Direct-write wafer level chip scale package

Abstract

A method and structure provides a Direct Write Wafer Level Chip Scale Package (DWWLCSP) that utilizes permanent layers/coatings and direct write techniques to pattern these layers/coatings, thereby avoiding the use of photoimagable materials and photo-etching processes.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of integrated circuit packaging and, in particular, to wafer level chip scale packaging processes and structures.

2. Description of Related Art

In the prior art, wafer level chip scale packaging techniques typically involved adding various layers to integrated circuit wafers and then patterning the layers using a complex series of masking and photo etching steps. Typically, additive layers were spun-on, sprayed-on as a vapor, or printed on the integrated circuit wafers. As noted above, prior art techniques also typically required the use of photoimagable materials such as Cyclotone™ products or polyimides and the use of extensive photo-definition processes, i.e., masking and photo-etching of the layers.

In the prior art, many of the coatings or layers discussed above, such as photoresist, were not permanent, and did not remain part of the finished product. Rather, many layers were used as temporary masks and were later removed. Consequently, the prior art techniques required multiple steps and significant amounts of discarded/wasted materials. In addition, the process of depositing the prior art layers described above, and then subsequently photo-patterning and photo-etching the layers, was inherently expensive and labor intensive as well as time consuming and complicated.

In addition, the prior art photoimagable materials had to be of specific and limited thickness for the prior art processes to work, and be practical. In the prior art, these thicknesses were typically limited to less than twenty (20) microns. Consequently, the resulting structures typically offered limited flexibility and opportunity for “compliance” between interconnections, and the surfaces of the dies comprising the integrated circuit wafers.

What is needed is a wafer level chip scale packaging method and structure that is not dependent on photolithography and therefore eliminates the need for photoimagable materials, non-permanent layers and the wasteful photo-definition process and makes feasible structures that would be impractical using prior art methods.

SUMMARY OF THE INVENTION

A method and structure according to one embodiment of the invention provides a Direct Write Wafer Level Chip Scale Package (DWWLCSP) that utilizes permanent layers/coatings and direct write techniques to pattern these layers/coatings.

According to one embodiment of the invention, a Direct Write Wafer Level Chip Scale Package is created by first preparing a silicon wafer and then a dielectric layer is attached directly to the wafer. In one embodiment of the invention, the dielectric layer is a layer of InterVia® 8000 or a similar material. The dielectric layer is then ablated to form vias and trench patterns. The surface of the dielectric layer is then plated with a conductive layer, such as copper, or another suitable metal, to fill in all of the related via and trench patterns and thereby form conductive patterns and connections to the die pads. According to one embodiment of the invention, the conductive layer is then partially removed through a controlled etching process, leaving only the conductor patterns and connections to the die pads. In one embodiment of the invention, these patterns are then processed through standard solder application techniques such as solder masking and/or other solder application methods known in the art.

In one embodiment of the invention, the dielectric layer is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. This particular structure provides a cushion of dielectric material between sub-vias for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers.

According to another embodiment of the invention, a Direct Write Wafer Level Chip Scale Package is created by first preparing a silicon wafer and then a dielectric layer is attached to the wafer using an adhesive layer. The dielectric layer is then ablated to form via and trench patterns. The surface of the dielectric layer is then plated with a conductive layer, such as copper or another suitable conductive material, to fill in all of via and trench patterns and thereby form conductor patterns and connections to the die pads. According to one embodiment of the invention, the conductive layer is then partially removed through a controlled etching process, leaving only the conductor patterns and connections to the die pads. In one embodiment of the invention, these patterns are then processed through any standard solder application techniques, such as solder masking and/or other solder application methods known in the art.

According to one embodiment of the invention, because of the flexible thicknesses of the dielectric available using the methods and structures of the invention, the dielectric and conductive layers of the invention can be laminated, which enables the creation of multilayer Direct Write Wafer Level Chip Scale Package structures at lower costs, and with improved reliability of the finished Direct Write Wafer Level Chip Scale Packaged electronic component.

As noted above, the Direct Write Wafer Level Chip Scale Packages of the invention include dielectric and conductive materials applied directly onto the wafer surface. The dielectric layers are then ablated, as opposed to imaged using photolithography. Consequently, using the method and structure of the present invention, the materials used need not be photoimagable materials, thus saving the cost of the materials themselves and the cost of indirect materials required for the masking and etching steps.

In addition, using the methods and structures of the present invention, the dielectric layers can be attached to the wafer with an adhesive layer and this adhesive layer need not be patterned using standard techniques. In addition, according to the method and structure of the invention, the conductive layer building process is solely additive, using the ablated dielectric layer as its mask. Consequently, the need for subsequent patterning and etching is eliminated.

In, addition, since using the method and structure of the present invention, the materials used need not be photoimagable materials, the materials need not be of the prior art specified limited thickness. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers.

