KR20160123964A - 불연속적인 중합체 층을 가지는 팬-아웃 팝 구조물 - Google Patents

불연속적인 중합체 층을 가지는 팬-아웃 팝 구조물 Download PDF

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KR20160123964A
KR20160123964A KR1020150166781A KR20150166781A KR20160123964A KR 20160123964 A KR20160123964 A KR 20160123964A KR 1020150166781 A KR1020150166781 A KR 1020150166781A KR 20150166781 A KR20150166781 A KR 20150166781A KR 20160123964 A KR20160123964 A KR 20160123964A
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die
dielectric layer
opening
package
layer
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KR1020150166781A
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KR101788412B1 (ko
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이린 차이
제프리 창
징쳉 린
나이웨이 리우
채청 푸
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타이완 세미콘덕터 매뉴팩쳐링 컴퍼니 리미티드
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Abstract

패키지가 소자 다이, 소자 다이의 적어도 일부를 내부에서 몰딩하는 몰딩 재료, 및 몰딩 재료를 실질적으로 관통하는 스루-비아를 포함한다. 그러한 패키지가 스루-비아 및 몰딩 재료와 접촉하는 유전체 층, 및 소자 다이의 후면에 부착되는 다이 부착 필름을 더 포함한다. 다이 부착 필름이 유전체 층 내에서 연장하는 부분을 포함한다.

Description

불연속적인 중합체 층을 가지는 팬-아웃 팝 구조물{FAN-OUT POP STRUCTURE WITH INCONSECUTIVE POLYMER LAYER}
본 발명은 집적 회로에 관한 것이고, 보다 구체적으로는 불연속적인 중합체 층을 가지는 팬-아웃 팝 구조물에 관한 것이다.
현대의 회로 제조는 전형적으로 몇 개의 단계를 포함한다. 집적 회로가 먼저 반도체 웨이퍼 상에 제조되고, 그러한 반도체 웨이퍼는 복수의 복제된 반도체 칩을 포함하고, 각각의 반도체 칩이 집적 회로를 포함한다. 이어서, 반도체 칩이 웨이퍼로부터 쏘잉(sawing)되고 패키지화된다. 패키징 프로세스가 2개의 주요 목적: 즉, 민감한 반도체 칩을 보호하고 내부 집적 회로를 외부 핀으로 연결하기 위한 목적을 갖는다.
보다 많은 기능이 점점 더 요구됨에 따라, 패키지의 집적 능력을 확장하기 위해서 둘 이상의 패키지가 결합되는 패키지-온-패키지(PoP) 기술이 개발되었다. 높은 집적도에서, 구성요소들 사이의 짧아진 연결 경로로부터의 이점으로, 결과적인 PoP 패키지의 전기적인 성능이 개선될 수 있다. PoP 기술을 이용하는 것에 의해서, 패키지 디자인이 보다 탄력적(flexible)이 되고 덜 복잡해지고 있다. 출시 시기(time-to-market)가 또한 단축된다.
첨부 도면과 함께 고려할 때, 이하의 구체적인 설명으로부터 본 개시 내용의 양태가 가장 잘 이해될 수 있을 것이다. 산업계에서의 표준 실무에 따라서, 여러 가지 특징부(feature)가 실척(scale)으로 도시되지 않았다는 것을 주목하여야 할 것이다. 사실상, 명료한 설명을 위해서, 여러 가지 특징부의 치수가 임의적으로 확대 또는 축소되어 있을 수 있을 것이다.
도 1 내지 도 15a는 일부 실시예에 따른 팬-아웃 패키지-온-패키지(PoP) 패키지의 형성에서의 중간 스테이지들의 횡단면도들을 도시한다.
도 15b는 대안적인 실시예에 따른 팬-아웃 PoP 패키지의 횡단면도를 도시한다.
도 16a 및 도 16b는 일부 실시예에 따른 팬-아웃 PoP 패키지의 상면도를 도시한다.
도 17은 일부 실시예에 따른 PoP 패키지를 형성하기 위한 프로세스 흐름을 도시한다.
이하의 개시 내용은, 제공된 청구 대상의 상이한 특징들을 실시하기 위한, 많은 상이한 실시예들, 또는 예들을 제공한다. 본 개시 내용을 단순화하기 위해서, 구성요소 및 배열에 관한 구체적인 예가 이하에서 설명된다. 물론, 그러한 구체적인 예는 단지 예시적인 것이고 제한적인 것은 아니다. 예를 들어, 이하의 설명에서 제2특징부 상에 또는 그 위에 제1 특징부를 형성하는 것이, 제1 및 제2 특징부들이 직접적으로 접촉되어 형성되는 실시예들을 포함할 수 있을 것이고, 또한 부가적인 특징부들이 제1 및 제2 특징부들 사이에 형성되어 제1 및 제2 특징부들이 직접적으로 접촉하지 않을 수 있는 실시예들을 포함할 수 있을 것이다. 또한, 본원 개시 내용은 여러 가지 예에서 참조 번호 및/또는 문자를 반복할 수 있을 것이다. 이러한 반복이 단순함 및 명료함을 위한 것이고 그리고 그것 자체가 개시된 여러 가지 실시예들 및/또는 구성들 사이의 관계를 구술하는 것은 아니다.
