Method of attaching a conformal chip carrier to a flip chip

Abstract
Mixtures for attaching a semiconductor chip to a substrate. The semiconductor chip has an array of joining material bumps, such as C4 solder balls. The substrate has an array of conductive pads corresponding to the array of joining material bumps. In a first embodiment the fixture has a body having a first cavity containing the semiconductor chip and a second cavity for containing the substrate. The substrate is placed over the semiconductor chip with the conductive pads opposing and in contact with the joining material bumps, such that during reflow of the joining material bumps, the weight of the substrate acts against the joining material bumps and aids in the attachment of the semiconductor chip to the substrate to form electrical connections therebetween.
Description




FIELD OF THE INVENTION




The field of art to which this invention relates is electronic packaging. More specifically, the present invention relates to a method and apparatus for assembling a conformal chip carrier to a flip chip.




DESCRIPTION OF THE RELATED ART




Typically, one or more semiconductor chips, or other such electronic devices, are mounted on a first circuitized substrate (called a semiconductor chip carrier, or more generally, a first level electronic package), which, in turn, is mounted on a second circuitized substrate such as a printed circuit card or board (more generally called a second level electronic package). The electronic devices mounted on the first level electronic package are electrically connected through the circuitry of the first level package to the circuitry of the second electronic package. The resulting structure may be used as part of a computer or other such equipment.




A particularly versatile first level electronic package is a flexible film, or conformal, semiconductor chip carrier. This type of first level electronic package comprises a circuitized flexible substrate and having circuitry formed on at least one side. A semiconductor chip, or other such electronic device, may be mounted on pads, such as controlled collapse chip connection (C


4


) pads, which are part of the circuitry formed on the flexible substrate. Conventional techniques are used to mount the flexible film chip carrier to the semiconductor chip. One such technique is called solder reflow which uses solder bumps, such as C


4


solder balls corresponding to the C


4


pads. With each contact pad on the chip carrier being positioned on the appropriate solder bump on the chip, the assembly is heated so as to liquefy the solder and bond each contact pad on the chip carrier to the confronting solder bump on the chip.




Conformal chip carriers are very difficult to assemble a flip chip to. The reason being is the organic substrate from which the chip carrier is fabricated, is very soft due to the dielectric being a thermal plastic (no polymer cross linking), being filled with silica particles, and not having glass cloth for stiffness. The problem arises when a flip chip is placed on top of a compliant structure and thermal cycled during solder reflow. The chip remains rigid but the compliant structure sags or bows during the thermal cycling causing it to separate or detach from the solder bumps on the chip surface. This separation causes opens between the chip and the organic carrier. This problem is magnified as the chip size and the number of C


4


solder balls on the chip increase.




More traditional organic chip carriers have been made out of epoxy (thermal set with polymer cross linking) and woven glass dielectrics which makes the total structure of the chip carrier and chip rigid. Thus, when the chip is placed onto the organic structure and thermal cycled during solder reflow the chip carrier does not pull away from the chip. However, these traditional chip carriers are for low temperature reflow and cannot be used with the high temperature reflows associated with C


4


techniques.




Another approach to the problem of chip carrier separation during reflow has been to attach a metal stiffener (a “picture frame”) to the conformal organic chip carrier with adhesives prior to chip attachment. This approach helps to some extent, but z-axis (sag or bow) movement still occurs in the chip area which will create opens. Another problem is that the adhesive used, limits the reflow temperatures allowed or would require new adhesives to be developed which would be able to withstand higher temperatures..




Yet another approach to the problem is to stretch the chip carrier taut. This is accomplished by pulling the carrier on four corners and holding it in tension during the reflow process. This requires additional room on the carrier for tooling holes and has only been done on flexible polyimide carriers at traditional reflow temperatures (i.e., peak temperatures of 220° C.).




