Antenna feeder package structure and packaging method

Abstract

The present disclosure provides an antenna package structure and packaging method. The package structure includes: a metal joint pin fabricated by using a wire bonding process; and a packaging layer, covering the metal joint pin. An antenna circuit chip and an antenna metal layer are electrically connected to two ends of the antenna feeder package structure.

Claims

1. An antenna feeder package structure, comprising: a first structure of antenna stack; a second structure of redistribution stack, wherein the first structure of antenna stack is disposed on a first side of the second structure of redistribution stack; and a third structure of chip connection, disposed on a second side of the second structure of redistribution stack, wherein the first side and the second side of the second structure of redistribution stack are opposite to each other; wherein the first structure of antenna stack comprises: a first antenna metal layer comprising a plurality of first patterned metal structures; a plurality of first metal joint pins, wherein each of the plurality of first metal joint pins is configured to align to one of the plurality of first patterned metal structures in an one-to-one correspondence; a first packaging layer, and a second antenna metal layer disposed on the first packaging layer, wherein the second antenna metal layer comprises a plurality of second patterned metal structures, wherein the first packaging layer covers the plurality of first metal joint pins except respective top surfaces, wherein each of the top surfaces of the plurality of first metal joint pins is in direct contact with one of the plurality of second patterned metal structures; a plurality of second metal joint pins, wherein each of the plurality of second metal joint pins is configured to align to said one of the plurality of second patterned metal structures in an one-to-one correspondence, wherein one of the plurality of the first metal joint pins is connected to one of the plurality of second metal joint pins in a one-to-one correspondence; a second packaging layer disposed to cover the plurality of second metal joint pins except respective top surfaces; and wherein the second structure of redistribution stack comprises: a conductive redistribution layer placed on the second packaging layer; wherein the conductive redistribution layer comprises three portions, wherein a first portion of the conductive redistribution layer is arranged in direct contact with the top surfaces of the plurality of second metal joint pins; wherein the third structure further including external interface, comprises: a metal solder ball; an antenna circuit chip; and a bottom filling layer; wherein a second portion of the conductive redistribution layer is arranged to be above the first portion of the conductive redistribution layer and is connected with the metal solder ball; wherein the metal solder ball is connected to one of the plurality of the first metal joint pins via one of the plurality of the second metal joint pins via said second portion of the conductive redistribution layer; wherein a third portion of the conductive redistribution layer is arranged to be in direct contact with pads of the antenna circuit chip, wherein the antenna circuit chip is disposed over the third portion of the conductive redistribution layer and at a side of the metal solder ball; and wherein the bottom filling layer is disposed outside the pads and between the third portion of the conductive redistribution layer and the antenna circuit chip.

2. The antenna feeder package structure according to claim 1, wherein each of the first and second metal joint pins comprises gold, silver, copper, or aluminum.

3. The antenna feeder package structure according to claim 1, wherein the first or the second packaging layer comprises polyimide, silica gel or epoxy resin.

4. The antenna feeder package structure according to claim 1, wherein each of a top surface of the first packaging layer and a top surface of the second packaging layer comprises a flat surface.

5. The antenna feeder package structure according to claim 1, wherein the antenna feeder package structure further comprises at least two metal joint pin layers and another packaging layer, wherein each of the at least two metal joint pin layers comprises a plurality of metal joint pins.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 to FIG. 14 show the steps of fabricating an antenna package and sequential structural diagrams according to an embodiment in the present disclosure.

(2) FIG. 15 to FIG. 27 show the steps of fabricating an antenna package and sequential structural diagrams according to another embodiment in the present disclosure.

(3) FIG. 28 shows the structural diagram of an antenna package according to the embodiment in FIGS. 15-27.

DESCRIPTIONS OF REFERENCE NUMERALS

(4) 101 Supporting substrate 102 Separation layer 103 First Antenna metal layer 104 First Metal joint pin 105 First Packaging layer 106 Second Antenna metal layer 107 Second Metal joint pin 108 Second Packaging layer 109 Redistribution layer 110 Metal bump 111 Antenna circuit chip 112 Bottom filling layer

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(5) Implementations of the present disclosure are illustrated below through specific embodiments. Those skilled in the art can easily understand other advantages and efficacy of the present disclosure according to the content disclosed in this specification. The present disclosure can also be implemented or applied through other different specific implementations. Various modifications or variations can also be made on details in this specification based on different opinions and applications without departing from the spirit of the present disclosure.

