Carrier Substrate

Abstract

This invention provides a carrier or submount for high power devices packaging and a method for forming the carrier or submount. The carrier comprises a thermal conductive ceramic substrate, a patterned adhesion layer on the substrate, a heat dissipation layer on the patterned adhesion layer, a conformal cover layer enclosing the heat dissipation layer and the adhesion layer, a diffusion barrier layer on the conformal cover layer, an eutectic bonding layer on the diffusion barrier layer, and a dissipation ceramic substrate with an L-shape bonding conductor, wherein one end of the L-shape bonding conductor bonds to the power device and the other end bonds to the conformal cover layer at the second region. The substrate includes a first region for bonding high power device, a second region for wire-bonding, and a third region for heat sink. The first region and second region are on a first surface of the substrate, and the third region is one the second surface, opposite to the first surface, of the substrate.

Claims

1. A carrier for packaging a power device, comprising: a thermal conductive ceramic substrate; an adhesion layer patterned on a first region on a first surface of the substrate, a second region on the first surface of the substrate, and a third region on a second surface of the substrate, the second surface opposite to the first surface; a heat dissipation layer patterned on the adhesion layer; a conformal cover layer for enclosing the adhesion layer and the heat dissipation layer; a diffusion barrier layer on the first region of the conformal cover layer; an eutectic bonding layer on the diffusion barrier layer; and a dissipation ceramic substrate with an L-shape bonding conductor, wherein one end of the L-shape bonding conductor bonds to the power device and the other end bonds to the conformal cover layer at the second region.

2. The carrier according to claim 1, wherein a material of the heat dissipation ceramic layer is AlN, and a material of the L-shape bonding conductor is Cu/Ni/Au.

3. The carrier according to claim 2, wherein a material of the thermal conductive ceramic substrate is selected from a group consisting of AlN, AlO, BeO, SiC, SiN, and BN.

4. The carrier according to claim 3, wherein a material of the adhesion layer includes Cu, Ti, W, Pd, Mo, Rh, Ru, Pt, and alloy thereof.

5. The carrier according to claim 4, wherein a material of the heat dissipation layer is selected from the group consisting of Cu, Ni, and alloy thereof.

6. The carrier according to claim 5, wherein a minute element is applied to the heat dissipation layer to match thermal expansion of the power device, and a material of the minute element is selected from a group consisting of Co, Fe, Ni, DLC, C, Si, and Ge.

7. The carrier according to claim 6, wherein a material of the conformal cover layer includes Pt/Au, Pd/Au, Ni/Pt/Au, or Ni/Pd/Au, and a surface of the conformal layer on the second region is roughness.

8. The carrier according to claim 7, wherein a material of the diffusion barrier layer is selected from a group consisting of Pt, Rh, Ru, and Mo.

9. The carrier according to claim 8, wherein a material of the bonding pad includes AuSn, SnAgCu, or InAuBiSn alloy.

10. A method for forming a carrier for packaging a power device, comprising: providing a thermal conductive ceramic substrate; forming a patterned adhesion layer on a first region on a first surface of the substrate, a second region on the first surface of the substrate, and a third region on a second surface of the substrate, the second surface opposite to the first surface, by sputtering, evaporating, or electroless plating; forming a heat dissipation layer patterned on the adhesion layer by plating; forming a conformal cover layer for enclosing the adhesion layer and the heat dissipation layer; forming a diffusion barrier layer on the first region of the conformal cover layer by sputtering, evaporating, or plating; forming an eutectic bonding layer on the diffusion barrier layer; and bonding an L-shape bonding conductor to the power device and the conformal cover layer at the second region by using Ag epoxy, Au/Sn paste, Ag paste, or Cu paste, wherein the L-shape bonding conductor is supported by a heat dissipation ceramic substrate.

11. The method according to claim 10, wherein a material of the heat dissipation ceramic layer is AlN, and a material of the L-shape bonding conductor is Cu/Ni/Au.

12. The method according to claim 11, wherein a material of the thermal conductive ceramic substrate is selected from a group consisting of AlN, AlO, BeO, SiC, SiN, and BN.

13. The method according to claim 12, wherein a material of the adhesion layer includes Ti, W, Pd, Mo, Rh, Ru, Pt, and alloy thereof.

