TW201603235A - 具有加強框的積體電路組件及製造方法 - Google Patents
具有加強框的積體電路組件及製造方法 Download PDFInfo
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Abstract
本案為一種組件,係藉由一或更多個加強框(410)來加強,其具有含有積體電路並且附接至佈線基板(120)的模組(110、1310)。模組位於加強框中的開孔(例如,空腔及/或通孔414)中,並提供其他的功能。
Description
本申請案為美國專利申請案序號第14/214,365號的部分連續案,其由Shen等人申請於2014年3月14日,標題為「INTEGRATED CIRCUITS PROTECTED BY SUBSTRATES WITH CAVITIES,AND METHODS OF MANUFACTURE(由具有空腔的基板保護之積體電路與製造方法)」,在此以引用之方式將其併入,其主張2014年3月12日申請之美國先行申請案序號第61/952,066號的優先權,標題為「INTEGRATED CIRCUITS PROTECTED BY SUBSTRATES WITH CAVITIES,AND METHODS OF MANUFACTURE(由具有空腔的基板保護之積體電路與製造方法)」,在此以引用之方式將其併入。本申請案也主張前述先行申請案序號第61/952,066號的優先權。
本案係關於積體電路,且更具體地,係關於具有包含半導體積體電路的晶粒之組件。
在積體電路的製造中,一或更多個電路製造在半導體晶圓中,且然後在所謂的「單分」或「切割」的處理中分離成「晶粒」(也稱為「晶片」)。晶粒(例如第1圖的110所示)附接至佈線基板(WS,wiring substrate,例如印刷佈線板)120,其具有導線130來連接晶粒至彼此且至系統的其他元件。更具體地,晶粒具有連接至晶粒的電路(未圖示)之接觸墊110C,且這些接觸墊附接至WS 120的接觸墊120C。墊120C藉由導線130而互連。藉由可包含焊料、導電環氧樹脂、或其他種類的連接140,來執行墊110C至墊120C的附接。
封裝劑150(例如,具有二氧化矽或其他粒子的環氧樹脂)保護晶粒110與連接140免於濕氣與其他污染物、紫外線、α粒子、以及其他可能的有害元素。封裝劑也強化了晶粒至WS的附接,來抵抗力學應力,且封裝劑協助將熱傳導遠離晶粒(至選擇性的散熱器160,或直接至周圍(例如,空氣))。然而,封裝劑會造成翹曲,如果封裝劑的熱膨脹係數(CTE)不匹配晶粒或WS的CTE。
佈線基板可為中介層,亦即,中間基板,用於調節晶粒製造技術與印刷佈線基板(PWS,printed wiring substrates)之間的失配。更具體地,晶粒的接觸墊110C可放置得遠遠較靠近彼此(以較小的間距),相較於PWS墊120C來說。因此(第2圖),中間基板120.1可使用在晶粒120與PWS(以120.2顯示)之間。中介層120.1包含基板120.1S(例如,半導體或其他材料)、基板120.1S的頂部上的再分佈層(RDL,redistribution layer)210.T、以及基板120.1S的底部上的另一再分佈層210.B。每一RDL
210.T、210.B包含互連線216,互連線216藉由RDL的介電質220而絕緣於彼此與基板120.1S。線216連接至中介層的頂部上的接觸墊120.1C.T以及底部上的接觸墊120.1C.B。RDL 210.T的線216藉由導電(例如,金屬化的)通孔224而連接至RDL 210.B的線216。墊120.1C.T藉由連接140.1而附接至晶粒的墊110C,如同第1圖中。墊120.1C.B利用連接140.2而附接至PWS 120.2的墊120.2C。墊120.1C.B比墊120.1C.T有較大的間距,以調節PWS接點120.2C的間距。
中介層基板120.1S應盡可能地薄,以縮短晶粒110與PWS120.2之間的信號路徑,且因此使系統更快且耗電更少。此外,如果中介層為薄的,可促進金屬化的通孔224的製造。然而,薄的中介層難以處理:它們為易碎的、易翹曲的、且在製造期間不吸收或散熱。因此,一般的製造處理在製造期間將中介層附接至暫時基板(「支撐晶圓」)。支撐晶圓稍後移除。附接與分離暫時的支撐晶圓為沉重的負擔,且如果可能的話應該極力避免。參見2005年10月25日頒發給Siniaguine的美國專利第6,958,285號。
所欲的是,提供晶粒免於力學應力、熱、以及有害元素的改良保護,以及用於薄的中介層的改良調適。
此章節總結了本發明的一些範例性實施。
在一些實施例中,晶粒由加強框保護,加強框為附接至佈線基板之分離的基板。晶粒位於加強框中的開孔中。每一開孔可為空腔、
通孔、或兩者(亦即,具有一或更多個通孔的空腔)。在一些空腔的實施例中,加強框類似於用於保護MEMS部件(Micro-Electro-Mechanical Structures,微機電結構)的覆蓋晶圓(cap wafer);參見K.Zoschke等人所寫的「Hermetic Wafer Level Packaging of MEMS Components Using Through Silicon Via and Wafer to Wafer Bonding Technologies(使用矽通孔與晶圓至晶圓接合技術之MEMS部件的全封閉晶圓級封裝)」(2013年電子元件與技術會議,IEEE,1500-1507頁);也參見2005年10月25日頒發給Siniaguine的美國專利第6,958,285號。然而,在一些實施例中,加強框改良從晶粒的散熱,並且可減少或消除對於封裝劑的需求。在一些實施例中(例如,具有通孔的那些),加強框允許在製造期間對於製造順序與中間測試的更大彈性。加強框可或可不具有連接至晶粒或至佈線基板之其自身的電路。
在一些實施例中,一開孔包含多個晶粒。
本發明不限於上述的特徵與優點,並且包含下述的其他特徵。
110‧‧‧晶粒
110C‧‧‧接觸墊
120‧‧‧佈線基板(WS)
120.1‧‧‧中間基板(中介層)
120.1C.B‧‧‧接觸墊
120.1C.T‧‧‧接觸墊
120.1S‧‧‧基板
120.2‧‧‧PWS(印刷佈線基板)
120.2C‧‧‧墊
120C‧‧‧接觸墊
130‧‧‧導線
140、140.1、140.2‧‧‧連接
140L‧‧‧腿部
150‧‧‧封裝劑
150.2‧‧‧封裝劑
160‧‧‧散熱器
210.B‧‧‧再分佈層(RDL)
210.T‧‧‧再分佈層
216‧‧‧互連線
220‧‧‧介電質
224、224B‧‧‧通孔
224M‧‧‧金屬
310‧‧‧層
320‧‧‧光阻
324‧‧‧介電質
410‧‧‧加強框(保護基板)
410S‧‧‧基板
410L‧‧‧腿部
414‧‧‧空腔
420‧‧‧輔助層
430‧‧‧光阻
504‧‧‧組件
504S‧‧‧堆(晶粒)
525‧‧‧溫度界面材料(TIM)
610‧‧‧黏合劑
610G‧‧‧區域
810、820‧‧‧接合層
910‧‧‧接觸墊
920‧‧‧介電質
