CN110197795A - 形成具有竖立指向的电子构件的电子装置结构的方法及相关结构 - Google Patents
形成具有竖立指向的电子构件的电子装置结构的方法及相关结构 Download PDFInfo
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Abstract
形成具有竖立指向的电子构件的电子装置结构的方法及相关结构。一种形成电子装置结构的方法,其包含提供第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面以及相对的第二边缘表面。提供具有基板第一主要表面和相对的基板第二主要表面的基板。所述第一电子构件的所述第二主要表面被放置接近于所述基板第一主要表面并且提供传导材料邻近于所述第一电子构件的所述第一边缘表面。所述传导材料被曝露于升高的温度以回流所述传导材料使所述第一电子构件抬起成直立位置,使得所述第二边缘表面与所述基板第一主要表面的间距是更远于所述第一边缘表面与所述基板第一主要表面的间距。所述方法适用于以垂直或竖立方式提供电子构件,例如天线、传感器或是光学装置。
Description
技术领域
本发明通常关于电子装置,特别是关于电子结构、其构造以及形成电子结构的方法。
背景技术
无线和携带型手持通信应用是持续成长和发展的应用范例,并致力于将更多电子功能整合到更小、更轻、更薄、更低成本的解决方案中。这些应用面临的持续挑战之一是将有效天线改进并整合到各种产品平台中。在过去,用于手持通信应用的组件结构使用可挠性电缆或是可挠性电路结构以将各种天线装置在相对于与所述天线装置共同封装的集成电路的不同方向上定向。在所述组件结构中,所述可挠性电缆被弯折以定向所述天线装置到期望位置以对于特定通信应用提供3轴涵盖范围。所述可挠性电缆增加组件制程的复杂度、增加所述组件结构的体积以及可能由于所述可挠性电缆的老化和曝露于恶劣的环境条件而导致可靠性问题。
此外,随着蜂巢式网络继续向下一代发展,如5G,需要解决许多工程挑战。例如,波束形成技术(其有助于将信号集中在仅指向用户方向的集中波束中)需要天线在用于通信应用的组装结构上的多个位置处提供3轴(即,x、y和z轴)定向能力。例如,预计在5G应用中,可以将多个天线装置放置在至少两个分离的位置以提供3轴信号覆盖。对于制造商而言,这将是一个挑战,尤其是需要更小、更轻、更薄和成本更低的解决方案。
因此,期望能有一种提供封装电子设备的方法和结构,其克服与可挠性电缆组件相关的问题并且又能支持下一代蜂巢式网络技术。此外,其对于利用现有制造设备的方法和结构以及用于支持多种电子应用的方法和结构(诸如天线、光学和感测装置应用)将是有益的。
发明内容
除其他特征之外,本发明说明书包括形成电子装置结构和具有以竖立(on-edge)或直立配置提供的电子构件的相关结构的方法。在某些实施例中,电子构件的边缘被放置邻近于在基板上的传导图案。传导材料被放置邻近于所述边缘和所述传导图案。所述传导材料被曝露于升高的温度以回流所述传导材料。在所述回流制程中,表面张力效应作用以将电子构件向上升高或转动成直立或竖立指向。在某些实施例中,所述传导材料包含焊料和多个传导凸块,其可沿着所述电子构件的所述边缘而被实质上均匀地分布。在某些实施例中,所述电子构件可以是天线结构,例如半导体天线结构。在某些实施例中,所述电子构件可以是感测装置,例如影像感测装置。在某些实施例中,所述电子构件可以是裸露的半导体晶粒或芯片(即未经封装的)。在某些实施例中,所述电子构件包含导体,其电性连接到沿着所述边缘而放置的所述多个传导凸块中的一个或多个。在某些实施例中,所述传导图案可以在所述电子构件的两个侧边上。多个电子构件可以竖立配置及以习知附接配置方式两者被设置在基板上以提供具有3轴定向能力的电子装置结构。本发明所描述的所述方法和相关结构提供具有经提升的设计灵活性和性能的电子装置结构。
更特别的是,在一个实施例中,一种形成电子装置结构的方法,其包含提供第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面以及相对的第二边缘表面。所述方法包含提供基板,所述基板具有基板第一主要表面和相对的基板第二主要表面。所述方法包含将所述第一电子构件的所述第二主要表面放置接近于所述基板第一主要表面。所述方法包含提供传导材料,所述传导材料邻近于所述第一电子构件的所述第一边缘表面。所述方法包含将所述传导材料曝露于升高的温度以回流所述传导材料,使所述第一电子构件抬起到直立位置,使得所述第二边缘表面与所述基板第一主要表面的间距是更远于所述第一边缘表面与所述基板第一主要表面的间距。所述方法包括:提供所述基板包含提供第一传导图案邻近于所述基板第一主要表面;提供所述传导材料包含将所述传导材料放置于邻近所述第一传导图案;以及提供所述传导材料包含使所述第一电子构件的所述第二边缘表面保留没有所述传导材料。所述方法进一步包含:形成底部填充层,其邻近于所述第一边缘表面;以及形成封装本体,其囊封所述第一电子构件,其中:提供所述第一电子构件包含提供天线装置、感测装置和光学装置中的一个;以及提供所述传导材料包含提供焊料材料和多个传导凸块。所述方法包括:提供所述第一电子构件包含提供传导图案邻近于所述第一电子构件的所述第一主要表面和所述第二主要表面中的一个或多个。所述方法包括:提供所述传导图案包含提供所述传导图案邻近于所述第一主要表面和所述第二主要表面两者。所述方法进一步包含:使用贯穿基板通孔以电性地耦接所述传导图案到所述传导材料。
