The semiconductor industry continues to improve the integration density of various electronic components (e.g., transistors, diodes, resistors, capacitors, etc.) by continual reductions in minimum feature size, which allow more components to be integrated into a given area. However, as the minimum features sizes are reduced, additional problems arise that should be addressed. For example, one problem of concern is the dissipation of heat.
Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” 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 apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.
In accordance with some embodiments of the present disclosure, thermoelectric (TE) components are bonded or attached to dies to form package components. The TE components may be utilized as thermoelectric generators (TEG) to generate electrical power from the waste heat of high-power dies and provide power to other TE components operated as thermoelectric coolers (TEC). In this manner, the electrical power generated from the heat dissipation of high-power packages is utilized to facilitate the heat dissipation of low-power packages, and the energy used for heat dissipation within a package may be reduced. Additionally, the thermal stability and temperature control of a package may be improved.
The bottom metallization pattern 12 may comprise conductive pads, conductive lines, conductive routing, or the like that is subsequently used to form electrical connections between n-type regions 20N and p-type regions 20P of the TE component 50, described in greater detail below. As an example to form the bottom metallization pattern 12, a seed layer is formed over the structure 10. In some embodiments, the seed layer is a metal layer, which may be a single layer or a composite layer comprising a plurality of sub-layers formed of different materials. In some embodiments, the seed layer comprises a titanium layer and a copper layer over the titanium layer. The seed layer may be formed using, for example, physical vapor deposition (PVD) or the like. A photoresist (not shown) is then formed and patterned on the seed layer. The photoresist may be formed by spin coating or the like and may be exposed to light for patterning. The pattern of the photoresist corresponds to the bottom metallization pattern 12. The patterning forms openings through the photoresist to expose the seed layer. A conductive material is formed in the openings of the photoresist and on the exposed portions of the seed layer. The conductive material may be formed by plating, such as electroplating or electroless plating, or the like. The conductive material may comprise a metal, such as copper, titanium, tungsten, aluminum, or the like. Then, the photoresist and portions of the seed layer on which the conductive material is not formed are removed. The photoresist may be removed by an acceptable ashing or stripping process, such as using an oxygen plasma or the like. Once the photoresist is removed, exposed portions of the seed layer are removed, such as by using an acceptable etching process, such as by wet or dry etching. The remaining portions of the seed layer and conductive material form the bottom metallization pattern 12.
The above is one example for forming the bottom metallization pattern 12, but the bottom metallization pattern 12 may be formed using any suitable techniques. As another example, the bottom metallization pattern 12 may be formed by depositing one or more metal layers on the structure 10 and then patterning the one or more metal layers using suitable photolithography and etching techniques. In some embodiments, the bottom metallization pattern 12 may include a liner, such as a barrier layer or the like.
In
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A conductive layer 22 is then deposited on the n-type regions 20N within the openings 13, in accordance with some embodiments. The conductive layer 22 provides electrical connection to the n-type regions 20 and facilitates adhesion of the overlying bond regions 24 (described below). The conductive layer 22 may comprise one or more metals, such as copper, titanium, tungsten, aluminum, indium, alloys thereof, or the like, and may be deposited using suitable techniques such as plating, CVD, PVD, ALD, or the like. The conductive layer 22 may or may not be formed of a material similar to that of the metallization pattern 12.
The bond regions 24 are then formed on the conductive layer 22, in accordance with some embodiments. A bond region 24 is formed on the conductive layer 22 within each opening 13. The bond regions 24 are subsequently bonded to corresponding bond regions 34 of a metallization component 30 (see
In
In
A conductive layer 22′ is then deposited on the p-type regions 20P within the openings 17, in accordance with some embodiments. The conductive layer 22′ may be similar to the conductive layer 22 described previously, and may be formed of similar materials using similar deposition techniques. In other embodiments, the conductive layer 22′ deposited on the p-type regions 20P comprises a different material than the conductive layer 22 deposited on the n-type regions 20N. For simplicity, the conductive layer 22′ and the conductive layer 22 may collectively be referred to as the conductive layer 22 in subsequent figures and their descriptions. In other embodiments, the conductive layer 22 is formed over both the n-type regions 20N and the p-type regions 20P using the same deposition step.
