1. Field of the Invention
Embodiments of the present invention relate to a method of forming a semiconductor device having tightly offset semiconductor chips, and a semiconductor device formed thereby.
2. Description of the Related Art
The strong growth in demand for portable consumer electronics is driving the need for high-capacity storage devices. Non-volatile semiconductor memory devices, such as flash memory storage cards, are becoming widely used to meet the ever-growing demands on digital information storage and exchange. Their portability, versatility and rugged design, along with their high reliability and large capacity, have made such memory devices ideal for use in a wide variety of electronic devices, including for example digital cameras, digital music players, video game consoles, PDAs and cellular telephones.
While a wide variety of packaging configurations are known, flash memory storage cards may in general be fabricated as system-in-a-package (SiP) or multichip modules (MCM), where a plurality of die are mounted on a substrate. The substrate may in general include a rigid, dielectric base having a conductive layer etched on one or both sides. Electrical connections are formed between the die and the conductive layer(s), and the conductive layer(s) provide an electric lead structure for connection of the die to a host device. Once electrical connections between the die and substrate are made, the assembly is then typically encased in a molding compound to provide a protective package.
A cross-section of a conventional semiconductor package 18 (without molding compound) is shown in
It is known to layer semiconductor die on top of each other either with an offset or in a stacked configuration. An offset configuration, shown partially in prior art
As the ball solidifies, the capillary is lowered to the surface of the die bond pad 40 receiving the first end of the wire bond. The surface may be heated to facilitate a better bond. The wire bond ball 47 is deposited on the die bond pad 40 under a load, while the transducer applies ultrasonic energy. The combined heat, pressure, and ultrasonic energy create a bond between the wire bond ball 46 and the die bond pad 40.
The wire is then payed out through the capillary and the wire bond device moves over to the substrate (or other semiconductor) receiving the second end of the wire bond. The second bond, referred to as a wedge or tail bond, is then formed again using heat, pressure and ultrasonic energy, but instead of forming a ball, the wire is crushed under pressure to make the second bond, for example at substrate bond pad 44. The wire bonding device then pays out a small length of wire and tears the wire from the surface of the second bond. The small tail of wire hanging from the end of the capillary is then used to form the wire bond ball for the next subsequent wire bond. The above-described cycle can be repeated about 20 to 30 times per second.
An offset configuration provides an advantage of convenient access to the bond pads on each of the semiconductor die for wire bonding. However, the offset requires a greater footprint on the substrate, where space is at a premium. It is thus desirable to minimize the offset. However, as shown in prior art
At present, in order to allow for clearance between an upper die and the capillary, offsets of 250 microns (μm) or more are typically required between die bond pads on a first semiconductor die and the edge of a second semiconductor die stacked thereon. However, at times it is not feasible to maintain a 250 μm clearance due to product size constraints. In such instances, methods other than ball bonding are required. There is therefore a need to allow tighter offset stacked die which may be bonded using a ball bonding process.
The present invention, roughly described, relates to a semiconductor device including die bond pads which are heightened to allow wire bonding of offset stacked die even in tight offset configurations. In accordance with embodiments of the invention, after a first die is affixed to a substrate, one or more layers of an electrical conductor may be provided on some or all of the die bond pads of the first die to raise the height of the bond pads. The conductive layers may for example be conductive balls deposited on the die bond pads of the first die using a known wire bond capillary. The size, shape and number of the conductive balls affixed to a given die bond pad may vary in alternative embodiments of the present invention.
After the conductive balls are formed on the die bond pads of the first die, a second die may be affixed to the first die. The first semiconductor die may next be wire bonded to the substrate. A wire bonding capillary having a wire bond ball at its tip may be lowered into contact with a conductive ball, and the wire bond ball may be affixed to the conductive ball using conventional wire bonding techniques. The height of the conductive ball above the surface of the first semiconductor die is provided so that the wire bonding capillary may lower the wire bond ball into contact with the conductive ball without any portion of wire bonding capillary contacting the second semiconductor die.
In a further embodiment of the present invention, instead of forming the conductive balls with a wire bonding capillary, the conductive balls may be formed at the wafer level during fabrication of the semiconductor die itself. In such an embodiment, the conductive balls may be formed by stud bumping, gold bumping, or any known process for forming raised surfaces on a semiconductor die. Such processes are often employed in forming a flip-chip semiconductor die. These processes include but are not limited to plating, evaporation, screen printing, or various deposition processes.
Embodiments will now be described with reference to
The present invention will now be described with reference to the flowchart of
Although not critical to the present invention, substrate 102 may be a variety of chip carrier mediums, including a PCB, a leadframe or a tape automated bonded (TAB) tape. Where substrate 102 is a PCB, the substrate may be formed of a core having top and/or bottom conductive layers formed thereon. The core may be various dielectric materials such as for example, polyimide laminates, epoxy resins including FR4 and FR5, bismaleimide triazine (BT), and the like.
The conductive layers may be formed of copper or copper alloys, plated copper or plated copper alloys, Alloy 42 (42FE/58NI), copper plated steel or other metals or materials known for use on substrates. The conductive layers may be etched into a conductance pattern as is known for communicating signals between the semiconductor die and an external device. A dummy pattern may also be provided in the conductive layers as is known to reduce mechanical stresses on the substrate otherwise resulting from uneven thermal expansion within the substrate.
