CN115295426A - 半导体器件和在用于系统级封装模块的包封物中嵌入电路图案的方法 - Google Patents

半导体器件和在用于系统级封装模块的包封物中嵌入电路图案的方法 Download PDF

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CN115295426A
CN115295426A CN202210325262.XA CN202210325262A CN115295426A CN 115295426 A CN115295426 A CN 115295426A CN 202210325262 A CN202210325262 A CN 202210325262A CN 115295426 A CN115295426 A CN 115295426A
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circuit pattern
encapsulant
semiconductor
conductive material
openings
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J·H·郑
C·O·金
李喜秀
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Stats Chippac Pte Ltd
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Stats Chippac Pte Ltd
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Abstract

公开了半导体器件和在用于系统级封装模块的包封物中嵌入电路图案的方法。SIP模块包括安装到互连基板的多个电组件。电组件和互连基板被包封物覆盖。导电柱被形成为通过包封物。通过激光以电路图案的形式在包封物中形成多个开口。导电材料被沉积在包封物的表面上并且沉积到开口中以形成电路图案。通过研磨机移除导电材料的一部分以暴露电路图案。研磨操作使包封物的表面和电路图案平坦化。电路图案可以是迹线、接触焊盘、RDL或其它互连结构。电路图案也可以是屏蔽层或天线。电组件被部署在SIP模块和电路图案上。

Description

半导体器件和在用于系统级封装模块的包封物中嵌入电路图 案的方法
技术领域
本发明一般涉及半导体器件，并且更特别地，涉及半导体器件和在系统级封装(SIP)模块的包封物中嵌入电路图案的半方法。
背景技术
半导体器件通常出现在现代电子产品中。半导体器件执行宽范围的功能，诸如信号处理、高速计算、发射和接收电磁信号、控制电子设备、进行光电作用以及创建用于电视显示的视觉图像。半导体器件出现在通信、功率转换、网络、计算机、娱乐和消费产品的领域中。半导体器件还出现在军事应用、航空、汽车、工业控制器和办公设备中。
针对半导体器件的共同设计目标是减少占位面积和外廓，同时获得功能性。半导体器件需要在更小区域中容纳更高密度的组件。在许多已知的封装布局、中，底部互连基板提供与形成在基板上的电路图案或RDL的机械和电连接，以支持到半导体器件的外部电互连。虽然难以控制，但是合期望的是具有电路图案的恒定或均匀的厚度。电路图案的不规则厚度可能引起互连破裂和组装问题。此外，具有其对应的电路图案的互连基板增加整个半导体封装的高度，这与设计目标相反。
附图说明
图1a至图1c图示具有由划片街区(saw street)分离的多个半导体管芯的半导体晶片；
图2a至图2n图示在SIP模块的包封物中嵌入电路图案的处理；
图3a至图3b图示将电组件安装到SIP模块中的电路图案；
图4a至图4f图示在SIP模块的包封物中嵌入屏蔽层和电路图案的处理；
图5a至图5b图示将电组件安装到SIP模块中的屏蔽层和电路图案的处理；以及
图6图示具有安装到印刷电路板(PCB)的表面的不同类型的封装的PCB。
具体实施方式
在以下的描述中参照各图在一个或多个实施例中描述本发明，各图中同样的标号表示相同或相似的要素。虽然就用于实现本发明的目的的最佳方式描述了本发明，但是本领域技术人员将领会，本发明旨在覆盖可以包括在由所附权利要求限定的本发明的精神和范围内的替换、修改和等同物以及由以下公开和附图支持的它们的等同物。如在此使用的术语“半导体管芯”指代用语的单数形式和复数形式这两者，并且因此可以指代单个半导体器件和多个半导体器件这两者。
