The present disclosure generally relates to an electronic device package and method of manufacturing the same, and more particularly to a three-dimensional (3D) stacking electronic device package and method of manufacturing the same.
In a 3D stacking electronic device package, electronic components including active electronic components and/or passive electronic components are stacked to increase area utility. For example, a first electronic component may be flip chip bonded to a substrate, and a second electronic component may be vertically overlapping with the first electronic component. The first and second electronic components may be encapsulated by a molding layer. The second electronic component overlapping the first electronic component, however, would impede detection of the molding layer between the substrate and the first electronic component. Therefore, there is a desire for, for example, but not limited to, an electronic device package that would allow a detection of molding layer.
In some embodiments, an electronic device package includes a substrate, at least one first electronic component and at least one electrical element. The substrate includes a first surface. The first surface comprises a plurality of electrical terminals including a first region and a second region, and a pitch of the electrical terminals of the first region is smaller than a pitch of the electrical terminals of the second region. The at least one first electronic component is electrically connected to the substrate and at least over the first region. The at least one electrical element is disposed above the first electronic component and farther from the substrate than the first electronic component. A number of the at least one electrical element under the first region is less than a number of the at least one electrical element under the second region.
In some embodiments, an electronic device package includes a substrate, at least one first electronic component and at least one electrical element. The substrate includes a first surface. The first surface comprises a plurality of electrical terminals including a first region and a second region, and a pitch of the electrical terminals of the first region is smaller than a pitch of the electrical terminals of the second region. The at least one first electronic component is electrically connected to the substrate and at least over the first region. The at least one electrical element is disposed above the first electronic component and farther from the substrate than the first electronic component. An area of the at least one electrical element under the first region projected on the first surface in a direction substantially perpendicular to the first surface is less than an area of the at least one electrical element under the second region projected on the first surface in the direction.
In some embodiments, an electronic device package includes a substrate, at least one first electronic component and at least one electrical element. The substrate includes a first surface. The first surface comprises a plurality of electrical terminals including a first region and a second region, and a pitch of the electrical terminals of the first region is smaller than a pitch of the electrical terminals of the second region. The at least one first electronic component is electrically connected to the substrate and at least over the first region. The at least one electrical element is disposed above the first electronic component and farther from the substrate than the first electronic component. A defect detectability in and/or under the first region is higher than a defect detectability in and/or under the second region.
Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that various features may not be drawn to scale, and the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
The following disclosure provides for many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to explain certain aspects of the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed or disposed in direct contact, and may also include embodiments in which additional features are formed or disposed between the first and second features, such that the first and second features are not in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
Some embodiments, or examples, illustrated in the figures are disclosed below using specific language. It will nevertheless be understood that the embodiments and examples are not intended to be limiting. Any alterations and modifications of some of the disclosed embodiments, and any further applications of the principles disclosed in this document, as would normally occur to one of ordinary skill in the pertinent art, fall within the scope of this disclosure.
Further, it is understood that several processing steps (e.g., operations) and/or features of a device may be briefly described. Also, additional processing steps and/or features can be added, and certain of the processing steps and/or features described herein can be removed or changed while implementing the methods described herein or while using the systems and devices described herein. Thus, the following description should be understood to represent examples, and are not intended to suggest that one or more steps or features are required for every implementation. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
As used herein, spatially relative terms, such as “beneath,” “below,” “above,” “over,” “on,” “upper,” “lower,” “left,” “right,” “vertical,” “horizontal,” “side” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. It should be understood that when an element is referred to as being “connected to” or “coupled to” another element, it may be directly connected to or coupled to the other element, or intervening elements may be present.
The first surface 101 may include a plurality of electrical terminals including a first region 10A and a second region 10B. In some embodiments, the substrate 10 further comprises a plurality of first electrical terminals 10C1 in the first region 10A, and a plurality of second electrical terminals 10C2 in the second region 10B. The first electrical terminals 10C1 and the second electrical terminals 10C2 are electrically connected to the embedded circuitry of the substrate 10. By way of example, the first electrical terminals 10C1 and the second electrical terminals 10C2 may be pads such as bonding pads disposed in the first region 10A and the second region 10B, respectively. In some embodiments, an electrical terminal density of the first electrical terminals 10C1 is greater than an electrical terminal density of the second electrical terminals 10C2. As used herein, the electrical terminal density may be referred to a ratio of an area of the electrical terminals disposed in a region of the substrate to an overall area of the region. In this embodiment, the ratio of the area of the first electrical terminals 10C1 in the first region 10A is greater than the ratio of the area of the second electrical terminals 10C2 in the first region 10B. In some embodiments, a pitch P1 of the first electrical terminals 10C1 of the first region 10A is smaller than a pitch P2 of the second electrical terminals 10C2 of the second region 10B.