930‧‧‧介電質
1110C‧‧‧接觸墊
1210‧‧‧結構
1310、1310.1、1310.2‧‧‧模組
1410、1420、1430、1440、1450‧‧‧步驟
1610‧‧‧測試墊
1810‧‧‧突伸部
1910‧‧‧突伸部
2230‧‧‧層
2310、2320、2330、2340、2350、2360、2370、2374、2380、2384、2390‧‧‧步驟
Cd‧‧‧空腔深度
第1與2圖為習用技術所建構並且包含積體電路的組件的垂直橫剖面圖。
第3A、3B、3C、3D、3E、4A、4B、4C、5A、5B、5C、5D、5E.1圖為本案實施例的結構的垂直橫剖面圖。
第5E.2與5E.3圖為本案實施例的水平橫剖面的底視圖。
第6.1、6.2、7、8A、8B、8C、9A、9B、9C、9D、10、11、12、13A、13B圖為本案實施例的結構的垂直橫剖面圖。
第14圖為本案實施例之設計與製造方法的流程圖,用於製造組件。
第15A、15B、16、17、18、19、20.1圖為本案實施例的結構的垂直橫剖面圖。
第20.2、21圖為本案實施例的組件的頂視圖。
第22.1圖為本案實施例的組件的垂直橫剖面圖。
第22.2圖為本案實施例的組件的頂視圖。
第23圖為本案實施例之製造方法的流程圖,用於製造組件。
第24、25、26圖為本案實施例的組件的垂直橫剖面圖。
此章節中敘述的實施例不限制本發明。具體地,本發明不限於特定的材料、處理、尺寸或其他細節,除了如同由所附申請專利範圍所界定的之外。
根據本發明的一些實施例,第3A圖為中介層120.1的製造的開始階段。中介層基板120.1S最初選擇為足夠厚,以提供在製造中易於處理與充分散熱。在一些實施例中,基板120.1S為200mm或300mm直徑與650微米或更大厚度的單晶矽晶圓。這些材料與尺寸為範例性的,且不限制本發明。例如,基板120.1S可由其他半導體材料(例如砷化鎵)、或玻璃、或藍寶石、或金屬、或可能的其他材料製成。可能的材料包含NbTaN與LiTaN。基板稍後將薄化;例如,在矽的實例中,最終的厚度可為5至50
微米。另外,這些尺寸並非限制。
基板120.1S受到圖案化,以形成盲通孔224B(第3B圖)。「盲」指的是通孔不穿過基板120.1S。例如在矽基板進行。首先,選擇性的層310(第3A圖)形成在基板120.1S上,以保護基板及/或改良隨後形成的光阻320的附著。例如,層310可為熱氧化、化學氣相沉積(CVD)或濺射所形成的二氧化矽。然後,沉積並且光微影圖案化光阻320,以界定通孔。在光阻320曝露的區域中蝕刻層310與基板120.1S,以形成盲通孔。通孔深度等於或稍微大於基板120.1S的最終深度,例如針對一些矽基板的實施例為5至51微米。通孔可藉由乾式蝕刻來形成,例如乾式反應離子蝕刻(DRIE,dry reactive ion etching)。每一通孔的範例性直徑可為60微米或更小,但是其他尺寸也可能。通孔可為垂直的(如圖所示),或者可具有傾斜的側壁。如同上述,特定的尺寸、處理與其他特徵為例示性,而非限制。例如,通孔可為雷射鑽孔的或藉由一些其他處理而製成。
通孔之後金屬化。如果基板120.1S為矽,這可如同以下進行。移除光阻320與保護層310,且介電質層324(第3C圖)形成於基板120.1S的整個頂表面上。介電質324使用作為通孔表面的襯裡。在一些實施例中,介電質324藉由矽基板的熱氧化或藉由CVD或物理氣相沉積(PVD)而形成。介電質324將基板電性絕緣於隨後形成在通孔224B中的金屬。介電質厚度取決於所欲的處理參數,且在範例性熱氧化物實施例中為1微米(熱氧化物為藉由熱氧化所形成的二氧化矽)。其他的尺寸與材料可用來替代。如果基板120.1S本身為介電質,介電質324可省略。
然後,金屬224M(第3D圖)形成於通孔224B中、介電質
324之上。在所示的實施例中,金屬224M填滿通孔,但是在其他實施例中,金屬為通孔表面上的襯裡。在範例性實施例中,金屬224M為電鍍銅。例如,阻障層(金屬或介電質,未單獨繪出)先形成於介電質324上,以協助銅附著並且防止銅擴散至介電質324或基板120.1S中。合適的阻障層可包含一層鈦-鎢(參見Kosenko等人於2012年9月13日公開之美國早期公開專利第2012/0228778號,在此以引用之方式將其併入),及/或含有鎳的層(Uzoh等人於2013年1月17日公開之US 2013/0014978,在此以引用之方式將其併入)。然後,種子層(例如銅)藉由物理氣相沉積(例如,PVD,可能為濺射)形成於阻障層上。然後,電鍍銅於種子層上,以填充通孔224B且覆蓋整個基板120.1S。然後,藉由化學機械研磨(CMP),從通孔之間的區域移除銅。選擇性地,CMP也可從這些區域移除阻障層(如果存在的話),並且可停止於介電質324上。因此,銅與阻障層僅保留在通孔224B中與之上。
為了便於敘述,我們將稱通孔224為「金屬化的」,但是也可使用非金屬的導電材料(例如,摻雜的多晶矽)。
如果層224M並未填充通孔,但是僅作為通孔表面上的襯裡,一些其他材料(未圖示)可形成在層224M上作為填料,以填充通孔且提供平坦的頂表面給晶圓。這種填料材料可為聚酰亞胺,例如藉由旋塗法來沉積。
選擇性地,RDL 210.T(第3E圖)形成在基板120.1S的頂部上,以提供接觸墊120.1C.T在特定的位置。RDL 210.T可藉由例如相關於第1與2圖之上述先前技術的技術來形成。如果接觸墊120.1C.T由金屬224M的
頂部區域提供,則省略RDL 210.T。在此種實例中,如果基板120.1S並非介電質,則介電質層可形成在基板上並且受到光微影圖案化來曝露接觸墊120.1C.T。
中介層120.1可包含在基板120.1S與再分佈層210.T中的電晶體、電阻器、電容器與其他裝置(未圖示)。可在通孔224與RDL 210.T的製造之前、期間及/或之後,使用上述的處理步驟及/或額外的處理步驟來形成這些裝置。此種製造技術為熟知的。參見例如前述的美國專利第6,958,285號以及早期公開的專利公開案2012/0228778,兩者在此以引用之方式將其併入。
可能使用相關於第1與2圖之上述先前技術的方法或其他方法(例如,擴散接合;在此種實例中,連接140.1並非額外的元件,但是為接觸墊110C及/或120.1C.T的部分),利用連接140.1將晶粒110附接至接觸墊120.1C.T。
選擇性地,可能藉由先前技術的技術(例如,包含模製及/或用於底部填充的毛細作用),將封裝劑(未圖示)形成於晶粒之下(作為底部填充)及/或晶粒的周圍(以完全或部分覆蓋晶粒的側壁)以及可能在晶粒之上(以完全覆蓋晶粒的頂部與側壁表面)。封裝劑可為任何合適的材料(例如,具有二氧化矽或其他粒子的環氧樹脂)。在一些實施例中並未使用封裝劑。其他實施例使用封裝劑,但是對於封裝劑的要求是寬鬆的,因為晶粒將由額外的保護基板410(第5A圖)的形式之加強框來保護,如同下述。在一些實施例中,封裝劑僅設置於晶粒的下方(作為底部填充),亦即,僅在晶粒與基板120.1S之間(圍繞著連接140.1)。