Furthermore, alignment of the chip carrier with the chip can be done with manual split field optical systems to view the ball surface of the chip and the pad surface of the chip carrier so that both can be aligned, or with fully automated and costly in-line advanced placement tools. This is a necessary step in the packaging processes of the prior art. However, the alignment of the balls with the pads does not have to be perfect, because of the inherent self-alignment properties of the C


4


techniques. If the ball is contacting any portion of a corresponding pad, the ball will self-align with the pad. However, the prior art methods for attaching a conformal chip carrier to a flip chip do not take full advantage of this self-aligning feature because of the configuration of the chip relative to the chip carrier during reflow.




Therefore, there is a need in the art for a method and apparatus for attaching a conformal chip carrier to a chip, such as a flip chip, which eliminates sagging or bowing of the chip carrier during reflow, and thus eliminates opens, resulting in increased yields. In addition, there is a need in the art for a method and apparatus which takes advantage of the self-alignment properties of the C


4


process and one which eases the alignment and attachment of complex chip patterns to conformal chip carriers.




SUMMARY OF THE INVENTION




Therefore, it is an object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which prevents the chip carrier from separating from the chip surface.




It is yet another object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which obviates the need for a rigid chip carrier structure.




It is yet another object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which eliminates the need for stiffener attachments to the conformal chip carriers during solder reflow.




It is yet another object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which is compatible with both low temperature reflow and C


4


reflow.




It is yet another object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which takes advantage of the self-aligning characteristics of C


4


solder balls.




It is still yet another object of the present invention to provide an apparatus and method for attaching a conformal chip carrier to a semiconductor chip which eliminates the need for costly and complicated alignment systems.




Accordingly, a first embodiment of a fixture for attaching a semiconductor chip to a substrate is disclosed. The semiconductor chip has an array of joining material bumps. The substrate has an array of conductive pads corresponding to the array of joining material bumps. The fixture has a body having a first cavity for containing the semiconductor chip and a second cavity in communication with the first cavity for containing the substrate. The substrate is placed over the semiconductor chip with the conductive pads opposing and in contact with the joining material bumps, such that during reflow of the joining material bumps, the weight of the substrate acts against the joining material bumps and aids in the attachment of the semiconductor chip to the substrate to form electrical connections therebetween. The dimensions of the first and second cavities preferably have tolerances such that upon holding of the tolerances, the joining material bumps are ensured to line up with at least an edge of the conductive pads thus eliminating the need for alignment systems.




A second embodiment of a fixture for attaching the semiconductor chip to the substrate is also disclosed. The fixture comprises a first plate having a first opening for disposal of the semiconductor chip therein, a second plate stacked below the first plate and having a thickness substantially equal to the thickness of the substrate, the second plate further having a second opening opposing the first opening for disposal of the substrate therein, and a third plate stacked below the second plate such that the substrate is flattened in the second opening under the weight of the first plate thereby aiding in the attachment of the joining material bumps to their corresponding conductive pads during solder reflow to form electrical connections therebetween.




Also disclosed are methods for attaching the semiconductor chip to the substrate using the fixtures of the present invention.




In a preferred embodiment of both the apparatus and method of the present invention, the joining material bumps are solder balls attached to the semiconductor chip in accordance with a C


4


process and the substrate is a conformal chip carrier.




BRIEF DESCRIPTION OF THE DRAWINGS




These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:





FIG. 1

illustrates a top, or plan view, of a first embodiment of the fixture of the present invention.





FIG. 2A

illustrates a sectional view of the fixture of

FIG. 1

taken about line


2


A—


2


A.





FIG. 2B

illustrates the sectional view of

FIG. 2A

with the chip, chip carrier, and weight disposed therein.





FIG. 3

illustrates a partial sectional view of the fixture of

FIG. 2

showing the relationship of the conductive pad relative with the solder ball before reflow.





FIG. 4

illustrates a partial sectional view of the fixture of

FIG. 2

showing the relationship of the conductive pad relative with the solder ball after reflow.





FIG. 5

illustrates a flow chart outlining the steps of a method of the present invention which utilizes the first embodiment of the fixture of the present invention.





FIG. 6

illustrates a sectional view of a second embodiment of the fixture of the present invention.





FIG. 7A

illustrates a plan view of the top plate of the fixture of FIG.


6


.





