Semiconductor device assembly with heat transfer structure formed from semiconductor material
10297577 ยท 2019-05-21
Assignee
Inventors
- Sameer S. Vadhavkar (Boise, ID, US)
- Jaspreet S. Gandhi (Milpitas, CA, US)
- James M. Derderian (Boise, ID, US)
Cpc classification
H01L23/373
ELECTRICITY
H01L25/18
ELECTRICITY
H01L2224/73204
ELECTRICITY
H01L2224/0401
ELECTRICITY
H01L21/78
ELECTRICITY
H01L2224/131
ELECTRICITY
H01L2224/73204
ELECTRICITY
H01L24/97
ELECTRICITY
H01L2225/06513
ELECTRICITY
H01L2924/167
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2225/06517
ELECTRICITY
H01L2224/94
ELECTRICITY
H01L2224/92242
ELECTRICITY
H01L2224/16146
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2924/16251
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L24/94
ELECTRICITY
H01L2224/16227
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L2225/06541
ELECTRICITY
H01L2924/16235
ELECTRICITY
H01L23/4012
ELECTRICITY
H01L2224/0557
ELECTRICITY
H01L2225/06555
ELECTRICITY
H01L2224/13025
ELECTRICITY
H01L2224/97
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L23/3178
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2224/97
ELECTRICITY
H01L2224/94
ELECTRICITY
H01L24/73
ELECTRICITY
International classification
H01L25/065
ELECTRICITY
H01L25/00
ELECTRICITY
H01L21/78
ELECTRICITY
H01L23/373
ELECTRICITY
H01L23/40
ELECTRICITY
Abstract
Semiconductor device assemblies with heat transfer structures formed from semiconductor materials are disclosed herein. In one embodiment, a semiconductor device assembly can include a thermal transfer structure formed from a semiconductor substrate. The thermal transfer structure includes an inner region, an outer region projecting from the inner region, and a cavity defined in the outer region by the inner and outer regions. The semiconductor device assembly further includes a stack of first semiconductor dies in the cavity, and a second semiconductor die attached to the outer region of the thermal transfer structure and enclosing the stack of first semiconductor dies within the cavity.
Claims
1. A semiconductor device assembly, comprising: a semiconductor substrate having an outer surface, a first cavity formed in the outer surface, a second cavity formed in the outer surface, and a dicing lane between the first and second cavities, wherein the first cavity is defined by a first recessed surface of the semiconductor substrate and a first sidewall surface of the semiconductor substrate extending from the first recessed surface, and the second cavity is defined by a second recessed surface of the semiconductor substrate and a second sidewall surface of the semiconductor substrate extending from the second recessed surface; a stack of first semiconductor dies in the first cavity, wherein the first sidewall surface is separated from the stack of first semiconductor dies by a first gap, a stack of second semiconductor dies in the second cavity, wherein the second sidewall surface is separated from the stack of second semiconductor dies by a second gap; a third semiconductor die attached to the outer surface of the semiconductor substrate and enclosing the stack of first semiconductor dies within the first cavity; a fourth semiconductor die attached to the outer surface of the semiconductor substrate and enclosing the stack of second semiconductor dies within the second cavity; and an underfill material having a first fillet in the first gap and a second fillet in the second gap.
2. The semiconductor device assembly of claim 1 wherein the first cavity has at least one dimension different than a corresponding dimension of the second cavity.
3. The semiconductor device assembly of claim 1 wherein the number of first semiconductor dies is greater than the number of second semiconductor dies.
4. The semiconductor device assembly of claim 3 wherein at least one dimension of the first cavity is greater than a corresponding dimension of the second cavity.
5. The semiconductor device assembly of claim 1 wherein a portion of a surface of the third semiconductor die is exposed in the first gap, and wherein a portion of a surface of the fourth semiconductor die is exposed in the second gap.
6. The semiconductor device assembly of claim 1 wherein the semiconductor substrate, the first semiconductor dies, the second semiconductor dies, the third semiconductor die, and the fourth semiconductor die are each formed from the same semiconductor material.
