The disclosure relates to an electronic device, and more particularly, to an electronic device with favorable structural reliability.
It is well known that the copper area on the ground plane of the carrier board of the antenna device accounts for more than 85% and is easily subjected to warpage. The warpage is generated due to poor adhesion between the metal copper layer and the dielectric layer of the insulating layer resulting from the difference of thermal expansion coefficients between the metal copper layer and the dielectric layer of the insulating layer (e.g., silicon nitride) after being processed, which further affects the overall structural reliability.
The disclosure is directed to an electronic device with favorable structural reliability.
According to an embodiment of the disclosure, an electronic device includes a substrate, at least one conductive composite structure, and an electronic element. The at least one conductive composite structure is disposed on the substrate. The at least one conductive composite structure includes a first metal layer, a second metal layer, and a third metal layer. The second metal layer is located between the first metal layer and the third metal layer, and the thickness of the second metal layer ranges from 0.5 μm to 12 μm. The electronic element is disposed on the at least one conductive composite structure and bonded to the at least one conductive composite structure.
In summary, in the embodiments of the disclosure, the conductive composite structure disposed on the substrate is composed of the first metal layer, the second metal layer, and the third metal layer. The thickness of the second metal layer located between the first metal layer and the third metal layer ranges from 0.5 μm to 12 μm.
In order to make the features and advantages of the disclosure comprehensible, embodiments accompanied with drawings are described in detail below.
Accompanying drawings are included to provide a further understanding of the disclosure and incorporated in the specification as a part thereof. The drawings illustrate embodiments of the disclosure and together with the specification serve to explain the principles of the disclosure.
The disclosure may be understood by referring to the following detailed description with reference to the accompanying drawings. It is noted that for comprehension of the reader and simplicity of the drawings, in the drawings of the disclosure, only a part of the electronic device is shown, and specific elements in the drawings are not necessarily drawn to scale. Moreover, the quantity and the size of each element in the drawings are only schematic and are not intended to limit the scope of the disclosure.
Throughout the specification and the appended claims of the disclosure, certain terms are used to refer to specific elements. Those skilled in the art should understand that electronic device manufacturers may probably use different names to refer to the same elements. This specification is not intended to distinguish between elements that have the same function but different names.
In the following specification and claims, the terms “including”, “containing”, “having”, etc., are open-ended terms, so they should be interpreted to mean “including but not limited to . . . ”.
In addition, relative terms, such as “lower” or “bottom” and “upper” or “top”, may be used in the embodiments to describe a relative relationship between one element and another element of the drawings. It may be understood that if the device in the drawings is turned upside down, the elements described on the “lower” side shall become the elements on the “upper” side.
In some embodiments of the disclosure, terms such as “connect” and “interconnect” with respect to bonding and connection, unless specifically defined, may refer to two structures that are in direct contact (in indirect contact) with each other, or may refer to two structures that are indirectly in contact with each other, wherein there are other structures set between these two structures. In addition, the terms that describe joining and connecting may apply to the case where both structures are movable or both structures are fixed. In addition, the term “coupling” involves the transfer of energy between two structures by means of direct or indirect electrical connection, or the transfer of energy between two separate structures by means of mutual induction.
It should be understood that when a element or a film layer is described as being “on” or “connected to” another element or film layer, it may be directly on or connected to the another element or film layer, or there is an intervening element or film layer therebetween (an indirect situation). When an element is described as being “directly on” or “directly connected” to another element or film layer, there is no intervening element or film layer therebetween.
The terms such as “about”, “substantially”, or “approximately” are generally interpreted as being within a range of plus or minus 10% of a given value or range, or as being within a range of plus or minus 5%, plus or minus 3%, plus or minus 2%, plus or minus 1%, or plus or minus 0.5% of the given value or range.
As the used herein, the terms “film” and/or “layer” may refer to any continuous or discontinuous structures and materials (e.g., materials deposited by the methods disclosed herein). For example, films and/or layers may include two-dimensional materials, three-dimensional materials, nanoparticles, or even partial or complete molecular layers, or partial or complete atomic layers, or clusters of atoms and/or molecules. The film or layer may include a material or layer having pinholes, which may be at least partially continuous.