FIG. 7B

illustrates a plan view of the middle plate of the fixture of FIG.


6


.





FIG. 7C

illustrates a plan view of the bottom plate of the fixture of FIG.


6


.





FIG. 8

illustrates a flow chart outlining the steps of a method of the present invention which utilizes the second embodiment of the fixture of the present invention.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




Although this invention is applicable to numerous and various types of semiconductor chips and substrates it has been found particularly useful in the environment of flip chips and conformal chip carriers. Therefore, without limiting the applicability of the invention to flip chips and conformal chip carriers, the invention will be described in such environment.




Referring now to

FIGS. 1

,


2


A and


2


B, therein is illustrated a first embodiment of a fixture of the present invention, generally referred to by reference numeral


100


. The fixture


100


is for attaching a semiconductor chip


102


to a substrate


104


. The substrate


104


is preferably a conformal chip carrier as previously described. The semiconductor chip


102


has an array of joining material bumps


106


. The substrate


104


has an array of conductive pads


108


corresponding to the array of joining material bumps


106


. Preferably, the semiconductor chip


102


is a flip chip in which the array of joining material bumps


106


are solder balls, individually referred to by reference numeral


107


, attached to the flip chip with a controlled collapse connection process (C


4


), the process of which is well known in the art.




The fixture


100


comprises a body


110


having a first cavity


112


for containing the semiconductor chip


102


and a second cavity


114


in communication with the first cavity


112


for containing the substrate


104


. A through hole


116


is preferably utilized for allowing heat transfer to the semiconductor chip


102


from the bottom of the fixture


100


, for reducing the weight of the fixture


100


, and to ensure that the semiconductor chip


102


lays flat about edges


118


. The substrate


104


is placed over the semiconductor chip


102


with the conductive pads


108


opposing and in contact with the joining material bumps


106


. Typically, the substrate is first fluxed to wet the solder bumps


106


and pads


108


before being placed over the semiconductor chip


102


. The depth of the first cavity


112


is such that when the joining material bumps


106


of the semiconductor chip


102


extend into the second cavity


114


and the substrate


104


is placed thereupon, the substrate


104


does not rest on the edges


120


of the second cavity


114


, but is elevated therefrom a predetermined distance.




Upon heating of the fixture


100


, semiconductor chip


102


and substrate


104


, the joining material bumps


106


melt, this is termed reflow. During reflow of the joining material bumps


106


, the weight of the substrate


104


acts against the joining material bumps


106


and aids in the attachment of the semiconductor chip


102


to the substrate


104


to form electrical connections therebetween. Furthermore, the substrate


104


is fully supported by the semiconductor chip


102


and joining material bumps


106


and is prevented from sagging.




Referring now to

FIGS. 3 and 4

, the first and second cavities


112


,


114


, respectively, of the fixture


100


are preferably toleranced such that upon holding of the tolerances, each of the joining-material bumps (shown in the form of an individual solder ball


107


) are ensured to line up with at least an edge


122


of each of the individual conductive pads


124


. The tolerances are determined by simple geometric considerations. The following discussion will focus on the tolerancing of the lengths of the first and second cavities


112


,


114


, respectively. It should be apparent to someone skilled in the art, that the same analysis is used concerning the tolerancing of the width of the first and second cavities


112


,


114


, respectively.




The conductive pads


124


have a certain diameter


126


. The semiconductor chip


102


and substrate


104


have certain lengths


128


,


130


, respectively, as do the first and second cavities


132


,


134


, respectively. In addition, each of the above, namely, the diameter


126


of the joining material bumps


107


, and the lengths


128


,


130


,


132


, and


134


of the semiconductor chip


102


, substrate


104


, and first and second cavities


112


,


114


, respectively, each have their own tolerances by which they are manufactured. Using all of these dimensions and tolerances, a length and tolerance are chosen for the first and second cavities


112


,


114


, such that each of the joining material bumps


107


of the joining material bump array


106


line up with at least an edge


122


of their corresponding conductive pad


124


. Put simply, the first and second cavities,


112


,


114


, respectively are sized such that even if the semiconductor chip


102


and substrate


104


shift within their respective cavities to opposite walls


136


,


138


, the joining material bumps


107


would still align with and contact at least an edge


122


of their corresponding conductive pad


124


, as shown in FIG.


