Classifications

• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
  • H10W70/60—Insulating or insulated package substrates; Interposers; Redistribution layers
  • H10W70/67—Insulating or insulated package substrates; Interposers; Redistribution layers characterised by their insulating layers or insulating parts
  • H10W70/68—Shapes or dispositions thereof
  • H10W70/685—Shapes or dispositions thereof comprising multiple insulating layers
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W20/00—Interconnections in chips, wafers or substrates
  • H10W20/20—Interconnections within wafers or substrates, e.g. through-silicon vias [TSV]
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W20/00—Interconnections in chips, wafers or substrates
  • H10W20/01—Manufacture or treatment
  • H10W20/021—Manufacture or treatment of interconnections within wafers or substrates
  • H10W20/023—Manufacture or treatment of interconnections within wafers or substrates the interconnections being through-semiconductor vias
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W20/00—Interconnections in chips, wafers or substrates
  • H10W20/01—Manufacture or treatment
  • H10W20/071—Manufacture or treatment of dielectric parts thereof
  • H10W20/081—Manufacture or treatment of dielectric parts thereof by forming openings in the dielectric parts
  • H10W20/082—Manufacture or treatment of dielectric parts thereof by forming openings in the dielectric parts the openings being tapered via holes
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
  • H10W70/01—Manufacture or treatment
  • H10W70/05—Manufacture or treatment of insulating or insulated package substrates, or of interposers, or of redistribution layers
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
  • H10W70/60—Insulating or insulated package substrates; Interposers; Redistribution layers
  • H10W70/62—Insulating or insulated package substrates; Interposers; Redistribution layers characterised by their interconnections
  • H10W70/65—Shapes or dispositions of interconnections
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
  • H10W70/60—Insulating or insulated package substrates; Interposers; Redistribution layers
  • H10W70/62—Insulating or insulated package substrates; Interposers; Redistribution layers characterised by their interconnections
  • H10W70/66—Conductive materials thereof

Definitions

• Integrated circuit technology has achieved great strides in advancing computing power through miniaturization of active and passive components.
• the package devices can be found in many electronic devices, including processors, servers, radio frequency (RF) integrated circuits, etc.
• Packaging technology becomes cost-effective in high pin count devices and/or high production volume components.
• Stack via structure design rules specify large pads for safe landing.
• larger landing pad also referred to as capture pad
• placement accuracy is directly related with via bottom stress and reliability problems.
• stack via pad affects all layer via pad dimensions and design flexibility due to reduction in routing space.
• the stack via structure may also comprise a first via stacked over and electrically coupled with the capture pad.
• the stack via structure may further comprise a second via stacked over and electrically coupled with the first via.
• the stack via structure may yet comprise a cover pad stacked over and electrically coupled with the second via.
• a top width of the first via may be wider than a bottom width of the second via.
• a recess may be formed in the first via to partially extend into a top surface thereof.
• a bottom portion of the second via may be within the recess.
• the bottom portion of the second via may extend from a bottom surface thereof up to a height equal to a depth of the recess.
• the second via may be in contact with the first via within the recess.
• the stack layer structure may comprise a capture pad and an inner via formed in an inner dielectric layer.
• the inner via may be stacked over and electrically coupled with the capture pad.
• the stack layer structure may also comprise one or more intermediate vias formed in corresponding one or more intermediate dielectric layers stacked over the inner dielectric layer.
• the one or more intermediate vias may be stacked over and electrically coupled with the inner via.
• the stack layer structure may further comprise an outer via formed in an outer dielectric layer stacked over the one or more intermediate dielectric layers.
• the outer via may be stacked over and electrically coupled with the one or more intermediate vias.
• the stack layer structure may yet comprise a cover pad stacked over and electrically coupled with the outer via.
• An exemplary method of fabricating a stack via structure may comprise forming a capture pad.
• the method may also comprise a first via stacked over and electrically coupled with the capture pad.
• the method may further comprise forming a second via stacked over and electrically coupled with the first via.
• the method may yet comprise forming a cover pad stacked over and electrically coupled with the second via.
• a top width of the first via may be wider than a bottom width of the second via.
• a recess may be formed in the first via to partially extend into a top surface thereof.
• a bottom portion of the second via may be within the recess.
• the bottom portion of the second via may extend from a bottom surface thereof up to a height equal to a depth of the recess.
• the second via may be in contact with the first via within the recess.
• An exemplary method of fabricating a stack layer structure may comprise forming a capture pad and an inner via in an inner dielectric layer.
• the inner via may be stacked over and electrically coupled with the capture pad.
• the method may also comprise forming one or more intermediate vias in corresponding one or more intermediate dielectric layers stacked over the inner dielectric layer.
• the one or more intermediate vias may be stacked over and electrically coupled with the inner via.
• the method may further comprise forming an outer via in an outer dielectric layer stacked over the one or more intermediate dielectric layers.
• the outer via may be stacked over and electrically coupled with the one or more intermediate vias.
• the method may yet comprise forming a cover pad stacked over and electrically coupled with the outer via.
• FIGS. 1A and IB illustrate a sectional view and a top view of a layer of a conventional stack via structure.
• FIGS. 2A and 2B illustrate a sectional view and a top view of a layer of an example stack via structure in accordance with one or more aspects of the disclosure.
