Silicon package for embedded semiconductor chip and power converter
10062624 ยท 2018-08-28
Assignee
Inventors
- Osvaldo Jorge Lopez (Annandale, NJ, US)
- Jonathan Almeria Noquil (Bethlehem, PA, US)
- Tom Grebs (Bethlehem, PA, US)
- Simon John Molloy (Allentown, PA, US)
Cpc classification
H01L2224/293
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/3303
ELECTRICITY
H01L2224/293
ELECTRICITY
H01L24/97
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/15153
ELECTRICITY
H01L2924/13091
ELECTRICITY
H01L2224/32227
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L21/481
ELECTRICITY
H01L2224/2929
ELECTRICITY
H01L2924/157
ELECTRICITY
H01L2224/04026
ELECTRICITY
H01L2224/2929
ELECTRICITY
H01L21/4846
ELECTRICITY
International classification
H01L23/14
ELECTRICITY
H01L23/373
ELECTRICITY
Abstract
A packaged transistor device (100) comprises a semiconductor chip (101) including a transistor with terminals distributed on the first and the opposite second chip side; and a slab (110) of low-grade silicon (l-g-Si) configured as a ridge (111) framing a depression including a recessed central area suitable to accommodate the chip, the ridge having a first surface in a first plane and the recessed central area having a second surface in a second plane spaced from the first plane by a depth (112) at least equal to the chip thickness, the ridge covered by device terminals (120; 121) connected to attachment pads in the central area having the terminals of the first chip side attached so that the terminals (103) of the opposite second chip side are co-planar with the device terminals on the slab ridge.
Claims
1. A packaged transistor device comprising: a semiconductor chip having a thickness, the chip including a transistor with terminals distributed on a first side and an opposite second side of the semiconductor chip; a slab of silicon including a recessed area and at least one ridge bordering the recessed area, the ridge having a first surface in a first plane, and the recessed area having a second surface in a second plane spaced from the first plane by a depth at least equal to the thickness, the at least one ridge having a metal layer configured as terminals of the transistor device and the recessed area having pads; and the terminals of the first side attached to the pads so that the terminals of the opposite second side are co-planar with the device terminals, wherein the slab serves as a package of the transistor device, and wherein the terminals of the opposite second side are exposed from the package.
2. The device of claim 1, wherein the silicon is selected from a group consisting of reclaimed silicon, unrefined silicon, undoped silicon, polycrystalline silicon, intrinsic polycrystalline silicon, doped n-type polycrystalline silicon, and doped p-type polycrystalline silicon.
3. The device of claim 1, wherein the transistor is a MOS field-effect transistor (FET) with the terminal on the first side being a drain terminal and the terminal on the opposite second side being a source terminal.
4. The device of claim 1, wherein the transistor is a bipolar transistor with the terminal on the first side being an emitter terminal and terminal on the opposite second side being a collector terminal.
5. The device of claim 1, wherein the chip is made of a single-crystalline material selected from a group consisting of silicon, silicon germanium, gallium nitride, gallium arsenide, and other III-V and II-VI compounds.
6. The device of claim 1, wherein the depth between the first plane and the second plane is bridged by a step of the silicon material inclined at an angle less than vertical.
7. The device of claim 6, wherein the pads are conductively connected to the device terminals across the step, the connection being covered with a passivation layer.
8. The device of claim 1, wherein the at least one ridge is selected from a group of configurations consisting of a single ridge, two ridges parallel to each other, three ridges, and four ridges arranged as a rectangle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10)
(11) In the example of
(12) As
(13) As indicated in
(14) While the exemplary device of
(15) With chip 101 inserted in the depression of slab 110, slab 110 can act as the package of transistor device 100. When chip 101 is made of silicon, there is practically no longer any difference of the coefficients of thermal expansion between chip and package, and thermo-mechanical stresses are in first order eliminated. Consequently, the risk of material-related delamination between chip and package is diminished and the device reliability greatly enhanced.
(16) Another embodiment of the invention is a method of fabricating semiconductor slabs suitable as device packages, and a method of fabricating a packaged transistor device.
(17) In the next process for both l-g-Si choices, a first insulating layer is formed on the surface of the wafer, the layer covering all slab sites. The preferred technique of forming an insulating surface layer is thermally oxidizing the silicon. Alternative techniques include depositing a layer of silicon dioxide, silicon nitride, silicon carbide, or a combination thereof, and depositing an insulating compound different from a silicon compound.
