Chip assembling on adhesion layer or dielectric layer, extending beyond chip, on substrate

Abstract

Electronic module, which comprises a first substrate, a first dielectric layer on the first substrate, at least one electronic chip, which is mounted with a first main surface directly or indirectly on partial region of the first dielectric layer, a second substrate over a second main surface of the at least one electronic chip, and an electrical contacting for the electric contact of the at least one electronic chip through the first dielectric layer, wherein the first adhesion layer on the first substrate extends over an area, which exceeds the first main surface.

Claims

1. A method of manufacturing at least one electronic module, the method comprising: applying a first adhesion layer at least to an entire component mounting area of a conductive first substrate; direct or indirect mounting of a first main surface of at least one electronic chip on a partial region of the first adhesion layer; applying a second adhesion layer on the second substrate; direct or indirect mounting of the second main surface of at least one electronic chip on a section of the second adhesion layer; electrical contacting of the at least one electronic chip through the first adhesion layer; and singularizing of a plurality of electronic chips between the first substrate and the second substrate to a plurality of electronic modules, wherein each electronic module comprises at least a section of the first substrate, a section of the first adhesion layer wherein edges of the first adhesion layer are exposed, a section of the second substrate, and at least one electronic chip.

2. The method of claim 1, wherein the second adhesion layer is applied at least to an entire component mounting area of the second substrate.

3. The method of claim 1, wherein at least one of the first adhesion layer and of the second adhesion layer is applied essentially completely on the respective substrate.

4. The method of claim 1, wherein at least one through hole for electrically contacting the respective main surface of the respective electronic chip is formed in at least one of the first adhesion layer and of the second adhesion layer.

5. The method of claim 4, wherein the at least one through hole for electrically contacting the respective main surface of the respective electronic chip is filled at least partially with electrically conductive material.

6. The method of claim 1, wherein at least one of the first adhesion layer and the second adhesion layer is formed of a first partial layer and a second partial layer on the first partial layer.

7. The method of claim 1, wherein at least one of the first substrate and the second substrate is structured to form electrically conductive paths.

8. The method of claim 1, wherein the first adhesion layer has a constant thickness throughout, except of the region where an electrical contacting is arranged.

9. A method for manufacturing at least one electronic module, the method comprising: applying a first adhesion layer at least to an entire component mounting area of a conductive first substrate; direct or indirect mounting of a first main surface of a plurality of electronic chips on a respective partial region of the first adhesion layer; applying a second adhesion layer on a conductive second substrate; direct or indirect mounting of a second main surface of the plurality of electronic chips on a respective partial region of the second adhesion layer; and singularizing of the plurality of electronic chips between the first substrate and the second substrate to a plurality of electronic modules, wherein each electronic module comprises at least a section of the first substrate, a section of the first adhesion layer wherein edges of the first adhesion layer are exposed, a section of the second adhesion layer wherein edges of the second adhesion layer are exposed, a section of the second substrate, and at least one electronic chip.

10. The method of claim 9, wherein the second adhesion layer is applied at least to an entire component mounting area of the second substrate.

11. The method of claim 9, wherein at least one of the first adhesion layer and the second adhesion layer is applied essentially completely on the respective substrate.

12. The method of claim 9, wherein at least one through hole for electrically contacting the respective main surface of the respective electronic chip is formed in at least one of the first adhesion layer and the second adhesion layer.

13. The method of claim 12, wherein the at least one through hole for electrically contacting the respective main surface of the respective electronic chip is filled at least partially with electrically conductive material.

14. The method of claim 9, wherein at least one of the first adhesion layer and the second adhesion layer is formed of a first partial layer and a second partial layer on the first partial layer.

15. The method of claim 9, wherein at least one of the first substrate and the second substrate is structured to form electrically conductive paths.

16. The method of claim 9, wherein the first adhesion layer has a constant thickness throughout, except of the region where an electrical contacting is arranged.

17. A method for manufacturing at least one electronic module, the method comprising: applying a first adhesion layer at least to an entire component mounting area of a conductive first substrate, wherein the first adhesion layer has a constant thickness throughout, except of the region where an electrical contacting is arranged; direct or indirect mounting of a first main surface of a plurality of electronic chips on a respective partial region of the first adhesion layer; applying a second adhesion layer on a conductive second substrate, wherein the second adhesion layer has a constant thickness throughout, except of the region where an electrical contacting is arranged; and direct or indirect mounting of a second main surface of the plurality of electronic chips on a respective partial region of the second adhesion layer.