• FIG. 3 illustrates a detailed view of an example via structure in accordance with one or more aspects of the disclosure.
• FIGS. 5 A - 5G illustrate examples of stages of fabricating another stack layer structure in accordance with one or more aspects of the disclosure.
• FIG. 6 illustrates a flow chart of an example method of fabricating a stack via structure in accordance with one or more aspects of the disclosure.
• FIGS. 7 and 8 illustrate flow charts of an example method of fabricating a stack layer structure in accordance with one or more aspects of the disclosure.
• FIG. 9 illustrates a flow chart of another example method of fabricating a stack layer structure in accordance with one or more aspects of the disclosure.
• FIG. 10 illustrates a flow chart of a further example method of fabricating a stack layer structure in accordance with one or more aspects of the disclosure.
• FIG. 11 illustrates various electronic devices which may utilize one or more aspects of the disclosure.
• instances are identified where various component structures and portions of operations can be taken from known, conventional techniques, and then arranged in accordance with one or more exemplary embodiments. In such instances, internal details of the known, conventional component structures and/or portions of operations may be omitted to help avoid potential obfuscation of the concepts illustrated in the illustrative embodiments disclosed herein.
• FIG. 1A illustrates a sectional view of a conventional stack via structure 100.
• the stack via structure 100 includes vias 130 vertically stacked on each other. Each via 130 is on and in contact with capture pad 110 (also referred to as landing pad). A cover pad 120 is on and in contact with the uppermost via 130.
• the stack via structure 100 uses the capture pads 110 and the cover pad 120 for top and bottom connection.
• stack via structure design rules specify large pads for safe landing.
• larger pad design rules apply for improvement in placement accuracy.
• the diameter of the capture pad 110 is larger than the diameter of the via 130. This is seen in FIG. IB, which illustrates a top view of a layer of the conventional stack via structure 100.
• the diameter of the capture pad 110 is designed to be larger than the diameter of the via 130.
• a pattern line 150 may electrically couple two vias 130 with each other within the layer through the capture pad 110. Note that the larger diameter of the capture pad 110 reduces real estate available for routing of signals, which in turn means that design flexibility is reduced.
• FIG. 2A An example of a proposed stack via structure 200 is illustrated in FIG. 2A.
• the stack via structure 200 may comprise - from bottom to top - a capture pad 210, an inner via 242, an intermediate via 240, an outer via 244, and a cover pad 220.
• terms such as top, bottom, upper, lower, left, right, etc. are used for ease of description. Unless specifically stated otherwise, these terms should not be taken to mean absolute orientations.
• the stack of vias 240, 242, 244 and/or pads 210, 220 may be formed from conductive materials such as copper (Cu), aluminum (Al), etc.
• the inner via 242 may be on and in contact with the capture pad 210
• the intermediate via 240 may be on and in contact with the inner via 242
• the outer via 244 may be on and in contact with the intermediate via 240
• the cover pad 210 may be on and in contact with the outer via 244.
• the capture pad 210 may be electrically coupled to the cover pad 220 through the inner via 242, the intermediate via 240, and the outer via 244, in that order.
• FIG. 2B illustrates a top view of a layer of the stack via structure 200.
• a pattern line 250 may electrically couple two vias 230 with each other within the layer. But unlike the situation illustrated in FIG. IB, there are no pads in the layer of the stack via structure 200. Thus, the pattern line 250 may contact the intermediate vias 240 directly. As a result, design flexibility may be enhanced by increasing area available for routing of signals.
• the first via 340A may be the inner via 242 or one of the one or more intermediate vias 240. Then the first via 340A may be stacked over and electrically coupled with the capture pad 210. It should be noted that stacked “on” does not necessarily require that the first via 340A be in contact with the inner via 242, although that is one of the possibilities. For example, all of the one or more intermediate vias 240 may be stacked over the capture pad 210. However, only the inner via 242 may be in contact with the capture pad 210. More particularly, a top surface of the capture pad 210 may be in contact with a bottom surface of the inner via 242.
• the second via 340B may be any via of the stack via structure 200 other than the inner via 242. That is, the second via 340B may be one of the one or more intermediate vias 240 or the outer via 244. Then the second via 340B may be stacked over and electrically coupled with the first via 340A. In this instance, since the first and second vias 340A, 340B are immediately adjacent vias, they may be in contact with each other.
• the cover pad 220 may be stacked over and electrically coupled with the second via 340B. Again, stacked “on” does not necessarily mean contact although that is a possibility. If the second via 340B is the outer via 244, then the cover pad 220 may be on and in contact with the second via 340B. More specifically, a bottom surface of the cover pad 220 may be in contact with a top surface of the outer via 244. But if the second via 340B is any one of the one or more intermediate vias 240, there would not be contact between the cover pad 220 and the second via 340B.
• the vias may be tapered so that their respective top widths are wider than their bottom widths.
• a top width thereof may be wider than a bottom width thereof.
• the top and bottom widths of the first via 340A may respectively be referred to as “first top width” and “first bottom width”.
• second top width top width of the second via 340B
• second bottom width bottom width of the second via 340B.
• the first top width may be wider than the second bottom width.
• a recess 345 may be formed to partially extend into the first via 340A from a top surface thereof. That is, the first via 340A may comprise the recess 345 that partially extends into the first via 340A from the top surface thereof.
