TWI517322B - 半導體元件及其製作方法 - Google Patents

半導體元件及其製作方法 Download PDF

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Publication number
TWI517322B
TWI517322B TW104105448A TW104105448A TWI517322B TW I517322 B TWI517322 B TW I517322B TW 104105448 A TW104105448 A TW 104105448A TW 104105448 A TW104105448 A TW 104105448A TW I517322 B TWI517322 B TW I517322B
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Taiwan
Prior art keywords
interposer
wafer
heat sink
substrate
contact pads
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TW104105448A
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English (en)
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TW201533869A (zh
Inventor
文強 林
王家忠
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鈺橋半導體股份有限公司
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Publication of TW201533869A publication Critical patent/TW201533869A/zh
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Publication of TWI517322B publication Critical patent/TWI517322B/zh

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Description

半導體元件及其製作方法
本發明是關於一種半導體元件及其製作方法，尤指一種將晶片嵌埋於散熱件中且電性連接至中介層之半導體元件及其製作方法。
為了整合行動、通訊以及運算功能，半導體封裝產業面臨極大的散熱、電性以及可靠度挑戰。儘管在文獻中已報導許多將半導體晶片嵌埋於電路板或模製化合物中之技術，但該些技術仍然存在許多製造與性能不足的問題。舉例來說，美國專利案號No.8,742,589、8,735,222、8,679,963及8,453,323中所揭露之半導體元件，其係將半導體晶片嵌埋於層壓材或模製化合物中，並使用微盲孔作為嵌埋晶片之電性連接。然而，因為該些技術中嵌埋晶片所產生之熱無法藉由熱絕緣材料(例如層壓材或模製化合物)適當地散逸，因此導致元件性能衰減之問題。此外，隨著晶片製造技術的進步，晶片之接觸墊數目持續地增加，造成接觸墊之間隔(間距)減小。因此，使用微盲孔之技術會因為微盲孔彼此非常靠近，而導致相鄰微盲孔短路。
上述元件之製作會造成另一嚴重之缺點是在封膠或層壓製程中，會造成嵌埋晶片之位移。如美國專利案號No.8,501,544中描述之晶片位移會造成微盲孔未完全金屬化之問題，其將導致電性連接品質變差，因 此降低元件之可靠度及生產良率。
為了上述理由及以下所述之其他理由，目前亟需發展一種用 於互連嵌埋晶片之新裝置與方法，其無須於I/O墊上形成微盲孔，以改善晶片級之可靠度，並且不使用熱絕緣材料(例如模製化合物或樹脂層壓材)封膠晶片，以避免元件可靠度及電性表現因晶片過熱而出現問題。
