Method of manufacturing semiconductor devices and corresponding semiconductor device having vias and pads formed by laser
11721614 · 2023-08-08
Assignee
Inventors
Cpc classification
H01L23/49579
ELECTRICITY
H01L25/0652
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L24/82
ELECTRICITY
H01L23/5389
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/92247
ELECTRICITY
H01L2224/92247
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L21/486
ELECTRICITY
H01L24/19
ELECTRICITY
H01L2225/06572
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2225/06524
ELECTRICITY
H01L2225/0651
ELECTRICITY
H01L24/73
ELECTRICITY
H01L21/4846
ELECTRICITY
H01L23/49827
ELECTRICITY
International classification
H01L21/768
ELECTRICITY
H01L23/498
ELECTRICITY
H01L23/522
ELECTRICITY
Abstract
A System in Package, SiP semiconductor device includes a substrate of laser direct structuring, LDS, material. First and second semiconductor die are arranged at a first and a second leadframe structure at opposite surfaces of the substrate of LDS material. Package LDS material is molded onto the second surface of the substrate of LDS material. The first semiconductor die and the package LDS material lie on opposite sides of the substrate of LDS material. A set of electrical contact formations are at a surface of the package molding material opposite the substrate of LDS material. The leadframe structures include laser beam processed LDS material. The substrate of LDS material and the package LDS material include laser beam processed LDS material forming at least one electrically-conductive via providing at least a portion of an electrically-conductive line between the first semiconductor die and an electrical contact formation at the surface of the package molding material opposite the substrate.
Claims
1. A method, comprising: arranging at least one first semiconductor die on a first die pad of a first leadframe structure formed at a first surface of a substrate of laser direct structuring (LDS) material and at least one second semiconductor die at a second die pad of a second leadframe structure formed at a second surface of the substrate of LDS material, the second surface of the substrate being opposite the first surface; molding package LDS material onto the second surface of the substrate of LDS material, the package LDS material encapsulating the at least one second semiconductor die arranged on the second leadframe structure; forming in the package LDS material a set of electrical contacts at a surface of the package LDS material opposite the substrate of LDS material; forming, by applying laser beam processing to the substrate of LDS material and the package LDS material, at least one first electrically-conductive via in the package LDS material, the at least one first electrically-conductive via being at least a portion of an electrically-conductive path between the at least one first semiconductor die and an electrical contact in the set of electrical contacts formed at the surface of the package LDS material opposite the substrate of LDS material; forming, by applying laser beam processing to the substrate of LDS material, the first leadframe structure at the first surface of the substrate of LDS material and the second leadframe structure at the second surface of the substrate of LDS material.
2. The method of claim 1, comprising forming, by applying laser beam processing to the package LDS material, the set of electrical contacts at the surface of the package LDS material opposite the substrate of LDS material.
3. The method of claim 1, wherein the first lead frame structure includes a first array of electrically-conductive leads and the second lead frame structure includes second array of electrically-conductive lead.
4. The method of claim 3, comprising forming, by applying laser beam processing to the substrate of LDS material, at least one second electrically-conductive via in the substrate of LDS material, wherein the at least one second electrically-conductive via in the substrate of LDS material electrically couples an electrically-conductive lead in the first array of electrically-conductive leads of the first leadframe structure with an electrically-conductive lead in the second array of electrically-conductive leads of the second leadframe structure.
5. The method of claim 3, comprising: forming, by applying laser beam processing to the package LDS material, at least one third electrically-conductive via in the package LDS material, wherein the at least one third electrically-conductive via in the package LDS material, electrically couples an electrically-conductive lead in the second array of electrically-conductive leads of the second leadframe structure with an electrical contact in the set of electrical contacts at the surface of the package LDS material opposite the substrate of LDS material.
6. The method of claim 3, wherein: the forming, by applying laser beam processing to the substrate of LDS material and the package LDS material, the at least one first electrically-conductive via includes forming the at least one first electrically-conductive via in the substrate of LDS material and in the package LDS material, the at least one first electrically-conductive via electrically coupling an electrically-conductive lead in the first array of electrically-conductive leads of the first leadframe structure with the electrical contact in the set of electrical contacts formed at the surface of the package LDS material opposite the substrate of LDS material.
7. The method of claim 3, comprising providing at least one of a first electrically-conductive wire bonding between a first semiconductor die of the at least one first semiconductor die and an electrically-conductive lead in the first array of electrically-conductive leads of the first leadframe structure or a second electrically-conductive wire bonding between a second semiconductor die of the at least one second semiconductor die and an electrically-conductive lead in the second array of electrically-conductive leads of the second leadframe structure.
