This disclosure relates generally to electronic packaging, and in particular to a reinforcing material applied to a package for reducing warpage.
In electronic packaging, circuit devices in a chip are being manufactured smaller and lighter, but are required to perform greater functionality. These packages must also include a larger number of input and output connections. The semiconductor devices must also protect the chip from moisture and mechanical damage (e.g., cracking, warpage, etc.). As the chip performs more functions, however, greater power is consumed and more heat is generated. Also, as the size of the chip is reduced, the generated heat is required to dissipate from a smaller surface area. In a silicon chip, for example, it can be difficult to control the silicon surface and junction temperature.
In wafer level packaging, wafer warpage continues to be a concern. This is particularly true with thin dies or wafer stacking and assembly. Warpage can prevent successful assembly of a die-to-wafer stack because of the inability to maintain the coupling of the die and wafer. Also, during temperature cycling, thermal stresses can cause other mechanical defects such as cracking. One solution to the warpage problem is using a window wafer-based die-to-wafer process. The drawback to this solution is that the process can be very long and it is difficult to manufacture these packages at a high volume. Another possible solution is using a low coefficient of thermal expansion mold compound material between the die and wafer. However, there continue to be reliability issues with this type of wafer-level package such that it too cannot be produced at high volumes.
Therefore, it would be desirable to develop an electronic package and method of manufacturing the package which could overcome the warpage and mechanical defects of conventional electronic packages. In addition, it would be desirable for the electronic package to be manufactured at high volumes while also reducing the reliability concerns of conventional packages.
For a more complete understanding of the present disclosure, reference is now made to the following detailed description and the accompanying drawings. In an exemplary embodiment, a method for forming an electronic package is provided. The method includes providing a wafer and coupling a die to the wafer. A mold compound material is applied to the wafer such that the mold compound material surrounds the die. The method further includes applying a reinforcing material to the mold compound material. The mold compound material is therefore disposed between the wafer and the reinforcing material. The reinforcing material can be glass and include mechanical properties similar to the wafer.
In one form of the method, the die is coupled to the wafer before applying the mold compound material. The wafer can also be mounted to a carrier and frontside bumping can be applied before mounting the wafer. After the wafer is mounted to the carrier, the wafer is later removed from the wafer. In doing so, the reinforcing material is applied before the wafer is removed from the carrier. The frontside bumping can be applied, however, after the wafer is removed from the carrier.
In another form of the method, a portion of the reinforcing material can be roughened before applying the reinforcing material. The thickness of the reinforcing material can be approximately between the thickness of the wafer and the combined thickness of the wafer, the die, and the mold compound material.
The reinforcing material can be prefabricated and then applied to the mold compound material. In addition, the reinforcing material can be applied to the mold compound material and then cured. The reinforcing material can be cured by using an adhesive material. In a different form of the present embodiment, a piston can be used for applying the reinforcing material to the mold compound material. A vacuum can also be used to apply the reinforcing material to the mold compound material. When coupling the die to the wafer, the die can comprise a plurality of die.
In another embodiment, an electronic package includes a stack of semiconductor die and a mold compound material for supporting the stack. The mold compound material can surround the stack. The package also can include a reinforcing material that has similar mechanical properties to the stack of semiconductor die. The mold compound material is disposed between the stack and the reinforcing material. The reinforcing material can be glass or silicon, and it can be applied non-continuously or as a layer. In addition, at least a portion of the reinforcing material has a roughened surface. The roughened surface can be disposed in contact with the mold compound material. Also, flip chip bumping can be completed on the front side of the stack of semiconductor die.
In a different embodiment, an electronic package assembly includes a stack of semiconductor die, a means for reducing warpage in the assembly, and a means for supporting the stack. The means for reducing has similar mechanical properties as the stack and the means for supporting surrounds the stack. The means for supporting is also disposed between the stack and the means for reducing.
In one form of this embodiment, the means for reducing can be glass or silicon. Also, at least a portion of the means for reducing can have a roughened surface. The roughened surface can be in contact with the means for supporting. In another form, the means for supporting can be an epoxy-based or silicon-based material. In addition, flip chip bumping can be completed on the front side of the stack of semiconductor die. This embodiment of the package can be incorporated into a device selected from a group consisting of a music player, a video player, an entertainment unit, a navigation device, a communications device, a personal digital assistant (PDA), a fixed location data unit, and a computer.
