TWI834682B - 模製直接接合且互連的堆疊 - Google Patents
模製直接接合且互連的堆疊 Download PDFInfo
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- TWI834682B TWI834682B TW108123487A TW108123487A TWI834682B TW I834682 B TWI834682 B TW I834682B TW 108123487 A TW108123487 A TW 108123487A TW 108123487 A TW108123487 A TW 108123487A TW I834682 B TWI834682 B TW I834682B
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- substrate
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- bonding surface
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- microelectronic
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Classifications
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Abstract
本發明係關於晶粒及/或晶圓,該些晶粒及/或晶圓以包括堆疊之各種配置而經堆疊且接合,且可覆蓋有模製物以便於處置、封裝以及類似操作。在各個實例中,該模製物可或多或少覆蓋一堆疊,以促進與該堆疊之裝置之連接性、增強熱管理等等。
Description
以下描述關於積體電路(integrated circuit;「IC」)之處理。更特定而言,以下描述關於用於封裝晶粒或晶圓及其他微電子組件之技術。
[優先權主張及相關申請案之交叉參考]
本申請案主張2019年7月2日申請之美國非臨時申請案第16/460,068號及2018年7月6日申請之美國臨時申請案第62/694,845號之權益,該些申請案以全文引用之方式併入本文中。
微電子元件通常包含半導體材料(諸如,矽或砷化鎵)之薄厚塊,其通常稱為半導體晶圓。晶圓可經形成為包括晶圓表面上及/或部分嵌入晶圓內之多個整合式晶片或晶粒。從晶圓分離之晶粒通常作為單獨的經預封裝單元提供。在一些封裝設計中,晶粒經安裝至基板或晶片載體,該基板或晶片載體繼而經安裝在諸如印刷電路板(printed circuit board;PCB)之電路板上。舉例而言,許多晶粒經設置於適合於表面黏著的封裝中。
經封裝半導體晶粒亦可以「堆疊」配置提供,其中一個封裝經設置於(例如)電路板或其他載體上,且另一封裝經黏著在第一封裝之頂部上。該些配置可允許數個不同晶粒或裝置經黏著於電路板上之單個佔據面積內,且可藉由在封裝之間設置短互連來進一步促成高速操作。通常,此互連距離可僅略大於晶粒自身之厚度。對於將在晶粒封裝之堆疊內達成的互連,用於機械及電性連接之互連結構可設置於每一晶粒封裝(除了最頂部封裝以外)之兩側(例如,面)上。
另外,晶粒或晶圓可以三維配置經堆疊作為各種微電子封裝方案之部分。此可包括在較大基底晶粒、裝置、晶圓、基板或類似者上堆疊一或多個晶粒、裝置及/或晶圓之層,以垂直或水平配置堆疊多個晶粒或晶圓,以及兩者之各種組合。
晶粒或晶圓可使用各種接合技術(其包括直接介電接合、非黏合性技術(諸如ZiBond®)或混合接合技術(諸如DBI®),二者均購自英帆薩斯邦德科技有限公司(Invensas Bonding Technologies, Inc.)(前Ziptronix公司)、Xperi公司)以堆疊配置來接合。直接介電接合技術包含自發性共價接合過程,當兩個所製備介電性表面接合在一起時,該自發性共價接合過程在環境條件下進行,而無需黏合劑或介入材料,且混合接合技術添加相應晶粒或晶圓之接合表面處之相應金屬接合墊之金屬對金屬接合,而亦無需介入材料,從而形成統一傳導結構(見例如,美國專利第6,864,585號及第7,485,968號,該些專利以全文引用之方式併如本文中)。金屬接合墊之加熱退火可用於加強金屬對金屬接合。
接合晶粒或晶圓之相應配合表面通常包括嵌入式傳導互連結構(其可為金屬)或類似者。在一些實例中,接合表面經配置且對準使得來自相應表面之傳導互連結構在接合期間結合。結合的互連結構在堆疊晶粒或晶圓之間形成連續傳導互連(用於信號、功率等)。
實施堆疊晶粒及晶圓配置可存在多種挑戰。當使用直接接合技術或混合接合技術來接合堆疊晶粒或晶圓時,通常需要待接合之晶粒或晶圓的表面極平坦、平滑且清潔。舉例而言,大體上,該些表面應具有極低的表面拓樸偏差(亦即,奈米尺度偏差),使得該些表面可緊密配合以形成持續接合。
雙側晶粒或晶圓可經形成及製備用於堆疊及接合,其中晶粒或晶圓之兩側將接合至其他基板、晶圓或晶粒,其諸如具有多個晶粒對晶粒或晶粒對晶圓應用。製備晶粒或晶圓之兩側包括:對兩個表面進行表面處理以符合介電質粗糙度規範及金屬層(例如銅等)凹進規範。混合表面可使用化學機械拋光(chemical mechanical polishing;CMP)製程、電漿製程、濕式及乾式清潔法或類似者來製備以與另一晶粒、晶圓或其他基板接合。
可能需要封裝呈各種組態之堆疊及接合晶粒及晶圓以用於連接性多樣性、性能優化及增強熱管理。
本發明的多種態樣中的第一態樣為一種微電子組件,其包含:第一基板,其具有第一接合表面及嵌入至該第一基板中之第一微電子電路元件,該第一基板之該第一電路元件之一部分在該第一基板之該第一接合表面處暴露;第二基板,其具有第一接合表面及嵌入至該第二基板中之第一微電子電路元件,該第二基板之該第一電路元件之一部分在該第二基板之該第一接合表面處暴露,該第二基板之該第一接合表面混合接合至該第一基板之該第一接合表面而無需黏合劑,使得該第二基板之該第一電路元件電耦接至該第一基板之該第一電路元件,其中該第一基板之側邊緣相對於該第二基板之側邊緣未對準;以及模製物,其覆蓋至少該第二基板之前述側邊緣。
第一態樣之微電子組件進一步包含第一傳導通孔,該第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板。
在第一態樣之微電子組件中,該第一基板包括與該第一接合表面相對之第二表面,且其中該第一傳導通孔延伸至該第一基板之該第二表面且提供從該第一基板之該第一接合表面至該第一基板之該第二表面之電連接性。
第一態樣之微電子組件進一步包含端子連接件,該端子連接件耦接至該第一基板之該第二表面且電耦接至該第一傳導通孔。
在第一態樣之微電子組件中,該第二基板包括與該第一接合表面相對之第二接合表面及嵌入至該第二基板中之第二微電子電路元件,該第二基板之該第二電路元件之一部分在該第二基板之該第二接合表面處暴露。
第一態樣之微電子組件進一步包含第二傳導通孔,該第二傳導通孔電耦接至該第二基板之該第一電路元件及該第二電路元件且至少部分地延伸穿過該第二基板,該第二傳導通孔提供從該第二基板之該第一接合表面至該第二基板之該第二接合表面之電連接性。
在第一態樣之微電子組件中,該第二傳導通孔提供從該第一基板之第二表面至該第二基板之該第二接合表面之電連接性,該第一基板之該第二表面與該第一基板之該第一接合表面相對。
第一態樣之微電子組件進一步包含第三基板,該第三基板具有第一接合表面及嵌入至該第三基板中之第一微電子電路元件,該第三基板之該第一電路元件之一部分在該第三基板之該第一接合表面處暴露,該第三基板之該第一接合表面接合至該第二基板之該第二接合表面,使得該第三基板之該第一電路元件電耦接至該第二基板之該第二電路元件。