8. The method of claim 1, comprising forming, by applying laser beam processing to the package LDS material, at least one fourth electrically-conductive via in the package LDS material, wherein the at least one fourth electrically-conductive via in the package LDS material electrically couples the at least one second semiconductor die on the second leadframe structure at the second surface of the substrate of LDS material with an electrical contact in the set of electrical contacts at the surface of the package LDS material opposite the substrate of LDS material.
9. The method of claim 1, comprising: molding further package LDS material onto the first surface of the substrate of LDS material, the first package LDS material encapsulating the at least one first semiconductor die arranged on the first leadframe structure; forming, by applying laser beam processing to the further package LDS material, to the substrate of LDS material and to the package LDS material, at least one electrically-conductive structure electrically coupling the at least one first semiconductor die arranged on the first leadframe structure with one of: an electrical contact in the set of electrical contacts at the surface of the package LDS material opposite the substrate of LDS material, or a passive component embedded in the package LDS material, the passive component electrically coupled with the at least one second semiconductor die arranged on the second leadframe structure.
10. The method of claim 1, wherein the forming the at least one first electrically-conductive via comprises metallizing at least a portion of the substrate of LDS material and the package LDS material to which the laser beam processing is applied.
11. A method, comprising: forming, by laser beam processing of a substrate of laser direct structuring (LDS) material, a first leadframe at a first surface of the substrate and a second leadframe at a second surface of the substrate of LDS material, the second surface being opposite the first surface; attaching a first semiconductor die to a first die pad of the first leadframe, the first leadframe including the first die pad and a first lead; attaching a second semiconductor die to a second die pad of the second leadframe, the second leadframe including the second die pad and a second lead; covering the second semiconductor die with package LDS material, the package LDS material contacting the second surface of the substrate of LDS material; and forming, by laser beam processing the package LDS material, a first electrically conductive pad at a surface of the package LDS material and a first electrically conductive via extending through and in the package LDS material from the first electrically conductive pad to the second lead of the second leadframe.
12. The method of claim 11, comprising: forming, by laser beam processing the substrate of LDS material and the package LDS material, a second electrically conductive pad at the surface of the package LDS material and a second electrically conductive via extending through the package LDS material and the substrate of LDS material from the second electrically conductive pad to the first lead of the first leadframe.
13. The method of claim 11, comprising: covering the first semiconductor die with a molding compound, the molding compound contacting the first surface of the substrate of LDS material.
14. The method of claim 13, wherein the molding compound is formed of a different material than the substrate of LDS material.
15. The method of claim 11, comprising: attaching the first semiconductor die to the first die pad with a first die attach film; and attaching the first semiconductor die to the second die pad with a second die attach film.
16. A method, comprising: forming, by laser beam processing of a substrate of laser direct structuring (LDS) material, a first leadframe at a first surface of the substrate and a second leadframe at a second surface of the substrate of LDS material, the second surface being opposite the first surface; attaching a first semiconductor die to a first die pad of the first leadframe, the first leadframe including the first die pad and a first lead; attaching a second semiconductor die to a second die pad of the second leadframe, the second leadframe including the second die pad and a second lead; forming a first wire bond electrically coupling the first semiconductor die to the first lead; forming a second wire bond electrically coupling the second semiconductor die to the second lead; covering the second semiconductor die with package LDS material, the package LDS material contacting the second surface of the substrate of LDS material; and forming, by laser beam processing the package LDS material, a first electrically conductive pad at a surface of the package LDS material and a first electrically conductive via extending through and in the package LDS material from the first electrically conductive pad to the second lead of the second leadframe.
17. The method of claim 16, comprising: forming, by laser beam processing the substrate of LDS material and the package LDS material, a second electrically conductive pad at the surface of the package LDS material and a second electrically conductive via extending through the package LDS material and the substrate of LDS material from the second electrically conductive pad to the first lead of the first leadframe.
18. The method of claim 16, comprising: covering the first semiconductor die with a molding compound, the molding compound contacting the first surface of the substrate of LDS material.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) One or more embodiments will now be described, by way of example only, with reference to the annexed figures, wherein:
(2)
(3)
(4) It will be appreciated that, for the sake of simplicity and ease of explanation, the various figures may not be drawn to a same scale, the same possibly applying to different parts of a same figure.