第4A-4C圖為保護基板410的製造。許多變化型都可能。基板410應該具有足夠的剛性,以促進組件的後續處理,如同下面解釋的。在所示的實施例中,基板410包含厚度為650微米或更大的單晶矽基板410S。其他材料(例如,玻璃、金屬、聚合物塑膠、與其他)與厚度都可能,取決於任何可能為重要的因素(包含材料與處理的可用性)。一個可能的因素為減少基板410與120.1S之間的熱膨脹係數(CTE)的不匹配:如果基板120.1S為矽,則基板410S可為矽或具有類似的CTE的另一種材料。另一個因素為減少基板410與晶粒110之間的CTE不匹配(特別是如果晶粒可實體接觸於基板410或可附接至基板410)。在一些實施例中,基板410S將不具有任何電路,但是如果想要在基板410S中或上有電路,則這會影響材料的選擇。在下述的步驟之前、及/或期間、及/或之後,可製造電路。
另一個可能的因素為高的熱傳導性,以促成基板410作用為散熱器。例如,金屬可為合適的。
開孔414(第4C圖)為形成在基板410中的空腔,以匹配晶粒110的尺寸與位置。範例性處理如下(此處理適合於矽基板410S,且可能不適合於其他材料;已知的處理可用於矽或其他材料)。首先,形成輔助層420(第4A圖),以覆蓋基板410S,來保護隨後形成的光阻430或改良隨後形成的光阻430的附著。然後,沉積光阻430且光微影圖案化光阻430,以界定空腔414。蝕刻掉光阻開孔所曝露的輔助層420。然後(第4B圖),在這些開孔中蝕刻基板410S,以形成具有傾斜、向上擴張的側壁之空腔414(例如,藉由濕式蝕刻)。空腔深度取決於晶粒414的厚度與連接140.1,如同下面解釋的。例如藉由各向異性乾式蝕刻,也可獲得非傾斜
(垂直)的側壁。逆行的側壁或其他側壁輪廓也可能。
然後,移除光阻430(第4C圖)。在所示的範例中,也移除輔助層420,但是在其他實施例中,層420保留在最終結構中。
如同第5A圖所示,基板410附接至中介層120.1,使得一或更多個晶粒110配接至對應的空腔414中。更具體地,保護基板410的腿部410L附接至中介層120.1的頂表面(例如,至RDL 210.T(如果RDL存在的話);腿部410L為保護基板410圍繞空腔的那些部分)。基板至中介層的附接係為直接接合,但是其他類型的附接(例如,藉由黏合劑)也可使用,如同下面進一步敘述的。整個組件以元件符號504來標示。
在第5A圖中,晶粒的頂表面實體接觸於空腔414的頂表面。在一些實施例中,每一晶粒的頂表面接合至空腔的頂表面(直接或以某種其他方式,例如,藉由黏合劑)。此接合增加了兩個基板之間的接合強度,並且改良了從晶粒至保護基板的熱路徑的熱傳導性。在其他實施例中,晶粒並未接合至基板410,並且可間隔於基板410。空氣或熱界面材料(TIM,thermal interface material,可能為凝膠狀)可至少部分填充晶粒與空腔的頂表面之間的空間;例如,TIM可實體接觸於晶粒與空腔頂表面,以改良對於離開晶粒的熱傳導。
在其他實施例中,晶粒並未接合至空腔的頂表面,且因此晶粒的頂表面在熱運動中可沿著空腔的頂表面橫向滑動。這可降低熱應力,例如,如果晶粒與中介層的CTE匹配較優於中介層與保護基板410之間的匹配。
如同上述,在一些實施例中,晶粒係底部填充及/或由合適
的保護材料(在第5A圖中未圖示)(例如,與第1圖相同的材料)從上方封裝。在從上方封裝的實例中,已固化的封裝劑可為實體接觸於空腔414的頂表面之固體材料(可能為熱固的)。封裝劑可或可不接合至空腔表面,如同上述,其中益處類似於針對無封裝劑的實施例所上述的那些。
為了確保晶粒(或封裝劑)與空腔之間的實體接觸,晶粒(或封裝劑)的頂表面應該具有一致的高度。為了改良高度一致性,在基板410接合至中介層120.1之前,可研磨晶粒(或封裝劑)。合適的研磨處理包含精研、研磨與化學機械研磨(CMP)。另外,在將晶粒插入空腔之前,空腔表面及/或晶粒可設有合適的溫度界面材料(TIM,在此未圖示,但是示於下面討論的第5E.2與5E.3圖中的525),以改良晶粒與基板410之間的熱轉移。TIM的熱傳導性通常可較高於空氣的熱傳導性。範例性的TIM為那些在預期的操作溫度範圍內(例如針對一些組件,0℃至200℃)以半固體、凝膠狀(潤滑脂狀)的狀態存在或者至少當溫度高時使晶粒冷卻得特別令人滿意的(例如針對一些組件,20℃至200℃)之材料。凝膠狀材料填充晶粒與基板410之間的自由空間,以提供遠離晶粒的導熱路徑。範例性TIM材料為可從銀北極公司((其在美國加州具有辦公室)取得的熱潤滑脂;該潤滑脂的熱傳導性為1W/mK。
在接合基板410至中介層120.1之後,從底部將中介層薄化,以曝露金屬224M(第5B圖)。薄化包含部分移除基板120.1S與介電質324(如果介電質存在的話)。薄化可藉由已知技術來執行(例如,在基板120.1S與介電質324的乾式或濕式、遮罩或未遮罩蝕刻之後,基板120.1S的機械研磨或精研;基板與介電質在一些實施例中為同時蝕刻)。在一些實
施例中,介電質324在薄化操作結束時突伸出金屬224M周圍的基板120.1S之外,且金屬224M突伸出介電質。參見例如前述的美國專利第6,958,285號。如同上述,本發明不限於特定的處理。
有利的是,中介層120.1藉由基板410來保持平坦,所以促進組件504的處理。基板410也改良機械的整合性(例如,增加剛性與重量),以進一步促進組件的處理。另外,基板410有助於吸收且散去在此製造階段與隨後的製造階段期間以及組件504的後續操作中所產生的熱。基板120.1S的最終厚度因此可非常小,例如50微米或甚至5微米或更小。因此,盲通孔224B(第3B圖)可為淺的。淺的深度可促進金屬化的通孔的製造(亦即,促進通孔的蝕刻以及後續沉積介電質與金屬進入通孔中)。淺的深度也縮短通過通孔的信號路徑。此外,如果通孔為淺的,每一通孔可較窄,同時仍然允許可靠的介電質與金屬的沉積。可因此減小通孔間距。
如果需要的話,保護基板410可從頂部薄化(這未示出於第5B圖中)。基板120.1S與410的組合厚度由所欲的特性界定,例如剛性、耐翹曲、散熱、以及組件尺寸。在一些實施例中,基板410薄化,以移除晶粒110之上的基板部分並且只留下腿部410L,因此獲得相關於第20.1圖所下述的結構類型。
隨後的處理步驟取決於特定的應用。在一些實施例中(第5C圖),可能使用先前技術的技術(例如如同第2圖中),將RDL 210.B形成在基板120.1S的底部上。RDL提供接觸墊120.1C.B且連接接觸墊120.1C.B至金屬224M。(如果省略RDL,則由金屬224M提供接觸墊)。如果需要的話,組件504可切割成堆504S(第5D圖)。然後,該等堆(或整個組件
504,如果省略切割的話)附接至其他結構,例如第5E.1圖中的佈線基板120.2(例如,印刷佈線基板)。在第5E.1圖的範例中,堆504S附接至PWS 120.2,且更具體地,堆的接點120.1C.B附接至PWS接點120.2C,可能係藉由如同第1或2圖中的相同技術。PWS 120.2的導線130連接接觸墊120.2C至彼此或其他元件。這些細節並非限制。