The bond regions 24′ are then formed on the conductive layer 22′, in accordance with some embodiments. The bond regions 24′ may be similar to the bond regions 24 described previously, and may be formed of similar materials using similar deposition techniques. For example, in some embodiments, the bond regions 24′ comprise indium formed using a suitable technique. In other embodiments, the bond regions 24′ deposited on the conductive layer 22′ comprises a different material than the bond regions 24 deposited on the conductive layer 22. For simplicity, the bond regions 24′ and the bond regions 24 may collectively be referred to as the bond regions 24 in subsequent figures and their descriptions. In other embodiments, the bond regions 24 are formed over both the n-type regions 20N and the p-type regions 20P using the same deposition step.
In
In
In some embodiments, the metallization component 30 also comprises bond regions 34 formed on the metallization pattern 32. In other embodiments, the bond regions 34 are not formed. In some embodiments, each bond region 34 comprises a region (e.g. layer, pad, etc.) of conductive material that corresponds to a respective bond region 24. The bond regions 34 may be similar to the bond regions 24 described previously, and may be formed of similar materials using similar deposition techniques. For example, in some embodiments, the bond regions 34 comprise indium formed using a suitable technique.
In some embodiments, the bond regions 34 of the metallization component 30 may be physically and electrically connected to the bond regions 24 using fusion bonding, direct bonding, metal-to-metal bonding, or the like. For example, the bond regions 34 may be placed on corresponding bond regions 24. A thermal process, such as an annealing process, a reflow process, or the like, may then be performed to bond each bond region 34 to its corresponding bond region 24. Other techniques are possible. After bonding, n-type regions 20N and p-type regions 20P may be serially connected in an alternating configuration, as shown in
Referring to
The substrate 101 may be a wafer, such as a silicon wafer, in some embodiments. Other substrates, such as a silicon-on-insulator (SOI) substrate, a multi-layered substrate, or a gradient substrate may also be used. The substrate 101 may be doped (e.g., with a p-type or an n-type dopant) or undoped. In some embodiments, the semiconductor material of the substrate 101 may include silicon; germanium; a compound semiconductor including silicon carbide, gallium arsenide, gallium phosphide, indium phosphide, indium arsenide, and/or indium antimonide; an alloy semiconductor including silicon-germanium, gallium arsenide phosphide, aluminum indium arsenide, aluminum gallium arsenide, gallium indium arsenide, gallium indium phosphide, and/or gallium indium arsenide phosphide; or combinations thereof. In other embodiments, the substrate 101 may be a dielectric material such as silicon oxide, glass, ceramic, plastic, or any other suitable material that allows for structural support of overlying devices. In some embodiments, multiple interposers 100 may be formed on a single substrate 101 and then may be subsequently singulated into individual interposers 100 or individual package components. In some embodiments, active devices (e.g., transistors, diodes, or the like), passive devices (e.g. capacitors, resistors, or the like), integrated circuits, and/or the like may be formed in the substrate 101. The substrate 101 may be free of passive or active devices, in other embodiments.
In some embodiments, the interposer 100 comprises through vias 102 extending into the substrate 101. The through vias 102 are electrically connected to the interconnect structure 104. The through vias 102 may be formed, for example, by forming openings extending into the substrate 101. The openings may be formed using acceptable photolithography and etching techniques, such as by forming and patterning a photoresist and then performing an etching process using the patterned photoresist as an etching mask. The etching process may include, for example, a dry etching process and/or a wet etching process. A conductive material may then be formed in the openings, thereby forming the through vias 102. In some embodiments, a liner (not shown) may be deposited in the openings prior to forming the conductive material. The conductive material may comprise, for example, a metal or a metal alloy such as copper, silver, gold, tungsten, cobalt, aluminum, alloys thereof, or the like. A planarization process (e.g., a CMP process or a grinding process) may be performed to remove excess conductive material along the surface of the substrate 101 such that surfaces of the through vias 102 and the substrate 101 are level. The through vias 102 may protrude from the substrate 101 and into the interconnect structure 104, in other embodiments. Other materials or techniques are possible.