DETAILED DESCRIPTION
(5) In the ensuing description, various specific details are illustrated in order to provide an in-depth understanding of various examples of embodiments according to the description. The embodiments may be obtained without one or more of the specific details, or with other methods, components, materials, etc. In other cases, known structures, materials, or operations are not illustrated or described in detail so that various aspects of the embodiments will not be obscured.
(6) Reference to “an embodiment” or “one embodiment” in the framework of the present description is intended to indicate that a particular configuration, structure, or characteristic described in relation to the embodiment is comprised in at least one embodiment. Hence, phrases such as “in an embodiment,” “in one embodiment,” or the like, that may be present in various points of the present description do not necessarily refer exactly to one and the same embodiment. Furthermore, particular conformations, structures, or characteristics may be combined in any adequate way in one or more embodiments. The references used herein are provided merely for convenience and hence do not define the extent of protection or the scope of the embodiments.
(7)
(8) As exemplified herein, the device 10 may comprise (at least one) pair of semiconductor chips or dice 12′, 12″ arranged, via die attach material 14′, 14″, for instance, on respective die pads 16a′, 16a″ surrounded by an array of electrically-conductive leads 16b′, 16b″ in a leadframe.
(9) The designation “leadframe” (or “lead frame”) is currently used (see, for instance the USPC Consolidated Glossary of the United States Patent and Trademark Office) to indicate a metal frame which provides support for an integrated circuit chip or die as well as electrical leads to interconnect the integrated circuit in the die or chip to other electrical components or contacts.
(10) Essentially, a leadframe comprises an array of electrically-conductive formations (leads) which from an outline location extend inwardly in the direction of a semiconductor chip or die thus forming an array of electrically-conductive formations from a die pad configured to have at least one semiconductor chip or die attached thereon. This may be via conventional means such as a die attach adhesive (a die attach film or DAF, for instance).
(11) As exemplified in
(12) Two semiconductor chips or dice 12′, 12″ will be exemplified throughout this description for the sake of simplicity and ease of understanding. It will be otherwise appreciated that the concepts exemplified herein can be extended to virtually any number of chips or dice in a SiP arrangement.
(13) Laser Direct Structuring (LDS) is a laser-based machining technique now widely used in various sectors of the industrial and consumer electronics markets, for instance for high-performance antenna integration, where an antenna design can be directly formed onto a molded plastic part. In an exemplary process, the molded parts can be produced with commercially available resins which include additives suitable for the LDS process; a broad range of resins such as polymer resins like PC, PC/ABS, ABS, LCP are currently available for that purpose.
(14) In LDS, a laser beam can be used to transfer a desired electrically-conductive pattern onto a plastic molding which may then be subjected to metallization (for instance via electroless plating with copper or other metals) to finalize a desired conductive pattern.
(15) As exemplified in
(16) As exemplified in
(17) Documents such as US2019/115287 A1 or Italian patent applications 102019000014829 (corresponding to U.S. application Ser. No. 16/990,748 filed Aug. 11, 2020) and 102019000014832 (corresponding to U.S. application Ser. No. 16/994,049 filed Aug. 14, 2020) are exemplary of a possible application of LDS technology which involves laser drilling and structuring a molding compound to provide therein electrically-conductive formations. In fact, LDS technology makes it possible to replace wires, clips or ribbons with lines/vias created by laser beam processing of a LDS material possibly followed by metallization (growing metal thick copper through plating process, for instance) without using a wholly metallic leadframe.
(18) It is noted that such an approach can be applied to System in Package (SiP) processes in order to facilitate achieving flexibility in layout design of the leadframe and interconnections.
(19) One or more embodiments may facilitate creating (more) flexible SiP layouts by relaxing constraints on leadframe and interconnection design.
(20) In one more embodiments as exemplified herein, LDS technology applied to System in Package (SiP) processes may take advantage of the possibility of (electrically) coupling two or more dice such as 12′ and 12″ regardless of their dimensions and/or their possible arrangement on different planes, which facilitates reducing overall package size with passive components possibly embedded in a package if desired.
(21) A first example of this approach is provided in
(22) For instance, these vias 20 can be configured to: (electrically) couple leads 16b′ and 16b″ on opposite surfaces of the leadframe, these leads in turn coupled to the dice 12′ and 12″, respectively: see the left-hand side of
(23) In one or more embodiments, applying LDS technology to packaging semiconductor devices can thus facilitate creating interconnections from one or more dice to leadframe leads or substrate terminals through vias and lines.