第5E.2圖為沿著第5E.1圖中的線5E.2-5E.2之水平橫剖面的可能底視圖。在第5E.2圖的範例中,晶粒由溫度界面材料(TIM)525圍繞。腿部410L形成完全圍繞每一空腔的區域,且接合至腿部的中介層區域也完全圍繞每一空腔。
第5E.3圖為相同水平橫剖面的另一可能的底視圖,也具有TIM 525。在此範例中,腿部410L僅設置在每一空腔的兩相對側上(左側與右側),但是並未設置在空腔的上方與下方。每一空腔414為基板410S中的水平凹槽,包含多個晶粒(凹槽也可僅具有一個晶粒)。凹槽可運行通過整個基板。其他空腔形狀也可能。
如同上述,保護基板410與中介層120.1可藉由黏合劑來接合,且第6.1圖之黏合劑610為此種接合。黏合劑610設置在腿部140L或中介層120.1的對應區域或兩者上。該結構顯示於第5A圖的階段(在中介層薄化之前)。在一些實施例中,黏合劑為彈性的,具有低彈性係數(例如,具有50MPa的彈性模數的矽橡膠),以協助吸收晶粒110及/或基板410及/或中介層120.1的熱膨脹的任何不匹配(例如,使得來自膨脹的晶粒110的壓力將不會損壞保護基板410或晶粒)。在一些實施例中,如果晶粒的CTE等於或大於保護基板410或基板410S的CTE,這是有益的。黏合劑的彈性也
吸收晶粒110的頂表面或空腔414的頂表面的高度不一致性。另外,為了吸收晶粒的膨脹,黏合劑可具有等於或大於晶粒的CTE之CTE。範例性的黏合劑為環氧樹脂型的底部填充。
在一些實施例中,黏合劑610為沖壓的膠帶。
第6.2圖為類似的實施例,其中黏合劑不存在於該結構將被切割的區域610G中。
第7圖為類似的實施例,但是黏合劑610覆蓋保護基板410S的整個底表面。黏合劑接合晶粒(或封裝劑)的頂表面至空腔的頂表面。黏合劑的CTE可等於、或大於、或小於晶粒的CTE。
第8A-8C圖為使用單獨的接合層810、820來直接接合保護基板410至中介層120.1。在一些實施例中,接合層為二氧化矽,但是也可使用其他材料(例如,用於共熔接合的金屬)。參見第8A圖,晶粒附接至中介層120.1(如同第3E圖中);晶粒之後選擇性地底部填充及/或從上方封裝(在第8A圖中,封裝劑150封裝且底部填充晶粒)。藉由任何合適的技術(例如,濺射),形成接合層810(例如,二氧化矽或金屬)來覆蓋中介層與晶粒(以及封裝劑,如果存在的話)。
參見第8B圖,保護基板410設有空腔,如同第4C圖中。然後,藉由任何合適的技術(例如,濺射,或熱氧化(如果基板410S為矽)),形成接合層820(例如,二氧化矽或金屬)來覆蓋基板表面。
參見第8C圖,中介層接合至基板410,使得層810、820實體接觸於彼此。然後,加熱該結構,以將層820接合至層810,其中兩層接觸,亦即,在腿部410L處與在空腔的頂表面處。然而,在一些實施例中,
在接合之前,層820在空腔的頂表面處移除,並未接合晶粒至空腔的頂表面。
第6.1-8A圖的結構的後續處理(中介層薄化,可能的切割等)可如同上述的其他實施例。
上述處理步驟的順序並非限制;例如,通孔224可在中介層薄化之後形成。第9A-9D圖為範例性處理。中介層120.1基本上如同在第3E或6.1或6.2或8A圖中所製造,但是沒有通孔224(通孔將在稍後形成)。具體地,介電質324為中介層基板120.1S上的平坦層。然後,接觸墊910在未來通孔224的位置處形成於基板120.1S上。RDL 210.T選擇性地製造在中介層的頂部上,以連接接觸墊910至中介層的頂部上的墊120.1C.T。(替代地,墊120.1C.T可由墊910提供。)晶粒110附接至墊120.1C.T,且選擇性地底部填充與封裝。接合層810(如圖所示)選擇性地沉積,如同第8A圖中,以接合至保護基板(替代地,該接合可藉由第6.1或6.2或7圖中的黏合劑,或藉由相關於第5A圖所上述的直接接合處理)。
具有晶粒附接的中介層120.1然後接合至保護基板410(第9B圖),如同上述的任何實施例中。然後,中介層薄化(第9C圖)。晶粒在後續步驟期間將由基板410保護。基板410可在任何所欲的階段薄化。
然後,金屬化的通孔224從中介層底部形成。範例性處理如下:
1.介電質920(例如,二氧化矽或氮化矽)沉積(例如,藉由濺射或CVD),以覆蓋中介層基板120.1S的底表面。
2.通孔(貫通孔)從底部形成通過介電質920與基板
120.1S(藉由遮罩蝕刻或雷射鑽孔或一些其他的處理)。通孔終止於接觸墊910處。
3.介電質930(例如,二氧化矽或氮化矽)沉積(例如,藉由濺射或CVD),以覆蓋中介層基板120.1S的底表面並且作為通孔的襯裡。介電質930從底部覆蓋接觸墊910。
4.蝕刻介電質930,以曝露接觸墊910。此可為遮罩蝕刻。替代地,可使用毯覆各向異性(垂直)蝕刻從每一接觸墊910的至少一部分之上移除介電質930,同時使介電質留在通孔側壁上。垂直蝕刻可或可不移除通孔外部的介電質930。
5.形成導電材料224M(例如,金屬)於通孔中,可能藉由上述相同的技術(例如,銅電鍍)。導電材料不存在於通孔外部(例如,它可藉由CMP研磨掉)。導電材料可填充通孔或僅作為通孔表面的襯裡。每一通孔中的導電材料實體接觸於對應的墊910。
隨後的處理步驟可如同相關於第5C-5E.3圖所上述的。具體地,底部的RDL 210.B(第5C圖)與連接140.2可如同上述地形成。如果需要,可切割該結構(第5D圖),並且附接至另一結構(例如,第5E.1圖中的PWS 120.2)。
通孔224為選擇性的,且進一步,基板120.1可為任何佈線基板,例如第10圖的120所示。此圖式顯示在腿部410L處與空腔頂表面處使用黏合劑610來接合保護基板410至WS 120之實施例,但是可使用上述的任何其他接合方法。並未顯示底部填充或其他封裝劑,但是整個晶粒可存在有或沒有封裝劑的底部填充。
在一些實施例中,通孔224部分在中介層薄化之前形成且部分在中介層薄化之後形成。例如,在一些實施例中,中介層受到處理至第3C圖的階段(介電質324形成,可能藉由高溫處理,例如矽的熱氧化),但是取代金屬,通孔填充有暫時填充,例如聚酰亞胺。然後,其他處理步驟則如同相關於第3E-5B圖所上述地執行,且具體地,當中介層薄化時,暫時填充係曝露於中介層底部處。移除暫時填充,且將金屬或其他導電材料224M置於通孔中,如同相關於第9D圖所上述的。這會是有利的,如果因為與後續處理步驟的不相容而需要避免金屬太早沉積至通孔中(在第3D圖的階段),且同時,不希望將介電質324的沉積延遲至第9D圖的階段(例如如果介電質324藉由高溫處理而形成)。其他變化也可能。
相關於第5A-10圖之上述技術可用於附接任何數量的單獨的保護基板410至相同的中介層120.1或WS 120;不同的保護基板410可附接至基板120.1或120的相同側,其中不同的晶粒在相同或不同的保護基板410的不同空腔中;參見第16圖,下面更詳細地敘述。其他保護基板410可附接至基板120.1或120的相對側。一些晶粒可不具有保護基板410來保護它們。每一基板120.1S或410S可為晶圓,且兩個基板在給定的組件504中可為相同的尺寸;但是在相同組件中也可能有不同的尺寸。
