TW423120B - Semiconductor device having a sub-chip-scale package structure and method for forming same - Google Patents

Semiconductor device having a sub-chip-scale package structure and method for forming same Download PDF

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Publication number
TW423120B
TW423120B TW087117327A TW87117327A TW423120B TW 423120 B TW423120 B TW 423120B TW 087117327 A TW087117327 A TW 087117327A TW 87117327 A TW87117327 A TW 87117327A TW 423120 B TW423120 B TW 423120B
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substrate
semiconductor
semiconductor die
dimension
semiconductor device
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TW087117327A
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Iii Leo M Higgins
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Motorola Inc
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    • H01L23/48Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/488Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
    • H01L23/498Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49827Via connections through the substrates, e.g. pins going through the substrate, coaxial cables
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    • H01L23/31Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
    • H01L23/3107Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
    • H01L23/3114Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed the device being a chip scale package, e.g. CSP
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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
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  • Structures Or Materials For Encapsulating Or Coating Semiconductor Devices Or Solid State Devices (AREA)
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Description

五、發明說明(ι) 先前申請之參考 本申請曾於1997年12月1曰以專利申請號碼08/980 ,783 於美國提出申請。 本發明之範疇 本發明乃關於供一半導體裝置用之封裝半導體裝置及方 法。特別關於晶片級封裝。 發明之背景 晶片級封裝(CSPs)為現代半導體封裝之主要興趣所在。 晶片級封裝係一種相當新的封裝技術,由此技術,半導體 晶粒結合在基質上,如塑膠或陶質基質,基質之大小約與 半導體晶粒大小相同,或者較半導體晶粒稍大。目前對晶 片級封裝之重視主要由於該封裝所提供之降低之足跡,其 可使電子裝置之最後裝配器得以在一固定空間併入最多半 導體裝置而改進其功能性。 依據現代科技,晶片級封裝相當昂貴並有許多可靠性問 題,主要是由於此種封裝之相當複雜性。此外,晶片級封 裝之可靠性與任何其他封裝之半導體裝置一樣,與模具之 尺寸成正比例。如半導體製造者併入更多功能於單一模具 中,模具尺寸之增加無法使科技降低模具之特性尺寸之降 低。當模具尺寸增加,在半導體晶粒及基質間之互連之可 靠度(即第一位準封裝互聯)成為令人懷疑之事。此外,當 封裝之半導體裝置之尺寸增加,(因而增加足跡尺寸),封 裝之半導體裝置及印刷電路板(即第二位準封裝互聯間之 互聯之可靠度成為令人關切之事°此一可靠度問題主要由
D:\Y87\55387.ptd 第5頁
於半導體 係數不同 在互聯上 晶粒之材料,基質及印刷電 之故’此種不同引起在溫度 W起應力。 路板枒料間之熱膨脹 改變及功率週期期間 晶圓Z: 封裝尺寸及保持可靠度問題之外’尚有曰增之 導體晶ίί裝之問題:…圓形式,在單-化之前將半 成本5 g 、。吾人認為晶圓位準封裝可改進可靠度及降低 成。作p降低必須以自動機器處理之個別組件之數目而達 褒,其利用傳統封裝技術之低成本方法以產生晶片級封 恥知'η可靠地將半導體晶粒及封裝基質間之熱膨脹不既 3匕解除,4 ’、 並可保證BGA (球柵陣列)可靠度尚未發展以達成 曰s圓位準封裝。 因f ’此技術中仍然需要改進之晶片級封裝,此種封裝 ’用標準裝配裝置可降低成本,可靠度高及可達成晶圓位 準封裝。 圖說之簡略說明 本發明之較佳了解可經由以下之詳細敘述及配合附圖而 達成,其中: 、 、圖1及2說明本發明之一具體實例,其中一模具與一基質 連接及以不滿之密封層填充; 圖3為本發明—具體實例之平面圖,其中許多模具係同 時封裝在一晶圓位準級上;及 圖4、5及6說明本發明另一旦體實例指出有關半導體晶 粒/基質尺寸之差異。 為了簡單及清楚地說明,圖中之元件並非與實際大小成
D:\Y87\55387.ptd 第6頁 ^2312〇
五、發明說明(3) 比例。例如’有些元件之尺寸已加時大以蛊 比 應 '、丹他元件料 以便清晰。此外’必要時元件參考號碼重複以 ’τ 或類比之元件。 胃出為對 如圖1所示,其中備有—半導體晶粒1 〇,包括— 分11及一中間位準電介質(ILD)層12位於主動部分主動部 其如此構造可使電路接觸墊1 4之形成於模具外周圍’ 近。吾人注意主動部分1 1包括一硅基質,其卜二 附 置以構成主動表面11a’主動表面11a由較高位進八s 裝 (未示出)互聯,此點在此技藝中已久所熟知,在此二 均了解,較高位準金屬層稱為Ml (金屬層丨)至料(金t中 6)。主動部分11之細節已為此技藝人士所了解,對二=層 之完全了解並非十分重要。再分布軌跡16連接至電路 墊1 4以路由内向方向電連接至半導體晶粒之中央部分。如 圖式,再分布軌跡1 6在下部沖擊金屬墊丨5處終止°。:如 鈍化層18沉積在UBM墊15之上,其圖案並留有開口於墊15 上,及焊接沖擊20在UBM墊1 5上分別形成。 依照上述之半導體晶粒1 〇,焊接沖擊2 〇與半導體晶粒】〇 之主動表面成電連接。如本技藝已知者,圖1中之半導體 晶粒被認為是“被沖擊”。被沖擊之模具為倒裝以便會主 動表面向下(如圖示)以便備隨後之接合至一基質。此種焊 接沖擊可根據已知之控制崩潰晶片連接(C4)技術形成,或 以他種沖擊技術形成(即型板印刷或焊接喷射應用)。此 外,切割衔102說明於模具外圍30,此切割將於圖3再予詳
