INTEGRATED CIRCUIT PACKAGE HAVING PIN UP INTERCONNECT

Abstract

An integrated circuit package and manufacturing method thereof are described. The integrated circuit package includes pin up conductive plating to form an interconnect, where an opening on a patterned fifth layer photo-resist material located at bottom portion of a base developed for etching selectively the base to form at least an internal opening and at least a positioning opening, wherein the internal opening corresponds with an inside area of a first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

Claims

1. A method of fabricating an integrated circuit packaging, comprising the steps of: establishing a base; developing a plurality of electrical circuits using a first patterned conductive layer on the base, wherein an electrical circuit are formed by using a masking material; developing a stud conductive layer, where the stud conductive layer is disposed on at least one side of the first patterned conductive layer by developing a second layer photo-resist material on the masking material; removing the masking material and second layer photo-resist material; developing an encapsulating material from epoxy or polyimide compound on the base and exposed area of the stud conductive layer; grinding the surface area of the encapsulating material to level the surface of the stud conductive layer and the encapsulating material to form a flattened surface area; developing third photo-resist materials on the flat surface area of the surface of the stud conductive layer and the encapsulating material; developing a second electrically conductive layer on the leveled stud conductive layer by removing at least one part of the layers of third photo-resist materials; developing an isolation layer on the flat surface area of the surface of the stud conductive layer and the encapsulating material; grinding the surface area of the isolation layer to level the surface primer ink layer and the second electrically conductive layer; developing an conductive seed layer on grinded surface of the isolation layer and the second electrically conductive layer; developing a fourth photo-resist materials on the conductive seed layer; developing a third electrically conductive layer by removing at least one part of the layers of fourth photo-resist materials; etching the conductive seed layer or third electrically conductive layer or any combination thereof by using etching process; developing a masking layer on the third electrically conductive layer disposed on the conductive seed layer. developing a solder mask or epoxy compound or polyimide compound layer by removing at least one part of the masking layer; developing a fifth layer photo-resist material disposed on the surface of the solder masked surface and bottom portion of the base; and developing an opening on the patterned fifth layer photo-resist material located at bottom portion of the base for etching selectively the base to form at least an internal opening and at least a positioning opening, wherein the internal opening corresponds with an inside area of the first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

2. The method of fabricating an integrated circuit packaging according to claim 1, further comprising the steps of: developing an interconnect on at least one side of the patterned conductive layer.

3. The method of fabricating an integrated circuit packaging according to claim 1, wherein the first patterned conductive layer and the second patterned conductive layer are disposed within the first patterned conductive layer, in which the other side of the first patterned conductive layer are located at the same plane with the second side of the second patterned conductive.

4. The method of fabricating an integrated circuit packaging according to claim 3, wherein the thickness of the first patterned conductive layer reduced by trimming at least one surface of the first patterned conductive layer.

5. The method of fabricating an integrated circuit packaging according to claim 1, wherein the surface of the first patterned conductive layer is trimmed by using chemical process or mechanical grinding process or laser trimming process or plasma treatment or any combination thereof.

6. The method of fabricating an integrated circuit packaging according to claim 1, wherein the masking material is a mask set or photolithography material or masked pattern or any combination thereof.

7. The method of fabricating an integrated circuit packaging according to claim 1, wherein the base is completely removed.

8. The method of fabricating an integrated circuit packaging according to claim 1, wherein the base is selectively removed to form at least an internal opening and at least a positioning opening of the first patterned conductive layer area, wherein the internal opening corresponds with an inside area of the first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

9. The method of fabricating an integrated circuit packaging according to claim 1, wherein positioning opening is formed using a positioning mark or half-etched indentation or patterns on the base.

10. The method of fabricating an integrated circuit packaging according to claim 1, wherein the base is a charge carrier.

11. The method of fabricating an integrated circuit packaging according to claim 1, wherein the step of removing the base, further comprising the steps of: etching the base by using the fifth layer photo-resist material; and removing the fifth layer photo-resist material.

12. The method of fabricating an integrated circuit packaging according to claim 1, wherein the step of etching the base further comprising the steps of: etching part of the first patterned conductive layer so that the surface of the etched first patterned conductive layer and the surface of the etched first patterned conductive layer are not located at the same plane.