本發明之主要目的係提供一種半導體元件，其係藉由複數個 凸塊，將晶片接置於中介層，以形成晶片-中介層堆疊次組體，藉此避免於晶片I/O墊上直接進行雷射或光顯像製程，進而改善半導體元件之生產良率及可靠度。
本發明之另一目的係提供一種半導體元件，其中中介層係對 於接置其上之晶片提供扇出路由。因為晶片係電性連接至中介層之一側，以藉由該中介層扇出，因此增層電路可連接至中介層具有較大接觸墊間距之另一側，藉以解決晶片I/O墊間彼此過於靠近之問題，進而改善半導體元件之生產良率及可靠度。
本發明之再一目的係提供一種半導體元件，其中晶片係封置 於散熱件之凹穴中，以有效地散逸晶片產生之熱，藉以改善半導體元件之信號完整性及電性表現。
依據上述及其他目的，本發明提出一種半導體元件，其包括 晶片、中介層、散熱件、封膠層、以及增層電路。中介層係藉由複數凸塊互連至晶片，並提供晶片之初級扇出路由，以避免因為過小I/O墊間距所可能導致的未連接接觸墊之問題。具有凹穴之散熱件係藉由導熱材料與晶片 熱性導通，俾使位於凹穴中之晶片得以散熱。增層電路係鄰接封膠層及中介層，並電性連接至中介層，以提供晶片之第二級扇出路由，並且具有與下一級組體電路板匹配之終端墊圖案陣列。
在本發明之另一實施態樣中，本發明提供一種半導體元件之 製作方法，其包括以下步驟：提供一晶片；提供一中介層半成品，其包含具有相對第一表面及第二表面之一基板、於該基板之第一表面上之複數個接觸墊、以及複數個金屬化導孔，其中每一金屬化導孔係形成於該基板中，並且具有電性耦接至該些接觸墊之一第一端、以及與該基板之第二表面保持距離之一相對第二端；藉由複數個凸塊，將該晶片電性耦接至該中介層半成品之該些接觸墊，以形成一晶片-中介層堆疊次組體；提供一散熱件，其具有相對之第一表面及第二表面、以及形成於該第二表面之一凹穴；使用一導熱材料，將該晶片-中介層堆疊次組體貼附至該散熱件，並使該晶片插入該凹穴中，且該中介層半成品側向延伸於該凹穴外；提供一封膠層，以覆蓋該散熱件之第二表面及該中介層半成品；移除部分該封膠層及部分該中介層半成品，以顯露該些金屬化導孔之該些第二端，並使該基板具有與該些金屬化導孔之該些第二端實質上共平面之一外露第二表面；於該基板之該外露第二表面上形成複數路由線路，以製作完成一中介層，其中該中介層包括分別位於其相對第一表面及第二表面上之該些接觸墊及該些路由線路、以及電性耦接至該些接觸墊及該些路由線路之該些金屬化導孔；以及於該封膠層及該中介層之該第二表面及該些路由線路上形成一增層電路，其中該增層電路係藉由該增層電路之複數導電盲孔電性耦接至該中介層之該些路由線路。
除非特別描述或必須依序發生之步驟，上述步驟之順序並無 限制於以上所列，且可根據所需設計而變化或重新安排。
在本發明之再一實施態樣中，本發明提供一種半導體元件， 其包括：一晶片、一中介層、一散熱件、一封膠層、及一增層電路，其中(i)該中介層具有一第一表面、與該第一表面相對之一第二表面、於該第一表面上之複數接觸墊，於該第二表面上之複數路由線路、以及電性耦接該些接觸墊與該些路由線路之複數個金屬化導孔；(ii)該晶片係藉由複數個凸塊電性耦接至該中介層之該些接觸墊，以形成一晶片-中介層堆疊次組體；(iii)該散熱件具有一第一表面、相對之一第二表面、以及形成於該第二表面之一凹穴；(iv)該晶片-中介層堆疊次組體係藉由一導熱材料貼附至該散熱件，並且該晶片係插入該凹穴中，且該中介層係側向延伸於該凹穴外；(v)該封膠層覆蓋該中介層之側壁及該散熱件之第二表面；以及(vi)該增層電路係形成於該封膠層及該中介層之第二表面及該些路由線路上，並且藉由該增層電路之複數個導電盲孔電性耦接至該中介層之該些路由線路。
本發明之半導體元件製作方法具有許多優點。舉例來說，先 形成晶片-中介層堆疊次組體後，再貼附至散熱件，其可確保晶片之電性連接，因此可避免於微盲孔製程中會遭遇的未連接接觸墊問題。使用中介層半成品以互連晶片，則無須於中介層整合於2.5D基板前，先在中介層中製作金屬化穿孔，藉此得以解決穿孔之金屬沉積問題，並改善生產良率。此外，由於該製程係於提供封膠層及散熱件以支撐中介層後，才對中介層進行研磨，故此作法可對研磨後之中介層提供足夠的機械剛性。再者，以兩步驟形成連線於晶片之互連基板是具有益處的，其原因在於，中介層可提 供初級扇出路由，而增層電路則可提供上元件與下元件間的進一步扇出路由及水平互連。