在第一態樣之微電子組件中,該第三基板之側邊緣相對於該第二基板之前述側邊緣或該第一基板之前述側邊緣未對準。
在第一態樣之微電子組件中,該模製物覆蓋該第一基板之前述側邊緣、該第二基板之前述側邊緣及該第三基板之前述側邊緣。
在第一態樣之微電子組件中,該模製物覆蓋該第二基板之前述側邊緣及該第三基板之前述側邊緣,而不覆蓋該第一基板之前述側邊緣。
在第一態樣之微電子組件中,該模製物覆蓋與該第三基板之該第一接合表面相對之該第三基板之第二表面。
在第一態樣之微電子組件中,該模製物覆蓋與該第一基板之該第一接合表面相對之該第二基板之第二表面。
本發明的多種態樣中的第二態樣為一種微電子組件,其包含複數個第一態樣之微電子組件。
在第二態樣之微電子組件中,第一基板、第二基板及第三基板之佔據面積為非均一的,且其中自該第一基板延伸至該第三基板之模製物之外部側邊緣為平面的。
本發明的多種態樣中的第三態樣為一種微電子組件,其包含:複數個模製微電子元件堆疊,每個堆疊包含:第一基板,其具有第一接合表面及嵌入至該第一基板中之第一微電子電路元件,該第一基板之該第一電路元件之一部分在該第一基板之該第一接合表面處暴露,且第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板;第二基板,其具有第一接合表面及嵌入至該第二基板中之第一微電子電路元件,該第二基板之該第一電路元件之一部分在該第二基板之該第一接合表面處暴露,且第二傳導通孔電耦接至該第二基板之該第一電路元件且至少部分地延伸穿過該第二基板,該第二基板之該第一接合表面混合接合至該第一基板之該第一接合表面而無需黏合劑,使得該第二基板之該第一電路元件電耦接至該第一基板之該第一電路元件,其中該第一基板之側邊緣相對於該第二基板之側邊緣未對準;以及模製物,其覆蓋至少該第二基板之前述側邊緣。
在第三態樣之微電子組件中,該第一基板包括與該第一接合表面相對之第二表面,且其中該第一傳導通孔延伸至該第一基板之該第二表面且提供從該第一基板之該第一接合表面至該第一基板之該第二表面之電連接性。
在第三態樣之微電子組件中,該第二基板包括與該第一接合表面相對之第二接合表面及嵌入至該第二基板中之第二微電子電路元件,該第二基板之該第二電路元件之一部分在該第二基板之該第二接合表面處暴露,且其中該第二傳導通孔電耦接至該第二基板之該第二電路元件。
在第三態樣之微電子組件中,該第二基板之該第一接合表面及該第二接合表面中之至少一者在該第二基板之周界邊緣處包括有意的凹部。
在第三態樣之微電子組件中,該模製物包含未具有顆粒之第一低黏度化合物,該第一低黏度化合物滲透該第二基板之該周界邊緣處的該凹部,且具有顆粒之第二化合物覆蓋在該第一低黏度化合物上方。
第三態樣之微電子組件進一步包含層合物及/或插入件,且其中該複數個模製微電子元件堆疊混合接合至該層合物或該插入件而無需黏合劑或中介材料。
第三態樣之微電子組件進一步在該層合物之表面上及/或在該插入件之表面上包含至少一個線接合墊。
在第三態樣之微電子組件中,該層合物使用接線來耦接至該插入件,該接線耦接於該層合物之表面上之線接合墊處及該插入件之表面上之線接合墊處。
在第三態樣之微電子組件進一步包含非模製晶粒,該非模製晶粒在無黏合劑之情況下混合接合至該層合物及/或該插入件。
在第三態樣之微電子組件中,至少該第二基板包含固態記憶體裝置。
本發明的多種態樣中的第四態樣為一種形成微電子組件之方法,其包含:形成微電子堆疊,其包含:提供具有前側及背側之第一基板,該背側具有包含非傳導接合層之接合表面以及經暴露電性傳導第一電路元件,該第一基板具有第一傳導通孔,該第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板;提供具有前側及背側之第二基板,該前側包括非傳導接合層及經暴露電性傳導第一電路元件;藉由使該第一基板之該非傳導接合層與該第二基板之該非傳導接合層接觸來將該第二基板之該前側耦接至該第一基板之該背側,該第一基板之側邊緣相對於該第二基板之側邊緣未對準,且使該第一基板之該第一電路元件與該第二基板之該第一電路元件接觸;以及用模製物覆蓋至少該第二基板之前述側邊緣。
第四態樣之方法進一步包含用該模製物覆蓋該第二基板之該背側。
在第四態樣之方法中,該第二基板之該背側包括第二非傳導接合層及經暴露電性傳導第二電路元件,該第二基板具有第二傳導通孔,該第二傳導通孔電耦接該第二基板之該第一電路元件及該第二電路元件。
第四態樣之方法進一步包含:提供具有前側及背側之第三基板,該前側包括非傳導接合層及經暴露電性傳導第一電路元件;藉由使該第三基板之該非傳導接合層與該第二基板之該非傳導接合層接觸來將該第三基板之該前側耦接至該第二基板之該背側,該第三基板之側邊緣相對於該第二基板之側邊緣及/或該第一基板之側邊緣未對準,且使該第三基板之該第一電路元件與該第二基板之該第二電路元件接觸;以及用該模製物覆蓋該第三基板之前述側邊緣。
第四態樣之方法進一步包含在該第一基板之一周界處之該第一基板之該接合層處及/或該第二基板之一周界處之該第二基板之該接合層處形成一凹部,及在用該模製物覆蓋該第一基板之該些側邊緣及該第二基板之該些側邊緣之前,用一低黏度化合物填充至少該凹部。
第四態樣之方法進一步包含將該微電子堆疊混合接合至具有至少一個線接合接觸墊之半導體插入件。
第四態樣之方法進一步包含將該插入件耦接至具有第二線接合接觸墊之層合物,及用接線將該插入件之該至少一個線接合接觸墊接合至該層合物之該第二線接合接觸墊。
在第四態樣之方法中,形成該微電子組件包含形成複數個微電子堆疊。
本發明的多種態樣中的第五態樣為一種微電子組件,其包含:第一晶粒,其具有第一接合表面及嵌入至該第一晶粒中之第一微電子電路元件,該第一電路元件之一部分在該第一晶粒之該第一接合表面處暴露;以及第二晶粒,其具有第一接合表面及嵌入至該第二晶粒中之第一微電子電路元件,該第二晶粒之該第一電路元件之一部分在該第二晶粒之該第一接合表面處暴露,該第一晶粒之該第一接合表面混合接合至該第二晶粒之該第一接合表面,使該第一晶粒電耦接至該第二晶粒而無需黏合層,其中該第一晶粒之側邊緣包含比安置於該第二晶粒之側邊緣上之模製層薄的模製層。
本發明的多種態樣中的第六態樣為一種微電子組件,其包含:第一晶粒,其具有包含第一微電子電路元件之第一接合表面;第二晶粒,其具有包含第二微電子電路元件之第一接合表面;該第一晶粒之該第一接合表面混合接合至該第二晶粒之該第一接合表面,使該第一晶粒電耦接至該第二晶粒而無需黏合層;以及模製層,其安置於該第一晶粒之側邊緣及該第二晶粒之側邊緣上,其中該第一晶粒上的該模製層之厚度不同於該第二晶粒上的該模製層之厚度。
第六態樣之微電子組件進一步包含第一傳導通孔,該第一傳導通孔電耦接至該第一晶粒之該第一電路元件且至少部分地延伸穿過該第一晶粒。
在第六態樣之微電子組件中,該第一晶粒之該第一接合表面或該第二晶粒之該第一接合表面包含具有小於20微米之間距的複數個電路元件。
在第六態樣之微電子組件中,該第一晶粒之該第一接合表面或該第二晶粒之該第一接合表面包含具有小於1微米之間距的複數個電路元件。
概述
揭示代表性技術及裝置,其包括用於堆疊及接合晶粒及/或晶圓(包括混合接合晶粒與晶粒、晶粒與晶圓及晶圓與晶圓而無需黏合劑)之製程步驟。在各種具體實例中,晶粒及/或晶圓以包括堆疊之各種配置而經堆疊且接合,且可覆蓋有模製物以便於處置、封裝以及類似操作。在各個實例中,模製物可或多或少覆蓋一堆疊,以促進與該堆疊之裝置之連接性、增強熱管理等等。
