Packaged Integrated Circuit With Interposing Functionality and Method for Manufacturing Such a Packaged Integrated Circuit

Abstract

A packaged integrated circuit includes a core structure with a cavity therein; a component accommodated in the cavity; an electrically insulating structure formed over the core structure and the component; a partially electrically insulating carrier structure formed below the core structure and the component; and an electrically conducting redistribution arrangement formed at least partially within the carrier structure. The redistribution arrangement includes conductor structures each having a first element extending through the carrier structure and electrically connecting a contact of the component and a second element below the carrier structure. A part of the second element is a contact pad for electrically connecting the redistribution arrangement with external circuitry. The carrier structure includes a polyimide layer and an adhesive layer. The adhesive layer is directly attached to an upper surface of the polyimide layer and to a lower surface of the core structure and a lower surface of the component.

Claims

1. A packaged integrated circuit, comprising: a core structure having a through passage cavity formed therein; an integrated circuit component being accommodated within the cavity; an electrically insulating cover structure formed over the core structure and the component; an at least partially electrically insulating carrier structure formed below the core structure and the component; and an electrically conducting redistribution arrangement formed at least partially within the carrier structure; wherein the redistribution arrangement comprises at least two conductor structures each having a first conductor element extending through the carrier structure and electrically contacting one contact element of the component and a second conductor element being formed below the carrier structure, wherein at least a part of the second conductor element is configured for electrically contacting the redistribution arrangement with external circuitry, wherein a first spacing between the two contact elements is smaller than a second spacing between the two second conductor elements; and wherein the carrier structure comprises at least a polyimide layer and an adhesive layer, wherein the adhesive layer is directly attached to an upper surface of the polyimide layer and to a lower surface of the core structure and a lower surface of the component.

2. The packaged integrated circuit as set forth in claim 1, wherein the second conductor element is directly attached to the polyimide layer.

3. The packaged integrated circuit as set forth claim 1, wherein the cover structure is a laminated cover structure.

4. The packaged integrated circuit as set forth in claim 3, wherein the cover structure fills at least one side gap being present between a side surface of the component and a side wall of the cavity.

5. The packaged integrated circuit as set forth in claim 3, wherein the laminated cover structure is made from a single laminating sheet which includes an electrically insulating layer and at least one electrically conductive layer formed at a surface of the electrically insulating layer.

6. The packaged integrated circuit as set forth in claim 1, wherein each conductor structure further has a third conductor element being formed between the adhesive layer and the component, wherein at least a part of the third conductor element is a further contact pad for electrically contacting the component with the redistribution arrangement.

7. The packaged integrated circuit as set forth in claim 1, wherein the first conductor element is a metallized via.

8. The packaged integrated circuit as set forth in claim 1, wherein the core structure comprises a cured first PCB material selected from the group consisting of resin, reinforced or non-reinforced resin, epoxy resin or Bismaleimide-Triazine resin, FR-4, FR-5, cyanate ester, polyphenylene derivate, glass, prepreg material, polyimide, polyamide, liquid crystal polymer, epoxy-based Build-Up Film, polytetrafluoroethylene, a ceramic, and a metal oxide.

9. The packaged integrated circuit as set forth in claim 1, wherein the cover structure is made from a second PCB material selected from the group consisting of a prepreg material, a resin, a resin sheet, a cyanate ester, a polyphenylene derivate, a liquid crystal polymer, a resin-based Build-Up Film, an epoxy-based Build-Up Film.

10. The packaged integrated circuit as set forth in claim 1, wherein at least one of the redistribution arrangement and the at least one electrically conducting layer comprise a material being selected from the group consisting of copper, aluminum, nickel, silver, gold, palladium, and tungsten, any of the mentioned materials being optionally coated with a supra-conductive material.

11. The packaged integrated circuit as set forth in claim 1, wherein the component is selected from a group consisting of an active electronic component, an electronic chip, a storage device, a filter, a signal processing component, a power management component, an optoelectronic interface element, a voltage converter, a cryptographic component, a transmitter and/or receiver, an electromechanical transducer, a microprocessor, and a logic chip.

12. A method for manufacturing an integrated circuit package as set forth in claim 1, the method comprising: providing a core structure having a through passage cavity formed therein; placing an integrated circuit component in the cavity; providing an at least partially electrically insulating carrier structure and an electrically conducting redistribution arrangement below the core structure or the component; and forming an electrically insulating cover structure over the core structure and the component.