(18) Then, the first insulating layer is removed from the central portion of each slab site to expose the underlying l-g-Si, while leaving un-removed the first insulating layer over the peripheral site portions to form a ridge framing each central portion.
(19) In the next process, the exposed l-g-Si of the central area of each slab site is etched, for instance using KOH, to create a depression with a second l-g-Si surface having a flat central portion in a second plane 291 recessed from the first plane by a depth 112. For the discrete slab site 401 in
(20) In the process flow leading up to the packaged transistor device of
(21) Next, at least one layer 202 of metal is deposited onto the second insulating layer 201, covering all slab sites. Preferably, first a layer of a refractory metal such as titanium is selected, followed by a compound layer such as titanium nitride. Alternative choices include a layer of tungsten, or titanium-tungsten, or another refractory metal. The refractory metal adheres strongly to insulating layer 201. Then, a layer 203 of aluminum is deposited onto the refractory metal layer; layer 203 is preferably thicker than layer 202. For some applications, it is preferred to deposit a layer of nickel and a thin layer of gold (both layers designated 204 in
(22) Next, the metal layers 202 and 203 are patterned in the central site portion of each slab site. The result of the patterning is a plurality of pads matching the terminals of a transistor; in addition, the metal on the ridges is retained as terminals.
(23) In the next process step, a plurality of chips 101 is provided, which include transistors with terminals on the first and the second chip side. As an example, the chips may have a FET with a source terminal 104 and a gate terminal 105 on the first chip side and a drain terminal 103 on the opposite second chip side. The terminals of the first chip sides are then attached to respective pads in the central portion of each slab site; the attachment is performed so that the terminals 103 of the opposite second chip side are co-planar with the metal layer of the ridges framing each central portion. It is preferred that for the attaching process of the chip to the slab, an adhesive conductive polymeric compound, such as a B-stage epoxy or polyimide, is used. Alternatively, a solder compound or a z-axis conductor may be employed. After the attachment, the metal layers of the ridges have morphed into device terminal 120 (source terminal) and device terminal 121 (gate terminal), and each slab 210 has morphed into the package of a transistor device 200.
(24)
(25) The discrete transistor device 200 offers a blank silicon surface 220 suitable for attaching a heat sink to the device surface opposite the attached chip, greatly improving the heat dissipation and thermal performance of the device.
(26) In the process flow leading up to the packaged transistor device of
(27) At each slab site, the second insulating layer 301 is removed, preferably by etching, from selected pads matching certain terminals of a transistor in order to expose the surface 310a of the underlying low-resistivity l-g-Si.
(28) Next, at least one layer 302 of metal is deposited onto the remaining second insulating layer 301 and the exposed surface 310a of the doped l-g-Si slab, covering all slab sites. Preferably, first a layer of a refractory metal such as titanium is selected, followed by a compound layer such as titanium nitride. Alternative choices include a layer of tungsten, or titanium-tungsten, or another refractory metal. The refractory metal adheres strongly to insulating layer 301 as well as to doped silicon surface 310a. Then, a layer 303 of aluminum is deposited onto the refractory metal layer; layer 303 is preferably thicker than layer 302. For some applications, it is preferred to deposit a layer of nickel and a thin layer of gold (both layers designated 304 in
(29) Next, the metal layers 302 and 303 are patterned in the central site portion of each slab site. The result of the patterning is a plurality of pads matching the terminals of a transistor; in addition, the metal on the ridges is retained as terminals. After the patterning, a layer 305 of passivation material such as silicon nitride is deposited onto the patterned metal layer, covering all slab sites. Passivation layer 305 is then removed, at each slab site, from the terminals on the ridges and from the pads in the central portion in order to expose the underlying metal; on the other hand, the passivation material 305 over the slopes and between the pads is left un-removed.
(30) In the next process step, a plurality of chips 101 is provided, which include transistors with terminals on the first and the second chip side. As an example, the chips may have a FET with a source terminal 104 and a gate terminal 105 on the first chip side and a drain terminal 103 on the opposite second chip side. The terminals of the first chip sides are then attached to respective pads in the central portion of each slab site; the attachment is performed so that the terminals 103 of the opposite second chip side are co-planar with the metal layer of the ridges framing each central portion. After the attachment, chip terminal 104 (in the example, the source terminal) is shorted to the slab, while chip terminal 105 (in the example, the gate terminal) is isolated from the slab.