14. The method according to claim 13, wherein a material of the heat dissipation layer is selected from the group consisting of Cu, Ni, and alloy thereof.

15. The method according to claim 14, wherein a minute element is applied to the heat dissipation layer to match thermal expansion of the power device, and a material of the minute element is selected from a group consisting of Co, Fe, Ni, DLC, C, Si, and Ge.

16. The method according to claim 15, wherein a material of the conformal cover layer includes Pt/Au, Pd/Au, Ni/Pt/Au, or Ni/Pd/Au, and a surface of the conformal layer on the second region is roughness.

17. The method according to claim 16, wherein a material of the diffusion barrier layer is selected from a group consisting of Pt, Rh, Ru, and Mo.

18. The method according to claim 17, wherein a material of the bonding pad includes AuSn, SnAgCu, or InAuBiSn alloy.

19. A carrier for packaging a power device, comprising: a thermal conductive ceramic substrate, wherein a thickness of said substrate matches thermal expansion of the power device; an adhesion layer patterned on a first region on a first surface of the substrate, a second region on the first surface of the substrate, and a third region on a second surface of the substrate, the second surface opposite to the first surface; a heat dissipation layer patterned on the adhesion layer; a cover layer for enclosing the adhesion layer and the heat dissipation layer; a diffusion barrier layer on the first region of the conformal cover layer; an eutectic bonding layer on the diffusion barrier layer; and a dissipation ceramic substrate with an L-shape bonding conductor, wherein one end of the L-shape bonding conductor bonds to the power device and the other end bonds to the conformal cover layer at the second region.

20. The carrier according to claim 19, wherein a material of the heat dissipation ceramic layer is AlN, and a material of the L-shape bonding conductor is Cu/Ni/Au.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein the same or like reference numerals designate the same or like structural elements, and in which:

[0031] FIG. 1 is a schematic illustration of cross-sectional view at various stages during the formation of the carrier substrate in accordance with one embodiment of the present invention;

[0032] FIG. 2 is a schematic illustration of cross-sectional view at various stages during the formation of an adhesion layer on the carrier substrate in accordance with one embodiment of the present invention;

[0033] FIG. 3 is a schematic illustration of cross-sectional view at various stages during the formation of a heat dissipation layer on the carrier substrate in accordance with one embodiment of the present invention;

[0034] FIG. 4 is a schematic illustration of cross-sectional view at various stages during the formation of a conformal cover layer on the carrier substrate in accordance with one embodiment of the present invention;

[0035] FIG. 5 is a schematic illustration of cross-sectional view at various stages during the formation of a diffusion barrier layer and an eutectic layer on the carrier substrate in accordance with one embodiment of the present invention;

[0036] FIG. 6 is a schematic illustration of cross-sectional view at various stages during the formation of a power device bonded to the carrier substrate in accordance with one embodiment of the present invention.

[0037] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

[0038] As used herein, the term substrate, carrier or submount generally refers to plates formed of a semiconductor or non-semiconductor material. Examples of such a semiconductor or non-semiconductor material include, but are not limited to, monocrystalline silicon, silicon carbide, gallium arsenide, indium phosphide, sapphire, ceramic, glass, and PCB. Such substrates, carrier or submount may be commonly found and/or processed in semiconductor or MEMS (Micro Electro Mechanical Systems) fabrication facilities. A bonding substrate refers to a plate with circuits and bonding pads thereon for receiving electronic devices.

[0039] For the substrate, one or more layers may be formed upon the substrate, carrier or submount. Many different types of such layers are known in the art, and the term substrate, carrier or submount as used herein is intended to encompass a board on which all types of such layers may be formed. One or more layers formed on a substrate, carrier or submount may be patterned. For example, a substrate, carrier or submount may include a plurality of circuits, each having patterned features. Formation and processing of such layers of material may ultimately result in completed devices.

[0040] Steps of the process flow in the present invention should be exchangeable generally, unless a logical sequence is required.

[0041] The conductive type of semiconductor in the present invention, such as n-type or p-type conductivity in the semiconductor layer, should be exchangeable.

[0042] In the present invention, power devices also refer to high power devices.