또한, 도면들에 도시된 바와 같이, 하나의 요소 또는 특징부의 다른 요소(들) 또는 특징부(들)에 대한 관계를 기술하기 위한 설명의 용이성을 위해서, "하부의(underlying)", "아래", "하부, "상부의(overlying)", "상부" 등과 같은 공간적으로 상대적인 용어가 본원에서 사용되어 있을 수 있을 것이다. 그러한 공간적으로 상대적인 용어들은, 도면들에 도시된 배향에 더하여, 사용 또는 동작 중에 디바이스의 상이한 배향들을 포함하도록 의도된 것이다. 장치가 달리(90도 회전된 또는 다른 배향으로) 배향될 수 있을 것이고 그리고 본원에서 사용된 공간적으로 상대적인 설명이 그에 따라 유사하게 해석될 수 있을 것이다.
팬-아웃 패키지-온-패키지(PoP) 구조물/패키지 및 그러한 패키지를 형성하는 방법이 여러 가지 예시적인 실시예에 따라서 제공된다. 실시예의 변경예들이 설명된다. 여러 도면 및 예시적인 실시예를 통해서 유사한 요소를 나타내기 위해서 유사한 참조 번호를 이용하였다.
도 1 내지 도 15a는 일부 실시예에 따른 패키지의 형성에서의 중간 스테이지들의 횡단면도들을 도시한다. 도 1 내지 도 15b에 도시된 단계가 또한 도 17에 도시된 프로세스 흐름(200)에서 개략적으로 도시되어 있다. 후속하는 설명에서, 도 1 내지 도 15a에 도시된 프로세스 단계가 도 17에서의 프로세스 단계를 참조하여 설명된다.
도 1을 참조하면, 캐리어(30)가 제공되고, 접착제 층(32)이 캐리어(30) 위에 배치된다. 캐리어(30)가 브랭크(blank) 유리 캐리어, 또는 브랭크 세라믹 캐리어 등일 수 있고, 둥근 상면도 형상을 가지는 반도체 웨이퍼의 형상을 가질 수 있을 것이다. 캐리어(30)가 종종 캐리어 웨이퍼로서 지칭된다. 접착제 층(32)이 예를 들어 광-열 변환(Light-to-Heat Conversion)(LTHC) 재료로 형성될 수 있을 것이나, 다른 유형의 접착제가 이용될 수도 있을 것이다. 본 개시 내용의 일부 실시예에 따라서, 접착 층(32)이 광의 열 아래에서 분해될 수 있고, 그에 따라 캐리어 상에 형성된 구조물로부터 캐리어(30)를 분리할 수 있다.
유전체 층(34)이 접착제 층(32) 위에 형성된다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(202)로서 도시되어 있다. 본 개시 내용의 일부 실시예에 따라서, 유전체 층(34)이 중합체로 형성된 중합체 층이고, 그러한 중합체가 폴리벤즈옥사졸(PBO), 또는 폴리이미드 등과 같은 감광성 중합체일 수 있을 것이다. 대안적인 실시예에 따라서, 유전체 층(34)이 실리콘 질화물과 같은 질화물, 실리콘 산화물과 같은 산화물, 포스포실리케이트 유리(PSG), 보로실리케이트 유리(BSG), 또는 붕소-도핑된 포스포실리케이트 유리(BPSG) 등으로 형성된다.
도 2를 참조하면, 유전체 층(34)이 패터닝되어 개구부(38)를 내부에 형성한다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(204)로서 도시되어 있다. 개구부(38)는 스루-개구부(through-opening)이다. 그에 따라, 본 개시 내용의 일부 실시예에 따라서, 접착제 층(32)이 개구부(38)를 통해서 노출된다. 비록 도 2가 하나의 개구부(38)를 도시하고 있지만, 유전체 층(34) 내에 복수의 개구부(38)가 있을 수 있다는 것을 이해할 수 있을 것이고, 그러한 복수의 개구부의 각각이 하나 이상의 소자 다이를 배치하기 위한 것이다. 또한, 개구부(38)가 어레이로서 할당될 수 있을 것이다. 유전체 층(34)이 감광성 재료로 형성되는 실시예에서, 유전체 층(34)이, 패터닝된 포토 리소그래피 마스크(미도시)를 이용한 노광, 및 이어지는 유전체 층(34)의 현상을 통해서 패터닝될 수 있을 것이다. 대안적인 실시예에 따라서, 유전체 층(34)을 패터닝하는 것이 유전체 층(34) 위에 포토 레지스트(미도시)를 도포하는 것, 포토 레지스트를 패터닝하는 것, 그리고 이어서 포토 레지스트를 식각 마스크로서 이용하여 유전체 층(34)을 식각하는 것을 포함한다.
