能,而发生产品可靠度问题。
发明内容
针对现有技术的上述不足,根据本发明的实施例,希望提供一种能有效减少或是消除薄膜封装基材在制程中或是封装程序中产生皱褶(wrinkle)或是板翘(warpage)的封装基材的制作方法。
根据实施例,本发明提供的一种封装基材的制作方法,其步骤至少包括:
准备核心基材;
制作下层重新分配电路于核心基材的下表面;其中,下层重新分配电路埋设于下层介电层中,包含有复数个第一上层金属垫以及复数个第一下层金属垫;
从核心基材的上层磨薄核心基材;
从核心基材的上方制作复数个孔;每个孔的底部裸露出对应的第一上层金属垫的上表面;
在每个孔的内部填充金属,形成复数个贯穿核心基材的金属柱;以及
切割,获得复数个半成品。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:
准备暂时性承载板,其中,暂时性承载板的上表面涂布有释放层;
安置复数个前述的半成品于释放层的上面;其中,每个半成品的设置以金属柱在上方、下层重新分配电路在下方的位置安置;
以第一封装胶体包裹封装每一半成品至少四个侧面周边;
在复数个金属柱的上面制作上层重新分配电路;其中,上层重新分配电路具有复数个第二上层金属垫以及复数个第二下层金属垫;其中,每个金属柱的上端分别电性耦合到对应的一个第二下层金属垫;
移除暂时性承载板;以及
从下层介电层的底面制作复数个底部开口,分别裸露对应的第一下层金属垫的下表面。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:在复数个第一下层金属垫的底表面设置至少一片芯片。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:在芯片和下层介电层的底表面之间的空间中填充下层填充材料。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:施加第二封装胶体,封装芯片。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:设置复数个焊锡球,每一个焊锡球设置于对应的一个第二上层金属垫的上表面。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:切割,获得复数个芯片封装单元。
根据实施例,本发明提供的另一种封装基材的制作方法,包括如下步骤:
准备核心基材;
制作下层重新分配电路于核心基材的底表面;其中,下层重新分配电路埋设于下层介电层中,具有复数个第一上层金属垫以及复数个第一下层金属垫;
从核心基材的上层磨薄核心基材;
从核心基材的上方制作复数个孔;每个孔的底部裸露出对应的第一上层金属垫的上表面;
在每个孔中填充金属,形成复数个贯穿核心基材的金属柱;
制作上层重新分配电路于复数个金属柱的上面;其中,上层重新分配电路埋设于上层介电层中,具有复数个第二上层金属垫,并且具有复数个第二下层金属垫;其中,每个金属柱的上端分别电性耦合到对应的第二下层金属垫的下表面;以及
从下层介电层的底面制作复数个底部开口,分别裸露对应的第一下层金属垫的下表面。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:在复数个第一下层金属垫的底表面上设置至少一片芯片。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:在芯片和下层介电层的底表面之间的空间中填充下层填充材料。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:施加封装胶体,封装芯片。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:从上层介电层的顶面制作复数个顶部开口,分别裸露对应的第二上层金属垫的上表面;以及设置复数个焊锡球,每一个焊锡球设置于对应的一个第二上层金属垫的上表面。
根据一个实施例,本发明前述封装基材的制作方法中,进一步包含如下步骤:切割,获得复数个芯片封装单元。