The first component layer 20 is disposed over the first surface 101 of the substrate 10. The first component layer 20 comprises a first electronic component 22 electrically connected to the substrate 10 and at least over the first region 10A. In some embodiments, the first electronic component 22 includes an active electronic device such as a semiconductor die. The first electronic component 22 may further includes a plurality of conductive structures 22C electrically connected to the first electrical terminals 10C1 of the first region 10A. In some embodiments, the first component layer 20 may further include a second electronic component 24 over the second region 10B. The electrical terminal density of the first electronic component 22 is greater than the electrical terminal density of the second electronic component 24. For example, the second electronic component 24 includes a passive electronic component such as a resistor, a capacitor, an inductor or a combination thereof. The second electronic component 24 may further include a plurality of conductive structures 24C electrically connected to the second electrical terminals 10C2 of the second region 10B. By way of example, the conductive structures 22C and 24C may include conductive studs, conductive pillars, solder bumps, solder pastes, solder balls or a combination thereof.
The second component layer 30 is disposed over the first component layer 20 and farther from the substrate 10 than the first component layer 20. In other words, the first component layer 30 is disposed between the substrate 10 and the second component layer 30. The second component layer 30 includes at least one electrical element 32 having a plurality of input/output (I/O) terminals 32C away from the first component layer 20. In some embodiments, the at least one electrical element 32 may include an active electrical element 32A and/or a passive electrical element 32B. The at least one electrical element 32 is without overlapping the first electronic component 22 in a direction D1 substantially perpendicular to the first surface 101 and under the first surface 101. The at least one electrical element 32 may overlap the second electronic component 24 in the direction D1. In some embodiments, the second component layer 30 may include a plurality of electrical elements 32, and an electrical element 32 of the electrical elements 32 proximal to the first electronic component 22 is without overlapping the first electronic component 22 in the direction D1. That is, all electrical elements 32 are without overlapping the first electronic component 22 in the direction D1. In some embodiments, a number of the electrical element 32 under the first region 10A is less than a number of the electrical element 32 under the second region 10B. In some embodiments, an area of the electrical element 32 under the first region 10A is less than an area of the at least one electrical element 32 under the second region 10B.
The electronic device package 1 may further include a first encapsulation layer 14 over the first region 10A and the second region 10B and encapsulating the first component layer 20 and the second component layer 30. By way of examples, the first encapsulation layer 14 encapsulates the first electronic component 22 and the second electronic component 24 of the first component layer 20, and the at least one electrical element 32 of the second component layer 30. In some embodiments, a surface of the first encapsulation layer 14 and a surface of the second component layer 30 are substantially coplanar. The I/O terminals 32C of the electrical element 32 are exposed from the first encapsulation layer 14 to electrically connect to an external electrical component (not shown) such as a printed circuit board (PCB). The first encapsulation layer 14 may include molding compound such as epoxy-based material (e.g. FR4), resin-based material (e.g. Bismaleimide-Triazine (BT), Polypropylene (PP)) or other suitable materials.
The electronic device package 1 may further include a plurality of electrical connection elements 36 electrically connected to the substrate 10, and extending through the first component layer 20 and the second component layer 30. In some embodiments, the electrical connection elements 36 may include conductive pillars 36P such as copper pillars, and electrical terminals 36C partially embedded in the first encapsulation layer 14 and exposed from an outer surface 14S of the first encapsulation layer 14 to electrically connect to the external electrical component. The electrical connection elements 36 are not disposed over the first region 10A. In some embodiments, the electrical connection elements 36 may be disposed over the second region 10B, or over other region of the substrate 10. By way of example, the electrical connection elements 36 are disposed to at least one edge 10E of the substrate 10.
The defect detectability in and/or under the first region 10A is higher than the defect detectability in and/or under the second region 10B. As used herein, the defect detectability may be referred to the ability of detecting defect. A higher defect detectability means the defect is easier to be detected, and a lower defect detectability means the defect is more difficult to be detected. By way of example, the defect detectability may include void detectability, i.e., the ability of detecting void defect. In the proximity of the high device density first region 10A, defects such as void defects tends to appear, and thus a higher defect detectability is required. In the proximity of the low device density second region 10B, defects are less likely to occur, and thus the requirement of defect detectability near the second region 10B may not be as important as the requirement of defect detectability near the first region 10A.
