This application claims priority to Korean Patent Application No. 10-2022-0096376, filed on Aug. 2, 2022, in the Korean Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.
The present disclosure relates to a package and a method of fabricating the same, and more particularly, to a fan-out package and a method of fabricating the same.
A size of semiconductor chip becomes smaller as integration of the semiconductor chip increases. However, intervals between bumps on the semiconductor chip should comply with international standards provided by the Joint Electronic Device Engineering Council (JEDEC), an international electronics standardization organization. It may be difficult to bond a desired number of the bumps to the semiconductor chip. In addition, as the size of the semiconductor chip becomes reduced, it may be hard to handle and test the semiconductor chip.
Some example embodiments provide a package capable of suppressing cracks of an upper substrate on a lower chip.
According to some embodiments, a package includes: a lower substrate including an upper pad; a lower chip on the lower substrate; a mold layer on the lower chip and the lower substrate; a post extending through the mold layer and provided on the upper pad around the lower chip, the post having a diameter less than a diameter of the upper pad; and an upper substrate on the post and the mold layer, the upper substrate including a lower pad having a diameter greater than the diameter of the post.
According to some embodiments, a package includes: a lower substrate including an upper pad; a lower chip on the lower substrate; a post on the upper pad, the post having a diameter less than a diameter of the upper pad; and an upper substrate on the post, the upper substrate including a lower pad having a diameter greater than the diameter of the post. The upper pad, the post, and the lower pad are connected to form an “I” shape when viewed in vertical section.
According to some embodiments, a method of fabricating a package, includes: providing a lower substrate having upper pads on a dummy substrate, the upper pads each having a diameter; providing posts on the upper pads, the posts each having a diameter less than the diameter of the upper pads; providing a lower chip on the lower substrate between the posts; providing a mold layer on the lower substrate that selectively exposes top surfaces of the posts; and providing an upper substrate that is on the posts and the mold layer, and has lower pads, each having a diameter greater than the diameter of the posts.
The above and other aspects and features will be more apparent from the following description of example embodiments, taken in conjunction with the accompanying drawings, in which:
Example embodiments will be described more fully with reference to the accompanying drawings, in which example embodiments are shown. Embodiments described herein are provided as examples, and thus, the present disclosure is not limited thereto, and may be realized in various other forms. Each example embodiment provided in the following description is not excluded from being associated with one or more features of another example or another example embodiment also provided herein or not provided herein but consistent with the present disclosure. It will be understood that when an element or layer is referred to as being “on,” “connected to” or “coupled to” another element or layer, it can be directly on, connected or coupled to the other element or layer, or intervening elements or layers may be present. By contrast, when an element is referred to as being “directly on,” “directly connected to” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. For example, the expression, “at least one of a, b, and c,” should be understood as including only a, only b, only c, both a and b, both a and c, both b and c, or all of a, b, and c.
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The lower substrate 10 may be provided below the posts 20 and the lower chip 30. For example, the lower substrate 10 may have a height ranging from about 80 μm to about 100 μm. The lower substrate 10 may include a redistribution substrate. According to an example embodiment, the lower substrate 10 may include first lower pads 12, a lower dielectric layer 14, a lower redistribution layer 15, first upper pads 16, and lower bumps 18.
The first lower pads 12 may be provided on a bottom surface of the lower dielectric layer 14. The first lower pads 12 may connect the lower redistribution layer 15 to the lower bumps 18. The first lower pad 12 may have the same diameter as that of the lower bump 18. The first lower pads 12 may include metal, such as gold (Au), aluminum (Al), copper (Cu), or silver (Ag), but example embodiments are not limited thereto.
The lower dielectric layer 14 may be provided on the first lower pads 12. The bottom surface of the lower dielectric layer 14 may be coplanar with those of the first lower pads 12. The lower dielectric layer 14 may be provided below the first upper pads 16. For example, the lower dielectric layer 14 may include a photo-imageable dielectric (PID) layer.
The lower redistribution layer 15 may be provided in the lower dielectric layer 14. The lower redistribution layer 15 and the lower dielectric layer 14 may be alternately stacked. The lower redistribution layer 15 may connect the first lower pads 12 to the first upper pads 16. For example, the lower redistribution layer 15 may have a “T” shape when viewed in vertical section. The lower redistribution layer 15 may include copper, but example embodiments are not limited thereto.
