The present application generally relates to semiconductor technology, and more particularly, to a semiconductor package stack and a method for forming a semiconductor package stack.
The semiconductor industry is constantly faced with complex integration challenges as consumers want their electronics to be smaller, faster and higher performance with more and more functionalities packed into a single device. This raises problems such as finding space to route traces along a printed circuit board (PCB) and integrating functionality into silicon integrated circuit devices.
Therefore, a need exists for an improved semiconductor package.
An objective of the present application is to provide a semiconductor package stack to further improve integration and reduce difficulty in the internal wiring design.
According to an aspect of the present application, a semiconductor package stack is provided. The semiconductor package stack comprises: a base substrate having one or more sets of base conductive patterns on its front surface; an anisotropic conductive film formed on the front surface of the base substrate; one or more semiconductor packages disposed on the base substrate via the anisotropic conductive film and extending vertically relative to the front surface of the base substrate, wherein each of the one or more semiconductor packages comprises a set of package interconnect structures which have a set of package conductive patterns exposed from a lateral surface of the semiconductor package; and wherein the set of package conductive patterns are aligned with a set of base conductive patterns to allow electrical connection therebetween via the anisotropic conductive film; and a vertical substrate disposed on the base substrate via the anisotropic conductive film and extending vertically relative to the front surface of the base substrate, wherein the vertical substrate comprises a set of vertical interconnect structures which have a set of vertical conductive patterns exposed from a lateral surface of the vertical substrate; and wherein the set of vertical conductive patterns are aligned with a set of base conductive patterns to allow electrical connection therebetween via the anisotropic conductive film.
According to another aspect of the present application, a method for forming a semiconductor package stack is provided. The method comprises: stacking one or more semiconductor packages with a vertical substrate, to align their respective lateral surfaces with each other in a horizontal direction, wherein each of the semiconductor packages comprises a set of package interconnect structures which have a set of package conductive patterns exposed from the lateral surface of the semiconductor package; and the vertical substrate comprises a set of vertical conductive patterns exposed from the lateral surface of the vertical substrate; providing a base substrate having one or more sets of base conductive patterns on its front surface; forming an anisotropic conductive film on the front surface of the base substrate; and attaching vertically the stack of the one or more semiconductor packages and the vertical substrate onto the front surface of the base substrate via the anisotropic conductive film, such that the sets of package conductive patterns and the set of vertical conductive patterns on the respective lateral surfaces of the one or more semiconductor packages and the vertical substrate are aligned with the one or more sets of base conductive patterns on the front surface of the base substrate to allow electrical connection therebetween via the anisotropic conductive film.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention. Further, the accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain principles of the invention.
The drawings referenced herein form a part of the specification. Features shown in the drawing illustrate only some embodiments of the application, and not of all embodiments of the application, unless the detailed description explicitly indicates otherwise, and readers of the specification should not make implications to the contrary.
The same reference numbers will be used throughout the drawings to refer to the same or like parts.
The following detailed description of exemplary embodiments of the application refers to the accompanying drawings that form a part of the description. The drawings illustrate specific exemplary embodiments in which the application may be practiced. The detailed description, including the drawings, describes these embodiments in sufficient detail to enable those skilled in the art to practice the application. Those skilled in the art may further utilize other embodiments of the application, and make logical, mechanical, and other changes without departing from the spirit or scope of the application. Readers of the following detailed description should, therefore, not interpret the description in a limiting sense, and only the appended claims define the scope of the embodiment of the application.
In this application, the use of the singular includes the plural unless specifically stated otherwise. In this application, the use of “or” means “and/or” unless stated otherwise. Furthermore, the use of the term “including” as well as other forms such as “includes” and “included” is not limiting. In addition, terms such as “element” or “component” encompass both elements and components including one unit, and elements and components that include more than one subunit, unless specifically stated otherwise. Additionally, the section headings used herein are for organizational purposes only, and are not to be construed as limiting the subject matter described.
As used herein, spatially relative terms, such as “beneath”, “below”, “above”, “over”, “on”, “upper”, “lower”, “left”, “right”, “vertical”, “horizontal”, “side” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. It should be understood that when an element is referred to as being “connected to” or “coupled to” another element, it may be directly connected to or coupled to the other element, or intervening elements may be present.
As shown in
In particular, the base substrate 102 may include one or more insulating or passivation layers, one or more conductive vias formed through the insulating layers, and one or more conductive layers formed over or between the insulating layers. The conductive vias and conductive layers form together various base interconnect structures in the base substrate 102. Furthermore, the base interconnect structures may include one or more sets of base conductive patterns 104 which are exposed from a front surface of the base substrate 102, as shown in
An anisotropic conductive film 106 is formed on the front surface of the base substrate 102. The anisotropic conductive film 106 is a curable material such as a thermoplastic or ultraviolet (UV) curable polymer composite material (epoxy, acryl, etc.) with special conductive particles such as micro solder balls distributed in the material. After being cured by heat, UV or pressure, the conductive particles in the anisotropic conductive film 106 can aggregate in its thickness direction and thus provide vertical electrical paths. However, the conductive particles in the anisotropic conductive film 106 are distributed far apart thus not electrically conductive in its plane direction (x&y-direction). It can be appreciated that the anisotropic conductive film 106 allows low height and fine pitch which enables high density and miniaturizing of the semiconductor package stack 100.