• a portion of the second via 340B extending from a bottom surface thereof up to a height equal to a depth of the recess 345 may be inserted within the recess 345.
• this bottom portion of the second via 340B may be referred to as “second bottom portion”.
• the depth of the recess 345 may nominally range between 5% and 15% of a total height of the first via 340A.
• the second bottom portion may be in contact with the first via 340A within the recess 345 as highlighted by dotted ovals.
• the recess 345 may be tapered such that a recess top width (top width of the recess 345) is wider than a recess bottom width (bottom width of the recess 345).
• the contact between the first and second vias 340A, 340B may be such that side surface of the second bottom portion is in contact with a side surface of the recess 345.
• the second bottom surface i.e., the bottom surface of the second bottom portion (which is also the bottom portion of the second via (340B) may be in contact with a bottom surface of the recess 345.
• contact area may be increased, which in turn can enhance structural integrity. That is, the first and second vias 340A, 340B may be better anchored to each other.
• another pattern line 250 may be in contact with the second via 340B and a same or different via (e.g., same or different via 240) on a same layer as the second via 340B.
• the capture pad 210 may be electrically coupled to the cover pad 220, the inner via 242, the one or more intermediate vias 240, and the outer via 244, in that order. In FIG. 3, this may be translated as the capture pad 210 being electrically coupled to the cover pad 220 through the first via 340A and the second via 340B in that order.
• FIGS. 4A - 41 illustrate examples of stages of fabricating a stack layer structure in accordance with one or more aspects of the disclosure. Before describing the stages, attention is brought to FIG. 41 illustrating an example stack layer structure 400 in which the stack via structure 200 may be incorporated.
• the stack layer structure 400 may be an example of a stack layer structure based on an embedded trace substrate (ETS).
• ETS embedded trace substrate
• the stack layer structure 400 may comprise an initial layer 460, also referred to as base layer 460.
• the inner via 242 may be stacked over and electrically coupled with the capture pad 210.
• the stack layer structure 400 may also comprise an intermediate via 240 formed in an intermediate dielectric layer 425, which may itself be stacked over the inner dielectric layer 415.
• the stack via structure may include any number of intermediate vias 240.
• one intermediate dielectric layer 425 is shown in FIG. 41, there can be any number of intermediate dielectric layers 425.
• the stack layer structure 400 may comprise one or more intermediate vias 240 formed in corresponding one or more intermediate dielectric layers 425 which may be stacked over the inner dielectric layer 415.
• the one or more intermediate vias 240 may be stacked over and electrically coupled with the inner via 242.
• the stack layer structure 400 may further comprise an outer via 244 formed in an outer dielectric layer 435, which may be stacked over the one or more intermediate dielectric layers 425.
• the outer via 244 may be stacked over and electrically coupled with the one or more intermediate vias 240.
• the stack layer structure 400 may yet comprise a cover pad 220 stacked over and electrically coupled with the outer via 244.
• the cover pad 220 may be formed in a cover layer 445, which may be the outermost layer of the stack layer structure 400.
• the cover pad 220 may be exposed. That is, the cover pad 220 may be configured to enable a signal connection between the stack layer structure 400 and a device external to the stack layer structure 400.
• multiple cover pads 220 may serve as ball grid arrays (BGA).
• the stack layer structure 400 comprises first vias 340A and a second via 340B as described with respect to FIG. 3.
• the second via 340B may be immediately stacked over the first via 340.
• the first via 340A may be the inner via 242 or one of the one or more intermediate vias 240.
• the second via 340B may be one of the one or more intermediate vias 240 or the outer via 244. Details of the first and second vias 340A, 340B are provided above, and thus are not repeated here for sake of brevity.
• FIG. 4A illustrates a stage in which the capture pad 210 may be formed on a carrier 405.
• FIG. 4B illustrates a stage in which the inner dielectric layer 415 may be formed on the carrier 405 and covers the capture pad 210.
• the inner dielectric layer 415 may be laminated on the carrier 405.
• FIG. 4C illustrates a stage in which the inner dielectric layer 415 may be processed to form an inner via hole 417 to expose the capture pad 210.
• the inner via hole 417 may be formed by laser drilling.
• FIG. 4D illustrates a stage in which the inner dielectric layer 415 and the inner via hole 417 may be plated with conductive materials (e.g., Cu, Al, etc.) to form the inner via 242 to fill the inner via hole 417. At this stage, the recess is not yet formed in the inner via 242.
• conductive materials e.g., Cu, Al, etc.
• FIG. 4E illustrates a stage in which an intermediate via hole 427 may be formed in the intermediate dielectric layer 425.
• the intermediate dielectric layer 425 may be laminated on the inner dielectric layer 415.
• the intermediate dielectric layer 425 may then be drilled, e.g., through laser drilling, to expose the inner via 242. The drilling may also drill the recess in the inner 242.
• FIG. 4F illustrates a stage in which the intermediate dielectric layer 425 and the intermediate via hole 427 may be plated with conductive materials (e.g., Cu, Al, etc.) to form the intermediate via 240 to fill the intermediate via hole 427.
• the intermediate via 240 may also fill the recess of the inner via 242. At this stage, the recess is not yet formed in the intermediate via 240.
• FIG. 4G illustrates a stage in which an outer via hole 437 may be formed in the outer dielectric layer 435.