本發明之上述及其他特徵與優點可藉由下述較佳實施例之 詳細敘述更加清楚明瞭。
10‧‧‧晶片-中介層堆疊次組體
11‧‧‧中介層面板半成品
11’‧‧‧中介層半成品
12‧‧‧中介層
13‧‧‧晶片
15‧‧‧凸塊
16‧‧‧底部填充材料
18‧‧‧封膠層
20‧‧‧散熱件
100、200‧‧‧半導體元件
101、201‧‧‧第一表面
102‧‧‧第一端
103、103’、203‧‧‧第二表面
104‧‧‧第二端
105、313、314‧‧‧盲孔
111‧‧‧基板
113‧‧‧金屬化導孔
115‧‧‧接觸墊
117‧‧‧路由線路
131‧‧‧主動面
133‧‧‧非主動面
135‧‧‧I/O墊
171‧‧‧導熱材料
173‧‧‧黏著劑
205‧‧‧凹穴
301‧‧‧增層電路
311‧‧‧絕緣層
315‧‧‧導線
317、318‧‧‧導電盲孔
L‧‧‧切割線
參考隨附圖式，本發明可藉由下述較佳實施例之詳細敘述更加清楚明瞭，其中：圖1及2分別為本發明之一實施態樣中，具有盲孔之基板剖視圖及頂部立體視圖；圖3為本發明之一實施態樣中，圖1之結構形成金屬化導孔後之剖視圖；圖4及5分別為本發明之一實施態樣中，圖3之結構形成路由線路以完成中介層面板半成品之剖視圖及頂部立體視圖；圖6為本發明之一實施態樣中，將凸塊設置於晶片上之剖視圖；圖7及8分別為本發明之一實施態樣中，圖6之晶片電性耦接至圖4及5中介層面板半成品之面板組體剖視圖及頂部立體視圖；圖9及10分別為本發明之一實施態樣中，圖7及8之面板組體切割後之剖視圖及頂部立體視圖；圖11及12分別為本發明之一實施態樣中，散熱件之剖視圖及頂部立體視圖；圖13及14分別為本發明之一實施態樣中，將圖9及10之切割後的晶片-中介層堆疊次組體貼附至圖11及12散熱件之剖視圖及頂部立體視圖；圖15為本發明之一實施態樣中，圖9及10之切割後的晶片-中介層堆疊次 組體貼附至圖11及12散熱件之另一態樣剖視圖；圖16為本發明之一實施態樣中，於圖15結構中提供另一黏著劑之剖視圖；圖17為本發明之一實施態樣中，形成封膠層於圖13結構上之剖視圖；圖18為本發明之一實施態樣中，移除部分圖17結構之剖視圖；圖19及20分別為本發明之一實施態樣中，形成路由線路於圖18結構上之剖視圖及頂部立體視圖；圖21為本發明之一實施態樣中，形成介電層於圖19結構上之剖視圖；圖22為本發明之一實施態樣中，於圖21之結構形成盲孔之剖視圖；圖23為本發明之一實施態樣中，形成導線於圖22結構上之剖視圖；圖24為本發明之一實施態樣中，將圖23之結構切割後之剖視圖；圖25為本發明之一實施態樣中，圖24之結構切割後之單件剖視圖；以及圖26為本發明之一實施態樣中，另一半導體元件之剖視圖。
在下文中，將提供一實施例以詳細說明本發明之實施態樣。本發明之優點以及功效將藉由本發明所揭露之內容而更為顯著。在此說明所附之圖式係簡化過且做為例示用。圖式中所示之元件數量、形狀及尺寸可依據實際情況而進行修改，且元件的配置可能更為複雜。本發明中也可進行其他方面之實踐或應用，且不偏離本發明所定義之精神及範疇之條件下，可進行各種變化以及調整。
圖1-25為本發明一實施態樣中，一種半導體元件之製作方法 圖，其中該半導體元件包括一中介層、一晶片、一散熱件、一封膠層、以及一增層電路。
如圖25所示，半導體元件100包括中介層12、晶片13、散熱 件20、封膠層18、以及增層電路301。中介層12及晶片13係藉由導熱材料171而貼附至散熱件20，且晶片13係置放於散熱件20之凹穴205中。封膠層18側向覆蓋且圍繞中介層12之側壁，並且自中介層12側向延伸至結構之外圍邊緣。增層電路301由上方覆蓋中介層12及封膠層18，並且藉由導電盲孔317電性耦接至中介層12之路由線路117。
圖1、3-4、6-7、及9為本發明一實施態樣之晶片-中介層堆疊 次組體製程剖視圖，圖2、5、8、及10分別為對應圖1、4、7、及9之頂部立體視圖。
