Electronic system comprising a lower redistribution layer and method for manufacturing such an electronic system
11133264 · 2021-09-28
Assignee
Inventors
Cpc classification
H01L2924/19105
ELECTRICITY
H01L25/18
ELECTRICITY
H01L21/4853
ELECTRICITY
H01L25/0652
ELECTRICITY
H01L2221/68372
ELECTRICITY
H01L24/20
ELECTRICITY
H01L25/50
ELECTRICITY
H01L23/3128
ELECTRICITY
H01L24/82
ELECTRICITY
H01L23/5389
ELECTRICITY
H01L21/568
ELECTRICITY
H01L2224/82001
ELECTRICITY
H01L24/19
ELECTRICITY
H01L23/49816
ELECTRICITY
H01L2221/68345
ELECTRICITY
International classification
H01L23/538
ELECTRICITY
H01L25/18
ELECTRICITY
H01L25/00
ELECTRICITY
H01L21/48
ELECTRICITY
H01L25/065
ELECTRICITY
Abstract
The invention relates to a method for producing an electronic system, comprising: a step of forming a plurality of interconnect paths obtained via metal deposition on the sacrificial member to form a lower redistribution layer defining a plurality of lower connection ports connected to a plurality of inner connection ports; a step of depositing at least one electronic component on the lower redistribution layer; and a step of forming a plurality of three-dimensional interconnect paths obtained via metal deposition in order to connect the connectors of the electronic component to the inner connection ports of the lower redistribution layer.
Claims
1. A method for manufacturing an electronic system comprising: a step of applying a sacrificial element on a carrier, a step of producing a lower redistribution layer defining a plurality of lower connection ports connected to a plurality of inner connection ports forming connection ports of the system, the lower redistribution layer being formed by a plurality of interconnections produced by metal deposition, a step of transferring at least one electronic component onto the lower redistribution layer, the at least one electronic component comprising a front surface comprising a plurality of connectors and a rear surface opposite to the front surface, the rear surface of the at least one electronic component being positioned facing the lower redistribution layer on a side of the inner connection ports, a step of depositing a passivation layer so as to cover a surface of the lower redistribution layer and the at least one electronic component while maintaining the plurality of connectors of the at least one electronic component and the inner connection ports uncovered, a step of producing a plurality of three-dimensional interconnections produced by metal deposition so as to connect the plurality of connectors of the at least one electronic component to the inner connection ports of the lower redistribution layer, the plurality of three-dimensional interconnections being produced by metal deposition in openings formed in a photosensitive resin layer, said openings defining shapes of the three-dimensional interconnections, an encapsulation step, and a step of separating the system from the sacrificial element.
2. The method according to claim 1, wherein the sacrificial element is an adhesive film.
3. The method according to claim 1, wherein the sacrificial element is configured to lose its adherence characteristics from a predetermined temperature.
4. The method according to claim 1, wherein the sacrificial element is configured to lose its adherence characteristics following an illumination.
5. The method according to claim 1, wherein lower connection ports extend under the at least one electronic component.
6. The method according to claim 1, further comprising a step of producing an opening in the system so as to uncover a front face of at least one electronic component having a sensor function.
7. The method according to claim 1, further comprising a step of forming a three-dimensional passive component on the at least one electronic component during the step of producing a plurality of three-dimensional interconnections.
8. The method according to claim 1, comprising a step of transferring at least two superimposed electronic components onto the lower redistribution layer and a step of connecting connectors of said at least two superimposed electronic components during the step of producing the plurality of three-dimensional interconnections.
9. The method according to claim 1, wherein the passivation layer is deposited conformally.
10. The method according to claim 1, further comprising a step of producing an upper redistribution layer connected to the plurality of connectors of said at least one electronic component.
11. The method according to claim 10, further comprising a step of depositing at least one electronic component on the upper redistribution layer, the at least electronic component on the upper redistribution layer comprising a front surface comprising a plurality of connectors and a rear surface opposite to the front surface, the rear surface of the at least one electronic component on the upper redistribution layer being positioned facing the upper redistribution layer.
12. The method according to claim 1, wherein at least one connector and at least one inner connection port of the lower redistribution layer are spaced apart by a vertical distance greater than 10 μm and three-dimensionally interconnected.