參考電性及電子構件以及變化之載體論述各種實施方案及配置。雖然提及具體構件(即,晶粒、晶圓、積體電路(IC)晶片晶粒、基板等),但此不意欲為限制性的,而是為了易於論述及便於說明。參考晶圓、晶粒、基板或類似者論述之技術及裝置適用於任一類型或數目之電性構件、電路(例如,積體電路(IC)、混合電路、ASICS、記憶體裝置、處理器等)、構件之群組、被動元件、微機電系統(Micro-Electro Mechanical Systems;MEMS)構件、封裝式構件、結構(例如,晶圓、面板、板、PCB等)及類似者,其可經整合及耦接以彼此介接,與外部電路、系統、載體及類似者介接。這些不同構件、電路、群組、封裝、結構及類似者中之每一者可大體上稱作「微電子構件」。為簡單起見,除非另外指定,否則接合至另一構件之構件將在本文中稱作「晶粒」。
例示性具體實例
圖1為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖。在所展示之實例中,藉由堆疊且接合(例如,混合接合而無需黏合劑)複數個晶粒102(例如,所需任何數量之晶粒102)來形成堆疊100(或微電子組件100)。在一替代具體實例中,藉由堆疊且接合(例如,混合接合而無需黏合劑)複數個晶圓來形成堆疊100,該複數個晶圓隨後單體化(singulation)為圖1中所展示之晶粒102。在一實施方案中,如圖1中所示,晶粒102在堆疊100中可不完全對準。換言之,晶粒102之邊緣不精確排列,且自堆疊100之一個晶粒102至另一晶粒102存在一些誤差或未對準「e」。在各個實例中,未對準「e」可歸因於取放工具之準確度容限或類似者。
可使用各種技術形成晶粒102(或晶圓),以包括基底基板104及一或多個絕緣層或介電層106。舉例而言,圖1處所展示之晶粒102可表示雙側晶粒102,其在基底層104之兩個表面上具有絕緣層106。如圖1中亦展示,亦可包含晶粒102',其可為單側或雙側主晶粒或主晶圓。單側晶粒102或102'可定位於堆疊100中作為頂部晶粒102、底部晶粒102或作為堆疊100中之任一其他晶粒102,在該任一其他晶粒中不需要與晶粒102之兩側之直接接合連接。除非另外規定,否則如本文中所使用之參考「晶粒102」包括單側及雙側晶粒及晶圓兩者。
基底基板104可包含矽、鍺、玻璃、石英、介電表面、直接或間接能隙半導體材料或層或另一合適的材料。絕緣層106沉積或形成於基板104上方,且可包含無機介電材料層,諸如氧化物、氮化物、氮氧化物、碳氧化物、碳化物、碳氮化物、金剛石、類金剛石材料、玻璃、陶瓷、玻璃陶瓷以及類似者。
晶粒102之接合表面108可包括傳導特徵110,諸如TSV、跡線、襯墊及互連結構,該些傳導特徵(例如)嵌入至絕緣層106中且經配置以使得在接合期間可視需要配合且結合來自相對裝置之相應接合表面108之傳導特徵110。結合的傳導特徵110可形成堆疊裝置之間的連續傳導互連(以用於信號、功率、接地等)。
鑲嵌製程(或類似者)可用以在絕緣層106中形成嵌入式傳導特徵110。傳導特徵110可包含金屬(例如,銅等)或其他傳導材料或材料組合,且包括結構、跡線、襯墊、圖案等等。在一些實例中,障壁層可在沉積傳導特徵110之材料之前經沉積於用於傳導特徵110之空腔中,使得障壁層安置於傳導特徵110與絕緣層106之間。障壁層可包含鉭層、鈦層、鎢層或具有其各種相應化合物或合金之其組合(例如,或另一傳導材料),以防止或減少傳導特徵110之材料擴散至絕緣層106中。在形成傳導特徵110後,裝置晶圓102(其包括絕緣層106及傳導特徵110)之經暴露表面可(例如,經由CMP)平面化以形成平坦接合表面108。
形成接合表面108包括對表面108進行表面處理以符合介電質粗糙度規範及金屬層(例如,銅等)凹進規範(若規定),從而製備用於混合接合之表面108。換言之,接合表面108經形成為儘可能平坦及平滑的,且具有極小(奈米尺度)表面拓樸偏差。各種習知製程(諸如化學機械拋光(CMP)、乾式或濕式蝕刻等等)可用於實現低表面粗糙度。此製程提供產生可靠接合之平坦且光滑的表面108。
部分地延伸至所製備表面108下方之介電基板106中之嵌入式傳導跡線112可用於貫穿晶粒102將傳導特徵110電耦接至所需構件。舉例而言,傳導特徵110可耦接至傳導(例如,銅)矽穿孔(through-silicon vias;TSV)114或類似者,該矽穿孔部分地或完全延伸穿過晶粒102以穿過晶粒102之厚度形成電連接。舉例而言,取決於晶粒102之厚度,在一些情況下,TSV 114可延伸約50微米。圖式展示晶粒102的實例,其具有傳導特徵110、跡線112及TSV 114之並不意欲為限制的各種配置。在各種具體實例中,傳導特徵110、跡線112及TSV 114中之一些可不存在於晶粒102(或晶圓)中,且在其他具體實例中,額外傳導特徵110、跡線112及TSV 114可存在,或其他電路構件以及類似者可存在。
晶粒102可(例如)在無黏合劑之情況下經混合接合至具有金屬襯墊110、跡線112及/或TSV 114之其他晶粒102,以在形成堆疊100時穿過晶粒102形成所需電連接。混合接合包括各晶粒102之相應絕緣層106之直接介電質對介電質接合(例如,ZIBOND®)而無需黏合劑或其他中介材料,以及各晶粒102之相應傳導特徵110之直接金屬對金屬接合(例如,DBI®)亦而無需中介材料。當在環境溫度下使相應接合表面108在一起時,介電質對介電質接合自發地進行。金屬對金屬接合(其可包括傳導特徵10之金屬之間的擴散)可在有壓力或無壓力之情況下憑藉加熱進行。
如圖1中所示,可(例如,經由傳導特徵110)自堆疊100之頂部晶粒102之頂部表面、(例如,經由傳導特徵110、跡線112及TSV 114)經過堆疊100之晶粒102(任何數目的晶粒102)且(例如,經由TSV 114)至堆疊100之底部晶粒102之底部表面建立電連接性。在圖1的實例中,傳導特徵110提供至堆疊100之頂部表面的連接性,且具有至少一個電耦接墊116之TSV 114提供至堆疊100之底部晶粒102之底部表面的連接性(在一些情況下,鈦層(圖中未示)或類似者可將TSV 114耦接至襯墊116)。在替代具體實例中,堆疊100之頂部表面及底部表面中的一者或兩者可不具有連接性,或與所展示不同的構件可提供至堆疊100之頂部表面或底部表面的連接性。舉例而言,在一些具體實例中,堆疊100可不包括堆疊100之頂部表面處之傳導特徵110,或頂部晶粒102中之TSV 114,或底部晶粒102中之TSV 114及襯墊116。
在一些實施方案中,TSV 114中之一或多者提供晶粒102之間的熱連接性。舉例而言,TSV可幫助將熱量自一些晶粒102耗散或傳輸至其他晶粒102及/或至外部環境。在實施方案中,TSV 114包含導熱材料,且可包括導熱障壁層(圖中未示)。在一些實例中,基於相關晶粒102之功能(例如,產熱),TSV 114可經大小設定以用於最佳熱耗散。
圖2為微電子組件200之橫截面剖面圖,該微電子組件包含晶粒102之多個堆疊100。在一些具體實例中,各堆疊100包括相同數量之晶粒102。在其他具體實例中,一些堆疊100可包括與組件200之其他堆疊100不同數量之晶粒102。在一實施方案中,如圖2中所示,晶粒102在堆疊100中不完全對準。換言之,晶粒102之邊緣在堆疊100內並不精確排列,且自晶粒102至晶粒102存在一些邊緣之誤差或未對準。在一些具體實例中,堆疊100自已如上文所論述經堆疊及接合之複數個晶圓中經單體化。
在一實施方案中,晶粒102'之底部集合包含用於堆疊100之主晶圓202。在實施方案中,晶粒102可堆疊至主晶圓202上,其隨後視需要在堆疊100之邊界處經單體化。在其他實施方案中,若存在,主晶圓202可在製程中之不同步驟處經單體化。