The interconnect structure 104 comprises one or more layers of conductive features 105 formed in one or more dielectric layers (not individually illustrated), in some embodiments. The conductive features 105 may comprise conductive lines, conductive vias, conductive pads, metallization patterns, redistribution layers, or the like that provide electrical interconnections and electrical routing. In some embodiments, the conductive features 105 comprise conductive pads (not illustrated) at a top surface of the interconnect structure 104. The conductive pads may be metal pads, bond pads, Under-Bump Metallizations (UBMs), or the like. In some embodiments, the interconnect structure 104 may have multiple layers of conductive features 105, but the precise number of layers of conductive features 105 may be dependent upon the design of the interconnect structure 104. The conductive features 105 may be formed using any suitable techniques such as deposition, damascene, dual damascene, or the like. The conductive features 105 may comprise a metal or a metal alloy such as copper, silver, gold, tungsten, cobalt, ruthenium, aluminum, alloys thereof, combinations thereof, or the like. Other materials are possible.
Acceptable dielectric materials for the dielectric layers of the interconnect structure 104 include oxides such as silicon oxide or aluminum oxide; nitrides such as silicon nitride; carbides such as silicon carbide; the like; or combinations thereof such as silicon oxynitride, silicon oxycarbide, silicon carbonitride, silicon oxycarbonitride or the like. Other dielectric materials may also be used, such as a polymer such as polybenzoxazole (PBO), polyimide, a benzocyclobuten (BCB) based polymer, or the like. The dielectric layers may be formed using any suitable techniques. In some embodiments, the interconnect structure 104 may have multiple dielectric layers, but the precise number of dielectric layers may be dependent upon the design of the interconnect structure 104. In other embodiments, an interposer 100 may comprise local silicon interconnects (LSIs) or the like that provide additional conductive routing.
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The devices 250 may include conductive connectors 255 that are used to connect to the interposer 100, in some embodiments. The conductive connectors 255 may include, for example, ball grid array (BGA) connectors, solder balls, metal pillars, controlled collapse chip connection (C4) bumps, micro bumps, electroless nickel-electroless palladium-immersion gold technique (ENEPIG) formed bumps, or the like. The conductive connectors 255 may include a conductive material such as solder, copper, aluminum, gold, nickel, silver, palladium, tin, the like, or a combination thereof. In some embodiments, the conductive connectors 255 are formed by initially forming a layer of solder through evaporation, electroplating, printing, solder transfer, ball placement, or the like. Once a layer of solder has been formed, a reflow may be performed in order to shape the material into the desired bump shapes. In another embodiment, the conductive connectors 255 include metal pillars (such as copper pillars) formed by sputtering, printing, electro plating, electroless plating, CVD, or the like. The metal pillars may be solder free and have substantially vertical sidewalls. In some embodiments, a metal cap layer is formed on the top of the metal pillars. The metal cap layer may include nickel, tin, tin-lead, gold, silver, palladium, indium, nickel-palladium-gold, nickel-gold, the like, or a combination thereof and may be formed by a plating process.
