Semiconductor integrated device for acoustic applications with contamination protection element, and manufacturing method thereof
09769554 · 2017-09-19
Assignee
Inventors
- Roberto Brioschi (Sesto San Giovanni, IT)
- Silvia ADORNO (Novate Milanese, IT)
- Kenneth Fonk (San Gwann, MT)
Cpc classification
B81C2203/0785
PERFORMING OPERATIONS; TRANSPORTING
B81B2207/012
PERFORMING OPERATIONS; TRANSPORTING
B81C1/00309
PERFORMING OPERATIONS; TRANSPORTING
B81B2201/0257
PERFORMING OPERATIONS; TRANSPORTING
H04R31/00
ELECTRICITY
B81B2203/0127
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/48137
ELECTRICITY
B81B7/0061
PERFORMING OPERATIONS; TRANSPORTING
International classification
B81B7/00
PERFORMING OPERATIONS; TRANSPORTING
H04R31/00
ELECTRICITY
B81C1/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A semiconductor integrated device, comprising: a package defining an internal space and having an acoustic-access opening in acoustic communication with an environment external to the package; a MEMS acoustic transducer, housed in the internal space and provided with an acoustic chamber facing the acoustic-access opening; and a filtering module, which is designed to inhibit passage of contaminating particles having dimensions larger than a filtering dimension and is set between the MEMS acoustic transducer and the acoustic-access opening. The filtering module defines at least one direct acoustic path between the acoustic-access opening and the acoustic chamber.
Claims
1. A semiconductor package, comprising: a package body having a base element and a covering element jointly defining an internal space of the package body and outer surfaces of the semiconductor package, said base element having an acoustic-access opening in acoustic communication with an environment external to the package body; a MEMS acoustic transducer housed in the internal space of said package body and including an acoustic chamber facing the acoustic-access opening; and a filtering module coupled to the package body and covering the acoustic-access opening, the filtering module being configured to inhibit passage of contaminating particles having dimensions larger than a filtering dimension, the filtering module being located between the MEMS acoustic transducer and the acoustic-access opening, said filtering module forming at least one direct acoustic path between the acoustic-access opening and the acoustic chamber.
2. The semiconductor package according to claim 1, wherein said filtering dimension is between 10 μm and 35 μm.
3. The semiconductor package according to claim 1, wherein said filtering module includes a filtering fabric having a plurality of threads interwoven according to a pattern that defines through openings of maximum dimension equal to said filtering dimension.
4. The semiconductor package according to claim 1, wherein the base element includes a first substrate having said acoustic-access opening that extends through an entire thickness of the first substrate, and a second substrate having a hole that extends through an entire thickness of the second substrate, said filtering fabric being integrated in the base element between the first and second substrates, wherein the first substrate, the second substrate, and the filtering fabric are coupled together in such a way that the acoustic-access opening and the hole are in direct acoustic connection with one another by the through openings of the filtering fabric.
5. The semiconductor package according to claim 3, wherein the filtering module includes a first supporting plate and a second supporting plate provided with respective first and second windows, said filtering fabric being located between the first and second supporting plates in such a way that the first and second windows expose the same through openings of the filtering fabric, and wherein the filtering module is housed in the internal space of the package so that the through openings directly face the acoustic chamber and the acoustic-access opening, thereby defining a direct acoustic path for an acoustic wave that propagates from the acoustic-access opening to the acoustic chamber through the second window, the first window, and the through openings.
6. The semiconductor package according to claim 1, wherein said filtering module is a membrane of semiconductor material having a plurality of through openings, said filtering module being completely housed in the internal space of the package so that the through openings directly face the acoustic chamber and the acoustic-access opening, thereby defining a direct acoustic path for an acoustic wave that propagates from the acoustic-access opening to the acoustic chamber through said through openings.
7. The semiconductor package according to claim 6, wherein said through openings have a serpentine profile.
8. The semiconductor package according to claim 1, wherein: the MEMS acoustic transducer includes a structural layer having a front surface and a membrane at the front surface of the structural layer that flexes in response to sound waves, the structural layer having a rear portion, said acoustic chamber extending through said rear portion to said membrane; and the rear portion of said structural layer is coupled to said filtering module and, the filtering module is coupled to an inner wall of said base element surrounding said acoustic-access opening.
