This application relates generally to semiconductor devices and methods for making such devices. More specifically, this application describes semiconductor packages that contain stacked chips on a micro-layered lead frame and methods for making such semiconductor packages.
Semiconductor packages are well known in the art. Often, these packages may include one or more semiconductor devices, such as an integrated circuit (“IC”) die or chip, which may be connected to a die pad that is centrally formed in a lead frame which contain a series of leads. In some cases, bond wires electrically connect the IC die to a series of terminals that serve as an electrical connection to an external device, such as a printed circuit board (“PCB”). An encapsulating material can be used to cover the bond wires, the IC die, the terminals, and/or other components of the semiconductor device to form the exterior of the semiconductor package. A portion of the terminals and possibly a portion of the die pad may be externally exposed from the encapsulating material. In this manner, the die may be protected from environmental hazards—such as moisture, contaminants, corrosion, and mechanical shock—while being electrically and mechanically connected to an intended device that is external to the semiconductor package.
After it has been formed, the semiconductor package is often used in an ever growing variety of electronic applications, such as disk drives, USB controllers, portable computer devices, cellular phones, and so forth. Depending on the die and the electronic application, the semiconductor package may be highly miniaturized and may need to be as small as possible.
This application relates to semiconductor packages that contain stacked chips on a micro-layered lead frame and methods for making such semiconductor packages. The semiconductor packages contain a full array of land pads that has been formed from a lead frame. The packages comprise multiple chips that are stacked vertically and separated by routing leads which are connected to the land pad array. The routing leads can be etched from a metal cladding layer that is provided between each set of stacked chips. Each chip and its routing leads can be encapsulated before the next chip is provided in the package. The semiconductor packages therefore have a high input/output capability with a small package footprint, a flexible routing capability, and a small thickness for multiple chips that are stacked in the package.
The following description can be better understood in light of the Figures, in which:
The Figures illustrate specific aspects of the semiconductor packages and methods for making such packages. Together with the following description, the Figures demonstrate and explain the principles of the methods and structures produced through these methods. In the drawings, the thickness of layers and regions are exaggerated for clarity. It will also be understood that when a layer, component, or substrate is referred to as being “on” another layer, component, or substrate, it can be directly on the other layer, component, or substrate, or intervening layers may also be present. The same reference numerals in different drawings represent the same element, and thus their descriptions will not be repeated.
The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the devices and associated methods of making and using the devices can be implemented and used without employing these specific details. Indeed, the devices and associated methods can be placed into practice by modifying the illustrated devices and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry. For example, while the description below focuses on methods for making for semiconductor packages in the IC industry, it could be used in and applied to other electronic devices like optoelectronic devices, solar cells, MEMS structures, lighting controls, power supplies, and amplifiers.
Some embodiments of the semiconductor packages and methods for making such packages are shown in
In some instances, the leadframe 10 can contain a layer of metal plating (not shown) if desired. For example, the leadframe (or lead frame) 10 may be electroplated or otherwise coated with a layer of a solderable conductive material, such as tin, gold, lead, silver, and/or another solderable material. In some embodiments, the leadframe 10 can have one or more recesses that define a die pad (or die attach pad) that supports a semiconductor die. For example, as shown in
Next, vias 12 can be provided on the upper surface of the lead frame 10 if the leadframe is not made with vias 12 already present. The vias 12 can be formed on the lead frame 10 using any known technique in the art, including any known masking and etching process which removes the material of the lead frame 10 where the vias 12 do not need to be present. In some instances, the vias 12 are formed while the lead frame 10 is being manufactured. The thickness of the vias 12 will depend on the leadframe thickness, and in some configurations the vias can have half of the thickness of the leadframe. In some embodiments, the vias 12 can have a thickness ranging from about 50 μm to about 112 μm.
