This U.S. non-provisional patent application claims priority under 35 U.S.C. §119 of Korean Patent Application No. 10-2015-0078681, filed on Jun. 3, 2015, the entire contents of which are hereby incorporated by reference.
The present disclosure herein relates to a semiconductor package and a method for manufacturing the same, and more particularly, to a semiconductor package for which a bonding process is performed for stacking a 3D semiconductor package and a method for manufacturing the same.
As a semiconductor device becomes high speed and high integration, the number of input and output pins rapidly increases, development of a connection technique using a through silicon via (TSV) electrode is enlarged, and development of a 3D semiconductor chip stacking structure using the same is enlarged. In particular, when a plurality of semiconductor chips are vertically stacked to realize high density chip stacking, semiconductor chips having various functions may be integrated on a small area. When semiconductor chips are stacked on an interposer or a wafer, bonding may be performed by using an adhesive film or underfill. When a bonding process is performed by using the adhesive film such as a non-conductive film (NCF), a thermal compression process is essentially accompanied. Accordingly, a processing time becomes longer and a processing efficiency may be lowered. When a bonding process using an underfill is proceeded, bubbles generated in the process may influence alignment of chips. When a compression process using a load is proceeded, the underfill may creep up to the top surface of the chip and contaminate a compression member. When a reflow process is proceeded without load, it is difficult to align the chips caused by bubble generation or an underfill flow.
The present disclosure provides a semiconductor package which has a vertical stacking structure and in which semiconductor elements may be easily aligned, and a method for manufacturing the same.
The present disclosure also provides a semiconductor package which prevents semiconductor chips from tilting caused by an underfill flow or bubble generation at the time of stacking semiconductor chips, and a method for manufacturing the same.
The objectives of the present invention are not limited to the above-described. The objectives not mentioned in the above should be clearly understood by those skilled in the art from description below.
An embodiment of the inventive concept provides a method for manufacturing a semiconductor package including: providing a first substrate; providing, over the first substrate, a second substrate including an active region in which a semiconductor element is disposed and a periphery region surrounding the active region; providing an adhesive membrane between the first and second substrates; and mounting the second substrate on the first substrate, wherein the mounting of the second substrate includes aligning the second substrate on the first substrate by using an alignment member protruding from the periphery region of the second substrate.
In an embodiment, the second substrate may include a front surface facing a top surface of the first substrate and a rear surface facing the front surface, when mounted on the first substrate, and the aligning of the second substrate may include using a first alignment member protruding from the front surface.
In an embodiment, the aligning of the second substrate may include contacting the first alignment member and a base alignment member protruding from the top surface of the first substrate each other to be aligned.
In an embodiment, the contacting of the first alignment member and the base alignment member each other to be aligned may include fixing the second substrate on the first substrate to prevent tilting or misalignment caused by a flow of the adhesive membrane.
In an embodiment, the method may further include: mounting a third substrate on the second substrate, wherein the mounting of the third substrate may include aligning the third substrate by using a second alignment member protruding from the rear surface of the second substrate.
In an embodiment, the third substrate may include a front surface facing the rear surface of the second substrate and a rear surface facing the front surface, when mounted on the second substrate, and the aligning of the third substrate may include contacting the second alignment member and a third alignment member protruding from the front surface of the third substrate each other to be aligned.
In an embodiment, the method may further include: compressing the second substrate on the rear surface of the second substrate after mounting the second substrate.
In an embodiment, the adhesive membrane may be an underfill.
In an embodiments of the inventive concept, a semiconductor package includes: a first substrate; a second substrate mounted on the first substrate and including an active region in which a semiconductor element is disposed and a periphery region surrounding the active region; an adhesive membrane configured to fill between the first and second substrates; and an alignment member protruding from the periphery region of the second substrate and configured to align the second substrate on the first substrate.
