U.S. patent application number 12/332118 was filed with the patent office on 2010-06-10 for semiconductor device and method of forming an interconnect structure for 3-d devices using encapsulant for structural support.
This patent application is currently assigned to STATS ChipPAC, Ltd.. Invention is credited to Kock Liang Heng, Pandi Chelvam Marimuthu, Nathapong Suthiwongsunthorn.
Application Number | 20100140815 12/332118 |
Document ID | / |
Family ID | 42230187 |
Filed Date | 2010-06-10 |
United States Patent
Application |
20100140815 |
Kind Code |
A1 |
Marimuthu; Pandi Chelvam ;
et al. |
June 10, 2010 |
SEMICONDUCTOR DEVICE AND METHOD OF FORMING AN INTERCONNECT
STRUCTURE FOR 3-D DEVICES USING ENCAPSULANT FOR STRUCTURAL
SUPPORT
Abstract
A semiconductor device has a first interconnect structure formed
over a first side of a substrate. A semiconductor die is mounted to
the first interconnect structure. An encapsulant is deposited over
the semiconductor die and first interconnect structure for
structural support. A portion of a second side of the substrate,
opposite the first side of the substrate, is removed to reduce its
thickness. The encapsulant maintains substrate robustness during
thinning process. A TSV is formed through the second side of the
substrate to the first interconnect structure. A second
interconnect structure is formed in the TSV. The TSV has a first
insulating layer formed over the second side of the substrate and
first conductive layer formed over the first insulating layer and
into the TSV. The second interconnect structure has a second
conductive layer formed over the first conductive layer in an area
away from the TSV.
Inventors: |
Marimuthu; Pandi Chelvam;
(Singapore, SG) ; Suthiwongsunthorn; Nathapong;
(Singapore, SG) ; Heng; Kock Liang; (Singapore,
SG) |
Correspondence
Address: |
Robert D. Atkins
605 W. Knox Road, Suite 104
Tempe
AZ
85284
US
|
Assignee: |
STATS ChipPAC, Ltd.
Singapore
SG
|
Family ID: |
42230187 |
Appl. No.: |
12/332118 |
Filed: |
December 10, 2008 |
Current U.S.
Class: |
257/787 ;
257/E21.502; 257/E23.116; 438/127 |
Current CPC
Class: |
H01L 2924/01078
20130101; H01L 23/5385 20130101; H01L 25/50 20130101; H01L
2924/13091 20130101; H01L 2224/16238 20130101; H01L 2924/01077
20130101; H01L 2924/01046 20130101; H01L 2924/01079 20130101; H01L
23/3121 20130101; H01L 23/3128 20130101; H01L 2924/19041 20130101;
H01L 21/486 20130101; H01L 2924/01322 20130101; H01L 25/0655
20130101; H01L 2924/09701 20130101; H01L 2224/73265 20130101; H01L
2924/01004 20130101; H01L 21/561 20130101; H01L 2924/1433 20130101;
H01L 2224/81385 20130101; H01L 23/5384 20130101 |
Class at
Publication: |
257/787 ;
438/127; 257/E21.502; 257/E23.116 |
International
Class: |
H01L 23/28 20060101
H01L023/28; H01L 21/71 20060101 H01L021/71 |
Claims
1. (canceled)
2. A method of making a semiconductor device, comprising: providing
a substrate; forming a first interconnect structure over a first
side of the substrate by, (a) forming a first conductive layer over
the first side of the substrate, (b) forming a first insulating
layer over the first conductive layer and substrate, (c) removing a
portion of the first insulating layer to expose the first
conductive layer, (d) forming a second conductive layer over the
first conductive layer, (e) forming a second insulating layer over
the second conductive layer and first insulating layer, and (f)
removing a portion of the second insulating layer to expose the
second conductive layer; mounting a semiconductor die or component
to the first interconnect structure; depositing an encapsulant over
the semiconductor die or component and first interconnect
structure; removing a portion of a second side of the substrate,
opposite the first side of the substrate, to reduce its thickness;
forming a through silicon via (TSV) through the second side of the
substrate to the first interconnect structure; and forming a second
interconnect structure over the TSV.
3. The method of claim 2, wherein forming the first interconnect
structure further includes: forming a conductive pillar over the
second conductive layer; forming a third insulating layer around
the conductive pillar; forming a third conductive layer over the
conductive pillar; and electrically connecting the semiconductor
die or component to the third conductive layer.
4. The method of claim 2, further including mounting the
semiconductor device to a printed circuit board through the second
interconnect structure.
5. A method of making a semiconductor device, comprising: providing
a substrate; forming a first interconnect structure over a first
side of the substrate; mounting a semiconductor die or component to
the first interconnect structure; depositing an encapsulant over
the semiconductor die or component and first interconnect
structure; removing a portion of a second side of the substrate,
opposite the first side of the substrate, to reduce its thickness;
forming a through silicon via (TSV) through the second side of the
substrate to the first interconnect structure by, (a) forming a
first insulating layer over the second side of the substrate, and
(b) removing a portion of the first insulating layer over the first
interconnect structure; and forming a second interconnect structure
over the TSV.
6. The method of claim 5, wherein forming the second interconnect
structure includes forming a first conductive layer over the first
insulating layer and into the TSV.
7. The method of claim 6, wherein forming the second interconnect
structure further includes: forming a second conductive layer over
the first conductive layer in an area away from the TSV; and
forming a solder bump on the second conductive layer.
8. (canceled)
9. A method of making a semiconductor device, comprising: providing
a substrate; forming a first interconnect structure over the
substrate by, (a) forming a first conductive layer over the
substrate, (b) forming a first insulating layer over the first
conductive layer and substrate, (c) removing a portion of the first
insulating layer to expose the first conductive layer, (d) forming
a second conductive layer over the first conductive layer, (e)
forming a second insulating layer over the second conductive layer
and first insulating layer, and (f) removing a portion of the
second insulating layer to expose the second conductive layer;
mounting a semiconductor die or component to the first interconnect
structure; depositing an encapsulant over the semiconductor die or
component and first interconnect structure; removing at least a
portion of the substrate to expose the first interconnect
structure; and forming a second interconnect structure over the
first interconnect structure.