도 3을 참조하면, 예를 들어, 물리기상증착(PVD)을 통해서, 전도성 시드(seed) 층(40)이 유전체 층(34) 위에 형성된다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(206)로서 도시되어 있다. 전도성 시드 층(40)이, 구리, 알루미늄, 티탄, 그 합금, 또는 그 다중-층을 포함하는 금속 시드 층일 수 있을 것이다. 본 개시 내용의 일부 실시예에 따라서, 전도성 시드 층(40)이 티탄 층(미도시)과 같은 제1 금속 층 및 그러한 제1 금속 층 위의 구리 층(미도시)과 같은 제2 금속 층을 포함한다. 이러한 실시예에서, 전도성 시드 층(40)이 개구부(38) 내로 연장하는 부분을 가지며, 그러한 부분이 접착제 층(32)과 접촉할 수 있을 것이다. 본 개시 내용의 대안적인 실시예에 따라서, 전도성 시드 층(40)이, 실질적으로 순수한 구리 또는 구리 합금으로 형성될 수 있는, 구리 층과 같은 단일 금속 층을 포함한다.
도 4 내지 도 7은 스루-비아(through-vias)의 형성을 도시한다. 도 4에 도시된 바와 같이, 패터닝된 마스크 층(42)(예를 들어, 포토 레지스트)이 전도성 시드 층(40) 위에 도포되고, 이어서 포토 리소그래피 마스크를 이용하여 패터닝된다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(208)로서 도시되어 있다. 본 개시 내용의 일부 실시예에 따라서, 포토 레지스트(42)가, 전도성 시드 층(40) 상으로 박판화된(laminated) 건성 필름이다. 대안적인 실시예에 따라서, 포토 레지스트(42)가 스핀 코팅에 의해서 형성된다. 패터닝(노광 및 현상)의 결과로서, 개구부(44)가 포토 레지스트(42) 내에 형성되고, 그러한 개구부(44)를 통해서 전도성 시드 층(40)의 일부 부분이 노출된다. 포토 레지스트(42)의 두께가 후속하여 배치되는 소자 다이(48)(도 8)의 두께에 의해서 결정된다. 본 개시 내용의 일부 실시예에 따라서, 포토 레지스트(42)의 두께가 소자 다이(48)의 두께 보다 두껍다.
도 5에 도시된 바와 같이, 스루-비아(46)가 도금(plating)을 통해서 개구부(44) 내에 형성되고, 그러한 도금이 전기 도금 또는 무전해 도금일 수 있을 것이다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(210)로서 도시되어 있다. 스루-비아(46)가 전도성 시드 층(40)의 노출된 부분 상에 도금된다. 스루-비아(46)가 전도적이고, 구리, 알루미늄, 텅스텐, 니켈, 또는 그 합금을 포함하는 금속 비아일 수 있을 것이다. 스루-비아(46)의 상면도 형상은, 비제한적으로, 직사각형, 정사각형, 및 원, 등을 포함한다. 스루-비아(46)의 높이가 후속하여 배치되는 소자 다이(48)(도 8)의 두께에 의해서 결정되고, 본 개시 내용의 일부 실시예에 따라서, 스루-비아(46)의 높이가 소자 다이(48)의 두께보다 약간 더 두껍거나 그와 같다.
쓰루-비아(46)의 도금 이후에, 포토 레지스트(42)가 제거되고, 결과적인 구조물이 도 6에 도시되어 있다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(212)로서 도시되어 있다. 결과적으로, 포토 레지스트(42)에 의해서 앞서서 커버된 전도성 시드 층(40)의 부분이 노출된다.
다음에, 도 7에 도시된 바와 같이, 식각 단계를 실시하여, 전도성 시드 층(40)의 노출된 부분을 제거하고, 그러한 식각이 이방성 또는 등방성 식각일 수 있을 것이다. 각각의 단계가 또한 도 17에 도시된 프로세스 흐름에서 단계(212)로서 도시되어 있다. 다른 한편으로, 스루-비아(46)에 의해서 중첩되는 전도성 시드 층(40)의 부분이 식각되지 않고 잔류된다. 설명 전반을 통해서, 전도성 시드 층(40)의 잔류하는 하부의 부분이 스루-비아(46)의 하단 부분으로서 지칭된다. 비록 전도성 시드 층(40)이 스루-비아(46)의 상부의 부분과의 구분 가능한 계면을 가지는 것으로 도시되어 있지만, 전도성 시드 층(40)이 각각의 상부의 스루-비아(46)의 재료와 유사한 또는 동일한 재료로 형성될 때, 전도성 시드 층(40)이 스루-비아(46)와 병합되어 그 사이에서 구분 가능한 계면을 가지지 않을 수 있을 것이다. 예를 들어, 전도성 시드 층(40) 내의 구리 층이, 구분 가능한 계면이 없이, 스루-비아(46)와 병합될 수 있을 것이다. 대안적인 실시예에 따라서, 전도성 시드 층(40)과 스루-비아(46)의 각각의 상부의 도금된 부분 사이의 구분 가능한 계면이 존재한다. 예를 들어, 전도성 시드 층(40) 내의 티탄 층이 구리-함유 스루-비아(46)로부터 구분될 수 있을 것이다. 전도성 시드 층(40)의 식각의 결과로서, 유전체 층(34)이 노출된다. 또한, 개구부(38)가 노출되고, 유전체 층(34) 하부의 층(예를 들어, 접착제 층(32))이 개구부(38)를 통해서 노출된다.