9. The semiconductor package according to claim 1, wherein said package further includes, in the internal space, a second die integrating a first ASIC electronic circuit functionally coupled to the MEMS acoustic transducer to receive and process a signal generated by the MEMS acoustic transducer as a function of an acoustic-pressure wave received by the MEMS acoustic transducer through said direct acoustic path.
10. The semiconductor package according to claim 1, wherein said filtering module, along said direct acoustic path, is hydrophobic.
11. An electronic device, comprising: a microprocessor; and a semiconductor package coupled to the microprocessor, the semiconductor package including: a package body defining an outer surface of the semiconductor package and an internal space, the package body having an acoustic-access opening in acoustic communication with an environment external to the package body; a MEMS acoustic transducer housed in the internal space of the package body and having an acoustic chamber facing the acoustic-access opening of the package body; and a filtering module coupled to the package body and located between the MEMS acoustic transducer and at least a portion of the acoustic-access opening, the filtering module configured to inhibit passage of contaminating particles having dimensions larger than a filtering dimension, the filtering module forming an acoustic path between the acoustic-access opening and the acoustic chamber.
12. The electronic device according to claim 11, wherein the electronic device is at least one of a cellphone, a PDA, a notebook, a voice recorder, an audio-file reader with voice-recorder function, a console for videogames, a hydrophone, and a wearable device.
13. The electronic device according to claim 11, wherein the filtering module includes a filtering fabric having a plurality of threads interwoven according to a pattern that defines through openings of maximum dimension equal to said filtering dimension.
14. The electronic device according to claim 11, wherein said filtering module is a membrane of semiconductor material having a plurality of through openings.
15. A method for assembling a semiconductor package, the method comprising: housing a MEMS acoustic transducer that includes an acoustic chamber in an internal space of a package body in such a way that the acoustic chamber faces an acoustic-access opening of the package body; and arranging a filtering module configured to inhibit passage of contaminating particles having dimensions larger than a filtering dimension between the MEMS acoustic transducer and at least a portion of the acoustic-access opening to form a direct acoustic path between the acoustic-access opening and the acoustic chamber through the filtering module, wherein the arranging comprises housing, between the MEMS acoustic transducer and the acoustic-access opening, a filtering fabric having a plurality of threads interwoven according to a pattern that defines through openings of a maximum dimension equal to said filtering dimension.
16. The method according to claim 15, wherein the base element comprises a first substrate having said acoustic-access opening that extends throughout the thickness of the first substrate, and a second substrate having a hole that extends throughout the thickness of the second substrate, wherein the step of arranging the filtering module comprising the steps of: integrating said filtering fabric between the first and second substrates; and coupling together the first substrate, the second substrate, and the filtering fabric in such a way that the acoustic-access opening and the hole are in direct acoustic connection with one another through the through openings of the filtering fabric.
17. The method according to claim 15, further comprising the step of manufacturing said filtering module, including the sub-steps of: forming a first window in a first supporting plate; forming a second window in a second supporting plate; and setting the filtering fabric between the first supporting plate and the second supporting plate in such a way that the first window and the second window expose the same through openings of the filtering fabric, thereby defining the acoustic path for an acoustic wave to propagate from the second window to the first window through said through openings.
18. A method for assembling a semiconductor package, the method comprising: housing a MEMS acoustic transducer that includes an acoustic chamber in an internal space of a package body in such a way that the acoustic chamber faces an acoustic-access opening of the package body; forming a filter module by processing a semiconductor wafer to form a membrane of semiconductor material having a plurality of through openings, wherein said through openings have a serpentine profile; and coupling the filtering module to package body and covering the acoustic-access opening, the filter module being configured to inhibit passage of contaminating particles having dimensions larger than a filtering dimension between the MEMS acoustic transducer and at least a portion of the acoustic-access opening to form a direct acoustic path between the acoustic-access opening and the acoustic chamber through the filtering module.
19. The method according to claim 18, wherein coupling the filter module to package body comprises coupling the filter module to an internal surface of the package body.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) For a better understanding of the present disclosure, preferred embodiments thereof are now described, purely by way of non-limiting example and with reference to the attached drawings, wherein:
(2)
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DETAILED DESCRIPTION
(11)
(12) In greater detail, the acoustic-transducer device 51 of
(13) The extension (in the horizontal plane xy) of the acoustic chamber 6 is greater than the extension thereof (once again in the horizontal plane xy) of the sound port 28, in such a way that the sound port 28 will communicate entirely with the acoustic chamber 6 without giving directly out into the internal space 8 of the package 50.