13. The method of fabricating an integrated circuit packaging according to claim 1, wherein the masking material has at least a first opening and at least a second opening, the first opening is corresponding with the inside area of the first patterned conductive layer, and the second opening is corresponding with the outside area of the first patterned conductive layer.

14. An integrated circuit packaging, comprising: a plurality of electrical circuits developed using a first patterned conductive layer on the base, wherein an electrical circuit formed by using a masking material; a stud conductive layer disposed on at least one side of the first patterned conductive layer developed by a second layer photo-resist material on the masking material; an epoxy or polyimide compound developed on the base and exposed area of the stud conductive layer as an encapsulating layer of material; a third photo-resist materials developed on the surface area of the surface of the stud conductive layer encapsulating material; a second electrically conductive layer developed on the stud conductive layer by removing at least one part of the layers of third photo-resist materials; an isolation layer developed on the flat surface area of the surface of the stud conductive layer and the encapsulation material; a conductive seed layer developed on grinded surface of the isolation layer and the second electrically conductive layer; a fourth photo-resist materials developed on the conductive seed layer; a third electrically conductive layer developed by removing at least one part of the layers of fourth photo-resist materials; a masking layer developed on the third electrically conductive layer disposed on the conductive seed layer; a solder mask or epoxy compound or polyimide compound layer developed by removing at least one part of the masking layer; a fifth layer photo-resist material developed on the surface of the solder masked surface and bottom portion of the base; and an opening on the patterned fifth layer photo-resist material located at bottom portion of the base developed for etching selectively the base to form at least an internal opening and at least a positioning opening, wherein the internal opening corresponds with an inside area of the first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

15. The integrated circuit packaging according to claim 14, wherein the third electrically conductive layer is an etched layer of the conductive seed layer or third electrically conductive layer or any combination thereof by using etching process.

16. The integrated circuit packaging according to claim 14, further include an interconnect on at least one side of the patterned conductive layer.

17. The integrated circuit packaging according to claim 14, wherein the first patterned conductive layer has at least one trimmed surface.

18. The integrated circuit packaging according to claim 17, wherein the trimmed surface of the first patterned conductive layer is trimmed by using chemical process, mechanical grinding process, laser trimming process, plasma etching or any combination thereof.

19. The integrated circuit packaging according to claim 14, wherein the masking material is a mask set, photolithography material, masked pattern or any combination thereof.

20. The integrated circuit packaging according to claim 14, wherein the base is selectively removed base, to form at least an internal opening and at least a positioning opening of the first patterned conductive layer exposed area.

21. The integrated circuit packaging according to claim 14, wherein the base is selectively removed base, to form at least an internal opening and at least a positioning opening of the first patterned conductive layer exposed area, wherein the internal opening corresponds with an inside area of the first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

22. The integrated circuit packaging according to claim 14, wherein the first patterned conductive layer and the second patterned conductive layer are disposed within the first patterned conductive layer, in which the other side of the first patterned conductive layer are located at the same plane with the second side of the second patterned conductive.

23. The integrated circuit packaging according to claim 14, wherein the first patterned conductive layer are exposed to form at least an internal opening and at least a positioning opening by a selectively removing the base.

24. The integrated circuit packaging according to claim 14, wherein the base is a selectively removed base that forms at least an internal opening and at least a positioning opening, wherein the internal opening corresponds with an inside area of the first patterned conductive layer, and the positioning opening corresponds with an outside area of the first patterned conductive layer.

25. The integrated circuit package according to claim 14, wherein the positioning opening has a positioning mark, half-etched indentation, full-etched indentation patterns or any combination thereof on any one of the dielectric layer.

26. The integrated circuit packaging according to claims 14, wherein the base is a charge carrier.

27. The integrated circuit packaging according to claim 14, wherein the base etched using the masking material as a mask.

28. The integrated circuit packaging according to claim 14, wherein the first patterned conductive layer is encapsulated.

29. The integrated circuit packaging according to claim 16, wherein the interconnect is a metal finishing or organic finishing or any combination thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] FIG. 1 illustrates an integrated circuit package according to at least one embodiment of the invention.

[0069] FIG. 2 illustrates layers of photo-resist materials are developed on a base, in which the layers are then developed or formed as patterned layers of photo-resist materials.