The first upper pads 16 may be provided on the lower dielectric layer 14 and the lower redistribution layer 15. The first upper pads 16 may be wider than the posts 20. When viewed in vertical section, the first upper pads 16 may each have the same shape as that of the lower redistribution layer 15. For example, the first upper pads 16 may have “T” shapes that correspond to the “T” shapes of the lower redistribution layer 15. The first upper pads 16 may each have a first diameter D1 ranging from about 80 μm to about 450 μm.
The lower bumps 18 may be provided below the first lower pads 12. For example, the lower bumps 18 may be connected to an external printed circuit board. The lower bumps 18 may include gold (Au), aluminum (Al), solder, copper (Cu), or silver (Ag), but example embodiments are not limited thereto.
The posts 20 may be provided on an edge of the lower substrate 10. The posts 20 may be disposed on the first upper pads 16 around the lower chip 30. The posts 20 may be connected, through the lower substrate 10, to the lower chip 30. The posts 20 may each have a height greater than the lower chip 30. The posts 20 may each be taller than the lower chip 30. The posts 20 may include copper (Cu), but example embodiments are not limited thereto. When viewed in plan, the post 20 may be narrower than the first upper pad 16. According to an example embodiment, each of the posts 20 may have a second diameter D2 less than the first diameter D1 of each first upper pads 16. For example, the second diameter D2 of each post 20 may range from about 70 μm to about 250 μm.
The lower chip 30 may be provided on a center of the lower substrate 10. The lower chip 30 may be disposed between the posts 20. The lower chip 30 may be provided on the first upper pads 16. The lower chip 30 may be connected, through first upper bumps 32, to the first upper pads 16 of the lower substrate 10. The lower chip 30 may have a tetragonal shape when viewed in plan. The first upper bumps 32 may be provided in a first under-fill layer 34. For example, the lower chip 30 may include an application processor chip. The lower chip 30 may have a top surface lower than those of the posts 20. For example, the lower chip 30 may have a height of about 200 μm.
The mold layer 40 may be provided on the lower chip 30 and the lower substrate 10. The mold layer 40 may be provided between the posts 20. The mold layer 40 may have a top surface coplanar with those of the posts 20. For example, the mold layer 40 may include an epoxy molding compound (EMC).
The upper substrate 50 may be provided on the posts 20 and the mold layer 40. The upper substrate 50 may include a redistribution substrate. According to an example embodiment, the upper substrate 50 may include second lower pads 52, a warpage control pattern 53, an upper dielectric layer 54, an upper redistribution layer 55, and second upper pads 56.
The second lower pads 52 may be provided on the lower substrate 10 and an edge of the mold layer 40. The second lower pads 52 may be provided on the posts 20 and the mold layer 40 adjacent to the posts 20. When viewed in plan, the second lower pad 52 may be wider than the post 20. The second lower pads 52 may be aligned with the first upper pads 16. The first upper pad 16, the post 20, and the second lower pad 52 may be connected to form an “I” shape when viewed in vertical section. The second lower pad 52 may have a third diameter D3 the same as the first diameter D1 of the first upper pad 16. When viewed in plan, the second lower pad 52 may be wider than the post 20. The third diameter D3 of each second lower pad 52 may be greater than the second diameter D2 of each post 20. For example, the third diameter D3 of the second lower pad 52 may range from about 80 μm to about 450 μm. The third diameter D3 of the second lower pad 52 may be greater, by about 10 μm to about 200 μm, than the second diameter D2 of the post 20. The second lower pad 52 may have a radius greater, by about 5 μm to about 100 μm, than that of the post 20. The second lower pads 52 may cover the posts 20 and boundaries between the posts 20, and may suppress the upper dielectric layer 54 from being cracked due to delamination between the posts 20 and the mold layer 40.
The warpage control pattern 53 may be provided on a center of the mold layer 40. The warpage control pattern 53 may be provided on the lower chip 30. For example, the warpage control pattern 53 may include a plurality of portions, each of which has a width or diameter ranging from about 1 μm to about 30 μm. The warpage control pattern 53 and the second lower pads 52 may have bottom surfaces that are coplanar with that of the upper dielectric layer 54. The warpage control pattern 53 may minimize or prevent warpage of the upper dielectric layer 54.