In some embodiments, the second component layer 30 defines a clearance region 30C over the first region 10A. The clearance region 30C overlaps the first electronic component 22 in the direction D1. As used herein, the clearance region 30C of the second component layer 30 may be referred to a region that allows detecting the first encapsulation layer 14 between the first electronic component 22 and the first region 10A of the substrate 10 to check if voids defects of the first encapsulation layer 14 appear. In some embodiments, the first encapsulation layer 14 is disposed in the clearance region 30C, i.e., the clearance region 30C may be a portion of the first encapsulation layer 14 in the absence of other electronic components. In some other embodiments, the clearance region 30C of the second component layer 30 may be a recessed region of the first encapsulation layer 14. The clearance region 30C allows acoustic wave to pass through such that voids of the first encapsulation layer 14 in a tiny gap between the substrate 10 and the first electronic component 22 can be detected.
In some embodiments, the substrate 10 may further include a plurality of third electrical terminals 10C3 exposed from the second surface 102, and electrically connected to the embedded circuitry of the substrate 10. The electronic device package 1 may further include at least one third electronic component 42 disposed over the second surface 102 of the substrate 10, and electrically connected to the substrate 10 through the third electrical terminals. For example, the at least one third electronic component 42 includes one or more active electronic components 42A such as application specific integrated circuit (ASIC) dies, memory dies or a combination thereof, and one or more passive electronic component 42B such as resistors, capacitors, inductors or a combination thereof. The electronic device package 1 may further include a second encapsulation layer 44 over the second surface 102 of the substrate 10, and encapsulating the at least one third electronic component 42. The second encapsulation layer 44 may include molding compound such as epoxy-based material (e.g. FR4), resin-based material (e.g. Bismaleimide-Triazine (BT), Polypropylene (PP)) or other suitable materials.
The stack of the first component layer 20 and the second component layer 30 increases the device integration of the electronic component device package 1. The clearance region 30C of the second component layer 30 allows to perform a detection such as a scan acoustic tomography (SAT) detection to detect mold void in the first encapsulation layer 14, particularly in the tiny space between the first electronic component 22 and the substrate 10 where mold voids tend to occur. Accordingly, the reliability of the electronic component device package 1 can be improved.
The electronic device packages and manufacturing methods of the present disclosure are not limited to the above-described embodiments, and may be implemented according to other embodiments. To streamline the description and for the convenience of comparison between various embodiments of the present disclosure, similar components of the following embodiments are marked with same numerals, and may not be redundantly described.
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In some embodiments of the present disclosure, the electronic device package is a three-dimensional (3D) stacking electronic device package including a substrate and a plurality of electronic components stacked on the substrate. The 3D stacking electronic device package includes one or more suspended electrical elements that do not overlap a joint region between a high-density electronic component and the substrate, and thus a molding condition in the joint region where mold voids tend to occur can be detected. Accordingly, the reliability of 3D stacking structure can be improved.
In the description of some embodiments, a component provided or disposed “on” or “over” another component can encompass cases where the former component is directly on (e.g., in physical or direct contact with) the latter component, as well as cases where one or more intervening components are located between the former component and the latter component.
Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It is to be understood that such range format is used for convenience and brevity and should be understood flexibly to include numerical values explicitly specified as limits of a range, but also to include all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.
As used herein, the terms “approximately,” “substantially,” “substantial,” “around” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, two numerical values can be deemed to be “substantially” the same if a difference between the values is less than or equal to ±10% of an average of the values, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, “substantially” parallel can refer to a range of angular variation relative to 0° that is less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1°, less than or equal to ±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°. For example, “substantially” perpendicular can refer to a range of angular variation relative to 90° that is less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1°, less than or equal to ±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°.
As used herein, the terms “conductive,” “electrically conductive” and “electrical conductivity” refer to an ability to transport an electric current. Electrically conductive materials typically indicate those materials that exhibit little or no opposition to the flow of an electric current. One measure of electrical conductivity is Siemens per meter (S/m). Typically, an electrically conductive material is one having a conductivity greater than approximately 104 S/m, such as at least 105 S/m or at least 106 S/m. The electrical conductivity of a material can sometimes vary with temperature. Unless otherwise specified, the electrical conductivity of a material is measured at room temperature.
While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations do not limit the present disclosure. It should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not be necessarily drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus due to manufacturing processes and tolerances. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations of the present disclosure.