• the outer dielectric layer 435 may be laminated on the intermediate dielectric layer 425.
• the outer dielectric layer 435 may then be drilled, e.g., through laser drilling, to expose intermediate via 240.
• the drilling may also drill the recess in the intermediate via 240.
• FIG. 4H illustrates a stage in which the outer dielectric layer 435 and the outer via hole 437 may be plated with conductive materials (e.g., Cu, Al, etc.) to form the outer via 244 to fill the intermediate via hole 427.
• the outer via 244 may also fill the recess of the intermediate via 240.
• FIG. 41 illustrates a stage in which the carrier 405 may be removed and the initial layer 460 may be formed below the inner dielectric layer 415. Also, the cover pad 220 may be formed on the outer dielectric layer 435, the cover layer 445 may then be formed (e.g., laminated) on the outer dielectric layer 435 and the cover pad 220, which may then be processed to expose cover pad 220.
• FIGS. 5A - 5G illustrate examples of stages of fabricating another stack layer structure in accordance with one or more aspects of the disclosure.
• FIG. 5G illustrating an example stack layer structure 500 in which the stack via structure 200 may be incorporated.
• the stack layer structure 500 may be an example of a stack layer structure based on a semi-additive process (SAP) or a modified SAP (mSAP) substrates.
• SAP semi-additive process
• mSAP modified SAP
• the stack layer structure 500 may comprise an initial layer 560, also referred to as a core layer 560. Note that there are two stack via structures, one above and other below the core layer. For ease of reference, the portion of the stack layer structure 500 above the core layer 560 will be referenced with elements ending with ‘A’ and the portion below the core layer 560 will be referenced with elements ending with ‘B’.
• the portion above the core layer 560 may be similar to the stack layer structure 400 of FIG. 41 above the base layer 460. That is, the stack layer structure 500 above the initial layer 560 may comprise a capture pad 210A and an inner via 242A formed in an inner dielectric layer 515A stacked over the initial layer 560. The inner via 242A may be stacked over and electrically coupled with the capture pad 210A.
• the stack layer structure 500 above the initial layer 560 may also comprise an intermediate via 240A formed in an intermediate dielectric layer 525A stacked over the inner dielectric layer 515 A.
• the stack layer structure 500 may comprise one or more intermediate vias 240A formed in corresponding one or more intermediate dielectric layers 525 A stacked over the inner dielectric layer 515A.
• the one or more intermediate vias 240A may be stacked over and electrically coupled with the inner via 242A.
• the stack layer structure 500 above the initial layer 560 may further comprise an outer via 244A formed in an outer dielectric layer 535A stacked over the one or more intermediate dielectric layers 525A.
• the outer via 244A may be stacked over and electrically coupled with the one or more intermediate vias 240 A.
• the stack layer structure 500 above the initial layer 560 may yet comprise a cover pad 220A stacked over and electrically coupled with the outer via 244A.
• the cover pad 220A may be formed in a cover layer 445A, which may be the outermost layer of the stack layer structure 500 above the initial layer 560.
• the cover pad 220A may be exposed.
• the cover pad 220A may be configured to enable a signal connection with a device external to the stack layer structure 500.
• the stack layer structure 500 above the initial layer 560 comprises a first via 340A and a second via 340B as described with respect to FIG. 3.
• the second via 340B may be immediately stacked over the first via 340A.
• the first via 340A may be the inner via 242 or one of the one or more intermediate vias 240.
• the second via 340B may be one of the one or more intermediate vias 240 or the outer via 244. Details of the first and second vias 340A, 340B are provided above, and thus are not repeated here for sake of brevity.
• the portion below the core layer 560 may be similar to the portion above the core layer 560, but in opposite orientation (e.g., below). Term “lower” will be used to distinguish the components below the core layer 560 from components above.
• the stack layer structure 500 below the initial layer 560 may comprise a lower capture pad 210B and a lower inner via 242B formed in a lower inner dielectric layer 515B stacked below the initial layer 560.
• the lower inner via 242B may be stacked below and electrically coupled with the lower capture pad 210B.
• the stack layer structure 500 below the initial layer 560 may also comprise a lower intermediate via 240B formed in a lower intermediate dielectric layer 525B stacked below the lower inner dielectric layer 515B. While one lower intermediate via 240B formed in one lower intermediate dielectric layer 525B is shown, the stack layer structure 500 may comprise one or more lower intermediate vias 240B formed in corresponding one or more lower intermediate dielectric layers 525B stacked below the lower inner dielectric layer 515B. The one or more lower intermediate vias 240B may be stacked below and electrically coupled with the lower inner via 242B. It should be noted that the number of intermediate dielectric layers 525 A above the core layer 560 may be independent of the number of lower intermediate layers 525B below the core layer 560.
• the stack layer structure 500 below the initial layer 560 may further comprise a lower outer via 244B formed in a lower outer dielectric layer 535B stacked below the one or more lower intermediate dielectric layers 525B.
• the lower outer via 244B may be stacked below and electrically coupled with the one or more intermediate vias 240B.
• the stack layer structure 500 below the initial layer 560 may yet comprise a lower cover pad 220B stacked below and electrically coupled with the lower outer via 244B.
• the lower cover pad 220B may be formed in a lower cover layer 445B, which may be the outermost layer of the stack layer structure 500 below the initial layer 560.
