SEMICONDUCTOR SUBSTRATE, SEMICONDUCTOR PACKAGE, METHOD OF MANUFACTURING THE SAME
20210159154 · 2021-05-27
Assignee
Inventors
Cpc classification
H01L2924/00012
ELECTRICITY
H01L21/76805
ELECTRICITY
H01L2224/18
ELECTRICITY
H01L23/3171
ELECTRICITY
H01L23/5389
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L23/3178
ELECTRICITY
H01L23/49861
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L21/563
ELECTRICITY
H01L23/3185
ELECTRICITY
H01L2224/04105
ELECTRICITY
H01L2224/02371
ELECTRICITY
H01L23/49833
ELECTRICITY
International classification
H01L23/498
ELECTRICITY
H01L21/768
ELECTRICITY
Abstract
A semiconductor substrate includes a first dielectric structure and a die. The first dielectric structure has a first surface and a second surface opposite to the first surface. The die is embedded within the first dielectric structure. The die includes an active surface facing the first surface of the first dielectric structure, a backside surface opposite to the active surface of the die and a metal layer disposed on the backside surface of the die. The metal layer is a recrystallized layer.
Claims
1. A semiconductor substrate, comprising: a first dielectric structure having a first surface and a second surface opposite to the first surface; and a die embedded within the first dielectric structure, wherein the die comprises an active surface facing the first surface of the first dielectric structure, a backside surface opposite to the active surface of the die and a metal layer disposed on the backside surface of the die, and wherein the metal layer is a recrystallized layer.
2. The semiconductor substrate of claim 1, further comprising a patterned conductive layer disposed on the first surface of the first dielectric structure and extending to the active surface of the die.
3. The semiconductor substrate of claim 1, wherein the metal layer is exposed from the second surface of the first dielectric structure.
4. The semiconductor substrate of claim 3, wherein the exposed surface of the metal layer is coplanar with the second surface of the first dielectric structure.
5. The semiconductor substrate of claim 2, further comprising an redistribution layer (RDL) structure disposed on the patterned conductive layer and the first surface of the first dielectric structure.
6. The semiconductor substrate of claim 1, further comprising a second dielectric structure attached to the second surface of the first dielectric structure.
7. The semiconductor substrate of claim 1, further comprising an redistribution layer (RDL) structure disposed on the second surface of the first dielectric structure.
8. The semiconductor substrate of claim 1, further comprising a conductive member penetrating through the first dielectric structure and electrically connecting to a patterned conductive layer disposed on the first surface of the first dielectric structure.
9. The semiconductor substrate of claim 1, further comprising a conductive member penetrating through the first dielectric structure and the second dielectric structure and electrically connecting to a patterned conductive layer disposed on the first surface of the first dielectric structure.
10. The semiconductor substrate of claim 1, wherein the recrystallized metal layer has a grain size greater than a grain size of a non- recrystallized metal layer made of same material.
11. The semiconductor substrate of claim 1, wherein the recrystallized metal layer has a grain size of 0.8 μm or more.
12. A semiconductor package, comprising: a semiconductor substrate, comprising: a first dielectric structure having a first surface and a second surface opposite to the first surface; and a die embedded within the first dielectric structure, wherein the die comprises an active surface facing the first surface of the first dielectric structure, a backside surface opposite to the active surface of the die and a metal layer disposed on the backside surface of the die, and wherein the metal layer is a recrystallized layer; one or more electronic components disposed on the semiconductor substrate; and an encapsulant covering the one or more electronic components and the semiconductor substrate.
13. The semiconductor package of claim 12, wherein the semiconductor substrate further comprises a patterned conductive layer disposed on the first surface of the first dielectric structure and extending to the active surface of the die.
14. The semiconductor package of claim 12, wherein the metal layer is exposed from the second surface of the first dielectric structure.
15. The semiconductor package of claim 12, wherein the exposed surface of the metal layer is coplanar with the second surface of the first dielectric structure.
16. The semiconductor package of claim 12, wherein the semiconductor substrate further comprises a redistribution layer (RDL) structure disposed on a first surface of the first dielectric structure and in contact with the electronic components.
17. The semiconductor package of claim 12, wherein the semiconductor substrate further comprises a redistribution layer (RDL) structure disposed on the second surface of the first dielectric structure.
18-20. (canceled)
21. The semiconductor substrate of claim 6, wherein the second dielectric structure covers the first dielectric structure and the die.