晶粒也可在相同的空腔中堆疊於彼此之上(參見第11圖,顯示如同第6.1圖的相同製造階段中的結構),其中每一堆疊僅頂部晶粒實體接觸於對應的空腔的頂表面(一堆疊可具有多個晶粒附接至下方晶粒的頂表面;多個晶粒的一或更多者可使其頂表面接觸於空腔的頂表面)。每一堆疊中的晶粒可具有它們各自的電路透過其接觸墊1110C與各自的連接
140(其可為上述的任何類型)而互連。在第11圖中,基板120.1S、410S藉由腿部410L上的黏合劑610接合在一起,如同第6.1圖中,但是也可使用上述的其他接合方法。堆疊的晶粒也可用於上述的其他變化型,例如,當保護基板直接接合至PWS時。晶粒堆疊可由任何積體電路封裝來取代。
在一些實施例中,基板410S具有電路,可能連接至晶粒及/或中介層120.1S或PWS中的電路。參見第12圖,藉由結構1210連接至基板410S的頂部晶粒;每一結構1210包含基板410S中的接觸墊、頂部晶粒110上的對應接觸墊、以及接合兩接觸墊至彼此的連接(例如,焊料或上述的任何其他類型)。在第12圖的範例中,封裝劑150底部填充且完全圍繞每一晶粒,接觸於空腔的頂表面。如同上述,封裝及/或底部填充為選擇性的。
本發明不限於上述或下述的實施例。例如,通孔224可在RDL之後形成,並且可蝕刻通過一或兩個RDL。上述或下述的不同的特徵可結合。例如,在下述的第13A與13B圖中,基板410藉由黏合劑610而接合至中介層120.1,但是可使用上述的其他接合方法。此外,在第13A與13B圖中,通孔224在中介層薄化之前形成,但是它們可在中介層薄化之後形成,如同第9C-9D圖中。顯示的細節僅用於例示的目的,且不限制本發明。
空腔414可包含晶粒、堆疊、或其他不同高度的封裝(例如,如同在第13A圖中),且較短模組的高度可增加,以改良力學強度及/或散熱--參見第13B圖。第13A與13B圖顯示在第11圖的階段的組件(在中介層薄化之前)。每一空腔414包含兩個模組1310.1、1310.2;模組1310.1包含堆疊的兩個晶粒,且模組1310.2包含單個晶粒(一模組可為包含堆疊或
其他封裝的任何晶粒或組件)。模組1310.2的晶粒110可做得較薄(第13A圖),但是空腔深度Cd必須容納模組1310.1,所以模組1310.2的晶粒110的厚度增加(第13B圖),以利用高Cd值。
第14圖為處理的流程圖,其可用來決定每一晶粒在設計階段的厚度。在步驟1410,決定每一模組1310的最小厚度。(Tmin可包含互連相同模組中的不同晶粒之連接140的高度,及/或連接該模組至中介層之連接140的高度;此外,如果任何模組的頂部將連接至保護基板410(如同第12圖中),則在一些實施例中,Tmin包含對應的連接的高度。)在第13B圖的範例中,模組1310.1的Tmin較大於模組1310.2的Tmin。
在步驟1420,決定最大的Tmin值(此值在第14圖中以M表示)。在第13B圖的範例中,M為模組1310.1的Tmin值。
在步驟1430,M值係用於決定空腔深度Cd。例如,Cd可設定為M值加上一值,該值可根據下述來決定:可用的製造容忍度(亦即,可能的製造誤差)及/或所欲的散熱性能及/或接合技術(例如,層610或810或820的厚度),及/或其他可能的參數。
在步驟1440,針對其Tmin小於最大值(M)的每一模組,模組的厚度如同所欲地增加。在第13B圖的範例中,針對模組1310.2,Tmin值小於M,所以如果增加晶粒厚度將促進晶粒製造或改良晶粒的散熱或者如果增加晶粒厚度將存在有其他益處,則增加模組1310.2的晶粒的厚度。在步驟1450,使用步驟1410-1440中所獲得的厚度參數來製造晶粒,空腔製造成在步驟1430中所獲得的厚度,使用任何上述方法,將保護基板410與晶粒附接至中介層。
步驟1420、1430、1440在一些實施例中自動執行,例如藉由包含電腦處理器的電腦或藉由一些其他電路,電腦處理器執行儲存在電腦儲存器(例如,記憶體)中的軟體指令。
此外,如同第15A圖中所示,空腔414可具有不同的深度:空腔在較短的模組(例如1310.2)之上可較淺於在較高的模組(例如1310.1)之上。有利的,在一些實施例中,減小較短的模組與頂部空腔表面之間的熱阻。例如,在一些實施例中,模組具有不同的高度,但是每一模組的頂表面與上方的空腔表面之間的間隙為相同,及/或具有相同的熱阻。除了熱阻的考量之外,如果任何模組的頂表面連接至晶圓410(如同第12圖中),模組的頂部晶粒的頂表面與上方的空腔表面之間的間隙係做成等於該等連接的所欲高度。
在一些實施例中,即使針對相同高度的模組,可提供具有不同深度的空腔。
另外(第15B圖),不同的空腔可具有在相同加強框中的不同深度。可選擇不同的深度,以適應於不同的模組高度,及/或針對其他原因。例如,產生較多熱的模組可置於淺空腔中,以減少模組與加強框之間的熱阻,但是產生較少熱的另一模組可置於較深的空腔中,以增加對於模組高度變化的容忍度。
如同上述,多個保護基板410可附接至相同的中介層。一範例顯示於第16圖中:每一加強框410具有一或更多個空腔,並且覆蓋一或更多個晶粒110(在上述與下述的所有範例中,晶粒110可由相關於第13B圖所上述的任何類型的模組1310來取代)。在所有其他態樣中,第16圖的
結構可如同上述的任何實施例。具體地,晶粒可封裝及/或底部填充,並且可藉由空氣或其他氣體或TIM潤滑脂或其他材料而分隔於頂部空腔表面,或者晶粒可實體接觸於空腔頂部表面或可接觸於可接觸空腔頂部表面的固體材料(例如,TIM)。上述的其他變化型也可存在於第16圖的結構類型中(例如,加強框可藉由黏合劑(例如,610)(例如,沖壓的膠帶或其他類型)而接合至中介層,黏合劑可或可不存在於加強框之間;也可使用其他的接合技術)。
這種結構可提供多個優點。具體地,加強框410之間的中介層區域為可使用的,並且可用於測試墊1610:測試墊可連接至RDL 210.T中的其他接觸墊及/或至金屬化的通孔224M。測試墊促進在切割之前及/或之後組件的測試(切割在一些實施例中省略)。在一些實施例中,測試墊位於切割線上,亦即,測試墊在切割期間可被切割通過,且可因此被破壞或可僅分成多個測試墊,其在切割之後可用於測試每一晶粒。
另外,切割之前可能存在的熱應力較小於晶圓尺寸的(連續的)加強框。
另外,因為每一加強框410覆蓋小於所有晶粒110,當每一加強框410放置在中介層上時,每一加強框410較容易對準(因為每一加強框必須僅對準於該加強框所覆蓋的模組)。此外,中介層可具有在加強框410的位置之間的頂表面中的對準標記(未圖示),以促進每一加強框的對準。
第17圖例示在中介層薄化以及第5D圖中的連接140.2與底部RDL 210.B形成之後,從第16圖的結構獲得的範例性晶粒。(如同上述,不
同特徵可用任何合適的方式結合,且具體地,連接140.2及/或RDL 210.B可省略。)在第17圖中,切割線置於加強框410之間,所以加強框410並未被切割。切割因此簡化。