10. The method of claim 9, wherein forming the first interconnect
structure further includes: forming a conductive pillar over the
second conductive layer; forming a third insulating layer around
the conductive pillar; forming a third conductive layer over the
conductive pillar; and electrically connecting the semiconductor
die or component to the third conductive layer.
11. The method of claim 9, further including mounting the
semiconductor device to a printed circuit board through the second
interconnect structure.
12. The method of claim 11, wherein the semiconductor die or
component is electrically connected to the printed circuit board
through the first and second interconnect structures.
13. A method of making a semiconductor device, comprising:
providing a substrate; forming a first interconnect structure over
the substrate; mounting a semiconductor die or component to the
first interconnect structure; depositing an encapsulant over the
semiconductor die or component and first interconnect structure;
removing at least a portion of the substrate to expose the first
interconnect structure; and forming a second interconnect structure
over the first interconnect structure by, (a) forming a first
insulating layer over the first interconnect structure, (b)
removing a portion of the first insulating layer, and (c) forming a
first conductive layer over the first insulating layer in the
removed portion of the first insulating layer.
14. (canceled)
15. A method of making a semiconductor device, comprising:
providing a substrate; forming a first interconnect structure over
a first side of the substrate; mounting a semiconductor die or
component to the first interconnect structure; depositing an
encapsulant over the semiconductor die or component and first
interconnect structure; removing a portion of a second side of the
substrate, opposite the first side of the substrate; and forming a
conductive through silicon via (TSV) through the substrate and
electrically connecting the conductive TSV to the first
interconnect structure by, (a) forming a first insulating layer
over the second side of the substrate, and (b) removing a portion
of the first insulating layer over the first interconnect
structure.
16. The method of claim 15, further including: forming a second
interconnect structure over the second side of the substrate; and
electrically connecting the second interconnect structure to the
conductive TSV.
17. The method of claim 16, wherein forming the second interconnect
structure includes forming a first conductive layer over the first
insulating layer and into the TSV.
18. The method of claim 16, further including mounting the
semiconductor device to a printed circuit board through the second
interconnect structure.
19. The method of claim 15, wherein forming the first interconnect
structure includes: forming a first conductive layer over the first
side of the substrate; forming a first insulating layer over the
first conductive layer and substrate; removing a portion of the
first insulating layer to expose the first conductive layer;
forming a second conductive layer over the first conductive layer;
forming a second insulating layer over the second conductive layer
and first insulating layer; and removing a portion of the second
insulating layer to expose the second conductive layer.
20. The method of claim 19, wherein forming the first interconnect
structure further includes: forming a conductive pillar over the
second conductive layer; forming a third insulating layer around
the conductive pillar; forming a third conductive layer over the
conductive pillar; and electrically connecting the semiconductor
die or component to the third conductive layer.
21-25. (canceled)
Description
FIELD OF THE INVENTION
[0001] The present invention relates in general to semiconductor
devices and, more particularly, to a process of forming an
interconnect structure for three-dimensional (3-D) devices using an
encapsulant for structural support.
BACKGROUND OF THE INVENTION
[0002] Semiconductor devices are commonly found in modern
electronic products. Semiconductor devices vary in the number and
density of electrical components. Discrete semiconductor devices
generally contain one type of electrical component, e.g., light
emitting diode (LED), transistor, resistor, capacitor, inductor,
and power metal oxide semiconductor field effect transistor
(MOSFET). Integrated semiconductor devices typically contain
hundreds to millions of electrical components. Examples of
integrated semiconductor devices include microcontrollers,
microprocessors, charged-coupled devices (CCDs), solar cells, and
digital micro-mirror devices (DMDs).
[0003] Semiconductor devices perform a wide range of functions such
as high-speed calculations, transmitting and receiving
electromagnetic signals, controlling electronic devices,
transforming sunlight to electricity, and creating visual
projections for television displays. Semiconductor devices are
found in the fields of entertainment, communications, power
generation, networks, computers, and consumer products.
Semiconductor devices are also found in electronic products
including military, aviation, automotive, industrial controllers,
and office equipment.
[0004] Semiconductor devices exploit the electrical properties of
semiconductor materials. The atomic structure of semiconductor
material allows its electrical conductivity to be manipulated by
the application of an electric field or through the process of
doping. Doping introduces impurities into the semiconductor
material to manipulate and control the conductivity of the
semiconductor device.
[0005] A semiconductor device contains active and passive
electrical structures. Active structures, including transistors,
control the flow of electrical current. By varying levels of doping
and application of an electric field, the transistor either
promotes or restricts the flow of electrical current. Passive
structures, including resistors, diodes, and inductors, create a
relationship between voltage and current necessary to perform a
variety of electrical functions. The passive and active structures
are electrically connected to form logic circuits, which enable the
semiconductor device to perform high-speed calculations and other
useful functions.
[0006] Semiconductor devices are generally manufactured using two
complex manufacturing processes, i.e., front-end manufacturing, and
back-end manufacturing, each involving potentially hundreds of
steps. Front-end manufacturing involves the formation of a
plurality of die on the surface of a semiconductor wafer. Each die
is typically identical and contains circuits formed by electrically
connecting active and passive components. Back-end manufacturing
involves singulating individual die from the finished wafer and
packaging the die to provide structural support and environmental
isolation.
[0007] One goal of semiconductor manufacturing is to produce
smaller semiconductor devices. Smaller devices typically consume
less power, have higher performance, and can be produced more
efficiently. In addition, smaller semiconductor devices have a
smaller footprint, which is desirable for smaller end products. A
smaller die size may be achieved by improvements in the front-end
process resulting in die with smaller, higher density active and
passive components. Back-end processes may result in semiconductor
device packages with a smaller footprint by improvements in
electrical interconnection and packaging materials.