도 8은 접착제 층(32) 위에 소자 다이(48)를 배치하는 것을 도시한다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(214)로서 도시되어 있다. 소자 다이(48)가 다이 부착 필름(50)을 통해서 접착제 층(32)에 부착될 수 있을 것이다. 다이 부착 필름(50)의 가장자리가 소자 다이(48)의 각각의 가장자리와 공통-종료된다(co-terminus with)(정렬된다). 다이 부착 필름(50)이 접착성 필름이다. 비록 도 8이 단일 소자 다이(48)의 배치를 도시하고 있지만, 소자 다이(48)와 동일한 복수의 소자 다이가 접착제 층(32) 위에 배치될 수 있을 것이고, 각각의 소자 다이가 개구부(38) 중 하나의 개구부에 상응하여 배치된다. 또한, 각각의 개구부(38)가, 배치된 단일의 또는 하나 초과의 소자 다이를 구비할 수 있을 것이다. 복수의 배치된 소자 다이(48)가 복수의 행(row) 및 복수의 열을 포함하는 어레이로서 배열될 수 있을 것이다. 소자 다이(48)가 다이 부착 필름(50)과 물리적으로 접촉하는 후방 표면(아래쪽을 대면하는 표면)을 가지는 반도체 기판을 포함할 수 있을 것이다. 소자 다이(48)가 반도체 기판의 전방 표면(위쪽을 대면하는 표면)에서 (예를 들어, 도시되지 않은, 트랜지스터를 포함하는, 능동 소자와 같은) 집적 회로 소자를 더 포함한다. 소자 다이(48)가 중앙 처리 유닛(CPU) 다이, 그래픽 프로세싱 유닛(GPU) 다이, 또는 모바일 애플리케이션 다이, 등과 같은 로직 다이(logic die)를 포함할 수 있을 것이다.
소자 다이(48)가 그 상단 표면에서 금속 기둥(pillar)(54)을 포함할 수 있을 것이다. 금속 기둥(54)이 소자 다이(48) 내부의 집적 회로로 전기적으로 커플링된다. 본 개시 내용의 일부 예시적인 실시예에 따라서, 도 8에 도시된 바와 같이, 금속 기둥(54)의 상단 표면이 노출된다. 금속 기둥(54)이 구리 기둥일 수 있을 것이고, 알루미늄, 또는 니켈, 등과 같은 다른 전도성/금속 재료를 또한 포함할 수 있을 것이다. 본 개시 내용의 일부 실시예에 따라서, 금속 기둥의 상단 표면이 유전체 층(55)의 상단 표면과 공통 평면적이다(coplanar). 본 개시 내용의 대안적인 실시예에 따라서, 금속 기둥(54)이 유전체 층(55) 내에 매립되고, 유전체 층(55)의 상단 표면이 금속 기둥(54)의 상단 표면 보다 더 높다. 유전체 층(55)이, PBO, 또는 폴리이미드 등을 포함할 수 있는, 중합체로 형성될 수 있을 것이다.
또한 도 9를 참조하면, 몰딩 재료(52)가 소자 다이(48) 및 스루-비아(46) 상으로 몰딩된다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(216)로서 도시되어 있다. 몰딩 재료(52)가 유체로서 분배되고 이어서, 예를 들어, 열적 경화 프로세스에서 경화된다. 몰딩 재료(52)가 소자 다이(48)와 스루-비아(46) 사이의 갭을 충전하고, 유전체 층(34)과 접촉할 수 있을 것이다. 몰딩 재료(52)가 몰딩 컴파운드(compound), 몰딩 언더필(underfill), 에폭시, 또는 수지를 포함할 수 있을 것이다. 몰딩 프로세스 이후에, 몰딩 재료(52)의 상단 표면이 금속 기둥(54) 및 스루-비아(46)의 상단 단부들 보다 높다.
다음에, 화학적 기계적 폴리싱(CMP) 단계 또는 연마 단계와 같은 평탄화 단계를 실시하여, 스루-비아(46)가 노출될 때까지, 몰딩 재료(52)를 평탄화한다. 각각의 단계가 또한 도 17에 도시된 프로세스 흐름에서 단계(216)로서 도시되어 있다. 결과적인 구조물이 도 10에 도시되어 있다. 소자 다이(48)의 금속 기둥(54)이 평탄화의 결과로서 또한 노출된다. 평탄화로 인해서, 스루-비아(46)의 상단 표면이 금속 기둥(54)의 상단 표면과 실질적으로 같은 높이를 가지고(공통 평면적이고), 몰딩 재료(52)의 상단 표면과 실질적으로 같은 높이를 갖는다(공통 평면적이다).