22. The semiconductor substrate of claim 6, wherein the second dielectric structure contacts the metal layer.
23. The semiconductor substrate of claim 1, wherein the metal layer has a relatively large specific weight as compared to the die.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Aspects of the present disclosure are readily understood from the following detailed description when read with the accompanying figures. It should be noted that various features may not be drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
[0007]
[0008]
[0009]
[0010]
[0011]
[0012]
[0013] Common reference numerals are used throughout the drawings and the detailed description to indicate the same or similar components. The present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings.
DETAILED DESCRIPTION
[0014] The following disclosure provides for many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below. These are, of course, merely examples and are not intended to be limiting. In the present disclosure, reference to the formation or disposal of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed or disposed in direct contact, and may also include embodiments in which additional features may be formed or disposed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
[0015] Embodiments of the present disclosure are discussed in detail below. It should be appreciated, however, that the present disclosure provides many applicable concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative and do not limit the scope of the disclosure.
[0016] The present disclosure describes techniques suitable for the manufacture of a semiconductor substrate with an embedded thin die. In some embodiments according to the present disclosure, a recrystallized metal layer is formed on the back surface of the die. The recrystallized metal layer has a relatively large specific weight as compared to the die and an enhanced mechanical strength due to recrystallization. The recrystallized metal layer can function as a die-warpage balance material and a heat dissipation material at the same time. Therefore, the semiconductor substrate according to the present disclosure may include a thinner die without the severe warpage that is found in the existing techniques.
[0017]
[0018] The first dielectric structure 11 has a first surface 11a and a second surface 11b opposite to the first surface 11a. The first dielectric structure may be made of a polymeric or a non-polymeric dielectric material. For example, the first dielectric structure 11 may include a flowable dielectric material in a hardened or semi-hardened state, such as a liquid crystal polymer, a resin with pre-impregnated fibers (e.g., a prepreg), Ajinomoto Buildup Film (ABF), a resin, an epoxy material, or other flowable dielectric material in a hardened or semi-hardened state.
[0019] The die 12 is embedded within the first dielectric structure 11. The die includes an active surface 12a facing the first surface of the first dielectric structure 11 and a backside surface 12b opposite to the active surface 12a of the die 12. In some embodiments, the die 12 includes a functional area 121 and a non-functional area 122. Integrated circuits and/or electronic devices are fabricated in the functional area 121 to provide the function of the die. The non-functional area 122 surrounds the functional area 121 and exposes the active surface 12a of the die 12.
[0020] The die 12 includes a metal layer 13. The metal layer 13 is disposed on and in direct contact with the backside surface 12b of the die 12. In some embodiments, the metal layer 13 is exposed from the second surface 11b of the first dielectric structure 11. The exposed surface 13b of the metal layer 13 may have a height higher than, substantially the same as or lower than a height of the second surface 11b of the first dielectric structure 11. In some embodiments as shown in
[0021] The metal layer 13 is a recrystallized layer. The metal layer 13 may be made of copper, nickel, silver, gold, iron, zinc, aluminum, tin, stainless steel, or other suitable metal or alloy. The recrystallized metal layer has a grain size greater than a grain size of a non-recrystallized metal layer made of same material. In some embodiments, the recrystallized metal layer has a grain size of 0.6 μm or more, 0.65 μm or more, 0.7 μm or more, 0.75 μm or more, 0.8 μm or more, 0.85 μm or more, or 0.9 μm or more. The recrystallized metal layer has a relatively large specific weight as compared to the die and an enhanced mechanical strength due to recrystallization. The recrystallized metal layer can function as a die-warpage balance material and also as a heat dissipation material. Therefore, by forming a recrystallized metal layer onto the backside surface of the die, a thinner die can be used without causing severe warpage.
[0022] As shown in
[0023]
[0024] The second dielectric structure 16 is attached to the second surface 11b of the first dielectric structure 11. As show in
[0025]
[0026] In some embodiments, the semiconductor substrate may further include an redistribution layer (RDL) structure 15 disposed on the patterned conductive layer 14 and the first surface 11a of the first dielectric structure 11 as shown in
[0027] In some embodiments, the semiconductor substrate may further include an redistribution layer (RDL) structure 17 disposed on the second surface 11b of the first dielectric structure 11. The RDL structure 17 may be in direct contact with the second surface 11b of the first dielectric structure 11 in some embodiments, or in direct contact with the second dielectric structure 16 disposed on the second surface 11b of the first dielectric structure 11 in some other embodiments, e.g., those illustrated in
[0028] The RDL structure 15 and 17 may include one or more redistribution layers and insulation material(s) or dielectric material(s) (not denoted in
[0029] The RDL structure 15 and 17 may include conductive trace(s), pad(s), contact(s), via(s) to electrically connect the one or more redistribution layers with each other, or electrically connect the RDL structure to the semiconductor component, or electrically connect the RDL structure to an external circuit or electronic component.