In another exemplary embodiment, a method of fabricating a reinforced electronic package is provided. The method includes providing a stack of semiconductor die and a reinforcing material. A mold compound material is applied to the stack such that the mold compound material surrounds a portion of the stack. The method further includes a step for reducing warpage in the package. The mold compound material can be disposed between the stack and the reinforcing material. In addition, the method includes mounting the stack to a carrier and applying frontside bumping after the stack is removed from the carrier. The stack can be removed from the carrier after the step for reducing warpage. In addition, a portion of the reinforcing material can be roughened.
In the above-described embodiments, a balanced system is achieved which reduces warpage. In at least one of the above-described embodiments, warpage can be reduced by 50-90% based on various glass thicknesses, mold compound material thicknesses, and glass properties. In addition, the above-described embodiments are more reliable and can be manufactured at high volume more easily than conventional packages.
An exemplary embodiment of the present invention is shown in
Referring to
Other assembly processes can include u-bumping, flip chip bumping, and backside processing. In block 106 of method 100 and
Referring to block 108 of method 100, a wafer-level molding process is performed. A mold compound 502, which can be, for example, an epoxy-based material, is applied to the package such that the plurality of dies 402 is substantially surrounded by the mold compound 502 and the backside of the wafer 202 is substantially covered by the mold compound 502. The mold compound 502 provides rigidity to the package, but it is unable to provide sufficient stiffness required to prevent or significantly reduce warpage. Even applying a thicker layer of mold compound 502 is undesirable because it increases the overall height of the package and can be expensive. Thus, the thickness of the mold compound 502 is applied such that the mold compound 502 surrounds the plurality of dies 402 and covers the backside of the wafer 202.
The mold compound 502 can be applied in several ways. In one embodiment, the mold compound 502 can be dispensed onto the backside of the wafer, spun in a circular motion to spread the mold compound 502 evenly, and then compressed. In the embodiment of block 110 and
Once the mold compound cures, a reinforcing material 504 can be applied to the mold compound 502. In block 112, a thin reinforcing material 504 is disposed on the backside of the mold compound 502. The reinforcing material 504 can be glass, for example, or any other material that has similar mechanical and thermal properties as the wafer 202. Since glass and silicon have similar properties such as stiffness and coefficient of thermal expansion (CTE), the two materials can advantageously balance or reduce stresses and warpage during assembly and use.
It is desirable for the reinforcing material 504 to have a small thickness so that the overall package height is minimal. The reinforcing layer 504 can be applied as a continuous or non-continuous layer on the mold compound 502. Advantageously, the mold compound 502 can have a thickness between 100-400 μm and the reinforcing material 504 can have a thickness of up to about 400 These thicknesses are non-limiting, however, and different embodiments of an electronic package can include a mold compound 502 and reinforcing material 504 having thicknesses outside of these ranges.
The reinforcing material 504 can be prefabricated or applied to the mold compound and then cured. As described above, the mold compound 504 can be cured before the reinforcing layer 504 is applied. However, in an alternative embodiment, the prefabricated reinforcing material 504 can be used for compressing the mold compound 502. For example, once the mold compound 502 is applied to the backside of the wafer 202, the prefabricated reinforcing material 504 can compress the mold compound 502 to its desired thickness. In this example, once the mold compound 502 is compressed, it cures at the curing temperature in block 114 of method 100.
The prefabricated reinforcing material 504 can be used solely or in combination with the piston 506 for compressing the mold compound. When used in combination, a vacuum can be created through channels 508 (
Once the mold compound 502 is compressed to the desired thickness, the mold compound 502 couples to the reinforcing material 504 and the vacuum pressure is released. The piston 506 can be removed from the reinforcing material 504 and the assembly is cured in block 114. In block 116 of the method 100 and
In block 112, the coupling of the mold compound 502 and reinforcing material 504 can be aided or promoted by a surface roughening process. The surface of the reinforcing material 504, for example, can be roughened before coupling the mold compound 502 and reinforcing material 504. There are several roughening processes or techniques that can be used. For example, the roughening process can be achieved by a dry or wet etching process. Plasma bombardment or etching is one form of a dry etching process that can be used.
Referring to
In
Other assembly processes can include u-bumping and backside processing. In block 706 of method 700 and
Referring to block 708 of method 700, a wafer-level molding process similar to that described above in block 108 is completed. A mold compound 1102, which can be an epoxy-based material, for example, is applied to the wafer 802 such that the plurality of dies 1002 is surrounded by the mold compound 1102. The mold compound 1102 can provide stability to the thin wafer 802, but it is unable to provide sufficient stiffness required to prevent or significantly reduce warpage. As described above, applying a thicker layer of mold compound 1102 is undesirable because it increases the overall height of the package and can be expensive. Thus, the mold compound 1102 is applied to a desired thickness such that the mold compound 1102 surrounds the plurality of dies 1002 and covers the backside of the wafer 802.
