Strain-Tolerant Die Attach with Improved Thermal Conductivity, and Method of Fabrication
20170323844 · 2017-11-09
Assignee
Inventors
Cpc classification
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L2924/00012
ELECTRICITY
H01L2224/291
ELECTRICITY
H01L2224/29294
ELECTRICITY
H01L2224/293
ELECTRICITY
H01L2224/29291
ELECTRICITY
H01L2224/29291
ELECTRICITY
H01L2224/29191
ELECTRICITY
H01L23/42
ELECTRICITY
H01L24/04
ELECTRICITY
H01L2224/2919
ELECTRICITY
H01L2224/29386
ELECTRICITY
H01L2224/2929
ELECTRICITY
H01L2224/2919
ELECTRICITY
H01L2224/83191
ELECTRICITY
H05K2201/0373
ELECTRICITY
H01L2224/27436
ELECTRICITY
H01L2224/04026
ELECTRICITY
H01L2224/29386
ELECTRICITY
H01L2224/2929
ELECTRICITY
H01L2224/83101
ELECTRICITY
H01L2224/27436
ELECTRICITY
H01L2224/83101
ELECTRICITY
H01L2224/29294
ELECTRICITY
H01L23/36
ELECTRICITY
H01L2224/29191
ELECTRICITY
H01L2224/293
ELECTRICITY
H01L2924/00014
ELECTRICITY
H05K2201/0367
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/83192
ELECTRICITY
H01L2924/00012
ELECTRICITY
H05K3/3463
ELECTRICITY
H01L2224/291
ELECTRICITY
H01L23/4951
ELECTRICITY
H05K1/0209
ELECTRICITY
International classification
H01L23/36
ELECTRICITY
Abstract
A mechanically-stable and thermally-conductive interface device between a semiconductor die and a package for the die, and related method of fabrication, comprising: a semiconductor die; a package for the die; a surface area-enhancing pattern on the package and/or the die; and die attach materials between the die and the package, the die attach materials attaching the die to the package through an interface provided by the die attach materials; wherein: an effective bonding area between the die attach materials and the package and/or the die is greater with the pattern than without the pattern; and the increase of the effective bonding area simultaneously increases the surface area for thermal transport between the package and/or the die, and the die attach materials; and increases the surface area for stably attaching the at least one of the package and the die to the die attach materials.
Claims
1. A mechanically-stable and thermally-conductive interface device between a semiconductor die and a package for said die, comprising: a semiconductor die; a package for said die; a surface area-enhancing pattern on at least one of said package and said die; and die attach materials between said die and said package, said die attach materials attaching said die to said package through an interface provided by said die attach materials; wherein: an effective bonding area between said die attach materials and said at least one of said package and said die is greater with said pattern than without said pattern; and said increase of said effective bonding area simultaneously increases the surface area for thermal transport between said at least one of said package and said die, and said die attach materials; and increases the surface area for stably attaching said at least one of said package and said die to said die attach materials.
2. The device of claim 1, wherein a ratio of said effective bonding area with said surface area-enhancing pattern over said effective bonding area without said surface area-enhancing pattern is given by:
3. The device of claim 2, wherein said surface area-enhancing pattern is configured such that said EBA≧1.5.
4. The device of claim 1, said surface area-enhancing pattern comprising a large plurality of microscopic pillars.
5. The device of claim 1, said die attach materials comprising conductive particles; wherein: external angles over surfaces of micro-components of said surface area-enhancing pattern are configured to be greater than or equal to an average radius of said conductive particles in said die attach materials.
6. The device of claim 1, said surface area-enhancing pattern comprising higher densities in center device regions which become the hotter during device operation, and lesser densities in outer device regions which become less hot during device operation.
7. The device of claim 1, said package comprising said surface area-enhancing pattern.
8. The device of claim 1, said die comprising said surface area-enhancing pattern.
9. The device of claim 1, said package and said die each comprising said surface area-enhancing pattern.
10. The device of claim 1, wherein said surface area-enhancing pattern has a height of at least 40% of a bond line thickness between a bottom of said die and a top of said package.