[0043] Various example embodiments of the present invention will now be described more fully with reference to the accompanying drawings in which some example embodiments of the invention are shown. Without limiting the scope of the protection of the present invention, all the description and drawings of the embodiments will exemplarily be referred to carrier or submount and manufacture method thereof. However, the embodiments are not be used to limit the present invention to carrier or submount.

[0044] The present invention provides a carrier, carrier substrate or submount for packaging high power devices. The carrier may include heat sinks for better heat dissipation with thermal expansion consideration. In the present invention, thickness of a substrate is increased to match thermal expansion coefficient of a heat dissipation layer. New materials of adhesion layer is introduced not only to keep high adhesion but also to increase thermal conductivity and to match thermal expansion to other layers. Minute elements also applied to the heat dissipation layer such that the strain and stress thereof can be adjustable to the high power device. A conformal cover layer is provided in the present invention such that heat dissipation layer can be protected from oxidation or chemical erosion much better. New materials of the conformal cover layer are provided for better heat dissipation and thermal expansion match other layers. Moreover, new materials of diffusion layer are introduced such that better heat dissipation is provided.

[0045] In the drawings, relative dimensions of each component and among every component may be exaggerated for clarity. Within the following description of the drawings the same or like reference numbers refer to the same or like components or entities, and only the differences with respect to the individual embodiments are described.

[0046] Please refer to FIG. 1, a substrate 100 is provided. The substrate 100 includes high thermal conductive ceramic materials, such as (AlN) Aluminum Nitride, Aluminum Oxide (AlO), Beryllium Oxide (BeO), Silicon Carbide (SiC), Silicon Nitride (SiN), or Boron Nitride (BN), or combination thereof. Ceramic materials are generally brittle, hard, strong in compression, and weak in shearing and tension, which can withstand chemical erosion that occur in other materials subjected to acidic or caustic environments. Ceramics generally can withstand very high temperatures, ranging from 1,000? C. to 1,600? C. In the present invention, a corrosion-resistant, dielectric ceramic material with high thermal conductivity is necessary.

[0047] A thickness of the substrate 100 should be high enough to meet heat dissipation requirement and thermal expansion of the power devices. In one embodiment, the substrate 100 has a thickness larger than about 150 ?m. However, the preferred dimension of the substrate 100 depends upon the materials thereof and the application of the carrier. Moreover, thermal expansion coefficients of the substrate 100 and the following heat dissipation layer 102 should match that of the high power device.

[0048] In the present invention, there are three regions, the first region 1, the second region 2 and the third region 3 defined on the opposite sides of the substrate 100, wherein the first region 1 and the second region 2 are on the first side of the substrate 100, while the third region 3 is on the second side opposite to the first side. The first region 1 is provided for bonding a high power device, the second region 2 is provided for wire-bonding the high power device, and the third region 3 is provided for heat dissipation or heat sink.

[0049] Please refer to FIG. 2, an adhesion layer 101 is formed on the first side and second side of the substrate 100. The adhesion layer 101 is provided for increasing adhesion between the following heat dissipation layer 102 and the substrate 100. Materials of the adhesion layer 101 may include Titanium (Ti), Tungsten (W), Palladium (Pd), Molybdenum (Mo), Rhodium (Rh), Ruthenium (Ru), Platinum (Pt), or alloy thereof. If the a material of the following heat dissipation layer is cupper (Cu), the adhesion layer 101 can be a composite layer, such as Ti/Cu(seed), Ti/Pt/Cu(seed), Mo/Cu(seed), Ti/Mo/Cu(seed), or Mo/TiW/Cu(seed). In one embodiment, Ti provides the main adhesion function, while Cu provides the seed layer for formation of the following heat dissipation layer 102 in the Ti/Cu adhesion layer 101. Different materials of the adhesion layer 101 provide different adhesion function plus heat dissipation function. In a preferred embodiment, a composite adhesion layer, such as Ti/Rh/Cu(seed), Ti/Ru/Cu(seed) or Ti/Pt/Cu(seed), will provide better adhesion function will excellent heat dissipation function.

