The present disclosure generally concerns devices comprising a plurality of integrated circuits and methods of manufacturing such devices.
In microelectronics, the trend is towards miniaturization to consume fewer raw materials and decrease production costs, or to be able to add new functionalities to a product without increasing its size. With this in mind, it is advantageous to stack integrated circuits on a same substrate so that they take up less space. Electrical connections between a first integrated circuit mounted on a substrate can be formed by direct connections between metal pads, and wire bonding offers a solution for forming electrical connections between a second integrated circuit mounted on the first integrated circuit. However, the use of wires requires a significant space around the integrated circuits to be connected.
There thus exists a need for a method of assembling a plurality of circuits stacked on each other on a same substrate, enabling to decrease the dimensions of the final device.
An embodiment provides a method comprising: forming on a substrate a first layer of a resin compatible with a direct laser structuring (LDS), wherein a first integrated circuit mounted on the substrate is incorporated (i.e., encapsulated) in the first layer, the substrate comprising a first connection terminal coupled to the first integrated circuit and a second connection terminal coupled to the first connection terminal and covered by the first layer; forming a first via by LDS, the first via crossing the first layer and forming an electrical contact with the second connection terminal; mounting a second integrated circuit on the first integrated circuit; forming on the substrate a second layer of the LDS-compatible resin, wherein the second integrated circuit is incorporated (i.e., encapsulated) in the second layer; and forming a second via by LDS crossing the second layer and forming an electrical contact with the first via.
According to an embodiment, forming the first layer comprises depositing an initial resin layer and thinning the initial resin layer to obtain the first layer.
According to an embodiment, forming the second layer comprises depositing an initial resin layer and thinning of the initial resin layer to obtain the second layer.
According to an embodiment, the method further comprises adding a device on the second layer, the device being coupled to the second via.
According to an embodiment, the method further comprises depositing a third layer made of resin on the second layer.
According to an embodiment, the first integrated circuit and the second integrated circuit each have a first surface comprising metallizations comprising one or a plurality of connection terminals and a second surface opposite to the first surface, the first and second integrated circuits being mounted with their second surfaces facing each other.
According to an embodiment, the vias are formed by autocatalytic growth or electroless plating.
According to an embodiment, the second via is laterally offset with respect to the first via.
According to an embodiment, the height of the first layer is at least equal to the distance separating the second connection terminal from the upper surface of the first integrated circuit.
According to an embodiment, the height of the second layer is at least equal to the distance separating the first via from the upper surface of the second integrated circuit.
Another embodiment provides a microelectronic device comprising: a substrate; a first integrated circuit mounted on the substrate; a first layer of a resin, compatible with a direct laser structuring (LDS) deposited on the substrate and having the first integrated circuit incorporated (i.e., encapsulated) therein; in the substrate, a first connection terminal coupled to the first integrated circuit and a second connection terminal coupled to the first connection terminal and covered by the first layer; a first via formed by LDS, the first via crossing the first layer and forming an electrical contact with the second connection terminal; a second integrated circuit mounted on the first integrated circuit; a second layer of the LDS-compatible resin, the second integrated circuit being incorporated (i.e., encapsulated) in the second layer; and a second via formed by LDS crossing the second layer and forming an electrical contact with the first via.
The foregoing features and advantages, as well as others, will be described in detail in the rest of the disclosure of specific embodiments given as an illustration and not limitation with reference to the accompanying drawings, in which:
Like features have been designated by like references in the various figures. In particular, the structural and/or functional features that are common among the various embodiments may have the same references and may dispose identical structural, dimensional and material properties.
For clarity, only those steps and elements which are useful to the understanding of the described embodiments have been shown and are described in detail. In particular, the steps of manufacturing of a laminated substrate and of the integrated circuits are usual and are not detailed.
Unless indicated otherwise, when reference is made to two elements connected together, this signifies a direct connection without any intermediate elements other than conductors, and when reference is made to two elements coupled together, this signifies that these two elements can be connected or they can be coupled using one or more other elements.
In the following description, where reference is made to absolute position qualifiers, such as “front”, “back”, “top”, “bottom”, “left”, “right”, etc., or relative position qualifiers, such as “top”, “bottom”, “upper”, “lower”, etc., or orientation qualifiers, such as “horizontal”, “vertical”, etc., reference is made unless otherwise specified to the orientation of the drawings.