11. A method for fabricating mechanically-stable and thermally-conductive interface device between a semiconductor die and a package for said die, comprising: providing a semiconductor die; providing a package for said die; fabricating a surface area-enhancing pattern on at least one of said package and said die; attaching said die to said package through an interface by introducing die attach materials between said die and said package; thereby: providing a greater effective bonding area between said die attach materials and said at least one of said package and said die with said pattern than without said pattern; and simultaneously increasing the surface area for thermal transport between said at least one of said package and said die, and said die attach materials; and increasing the surface area for stably attaching said at least one of said package and said die to said die attach materials.
12. The method of claim 11, wherein a ratio of said effective bonding area with said surface area-enhancing pattern over said effective bonding area without said surface area-enhancing pattern is given by:
13. The method of claim 12, further comprising configuring said surface area-enhancing pattern such that said EBA≧1.5.
14. The method of claim 11, further comprising fabricating said surface area-enhancing pattern to comprise a large plurality of microscopic pillars.
15. The method of claim 11, further comprising: fabricating external angles over surfaces of micro-components of said surface area-enhancing pattern to be greater than or equal to an average radius of conductive particles in die attach materials contained within said die attach materials; and bonding said die with said package using said die attach materials comprising said conductive particles.
16. The method of claim 11, further comprising fabricating said surface area-enhancing pattern to comprise higher densities in center device regions which become the hotter during device operation, and lesser densities in outer device regions which become less hot during device operation.
17. The method of claim 16, said die attach materials comprising a solder including a flux material to facilitate wetting; and bonding said die with said package using said die attach materials including said flux material; wherein: wetting naturally proceeds from said center to said outer regions of said device, thereby promoting escape of said flux and any developing voids through said outer regions.
18. The method of claim 11, further comprising fabricating said package to comprise said surface area-enhancing pattern.
19. The method of claim 11, further comprising fabricating said die to comprise said surface area-enhancing pattern.
20. The method of claim 11, further comprising fabricating said package and said die to each comprise said surface area-enhancing pattern.
21. The method of claim 11, further comprising fabricating said surface area-enhancing pattern to comprise a height of at least 40% of a bond line thickness between a bottom of said die and a top of said package.
22. A mechanically-stable and thermally-conductive interface device between a printed circuit board, and either a die package or a heat sink, comprising: a printed circuit board; either a die package or heat sink; a surface area-enhancing pattern on at least one of said printed circuit board, and said die package or heat sink; and attach materials between said printed circuit board and said die package or heat sink, said attach materials attaching said printed circuit board to said die package or heat sink through an interface provided by said attach materials; wherein: an effective bonding area between said attach materials and said least one of said printed circuit board and said die package or heat sink, is greater with said pattern than without said pattern; and said increase of said effective bonding area simultaneously increases the surface area for thermal transport between said least one of said printed circuit board and said die package or heat sink, and said attach materials; and increases the surface area for stably attaching said least one of said printed circuit board and said die package or heat sink, to said attach materials.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The features of the invention believed to be novel are set forth in the appended claims. The invention, however, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawing(s) summarized below.
[0022]
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[0024]
[0025]
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[0027]
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[0029]
[0030]
DETAILED DESCRIPTION
[0031] To improve both mechanical stability and thermal performance, this invention employs a specialized structuring of the package 3 and/or die 1 surfaces specifically to increase the contact surface area to the D/A material 2. A side cross-sectional view of an exemplary preferred embodiment of this invention is shown in
[0032] The structure shown in
[0033] Throughout this disclosure and the claims, references to the package 3 and attachments to the package 3 refer to that portion of a package or housing where the die 1 is attached to a metal base primarily for improved thermal performance of the die 1. This portion of the package is often referred to in the art as a die pad, thermal slug, die attach paddle, die attach pad or lead frame (the metal part of a package around which a plastic material is typically molded to form a cavity for the die). In some cases, the final package is referred to as a housing, which terminology is used primarily for air cavity packages where the die is surrounded primarily by a vacuum or some gas mixture inside a housing that provides physical and optical protection for the die. So, this invention applies, but is not limited to, that part of a semiconductor device package 3 or housing where the die 1 is attached to the package 3 for the purpose of improved thermal performance of the die 1.