In addition, as discussed above, according to one embodiment of the invention, the dielectric layer is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. This particular structure provides a cushion of dielectric material between sub-vias for thermal expansion and therefore provides better compliance properties.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a silicon wafer, including one or more electronic components such as integrated circuits;

FIG. 1B shows the silicon wafer of FIG. 1A, including a dielectric layer applied to the silicon wafer in accordance with the principles of one embodiment of the present invention;

FIG. 1C shows the silicon wafer of FIG. 1B after the dielectric layer has been ablated to form vias and trenches in accordance with the principles of one embodiment of the present invention;

FIG. 1D shows a layer of conductive material applied to the structure of FIG. 1C in accordance with the principles of one embodiment of the present invention;

FIG. 1E shows the structure of FIG. 1D after the layer of conductive material is etched using a controlled etching process in accordance with the principles of one embodiment of the present invention;

FIG. 1F shows the structure of FIG. 1E with solder bumps attached to points on the conductive layer in accordance with the principles of one embodiment of the present invention;

FIG. 1G shows the structure of FIG. 1F being singulated into individual Direct Write Wafer Level Chip Scale Packaged electronic components, in accordance with the principles of one embodiment of the present invention;

FIG. 1H shows a singulated Direct Write Wafer Level Chip Scale Package in accordance with the principles of one embodiment of the present invention;

FIG. 2A shows a silicon wafer, including an adhesive layer applied in to the silicon wafer in accordance with the principles of one embodiment of the present invention;

FIG. 2B shows the structure of FIG. 2A, including a dielectric layer applied to the silicon wafer using the adhesive layer of FIG. 2A in accordance with the principles of one embodiment of the present invention;

FIG. 2C shows the structure of FIG. 2B after the dielectric layer has been ablated to form vias and trenches in accordance with the principles of one embodiment of the present invention;

FIG. 2D shows a layer of conductive material applied to the structure of FIG. 2C in accordance with the principles of one embodiment of the present invention;

FIG. 2E shows the structure of FIG. 2D after the layer of conductive material is etched using a controlled etching process in accordance with the principles of one embodiment of the present invention;

FIG. 2F shows the structure of FIG. 2E with solder bumps attached to points on the conductive layer in accordance with the principles of one embodiment of the present invention;

FIG. 2G shows the structure of FIG. 2F being singulated into individual Direct Write Wafer Level Chip Scale Packaged electronic components, in accordance with the principles of one embodiment of the present invention;

FIG. 2H shows a singulated Direct Write Wafer Level Chip Scale Packaged electronic component in accordance with the principles of one embodiment of the present invention;

FIG. 3A shows the silicon wafer, including an adhesive layer applied in to the silicon wafer in accordance with the principles of one embodiment of the present invention;

FIG. 3B shows the structure of FIG. 3A, including a dielectric layer applied to the silicon wafer using the adhesive layer of FIG. 3A in accordance with the principles of one embodiment of the present invention;

FIG. 3C shows the structure of FIG. 3B after the dielectric layer has been ablated to form vias and trenches in accordance with the principles of one embodiment of the present invention;

FIG. 3D shows a layer of conductive material applied to the structure of FIG. 3C in accordance with the principles of one embodiment of the present invention;

FIG. 3E shows the structure of FIG. 3D after the layer of conductive material is etched using a controlled etching process in accordance with the principles of one embodiment of the present invention;

FIG. 3F shows the structure of FIG. 3E, including a second dielectric layer applied in accordance with the principles of one embodiment of the present invention;

FIG. 3G shows the structure of FIG. 3F after the second dielectric layer has been ablated to form vias and trenches in accordance with the principles of one embodiment of the present invention;

FIG. 3H shows a second layer of conductive material applied to the structure of FIG. 3G in accordance with the principles of one embodiment of the present invention;

FIG. 3I shows the structure of FIG. 3H after the second layer of conductive material has been etched using a controlled etching process in accordance with the principles of one embodiment of the present invention;

FIG. 3J shows the structure of FIG. 3I with solder bumps attached to points on the second conductive layer in accordance with the principles of one embodiment of the present invention;

FIG. 3K shows the structure of FIG. 3J being singulated into multi-layer Direct Write Wafer Level Chip Scale Packaged electronic components, in accordance with the principles of one embodiment of the present invention;

FIG. 3L shows a singulated multi-layer Direct Write Wafer Level Chip Scale Packaged electronic component in accordance with the principles of one embodiment of the present invention;

FIG. 3M shows the singulated multi-layer Direct Write Wafer Level Chip Scale Packaged electronic component of FIG. 3L in detail in accordance with the principles of one embodiment of the present invention;

FIG. 4A shows a detail portion of a Direct Write Wafer Level Chip Scale Packaged electronic component wherein a dielectric layer has been ablated in such a way as to form patterned vias; and

FIG. 4B shows a detail portion of a Direct Write Wafer Level Chip Scale Packaged electronic component wherein a metal buildup region is formed on bonding points of a conductive layer second surface.

Common reference numerals are used throughout the drawings and detailed description to indicate like elements.