7. The semiconductor device assembly of claim 1 wherein the semiconductor substrate comprises silicon.
8. The semiconductor device assembly of claim 1 wherein the third semiconductor die has a base region attached to an uppermost one of the first semiconductor dies, and a peripheral region adjacent to the base region and attached to the outer surface of the semiconductor substrate, and the fourth semiconductor die has a base region attached to an uppermost one of the second semiconductor dies, and a peripheral region adjacent to the base region and attached to the outer surface of the semiconductor substrate.
9. A method of forming semiconductor device assemblies, comprising: positioning a stack of first semiconductor dies in a first cavity of a semiconductor wafer formed from a semiconductor material, wherein the first cavity is defined by a first recessed surface of the semiconductor wafer and a first sidewall surface of the semiconductor wafer extending from the first recessed surface, and wherein the first sidewall surface is separated from the stack of first semiconductor dies by a first gap; positioning a stack of second semiconductor dies in a second cavity of the semiconductor wafer, wherein the second cavity is defined by a second recessed surface of the semiconductor substrate and a second sidewall surface of the semiconductor substrate extending from the second recessed surface, and wherein the second sidewall surface is separated from the stack of second semiconductor dies by a second gap; disposing an underfill material in the first and second cavities such that the underfill material has (a) a first fillet in the first gap and (b) a second fillet in the second gap; attaching a portion of a third semiconductor die to the semiconductor wafer such that the third semiconductor die covers an opening of the first cavity; attaching a portion of a fourth semiconductor die to the semiconductor wafer such that the fourth semiconductor die covers an opening of the second cavity; and singulating the semiconductor wafer along a dicing lane between the first and second cavities.
10. The method of claim 9, further comprising forming the first and second cavities in the semiconductor wafer.
11. The method of claim 10 wherein at least one of a width, length, or shape of the first cavity is based on a shape of the stack of first semiconductor dies, and wherein at least one of a width, length, or shape of the second cavity is based on a shape of the stack of second semiconductor dies.
12. The method of claim 11 wherein at least one of the width, length, or shape of the first cavity is different than the width, length, or shape of the second cavity.
13. The method of claim 9 wherein positioning the stack of first semiconductor dies in the first cavity includes positioning an initial one of the first semiconductor dies in the first cavity and subsequently stacking additional ones of the first semiconductor dies upon the initial one of the first semiconductor dies, and/or positioning the stack of second semiconductor dies in the second cavity includes positioning an initial one of the second semiconductor dies in the second cavity and subsequently stacking additional ones of the second semiconductor dies upon the initial one of the second semiconductor dies.
14. The method of claim 9 wherein positioning the stack of first semiconductor dies in the first cavity includes mounting the first semiconductor dies in the first cavity collectively as a single unit, and/or positioning the stack of second semiconductor dies in the second cavity includes mounting the second semiconductor dies in the second cavity collectively as a single unit.
15. The method of claim 9, further comprising thinning the semiconductor wafer at least below the first and second cavities.
16. A semiconductor device assembly, comprising: a semiconductor wafer formed from a semiconductor material, wherein the semiconductor wafer includes an inner region, an outer region projecting from the inner region, and a plurality of cavities defined in the outer region by the inner and outer regions, and wherein individual ones of the cavities are defined by a recessed surface of the semiconductor wafer and a sidewall surface of the semiconductor wafer extending from the recessed surface; memory dies stacked in the cavities, wherein the memory dies in individual ones of the cavities are spaced apart from the sidewall surface of the cavity by a gap; an underfill material having fillets in the gaps; logic dies including a base region and a peripheral region adjacent to the base region, wherein the peripheral region of each logic die is attached to the semiconductor wafer, and wherein the logic dies enclose respective ones of the memory dies within the cavities; and wherein the semiconductor wafer further includes a plurality of dicing lanes between the logic dies.
17. The semiconductor device assembly of claim 16 wherein the inner region of the semiconductor wafer below the cavities has a thickness of from about 50 m to about 200 m.