半导体器件一般是使用两种复杂的制造处制造的：前端制造和后端制造。前端制造涉及在半导体晶片的表面上形成多个管芯。晶片上的每个管芯包含被电连接以形成功能电路的有源电组件和无源电组件。诸如晶体管和二极管的有源电组件具有控制电流流动的能力。诸如电容器、电感器和电阻器的无源电组件创建电压和电流之间的执行电路功能所需要的关系。
后端制造指代将完成的晶片切割或单体化成单独的半导体管芯，并且封装半导体管芯以用于结构支承、电互连和环境隔离。为了单体化半导体管芯，晶片被沿着晶片的被称为划片街区或划痕区的非功能区划刻并且断裂。使用激光切割工具或锯切刃将晶片单体化。在单体化之后，将单独的半导体管芯安装到封装基板，封装基板包括用于与其它系统组件互连的管脚或接触焊盘。然后将形成在半导体管芯上的接触焊盘连接到封装内的接触焊盘。可以利用导电层、凸块、柱形凸块、导电焊膏或布线接合来进行电连接。包封物或其它模制材料被沉积在封装上以提供物理支承和电隔离。然后将完成的封装插入到电系统中，并且使半导体器件的功能性可用于其它系统组件。
图1a示出具有基底基板材料102的半导体晶片100，基底基板材料102诸如为硅、锗、磷化铝、砷化铝、砷化镓、氮化镓、磷化铟、碳化硅或用于结构支承的其它块体材料。多个半导体管芯或组件104被形成在晶片100上，由非有源的、管芯间晶片区域或划片街区106分离开。划片街区106提供切割区域以将半导体晶片100单体化成单独的半导体管芯104。在一个实施例中，半导体晶片100具有100-450毫米(mm)的宽度或直径。
图1b示出半导体晶片100的一部分的横截面视图。每个半导体管芯104具有背侧或非有源表面108和有源表面110，其包含被实现为形成在管芯内并且被根据管芯的电设计和功能电互连的有源器件、无源器件、导电层和电介质层的模拟或数字电路。例如，电路可以包括一个或多个晶体管、二极管和形成在有源表面110内的其它电路元件，以实现模拟电路或数字电路，诸如数字信号处理器(DSP)、专用集成电路(ASIC)、存储器或其它信号处理电路。半导体管芯104还可以包含用于RF信号处理的IPD，诸如电感器、电容器和电阻器。
使用PVD、CVD、电解电镀、无电电镀处理或其它合适的金属沉积处理在有源表面110上形成导电层112。导电层112可以是一层或多层的铝(Al)、铜(Cu)、锡(Sn)、镍(Ni)、金(Au)、银(Ag)或其它合适的导电材料。导电层112作为电连接到有源表面110上的电路的接触焊盘进行操作。
使用蒸发、电解电镀、无电电镀、球滴或丝网印刷处理在导电层112上沉积导电凸块材料。凸块材料可以是Al、Sn、Ni、Au、Ag、Pb、Bi、Cu、焊料以及它们的组合，具有可选的助熔剂溶液。例如，凸块材料可以是共晶Sn/Pb、高铅焊料或无铅焊料。使用合适的附接或接合处理将凸块材料接合到导电层112。在一个实施例中，通过将凸块材料加热到其熔点以上来使凸块材料回流以形成球或凸块114。在一个实施例中，凸块114被形成在具有润湿层、阻挡层和粘合剂层的凸块下金属化(UBM)上方。凸块114也可以被压缩接合或热压缩接合到导电层112。凸块114表示可以被形成在导电层112上的一种类型的互连结构。互连结构还可以使用接合布线、导电焊膏、柱形凸块、微凸块或其它电互连。
在图1c中，使用锯切刃或激光切割工具118通过划片街区106将半导体晶片100单体化成单独的半导体管芯104。单独的半导体管芯104可以被检查和电测试以用于标识单体化之后的KGD。
图2a至图2n图示在互连基板上部署电组件以形成SIP模块或电组件组装的处理。然后将电路图案嵌入在SIP模块的包封物中。图2a示出包括导电层122和绝缘层124的互连基板120的横截面视图。导电层122可以是一层或多层的Al、Cu、Sn、Ni、Au、Ag或其它合适的导电材料。导电层122提供跨基板120的水平电互连和在基板120的顶表面126和底表面128之间的竖向电互连。导电层122的部分可以是电共用的或电隔离的，这取决于半导体管芯104和其它电组件的设计和功能。绝缘层124包含一层或多层的二氧化硅(SiO2)、氮化硅(Si3N4)、氮氧化硅(SiON)、五氧化二钽(Ta2O5)、氧化铝(Al2O3)、阻焊剂、聚酰亚胺、苯并环丁烯(BCB)、聚苯并恶唑(PBO)和具有类似的绝缘和结构性质的其它材料。绝缘层124提供导电层122之间的隔离。