Although the terms first, second, third . . . can be used to describe a variety of elements, the elements are not limited by this term. This term is only used to distinguish a single element from other elements in the specification. Different terminologies may be adopted in claims, and replaced with the first, second, third . . . in accordance with the order of elements specified in the claims. Therefore, in the following description, the first element may be described as the second element in the claims.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by people skilled in the art to which the disclosure pertains. It is understood that these terms, such as those defined in commonly used dictionaries, should be interpreted as having meanings consistent with the relevant art and the background or context of the disclosure, and should not be interpreted in an idealized or overly formal manner unless otherwise defined in the embodiments of the disclosure.
In the disclosure, the features of multiple embodiments to be described below may be replaced, recombined, or mixed to form other embodiments without departing from the spirit of the disclosure.
Reference will now be made in detail to the exemplary embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals are used to represent the same or similar parts in the accompanying drawings and description.
In detail, the electronic device 100a of the disclosure may include a display device, an antenna device, a sensing device, a light-emitting device, or a splicing device, but the disclosure is not limited thereto. The electronic device 100a may include a bendable or flexible electronic device. The electronic device 100a includes a liquid crystal layer or alight emitting diode (LED), for example. The electronic device 100a may include the electronic element 130. The electronic element 130 may include passive elements, active elements, integrated circuits or a combination thereof, such as capacitors, resistors, inductors, variable capacitors, filters, diodes, transistors, inductors, MEMS, liquid crystal chips, and the like, but the disclosure is not limited thereto. The diodes may include light emitting diodes or photodiodes. The light emitting diodes may, for example, include organic light emitting diodes (OLEDs), mini LEDs, micro LEDs, quantum dot LEDs, fluorescence, phosphorescence or other suitable materials, or a combination thereof, but the disclosure is not limited thereto. The variable capacitors may include antenna element, but the disclosure is not limited thereto. The sensors may include, for example, capacitive sensors, optical sensors, electromagnetic sensors, fingerprint sensors (FPS), touch sensors, antennas, or pen sensors, and the like, but the disclosure is not limited thereto.
Furthermore, the at least one conductive composite structure 120a in the embodiment includes a first conductive composite structure 122a and a second conductive composite structure 124a, and the first conductive composite structure 122a and the second conductive composite structure 124a are disposed at intervals. The at least one conductive composite structure 120a may further include a third conductive composite structure 126a. The first conductive composite structure 122a is located between the second conductive composite structure 124a and the third conductive composite structure 126a. The first conductive composite structure 122a, the second conductive composite structure 124a, and the third conductive composite structure 126a are disposed apart from one another in a discontinuous manner. In one embodiment, the horizontal distance between the first conductive composite structure 122a and the second conductive composite structure 124a and the horizontal distance between the first conductive composite structure 122a and the third conductive composite structure 126a for example, range from 10 μm to 100 μm (10 μm≤horizontal distance≤100 μm), but the disclosure is not limited thereto. In some embodiments, each of the first conductive composite structure 122a, the second conductive composite structure 124a and the third conductive composite structure 126a is composed of the first metal layer M11, the second metal layer M12, and the third metal layer M13, but the disclosure is not limited thereto.
The material of the third metal layer M13 may have corrosion resistance and may be well compatible with the material of the second metal layer M12. In one embodiment, the material of the first metal layer M11 and the material of the third metal layer M13 may include, for example, titanium, titanium alloy, molybdenum, molybdenum alloys (e.g., molybdenum-titanium alloys, molybdenum-tantalum alloys, molybdenum-niobium alloys, and the like), indium tin oxide (ITO) or indium zinc oxide (IZO). The material can be selected according to different etch processes, the material of the second metal layer M12 can be, for example, copper or aluminum, but the disclosure is not limited thereto. In one embodiment, one of the first metal layer M11 and the third metal layer M13 can be made of oxide, which can improve the adhesion with an adjacent insulating layer 114 and can protect the second metal layer M12. The thickness of the first metal layer M11 is, for example, 10 nm to 0.5 μm. The thickness of the third metal layer M13 is, for example, 10 nm to 0.5 μm, but can be regarded as a protective layer. In the manufacturing process, the second metal layer M12 and the first metal layer M11 may be etched through an etching process, and then a third metal layer M13 covering a side surface S2 of the second metal layer M12 and an upper surface S1 of the first metal layer M11 is formed.