DETAILED DESCRIPTION

A method and structure according to one embodiment of the invention provides a Direct Write Wafer Level Chip Scale Package (DWWLCSP) that utilizes permanent coatings/layers and direct write techniques to pattern these coatings/layers.

According to one embodiment of the invention, a Direct Write Wafer Level Chip Scale Package (121 in FIG. 1H) is created by first preparing a silicon wafer (100 in FIG. 1A) and then a dielectric layer, also called a first dielectric layer, (107 in FIG. 1B) is attached directly to the wafer. The dielectric layer is then ablated to form vias and trench patterns (104 in FIG. 1C). In one embodiment of the invention, the dielectric layer (407 in FIG. 4B) is ablated in such a way as to form patterned vias (411 in FIG. 4B) to the die pads (498 in FIG. 4B). The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular sub-vias (416A, 416B, 416C in FIG. 4A) are formed. This particular structure provides a cushion of dielectric material (407A and 407B) between sub-vias for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers. The surface of the dielectric layer is then plated with a conductive layer, also called a first conductive layer, (111 in FIG. 1D), such as copper, or another suitable metal, to fill in all of related via and trench patterns and thereby form conductor patterns and connections to the die pads (FIG. 1D). According to one embodiment of the invention, the conductive layer is then partially removed through a controlled etching process, leaving only the conductor patterns and connections to the die pads (FIG. 1E). In one embodiment of the invention, these patterns are then processed through standard solder application techniques (FIG. 1F).

According to another embodiment of the invention, a Direct Write Wafer Level Chip Scale Package (221 in FIG. 2H) is created by first preparing a silicon wafer (200 in FIG. 2A) and then a dielectric layer, also called a first dielectric layer, (207 in FIG. 2B) is attached to the wafer using an adhesive (204 in FIG. 2B). The dielectric layer is then ablated to form via and trench patterns (FIG. 2C). In one embodiment of the invention, the dielectric layer is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. As discussed above, this particular structure provides for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers. The surface of the dielectric layer is then plated with a conductive layer, also called a first conductive layer, (211 in FIG. 2D), such as copper or another suitable conductive material, to fill in all of via and trench patterns and thereby form conductor patterns and connections to the die pads (FIG. 2D). According to one embodiment of the invention, the conductive layer is then partially removed through a controlled etching process, leaving only the conductor patterns and connections to the die pads (FIG. 2E). In one embodiment of the invention, these patterns are then processed through any standard solder application techniques (FIG. 2F).

According to one embodiment of the invention, because of the flexible thicknesses available using the methods and structures of the invention, the dielectric and conductive layers of the invention can be laminated (FIGS. 3A to 3M), which enables the creation of multilayer Direct Write Wafer Level Chip Scale Package structures (FIG. 3M) at lower costs, and with improved reliability of the finished Direct Write Wafer Level Chip Scale Package.

As noted above, the Direct Write Wafer Level Chip Scale Packages of the invention include dielectric and conductive materials applied directly onto the wafer surface. The dielectric layers are then ablated, as opposed to imaged using photolithography. Consequently, using the method and structure of the present invention. The materials used need not be photoimagable materials, thus saving the cost of the materials themselves and the cost of the masking and etching steps.

In addition, using the methods and structures of the present invention, the dielectric layers can be attached to the wafer with an adhesive layer and this adhesive layer need not be patterned using standard techniques. In addition, according to the method and structure of the invention, the conductive layer building process is solely additive using the ablated dielectric layer as its mask. Consequently, the need for subsequent patterning and etching is eliminated.

In, addition, since using the method and structure of the present invention, the materials used need not be photoimagable materials, the materials need not be of the prior art predetermined and specified thicknesses. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers. In addition, since using the method and structure of the present invention, the materials used need not be photoimagable materials, any one of numerous known adhesives and intermediate layer materials can be used with the method and structure of the invention.

In particular, FIG. 1A shows a silicon wafer 100 that has been prepared for the packaging process and includes bonding locations, or pads, 105. As shown in FIG. 1A, silicon wafer 100 has a silicon wafer first surface 101 and a silicon wafer second surface 103. Silicon wafers are well known to those of skill in the art and typically include one or more electronic components, such as integrated circuits, (not shown) formed in, or on, silicon wafer 100 by methods well known to those of skill in the art.

Once silicon wafer 100 is prepared, according to a first embodiment of the invention, a dielectric layer 107 is applied directly to silicon wafer second surface 103 of silicon wafer 100. FIG. 1B shows silicon wafer 100 of FIG. 1A including a dielectric layer, also called a first dielectric layer, 107 applied directly to silicon wafer second surface 103 of silicon wafer 100 in accordance with the principles of one embodiment of the present invention. As shown in FIG. 1B, a dielectric layer first surface 110 of dielectric layer 107 is applied directly to silicon wafer second surface 103 of silicon wafer 100.