針對對準的目的,加強框410可具有突伸部或狹縫,其匹配於中介層上的狹縫或突伸部。參見第18與19圖,其顯示在第17圖的階段的結構。在第18圖中,加強框410具有突伸部1810係匹配於中介層上的狹縫(突伸部1810可延伸至中介層基板120.1中或僅進入RDL 210.T中)。在第19圖中,加強框410具有狹縫係匹配於中介層的突伸部1910(中介層的突伸部可為中介層基板的延伸,或者可為RDL 210.T的部分)。此種對準特徵可結合(突伸部可存在於中介層與加強框410兩者上,具有匹配的狹縫在加強框410與中介層上)。此種對準特徵可上述的任何實施例中,包含具有單個加強框410的實施例(參見第5C圖)。
如同上述,開孔410可為如同上面所示的空腔,或者可為通孔,或者可為具有通孔的空腔。第20.1、20.2圖分別為通孔實施例的垂直橫剖面與頂視圖;第20.1圖的垂直橫剖面在第20.2圖中標示為「20.1」。此實施例類似於第17圖,但是開孔414為加強框410中的通孔;加強框410橫向圍繞晶粒。通孔促進加強框對準與附接至中介層(因為在加強框的放置與附接期間,晶粒區域為可見且可使用的)。此外,測試墊1610可置於通孔414內(例如,在RDL 210.T的頂部或晶粒110處);測試墊可連接至彼此及/或晶粒與中介層中的其他電路,且可經由通孔414來使用。
類似於第16圖,在開孔414為通孔的實施例中,在附接至中介層之前,每一加強框410可提供作為單獨的結構。優點包含相關於第16
圖所上述的那些。或者,加強框410可為第5A圖的單個晶圓的部分;參見第21圖,其為具有四個孔414的晶圓尺寸的加強框410的一部分的範例性頂視圖;加強框與中介層將沿著切割線2110被切割。如同上述的其他方案,在一些實施例中省略切割。
雖然通孔型加強框410(例如第20.1、20.2圖中)並不像空腔型加強框(例如第5D圖中)那樣強固,但是通孔型加強框可具有優點。具體地,如同上述,它們允許測試墊1610的更多位置,且它們可較容易對準與接合至中介層。此外,它們可具有較小的力學應力。此外,它們可支撐直接接合至晶粒的散熱器:參見例如第22.1圖(垂直橫剖面圖)與第22.2圖(頂視圖)中的散熱器(傳熱器)160:這些圖式如同第20.1、20.2圖的相同結構與相同視圖,但是其中散熱器160係支撐於加強框410的兩相對側部上。散熱器可由加強框410的所有側部、三個側部、或以一些其他方式來支撐(注意到,通孔414可具有多於四個側部並且在頂視圖中不必是矩形,例如,通孔可為圓形或任何其他形狀)。在第22.1與22.2圖中,散熱器藉由接合層2230而接合至晶粒110。層2230可為黏合劑及/或TIM及/或金屬及/或適於接合的其他類型的層。散熱器可接合至少於所有晶粒110。如果使用直接接合,層2230可省略。此接合為選擇性的:取代地或額外地,散熱器可藉由接合層或藉由直接接合而接合至加強框410。散熱器可覆蓋在相同或多個加強框中的多個通孔或由該多個通孔支撐;此種散熱器可接合至在相同或不同通孔中的多個加強框及/或多個晶粒。
通孔方案增加了製造的彈性,因為晶粒110與加強框410可用任何順序附接至中介層120.1。範例性的製造順序例示於第23圖的流程圖
中。在此實施例中,步驟2310例示製造中介層120(亦即,120.1)、加強框或多個加強框410、與模組1310(例如,晶粒110)。中介層可或可不包含金屬化的通孔224M(通孔稍後可如同相關於第9D圖所上述地形成)。在步驟2320,加強框或多個加強框410附接至中介層。在步驟2330,晶粒110(或模組)附接至中介層,並且在所有側部上被底部填充及/或封裝(橫向地、從上方與下方),例如如同第1圖中。(晶粒可在步驟2320之後製造,或者可在步驟2320之前製造與附接)。在步驟2340,中介層薄化。在步驟2350中,金屬化的通孔224M形成在中介層中(如同上述,在步驟2310可形成一些或全部的這些通孔,並且在步驟2340曝露於中介層背側上)。在步驟2360,測試該組件(使用測試墊1610)。在步驟2370,一或更多個散熱器160附接於孔414之上。在步驟1374,可分配封裝劑(例如,第1圖中的150)來封裝中介層之上的晶粒。封裝劑為選擇性的,且封裝可在散熱器附接之前執行或可在散熱器附接之後執行(如果散熱器未完全覆蓋孔414)。或者,一些封裝(或晶粒110的至少底部填充)可在散熱器附接之前執行(取代步驟2330的底部填充,或除了步驟2330的底部填充之外),且額外的封裝可在散熱器附接之後執行。注意到,封裝劑的數量可基於中介層的翹曲來控制。封裝劑的類型也可基於翹曲來控制。例如,如果中介層向上彎曲(亦即,中間部分較高於邊緣),且封裝劑引致壓縮應力,則可分配更多的封裝劑來抵消翹曲,及/或可選擇封裝劑材料,以提供更多的壓縮應力來抵消翹曲。在這些後期階段的封裝(可能包含散熱器附接之後)允許封裝劑材料與數量可基於封裝之前對組件執行的翹曲測量來選擇。
切割執行於步驟2380。如果需要的話(步驟2384),步驟2380所獲得的每一晶粒(亦即,每一堆疊)504S附接至另一基板,例如PWS 120.2(示於第24圖中,針對第22.1圖的組件;第23圖的處理也可執行於上面討論的其他類型的組件)。然後,如同步驟2390所指示的,整個晶粒504S(包含中介層)可被封裝。例如,在第24圖中,封裝劑層150.1(底部填充)與150.2(例如,環氧樹脂)已經被分配且固化,以從下方與側部上封裝(覆蓋)晶粒504S,來保護晶粒或僅減小翹曲:封裝劑所引致的應力可抵消組件中及/或PWS中的其他翹曲應力。在一些實施例中,翹曲減小至100微米以下。在第24圖的範例中,封裝劑不會到達晶粒504S的頂部,但是僅從下方與側部上覆蓋晶粒,部分分道至散熱器160。封裝劑150.2也填充包含晶粒110的空腔。封裝劑150.2的部分可已經形成於上述的步驟2330及/或2374時。在其他實施例中,封裝劑可升高至高於或低於第24圖所示的位準之任何位準;例如,封裝劑可在側部與頂部上完全覆蓋散熱器,如同例如第25-26圖所示。
許多變化都可能。第25圖例示如同第24圖的相同組件,但是晶粒504S為如同第20.1圖中(無散熱器160)。另外,在此範例中,封裝劑層150.2完全覆蓋晶粒504S,但是封裝劑可形成至較低的位準(例如,如同第24圖中),如果適於補償翹曲或用於任何其他的目的。封裝劑可如同第24圖所上述地形成。
第26圖為相同組件,但是晶粒504S為如同第17圖中。同樣地,封裝劑層150.2完全覆蓋晶粒504S,但是封裝劑可形成至較低的位準。可使用其他類型的晶粒504S。
一些實施例的一些態樣藉由以下的條款來敘述:
條款1敘述一種製品,包含:一第一基板(例如,中介層120或120.1,或中介層基板120.1S),其包含一或更多個第一接觸墊(例如,頂部接觸墊120.1C.T);複數個模組(例如,晶粒110或其他組件/封裝,例如,模組1310),其附接至該第一基板,至少一模組包含一半導體積體電路,該模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊(注意到,也可有虛擬模組,例如,虛擬晶粒,如果組件最初設計成容納針對特定實施例所需的更多的模組);一加強框(例如,410或410S),其包含一或更多個空腔,該加強框係附接至該第一基板,其中每一模組的至少部分係位於該加強框中的一對應空腔中(參見例如第13A圖),其中至少兩模組具有不同的高度並且係至少部分位於該加強框中的該相同空腔中。
