CN1555573A - 具有集成的散热片和增加层的微电子封装件 - Google Patents

具有集成的散热片和增加层的微电子封装件 Download PDF

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Publication number
CN1555573A
CN1555573A CNA018202551A CN01820255A CN1555573A CN 1555573 A CN1555573 A CN 1555573A CN A018202551 A CNA018202551 A CN A018202551A CN 01820255 A CN01820255 A CN 01820255A CN 1555573 A CN1555573 A CN 1555573A
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Prior art keywords
core
microelectronic
encapsulating material
conductive traces
microelectronics packaging
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CNA018202551A
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English (en)
Inventor
M��V����
M·V·赫瑙
X·C·穆
Q·马
Q·T·吴
S·N·托勒
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Intel Corp
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Intel Corp
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Publication of CN1555573A publication Critical patent/CN1555573A/zh
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Abstract

一种微电子封装件制造方法,包括将至少一个微电子管芯连附到一散热器并将所述微电子管芯/多个管芯封装于其上,还可以包括使微电子封装芯靠接该散热器,其中微电子管芯/多个管芯处于所述微电子封装芯内的至少一个开口中。在封装后,可以制造多个增加层以形成与所述微电子管芯/多个管芯相连的电连接。

Description

具有集成的散热片和增加层的微电子封装件
发明背景
发明领域
本发明涉及用于制造微电子封装件的设备和方法。更具体说,本发明涉及将至少一个微电子管芯连接到散热器以及将微电子管芯封装到其上的制造方法。
背景技术
集成电路元件的高性能、低成本和不断小型化以及集成电路的较大集成密度是计算机产业的发展目标。随着这些目标的实现,微电子管芯变得更小。当然,更大封装密度的目标需要整个微电子管芯封装件等于或略微大于(约10%至30%)微电子管芯本身的尺寸。这样的微电子管芯封装被称为“芯片尺寸封装”或“CSP”。
如图27所示,实际的CSP涉及直接在微电子管芯202的有效表面204上制造增加层。增加层可以包括设于微电子管芯有效表面204上的介电层206。可以在所述介电层206上形成导电轨迹208,其中每个导电轨迹208的一部分与所述有效表面上的至少一个触点212接触。用于与外部元件(未示出)接触的外部触点例如焊料球或导电引线可以制造成与至少一个导电轨迹208电接触。图27示出了被介电层上的焊料掩模材料216包围的外部触点例如焊料球214。但在这种实际的CSP中,由微电子管芯有效表面204提供的表面积一般不能给某些类型的微电子管芯(如逻辑类型的)提供足够的用于与外部元件(未示出)接触所需的全部外部触点的表面。
另外的表面可以通过使用内插器例如衬底(基本是刚性的材料)或挠性元件(基本是挠性的材料)。图28示出了具有通过小焊料球228连接到衬底内插器222的第一表面226并与之电接触的微电子管芯224的衬底内插器222。小焊料球228在微电子管芯224上的触点232与衬底内插器第一表面226上的导电轨迹234之间延伸。导电轨迹234与衬底内插器222的第二表面238上的焊盘236通过通路242分立地电连接,所述通路242延伸通过衬底内插器222。外部触点244(以焊料球示出)形成于焊盘236上。外部触点244用于实现微电子管芯224与外部电系统(未示出)之间的电连通。