Next, as shown in
The first die 25 can contain any number of IC devices. The IC device(s) may be any known integrated circuit (including any discrete device) in the art. Some non-limiting examples of these devices may include logic or digital IC device, linear regulators, audio power amplifiers, LDO, driver IC, diodes, and/or transistors, including zener diodes, schottky diodes, small signal diodes, bipolar junction transistors (“BJT”), metal-oxide-semiconductor field-effect transistors (“MOSFET”), insulated-gate-bipolar transistors (“IGBT”), and insulated-gate field-effect transistors (“IGFET”).
Any known flipchip process can be used to attach the first die 25 to the DAP 18. In these embodiments, the IC device(s) on the first die 25 can be provided with a bond pad as known in the art. In some embodiments, the bond pads can be provided in those areas that overlay the IC device(s). The bond pads can be formed in the desired location by any process known in the art (such as a redistribution method) and can be made of any known solderable material, including Au, Cu, Ag, Ti, Ni, Sn, W, Ni, or combinations thereof.
An array of solder bumps (or pillars) can then be provided on the bond pads. The bumps can be made of conductive material such as Ag, Sn, Pb, Cu, Sb, Au or combinations thereof. The bumps can be provided on the bond pads through any process known in the art, including electroless plating, ball drop, or printing. Then, the die 25 is flipped and placed on the interconnect structure so the bond pad (through the bumps) is attached to the desired locations of the DAP 18, as shown in
In some embodiments, the DAP 18 can be altered prior to the first die 25 being attached to it. In these embodiments, a solder mask (or resist) layer could be formed on the DAP 18. Alternatively, solder-confining features like embossed or cavity-etched features could be formed on the DAP 18. The solder mask and solder-confining features can be used to aid in the attachment process because they align with the bond pads/bumps formed on the first die 25 and prevent the solder from reflowing excessively that can cause solder bridging.
As shown in
As shown in
In other embodiments, the structure containing the metal cladding layer depicted in
In some embodiments, a cavity can be provided between the first die 25 and the metal cladding layer. The cavity is incorporated into the semiconductor packages to make sure there exists proper clearance (and therefore insulation) between the first die 25 and the interconnect structure formed from the metal cladding layer.
In these embodiments, the metal cladding layer 26a is made with an opening formed therein. When the metal cladding layer 26a is then attached to the vias 12, a cavity 28 is then created between the first die 25 and the metal cladding layer 26a. One example of the cavity 28 can be seen in plan view in
Once the first pre-molding layer 24 has been formed, the metal cladding layer 26 can then be etched. The metal cladding layer 26 can be etched using any known chemical etching process, such as photomask etching. The result of the etching process includes the formation of an interconnect structure containing routing leads 30 which run from the vias 12 to the backside of the first die 25. As shown in
Next, as shown in
The second semiconductor die 35 can be attached to the routing leads 30 using any known flipchip process. Accordingly, similar to the first semiconductor die, bond pads are formed on the desired locations of the IC die(s) and bumps are applied to the bonds pads. The die 35 is then flipped and attached so that the bond pads are attached to the desired locations of the routing leads 30 through the bumps.
As shown in
A second metal cladding layer can then be provided on the second pre-molding layer 34 and the upper surfaces via extensions 32. The second metal cladding layer can be made of the same or different than the material used for the first metal cladding layer 26. The second metal cladding layer can be provided in any manner known in the art, including the process used to make the first metal cladding layer 26. The second metal cladding layer can optionally contain a cavity similar to the cavity 28 in the first metal cladding layer. In some embodiments, similar to those described above, the second metal cladding layer can be disposed on the via extensions 32 before the second pre-molded layer 34 is formed.
The second metal cladding layer can then be etched. The second metal cladding layer 36 can be etched using any known chemical etching process, including one that is the same or different than the etching process for the first metal cladding layer 26. The result of the etching process includes the formation of a second interconnect structure containing routing leads 50 which run from the vias extensions 32 to the backside of the second die 35. As shown in
Next, as shown in
The third semiconductor die 45 can be attached to the routing leads 50 using any known flipchip process. Accordingly, similar to the first semiconductor die, bond pads are formed on the desired locations of the IC die(s) and bumps are applied to the bonds pads. The third die 45 is then flipped and attached so that the bond pads are attached to the desired locations of the routing leads 50 through the bumps.
