This description relates to packaging of semiconductor optical sensors.
Digital image sensors (e.g., a complementary metal-oxide-semiconductor image sensor (CIS) or a charge-coupled device (CCD)) are typically packaged as single die in an integrated circuit (IC) package (i.e., a ceramic ball grid array package (CBGA) or a plastic ball grid array (PBGA) package. However, newer applications (e.g., automotive applications such as advanced driver assistance systems (ADAS) and autonomous driving (AD) systems) need other circuitry (e.g., image signal processor (ISP) or ASIC die) to be included in the same IC package as the CIS die for improved imaging performance.
In a general aspect, a package includes an optical sensor die fabricated in a semiconductor wafer. The optical sensor die has an optically active area on a front side of the semiconductor wafer generating a raw image signal. A transparent cover is attached to the front side of the semiconductor wafer above the optically active area of the optical sensor die. An image signal processor (ISP) die processing the raw image signal is embedded in a layer of molding material attached to a back side the semiconductor wafer opposite the front side of the semiconductor wafer.
In a general aspect, a method includes attaching a semiconductor wafer to a sheet of transparent material. The semiconductor wafer includes a plurality of optical sensor dies. The method further includes attaching a plurality of individual image signal processor (ISP) dies to back surfaces of the plurality of the optical sensor dies in the semiconductor wafer, embedding the plurality of the individual ISP dies attached to the back surfaces of the plurality of the optical sensor dies in a wafer-level molding layer, and singulating a wafer-level assembly of the sheet of the transparent material attached to the semiconductor wafer and the wafer-level molding layer to produce at least one individual stacked optical sensor package.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
An optical sensor (e.g., a RGB visible light image sensor of a camera, an image sensor) is configured for converting a radiation intensity and color spectrum into electrical signals. In some implementations, optical sensors (including, e.g., digital image sensors) can be devices for detecting light intensity. In some implementations, an optical sensor can produce an electrical output. The raw image (RAW) data generated by the optical sensor may, for example, be in the form of zeroes and ones for each pixel of the optical sensor array. An image signal processor (ISP) is a dedicated processor that converts the RAW data generated by the optical sensor into a workable image output through various signal conditioning processes. These various signal conditioning processes may, for example, include one or more of noise reduction, lens shading correction, gamma correction, auto exposure, or auto white balance, etc.
This disclosure describes multi-die optical sensor packages and methods for fabricating the multi-die optical sensor packages. An example multi-die optical sensor package may, for example, be a stacked wafer-level chip scale package (CSP). In a stacked optical sensor CSP, a digital image sensor die (e.g., a complementary metal— oxide—semiconductor image sensor (CIS) die, or a charge-coupled device (CCD) die) is arranged in a stack with an image signal processor (ISP) die. The stacked optical sensor CSP includes a transparent window, cover, or lid over the stack of the optical sensor die and the ISP die. In example implementations, the stacked optical sensor CSP is fabricated as a wafer-level chip scale package (WL-CSP), for example, with the top and bottom outer layers of the packaging and solder bumps attached to the package while the optical sensor dies are still in the wafer, and then dicing the wafer.
As shown in
Layer A may include ISP die 10 embedded in a layer of molding material 12. ISP die 10 may have a width W1 (in the x direction) and a height H1 (in the z direction). A first redistribution layer (e.g., RDL 16-1) may be disposed on a first surface (e.g., surface S1) of layer A, and a second redistribution layer ISP (e.g., RDL 16-2) may be disposed on a second surface (e.g., surface S2) of layer A. The first surface (e.g., surface S1) of layer A may be the outer surface (bottom surface) of stacked optical sensor package 100. The second surface (e.g., surface S2) of layer A may be an inner surface of stacked optical sensor package 100 next to layer B. The redistribution layers (e.g., RDL 16-1, RDL 16-2) may be made of metal or metal alloy and may include circuit traces and contact pads (not shown) for electrical connection to the dies in stacked optical sensor package 100. Further, in example implementations, solder bumps 40 may be attached to surface S1 (i.e., to the redistribution layer (e.g., RDL 16-1)) for external electrical connections (e.g., via a printed circuit board (PCB) (not shown)) to stacked optical sensor package 100.