在图2b中，多个电组件130a-130c被安装到互连基板120的表面126并且电气地和机械地连接到导电层122。使用拾取和放置操作将每个电组件130a-130c定位在基板120上。例如，电组件130b可以是来自图1c的半导体管芯104，其中有源表面110和凸块114被定向为朝向基板120的表面126并且电连接到导电层122。电组件130a和130c是分立的电子器件或IPD，诸如电阻器、电容器和电感器。电组件130a使用端子132和134进行对于互连基板120上的导电层122的电气和机械连接。电组件130c使用端子136和138进行对于互连基板120上的导电层122的电气和机械连接。替换地，电组件130a-130c可以包括其它半导体管芯、半导体封装、表面安装器件、分立电子器件或IPD，诸如电阻器、电容器和电感器。如在图2c中示出那样，电组件130a-130d被安装到互连基板120，其中凸块114和端子132-138进行对于导电层122的机械和电气连接。
在图2d中，使用焊膏印刷、压缩模制、转印模制、液体包封物模制、真空层压、旋涂或其它合适的施加器，将包封物或模制化合物140沉积在电组件130a-130c和基板120之上和周围。包封物140可以是聚合物复合材料，诸如具有填充物的环氧树脂、具有填充物的环氧丙烯酸酯、或具有适当填充物的聚合物。包封物140是不导电的，提供结构支承，并且在环境上保护半导体器件不受外部因素和污染物影响。
在图2e中，使用蒸发、电解电镀、无电电镀、球滴或丝网印刷处理在互连基板120的表面128上的导电层122上沉积导电凸块材料。凸块材料可以是Al、Sn、Ni、Au、Ag、Pb、Bi、Cu、焊料和它们的组合，具有可选的助熔剂溶液。例如，凸块材料可以是共晶Sn/Pb、高铅焊料或无铅焊料。使用合适的附接或接合处理将凸块材料接合到导电层122。在一个实施例中，通过将凸块材料加热到其熔点以上来使凸块材料回流以形成球或凸块144。在一个实施例中，凸块144被形成在具有润湿层、阻挡层和粘合剂层的UBM上方。凸块144也可以被压缩接合或热压缩接合到导电层122。凸块144表示可以被形成在导电层122上的一种类型的互连结构。互连结构还可以使用接合布线、导电焊膏、柱形凸块、微凸块或其它电互连。
在图2f中，使用蚀刻、钻孔或利用激光器150的激光直接烧蚀(LDA)将多个通孔146形成到包封物140的表面148中。通孔146与互连基板120上的导电层122的部分对准并且延伸到该部分。在图2g中，使用焊膏印刷和回流、电解电镀、无电电镀处理或其它合适的金属沉积处理，利用Al、Cu、Sn、Ni、Au、Ag、Ti、W、多晶硅或其它合适的导电材料填充通孔146，以形成z方向的竖向导电柱152。导电柱152电连接到导电层122。
在图2h中，使用蚀刻或利用激光器156的LDA在包封物140的表面148中形成多个开口154。开口154被布置在电路图案中，电路图案被指定为经由迹线、重分布层(RDL)、接触焊盘和其它互连结构互连各种电组件。图2i示出作为一般电路图案158形成在包封物140的表面148中的开口154的顶视图。例如，开口154a将形成迹线线路，开口154b将形成接触焊盘，并且开口154c将形成RDL。为了说明的目的，开口154在图2h至图2i中被示出为是宽的，即开口不是按比例的。在实践中，开口154对应于实际的半导体尺度电路图案中的特征的宽度。
在图2j中，使用电解电镀、无电电镀处理、溅射或其它合适的金属沉积处理将导电材料160共形地施加到表面148。导电材料160可以是Al、Cu、Sn、Ni、Au、Ag、Ti、W、多晶硅或其它合适的导电材料。导电材料160被部署在表面148上或覆盖表面148，并且填充开口154，包括电路图案158的所有部分。导电材料160接触导电柱152。图2k示出部署在表面148上或覆盖表面148并且填充开口154的导电材料160的顶视图，包括电路图案158的所有部分。
在图2l中，通过研磨机164移除导电层160的一部分，以暴露出表面148和开口154中的导电材料。开口154中的导电材料的部分保持在位。研磨机164平坦化包封物140的表面148和导电材料160的表面。替换地，通过化学蚀刻、化学机械抛光(CMP)或LDA移除导电材料160的一部分，以暴露出表面148和开口154中的导电材料。图2m示出研磨后的SIP模块或半导体组件组装166，在开口154中具有导电材料160。实际上，研磨处理暴露出开口154中的导电材料160以形成电路图案168，如在图2n中示出那样。因此，电路图案168嵌入有包封物140。