在另一个实施例中,一种形成电子装置结构的方法,其包含提供第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面以及相对的第二边缘表面。所述方法包含提供基板,其具有基板第一主要表面、相对的基板第二主要表面以及邻近所述基板第一主要表面的第一传导图案。所述方法包含将所述第一电子构件的所述第二主要表面放置接近于所述基板第一主要表面。所述方法包含提供传导材料,其邻近于所述第一电子构件的所述第一边缘表面和所述第一传导图案。所述方法包含将所述传导材料曝露于升高的温度以回流所述传导材料,使所述第一电子构件抬起到直立位置,使得所述第二边缘表面与所述基板第一主要表面的间距是更远于所述第一边缘表面与所述基板第一主要表面的间距。在某些实施例中,所述方法可包含将第二电子构件附接至所述基板第一主要表面、将第三电子构件附接至所述基板第二主要表面并且提供封装本体以囊封所述第一电子构件和所述第二电子构件。在其他的实施例中,所述提供所述传导材料可包含提供焊料材料和沿着所述第一电子构件的所述第一边缘表面实质上均匀分布的多个传导凸块。在其他的实施例中,所述方法可包含将所述传导材料曝露于所述升高的温度以使所述第一电子构件抬起,使得所述第一电子构件的所述第一主要表面通常与所述基板第一主要表面正交。在某些实施例中,提供所述第一电子构件包含半导体晶粒,所述半导体晶粒经建构为天线装置、感测装置(例如影像感测装置)或光学装置。
在另外的实施例中,电子装置结构包含基板,所述基板具有基板第一主要表面、相对的基板第二主要表面和邻近于所述基板第一主要表面的第一传导图案;以及第一电子构件,所述第一电子构件具有第一主要表面、相对的第二主要表面、第一边缘表面、相对的第二边缘表面以及设置至少邻近于所述第一主要表面的第一传导图案。所述第一边缘表面是藉由传导材料而附接到所述第一传导图案。所述第一主要表面通常被设置为与所述基板第一主要表面正交,使得所述第二边缘表面是远离于所述基板第一主要表面。在某些实施例中,所述传导材料是电性地耦接至所述第一传导图案。在其他的实施例中,所述电子装置结构进一步包含:第二电子构件,其附接到所述基板第一主要表面;第三电子构件,其附接到所述基板第二主要表面;封装本体,其囊封所述第一电子构件和所述第二电子构件,其中:所述第二电子构件包含第三主要表面、相对的第四主要表面、第三边缘表面以及相对的第四边缘表面;所述传导材料包含焊料材料和多个传导凸块;所述第一电子构件的所述第一主要表面面向所述基板的第一边缘;所述第三边缘表面是藉由额外的焊料材料和额外的多个传导凸块而附接到所述第一传导图案的另一部份;所述第三主要表面通常被设置为与所述基板第一主要表面正交,使得所述第四边缘表面是远离于所述基板第一主要表面;所述第二电子构件的所述第三主要表面面向所述基板的第二边缘;以及所述结构进一步包含底部填充层,其被设置为邻近于所述第一电子构件的第一边缘表面和所述第二电子构件的所述第三边缘表面中的一个或多个。
其他实施例也被包含在本发明说明书的揭露范围中。这些实施例可以在附图、权利要求书及/或本发明说明书的描述中找到。
附图说明
图1为根据本发明实施例的经封装的电子装置而沿着图2的参考线1-1所得到的横截面视图;
图2为根据本发明实施例的经封装的电子装置的俯视平面图;
图3为根据本发明实施例的在制造步骤中的电子装置的部分横截面视图;
图4为根据本发明实施例的电子构件的俯视平面图;
图5为图3的电子装置在制造设备之中的另外的制造步骤中的部分横截面视图;
图6为根据本发明实施例的经封装的电子装置的制造流程图;
图7为根据本发明实施例的电子装置的部分横截面视图;
图8为根据本发明实施例的电子装置的部分横截面视图;
图9为根据本发明实施例的电子装置的部分横截面视图;
图10为根据本发明实施例的电子装置的部分横截面视图;
图11为根据本发明实施例的电子装置的部分横截面视图;
图12为根据本发明实施例的电子装置的部分横截面视图;以及
图13为根据本发明实施例的电子装置的部分横截面视图。
具体实施方式
