CN110537253B - 带有具有用于上部封装的激光钻孔的开口的模制基底的堆叠电路封装 - Google Patents
带有具有用于上部封装的激光钻孔的开口的模制基底的堆叠电路封装 Download PDFInfo
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Abstract
描述了堆叠的封装配置,包括底部封装和上部封装。底部封装包括基板,该基板具有带有第一电路的顶部表面以及金属第一焊盘。然后在基板上方形成模制层。然后通过模制层的孔经过激光钻孔以暴露第一焊盘。孔和第一焊盘与上部封装的引线对齐,后者包含更多的电路组件。然后用焊膏部分填充孔。在模制层和上部封装之间施加热环氧树脂。然后将上部封装的引线插入孔中,并将焊膏回流以电、热和机械连接上部封装到底部封装。回流热还可以固化环氧树脂。然后在基板的底部形成球栅阵列。
Description
相关申请的交叉引用
本申请基于并要求2018年3月27日由John D.Brazzle等人提交的美国临时专利申请序列号62/648,835的优先权,该申请通过引用结合在此。
技术领域
本发明涉及电子元件的包装,尤其涉及一种具有基础封装和互连的上部封装的叠层封装结构。
背景技术
通常在具有标准化端子配置的单个密封封装中提供集成电路或由分立元件形成的电路(例如,球栅阵列、直列引脚、表面安装引线等)。然后通常将封装的端子与其他封装和组件一起焊接到印刷电路板上。
封装设计中的相关因素包括尺寸、端子数、散热、电流/电压要求以及电/磁干扰问题。
为了减小电气系统的尺寸,已知将封装堆叠在彼此之上,其中底部封装包括底部端子,用于焊接到印刷电路板,以及顶部端子用于焊接到上部的端子封装。底部封装具有通孔,从其顶部端子通向内部电路或底部封装的底部端子。这也称为三维封装。
对于某些应用,例如高功率应用,堆叠封装需要更坚固的结构。对于诸如20A-100A开关电压调节器之类的高功率应用,希望提供非常低阻抗的电流路径以最小化热量和电压降,以及提供到空气和金属芯印刷电路板的良好热路径。此外,某些元件,如电感器和变压器,应与其他电路分开,以尽量减少磁耦合和噪声。
因此,需要一种更坚固的封装,其解决了传统堆叠封装技术的一些现有问题。
发明概述
在本发明的一个实施方案中,电路由包括在底部封装和上部封装中的部件形成。底部封装可包括用于高功率开关电压调节器的开关晶体管和控制电路。底部封装包括在其顶部表面电路上具有用于互连电路的金属迹线的基板,以及连接到电路的金属焊盘。金属焊盘与上部封装的引线对齐。底部封装的底部表面可包括用于焊接到传统金属芯印刷电路板的球栅阵列。
然后用模制的热塑料封装底部封装上的电路,以形成具有顶部平面表面的矩形封装。
然后控制编程的激光器以在模制塑料中钻出开口,该开口向下延伸到基板上的金属焊盘。然后用焊料、焊膏或其他导电材料部分填充孔。激光不仅可以钻孔,还可以清洁基板上的金属焊盘。
接下来,上部封装,例如包含用于开关调节器的相对大的平滑电感器,定位在底部封装上方。上部封装具有底部端子,例如支柱或钉头型引线,其延伸穿过孔并电接触通过孔暴露的焊盘。
优选地,在上部封装的引线的端部与形成在底部封装的基板上的刚性金属焊盘之间存在小的间隙,因此上部封装可以根据需要倾斜,以具有顶部平坦表面,无论上部封装的引线的非平面性如何,都与底部封装的底部表面精确平行。这确保了上部封装的顶部将与印刷电路板上的其他上部封装的顶部共面,例如用于使单个散热器与平坦表面接触。间隙预先填充有焊膏、焊料或其他合适的导电材料,其在回流期间熔化并允许上部封装的顶部倾斜以与底部封装的底部精确平行。
然后对堆叠结构进行回流以熔化并固化任何焊膏、焊料或其他导电材料,使得上部封装与底部封装电连接、热连接和机械连接。上部封装也可以使用热环氧树脂环氧化到底部封装的顶部,热环氧树脂在回流期间固化。
然后可以在底部封装的底部形成用于球栅阵列的焊料球并回流。上部封装和底部封装之间的固化环氧树脂确保上部封装在球栅阵列回流期间不会改变其位置。
如果上部封装是用于开关稳压器的平滑电感器,并且底部封装包含开关稳压器电路的其余部分,则电感器和金属芯印刷电路板之间将具有极好的热传递,因为电感器的引线是直接连接到底部封装基板上的金属焊盘。而且,电感器与其余电路垂直分离,并且可以与底部电路磁隔离。