圖1及2分別為基板111之剖視圖及頂部立體視圖，其包括第 一表面101、相對之第二表面103、以及形成於第一表面101之盲孔105。基板111可由矽、玻璃、陶瓷、石墨、或樹脂製成，並且具有50微米至500微米之厚度。盲孔105具有25微米至250微米之深度。在本實施態樣中，基板111為矽製成並且具有200微米之厚度，盲孔105則具有150微米之深度。
圖3為形成金屬化導孔113後之剖視圖。藉由沉積金屬於盲孔 105中，以於基板111中形成金屬化導孔113。每一金屬化導孔113具有與基板111之第一表面101實質上共平面之第一端102，以及與基板111之第二表面103保持距離之相對第二端104。於矽或石墨基板之態樣中，因為矽為半導體材料，而石墨為導電材料，因此在沉積金屬前，盲孔105之側壁需形成例如氧化矽層之絕緣/保護層(圖未繪示)。
圖4及5分別為中介層面板半成品11之剖視及頂部立體視 圖，其基板111之第一表面101上具有接觸墊115。基板111之第一表面101可藉由各種技術進行金屬化，例如電鍍、無電電鍍、蒸鍍、濺鍍、或其組合。 一旦達到所須之厚度後，施行金屬圖案化製程以形成電性耦接至金屬化導孔113第一端102之接觸墊115。同樣地，於使用矽或石墨基板時，在形成接觸墊前須先形成絕緣/保護層(圖未繪示)於基板表面上。
圖6為凸塊15設置於晶片13上之剖視圖。晶片13包括主動面 131、與主動面131相對之非主動面133、以及位於主動面131上之I/O墊135。 凸塊15係設置於晶片13之I/O墊135上，並且可為錫凸柱、金凸柱、或銅凸柱。
圖7及8分別為面板組體(panel-scale assembly)之剖視圖及頂 部立體視圖，其係將晶片13電性耦接至中介層面板半成品11。藉由熱壓、迴焊、或熱超音波接合技術，可將晶片13藉由凸塊15電性耦接至中介層面板半成品11之接觸墊115。或者，可先沉積凸塊15於中介層面板半成品11之接觸墊115上，然後晶片13再藉由凸塊15電性耦接至中介層面板半成品11。 此外，可選擇性地進一步提供底部填充材料16，以填充中介層面板半成品11與晶片13間之間隙。
圖9及10分別為面板組體切割成個別單件之剖視圖及頂部立 體視圖。面板組體沿著切割線“L”被單離成個別的晶片-中介層堆疊次組體(chip-on-interposer subassembly)10。因此，每一晶片-中介層堆疊次組體10包含自中介層面板半成品11單離出的中介層半成品11’。
圖11及12分別為散熱件20之剖視圖及頂部立體視圖，其具有 第一表面201、相對之第二表面203、以及凹穴205。散熱件20之厚度可為0.1 毫米至10毫米，並且可由銅、鋁、不銹鋼、或其他合金所製成。凹穴205於第二表面203處設有一入口，並且每一凹穴205可具有不同尺寸及凹穴深度。凹穴深度之範圍可為0.05毫米至1.0毫米。在此實施態樣中，散熱件20為厚度2毫米之銅板，並且具有0.21毫米深度之凹穴205(以容置0.15毫米晶片及0.05毫米導電凸塊)。
圖13及14分別為晶片-中介層堆疊次組體10藉由導熱材料 171貼附至散熱件20之剖視圖及頂部立體視圖。晶片13位於凹穴205中，中介層半成品11’位於凹穴205外，同時基板111之第一表面101貼附至散熱件20之第二表面203上。藉由塗佈導熱材料171於凹穴底部上，然後將晶片-中介層堆疊次組體10之晶片13插入凹穴205中，以將晶片13貼附至散熱件20。凹穴205中之導熱材料171(通常為導熱但不導電之黏著劑)受到晶片13擠壓，向上流入晶片13與凹穴側壁之間隙中，並且溢流至散熱件20之第二表面203上。因此，導熱材料171圍繞嵌埋之晶片13，且擠出之部分接觸中介層半成品11’之第一表面101及散熱件20之第二表面203，並夾置於中介層半成品11’之第一表面101與散熱件20之第二表面203間。
圖15及16為晶片-中介層堆疊次組體10貼附至散熱件20之另 一製程剖視圖。
圖15為藉由塗佈於凹穴205底部之導熱材料171，將晶片-中 介層堆疊次組體10貼附至散熱件20之剖視圖。導熱材料171通常為導熱黏著劑，並提供晶片13及散熱件20間之機械性接合。