(6) It should be noted that, the figures provided in this embodiment merely illustrate the basic conception of the present disclosure schematically. Therefore, the figures only show components related to the present disclosure, and are not drawn according to the quantity, shapes and sizes of components during actual implementation. The pattern, quantity and ratio of components during actual implementation can be changed arbitrarily, and the component layout may also be more complex.

Embodiment 1

(7) As shown in FIG. 28, the present embodiment provides a packaging structure for an antenna. The packaging structure comprises a redistribution layer 109, a second metal joint pin 107, a second packaging layer 108, a second antenna metal layer 106, a first metal joint pin 104, a first packaging layer 105, a first antenna metal layer 103, a metal bump 110, an antenna circuit chip 111, and a bottom filling layer 112.

(8) As shown in FIG. 28, the redistribution layer 109 has a first surface facing the chip and an opposite second surface.

(9) As shown in FIG. 28, the redistribution layer 109 comprises a patterned first dielectric layer (not shown in the figures), a patterned first metal wiring layer (not shown in the figures), a patterned second dielectric layer (not shown in the figures), and a patterned second metal wiring layer (not shown in the figures) which are sequentially stacked, wherein the first metal wiring layer is electrically connected with the second metal wiring layer. Further, the first dielectric layer and the second dielectric layer are made from one or a combination of two or more of epoxy resin, silica gel, Polyimide (PI), Polybenzoxazole (PBO), Benzocyclobutene (BCB), silicon oxide, phosphorosilicate glass and fluorine-containing glass, and the first metal wiring layer and the second metal wiring layer are made from one or a combination of two or more of copper, aluminum, nickel, gold, silver and titanium.

(10) As shown in FIG. 28, the second metal joint pin 107 is formed on the second surface of the redistribution layer 109, and is electrically connected with the redistribution layer 109.

(11) The second metal joint pin 107 is made from a metal material like Au, Ag, Cu, and Al.

(12) As shown in FIG. 28, the second packaging layer 108 covers the second metal joint pin 107 and the redistribution layer 109. Meanwhile, the second metal joint pin 107's top surface is exposed.

(13) The second packaging layer 108 is made from one of polyimide, silica gel and epoxy resin. The top surface of the second packaging layer 108 is a grounded or polished flat surface, to improve the quality of the second antenna metal layer 106.

(14) As shown in FIG. 28, the second antenna metal layer 106 is formed on the second packaging layer 108, and the second antenna metal layer 106 is electrically connected with the second metal joint pin 107.

(15) The material of the second antenna metal layer 106 may be Au, or Cu, etc. The second antenna metal layer 106 may have various different patterns according to performance requirements.

(16) As shown in FIG. 28, the second metal joint pin 107 is formed on the second antenna metal layer 106.

(17) The second metal joint pin 107 is made from one of Au, Ag, Cu, and Al.

(18) As shown in FIG. 28, the first packaging layer 105 covers the second antenna metal layer 106, and exposes the second metal joint pin 107, and the second metal joint pin 107 the top surface of the first packaging layer 105.

(19) The first packaging layer 105 is made from one of polyimide, silica gel and epoxy resin. The top surface of the first packaging layer 105 is a ground or polished flat surface, so as to improve the quality of the first antenna metal layer 103.

(20) As shown in FIG. 28, the first antenna metal layer 103 is formed on the first packaging layer 105, and the first antenna metal layer 103 protrudes from the surface of the first packaging layer 105. The second antenna metal layer 106 may be made from Au, Cu, etc., and the second antenna metal layer 106 may have various different patterns according to performance requirements.

(21) As shown in FIG. 28, the metal bump 110 is formed on the first surface of the redistribution layer 109. The metal bump 110 comprises a solder material like f tin solder, silver solder and gold-tin alloy solder.