如圖2中所示,組件200之堆疊100中之一或多者可經覆蓋於包含密封體或類似者之模製物204中。在各種具體實例中,模製物204可包含高強度、高熱應力(高耐熱性)密封體材料,其亦可具有高熱耗散特徵。此外,模製物204可需要具有小於20之熱膨脹係數(coefficient of thermal expansion;CTE),以輔助控制翹曲。舉例而言,HITACHI®提供此類密封體或「環氧模製化合物」,其稱作「CEL」。其他相似產品亦可購得。在一個具體實例中,組件200覆蓋有模製物204,隨後組件200分割成多個堆疊100。單獨堆疊100可視需要覆蓋有額外密封體204。在其他具體實例中,堆疊100在堆疊100之形成後經模製,該堆疊之形成包括將單獨晶粒102堆疊且接合至堆疊100中或晶圓之單體化以形成晶粒102及堆疊100。舉例而言,模製物204可在晶粒102之單體化之前或之後經沉積。在任一情況下,模製物204可覆蓋晶粒102或所選晶粒102之整個堆疊100。舉例而言,在一具體實例中,主晶圓202(及晶粒102')可不覆蓋有模製物204。此可歸因於製造製程或因為設計。
對於本文中所揭示之所有實施方案,模製物204可包含覆蓋在堆疊100之晶粒102中的一些或全部上方及/或圍繞其之單層密封體,或模製物204可包含相同或不同材料之密封體之多個層(例如,層合物)。此外,在一實施方案中,模製物204包含密封體內之顆粒,且模製物204具有進展之顆粒密度,即自在堆疊100之頂部或底部處低顆粒或無顆粒之狀態至在堆疊100之頂部或底部中之另一者處較高顆粒密度之狀態。在一個實例中,當存在時,顆粒可以不同密度存在於密封體之多個層中。在各種具體實例中,模製物204包含無機殼體或類似者。
在一些實例中,將模製物204添加至晶粒102之堆疊100及/或組件200向堆疊100或組件200提供最終封裝。堆疊解決方案使得易於處理期間之處置及組裝,以及應用中之部署。模製物204對晶粒102及堆疊100以及組件200及可封裝有晶粒102之任何離散構件提供保護。
在一實施方案中,如圖2處所示,堆疊100中之一或多者(或所有堆疊100)之頂部表面可不含模製物204。頂部晶粒102之裸頂部表面可用於堆疊100之頂部晶粒102與其他電路、裝置(例如,光學、射頻(radio frequency;RF)、類比、數位、邏輯、記憶或其他裝置)或(例如)包括額外晶粒102或組件200之類似者(例如,當傳導特徵110存在於頂部晶粒102之頂部表面處時)之進一步互連。替代地或額外地,頂部晶粒102之頂部表面可經覆蓋以增強熱耗散。舉例而言,熱量可自晶粒102更容易及有效地耗散而無需組件200之頂部晶粒102之頂部表面處的密封體204。在此類情況下,傳導特徵110(以及跡線112)可不存在於頂部晶粒102之頂部表面處。舉例而言,若TSV 114用於經由頂部表面幫助耗散熱量,則TSV可存在。
在一實施方案中,組件200包括組件200之表面(諸如,底部表面)處之一或多個電接觸或端子206。端子206可用於將組件電耦接至另一電路、裝置、印刷電路板(PCB)或類似者。如圖2中所示,端子206可經由襯墊116電耦接至組件200之堆疊100之晶粒102(諸如,最底部晶粒102)之TSV 114(或其他互連件)。舉例而言,組件200可包括自堆疊100中之一或多者之頂部晶粒102(例如,在一些情況下,頂部晶粒102之頂部表面)穿過堆疊100之晶粒102至端子206的電連接性。
在一些具體實例中,額外層、電路構件、通孔以及類似者亦可視需要併入至堆疊100及/或組件200中。在替代實施方案中,TSV 114可在一些晶粒102中及/或一些堆疊100中為可選的。
在一實施方案中,如圖3處所示,堆疊100中之一或多者(或所有堆疊100)之頂部表面可包括模製物204。在實施方案中,堆疊100及組件200之頂部表面處之模製物204在處置、組裝、部署等等期間保護堆疊100及組件200。在一具體實例中,堆疊100中之每一者分別覆蓋有模製物204,此包括堆疊100之頂部及側部。在一具體實例中,主晶圓202(及晶粒102')可不覆蓋有模製物204。如圖3的實例中所示,在一些具體實例中,當不在晶粒102及組件200之頂部表面處形成電連接時,組件200之頂部晶粒102可不包括傳導特徵110(或跡線112及/或TSV 114)。舉例而言,當這些構件用於其他目的時(例如,當電路構件安置於上部絕緣層106上或內時,或類似者),這些構件可為可選的。
亦如圖3在的實例中所示,在一些應用中,晶粒102可具有構件之各種組態及配置。舉例而言,如圖3處所示,晶粒102"可包括TSV 114,該些TSV直接耦接至鄰近晶粒102上之傳導墊110以提供與相鄰接合晶粒102之連接性。舉例而言,TSV 114之末端表面可在晶粒102"之接合表面108處暴露,從而形成與相鄰晶粒102上之傳導墊110接合之接觸表面。在其他具體實例中,亦如圖3處所示,晶粒102"可包括接合表面處之傳導墊110,其中TSV 114直接耦接至傳導墊110。這些傳導墊110可接合至相鄰晶粒102上之傳導墊110(或其他傳導結構)。
在一實施方案中,如圖4及5所示,整個堆疊100可覆蓋有模製物204,此包括主晶圓202及晶粒102'。在實施方案中,主晶圓202可在密封步驟之前單體化為晶粒102',從而有助於該主晶圓由模製物204覆蓋。多個晶粒102可經堆疊(以群組方式或一次一個地)至主晶粒102'上以形成堆疊100,該堆疊可隨後覆蓋有模製物204。替代地,在所有晶粒102經堆疊及接合至堆疊100中後,模製物204可應用於組件200。在任何情況下,模製物204可存在於堆疊100之側部上。此外,在替代具體實例中之模製步驟後,組件200之堆疊100可彼此分隔開。
如所示,圖4說明例示性組件200,其中組件200及堆疊100之頂部表面(亦即,背部)不含模製物204。在一具體實例中,模製物204可沉積於組件200上方,且隨後自堆疊100之頂部表面經移除。在各個實例中,模製物204可自堆疊100之頂部表面經移除以提供與頂部晶粒102之互連,以用於改良的熱耗散或類似者。圖5說明頂部表面(亦即,背部)覆蓋有模製物204的情況。
如圖6及7中所示,堆疊100之晶粒102可不為大小均一的(例如,尺寸、面積、佔據面積、厚度等)。具有不同佔據面積或厚度之晶粒102(例如)可經堆疊及接合以形成堆疊100。在無模製物204之情況下,非均一晶粒102之堆疊100呈現不均勻側邊緣及/或不同高度之堆疊100。用模製物204覆蓋堆疊100可呈現均一封裝(在側邊緣/表面中以及高度),如堆疊100及/或組件200。
圖6處所說明之實例展示一具體實例,其中晶粒102覆蓋有模製物204,但主晶圓(主晶粒102')不覆蓋有模製物204。在一些具體實例中,頂部晶粒102之側邊緣上之模製層204的厚度比安置於下方第二晶粒102之側邊緣上之模製層204的厚度厚。圖7之實例展示一具體實例,其中晶粒102及主晶粒102'全部覆蓋有模製物204,如上文所論述。
如圖8及9處所示,在一些實施方案中,堆疊100可包括晶粒102,該些晶粒在一側上具有互連件而在另一側上不具有互連件。舉例而言,如圖解中所示,頂部晶粒102可不具有與晶粒102之頂部表面之互連件。在此類情況下,在堆疊100或組件200之頂部(例如,背部)表面上可不需要互連件。在替代具體實例中,其他晶粒102可包括僅一側上之互連件。在一些具體實例中,TSV 114亦可選用於頂部晶粒102,然而,TSV 114可用於熱耗散。
在一些實例中,如圖8及9處所示,散熱片802或其他構件902(例如,感測器、光學構件等)可包括於堆疊100中。舉例而言,散熱片802可位於堆疊100之頂部處以幫助熱量自堆疊100之一或多個晶粒102耗散至環境中。在一些情況下,導熱TSV 114可幫助將餘熱自一些晶粒102轉移至其他晶粒102且轉移至散熱片802。在替代具體實例中,散熱片802或其他構件902可視其應用及效能需要定位於堆疊100內的某處或堆疊100之底部處的某處。