An encapsulation process is then performed on the resulting structure. The encapsulation process uses any molding material known in the art. In some embodiments, the molding material can comprise an epoxy molding compound, a thermoset resin, a thermoplastic material, or potting material. In other embodiments, the molding material comprises an epoxy molding compound. In
The leadframe 10 is then etched to form the array of land pads 90 (or lands). The etching results in the formation of lands having an array that is configured for the external electronic device to which the semiconductor package will be attached (such as a printed circuit board). The land pads (or lands) can have any configuration known in the art consistent with their operation as terminals for the semiconductor package. Thus, in the illustrated embodiments, the lands are given a substantially rectangular configuration with a size ranging from about 0.30 mm2 to about 0.50 mm2. In other embodiments, though, the lands can have a round or other geometrical shape.
Any etching process known in the art can be used to form the land pad array, including photomask etching and mechanical mask etching. One example of one land pad array is depicted in
The resulting structure can be singulated into individual semiconductor packages 100. The singulation can be carried out using any process known in the art, including a saw singulation process. The semiconductor package 100, as shown in
The completed semiconductor package 100 is shown in the side views depicted in
Other embodiments of the semiconductor packages and methods for making such packages are shown in
The methods for making the semiconductor packages begin by providing a leadframe 110 which is substantially similar to leadframe 10. The leadframe 110 is configured to contain a die attach pad 118 bigger than DAP 18. This allows the leadframe 110 to have multiples dies placed on its surface. In the embodiments depicted in
Next, vias 112 can be provided on the upper surface of the lead frame 110 if the leadframe is not made with vias 112 already present. The vias 112 can be substantially similar to vias 12, with the exception of the number and layout of the vias 112.
Next, as shown in
As shown in
The metal cladding layer can then be etched to form an interconnect structure containing routing leads 130 which run from the vias 112 to the backside of the first die 125 and/or the second die 135. As shown in
Next, as shown in
Depending on the system electrical design and target package size, more than a single die can be incorporated on the routing leads 130. As well, depending on the system electrical design and target package size, additional routing leads could be formed over the third die and an additional die could be provided over these additional routing leads.
An encapsulation process is then performed on the resulting structure. The encapsulation process uses any molding material known in the art, including those described herein. In
The leadframe 110 is then etched to form the array of land pads 190 (or lands) that is configured for the external electronic device to which the semiconductor package will be attached (i.e., PCB). Any etching process known in the art can be used to form the land pad array, including those used to form land pads 90. The land pads (or lands) 190 can have any configuration known in the art consistent with their operation as terminals for the semiconductor package, including those described herein. One example of one land pad array is depicted in
The resulting structure can be singulated into individual semiconductor packages 200. The singulation can be carried out using any process known in the art, including a saw singulation process. The semiconductor package 200, as shown in
The completed semiconductor package 200 is shown in
The semiconductor packages described herein have several features. These packages contain multiple semiconductor dies that can be manufactured more efficiently that eliminates multiple singulation process when using stackable micro-leadframe packages (MLP) because the chips are stacked completely prior to any singulation. The packages are also relatively thin with a thickness ranging from about 0.50 mm to about 1 mm while also have the capability of a full land pad array. The metal layering provided by the leadframe and metal cladding layers provide a high degree of routing flexibility and provide an optimal bonding layout. The packages have a higher input/output (I/O) capability with a smaller package footprint when compared to conventional semiconductor packages.
In addition to any previously indicated modification, numerous other variations and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of this description, and appended claims are intended to cover such modifications and arrangements. Thus, while the information has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred aspects, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, form, function, manner of operation and use may be made without departing from the principles and concepts set forth herein. Also, as used herein, examples are meant to be illustrative only and should not be construed to be limiting in any manner.
This patent application claims priority of U.S. application Ser. No. 12/199,065, filed Aug. 27, 2008, the entire disclosure of which is hereby incorporated by reference.