五、發明說明(4) --- f。ILD層12可由任何適合之電介質材料形成,如二氧化 5 化硅,氮氧化硅及聚亞硫胺等。鈍化層1 8之提供係 保護,動表面之用,其形式可為一混合結構包括磷硅玻 璃,氮化硅,聚亞硫胺層等。此外,為澄清圖】中所用之 名稱:焊接沖擊20與UBM墊15組合稱為一電接點,形成於 半導晶粒之表面上。吾人了解此種電接點可為其他形成。 例如’烊接沖擊2 0可由其他金屬沖擊,如金線柱沖擊及無 電極鎳/鍍金沖擊’或導電之聚合物沖擊。電接點亦可為 未沖擊之金屬墊’該未沖擊之金屬墊與含有導電組件之聚 合物層’如鎳粉末或鍍金聚合物墊圈成層以熱固或熱塑薄 膜或膏狀消散其争。如此藝中已知,電連接係由在半導體 晶粒及基質之間加壓力而成以便保留一薄的導體組件層於 未沖擊金屬接觸墊及基質上結合之軌跡之間(即直接晶片 連接(DCA)接合墊)。此種聚合物村料通常稱為各向異性導 電膠合物。此種膠合物亦可與上述之金線柱沖擊及無電極 鎳/金沖擊及相似結構共用。 現在參考圖1及2中之基質50,其中之包括一絕緣層51之 結構最好形成於一有機聚合物上。但絕緣層5 1亦可在一絕 緣陶質材料之上,此點在本技藝中久為人知,以及一含有 絕緣薄膜之金屬層形成於反面表面上及經由通路延伸。根 據本發明之一具體實例,形成絕緣層5 1之有機聚合物可由 聚亞硫胺軟性電路,或纖維玻瑀強力之環氧層組成。有機 加強物如A R A ΜI D纖維亦可用來代替纖維玻璃成分。如圖1 所示’在絕緣層5 1之第一表面上(即頂表面)有許多直接晶
D:\Y87\55387. ptd 苐8頁 4-^3 12〇 五、發明說明(5) 片連接(DC A )結合墊5 2形成’此等墊分別與半導體晶粒i 〇 之焊接沖擊20對齊成一直線。備有一焊接罩53以防止不要 之3 4接塊2 0之物質流在棊質5 〇與半導體晶粒丨〇間連接時 =再流動步驟中出現。如圖式,許多以通路54方式或電鍍 通孔方式之電内聯將DCA接合墊5 2連接至備於基質第二 底表面上之球柵陣列(BGA)接合墊56。在BGA墊56上備有一 第二焊接罩57 ’其上形成球栅陣列(BGA)球58,通常由焊 接1料形成。參考號碼60說明基質之外圍表面。此處所用 之 基質’’一詞表示一機械組件,用來載負半導體晶粒及 其有(即支撐)電連接元件(此處為元件52,54,56及58)以 提供自半導體晶粒至次位準之内聯如經由—印刷電路板之 電連接。 現在參考圖2,其中顯示一完全封裝之半導體裝置1,其 中之基質50與半導體晶粒1〇連接。基質5〇置於半導體1〇之 上 在半導體晶粒1〇及基質之間有一不滿之密封層7〇。 不滿之密封層包括一平邊72,將基質所暴露之半導體晶粒 之主動表面及基質外圍表面60跨接。此平邊72由未滿之密 封層70之材料之濕潤行為沿基質外圍表面6〇而成。電連接 之實施可與不滿密封層7 〇形成之同時,或在未滿之密封層 7 0形成之前實施,由再流動實施°不滿密封層之材料通常 係由球狀熔硅顆料填充之環氧樹脂構成,再由一般技術凝 固(即加熱)β此不滿密封層70可由已知之技術沉積,如在 至少在模具之一邊緣沉積此種材料,再依靠毛細管作用以 使材料進入半導體晶粒1 0及基質5 0之間之介面。
D:\Y87\55387.ptd 第9頁 423120 五、發明說明(6) 此外,所有多個電接點(即焊接沖擊2〇及UBM墊1 5 )均位 於基質50之外周圍之内。本發明之特殊特點在絕緣所有自 封裝半導體裝置以外之環境上特別優異。此外,本發明亦 可使在半導體晶粒及基質間之以CSP而非周圍結合之陣列 結合。此外,本發明之陣列結合(與利用周圍結合之CSPs 相比較)可有較大之尺寸差異於半導體晶粒及基質之間。 在已知之CSPs中,基質之尺寸之降低會引起模‘具及基質間 之不尋常長度之結合引線。此種長結合引線較目前使用之 周圍結合塑CSPs缺少相當短結合引線之熱穩定性,並且易 於損壞。 在圖1及2中之具體實例中’ A 5 8係在連接在半導體晶 粒10之前備於基質50之上’吾人了解㈣A球58可在連接在 半導體晶粒1 〇之後以較佳之晶圓格式或在模具單獨化之後 再連接在基質5 0上。根據圖1及2中之一具體實例,焊接沖 擊?0用來在以不滿之密封材料填充後,實施基質50與半導 體晶粒1 0間之電連接。不滿密封可同時形成作為電連接。 在此具體實例中,形成不滿密封層7 0之材料在放置基質之 後首先沉積於半導體晶粒之上。在隨後之程序中,沖擊2 〇 及D C A接合墊5 2 (以再流動方式)間之電連接及不滿密封層 7 0之安裝於是完成(即由凝固)。再流動及凝固可同時進 行。 參考圖3 ’其中顯示以晶圓形式封裝許多半導體晶粒之 平面圖。如圖3所示,許多半導體晶粒(此實例中為丨3 )均 同時封裝。基質之X’及Y,尺寸及半導體晶粒之χ及¥尺寸彼