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The upper redistribution layer 55 may be provided in the upper dielectric layer 54. The upper redistribution layer 55 and the upper dielectric layer 54 may be alternately stacked. The upper redistribution layer 55 may connect the second lower pads 52 to the second upper pads 56. The upper redistribution layer 55 may have a “T” shape when viewed in vertical section. The upper redistribution layer 55 may include copper, but example embodiments are not limited thereto.
The second upper pads 56 may be provided on the upper dielectric layer 54. The second upper pads 56 may be connected to the upper redistribution layer 55. The second upper pads 56 may each have a “T” shape when viewed in vertical section. The second upper pads 56 may include copper, but example embodiments are not limited thereto.
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The following will describe a method of fabricating the package 100 configured above according to example embodiments.
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A lower dielectric layer 14 may be formed on the first lower pads 12 and the dummy substrate 200 (S14). The lower dielectric layer 14 may be formed by a spin coating process and a photolithography process. For example, the lower dielectric layer 14 may expose portions of the first lower pads 12. The lower dielectric layer 14 may include a photo-imageable dielectric (PID) layer, but example embodiments are not limited thereto.
A lower redistribution layer 15 may be formed on the first lower pads 12 exposed by the lower dielectric layer 14 (S16). The lower redistribution layer 15 may include copper (Cu) formed by an electroplating process. The lower redistribution layer 15 may further include a seed metal, but example embodiments are not limited thereto. The lower redistribution layer 15 may have a “T” shape when viewed in vertical section.
When it is necessary to additionally form the lower dielectric layer 14 and the lower redistribution layer 15 (no in operation S17), the operation S14 and the operation S16 may be repeatedly performed. The lower dielectric layer 14 and the lower redistribution layer 15 may be alternately formed. The lower dielectric layer 14 may be formed on the lower redistribution layer 15, but example embodiments are not limited thereto.
When it is determined to stop forming the lower dielectric layer 14 and the lower redistribution layer 15 (yes in operation S17), first upper pads 16 may be formed on the lower redistribution layer 15 and the lower dielectric layer 14 (S18). The first upper pads 16 may be formed by the same method as that used for forming the lower redistribution layer 15. The first upper pads 16 may include copper (Cu) formed by an electroplating process. Each of the first upper pads 16 may have a first diameter (see D1 of
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An upper redistribution layer 55 may be formed on the second lower pads 52 exposed by the upper dielectric layer 54 (S56). The upper redistribution layer 55 may include copper (Cu) formed by an electroplating process. The upper redistribution layer 55 may further include a seed metal, but example embodiments are not limited thereto. The lower redistribution layer 15 may have a “T” shape.
When it is necessary to additionally form the upper dielectric layer 54 and the upper redistribution layer 55 (no in operation S57), the operation S54 and the operation S56 may be repeatedly performed. The upper dielectric layer 54 and the upper redistribution layer 55 may be alternately formed. The upper dielectric layer 54 may be formed on the upper redistribution layer 55, but example embodiments are not limited thereto.
When it is determined to stop forming the upper dielectric layer 54 the upper redistribution layer 55 (yes in operation S57), second upper pads 56 may be formed on the upper redistribution layer 55 and the upper dielectric layer 54 (S58). The second upper pads 56 may be formed by the same method as that used for forming the upper redistribution layer 55. The second upper pads 56 may include copper (Cu) formed by an electroplating process.
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Afterwards, the dummy substrate 200 may be removed.
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The lower substrate 10, the posts 20, the lower chip 30, the mold layer 40, the upper substrate 50, and the upper package 60 may be configured identically to those depicted in
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The lower substrate 10, the posts 20, the lower chip 30, the mold layer 40, the upper substrate 50, and the upper package 60 may be configured identically to those depicted in
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The lower substrate 10, the posts 20, the lower chip 30, the mold layer 40, the upper substrate 50, and the upper package 60 may be configured identically to those depicted in
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As discussed above, a package according to some example embodiments may include an upper substrate having upper pads wider than posts, and the upper substrate may be used to suppress a crack of the upper substrate on a lower chip.
While aspects of example embodiments have been particularly shown and described, it will be understood that various changes in form and details may be made therein without departing from the spirit and scope of the following claims.
Number | Date | Country | Kind |
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10-2022-0096376 | May 2022 | KR | national |