[0050] The adhesion layer 101 can be formed on the substrate 100 by using sputtering, evaporation or electroless plating (chemical plating). The patterned adhesion layer 101, including the first adhesion layer 101-1, second adhesion layer 101-2 and third adhesion layer 101-3, is formed on the first region 1, second region 2 and third region 3 respectively by using conventional lift-off method or conventional lithography with etching method. Thickness of the adhesion layer 101 in the present invention is less than about 5 ?m, and preferred about 0.5 ?m.

[0051] Please refer to FIG. 3, a heat dissipation layer 102 is provided on the adhesion layer 101. The heat dissipation layer 102 provides majority heat dissipation function of the carrier in the present invention. Materials of the heat dissipation 102 may include Cu, Nickel (Ni) or alloy thereof, and the heat dissipation layer 102 is formed by using conventional electroless plating. The patterned heat dissipation layer 102, including the first heat dissipation layer 102-1, second heat dissipation layer 102-2 and third heat dissipation layer 102-3, is formed on the first adhesion layer 101-1, second adhesion layer 101-2 and third adhesion layer 101-3 respectively.

[0052] A thickness of the heat dissipation layer 102 should match to the high power device to be bonded, and can be 1 ?m, 30 ?m, 70 ?m, 100 ?m, or larger than about 100 ?m. In the present invention, the thickness of the heat dissipation layers 102-1 and 102-2 or the heat dissipation layer 102-3 should be determined to match thermal expansion coefficient of the power device and the substrate 100. First, if a power device is determined, for example a LASER device will be bonded to the carrier, the thickness of the heat dissipation layer 102 is thus determined to match the thermal expansion coefficient of the power device. Then, while the thickness of the heat dissipation layer 102 is determined, the thickness of the substrate 100 will also be determined according to the thermal expansion coefficients of the substrate 100 and the heat dissipation layer 102.

[0053] In one embodiment, minute elements can be applied or doped into the heat dissipation layer 102 to lower strain and stress thereof to match thermal coefficient of the high power device to be bonded. Materials of the minute elements may include Cobalt (Co), Iron (Fe), Ni, Silicon (Si), Germanium (Ge), (Diamond like Carbon) DLC, or combination thereof. About less than 10% minute elements can be applied or doped as particles in to the heat dissipation layer 102.

[0054] Detailed thickness of the patterned heat dissipation layer 102 is critical in the present invention. The first heat dissipation layer 102-1 as well as the second heat dissipation layer 102-2 should have a thickness close to the third heat dissipation layer 102-3, and thickness difference between the first heat dissipation layer 102-1 as well as the second heat dissipation layer 102-2 and the third heat dissipation layer 102-3 should be less than about 5%. High thermal conductivity and high electrical conductivity of the first heat dissipation layer 120-1, the second heat dissipation layer 102-2 and the third heat dissipation layer 102-3 should be kept similarity.

[0055] Thickness of the heat dissipation layer 102 should be similar enough at the first, second and third region in the present invention. Thickness ratio x between the first heat dissipation layer 102-1 and the third heat dissipation layer 102-3 should be among 0.8<x<1.2, to avoid bonding between the power device and the substrate 100 failure due to strain and stress of the heat dissipation layer 102 at high temperature. Thickness difference between the first heat dissipation layer 102-1 and the third heat dissipation layer 102-3 should be within ?15%. Thickness of the substrate 100 should be larger than that of heat dissipation layer 102.

[0056] Volume of the first heat dissipation layer 102-1 and the second heat dissipation layer 102-2 should be close to that of the third heat dissipation layer 102-3, because the third heat dissipation layer 102-3 could afford total heats from the first heat dissipation layer 102-1 and second heat dissipation layer 102-2. Volume ration y between the first heat dissipation layer 102-1 with the second heat dissipation layer 102-2 to the third heat dissipation layer 102-3 should be about 0.9<y<1.10

[0057] Please refer to FIG. 4, a conformal cover layer 103 is provided to encompass or enclose the heat dissipation layer 102. The conformal cover layer 103 protects the underlying heat dissipation layer 102 from oxidation or etching. Materials of the conformal cover layer 103 may include Ni/Gold (Au), Pt/Au, Pd/Au, Ni/Pt/Au, or Ni/Pd/Au. Formation method of Ni/Au, Pt/Au and Pd/Au may be conventional sputtering or e-gun, while that of Ni/Pt/Au, or Ni/Pd/Au may be conventional electroless plating or plating. The patterned conformal cover layer 103, including the first conformal cover layer 103-1, second conformal cover layer 103-2 and third conformal cover layer 103-3, is formed by using conventional lift-off method or conventional lithography with etching method. In one embodiment, a surface of the second conformal cover layer 103-2 can be roughness such that adhesion between the second conformal cover layer 103-2 and Al wire can be increased. Thickness of the conformal cover layer 103 may be less than about 20 ?m. In one embodiment, if Ni exists in the conformal cover layer 103, thickness of the Ni should be less than about 10 ?m. In one embodiment, thickness of Au should be less than about 3 ?m.