3


. If such is the case, then the self-aligning capability of the joining material bumps


106


, such as C


4


solder balls, will ensure that the joining material bumps


106


align with their corresponding conductive pads


108


during reflow, as shown in FIG.


4


. This eliminates the need for costly automated placement equipment or time consuming manual alignment systems used in the art. This also allows the use of more complex joining material bump arrays


106


, since their alignment is ensured by being built-in to the fixture


100


.




Referring back to

FIG. 2B

, the fixture


100


of the present invention can also include a weight


140


placed over the substrate


104


and acting against the substrate


104


for further aiding in the attachment of the semiconductor chip


102


to the substrate


104


. The principle purpose of the weight


140


is to correct any deformities of the substrate


104


. Typically, the substrate


104


can have a wavy surface. The weight


140


aids in flattening the substrate


104


such that the proper connections can be made between the solder bumps


106


and corresponding solder pads


108


. The weight


140


is preferably fabricated from a ceramic material and can even aid in the self-aligning capability of the joining material bumps


106


as long as a critical weight is not exceeded. The critical weight is the weight after which the joining material bumps


106


do not self-align with the conductive pads


108


due to the increased normal force the two exert upon each other.




A method of attaching the semiconductor chip


102


to the substrate


104


utilizing the first embodiment of the fixture


100


of the present invention will now be summarized with reference to FIG.


5


.

FIG. 5

illustrates the method of the present invention, generally referred to by reference numeral


200


.




The method


200


includes step


202


in which the fixture


100


of the first embodiment of the present invention is provided. The fixture


100


, in its simplest form, comprises the body


110


having the first cavity


112


for containing the semiconductor chip


102


and the second cavity


114


in communication with the first cavity


112


for containing the substrate


102


. Preferably step


204


is performed in which the first and second cavities


112


,


114


, respectively, are dimensioned and fabricated to have tolerances such that upon holding of the tolerances, the joining material bumps


106


are ensured to line up with at least an edge


122


of the conductive pads


124


. Thus, step


204


replaces the complicated, costly, and time consuming alignment steps of the prior art.




At step


206


, the semiconductor chip is inserted into the first cavity


112


in the fixture


100


with the joining material bumps


106


facing upward. At step


208


, the substrate is placed over the semiconductor chip with the conductive pads


108


opposing and in contact with the joining material bumps


106


. As discussed previously, the substrate is typically fluxed before being placed over the semiconductor chip. If required due to surface deformities of the substrate, step


210


is performed in which the weight


140


is placed over the substrate


104


which acts to flatten the substrate for further aiding in the attachment of the semiconductor chip


102


to the substrate


104


. Lastly, at step


212


, the joining material bumps


106


are heated whereby the weight of the substrate


104


acts against the joining material bumps


106


and aids in the attachment of the semiconductor chip


102


to the substrate


104


to form electrical connections therebetween. The heating of the joining material bumps


106


is done at a temperature sufficient to cause reflow of the same and carried out using processes known in the art.




Referring now to

FIG. 6

, there is illustrated a second embodiment of a fixture of the present invention, generally referred to by reference numeral


600


, in which like elements from the first embodiment are numbered with like reference numerals. The fixture


600


is for attaching a semiconductor chip


102


to a substrate


104


. The substrate


104


is preferably a conformal chip carrier as previously described. The semiconductor chip


102


has an array of joining material bumps


106


. The substrate


104


has an array of conductive pads


108


corresponding to the array of joining material bumps


106


. Preferably, the semiconductor chip


102


is a flip chip in which the array of joining material bumps


106


are solder balls attached to the flip chip with a controlled collapse connection process (C


4


), the process of which is well known in the art.




The fixture comprises a first plate


602


having a first opening


604


for disposal of the semiconductor chip


102


therein. The first opening


604


is better illustrated with reference to FIG.