13. The method as set forth in claim 12, wherein, before placing the component in the cavity, the at least partially electrically insulating carrier structure is formed at a lower surface of the core structure such that, when placing the component in the cavity, the component is directly attached to an adhesive layer.

14. The method as set forth in claim 12, further comprising: before placing the component within the cavity, forming a temporary carrier structure at a lower surface of the core structure such that, when placing the component within the cavity, the component is directly attached to the temporary carrier structure; after forming the cover structure over the core structure and the component, removing the temporary carrier structure from the core structure or the component, respectively, and forming a carrier structure below the core structure and the component.

15. The method as set forth in claim 14, wherein, after the carrier structure has been formed below the core structure and the component, forming the redistribution arrangement at least partially within the carrier structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] FIG. 1A, FIG. 1B and FIG. 1C illustrate a procedure for manufacturing a packaged integrated circuit, in which an embedded integrated circuit component is mounted to a polyimide layer with an adhesive layer being sandwiched between the polyimide layer and the component.

[0048] FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D and FIG. 2E illustrate a manufacturing procedure for producing a packaged integrated circuit also having an adhesive layer being sandwiched between a polyimide layer and an embedded component, wherein a temporary carrier structure is used.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

[0049] The illustrations in the drawings are schematically presented. It is noted that in different figures, similar or identical elements or features are provided with the same reference signs or with reference signs, which are different from the corresponding reference signs only within the first digit. In order to avoid unnecessary repetitions elements or features, which have already been elucidated with respect to a previously described embodiment, are not elucidated again at a later position of the description.

[0050] Further, spatially relative terms, such as front and back, above and below, left and right, et cetera are used to describe an element's relationship to one or more other elements as illustrated in the figures. Thus, the spatially relative terms may apply to orientations in use which differ from the orientation depicted in the figures. Obviously, all such spatially relative terms refer to the orientation shown in the figures only for ease of description and are not necessarily limiting as an apparatus according to an embodiment of the invention can assume orientations different than those illustrated in the figures when in use.

[0051] FIG. 1A to FIG. 1C illustrate a procedure for manufacturing a packaged integrated circuit 100 in accordance with an embodiment of the invention.

[0052] As can be taken from FIG. 1A showing an intermediate product, an integrated circuit component 120 has been placed within a cavity 110a which has been formed within the core structure 110. The core structure 110 comprises at least one cured PCB material as specified above. In between a body of the integrated circuit component 120 and a sidewall of the cavity 110a there is an unfilled side gap 110b. In FIG. 1A, two of such side gaps 110b can be seen.

[0053] According to the embodiment described here, there is provided an upper structured metal layer 112, which is formed on the top surface of the core structure 110. This upper structured metal layer 112 may be used in a known manner for forming conductor paths and/or contact pads for contacting the embedded component 120 with external and/or internal circuitry.

[0054] The bottom of the cavity 110a, which has been originally formed as the so-called through passage cavity is closed by a carrier structure 140. In between the carrier structure 140 and a bottom surface of the core structure 100 there is formed a lower structured metal layer 114, which may also be used for forming conductor paths and/or contact pads.

[0055] The carrier structure 140 comprises a stack of electrically conducting and electrically insulating layers. Specifically, according to the embodiment described here the carrier structure 140 comprises an adhesive layer 144 being located at the bottom surface of the core structure 110 and, within the region of the cavity 110a at the bottom surface of the component 120. Further, within the regions of the pieces of the lower structured metal layer 114 the adhesive layer 144 adheres to these pieces. Below the adhesive layer 144 there is formed a polyimide layer 142. A stickiness of the adhesive layer 144 ensures that there is a reliable mechanical contact between the polyimide layer 142 and in particular the core structure 110 and (or respectively) the embedded integrated circuit component 120. Further, within the carrier structure 114 and below the polyimide layer 142 there is formed a metal layer 146, which according to the embodiment described here is copper layer 146.

[0056] FIG. 1B shows a further intermediate product which is formed when manufacturing the packaged integrated circuit 100. In this further intermediate product, a cover structure 130 has been laminated on top of the core structure 110 or the component 120, respectively. The cover structure 130 comprises a prepreg material layer, a resin sheet, or any as a suitable PCB material as specified above, wherein at least before a corresponding lamination procedure this PCB material is in an uncured state. As can be taken from FIG. 1B, after completing the lamination procedure the (PCB) material the cover structure 130 also fills the side gaps 110b, which improves the (mechanical) stability of the embedded integrated circuit component 120.