Furthermore, in the embodiment, a width W11 of the first metal layer M11 is greater than a width W12 of the second metal layer M12. Meanwhile, the width refers to the maximum width along the extending direction E parallel to the substrate 110. The third metal layer M13 is at least partially in contact with the side surface S2 of the second metal layer M12. Meanwhile, the third metal layer M13 completely covers and is in contact with the side surface S2 of the second metal layer M12, and part of a lower surface S3 of the third metal layer M13 is in contact with part of the upper surface S1 of the first metal layer M11. That is, the second metal layer M12 is completely encapsulated by the lower surface of the third metal layer M13 and the upper surface of the first metal layer M11. In one embodiment, when the thickness T of the second metal layer M12 is thick enough, such as more than 1 μm, electromagnetic waves cannot pass therethrough.
As shown in
In one embodiment, the materials of the insulating layer 112, the insulating layer 114 and the insulating layer 116 can be, for example, silicon nitride, silicon oxide, epoxy resin, silicon material, or a combination thereof, but the disclosure is not limited thereto. In one embodiment, if the material of the first metal layer M11 is titanium, the first metal layer M11 and the insulating layer 112 and the insulating layer 114 of silicon nitride have good film adhesion. Accordingly, the difference in thermal expansion coefficient between the second metal layer M12 and the insulating layer 112 and the insulating layer 114 of silicon nitride can be buffered, and the problem of adhesion peeling between the second metal layer M12 and the insulating layer 112 and the insulating layer 114 of silicon nitride can be effectively improved. In addition, the sandwich-type composite structure 120a also reduces pin holes generated by the deposition of the silicon nitride passivation layer, which can subsequently reduce the risk of copper corrosion in the post-process.
Referring to
In addition, referring to
In addition, the electronic device 100a of the embodiment further includes a circuit board 180 and an anisotropic conductive adhesive 185. A circuit board 180g and the anisotropic conductive adhesive 185 are disposed on the substrate 110, and the circuit board 180g is electrically connected to the metal layer M on the substrate 110 through the anisotropic conductive adhesive 185 and the metal intermediate layer 125. The circuit board 180 may be, for example, a chip on film (COF) or a chip on glass (COG). The metal intermediate layer 125 can be selected from materials with corrosion resistance and oxidation resistance and can be used as a conduction structure with the out lead bonding (OLB) area. In one embodiment, the area of all metal layers (including the first metal layer M11, the second metal layer M12, the third metal layer M13, the metal layer M, etc.) accounts for 0.3 times or more the area of the substrate 110.
In short, in the embodiment of the disclosure, the conductive composite structure 120a disposed on the substrate 110 includes the first metal layer M11, the second metal layer M12, and the third metal layer M13. The thickness of the second metal layer M12 located between the first metal layer M11 and the third metal layer M13 ranges from 0.5 μm to 12 μm. That is, the thicker second metal layer M12 and the substrate 110 are separated from the first metal layer M11, thereby effectively reducing the warpage of the second metal layer M12 resulting from the difference in thermal expansion coefficient between the second metal layer M12 and the substrate 110. Accordingly, the electronic device 100a of the disclosure can have favorable structural reliability.
Meanwhile, note that the following embodiments use the reference numerals and part of the contents of the previous embodiments, the same reference numerals are used to represent the same or similar elements, and the description of the same technical contents is omitted. For the description of the omitted part, refer to the foregoing embodiments, which is not repeated in the following embodiments.
During the manufacturing process, the first opening O61 and the second opening O62 may be formed by dry etching the third metal layer M63 and the insulating layer 118f. Next, an electroless nickel immersion gold (ENIG) process is performed, the desired surface treatment layer 175 is formed on the inner wall of the first opening O61 and the inner wall of the second opening O62 and extends to part of the insulating layer 118f. Finally, the solder 170 is filled in the first opening O61 and the second opening O62.
In summary, in the embodiments of the disclosure, the conductive composite structure disposed on the substrate may include a first metal layer, a second metal layer, and a third metal layer. The thickness of the second metal layer located between the first metal layer and the third metal layer ranges from 0.5 μm to 12 μm. That is, the thicker second metal layer and the substrate are separated from the first metal layer, thereby effectively reducing the warpage of the second metal layer resulting from the difference in thermal expansion coefficient between the second metal layer and the substrate. Accordingly, the electronic device of the disclosure can have favorable structural reliability.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
Number | Date | Country | Kind |
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202210976960.6 | Aug 2022 | CN | national |
This application claims the priority benefit of U.S. provisional application Ser. No. 63/287,536, filed on Dec. 9, 2021, and China application serial no. 202210976960.6, filed on Aug. 15, 2022. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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63287536 | Dec 2021 | US |