(22) As shown in FIG. 28, the antenna circuit chip 111 is bonded to the first surface of the redistribution layer 109, and the antenna circuit chip 111 is electrically connected with the second antenna metal layer 106 and the first antenna metal layer 103 through the redistribution layer 109, the second metal joint pin 107 and the first metal joint pin 104, so as to realize the functions of the antenna. Based on the structure, an antenna packaging structure with more layers can be realized by more metal joint pins, packaging layers and antenna metal layers.

(23) As shown in FIG. 28, the packaging structure further comprises a bottom filling layer 112 filled between the antenna circuit chip 111 and the redistribution layer 109 to increase the bonding strength of the antenna circuit chip 111 to the redistribution layer 109 and protect the redistribution layer 109.

(24) As shown in FIG. 15 to FIG. 28, the embodiment further provides a packaging method for an antenna, comprising the following steps:

(25) Step 1), providing a supporting substrate 101, and forming a separation layer 102 on the supporting substrate 101 as shown in FIG. 15.

(26) As an example, the supporting substrate 101 may be one of a glass substrate, a metal substrate, a semiconductor substrate, a polymer substrate and a ceramic substrate. In the present embodiment, the supporting substrate 101 is a glass substrate, the cost of the glass substrate is lower than other types, it is easy to form the separation layer 102 on the surface of the glass substrate, and so it is easier for the subsequent separation process.

(27) As an example, the separation layer 102 may be an adhesive tape or a polymer layer. In the case of a polymer layer, the polymer is first applied to the surface of the supporting substrate 101 by a spin-coating process, and then cured by a UV curing or thermal curing process.

(28) In the present embodiment, the polymer layer comprises an LTHC photo-thermal conversion layer, and the LTHC photo-thermal conversion layer can be heated later in step 9) by laser light, so that a subsequently formed packaging layer 105 and the supporting substrate 101 are separated from each other at the LTHC photo-thermal conversion layer.

(29) Step 2), forming a redistribution layer 109 on the separation layer 102, wherein the redistribution layer 109 comprises a first surface connected with the separation layer 102 and an opposite second surface, as shown in FIG. 16.

(30) Forming the redistribution layer 109 of step 2) comprises the following steps:

(31) step 2-1), forming a first dielectric layer as part of 109 on the surface of the separation layer 102 by a chemical vapor deposition process or a physical vapor deposition process, and etching the first dielectric layer to form a patterned first dielectric layer, wherein the first dielectric layer is made from one or a combination of two or more of epoxy resin, silica gel, PI, PBO, BCB, silicon oxide, phosphorosilicate glass and fluorine-containing glass;

(32) step 2-2) forming a first metal layer (not shown) on the surface of the patterned first dielectric layer by a chemical vapor deposition process, an evaporation process, a sputtering process, an electroplating process, or an electroless plating process, and etching the first metal layer to form a patterned first metal wiring layer, wherein the first metal wiring layer is made from one or a combination of two or more of copper, aluminum, nickel, gold, silver and titanium;

(33) step 2-3) forming a second dielectric layer on the surface of the patterned first metal wiring layer by a chemical vapor deposition process or a physical vapor deposition process, and etching the dielectric layer to form a patterned second dielectric layer, wherein the second dielectric layer is made from one or a combination of two or more of epoxy resin, silica gel, PI, PBO, BCB, silicon oxide, phosphorosilicate glass and fluorine-containing glass; and

(34) step 2-4) forming a second metal layer on the surface of the patterned second dielectric layer by a chemical vapor deposition process, an evaporation process, a sputtering process, an electroplating process, or an electroless plating process, and etching the second metal layer to form a patterned second metal wiring layer, wherein the second metal wiring layer is electrically connected with the first metal wiring layer. The second metal wiring layer is made from one or a combination of two or more of copper, aluminum, nickel, gold, silver, and titanium.

(35) Step 3), forming a second metal joint pin 107 on the second surface of the redistribution layer 109, as shown in FIG. 17.