相对于现有技术,本发明先以单纯厚片核心基材(core substrate)当作基础,在厚片核心基材下方制作下层电路重新分配层RDL1,借着厚片核心基材的固有的坚固性与较低的CTE,可以获得尺寸稳定度较高的下层电路重新分配层RDL1;之后,再进行磨薄基材、挖孔、填充金属…等制作完成第一金属柱,呈现第一金属柱贯通核心基材的结构。本发明揭露的芯片用封装基材的制程中:首先,准备核心基材,形成底部电路重新分配层(RDL1)于核心基材下方;在底部重新分配层的制程中,底部重新分配层的任何可能的皱褶或是板翘,通过在核心基材的坚硬度所抑制,而不会发生皱褶或是板翘;然后制作多个第一金属柱,贯穿核心基材;最后,制作顶部电路重新分配层(RDL2)于核心基材上方。底部电路重新分配层(RDL1)的底表面适合芯片的安置,顶部电路重新分配层(RDL2)的上表面适合焊锡球的设置用以匹配片封装单元至系统电路板。
附图说明
图1A~1E是先前技艺之封装基材的制作过程示意图。
图2A~2E是本发明的一个半成品的制作过程示意图。
图3是本发明的一个半成品的结构示意图。
图4~9是本发明封装基材的第一制作过程示意图。
图10A~10E和图11~14是本发明封装基板的第二制作过程示意图。
其中:1B为第一下层金属垫;1T为第一上层金属垫;20为核心基材;200为半成品;21为孔;22为第一金属柱;231,232,233,234为介电层;23B为下层重新分配电路;23T为上层重新分配电路;24为第一封装胶体;25为底部开口;252为顶部开口;26为芯片;261为第二金属柱;262为底部填充材料;263为第二封装胶体;27为焊锡球;29为暂时承载板;291为释放层;2B为第二下层金属垫;2T为第二上层金属垫;RDL1为下层电路重新分配层;RDL2为上层电路重新分配层。
具体实施方式
下面结合附图和具体实施例,进一步阐述本发明。这些实施例应理解为仅用于说明本发明而不用于限制本发明的保护范围。在阅读了本发明记载的内容之后,本领域技术人员可以对本发明作各种改动或修改,这些等效变化和修改同样落入本发明权利要求所限定的范围。
本发明提供一个制作封装基材(package substrate)的制程,不同于先前技艺的制程。本发明先以单纯厚片核心基材(core substrate)当作基础,在厚片核心基材下方制作下层电路重新分配层RDL1,借着厚片核心基材的固有的坚固性与较低的CTE,可以获得尺寸稳定度较高的下层电路重新分配层RDL1;之后,再进行磨薄基材、挖孔、填充金属…等制作完成第一金属柱,呈现第一金属柱贯通核心基材的结构。
本发明揭露一种封装基材的制程,包含制作一个下层电路重新分配层(redistribution layer;RDL)于厚片核心基材下方,且是在第一金属柱(metal pillars)被制作之前制作完成下层电路重新分配层RDL1的。即是:如图2C所示,先制作下层电路重新分配层RDL1于厚片核心基材20下方;接着如图2D~2E所示,复数个第一金属柱22被制作使贯穿厚片核心基材20。其中,下层电路重新分配层RDL1于制程中,原本可能产生的皱褶或是板翘,都可以被起始作业所使用的厚片核心基材20的坚固性所压制,而不会发生皱褶或是板翘。厚片核心基材20系使用具有低的CTE的材料,例如:因瓦合金(Invar 1ppm)、氮化硅(Silicon Nitride 2.6ppm)、硅(Silicon 3ppm)、或是玻璃(Glass 4ppm)…等材料。
图2A~2E显示本发明的一个半成品的制作过程。
依据下述制程,可以制作得到复数个半成品200:
图2A显示:准备核心基材20;
图2B显示:制作下层电路重新分配层RDL1于核心基材20下方;下层电路重新分配层RDL1系包含下层重新分布电路(redistribution circuitry)23B埋设于下层介电材料层231,232中。复数个第一上层金属垫1T设置于下层重新分布电路23B的上方,复数个第一下层金属垫1B设置于下层重新分布电路23B的下方。厚片核心基材20的坚固性以及具有低的CTE的特性,可以压制下层电路重新分配层RDL1在制程中的尺寸变化,而不会发生皱褶或是板翘,可以保持下层重新分布电路23B的尺寸定性。
图2C显示:从核心基材20上方,磨薄核心基材20;
图2D显示:从核心基材20上方,制作复数个孔21;每一个孔21的底部,裸露对应的一个上层金属垫1T的上表面;
图2E显示:填充金属到每一个孔21中,制成复数个第一金属柱22,除去上方多余的材料(图中未表示)以后,呈现第一金属柱22贯通核心基材20的结构;图2E的结构,经过切割以后,可以获得复数个半成品200。
图3显示本发明的一个半成品。