[0070] FIG. 3 illustrates development of an electrically conductive layer within the removed or etched part of the layers of photo-resist materials.

[0071] FIG. 4 illustrates the layers of photo-resist materials being removed, leaving the electrically conductive layer, wherein a first conductive layer can be used as electrical circuits or electrical routing.

[0072] FIG. 5 illustrates a second layer photo-resist material disposed on a surface of a first electrically conductive layer.

[0073] FIG. 6 illustrates a cavity developed on a patterned second layer photo-resist material.

[0074] FIG. 7 illustrates a stud conductive layer developed or disposed in the cavity.

[0075] FIG. 8 illustrates remaining first photo-resist materials and second layer photo-resist material being removed or stripped, leaving the stud conductive layer disposed above the electrically conductive layer along the base.

[0076] FIG. 9 illustrates an epoxy or polymide process being developed or disposed on the base and exposed area of the stud conductive layer.

[0077] FIG. 10 illustrates, on the surface of the disposed epoxy molding compound, there is performed a grinding or polishing or trimming process known as surface grinding by either mechanical wheel grinding or chemical etching process.

[0078] FIG. 11 illustrates layers of third photo-resist materials being developed on the flat surface area of the surface of the stud conductive layer and the epoxy molding compound.

[0079] FIG. 12 illustrates development of a second electrically conductive layer within the removed or etched part of the layers of third photo-resist materials.

[0080] FIG. 13 illustrates the exposed third photo-resist materials being removed, leaving the second electrically conductive layer disposed on the flat surface area of the surface of the stud conductive layer and the encapsulation material being preferably epoxy molding compounds, epoxy laminates or polyimide laminates.

[0081] FIG. 14 illustrates a laminating layer developed or disposed on the base and exposed area of the stud conductive layer.

[0082] FIG. 15 illustrates the surface of the laminated area going through a grinding or polishing or trimming process known as surface grinding by either mechanical wheel grinding, chemical etching, laser trimming or plasma etching or any combination thereof.

[0083] FIG. 16 illustrates a plating conductive seed layer disposed on the laminated area and the second electrically conductive layer.

[0084] FIG. 17 illustrates layers of fourth photo-resist materials developed on the conductive seed layer.

[0085] FIG. 18 illustrates development of a third electrically conductive layer within the removed or etched part of the layers of fourth photo-resist materials.

[0086] FIG. 19 illustrates the exposed fourth photo-resist materials will be removed, leaving the third electrically conductive layer disposed on the conductive seed layer.

[0087] FIG. 20 illustrates selectively etching away a layer of the conductive seed layer by using semi-additive processing (SAP) or etching line.

[0088] FIG. 21 illustrates exposing the solder masked surface with a UV exposure machine or other similar process, in which this process will be able to remove the unexposed zone by developer processes.

[0089] FIG. 22 illustrates a fifth layer photo-resist material disposed on the surface of the solder masked surface and bottom portion of the base.

[0090] FIG. 23 illustrates an opening developed on the patterned fifth layer photo-resist material located at bottom portion of the base, wherein it is developed by using an Ultra Violet (UV) exposure process or similar developer processes, in which the unexposed zone will be removed by using developer processes.

[0091] FIG. 24 illustrates a part of the base being removed, such that the area of the first patterned conductive layer is exposed to form at least an internal opening and at least a positioning opening.

[0092] FIG. 25 illustrates a part of the first patterned conductive layer being removed, such that the area of the first patterned conductive layer is exposed to form at least an internal opening and at least a positioning opening.

DETAILED DESCRIPTION OF THE INVENTION

[0093] To further clarify various aspects of some embodiments of the present invention, a more particular description of the invention will be rendered by references to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the accompanying drawings in which:

[0094] FIGS. 1-25 are detailed process flowcharts of manufacturing and connecting for an integrated circuit package according to a first embodiment of the invention.

[0095] FIG. 1 illustrates an integrated circuit package according to at least one embodiment of the invention. Firstly, a carrier or base (101) is established or developed, wherein the base (101) is a steel material or copper or conductive material such as charge carrier. Preferably, the carbon steel or steel having thickness in the range of 0.005-0.500 mm, wherein the plated conductive layer having thickness in the range of 3-120 μm.