The mold compound 1102 can be applied in several ways. In one embodiment, the mold compound 1102 can be dispensed onto the backside of the wafer 802, spun in a desired motion to spread the mold compound 1102 evenly, and then compressed. In the embodiment of block 710 and
In this embodiment, before the mold compound 1102 cures a reinforcing material 1104 can be applied to the mold compound 1102. In block 712, a thin reinforcing material 1104 is disposed on the backside of the mold compound 1102. The reinforcing material 1104 can be glass, for example, or any other material that has similar mechanical and thermal properties as the wafer 802. Since glass and silicon have similar mechanical and thermal properties such as stiffness and coefficient of thermal expansion (CTE), the two materials can advantageously balance or reduce stresses and warpage during assembly and use. In addition, it is desirable for the reinforcing material 1104 to have a small thickness so that the overall package height is minimal.
In another embodiment, the reinforcing material 1104 can be prefabricated, applied to the mold compound 1102, and then the mold compound 1102 is cured. In this embodiment, the prefabricated reinforcing material 1104 can be used for compressing the mold compound 1102. For example, once the mold compound 1102 is applied to the backside of the wafer 802, the prefabricated reinforcing material 1104 can compress the mold compound 1102 to its desired thickness. In this example, once the mold compound 1102 is compressed, it cures at the curing temperature in block 714 of method 700.
The prefabricated reinforcing material 1104 can be used solely or in combination with the piston 1106 for compressing the mold compound 1102. When used in combination, a vacuum can be created through channels 1108 (
Once the mold compound 1102 is compressed to the desired thickness, the mold compound 1102 couples to the reinforcing material 1104 and the vacuum pressure is released. The piston 1106 can be removed from the reinforcing material 1104 and the assembly is cured in block 714.
In block 712, the coupling of the mold compound 1102 and reinforcing material 1104 can be aided or promoted by a surface roughening process. The surface of the reinforcing material 1104, for example, can be roughened before coupling the mold compound 1102 and reinforcing material 1104. There are several roughening processes or techniques that can be used. For example, the roughening process can be achieved by a dry or wet etching process. Plasma bombardment or etching is one form of a dry etching process that can be used.
In block 716 of the method 700 and
In the embodiment of
In the first embodiment (e.g., method 100), the frontside bumps 306 can increase the surface height of the wafer 202 by 80-90 μm. This difference in surface height, or irregular surface flatness, can make it difficult to apply a substantially equal amount of adhesive along the surface of the wafer. In addition, if there are pockets or gaps along the wafer where there is an unequal amount of adhesive, it can be difficult to mount the carrier 302 to the wafer 202. More particularly, when the carrier 302 is not effectively mounted to the wafer 202, the carrier 302 provides less stiffness to the wafer 202. Thus, the wafer 202 can bend, warp, or suffer other structural damage. To overcome this variation in surface height, the wafer 202 may require a stricter manufacturing process that includes tighter tolerances. For instance, in some embodiments, the surface variation of the wafer may not exceed 5 μm and this can be difficult to manufacture.
Conversely, in the second embodiment, the frontside bumping process is completed near the end of method 700. In this instance, the adhesive material 904 can be applied more effectively to the surface of the wafer 802. More importantly, the carrier 902 can more effectively be mounted to the wafer 802. This improves the performance of the carrier 902 and provides a more desirable stiffness to the wafer 802 during the assembly process.
In addition, in the second embodiment, the wafer 802 can have a larger variation in surface height. For example, the wafer 802 can have a surface variation between 5-10 μm that does not require as stringent of a manufacturing process as in the first embodiment. The tolerances are not as strict and this can reduce the cost of manufacturing the wafer 802. Also, because the carrier 902 is able to mount more easily to the wafer 802 in this embodiment, it is also able to demount from the wafer 802 more easily.
Although there is at least one distinction between the embodiments described in methods 100 and 700, both methods can substantially reduce the warpage of the electronic package. In one non-limiting example, a study was performed on an electronic package similarly configured as the two embodiments shown in
In this non-limiting example, the warpage was reduced by 50-90% over conventional methods known in the art. The greatest reduction of warpage was measured when the thickness of the reinforcing material was similar to the thickness of the Tier 1 die. Regardless, however, of the different thicknesses of each material, the warpage was significantly reduced when the electronic package included the mold compound disposed between the wafer and the reinforcing material. When the electronic package was assembled without a reinforcing material, a substantial amount of warpage was measured. Thus, the reinforcing material can provide significant reduction to warpage over conventional electronic packages.
In
While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.