[0058] Heat sink may be fastened to the third conformal cover layer 103-3 to dissipate heats from the first heat dissipation layer 102-1 and second heat dissipation layer 102-2, such that heats may not accumulate in the substrate 100 and the power device.

[0059] Please refer to FIG. 5, a diffusion barrier layer 110 is provided on the first conformal cover layer 103-1. The diffusion layer 110 protects the conformal cover layer 103-1 from diffusing by the following eutectic layer 112. Materials of the diffusion barrier layer 110 may include Ni, Pt, Rh, Ru, Mo or combination thereof. Formation method of the diffusion barrier layer 110 may be conventional plating, evaporation or sputtering. Thickness of the diffusion barrier layer 110 can be ranged about 0.2 to 3 ?m. In one embodiment, thickness of Ni layer should be about 3 ?m. In one embodiment, thickness of Pt should be about 0.3 ?m. In a preferred embodiment, Rh, Ru or Mo should have better heat dissipation than the Ni or Pt.

[0060] An eutectic layer 112 is provided on the diffusion barrier layer 110 as a bonding pad. Material of the eutectic layer 112 can be AuSn, SnAgCu, or InAuBiSn alloy. High power devices, such as LASER diode, IGBT can be bonded on the eutectic layer 112.

[0061] The heat dissipation layer at the second region 102-2 will receive less heat from the power device in general, due to power device is bonded to the heat dissipation layer at the first region 102-1. Only a bonding-wire is connected to the heat dissipation layer at the second region 102-2. Thus, in the present invention, the heat dissipation layer at the second region 102-2 is used to dissipate heats from the heat dissipation layer at the first region 102-1.

[0062] Please refer to FIG. 6, a high power device 10 is bonded to the eutectic layer 112. Then, a dissipation ceramic substrate 320 with an L-shape bonding conductor 310 is provided to electrical connecting the power device 10 and the conformal cover layer at the second region 103-2 by using silver (Ag) epoxy, such that one electrode of the power device 10 can be electrically connected to the conformal cover layer 103-2. In another embodiment, the L-shape bonding conductor 310 can be bonded to the power device 10 and the conformal cover layer at the second region 103-2 by using Au/Sn paste, Ag paste, or Cu paste. A material of the L-shaped bonding conductor 310 can be Cu/Ni/Au, and a material of the dissipation ceramic substrate 320 can be AlN.

[0063] The dissipation ceramic substrate 320 provides a suitable support for the L-shape bonding conductor 310 as well as heat dissipation, due to the AlN ceramic material. In the drawing, the L-shaped bonding conductor 310 is exaggerated. In fact, the thickness of the diffusion barrier layer 110 and the eutectic layer 112 are very thin. A thickness of the power device is also think enough, such that total length of the diffusion barrier layer 110, eutectic layer 112 and power device 10 will contribute only a few height difference, and this height offset can be eliminated in the Ag epoxy formation process. In the present invention, the L-shape bonding conductor 310 also provides better thermal conduction than the conventional bonding-wire. Thus, a portion of heats generated by the power device 10 can be conducted through the L-shape bonding conductor 310 as well as the dissipation ceramic substrate 320.

[0064] The present invention thus provides better heat dissipation with small package volume, because new materials are introduced to different layers. Heat dissipation is enhanced with compact dimension of the carrier.

[0065] The carrier or submount in the present invention has better life and duration in the application, because strain and stress of different layers can be adjustable. Layers of the carrier or submount can be expand all together and less issue incurred by the thermal expansion is avoided.

[0066] The L-shape bonding conductor and dissipation ceramic substrate provides another heat dissipation route for the power device.

[0067] Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.