In example implementations, a through mold via (TMV) (e.g., TMV 18) extending across layer A between surface S1 and surface S2 may provide a passage for connections between the two redistribution layers to the redistribution layer (e.g., RDL 16-1 and RDL 16-2).
In example implementations, ISP die 10 may be attached to surface S2 (i.e., to the redistribution layer (e.g., RDL 16-2)) (and to optical sensor die 20, layer B) with a die bonding adhesive (e.g., die bonding adhesive 14). The die bonding adhesive may, for example, be a thermosetting polymer such as epoxies, acrylics, bismaleimides and polyimides.
In stacked optical sensor package 100, optical sensor die 20 in layer B is disposed above (e.g., in the z direction) ISP die 10. Optical sensor die 20 (having a width W2 and a height H2) may be a portion of a semiconductor wafer (e.g., silicon wafer 50). A passivation layer (e.g., layer 22) (e.g., an oxide or a nitride layer) may be grown or deposited on a bottom surface (e.g., surface S3) of silicon wafer 50. Optical sensor die 20 may include an active region 20A disposed on a top surface (e.g., surface S4) of the die. Active area 20A may, for example, include active pixels, color filters and/or micro lens assemblies, etc., for imaging with optical sensor die 20. Active area 20A may have a height AH above the top surface (e.g., surface S4) of the die.
In example implementations of stacked optical sensor package 100, optical sensor die 20 in layer B is disposed over ISP die 10 on the redistribution layer (e.g., RDL 16-2) of layer A with the passivation layer (e.g., layer 22) on surface S3 coupled to the redistribution layer (e.g., RDL 16-2) on surface S2.
In example implementations of stacked optical sensor package 100, optical sensor die 20 in layer B may be isolated from other portions of semiconductor wafer 50 by through-semiconductor vias (e.g., TSV 24) extending between surface S4 and surface S2 through height H2 of the die. In example implementations, TSV 24 may be lined with a passivation layer (e.g., layer 22).
Further, in example implementations, a sheet of transparent material (e.g., cover glass 30) is disposed (in layer C) over optical sensor die 20. The sheet of transparent material may be made of any transparent material (e.g., glass, plastics, etc.). The sheet of transparent material may be transparent to light (e.g., visible light) directed to active region 20A of optical sensor die 20 for imaging.
In example implementations, a dam material (e.g., an epoxy or resin, etc.) may be used to bond the sheet of transparent material (e.g., cover glass 30) to optical sensor die 20. The dam material may, for example, be disposed as a dam layer 32 around a periphery (P) of active region 20A (i.e., outside of edges E of the active region) disposed on the top surface (e.g., surface S4) of the die. In example implementations, dam layer 32 may have a thickness GH (in the z direction) which is greater than the thickness AH of active area 20A above the top surface (0078 of the die. This thickness (i.e., thickness GH>thickness AH) of dam layer 32 may create an air gap (e.g., air gap 34) between glass cover 30 and optical sensor die 20.
In some example implementations, the dam material may be used to fill all of the space between glass cover 30 and optical sensor die 20 resulting in a gapless (i.e., without an air gap) optical sensor package.
In some example implementations, a black coating may be applied to side surfaces of stacked optical sensor package 100 to prevent or reduce the amount of light reaching the semiconductor material in the package other than the intended active region (i.e., active region 20A of optical sensor die 20) for imaging. In some example implementations, a black paint or coating may be applied to the vertical sides of stacked optical sensor package 100. In some example implementations, a black paint or coating may be applied to an edge strip on a top surface of the glass cover in addition to the black paint or coating applied to the vertical sides of stacked optical sensor package 100.
Method 200 involves wafer-level chip scale packaging with the top and bottom outer layers of the packaging and solder bumps attached to the package while the optical sensor dies are still in the wafer, and then dicing (singulating) the wafer. In example implementations, a glass cover sheet is used a starting substrate to support a stack of a semiconductor wafer including optical sensor die and a wafer-level molding layer including embedded individual ISP die. The wafer-level molding layer can include fan out of electrical routing from the ISP die.
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In method 200, attaching the semiconductor wafer including the optical sensor die to the sheet of transparent material 210 includes attaching the semiconductor wafer to a glass cover, and thinning a back side of the semiconductor wafer attached to the glass cover.