[0034] Note also that this invention can also be applied to the attachment surfaces of a printed circuit board and the external surfaces of the package, or between the attachment surfaces of the circuit board and the heat sink such as may be illustrated by
[0035] It is helpful at this point to introduce the concept of surface area enhancement in more detail, because this is a key part of the invention. In the absence of micro-pillar patterning of the die 1 or package 3 surfaces, the surface area that provides adhesion of the die 1 to the package 3 and through which heat can flow is approximately equal to the area of the die 1 itself, or:
A.sub.bond=A.sub.die. (1)
Consider now the structure in
A.sub.bond=A.sub.die+A.sub.pattern (2)
where A.sub.pattern is the surface area represented by the side walls of the pattern 5 pillars, or given by
A.sub.pattern=2πrhn (3)
where r is the radius of the pattern 5 pillars, h is the height of each pillar, and n is the number of pillars directly under the die 1. Thus the Effective Bonding Area (EBA) ratio for the example shown in
Note that in the simplified illustration of
[0036] In addition to pattern 5 pillars, which here are envisioned to simply be round, unshaped pillars, other structures could be employed to form the surface area-enhancing pattern 5, as shown for illustration, not limitation, in the top-down views of
[0037] Ordinarily, the die attach material 2 between the die 1 and the package 3 is a composite comprised of an adhesive, flux or other viscous material and particles of high thermal conductivity material (Ag particles, Cu particles, solder particles, BN (boron nitride), etc.). In order to maximize the contact between the die attach material 2 and the surfaces of the patterned substrate 5, it is preferred that any features introduced that increase the surface area of the patterned features 5 contain only external angles with a radius of curvature at the vertex which is sufficiently-obtuse as to be equal to or greater than the radius of the average conductive particle in the die attach composite D/A material 2. If the external angles are acute or in any other way create surface features too small for the particles of the composite D/A 2 to enter, then the potential is raised for voiding and reduced interfacial contact and poorer thermal performance. It will be seen that the top view cross-sections in each of
[0038] We turn now to
[0039] Another embodiment, shown in
[0040] In general, the selection of various advantageous pillar shapes and patterns can be modeled using various finite element analysis tools that compute both thermal and strain fields in complex multicomponent systems such as are envisioned here, in which pillar shapes, pillar heights, total D/A material 2 thickness, and customized patterns (e.g. spacings between pillars) can be optimized and employed in various combinations without limitation, for the particular bonding requirements of a given application.
[0041] It is instructive to consider the non-periodic layout of the pillar structure shown in
[0042] For example, one case where this provides and advantage is the fabrication of the assembly using a solder as the D/A material 2. Ordinarily, a solder includes a flux material designed to promote the wetting of the solder when molten to the material it is intended to attach to. Ordinarily, the flux needs to escape during the bonding process, but sometimes cannot, and so leaves behind voids 4 where the flux could not escape during fabrication. For the pattern in
[0043] Now let us discuss materials, applications, and methods of fabrication. The use of patterned interfaces for improved bonding of semiconductor devices can be applied to a wide variety of electronic die, including silicon integrated circuits (e.g. microprocessors) and discrete electronic devices (power transistors or light emitting diodes). In addition, the invention can also be used to attach packaged semiconductor devices to other surfaces where both strength and thermal management are important, in particular surface mount packed devices on printed circuit boards (PCBs) or metal clad PCBs (MCPCBs), and in the attachment of PCBs or MCPCBs to heat sinks.
[0044] Other D/A materials 2 can be any adhesive (epoxies, silicones), including filled adhesives (e.g., Ag filled epoxy) provided the size of the thermally conductive filler is substantially smaller than the minimum separation between the surface area enhancing pattern 5 pillars. This also includes solder paste or solder preforms, nano-metal paste or nano-metal preforms (both Ag and Cu nano-metallic die attach materials are available now), or die attach with a hybrid composite such as solder in epoxy, solder in silicone, Ag filled epoxies, and silicones. In some cases, it may be desirable to use pressure bonding techniques to ensure that the die attach material used completely fills all of the spaces between the die 1, the pillars, and the base of the housing. Ordinarily, such pressures are in the range of 1 to 10 MPa, depending on the die attach material and the BLT. Performing the die attach under pressured as high as 10 MPa ensure void minimization.