(31) Another embodiment of the invention, a packaged electronic system generally designated 700, is illustrated in
(32) In the exemplary embodiment of a packaged electronic system depicted in
(33) The ridge with its insulating layer is covered by a metal layer patterned as system terminals. In the converter example of
(34) In the attaching process of the chips, the drain of low-side FET 720 is attached, without flipping the chip, to the recessed central slab area so that the source terminal 721 and gate terminal 722 of the low side become co-planar with the system terminals 750 and 741 of the slab ridge. Terminal 721 is electrically connected to ground potential. In analogous fashion, the source of the high-side FET 730 is attached, without flipping the chip, to the recessed central slab area so that the drain terminal 731 and the gate terminal 732 of the high side become co-planar with the system terminals 750 and 741 of the slab ridge. Terminal 731 is electrically connected to input supply V.sub.IN. For the attachment, chip 740 is flipped so that its terminals are facing slab 710 and can be attached to respective slab pads; the opposite and blank (terminal-free) side of chip 740 becomes co-planar with the ridge terminals of the slab. With co-planarity of chip and slab terminals established, slab 710 can serve as the package of the system.
(35) The method for fabricating a packaged electronic system as shown in
(36) In the next process step, the metal layers of each site are patterned into interconnected pads and terminals. The pads are in the central area and match the chip terminals of transistors and circuits; the terminals are on the ridges and are operable as terminals for the system. The techniques for depositing and patterning the metal layers are described above.
(37) Next, semiconductor chips are provided. In the example of
(38) In the next process, the terminals of the first chip sides of both sets of chips are attached to respective pads in the central area of each slab site. It is preferred that a conductive adhesive polymeric compound is used for the attachment; alternatively, solder may be used. In either approach, the attachment is performed so that the opposite second chip sides are co-planar with the ridges, which frame each central area. The co-planarity facilitates an attachment of the system to an integrated circuit board or other mother board of end-users. By establishing the co-planarity, the slab serves as the package of the electronic system.
(39) Another embodiment of the invention, a packaged power converter system 800 with different transistor chip arrangement from
(40) In the exemplary embodiment of a packaged electronic system depicted in
(41) The ridge with its insulating layer is covered by a metal layer patterned as system terminals. In the converter example of
(42) In the attaching process of the chips, the low side FET 820 (a source down FET) is flipped so that the drain terminal 823 and the gate terminal 822 can be attached to the recessed central slab area, while the source terminal 721 becomes co-planar with the system terminals 750 and 741 of the slab ridge. Terminal 821 is electrically connected to ground potential. In analogous fashion, the high-side FET 730 (a drain down FET) is flipped so that the source terminal 831 and the gate terminal 832 can be attached to the recessed central slab area, while the drain terminal 833 becomes co-planar with the system terminals 750 and 741 of the slab ridge. Terminal 833 is electrically connected to input supply V.sub.IN. For the attachment, chip 740 is flipped so that its terminals are facing slab 810 and can be attached to respective slab pads; the opposite and blank (terminal-free) side of chip 840 becomes co-planar with the ridge terminals of the slab. With co-planarity of chip and slab terminals established, slab 810 can serve as the package of the system.
(43) The method for fabricating a packaged electronic system as shown in
(44) In the next process step, the metal layers of each site are patterned into interconnected pads and terminals. The pads are in the central area and match the chip terminals of transistors and circuits; the terminals are on the ridges and are operable as terminals for the system. The techniques for depositing and patterning the metal layers are described above.
(45) Next, semiconductor chips are provided. In the example of
(46) In the next process, the terminals of the first chip sides of both sets of chips are attached to respective pads in the central area of each slab site. It is preferred that a conductive adhesive polymeric compound is used for the attachment; alternatively, solder may be used. In either approach, the attachment is performed so that the opposite second chip sides are co-planar with the ridges, which frame each central area. The co-planarity facilitates an attachment of the system to an integrated circuit board or other mother board of end-users. By establishing the co-planarity, the slab serves as the package of the electronic system.
(47) While this invention has been described in reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. As an example, the invention applies not only to field effect transistors, but also to other suitable power transistors, to bipolar transistors, insulated gate transistors, thyristors, and others.
(48) As another example, the above considerations for structure and fabrication method of power converters apply to regulators, multi-output power converters, applications with sensing terminals, applications with Kelvin terminals, and others.
(49) As another example, the high current capability of the packaged transistors and converter can be further extended, and the efficiency further enhanced, by using the blank backside of the l-g-Si, after attachment of the devices to a board, so that the back side can be connected to a heat sink, preferably. In this configuration, the device can dissipate its heat into the board as well as into the heat sink.
(50) It is therefore intended that the appended claims encompass any such modifications or embodiments.