各种电组件可以被安装到来自图2m至图2n的电路图案168。在图3a中，使用拾取和放置操作将每个电组件定位在包封物140和电路图案168上。电组件被安装到电路图案168。例如，分立半导体器件170被机械地和电气地连接到电路图案168。分立半导体器件可以是电容器、电阻器、电感器或分立晶体管。半导体封装172包括互连基板174、布线接合到互连基板的半导体管芯176、以及机械地和电气地连接到互连基板的分立半导体器件178。半导体管芯176、分立半导体器件178和互连基板174被包封物180覆盖。半导体封装172被利用凸块184机械地和电气地连接到电路图案168。半导体管芯186被利用凸块188机械地和电气地连接到电路图案168。图3b示出安装到电路图案168的电组件170、172和186。可选的包封物190可以被沉积在SIP模块166和电组件170、172和186上。
嵌入在包封物140内的电路图案158提供设计灵活性，同时减小SIP模块高度。由于切割初始开口的激光的准确性和在开口中沉积导电材料之后的平坦化，包封物140内的电路图案158的厚度保持恒定。
在替换的实施例中，从图2g继续，使用蚀刻或利用激光器156的LDA在包封物140的表面148中形成开口200和202，如在图4a中示出那样。具有相似功能的组件被分配相同的参考标号。开口200被配置为电磁屏蔽层。导电柱204通过围绕开口200的包封物140而形成，类似于图2f至图2g中的导电柱152。开口202被布置在电路图案中，电路图案被设计为经由迹线、RDL、接触焊盘和其它互连结构互连各种电组件。图4b示出作为一般电路图案208形成在包封物140的表面148中的开口200和202的顶视图。例如，开口202a将形成迹线线路，开口202b将形成接触焊盘，并且开口202c将形成RDL。为了说明的目的，开口200和202在图4a至图4b中被示出为是宽的，即开口不是按比例的。在实践中，开口200和202对应于实际半导体尺度电路图案中的特征的宽度。
在图4c中，导电材料210被共形地施加到包封物140的表面148。导电材料210可以是Al、Cu、Sn、Ni、Au、Ag、Ti、W、多晶硅或其它合适的导电材料。导电材料210被部署在表面148上或覆盖表面148，并且填充开口200和202，包括电路图案208的所有部分，类似于图2k。导电材料210接触导电柱204。
在图4d中，通过研磨机164移除导电层210的一部分，以暴露出表面148和开口200和202中的导电材料。开口200和202中的导电材料的部分保持在位。研磨机164使包封物140的表面148和导电材料210的表面平坦化。替换地，通过蚀刻处理或LDA移除导电材料210的一部分以暴露出表面148和开口200和202中的导电材料。图4e示出研磨后的SIP模块或半导体组件组装214，具有在开口200和202中的导电材料210。实际上，研磨处理暴露出开口200和202中的导电材料210以形成电磁屏蔽层216和电路图案218，如在图4f中示出那样。因此，电路图案218被嵌入有包封物140。电磁屏蔽层216可以通过导电柱204接地。
各种电组件可以被安装到来自图4e至图4f的电路图案218。在图5a中，使用拾取和放置操作将电组件220定位在包封物140和电磁屏蔽层216上。在图5b中，电组件220被利用管芯附接粘合剂222安装到电磁屏蔽层216。电组件222被利用布线接合224电连接到电路图案218。
具有电组件130a-130c和电组件220的SIP模块214可以包含IPD，其易受EMI、RFI、谐波失真和器件间干扰影响或生成EMI、RFI、谐波失真和器件间干扰。例如，包含在电组件220内的IPD提供高频应用所需要的电气特性，高频应用诸如为谐振器、高通滤波器、低通滤波器、带通滤波器、对称Hi-Q谐振变压器和调谐电容器。在另一实施例中，电组件220包含在高频下开关的数字电路，这可能干扰SIP模块214中的IPD的操作。电磁屏蔽层216减少或抑制EMI、RFI和例如由高速数字器件辐射的其它器件间干扰影响SIP模块214或电组件220内或相邻于SIP模块214或电组件220的邻近器件。
嵌入在包封物140内的电路图案218提供设计灵活性，同时减小SIP模块高度。由于切割初始开口的激光的准确性以及在开口中沉积导电材料之后的平坦化，包封物140内的电路图案218的厚度保持恒定。其它电路图案可以被形成在包封物140内，诸如天线图案和连接器电极。
图6图示具有芯片载体基板或PCB 302的电子设备300，其中多个半导体封装被安装在PCB 302的表面上，包括SIP模块166和214。取决于应用，电子设备300可以具有一种类型的半导体封装或者多种类型的半导体封装。