18. The method of claim 17, further comprising: singularizing of the plurality of electronic chips between the first substrate and the second substrate to a plurality of electronic modules, wherein each electronic module comprises at least a section of the first substrate, a section of the first adhesion layer wherein edges of the first adhesion layer are exposed, a section of the second adhesion layer wherein edges of the second adhesion layer are exposed, a section of the second substrate, and at least one electronic chip.

19. The method of claim 17, wherein at least one of the first adhesion layer and the second adhesion layer is applied essentially completely on the respective substrate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Exemplary embodiments are illustrated in the figures and will be discussed in detail below.

(2) It shows:

(3) FIG. 1: a cross-sectional view of an electronic module according to an exemplary embodiment example.

(4) FIG. 2 to FIG. 11: Cross-section views of structures, which during a process for the manufacturing of electronic modules are obtained in accordance with an exemplary embodiment example.

DETAILED DESCRIPTION OF EMBODIMENT EXAMPLES

(5) The same or similar components in different figures are provided with the same reference numbers.

(6) FIG. 1 illustrates a cross-sectional view of an electronic module 100 according to an exemplary embodiment example.

(7) The electronic module 100 shown in FIG. 1 has a first substrate 102 designed as a structured copper foil, a related first dielectric layer 104 made of adhesive resin on the first substrate 102 and two electronic chips 106 designed here as a MOSFET power semiconductor chips. Each of the electronic chips 106 is mounted with one or two pads 171, 173, 175 on its first main surface 108 directly on a section area of the first dielectric layer 104.

(8) The electronic module 100 has also a second substrate 110, designed as a structured copper foil, and a related second dielectric layer 112 made of adhesive resin on the second substrate 110. Thus the first substrate 102 and the second substrate 110 are designed of an electrically conductive and thermally conductive material. On the other hand, the first dielectric layer 104 and the second dielectric layer 112 are designed of an electrically insulating material. The materials of the first dielectric layer 104 and the second dielectric layer 112 can be soft to provide a good adhesive ability during the applying and can be hardened or dried to the complete manufacturing of the electronic module 100. Each of the electronic chips 106 is mounted with one or two pads 171, 173, 175 on its second main surface 114 (which is opposite to the first main surface 108) directly on a section area of the second dielectric layer 112.

(9) In addition, an electric contact 116 of copper is made for electrical contacting of electronic chips 106 through the first dielectric layer 104 and the second dielectric layer 112 as electrically conductive structure. The electrical contacting 116 fills clearance holes 118, which penetrate the first dielectric layer 104 and the second dielectric layer 112. The electronic chips 106 are so mounted between the first dielectric layer 104 and the second dielectric layer 112 that metal-filled clearance holes 118 are adjacent of a current respective of the main surfaces 108, 114 of the respective electronic chip 106 and thus to its respective pads 171, 173, 175.

(10) As it is illustrated in FIG. 1, a part of the first dielectric layer 104 and a part of the second dielectric layer 112 of the electronic chips 106 remain uncovered. Such uncovered sections of dielectric layers 104, 112 of the electronic chips 106 connect a dielectric structure 120 which is filling hollow spaces between the first dielectric layer 104 and the second dielectric layer 112. The dielectric structure 120 can be designed, for example, as laminate or melting resin foil. The dielectric structure 120 can be designed as section of a perforated foil and is structured in such a way that it fills the targeted gaps between the electronic chips 106 on the first dielectric layer 104.

(11) How it is evident on the basis of a first detail 140 and a second detail 150 in FIG. 1, in accordance with the execution example, both the first dielectric layer 104 and the second dielectric layer 112, each consisting of a first part of layer 122, are mounted directly on the respective substrates 102, 110 and a separate second part of layer 124 on the first part of layer 122. The first part of layer 122 can be manufactured from a material that is different from a material of the second part of layer 124. It is also possible alternatively that the first part of layer 122 and the second part of layer 124 consist of the same material, but are applied in two separate procedures. It has been illustrated that thereby the mounting strength and the proper orientation of the electronic chips 106 will be particularly beneficial, without the electrical insulation between the electronic chips 106 and the respective substrates 102, 110 is at risk.

(12) Two pads 173, 171 of the two electronic chips 106 are electrically coupled with each other on their first main surfaces 108 by means of the electrical contacting 116 and by means of a structured section of the first substrate 102. On the other hand, the two electronic chips 106 are each electrically decoupled on their second main surfaces 114.