도 11을 참조하면, 유전체 층(56) 중 하나 이상의 층 및 각각의 재배선 라인(Redistribution Line)(RDL)(58)이 몰딩 재료(52), 스루-비아(46), 및 금속 기둥(54) 위에 형성된다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(218)로서 도시되어 있다. RDL(58)이 전방측면(front side) RDL(58)으로서 지칭되는데, 이들이 소자 다이(48)의 전방측면 상에 있기 때문이다. 본 개시 내용의 일부 실시예에 따라서, 유전체 층(56)이 PBO, 또는 폴리이미드 등과 같은 중합체(들)로 형성된다. 본 개시 내용의 대안적인 실시예에 따라서, 유전체 층(56)이 실리콘 질화물, 실리콘 산화물, 또는 실리콘 산질화물, 등과 같은 무기 유전체 재료(들)로 형성된다.
RDL(58)이 금속 기둥(54) 및 스루-비아(46)로 전기적으로 커플링되도록 형성된다. RDL(58)이 또한 금속 기둥(54) 및 스루-비아(46)를 서로에 대해서 상호 연결할 수 있을 것이다. RDL(58)이 금속 트레이스(trace)(금속 라인), 및 그러한 금속 트레이스의 하부에서 금속 트레이스로 연결된 비아를 포함할 수 있을 것이다. 본 개시 내용의 일부 실시예에 따라서, RDL(58)이 도금 프로세스를 통해서 형성되고, RDL(58)의 각각이 시드 층(미도시) 및 그러한 시드 층 위의 도금된 금속 재료를 포함한다. 시드 층 및 도금된 금속 재료가 동일한 재료로 또는 상이한 재료들로 형성될 수 있을 것이다.
도 12는 본 개시 내용의 일부 예시적인 실시예에 따른 전기적 연결부(60)의 형성을 도시한다. 전기적 연결부(60)가 RDL(58), 금속 기둥(54) 및/또는 스루-비아(46)로 전기적으로 커플링된다. 전기적 연결부(60)의 형성이 RDL(58) 위에 납땜 볼(solder ball)을 배치하는 것 그리고 이어서 납땜 볼을 리플로우시키는 것(reflowing)을 포함할 수 있을 것이다. 본 개시 내용의 대안적인 실시예에 따라서, 전기적 연결부(60)의 형성이 RDL(58) 위에 납땜 영역을 형성하기 위해서 도금하는 단계를 실시하는 것 그리고 이어서 납땜 영역을 리플로우시키는 것을 포함한다. 전기적 연결부(60)가 또한 금속 기둥, 또는 금속 기둥 및 납땜 캡을 포함할 수 있을 것이고, 그러한 납땜 캡이 또한 도금을 통해서 형성될 수 있을 것이다. 설명 전반을 통해서, 복수의 소자 다이(48)를 포함하는 복합 웨이퍼일수 있는, 소자 다이(48), 스루-비아(46), 몰딩 재료(52), RDL(58), 및 유전체 층(56)을 포함하는 조합된 구조물이 패키지(62)로서 지칭될 것이다.
다음에, 테스트를 실시하여, 패키지(162)가 결함 없이 적절하게 기능하는지의 여부를 결정할 수 있을 것이다. 그러한 테스트가, 탐침(probe) 카드(미도시)를 이용하여 전기적 연결부(60)를 확인하는 것(probing)에 의해서 실시될 수 있을 것이다. 테스트를 통해서, 패키지(162) 내의 결함을 가지는 패키지가 결정되고, 그에 따라 패키지(162)가 개별적인 패키지로 쏘잉되어 분리된 후에, 결함을 가지는 개별적인 패키지가 PoP 패키지 형성을 위해서 이용되지 않는다.
도 12는 2개의 RDL 층(58)을 도시한다. 대안적인 실시예에 따라서, 각각의 패키지의 라우팅(routing) 요건에 의존하여, RDL(58)의 단일 층 또는 RDL(58)의 둘 초과의 층이 존재할 수 있을 것이다. 본 개시 내용의 대안적인 실시예에 따라서, RDL이 존재하지 않고, 전기적 연결부(60)가 스루-비아(46) 및 금속 기둥(54) 위에 직접적으로 형성되고, 연결부(60)와 하부의 스루-비아(46) 및 금속 기둥(54) 사이에 RDL이 형성되지 않는다.
다음에, 패키지(62)가 캐리어(30)로부터 결합-분리(de-bond)된다. 일부 예시적인 결합-분리 프로세스에 따라서, 다이싱(dicing) 테이프(64)(도 13)가 패키지(62)에 부착되어 전기적 연결부(60)를 보호하고, 그러한 다이싱 테이프(64)가 다이싱 프레임(66)으로 고정된다. 예를 들어, UV 광 또는 레이저를 접착제 층(32)(도 12)으로 투사하는 것에 의해서, 결합-분리가 실시된다. 예를 들어, 접착제 층(32)이 LTHC로 형성될 때, 광 또는 레이저로부터 생성된 열이 LTHC의 분해를 유도하고, 그에 따라 캐리어(30)가 패키지(62)로부터 탈착된다. 결과적인 구조물이 도 13에 도시되어 있다.