(36) In step 3), the second metal joint pin 107 is manufactured by a wire bonding process, wherein the wire bonding process comprises one of a hot press wire bonding process, an ultrasonic wire bonding process and a hot press ultrasonic wire bonding process, and the second metal joint pin 107 is made from one of Au, Ag, Cu and Al.

(37) Step 4), packaging the second metal joint pin 107 and the redistribution layer 109 with a packaging layer 108, and then grinding the second packaging layer 108 until the second metal joint pin 107 is exposed from the top surface of the second packaging layer 108, as shown in FIG. 18 to FIG. 19.

(38) Packaging the second metal joint pin 107 and the redistribution layer 109 with the second packaging layer 108 in step 4) adopts one of the following methods: compression molding, transfer molding, liquid seal molding, vacuum lamination and spin coating, and the second packaging layer 108 is made from one of polyimide, silica gel and epoxy resin.

(39) Step 5), forming a second antenna metal layer 106 on the surface of the second packaging layer 108, wherein the second antenna metal layer 106 is electrically connected with the second metal joint pin 107, as shown in FIG. 20.

(40) For example, a metal layer may be formed on the surface of the second packaging layer 108 by evaporation or sputtering, and then the metal layer is patterned to form the second antenna metal layer 106 by an etching process. Optionally, the second antenna metal layer 106 may also be formed by a metal lift-off process, that is, forming a photoresist pattern on the surface of the second packaging layer 108 first, then forming a metal layer on the photoresist pattern by an evaporation or sputtering method, and finally removing the photoresist pattern and separating the metal layer from the photoresist pattern, with the patterned antenna metal layer 106 left on the surface of the second packaging layer 108.

(41) Step 6), forming a first metal joint pin 104 on the second antenna metal layer 106, as shown in FIG. 21.

(42) In step 6), the first metal joint pin 104 is manufactured by a wire bonding process, wherein the wire bonding process is one of a hot press wire bonding process, an ultrasonic wire bonding process and a hot press ultrasonic wire bonding process, and the first metal joint pin 104 is made from one of Au, Ag, Cu and Al.

(43) Step 7), packaging the second antenna metal layer 106 and the first metal joint pin 104 with a packaging layer 105, and then grinding the first packaging layer 105 until the first metal joint pin 104 is exposed from the top surface of the first packaging layer 105, as shown in FIG. 22 to FIG. 23.

(44) Step 7) of packaging the second antenna metal layer 106 and the first metal joint pin 104 with a packaging layer 105 adopts one of the following methods: compression molding, transfer molding, liquid seal molding, vacuum lamination and spin coating, and the first packaging layer 105 is made from one of polyimide, silica gel and epoxy resin.

(45) Step 8), forming an antenna metal layer 103 on the surface of the first packaging layer 105, as shown in FIG. 24.

(46) For example, a metal layer may be formed on the surface of the first packaging layer 105 by evaporation or sputtering method first, and the metal layer is patterned to form the first antenna metal layer 103 by an etching process. Of course, the first antenna metal layer 103 may also be formed by a metal lift-off process, that is, forming a photoresist pattern on the surface of the first packaging layer 105 first, then forming a metal layer on the photoresist pattern by an evaporation or sputtering method, and finally removing the photoresist pattern and separating the metal layer from the photoresist pattern, with the patterned antenna metal layer 103 left on the surface of the first packaging layer 105.

(47) Step 9), separating the redistribution layer 109 from the supporting substrate 101 based on the separation layer 102 to expose the first surface of the redistribution layer 109, as shown in FIG. 25.

(48) For example, the LTHC photo-thermal conversion layer is heated by laser light, so that the subsequently formed packaging layer 105 and the supporting substrate 101 are separated from each other at the LTHC photo-thermal conversion layer.

(49) Step 10), forming a metal bump 110 on the first surface of the redistribution layer 109, as shown in FIG. 26.

(50) The metal bump 110 comprises one of tin solder, silver solder and gold-tin alloy solder.