电子设备300可以是使用半导体封装来执行一个或多个电气功能的单独的系统。替换地，电子设备300可以是更大系统的子组件。例如，电子设备300可以是平板电脑、蜂窝电话、数码相机、通信系统或其它电子设备的一部分。替换地，电子设备300可以是图形卡、网络接口卡或可以被插入到计算机中的其它信号处理卡。半导体封装可以包括微处理器、存储器、ASIC、逻辑电路、模拟电路、RF电路、分立器件或其它半导体管芯或电组件。小型化和重量减轻对于产品被市场接受而言是至关重要的。可以减小半导体器件之间的距离以实现更高的密度。
在图6中，PCB 302提供用于安装在PCB上的半导体封装的结构支承和电互连的一般基板。使用蒸发、电解电镀、无电电镀、丝网印刷或其它合适的金属沉积处理在PCB 302的层的表面上或内部形成导电信号迹线304。信号迹线304提供在半导体封装、安装的组件和其它外部系统组件的每个之间的电通信。迹线304还向每个半导体封装提供功率和接地连接。
在一些实施例中，半导体器件具有两个封装层级。第一层级封装是用于将半导体管芯机械地和电气地附接到中间基板的技术。第二层级封装涉及将中间基板机械地和电气地附接到PCB。在其它实施例中，半导体器件可以仅具有第一层级封装，其中管芯被机械地和电气地直接安装到PCB。
为了说明的目的，在PCB 302上示出若干种类型的第一层级封装，包括接合布线封装306和倒装芯片308。附加地，示出安装在PCB 302上的若干种类型的第二层级封装，包括球栅阵列(BGA)310、凸块芯片载体(BCC)312、平面网格阵列(LGA)316、多芯片模块(MCM)或SIP模块318、四方扁平无引线封装(QFN)320、四方扁平封装322、嵌入式晶片级球栅阵列(eWLB)324和晶片级芯片尺度封装(WLCSP)326。在一个实施例中，eWLB 324是扇出晶片级封装(Fo-WLP)并且WLCSP 326是扇入晶片级封装(Fi-WLP)。取决于系统要求，配置有第一层级封装类别和第二层级封装类别的任何组合的半导体封装的任何组合以及其它电组件可以被连接到PCB 302。在一些实施例中，电子设备300包括单个附接的半导体封装，而其它实施例要求多个互连的封装。通过在单个基板上组合一个或多个半导体封装，制造商可以将预制组件合并到电子设备和系统中。因为半导体封装包括复杂的功能性，所以可以使用更便宜的组件和流水线制造处理来制造电子设备。所得到的设备不太可能失效，并且制造起来更便宜，造成对于消费者而言的更低的成本。
虽然已经详细地说明了本发明的一个或多个实施例，但是本领域技术人员将领会，可以在不脱离如在随后的权利要求中阐述的本发明的范围的情况下作出对那些实施例修改和适配。

Claims (15)

1.一种制造半导体器件的方法，包括：
提供半导体组件组装，半导体组件组装包括部署在半导体组件组装上的包封物；
以电路图案的形式在包封物中形成多个开口；
在开口中沉积导电材料以形成电路图案；以及
在电路图案上部署电组件。
2.根据权利要求1所述的方法，进一步包括：
将导电材料施加在包封物的表面上；以及
移除导电材料的一部分以暴露电路图案。
3.根据权利要求1所述的方法，进一步包括使包封物的表面和电路图案平坦化。
4.根据权利要求1所述的方法，其中电路图案包括互连结构或屏蔽层。
5.一种制造半导体器件的方法，包括：
以电路图案的形式在包封物中形成多个开口；以及
在开口中沉积导电材料以形成电路图案。
6.根据权利要求5所述的方法，进一步包括在电路图案上部署电组件。
7.根据权利要求5所述的方法，进一步包括：
将导电材料施加在包封物的表面上；以及
移除导电材料的一部分以暴露电路图案。
8.根据权利要求5所述的方法，进一步包括使包封物的表面和电路图案平坦化。
9.根据权利要求5所述的方法，其中电路图案包括互连结构或屏蔽层。
10.一种半导体器件，包括：
半导体组件组装；
包封物，其被部署在半导体组件组装上；
多个开口，其被以电路图案的形式形成在包封物中；
导电材料，其被沉积在开口中以形成电路图案；以及
电组件，其被部署在电路图案上。
11.根据权利要求10所述的半导体器件，其中导电材料被部署在包封物的表面上。
12.根据权利要求10所述的半导体器件，其中包封物的表面和电路图案被平坦化。
13.根据权利要求10所述的半导体器件，其中电路图案包括互连结构。
14.根据权利要求10所述的半导体器件，其中电路图案包括屏蔽层。
15.根据权利要求10所述的半导体器件，进一步包括激光器以在包封物中形成所述多个开口。
CN202210325262.XA 2021-05-04 2022-03-30 半导体器件和在用于系统级封装模块的包封物中嵌入电路图案的方法 Pending CN115295426A (zh)

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