7


A. Referring back to

FIG. 6

, the fixture also has a second plate


606


which is stacked below the first plate


602


. The second plate


606


preferably has a thickness


608


substantially equal to the thickness of the substrate


104


. The second plate


606


also has a second opening


610


which opposes the first opening


604


of the first plate


602


for disposal of the substrate


104


therein. The second opening


610


is better illustrated with reference to FIG.


7


B.




Referring back to

FIG. 6

, the fixture lastly has a third plate


612


stacked below the second plate. The third plate


612


preferably has a third opening


614


opposing the second opening


610


to allow heat during solder reflow to contact the substrate


104


disposed in the second opening


610


for eliminating “oil canning” of the substrate that might occur if the third plate


612


did not have the third openings


614


. The third opening


614


are illustrated better with reference to

FIG. 7C

, and preferably are configured with a central opening


614




a


surrounded by a number of slots


614




b


. Preferably, the first, second, and third plates


602


,


606


, and


612


, respectively, are fabricated from 440 stainless steel to match the CTE of the substrate, thus eliminating CTE mismatches during reflow.




In a preferred version of the fixture


600


of the second embodiment of the present invention, the fixture


600


can accommodate more than one chip


102


and substrate


104


pair. In the fixture


600


shown in FIGS.


6


and


7


A-


7


C, three such pairs are accommodated.




The fixture


600


of

FIG. 6

preferably includes an aligning means for aligning the first, second, and third plates


602


,


606


, and


612


, respectively. The aligning means preferably comprises at least two dowel pins


616


, and most preferably at least four, each of which is disposed in aligned holes


618


,


620


, and


622


in the first, second, and third plates


602


,


606


, and


612


, respectively. Aligned holes


618


,


620


, and


622


are better illustrated with reference to

FIGS. 7A-7C

.




The fixture


600


of

FIG. 6

also preferably includes a clamping means for clamping the first, second, and third plates


602


,


606


, and


612


, respectively, together. The clamping means preferably comprises at least two threaded screws


624


and most preferably four as shown in

FIGS. 6 and 7C

. The threaded screw preferably has a head portion


624




a


and a threaded portion


624




b


. Each of the threaded screws


624


is disposed in aligned clearance holes


626


,


628


in the first and second plates


602


,


606


, respectively, and mating with aligned threaded holes


630


in the third plate


612


. Aligned clearance holes


626


and


628


, and aligned threaded holes


630


are better illustrated with reference to

FIGS. 7A-7C

.




In operation, since the substrate


104


is substantially the same thickness as the second plate


606


, the substrate


104


is flattened in the second opening


610


under the weight of the first plate


602


, thereby aiding in the attachment of the joining material bumps


106


to their corresponding conductive pads


108


during solder reflow to form electrical connections therebetween. For this reason the first plate


602


is preferably relatively heavy such that the particular type and size substrate


104


used is flattened under its weight.




A method of attaching the semiconductor chip


102


to the substrate


104


utilizing the second embodiment of the fixture


600


of the present invention will now be summarized with reference to FIG.


8


.

FIG. 8

illustrates the method of the present invention, generally referred to by reference numeral


800


.




The method


800


comprises providing the fixture


800


of the second embodiment of the present invention at step


802


. At step


804


the second plate


606


is stacked upon the third plate


612


. As discussed previously, the third plate


612


preferably includes third openings


614


. In this preferable configuration of fixture


800


, the method preferably includes step


806


in which the second and third openings


610


,


614


, respectively are aligned with each other such that the material joining bumps


106


are aligned with their corresponding conductive pads


108


. It should be noted that an alignment system, as typically used in the art is also necessary with the fixture


800


of the second embodiment of the present invention.




At step


808


, the substrate


104


is inserted into the second opening


610


with its conductive pads


108


facing upward toward the first plate


602


. At step


810


, the first plate


602


is stacked on top of the second plate


606


such that the substrate


104


is flattened in the second opening


610


under the weight of the first plate


602


. Preferably, method


800


includes step


812


in which the first, second, and/or third openings


604


,


610


, and


614


respectively, are aligned with each other.