(51) Step 11) and step 12) providing an antenna circuit chip 111, bonding the antenna circuit chip 111 to the first surface of the redistribution layer 109, and finally forming a bottom filling layer 112 between the antenna circuit chip 111 and the redistribution layer 109 to increase the bonding strength of the antenna circuit chip 111 and the redistribution layer 109 and protect the redistribution layer 109, as shown in FIG. 27 to FIG. 28.

Embodiment 2

(52) As shown in FIG. 1 to FIG. 14, the present embodiment provides a packaging method for an antenna, comprising the following steps:

(53) Step 1), providing a supporting substrate 101, and forming a separation layer 102 on the supporting substrate 101, as shown in FIG. 1.

(54) As an example, the supporting substrate 101 comprises one of a glass substrate, a metal substrate, a semiconductor substrate, a polymer substrate and a ceramic substrate. In the present embodiment, the supporting substrate 101 is a glass substrate, the cost of the glass substrate is low, it is easy to form the separation layer 102 on the surface of the glass substrate, and the difficulty of the subsequent separation process can be reduced.

(55) As an example, the separation layer 102 comprises one of an adhesive tape and a polymer layer. The polymer layer is first applied to the surface of the supporting substrate 101 by a spin-coating process, and then cured by a UV curing or thermal curing process.

(56) The polymer layer comprises an LTHC photo-thermal conversion layer, and the LTHC photo-thermal conversion layer can be heated later in step 11) by laser light, so that the first packaging layer 105 and the supporting substrate 101 are separated from each other at the LTHC photo-thermal conversion layer.

(57) Step 2), forming an antenna metal layer 103 on the separation layer 102, as shown in FIG. 2.

(58) For example, a metal layer may be formed on the surface of the separation layer 102 by an evaporation or sputtering method first, and then the metal layer is patterned form the first antenna metal layer 103 by an etching process. Optionally, the first antenna metal layer 103 may also be formed by a metal lift-off process, that is, forming a photoresist pattern on the surface of the separation layer 102 first, then forming a metal layer on the photoresist pattern by an evaporation or sputtering method, and finally removing the photoresist pattern and separating the metal layer from the photoresist pattern, with the patterned antenna metal layer 103 left on the surface of the separation layer 102.

(59) Step 3), forming a first metal joint pin 104 on the first antenna metal layer 103, as shown in FIG. 3.

(60) The first metal joint pin 104 is manufactured by a wire bonding process, wherein the wire bonding process is one of a hot press wire bonding process, an ultrasonic wire bonding process and a hot press ultrasonic wire bonding process, and the first metal joint pin 104 is made from one of Au, Ag, Cu, and Al.

(61) Step 4), packaging the first antenna metal layer 103 and the first metal joint pin 104 with a packaging layer 105, so that the first metal joint pin 104 is exposed from the top surface of the first packaging layer 105, as shown in FIG. 4 to FIG. 5.

(62) The packaging of the first antenna metal layer 103 and the first metal joint pin 104 with a packaging layer 105 adopts one of the following methods: compression molding, transfer molding, liquid seal molding, vacuum lamination and spin coating, and the first packaging layer 105 is made from one of polyimide, silica gel and epoxy resin.

(63) Step 5), forming an antenna metal layer 106 on the surface of the first packaging layer 105, wherein the second antenna metal layer 106 is electrically connected with the first metal joint pin 104, as shown in FIG. 6.

(64) Step 6), forming a second metal joint pin 107 on the second antenna metal layer 106, as shown in FIG. 7.

(65) The second metal joint pin 107 is manufactured by a wire bonding process, wherein the wire bonding process is one of a hot press wire bonding process, an ultrasonic wire bonding process and a hot press ultrasonic wire bonding process, and the first metal joint pin 107 and second metal joint pin 107 are made from one of Au, Ag, Cu and Al.

(66) Step 7), packaging the second antenna metal layer 106 and second metal joint pin 107 with a packaging layer 108, so that second metal joint pin 107 is exposed from the top surface of the second packaging layer 108, as shown in FIG. 8 to FIG. 9.

(67) The packaging of the second antenna metal layer 106 and second metal joint pin 107 with a packaging layer 108 adopts one of the following methods: compression molding, transfer molding, liquid seal molding, vacuum lamination and spin coating, and the second packaging layer 108 is made from one of polyimide, silica gel and epoxy resin.