为了图示的简单和清楚,图式中的组件不一定按比例绘制,并且不同图式中的相同的组件符号表示相同组件。此外,为了简化描述,省略了众所周知的步骤和组件的描述和细节。如本文中所使用的,用语“及/或”包含一个或多个相关所列项目的任何和所有组合。此外,在本文中所使用的术语仅用于描述特定实施例的目的,而不意图限制本发明所揭露的内容。如本文中所使用的,除非上下文另有明确指示,否则单数形式也意图包括复数形式。将进一步理解的是,当在本说明书中使用时,用语"包括"、"包含"、"含有"及/或"具有"指定目前所描述的特征、数字、步骤、操作、组件及/或组件,但不排除有一个或多个其他特征、数字、步骤、操作、元素、组件及/或其组合的存在或添加。将理解的是,虽然用语"第一"、"第二"...等等在本文中被用来描述各种构件、组件、区域、层及/或区段,然而这些构件、组件、区域、层及/或区段不应受这些用语的限制。这些用语仅用来将构件、组件、区域、层及/或区段和另外其他的构件、组件、区域、层及/或区段做区别。因此,举例来说,下文中所讨论的第一构件、第一组件、第一区域、第一层及/或第一区段可以被称为第二构件、第二组件、第二区域、第二层和/或第二区段,而不背离本公开的教示。对“一个实施例”或“实施例”的引用代表着结合该实施例描述的特定特征、结构或特性被包括在本发明的至少一个实施例中。因此,在整个说明书各处出现的用词“在一个实施例中”或“在实施例中”不一定都指同一实施例,但在某些情况下可能是指统一实施例。再者,在一个或多个实施例中,如对所属技术领域中具有通常知识者是显而易见的,则可以以任何合适的方式组合特定的特征、结构或特性。此外,另外,用语"当...时"意味着至少在发起动作的持续时间的某个部分内发生某个动作。使用文字"约"、"大约"或"实质上"代表期望组件的数值是接近状态值或位置。然而,正如本领域所熟知的那样,总是存在微小的差异,从而不能准确地说明数值或位置。除非另有说明,否则如本文所用,用词“上方”或“上”包括指定组件可以直接或间接物理接触的方向、位置或关系。应该进一步理解的是,在下文中说明和描述的实施例可以适当地具有实施例及/或可以在缺少本文未具体描述的任何组件的情况下实施。
图1为根据第一实施例的经封装的电子装置的横截面视图,所述经封装的电子装置具有连接到基板11的电子构件12、14、16和17。图1是沿着图2的参考线1-1所截取的,图2显示经封装的电子装置10的俯视平面图。如图2中所示,经封装的电子装置10进一步包含电子构件18和19。图1和图2图示具有3轴定向能力的电子装置结构的范例。
根据本实施例,电子构件12和18被提供作为竖立型构件12和18或是对于基板11的主要表面110是非平行指向的电子构件。在某些实施例中,电子构件12和电子构件18可以相对于基板11的主要表面110通常是正交的指向提供。在某些实施例中,电子构件12、14、16、17、18和19可被建构为设置在基板11上的天线装置以提供3轴涵盖范围。在某些实施例中,所述电子构件12、14、16、17、18和19中的一个或多个包含封装的半导体晶粒或未经封装的半导体晶粒(裸露的半导体晶粒)。在其他范例中,所述电子构件12、14、16、17、18和19中的一个或多个包含被动构件。作为范例,电子构件12和17被指向为沿着图1和图2的x轴发送和接收讯号120;电子构件14和16被指向为沿着图1的z轴发送和接收讯号121;并且电子构件18和19被指向为沿着图2的y轴发送和接收讯号122。
将理解的是,其他电子构件可被放置到基板11上,但是这里没有显示出来,以免挤压这些图式。其他构件可以包括集成电路装置,例如数字信号处理(DSP)装置、微处理器、内存装置、微控制器装置、功率装置、被动装置或所属技术领域中具有通常知识者已知的其它装置。可以进一步理解的是,电子构件12、14、16、17、18和19中的一个或多个可以是其他类型的电子装置,例如是传感器装置(例如CMOS或CCD影像传感器)、光学装置或是所属技术领域中具有通常知识者已知的其它装置。所属技术领域中具有通常知识者将会理解,所述电子构件以简化形式示出,并且还可以包括多个扩散区域、多个导电层和多个介电质层。
基板11可以是任意种类的电子构件基板,例如印刷电路板(PCB)、组成基板、层叠基板、引线架基板、陶瓷基板、模制基板、模制引线架或是所属技术领域中具有通常知识者已知的其它基板。在一个实施例中,基板11被提供以具有邻近于主要表面110的传导图案21以及邻近于与主要表面110相对的主要表面111的传导图案22。传导图案21和22可包含传导衬垫、传导迹线或是其之组合。在大部分的实施例中,传导图案21和22包含一个或多个材料,例如铜、铜合金、被镀材料、金、镍或是所属技术领域中具有通常知识者已知的其它材料。
基板11可进一步包含埋藏的迹线和传导互连通孔(未显示),其将传导图案21的特定部分电性连接到传导图案21的其他部分、电性连接到传导图案22或电性连接到邻近于基板11的主要表面111的传导凸块23。作为范例,传导凸块23包含可温度回流焊料凸块、热音波(thermosonic)或热压缩接合凸块(例如,金凸块)、黏着接合凸块或是所属技术领域中具有通常知识者已知的其它凸块材料。传导凸块23经建构以用于附接或电性连接经封装的电子装置10到组件的下一层级。