At step


814


the semiconductor chip


104


is inserted into the first opening


604


with its joining-material bumps


106


opposing and in contact with their corresponding conductive pads


108


. As noted above, an alignment system as known in the art is needed for full alignment of the material joining bumps


106


with the conductive pads


108


. Preferably, method


800


includes step


816


in which the first, second, and third plates


602


,


606


, and


612


, respectively, are clamped together. Step


816


can be performed either immediately before or after step


814


. Lastly, at step


818


, the joining material bumps


106


are heated by known methods in the art, such as by C


4


attachment, thereby attaching the joining material bumps


106


to their corresponding conductive pads


108


during solder reflow to form electrical connections therebetween.




While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.



Claims
  • 1. A method of attaching a semiconductor chip in a solder-effected connection to a substrate consisting of a conformal chip carrier, the semiconductor chip comprising a flip chip having an array of joining material bumps consisting of solder balls attached to said flip chip with a controlled collapse chip connection (C4) process, the substrate having an array of conductive pads corresponding to the array of joining material bumps, the method comprising:providing a fixture comprising a body having a first cavity for containing the semiconductor chip and a second cavity in communication with the first cavity for containing the substrate, placing the substrate over the semiconductor chip with the conductive pads opposing and in contact with the joining material bumps, such that during reflow of the joining material bumps, at elevated temperatures commensurate with the type of solder utilized, causing the weight of the substrate to act against the joining material bumps and aid in the attachment of the semiconductor chip to the substrate to form electrical connections therebetween, and removing said fixture upon completion of said electrical connections between said semiconductor chip and said substrate.
  • 2. The method of claim 1, wherein the dimensions of the first and second cavities have tolerances such that upon holding of the tolerances, the joining material bumps are ensured to line up with at least an edge of the conductive pads.
  • 3. The method of claim 1, further comprising placing a weight over the substrate to act against the joining material bumps for further aiding in the attachment of the semiconductor chip to the substrate.
  • 4. The method of claim 3, wherein the weight is fabricated from a ceramic material.
  • 5. A method of fixture for attaching a semiconductor chip in a solder-effected connection to a substrate consisting of a conformal chip carrier, the semiconductor chip comprising a flip chip having an array of joining material bumps consisting of solder balls attached to said flip chip with a controlled collapse chip connection (C4) process, the substrate having an array of conductive pads corresponding to the array of joining material bumps, the method comprising:providing a removable fixture comprising a first plate having a first opening for disposal of the semiconductor chip therein, stacking a second plate below the first plate, said second plate having a thickness substantially equal to the thickness of the substrate, the second plate further having a second opening opposing the first opening for disposal of the substrate therein, stacking a third plate below the second plate such that the substrate is flattened in the second opening under the weight of the first plate thereby aiding in the attachment of the joining material bumps to their corresponding conductive pads during solder reflow to form electrical connections therebetween; said third plate further being provided with a third opening opposing the second opening to allow heat during solder reflow at elevated temperatures commensurate with the type of solder utilized to contact the substrate disposed in the second opening, and removing said fixture from said interconnected chip carrier and chip upon completion of the solder-effected connections between said conformal chip carrier and said semiconductor chip.
  • 6. The method of claim 5, further comprising providing an aligning means for aligning the first, second, and third plates.
  • 7. The method of claim 6, wherein the means for aligning comprises at least two dowel pins each of which is disposed in aligned holes in the first, second, and third plates.
  • 8. The method of claim 5, further comprising providing a clamping means for clamping the first, second, and third plates together.
  • 9. The method of claim 8, wherein the clamping means comprises at least two threaded screws each of which is disposed in aligned clearance holes in the first and second plates and mating with aligned threaded holes in the third plate.
  • 10. The method of claim 5, wherein the first, second and third plates are fabricated from stainless steel.
  • 11. The method of claim 10, wherein the stainless steel is a series 440 stainless steel.
BACKGROUND OF THE INVENTION

This application is a divisional of U.S. application Ser. No. 09/116,368, filed Jul. 16, 1998; now U.S. Pat. No. 6,337,509.

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Entry
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