13. The method according to claim 12, wherein at least one interconnection, connecting at least one connector and at least one inner connection port, has an aspect ratio greater than 2.5:1 for a vertical distance comprised between 10 μm and 100 μm.
14. A method for manufacturing an electronic system comprising: a step of applying a sacrificial element on a carrier, a step of producing a lower redistribution layer defining a plurality of lower connection ports connected to a plurality of inner connection ports forming connection ports of the system, the lower redistribution layer being formed by a plurality of interconnections produced by metal deposition, a step of transferring at least one electronic component onto the lower redistribution layer, the at least one electronic component comprising a front surface comprising a plurality of connectors and a rear surface opposite to the front surface, the rear surface of the at least one electronic component being positioned facing the lower redistribution layer on a side of the inner connection ports, a step of producing a plurality of three-dimensional interconnections produced by metal deposition so as to connect the plurality of connectors of the at least one electronic component to the inner connection ports of the lower redistribution layer, the plurality of three-dimensional interconnections being produced by metal deposition in openings formed in a photosensitive resin layer, said openings defining shapes of the three-dimensional interconnections, a step of producing an opening in the system so as to uncover a front face of at least one electronic component having a sensor function, an encapsulation step, and a step of separating the system from the sacrificial element.
15. A method for manufacturing an electronic system comprising: a step of applying a sacrificial element on a carrier, a step of producing a lower redistribution layer defining a plurality of lower connection ports connected to a plurality of inner connection ports forming connection ports of the system, the lower redistribution layer being formed by a plurality of interconnections produced by metal deposition, a step of transferring at least one electronic component onto the lower redistribution layer, the at least one electronic component comprising a front surface comprising a plurality of connectors and a rear surface opposite to the front surface, the rear surface of the at least one electronic component being positioned facing the lower redistribution layer on a side of the inner connection ports, a step of producing a plurality of three-dimensional interconnections produced by metal deposition so as to connect the plurality of connectors of the at least one electronic component to the inner connection ports of the lower redistribution layer, the plurality of three-dimensional interconnections being produced by metal deposition in openings formed in a photosensitive resin layer, said openings defining shapes of the three-dimensional interconnections, a step of transferring at least two superimposed electronic components onto the lower redistribution layer and a step of connecting connectors of said at least two superimposed electronic components during the step of producing the plurality of three-dimensional interconnections, an encapsulation step, and a step of separating the system from the sacrificial element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will be better understood on reading the description that follows, given uniquely as an example, and by referring to the appended drawings in which:
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(12) The figures may obviously serve to better define the invention if need be.
DETAILED DESCRIPTION
(13) An electronic system will now be described comprising a plurality of electronic components capable of being mounted on a printed circuit in order to form an electronic board. Such an electronic board may be mounted in any sort of electronic device, for example, a computer, a watch, a smartphone, a connected object, an item of clothing, a portable item of equipment, etc.
(14) A “system in package” type system is advantageously formed, which comprises several electronic components. In the example that follows, the production of a system comprising conductive balls will be described but it goes without saying that it is also possible to produce a system of the QFN or LGA type of which the connection ports extend in a same plane in the continuity of said system, that is to say, without projecting.
(15) An example of manufacture of a system according to the invention will be described with reference to
(16) Firstly, with reference to
(17) In a preferred manner, the carrier 1 is in the form of a flat surface based on silicon, glass, ceramic, metal, organic materials or any type of material capable of serving as support. The carrier 1 is preferably circular or rectangular but it goes without saying that other shapes could be suitable. Preferably, the surface area of the support is greater than 2000 mm.sup.2.
(18) The sacrificial element 2 has a double function. It makes it possible, on the one hand, to position in a precise and robust manner the lower redistribution layer 7 of the system during its production and, on the other hand, to be able to release it when the system is produced. In other words, the sacrificial element 2 forms a temporary support for the lower redistribution layer 7 in order that it is integrated in the system S.