[0008] The electrical interconnection between the semiconductor
package containing semiconductor devices on multiple levels (3-D
device integration) and an external printed circuit board (PCB) or
substrate is typically accomplished with wire bonds, through hole
vias (THV), or through silicon vias (TSV). Wire bonds require
additional package area to form the bend in the leads. To make
electrical interconnect using THVs or TSVs, a temporary carrier is
bonded to the package substrate for structural support while
forming the THVs and TSVs. For thin wafers, e.g., less than 250
micrometers (.mu.m), excessive handling can lead to breakage and
slippage. The temporary carrier adds manufacturing costs. The
bonding material for the temporary carrier limits processing
temperatures to about 200.degree. C.
SUMMARY OF THE INVENTION
[0009] A need exists to provide interconnect for 3-D semiconductor
devices. Accordingly, in one embodiment, the present invention is a
method of making a semiconductor device comprising the steps of
providing a substrate, forming a first interconnect structure over
a first side of the substrate, mounting a semiconductor die or
component to the first interconnect structure, depositing an
encapsulant over the semiconductor die and first interconnect
structure, removing a portion of a second side of the substrate,
opposite the first side of the substrate, to reduce its thickness,
forming a through silicon via (TSV) through the second side of the
substrate to the first interconnect structure, and forming a second
interconnect structure over the TSV.
[0010] In another embodiment, the present invention is a method of
making a semiconductor device comprising the steps of providing a
substrate, forming a first interconnect structure over the
substrate, mounting a semiconductor die or component to the first
interconnect structure, depositing an encapsulant over the
semiconductor die and first interconnect structure, removing at
least a portion of the substrate to expose the first interconnect
structure, and forming a second interconnect structure over the
first interconnect structure.
[0011] In another embodiment, the present invention is a method of
making a semiconductor device comprising the steps of providing a
substrate, forming a first interconnect structure over a first side
of the substrate, mounting a semiconductor die or component to the
first interconnect structure, depositing an encapsulant over the
semiconductor die and first interconnect structure, removing a
portion of a second side of the substrate, opposite the first side
of the substrate, and forming a conductive TSV through the
substrate and electrically connecting the conductive TSV to the
first interconnect structure.
[0012] In another embodiment, the present invention is a
semiconductor device comprising a substrate and first interconnect
structure formed over a first side of the substrate. A
semiconductor die or component is mounted to the first interconnect
structure. An encapsulant is deposited over the semiconductor die
and first interconnect structure. A conductive TSV is formed
through the substrate and electrically connected to the first
interconnect structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a printed circuit board (PCB) with
different types of packages mounted to its surface;
[0014] FIGS. 2a-2c illustrate further detail of the representative
semiconductor packages mounted to the PCB;
[0015] FIGS. 3a-3g illustrate a process of forming an interconnect
structure for 3-D devices involving partial removal of the
substrate and formation of TSVs using encapsulant for structural
support;
[0016] FIGS. 4a-4c illustrate a process of forming an interconnect
structure for 3-D devices involving complete removal of the
substrate using encapsulant for structural support; and
[0017] FIGS. 5a-5e illustrate another process of forming an
interconnect structure for 3-D devices involving partial removal of
the substrate and formation of TSVs using encapsulant for
structural support.
DETAILED DESCRIPTION OF THE DRAWINGS
[0018] The present invention is described in one or more
embodiments in the following description with reference to the
Figures, in which like numerals represent the same or similar
elements. While the invention is described in terms of the best
mode for achieving the invention's objectives, it will be
appreciated by those skilled in the art that it is intended to
cover alternatives, modifications, and equivalents as may be
included within the spirit and scope of the invention as defined by
the appended claims and their equivalents as supported by the
following disclosure and drawings.
[0019] Semiconductor devices are generally manufactured using two
complex manufacturing processes: front-end manufacturing and
back-end manufacturing. Front-end manufacturing involves the
formation of a plurality of die on the surface of a semiconductor
wafer. Each die on the wafer contains active and passive electrical
components, which are electrically connected to form functional
electrical circuits. Active electrical components, such as
transistors, have the ability to control the flow of electrical
current. Passive electrical components, such as capacitors,
inductors, resistors, and transformers, create a relationship
between voltage and current necessary to perform electrical circuit
functions.
[0020] Passive and active components are formed on the surface of
the semiconductor wafer by a series of process steps including
doping, deposition, photolithography, etching, and planarization.
Doping introduces impurities into the semiconductor material by
techniques such as ion implantation or thermal diffusion. The
doping process modifies the electrical conductivity of
semiconductor material in active devices, transforming the
semiconductor material into a permanent insulator, permanent
conductor, or changing the way the semiconductor material changes
in conductivity in response to an electric field. Transistors
contain regions of varying types and degrees of doping arranged as
necessary to enable the transistor to promote or restrict the flow
of electrical current upon the application of an electric
field.
[0021] Active and passive components are formed by layers of
materials with different electrical properties. The layers can be
formed by a variety of deposition techniques determined in part by
the type of material being deposited. For example, thin film
deposition may involve chemical vapor deposition (CVD), physical
vapor deposition (PVD), electrolytic plating, and electroless
plating processes. Each layer is generally patterned to form
portions of active components, passive components, or electrical
connections between components.
[0022] The layers can be patterned using photolithography, which
involves the deposition of light sensitive material, e.g.,
photoresist, over the layer to be patterned. A pattern is
transferred from a photomask to the photoresist using light. The
portion of the photoresist pattern subjected to light is removed
using a solvent, exposing portions of the underlying layer to be
patterned. The remainder of the photoresist is removed, leaving
behind a patterned layer. Alternatively, some types of materials
are patterned by directly depositing the material into the areas or
voids formed by a previous deposition/etch process using techniques
such as electroless and electrolytic plating.
[0023] Depositing a thin film of material over an existing pattern
can exaggerate the underlying pattern and create a non-uniformly
flat surface. A uniformly flat surface is required to produce
smaller and more densely packed active and passive components.
Planarization can be used to remove material from the surface of
the wafer and produce a uniformly flat surface. Planarization
involves polishing the surface of the wafer with a polishing pad.
An abrasive material and corrosive chemical are added to the
surface of the wafer during polishing. The combined mechanical
action of the abrasive and corrosive action of the chemical removes
any irregular topography, resulting in a uniformly flat
surface.