衬底内插器222需要数个加工步骤。这些加工步骤使封装件的成本增加。另外,即使采用小焊料球228仍然存在拥挤问题,该问题会导致小焊料球228之间的短路并会使为防止沾污和提供机械稳定性而在微电子管芯224和衬底内插器222之间嵌入底层填料存在困难。此外,电路封装件也许不能满足由衬底内插器222的厚度带来的对未来的微电子管芯224的功率传输需要,因为衬底内插器引起焊接区侧(land side)电容器具有过高的电感。
图29示出了挠性元件内插器252,其中微电子管芯256的有效表面254被连接到带有一层粘接剂262的挠性元件内插器252的第一表面258。微电子管芯256被封装在封装材料264中。在挠性元件内插器252中通过激光烧蚀形成有穿过挠性元件内插器252到达微电子管芯有效表面254上的触点266以及到达处于挠性元件内插器252内的选定金属衬垫的多个开口。导电材料层形成于挠性元件内插器252的第二表面272上和所述开口内。导电材料层被通过标准的光掩模/蚀刻工艺图形化成以形成导电通路274和导电轨迹276。外部触点形成于导电轨迹276上(图中以被导电轨迹276附近的焊料掩模材料282包围的焊料球248表示)。
使用挠性元件内插器252需要粘接形成挠性元件内插器252的材料层,并需要将挠性元件内插器252粘接到微电子管芯256上。这些粘接处理比较困难且会增加封装成本。另外,还发现所得到的封装的可靠性差。
因此,开发能够克服上述问题的用来提供额外的表面积的新设备和技术是有利的,所述表面积用于形成CSP应用中使用的轨迹。
附图简要说明
尽管权利要求书对本说明书进行总结,特别指出并清除地要求了有关本发明的有关内容,但本发明的优点可以从下面结合附图对本发明进行的描述中更清除地了解,其中:
图1-4是侧剖面图,示出了根据本发明形成微电子结构的方法中的步骤;
图5-11是侧剖面图,示出了根据本发明制造另一微电子结构的实施例;
图12-19是侧剖面图,示出了根据本发明在微电子结构上制造增加层的方法;
图20和21是侧剖面图,示出了根据本发明制造另一微电子结构的实施例;
图22和23是侧剖面图,示出了根据本发明具有微电子封装芯的微电子封装件;
图24是侧剖面图,示出了根据本发明的多芯片模块;
图25和26是侧剖面图,示出了根据本发明不具有微电子封装芯的微电子封装件;
图27是侧剖面图,示出了现有技术的微电子器件的实际CSP;
图28是侧剖面图,示出了现有技术的利用衬底内插器的微电子器件的CSP;
图29是侧剖面图,示出了现有技术的利用挠性元件内插器的微电子器件的CSP。
具体实施例的详细说明
在下面的详细说明中,将参照以示例方式示出本发明的具体实施例的附图。这些实施例描述的足够详细,以使本领域技术人员可以实施本发明。应知道,本发明的各实施例虽然不同,但不一定是相互排斥的。例如,结合一个实施例说明的具体特征、结构、或特性可以在其它实施例中实施,而不脱离本发明的精神和范围。另外,应理解的是,每个公开的实施例中的单独元件的位置和布置可以被改变,而不脱离本发明的精神和范围。因而下面的详细说明不是限制性的,本发明的范围仅由所附的权利要求书限定,权利要求书应解释为包括与权利要求书所要求的内容等效的全部范围。所有附图中,相似的标号表示相同或相似的功能。
本发明包括将至少一个微电子管芯连附到散热器上并将微电子管芯/多个管芯封装到其上的微电子封装制造技术。本发明还可以包括靠接着散热器的微电子封装芯,其中微电子管芯/多个管芯处于微电子封装芯内的至少一个开口内,并且封装材料将微电子管芯/多个管芯固定到所述开口内。在封装之后,可以制造增加层以形成与微电子管芯/多个管芯相连的电连接。
图1-4示出了用于制造微电子结构的方法中的步骤。如图1所示,提供大致平的散热片102。该散热片102最好包括高导热性材料,其可以包括但不限于金属,如铜、铜合金、钼、钼合金、铝、铝合金等。用于制造散热器102的材料可以包括但不限于导热性陶瓷材料,如AlSiC、AlN等。还应理解的是,散热器102可以是更复杂的器件,例如热管或散热片内的多个小热管。
如图2所示,一层粘接层104(最好是导热性的)被图形化在散热片102上。粘接层104可以包括填充有导热颗粒材料(例如银或氮化率)的树脂或环氧树脂材料。粘接层104也可以包括具有低熔化温度的金属或金属合金(如焊料材料等)。