图3显示本发明的一个半成品200,其具有复数个第一金属柱22,贯穿核心基材20。核心基材20底部设置有下层重新分配电路23B,复数个上层金属垫1T设置于下层重新分配电路23B的上方;复数个下层金属垫1B设置于下层重新分配电路23B的下方;每一个上层金属垫1T分别电性耦合于对应的一个第一金属柱22的下端。
图4~9显示本发明封装基材的第一制程。
图4显示:准备一片暂时承载板29;暂时承载板29的表面涂布有一层释放层(release layer)291;安置复数个半成品200于释放层291的上面;其中,每个半成品200以第一金属柱22在上、下层电路重新分配层RDL1在下的位置,放置于释放层291上面。
图5显示:用第一封装胶体(molding compound)24包裹封装半成品200的至少四个侧面;移除上方多余的材料,使得第一封装胶体24上表面与半成品200上表面,呈现共平面状。
图6显示:在复数个第一金属柱22与第一封装胶体24的上面,制作上层电路重新分配层RDL2;其中,上层电路重新分配层RDL2包含有上层重新分配电路23T埋设于介电层233,234,235中。复数个第二上层金属垫2T设置于上层重新分配电路23T的上方,复数个第二下层金属垫2B设置于上层重新分配电路23T的下方;其中,每个第一金属柱22具有一个上端,分别电性耦合至相对应的一个第二下层金属垫2B;接着,在介电层235的顶部,制作复数个顶部开口252,分别暴露一个对应的第二上层金属垫2T的上表面上;并移除临时承载板29。
图7显示:从下层介电层232的底部,制作复数个底部开口25,以分别暴露第一下层金属垫1B的底面。
图8显示:准备至少一片芯片26,安置于复数个第一下层金属垫1B的下方;芯片26利用复数个第二金属柱261电性耦合至第一下层金属垫1B;然后,在芯片26和下方介电层232之间的空间中,填充底部填充材料(underfill)262;接着,施加第二封装胶体263用以封装芯片26;设置复数个焊锡球27,每一个焊锡球27设置于对应的第二上层金属垫2T的上表面;最后,经由切割,获得复数个芯片封装单元。
图9显示:在单一芯片封装中,具有核心基材20,复数个金属柱22贯穿核心基材20;下层电路重新分配层RDL1设置于金属柱22的下方,上层电路重新分配层RDL2设置于金属柱22的上方;下层电路重新分配层RDL1与上层电路重新分配层RDL2经由金属柱22互相电性耦合;第一封装胶体24包裹核心基材20和下层电路重新分配层RDL1的至少四个侧面。芯片26经由复数个第二金属柱261电性耦合到第一下层金属垫1B的底面。
图10A~10E和图11~14显示本发明封装基板的第二制程。
第二制程与第一制程的不同点,在于第二制程省略了第一制程图3~图5的切割、安置、封装胶体等步骤。
图10A显示:准备一片核心基材20;
图10B显示:成在核心基材20的下表面,制作下层电路重新分配层RDL1;其中,下层电路重新分配层RDL1具有下层重新分配电路23B埋设于下层介电层231,232中,下层重新分配电路23B具有复数个第一上层金属垫1T设置于上方,也具有复数个第一下层金属垫1B设置于下方。
图10C显示:从核心基材20的顶部向下磨薄;
图10D显示:从核心基材20的上方,制作复数个孔21;每一个孔21的底部,裸露出对应的第一上层金属垫1T的上表面;
图10E显示:在每个孔21中,填充金属以形成复数个金属柱22;金属柱22贯穿核心基材20,下端电性耦合到下层重新分配电路23B。
图11显示:在复数个金属柱22的上面,制作上层电路重新分配层RDL2;其中,上层电路重新分配层RDL2具有上层重新分配电路23T埋设于上层介电层233,234,235中;复数个第二上层金属垫2T设置于上层重新分配电路23T的上方,复数个第二下层金属垫2B设置于上层重新分配电路23T的下方;其中,每个金属柱22具有一个顶部表面,电性耦合到对应的第二下层金属垫2B。从上层介电层235的上方,制作复数个开口252,分别暴露对应的第二上层金属垫2T的上表面。
图12显示:从底部介电层232的底部,制作复数个底部开口25,以分别暴露每个对应的第一下层金属垫1B的底面。
图13显示:至少一片芯片26,安置于复数个第一下层金属垫1B下方;芯片26借着第二金属柱261,与电性耦合至第一下层金属垫1B。下方介电层232的下表面与芯片26之间的空间中,填充底部填充材料(underfill)262;施加第二封装胶体263,包裹封装芯片26;设置复数个焊锡球27,每一个焊锡球27分别设置于对应的一个第二上层金属垫2T的上表面。