In some embodiments, a TE component 50 of a device 250 is electrically connected to a conductive connector 255 of the device 250 by one or more via structures 251. The via structures 251 may comprise through-vias, conductive vias, conductive lines, and/or the like that extend through the die 240. A via structure 251 is electrically coupled to one or more TE components 50 at the top of the die 240 and is electrically coupled to one or more conductive connectors 255 at the bottom of the die 240. In this manner, the via structures 251 electrically couple the TE component(s) 50 of a device 250 to the conductive connector(s) 255 of the device 250. For example, the electrical power generated by a TE component 50 operated as a TEG may be transmitted to a conductive connector 255 by a via structure 251. As another example, an electrical current may be transmitted to a TE component 50 operated as TEC to provide cooling for the die 240. The via structures 251 shown in
In some embodiments, the devices 250 are bonded to the interposer 100 by aligning the conductive connectors 255 with corresponding conductive features (not shown) at the top of the interconnect structure 104. For example, the conductive features of the interconnect structure 104 may be conductive pads, conductive pillars, solder bumps, or the like. The conductive connectors 255 are then placed into contact with the corresponding conductive features. Then, a reflow process may be performed to bond the conductive connectors 255 to the conductive features. In this manner, the devices 250 may be physically and electrically connected to the interconnect structure 104. In other embodiments, the devices 250 may be bonded to the interconnect structure 104 using fusion bonding, such as dielectric-to-dielectric bonding and/or metal-to-metal bonding.
In
The molding material 262 is deposited over the interposer 100, over the devices 250, and between adjacent devices 250. The molding material 262 may be deposited between the devices 250 and the interposer 100 if an underfill 260 is not present. The molding material 262 may be a molding compound, an encapsulant, an epoxy, a polymer, a silicon oxide filler material, or the like. The molding material 262 may be applied by compression molding, transfer molding, deposition, or the like. The molding material 262 may be applied in liquid or semi-liquid form and then subsequently cured. In some embodiments, a planarization process, such as a CMP process or a grinding process, may be performed to remove excess portions of the molding material 262. In some embodiments, the molding material 262 covers the TE components 50 of the devices 250 after performing the planarization process, as shown in
In
The package substrate 302 may be any suitable substrate or component, such as a device die, a redistribution structure, an interposer, a wafer, a semiconductor substrate, a panel, a core substrate, a printed circuit board (PCB), a motherboard, a main board, or the like. The package substrate 302 may comprise conductive features such as conductive lines, conductive vias, conductive pads, or the like to make electrical interconnections within the package substrate 302 and to make electrical connections to the package component 200 or other components attached to the package substrate 302. The package substrate 302 may or may not comprise active devices and/or passive devices. In some embodiments, conductive connectors 310 are formed on the package substrate 302, which may be similar to the conductive connectors 264 described previously.
In some embodiments, a thermal component 330 is attached to the lid 320 to provide additional heat dissipation or cooling for the package 300. The thermal component 330 may comprise, for example, a heat sink (as shown in
In some embodiments, one TE component 50 of the package component 200 may be operated as a thermoelectric generator (TEG) that provides electrical power to another TE component 50 of the package component 200 that is operated as a thermoelectric cooler (TEC). In this manner, the excess heat generated from one device 250 may be utilized to facilitate cooling of another device 250, which can increase the thermal management efficiency, improve thermal stability, or reduce energy consumption of the package component 200 or of the package 300.
As an example,
In some embodiments, a high-power device 250 that generates relatively more heat may have its TE component 50 operated as a TEG to provide electrical power to one or more TEC-operated TE components 50 of other devices 250. For example, with reference to
Temperature-sensitive devices may be sensitive to thermal cross-talk within the package 300 or may be sensitive to thermal instability within the package 300, which can cause undesired variation in operating characteristics. Accordingly, by integrating a TE component 50 into a device 250 as described herein, the TE component 50 may be operated as TEC to cool the device 250 into a desired temperature range or may be operated as a thermoelectric heater to heat the device 250 into a desired temperature range. The TE component 50 may be utilized to adjust the temperature of the device 250 in order to maintain a more stable temperature, such as maintaining the temperature of the device 250 within a desired range. In this manner, the operation of a temperature-sensitive device 250 may be made more reliable, stable, and predictable by controlling the temperature of the device 250 using its integrated TE component 50. Further, powering one TE component 50 using another TE component 50 as described herein can reduce energy consumption, improve efficiency, or improve Power Usage Effectiveness (PUE) of the package 300. In some cases, the use of TE components 50 to control device 250 temperature as described herein can be used to stabilize the device 250 at a desired temperature that is different than the working temperature of the package 300. In some embodiments, a TE component 50 may be used to cool a device 250 to a temperature lower than the temperature of its environment. As another example, if the package 300 is cooled using a cold plate, a TE component 50 may be used to heat a device 250 to a desired higher operating temperature.