(68) Step 8), forming a redistribution layer 109 on the surface of the second packaging layer 108, wherein the redistribution layer 109 is electrically connected with second metal joint pin 107, As shown in FIG. 10.

(69) Step 8) of forming the redistribution layer 109 comprises the following steps:

(70) 8-1), forming a first dielectric layer on the surface of the second packaging layer 108 by a chemical vapor deposition process or a physical vapor deposition process, and etching the first dielectric layer to form a patterned first dielectric layer;

(71) 8-2) forming a first metal layer on the surface of the patterned first dielectric layer by a chemical vapor deposition process, an evaporation process, a sputtering process, an electroplating process, or an electroless plating process, and etching the first metal layer to form a patterned first metal wiring layer, wherein the first metal wiring layer is electrically connected with second metal joint pin 107;

(72) 8-3) forming a second dielectric layer on the surface of the patterned first metal wiring layer by a chemical vapor deposition process or a physical vapor deposition process, and etching the dielectric layer to form a patterned second dielectric layer; and

(73) 8-4) forming a second metal layer on the surface of the patterned second dielectric layer by a chemical vapor deposition process, an evaporation process, a sputtering process, an electroplating process, or an electroless plating process, and etching the second metal layer to form a patterned second metal wiring layer, wherein the second metal wiring layer is electrically connected with the first metal wiring layer.

(74) The first dielectric layer and the second dielectric layer are made from one or a combination of two or more of epoxy resin, silica gel, PI, PBO, BCB, silicon oxide, phosphorosilicate glass and fluorine-containing glass, and the first metal wiring layer and the second metal wiring layer are made from one or a combination of two or more of copper, aluminum, nickel, gold, silver and titanium.

(75) Step 9), forming a metal bump 110 on the redistribution layer 109, as shown in FIG. 11.

(76) The metal bump 110 comprises one of tin solder, silver solder and gold-tin alloy solder.

(77) Step 10), providing an antenna circuit chip 111, and bonding the antenna circuit chip 111 to the redistribution layer 109, as shown in FIG. 12.

(78) Between step 10) and step 11), the packaging method further comprises: forming a bottom filling layer 112 between the antenna circuit chip 111 and the redistribution layer 109 to increase the bonding strength of the antenna circuit chip 111 and the redistribution layer 109 and protect the redistribution layer 109.

(79) Step 11), separating the first packaging layer 105 from the supporting substrate 101 based on the separation layer 102, as shown in FIG. 13 to FIG. 14.

(80) As shown in FIG. 14, the present embodiment further provides a packaging structure for an antenna. The basic structure is the same as that of embodiment 1, and the main difference from embodiment 1 lies in that the first antenna metal layer 103 of the packaging structure sinks into the first packaging layer 105, such that the side face of the first antenna metal layer 103 is covered by the first packaging layer 105, which can greatly improve the mechanical stability of the first antenna metal layer 103 and improve the overall performance of the packaging structure.

(81) The disclosed device have the following benefits:

(82) the packaging structure for an antenna according to the present disclosure adopts the redistribution layer to realize the integration of two or more antenna metal layers, greatly improving the efficiency and performance of the antenna, and the packaging structure and packaging method for an antenna according to the present disclosure have a high integration level; and

(83) in the present disclosure, a fan-out packaging method is adopted to package the antenna, which can effectively reduce the packaging volume, and make the packaging structure for an antenna have a high integration level and better packaging performance, thereby having a wide application prospect in the field of semiconductor packaging.

(84) Therefore, the present disclosure effectively overcomes various disadvantages in the prior art and has high industrial utilization value.

(85) The above-described embodiments merely illustrate the principles and effects of the present disclosure, but are not intended to limit the present disclosure. Any person skilled in the art can modify or change the above embodiments without departing from the spirit and scope of the present disclosure. Therefore, all equivalent modifications or changes made by persons of ordinary skill in the art without departing from the spirit and technical thought disclosed in the present disclosure shall still be covered by the claims of the present disclosure.