According to the principles of one embodiment of the present invention, dielectric layer 107 is a polymer layer. In one embodiment of the invention, dielectric layer 107 is made of InterVia® 8000 material and has a thickness of approximately forty (40) microns. However, those of skill in the art will readily recognize, in light of this disclosure, that many different types of materials and thicknesses can be used for dielectric layer 107.

According to the principles of the invention, dielectric layer 107 is then ablated, using a laser or other ablation means, to form various predetermined patterns 104 in dielectric layer 107. FIG. 1C shows the structure of FIG. 1B after dielectric layer 107 has been ablated to form vias and trenches 104 in accordance with the principles of one embodiment of the present invention. As discussed in more detail below with respect to FIGS. 4A and 4B, in one embodiment of the invention, dielectric layer 107 is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern or multiple smaller cylindrical or rectangular vias are formed. As discussed in more detail below, this particular structure provides for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers.

As noted above, in one embodiment of the invention, the Direct Write Wafer Level Chip Scale Packages of the invention include dielectric layer 107 laminated directly onto the silicon wafer second surface 103 and the dielectric layer 107 is then ablated, as opposed to imaged using the photolithography techniques of the prior art. Consequently, using the method and structure of the present invention, the materials used need not be photoimagable materials.

As shown in FIG. 1D, according to the principles of the invention, a conductive layer, also called a first conductive layer, 111 is then applied to silicon wafer second surface 103 and dielectric layer second surface 109. In one embodiment of the invention conductive layer 111 is copper, or another suitable metal, and is applied to an approximate thickness of approximately five (5) microns above dielectric layer second surface 109.

According to the principles of one embodiment of the invention, conductive layer 111 includes a conductive layer first surface 115 that is in electrical contact with bonding locations 105 and a conductive layer second surface 113. According to the principles of one embodiment of the invention, conductive layer 111 is then etched away in a controlled etch process that results in conductive layer second surface 113 being made level with dielectric layer second surface 109. By this process electrically conductive traces and vias 116 are formed As discussed in more detail below with respect to FIG. 4B, using controlled etching, and the methods of the present invention, portions of conductive layer second surface 113, such as bonding points 198 for solder balls and other interconnections, can, in one embodiment of the invention, be left higher that dielectric layer second surface 109 to facilitate better bonding and compliance.

FIG. 1E shows the structure of FIG. 1D after conductive layer 111 is etched using the controlled etching process in accordance with the principles of one embodiment of the present invention. Depth controlled etching processes such as that used to bring conductive layer second surface 113 level with, or with potions slightly raised above, dielectric layer second surface 109 are well known to those of skill in the art and are therefore not discussed in further detail herein to avoid detracting from the present invention.

As shown above, according to the method and structure of the invention, the conductive layer 111 building process is solely additive using the ablated dielectric layer 107 as a mask. Consequently, the need for subsequent masks, patterning, and etching, as required in the prior art, is eliminated.

Since using the method and structure of the present invention, the materials used for dielectric layer 107 need not be photoimagable materials, the materials need not be of the prior art predetermined and specific thicknesses. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the integrated circuit wafers.

FIG. 1F shows the structure of FIG. 1E with solder bumps 119 attached to selected bonding points 198 on conductive layer 111 using standard bumping techniques in accordance with the principles of one embodiment of the present invention.

FIG. 1G shows the structure of FIG. 1F being singulated into individual Direct Write Wafer Level Chip Scale Packaged electronic components 121, 123 and 125 using a standard cutting means 127 such as a saw.

FIG. 1H shows a singulated Direct Write Wafer Level Chip Scale Packaged electronic component 121 in accordance with the principles of one embodiment of the present invention.

Referring to FIG. 2A, according to one embodiment of the invention, a silicon wafer 200 is first prepared for the packaging process, as discussed above. In this embodiment of the invention silicon wafer 200 includes a silicon wafer first surface 201, a silicon wafer second surface 203, and bonding locations, or pads, 205. In addition, an adhesive layer 204 is applied to silicon wafer second surface 203 using methods well known to those of skill in the art such as spinning or spraying.

FIG. 2B shows the structure of FIG. 2A, including a dielectric layer, also called a first dielectric layer, 207 applied to silicon wafer second surface 203 using adhesive layer 204 of FIG. 2A. According to the principles of the invention, dielectric layer 207 is then ablated, using a laser or other ablation means, to form various predetermined patterns 206 in dielectric layer 207. As discussed in more detail below with respect to FIGS. 4A and 4B, in one embodiment of the invention, dielectric layer 207 is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. As discussed below, this particular structure provides for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers. FIG. 2C shows silicon wafer 200 of FIG. 2B after dielectric layer 207 and adhesive layer 204 have been ablated to form vias and trenches 206 in accordance with the principles of one embodiment of the present invention.

As noted above, the Direct Write Wafer Level Chip Scale Packages of the invention include dielectric layer 207 applied onto the silicon wafer second surface 203 and dielectric layer 207 is then ablated, as opposed to imaged using the photolithography techniques of the prior art. Consequently, using the method and structure of the present invention, the materials used need not be photoimagable materials.