In
Referring to
The TE structure 50′ may be similar to the TE component 50 described previously, and may be formed using similar materials and techniques. For example, the TE structure 50′ may be formed on the bottom substrate 11 in a manner similar to that of the TE component 50 being formed on the structure 10. The TE structure 50′ may comprise a plurality of n-type regions 20N and p-type regions 20P between a bottom metallization pattern 12 and a metallization pattern 32. The metallization pattern 32 may be formed on an upper substrate 31. In some embodiments, a TE component 70 may have a thickness in the range of about 20 μm to about 100 μm, though other thicknesses are possible.
In
Each of the devices 650 comprises a TE component 660, which may be similar to the TE components 50 or 70 described previously. The TE components 660 operated as a thermoelectric cooler (TEC) are indicated as TE components 660-C, and TE components 660 operated as a thermoelectric generator (TEG) are indicated as TE components 660-G. In some cases, some TE components 660 may be operated as either a TEC or as a TEG, indicated as TE components 660-G/C. For example, as shown in
In some embodiments, the TE components 660-G may be configured to provide electrical power to the TE components 660-C, similar to the other package components described previously. In some embodiments, the TE components 660-G/C may be configured to switch between TEG operation and TEC operation when desired. For example, the TE components 660-G/C may be configured to provide electrical power to the TE components 660-C or to receive electrical power (e.g., from a TE components 660-G and/or 660-G/C) to provide cooling (or heating) of the devices 650C. In this manner, the TE component(s) 660-G may be used to capture thermal energy from device(s) 650A, the TE components 660-C may be used to cool devices 650B, and the TE components 660-G/C may be used in various modes to provide thermal stabilization for the package component 600. This can result in increased efficiency, improved thermal stability, and improved thermal performance.
In some embodiments, each group 665 of TE components 660-G/C may be separately operated in a TEG mode or in a TEC mode. As an example, the group 665A may be operated in a TEG mode while the group 665C is operated in a TEC mode. Subsequently, the group 665A and the group 665C may both be operated in a TEG mode or in a TEC mode. This is an illustrative example, and any suitable combination of groups 665 operated in a TEG mode or a TEC mode is possible, and the modes of the various groups 665 may be changed as desired. In some cases, a TEG-operated group 665 may supply power to a TEC-operated group 665. The groups 665 may be switched between a TEG mode and a TEC mode in order to efficiently provide thermal management for the device 650. For example, the groups 665A-C may all be operated in a TEG mode, and one or more individual groups 665A-C may be switched to a TEC mode to cool the device 250 if the temperature of the device 250 rises to a certain temperature threshold. A group 665 may be switched between TEG mode and TEC mode based on the local heat generated near that group 665 to provide local thermal management of the device 650. These are examples, and other configurations or applications are possible.
Other features and processes may also be included. For example, testing structures may be included to aid in the verification testing of the 3D packaging or 3DIC devices. The testing structures may include, for example, test pads formed in a redistribution layer or on a substrate that allows the testing of the 3D packaging or the 3DIC, the use of probes and/or probe cards, and the like. The verification testing may be performed on intermediate structures as well as the final structure. Additionally, the structures and methods disclosed herein may be used in conjunction with testing methodologies that incorporate intermediate verification of known good dies to increase the yield and decrease costs.