(13) A via 130 (as a clearance hole, that is filled with electrically conductive material) provides electrical coupling of the first substrate 102 with the second substrate 110 and extends vertically through the dielectric structure 120. Exposed electrical conductive surfaces on the bottom of the electronic module 100, which are mounted through the first substrate 102 and additional separated electrically conductive material, are covered with an electrical connector structure 134, designed here in the form of solder structures, to connect electrically the electronic module 100 with an electronic peripheral device not illustrated in FIG. 1 (in particular to solder it thereto). The top and bottom of the electronic module 100 (with the exception of the electrical connector structure 134) can be covered with a protective layer 132 (which can be also called passivation layer) to protect the electronic module 100 mechanically and to isolate it electrically. Optionally also the side areas of the electronic module 100 can be covered with a such protection layer 132, what, according to FIG. 1, due to the lateral continuously electrically insulating layers is not necessary.

(14) Thus, FIG. 1 illustrates the electronic module 100 with the electronic chips 106 designed as semiconductor chips between the first substrate 102 as structured lower conductive layer and the second substrate 110 as structured upper electrically conductive layer. The two electronic chips 106 are adjusted in opposite directions to each other. Between the front and the back side of the electronic chips 106, on the one hand, and the substrates 102, 110, on the other hand, the dielectric layers 104, 112 are included as hardened polymer layers. Each of the dielectric layers 104 and 112 is designed in accordance with the embodiment example of two separate parts of layer 122, 124 with different material compositions. Metal vias as part of the electrical contacting 116 penetrate the dielectric layers 104, 112 in the form of the clearance holes 118 to connect electrically the two electronic chips 106 of two main surfaces 108, 114 with the electrically conductive layers in the form of the substrates 102, 110.

(15) As illustrated in FIG. 1, the relevant dielectric layer 104, 112 of the electronic module 100 with the exception of electrical contacts (see reference marks 116, 118, 130) is mounted with full surface between the individual sections of the first substrate 102 on the one hand and the electronic chips 106/the dielectric structure 120 on the one hand or between the individual sections of the second substrate 112 on the one hand and the electronic chips 106/dielectric structure 120 on the other hand. Thus, the first dielectric layer 104 extends on the first substrate 102 over a surface area, which exceeds the overall length of the first main surface 108. In other words, the first dielectric layer 104 is so extensively mounted, that it is mounting more structural components of the electronic module 100 on the first substrate 102 over the mounting of electronic chips 106 on the first substrate 102. Similarly, the second dielectric layer 112 extends on the second substrate 110 over a surface area, which exceeds the overall length of the second main surface 114. In other words, the second dielectric layer 112 is mounted so extensively, that it is mounting more structural components of the electronic module of the second substrate 110 over the mounting of electronic chips 106 on the second substrate 110.

(16) On the electronic module 100, electronic chips 106 are designed as field effect transistors (MOSFET). A particular drain pad is 171 is marked with reference mark 171, a particular source pad with reference mark 173 and a particular gate pad is marked with reference mark 175. FIG. 1 illustrates that one of the electronic chips 106 is arranged with its active side upwards, the other with its active site is arranged downwards.

(17) FIG. 2 to FIG. 11 illustrate cross-sectional views of structures, which during the method for the manufacturing of electronic modules 100 are obtained in accordance with an exemplary embodiment example.

(18) In the description of the electronic module 100, referring to FIG. 1, it was spoken about dielectric layers 104, 112. Dielectric layers 104, 112 can be obtained, when adhesion layers 104, 112 which were mounted during the manufacturing process and afterwards closer described will be hardened.

(19) To get a structure 200 illustrated in FIG. 2, a foil layer stack as a first substrate 102 is provided. Optionally (for example using drilling, or etching, or a laser treatment, for example an UV-laser treatment), in a main surface of the first substrate 102, a plurality of blind holes 202 (as pre-structures, which later can be used as a base for making openings, for example, two-dimensional holes or vias, for the rear contact of electronic chips 106) or at least an alignment mark 204 (here in the form of a register hole). The alignment marks 204 can be used as an alignment aid when placing the electronic chips 106 (see FIG. 4), when mounting a dielectric structure 120 (see FIG. 6), in the composition of vias (see FIG. 8) or be used in lithographic etching of electrical conductive structures (see FIG. 10), to perform exactly position of the corresponding procedure. The blind holes 202 serve as rear connectors for the electronic chips 106.