D:\Y87\55387. ptd 第〗0頁 -23120
此垂直。此圖式中 之X尺寸,及(ii)技(ί)基質之Χ,尺寸小於半導體晶粒 但根據本發明,—質之γ’尺寸小於半導體晶粒之Υ尺寸。 導體晶粒之)ί或γ尺或另一χ’ ’尺寸可使其小於對應之半 1 0 2單獨化期間,寸。在此具體實例中,在模具沿切割街 時切割而離開與其延紐伸超過模具1 0邊緣之基質邊緣將被同 及Υ,尺寸均較ϋ質之邊緣對齊之模具邊緣。但,最好χ, 如圖3所示,半卜導體/曰粒之⑴尺寸為小。 模具彼此分開。晶粒10〇有一切割街102,其將個別 圖㈤之虛線所=刻衝102之材料實質上已被除去 如 練f6顯不本發明之另-具體實例,與圖卜3中之具 體::相似。圖“中之半導體晶粒1〇為1〇 _平方,其有 T又為0.4 mm ’及有1〇〇個電接點。此基質之厚度為0.5 mm。雖然圖4-6實質上說明一相同之半導體晶粒丄〇,但有 三個不同之再分布計劃如所示者。 瓦先圖4中’顯示—進取之再分布計劃,其中有81個BGA 球5 8於一0 5 mm間距於5平方_基質上。圖5說明12〇個bga 球58安排在一7. 5平方mm之〇. 65 _間距上。最後,圖6說 明144個BGA球58安排在9·5平方·基質之080 mm間距間。 根據圖4,其中顯示一進取之再分布計劃,在基質5 〇上之 足跡最小化觀點上亦頗為優異。基質5 〇上之足跡最小化之 結果可使基質與連於其上之印刷電路板之間的連接可靠性 有大改進。如圖示,半導體晶粒丨〇之部分延伸超過及包圍 基質50並未造成BGA球與電路板限定之接點上之應力,該
D:\Y87\55387.ptd 第11頁 4 2 3 ’丨 2 Ο 五、發明說明(8) 應力係由於熱膨脹係數之不呸配而引起。延伸超過基質5 0 之邊緣之模具區域由圖3中所示之不滿密封層7〇之平邊72 所熱機械耦合至基質5 0。儘管此一優點’假定電路接點墊 在半導體晶粒1 0之外圍附近形成,如圖卜2之具體實例所 示,必須有一相當長之再分布網’其可能感應不理想之寄 生損失,亦可能在自半導體晶粒至基質之熱傳輸正有 不良景彡響。吾人應注意銷數目亦自1 〇 〇個電接點減為81個 電接點(模具與基質間)°此一降低之電接點數目係由使用 共同電源及接地平面’或基質中之平面片斷而達成Q 與圖1之進取性再分布計劃有關之設計上限制問題,較 高頻率及/或較高電源裝置需要較少之圖5及6中之進取性 再分布計劃。圖5及6提供數目增加之BGA球’其可改進電 性能及功率損耗。吾人注意所有具體實例均可與現代科括 之吸熱設備相容’如可連接在半導體晶粒10之無溽表面上 吸熱設備。 ' 如以上讨論者,非常明顯,本發明可提供一改進之-Λ>曰 片级封裝,其已根據現代科技提出數項需求。根據本^晶 明,不但在模具與基質間之互聯可靠性已獲得大幅改進, 基質與電路板間之互聯可靠性亦由於基質足跡之減少 舉提高◊關於此點,_真晶片級封裝不同,其中之基大 半導體晶雜之尺寸却同大小,本發明提供構成一不滿六〜 平片,其 < 將延伸超過基質邊緣之模具之區域覆蓋住/封 不會使基質之月斷在典型CSP中之此區域中與模具重疊’。而 此改進可顯杀出在基質與模具間’由於熱膨脹係赵 取 < 不匹
五、發明說明(9) 配而引起之應力降低。此外,與現代科技之次晶片級封裝 不同,本發明在製造上及實施上由於所揭示者之簡單結構 而合乎成本妹益。此外,因為基質尺寸已減小本發明提供 一方法可降低基質成本約%。尤有進者,本發明不需 要半導體製造者額外或更多設備費用,因為根據本發明之 原理,傳統之倒裝片封裝設備可以併入以構成封裝之半導 體裝置。本發明尚可作晶圓位準封裝’因此在—晶圓上之 所有半導體晶粒皆可同時封裝。 此外,本發明可在封裝期間提供增加之較高產量之輪 出。特別是與以往技藝不同,本發明之一具體實例之基質 係在單獨化為晶圓形式之前置於半導體晶粒上°由於半導 體晶粒在一晶圓上形成之精碟性,在晶圓上可形成高度準 確之基準,該晶圓與在其上之模具有確切之關係。一個適 切之圖像系統可偵出晶圓上之全面標準’因而可僅利用全 面標準即可提供極準破之基質放置於一錢別模具上。反 之’依照以在技藝’備有準備單獨化為許多基質之印刷電 路板’單獨化模具即連接其上^但,依照以往技藝,印刷 電路板係由相當低準確度全球標準而製成,其不能像本發 明一樣提供之晶圓之全球標準之對齊程度。由於视界系統 必須找出基質上之模具及本地標準。 吾人了解不同之改變均可實行而不致有悖本發明申請專 利範圍内之精神及範疇。例如,雖未示於圖式中,基質可 用單片方式,或數個多單元片斷方式連接一起,再與一全 晶圓重疊°順序之切割將可使基質'彼此分開。較偏愛使用