Substrate 102 may additionally include exposed metal portions forming contact pads 106 (
In accordance with embodiments of the invention, in step 204, layers of an electrical conductor may be provided on some or all of die bond pads 110 to raise the height of the bond pads above the surface of die 100, as shown for example in
In embodiments, conductive balls 112 may be deposited using a conventional wire bonding capillary. For example, in one embodiment, conductive balls 112 may be deposited by forming a ball at the tip of the capillary via a transducer associated with the capillary. The capillary may then be lowered to respective die bond pads 110. The surface 104 of semiconductor die 100 may or may not be heated to facilitate bonding of conductive balls 112. After a ball 112 is formed, the ball 112 may then be deposited on a die bond pad 110 under a load, while the transducer applies ultrasonic energy. The combined heat, pressure, and/or ultrasonic energy create a bond between the conductive ball 112 and the die bond pad 110. The wire bonding device may then pay out a small length of wire, and the wire may be severed at the conductive ball to leave the conductive ball on the die bond pad. The small tail of wire hanging from the end of the capillary may then be used to form the conductive ball 112 for the next subsequent die bond pad 110.
As explained hereinafter, conductive balls 112 may be formed at the bond pads of semiconductor die 100 by a variety of other methods including for example stud bumping or gold bumping at the wafer level, or by a variety of other methods. Although bond pads 110 and conductive balls 112 are shown along a single edge of semiconductor die 100 in
The size and shape of conductive balls 112 may vary in alternative embodiments of the present invention. In embodiments, conductive balls 112 may each be spherical, ovoid having a length greater than its width or ovoid having a width greater than its length. Such shapes may be formed in a known manner when a wire at the tip of the capillary is melted and then applied to a bond pad in a ball bonding process. It is understood that conductive balls 112 may be other shapes in further embodiments of the present invention. Having a shape as described in any of the embodiments above, each conductive ball 112 may extend above the surface 104 of a semiconductor die 100 to a height which is less than, equal to or greater than the thickness of a second die mounted on die 100 as explained hereinafter. In embodiments, the height of a conductive ball 112 may be a few hundred microns to 5-10 mils, depending in part on a thickness of the semiconductor die used, and the configuration of the wire bonding capillary used. It is understood that the height of conductive balls 112 may be less than a few hundred microns and greater than 10 mils in alternative embodiments of the present invention.
Referring now to
The offset of the edge 122 of die 120 from the edge of die 100 may be small or large, with the understanding that at sufficiently large offsets, a conventional wire bond capillary may reach bond pads 110 without the aid of conductive balls 112. In embodiments, the spacing between the edge 122 and the die bond pads 110 may be 250 μm or less, and may be as small as zero microns in embodiments of the present invention.
Referring now to
In one example, die 120 may have a thickness of 2 mils, and the conductive balls may have a height of 2 mils or greater. In such an example, the die 120 may be spaced any distance, d, from the die bond pads 110 (including zero microns) and there would be no interference between the die bond capillary and the die 120 during a die bond operation on the die 100. In a further embodiment, the wafer may be 500 μm, the conductive balls may have a height of 250 μm and the combined height of the neck, Ltip, and wire bond ball 132 may be 250 μm. Again, in such an embodiment, the die 120 may be spaced any distance, d, from the die bond pads 110 (including zero microns) and there would be no interference between the die bond capillary and the die 120 during a die bond operation on the die 100. Those of skill in the art will appreciate other thicknesses of the conductive balls, based on the thickness of the die 120, the offset, d, and the geometric configuration of the wire bond capillary 130.
As seen in
In the embodiments shown for example in
As indicated above, the conductive layers used to raise the height of the wire bond pads of semiconductor die 100 may take a variety of forms. In an embodiment shown in
In an alternative embodiment of the present invention shown in
As mentioned above, conductive balls 112 may have a shape other than spherical. Such an embodiment is shown in
In an embodiment described above, conductive balls 112 are deposited on die bond pads 110 by a wire bonding capillary. However, in a further embodiment of the present invention shown in
The conductive balls 112 on semiconductor die 152 may be formed by stud bumping, gold bumping, or any known process for forming raised surfaces on a semiconductor die. Such processes are often employed in forming a flip-chip semiconductor die. These processes include but are not limited to plating, evaporation, screen printing, or various deposition processes. As used herein, the raised electrical conductor of a die bond pad may be the layers added to the die bond pad, or it may be the die bond pad plus the layers added to the die bond pad.
Referring again to the embodiments shown in
Once all semiconductor die are affixed and wire bonded to substrate 102, the semiconductor die may be cured in a reflow process of step 210 to harden any adhesive layers. Curing may be accomplished by a variety of known methods, depending on the adhesive material used, including for example by heating and/or by ultraviolet radiation.
As shown in
In embodiments, the semiconductor die described above may include one or more flash memory chips, and possibly a controller such as an ASIC, so that the package 160 may be used as a flash memory device. It is understood that the package 160 may include semiconductor die configured to perform other functions in further embodiments of the present invention.
The foregoing detailed description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
The following application is related to U.S. patent application Ser. No. ______ [Attorney Docket No. SAND-01153US1], entitled “Semiconductor Die Stack Having Heightened Contact For Wire Bond,” by Hem Takiar et al., filed the same day as the present application, which application is incorporated herein by reference in its entirety.