圖16為黏著劑173填充至中介層半成品11’與散熱件20之 間，並進一步延伸進入凹穴205中之剖視圖。黏著劑173通常為電性絕緣之 底部填充材料，其塗佈於中介層半成品11’與散熱件20之間，且填入凹穴205之剩餘空間中。因此，導熱材料171提供晶片13及散熱件20間之機械性接合及熱性連接，而黏著劑173則提供晶片13與散熱件20間、以及中介層半成品11’與散熱件20間之機械性接合。
圖17為封膠層18形成於晶片-中介層堆疊次組體10及散熱件 20上之剖視圖。封膠層18可藉由模製、樹脂塗佈、或樹脂層壓形成，並且由上方覆蓋晶片-中介層堆疊次組體10及散熱件20。
圖18為金屬化導孔113之第二端104自上方顯露之剖視圖。移 除封膠層18及基板111之頂部區域，以使金屬化導孔113之第二端104顯露於基板111之外露第二表面103’，其中移除方式通常係藉由拋光、研磨或雷射技術。基板111之外露第二表面103’與金屬化導孔113之第二端104及封膠層18之頂部表面實質上共平面。
圖19及20分別為藉由金屬沉積及圖案化製程形成路由線路 117之剖視圖及頂部立體視圖。基板111之第二表面103’可藉由各種技術進行金屬化，例如電鍍、無電電鍍、蒸鍍、濺鍍、或其組合。一旦達到所須之厚度後，施行金屬圖案化製程以形成路由線路117。路由線路117側向延伸於基板111之第二表面103’上，並且電性耦接至金屬化導孔113之第二端104。金屬圖案化技術包括濕蝕刻、電化學蝕刻、雷射輔助蝕刻及其組合，並使用蝕刻光罩(圖未示)，以定義出路由線路117。
進行至此階段，每一晶片-中介層堆疊次組體10包括一製作 完成之中介層12，其具有位於第一表面101上之接觸墊115、第二表面103’上之路由線路117、以及電性耦接接觸墊115及路由線路117之金屬化導孔 113。因為中介層12之路由線路117的墊尺寸及間隔較晶片I/O墊135大，因此中介層12可提供晶片13之初級扇出路由，以確保下一級增層電路互連具有較高之生產良率。
圖21為絕緣層311形成於封膠層18及中介層12之第二表面 103’及路由線路117上之剖視圖，其形成方法通常係藉由層壓或塗佈。絕緣層311自上方接觸且覆蓋封膠層18及中介層12之第二表面103’及路由線路117，並側向延伸於中介層12之第二表面103’及封膠層18上，且通常具有50微米之厚度。絕緣層311可由環氧樹脂、玻璃環氧樹脂、聚醯亞胺、或其類似物所製成。
圖22為形成盲孔313之剖視圖。盲孔313延伸穿過絕緣層311 並對準路由線路117之選定部分。盲孔313可藉由各種技術形成，其包括雷射鑽孔、電漿蝕刻、及微影技術，且通常具有50微米之直徑。可使用脈衝雷射提高雷射鑽孔效能。或者，可使用金屬光罩以及雷射光束。
參照圖23，藉由金屬沉積及圖案化製程，於絕緣層311上形 成導線315。導線315自中介層12之路由線路117朝向上方向延伸，並填滿盲孔313，以形成直接接觸中介層12之路由線路117的導電盲孔317，同時側向延伸於絕緣層311上。因此，導線315可提供X及Y方向的水平信號路由以及穿過盲孔313的垂直路由，以作為中介層12的信號連接。
導線315可藉由各種技術形成單層或多層，例如電鍍、無電 電鍍、蒸鍍、濺鍍、或其組合。舉例來說，首先藉由將該結構浸入活化劑溶液中，使絕緣層311與無電鍍銅產生觸媒反應，接著以無電電鍍方式被覆一薄銅層做為晶種層，然後以電鍍方式將所需厚度之第二銅層形成於晶種 層上。或者，於晶種層上沉積電鍍銅層前，該晶種層可藉由濺鍍方式形成如鈦/銅之晶種層薄膜。一旦達到所需之厚度，即可使用各種技術圖案化被覆層以形成導線315，其包括濕蝕刻、電化學蝕刻、雷射輔助蝕刻及其組合，並使用蝕刻光罩(圖未示)，以定義出導線315。
圖24為圖23之結構切割成個別單件之剖視圖。圖23之結構沿 著切割線“L”被單離成個別的半導體元件100。