The embodiments described herein may achieve advantages. In some cases, computing systems, photonic systems, or other packages may have multiple package components which generate different amounts of heat. Embodiments herein describe the use of thermoelectric components that are bonded to or attached to the package components to facilitate thermal management of the package. The thermoelectric (TE) components may be operated as thermoelectric generators (TEG) to generate electrical power from waste heat and/or as thermoelectric coolers (TEC) to provide cooling from received electrical power. The integrated TE components described herein have a small form factor and can be arranged and connected flexibly into thermal management systems that are application-specific. In some embodiments, some TE components operated as TEG may be used to power other TE components operated as TEC. Thus, waste heat can be converted to electricity within the same system, which can reduce the external power needed, reduce cost, and improve the efficiency of the thermal management of the system. In some embodiments, some TE components may be switched between a TEG mode and a TEC mode. The amount of electrical power generated by TEG-operated TE components and the cooling provided by TEC-operated TE components can be controlled to provide efficient heat dissipation for both high-power packages components and low-power package components. In this manner, the thermal stability of package components, such as those comprising temperature-sensitive features, may be improved. In some cases, the techniques and structures described herein can reduce lateral thermal cross-talk.
In an embodiment of the present disclosure, a method includes forming a first thermoelectric component on a first die; forming a second thermoelectric component on a second die; and connecting the first die and the second die to an interposer, wherein connecting the first die and the second die to the interposer electrically couples the first thermoelectric component and the second thermoelectric component to the interposer. In an embodiment, the first thermoelectric component is formed on the first die before the first die is connected to the interposer. In an embodiment, the first thermoelectric component is a thermoelectric generator. In an embodiment, the second thermoelectric component is a thermoelectric cooler. In an embodiment, the method includes forming a third thermoelectric component on the first die, wherein the third thermoelectric component is electrically coupled to the first thermoelectric component. In an embodiment, the method includes depositing a molding material over the first die, the second die, the first thermoelectric component, and the second thermoelectric component. In an embodiment, forming the first thermoelectric component on the first die includes depositing a conductive layer on the first die; depositing an n-type material on the conductive layer; and depositing a p-type material on the conductive layer. In an embodiment, forming the first thermoelectric component on the first die includes forming a thermoelectric structure on a substrate; and bonding the substrate to the first die.
In an embodiment of the present disclosure, a method includes forming a first thermoelectric structure on a first substrate, including depositing a first conductive layer on the first substrate; forming n-type regions on the first conductive layer; and forming p-type regions on the first conductive layer; forming a metallization component on a second substrate, including depositing a second conductive layer on the second substrate; bonding the second conductive layer to the first thermoelectric structure; and attaching the first substrate to a structure including a conductive feature, wherein the first conductive layer is electrically connected to the conductive feature. In an embodiment, the first substrate is a first semiconductor device and the structure is an interposer. In an embodiment, structure is a second semiconductor device. In an embodiment, the first substrate is a silicon substrate. In an embodiment, the method includes attaching a third semiconductor device to the structure, wherein the third semiconductor device includes a second thermoelectric structure, wherein the first thermoelectric structure is electrically connected to the second thermoelectric structure. In an embodiment, the conductive feature includes a solder bump. In an embodiment, the method includes depositing a molding material over the first thermoelectric structure.
In accordance with an embodiment of the present disclosure, a package includes a first semiconductor die attached to an interposer; a second semiconductor die attached to the interposer; a first thermoelectric component on a top surface of the first semiconductor die; and a second thermoelectric component on a top surface of the second semiconductor die, wherein the first thermoelectric component is electrically connected to the second thermoelectric component through the interposer. In an embodiment, the first thermoelectric component is a thermoelectric generator. In an embodiment, the second thermoelectric component is a thermoelectric cooler. In an embodiment, the package includes a molding material covering the first thermoelectric component and the second thermoelectric component. In an embodiment, the package includes a thermal interface material covering the first thermoelectric component and the second thermoelectric component
The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application claims the benefit of U.S. Provisional Application No. 63/614,698, filed on Dec. 26, 2023, which application is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63614698 | Dec 2023 | US |