In an embodiment, the second substrate may include a front surface facing a top surface of the first substrate and a rear surface facing the front surface, when mounted on the first substrate, and the alignment member may be provided to at least one of the front surface and the rear surface.
In an embodiment, the alignment member may include: a first alignment member protruding from the front surface; and a second alignment member protruding from the rear surface.
In an embodiment, the alignment member may further include a base alignment member protruding from a top surface of the first substrate to face the first alignment member and configured to contact the first alignment member.
In an embodiment, an inner surface of the first alignment member may contact an outer surface of the base alignment member.
In an embodiment, the semiconductor package may further include: a third substrate mounted on the second substrate and including a front surface facing the rear surface of the second substrate and a rear surface facing the front surface, wherein the third substrate may further include a third alignment member protruding from the front surface and configured to contact the second alignment member to align the third substrate.
In an embodiment, the adhesive membrane may be an underfill.
The accompanying drawings are included to provide a further understanding of the inventive concept, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the inventive concept and, together with the description, serve to explain principles of the inventive concept. In the drawings:
Advantages and features of the present invention, and methods for achieving the same will be cleared with reference to exemplary embodiments described later in detail together with the accompanying drawings. However, the present invention is not limited to the following exemplary embodiments, but realized in various forms. In other words, the present exemplary embodiments are provided just to complete disclosure the present invention and make a person having an ordinary skill in the art understand the scope of the invention. The present invention should be defined by only the scope of the accompanying claims. Throughout this specification, like numerals refer to like elements.
The terms and words used in the following description and claims are to describe embodiments but are not limited the inventive concept. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” used herein specify the presence of stated components, operations and/or elements but do not preclude the presence or addition of one or more other components, operations and/or elements.
Example embodiments are described herein with reference to cross-sectional views and/or plan views that are schematic illustrations of example embodiments. In the drawings, the thicknesses of layers and regions are exaggerated for clarity. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may be to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may, typically, have rounded or curved features. Thus, the regions illustrated in the figures are schematic in nature and their shapes may be not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of example embodiments.
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The first substrate 10 may be mounted on the second substrate 20. For example, the second substrate 20 may be an interposer 20. Hereinafter, the second substrate 20 will be exemplified and described as the interposer 20. The interposer 20 may be a silicon interposer. The interposer 20 may have the same through-electrodes (not illustrated) as the semiconductor chip 10. The interposer 20 may further include the bonding pads 22 electrically connected to the stacked semiconductor chip 10. In addition, the interposer 20 may include at least one re-distribution layer (RDL) including interconnections. In addition, although not illustrated in the drawing, the interposer 20 may be connected to a carrier substrate (not illustrated) disposed therebelow. For example, the carrier substrate (not illustrated) may be a printed circuit board. At this point, the through-electrodes (not illustrated) of the interposer 20 may be electrically connected to the interconnections and bonding pads 22 to electrically connect the stacked semiconductor chip 10 and the carrier substrate (not illustrated). In addition, the through-electrodes may electrically connect a passive device such as an inductor, a capacitor, or a resistor included in the interposer 20, or a logic device such as a processor, and the stacked semiconductor chip 10 and the carrier substrate (not illustrated).
When an adhesive membrane 24 may be provided between the first substrate 10 and the second substrate 20. The adhesive membrane 24 may be provided on the second substrate 20. The adhesive membrane 24 may connect the first substrate 10 onto the second substrate 20. The adhesive membrane 24 may bond the semiconductor chip 10 onto the interposer 20. The adhesive membrane 24 may include the underfill 24. The underfill 24 may be a flowable underfill or non-flowable underfill. Hereinafter, a description will be provided about a case where the underfill 24 is exemplified as adhesive film 24. For example, the underfill 24 may include at least one of epoxy, benzocyclobutene, polyimide, a silica filler, or flux. However, the adhesive membrane 24 is not limited thereto and may be a material having various compositions.