• the lower cover pad 220B may be exposed.
• the lower cover pad 220B may be configured to enable a signal connection with a device external to the stack layer structure 500.
• the stack layer structure 500 below the initial layer 560 comprises first and second lower vias, which may be similar to the first and second vias 340A, 340B as described with respect to FIG. 3, except that the orientations may be reversed (not shown). Then it may be said that the second lower via may be immediately stacked below the first lower via.
• the first lower via may be the lower inner via 242B or one of the one or more lower intermediate vias 240B.
• the lower second via may be one of the one or more lower intermediate vias 240B or the lower outer via 244B.
• stack via structures on both sides of the initial layer 560 are shown, this is merely an example. It is contemplated that the proposed stack via structure of FIGS. 2A, 2B, 3 may be on one or both sides of the initial layer 560.
• FIG. 5A illustrates a stage in which the capture pad 210A may be formed on the initial (or core) layer 560, and the lower capture pad 210B may be formed below the initial layer 560. One or both of the capture pad 210A and the lower capture pad 210B may be in contact with the initial layer 560.
• FIG. 5B illustrates a stage in which the inner dielectric layer 515A may be formed on the initial layer 560 and cover the capture pad 210A. Also, the lower inner dielectric layer 515B may be formed below the initial layer 560 and cover the lower capture pad 21 OB. For example, the inner dielectric layer 515A may be laminated on the initial layer 560. Alternatively or in addition thereto, the lower inner dielectric layer 515B may be laminated below the initial layer 560.
• FIG. 5C illustrates a stage in which the inner dielectric layer 515A may be processed to form an inner via hole 517A to expose the capture pad 210A.
• the lower inner dielectric layer 515B may be processed to form a lower inner via hole 517B to expose the lower capture pad 210B.
• the inner via hole 517A and/or the lower inner via hole 517B may be formed by laser drilling.
• FIG. 5D illustrates a stage in which the inner dielectric layer 515 A and the inner via hole 517A may be plated with conductive materials (e.g., Cu, Al, etc.) to form the inner via 242A to fill the inner via hole 517A.
• the recess is not yet formed in the inner via 242A.
• the lower inner dielectric layer 515B and the lower inner via hole 517B may be plated with conductive materials (e.g., Cu, Al, etc.) to form the lower inner via 242B to fill the lower inner via hole 517B.
• the lower recess is not yet formed in the lower inner via 242B.
• FIG. 5E illustrates a stage in which an intermediate via hole 527A may be formed in the intermediate dielectric layer 525A.
• the intermediate dielectric layer 525A may be laminated on the inner dielectric layer 515A, and then drilled, e.g., through laser drilling. The drilling may also drill the recess in the inner via 242A.
• a lower intermediate via hole 527B may be formed in the lower intermediate dielectric layer 525B.
• the lower intermediate dielectric layer 525B may be laminated below the lower inner dielectric layer 515B, and then drilled, e.g., through laser drilling. The drilling may also drill the lower recess in the lower inner via 242B.
• FIG. 5F illustrates a stage in which the intermediate dielectric layer 525A and the intermediate via hole 527A may be plated with conductive materials (e.g., Cu, Al, etc.) to form the intermediate via 240A to fill the intermediate via hole 527 A.
• the intermediate via 240A may also fill the recess of the inner via 242A. At this stage, the recess is not yet formed in the intermediate via 240A.
• the lower intermediate dielectric layer 525B and the lower intermediate via hole 527B may be plated with conductive materials (e.g., Cu, Al, etc.) to form a lower intermediate via 240B to fill the lower intermediate via hole 527B.
• the lower intermediate via 240B may also fill the recess of the lower inner via 242B. At this stage, the lower recess is not yet formed in the lower intermediate via 240B.
• FIG. 5G illustrates a stage in which the outer dielectric layer 535A may be laminated on the intermediate dielectric layer 525A and drilled (e.g., by laser), which may also form the recess in the intermediate via 240A.
• the outer dielectric layer 535A and the intermediate via 240A may be plated with conductive materials (e.g., Cu, Al, etc.) to form the outer via 244A, which also fills the recess of the intermediate via 240 A.
• the cover pad 220A may be formed on the outer dielectric layer 535A, the cover layer 545A may then be formed (e.g., laminated) on the outer dielectric layer 535A and the cover pad 220 A. the cover layer 545 A may then be further processed, e.g., to enable connections with external devices.
• the lower outer dielectric layer 535B may be laminated below the lower intermediate dielectric layer 525B and drilled (e.g., by laser), which may also form the lower recess in the lower intermediate via 240B.
• the lower outer dielectric layer 535B and the lower intermediate via 240B may be plated with conductive materials (e.g., Cu, Al, etc.) to form the lower outer via 244B, which also fills the lower recess of the lower intermediate via 240B.
• the lower cover pad 220B may be formed below the lower outer dielectric layer 535B, the lower cover layer 545B may then be formed (e.g., laminated) below the lower outer dielectric layer 535B and the lower cover pad 220B.
• the lower cover layer 545B may then be further processed, e.g., to enable connections with external devices.
• multiple intermediate dielectric layers 525A and corresponding multiple intermediate vias 240A may be fabricated.
• multiple lower intermediate dielectric layers 525B and corresponding multiple lower intermediate vias 240B may be fabricated.