在某些实施例中,电子构件14藉由传导凸块31被附接到传导图案21并且电子构件16相似地藉由传导凸块31而被附接到传导图案22。传导凸块31可包含可温度回流焊料凸块、热音波或热压缩接合凸块(例如,金凸块)、黏着接合凸块或是所属技术领域中具有通常知识者已知的其它凸块材料。
根据本实施例,电子构件12的边缘126利用一个或多个传导凸块32和焊料33而被附接到传导图案21。在某些实施例中,边缘126仅部分地交叠传导图案21,而传导凸块32和焊料33交叠传导图案21。相对边缘127被设置远离基板11的主要表面110。电子构件17的边缘176利用一个或多个传导凸块32和焊料33而被附接到传导图案21。相对边缘177被设置远离基板11的主要表面110。作为范例,传导凸块32包含多个无铅焊料球或凸块(例如,锡(Sn)、银(Ag))。根据本实施例,将参照图3和图5更详细地解释,在将电子装置12、14、16、17、18和19附接或接合到基板11的回流制程中,利用来自熔化或软化的焊料和所述传导凸块的张力效应来将电子构件12、17、18和19升起或推高成相对于基板11的主要表面110呈直立或非平行指向。换句话说,在所述回流制程之后,电子构件12、17、18和19以竖立配置方式而被设置在基板11上,使得这些构件的所述主要表面与基板11的主要表面110的配置关系是除了平行之外的其他配置关系。在一个实施例中,底部填充层34可被设置相邻于电子构件12、17、18和19的边缘而接近基板11的主要表面110以在电子构件12、17、18、和19被放置在期望的直立指向之后对于电子构件12、17、18和19提供额外的支撑或保护。虽然没有图标于本范例中,可使用多个底部填充层于电子构件14和16的下方。焊料33可以是无铅焊料,例如,锡(Sn)、银(Ag)焊料,并且可被提供为焊料膏。根据本实施例,电子构件12、17、18和19仅被附接到基板11的一个边缘。在某些实施例中,焊料33和传导凸块中的一个或多个可被称为传导材料。如图1中所示,电子构件12具有主要表面125,其面向基板11的边缘112,并且电子构件17具有主要表面175,其面向基板的边缘113。将理解的是,电子构件18和19也具有主要表面,所述主要表面面向基板11的其他边缘118和116,如图2中所示。
在某些实施例中,封装本体36囊封或覆盖电子构件12、14、17、18和19。在某些实施例中,封装本体36可以是基于聚合物的复合材料,例如具有填充物的环氧树脂、具有填充物的环氧丙烯酸酯或是具有适当填充物的聚合物。封装本体36包含非传导和环境保护材料,其保护电子构件12、14、17、18和19免于外部组件和污染物的影响。封装本体36的形成可利用钢板印刷(paste printing)、压缩成形、转移成形、覆盖成形(over-molding)、液体囊封成形、真空层压、其他适合的施用器或是所属技术领域中具有通常知识者已知的其它制程。在某些实施例中,封装本体36是环氧模压树脂(epoxy mold compound,EMC),并且可利用转移或射出成形技术而被形成。在某些实施例中,另外的封装本体(未显示)可被用来囊封设置在邻近于基板11的主要表面111的电子构件16。在其他的实施例中,封装本体36可包含帽盖、盖子或是所属技术领域中具有通常知识者已知的其它覆盖结构。在其他实施例中,没有使用封装本体36。
参照图2,将描述附接方式的范例。在一个实施例中,只有电子构件12的一个侧边或边缘126利用多个传导凸块32A到32F以及焊料层33或多个焊料层33而被附接到个别的传导衬垫21A到21F。在一个实施例中,只有电子构件17的一个侧边或边缘176利用多个传导凸块32G到32L以及焊料层33或多个焊料层33而被附接到个别的传导衬垫21G到21L(多个焊料层33的范例显示于图1中)。在某些实施例中,较佳的是所述传导衬垫21A到21F是实质上均匀地沿着电子构件12的边缘126分布以及所述传导衬垫21G到21L是实质上均匀地沿着电子构件17的边缘176分布。如图2中所示,传导衬垫21A到21F和传导凸块32A到32F被设置在基板11和电子构件12的外侧边缘115。也就是,电子构件12的主动表面是邻近或是接近传导凸块32A到32F。进一步如图2所示,传导衬垫21G到21L和传导凸块32G到32L被设置在基板11和电子构件17的外侧边缘117。也就是,电子构件17的主动表面是邻近或是接近传导凸块32G到32L。
在一个实施例中,只有电子构件18的一个侧边或边缘186利用多个传导凸块32M到32W以及焊料层33或多个焊料层33而被附接到个别的传导衬垫21M到21P。在本实施例中,传导衬垫21M到21P中的至少一些容纳一个以上的传导凸块32M到32W。在某些实施例中,较佳的是所述传导衬垫21M到21P是实质上均匀地沿着电子构件18的下边缘186分布。如图2中所示,电子构件18被设置在基板11的外侧边缘116以及传导衬垫21M到21P与传导凸块32M到32W之间。也就是,电子构件18的主动表面是相对于传导凸块32M到32W。