(14) According to one aspect of the present disclosure, the acoustic chamber 6 of the first die 21 is in acoustic communication with the sound port 28 exclusively through a filtering module 52, which is set between the sound port 28 and the acoustic chamber 6 of the first die 21.
(15) The first die 21, which houses the MEMS structure 1, is set on a top side 52a of the filtering module 52, in particular in such a way that the acoustic chamber 6 directly faces the filtering module 52. Thus, the filtering module 52 creates an obstacle for passage of dust and/or contaminating particles, coming from the environment external to the package 50, towards the acoustic chamber 6. The filtering module 52 has a plurality of through openings such that the flow of air and sound waves is not interrupted or sensibly degraded by the presence of the filtering module 52 itself. Acoustic communication of the acoustic chamber 6 towards the outside of the package 50 is thus provided.
(16) The base substrate 23 is, for example, a multilayer structure, made up of one or more layers of conductive material (generally metal) separated by one or more dielectric layers (for example, bismaldehide-triazine (BT) laminate). Electrical paths 49 are provided through the base substrate 23 for connecting an inner surface 23a thereof, facing the internal space 8, to an outer surface 23b thereof, facing the external environment, that carries the electrical-connection elements 29. The latter are provided, in particular, in the form of lands (in the case of packages of the so-called LGA—Land-Grid Array—type, as is the case illustrated in
(17) According to a different embodiment, the base substrate 23 does not comprise metal layers or conductive material in general and, for example, is of plastic material.
(18) The covering element 27 may also be formed of multilayers, for example including one or more plastic and/or metal layers, and may advantageously present a metal coating (not illustrated) on an own inner surface 27a, facing the internal space 8, for providing an electromagnetic display. Alternatively, the covering element 27 is of metal.
(19) The covering element 27 is further coupled to the base substrate 23 for sealing the internal space 8 hermetically.
(20)
(21) With joint reference to
(22) With reference to
(23) Optionally, the through opening 66 is surrounded by a ring 68, in relief, having the function of preventing entry into the through opening 66 of any possible glue used for fixing the first die 21 and the filtering module 52 together. The ring 68 may be replaced by a trench, or else by a region, substantially coplanar to the top face 52a, of hydrophobic material, that is to react with water-based glues in order to prevent penetration of said glues into the through opening 66. In this case, when the filtering module 52 is set underneath the first die 21 as in
(24) With reference to
(25)
(26) The filter 62 is of a material chosen according to the desire, for example obtained using threads 74 of PET (Polyethylene terephthalate), or thermoplastic organic polymers such as for example poly-ether-ether-ketone (PEEK), or some other material. A fabric suitable for the purpose is commercially available and marketed under the trade name “Acoustex”, manufactured by Saati S.p.A.
(27) The first and second plates 61, 63 are of semiconductor material, such as silicon, or else of metal material, such as stainless steel. However, any other material compatible with MEMS microprocessing and suitable to be processed to form the first and second plates 61, 63 may be used, according to the desire, for example a plastic material.
(28) With reference to the steps for manufacturing the filtering module 52, these are illustrated by way of example with reference to
(29) With reference to
(30) With reference to
(31) As an alternative to what has been described, it is further possible to stretch the fabric, and glue it to the second plate 63 prior to cutting of the fabric itself. In this case, cutting of the fabric is carried afterwards, in any one of the subsequent manufacturing steps.
(32) With reference to
(33) A layer of glue 76 is dispensed over the surface 61b of the first plate 61. Said surface 61b is opposite to the surface of the first plate 6, which, at the end of manufacturing, forms the top face 52a of the filtering module 52. The layer of glue is, for example, a non-conductive epoxy glue, or silicone, and is formed by dispensing the glue over a peripheral region of the surface 61b of the first plate 61, in such a way that the glue does not penetrate into the through opening 66. Alternatively, it is further possible to use a biadhesive tape, appropriately shaped. In this case, the ring 68 is not necessary in so far as there is no risk of penetration of the glue into the through opening 66.
(34) The step of dispensing of glue over the surface 61b of the first plate 61 may further be omitted in the case where the amount of glue dispensed over the second plate 63 is such that said glue, as a result of pressure between the filter 62 and the second plate 63, flows into the through openings 72 of the filter, and reaches the opposite surface, i.e., the surface of the filter that is set in direct contact with the first plate 61. Also in this case, the ring 68 may be omitted.