[0024] Back-end manufacturing refers to cutting or singulating the
finished wafer into the individual die and then packaging the die
for structural support and environmental isolation. To singulate
the die, the wafer is scored and broken along non-functional
regions of the wafer called saw streets or scribes. The wafer is
singulated using a laser cutting device or saw blade. After
singulation, the individual die are mounted to a package substrate
that includes pins or contact pads for interconnection with other
system components. Contact pads formed over the semiconductor die
are then connected to contact pads within the package. The
electrical connections can be made with solder bumps, stud bumps,
conductive paste, or wirebonds. An encapsulant or other molding
material is deposited over the package to provide physical support
and electrical isolation. The finished package is then inserted
into an electrical system and the functionality of the
semiconductor device is made available to the other system
components.
[0025] FIG. 1 illustrates electronic device 10 having a chip
carrier substrate or printed circuit board (PCB) 12 with a
plurality of semiconductor packages mounted on its surface.
Electronic device 10 may have one type of semiconductor package, or
multiple types of semiconductor packages, depending on the
application. The different types of semiconductor packages are
shown in FIG. 1 for purposes of illustration.
[0026] Electronic device 10 may be a stand-alone system that uses
the semiconductor packages to perform an electrical function.
Alternatively, electronic device 10 may be a subcomponent of a
larger system. For example, electronic device 10 may be a graphics
card, network interface card, or other signal processing card that
can be inserted into a computer. The semiconductor package can
include microprocessors, memories, application specific integrated
circuits (ASICs), logic circuits, analog circuits, RF circuits,
discrete devices, or other semiconductor die or electrical
components.
[0027] In FIG. 1, PCB 12 provides a general substrate for
structural support and electrical interconnect of the semiconductor
packages mounted on the PCB. Conductive signal traces 14 are formed
on a surface or within layers of PCB 12 using evaporation,
electrolytic plating, electroless plating, screen printing, PVD, or
other suitable metal deposition process. Signal traces 14 provide
for electrical communication between each of the semiconductor
packages, mounted components, and other external system components.
Traces 14 also provide power and ground connections to each of the
semiconductor packages.
[0028] In some embodiments, a semiconductor device has two
packaging levels. First level packaging is a technique for
mechanically and electrically attaching the semiconductor die to a
carrier. Second level packaging involves mechanically and
electrically attaching the carrier to the PCB. In other
embodiments, a semiconductor device may only have the first level
packaging where the die is mechanically and electrically mounted
directly to the PCB.
[0029] For the purpose of illustration, several types of first
level packaging, including wire bond package 16 and flip chip 18,
are shown on PCB 12. Additionally, several types of second level
packaging, including ball grid array (BGA) 20, bump chip carrier
(BCC) 22, dual in-line package (DIP) 24, land grid array (LGA) 26,
multi-chip module (MCM) 28, quad flat non-leaded package (QFN) 30,
and quad flat package 32, are shown mounted on PCB 12. Depending
upon the system requirements, any combination of semiconductor
packages, configured with any combination of first and second level
packaging styles, as well as other electronic components, can be
connected to PCB 12. In some embodiments, electronic device 10
includes a single attached semiconductor package, while other
embodiments call for multiple interconnected packages. By combining
one or more semiconductor packages over a single substrate,
manufacturers can incorporate pre-made components into electronic
devices and systems. Because the semiconductor packages include
sophisticated functionality, electronic devices can be manufactured
using cheaper components and a shorter manufacturing process. The
resulting devices are less likely to fail and less expensive to
manufacture resulting in lower costs for consumers.
[0030] FIG. 2a illustrates further detail of DIP 24 mounted on PCB
12. DIP 24 includes semiconductor die 34 having contact pads 36.
Semiconductor die 34 includes an active region containing analog or
digital circuits implemented as active devices, passive devices,
conductive layers, and dielectric layers formed within
semiconductor die 34 and are electrically interconnected according
to the electrical design of the die. For example, the circuit may
include one or more transistors, diodes, inductors, capacitors,
resistors, and other circuit elements formed within the active
region of die 34. Contact pads 36 are made with a conductive
material, such as aluminum (Al), copper (Cu), tin (Sn), nickel
(Ni), gold (Au), or silver (Ag), and are electrically connected to
the circuit elements formed within die 34. Contact pads 36 are
formed by PVD, CVD, electrolytic plating, or electroless plating
process. During assembly of DIP 24, semiconductor die 34 is mounted
to a carrier 38 using a gold-silicon eutectic layer or adhesive
material such as thermal epoxy. The package body includes an
insulative packaging material such as polymer or ceramic. Conductor
leads 40 are connected to carrier 38 and wire bonds 42 are formed
between leads 40 and contact pads 36 of die 34 as a first level
packaging. Encapsulant 44 is deposited over the package for
environmental protection by preventing moisture and particles from
entering the package and contaminating die 34, contact pads 36, or
wire bonds 42. DIP 24 is connected to PCB 12 by inserting leads 40
into holes formed through PCB 12. Solder material 46 is flowed
around leads 40 and into the holes to physically and electrically
connect DIP 24 to PCB 12. Solder material 46 can be any metal or
electrically conductive material, e.g., Sn, lead (Pb), Au, Ag, Cu,
zinc (Zn), bismuthinite (Bi), and alloys thereof, with an optional
flux material. For example, the solder material can be eutectic
Sn/Pb, high-lead, or lead-free.
[0031] FIG. 2b illustrates further detail of BCC 22 mounted on PCB
12. Semiconductor die 47 is connected to a carrier by wire bond
style first level packaging. BCC 22 is mounted to PCB 12 with a BCC
style second level packaging. Semiconductor die 47 having contact
pads 48 is mounted over a carrier using an underfill or epoxy-resin
adhesive material 50. Semiconductor die 47 includes an active
region containing analog or digital circuits implemented as active
devices, passive devices, conductive layers, and dielectric layers
formed within semiconductor die 47 and are electrically
interconnected according to the electrical design of the die. For
example, the circuit may include one or more transistors, diodes,
inductors, capacitors, resistors, and other circuit elements formed
within the active region of die 47. Contact pads 48 are made with a
conductive material, such as Al, Cu, Sn, Ni, Au, or Ag, and are
electrically connected to the circuit elements formed within die
47. Contact pads 48 are formed by PVD, CVD, electrolytic plating,
or electroless plating process. Wire bonds 54 and bond pads 56 and
58 electrically connect contact pads 48 of semiconductor die 47 to
contact pads 52 of BCC 22 forming the first level packaging.