圖25為個別的半導體元件100之剖視圖。半導體元件100包括 中介層12、晶片13、封膠層18、散熱件20、以及增層電路301。在此圖中，增層電路301包括絕緣層311及導線315。晶片13係藉由覆晶製程電性耦接至中介層12，並置放於散熱件20之凹穴205中，並藉由導熱材料171將晶片13貼附並導熱至散熱件20。中介層12側向延伸於散熱件20之凹穴205外，並且藉由中介層12第一表面101與散熱件20第二表面203間之導熱材料171擠出部分，將中介層12貼附至散熱件20。封膠層18側向覆蓋、圍繞及共形塗佈於中介層12之側壁，並且與基板111之第二表面103’實質上共平面。藉由與中介層12之路由線路117直接接觸之導電盲孔317，增層電路301電性耦接至中介層12，因此中介層12與增層電路301間的電性連接無須用到焊接材料。
圖26為另一態樣之半導體元件200剖視圖。半導體元件200 與上述之半導體元件100類似，惟差異處僅在於，半導體元件200之增層電路301更包含與散熱件20之選定部分接觸的額外導電盲孔318。導線315自中介層12之路由線路117及散熱件20之選定部分朝向上方向延伸，並填滿盲孔313、314，以形成導電盲孔317、318，同時側向延伸於絕緣層311上。據此，增層電路301可藉由與中介層12之路由線路117直接接觸之導電盲孔317而 電性耦接至中介層12之路由線路117，並可藉由與散熱件20直接接觸之額外導電盲孔318而電性耦接至散熱件20。
上述之半導體元件僅為說明範例，本發明尚可透過其他多種 實施例實現。此外，上述實施例可基於設計及可靠度之考量，彼此混合搭配使用或與其他實施例混合搭配使用。晶片可獨自使用一凹穴，或與其他晶片共用一凹穴。舉例來說，一凹穴可容納單一晶片，且散熱件可包括多個排列成陣列形狀之凹穴，以容納多個晶片。或者，單一凹穴內能放置數個晶片。同樣地，晶片可獨自使用一中介層，或與其他晶片共用一中介層。 舉例來說，可將單一晶片電性耦接至一中介層。或者，將數個晶片耦接至同一中介層。舉例來說，可將四枚排列成2x2陣列之小型晶片耦接至一中介層，並且該中介層可包括額外的接觸墊，以接收額外元件墊，並提供額外元件墊之路由。此外，增層電路亦可包括額外的導線，以連接該中介層之額外的接觸墊。
如上述實施態樣所示，本發明建構出一種半導體元件，其可 展現較佳之散熱性能及可靠度，並且包括晶片、中介層、散熱件、封膠層、及增層電路。
晶片係藉由複數凸塊電性耦接至中介層，以形成晶片-中介 層堆疊次組體。晶片可為已封裝或未封裝之晶片。舉例來說，晶片可為裸晶，或是晶圓級封裝晶片等。
散熱件可延伸至半導體元件之外圍邊緣，以提供晶片、中介 層、以及增層電路之機械性支撐。在一較佳實施態樣中，散熱件包括金屬板及延伸至金屬板中之凹穴。金屬板可提供嵌埋晶片之必要散熱，且具有 0.1毫米至10毫米之厚度。可依據散熱考量來選擇金屬板之材料，並且金屬板之材料可包括銅、鋁、不銹鋼、或其他合金。據此，晶片所產生之熱可藉由提供熱接觸表面之金屬板散逸。
散熱件之凹穴可在其入口處具有較其底部更大之直徑或尺 寸，並且具有0.05毫米至1.0毫米之深度。舉例來說，凹穴可具有橫切之圓錐或方錐形狀，其直徑或大小係自底部向入口遞增。或者，凹穴可為具有固定直徑之圓柱形狀。凹穴亦可在其入口及底部具有圓形、正方形或矩形之周緣。
晶片-中介層堆疊次組體可藉由導熱材料(例如導熱黏著劑) 貼附至散熱件，其中導熱材料先塗佈於凹穴底部上，然後當晶片插入散熱件之凹穴中時，部分導熱材料擠出凹穴外。因此，導熱材料可接觸並圍繞散熱件凹穴中之嵌埋晶片。導熱材料之擠出部分可接觸中介層之第一表面及自凹穴入口側向延伸之散熱件第二表面，並夾置於中介層之第一表面及自凹穴入口側向延伸之散熱件第二表面間。或者，導熱材料(例如導熱黏著劑)可塗佈於凹穴底部，且當晶片插入凹穴中時，導熱材料仍位於凹穴中。 然後可將第二黏著劑(通常為電性絕緣之底部填充材料)塗佈並填入凹穴之剩餘空間中，並延伸至中介層之第一表面及自凹穴入口側向延伸之散熱件第二表面間。據此，導熱材料提供晶片與散熱件間之機械性接合及熱性連接，而第二黏著劑則提供中介層與散熱件間之機械性接合。