尽管在该示例中已经使用了具有电感器的规则切换,但是该技术可以用于形成任何其他电路。例如,上部封装可以包括变压器。
上部封装不需要是电气元件。上部器件可以是具有坚固突片的金属散热器,所述突片延伸穿过底部封装中的孔并且与底部封装的基板上的金属焊盘热接触。上部器件还可以提供RF屏蔽,例如作为接地板,或提供任何其他功能。
可以在分割封装之前同时形成堆叠封装的阵列,例如通过锯切。
附图简述
图1是基板的横截面透视图,其中电路安装在基板的顶部上,并且导电的通孔与基板的底部焊盘电接触。还示出了在基板顶部上的相对大的金属焊盘,其将与上部封装的引线接触。
图2示出了在热塑料模制在基板顶部上以封装电路并提供平面顶部表面之后的图1的基板。
图3示出了热塑料中的编程激光钻孔,以暴露基板上的焊盘。
图4示出了封装的底部,示出了用于焊接到印刷电路板的球栅阵列配置。
图5示出了一种类型的上部封装,其金属支柱穿过底部封装中的孔插入,以电接触形成在基板上的焊盘。
图6示出了图5的上部封装以及透明底部封装。
图7示出了图6的替代方案,其中多余的焊料或其他导电材料沉积在孔中并且在熔化时芯吸柱以实现稳固的电连接。
图8示出了完整的堆叠封装,其中上部封装使用围绕上部封装的周边的钉头型引线,并且其中钉头型引线插入底部封装中的激光钻孔槽中并且在底部封装电接触基板上的金属焊盘。
图9示出了具有透明底部封装的图8的堆叠封装。
图10示出了安装在单个底部封装上的多个上部封装,其中所有上部封装的顶部是共面的。
图11示出了金属散热器,其具有插入底部封装中的孔的突片,所述突片热连接到底部封装的基板上的金属焊盘。
发明详述
尽管堆叠封装可以用于任何类型的电路,但是将提供具有堆叠变压器或电感器的高功率开关调节器的示例。由于所描述的特定设计,调节器可以向负载提供高达100A的输出电流。
图1是用于底部封装的起始基板10的横截面图。基板10可以是传统的印刷电路板材料或模制的热塑料。在一个实施例中,基板10的厚度约为0.3mm。基板10具有导电通孔12,导电通孔12可以与基板10的表面顶部上的金属迹线接触,该金属迹线互连电路元件14。元件14可以包括集成电路和分立元件。通孔12终止于底部金属焊盘中,例如用于球栅阵列。
还示出了相对大的顶部焊盘16,其与上部封装的引线对准。一些通孔12可以终止于顶部焊盘16。焊盘16可以互连到基板10上的其他电路。通孔12可以用于将热量从上部封装传导到金属芯印刷电路板。一些通孔12可以连接在一起用于并联传导路径。
在该示例中,电路形成开关晶体管和用于开关电压调节器的控制电路。
图2示出了在基板10上模制以封装电路的热塑料18。塑料18的顶部是平面的。塑料18是非常好的导热体并且是电介质。
在图3中,编程激光器20烧蚀塑料18中的孔21(任何形状)以暴露基板10上的焊盘16。在一个实施例中,焊盘16形成为具有焊料层以便更好地芯吸到上部封装的金属引线。激光钻孔自动停在焊料/焊盘表面,可以清洁表面。所得到的结构是用于堆叠封装结构的底部封装22。
图4示出了底部封装22的可能的底部表面,示出了用于球栅阵列的小金属焊盘24。
然后将诸如焊料、焊膏或导电环氧树脂的导电材料分配到每个孔21中,并且将用于将上部封装的引线电连接到焊盘16,同时不需要引线直接邻接焊盘16。填充引线和焊盘16之间的间隙的这种导电材料允许上部封装在回流步骤期间倾斜,即使引线不是平面的,也要精确地平行于底部封装22。
图5示出了上部封装26,其具有形成为矩形支柱28的引线。底部封装22中的孔21与支柱28的图案对准。上部封装26的底部表面不需要接触底部封装22的顶部表面,并且可以在回流期间调节上部封装26的角度,以实现上部封装26与底部封装22的精确对准。在一个实施例中,上部封装26包含变压器。
图6示出了图5的结构,但底部封装22是透明的。如果支柱28或焊盘16不是共面的,则支柱28的端部将不会全部邻接基板10上的焊盘16。
如图7所示,为了解决这种共面性的缺陷,在将支柱28插入孔21之前,底部封装22中的孔部分地填充有导电材料32,例如焊料、焊膏或允许上部封装26与底部封装22精确平行地定位的其他导电材料。导电材料32可以用针分配或者挤压到孔21中。因此,希望形成比支柱28明显更宽的孔21,使得导电材料32不会被支柱28推出。