도 14는 유전체 층(34) 내에 개구부(63)를 형성하기 위한 패터닝을 도시한다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(220)로서 도시되어 있다. 예를 들어, 유전체 층(34)이 중합체 층일 때, 스루-비아(46)가 개구부(63)를 통해서 노출되도록, 스루-비아(46)와 중첩하는 부분을 제거하기 위해서 레이저 드릴을 이용하여 유전체 층을 패터닝할 수 있을 것이다.
전도성 시드 층(40)의 부분이 티탄으로 형성되는 실시예에서, 전도성 시드 층(40)의 티탄 층이 또한 제거될 수 있을 것이다. 예를 들어, 불화 수소(HF) 가스 또는 희석된 HF 용액을 이용하여 티탄을 식각할 수 있을 것이다. 전도성 시드 층(40) 내의 구리가 노출되고, 그에 따라 후속하여 형성되는 후면 RDL 또는 납땜 영역과 같은 전기 연결부가 그 위에 형성될 수 있을 것이다.
본 개시 내용의 일부 실시예에 따라서, 납땜 영역은 이때(다이 쏘잉 이전) 패키지(62)의 후면에 형성되지 않는다. 또한, 후면 RDL이 형성되지 않는다. 본 개시 내용의 대안적인 실시예에 따라서, 후면 RDL(미도시) 및/또는 전기 연결부가 소자 다이(48)의 후면(도 14에서 도시된 상단측면) 상에 형성되고, 후면 RDL이 스루-비아(46)로 전기적으로 커플링된다. 본 개시 내용의 일부 예시적인 실시예에 따라서, 단일 후면 RDL 층이 존재한다. 대안적인 실시예에 따라서, 복수의 RDL 층이 존재하며, 비아가 형성되어 상이한 RDL 층들 내의 상이한 금속 트레이스들을 상호 연결한다. 후면 유전체 층이 또한 PBO, BCB, 폴리이미드와 같은 중합체, 또는 실리콘 산화물, 실리콘 질화물, 실리콘 산질화물과 같은 무기 재료, 등으로 형성될 수 있을 것이다. 납땜 영역과 같은 전기적 연결부, 또는 납땜 캡을 가지는 금속 기둥, 등이 형성될 수 있을 것이다.
후속 단계에서, 패키지(62)를 쏘잉하여 복수의 패키지(162)로 분리하고, 그러한 각각의 패키지(162)가 소자 다이(48) 및 상응하는 스루-비아(46) 중 하나를 포함한다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(222)로서 도시되어 있다. 패키지(162) 중 하나가 도 15a에 도시되어 있다.
도 15a는 패키지(300)를 패키지(162)로 결합하여 PoP 패키지(20)를 형성하는 것을 도시한다. 각각의 단계가 도 17에 도시된 프로세스 흐름에서 단계(224)로서 도시되어 있다. 패키지(300 및 162)가 또한 PoP 패키지(20)의 상단 패키지 및 하단 패키지로서 각각 지칭된다. 도 15a에 도시된 예시적인 실시예에서, 후면 RDL이 도시되어 있지 않은 반면, 대안적인 실시예에 따라서 후면 RDL이 형성될 수 있을 것이다. 결합이 납땜 영역(70)을 통해서 실시되고, 이는 스루-비아(46)를 상부의 패키지(300) 내의 금속 패드로 결합시킨다. 일부 실시예에서, 패키지(300)가 소자 다이(들)(304)를 포함하고, 그러한 소자 다이가 정적 랜덤 액세스 메모리(Static Random Access Memory)(SRAM) 다이, 또는 동적 랜덤 액세스 메모리(DRAM) 다이, 등과 같은 메모리 다이일 수 있을 것이다. 일부 예시적인 실시예에서, 메모리 다이가 또한 패키지 기판(302)으로 결합될 수 있을 것이다.
상단 패키지(300)를 하단 패키지(162)로 결합한 후에, 언더필(72)이 상단 패키지(300)와 하단 패키지(162) 사이의 갭 내로 배치되고, 이어서 경화된다. 그에 따라, 결과적인 언더필(72)이 다이 부착 필름(50)과 접촉한다.
도 15a에 도시된 바와 같이, 유전체 층(34)의 상단 표면이 다이 부착 필름(50)의 상단 표면과 공통 평면적이다. 본 개시 내용의 일부 실시예에 따라서, 스루-비아(46)의 상단 표면의 일부 부분이 유전체 층(34)의 하단 표면과 접촉한다. 다이 부착 필름(50) 및 소자 다이(48)가 유전체 층(34) 내로 연장하고, 유전체 층(34)의 가장자리가 다이 부착 필름(50)의 가장자리와 물리적으로 접촉한다. 이러한 실시예는, 다이 부착 필름(50)의 가장자리와 소자 다이(48)의 가장자리를 유전체 층(34)의 각각의 가장자리로부터 분리하는 과다 공간이 없는 상태로, 다이 부착 필름(50) 및 소자 다이(48)가 개구부(38) 내로 정확하게 피팅(fit)되도록 개구부(38)(도 7 및 도 8 참조)의 크기를 정확하게 디자인하는 것에 의해서 달성될 수 있을 것이다. 다이 부착 필름(50)이 유전체 층(34) 보다 더 얇을 때, 유전체 층(34)의 가장자리가 또한 소자 다이(48)의 가장자리와 물리적으로 접촉될 수 있을 것이다.
