The present invention generally relates to a microelectronic assembly and a method for forming a microelectronic assembly, and more particularly relates to a microelectronic assembly having a support member interconnecting separate substrates.
Integrated circuits are formed on semiconductor substrates, or wafers. The wafers are then sawed into microelectronic dies (or “dice”), or semiconductor chips, with each die carrying, for example, a respective integrated circuit (e.g., a microprocessor) or a microelectromechanical system (MEMS) device (e.g., an accelerometer). In some examples, each semiconductor chip is mounted to a package or carrier substrate using either wirebonding or “flip-chip” connections. The packaged chip is then typically mounted to a circuit board, or motherboard, before being installed in a system, such as an electronic or a computing system.
Often it is desirable to integrate a MEMS device with an integrated circuit (e.g., a microprocessor to interpret the signals generated by the MEMS device) that is formed using convention semiconductor processing techniques, such as complementary metal-oxide semiconductor (CMOS) processing steps. One approach for such integration involves the use of a cap wafer attached to the MEMS die with a seal (or “frit”) to form a cavity to protect the MEMS device, as is often required. Another approach is the use of processing techniques that are compatible with methods used to form the MEMS device (i.e., “MEMS friendly processing techniques), such as bipolar CMOS processing. A third approach utilizes through vias (i.e., electrical connectors) formed through the integrated circuit die, which are connected to the MEMS device by soldering.
Each of the above mentioned integration methods described above may have at least one considerably undesirable characteristic. For example, the cap wafers and frits significantly add to the cost of the assembly. Additionally, due to the possibility that the frit may contaminate the MEMS device element (e.g., a proof mass), the frits are often intentionally oversized to provide a relatively large gap between the frit and the MEMS device, which adds to the overall size of the assembly. The use of MEMS friendly processing techniques significantly increases the manufacturing costs of the integrated circuit, while the through vias increase both manufacturing time and costs.
Accordingly, it is desirable to provide an improved method for integrating multiple die (e.g., such as an integrated circuit and a MEMS device). Other desirable features and characteristics of the invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
The various embodiments will hereinafter be described in conjunction with the following drawings, wherein like numerals denote like elements, and
The following detailed description is merely exemplary in nature and is not intended to limit the invention or application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description. It should also be noted that
In one embodiment, the first microelectronic device is an integrated circuit (e.g., a microprocessor, a digital logic or analog circuit transducer), and the second microelectronic device is a microelectromechanical system (MEMS) device. Examples of MEMS devices include accelerometers and switches. The structural support member and the first and second substrates may form a cavity in which a MEMS device element is located.
Referring to
In the depicted embodiment, the IC die 32 includes a substrate portion 34, with multiple semiconductor devices 36 formed thereon, and a build-up (or backend) layer 38 formed over the substrate portion 34 and the semiconductor devices 36. In the embodiment shown, the substrate portion 34 is in a bulk semiconductor configuration but in other embodiments may be in, for example, a semiconductor-on-insulator configuration. The semiconductor devices 36 are, for example, semiconductor transistors that include source regions, drain regions, and gate formations (including a gate electrode and a gate dielectric layer), as is commonly understood, and may at least partially form an integrated circuit (along other various components such as resistors, capacitors, and inductors), such as a microprocessor or an application specific integrated circuit (ASIC). The integrated circuit may be formed using, for example, masking (e.g., lithography), reactive ion etching (RIE), physical sputtering, damascene patterning, physical vapor deposition, electroplating, and chemical vapor (CVD), low pressure chemical vapor (LPCVD), and/or plasma enhanced chemical vapor deposition (PECVD) techniques. For example, the integrated circuit may be manufactured using complementary metal-oxide semiconductor (CMOS) processing techniques.
The build-up layer 38 includes various insulating layers (e.g., interlayer dielectric layers) 40, conductive members 42 (e.g., traces and through vias), and bond pads 44. The insulating layers 40 are made of, for example, silicon oxide (SiO2), silicon nitride (SiN), tetraethylorthosilicate (TEOS), and/or borophosphosilicate tetraethylorthosilicate (BPTEOS) and formed using CVD, LPCVD, and/or PECVD. The bond pads 44 are formed on an upper surface of the build-up layer 38 to provide an electrical connection to the integrated circuit through the conductive members 42. Still referring to
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In the depicted embodiment, the MEMS device element 80 is formed on an exposed, central portion of the substrate portion 70. In one embodiment, the MEMS device element 80 may include an electromechanical component (e.g., a proof mass) of a MEMS device (or sensor) that is generally configured to sense physical, electrical, magnetic, environmental, and/or other conditions. The MEMS sensor may be a mechanical sensor (e.g., a vibration sensor, an accelerometer, or a stress/strain sensor), a magnetic field sensor, an electrical attribute sensor (e.g., a voltage sensor, a current sensor, an impedance or resistance sensor, a temperature sensor, a capacitance sensor, or an inductance sensor), or a switch or other actuating device. In a manner similar to the IC die 32 described above, the MEMS die 68 has a first (or upper or “active”) side 82 and a second (or lower or “inactive”) side 84.
As shown in
A force (represented by arrows 101) may be applied to the IC die 32 and the MEMS die 68 while the assembly 96 is heated (e.g., to approximately between 300° C. and 420° C.). In one embodiment, the force 101 is caused by placing a weight (e.g., 50 lbs.) over the IC die 32. The combination of the force 101 and the heating process causes a bond to be formed between first and second structural support components 58 and 86. In particular, in one embodiment, a eutectic bond is formed by the second portion 62 (e.g., tin) of the first structural support component 58 and the second portion 90 (e.g., titanium tungsten) of the second structural support component 86. As a result, a structural support member 100 (
As will be appreciated by one skilled in the art, the materials used to form the first and second structural support components 58 and 86 may be varied such that different temperatures are used during the heating process to form the eutectic bond. For example, if the bond is formed from gold and tin (e.g., AuSn), the assembly 96 may be heated to between approximately 300 and 320° C. (e.g., 310° C.). If the bond is formed from gold and silicon (AuSi), the assembly 96 may be heated to between 360° C. and 420° C.