(35) The filtering module 52 of
(36) It is evident that, in a per se known manner, the steps of
(37) Integration of the filtering module 52 in the package 50 is obtained by using the known MEMS microprocessing techniques.
(38) In greater detail, after the base substrate 23 has been processed (in particular after the sound port 28 is formed), the filtering module 52 is coupled to the surface 23a of the substrate 23 by glue dispensed on the rear face 52b, for example a non-conductive epoxy glue, or silicone, or else by a biadhesive tape, appropriately shaped so as not to occlude the through openings of the filter. An adequate amount of glue is further dispensed on the top face 52a, alongside the through opening 66 and the ring 68 (if present), and physical coupling of the first die 21 to the filtering module 52 is carried out. As an alternative to the glue, it is possible to use a biadhesive tape appropriately shaped so as not to occlude the through openings of the filter.
(39) The structure of
(40)
(41) The acoustic-transducer device 81 is similar to the acoustic-transducer device 51 of
(42) The acoustic-transducer device 81 differs from the acoustic-transducer device 51 in that it has a filtering module 82 of a different type. In particular, the filtering module 82 is formed starting from a wafer of semiconductor material, for example silicon, appropriately processed to form, through said wafer, a plurality of through openings of dimensions such as to prevent passage of the contaminating particles that are to be blocked. In other words, the filtering module 82 is in the form of a membrane having a plurality of holes. The thickness of the filtering module 82 is comprised in the interval 80-120 μm, for example 100 μm.
(43) Since the filtering module 82, according to this embodiment, is of semiconductor material, it is not necessary to set it between two plates as described with reference to the filter 62 of
(44)
(45) Two consecutive sub-openings 84′ fluidically coupled together form substantially an L, and a plurality of consecutive sub-openings 84′ fluidically coupled together form the aforesaid serpentine geometrical shape.
(46) More in particular, the main extension d.sub.MAX of each sub-opening 84′ (length), measured along the respective reference axis x or y, has a value comprised between 30 μm and 90 μm, for example equal to 45 μm. The secondary extension d.sub.MIN of each sub-opening (width) has a value, measured along the respective reference axis y or x orthogonal to the respective axis x or y of main extension, in the interval comprised between 5 μm and 30 μm, more in particular between 10 μm and 20 μm, for example 15 μm.
(47) The filtering module 82 comprises a plurality of serpentine through openings, separated from one another, along x and y, by respective first and second intermediate interruption regions 86, 88. The first intermediate interruption regions 86 have a main extension parallel to the axis y, and the second intermediate interruption regions 88 have a main extension parallel to the axis x.
(48) The first and the second intermediate interruption regions 86, 88 are full regions, i.e., they do not have through openings, and have the function of improving the strength of the filtering module 82, in order to reduce the probability of undesired failure thereof. Also the serpentine shape described is deemed, by the present applicant, suited to guaranteeing a good filtering power together with a good resistance to failure.
(49) It is however evident that other embodiments may be provided for the filtering module 82, for example having, as an alternative to the serpentine through openings, rounded or quadrangular holes set to form an array, or set according to any other pattern. More in general, the through openings of the filtering module 82 may have a generic geometrical shape chosen freely according to the desire. In order to guarantee a good filtering, it is in any case advisable for said through openings, whatever their geometrical shape, to present a maximum dimension equal to the values indicated for d.sub.MAX.
(50) In order to guarantee good filtering and at the same time good strength of the filtering module 82, the ratio between the area occupied by the trench regions and the area occupied by the full regions of the portion of the filtering module 82 effectively used for the filtering purposes (i.e., of the portion of the filtering module 82 directly facing the acoustic chamber 6 of the first die 21) is chosen in the interval 1-2 (where “1” means that 50% of the area of the filtering module 82 is occupied by the filtering openings 84 and the remaining 50% of the area is occupied by the first and second intermediate interruption regions 86, 88, and “2” means that the filtering openings 84 occupy twice the area occupied by the first and second intermediate interruption regions 86, 88). The present applicant has noted that said ratio affords a good compromise between strength of the filtering module 82 and access to the acoustic chamber 6 by sound waves coming from the environment external to the package.