Molding compound or encapsulant 60 is deposited over semiconductor
die 47, wire bonds 54, contact pads 48, and contact pads 52 to
provide physical support and electrical isolation for the device.
Contact pads 64 are formed on a surface of PCB 12 using
evaporation, electrolytic plating, electroless plating, screen
printing, PVD, or other suitable metal deposition process and are
typically plated to prevent oxidation. Contact pads 64 electrically
connect to one or more conductive signal traces 14. Solder material
is deposited between contact pads 52 of BCC 22 and contact pads 64
of PCB 12. The solder material is reflowed to form bumps 66 which
form a mechanical and electrical connection between BCC 22 and PCB
12.
[0032] In FIG. 2c, semiconductor die 18 is mounted face down to
carrier 76 with a flip chip style first level packaging. BGA 20 is
attached to PCB 12 with a BGA style second level packaging. Active
region 70 containing analog or digital circuits implemented as
active devices, passive devices, conductive layers, and dielectric
layers formed within semiconductor die 18 is electrically
interconnected according to the electrical design of the die. For
example, the circuit may include one or more transistors, diodes,
inductors, capacitors, resistors, and other circuit elements formed
within active region 70 of semiconductor die 18. Semiconductor die
18 is electrically and mechanically attached to carrier 76 through
a large number of individual conductive solder bumps or balls 78.
Solder bumps 78 are formed on bump pads or interconnect sites 80,
which are disposed on active region 70. Bump pads 80 are made with
a conductive material, such as Al, Cu, Sn, Ni, Au, or Ag, and are
electrically connected to the circuit elements formed in active
region 70. Bump pads 80 are formed by PVD, CVD, electrolytic
plating, or electroless plating process. Solder bumps 78 are
electrically and mechanically connected to contact pads or
interconnect sites 82 on carrier 76 by a solder reflow process.
[0033] BGA 20 is electrically and mechanically attached to PCB 12
by a large number of individual conductive solder bumps or balls
86. The solder bumps are formed on bump pads or interconnect sites
84. The bump pads 84 are electrically connected to interconnect
sites 82 through conductive lines 90 routed through carrier 76.
Contact pads 88 are formed on a surface of PCB 12 using
evaporation, electrolytic plating, electroless plating, screen
printing, PVD, or other suitable metal deposition process and are
typically plated to prevent oxidation. Contact pads 88 electrically
connect to one or more conductive signal traces 14. The solder
bumps 86 are electrically and mechanically connected to contact
pads or bonding pads 88 on PCB 12 by a solder reflow process.
Molding compound or encapsulant 92 is deposited over semiconductor
die 18 and carrier 76 to provide physical support and electrical
isolation for the device. The flip chip semiconductor device
provides a short electrical conduction path from the active devices
on semiconductor die 18 to conduction tracks on PCB 12 in order to
reduce signal propagation distance, lower capacitance, and achieve
overall better circuit performance. In another embodiment, the
semiconductor die 18 can be mechanically and electrically attached
directly to PCB 12 using flip chip style first level packaging
without carrier 76.
[0034] FIGS. 3a-3g illustrate a process of forming an interconnect
structure for 3-D devices using an encapsulant for structural
support during formation of additional interconnect structures. In
FIG. 3a, a substrate or wafer 100 contains dummy or sacrificial
base material such as silicon (Si), polymer, polymer composite,
metal, ceramic, glass, glass epoxy, beryllium oxide, or other
suitable low-cost, rigid material or bulk semiconductor material
for structural support. Alternatively, substrate 100 can be other
semiconductor base materials such as germanium, gallium arsenide,
indium phosphide, or silicon carbide. A plurality of semiconductor
die is formed on substrate 100 using semiconductor manufacturing
processes described above. Each semiconductor die contains analog
or digital circuits formed in active region 101. The semiconductor
die may also contain IPD, such as inductors, capacitors, and
resistors, in or above active region 101.
[0035] The IPDs contained within substrate 100 provide the
electrical characteristics needed for high frequency applications,
such as resonators, high-pass filters, low-pass filters, band-pass
filters, symmetric Hi-Q resonant transformers, matching networks,
and tuning capacitors. The IPDs can be used as front-end wireless
RF components, which can be positioned between the antenna and
transceiver. The IPD inductor can be a hi-Q balun, transformer, or
coil, operating up to 100 Gigahertz. In some applications, multiple
baluns are formed on a same substrate, allowing multi-band
operation. For example, two or more baluns are used in a quad-band
for mobile phones or other global system for mobile (GSM)
communications, each balun dedicated for a frequency band of
operation of the quad-band device. A typical RF system requires
multiple IPDs and other high frequency circuits in one or more
semiconductor packages to perform the necessary electrical
functions.
[0036] An electrically conductive layer 102 is formed on substrate
100 using a patterning and deposition process to form individual
portions or sections. The individual portions of conductive layer
102 can be electrically common or electrically isolated depending
on the connectivity of the semiconductor device. Conductive layer
102 can be Al, Cu, Sn, Ni, Au, Ag, or other suitable electrically
conductive material. The deposition of conductive layer 102 uses
PVD, CVD, electrolytic plating, or electroless plating process.
[0037] An insulating or passivation layer 104 is formed on
conductive layer 102 and active surface 101 of substrate 100. The
insulating layer 102 can be silicon dioxide (SiO2), silicon nitride
(Si3N4), silicon oxynitride (SiON), tantalum pentoxide (Ta2O5),
zircon (ZrO2), aluminum oxide (Al2O3), polyimide, benzocyclobutene
(BCB), polybenzoxazoles (PBO), or other material having similar
insulating and structural properties. The insulating layer 104 is
deposited using PVD, CVD, printing, spin coating, spray coating,
sintering or thermal oxidation. The insulating layer 104 can be
single or multiple layers. A portion of insulating layer 104 is
removed by an etching process to expose conductive layer 102.