(20) FIG. 2 illustrates a detail 280, representing a top view of the first main surface of the first substrate 102. There also a component mounting area 260 is illustrated which corresponds to the main part of the first main surface of the first substrate 102, except only a ring-shaped edge area 250 and alignment marker 270 in the central area. The structure illustrated in FIG. 2 200 corresponds to a small central section of the component mounting area 260 of the first substrate 102, that can be dimensioned for example with a length of 40 cm and a width of 20 cm. The component mounting area 260 corresponds to the range of the first substrate 102, which after the processing and separating, how as referring to FIG. 11 closer described, a basis for the individual electronic modules to be manufactured. This component mounting area 260 will be, how referring to FIG. 3 described in more detail, completely or fully covered with adhesive material. The same applies to a below described second substrate 110 (see FIG. 6), which component mounting area 260 will be also completely or fully covered with adhesive material.

(21) Another detail 290 in accordance with FIG. 2 illustrates that the first substrate 102 upon closer inspection as a layer stack can be made of three components. A temporary carrier 102c is a copper structure (alternatively made of aluminum or nickel) with a thickness of for example 70 m. One carrier 102b, for example, only a few nanometers thick, separates the temporary carrier 102c by a functional layer 102a, which can be, for example, a copper layer with a thickness of 9 m. The temporary carrier 102c simplifies the handling of the thin first substrate 102 for the chip mounting. The providing of the separation layer 102b allows a detachment of the temporary carrier 102c from the functional layer 102a (see junction from FIG. 7 to FIG. 8). It is possible, that the blind holes 202 and the alignment marks 204 extend only through the functional layer 102a, but not through the temporary carrier 102c.

(22) To get a structure 300 illustrated in FIG. 3 starting from the structure 200, a first adhesion layer 104 will be mounted fully on the first substrate 102 by means, for example, of pressing, or separating, or lamination (i.e. connection by pressing under high pressure) to cover its component mounting area 260 completely and fully. In particular also the blind holes 202 will be covered with the adhesive material (such as resin) of the first adhesion layer 104. The material of the first adhesion layer 104 can be optionally pre-dried or treated in any other way, so that it retains even a desired level of stickiness. For example, a thickness of the first adhesion layer 104 can be adjusted in a range between 5 m and 100 m (as well as a thickness of a second adhesion layer 112, which will be mounted in a later process step), in particular in a range between 20 m and 30 m.

(23) It is also optionally possible to mount the first adhesion layer 104 from two partial layers (see reference marks 122, 124 in FIG. 1), wherein the first partial layer can be treated at first (for example, can be pre-dried), before the second partial layer is mounted.

(24) To get a structure 400 illustrated in FIG. 4 starting from the structure 300, a plurality of electronic chips 106 will be put on the first adhesion layer 104 with their respective first main surfaces 108 and thereby attached by means of glue and mounted on the first substrate 102. The mounting of electronic chips 106 on the sticky and still wet first adhesion layer 104 can be done by means of a Pick & Place machine with a high speed. During this procedure, the alignment of the electronic chips 106 relative to the first adhesion layer 104 and the first substrate 102 can be performed using the alignment marks 204.

(25) To get a structure 500 illustrated in FIG. 5 starting from the structure 400, the material of the first adhesion layer 104 will be at least partially dried or at least partially hardened to remove contained solvent in the adhesive material, to improve the handling of the already mounted electronic chips 106 and to strengthen the adhesion.

(26) To get a structure 600 illustrated in FIG. 6 starting from the structure 500, at first, the second substrate 110 which is mounted as foil stack in its component mounting area 260 (see according to detail 280 in FIG. 2) will be fully equipped with a second adhesion layer 112 made from adhesive material.

(27) A detail 650 according to FIG. 6 illustrates that the second substrate 110 upon closer inspection can be designed as a layer stack of three components. A temporary carrier 110c is a copper structure with a thickness of, for example, 70 m (alternatively made of aluminum or nickel). One carrier layer 110b, for example, only a few nanometers thick, separates the temporary carrier 110c by a functional layer 110a, which can be, for example, a copper layer with a thickness of 9 m. The temporary carrier 110c simplifies the handling of thin second substrate 110 during the bonding. The providing of the separation layer 110b allows a detachment of the temporary carrier 110c from the functional layer 110a (see junction from FIG. 7 to FIG. 8).

(28) Although this is not illustrated in the figure, is it optionally possible to mount one or more electronic chips 106 on the formation of the second substrate 110 and the second adhesion layer 112 before the formation of the second substrate 110 and second adhesion layer 112 will be mounted on the formation of the first substrate 102 and the first adhesion layer 100 of the electronic chips 106 being mounted together.

(29) The structure 500 according to FIG. 5 is connected with the second substrate 110 covered with a second adhesion layer 112, wherein the hollow spaces between them will be filled through a dielectric structure 120. The dielectric structure 120 can be provided in the form of individual bodies or as structured or perforated layer and be made, for example, of prepreg material.