图14显示:切割获得复数个芯片封装单元。图14显示:在单一芯片封装中,包含有核心基材20,复数个金属柱22贯穿核心基材20;金属柱22的下端电性耦合至下层电路重新分配层RDL1;复数个金属柱22的上端电性耦合至上层电路重新分配层RDL2;复数个焊锡球27设置于顶部,每个焊锡球27分别设置于对应的一个第二上层金属垫2T的上表面。芯片26借着复数个第二金属柱261电性耦合至第一下层金属垫1B的底面,底部填充材料262填充于芯片26和下层电路重新分配层RDL1的下表面之间的空间中;第二封装胶体263包裹方装芯片26至少周围四边,芯片26的底面裸露提供散热用。
Claims (13)
1.一种封装基材的制作方法,其特征是,其步骤至少包括:
准备核心基材;
制作下层重新分配电路于核心基材的下表面;其中,下层重新分配电路埋设于下层介电层中,包含有复数个第一上层金属垫以及复数个第一下层金属垫;
从核心基材的上层磨薄核心基材;
从核心基材的上方制作复数个孔;每个孔的底部裸露出对应的第一上层金属垫的上表面;
在每个孔的内部填充金属,形成复数个贯穿核心基材的金属柱;以及
切割,获得复数个半成品。
2.如权利要求1所述的封装基材的制作方法,其特征是,进一步包含如下步骤:
准备暂时性承载板,其中,暂时性承载板的上表面涂布有释放层;
安置复数个前述的半成品于释放层的上面;其中,每个半成品的设置以金属柱在上方、下层重新分配电路在下方的位置安置;
以第一封装胶体包裹封装每一半成品至少四个侧面周边;
在复数个金属柱的上面,制作上层重新分配电路;其中,上层重新分配电路具有复数个第二上层金属垫以及复数个第二下层金属垫;其中,每个金属柱的上端分别电性耦合到对应的一个第二下层金属垫;
移除暂时性承载板;以及
从下层介电层的底面制作复数个底部开口,分别裸露对应的第一下层金属垫的下表面。
3.如权利要求2所述的封装基材的制作方法,其特征是,进一步包含如下步骤:在复数个第一下层金属垫的底表面设置至少一片芯片。
4.如权利要求3所述的封装基材的制作方法,其特征是,进一步包含如下步骤:在芯片和下层介电层的底表面之间的空间中填充下层填充材料。
5.如权利要求4所述的封装基材的制作方法,其特征是,进一步包含如下步骤:施加第二封装胶体,封装芯片。
6.如权利要求5所述的封装基材的制作方法,其特征是,进一步包含如下步骤:设置复数个焊锡球,每一个焊锡球设置于对应的一个第二上层金属垫的上表面。
7.如权利要求6所述的封装基材的制作方法,其特征是,进一步包含如下步骤:切割,获得复数个芯片封装单元。
8.一种封装基材的制作方法,其特征是,包括如下步骤:
准备核心基材;
制作下层重新分配电路于核心基材的底表面;其中,下层重新分配电路埋设于下层介电层中,具有复数个第一上层金属垫以及复数个第一下层金属垫;
从核心基材的上层磨薄核心基材;
从核心基材的上方制作复数个孔;每个孔的底部裸露出对应的第一上层金属垫的上表面;
在每个孔中填充金属,形成复数个贯穿核心基材的金属柱;
制作上层重新分配电路于复数个金属柱的上面;其中,上层重新分配电路埋设于上层介电层中,具有复数个第二上层金属垫,并且具有复数个第二下层金属垫;其中,每个金属柱的上端分别电性耦合到对应的第二下层金属垫的下表面;以及
从下层介电层的底面制作复数个底部开口,分别裸露对应的第一下层金属垫的下表面。
9.如权利要求8所述的封装基材的制作方法,其特征是,进一步包含如下步骤:在复数个第一下层金属垫的底表面上设置至少一片芯片。
10.如权利要求9所述的封装基材的制作方法,其特征是,进一步包含如下步骤:在芯片和下层介电层的底表面之间的空间中填充下层填充材料。
11.如权利要求10所述的封装基材的制作方法,其特征是,进一步包含如下步骤:施加封装胶体,封装芯片。
12.如权利要求11所述的封装基材的制作方法,其特征是,进一步包含如下步骤:从上层介电层的顶面制作复数个顶部开口,分别裸露对应的第二上层金属垫的上表面;以及设置复数个焊锡球,每一个焊锡球设置于对应的一个第二上层金属垫的上表面。
13.如权利要求12所述的封装基材的制作方法,其特征是,进一步包含如下步骤:切割,获得复数个芯片封装单元。
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