Attaching the semiconductor wafer including the optical sensor die to the sheet of transparent material 210 may further include forming through-semiconductor vias (TSVs) at edges of the optical sensor dies from the back side of the thinned semiconductor wafer, passivating a back surface of the die including the TSVs, and forming a first signal redistribution layer (RDL) on a back surface of the semiconductor wafer including the optical sensor die.
In method 200, embedding the individual ISP die attached to the back surfaces of the optical sensor die in a wafer-level molding layer 230 may include forming through-mold vias (TMVs) through the wafer-level molding layer and forming a second redistribution layer (RDL) on a back surface of the wafer-level molding layer including the individual embedded ISP die.
Method 200 may further include coating the sides (vertical sides) of the individual stacked optical sensor packages with black material, and/or coating an edge strip of the cover glass of the individual stacked optical sensor packages with black material.
The semiconductor wafer may have a thickness T (
In some example implementations, as previously mentioned, the dam material may be used to fill all the space between glass cover 30 and optical sensor die 20 resulting in a gapless (i.e., without an air gap) stacked optical sensor package (e.g., stacked optical sensor package 100B,
In example implementations, a process for bonding semiconductor wafer and cover glass 30 to each other may include a heat treatment phase (e.g., 120° C. for min) after application of dam material layer 32 to the periphery P, followed by a curing phase (e.g., 150° C. for 4 hrs.).
In example implementations, TSV 24 may have a diameter in a range from several μm to several tens of μm (e.g., 50 μm) and a depth corresponding to the thickness t (e.g., 100 μm) of the thinned semiconductor wafer. TSV 24 may be formed by plasma etching or laser drilling, followed by formation of the passivation layers (passivation layer 22) and metallization (e.g., RDL 16-2). The metallization in RDL 16-2 may include conductive traces and contact pads made of metals such as titanium (Ti), copper (Cu), aluminum (Al), or nickel (Ni), or alloys thereof.
In example implementations, the conductive bumps (e.g., solder bumps 40) may be composed of solder or lead-free solder. In some example implementations, the conductive bumps may be composed of copper (e.g., copper balls or pillars, or copper pillars capped with solder).
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While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes, and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the scope of the implementations. It should be understood that they have been presented by way of example only, not limitation, and various changes in form and details may be made. Any portion of the apparatus and/or methods described herein may be combined in any combination, except mutually exclusive combinations. The implementations described herein can include various combinations and/or sub-combinations of the functions, components and/or features of the different implementations described.
It will be understood that, in the foregoing description, when an element is referred to as being on, connected to, electrically connected to, coupled to, or electrically coupled to another element, it may be directly on, connected or coupled to the other element, or one or more intervening elements may be present. In contrast, when an element is referred to as being directly on, directly connected to or directly coupled to another element, there are no intervening elements present. Although the terms directly on, directly connected to, or directly coupled to may not be used throughout the detailed description, elements that are shown as being directly on, directly connected or directly coupled can be referred to as such. The claims of the application, if any, may be amended to recite exemplary relationships described in the specification or shown in the figures.
As used in this specification, a singular form may, unless definitely indicating a particular case in terms of the context, include a plural form. Spatially relative terms (e.g., over, above, upper, under, beneath, below, lower, and so forth) are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. In some implementations, the relative terms above and below can, respectively, include vertically above and vertically below. In some implementations, the term adjacent can include laterally adjacent to or horizontally adjacent to.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure. As used in the specification, and in the appended claims, the singular forms “a,” “an,” “the” include plural referents unless the context clearly dictates otherwise. The term “comprising,” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. The terms “optional” or “optionally” used herein mean that the subsequently described feature, event or circumstance may or may not occur, and that the description includes instances where said feature, event or circumstance occurs and instances where it does not. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, an aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
Some implementations may be implemented using various semiconductor processing and/or packaging techniques. Some implementations may be implemented using various types of semiconductor processing techniques associated with semiconductor substrates including, but not limited to, for example, Silicon (Si), Gallium Arsenide (GaAs), Gallium Nitride (GaN), Silicon Carbide (SiC) and/or so forth.