(24) As exemplified in
(25) As exemplified in
(26) In one or more embodiments, the package molding compound 24 may comprise LDS material, to which LDS processing as known to those of skill in the art (including laser beam processing possibly followed by metallization) can be applied to form in the LDS compound one or more vias 26 extending through the LDS compound 24.
(27) For instance, these vias 26 can be configured to: cause die pads formed on the front surface (here, facing downward) of the die 12″ to become accessible at the surface of the package of the device 10 (here, at the lower surface of the compound 24), via pads or lands 26a: see
(28) In this latter case, as exemplified herein: accessibility of leads such as 16b″ formed at the lower surface of the leadframe (LDS material layer 16) at the surface of the package of the device 10 may be provided by vias 26 extending through the compound 24, accessibility of leads such as 16b′ formed at the upper surface of the leadframe (LDS material layer 16) at the surface of the package of the device 10 may be provided by vias 20 extending through the LDS material layer 16 and by vias 26 extending through the LDS compound 24.
(29)
(30)
(31) In
(32) It will be otherwise appreciated that one or more features as exemplified herein in connection with a semiconductor device 10 as exemplified in
(33) Briefly, in embodiments as exemplified in
(34) Conversely, in embodiments as exemplified in
(35) In one or more embodiments (as exemplified in both
(36) In embodiments as exemplified in
(37) After molding thereon (in a single step or multiple steps at 200, 241, and possibly 242) LDS compound material electrically-conductive formations such as lines (traces) and/or vias (collectively designated 260) can be provided (in the form of an even quite complex routing of electrically-conductive formations).
(38) In one or more embodiments, formations such as 260 can at least partly replace bonding formations such as 18′ (and 18″).
(39) Again, laser processing of the LDS material may involve LDS compound activation via a laser beam, plus possible metallization such as plating to increase electrical conductivity as conventional in the art.
(40) For instance, the lines/vias 260 can be configured to cause die pads formed on the front surface (here, facing upward) of the die 12′ to become accessible at the surface of the package of the device 10 (here, at the lower surface of the compound 241, 242).
(41) As exemplified in
(42)
(43)
(44)
(45) Those of skill in the art will otherwise appreciate that most of these acts may be applied to manufacturing a semiconductor device 10 as exemplified in
(46) Likewise, one or more features as exemplified in connection with a semiconductor device 10 as exemplified in
(47) Just by way of simple, non-limiting example, in one or more embodiments, one or both of the wire bonging patterns as exemplified at 18′ and 18″ in
(48) Those of skill in the art will likewise appreciate that, while manufacturing a single device 10 is exemplified here for simplicity, one or more embodiments may involve manufacturing simultaneously a plurality of devices 10 intended to be eventually separated via a “singulation” act as conventional in the art.
(49)
(50) A method as exemplified herein may comprise: providing a substrate (for instance, 16) of laser direct structuring material (briefly, LDS material), the substrate having a first surface and a second surface, the second surface opposed to the first surface, arranging (for instance, attaching as exemplified at 14′, 14″) at least one first semiconductor die (for instance, 12′) at a first leadframe structure (for instance, at a die pad like 16a′) at the first surface of the substrate of LDS material and at least one second semiconductor die (for instance, 12″) at a second leadframe structure (for instance, at a die pad like 16a″) at the second surface of the substrate of LDS material (16), molding package LDS material (for instance, 24 or 241, 242) onto the second surface of the substrate of LDS material having the at least one second semiconductor die arranged at said second leadframe structure, wherein the at least one first semiconductor die and the package LDS material lie on opposite sides of the substrate of LDS material (see, for instance,
(51) A method as exemplified herein may comprise applying laser beam processing to the package LDS material (for instance, 24; 241, 242) to form therein said set of electrical contact formations (for instance, 26a) at a surface of the package molding material opposite the substrate of LDS material.
(52) A method as exemplified herein may comprise applying laser beam processing to the substrate of LDS material to form therein a first leadframe structure and a second leadframe structure (see, for instance, 16a′, 16b′ and 16a″, 16b″ in
(53) A method as exemplified herein may comprise applying laser beam processing to the substrate of LDS material to form therein at least one electrically-conductive via through the substrate of LDS material (see, for instance, the leftmost via 20 in
(54) A method as exemplified herein may comprise applying laser beam processing to the package LDS material (for instance, 24) to form therein at least one electrically-conductive via (see, for instance, the second via 26 from right in
(55) A method as exemplified herein may comprise providing an electrically-conductive bonding pattern (for instance, 18′, 18″ in
(56) A method as exemplified herein may comprise applying laser beam processing to the package LDS material to form therein at least one electrically-conductive via (see, for instance the vias 26 at the bottom center of both
(57) A method as exemplified herein may comprise: molding further package LDS material (for instance, 220 in
(58) A method as exemplified herein may comprise laser beam processing of LDS material and metallizing LDS material to which laser beam processing is applied.