上部封装26的底部表面可以可选地使用热环氧树脂固定到底部封装22的顶部,以在回流步骤之后将上部封装26的位置牢固地设定在底部封装22上。在回流期间,导电材料32将熔化并芯吸到支柱28和焊盘16以实现良好的电气、热和机械连接,而上部封装26使用对准工具与底部封装22精确对准。在回流期间,热量也固化热环氧树脂。
示出了基板10上的导电迹线29互连电路元件14和焊盘16。
在将上部封装26的支柱28焊接到焊盘16之后,可以翻转该结构并将焊球放置在底部封装22的底部焊盘24(图4)上以形成球栅阵列。回流步骤使焊料熔化在焊盘24上。如果上部封装26被环氧化到底部封装22,则这种回流步骤不会影响上部封装26的位置。
图8-10示出了用于上部封装40的不同类型的引线,称为钉头引线42。钉头引线是细而宽的引线,是高电流和高热量的良导体。当上部封装40是用于开关调节器的高功率电感器时是特别期望的。在一个实施例中,电感器被包裹在高导热的铁氧体材料中。
除了焊盘和激光钻孔43的位置和形状之外,底部封装44可以与图3的底部封装相同。
图9示出了底部封装44是透明的并且示出了钉头引线42如何延伸穿过底部封装44中的激光钻孔43(图8)并且可以或可以不邻接形成在底部封装44的基板48上的金属焊盘46。如前所述,在形成孔43之后,它们部分地填充有导电材料45,导电材料45回流并芯吸到焊盘46和钉头引线42,以实现良好的电气、热和机械连接。
上部封装40的底部可以使用热环氧树脂环氧树脂到底部封装44的顶部,以在回流步骤期间操纵其对准。环氧树脂在回流步骤中固化。
图10示出了多个上部封装50-53如何安装在单个底部封装56上。上部封装50-53各自具有四个钉头引线42,其插入底部封装56中的激光钻孔58中并与形成在基板60上的焊盘电连接。底部表面可以是球栅阵列。可以使用任何其他类型的终端配置。
重要的是,在回流步骤期间使每个上部封装50-53相对于底部封装56并且彼此对准的能力使得所有上部封装50-53的顶部表面精确地共面。因此,具有平坦表面的单个散热器可以定位在上部封装50-53上方并且均等地接触所有顶部表面。
图11示出了安装在底部封装66上方的散热器64。散热器64可以由铜或其他导热材料形成。散热器64具有坚固的突出部68,突出部68延伸到激光钻入底部封装66的模制塑料中的孔70(槽)中。沿着散热器64的底部可以存在分布的突出部68,或者突出部68可以仅沿着散热器64的两侧或更多侧。
底部封装66的基板72具有坚固的金属焊盘,类似于图9中所示的焊盘46,其热耦合到接头68。在一个实施例中,在安装散热器64之前,焊膏、导电环氧树脂、可烧结材料或一些其他导热材料部分地填充孔70,并且散热片68插入孔70中。导热材料填充突片68和焊盘之间的任何间隙。在回流时,导热材料流动然后硬化,导致散热器64与底部封装66的良好的热和机械连接。散热器64的底部表面可以热环氧树脂到底部封装66的顶部表面,以进行额外的热接触。在回流步骤期间,即使突片68不是共面的,散热器64也可以与底部封装66精确对准,因为突片68不直接邻接基板72上的金属焊盘。
基板72上的金属焊盘可以接地。焊盘也可以延伸穿过基板72,以终止于图4所示的底部焊盘24中。然后,这种底部焊盘24可以热接触金属芯印刷电路板中的金属层,以进行额外的散热。
散热器64本身包含新颖的特征。使用常规技术机加工一系列分段金属柱76,以提供用于空气冷却的大表面积。提供具有平坦顶部的较大中心突起78,以允许机器人臂或吸力夹持突起78并在自动机器拾取和放置步骤中将散热器64精确地安装在底部封装66上。
在其他实施例中,上部封装或其他上部组件可以提供频率隔离和/或屏蔽RF、IF或其他辐射信号。
可以同时形成多个封装结构,然后将封装分割,例如通过锯切。
在另一个实施例中,可以使用上述技术垂直堆叠两个以上的封装,其中每个上部封装具有延伸到在其下层封装中形成的激光钻孔的引线。
所描述的技术通过在封装之间提供接地屏蔽或通过在相关部件之间提供足够的间隔来实现上部封装和底部封装之间的任何程度的磁场隔离。
代替对孔进行激光钻孔,可以通过任何其他合适的方法形成孔,例如在底部封装或机械钻孔或化学蚀刻的模制期间。