(19) Further preferably, the sacrificial element 2 is in the form of a layer which is organic, inorganic, polymeric or metallic. The sacrificial element 2 may be deposited by spin coating, by spray, by lamination, by stamping, by growth or analogous. As an example, a sacrificial element 2 of the “ZoneBond”®, “WaferBond”® and “BrewerBond”® from Brewer Science, “WSS”® from 3M, “SELFA”® from Sekisui and “Revalpha”® from Nitto type. In a preferred manner, the sacrificial element 2 is in the form of an adhesive film which is simple to handle, in particular, double-sided. Preferably, the sacrificial element 2 is configured to lose its adherence characteristics from a predetermined temperature. For this purpose, a sacrificial element 2 of the “Revalpha”® from Nitto type is particularly suited. In another preferred manner, the sacrificial element 2 is configured to lose its adherence characteristics following an illumination, in particular, by a UV light source such as a laser and/or a mercury lamp. During such an illumination, the sacrificial element 2 converts the light into thermal energy or generates a gas, which cancels the adherence characteristics. For this purpose, a sacrificial element 2 of the “BrewerBond”® from Brewer Science or “WSS”® from 3M or “SELFA”® from Sekisui type is particularly suited. Further preferably, the sacrificial element 2 enables a lift-off of the system by mechanical action without deterioration. For this purpose, a sacrificial element 2 of the “TM-X12”® from Hitachi Chemicals type is particularly suited.
(20) With reference to
(21) The lower redistribution layer 7 comprises lower connection ports 71 in contact with the sacrificial element 2 and inner connection ports 72, in the upper part, intended to connect with the electronic components 3. The lower connection ports 71 form the connection ports of the system S.
(22) With reference to
(23) The first passivation layer 4 may be composed of an organic or inorganic material, such as a semiconductor oxide, a metal oxide, a polymer or any other electrically insulating material. It may be deposited by spin coating, by spray, by lamination, by stamping, by growth, by printing (inkjet), by vacuum deposition or by any type of deposition known to those skilled in the art. Preferably, the openings 40 are produced by means of a photolithography method or by means of a wet and/or dry chemical etching, by plasma or by laser. In a preferred manner, photosensitive materials are favoured given the advantages offered by photolithography methods.
(24) The deposition of the first passivation layer 4 is optional, the electronic components 3 being able to be deposited directly on the lower redistribution layer 7.
(25) With reference to
(26) In this example, as illustrated in
(27) The positioning of the electronic components 3 is preferably achieved by a so-called “pick and place” transfer method. Furthermore, an adhesive layer is applied between two superimposed electronic components 3. The adhesive layer is deposited between the rear surface 3B of the upper level electronic component 3 and the front surface 3A of the lower level electronic component 3. The precise positioning makes it possible to guarantee an optimal interconnection.
(28) In a preferred manner, the total vertical thickness (electronic component(s) 3 and adhesive layer(s)) is greater than 10 μm, more particularly, greater than 40 μm. The sides of the electronic components 3 may be straight, overcut and/or undercut. For the sake of clarity, only electronic components 3 having straight sides have been used in the figures.
(29) With reference to the right part of
(30) In a preferred manner, each upper level electronic component 3 of a stack has dimensions smaller than the lower level electronic component 3 so as to form a stack facilitating the formation of three-dimensional interconnections between the different electronic components 3. The compactness and integration density are thus increased in a practical manner.
(31) In a preferred manner, the stack is pyramidal or staircase-shaped. According to the latter case, it is possible to stack electronic components 3 having an identical size or instead electronic components 3 of larger size above electronic components 3 of smaller size. It goes without saying that the electronic components 3 may have different dimensions.
(32) In the absence of passivation layer 4, the electronic components 3 are transferred directly onto the lower redistribution layer 7.
(33) With reference to
(34) According to the need of the system, the second passivation layer 4′ is deposited conformally or so as to adapt the angle of the sides of the electronic components 3. The second passivation layer 4′ may be composed of an organic or inorganic material, such as a semiconductor oxide, a metal oxide, a polymer or any other electrically insulating material. It may be deposited by spin coating, by spray, by lamination, by stamping, by growth, by printing (inkjet), by vacuum deposition or by any type of deposition known to those skilled in the art.
(35) Still with reference to
(36) According to the need of the system, the passivation layer 4′ is deposited uniquely to cover the sides of the electronic components 3 as well as a part of the surface of the electronic component 3, thus forming a sarcophagus around said electronic component 3. In this case, the openings 40 in the passivation layer 4 are directly accessible to the three-dimensional interconnections.