中介層係側向延伸於凹穴外，並可經由將中介層之第一表面 貼附至散熱件之第二表面的方式，使中介層貼附至散熱件。中介層可由矽、玻璃、陶瓷、石墨或樹脂材料製成，並且當中介層電性耦接至晶片及貼附 至散熱件時，中介層為半成品。在一較佳實施態樣中，中介層半成品包括厚度50至500微米之基板、深度25至250微米之金屬化導孔、以及匹配晶片I/O墊之接觸墊。在進行中介層背面研磨製程及形成中介層背面電路後，中介層可包含由第一表面較細微間距扇出至第二表面較粗間距之導線圖案。據此，中介層能提供晶片之第一級扇出路由/互連。此外，因為中介層通常係由高彈性係數材料製成，且該高彈性係數材料具有與晶片近似之熱膨脹係數(例如，每攝氏3至10ppm)，因此，可大幅降低或補償熱膨脹係數不匹配所導致之晶片及其電性互連處之內部應力。為了方便下文描述，中介層之第一表面所面對的方向定義為第一垂直方向，中介層之第二表面所面對的方向定義為第二垂直方向。
在貼附晶片-中介層堆疊次組體後，可藉由模製、樹脂塗佈、 或樹脂層壓，於中介層及散熱件上形成封膠層，然後再移除部分封膠層(通常藉由拋光、研磨或雷射技術)，以使封膠層與中介層基板之外露第二表面實質上共平面。因此，封膠層可自第二垂直方向覆蓋並接觸散熱件之第二表面，並且側向覆蓋、圍繞及共形塗佈於中介層之側壁，同時自中介層側向延伸至元件之外圍邊緣。
增層電路係由第二垂直方向覆蓋封膠層及中介層之第二表 面及路由線路，並且可提供第二級扇出路由/互連。此外，增層電路可進一步藉由額外導電盲孔電性耦接至散熱件之金屬第二表面，以作為接地連接用。增層電路包括絕緣層、以及一或複數導線。絕緣層形成於封膠層及中介層之第二表面及路由線路上。導線側向延伸於絕緣層上，並且延伸穿過絕緣層中之盲孔，以形成與中介層之接觸墊直接接觸之導電盲孔，並且其 可選擇性地與散熱件直接接觸。據此，導線可直接接觸接觸墊，以提供中介層之信號路由，因此中介層與增層電路間之電性連接無須使用焊接材料。假如需要更多的信號路由，增層電路可進一步包括額外之絕緣層、額外之盲孔、以及額外之導線。增層電路之最外側導線可容置導電接點，例如焊球，以與下一級組體或另一電子元件(如半導體晶片、塑膠封裝件、或另一半導體元件)電性傳輸及機械性連接。
「覆蓋」一詞意指於垂直及/或側面方向上不完全以及完全 覆蓋。例如，在凹穴向下之狀態下，散熱件則於上方覆蓋晶片，不論另一元件例如導熱材料是否位於散熱件及晶片間，同時增層電路於下方覆蓋散熱件，不論兩者間是否具有其他元件。
「電性連接」、以及「電性耦接」之詞意指直接或間接電性 連接。例如，導線直接接觸並且電性連接至中介層之路由線路，以及導線與中介層之接觸墊保持距離，並且藉由路由線路及金屬化黨導孔電性連接至中介層之接觸墊。
「第一垂直方向」及「第二垂直方向」並非取決於元件之定 向，凡熟悉此項技藝之人士即可輕易瞭解其實際所指之方向。例如，中介層之第一表面係面朝第一垂直方向，且中介層之第二表面係面朝第二垂直方向，此與元件是否倒置無關。因此，該第一及第二垂直方向係彼此相反且垂直於側面方向。再者，在凹穴向下之狀態，第一垂直方向係為向上方向，第二垂直方向係為向下方向；在凹穴向上之狀態，第一垂直方向係為向下方向，第二垂直方向係為向上方向。
本發明之半導體元件具有許多優點。舉例來說，藉由習知之 覆晶接合製程(例如熱壓或迴焊)，將晶片電性耦接至中介層，其可避免多數習知技術使用黏著載體作為暫時接合時所遭遇到的位置準確度問題。中介層提供晶片之第一級扇出路由/互連，而增層電路則提供第二級扇出路由/互連。由於增層電路形成於具有較大墊尺寸及間距之中介層上，與傳統之增層電路直接形成在晶片之I/O墊上，並且不具扇出路由之技術相比，前者具有較後者大幅改善之生產良率。散熱件可提供嵌埋晶片之散熱、電磁屏蔽、及濕氣阻障，並且提供晶片、中介層、以及增層電路之機械性支撐。 中介層與增層電路間係直接電性連接，而未使用焊料，因此有利於展現高I/O值以及高性能。藉由此方法製備成的元件係為可靠度高、價格低廉、且非常適合大量製造生產。
本案之製作方法具有高度適用性，且係以獨特、進步之方式 結合運用各種成熟之電性及機械性連接技術。此外，本案之製作方法不需昂貴工具即可實施。因此，相較於傳統技術，此製作方法可大幅提升產量、良率、效能與成本效益。