虽然已经示出和描述了本发明的特定实施例,但是对于本领域技术人员来说显而易见的是,在不脱离本发明的更广泛方面的情况下可以进行改变和修改,因此,所附权利要求在其范围内包含在本发明的真实精神和范围内的所有这些变化和修改。
Claims (23)
1.一种电路封装结构,包括:
底部封装,包括:
基板,具有其上安装第一电路的顶部表面和具有在所述基板的顶部表面上的金属第一焊盘;
在所述基板的顶部表面上方的模制层,封装所述第一电路,所述模制层具有顶部表面;和
通过所述模制层的顶部表面形成的孔,允许进入所述基板上的第一焊盘;
上部器件,包括:
具有钉头引线的至少一个组件,所述钉头引线与所述孔对齐并延伸穿过所述孔,以电接触或热接触所述基板上的第一焊盘,其中所述钉头引线具有厚度和大于该厚度的宽度。
2.权利要求1所述的结构,其中所述上部器件包括:
上部封装,至少包含连接到底部封装中的第一电路的电路组件;和
其中所述钉头引线包括电引线,其与所述孔对齐并延伸穿过所述孔以电接触所述基板上的第一焊盘。
3.权利要求2所述的结构,还包括导电材料,该导电材料部分地填充所述孔,用于将所述上部封装的钉头引线电连接到所述基板上的第一焊盘,而不需要所有钉头引线同时邻接所述第一焊盘。
4.权利要求2所述的结构,其中所述第一电路包括开关调节器的至少一部分,并且所述上部封装中的至少一个电路组件包括变压器。
5.权利要求2所述的结构,其中所述第一电路包括开关调节器的至少一部分,并且所述上部封装中的至少一个电路组件包括电感器。
6.权利要求1所述的结构,其中所述基板具有底部表面,在该底部表面上形成电端子。
7.权利要求6所述的结构,其中所述电端子包括球栅阵列。
8.权利要求1所述的结构,其中所述孔是激光钻孔的。
9.权利要求1所述的结构,其中所述上部器件包括具有所述钉头引线的散热器,所述钉头引线与所述孔对齐并延伸穿过所述孔以与所述基板上的第一焊盘热接触,以从所述基板移除热量。
10.权利要求9所述的结构,其中所述散热器在其顶部表面上有分段列。
11.权利要求9所述的结构,其中所述散热器在其顶部表面上具有突起,用于在拾取和放置过程中通过机器人臂保持所述散热器。
12.一种形成封装结构的方法,包括:
形成具有顶部表面的基板;
在所述基板的顶部表面上安装第一电路,并在所述基板的顶部表面上形成金属第一焊盘;
在封装所述第一电路的基板的顶部表面上方模制模制层,所述模制层具有顶部表面;
通过所述模制层的顶部表面形成的孔,允许进入所述基板上的第一焊盘,所述基板和所述模制层形成底部封装;
提供上部器件,包括具有与孔对齐的钉头引线的至少一个部件,其中所述钉头引线具有厚度和大于该厚度的宽度;和
将所述钉头引线插入所述孔中以电接触或热接触所述基板上的第一焊盘。
13.权利要求12所述的方法,其中提供上部器件的步骤包括在上部封装中提供至少一个电路组件用于连接所述底部封装中的第一电路,并且其中插入钉头引线的步骤包括通过孔插入所述上部封装的电引线以电接触所述基板上的第一焊盘。
14.权利要求12所述的方法,还包括在将钉头引线穿过孔之前使用导电材料至少部分地填充所述孔。
15.权利要求14所述的方法,还包括加热所述导电材料以使所述导电材料流动到所述上部器件的钉头引线的芯部和所述基板的第一焊盘。
16.权利要求14所述的方法,其中所述导电材料包括焊膏。
17.权利要求12所述的方法,其中形成孔的步骤包括对所述孔进行激光钻孔。
18.权利要求12所述的方法,还包括在模制步骤之前使用焊料润湿所述第一焊盘。
19.权利要求12所述的方法,还包括在所述基板的底部表面上形成球栅阵列。
20.权利要求12所述的方法,其中所述第一电路包括开关调节器的至少一部分,并且所述上部器件包括变压器。
21.权利要求12所述的方法,其中所述第一电路包括开关调节器的至少一部分,并且所述上部器件包括电感器。
22.权利要求12所述的方法,其中所述上部器件包括散热器,该散热器具有所述钉头引线,所述钉头引线与所述孔对齐并延伸穿过所述孔以热接触所述基板上的第一焊盘,从而从所述基板移除热量。
23.权利要求22所述的方法,其中所述散热器在其顶部表面上具有突起,该方法还包括在拾取和放置过程中通过机器人臂保持所述突起以将所述散热器定位在所述底部封装上。
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