(30) In this connection process, the second main surfaces 114 of the electronic chips 106 will be simultaneously connected with different sections of the second adhesion layer 112, as is illustrated in a structure 700 in FIG. 7. Because an additional electrically insulating layer in the form of adhesion layers 104, 112 is imprinted on the respective substrates 102, 110, it is beneficial, for example, just exactly one structured layer of prepreg as a dielectric structure 120 being sufficient to laminate the two substrates 104, 110 with each other including their mounting. The lamination can be done by means of a vacuum PCB laminator press. The layer of prepreg can also be replaced through a structured core layer. Although this is not illustrated in the figure, it is also possible to mount more electronic chips 106 on the second substrate 110 before mounting the substrates 102, 110 with each other.

(31) To get a structure 800 illustrated in FIG. 8 starting from the structure 700, at first the temporary carriers 102c, 110c will be taken off or removed. In addition, clearance holes 118 to form micro vias will be created by means of etching or laser drilling, which extend through the substrates 102, 110 and adhesion layers 104, 112. Alternatively, it is possible to make the clearance holes 118 in the remains of the substrates of 102, 110 previously. Also a cleaning process can be carried out, if necessary.

(32) To get a structure 900 illustrated in FIG. 9 starting from the structure 800, electrically conductive material on two opposite main surfaces of the structure 800 will be separated to make electrical contacts 116 in the clearance holes 118 and to increase the thickness of the substrates 102, 112. At first, a germ layer to the front and to the back can be made using an electro-less copper separation process, and after that can be continued with an electrochemical separation process or with a direct metal separation process.

(33) To get a structure 1000 illustrated in FIG. 10 starting from the structure 900, the thickened substrates 102, 110 in accordance with the process of FIG. 9 will be structured, for example, by means of lithography or etching method, wherein the individual pads of each electronic chips 106 stay electrically coupled with each other in a desired manner to one part or will be electrically decoupled from each other to another part. As an alternative to such developing-etching-stripping method, even a structured separation method can be used.

(34) Although this is not illustrated in the figure, it is possible to mount more layers on the upper or lower side of the structure 1000. It is also possible to install solder structures, to perform a finishing process, etc.

(35) To get the electronic modules 100 illustrated in FIG. 11 starting from the structure 1000, the structure 1000 will be separated on separating lines 1002, for example, by means of etching, laser treatment, or sawing, wherewith the electronic modules 100 will be singularized.

(36) A conversion of the adhesion layers 104, 112 (compare FIG. 3 to FIG. 11) in the dielectric layers 104, 112 (compare FIG. 1), in particular through hardening, can be performed to one or more different times during the manufacturing method (for example, in the phase in accordance with FIG. 5, FIG. 7, FIG. 8 and/or FIG. 11, or in other phases).

(37) Instead of the processes referring to described in FIG. 9 to FIG. 11, it is alternatively possible to use other contact manufacturing methods, as they are known from the conventional printed circuit technology.

(38) The description referred to in FIG. 2 to FIG. 11 illustrates that a large part of the processes for the production of electronic modules 100, according to exemplary embodiment examples, can be performed as batch-process, i.e. for many electronic modules 100 in a common parallel manufacturing method. However, it is also possible to perform individual of the listed above processes only after singularizing, for example, the mounting of solder structures (see reference mark 134 in FIG. 1).

(39) A professional will recognize that many alternatives to the described manufacturing methods are possible. According to another option, it is possible, at first, to mount the electronic chips 106 to the adhesion layers 104, 112 with heat. In addition, it is possible to mount multiple-layer adhesion layers 104, 112, wherein a first respective mounted part of layer can be at first hardened, before a respective different part layer is mounted. In this case, it may be possible to omit a dielectric structure 120 at all. It is also possible to pre-laminate a dielectric structure 120 (for example made as a core layer) before the actual bonding. In addition, it is possible to arrange the electronic chips 106 on still wet adhesion layers 104, 112 before the adhesive material is hardened. It is possible to bond electronic chips 106 on two opposite substrates 102, 110 by the means of the adhesion layers 104, 112. A front side-back side connection can be made by means of drilled or etched clearance holes.

(40) In addition, it shall be pointed out that comprising does not exclude any other elements or steps and one or a do not exclude any plurality. It also should be pointed out that features or steps, which have been described with reference to one of the above embodiment examples, can be used also in combination with other features or steps of other of the embodiment examples described above. Reference marks in the claims shall not be understood as restrictions.