在一个实施例中,只有电子构件19的一个侧边或边缘196利用多个传导凸块32X到32AF以及焊料层33或多个焊料层33而被附接到个别的传导衬垫21Q到21T。在本实施例中,传导衬垫21Q到21T中的至少一些容纳一个以上的传导凸块32X到32AF。在某些实施例中,较佳的是所述传导衬垫21Q到21T是实质上均匀地沿着电子构件19的下边缘196分布。如图2中所示,电子构件19被设置在基板11的外侧边缘118以及传导衬垫21Q到21T与传导凸块32X到32AF之间。也就是,电子构件19的主动表面是相对于传导凸块32X到32AF。
可以理解的是,传导衬垫和焊料凸块的数量由电子构件的电性I/O需求和将电子组件升高到期望的直立位置所需的材料的累积体积来决定。进一步可以理解的是,传导衬垫和焊料凸块中的一些可能不会提供电性连接,但是可能被用来提供本发明的表面张力效应以附接所述电子构件到基板。
图3为根据本发明实施例的范例性电子装置30在制造过程的初期步骤中的部分横截面视图。在本实施例中,电子构件12包含被放置在面朝上的主要表面129上的传导图案128并且以边缘126邻接在基板11上的传导图案21的方式被设置。在本实施例中,电子构件12的主要表面131面向基板11的主要表面110,但是与主要表面110分隔开以提供间隙113。传导凸块32被设置在相邻于电子构件12的主要表面129,并且焊料层33被设置在传导图案21上并且接触边缘126和焊料凸块32。在本实施例中,主要表面129可以是电子构件12的主动表面,其与传导凸块32在相同侧上。根据本实施例,电子构件12相对于边缘126的边缘127被提供为缺乏任何传导凸块32。换句话说,传导凸块32被设置为仅沿着或是相邻于电子构件12的边缘126。
图4是根据本发明较佳实施例的电子构件12的俯视平面图。更具体地说,电子构件12较佳地具有宽度1200对高度1201的比率或长宽比大于1,例如大约5到1的宽高比例,其中标准厚度在大约100微米至约200微米。此长宽比较佳地是用来方便于在后续的制程步骤(例如焊料回流制程)中升高电子构件12到升高的位置(例如直立位置)。再者,根据本实施例,电子构件12的所述宽高比可被用来决定传导凸块的数量和尺寸以及焊料33的体积以用来在所述焊料回流制程中将电子构件12升高到期望的位置。
图5为图3的电子装置30在根据一实施例的制造设备50之中的后段步骤中的部分横截面视图。作为范例,制造设备50可以是回流炉,其具有腔室500、支撑结构501以及热源502。根据本实施例,在所述回流制程中,表面张力作用以移动电子构件12到升高的指向,例如直立指向。更特别是,焊料33、传导凸块31和电子构件12之间的附着力造成了表面张力转动电子构件12的边缘126因而升高电子构件12成直立位置的一瞬间504。根据本实施例,瞬间504是因为在回流制程期间电子构件12的相对边缘127未附着到基板11所导致。在一实施例中,电子构件12通常对于基板11的主要表面110具有正交指向。作为范例,当使用无铅焊料材料时,电子装置30可被曝露到大约220度C到250度C的范围中的一温度大约30到90秒。
图6是根据本发明实施例的经封装的电子装置的制造流程图。在步骤601中,提供电子构件,其被建构为相对于基板为非平行指向。作为范例,所述电子构件可以是天线装置、感测装置或光学装置。在某些实施例中,所述电子构件可以是如图1-3中的电子构件12或电子构件18,或者是下文中图7-13中所示的任何电子构件。在某些较佳的实施例中,所述电子构件具有大约5到1的宽高比。在某些实施例中,所述电子构件是提供有传导凸块,例如传导凸块32,其被设置在所述电子构件的表面上邻近于所述电子构件的边缘沿着所述电子构件的宽度维度。
在步骤602中,提供有用于支撑所述电子构件的基板。作为范例,所述基板可以是PCB基板、组成基板、层叠基板、引线架基板、陶瓷基板、模制基板、模制引线架或是所属技术领域中具有通常知识者已知的其它基板。在某些实施例中,所述基板可以是基板11,其被提供具有传导图案21和22用于接收一个或多个电子构件。
在步骤603中,所述电子构件利用焊料材料被附接到所述基板。作为范例,取放设备可被用来放置所述电子构件到所述基板上的期望位置处。在某些实施例中,焊料材料33被用来初步附接所述电子构件18仅沿着具有传导凸块32的所述边缘。也就是说,与具有传导凸块32的所述边缘相对的所述边缘没有被附接到所述基板。作为范例,所述焊料材料可以在所述电子构件被放置到所述基板之前被首先以所期望的数量被分配到所述传导图案上的期望的位置上。分配或网印制程可被用来提供所述焊料材料余所述基板的期望位置上。在某些实施例中,所述焊料材料至少部分地覆盖传导图案21的各别部份,在所述各别部份中所述电子构件被附接到所述基板。作为范例,所述焊料材料可包含SnAg或其他无铅焊料,可包含助焊材料,并且可被提供为焊料膏。在步骤603中,其他电子构件可以以习知的组态方式被附接到所述基板。例如其他构件可以包括集成电路装置,例如数字信号处理(DSP)装置、微处理器、内存装置、微控制器装置、功率装置、被动装置或所属技术领域中具有通常知识者已知的其它装置。