在此所述之實施例係為例示之用，其中該些實施例可能會簡 化或省略本技術領域已熟知之元件或步驟，以免模糊本發明之特點。同樣地，為使圖式清晰，圖式亦可能省略重覆或非必要之元件及元件符號。
12‧‧‧中介層
13‧‧‧晶片
18‧‧‧封膠層
20‧‧‧散熱件
100‧‧‧半導體元件
111‧‧‧基板
117‧‧‧路由線路
171‧‧‧導熱材料
205‧‧‧凹穴
301‧‧‧增層電路
311‧‧‧絕緣層
313‧‧‧盲孔
315‧‧‧導線
317‧‧‧導電盲孔

Claims (4)

  1. 一種半導體元件之製作方法，包含以下步驟：提供一晶片；提供一中介層半成品，其包含具有一第一表面及一相對第二表面之一基板、於該基板之該第一表面上之複數個接觸墊、以及複數個金屬化導孔，其中每一該些金屬化導孔係形成於該基板中，並且具有電性耦接至該些接觸墊之一第一端、以及與該基板之該第二表面保持距離的一相對第二端；藉由複數個凸塊電性耦接該晶片至該中介層半成品之該些接觸墊，以形成一晶片-中介層堆疊次組體；提供一散熱件，其具有相對之一第一表面及一第二表面、以及形成於該第二表面之一凹穴；使用一導熱材料貼附該晶片-中介層堆疊次組體至該散熱件，並使該晶片插入該凹穴中，且該中介層半成品側向延伸於該凹穴外；提供一封膠層，以覆蓋該散熱件之該第二表面及該中介層半成品；移除部分該封膠層及部分該中介層半成品，以顯露該些金屬化導孔之該些第二端，並使該基板具有與該些金屬化導孔之該些第二端實質上共平面之一外露第二表面；於該基板之該外露第二表面上形成複數路由線路，以製作完成一中介層，其中該中介層包括分別位於其相對第一表面及第二表面上之該些接觸墊及該些路由線路、以及電性耦接至該些接觸墊及該些路由線路之該些金屬化導孔；以及於該封膠層及該中介層之該第二表面及該些路由線路上形成一增層電 路，其中該增層電路係藉由該增層電路之複數導電盲孔電性耦接至該中介層之該些路由線路。
  2. 如申請專利範圍第1項所述之方法，其中電性耦接該晶片至該中介層半成品之該些接觸墊之該步驟係以面板規模進行，並且於貼附該晶片-中介層堆疊次組體至該散熱件之該步驟前執行一單片化步驟，以分離個別的晶片-中介層堆疊次組體。
  3. 如申請專利範圍第1項所述之方法，其中該增層電路包含複數額外之導電盲孔，以電性耦接至該散熱件。
  4. 一種半導體元件，其係藉由下述步驟製成：提供一晶片；提供一中介層半成品，其包含具有一第一表面及一相對第二表面之一基板、於該基板之該第一表面上之複數個接觸墊、以及複數個金屬化導孔，其中每一該些金屬化導孔係形成於該基板中，並且具有電性耦接至該些接觸墊之一第一端、以及與該基板之該第二表面保持距離的一相對第二端；藉由複數個凸塊電性耦接該晶片至該中介層半成品之該些接觸墊，以形成一晶片-中介層堆疊次組體；提供一散熱件，其具有相對之一第一表面及一第二表面、以及形成於該第二表面之一凹穴；使用一導熱材料貼附該晶片-中介層堆疊次組體至該散熱件，並使該晶片插入該凹穴中，且該中介層半成品側向延伸於該凹穴外；提供一封膠層，以覆蓋該散熱件之該第二表面及該中介層半成品；移除部分該封膠層及部分該中介層半成品，以顯露該些金屬化導孔之 該些第二端，並使該基板具有與該些金屬化導孔之該些第二端實質上共平面之一外露第二表面；於該基板之該外露第二表面上形成複數路由線路，以製作完成一中介層，其中該中介層包括分別位於相對之第一及第二表面上之該些接觸墊及該些路由線路、以及電性耦接至該些接觸墊及該些路由線路之該些金屬化導孔；以及於該封膠層及該中介層之該第二表面及該些路由線路上形成一增層電路，其中該增層電路係藉由該增層電路之複數導電盲孔電性耦接至該中介層之該些路由線路。
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TWI685930B (zh) * 2017-02-24 2020-02-21 美商美光科技公司 具有電功能熱傳導結構之半導體裝置組件

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