[0038] An electrically conductive layer 106 is deposited on the
exposed portion of conductive layer 102 using PVD, CVD,
evaporation, electrolytic plating, electroless plating, or other
suitable metal deposition process. Conductive layer 106 can be Al,
Cu, Sn, Ni, Au, Ag, tungsten (W), or other suitable electrically
conductive material. Conductive layer 106 is an under bump
metallization (UBM) in electrical contact with conductive layer
102. UBMs 106 can be a multi-metal stack with adhesion layer,
barrier layer, and seed or wetting layer. The adhesion layer is
formed over conductive layer 102 and can be titanium (Ti), or
titanium nitride (TiN), titanium tungsten (TiW), Al, or chromium
(Cr). The barrier layer is formed over the adhesion layer and can
be made of Ni, NiV, platinum (Pt), palladium (Pd), TiW, or chromium
copper (CrCu). The barrier layer inhibits the diffusion of Cu into
the active area of the die. The seed layer can be Cu, Ni, NiV, Au,
or Al. The seed layer is formed over the barrier layer and acts as
an intermediate conductive layer between conductive layer 102 and
subsequent solder bumps or other interconnect structure. UBMs 106
provide a low resistive interconnect to conductive layer 102, as
well as a barrier to solder diffusion and seed layer for solder
wettability.
[0039] An insulating or passivation layer 108 is formed on
insulating layer 104 and conductive layer 106. The insulating layer
108 can be SiO2, Si3N4, SiON, Ta2O5, ZrO2, Al2O3, polyimide, BCB,
PBO, or other material having similar insulating and structural
properties. The insulating layer 108 is deposited using PVD, CVD,
printing, spin coating, spray coating, sintering or thermal
oxidation. The insulating layer 108 can be single or multiple
layers. A portion of insulating layer 108 is removed by an etching
process to expose conductive layer 106.
[0040] Conductive pillars or posts 110 are formed over conductive
layer 106. Conductive pillars 110 can be Cu, Al, W, Au, solder, or
other suitable electrically conductive material. In one embodiment,
the conductive pillars 110 can be Cu and formed by a plating
process. A thick layer of photoresist is deposited over insulating
layer 108 and conductive layer 106. The photoresist can be a liquid
or a dry film with a thickness of 50 to 125 .mu.m. Two layers of
photoresist may be applied to achieve the desired thickness. In one
embodiment, conductive pillars have a height of 2 .mu.m to 120
.mu.m. The photoresist is patterned using photolithography. Cu is
deposited in the patterned areas of the photoresist using
electrolytic plating. The photoresist is stripped away leaving
behind individual conductive pillars 110. In another embodiment,
conductive pillars 110 can be replaced with solder balls or stud
bumps.
[0041] An insulating or passivation layer 112 is formed around
conductive pillars 110. The insulating layer 112 can be SiO2,
Si3N4, SiON, Ta2O5, ZrO2, Al2O3, polyimide, BCB, PBO, or other
material having similar insulating and structural properties. The
insulating layer 112 is deposited using PVD, CVD, printing, spin
coating, spray coating, sintering or thermal oxidation. The
insulating layer 112 can be single or multiple layers.
[0042] In FIG. 3b, an electrically conductive layer 114 is
deposited on conductive pillar 110 using PVD, CVD, evaporation,
electrolytic plating, electroless plating, or other suitable metal
deposition process. Conductive layer 114 can be Al, Cu, Sn, Ni, Au,
Ag, W, or other suitable electrically conductive material.
Conductive layer 114 is a UBM in electrical contact with conductive
pillar 110. UBMs 114 can be a multi-metal stack with adhesion
layer, barrier layer, and seed or wetting layer. The adhesion layer
is formed over conductive pillar 110 and can be Ti, TiN, TiW, Al,
or Cr. The barrier layer is formed over the adhesion layer and can
be made of Ni, NiV, platinum Pt, Pd, TiW, or CrCu. The barrier
layer inhibits the diffusion of Cu into the active area of the die.
The seed layer can be Cu, Ni, NiV, Au, or Al. The seed layer is
formed over the barrier layer and acts as an intermediate
conductive layer between conductive pillar 110 and subsequent
solder bumps or other interconnect structure. UBMs 114 provide a
low resistive interconnect to conductive pillar 110, as well as a
barrier to solder diffusion and seed layer for solder
wettability.
[0043] An electrically conductive solder material is deposited over
UBM 114 using an evaporation, electrolytic plating, electroless
plating, ball drop, or screen printing process. The solder material
can be any metal or electrically conductive material, e.g., Sn, Ni,
Au, Ag, Pb, Bi, and alloys thereof, with an optional flux material.
For example, the solder material can be eutectic Sn/Pb, high-lead,
or lead-free. The solder material is reflowed by heating the
material above its melting point to form spherical balls or bumps
120. In some applications, solder bumps 120 are reflowed a second
time to improve electrical contact to UBM 114. Solder bumps 120
represent one type of interconnect structure that can be formed on
UBM 114. The interconnect structure can also use bond wires, 3-D
interconnects, conductive paste, stud bump, micro bump, or other
electrical interconnect.
[0044] Semiconductor die 126 each having contact pads 128 are
metallurgically and electrically connected to solder bumps 120.
Likewise, passive device or component 130 is structurally and
electrically connected to UBM 114 using bonds 132. Semiconductor
die 126 and passive device 130, in combination with the IPD formed
in active region 101, provides a 3-D structure.
[0045] The resulting semiconductor device 134 is encapsulated to
protect the device and provide robust structural support during
formation of additional interconnect structures. FIG. 3c shows an
encapsulant or molding compound 136 deposited over the structure
described in FIG. 2d using a paste printing, compressive molding,
transfer molding, liquid encapsulant molding, or other suitable
applicator. Encapsulant 136 can be epoxy resin, epoxy acrylate,
polymer, or polymer composite material. Encapsulant 136 is
non-conductive and environmentally protects the semiconductor
device from external elements and contaminants.