As shown in FIG. 2D, according to the principles of the invention, a conductive layer, also called a first conductive layer, 211 is then applied to silicon wafer second surface 203 and dielectric layer second surface 209. In one embodiment of the invention conductive layer 211 is copper, or another suitable metal, and is applied to an approximate thickness of five (5) microns above dielectric layer second surface 209.

According to the principles of one embodiment of the invention, conductive layer 211 includes a conductive layer first surface 215 that is in electrical contact with bonding locations 205 and a conductive layer second surface 213. According to the principles of one embodiment of the invention, conductive layer 211 is then etched away in a controlled etch process that results in conductive layer second surface 213 being made level with dielectric layer second surface 209. In this way electrically conductive traces and vias 216 are formed. As discussed in more detail below with respect to FIG. 4B, using controlled etching, and the methods of the present invention, portions of conductive layer second surface 213, such as bonding locations for solder balls and other interconnections, can, in one embodiment of the invention, be left higher than dielectric layer second surface 209 to facilitate better bonding and compliance.

FIG. 2E shows the structure of FIG. 2D after conductive layer 211 is etched using the controlled etching process in accordance with the principles of one embodiment of the present invention. Depth controlled etching processes such as that used to bring conductive layer second surface 213 level with, or with selected portions raised above, dielectric layer second surface 209 are well known to those of skill in the art and are therefore not discussed in further detail herein to avoid detracting from the present invention.

As shown above, according to the method and structure of the invention, the conductive layer 211 building process is solely additive using the ablated dielectric layer 207 as a mask. Consequently, the need for subsequent masks, patterning, and etching, as required in the prior art, is eliminated.

Since using the method and structure of the present invention the materials used for dielectric layer 207 need not be photoimagable materials, the materials need not be of the prior art predetermined and specific thicknesses. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the integrated circuit wafers.

FIG. 2F shows the structure of FIG. 2E with solder bumps 219 attached to selected bonding points 298 on conductive layer 211 using standard bumping techniques in accordance with the principles of one embodiment of the present invention.

FIG. 2G shows the structure of FIG. 2F being singulated into individual Direct Write Wafer Level Chip Scale Packaged electronic components 221, 223 and 225 using a standard cutting means 227 such as a saw.

FIG. 2H shows a singulated Direct Write Wafer Level Chip Scale Packaged electronic component 221 in accordance with the principles of one embodiment of the present invention.

Using the methods and structure of the present invention the permanent layers of the invention, i.e., the dielectric and conductive layers 107, 207 and 111, 211 respectively can be laminated or glued, which enables the creation of multilayer Direct Write Wafer Level Chip Scale Packaged electronic components at lower costs, and with improved reliability of the finished package.

FIGS. 3A to 3M show the process and structure for a multilayer Direct Write Wafer Level Chip Scale Package in which a first dielectric layer is attached using an adhesive layer, such as discussed above with respect to FIGS. 2A to 2H, and a second dielectric layer is directly attached, such as discussed above with respect to FIGS. 1A to 1H.

Referring to FIG. 3A, according to one embodiment of the invention, a silicon wafer 300 is first prepared for the packaging process, as discussed above. In this embodiment of the invention, silicon wafer 300 includes a silicon wafer first surface 301, a silicon wafer second surface 303, and bonding locations or pads 305. In addition, an adhesive layer 304 is applied to silicon wafer second surface 303 using methods well known to those of skill in the art such as spinning or spraying.

FIG. 3B shows the structure of FIG. 3A, including a first dielectric layer 307 applied to silicon wafer second surface 303 using adhesive layer 304 of FIG. 3A.

According to the principles of the invention, first dielectric layer 307 is then ablated, using a laser or other ablation means, to form various predetermined patterns 306 in first dielectric layer 307. FIG. 3C shows silicon wafer 300 of FIG. 3B after first dielectric layer 307 has been ablated to form vias and trenches 306 in accordance with the principles of one embodiment of the present invention.

As noted above, one embodiment of the multilayer Direct Write Wafer Level Chip Scale Packages of the invention includes first dielectric layer 307 laminated directly onto the silicon wafer second surface 303 and first dielectric layer 307 is then ablated, as opposed to imaged using the photolithography techniques of the prior art. Consequently, using the method and structure of the present invention, the materials used need not be photoimagable materials.

As shown in FIG. 3D, according to the principles of the invention, a first layer of conductive material 311 is then applied to silicon wafer second surface 303 and first dielectric layer second surface 309 of first dielectric layer 307. In one embodiment of the invention first conductive layer 311 is copper, or another suitable metal, and is applied to an approximate thickness of five (5) microns above first dielectric layer second surface 309 of first dielectric layer 307.