• the number of intermediate dielectric layers 525A may be independent of the number of lower intermediate dielectric layers 525B.
• FIG. 6 illustrates a flow chart of an example method 600 of fabricating a stack via structure, such as the stack via structure 200, in accordance with one or more aspects of the disclosure.
• a capture pad 210 may be formed.
• a first via 340A may be formed.
• the first via 340A may be stacked over and electrically coupled with the capture pad 210.
• a recess 345 may be formed to partially extend into the first via 340A from a top surface thereof.
• the recess 345 may be formed through drilling, such as laser drilling.
• the second via 340B may be formed.
• the second via 340B may be stacked over and electrically coupled with the first via 340A.
• a second bottom portion portion of the second via 340B extending from a bottom surface thereof up to a height equal to a depth of the recess 345) may be within the recess 345.
• the second via 340B may be in contact with the first via 340A within the recess 345. Details of the first and second vias 340 A, 340B are described above with respect to FIGS. 2A, 2B and 3, and thus will not be repeated here for sake of brevity.
• a cover pad 220 may be formed.
• the cover pad 220 may be stacked over and electrically coupled with the second via 340B.
• FIG. 7 illustrates a flow chart of an example method 700 of fabricating a stack layer structure, such as the stack layer structure 400 or 500, in accordance with one or more aspects of the disclosure.
• a capture pad 210, 210A and an inner via 242, 242 A may be formed in an inner dielectric layer 415, 515A.
• the inner via 242, 242 A may be stacked over and electrically coupled with the capture pad 210, 210A.
• one or more intermediate vias 240, 240A may be formed in corresponding one or more intermediate dielectric layers 425, 525 A, which may be stacked over the inner dielectric layer 415, 515A.
• the one or more intermediate vias 240, 240A may be stacked over and electrically coupled with the inner via 242, 242A.
• an outer via 244, 244A may be formed in an outer dielectric layer 435, 535A, which may be stacked over the one or more intermediate dielectric layers 425, 525 A.
• the outer via 244, 244A may be stacked over and electrically coupled with the one or more intermediate vias 240, 240A.
• the inner via 242, 242A or one of the one or more intermediate vias 240, 240A may serve as the first via 340A.
• one of the one or more intermediate vias 240, 240A or the outer via 244A may serve as the second via 340B. Details of the first and second vias 340 A, 340B are described above with respect to FIGS. 2A, 2B and 3, and thus will not be repeated here for sake of brevity.
• a cover pad 220, 220A may be formed.
• the cover pad 220, 220A may be stacked over and electrically coupled with the outer via 244, 244A.
• Implementing blocks 710 - 740 may fabricate the stack layer structure 400 or may fabricate a portion of the stack layer structure 500 above the initial layer 560.
• block 750 may be performed to fabricate a portion of the stack layer structure 500 below the initial layer 560.
• FIG. 8 illustrates a flow chart of an example process to implement block 750.
• a lower capture pad 210B and a lower inner via 242B may be formed in a lower inner dielectric layer 515B.
• the lower inner via 242B may be stacked below and electrically coupled with the lower capture pad 210B.
• one or more lower intermediate vias 240B may be formed in corresponding one or more lower intermediate dielectric layers 525B, which may be stacked over the lower inner dielectric layer 515B.
• the one or more lower intermediate vias 240B may be stacked over and electrically coupled with the lower inner via 242B.
• a lower outer via 244B may be formed in a lower outer dielectric layer 535B, which may be stacked over the one or more lower intermediate dielectric layers 525B.
• the lower outer via 244B may be stacked over and electrically coupled with the one or more lower intermediate vias 240B.
• the lower inner via 242B or one of the one or more lower intermediate vias 240B may serve as the first lower via.
• one of the one or more lower intermediate vias 240B or the lower outer via 244B may serve as the second lower via. Details of the first and second lower vias are described above, and thus will not be repeated here for sake of brevity.
• a lower cover pad 220B may be formed.
• the lower cover pad 220B may be stacked over and electrically coupled with the lower outer via 244B.
• FIG. 9 illustrates a flow chart of another example method 900 of fabricating a stack layer structure, such as the stack layer structure 400, in accordance with one or more aspects of the disclosure.
• a pattern layer may be formed on a carrier (e.g. carrier 405).
• a capture pad e.g., capture pad 210) may be formed as a part of the pattern layer.
• the carrier e.g., carrier 405
• a dielectric layer e.g., inner dielectric layer 415
• the dielectric layer (e.g., inner dielectric layer 415) may be drilled to expose the capture pad (e.g., capture pad 210).
• a pattern layer may be formed on the dielectric layer (e.g., inner dielectric layer 415, intermediate dielectric layer 425).
• the pattern layer may include a via (e.g., inner via 242, intermediate via 240).
• the dielectric layer e.g., inner dielectric layer 415, intermediate dielectric layer 425) may be laminated with another dielectric layer (e.g., intermediate dielectric layer 425, outer dielectric layer 435).
• the another dielectric layer (e.g., intermediate dielectric layer 425, outer dielectric layer 435) may be drilled to expose the via (e.g., inner via 242, intermediate via 240).
• Blocks 940, 950, 960 may be repeated multiple times to form one or more intermediate dielectric layers (e.g., one or more intermediate dielectric layers 425) and corresponding one or more intermediate vias (e.g., one or more intermediate vias 240).