[0096] FIG. 2 illustrates layers of photo-resist materials (102) are developed on the base (101), in which the layers are then developed or formed as patterned layers of photo-resist materials (102). Alternatively, the layers of photo-resist materials (102) are also formed on both surfaces of the carrier or base (101), bottom part and top part. The purpose of photo-resist materials (102) on the top portion is to create a masking for circuit patterning. However, the photo-resist materials (102) on the bottom portion are to avoid unnecessary buildup of plating material to avoid wastage of the plating material. This photo-resist materials (102) has to on the bottom portion of the carrier or base (101) until demasking process. This process is also known as dry film laminating process by using dry film laminator process, in which the dry film preferably has a thickness in the range of 5-100 μm.

[0097] FIG. 3 illustrates development of an electrically conductive layer (103) within the removed or etched part of the layers of photo-resist materials (102). The electrically conductive layer (103) is developed by using electroplating method. Thereafter, the layers of photo-resist materials (102) will be removed, leaving the electrically conductive layer (103) wherein the first conductive layer can be used as electrical circuits or electrical routing as illustrated in FIG. 4. The layers of photo-resist materials (102) on the bottom part of the carrier or base (101) will still remain. Preferably, the layers of photo-resist materials are removed by Ultra Violet (UV) exposure process, in which the unexposed zone will be removed by developer process. Preferably, the development process of the electrically conductive layer (103) is also known as the process of tracing conductive plating by using copper plating line, in which the conductive trace has a thickness in the range of 5˜100 μm.

[0098] Then, the electrically conductive layer (103) is developed into a plurality of electrical circuits, which are electrically isolated and used as a package trace layout unit or electrical circuits unit, wherein the electrical circuits unit will be electrically connected to each other. This formation has the same pattern to the integrated circuit that are ready for packaging.

[0099] FIG. 5 illustrates a second layer photo-resist material (112) disposed on the surface of the first electrically conductive layer (103′), and a cavity (104′) is developed on the patterned second layer photo-resist material (112) as shown in FIG. 6. Preferably, the second layer photo-resist material (112) or second dry film laminate with dry film laminator has a thickness in the range of 5˜150 μm.

[0100] Then, stud conductive layer (105) is developed or disposed in the cavity (104′) as shown in FIG. 7, wherein the stud conductive layer (105) is developed by way of electroplating. Preferably, the stud conductive layer (105) is an “I” shaped stud conductive layer developed by a plating line.

[0101] Then, the remaining first photo-resist materials (102) and second layer photo-resist material (112) will be removed or stripped, leaving the stud conductive layer (105) disposed above the electrically conductive layer (103) along the base (101) as illustrated in FIG. 8. Preferably, this process is known as the dry film stripping process.

[0102] Then, an epoxy or polymide process is developed or disposed on the base (101) and exposed area of the stud conductive layer (105) as illustrated in FIG. 9. This process is known as an encap process by using an epoxy molding or polyimide compound.

[0103] Preferably, by molding or laminate and curing with b-stage adhesive laminate film or laminate and curing with prepreg resin or laminate and curing with resin. Thereafter, on the surface of the disposed epoxy molding compound, there is performed a grinding or polishing or trimming process known as surface grinding by either mechanical wheel grinding or chemical etching process as illustrated in FIG. 10. Preferably, the etching process has a thickness in the control range of 5˜200 μm. The surface grinding will flatten the surface of the stud conductive layer (105) and the disposed epoxy molding compound or polyimide laminate to form a flattened surface area, in which the stud conductive layer (105) has a curved angle on the top portion and will be flattened by grinding or polishing the curved angle portion.

[0104] Further, the process includes layers of third photo-resist materials (122) are developed on the flat surface area of the surface of the stud conductive layer (105) and the epoxy molding compound as illustrated in FIG. 11. This process is also known as pin up dry film laminate with a dry film laminator, in which the dry film preferably has a thickness in the range of 5˜75 μm. FIG. 12 illustrates development of a second electrically conductive layer (113) within the removed or etched part of the layers of third photo-resist materials (122). Preferably, the third photo-resist materials exposed by Ultra Violet (UV) exposure process, in which the unexposed zone will be removed by using developer process. The second electrically conductive layer (113) developed by using electroless or electroplating method. Preferably, the development process of the electrically conductive layer (113) is also known as the process of tracing conductive plating by using copper plating line, in which the conductive trace has a thickness in the range of 5˜75 μm. Thereafter, the exposed third photo-resist materials (122) will be removed, leaving the second electrically conductive layer (113) disposed on the flat surface area of the surface of the stud conductive layer (105) and the encapsulation material being preferably epoxy molding compounds, epoxy laminates or polyimide laminates as illustrated in FIG. 13.