According to the principles of one embodiment of the invention, first conductive layer 311 includes a first conductive layer first surface 315 that is in electrical contact with bonding locations 305 and a first conductive layer second surface 313. According to the principles of one embodiment of the invention, first conductive layer 311 is then etched away in a controlled etch process that results in first conductive layer second surface 313 of first conductive layer 311 being made level with first dielectric layer second surface 309 of first dielectric layer 307. FIG. 3E shows the structure of FIG. 3D after first conductive layer 311 is etched using the controlled etching process in accordance with the principles of one embodiment of the present invention. Depth controlled etching processes can be used to bring first conductive layer second surface 313 of first conductive layer 311 level with first dielectric layer second surface 309 of first dielectric layer 307 as well known to those of skill in the art and are therefore not discussed in further detail herein to avoid detracting from the present invention.

As shown above, according to the method and structure of the invention, the conductive layer 311 building process is solely additive using the ablated first dielectric layer 307 as its mask. Consequently, the need for subsequent masks, patterning, and etching, as required in the prior art, is eliminated using the present invention.

According to this embodiment of the invention a second dielectric layer is now applied to the structure of FIG. 3E. FIG. 3F shows the structure of FIG. 3E including a second dielectric layer 337. As shown in FIG. 3F, a second dielectric layer first surface 336 of second dielectric layer 337 is applied directly to first dielectric layer second surface 309 of first dielectric layer 307 and first conductive layer second surface 313 of first conductive layer 311 in accordance with the principles of one embodiment of the present invention. According to the principles of one embodiment of the present invention, second dielectric layer 337 is a polymer layer of InterVia® 8000, or a similar material having a thickness of forty (40) microns. However, those of skill in the art will readily recognize, in light of this disclosure, that many different types of materials and thicknesses can be used for second dielectric layer 337.

According to the principles of the invention, second dielectric layer 337 is then ablated, using a laser or other ablation means, to form various predetermined patterns 344 in dielectric layer 337. As discussed in more detail below with respect to FIGS. 4A and 4B, in one embodiment of the invention, dielectric layer 337 is ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. As discussed in more detail below, this particular structure provides for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers. FIG. 3G shows the structure of FIG. 3F after second dielectric layer 337 has been ablated to form vias and trenches 344 in accordance with the principles of one embodiment of the present invention.

As shown in FIG. 3H, according to the principles of the invention, a second conductive layer 345 is then applied to second dielectric layer second surface 339 of second dielectric layer 337. In one embodiment of the invention second conductive layer 345 is copper, or another suitable metal, and is applied to an approximate thickness of five (5) microns or less.

According to the principles of one embodiment of the invention, second conductive layer 345 includes a second conductive layer first surface 346 that is in electrical contact with bonding locations 305 and a second conductive layer second surface 353. According to the principles of one embodiment of the invention, second conductive layer 345 is then etched away in a controlled etch process that results in second conductive layer second surface 353 of second conductive layer 345 being made level with second dielectric layer second surface 339 of second dielectric layer 337. As discussed in more detail below with respect to FIG. 4B, using controlled etching, and the methods of the present invention, portions of conductive layer second surface 353, such as bonding locations for solder balls and other interconnections, can, in one embodiment of the invention, be left higher that dielectric layer second surface 339 to facilitate better bonding and compliance. FIG. 3I shows the structure of FIG. 3H after second conductive layer 345 is etched using the controlled etching process in accordance with the principles of one embodiment of the present invention.

As shown above, according to the method and structure of the invention, the second conductive layer 345 building process is solely additive using the ablated second dielectric layer 337 as a mask. Consequently, the need for subsequent masks, patterning, and etching, as required in the prior art, is eliminated.

Since using the method and structure of the present invention, the materials used for second dielectric layer 337 need not be photoimagable materials, the materials need not limited to the prior art predetermined and specific thicknesses. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the integrated circuit wafers.

FIG. 3J shows the structure of FIG. 3I with solder bumps 319 attached to selected points on second conductive layer 345 using standard techniques in accordance with the principles of one embodiment of the present invention.

FIG. 3K shows the structure of FIG. 3J being singulated into individual multilayer Direct Write Wafer Level Chip Scale Packaged electronic components 321, 323 and 325 using a standard cutting means 327, such as a saw.

FIG. 3L shows a singulated multilayer Direct Write Wafer Level Chip Scale Packaged electronic component 321 in accordance with the principles of one embodiment of the present invention. FIG. 3M shows the singulated multilayer Direct Write Wafer Level Chip Scale Packaged electronic component 321 of FIG. 3L in more detail.

The process and structure shown in FIGS. 3A to 3M is for a multilayer Direct Write Wafer Level Chip Scale Package 321 in which a first dielectric layer is attached using an adhesive layer, such as discussed above with respect to FIGS. 2A to 2H, and a second dielectric layer is directly attached, such as discussed above with respect to FIGS. 1A to 1H. However, those of skill in the art will readily recognize, in light of this disclosure, that the multilayer Direct Write Wafer Level Chip Scale Packages of the invention can also be formed where all dielectric layers are attached using an adhesive layer, such as discussed above with respect to FIGS. 2A to 2H, or all dielectric layers are directly attached, such as discussed above with respect to FIGS. 1A to 1H.