• an outer dielectric layer e.g., outer dielectric layer 435) and an outer via (e.g., outer via 244) may be formed.
• the carrier e.g., carrier 405
• the carrier may be detached.
• a base layer (e.g., base layer 460) may be formed.
• the base layer may be below and in contact with the inner dielectric layer (e.g., inner dielectric layer 415).
• a cover layer (e.g., cover layer 445) including a cover pad (e.g., cover pad 220) may be formed on the outer dielectric layer (e.g., outer dielectric layer 435).
• FIG. 10 illustrates a flow chart of a further example method 1000 of fabricating a stack layer structure, such as the stack layer structure 500, in accordance with one or more aspects of the disclosure.
• an upper pattern layer may be formed on a core layer (e.g., core layer 560).
• An upper capture pad e.g., capture pad 210A
• a lower pattern layer may be formed below the core layer.
• a lower capture pad e.g., lower capture pad 210B
• an upper dielectric layer e.g., inner dielectric layer 515A
• the core layer e.g., core layer 560
• a lower dielectric layer e.g., lower inner dielectric layer 515B
• the upper dielectric layer e.g., inner dielectric layer 515A
• the lower dielectric layer e.g., lower inner dielectric layer 515B
• the lower capture pad e.g., lower capture pad 210B
• an upper pattern layer may be formed on the upper dielectric layer (e.g., inner dielectric layer 515A, intermediate dielectric layer 525 A).
• the upper pattern layer may include an upper via (e.g., inner via 242A, intermediate via 240 A).
• a lower pattern layer may be formed on the lower dielectric layer (e.g., lower inner dielectric layer 515B, lower intermediate dielectric layer 525B).
• the lower pattern layer may include a lower via (e.g., lower inner via 242B, lower intermediate via 240B).
• the upper dielectric layer e.g., inner dielectric layer 515A, intermediate dielectric layer 525 A
• another upper dielectric layer e.g., intermediate dielectric layer 525A, outer dielectric layer 535A
• the lower dielectric layer e.g., lower inner dielectric layer 515B, lower intermediate dielectric layer 525B
• another lower dielectric layer e.g., lower intermediate dielectric layer 525B, lower outer dielectric layer 535B.
• the another upper dielectric layer e.g., intermediate dielectric layer 525A, outer dielectric layer 535A
• the upper via e.g., inner via 242A, intermediate via 240 A
• the another lower dielectric layer e.g., lower intermediate dielectric layer 525B, lower outer dielectric layer 535B
• the lower via e.g., lower inner via 242B, intermediate via 240B
• Blocks 1040, 1050, 1060 may be repeated multiple times to form one or more upper intermediate dielectric layers (e.g., one or more intermediate dielectric layers 525 A) and corresponding one or more upper intermediate vias (e.g., one or more intermediate vias 240A).
• blocks 1040, 1050, 1060 may be repeated multiple times to form one or more lower intermediate dielectric layers (e.g., one or more lower intermediate dielectric layers 525B) and corresponding one or more lower intermediate vias (e.g., one or more lower intermediate vias 240B).
• an upper outer dielectric layer e.g., outer dielectric layer 535A
• an upper outer via e.g., outer via 244A
• a lower outer dielectric layer e.g., lower outer dielectric layer 535B
• a lower outer via e.g., lower outer via 244B
• an upper cover layer e.g., cover layer 545 A including an upper cover pad (e.g., cover pad 220A) may be formed on the upper outer dielectric layer (e.g., outer dielectric layer 535A).
• a lower cover layer e.g., lower cover layer 545B including a lower cover pad (e.g., lower cover pad 220B) may be formed below the lower outer dielectric layer (e.g., lower outer dielectric layer 535B).
• the fabrication process known to those skilled in the art may have been omitted or combined in summary process portions to facilitate an understanding of the various aspects disclosed without a detailed rendition of each detail and/or all possible process variations.
• the illustrated configurations and descriptions are provided merely to aid in the explanation of the various aspects disclosed herein.
• the number and location of the inductors, the metallization structure may have more or less conductive and insulating layers, the cavity orientation, size, whether it is formed of multiple cavities, is closed or open, and other aspects may have variations driven by specific application design features, such as the number of antennas, antenna type, frequency range, power, etc. Accordingly, the forgoing illustrative examples and associated figures should not be construed to limit the various aspects disclosed and claimed herein.
• FIG. 11 illustrates various electronic devices which may utilize one or more aspects of the disclosure.
• a mobile phone device 1102, a laptop computer device 1104, and a fixed location terminal device 1106 may each be considered generally user equipment (UE) and may include any of the structures 1100 (e.g., the stack via structure 200, the stack layer structure 400, or the stack layer structure 500) as described herein.
• the devices 1102, 1104, 1106 illustrated in FIG. 11 are merely exemplary.
• Other electronic devices may also include the stack via structure and/or the stack layer structure including, but not limited to, a group of devices (e.g., electronic devices) that includes mobile devices, hand-held personal communication systems (PCS) units, portable data units such as personal digital assistants, global positioning system (GPS) enabled devices, navigation devices, set top boxes, music players, video players, entertainment units, fixed location data units such as meter reading equipment, communications devices, smartphones, tablet computers, computers, wearable devices, servers, routers, electronic devices implemented in automotive vehicles (e.g., autonomous vehicles), an Internet of things (loT) device or any other device that stores or retrieves data or computer instructions or any combination thereof.