(37) In the case where the surfaces and the sides of the electronic components 3 are insulating except at the level of the connectors 30, the deposition of the second passivation layer 4′ may not be applied, thus reducing the manufacturing time and cost.
(38) With reference to
(39) The three-dimensional interconnections are known per se, in particular, by the patent application FR2965659. In this example, to produce the three-dimensional interconnections 5, the method comprises: a step of depositing a metal layer by evaporation, by spray or other, which fulfils both a function of seed and growth base for the metal constituting the three-dimensional interconnections. This metal layer may be composed of a single or of several electrically conductive materials and/or semiconductors. a step of depositing a thick layer of photosensitive resin and a step of producing openings by photolithography techniques, by laser ablation or others, in order to create a mould necessary for the deposition of the metal constituting the three-dimensional interconnections. These openings define the shape of the three-dimensional interconnections 5 as well as those of the metal tracks connecting the connectors 30 of the electronic component 3 to the inner connection ports 72. According to the integration need, the thickness of the photosensitive resin layer can vary from 20 to 700 μm and the aspect ratio (resolution) from 0.5:1 to 50:1. a step of depositing a metal layer by electrolysis or any other metal growth technique. The deposited metal may be copper, gold, silver, nickel, an alloy of metals or any other electrically conductive material. a step of dissolution of the resin mould and a step of etching of the seed layer. These methods are known to those skilled in the art. However, in the case where the seed layer contains gold, a solution based on KI+I2 and additives could be used to etch this layer without damaging the three-dimensional interconnections.
(40) In this example, the lower connection ports 71 and the connectors 30 of the electronic components 3 are respectively connected together by the redistribution layer formed by the three-dimensional interconnections 5 produced by metal deposition and by the lower redistribution layer 7. Advantageously, even in the case of a plurality of electronic components 3, the three-dimensional interconnections 5 are produced during a single and same step, which procures an important time saving. The number of connectors 30 connected together depends on the degree of interaction between the two electronic components 3 in the electronic system S. The planar redistribution layer makes it possible to improve the routing between the electronic components 3 as well as the input/output ports of the system S, in particular, in the case of high density of connectors 30.
(41) With reference to
(42) With reference to
(43) With reference to
(44) With reference to
(45) Several other embodiments of an electronic system S according to the invention are represented with reference to
(46) With reference to
(47) With reference to
(48) With reference to
(49) With reference to
(50) With reference to
(51) According to an aspect of the invention, not represented, the electronic component 3 comprises built-up conductive pads transferred onto the connectors 30 of said electronic component 3. Such built-up pads make it possible to offset vertically the connectors 30 with respect to the front surface 3A of the electronic component 3. In other words, the conductive pads extend vertically projecting from the front surface 3A of the electronic component 3. Such built-up pads make it possible to improve the compatibility with the interconnections 5 or to offset the position of the connectors 30 in order to limit the risk of interference between the three-dimensional interconnections 5 and the electronic component 3. In a preferred manner, the transferred built-up pads are formed prior to the step of producing three-dimensional interconnections. Advantageously, the built-up pads make it possible to make the three-dimensional interconnections 5 compatible with the connectors 30 of the electronic component 3 by forming a compatible metal interface.
(52) With reference to
(53) With reference to
(54) With reference to
(55) Thanks to the invention, electronic systems S enabling a heterogeneous and three-dimensional integration may be produced. This type of integration enables considerable miniaturisation and an improvement in the performances of the systems S without using complex technologies such as that of through vias.
(56) Advantageously, the manufacturing method only necessitates a small number 10 of technological steps making it possible to produce several electronic systems S simultaneously, which reduces the manufacture time and cost.
(57) This method enables great design flexibility. Furthermore, the topology may be optimised to improve the electrical and thermal performances and to respond to the needs of applications having a large number of inputs/outputs and/or integrating sensors. The three-dimensional integration, by use of a same metallisation layer or by integrating several metal layers, makes it possible to obtain optimal miniaturisation without degrading the functions.
(58) The different exemplary embodiments have been described for electronic components being in the form of electronic chips. Nevertheless, it is recalled that other types of electronic components could be suitable.