D:\Y87\55387.ptd 第13頁 423120 五、發明說明(ίο) 單基質係其可消除浪費及放置在先前測試之晶圓上基質之 成本。 1__1 D:\Y87\55387. ptd 第14頁

Claims (1)

  1. 4 23 12 0 ^ 索號^Ϊ87117327 巧年:?月^日 修正 _,、 六、申請專利範圍 1. 一種半導體裝置,包含: —半導體晶粒(10),具有一表面、外圍X及外圍Υ尺 寸,半導體晶粒之外圍X及外圍Υ尺寸係彼此垂直; 多個位於半導體晶粒表面上之電接點(2 0 ); —封裝基質(5 0 ),重疊於半導體晶粒且與多個電接 點電氣連接; 其中:封裝基質具有彼此垂直之外圍X’及外圍Υ’尺 寸,至少符合下列二個條件之一(i )封裝基質之外圍X ’尺 寸小於半導體晶粒之外圍X尺寸,及(i i )封裝基質之外圍 Y ’尺寸小於半導體晶粒之外圍Y尺寸,及多個電接點係位 於封裝基質之外圍X尺寸及外圍Y尺寸之内。 2. 如申請專利範圍第1項之半導體裝置,尚包含一未充 滿之密封層(7 0 )位於半導體晶粒與基質之間。 3. 如申請專利範圍第2項之半導體裝置,其中之基質有 —外圍表面,及未充滿之密封層形成一平板圓角(7 2)沿基 質之外圍表面延伸。 4. 如申請專利範圍第1項之半導體裝置,其中半導體晶 粒尚包含許多安排在外圍附近之電接點及許多再分布執跡 自許多電路接點墊延伸至半導體晶粒之中央部分。 5. —種半導體裝置,包含: 一半導體晶粒,具有一表面、X及Y尺寸,半導體晶 粒之X、Y尺寸係彼此垂直; 多個位於半導體晶粒表面上電接點:及 一基質,於一第一外表面之導電部份與一第二外表 面之導電部份之間具有許多電氣連接,第一外表面位於第
    O:\55\55387.ptc 第1頁 2000.03. 28.015 ^ ^ Θ案號87117327_年j月^曰 修正_1_ 六、申請專利範圍 二外表面及半導體晶粒之表面之間且靠近第二外表面,其 中多個基質電氣連接之一係電氣連接至位於半導體晶粒表 面上多個電接點之至少一接點,其中基質之第一外表面有 彼此垂直之X’及Y’尺寸,且至少符合下列二個條件之一 (i)第一外表面基質之X’尺寸係小於半導體晶粒之X尺寸, 且(i i)第一外表面基質之Y’尺寸係小於半導體晶粒之Y尺 寸,此外,基質有一外周圍,且多個電接點係位於基質之 外周圍内。 6. 如申請專利範圍第5項之半導體裝置,其中許多電接 點位於該基質之外周圍之内。 7. 如申請專利範圍第5項之半導體裝置,尚包括一不滿 之密封層位於該基質及該半導體晶粒之間。 8. —種半導體裝置,包含: 沿著垂直於裝置表面之一第一線之第一截面成分, 及一沿著垂直於裝置表面之一第二線之第二載面成分; 自第一表面至第二表面,第一截面成分包含以下各 層: 一第一導電墊; 一絕緣層: 一密封層材料;及 一半導體晶粒;以及 自第一表面至第二表面,第二截面成分包含以下各 層: 形成第一表面之一部分之密封層材料:及 緊靠於密封層材料之半導體晶粒。
    O:\55\55387.ptc 第2頁 2000.03.28. 016
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US6064114A (en) 2000-05-16
JPH11233687A (ja) 1999-08-27
US6294405B1 (en) 2001-09-25
KR100572813B1 (ko) 2006-09-11
KR19990062634A (ko) 1999-07-26
CN1147928C (zh) 2004-04-28
MY123187A (en) 2006-05-31
JP4343296B2 (ja) 2009-10-14
HK1019819A1 (en) 2000-02-25
CN1219763A (zh) 1999-06-16

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