This application claims the priority benefit of Taiwan application serial no. 112100272, filed on Jan. 4, 2023. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of specification.
The disclosure relates to a carrier structure, a manufacturing method thereof, and a package structure, and in particular, to a package carrier, a manufacturing method thereof, and a chip package structure.
In the prior art, when producing a chip-last (or referred to as an RDL first), a circuit layer of a redistribution circuit layer is first produced on a temporary substrate. Next, the redistribution circuit layer needs to be transferred from the original temporary substrate and electrically connected to a second substrate, and debonded with the original temporary substrate. After the board transfer and board removal operations, a composite substrate composed of the redistribution circuit layer and the second substrate can become a product and commodity and undergo electrical testing. The yield loss of one of the two will cause unnecessary loss of the other part, and the redistribution circuit layer itself cannot become a product, which will affect its degree of freedom in design and application.
The disclosure provides a package carrier with a smaller yield loss and a better degree of freedom in design and application.
The disclosure also provides a manufacturing method of a package carrier, which is configured to manufacture the above-mentioned redistribution circuit carrier to become an independent product and commodity, thus effectively reducing the production cost.
The disclosure also provides a chip package structure. A package mold plate produced before a chip is mounted eliminates the need to form an encapsulation layer after the chip is mounted, thereby achieving a better package yield.
A package carrier of the disclosure includes a redistribution circuit layer, a plurality of first conductive pillars, and a package mold plate. The redistribution circuit layer has a first surface and a second surface opposite to each other, and includes a plurality of redistribution circuits, a plurality of conductive vias, a plurality of dielectric layers, and a plurality of output pads. The redistribution circuits and the dielectric layers are alternately stacked, and the conductive vias are electrically connected to two adjacent redistribution circuits. The conductive vias are flush with the first surface, and the output pads protrude from the second surface. The first conductive pillars are disposed on the first surface of the redistribution circuit layer and electrically connected to part of the conductive vias. The package mold plate is disposed on the first surface of the redistribution circuit layer and has a recess in a middle region of the package mold plate. The recess exposes the first conductive pillars. The first conductive pillars pass through part of the package mold plate located in the middle region, and a thickness of an edge region of the package mold plate provides mechanical stability.
In an embodiment of the disclosure, a thickness of the package mold plate is greater than or equal to 100 microns and less than or equal to 600 microns.
In an embodiment of the disclosure, a line width of each of the redistribution circuits is greater than or equal to 0.5 microns and less than or equal to 30 microns.
In an embodiment of the disclosure, the package carrier further includes a solder mask, which is disposed on the second surface of the redistribution circuit layer and exposes part of the output pads.
In an embodiment of the disclosure, the package carrier further includes a plurality of second conductive pillars, which penetrate the package mold plate and are electrically connected to the conductive vias of the redistribution circuit layer.
A manufacturing method of a package carrier of the disclosure includes the following steps. A substrate is provided. The substrate includes a base material, a stainless steel layer, and a metal layer. The base material includes a first part and a second part disposed on the first part and exposing part of the first part. The stainless steel layer is located on the base material and conformally covers the base material. The metal layer is formed on the stainless steel layer and conformally covers the stainless steel layer. A plurality of first conductive pillars are formed on the substrate, and the first conductive pillars correspond to the second part of the base material. A package mold plate is formed on the substrate, and the package mold plate covers the metal layer and exposes each of the first conductive pillars. A redistribution circuit layer is provided on the substrate. The redistribution circuit layer has a first surface and a second surface opposite to each other, and includes a plurality of redistribution circuits, a plurality of conductive vias, a plurality of dielectric layers, and a plurality of output pads. The redistribution circuits and the dielectric layers are alternately stacked, and the conductive vias are electrically connected to two adjacent redistribution circuits. The conductive vias are flush with the first surface, and part of the conductive vias are electrically connected to each of the first conductive pillars respectively. The output pads protrude from the second surface. The substrate is removed so that there is a recess in a middle region of the package mold plate. The recess exposes the first conductive pillars. The first conductive pillars pass through part of the package mold plate located in the middle region, and a thickness of an edge region of the package mold plate provides mechanical stability.