[0030] In some embodiments, the semiconductor substrate may further include a conductive member 18. The conductive member 18 may penetrate through the first dielectric structure 11 in some embodiments, or penetrate through the first dielectric structure 11 and the second dielectric structure 16 in some other embodiments, e.g., those illustrated in
[0031] As shown in
[0032]
[0033] In some embodiments, the semiconductor substrate 10 may have a similar structure to that of the semiconductor substrate 200 illustrated in
[0034] The semiconductor package 500 includes one or more electronic components 41 and 42 disposed on the semiconductor substrate 10. The electronic components 41 and 42 may be an active component, e.g., a processor component, a switch component, an application specific IC (ASIC) or another active component, or a passive component e.g., a capacitor, a resistor, or the like. The electronic components 41 and 42 may be electrically connected to the semiconductor substrate, for example, by way of flip-chip or other techniques. In the embodiments as shown in
[0035] RDL structure 15 of the semiconductor substrate 10 via solder balls 43.
[0036] The semiconductor package 500 includes an encapsulant 20. The encapsulant 20 covers or encapsulates the electronic components 41 and 42 and the semiconductor substrate 10. The encapsulant 20 may include insulation or dielectric material. In some embodiment, the encapsulant 20 be made of molding material that may include, for example, a Novolac-based resin, an epoxy-based resin, a silicone-based resin, or other another suitable encapsulant. Suitable fillers may also be included, such as powdered SiO.sub.2.
[0037]
[0038] The method for manufacturing a semiconductor substrate in accordance with some embodiments of the present disclosure includes: (a) providing a die having an active surface, a backside surface opposite the active surface of the die and a recrystallized metal layer disposed on the backside surface of the die; (b) providing a first dielectric structure having a first surface and a second surface opposite the first surface to cover the die wherein the recrystallized metal layer is exposed from the second surface of the first dielectric structure; and (c) forming a patterned conductive layer on the first surface of the first dielectric structure and extending to the active surface of the die.
[0039]
[0040] Referring to
[0041] Referring to
[0042] Referring to
[0043] Referring to
[0044] Referring to
[0045]
[0046] Referring to
[0047] Referring to
[0048] Referring to
[0049]
[0050] Referring to
[0051] Referring to
[0052] In
[0053] Spatial descriptions, such as “above,” “below,” “up,” “left,” “right,” “down,” “top,” “bottom,” “vertical,” “horizontal,” “side,” “higher,” “lower,” “upper,” “over,” “under,” and so forth, are indicated with respect to the orientation shown in the figures unless otherwise specified. It should be understood that the spatial descriptions used herein are for purposes of illustration only and that practical implementations of the structures described herein can be spatially arranged in any orientation or manner, provided that the merits of embodiments of this disclosure are not deviated from by such an arrangement.
[0054] As used herein, the term “vertical” is used to refer to these upward and downward directions, whereas the term “horizontal” refers to directions transverse to the vertical directions.
[0055] As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, a first numerical value can be deemed to be “substantially” the same or equal to a second numerical value if the first numerical value is within a range of variation of less than or equal to ±10% of the second numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, “substantially” perpendicular can refer to a range of angular variation relative to 90° that is less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1°, less than or equal to ±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°.
[0056] Two surfaces can be deemed to be coplanar or substantially coplanar if a displacement between the two surfaces is no greater than 5 μm, no greater than 2 μm, no greater than 1 μm, or no greater than 0.5 μm. A surface can be deemed to be substantially flat if a displacement between the highest point and the lowest point of the surface is no greater than 5 μm, no greater than 2 μm, no greater than 1 μm, or no greater than 0.5 μm.
[0057] As used herein, the singular terms “a,” “an,” and “the” may include plural referents unless the context clearly dictates otherwise.
[0058] As used herein, the terms “conductive,” “electrically conductive” and “electrical conductivity” refer to an ability to transport an electric current. Electrically conductive materials typically indicate those materials that exhibit little or no opposition to the flow of an electric current. One measure of electrical conductivity is Siemens per meter (S/m). Typically, an electrically conductive material is one having a conductivity greater than approximately 10.sup.4 S/m, such as at least 10.sup.5 S/m or at least 10.sup.6 S/m. The electrical conductivity of a material can sometimes vary with temperature. Unless otherwise specified, the electrical conductivity of a material is measured at room temperature.
[0059] Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It is to be understood that such range format is used for convenience and brevity and should be understood flexibly to include numerical values explicitly specified as limits of a range, but also to include all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.
[0060] While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations are not limiting. It should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not be necessarily drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus due to manufacturing processes and tolerances. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit, and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations of the present disclosure.