As discussed above, in some embodiments of the invention, the dielectric layers, such as dielectric layer 107, dielectric layer 207, and dielectric layer 337 are ablated in such a way as to form patterned vias to the die pads. The vias can be patterned in any way that the user of the invention deems necessary. For instance, in one embodiment of the invention, rather than simply ablating a single cylindrical or rectangular via to the die pads, a pattern of multiple smaller cylindrical or rectangular vias are formed. This particular structure provides for thermal expansion and therefore provides better compliance properties between solder bumps, or other interconnections, and the surfaces of the dies comprising the silicon wafers.

FIG. 4A shows a detail portion 400A, such as portion 299 of FIG. 2F, of a Direct Write Wafer Level Chip Scale Packaged electronic component of the invention, such as Direct Write Wafer Level Chip Scale Packaged electronic component 121 or 221 discussed above, wherein a dielectric layer 407, such as dielectric layer 107 or dielectric layer 207 discussed above, has it's dielectric layer second surface 409A ablated in such a way as to form a patterned via 416A, such as electrically conductive vias 116 and 216 discussed above, between bonding location or pad 405, such as bonding locations or pads 105 and 205 discussed above, and bonding point 498, such as bonding points 198 and 298 discussed above.

As shown in FIG. 4A, in one embodiment, patterned via 416 includes multiple sub-vias 416A, 416B and 416C as opposed to a single cylindrical or rectangular opening. This particular structure allows for better thermal expansion by providing dielectric columns 407A and 407B to absorb thermal expansion of sub-vias 416A, 416B and 416C. Consequently, this particular embodiment of the invention provides better compliance properties between solder bump 419 and bonding point 498 and bonding location or pad 405 on the surfaces of the dies comprising the silicon wafers (not shown).

Those of skill in the art will readily recognize that many different patterns can be ablated in dielectric layer 407 to form many different vias 416A depending on the needs of the designer.

As discussed above, in some embodiments of the invention, portions of conductive layer second surfaces 113, 213 such as bonding points 198 and 298 for solder bumps 119 and 219 discussed above, and other interconnections, are be left higher that dielectric layer second surfaces 109, 209, respectively, to facilitate better bonding and compliance.

FIG. 4B shows detail portion 400B, such as portion 299 of FIG. 2F, of a Direct Write Wafer Level Chip Scale Packaged electronic component of the invention, such as Direct Write Wafer Level Chip Scale Packaged electronic component 121 or 221 discussed above, wherein bonding point 498 includes a metal buildup region 451 that extends a height “h” above dielectric second surface 409B. Metal buildup region 451 is formed by either selective etching away of conductive layer second surfaces 113, 213 (see FIGS. 1D and 1E and FIGS. 2D and 2E) or by an additive process wherein metal buildup region 451 is applied after conductive layer second surface 113 or 213 is etched away.

As shown above, the present invention provides a method and structure for Direct Write Wafer Level Chip Scale Package (DWWLCSP) that utilizes permanent layers/coatings and direct write techniques to pattern these layers/coatings.

As noted above, the Direct Write Wafer Level Chip Scale Packages of the invention include materials laminated directly onto the wafer surface. The layers are then ablated, as opposed to imaged using photolithography. Consequently, using the method and structure of the present invention, the materials used need not be photoimagable materials, thus saving the cost of the materials themselves and the cost of the masking steps.

In addition, using the methods and structures of the present invention, the dielectric layers can be attached to the wafer with an adhesive layer and this adhesive layer need not be patterned using standard techniques. In addition, according to the method and structure of the invention, the metal layer building process is solely additive using the ablated dielectric layer as its mask. Consequently, the need for subsequent patterning and etching is eliminated.

In addition, since using the method and structure of the present invention, the materials used need not be photoimagable materials, the materials need not be limited to the prior art predetermined and specific thicknesses. Consequently, the resulting structures of the invention provide the opportunity for greater flexibility and “compliance” between solder bumps, or other interconnections, and the surfaces of the dies comprising the integrated circuit wafers.

This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by these exemplary embodiments. Consequently, numerous variations, whether explicitly provided for by the specification or implied by the specification or not, may be implemented by one of skill in the art in view of this disclosure.

Claims

1. A method for packaging an electronic component comprising: providing a silicon wafer, the silicon wafer having a silicon wafer first surface and a silicon wafer second surface, opposite the silicon wafer first surface;applying a first dielectric layer, the first dielectric layer having a first dielectric layer first surface and a first dielectric layer second surface, opposite the first dielectric layer first surface, the first dielectric layer first surface being applied to the silicon wafer second surface;ablating patterns in the first dielectric layer to create vias extending vertically in the first dielectric layer and trenches extending horizontally in the first dielectric layer;applying a first conductive layer, the first conductive layer having a first conductive layer first surface and a first conductive layer second surface, opposite the first conductive layer first surface, the first conductive layer being applied directly to the first dielectric layer second surface, the first conductive layer completely filling the patterns ablated in the first dielectric layer such that the first conductive layer second surface is at least substantially co-planar with the first dielectric layer second surface to create conductive vias extending vertically in the first dielectric layer and traces extending horizontally in the first dielectric layer; andsingulating the silicon wafer with the applied first dielectric layer and the applied first conductive layer into individual packaged electronic components.