[0046] In FIG. 3d, semiconductor device 134 is inverted and back
surface 138 undergoes back grinding by mechanical grinding, CMP,
wet etching, dry etching, plasma etching, or another thinning
process. Since substrate 100 is covered with encapsulant 136, the
structure is sufficiently robust to reduce substrate thickness to
10-50 micrometers (.mu.m). Encapsulant 136 provides the support to
maintain the structural integrity of the device, even with the
reduced substrate thickness. In other embodiments, substrate 100
can be reduced to 30-300 .mu.m in thickness.
[0047] In FIG. 3e, substrate 100 is patterned and etched using a
photoresist layer on back surface 138 to form through silicon vias
(TSV) 140 over conductive layer 102 using infrared (IR) alignment.
TSVs 140 can be formed by etching or laser drilling to have a
tapered or vertical geometry. TSVs 140 extend to conductive layer
102.
[0048] In FIG. 3f, an insulating layer 142 is conformally applied
over back surface 138 using a patterning and deposition process.
The insulating layer 142 covers the back surface 138 and further
follows the contour of TSV 140. The insulating layer 142 can be
Si3N4, SiO2, SiON, Ta2O5, ZnO, ZrO2, Al2O3, or other suitable
insulating material. The deposition of insulating layer 142 may
involve CVD, PVD, spin coating, printing, or molding process. A
portion of insulating layer 142 is removed using an etching process
to expose conductive layer 102.
[0049] An electrically conductive layer 144 is deposited on
conductive layer 102 using PVD, CVD, evaporation, electrolytic
plating, electroless plating, or other suitable metal deposition
process. Conductive layer 144 can be Al, Cu, Sn, Ni, Au, Ag, W, or
other suitable electrically conductive material. Conductive layer
144 is a UBM in electrical contact with conductive layer 102. UBMs
144 can be a multi-metal stack with adhesion layer, barrier layer,
and seed or wetting layer. The adhesion layer is formed over
conductive layer 102 and can be Ti, TiN, TiW, Al, or Cr. The
barrier layer is formed over the adhesion layer and can be made of
Ni, NiV, platinum Pt, Pd, TiW, or CrCu. The barrier layer inhibits
the diffusion of Cu into the active area of the die. The seed layer
can be Cu, Ni, NiV, Au, or Al. The seed layer is formed over the
barrier layer and acts as an intermediate conductive layer between
conductive layer 102 and subsequent solder bumps or other
interconnect structure. UBMs 144 provide a low resistive
interconnect to conductive layer 102, as well as a barrier to
solder diffusion and seed layer for solder wettability.
[0050] In FIG. 3g, semiconductor device 134 is inverted again and
then metallurgically and electrically connected to contact pads 148
on printed circuit board (PCB) 150 using solder bumps 146.
Semiconductor die 126 and passive device 130 electrically connect
to PCB 150 through solder bumps 120 and 146, UBMs 106, 114, and
144, conductive pillars 110, bonds 132, and conductive layer
102.
[0051] Another embodiment of forming an interconnect structure for
3-D devices using an encapsulant for structural support begins with
the structure shown in FIG. 3c. At this point, conductive layer
102, UBMs 106 and 114, conductive pillars 110, solder bumps 120,
semiconductor die 126, passive device 130, bonds 132, and
insulating layers 104, 108, and 112 have been formed on substrate
100. Encapsulant 136 is deposited over the structure 102-132 for
structural support during formation of additional interconnect
structures. The structure 102-136 is inverted and substrate 100 is
completely removed by mechanical grinding, CMP, wet etching, or dry
etching, as shown in FIG. 4a. Encapsulant 136 provides the support
to maintain the structural integrity of the device, even without a
substrate.
[0052] In FIG. 4b, an insulating or passivation layer 154 is formed
on insulating layer 104 and conductive layer 102. The insulating
layer 154 can be SiO2, Si3N4, SiON, Ta2O5, ZrO2, Al2O3, polyimide,
BCB, PBO, or other material having similar insulating and
structural properties. The insulating layer 154 is deposited using
PVD, CVD, printing, spin coating, spray coating, sintering or
thermal oxidation. The insulating layer 154 can be single or
multiple layers. A portion of insulating layer 154 is removed by an
etching process to expose conductive layer 102.
[0053] An electrically conductive layer 152 is deposited on
conductive layer 102 using PVD, CVD, evaporation, electrolytic
plating, electroless plating, or other suitable metal deposition
process. Conductive layer 152 can be Al, Cu, Sn, Ni, Au, Ag, W, or
other suitable electrically conductive material. Conductive layer
152 is a UBM in electrical contact with conductive layer 102. UBMs
152 can be a multi-metal stack with adhesion layer, barrier layer,
and seed or wetting layer. The adhesion layer is formed over
conductive layer 102 and can be Ti, TiN, TiW, Al, or Cr. The
barrier layer is formed over the adhesion layer and can be made of
Ni, NiV, platinum Pt, Pd, TiW, or CrCu. The barrier layer inhibits
the diffusion of Cu into the active area of the die. The seed layer
can be Cu, Ni, NiV, Au, or Al. The seed layer is formed over the
barrier layer and acts as an intermediate conductive layer between
conductive layer 102 and subsequent solder bumps or other
interconnect structure. UBMs 152 provide a low resistive
interconnect to conductive layer 102, as well as a barrier to
solder diffusion and seed layer for solder wettability.
[0054] An electrically conductive solder material is deposited over
UBM 152 using an evaporation, electrolytic plating, electroless
plating, ball drop, or screen printing process. The solder material
can be any metal or electrically conductive material, e.g., Sn, Ni,
Au, Ag, Pb, Bi, and alloys thereof, with an optional flux material.
For example, the solder material can be eutectic Sn/Pb, high-lead,
or lead-free. The solder material is reflowed by heating the
material above its melting point to form spherical balls or bumps
156. In some applications, solder bumps 156 are reflowed a second
time to improve electrical contact to UBM 152. Solder bumps 156
represent one type of interconnect structure that can be formed on
UBM 152. The interconnect structure can also use bond wires, 3-D
interconnects, conductive paste, stud bump, micro bump, or other
electrical interconnect.
[0055] In FIG. 4c, the resulting semiconductor device 158 is
inverted again and then metallurgically and electrically connected
to contact pads 160 on PCB 162 using solder bumps 156.