18. The semiconductor device assembly of claim 16, further comprising package support substrates electrically coupled to corresponding ones of the logic dies.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(5) Specific details of several embodiments of stacked semiconductor die assemblies with a thermal transfer structure formed from a semiconductor material are described below. The term semiconductor device generally refers to a solid-state device that includes semiconductor material. A semiconductor device can include, for example, a semiconductor substrate, wafer, or die that is singulated from a wafer or substrate. Throughout the disclosure, semiconductor devices are generally described in the context of semiconductor dies; however, semiconductor devices are not limited to semiconductor dies.
(6) The term semiconductor device package can refer to an arrangement with one or more semiconductor devices incorporated into a common package. A semiconductor package can include a housing or casing that partially or completely encapsulates at least one semiconductor device. A semiconductor device package can also include an interposer substrate that carries one or more semiconductor devices and is attached to or otherwise incorporated into the casing. The term semiconductor device assembly can refer to an assembly of one or more semiconductor devices, semiconductor device packages, and/or substrates (e.g., interposer, support, or other suitable substrates).
(7) As used herein, the terms vertical, lateral, upper, and lower can refer to relative directions or positions of features in the semiconductor device in view of the orientation shown in the Figures. For example, upper or uppermost can refer to a feature positioned closer to the top of a page than another feature. These terms, however, should be construed broadly to include semiconductor devices having other orientations, such as inverted or inclined orientations where top/bottom, over/under, above/below, up/down, and left/right can be interchanged depending on the orientation.
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(9) The first die 104 includes a base region 122 and a peripheral region 124 (known to those skilled in the art as a porch or shelf) adjacent the base region 122 and attached to the outer surface 120 of the TTS 106 with a first adhesive 126. The second dies 108 are arranged in a stack 128 (die stack 128) on the base region 122 of the first die 104 and are attached to the recessed surface 116 of the TTS 106 by a second adhesive 130, which can be the same adhesive as the first adhesive 126 or a different adhesive. Suitable adhesives can include, for example, a thermal interface material (TIM) or other adhesive containing, e.g., silicone-based greases, gels, or adhesives that are doped with conductive materials (e.g., carbon nano-tubes, solder materials, diamond-like carbon (DLC), etc.), as well as phase-change materials. The assembly 100 further includes an underfill material 132 between each of the second dies 108 and between the first die 104 and the bottom second die 108. The underfill material 132 can include an excess portion 134 that extends into a gap g.sub.1 between the die stack 128 and the sidewall surface 118 of the outer region 112. In some embodiments, the gap g.sub.1 can be sized to prevent or inhibit the spread of the excess underfill material 132 onto the outer surface 120 of the outer region 112 during deposition of the underfill material 132.
(10) Each of the first and second dies 104 and 108 can be formed using a semiconductor substrate 151a and 151b, respectively, and can include various types of semiconductor components and functional features, such as dynamic random-access memory (DRAM), static random-access memory (SRAM), flash memory, other forms of integrated circuit memory, processing circuits, imaging components, and/or other semiconductor features. In various embodiments, for example, the assembly 100 can be configured as a hybrid memory cube (HMC) in which the stacked second dies 108 are DRAM dies or other memory dies that provide data storage and the first die 104 is a high-speed logic die that provides memory control (e.g., DRAM control) within the HMC. In other embodiments, the first and second dies 104 and 108 may include other semiconductor components and/or the semiconductor components of the individual second dies 108 in the die stack 128 may differ. In the embodiment illustrated in
(11) The die stack 128 can be electrically coupled to the package support substrate 102 and to one another by a plurality of electrically conductive elements 138 (e.g., copper pillars, solder bumps, and/or other conductive features). Each of the first and second dies 104 and 108 can include a plurality of through-silicon vias (TSVs) 140 that are coupled on opposite sides to the conductive elements 138. In addition to electrical communication, the conductive elements 138 and the TSVs 140 transfer heat away from the die stack 128 and toward the semiconductor material 150 of the TTS 106. In some embodiments, the assembly 100 can also include a plurality of thermally conductive elements or dummy elements (not shown) positioned interstitially between the first and second dies 104 and 108 to further facilitate heat transfer through the die stack 128. Such dummy elements can be at least generally similar in structure and composition to the conductive elements 138 and/or the TSVs 140 except that they are not electrically coupled to the other circuitry of the first and second dies 104 and 108.