如圖8及9處所示,當散熱片802或其他構件902位於堆疊100之頂部處時,堆疊100之頂部(例如,晶粒102之頂部或「背部」表面)可不含模製物204。在一些情況下,當其他堆疊100(例如,包括散熱片802或其他構件902之堆疊100)可不含頂部表面處之模製物204,同時具有堆疊100之側部處之模製物204時,組件200之堆疊100中之一些可包括模製物204,該模製物整個圍繞堆疊100且包括堆疊100之頂部表面處。
如圖10及11處所示,在一些具體實例中,均一及/或非均一晶粒102可經堆疊及接合以形成堆疊100,其中多個晶粒102橫向地放置於組件200封裝內之單一層級(level)上。舉例而言,如圖10處所示,主晶圓202可不在堆疊100中之每一者處經單體化。因此,超過一個堆疊100可經接合至單個主晶粒102'。舉例而言,在圖10的實例中,第二及第三堆疊100經接合至單個主晶粒102',且第四及第五堆疊100經接合至另一主晶粒102'。
如圖10處所示,接合至主晶粒102'之堆疊100之群組可一起經覆蓋於模製物204中。舉例而言,在實例中,第二及第三堆疊100可一起覆蓋於模製物204中(例如,通常經密封),且第四及第五堆疊100可一起經覆蓋於模製物204中(例如,通常經密封)。替代地或組合地,接合至共同主晶粒102'之堆疊100之一些群組的模製物204可經分隔,其中分隔的模製物204分別圍繞每一堆疊100。主晶粒102'(或晶圓)可不含模製物,如實例中所示。替代地,主晶粒102'(或晶圓)可覆蓋有模製物204。
如圖11處所示,在一些具體實例中,額外晶粒102可以橫向配置堆疊於組件200之單一層級上,從而形成一或多個共同堆疊或部分共同堆疊1100。舉例而言,圖11展示部分共同堆疊1100之實例。在實例中,接合至主晶粒102'之第一列晶粒102在堆疊100中之每一者處可不經單體化。因此,超過一個堆疊100可經接合至單個主晶粒102'及單個「第一列」晶粒102。
舉例而言,在圖11的實例中,第二及第三堆疊100包含接合至單個主晶粒102'之單個第一列晶粒102。第二及第三堆疊100之晶粒102之後續列接合至單個第一列晶粒102。相應地,第二及第三堆疊100共用共同主晶粒102'及共同第一列晶粒102。當一些晶粒102為多個堆疊100所共用時,此產生部分共同堆疊1100。在其他具體實例中,晶粒102之額外列可為第二及第三堆疊100所共用。舉例而言,若多個堆疊100之所有列之晶粒102為多個堆疊100所共用,則此將產生共同堆疊1100。
如圖11中所示,第四及第五堆疊100亦包含接合至單個主晶粒102'之單個第一列晶粒102。第四及第五堆疊100之晶粒102之後續列接合至單個第一列晶粒102。相應地,第四及第五堆疊100共用共同主晶粒102'及共同第一列晶粒102,從而產生部分共同堆疊1100。
如圖10及11處所示,第一堆疊100覆蓋有模製物204(除主晶粒102'以外),且部分共同堆疊1100中之每一者亦覆蓋有模製物204(除主晶粒102'以外)。然而,如圖10及11處所示,一或多個部分共同堆疊1100可包括部分共同堆疊1100之晶粒102之頂部表面處的模製物204,且一或多個部分共同堆疊1100可不含部分共同堆疊1100之晶粒102之頂部表面處的模製物204。如上文所論述,移除頂部晶粒102之頂部表面處之模製物204(或不沉積模製物204)可允許與頂部晶粒102之互連性,可允許自頂部晶粒102之改良熱耗散,等等。
額外具體實例
圖12及13說明組件200之例示性具體實例,其中接合晶粒102之一或多個堆疊100接合至主晶圓202。在一些實例中,主晶圓202可經單體化為主晶粒102'(圖中未示)。在如所示的各種具體實例中,晶粒102可為雙側晶粒,該些雙側晶粒具有嵌入於基底層104之任一側上之絕緣層106內之傳導特徵110。可假定諸如跡線112及TSV 114之一些細節存在於一些具體實例中,但為了圖式清楚起見,未說明該些細節。
在一實施方案中,如圖12及13處所示,絕緣層106中之一或多者可在晶粒102之周界邊緣處經蝕刻(見1202),從而移除周界處之絕緣層106中之一些。周界蝕刻1202可基於裝置、封裝、處理或類似者之規範而為有意的(intentional)。在實施方案中,蝕刻1202可存在於晶粒102之一或多個側部或邊緣上。在一些情況下,蝕刻1202包含移除周界處之絕緣層106之一部分及暴露下方之基底層104。在其他情況下,蝕刻1202並不暴露基底層104,或蝕刻1202亦同樣移除基底層104中之一些。
圖14為根據一具體實例之具有經蝕刻周界邊緣(凹部1202)之晶粒102之額外圖解。在一例示性具體實例中,圖14之圖解更緊密展示凹部1202相對於基底層104及絕緣層106之相對尺度。在其他具體實例中,其他比例可存在。
在一些情況下,模製物204化合物可經顆粒填充,如上文所論述。舉例而言,顆粒可添加至模製物204以改變模製物204之熱膨脹係數(CTE)。此可例如藉由均衡跨封裝(例如,組件200)之CTE來幫助減少封裝翹曲。然而,在一些情況下,模製物204中之顆粒可過大以至於不能裝配於由周界蝕刻形成之較小凹部1202內。在模製物204應用於堆疊100後留下之任何空隙可引起封裝(例如,組件200)之組件中的「爆米花(popcorn)」故障。
在各種實施方案中,如圖13處所示,模製物204之多個層可用於降低可能的故障,而非不包括模製物204中之顆粒(且不接受如此操作之益處)。舉例而言,第一低黏度化合物1302可圍繞堆疊100經應用,從而形成圍繞堆疊100且滲透經蝕刻凹部1202之一層化合物1302。層1302可隨後緊接有一層模製物204。
在實施方案中,第一層化合物1302可不包括填充劑或顆粒。舉例而言,由於具有低黏度,化合物1302之主要目的可為填充晶粒102中之經蝕刻凹部1302。然而,化合物1302亦可在堆疊100之晶粒102之垂直壁上方形成層。在應用第一層化合物1302後,堆疊100及/或組件200可覆蓋有模製物204。在替代具體實例中,額外層亦可用以覆蓋堆疊100及/或組件200。
在其他實施方案中,第一層(低黏度)化合物1302(或樹脂)可包括足夠小之亞微米顆粒或甚至奈米顆粒以併入於凹部1202內。亞微米或奈米顆粒可包含二氧化矽(silica)、矽、二氧化矽/矽化合物或類似者。奈米顆粒可在一些情況下平均為20 nm大小(例如,直徑),且可在其他情況下更小或更大。
在一具體實例中,第一層化合物1302(具有亞微米或奈米級填充劑顆粒)在晶粒102之垂直壁及凹部1202上方形成層。在一些具體實例中,較佳的係第一層化合物1302之亞微米或奈米顆料含量大於5%。模製層204通常包含顆粒含量通常大於50%之強化顆粒,且可較佳的係模製層204之顆粒含量高於凹部1202內之第一層化合物1302之顆粒含量。類似地,在一些應用中,可較佳的係模製層204中之顆粒的標稱大小大於第一層化合物1302中之顆粒的標稱大小。
參考圖15及16,在通常實踐中,使用球柵格陣列(ball-grid arrays;BGA)及其他類似技術將記憶體晶粒耦接至其他記憶體晶粒。在那些情況中,記憶體晶粒對記憶體晶粒間距通常為約45微米。使用類似技術,邏輯晶粒對插入件間距為約90至100微米。然而,在一些具體實例中,可能及切實可行的係分別以較細間距來組裝記憶體晶粒堆疊(諸如堆疊100),且然後將其堆疊在邏輯晶粒上。應注意在一些情況下,邏輯晶粒可不大於記憶體晶粒。