Semiconductor die 126 and passive device 130 electrically connect
to PCB 162 through solder bumps 120 and 156, UBMs 106, 114, and
152, conductive pillars 110, bonds 132, and conductive layer
102.
[0056] Another embodiment of forming an interconnect structure for
3-D devices using an encapsulant for structural support begins with
the structure shown in FIG. 3d. At this point, conductive layer
102, UBMs 106 and 114, conductive pillars 110, solder bumps 120,
semiconductor die 126, passive device 130, bonds 132, and
insulating layers 104, 108, and 112 have been formed on substrate
100. Encapsulant 136 is deposited over the structure 102-132 for
structural support during formation of additional interconnect
structures. The structure 102-136 is inverted and back surface 138
undergoes back grinding to reduce substrate thickness to 30-300
.mu.m. The backgrinding may involve mechanical grinding, CMP, wet
etching, dry etching, plasma etching, or another thinning process.
Encapsulant 136 provides the support to maintain the structural
integrity of the device, even with the reduced substrate
thickness.
[0057] In FIG. 5a, substrate 100 is patterned and etched using a
photoresist layer on back surface 168 to form TSV 170 over
conductive layer 102 using IR alignment. TSVs 170 can be formed by
etching or laser drilling to have a tapered or vertical geometry.
TSVs 170 extend to conductive layer 102.
[0058] An insulating layer 172 is conformally applied over back
surface 168 using a patterning and deposition process. The
insulating layer 172 covers the back surface 168 and further
follows the contour of TSV 170. The insulating layer 172 can be
Si3N4, SiO2, SiON, Ta2O5, ZnO, ZrO2, Al2O3, or other suitable
insulating material. The deposition of insulating layer 172 may
involve CVD, PVD, spin coating, spray coating, printing, or molding
process. A portion of insulating layer 172 is removed using an
etching process to expose conductive layer 102.
[0059] An electrically conductive layer 174 is deposited on
insulating layer 172 and conductive layer 102 using PVD, CVD,
evaporation, electrolytic plating, electroless plating, or other
suitable metal deposition process. Conductive layer 174 can be Al,
Cu, Sn, Ni, Au, Ag, W, or other suitable electrically conductive
material. Conductive layer 174 operates as a redistribution layer
(RDL) to extend electrical connection for conductive layer 102.
[0060] In FIG. 5b, an insulating or passivation layer 176 is formed
on insulating layer 172 and conductive layer 174. The insulating
layer 176 can be SiO2, Si3N4, SiON, Ta2O5, ZrO2, Al2O3, polyimide,
BCB, PBO, or other material having similar insulating and
structural properties. The insulating layer 176 is deposited using
PVD, CVD, printing, spin coating, spray coating, sintering or
thermal oxidation. FIG. 5c shows insulating layer 176 formed by
spray coating. The insulating layer 176 can be single or multiple
layers. A portion of insulating layer 176 is removed by an etching
process to expose conductive layer 174.
[0061] In FIG. 5d, an electrically conductive layer 178 is
deposited on conductive layer 174 using PVD, CVD, evaporation,
electrolytic plating, electroless plating, or other suitable metal
deposition process. Conductive layer 178 can be Al, Cu, Sn, Ni, Au,
Ag, W, or other suitable electrically conductive material.
Conductive layer 178 is a UBM in electrical contact with conductive
layers 174 and 102. UBMs 178 can be a multi-metal stack with
adhesion layer, barrier layer, and seed or wetting layer. The
adhesion layer is formed over conductive layer 174 and can be Ti,
TiN, TiW, Al, or Cr. The barrier layer is formed over the adhesion
layer and can be made of Ni, NiV, platinum Pt, Pd, TiW, or CrCu.
The barrier layer inhibits the diffusion of Cu into the active area
of the die. The seed layer can be Cu, Ni, NiV, Au, or Al. The seed
layer is formed over the barrier layer and acts as an intermediate
conductive layer between conductive layer 174 and subsequent solder
bumps or other interconnect structure. UBMs 178 provide a low
resistive interconnect to conductive layer 174, as well as a
barrier to solder diffusion and seed layer for solder
wettability.
[0062] An electrically conductive solder material is deposited over
UBM 178 using an evaporation, electrolytic plating, electroless
plating, ball drop, or screen printing process. The solder material
can be any metal or electrically conductive material, e.g., Sn, Ni,
Au, Ag, Pb, Bi, and alloys thereof, with an optional flux material.
For example, the solder material can be eutectic Sn/Pb, high-lead,
or lead-free. The solder material is reflowed by heating the
material above its melting point to form spherical balls or bumps
180. In some applications, solder bumps 180 are reflowed a second
time to improve electrical contact to UBM 178. Solder bumps 180
represent one type of interconnect structure that can be formed on
UBM 178. The interconnect structure can also use bond wires, 3-D
interconnects, conductive paste, stud bump, micro bump, or other
electrical interconnect.
[0063] In FIG. 5e, semiconductor device 182 is inverted again and
then metallurgically and electrically connected to contact pads 182
on PCB 184 using solder bumps 180. Semiconductor die 126 and
passive device 130 electrically connect to PCB 182 through solder
bumps 120 and 180, UBMs 106, 114, and 178, conductive pillars 110,
bonds 132, and conductive layers 174 and 102.
[0064] In summary, the encapsulation process makes the substrate or
wafer structurally robust during formation of additional
interconnect structures. The encapsulant permits backside grinding
to substantially reduce its thickness or completely remove it. A
thin substrate simplifies formation of TSVs for electrical
connection to the PCB. The encapsulant eliminates the need for
bonding & de-bonding to a temporary carrier, lowers
manufacturing cost, reduces breakage and slip, simplifies handling,
and enables higher processing temperatures. The electrical
connection to the PCB on the backside of the substrate reduces
silicon area and corresponding package size and thickness.
[0065] While one or more embodiments of the present invention have
been illustrated in detail, the skilled artisan will appreciate
that modifications and adaptations to those embodiments may be made
without departing from the scope of the present invention as set
forth in the following claims.
* * * * *