在步骤604中,所述基板和电子构件被曝露到升高的温度以回流所述传导凸块和焊料材料而将所述电子构件永久性地附接到所述基板。根据本实施例,至少一个电子构件在步骤604的期间被升高到提高的位置使得所述至少一个电子构件最后是以与所述基板不平行的指向方式而被附接到所述基板。作为范例,其可以是图1和图5中所示的电子构件12、图10中所示的电子构件1012或图13中所示的电子构件12。换句话说,在步骤604之后,如图5所示,电子构件12的主要表面129对于基板11的主要表面110是非平行指向。
在可选择的步骤605中,封装本体可被提供以覆盖或囊封所述基板和所述电子构件的至少部份。在某些实施例中,封装本体36可被使用并且可以是基于聚合物的复合材料,例如具有填充物的环氧树脂、具有填充物的环氧丙烯酸酯或是具有适当填充物的聚合物。所述封装本体的形成可利用钢板印刷、压缩成形、转移成形、覆盖成形(over-molding)、液体囊封成形、真空层压、其他适合的施用器或是所属技术领域中具有通常知识者已知的其它制程。在某些实施例中,在所述封装本体被提供之前,底部填充材料(例如图1中所示的底部填充材料34)被放置在所述电子构件和所述基板之间。
关于图7-13,将描述其他的实施例。在图7-9、11和12中,显示为在所述回流制程之前的所述电子构件。换句话说,所述电子构件还没有被升高到直立位置。应了解的是,在回流制程之后,在图7-9、11和12中的电子构件是在升高的组态。在图10和13中,所述电子构件被图标为在升高的组态。
图7为根据第一实施例的电子装置70的部分横截面视图,其具有在边缘726处附着到基板11上的导电图案21的电子构件712。电子装置70相似于电子装置30,并且主要的不同将描述于下文中。在本实施例中,基板11被进一步提供而具有结构72(例如支柱(stand-off)72、衬垫72或凸块72),其经建构以在电子构件712被升高到提高的位置高于基板11的主要表面110之前对于相邻于主要表面731的电子构件712提供暂时性的支撑。结构72可包含一材料,其在所述回流制程中不黏着到电子构件712。在某些实施例中,结构72包含聚合物材料、陶瓷材料或是所属技术领域中具有通常知识者已知的其它材料。此外,电子构件712在主要表面729上具有传导层728,其横向地与传导凸块32分隔开。更特别的是,电子构件712不与至少一个传导凸块32电性通讯。相似于电子装置30,电子构件712的边缘726仅重叠传导图案21的一部份。根据本实施例,电子构件712中与边缘726相对的边缘727被提供为缺乏传导凸块32。换句话说,传导凸块32被设置为仅沿着或是相邻于电子构件712的边缘726。
图8为根据另一实施例的电子装置80的部分横截面视图,其具有在边缘826处附着到基板11上的导电图案21的电子构件812。电子装置80相似于电子装置30和70,并且仅将主要的不同部分描述于下文中。在本实施例中,电子构件812在主要表面829上具有传导层828并且在主要表面831上具有传导层838。换句话说,电子构件812在两个相对的主要表面上具有主动装置。此外,传导凸块321和322被分别地提供于电子构件812的所述相对的主要表面829和831上。更特别地,在本实施例中,传导凸块322在接近电子构件812的边缘826物理性地接触传导图案21。根据本实施例,电子构件812相对于边缘826的边缘827被提供为缺乏任何传导凸块321或322。换句话说,传导凸块321和322被设置为仅沿着或是相邻于电子构件812的边缘826。
图9为根据另一实施例的电子装置90的部分横截面视图,其具有在边缘926处附着到基板11上的导电图案21的电子构件912。电子装置90相似于电子装置30、70和80,并且仅将主要的不同部分描述于下文中。在本实施例中,电子构件912在主要表面929上具有传导层928,所述传导层928延伸覆盖边缘926并且延伸以邻近于主要表面931的至少部份。传导凸块321和322被分别地提供于电子构件912的所述相对的主要表面929和931上。更特别地,在本实施例中,传导凸块322在接近电子构件912的边缘926物理性地接触传导图案21。根据本实施例,电子构件912的与边缘926相对的边缘927被提供为缺乏任何传导凸块321或322。换句话说,传导凸块321和322被设置为仅沿着或是相邻于电子构件912的边缘926。