A MEMS cavity 102 is formed between the opposing sides of the structural support member 100, the second side 48 of the IC die 32, and the first side 82 of the MEMS die 68. As shown in
Still referring to
The formation of wire bonds 98 may substantially complete the formation of the microelectronic assembly 96. After final processing steps, the microelectronic assembly 96 may be further packaged and installed in various electrical systems, such as the electrical system of a vehicle.
During operation, the MEMS device of one embodiment within the MEMS die 68 detects various physical quantities (e.g., accelerations), depending on the exact type of MEMS device, and transmits appropriate electrical signals to the integrated circuit within the IC die 32, which may further process the signals before sending them to other components within the electrical system in which the microelectronic assembly 96 is installed.
One advantage of the microelectronic assembly and method described above is that a practical and inexpensive integration of conventional semiconductor processing techniques and MEMS device fabrication techniques it provided. In particular, the MEMS cavity may be formed without the use of a separate cap wafer. That is, an otherwise useful component (i.e., the IC die) is used to form the MEMS cavity. As a result, the number of components required is reduced, as is the overall cost of the assembly. Another advantage is that because the substrates (i.e., the IC die and the MEMS die) are stacked, the overall size (i.e., the “footprint”) of the assembly is reduced. A further advantage is that the processing steps (e.g., CMOS) used to form the structural support member reduce the likelihood that the MEMS device element will be contaminated. Therefore, the structural support member may be located closer to the MEMS device element, and the size of the assembly may be further reduced.
Other embodiments may use different methods and materials for forming the structural support member. For example, rather than deposited materials on the second side of the IC die, the substrate portion may be etched in such a way that the structural support member is formed from the semiconductor material of the wafer from which the IC die is formed (e.g., silicon). In such an embodiment, the substrate portion may form a silicon-gold eutectic bond, as is commonly understood. The structural support member may have other shapes (e.g., square) and sizes and may not form a hermetic seal around the MEMS device (and/or MEMS device element).
In one embodiment, the invention provides a method for forming a microelectronic assembly. First and second substrates are provided. Each substrate has first and second opposing sides. The first substrate has a first microelectronic device formed on the first side thereof, and the second substrate has a second microelectronic device formed on the first side thereof. The first and second substrates are interconnected with at least one support member such that the at least one support member is positioned between the second side of the first substrate and the first side of the second substrate. At least one conductive member is provided that electrically connects the first microelectronic device to the second microelectronic device.
The at least one support member may be formed on the second side of the first substrate, the first side of the second substrate, or a combination thereof. The first microelectronic device may be an integrated circuit. The second microelectronic device may be a microelectromechanical system (MEMS) device comprising a MEMS device element.
The at least one support member may include a metal. The at least one support member may surround the MEMS device element. The first substrate, the second substrate, and the at least one support member may jointly form a sealed MEMS cavity.
The at least one support member may interconnect first portions of the respective first and second substrates, and the at least one conductive member may interconnect second portions of the respective first and second substrates. The first portions of the first and second substrates may be central portions of the first and second substrates, and the second portions of the first and second substrates may be outer portions of the first and second substrates. The at least one conductive member may include a plurality of wire bonds.
In another embodiment, a method of forming a microelectronic assembly is provided. A first substrate having first and second opposing sides and an integrated circuit formed on the first side thereof is provided. A second substrate having first and second opposing sides and a microelectromechanical system (MEMS) device formed on the first side thereof is provided. At least one support member is formed on the second side of the first substrate, the first side of the second substrate, or a combination thereof. The second side of the first substrate and the first side of the second substrate are interconnected with the at least one support member such that the at least one support member is positioned between respective first portions of the first and second substrates. At least one conductive member is provided that electrically connects the integrated circuit to the MEMS device and contacts respective second portions of the first and second substrates.
The MEMS device may include a MEMS device element, and the at least one support member may surround the MEMS device element. The first substrate, the second substrate, and the at least one support member may jointly form a hermetically sealed MEMS cavity. The first portions of the first and second substrates may be central portions of the first and second substrates, and the second portions of the first and second substrates may be outer portions of the first and second substrates.
The forming of the at least one support member may include forming a first ring on the second side of the first substrate and forming a second ring on the first side of the second substrate. The interconnecting the second side of the first substrate and the first side of the second substrate with the at least one support member may include bonding the first ring to the second ring.
The bonding of the first ring to the second ring may include placing the first ring into contact with the second ring, heating the first and second rings, and applying a force to the first and second rings. The heating the first and second rings may include heating the first and second rings to a temperature of between 300 and 420° C.
In a further embodiment, a microelectronic assembly is provided. The microelectronic assembly includes a first substrate having first and second opposing sides and an integrated circuit formed on the first side thereof, a second substrate having first and second opposing sides and a microelectromechanical (MEMS) device formed on the first side thereof, a support member interconnecting the second side of the first substrate and the first side of the second substrate, the support member being sized and shaped such that the support member is between the second side of the first substrate and the first side of the second substrate, and a plurality of conductive members electrically interconnecting the integrated circuit and the MEMS device.
The support member may be positioned between respective first portions of the first and second substrates, and the plurality of conductive members may contact respective second portions of the first and second substrates. The MEMS device may include a MEMS device element on the first side of the second substrate. The first substrate, the second substrate, and the support member may jointly form an enclosed cavity, and the MEMS device element may be positioned within the cavity.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.