(51) Mechanical coupling of the filtering module 82 to the base substrate 23 is obtained, according to one embodiment, by dispensing a layer of glue (not shown) over peripheral regions of the filtering module 82, in particular on both of the faces 82a, 82b of the filtering module 82 in surface regions of the faces 82a, 82b that, in use, are set in contact with the structural layer 5 of the first die 21 and, respectively, with the base substrate 23. In a per se known manner, the glue is not dispensed in regions of the filtering module 82 that, in use, directly face the acoustic chamber 6 and the through opening 28.
(52) As an alternative to the glue, it is possible to use a biadhesive tape, appropriately shaped that does not block the through openings of the filter.
(53) By gluing, the filtering module 82 is coupled on the base substrate 23 so that the filtering module 82 extends to cover the sound port 28 with the face 82b; by gluing, the first die 21 is coupled on the filtering module 82 so that the acoustic chamber 6 gives completely out onto the face 82a of the filtering module 82 and is in acoustic communication with the sound port 28 through the filtering openings 84.
(54) It is evident that it is possible, as an alternative, to couple together the first die 21 and the filtering module 82 prior to the step of coupling of the filtering module 82 to the base substrate 23.
(55) Relative coupling between the through opening 28, the filtering module 82, and the first die 21 shown in
(56) According to a further embodiment, filtering module 82 comprises a surface layer of hydrophobic material, for example silicon carbide or Teflon. The hydrophobic layer is obtained, for example, with a sputtering technique, after the step of etching for formation of the filtering openings 84. Since the hydrophobic layer does not require a particularly large thickness (from some hundreds of nanometers up to a few micrometers), the sputtering step carried out after formation of the through openings does not block said through openings significantly.
(57) The hydrophobic layer thus formed has the function of inhibiting entry of water into the acoustic chamber 6 of the first die 21. For this purpose, it is sufficient for the hydrophobic layer to extend alongside the filtering module 82 facing the outside of the package 50. In this case, the hydrophobic layer forms the face 82b of the filtering module 82.
(58)
(59) According to one embodiment, the supporting element 94 is an LGA (land grid array) substrate (provided with the lands 29 for electrical connection towards the outside environment), and the support element 95 is a generic semiconductor substrate, having purposely provided metallization layers and vias (not shown in detail) for routing the electrical signals towards the outside of the package.
(60) Through openings 98a and 98b extend, mutually aligned along the z axis, through the supporting elements 94, 95 and are fluidically connected together through the filter 96. The through openings 98a and 98b form a sound port in a way similar to the through opening 28 described previously.
(61)
(62) The electronic device 100 comprises, in addition to at least one of the acoustic-transducer devices 51, 81, 91, a microprocessor (CPU) 101, a memory block 102 connected to the microprocessor 101, and an input/output interface 103, for example a keyboard and/or a display, which is also connected to the microprocessor 101.
(63) The at least one of the acoustic-transducer devices 51, 81, 91 communicates with the microprocessor 101, and in particular transmits the electrical signals processed by the ASIC 22′ of the die 22 associated to the MEMS detection structures of the die 21.
(64) The electronic device 100 is, for example, a mobile communication device, such as, for instance, a cellphone, a PDA (personal digital assistant), a notebook, but also a voice recorder, an audio-file reader with voice-recording capacity, a console for videogames, a wearable device, such as a watch, a hydrophone, etc.
(65) The advantages of the assembly proposed for an integrated acoustic device emerge clearly from the foregoing description.
(66) In particular, it is once again emphasized that the assembly described enables integration, within a same package, of a MEMS acoustic transducer and a filter designed to protect said MEMS acoustic transducer from contamination of particles of dimensions equal to some micrometers, or some tens, of micrometers coming from the environment external to the package.
(67) It is thus possible to reduce the occupation of space and provide a complete system, having a filtering function, within a single package.
(68) Finally, it is clear that modifications and variations may be made to what has been described and illustrated herein, without thereby departing from the scope of the present disclosure.
(69) In particular, as already highlighted, there may be envisaged a different configuration of the MEMS acoustic transducer, in particular with regards to the geometrical shape of the constitutive elements. In the case where the space internal to the package so allows, there may be housed inside the package itself also a number of MEMS sensors in addition to the MEMS acoustic transducer, each possibly provided with a sensitive element that is in communication with the external environment. Further integrated circuits (e.g., ASICs) may further be provided and housed inside the same package.
(70) The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.