An alignment member 30 may be provided to the semiconductor chip 10. The alignment member 30 may be disposed to protrude from the periphery region PR of the semiconductor chip 10. The alignment member 30 may include first alignment members 32 and second alignment members 34. The first alignment members 32 may protrude from the front surface 10a of the semiconductor chip 10. For example, the first alignment members 32 may vertically protrude from the front surface 10a of the semiconductor chip 10. The first alignment members 32 may be disposed on both sides of the periphery region PR. The second alignment members 34 may protrude from the rear surface 10b of the semiconductor chip 10. For example, the second alignment members 34 may vertically protrude from the front surface 10b of the semiconductor chip 10. The second alignment members 34 may be disposed on both sides of the periphery region PR. Alternatively, the alignment member 30 may further include third alignment members 36 provided on the second substrate 20. The third alignment members 36 can be referred to as a base alignment member 36. For example, the third alignment members 36 may protrude from the top surface of the interposer 20. The third alignment members 36 may vertically protrude from the top surface of the semiconductor chip 20. The third alignment members 36 may be disposed on both sides of the interposer 20, which face the periphery region PR. The third alignment members 36 may be disposed to face the first alignment members 32. For example, outer surfaces of the third alignment members 36 and inner surfaces of the first alignment members 32 contact each other, and the third alignment members 36 may be intervened and fixed between the first alignment members 32. Unlike this, inner surfaces of the third alignment members 36 and outer surfaces of the first alignment members 32 contact each other, and the first alignment members 32 may be intervened and fixed between the third alignment members 36.
The alignment members 30 may be manufactured in a silicon micro-fabrication process based on a semiconductor photolithography process. In other words, the alignment members 30 may be formed by applying a photoresist on a substrate, patterning with a mask pattern, and then proceeding a plating process. The alignment members 30 may be formed with a metal material. For example, the alignment members 30 may include Cu. However, the alignment members 30 are disposed on the periphery region PR or a region facing the periphery region PR on the second substrate 20 so as not to have an electrical influence on the semiconductor package. At this point, the alignment members 30 may have lower heights than the bumps 14. Unlike this, the alignment members 30 may have equal to or higher heights than the bumps 14. In order to adjust the heights of the alignment members 30, the number of mask patterns may be variously provided at a process for manufacturing the alignment members 30. In addition, the manufacturing method of the alignment members 30 is not limited thereto and the alignment members 30 may be formed in various methods.
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In the above-described embodiments, a semiconductor package is exemplified which has the structure in which the plurality of semiconductor chips 10 are stacked on the interposer 20. However, the semiconductor package is not limited thereto and the interposer 20 may be mounted on a carrier wafer. In addition, the first substrate 10 may be various semiconductor elements other than the semiconductor chip 10, and the second substrate 20 may include various semiconductor elements other then the interposer 20. In addition, the alignment members are exemplified as formed on both sides of the semiconductor chip 10, but may be formed on only one side of the semiconductor chip 10.
In addition, in the above-described embodiments, the alignment members are exemplified as provided in a rod type, but may have various shapes.
In addition, in the above-described embodiments, a die-to-wafer (D2W) manner in which a plurality of chips are bonded on a wafer is exemplified, but the embodiments may also be applied to a wafer-to-wafer (W2W) manner in which a plurality of chips in a wafer state are boned to another wafer and to a die-to-die manner in which a chip and another chip are bonded.
According to embodiments of the inventive concept, a semiconductor package and a method for manufacturing the same may be provided which may physically support and align a plurality of semiconductor chips to prevent miss-alignment and tilting caused by bubble generation or a underfill flow, etc. during a process, when the plurality of semiconductor chips are vertically stacked.
The above-disclosed subject matter is to be considered illustrative and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the inventive concept. Thus, to the maximum extent allowed by law, the scope of the inventive concept is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
Number | Date | Country | Kind |
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10-2015-0078681 | Jun 2015 | KR | national |