[0045] The methods for forming the patterned surfaces can, in the case of the package 3 surface, include coining, electroplating or skiving (the use of a blade to form surface area enhancing pattern 5 fins or pillars akin to how a plow shapes furrows in soil). Ordinarily, the preferred pillar composition is copper, which may for purposes of improved adhesion to the D/A material 2 may be plated with another metal (ordinarily gold or nickel). Other materials employed in the art for electronic device fabrication can also be used, depending on the application. For pillars formed directly on the die 1 (which will momentarily be elaborated in
[0046] Ideally, the pillar surface area should be maximized per equation (4). But, the height of the pillar should be roughly on the order of conventional D/A material 2 thicknesses, that is, ˜25 μm or less. Furthermore, if the patterning only occurs on one of the surfaces (i.e., the die 1 or the package 3 but not both), the application of the D/A material 2 (solder, adhesive or nano-Ag) should be thick enough so that when assembly is completed (soldering, sintering, curing), the top of the pillar is not in contact with the die 1 if the pillars 5 are on the package 3, or with the package 3 if conversely the pillars 5 are on the die 1. This is all shown in
[0047] One preferred embodiment for fabrication method is to use nano-Ag materials that are available in a film form, wherein the film is laminated to the patterned surface prior to die attach. Lamination is preferred to force the formable nano-Ag film into the spaces between the pillars and to the bottom plane between the pillars. In this case, the pillar height and nano-Ag film thickness should be selected so that once the final sintering operation (to complete the D/A process) is finished, the pillar height is at least 40% or 50% to at most 80% or 90% of the total separation (bond line thickness) between the bottom of the die 1 and the base of the pillars where they meet the package 3, see
[0048] It is also possible to pattern both die 1 and package 3 surfaces with surface area enhancing pattern 5 pillars, as shown in
[0049] It should also be noted in
[0050] Ordinarily, all die 1 have a specially-designed metallization on the surface involved in the die attach process. This metallization is intended to protect the die 1 from any reactive components in the die attach material 2, to improve adhesion between the die 2 and the die attach material 2. In some cases, it also provides a nominally ohmic electrical contact to the die 1 itself. In the event that a die 1 is patterned with surface area enhancing pattern 5 e.g. pillars at its attach surface to reduce thermal interface impedance in the manner illustrated by
[0051] The mechanical strength and reliability of this approach to D/A is due to both the increased surface area (EBA>1) that provides greater area for adhesion of the D/A material 2 to both the package 3 and the die 1, and the difficulty of crack propagation in the D/A material 2 between the die 1 and the package 3 because of the presence of the surface area enhancing pattern 5 such as but not limited to the pillars.
[0052] Finally, it will be seen through even a rough geometric examination of
[0053] The knowledge possessed by someone of ordinary skill in the art at the time of this disclosure, including but not limited to the prior art disclosed with this application, is understood to be part and parcel of this disclosure and is implicitly incorporated by reference herein, even if in the interest of economy express statements about the specific knowledge understood to be possessed by someone of ordinary skill are omitted from this disclosure. While reference may be made in this disclosure to the invention comprising a combination of a plurality of elements, it is also understood that this invention is regarded to comprise combinations which omit or exclude one or more of such elements, even if this omission or exclusion of an element or elements is not expressly stated herein, unless it is expressly stated herein that an element is essential to applicant's combination and cannot be omitted. It is further understood that the related prior art may include elements from which this invention may be distinguished by negative claim limitations, even without any express statement of such negative limitations herein. It is to be understood, between the positive statements of applicant's invention expressly stated herein, and the prior art and knowledge of the prior art by those of ordinary skill which is incorporated herein even if not expressly reproduced here for reasons of economy, that any and all such negative claim limitations supported by the prior art are also considered to be within the scope of this disclosure and its associated claims, even absent any express statement herein about any particular negative claim limitations.
[0054] Finally, while only certain preferred features of the invention have been illustrated and described, many modifications, changes and substitutions will 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 true spirit of the invention.