• a group of devices e.g., electronic devices
• devices that includes mobile devices, hand-held personal communication systems (PCS) units, portable data units such as personal digital assistants, global positioning system (GPS) enabled devices, navigation devices, set top boxes, music players, video players, entertainment units, fixed location data units such as meter reading equipment, communications devices, smartphones, tablet computers,
• the foregoing disclosed devices and functionalities may be designed and configured into computer files (e.g., RTL, GDSII, GERBER, etc.) stored on computer-readable media. Some or all such files may be provided to fabrication handlers who fabricate devices based on such files. Resulting products may include semiconductor wafers that are then cut into semiconductor die and packaged into an antenna on glass device. The antenna on glass device may then be employed in devices described herein.
• computer files e.g., RTL, GDSII, GERBER, etc.
• Some or all such files may be provided to fabrication handlers who fabricate devices based on such files.
• Resulting products may include semiconductor wafers that are then cut into semiconductor die and packaged into an antenna on glass device. The antenna on glass device may then be employed in devices described herein.
• a stack via structure comprising: a capture pad; a first via stacked over and electrically coupled with the capture pad; a second via stacked over and electrically coupled with the first via; and a cover pad stacked over and electrically coupled with the second via, wherein a top width of the first via is wider than a bottom width of the second via, wherein a recess is formed in the first via to partially extend into a top surface thereof, and wherein a bottom portion of the second via is within the recess, the bottom portion of the second via extending from a bottom surface thereof up to a height equal to a depth of the recess, the second via being in contact with the first via within the recess.
• Clause 2 The stack via structure of clause 1, wherein the first via is tapered such that the top width thereof is wider than a bottom width thereof, wherein the second via is tapered such that a top width thereof is wider the bottom width thereof, and wherein the recess is tapered such that a top width thereof is wider than a bottom width thereof.
• Clause 3 The stack via structure of any of clauses 1-2, wherein a side surface of the bottom portion of the second via is in contact with a side surface of the recess, and a bottom surface of the bottom portion of the second via is in contact with a bottom surface of the recess.
• Clause 4 The stack via structure of any of clauses 1-3, wherein there is no capture pad between the first via and the second via.
• Clause 6 The stack via structure of any of clauses 1-5, wherein the cover pad is a pad within a cover layer of a stack layer structure that comprises the stack via structure, the cover layer being an outermost layer of the stack layer structure, and the cover pad being configured to a signal connection with an external device.
• a method of fabricating a stack via structure comprising: forming a capture pad; forming a first via stacked over and electrically coupled with the capture pad; forming a second via stacked over and electrically coupled with the first via; and forming a cover pad stacked over and electrically coupled with the second via, wherein a top width of the first via is wider than a bottom width of the second via, wherein a recess is formed in the first via to partially extend into a top surface thereof, and wherein a bottom portion of the second via is within the recess, the bottom portion of the second via extending from a bottom surface thereof up to a height equal to a depth of the recess, the second via being in contact with the first via within the recess.
• Clause 20 The method of any of clauses 11-19, wherein the top surface of the first via is drilled to form the recess, and wherein the bottom portion of the second via fills the recess when the second via is being formed.
• Clause 48 The method of clause 47, wherein the recess is formed by laser drilling the top surface of the first via.
• the terms “user equipment” (or “UE”), “user device,” “user terminal,” “client device,” “communication device,” “wireless device,” “wireless communications device,” “handheld device,” “mobile device,” “mobile terminal,” “mobile station,” “handset,” “access terminal,” “subscriber device,” “subscriber terminal,” “subscriber station,” “terminal,” and variants thereof may interchangeably refer to any suitable mobile or stationary device that can receive wireless communication and/or navigation signals.
• the wireless communication between electronic devices can be based on different technologies, such as code division multiple access (CDMA), W-CDMA, time division multiple access (TDMA), frequency division multiple access (FDMA), Orthogonal Frequency Division Multiplexing (OFDM), Global System for Mobile Communications (GSM), 3GPP Long Term Evolution (LTE), 5G New Radio, Bluetooth (BT), Bluetooth Low Energy (BLE), IEEE 802.11 (WiFi), and IEEE 802.15.4 (Zigbee/Thread) or other protocols that may be used in a wireless communications network or a data communications network.
• CDMA code division multiple access
• TDMA time division multiple access
• FDMA frequency division multiple access
• OFDM Orthogonal Frequency Division Multiplexing
• GSM Global System for Mobile Communications
• LTE Long Term Evolution
• LTE Long Term Evolution
• BLE Bluetooth Low Energy
• IEEE 802.11 WiFi
• IEEE 802.15.4 Zigbee/Thread
• exemplary is used herein to mean “serving as an example, instance, or illustration.” Any details described herein as “exemplary” is not to be construed as advantageous over other examples. Likewise, the term “examples” does not mean that all examples include the discussed feature, advantage or mode of operation. Furthermore, a particular feature and/or structure can be combined with one or more other features and/or structures. Moreover, at least a portion of the apparatus described herein can be configured to perform at least a portion of a method described herein.

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• 2021
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