With continued reference to
Each semiconductor package 108 may include some package interconnect structures 110 embedded within an insulating material of the semiconductor package 108. In the embodiment, two sets of package interconnect structures 110 are illustrated, i.e., an upper set of package interconnect structures which are formed close to a top lateral surface of the semiconductor package 108 and a lower set of package interconnect structures which are formed close to a bottom lateral surface of the semiconductor package 108. The “lateral surface” herein refers to a surface of the semiconductor package that is substantially perpendicular to a package substrate of the semiconductor package, i.e., as relative to a front surface and a back surface which are generally extending in parallel with a plane of the package substrate. For a cuboid semiconductor package such as the semiconductor package 108, it has four lateral surfaces except a front surface and a back surface. In some embodiments, the package interconnect structures may be exposed from all the four lateral surfaces.
In particular, each of the bottom sets of package interconnect structures 110 have a set of package conductive patterns 112 exposed from the bottom lateral surface of the semiconductor package 108. In order to electrically connect the semiconductor package 108 with the base substrate 102, the exposed set of package conductive patterns 112 may be aligned with a set of base conductive patterns 104, as shown in
Each semiconductor package 108 may include a package substrate 114 having one or more electronic components 116 mounted on its front surface and package connectors 118 such as solder bumps mounted on its back surface. By way of example, the package substrate 114 can include a PCB, a carrier substrate, a semiconductor substrate with electrical interconnections, or a ceramic substrate. In some other examples, the package substrate 114 may include a laminate interposer, a strip interposer, a leadframe, or other suitable substrates. In some embodiments, the electronic components 116 may include active components such as semiconductor dice or smaller semiconductor packages, or passive components such as resistors, capacitors, connectors, antennas or the like. Although only one electronic component 116 is shown in
The package interconnect structures 110 of each semiconductor package 108 may be formed in the encapsulant layer 120, which is the middle layer of the semiconductor package 108. In this way, each package interconnect structure 110 may have three conductive patterns exposed from three respective surfaces of the encapsulant layer 120, i.e., the front surface adjacent to the interposer 122, the back surface adjacent to the package substrate 114 and the lateral surface adjacent to the anisotropic conductive film 106. In other words, each package interconnect structure 110 may take the form of a metal pillar with a branch. In this way, the interposer 122 and the package substrate 114 can be electrically coupled to each other via the package interconnect structures 110, and can be further electrically coupled to the base substrate 102.
It can be appreciated that, the semiconductor package stack 100 includes a layer of semiconductor packages disposed on a base substrate 102, however, one or more other layers of semiconductor packages may be further stacked on the layer of semiconductor packages to further improve integration of the semiconductor package stack. Moreover, although it is shown only three semiconductor packages which are arranged in a row, an array of semiconductor packages may be formed by arranging the semiconductor packages in multiple rows and columns in one layer, and each adjacent two semiconductor packages may be electrically connected with each other, for example, through their respective package interconnect structures that are aligned with each other. For example, as shown in
Still referring to
In some examples, the vertical substrate 124 can include a PCB, a carrier substrate, a semiconductor substrate with electrical interconnections, or a ceramic substrate. In some other examples, the vertical substrate 124 may include a laminate interposer, a strip interposer, a leadframe, or other suitable substrates. The vertical substrate 124 may have a set of vertical interconnect structures 126 which are electrically connected to a semiconductor package 108 adjacent to the vertical substrate 124. In some embodiments, the set of vertical interconnect structures 126 may include a set of vertical conductive patterns 128 exposed from a lateral surface of the vertical substrate 124, and the vertical conductive patterns 128 may be further aligned with a set of base conductive patterns 104 to allow electrical connection therebetween via the anisotropic conductive film 106. In some alternative embodiments, the vertical interconnect structures 126 may not be aligned with and connected with the base conductive patterns 104. Moreover, the vertical interconnect structures 126 may have another set of vertical conductive patterns 130 exposed from a front surface of the vertical substrate 124, which are electrically connected with the package connectors 118 of the semiconductor package 108 adjacent to the vertical substrate 124.
After the semiconductor packages 108 and the vertical substrate 124 are assembled together and attached onto the base substrate 102, an insulative filler material 132 may be formed on the back surfaces of the semiconductor packages 108 and around the package connectors 118 which are internal to the semiconductor package stack 100, to provide insulation and protection for them. The filler material 132 also improves the firmness of the entire semiconductor package stack 100. Furthermore, in some alternative embodiments, the insulative filler material 132 may be formed prior to the attachment of the semiconductor packages 108 and the vertical substrate 124 to the base substrate 102.
As shown in
As shown in
Next, as shown in
Next, as shown in
The semiconductor package may be assembled and formed in other processes, as long as the package interconnect structures can be embedded within the semiconductor package but have at least some conductive patterns exposed from lateral surface(s) of the semiconductor package.
As shown in
Next, as shown in
Next, as shown in
As shown in
Next, as shown in
Next, as shown in
Afterwards, as shown in
The discussion herein included numerous illustrative figures that showed various portions of a semiconductor package stack and a method for forming a semiconductor package stack of the present application. For illustrative clarity, such figures did not show all aspects of each example assembly. Any of the example assemblies and/or methods provided herein may share any or all characteristics with any or all other assemblies and/or methods provided herein.
Various embodiments have been described herein with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. Further, other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of one or more embodiments of the invention disclosed herein. It is intended, therefore, that this application and the examples herein be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following listing of exemplary claims.
Number | Date | Country | Kind |
---|---|---|---|
202310536338.8 | May 2023 | CN | national |