Unless specified otherwise, the expressions “about”, “approximately”, “substantially”, and “in the order of” signify plus or minus 10%, preferably of plus or minus 5%.
In the example of
Substrate 104 and dielectric layer 105 are, for example, made of Ajinomoto Build-up Film (ABF) or, for example, of polymer. Substrate 104 has a thickness, for example, at least equal to 50 μm. Dielectric layer 105 has a thickness, for example, at least equal to 10 μm.
Integrated circuits 101 and 102 each have metallizations comprising one or a plurality of connection terminals 123, 130, 123′, 130′ on a first surface of each of integrated circuits 101, 102, and have, for example, no metallization or connection terminal on a second surface opposite to the first surface. The second integrated circuit 102 is mounted on the first integrated circuit 101 so that the second surfaces of the circuits 101 and 102 face each other and so that the connection terminals present on their first surfaces remain accessible.
The connection terminal 123 of integrated circuit 101 is, for example, on its lower surface, and is, for example, connected by one or a plurality of metal tracks 124 to a connection terminal 125 on the upper surface of substrate 104. Metal tracks 124 are, for example, made of copper, of gold, of tin, of silver, or of an alloy of a plurality of these materials.
In certain embodiments, connection terminals 123 and 125 are also connected using metal tracks 124 to a connection terminal 128 enabling to couple device 100 to an external electronic device, not shown. Connection terminal 128 is. for example. present on the lower surface of substrate 104.
The connection terminal 130 of integrated circuit 102 is, for example, on its upper surface. Connection terminals 125 and 130 are connected to each other using via 112 and via 118. In the example of
According to an embodiment, vias 112 and 118 are laterally offset, that is, offset in a direction parallel to the plane of substrate 104, from each other by a distance 8. Vias 112 and 118 are, for example, connected to each other using metal track 114.
A via 117 is connected, on the one hand, to the connection terminal 130 of integrated circuit 102 and, on the other hand, to via 118 using one or a plurality of metal tracks 119.
The resin 106 used to encapsulate integrated circuit 101 is, for example, a specific resin compatible with a direct laser structuring (LDS) in that it includes additives or particles which can be activated by laser processing at locations where vias and tracks are desired. The thickness of resin layer 106 is, for example, at least equal to the sum of the heights of vias 112 and 118. In the example of
In the example of
Certain elements of
In the following description of
The device 200 of
Device 200, in the example of
The final height h1′ of resin layer 106A′ is, in the example of
In the following description of
During the laser ablation step, the laser beam used to perforate resin 106A′ interacts with LDS additives present in resin 106A′ and locally activates the periphery of perforations 110.
Further, the locations of future formations of the metal tracks 114, on the upper surface of resin 106A′, that is, the surface most distant from substrate 104, are for example illuminated by the laser beam during this step in order to locally activate them.
Although
Vias 112 are, for example, made of copper, of gold, of tin, of silver, or of an alloy of a plurality of these materials.
The steps described hereabove in relation with
According to an embodiment, in the case where the thinning step of
The deposition of resin layer 106B is, for example, performed by compression molding, the resin being for example deposited on the surface of the device of
The thickness h2 of layer 106B is, for example, at least equal to the height of the future vias 118, that is, for example, at least sufficient to cover integrated circuit 102.
As for height h2, the final height h2′ of resin layer 106B′ is, in the example shown in
In the following description of
After the laser ablation step, the periphery of perforations 115, 116 is activated.
Further, the locations of future formations of metal tracks 119, on the upper surface of resin 106B′, are illuminated, for example, by the laser beam during this step to locally activate them.
The steps described above in relation with
According to an embodiment, the vias formed by autocatalytic growth at steps 2C and 2H are created by forming a metal layer on the walls of perforations 110, 116, 115. The vias 112, 118, 117 thus created form, for example, cones partially filled at their center. Vias 112 and 118 are, for example, offset from one another by a distance 8 and connected by metal tracks 114 to ensure a good connection.