图10为根据另一实施例的电子装置100的部分横截面视图,其具有在边缘1026处附着到基板11上的导电图案21的电子构件1012。电子装置100相似于电子装置30、70、80和90,并且仅将主要的不同部分描述于下文中。在本实施例中,电子构件1012被图标为在升高或直立的组态。在本实施例中,电子构件1012具有传导贯通基板通孔(through-substratevia,TSV)1127,所述传导贯通基板通孔1127从电子构件1012的主要表面1029延伸至相对主要表面1031,所述传导贯通基板通孔1127将相邻于主要表面1029的传导凸块32电性连接到被设置相邻于主要表面1031的传导层1033。在电子构件1012中,主要表面1031是主动表面,其透过TSV1127、传导凸块32和焊料33与传导图案21电性通讯。根据本实施例,电子构件1012的与边缘1026相对的边缘1027被提供为缺乏任何传导凸块32。换句话说,传导凸块32被设置为仅沿着或是相邻于电子构件1012的边缘1026。
图11为根据本发明的另一实施例的电子装置301的部分横截面视图,其具有在边缘126处附着到基板11上的导电图案21的电子构件12。电子装置301相似于电子装置30,并且两个装置之间的主要不同将描述于下文中。在本实施例中,电子构件12与大部分的传导图案21交叠。也就是,在横截面视图中,电子构件12与传导图案21的至少一半交叠。根据本实施例,电子构件12的与边缘126相对的边缘127被提供为缺乏任何传导凸块32。换句话说,传导凸块32被设置为仅沿着或是相邻于电子构件12的边缘126。
图12为根据本发明的另一实施例的电子装置302的部分横截面视图,其具有在边缘126处附着到基板11上的导电图案21的电子构件12。电子装置302相似于电子装置30和301,并且这些装置之间的主要不同将描述于下文中。在本实施例中,电子构件12在电子构件上升到直立位置之前不与导电图案21交迭。
图13为根据本发明的另一实施例的电子装置303的部分横截面视图,其具有在边缘126处附着到基板11上的导电图案21的电子构件12。在本实施例中,电子构件被提供为在升高的位置,使得电子构件12的主要表面129不平行于基板11的主要表面110。此外,在本实施例中,电子构件12的主动表面129不是与基板11的主要表面110正交。换句话说,电子构件12是在升高的位置,其相对于基板11的主要表面110是大于0度且小于90度。
从前述所有内容中,根据一个实施例,所属技术领域中具有通常知识者可以确定,一种方法可以进一步包括在第一边缘表面附近形成底部填充层。在另一实施例中,所述提供所述传导材料可包含提供沿着所述第一电子构件的所述第一边缘表面实质上均匀分布的多个传导凸块。在另外的实施例中,提供邻近所述第一主要表面和第二主要表面两者的传导图案可包括藉由延伸传导图案交迭所述第一电子构件的所述第一边缘表面而将在所述第一主要表面上的所述传导图案耦合到所述第二主要表面上的传导图案。在又另一实施例中,提供基板可包括提供支柱邻近于所述基板第一主要表面,并且放置所述第一电子构件的所述第二主要表面可包含放置所述第二主要表面邻近于所述支柱。
从前述所有内容中,根据另一实施例,所属技术领域中具有通常知识者可以确定,所述第一电子构件可以包括具有大约5到大约1的宽高比的半导体晶粒。
根据上述所有内容,显然已经揭示了一种新颖的方法和相关结构,其提供有竖立或直立配置的电子构件。在某些实施例中,电子构件的边缘被放置邻近于在基板上的传导图案。传导材料被放置邻近于所述边缘和所述传导图案。述传导材料被曝露于升高的温度以回流所述传导材料。在所述回流制程中,表面张力效应作用以将电子构件向上升高或转动成直立或竖立指向。在某些范例中,所述传导材料包含焊料和多个传导凸块,其可沿着所述电子构件的所述边缘而被实质上均匀地分布。在某些实施例中,所述电子构件可以是天线结构,例如半导体天线结构。在某些实施例中,所述电子构件可以是感测装置,例如影像感测装置。在某些实施例中,所述电子构件可以是裸露的半导体晶粒或芯片(即未经封装的)。在某些实施例中,所述电子构件包含导体,其电性连接到沿着所述边缘而放置的所述多个传导凸块中的一个或多个。在某些实施例中,所述传导图案可以在所述电子构件的两个侧边上。多个电子构件可以竖立配置及以习知附接配置方式两者被设置在基板上以提供具有3轴定向能力的电子装置结构。本发明所描述的所述方法和相关结构提供具有经提升的设计灵活性和性能的电子装置结构。此外,所述方法和相关结构可以支持即将到来的电子构件需求,例如5G应用。
虽然本发明的目标藉由具体较佳的实施例和示例性实施例来描述,但是前述图式和其描述仅描绘了所述目标的典型实施例,并且因此不被认为是对其范围的限制。对于所属技术领域中具有通常知识者而言,许多替代和变化将显然是显而易见的。作为范例,多个电子装置可以以并排配置、堆栈配置、其组合或所属技术领域中具有通常知识者已知的其他配置方式附接到基板。