본 개시 내용의 대안적인 실시예에 따라서, 도 15b에 도시된 바와 같이, 개구부(38)(도 7 참조)의 크기가 다이 부착 필름(50) 및 소자 다이(48)의 크기 보다 크다. 따라서, 일부 공간이 남아서, 다이 부착 필름(50)의 가장자리 및 소자 다이(48)의 가장자리를 유전체 층(34)의 각각의 가장자리로부터 분리한다. 도 15b에 도시된 바와 같이, 언더필(72)이, 유전체 층(34) 내로 연장하는 몰딩 재료(52)의 부분과 물리적으로 접촉할 수 있을 것이다.
도 16a 및 도 16b는 도 15a 및 도 15b에 각각 도시된 PoP 패키지(20)의 일부 부분의 상면도를 도시한다. 도 16a를 참조하면, 유전체 층(34)이 다이 부착 필름(50) 및 소자 다이(48)를 둘러싼다. 또한, 스루-비아(46) 및 납땜 영역(70)이 다이 부착 필름(50) 및 소자 다이(48)를 둘러싸는 링에 대해서 정렬된다. 다이 부착 필름(50)의 가장자리(그리고 가능하게는 소자 다이(48)의 가장자리)가 유전체 층(34)의 내측 가장자리와 접촉하고, 그러한 내측 가장자리가 개구부와 대면한다. 도 16b를 참조하면, 유전체 층(34)이 다시 다이 부착 필름(50) 및 소자 다이(48)를 둘러싸고, 일부 공간이 유전체 층(34)을 다이 부착 필름(50) 및 소자 다이(48)로부터 분리한다. 몰딩 컴파운드(52)가 공간을 충전한다. 본 개시 내용의 일부 실시예에 따라서, 공간이 다이 부착 필름(50) 및 소자 다이(48)를 둘러싸는 링을 형성한다. 본 개시 내용의 대안적인 실시예에 따라서, 다이 부착 필름(50)의 하나의 가장자리 또는 2개의 가장자리가 유전체 층(34)의 각각의 내측 가장자리(들)와 접촉할 수 있는 한편, 다이 부착 필름(50)의 다른 가장자리가 유전체 층(34)의 각각의 내측 가장자리(들)로부터 이격된다.
본 개시 내용의 실시예가 일부 유리한 특징을 갖는다. 접착제 층 위의 유전체 층(중합체 층)을 패터닝하는 것에 의해서, 중합체 층이 큰 개구부를 내부에서 갖는다. 이는 중합체 층 내에 불연속성을 생성하고, 이는 중합체 층에 의해서 결과적인 PoP 패키지로 유도되는 응력을 감소시킨다. 그에 따라, 패키지의 왜곡이 감소될 수 있을 것이다. 또한, 중합체 층이 비교적 연성의 재료이고, 그에 따라 소자 다이가 중합체 층 상에 배치되는 경우에, 중합체의 상이한 부분들 상으로 가해지는 불균일할 수 있는 압력으로 인해서, 결과적인 중합체 층의 두께가 불균일할 수 있고, 그에 따라 결과적인 소자 다이의 상단 표면이 캐리어의 표면에 평행하지 않을 수 있고, 결과적으로 후속 프로세스에서 프로세스 어려움을 초래할 수 있을 것이다. 그러나, 본 개시 내용의 실시예에서, 소자 다이가 중합체 층 상에 배치되지 않고, 그에 따라 전술한 문제가 제거된다. 또한, 중합체 층 내의 개구부가 소자 다이 및 다이 부착 필름의 이동을 제한하는 기능을 가지며, 그에 따라 다이 천이(shift)의 발생 가능성이 감소된다.
본 개시 내용의 일부 실시예에 따라서, 패키지가 소자 다이, 소자 다이의 적어도 일부분을 내부에 몰딩하는 몰딩 재료, 및 몰딩 재료를 실질적으로 관통하는 스루-비아를 포함한다. 그러한 패키지가 스루-비아 및 몰딩 재료와 접촉하는 유전체 층, 및 소자 다이의 후면에 부착되는 다이 부착 필름을 더 포함한다. 다이 부착 필름이 유전체 층 내에서 연장하는 부분을 포함한다.
본 개시 내용의 대안적인 실시예에 따라서, 패키지가 스루-개구부를 내부에 가지는 중합체 층, 스루-개구부 내에 적어도 일부분을 가지는 다이 부착 필름, 다이 부착 필름에 부착된 후면을 가지는 소자 다이, 및 몰딩 컴파운드를 포함한다. 소자 다이가 몰딩 컴파운드 내에 몰딩되고, 중합체 층이 몰딩 컴파운드와 접촉한다.