注意到,用語「空腔」在本文使用時涵蓋具有通孔的空腔。然而,用語「空腔」在本文使用時具有深度,其為限制可放置在空腔中的模組的高度之參數。因此,如果開孔414具有垂直的壁部且無「頂部」(例如如同第20.1圖中),則開孔並非空腔,因為開孔不限制可放置在開孔中的任何模組的高度。
條款2敘述一種製品,包含:一第一基板(例如,中介層120或120.1,或中介層基板120.1S),其包含一或更多個第一接觸墊;複數個模組,其附接至該第一基板,每一模組包含一半導
體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;一加強框,其包含一或更多個空腔,該加強框附接至該第一基板,其中每一模組的至少部分係位於該加強框中的一對應空腔中(注意到,多個模組可位於相同的空腔中);其中,複數個模組包含一第一模組與一第二模組,其至少部分位於相同的空腔中,該空腔在第一模組之上比在第二模組之上更深(例如如同第15A圖中)。
條款3敘述一種製品,包含:一第一基板,其包含一或更多個第一接觸墊;複數個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;一加強框,其包含複數個空腔,該加強框附接至該第一基板,其中每一模組的至少部分係位於該加強框中的一對應空腔中;其中,複數個模組包含一第一模組與一第二模組,第二模組高於第一模組,且對應於第二模組的空腔係較深於對應於第一模組的空腔(例如如同第15B圖中)。
條款4敘述一種方法(例如,如同第14圖中),用於設計一製品,該製品包含附接至一第一基板且由一加強框覆蓋的複數個模組,該加強框包含一第一空腔,該第一空腔覆蓋複數個模組,每一模組包含一半導體積體電路(例如如同第13B圖中),該方法包含:
(a)決定每一模組的一最小厚度Tmin;(b)決定該等模組的該等最小厚度的一最大值M;(c)藉由使用該最大值M的一程序,決定該第一空腔的一深度;(d)如果任何模組的最小厚度Tmin小於M,則針對最小厚度Tmin小於M的至少一模組決定是否該模組的厚度將增加,且如果該模組的厚度將增加,則增加該模組的厚度。
條款5敘述條款4的該方法另包含:基於該等模組的厚度來製造該等模組。
條款6敘述條款4或5的該方法,其中至少一模組的厚度在操作(d)中增加,且增加該模組的厚度包含:增加該模組中的至少一半導體積體電路的一厚度。
條款7敘述一種製品,包含:一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及複數個加強框,其附接至該第一基板(例如如同第16圖中),每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中。
在一些實施例中,至少一開孔為圓柱形通孔。「圓柱形」不
限於「圓形」;例如,在第22.2圖中,在頂視圖中通孔414可為矩形、或橢圓形、或任何其他形狀。另外,「圓柱形」不限於「直的圓柱」;換句話說,通孔414的壁部不必是垂直的,但是相對於加強框410或中介層120.1可有一些其他的(非90°)角度。
條款8敘述條款7的該製品,其中該等加強框彼此間隔。
條款9敘述條款7或8的該製品,其中該第一基板包含一或更多個測試墊(例如,1610),用於測試位於該等加強框之外的該製品。
條款10敘述條款9的該製品,其中至少一測試墊位於至少兩加強框之間。
條款11敘述一種方法,用於製造一製品,該方法包含:獲得一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;獲得一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及附接複數個加強框至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中。參見例如第16圖。
條款12敘述條款11的該方法,其中該等加強框係彼此間隔。
條款13敘述條款11或12的該方法,另包含:切割在至少兩加強框之間的該第一基板,以形成複數個晶粒,每一加強框係在該等晶粒
的一者中。第17圖為實施例中的一種晶粒。
條款14敘述條款11、12或13的該方法,其中該第一基板包含一或更多個測試墊,用於測試位於該等加強框之外的該製品。
條款15敘述條款14的該方法,其中至少一測試墊位於至少兩加強框之間。
條款16敘述一種製品,包含:一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及一或更多個加強框,其附接至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中;其中,該第一基板包含橫向圍繞該一或更多個加強框的一部分。例如,在第17圖中,中介層包含橫向圍繞該加強框410的一部分(包含測試墊1610)。
條款17敘述條款16的該製品,其中橫向圍繞該一或更多個加強框的該部分包含用於測試該製品的一或更多個測試墊。
條款18敘述條款17的該製品,其中至少一測試墊電連接至該至少一模組(例如,藉由第17圖中的RDL 210.T中的互連線)。
條款19敘述一種製品,包含:
一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及一或更多個加強框,其附接至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中;其中在至少一加強框中,至少一開孔包含一通孔。參見例如第20.1圖。注意到,通孔的側壁不需要為垂直的,且該開孔可為具有通孔(可能為多個通孔)的空腔。
條款20敘述條款19的該製品,其中該製品包含一或更多個測試墊,用於測試該製品,該製品可通過該通孔來使用並且由該至少一加強框橫向圍繞。參見例如第20.1圖中的測試墊1610。
條款21敘述條款20的該製品,其中至少一測試墊為該第一基板的部分。(例如,作為測試墊1610,其為第20.1圖中的RDL 210.T的部分)。
條款22敘述條款20或21的該製品,其中至少一測試墊為至少部分位於該至少一開孔中之一模組的部分(例如,第20.1圖中的晶粒110的頂部上的測試墊)。
條款23敘述一種方法,用於製造一製品(例如如同第23圖中),該方法包含:
獲得一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;獲得一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及附接一或更多個加強框至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中;其中在至少一加強框中,至少一開孔包含一通孔。
條款24敘述條款23的該方法,其中在該至少一模組的至少部分係部分位於該通孔中之前,該至少一加強框係附接至該第一基板。
條款25敘述條款19的該製品,另包含一或更多個散熱器(例如,160),每一散熱器位於一或更多個加強框中的一或更多個通孔之上,其中位於至少一加強框中的至少一通孔之上的至少一散熱器係附接至該加強框及/或至少部分位於該通孔中的至少一模組,每一散熱器具有高於每一加強框的一熱傳導性。