圖15及16展示「高頻寬記憶體」組件200之實例,該組件包括耦接至邏輯晶粒1502之記憶體晶粒102(例如,動態隨機存取記憶體(dynamic random access memory;DRAM)、靜態隨機存取記憶體(static random access memory;SRAM)、快閃記憶體等)之堆疊100。在各種實施方案中,晶粒102經混合接合(DBI®)以形成堆疊100,如上文所論述。如圖15中所示,堆疊100(或底部晶粒102)可經混合接合至邏輯晶粒1502。邏輯晶粒1502可包括端子206,該些端子用於將組件200耦接至電路、PCB、裝置或類似者,如上文所論述。使用直接或混合接合技術,晶粒102之間及晶粒102與邏輯晶粒1502之間的距離極大地減小(由於晶粒厚度相對於當前技術,距離為晶粒厚度加上Cu柱及焊球高度)。在一個具體實例中,經接合晶粒102中之一或多者之接合表面處的電路元件(諸如傳導特徵110或類似者)小於20微米且在其他應用中小於5微米或甚至小於1微米。
如圖16中所示,可使用覆晶技術或類似者替代地將堆疊100耦接至邏輯晶粒1502。舉例而言,覆晶端子1602可耦接至底部晶粒102之底部側,該底部晶粒之底部側與邏輯晶粒1502之頂部表面處之端子1602介接。相應地,混合接合及覆晶技術之組合可與組件200一起使用。在替代具體實例中,其他耦接技術亦可視需要用以將混合接合之堆疊100耦接至邏輯晶粒1502、插入件或類似者。
亦展示於圖16中的為模製物1604,該模製物覆蓋覆晶端子1602且填充堆疊100與邏輯晶粒1502之間的間隙。在一些具體實例中,組件200亦可視需要覆蓋有模製物204以供處置、封裝等等。
圖17至20展示在各種應用中使用堆疊100及/或組件200之額外實施方案。舉例而言,在圖17處,展示包括各種晶粒102之組件1700,該組件包括混合接合至插入件1702之晶粒102之堆疊100。在一具體實例中,插入件1702包含半導體,例如矽。為了清楚起見簡化圖式。
在各種具體實例中,如圖17處所示,一些晶粒102可經模製,且其他晶粒102可未經模製。散熱片或其他冷卻裝置1704(例如,風扇等)耦接至未模製晶粒102以冷卻晶粒102(其可包含大功率構件,諸如處理器或類似者)。插入件1702包括混合接合墊110以及至少一個線接合墊1706。
如圖18中所示,線接合墊1706可用於經由接線1804將遠端構件(例如,耦接至(或穿過)層合物1802或與該層合物一體化之構件)耦接至襯墊1706。在所展示之一具體實例中,層合物1802混合接合至插入件1702。替代地,層合物1802可藉由另一接合技術耦接至插入件1702。
舉例而言,如圖19中所示,層合物1802可藉由BGA技術、另一表面黏著技術或類似者來耦接至插入件1702。在一實施方案中,如圖19所示,層合物1802可包括一或多個線接合墊1902,該些線接合墊可與接線1804一起使用以耦接至線接合墊1706或類似者。
在一具體實例中,如圖19所示,組件200或堆疊100可封裝有另一構件1904,該另一構件可混合接合至插入件1702。構件1904及組件200或堆疊100可經覆蓋於模製物1906中,該模製物視需要包含密封體(或其他封裝)。封裝或堆疊100及構件1904可混合接合至插入件1702。冷卻裝置1704可耦接至構件1904及/或堆疊100,如圖19中所示。或者,填充物1604可用於覆蓋端子206且填充插入件1702與層合物1802之間的間隙。或者,插入件1702可與其他構件一起或單獨地經密封。
如圖20所示,堆疊100可覆蓋有模製物204,且其他晶粒102及/或構件可不覆蓋有該模製物。散熱片或其他冷卻裝置1704(例如,風扇等)耦接至未模製晶粒102以冷卻晶粒102(其可包含大功率構件,諸如處理器或類似者)。額外冷卻裝置亦可耦接至堆疊100,該堆疊在堆疊100之頂部表面處可不含模製物204。插入件1702包括混合接合墊110以及至少一個線接合墊1706。如所示,插入件1702可經由BGA配置或其他耦接技術來耦接至層合物1802。
例示性製程
圖21為說明形成包含晶粒堆疊(諸如,晶粒102之堆疊100)之經堆疊及接合之微電子組件(諸如,微電子組件200)之例示性製程2100的流程圖。在一些具體實例中,晶粒之堆疊可覆蓋有模製物(諸如,模製物204)以供處置、處理、應用以及類似者。製程2100係指圖1至20。
描述製程之次序並不意欲理解為限制,且製程中之任何數目的所描述程序區塊可按任何次序組合以實施該製程或替代製程。或者,可在不脫離本文中所描述之主題之精神及範疇的情況下自製程刪除單獨區塊。此外,可在不脫離本文中所描述之主題之範疇的情況下以任何適合之硬體、軟體、韌體或其組合實施製程。在替代實施方案中,其他技術可以各種組合包括於製程中且保持在本發明之範疇內。
在區塊2102處,製程包括形成微電子堆疊(諸如,晶粒102之堆疊100)。在一替代具體實例中,製程包含形成複數個微電子堆疊。在一實施方案中,形成微電子堆疊包括以下區塊:
在區塊2104處,製程包括提供具有前側及背側之第一基板(諸如,第一晶粒102)。背側具有包含非傳導接合層之接合表面及經暴露電性傳導第一電路元件。第一基板具有第一傳導通孔,該第一傳導通孔電耦接至第一基板之第一電路元件且至少部分地延伸穿過第一基板。
在區塊2106處,製程包括提供具有前側及背側之第二基板。前側包括非傳導接合層及經暴露電性傳導第一電路元件。
在區塊2108處,製程包括藉由接觸第一基板之非傳導接合層及第二基板之非傳導接合層來將第二基板之前側耦接至第一基板之背側。在一具體實例中,第一基板之側邊緣相對於第二基板之側邊緣未對準。耦接包括使第一基板之第一電路元件與第二基板之第一電路元件接觸(例如,混合接合)。
在區塊2110處,製程包括用模製物(諸如,模製物204)覆蓋第一基板之側邊緣及第二基板之側邊緣。在一實施方案中,製程包括用模製物覆蓋第二基板之背側。在各種具體實例中,模製物包括超過一個層或超過一種材料或化合物。在一些具體實例中,複數個模製物層中之至少一者包括顆粒以幫助均衡組件之CTE,從而避免組件之翹曲。
在一具體實例中,第二基板之背側包括第二非傳導接合層及經暴露電性傳導第二電路元件。在具體實例中,第二基板具有第二傳導通孔,該第二傳導通孔電耦接第二基板之第一電路元件及第二電路元件。
在一實施方案中,製程包括提供具有前側及背側之第三基板,前側包括非傳導接合層及經暴露電性傳導第一電路元件。製程包括藉由使第三基板之非傳導接合層與第二基板之非傳導接合層接觸來將第三基板之前側耦接至第二基板之背側。在一具體實例中,第三基板之側邊緣相對於第二基板之側邊緣及/或第一基板之側邊緣未對準。耦接包括使第三基板之第一電路元件與第二基板之第二電路元件接觸(例如,混合接合)。
在實施方案中,製程包括在第一基板之周界及/或第二基板之周界處形成第一基板之接合層及/或第二基板之接合層處之凹部,及在用模製物覆蓋第一基板之側邊緣及第二基板之側邊緣之前用低黏度化合物填充至少該凹部。
在另一實施方案中,製程包括用模製物覆蓋第三基板之側邊緣。在再一實施方案中,製程包括用模製物覆蓋第三基板之背側。
在一實施方案中,製程包括將微電子堆疊混合接合至具有至少一個線接合接觸墊之半導體插入件。在另一實施方案中,製程包括將插入件耦接至具有第二線接合接觸墊之層合物,及用接線將插入件之至少一個線接合接觸墊接合至層合物之第二線接合接觸墊。舉例而言,插入件可混合接合至層合物。
在其他實施方案中,微電子組件之各種部分覆蓋有一或多個模製物層,而其他部分不覆蓋有模製物。
儘管在此處論述各種實施方案及實例,但其他實施方案及實例可藉由組合個別實施方案及實例之特徵及元件來成為可能。在各種具體實例中,相較於本文中所描述之製程步驟,一些製程步驟可經修改或消除。
本文中所描述之技術、構件及裝置不限於圖1至21之說明,且可在不脫離本發明之範疇的情況下應用於包括其他電性構件之其他設計、類型、配置及構造。在一些情況下,額外或替代構件、技術、序列或製程可用於實施本文中所描述之技術。此外,構件及/或技術可以各種組合經配置及/或組合,同時引起類似或大致相同之結果。