(59) A device (for instance, 10) as discussed herein may comprise features as exemplified in
(60) These features may comprise: a substrate of laser direct structuring (briefly LDS), material, the substrate having a first surface and a second surface, the second surface opposed to the first surface, at least one first semiconductor die arranged at a first leadframe structure at the first surface of the substrate of LDS material and at least one second semiconductor die arranged at a second leadframe structure at the second surface of the substrate of LDS material, package LDS material molded onto the second surface of the substrate of LDS material having the at least one second semiconductor die arranged at said second leadframe structure, wherein the at least one first semiconductor die and the package LDS material lie on opposite sides of the substrate of LDS material, a set of electrical contact formations at a surface of the package molding material opposite the substrate of LDS material, wherein: the first leadframe structure at the first surface of the substrate of LDS material and the second leadframe structure at the second surface of the substrate of LDS material comprise laser beam processed LDS material, the substrate of LDS material and the package LDS material comprise laser beam processed LDS material forming at least one electrically-conductive via providing at least a portion of an electrically-conductive formation between said at least one first semiconductor die and an electrical contact formation in said set of electrical contact formations at the surface of the package molding material opposite the substrate of LDS material.
(61) A device as exemplified herein may comprise one or more of the following features: said set of electrical contact formations at a surface of the package molding material opposite the substrate of LDS material comprise laser beam processed LDS material, and/or said first leadframe structure and said second leadframe structure comprise laser beam processed LDS material providing a die pad configured for arranging thereon at least one semiconductor die and an array of electrically-conductive leads, and/or at least one electrically-conductive via comprising laser beam processed LDS material is provided through the substrate of LDS material electrically coupling an electrically-conductive lead in the array of electrically-conductive leads in said first leadframe structure with an electrically-conductive lead in the array of electrically-conductive leads in said second leadframe structure, and/or at least one electrically-conductive via comprising laser beam processed LDS material is provided through the package LDS material electrically coupling an electrically-conductive lead in the array of electrically-conductive leads in said second leadframe structure with an electrical contact formation in the set of electrical contact formations at a surface of the package molding material (24) opposite the substrate of LDS material (16), and/or at least one electrically-conductive via comprising laser beam processed LDS material is provided through the substrate of LDS material and the package LDS material electrically coupling an electrically-conductive lead in the array of electrically-conductive leads in said first leadframe structure with an electrical contact formation in the set of electrical contact formations at a surface of the package molding material opposite the substrate of LDS material, and/or at least one electrically-conductive via comprising laser beam processed LDS material is provided through the package LDS material electrically coupling said at least one second semiconductor die at a second leadframe structure at the second surface of the substrate of LDS material with an electrical contact formation in the set of electrical contact formations at a surface of the package molding material opposite the substrate of LDS material, and/or further package LDS material provided molded onto the first surface of the substrate of LDS material having the at least one first semiconductor die arranged at said first leadframe structure, wherein at least one electrically-conductive formation comprising laser beam processed LDS material is provided in the further package LDS material, the substrate of LDS material and the package LDS material (24) electrically coupling said at least one first semiconductor die arranged at said first leadframe structure with one of: an electrical contact formation in the set of electrical contact formations at a surface of the package molding material opposite the substrate of LDS material (16), a passive component embedded in the package LDS material, the passive component optionally electrically coupled with the at least one second semiconductor die arranged at said second leadframe structure.
(62) In a device as exemplified herein, an electrically-conductive bonding pattern (for instance, 18′, 18″) may be provided between at least one semiconductor die arranged at the die pad of one of said first leadframe structure and said second leadframe structure and an electrically-conductive lead in the array of electrically-conductive leads of the leadframe structure in said one of said first leadframe structure and said second leadframe structure.
(63) A device as exemplified herein may comprise metallization material (copper, for instance) at said laser beam processed LDS material.
(64) Without prejudice to the underlying principles, the details and the embodiments may vary, even significantly, with respect to what has been described by way of example only without departing from the scope of the embodiments.
(65) 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.