In an embodiment of the disclosure, a material of the substrate includes glass.
In an embodiment of the disclosure, the material of the substrate includes fiberglass resin.
In an embodiment of the disclosure, the first part and the second part of the base material are fixed together through an adhesive.
In an embodiment of the disclosure, the manufacturing method of the package carrier further includes forming a plurality of second conductive pillars on the substrate before forming the package mold plate on the substrate, and the second conductive pillars correspond to the first part exposed by the second part of the base material.
In an embodiment of the disclosure, the manufacturing method of the package carrier further includes forming a solder mask on the second surface of the redistribution circuit layer and exposing part of the output pads before removing the substrate.
In an embodiment of the disclosure, the thickness of the package mold plate is greater than or equal to 100 microns and less than or equal to 600 microns.
In an embodiment of the disclosure, a line width of each of the redistribution circuits is greater than or equal to 0.5 microns and less than or equal to 30 microns.
A chip package structure of the disclosure includes a circuit board, a package carrier, and a chip. The package carrier is disposed on the circuit board and electrically connected to the circuit board. The package carrier includes a redistribution circuit layer, a plurality of first conductive pillars, and a package mold plate. The redistribution circuit layer has a first surface and a second surface opposite to each other, and includes a plurality of redistribution circuits, a plurality of conductive vias, a plurality of dielectric layers, and a plurality of output pads. The redistribution circuits and the dielectric layers are alternately stacked, and the conductive vias are electrically connected to two adjacent redistribution circuits. The conductive vias are flush with the first surface, and the output pads protrude from the second surface and are electrically connected to the circuit board. The first conductive pillars are disposed on the first surface of the redistribution circuit layer and electrically connected to part of the conductive vias. The package mold plate is disposed on the first surface of the redistribution circuit layer and has a recess in a middle region of the package mold plate. The recess exposes the first conductive pillars. The first conductive pillars pass through part of the package mold plate located in the middle region, and a thickness of an edge region of the package mold plate provides mechanical stability. The chip is disposed in the recess of the package mold plate and electrically connected to the first conductive pillars.
In an embodiment of the disclosure, the chip package structure further includes a plurality of solder balls and an underfill. The solder balls are disposed between the circuit board and the package carrier. The output pads of the redistribution circuit layer are electrically connected to the circuit board through the solder balls. The underfill is filled between the circuit board and the package carrier and covers the solder balls.
In an embodiment of the disclosure, the chip package structure further includes the underfill, which is filled between the recess of the package mold plate and the chip, and covers the first conductive pillars.
In an embodiment of the disclosure, the chip package structure further includes the plurality of solder balls disposed on a side of the circuit board relatively away from the package carrier.
In an embodiment of the disclosure, a thickness of the package mold plate is greater than or equal to 100 microns and less than or equal to 600 microns.
In an embodiment of the disclosure, a line width of each of the redistribution circuits is greater than or equal to 0.5 microns and less than or equal to 30 microns.
In an embodiment of the disclosure, the package carrier further includes the solder mask, which is disposed on the second surface of the redistribution circuit layer and exposes part of the output pads.
In an embodiment of the disclosure, the package carrier further includes a plurality of second conductive pillars that penetrate the package mold plate and are electrically connected to the conductive vias of the redistribution circuit layer.
In an embodiment of the disclosure, the chip package structure further includes a package on package (POP) component, the plurality of solder balls, and the underfill. The POP component is disposed on the package carrier and electrically connected to the second conductive pillars. The chip is located between the POP component and the circuit board. The solder balls are disposed between the POP component and the second conductive pillars, and the POP component is electrically connected to the second conductive pillars through the solder balls. The underfill is filled between the POP component and the package carrier, between the POP component and the chip, and between the recess of the package mold plate and the chip, and covers the first conductive pillars and the solder balls.