結論
儘管已以特定針對於結構特徵及/或方法行動之語言描述了本發明之實施方案,但應理解,實施方案不一定限於所描述之特定特徵或行動。確切而言,將特定特徵及動作揭示為實施實例裝置及技術之代表性形式。
本文之每項申請專利範圍構成單獨具體實例,且組合不同申請專利範圍之具體實例及/或不同具體實例在本發明之範疇內,且將在查閱本發明之後對於所屬領域中具有通常知識者顯而易見。
100‧‧‧堆疊/微電子組件
102‧‧‧晶粒
102'‧‧‧晶粒
102"‧‧‧晶粒
104‧‧‧基底基板
106‧‧‧絕緣層/介電層
108‧‧‧接合表面
110‧‧‧傳導特徵
112‧‧‧傳導跡線
114‧‧‧傳導矽穿孔
116‧‧‧電耦接墊/襯墊
200‧‧‧微電子組件
202‧‧‧主晶圓
204‧‧‧模製物
206‧‧‧電接觸/端子
802‧‧‧散熱片
902‧‧‧其他構件
1100‧‧‧共同堆疊/部分共同堆疊
1202‧‧‧蝕刻/凹部
1302‧‧‧第一低黏度化合物
1502‧‧‧邏輯晶粒
1602‧‧‧覆晶端子
1604‧‧‧模製物
1700‧‧‧組件
1702‧‧‧插入件
1704‧‧‧散熱片/冷卻裝置
1706‧‧‧線接合墊
1802‧‧‧層合物
1804‧‧‧接線
1902‧‧‧線接合墊
1904‧‧‧構件
1906‧‧‧模製物
2100‧‧‧製程
2102‧‧‧區塊
2104‧‧‧區塊
2106‧‧‧區塊
2108‧‧‧區塊
2110‧‧‧區塊
e‧‧‧誤差/未對準
參看隨附圖式闡述具體實施方式。在圖式中,元件符號之一或多個最左側數字鑑別首次出現該元件符號之圖式。在不同圖式中使用相同元件符號指示類似或相同物件。
對此論述,圖式中所說明之裝置及系統展示為具有大量構件。如本文中所描述,裝置及/或系統之各種實施方案可包括較少構件且保持在本發明之範疇內。替代地,裝置及/或系統之其他實施方案可包括額外構件或所描述構件之各種組合,且保持在本發明之範疇內。
圖1為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖。
圖2為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中不覆蓋該堆疊之頂部。
圖3為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中覆蓋該堆疊之頂部。
圖4為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中不覆蓋該堆疊之頂部且模製物延伸至堆疊之底部。
圖5為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中覆蓋該堆疊之頂部且模製物延伸至堆疊之底部。
圖6為根據一具體實例之具有大小不等晶粒之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中覆蓋該堆疊之頂部。
圖7為根據一具體實例之具有大小不等晶粒之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中覆蓋該堆疊之頂部且模製物延伸至堆疊之底部。
圖8為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中堆疊之頂部晶粒在一側上並不具有互連件。
圖9為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖,在該具體實例中堆疊之頂部晶粒在一側上並不具有互連件且模製物延伸至堆疊之底部。
圖10為根據一具體實例之包括晶粒在單一層級上之一些橫向放置的例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖。
圖11為根據一具體實例之包括晶粒及晶圓在單一層級上之一些橫向放置的例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖。
圖12為根據一具體實例之包括晶粒邊緣之一些蝕刻的例示性晶粒對晶圓及/或晶粒對晶粒堆疊之橫截面剖面圖。
圖13為根據一具體實例之包括晶粒邊緣之一些蝕刻的例示性晶粒對晶圓及/或晶粒對晶粒堆疊及模製物之橫截面剖面圖。
圖14為根據另一具體實例之包括晶粒邊緣之一些蝕刻的例示性晶粒對晶圓及/或晶粒對晶粒混合接合堆疊之橫截面剖面圖。
圖15為根據一具體實例之例示性晶粒對晶圓及/或晶粒對晶粒記憶體堆疊之橫截面剖面圖。
圖16為根據一具體實例之包括覆晶封端的例示性晶粒對晶圓及/或晶粒對晶粒混合接合堆疊之橫截面剖面圖。
圖17至20展示根據各種具體實例之包括基板上之各種組合的例示性晶粒對晶圓及/或晶粒對晶粒混合接合堆疊之橫截面剖面圖。
圖21為根據一具體實例之說明用於形成經堆疊及經接合結構之例示性製程的流程圖。
100‧‧‧堆疊/微電子組件
102‧‧‧晶粒
102'‧‧‧晶粒
104‧‧‧基底基板
106‧‧‧絕緣層/介電層
108‧‧‧接合表面
110‧‧‧傳導特徵
112‧‧‧傳導跡線
114‧‧‧傳導矽穿孔
116‧‧‧電耦接墊/襯墊
e‧‧‧誤差/未對準
Claims (35)
- 一種微電子組件,其包含:第一基板,其具有第一接合表面及嵌入至該第一基板中之第一微電子電路元件,該第一基板之該第一電路元件之一部分在該第一基板之該第一接合表面處暴露;第二基板,其具有第一接合表面及嵌入至該第二基板中之第一微電子電路元件,該第二基板之該第一電路元件之一部分在該第二基板之該第一接合表面處暴露,該第二基板之該第一接合表面混合接合至該第一基板之該第一接合表面而無需黏合劑,使得該第二基板之該第一電路元件電耦接至該第一基板之該第一電路元件,其中該第一基板之側邊緣相對於該第二基板之側邊緣未對準;以及多層密封體,其覆蓋至少該第二基板之前述側邊緣,其中所述多層密封體包括所述第二基板的周界表面處具有第一熱膨脹係數的第一層以及覆蓋在所述第一層上的具有與所述第一熱膨脹係數不同的熱膨脹係數的第二層。
- 如請求項1所述之微電子組件,其進一步包含第一傳導通孔,該第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板。
- 如請求項2所述之微電子組件,其中該第一基板包括與該第一接合表面相對之第二表面,且其中該第一傳導通孔延伸至該第一基板之該第二表面且提供從該第一基板之該第一接合表面至該第一基板之該第二表面之電連接性。
- 如請求項3所述之微電子組件,其進一步包含端子連接件,該端子連接件耦接至該第一基板之該第二表面且電耦接至該第一傳導通孔。
- 如請求項2所述之微電子組件,其中該第二基板包括與該第一接合 表面相對之第二接合表面及嵌入至該第二基板中之第二微電子電路元件,該第二基板之該第二電路元件之一部分在該第二基板之該第二接合表面處暴露。
- 如請求項5所述之微電子組件,其進一步包含第二傳導通孔,該第二傳導通孔電耦接至該第二基板之該第一電路元件及該第二電路元件且至少部分地延伸穿過該第二基板,該第二傳導通孔提供從該第二基板之該第一接合表面至該第二基板之該第二接合表面之電連接性。
- 如請求項6所述之微電子組件,其中該第二傳導通孔提供從該第一基板之第二表面至該第二基板之該第二接合表面之電連接性,該第一基板之該第二表面與該第一基板之該第一接合表面相對。
- 如請求項6所述之微電子組件,其進一步包含第三基板,該第三基板具有第一接合表面及嵌入至該第三基板中之第一微電子電路元件,該第三基板之該第一電路元件之一部分在該第三基板之該第一接合表面處暴露,該第三基板之該第一接合表面接合至該第二基板之該第二接合表面,使得該第三基板之該第一電路元件電耦接至該第二基板之該第二電路元件。