至少一个微电子管芯106的背面110被设于粘接层104上以将其连附到散热片102上,如图3所示。最好,粘接层104被图形化成与微电子管芯106的尺寸大致相同。微电子管芯106可以是任何已知的有源或无源微电子器件,包括但不限于逻辑电路(CPU)、存储器(DRAM、SRAM、SDRAM等)、控制器(芯片组)、电容器、电阻器、电感器等。所述微电子管芯106最好被以电方式或其它方式测试过,以在使用前淘汰不能工作的管芯。
如图4所示,在微电子管芯106和散热器102上淀积介电封装材料108,例如塑料、树脂、环氧树脂、弹性的(如橡胶)等材料)。介电封装材料108应选择为具有足够粘性的,以进行填充和形成大致平的上表面120。
图5-11示出了至少另一微电子结构的实施例。如图5所示,提供大致平的散热片102。如图6所示,一层粘接层104(最好是导热性的)被图形化在散热片102上。至少一个微电子管芯106的背面110被放置在粘接层104上以将其连附到散热片102上,如图7所示。
图8-9示出了用于制造本实施例的微电子器件的微电子封装芯112。在微电子封装芯112最好包括大致平的材料。用于制造微电子封装芯112的材料包括但不限于基于双马来酰亚胺三嗪树脂(BT)的层压材料、FR4(阻燃玻璃/环氧树脂)层压材料、各种聚酰亚胺材料、陶瓷材料等,以及金属材料(例如铜)等。微电子封装芯112具有至少一个从微电子封装芯112的第一表面116延伸到微电子封装芯112的相对的第二表面118的开口114。如图9所示,开口114可以具有任何形状和尺寸,包括但不限于矩形/方形114a、具有圆角的矩形/方形114b、圆形114c。对开口114的尺寸和形状唯一限制是它们必须具有用于将微电子管芯或多个管芯容纳于其中的适当的尺寸和形状,下面将会对此进行说明。
如图10所示,微电子封装芯的第二表面118被设置在散热器102上。开口114定位成使微电子管芯处于其中。然后将介电封装材料108淀积到微电子管芯106上(覆盖其有效表面124)、微电子封装芯112上(覆盖其第一表面116)以及开口114内未被微电子管芯106占据的部分中,如图11所示。介电封装材料108将微电子管芯106固定到微电子封装芯112内并提供用于后来形成增加层的有效表面。
图12示出了用介电封装材料108封装在微电子封装芯112内的单个微电子管芯106的视图。微电子管芯106当然包括多个设于其有效表面124上的电触点122。电触点122电连接至微电子管芯106内的电路(未示出)。为了简洁和清除,图中只示出了4个电触点122。
如图13所示,然后穿过覆盖微电子管芯有效表面124的介电封装材料108形成多个通路126。多个通路126最好是通过激光穿孔形成的,但也可以通过现有技术中任何已知的方法形成,包括但不限于光刻。
在介电封装材料上表面120上形成多个导电轨迹128,如图14所示,其中多个导电轨迹128中每个的一部分延伸到所述多个通路126(见图13)中的至少一个内,以与所述电触点电接触。所述多个导电轨迹可以由任何可以使用的导电材料(例如铜、铝及其合金等)制成。
多个导电轨迹128可以利用任何已知技术制成,包括但不限于半附加镀覆和光刻技术。半附加镀覆技术可以包括淀积一籽层,例如在介电封装材料108上溅射淀积或化学镀覆金属。然后将一抗蚀剂层图形化在所述籽层上,之后在由已图形化的抗蚀剂层内的开口区域所暴露的籽层上电解镀覆一层金属(例如铜)。被图形化的抗蚀剂层被剥离,并将其上没有镀覆金属层的籽层部分蚀刻掉。形成多个导电轨迹128的其它方法对于本领域技术人员来说也是显而易见的。
如图15所示,在多个导电轨迹128和介电封装材料108上淀积一介电层132,例如环氧树脂、聚酰亚胺、二苯并环丁烯等。介电层132的形成可以通过任何已知方法实现,包括但不限于薄膜层压、旋涂、辊涂和喷涂淀积等。本发明的介电层最好是有可从Ibiden U.S.A.Corp.,Santa Clara,California,U.S.A.和AjinomotoU.S.A.,Inc.,Paramus,New Jersey,U.S.A.获得的环氧树脂填充。
如图16所示,然后穿过介电层132形成多个第二通路134。所述多个通路134最好是利用激光钻孔形成,但是可由本领域已知的任何方法形成。
如果所述多个导电轨迹128不能将多个第二通路134设置在适当的位置,或者如果布线受到限制,使得关键的电性能要求(例如功率输送、阻抗控制和串扰最小化等)不能得到满足,就需要在所述多个第二通路134内和介电层132上形成其它部分的导电轨迹,然后如图14-16所示那样在其上形成另外一个介电层,再在该另外一个介电层内形成另外的多个通路。介电层的设置和导电轨迹的形成可以重复进行,直到通路处于适当的位置并满足了电性能要求。因而,单个导电轨迹的各部分是由多个部分形成的并可处于不同的介电层上。