본 개시 내용의 대안적인 실시예에 따라서, 방법이 캐리어 위에 중합체 층을 형성하는 단계, 제1 개구부를 형성하기 위해서 중합체 층을 패터닝하는 단계, 패터닝된 중합체 층 위에 스루-비아를 형성하는 단계, 및 소자 다이를 배치하는 단계를 포함하고, 소자 다이에 부착된 다이 부착 필름의 적어도 일부분이 제1 개구부 내에 위치된다. 그러한 방법은 소자 다이 및 스루-비아를 몰딩 컴파운드 내에 몰딩하는 단계, 소자 다이 및 스루-비아로 전기적으로 커플링된 재배선 라인을 형성하는 단계, 중합체 층으로부터 캐리어를 제거하는 단계, 및 스루-비아를 노출시키기 위해서 중합체 층 내에 제2 개구부를 형성하는 단계를 더 포함한다.
당업자가 본 개시 내용의 양태를 보다 잘 이해할 수 있도록, 전술한 내용이 몇몇 실시예의 특징을 개략적으로 설명하였다. 당업자들이 본원에서 소개된 실시예와 동일한 목적을 달성하고 및/또는 동일한 장점을 성취하기 위해서 다른 프로세스 및 구조를 설계 또는 수정하기 위한 기본으로서 본 개시 내용을 용이하게 이용할 수 있다는 것을, 당업자는 이해하여야 할 것이다. 또한, 당업자는, 그러한 균등한 구성이 본원 개시 내용의 사상 및 범위를 벗어나지 않는다는 것을, 그리고 본원 개시 내용의 사상 및 범위를 벗어나지 않고도 당업자가 여러 가지 변화, 치환, 대안을 안출할 수 있다는 것을 이해하여야 할 것이다.

Claims (10)

  1. 패키지에 있어서,
    소자 다이;
    상기 소자 다이의 적어도 일부분을 내부에 몰딩하는 몰딩 재료;
    상기 몰딩 재료를 관통하는 스루-비아;
    상기 스루-비아 및 상기 몰딩 재료와 접촉하는 유전체 층; 및
    상기 소자 다이의 후면에 부착되고, 상기 유전체 층 내에서 연장하는 부분을 포함하는 다이 부착 필름
    을 포함하는, 패키지.
  2. 제1항에 있어서,
    상기 유전체 층은 스루-개구부(through-opening)를 포함하고, 상기 다이 부착 필름이 상기 스루-개구부 내로 연장되는 것인, 패키지.
  3. 제2항에 있어서,
    상기 유전체 층은 상기 스루-개구부에 노출된 가장자리를 포함하고, 상기 다이 부착 필름은 상기 유전체 층의 가장자리와 접촉하는 가장자리를 포함하는 것인, 패키지.
  4. 제2항에 있어서,
    상기 유전체 층은 상기 스루-개구부에 노출된 가장자리를 포함하고, 상기 다이 부착 필름은 간격에 의해서 상기 유전체 층의 가장자리로부터 분리된 가장자리를 포함하고, 상기 몰딩 재료가 상기 개구부를 충전하는 것인, 패키지.
  5. 제1항에 있어서,
    상기 스루-비아와 접촉하도록 상기 유전체 층 내로 연장되는 납땜 영역을 더 포함하는, 패키지.
  6. 제5항에 있어서,
    상기 납땜 영역에 결합된(bonded) 상단 패키지를 더 포함하는, 패키지.
  7. 제1항에 있어서,
    상기 유전체 층은 중합체를 포함하는 것인, 패키지.
  8. 제1항에 있어서,
    상기 유전체 층은 또한 상기 소자 다이 내에서 금속 기둥(metal pillar)과 접촉하는 것인, 패키지.
  9. 패키지에 있어서,
    쓰루-개구부를 내부에 가지는 중합체 층;
    상기 스루-개구부 내에 적어도 일부분을 가지는 다이 부착 필름;
    상기 다이 부착 필름에 부착된 후면을 가지는 소자 다이; 및
    몰딩 컴파운드
    를 포함하고,
    상기 소자 다이가 상기 몰딩 컴파운드 내에 몰딩되고, 상기 중합체 층이 상기 몰딩 컴파운드와 접촉하는 것인, 패키지.
  10. 캐리어 위에 중합체 층을 형성하는 단계;
    제1 개구부를 형성하기 위해서 상기 중합체 층을 패터닝하는 단계;
    상기 패터닝된 중합체 층 위에 스루-비아를 형성하는 단계;
    소자 다이에 부착된 다이 부착 필름의 적어도 일부분이 상기 제1 개구부 내에 있도록 상기 소자 다이를 배치하는 단계;
    상기 소자 다이 및 상기 스루-비아를 몰딩 컴파운드 내에 몰딩하는 단계;
    상기 소자 다이 및 상기 스루-비아에 전기적으로 커플링된 재배선 라인을 형성하는 단계;
    상기 중합체 층으로부터 상기 캐리어를 제거하는 단계; 및
    상기 스루-비아를 노출시키기 위해서 상기 중합체 층 내에 제2 개구부를 형성하는 단계
    를 포함하는, 방법.
KR1020150166781A 2015-04-17 2015-11-26 불연속적인 중합체 층을 가지는 팬-아웃 팝 구조물 KR101788412B1 (ko)

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