2. The method for packaging an electronic component of claim 1, wherein: the first dielectric layer first surface is directly applied to the silicon wafer second surface by lamination.

3. The method for packaging an electronic component of claim 2, wherein: ablating patterns in the first dielectric layer to create vias and trenches is performed by LASER ablation of portions of the first dielectric layer.

4. The method for packaging an electronic component of claim 1, wherein: the first dielectric layer first surface is applied to the silicon wafer second surface by an adhesive.

5. The method for packaging an electronic component of claim 4, wherein: ablating patterns in the first dielectric layer to create vias and trenches is performed by LASER ablation of portions of the first dielectric layer.

6. The method for packaging an electronic component of claim 1, wherein: the first conductive layer is applied such that the first conductive layer completely fills the patterns ablated in the first dielectric layer and covers the first dielectric layer second surface; further wherein,at least a portion of the first conductive layer is removed such that the first conductive layer second surface is substantially co-planar with the first dielectric layer second surface to create the conductive vias and traces.

7. A method for packaging an electronic component comprising: providing a silicon wafer;applying a first dielectric layer to the silicon wafer;ablating patterns in the first dielectric layer to create vias extending vertically in the first dielectric layer and trenches extending horizontally in the first dielectric layer;applying a first conductive layer directly to the first dielectric layer, the first conductive layer filling the patterns ablated in the first dielectric layer to create conductive vias extending vertically in the first dielectric layer and traces extending horizontally in the first dielectric layer; andsingulating the silicon wafer with the applied first dielectric layer and the applied first conductive layer into individual packaged electronic components.

8. The method for packaging an electronic component of claim 7, wherein: the first dielectric layer is directly applied to the silicon wafer by lamination.

9. The method for packaging an electronic component of claim 7, wherein: ablating patterns in the first dielectric layer to create vias and trenches is performed by LASER ablation of portions of the first dielectric layer.

10. The method for packaging an electronic component of claim 7, wherein: the first dielectric layer is applied to the silicon wafer by an adhesive.

11. The method for packaging an electronic component of claim 10, wherein: ablating patterns in the first dielectric layer to create vias and trenches is performed by LASER ablation of portions of the first dielectric layer.

12. The method for packaging an electronic component of claim 7, wherein the first dielectric layer comprise: a first dielectric layer first surface; anda first dielectric layer second surface, and wherein the first conductive layer comprises:a first conductive layer first surface; anda first conductive layer second surface.

13. The method for packaging an electronic component of claim 12, wherein: the first conductive layer is applied such that the first conductive layer covers the first dielectric layer; further wherein,at least a portion of the first conductive layer is removed such that the first conductive layer second surface is substantially co-planar with the first dielectric layer second surface.

14. A method for packaging an electronic component comprising: providing a silicon wafer;applying a first dielectric layer to the silicon wafer;ablating patterns in the first dielectric layer;filling the patterns ablated in the first dielectric layer with a first conductive layer to create conductive vias extending vertically in the first dielectric layer and traces extending horizontally in the first dielectric layer in the patterns;applying a second dielectric layer to the first dielectric layer and the first conductive layer;ablating patterns in the second dielectric layer; andfilling the patterns ablated in the second dielectric layer with a second conductive layer to create conductive vias and traces in the patterns in the second dielectric layer.

15. The method for packaging an electronic component of claim 14 further comprising: singulating the silicon wafer, the first dielectric layer, the first conductive layer, the second dielectric layer, and the second conductive layer into individual packaged electronic components.

16. The method of claim 14 wherein the first dielectric layer comprises a non photoimagable material.

17. The method of claim 14 wherein the second dielectric layer comprises a non photoimagable material.

18. The method for packaging an electronic component of claim 14, wherein the first dielectric layer is applied to the silicon wafer by an adhesive.

19. The method for packaging an electronic component of claim 14, wherein the first dielectric layer comprises: a first dielectric layer first surface; anda first dielectric layer second surface, and wherein the first conductive layer comprises:a first conductive layer first surface; anda first conductive layer second surface, the first conductive layer second surface being substantially co-planar with the first dielectric layer second surface.

20. The method for packaging an electronic component of claim 14, wherein the second dielectric layer comprises: a second dielectric layer first surface; anda second dielectric layer second surface, and wherein the second conductive layer comprises:a second conductive layer first surface; anda second conductive layer second surface, the second conductive layer second surface being substantially co-planar with the second dielectric layer second surface.