如本发明的权利要求书所反映的,发明的态样可能在于少于单个前述公开实施例的所有特征。因此,下文中表达的权利要求在此明确地并入所述图式的详细描述中,每个权利要求自身作为本发明的单独实施例。此外,尽管本文描述的一些实施例包括其他实施例中包括的一些特征但不包括其他特征,但是如所属技术领域中具有通常知识者将理解的那样,不同实施例的特征的组合也被认为是在本发明的范畴内并且用意是形成不同的实施例。
Claims (10)
1.一种形成电子装置结构的方法,其包含:
提供第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面以及相对的第二边缘表面;
提供基板,其具有基板第一主要表面和相对的基板第二主要表面;
将所述第一电子构件的所述第二主要表面放置接近于所述基板第一主要表面;
提供传导材料,其邻近于所述第一电子构件的所述第一边缘表面;以及
将所述传导材料曝露于升高的温度以回流所述传导材料使所述第一电子构件抬起成直立位置,使得所述第二边缘表面与所述基板第一主要表面的间距是更远于所述第一边缘表面与所述基板第一主要表面的间距。
2.如权利要求1所述的方法,其中:
提供所述基板包含提供第一传导图案邻近于所述基板第一主要表面;
提供所述传导材料包含将所述传导材料放置于邻近所述第一传导图案;以及
提供所述传导材料包含使所述第一电子构件的所述第二边缘表面保留没有所述传导材料。
3.如权利要求1所述的方法,其进一步包含:
形成底部填充层,其邻近于所述第一边缘表面;以及
形成封装本体,其囊封所述第一电子构件,其中:
提供所述第一电子构件包含提供天线装置、感测装置和光学装置中的一个;以及
提供所述传导材料包含提供焊料材料和多个传导凸块。
4.如权利要求1所述的方法,其中提供所述第一电子构件包含提供传导图案邻近于所述第一电子构件的所述第一主要表面和所述第二主要表面中的一个或多个。
5.如权利要求4所述的方法,其中提供所述传导图案包含提供所述传导图案邻近于所述第一主要表面和所述第二主要表面两者。
6.如权利要求4所述的方法,其进一步包含使用贯穿基板通孔以电性地耦接所述传导图案到所述传导材料。
7.一种形成电子装置结构的方法,其包含:
提供第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面以及相对的第二边缘表面;
提供基板,其具有基板第一主要表面、相对的基板第二主要表面以及邻近所述基板第一主要表面的第一传导图案;
将所述第一电子构件的所述第二主要表面放置接近于所述基板第一主要表面;
提供传导材料,其邻近于所述第一电子构件的所述第一边缘表面和所述第一传导图案;以及
将所述传导材料曝露于升高的温度以回流所述传导材料使所述第一电子构件抬起成直立位置,使得所述第二边缘表面与所述基板第一主要表面的间距是更远于所述第一边缘表面与所述基板第一主要表面的间距。
8.如权利要求7所述的方法,其进一步包含:
将第二电子构件附接到所述基板第一主要表面;
将第三电子构件附接到所述基板第二主要表面;以及
形成封装本体,其囊封所述第一电子构件和所述第二电子构件,其中:
提供所述传导材料包含提供焊料材料和沿着所述第一电子构件的所述第一边缘表面实质上均匀分布的多个传导凸块;
将所述传导材料曝露于所述升高的温度以使所述第一电子构件抬起,使得所述第一电子构件的所述第一主要表面通常与所述基板第一主要表面正交;以及
提供所述第一电子构件包含提供半导体晶粒。
9.一种电子装置结构,其包含:
基板,其具有基板第一主要表面、相对的基板第二主要表面以及邻近所述基板第一主要表面的第一传导图案;以及
第一电子构件,其具有第一主要表面、相对的第二主要表面、第一边缘表面、相对的第二边缘表面以及设置至少邻近于所述第一主要表面的第一传导图案,其中:
所述第一边缘表面是藉由传导材料而附接到所述第一传导图案;
所述第一主要表面通常被设置为与所述基板第一主要表面正交,使得所述第二边缘表面是远离于所述基板第一主要表面;以及
所述传导材料是电性地耦接至所述第一传导图案。
10.如权利要求9所述的结构,其进一步包含:
第二电子构件,其附接到所述基板第一主要表面;
第三电子构件,其附接到所述基板第二主要表面;
封装本体,其囊封所述第一电子构件和所述第二电子构件,其中:
所述第二电子构件包含第三主要表面、相对的第四主要表面、第三边缘表面以及相对的第四边缘表面;
所述传导材料包含焊料材料和多个传导凸块;
所述第一电子构件的所述第一主要表面面向所述基板的第一边缘;
所述第三边缘表面是藉由额外的焊料材料和额外的多个传导凸块而附接到所述第一传导图案的另一部份;
所述第三主要表面通常被设置为与所述基板第一主要表面正交,使得所述第四边缘表面是远离于所述基板第一主要表面;
所述第二电子构件的所述第三主要表面面向所述基板的第二边缘;以及
所述结构进一步包含底部填充层,其被设置为邻近于所述第一电子构件的第一边缘表面和所述第二电子构件的所述第三边缘表面中的一个或多个。
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