可以形成第二多个导电轨迹136,其中第二多个导电轨迹136中每个的一部分延伸到所述第二多个通路132中的至少一个内。第二多个导电轨迹136中每个包括一接合垫138(由虚线140划分出的轨迹上的加大的区域),如图17所示。
一旦形成了所述第二多个导电轨迹136和接合垫138,它们就可用于形成导电互连件,例如焊料块、焊料球、引线等,用于与外部元件(未示出)连通。例如,焊料掩模材料142可设于第二介电层132、第二多个导电轨迹136以及接合垫138上,如图18所示。然后在焊料掩模材料142中形成多个通路,以暴露出每个接合垫138的至少一部分。通过丝网印刷焊料糊然后进行回流工艺或通过已知的镀覆技术等在每个接合垫138的暴露部分上可以形成多个导电块144(例如,焊料块),如图19所示。当然应该知道,图12-19所示的增加层制造技术可以用于图4所示的微电子结构。
图20和21示出了本发明的另一实施例。如图20所示,微电子封装芯112比微电子管芯106略厚,并使介电封装材料108设于微电子管芯106、微电子封装芯112上以及开口114(见图10)内未被微电子管芯106占据的部分中。例如,封装芯112可以是约800μm厚,而微电子管芯可以是725μm到775μm厚(300mm晶片的厚度)·介电封装材料108的上部被利用例如蚀刻、研磨或化学机械平整等工艺除去,这些工艺停止于微电子封装芯112上。这样提供了在整个微电子管芯表面124上提供大致均匀厚度的介电封装材料108。之后的制造步骤与结合图13-18示出和描述的方式相同。
图22示出了利用介电封装材料108封装在微电子封装芯112内的多个微电子管芯106。然后可以沿着线146(切割)通过任何介电层和轨迹(共同表示为增加层148)和微电子封装芯112可将单个微电子管芯106分开以形成至少一个分成单个的微电子管芯封装件150,如图23所示。当然,应当知道,多个微电子管芯106不需分成被单个的,而是可以作为多芯片模块。而且,微电子管芯106不需具有相同的功能或尺寸相同。另外,应知道,尺寸和功能不同的多个微电子管芯106可以用介电封装材料108封装在微电子封装芯112的一个开口内,以形成多芯片模块152,如图24所示。
当然,如图1-4所示,微电子封装芯112是任选的。因而,微电子管芯106可以简单地被封装在介电封装材料108内,如图25所示。然后沿着线154(切割)通过增加层148和介电封装材料108来将分开单个的微电子管芯106,以形成至少一个分成单个的微电子管芯封装件156,如图26所示。
已经对本发明的实施例进行了详细说明,但应知道,本发明是由所附权利要求书限定的,不限于上述说明中列出的具体细节,不脱离本发明的精神和范围可以对本发明最出很多显而易见的改变。

Claims (28)

1.一种微电子封装件,包括:
一散热片;
至少一个微电子管芯,其具有一有效表面和一背面,所述至少一个微电子管芯背面邻接所述散热片;
设于所述散热片和所述微电子管芯有效表面上的封装材料。
2.如权利要求1所述的微电子封装件,还包括设于所述封装材料的上表面上的增加层。
3.如权利要求2所述的微电子封装件,其中所述增加层包括设于所述封装材料上表面上的至少一个导电轨迹,所述至少一个导电轨迹的一部分延伸穿过所述封装材料从而与所述至少一个微电子管芯有效表面接触。
4.如权利要求3所述的微电子封装件,其中所述增加层还包括设于封装材料上表面的至少一部分和所述至少一个导电轨迹上的至少一个介电层,和延伸穿过所述至少一个介电层从而与所述至少一个导电轨迹接触的至少一个第二导电轨迹。
5.如权利要求1所述的微电子封装件,还包括设于所述至少一个微电子管芯和所述散热片之间的导热粘接层。
6.一种制造微电子封装件的方法,包括:
提供一散热片;
将至少一个微电子管芯的背面邻接所述散热片设置;
将封装材料设于所述至少一个微电子管芯和所述散热片上。
7.如权利要求6所述的方法,还包括在所述封装材料的上表面上形成一增加层。
8.如权利要求7所述的方法,其中形成所述增加层包括形成至少一个从所述封装材料上表面到所述至少一个微电子管芯有效表面的至少一个通路,并在所述封装材料上表面上设置至少一个导电轨迹,其中所述至少一个导电轨迹的一部分延伸穿过所述至少一个通路从而与所述至少一个微电子管芯有效表面接触。