(12) During operation of the assembly 100, the semiconductor material 150 of the TTS 106 absorbs and dissipates the thermal energy produced by the first and second dies 104 and 108. In the embodiment illustrated in
(13) In some embodiments described in greater detail below, the features of the TTS 106 are formed using semiconductor fabrication techniques. For example, in one embodiment, the cavity 114 can be formed in a semiconductor wafer using etching techniques having relatively tight dimensional tolerances to increase the planarity of the sidewall surface 118 and to precisely control the size of the gap g.sub.1 between the sidewall surface 118 and the die stack 128. For example, in some embodiments, the gap g.sub.1 can have a thickness that is less than or equal to 500 m, such as less than or equal to 200 m (e.g., 100 m or 50 m or less). In another embodiment, the gap g.sub.1 can be eliminated or nearly eliminated, and the sidewall surface 118 can directly contact one or more of the second dies 108 along corresponding edges 109 of the dies 108. Such precise control of the size of the gap g.sub.1 can decrease or eliminate the gap compared to other processing techniques. Decreasing the gap g.sub.1 allows the outer region 112 of the TTS 106 to be located closer to the die stack 128 and can increase the footprint of the outer region over a coverage area (A) of the peripheral region 124 of the first die 104 adjacent the stack 128, thereby increasing heat transfer efficiency between the outer and peripheral regions 112 and 124. Decreasing the gap g.sub.1 also reduces the amount of underfill material 132 needed to fill the cavity 114. By contrast, other devices that employ a thermally conductive structure typically include a metal lid formed from a malleable metal (e.g., aluminum) that is mechanically bent or folded into a lid to cover the die stack. Because such lids are shaped by bending the metal lid material, these devices typically have relatively larger dimensional tolerances for the gap between the interior side of the lid and the die stack. These devices can also require a relatively larger amount of underfill material due to the larger gap.
(14) In certain embodiments, the semiconductor material 150 of the TTS 106 is the same material as the substrate 151a of the first die 104 and/or the substrate 151b of one or more of the second dies 108. Therefore, the semiconductor material 150 can have a coefficient of thermal expansion (CTE) that is substantially similar to the CTE of the substrates of the first die 104 and/or the second dies 108. As a result, the TTS 106 can have generally the same amount of volumetric thermal expansion as the first die 104 and/or the second dies 108 at elevated operating temperatures. For example, when the outer region 112 of the TTS 106 and the peripheral region 124 of the first die 104 expand due to an increase in temperature, as shown in
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(16) As further shown in
(17) The wafer 250 can be used to form several TTSs 106, and as such several cavities 114 can be formed such that each cavity 114 is associated with an individual TTS 106. In some embodiments, all of the cavities 114 can be configured the same, but in other embodiments one or more of the cavities 114 can have different configurations than the others to accommodate differently sized die stacks. In such cases, some cavities 114 can contain a different number and/or sizes of semiconductor dies than other cavities 114.
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(21) As further shown in
(22) In alternate embodiments, the second dies 108 are mounted in the cavity 114 of the TTS 106 (e.g., individually or collectively as a single unit) after it has been singulated from the wafer 250 (e.g., rather than mounting the second dies 108 at the stage shown in
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(24) Any one of the stacked semiconductor device assemblies described above with reference to
(25) From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the disclosure. For example, in one embodiment, the cavity 114 can be positioned off center, and the outer region 112 on one side of the cavity may be larger than the outer region on the other. Further, although many of the embodiments of the semiconductor dies assemblies are described with respect to HMCs, in other embodiments the semiconductor die assemblies can be configured as other memory devices or other types of stacked die assemblies. In addition, certain aspects of the new technology described in the context of particular embodiments may also be combined or eliminated in other embodiments. Moreover, although advantages associated with certain embodiments of the new technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.