Based on the above, in the design of the package carrier of the disclosure, the thickness of the edge region of the package mold plate can provide mechanical stability, so that the redistribution circuit layer attached to it on all four sides will not be deformed, and the recess in the middle region of the package mold plate can expose the first conductive pillars electrically connected to the conductive vias of the redistribution circuit layer. In this way, by disposing the package mold plate, not only the structural strength of the overall package carrier can be increased, but also the first conductive pillars exposed by the recess and the output pads can be electrically tested at the same time, thus improving the electrical reliability of the package carrier. Furthermore, when the chip is subsequently assembled on the package carrier, since the chip is located in the recess and electrically connected to the first conductive pillars, a better package yield can be achieved to achieve the structure required for the chip last without the need to manufacture an encapsulant. In addition, in the manufacturing method of the package carrier of the embodiment, the removed base material can be reusable, which can significantly reduce the manufacturing cost.
In order to make the above-mentioned features and advantages of the disclosure clearer and easier to understand, the following embodiments are given and described in details with accompanying drawings as follows.
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In short, the thickness T1 of the edge region of the package mold plate 120 can provide mechanical stability, so that the redistribution circuit layer 130 attached to it on all four sides will not be deformed, and the recess 125 in the middle region of the package mold plate 120 can expose the first conductive pillars 110 that are electrically connected to the redistribution circuit layer 130. In this way, by disposing the package mold plate 120, not only the structural strength of the overall package carrier 100a can be increased, but also the first conductive pillars 110 exposed by the recess 125 and the output pads 138 can be electrically tested at the same time, thus improving the electrical defects detections of the package carrier 100a and reducing the logistics and inventory costs of electrical test yield losses after chip placement production. In addition, in the manufacturing method of the package carrier 100a of the embodiment, the removed base material 12 can be reusable, which can significantly reduce the manufacturing cost.
Specifically, in the embodiment, the chip package structure 200a also includes a plurality of solder balls 230 and an underfill 235. The solder balls 230 are disposed between the circuit board 210 and the package carrier 100a. The output pads 138 of the redistribution circuit layer 130 are electrically connected to the circuit board 210 through the solder balls 230. The underfill 235 is filled between the circuit board 210 and the package carrier 100a and covers the solder balls 230. Furthermore, the chip package structure 200a further includes an underfill 225, which is filled between the recess 125 of the package mold plate 120 and the chip 220 and covers the first conductive pillars 110. The chip 220 is fixed in the recess 125 through the underfill 225. In addition, the chip package structure 200a may further include a plurality of solder balls 240, which are disposed on a side of the circuit board 210 relatively away from the package carrier 100a for electrical connection with external circuits.
Since the chip 220 of the embodiment is disposed in the recess 125 of the package mold plate 120 and electrically connected to the first conductive pillars 110, it is not necessary to add external mold to seal the chip 220, and the package thickness of the overall chip package structure 200a can also be reduced. In addition, since the package carrier 100a can be electrically tested before packaging, the chip package structure 200a can have a better package yield after the chip 220 is packaged.
It must be noted here that the reference numerals and a part of the contents in the previous embodiment are applicable to the following embodiments, in which identical reference numerals indicate identical or similar components, and repeated descriptions of the same technical contents are omitted. For the detailed descriptions of the omitted parts, reference can be found in the previous embodiments, and no repeated description is contained in the following embodiments.
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To sum up, in the design of the package carrier of the disclosure, the thickness of the edge region of the package mold plate can provide mechanical stability, so that the redistribution circuit layer attached to it on all four sides will not be deformed, and the recess in the middle region of the package mold plate can expose the first conductive pillars electrically connected to the redistribution circuit layer. In this way, by disposing the package mold plate, not only the structural strength of the overall package carrier can be increased, but also the first conductive pillars exposed by the recess and the output pads can be electrically tested at the same time, thus improving the electrical reliability of the package carrier. Furthermore, when the chip is subsequently assembled on the package carrier, since the chip is located in the recess and electrically connected to the first conductive pillars, the package thickness of the overall chip package structure can be reduced and a better package yield can be achieved. In addition, in the manufacturing method of the package carrier of the embodiment, the removed base material can be reusable, which can significantly reduce the manufacturing cost.
Although the disclosure has been described with reference to the embodiments above, the embodiments are not intended to limit the disclosure. Any person skilled in the art can make some changes and modifications without departing from the spirit and scope of the disclosure. Therefore, the scope of the disclosure will be defined in the appended claims.
Number | Date | Country | Kind |
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112100272 | Jan 2023 | TW | national |