Although
After a step of deposition of a third resin layer on the surface of the device of
Certain elements of
According to an embodiment alternative to that shown in
In the example of
During the method thus described, two series of vias 112 and 118 are successively created. An advantage of creating these two series of vias instead of a single via is that the height of each via is decreased, making the final device more compact. Indeed, the aspect ratio of a via is generally limited. For example, in the case of a via formed by LDS, the aspect ratio is limited to 1:1, that is, the height cannot exceed the diameter of the via. Creating two successive vias thus takes up less surface area than creating a single via which is higher and thus wider. For example, when it is desired to form a 300-μm high via, it is possible to create two vias having a 150-μm height and a 150-μm maximum diameter one above the other, for a total 300-μm height and a maximum 150-μm diameter, if the aspect ratio is limited to 1. For comparison, a single 300-μm high via would require a 300-μm maximum diameter. The surface area required for the vias is thus effectively decreased.
Elements of
The PEP encapsulation process is for example used to obtain the device 200 of
At a step A, a substrate, for example a wafer 301 of a semiconductor material, for example silicon, comprising integrated circuits (not illustrated at step A) is covered with dielectric layer 105. Dielectric layer 105 is, for example, an ABF or polymer film.
At a step B, after the deposition of dielectric layer 105, layer 105 is, for example, locally opened by laser and/or plasma etching to create perforations for example at the location of the connection terminal 123 of the integrated circuit 101 of
At a step C, the wafer 301 of step B is then, for example, ground to remove a substrate thickness useless for the operation of the integrated circuits, and diced to separate integrated circuits 101 into individual electronic chips.
At a step D, following step C, the electronic chips are turned over and repositioned on a support board made, for example, of stainless steel, so that dielectric layer 105 is bonded to the board by a temporary bonding film 302.
At a step E, following step D, the chips are then, for example, spaced apart, the spacing between chips being sufficient, for example, for the creation of the future vias 112 of
At a step F, after the deposition of resin layer 106A, it is for example thinned by abrasive polishing.
At a step G, following step F, the chips encapsulated in resin 106A are separated from the support board, turned over to expose dielectric layer 105, and their opposite surface is bonded to the support board by a temporary bonding film 304. An automatic optical inspection (AOI) is, for example, carried out to detect defects on the chips.
At a step H, following step G, metal particles 306, for example of copper and titanium, are deposited on the surface of the encapsulated chips. These particles will be used as seeds for a subsequent autocatalytic or electrocatalytic growth step.
At a step I, after the deposition of metal particles 306, a photoresist layer 308 is for example deposited.
At a step J, after the deposition of layer 308, it is exposed by laser direct imaging (LDI) and developed to create openings in the dielectric layer. The use of a laser rather than of a mask for this photolithography step allows an adjustment of the illumination pattern of the dielectric layer. The position of the electronic chips on the support board may vary from one board to another, and the LDI imaging enables to adapt to the variations.
At a step K, after the forming of openings, metal vias and tracks 124 are formed, for example, by electroplating.
At a step L, after the forming of metal tracks 124, a photoresist layer 310 is, for example, deposited.
At a step M, layer 310 is exposed by LDI and developed to create openings in photoresist layer 310.
At a step N, following step M, metal tracks 128, for example made of copper, are created on the metal tracks deposited at step K, for example by electroplating according to the openings in layer 310. Tracks 128 form, for example, connection terminals.
At a step O, following step N, layers 308 and 310 as well as the precursor particles 306 remaining under layers 308 and 310 are removed, for example by etching.
At a step P, after the etching step, a dielectric layer 104 is deposited to encapsulate the metal tracks and vias.
At a step Q, after the deposition of dielectric layer 104, it is for example thinned to expose metal tracks 328, and a succession of layers, for example comprising nickel and/or gold layers, is for example deposited by electroplating at the surface of metal tracks 328 to make them corrosion-resistant. The structure comprising two integrated circuits 101 is separated from the support board.
The method described by the steps A to Q detailed in relation with
As a variant, after step Q, at a step R, the electronic chips are for example separated into individual electronic chips, for example by laser cutting or mechanical sawing. In this case, the method described in relation with
Various embodiments and variants have been described. Those skilled in the art will understand that certain features of these various embodiments and variants may be combined, and other variants will occur to those skilled in the art. In particular, the method described in
Number | Date | Country | Kind |
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FR2400206 | Jan 2024 | FR | national |
This application claims the priority benefit of French Application for U.S. Pat. No. 2,400,206, filed on Jan. 10, 2024, the content of which is hereby incorporated by reference in its entirety to the maximum extent allowable by law.