- 如請求項8所述之微電子組件,其中該第三基板之側邊緣相對於該第二基板之前述側邊緣或該第一基板之前述側邊緣未對準。
- 如請求項8所述之微電子組件,其中該密封體覆蓋該第一基板之前述側邊緣、該第二基板之前述側邊緣及該第三基板之前述側邊緣。
- 如請求項8所述之微電子組件,其中該密封體覆蓋該第二基板之前述側邊緣及該第三基板之前述側邊緣,而不覆蓋該第一基板之前述側邊緣。
- 如請求項8所述之微電子組件,其中該密封體覆蓋與該第三基板之該第一接合表面相對之該第三基板之第二表面。
- 如請求項1所述之微電子組件,其中該模製物覆蓋與該第一基板之該第一接合表面相對之該第二基板之第二表面。
- 一種微電子組件,其包含第一微電子組件和第二微電子組件,其中所述第一微電子組件和第二微電子組件皆為如請求項10所述之微電子組件。
- 如請求項14所述之微電子組件,其中第一基板、第二基板及第三基板之佔據面積為非均一的,且其中自該第一基板延伸至該第三基板之密封體之外部側邊緣為平面的。
- 一種微電子組件,其包含:多個微電子元件的複數個相鄰堆疊,每個堆疊包含:第一基板,其具有第一接合表面及嵌入至該第一基板中之第一微電子電路元件,該第一基板之該第一電路元件之一部分在該第一基板之該第一接合表面處暴露,且第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板;第二基板,其具有第一接合表面及嵌入至該第二基板中之第一微電子電路元件,該第二基板之該第一電路元件之一部分在該第二基板之該第一接合表面處暴露,且第二傳導通孔電耦接至該第二基板之該第一電路元件且至少部分地延伸穿過該第二基板,該第二基板之該第一接合表面混合接合至該第一基板之該第一接合表面而無需黏合劑,使得該第二基板之該第一電路元件電耦接至該第一基板之該第一電路元件,其中該第一基板之側邊緣相對於該第二基板之側邊緣未對準;以及密封體,其覆蓋每個堆疊中的至少該第二基板之前述側邊緣,每個堆疊包括面向相鄰堆疊的側邊緣之所述側邊緣。
- 如請求項16所述之微電子組件,其中該第一基板包括與該第一接合表面相對之第二表面,且其中該第一傳導通孔延伸至該第一基板之該第二表面且提供從該第一基板之該第一接合表面至該第一基板之該第二表面之電連接性。
- 如請求項17所述之微電子組件,其中該第二基板包括與該第一接合表面相對之第二接合表面及嵌入至該第二基板中之第二微電子電路元件,該第二基板之該第二電路元件之一部分在該第二基板之該第二接合表面處暴露,且其中該第二傳導通孔電耦接至該第二基板之該第二電路元件。
- 如請求項18所述之微電子組件,其中該第二基板之該第一接合表面及該第二接合表面中之至少一者包括該第一接合表面及該第二接合表面中之前述至少一者的周界的蝕刻部分,其在該第二基板之周界邊緣處形成有意的凹部。
- 如請求項19所述之微電子組件,其中該密封體包含未具有顆粒之第一低黏度材料,該第一低黏度材料滲透該第二基板之該周界邊緣處的該凹部,且具有顆粒之第二材料覆蓋在該第一低黏度材料上方。
- 如請求項16所述之微電子組件,其進一步包含層合物及/或插入件,且其中複數個經密封的該微電子元件之堆疊混合接合至該層合物或該插入件而無需黏合劑或中介材料。
- 如請求項21所述之微電子組件,其進一步在該層合物之表面上及/或在該插入件之表面上包含至少一個線接合墊。
- 如請求項21所述之微電子組件,其中該層合物使用接線來耦接至該插入件,該接線耦接於該層合物之表面上之線接合墊處及該插入件之表面上之線接合墊處。
- 如請求項21所述之微電子組件,其進一步包含非密封晶粒,該非密封晶粒在無黏合劑之情況下混合接合至該層合物及/或該插入件。
- 如請求項16所述之微電子組件,其中至少該第二基板包含固態記憶體裝置。
- 一種形成微電子組件之方法,其包含: 形成微電子堆疊,其包含:提供具有前側及背側之第一基板,該背側具有包含非傳導接合層之接合表面以及經暴露電性傳導第一電路元件,該第一基板具有第一傳導通孔,該第一傳導通孔電耦接至該第一基板之該第一電路元件且至少部分地延伸穿過該第一基板;提供具有前側及背側之第二基板,該前側包括非傳導接合層及經暴露電性傳導第一電路元件;藉由使該第一基板之該非傳導接合層與該第二基板之該非傳導接合層接觸來將該第二基板之該前側耦接至該第一基板之該背側,該第一基板之側邊緣相對於該第二基板之側邊緣未對準,且使該第一基板之該第一電路元件與該第二基板之該第一電路元件接觸;以及用多層密封體覆蓋至少該第二基板之前述側邊緣,所述多層密封體包括在所述第二基板的周界表面處具有每體積第一顆粒含量的第一層和覆蓋在所述第一層上的每顆粒含量大於所述每體積第一顆粒含量的第二層。
- 如請求項26所述之方法,其進一步包含用該密封體覆蓋該第二基板之該背側。
- 如請求項26所述之方法,其中該第二基板之該背側包括第二非傳導接合層及經暴露電性傳導第二電路元件,該第二基板具有第二傳導通孔,該第二傳導通孔電耦接該第二基板之該第一電路元件及該第二電路元件。
- 如請求項28所述之方法,其進一步包含:提供具有前側及背側之第三基板,該前側包括非傳導接合層及經暴露電性傳導第一電路元件;藉由使該第三基板之該非傳導接合層與該第二基板之該非傳導接合層接觸來將該第三基板之該前側耦接至該第二基板之該背側,該第三基板之側邊緣相 對於該第二基板之側邊緣及/或該第一基板之側邊緣未對準,且使該第三基板之該第一電路元件與該第二基板之該第二電路元件接觸;以及用該密封體覆蓋該第三基板之前述側邊緣。
- 如請求項26所述之方法,其進一步包含在該第一基板之一周界處之該第一基板之該接合層處及/或該第二基板之一周界處之該第二基板之該接合層處形成一凹部,及在用該密封體覆蓋該第一基板之該些側邊緣及該第二基板之該些側邊緣之前,用一低黏度層填充至少該凹部。
- 如請求項26所述之方法,其進一步包含將該微電子堆疊混合接合至具有至少一個線接合接觸墊之半導體插入件。
- 如請求項31所述之方法,其進一步包含將該插入件耦接至具有第二線接合接觸墊之層合物,及用接線將該插入件之該至少一個線接合接觸墊接合至該層合物之該第二線接合接觸墊。
- 如請求項26所述之方法,其中形成該微電子組件包含形成複數個微電子堆疊。
- 一種微電子組件,其包含:第一晶粒,其具有第一接合表面及嵌入至該第一晶粒中之第一微電子電路元件,該第一電路元件之一部分在該第一晶粒之該第一接合表面處暴露;以及第二晶粒,其具有第一接合表面及嵌入至該第二晶粒中之第一微電子電路元件,該第二晶粒之該第一電路元件之一部分在該第二晶粒之該第一接合表面處暴露,該第一晶粒之該第一接合表面混合接合至該第二晶粒之該第一接合表面,使該第一晶粒電耦接至該第二晶粒而無需黏合層,其中該第一晶粒之側邊緣包含比安置於該第二晶粒之側邊緣上之密封體層薄的密封體層,以及其中在該第一晶粒處的所述密封體層及/或在該第二晶粒處的所述密封體層具有不均勻的密度。
- 一種微電子組件,其包含:第一晶粒,其具有第一接合表面以及嵌入所述第一晶粒的第一微電子電路元件,所述第一微電子電路元件的一部分在所述第一晶粒的所述第一接合表面處暴露;第二晶粒,其具有第一接合表面以及嵌入所述第二晶粒的第一微電子電路元件,所述第二晶粒的所述第一微電子電路元件的一部分在所述第二晶粒的所述第一接合表面處暴露,該第一晶粒之該第一接合表面混合接合至該第二晶粒之該第一接合表面,使該第一晶粒電耦接至該第二晶粒而無需黏合劑並且形成堆疊;密封體,其覆蓋至少該第二晶粒之側邊緣;以及半導體插入件,其具有至少一個線接合接觸墊,所述堆疊混合接合到所述插入件。
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