[0105] Then, a laminating layer is developed or disposed on the base (101) and the exposed area of the stud conductive layer (105) as illustrated in FIG. 14. This process is known as an isolation layer by using screen printing or coating, in which the isolation layer has a thickness in the control range of 5˜50 μm. This isolation layer can also be alternatively executed by using an encap process by using an epoxy molding compound. Preferably, by molding or laminate and curing with b-stage adhesive laminate film or laminate and curing with prepreg resin or laminate and curing with resin.

[0106] Thereafter, the surface of the laminated area will go through a grinding or polishing or trimming process known as surface grinding by either mechanical wheel grinding, chemical etching, laser trimming or plasma etching or any combination thereof as illustrated in FIG. 15, preferably having thickness in the control range of 5˜70 μm. The surface grinding will flatten the surface of the laminated area and the second electrically conductive layer (113) as illustrated in FIG. 16. Preferably, the etching process will have a thickness in the control range of 5˜70 μm.

[0107] FIG. 16 illustrates a plating conductive seed layer (114) disposed on the laminated area and the second electrically conductive layer (113). Preferably, the conductive seed layer (114) is developed by using electroless plating line, in which the conductive seed layer (114) has a thickness in the range of 0.1˜5 μm.

[0108] Further, the process includes layers of fourth photo-resist materials (132) are developed on the conductive seed layer (114) as illustrated in FIG. 17. This process is also known as photo resist masking, in which the masking material can be dry film or liquid resist preferably having a thickness in the range of 5˜100 μm.

[0109] FIG. 18 illustrates development of a third electrically conductive layer (123) within the removed or etched part of the layers of fourth photo-resist materials (132). Preferably, the fourth photo-resist materials are exposed by Ultra Violet (UV) exposure process, in which the unexposed zone will be removed by using a developer process. The third electrically conductive layer (123) developed by using an electroplating method. Preferably, the development process of the third electrically conductive layer (123) is also known as process of tracing conductive plating by using plating line, in which the conductive trace has a thickness in the range of 5˜70 μm. Thereafter, the exposed fourth photo-resist materials (132) will be removed, leaving the third electrically conductive layer (123) disposed on the conductive seed layer (112) as illustrated in FIG. 19.

[0110] Then, selectively etch away a layer of the conductive seed layer (112) by using semi-additive processing (SAP) or etching line as illustrated in FIG. 20. Thereafter, an isolation layer with a thickness in the range of 5˜50 μm is printed, laminated or coated onto the surface by a screen printing machine or coater or a lamination process on the third electrically conductive layer (123) disposed on the conductive seed layer (112). Preferably, this process is referred to as a solder masking process. The process is further continued by exposing the solder masked surface with UV exposure machine or other similar process, in which this process will be able to remove the unexposed zone by developer processes as illustrated in FIG. 21.

[0111] FIG. 22 illustrates a fifth layer photo-resist material disposed on the surface of the solder masked surface and bottom portion of the base (101). Preferably, the process is known as a window etching dry film laminate process with dry film laminator, wherein the dry film having thickness in the range of 5˜00 μm. Then, an opening is developed on the patterned fifth layer photo-resist material located at bottom portion of the base (101), wherein it is developed by using Ultra Violet (UV) exposure process or similar developer processes, in which the unexposed zone will be removed by using developer processes as shown in FIG. 23.

[0112] Thereafter, the base (101) can be removed fully or selectively, to form at least an internal opening and at least a positioning opening, wherein the internal opening corresponds with an inside area of the first patterned conductive layer (103), and the positioning opening corresponds with an outside area of the first patterned conductive layer (103). The base (101) also can be removed, as well as at least one part of the first patterned conductive layer (103), such that the area of the first patterned conductive layer (103) is exposed to form at least an internal opening (107) and at least a positioning opening (107), as illustrated in FIGS. 24, 25, respectively.

[0113] The present invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore indicated by the appended claims rather than by the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are to be embraced within their scope.