[0057] As can be further taken from FIG. 1B, a further processing has been carried out within or at the carrier structure 140. Specifically, the lower metal layer 146 has been structured such that contact pads 164 are formed. The contact pads 164 form part of an electric redistribution arrangement 150. Within the context of this document, the contact pads 164 are denominated second conductor elements 164. Specifically, each one of the second conductor elements 164 forms a part of a conductor structure 160, which itself forms a part of a redistribution arrangement 150. Preferably, as can be taken from FIG. 1B, the number of conductor structures 160 (of the redistribution arrangement 150) corresponds to the number of non-depicted contact elements or contact structures of the integrated circuit component 120. The entirety of the conductor structures 160 is used for electrically connecting the component 120 with not depicted external circuitry.

[0058] Apart from the above mentioned second conductor element 164, each conductor structure 160 comprises a second conductor element 164 which corresponds to pieces of the lower structured metal layer 114. Further, each conductor structure 160 comprises one first conductor element 162, which is realized by means of a metallized via 162 and which electrically connects the respective second conductor element 164 with a corresponding further contact pad 166, which corresponds to one of the above mentioned pieces of the lower structured metal layer 114.

[0059] FIG. 1C shows the packaged integrated circuit 100 as the final product of the above described manufacturing procedure. The final packaged integrated circuit 100 is obtained by performing a known separating or singularizing procedure. Thereby, a superordinate PCB structure comprising a plurality of structures as depicted in FIG. 1B is subdivided or singularized into a plurality of individual packaged integrated circuits 100.

[0060] FIG. 2A to 2E illustrate in accordance with a further embodiment of the invention a manufacture procedure for a packaged integrated circuit 200 also having an adhesive layer 144 being sandwiched between a polyimide layer 142 and an embedded component 120 or a core structure 110, respectively. It is mentioned that this embodiment is illustrated by way of example with an integrated circuit component 120, which, at least in the cross-sectional view shown in these Figures, only comprises two contact elements or contact structures.

[0061] As can be taken from a comparison between FIG. 1A elucidated above and FIG. 2A, a temporary carrier structure 270 is used instead of the carrier structure 140. Specifically, the temporary carrier structure 270 is used for closing the cavity 110a being originally a through passage cavity 110a at its bottom side. This means that when inserting the integrated circuit component 120 into the cavity 110a, the component 120 is placed onto the upper surface of the temporary carrier structure 270.

[0062] As can be taken from FIG. 2B, the cover structure 130 is laminated on top of the core structure 110 or the component 120. This procedure completely corresponds to the procedure illustrated in FIGS. 1A and 1B.

[0063] Next, as can be taken from FIG. 2C, the temporary carrier structure 270 is replaced by the carrier structure 140. The design of this carrier structure 140 has already been described above.

[0064] As can be taken from the FIGS. 2D and 2E, which correspond to the FIGS. 1B and 1C, respectively, for finalizing the packaged integrated circuit 200 an appropriate redistribution arrangement 150 is formed within the carrier structure 140 in order to provide an electric connection between the component 120 and external circuitry (not depicted). Further, a known separating or singularizing procedure is carried out in order to end up with the final packaged integrated circuit 200.

[0065] It should be noted that the term comprising does not exclude other elements or steps and the use of articles a or an does not exclude a plurality. Also, elements described in association with different embodiments may be combined.

LIST OF REFERENCE SIGNS

[0066] 100 packaged integrated circuit [0067] 110 core structure [0068] 110a cavity [0069] 110b side gap [0070] 112 upper structured metal layer [0071] 114 lower structured metal layer [0072] 120 integrated circuit component [0073] 130 cover structure [0074] 140 carrier structure [0075] 142 polyimide layer [0076] 144 adhesive layer [0077] 146 metal layer/copper layer [0078] 150 redistribution arrangement [0079] 160 conductor structure [0080] 162 first conductor element/metallized via [0081] 164 second conductor element/contact pad [0082] 166 third conductor element/further contact pad [0083] 200 packaged integrated circuit [0084] 270 temporary carrier structure