條款26敘述條款25的該製品,其中位於至少一加強框中的至少一通孔之上的至少一散熱器係附接至該加強框。
條款27敘述條款25的該製品,位於至少一通孔之上的至少一散熱器係附接至至少部分位於該通孔中的至少一模組。
條款28敘述條款19的該製品,其中該第一基板包含一第一對準特徵,且至少一加強框包含一第二對準特徵,且該第一與第二對準特
徵之一者為一凹槽,該第一與第二對準特徵之另一者為一突伸部,該突伸部不具有電性功能並且至少部分位於該凹槽中。
本發明並不限於上述範例。其他實施例與變化例都在本發明的範圍內,如同由所附申請專利範圍所界定的。
110‧‧‧晶粒
110C‧‧‧接觸墊
120.1‧‧‧中介層
140‧‧‧連接
210.T‧‧‧再分佈層
224‧‧‧通孔
324‧‧‧介電質
410‧‧‧加強框(保護基板)
410L‧‧‧腿部
410S‧‧‧基板
610‧‧‧黏合劑
1110C‧‧‧接觸墊
1310.1‧‧‧模組
1310.2‧‧‧模組
Claims (19)
- 一種組件,包含:一第一基板,其包含一或更多個第一接觸墊;複數個模組,其附接至該第一基板,至少一模組包含一半導體積體電路,該模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;一加強框,其包含一或更多個空腔,該加強框係附接至該第一基板,其中每一模組的至少部分係位於該加強框中的一對應空腔中,其中至少兩模組的高度不同,並且係至少部分位於該加強框中的該相同空腔中。
- 一種組件,包含:一第一基板,其包含一第一側與在該第一側處的一或更多個第一接觸墊;一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及複數個加強框,其附接至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中。
- 如申請專利範圍第2項之組件,其中至少一開孔為一圓柱形通孔。
- 如申請專利範圍第2項之組件,其中該等加強框係彼此間隔。
- 如申請專利範圍第2項之組件,其中該第一基板包含一或更多個測試墊,用於測試位於該等加強框之外的該組件。
- 如申請專利範圍第5項之組件,其中至少一測試墊位於至少兩加強框之間。
- 一種方法,用於製造一組件,該方法包含:獲得一第一基板,其包含一第一側,而該第一側具有一或更多個第一接觸墊;獲得一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及附接複數個加強框至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中。
- 如申請專利範圍第7項之方法,其中該等加強框係彼此間隔。
- 如申請專利範圍第7項之方法,另包含切割在至少兩加強框之間的該第一基板,以形成複數個晶粒,每一加強框係在該等晶粒的一者中。
- 如申請專利範圍第7項之方法,其中該第一基板包含一或更多個測試墊, 用於測試位於該等加強框之外的該組件。
- 如申請專利範圍第10項之方法,其中至少一測試墊位於至少兩加強框之間。
- 一種組件,包含:一第一基板,其包含一第一側,而該第一側具有一或更多個第一接觸墊;一或更多個模組,其附接至該第一基板,每一模組包含一半導體積體電路,每一模組包含一或更多個接觸墊,每一接觸墊係附接至一個別的第一接觸墊;及一或更多個加強框,其附接至該第一基板,每一加強框包含一或更多個開孔,每一模組的至少部分係位於一對應加強框中的一對應開孔中;其中在至少一加強框中,至少一開孔包含一通孔。
- 如申請專利範圍第12項之組件,其中該組件包含一或更多個測試墊,用於測試該組件,該組件可通過該通孔來使用,並且由該至少一加強框橫向圍繞。
- 如申請專利範圍第13項之組件,其中至少一測試墊為該第一基板的部分。
- 如申請專利範圍第13項之組件,其中至少一測試墊為至少部分位於該至 少一開孔中之一模組的部分。
- 如申請專利範圍第12項之組件,另包含一或更多個散熱器(Heat sinks),每一散熱器位於一或更多個加強框中的一或更多個通孔之上,其中位於至少一加強框中的至少一通孔之上的至少一散熱器係附接至該加強框及/或至少部分位於該通孔中的至少一模組,每一散熱器具有高於各自之加強框的一熱傳導性。
- 如申請專利範圍第16項之組件,其中位於至少一加強框中的至少一通孔之上的至少一散熱器係附接至該加強框。
- 如申請專利範圍第16項之組件,其中位於至少一通孔之上的至少一散熱器係附接至至少部分位於該通孔中的至少一模組。
- 如申請專利範圍第12項之組件,其中該第一基板包含一第一對準機構(Alignment feature),且至少一加強框包含一第二對準機構,且該第一與第二對準機構之一者為一凹槽,且該第一與第二對準機構之另一者為一突伸部,該突伸部不具有電性功能並且至少部分位於該凹槽中。
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TWI778560B (zh) * | 2021-03-30 | 2022-09-21 | 力成科技股份有限公司 | 封裝結構及其製造方法 |
US11848318B2 (en) | 2021-03-30 | 2023-12-19 | Powertech Technology Inc. | Package structure and manufacturing method thereof |
US11984381B2 (en) | 2021-05-13 | 2024-05-14 | Taiwan Semiconductor Manufacturing Company, Ltd. | Semiconductor package structure and method for forming the same |
CN114038836A (zh) * | 2021-11-24 | 2022-02-11 | 苏州科阳半导体有限公司 | 一种半导体芯片的封装结构及封装方法 |
Also Published As
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WO2015183884A2 (en) | 2015-12-03 |
WO2015183884A3 (en) | 2016-01-21 |
US9887166B2 (en) | 2018-02-06 |
KR20170013310A (ko) | 2017-02-06 |
US20150262972A1 (en) | 2015-09-17 |
TWI588966B (zh) | 2017-06-21 |
KR102275890B1 (ko) | 2021-07-08 |
US9355997B2 (en) | 2016-05-31 |
US20160276294A1 (en) | 2016-09-22 |
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