9.如权利要求8所述的方法,还包括在封装材料上表面的至少一部分和所述至少一个导电轨迹上设置至少一个介电层,形成穿过所述介电层的通路,以及在所述介电层上形成至少一个第二导电轨迹,其中所述第二导电轨迹的一部分延伸穿过所述至少一个介电层从而与所述至少一个导电轨迹接触。
10.一种微电子封装件,包括:
一散热片;
一微电子封装芯,其具有一第一表面和相反的第二表面,所述微电子管芯具有至少一个设于其中的从所述微电子封装芯第一表面延伸到所述微电子封装芯第二表面的开口,其中所述微电子封装芯第二表面靠接所述散热片;
在所述至少一个微电子封装芯开口内并邻接所述散热片设置的至少一个微电子管芯,所述至少一个微电子管芯具有一有效表面;
在所述微电子管芯上和至少一个微电子封装芯开口的一部分内设置的封装材料。
11.如权利要求10所述的微电子封装件,还包括设于所述封装材料的上表面上的增加层。
12.如权利要求11所述的微电子封装件,其中所述增加层包括设于所述封装材料上表面上的至少一个导电轨迹,其中所述至少一个导电轨迹的一部分延伸穿过所述封装材料从而与所述至少一个微电子管芯有效表面接触。
13.如权利要求12所述的微电子封装件,其中所述增加层还包括设于封装材料上表面的至少一部分和所述至少一个导电轨迹上的至少一个介电层。
14.如权利要求11所述的微电子封装件,其中所述封装材料覆盖所述微电子封装芯第一表面。
15.如权利要求10所述的微电子封装件,其中所述微电子封装芯的厚度大于所述至少一个微电子管芯的厚度。
16.如权利要求10所述的微电子封装件,其中所述微电子封装芯是从这样的组中选择的材料,该组包括:基于双马来酰亚胺三嗪树脂的材料、阻燃玻璃/环氧树脂材料、聚酰亚胺、陶瓷和金属。
17.如权利要求10所述的微电子封装件,还包括设于所述至少一个微电子管芯和所述散热片上的导热粘接层。
18.一种制造微电子封装件的方法,包括:
提供一散热片;
将至少一个微电子管芯的背面邻接所述散热片设置;
将一微电子封装芯靠接所述散热片,所述微电子封装芯具有至少一个设于其中的从所述微电子封装芯第一表面延伸到所述微电子封装芯第二表面的开口,所述至少一个微电子管芯处于所述至少一个微电子封装芯开口内;
在所述至少一个微电子管芯上和所述至少一个微电子封装芯开口的一部分内封装材料。
19.如权利要求18所述的方法,还包括在所述封装材料的上表面上形成一增加层。
20.如权利要求19所述的方法,其中形成所述增加层包括形成至少一个从所述封装材料上表面到所述至少一个微电子管芯有效表面的通路,并在所述封装材料上设置至少一个导电轨迹,其中所述至少一个导电轨迹的一部分延伸穿过所述至少一个通路从而与所述微电子管芯有效表面接触。
21.如权利要求20所述的方法,还包括在封装材料上表面的至少一部分和所述至少一个导电轨迹上设置至少一个介电层,形成穿过所述介电层的通路,以及在所述介电层上形成至少一个第二导电轨迹,其中所述第二导电轨迹的一部分延伸穿过所述至少一个介电层从而与所述至少一个导电轨迹接触。
22.如权利要求18所述的方法,其中在所述至少一个微电子管芯上和至少一个微电子封装芯开口的一部分内设置所述封装材料包括:将所述封装材料设于所述至少一个微电子管芯上,至少一个微电子封装芯开口的一部分内,以及所述微电子封装芯第一表面上。
23.如权利要求22所述的方法,其中将微电子封装芯靠接所述散热片包括:将比所述至少一个微电子管芯厚的微电子封装芯靠接所述散热片。
24.如权利要求23所述的方法,其中将所述封装材料设置在所述至少一个微电子管芯上和至少一个微电子封装芯开口的一部分内包括:将所述封装材料设置在所述至少一个微电子管芯上,至少一个微电子封装芯开口的一部分内,以及所述微电子封装芯第一表面上。
25.如权利要求24所述的方法,还包括去除所述微电子封装芯上的所述封装材料的一部分,从而在所述至少一个微电子管芯上形成均匀厚度的封装材料。
26.如权利要求25所述的方法,还包括在所述封装材料的上表面上形成一增加层。
27.如权利要求26所述的方法,其中形成所述增加层包括形成至少一个从所述封装材料上表面到所述至少一个微电子管芯有效表面的通路,并且在所述封装材料上表面上设置至少一个导电轨迹,其中所述至少一个导电轨迹的一部分延伸穿过所述至少一个通路从而与所述微电子管芯有效表面接触。
28.如权利要求27所述的方法,还包括在封装材料上表面的至少一部分和所述至少一个导电轨迹上设置至少一个介电层,形成穿过所述介电层的通路,以及在所述介电层上形成至少一个第二导电轨迹,其中所述第二导电轨迹的一部分延伸穿过所述至少一个介电层从而与所述至少一个导电轨迹接触。
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