Electronic Package with Components Mounted at Two Sides of a Layer Stack
20230092954 · 2023-03-23
Inventors
Cpc classification
H01L24/95
ELECTRICITY
H01L25/18
ELECTRICITY
H01L2224/81395
ELECTRICITY
H01L2221/68359
ELECTRICITY
H01L2224/12105
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L24/20
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2225/1041
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/95
ELECTRICITY
H01L24/10
ELECTRICITY
H01L2225/1058
ELECTRICITY
H01L2224/95
ELECTRICITY
H01L2224/04105
ELECTRICITY
H01L23/552
ELECTRICITY
H01L25/16
ELECTRICITY
H01L23/5226
ELECTRICITY
H01L2221/68345
ELECTRICITY
H01L2223/6677
ELECTRICITY
H01L2224/16227
ELECTRICITY
H01L2224/81395
ELECTRICITY
H01L2225/06541
ELECTRICITY
International classification
H01L23/498
ELECTRICITY
H01L23/522
ELECTRICITY
Abstract
A method includes forming a layer stack with at least one electrically insulating layer structure and at least one patterned electrically conductive layer structure on a temporary carrier, the layer stack includes a lower surface adjoining the temporary carrier and an upper surface opposite to the lower surface; mounting a first component at the upper surface; placing a first frame structure at the upper surface, the first frame structure surrounding at least partially the first component; covering the first component with a first coating material, the first coating material spatially extending at least partially into voids at or within the first frame structure and into voids at or within the layer stack; and removing the temporary carrier. The lower surface of the layer stack is an even surface. The opposite upper surface of the layer stack is an uneven surface. An electronic package can be manufactured with the described method.
Claims
1. A method for manufacturing an electronic package, the method comprising: providing a temporary carrier; forming a layer stack comprising at least one electrically insulating layer structure and at least one patterned electrically conductive layer structure on the temporary carrier, wherein the layer stack comprises a lower surface adjoining the temporary carrier and an upper surface opposite to the lower surface; mounting a first component at the upper surface of the layer stack; placing a first frame structure at the upper surface of the layer stack, the first frame structure surrounding at least partially the first component; covering the first component with a first coating material, the first coating material spatially extending at least partially into voids at or within the first frame structure as well as into voids at or within the layer stack; and removing the temporary carrier from the layer stack; wherein the lower surface of the layer stack is an even surface and the opposite upper surface of the layer stack is an uneven surface.
2. The method as set forth in claim 1, wherein the first coating material is a first filler material, which monolithically fills at least partially communicating voids existing between the first component and the first frame structure and which extends into the layer stack.
3. The method as set forth in claim 1, further comprising: mounting a second component at the lower surface of the layer stack.
4. The method as set forth in claim 3, further comprising: placing a second frame structure at the lower surface of the layer stack, the second frame structure surrounding at least partially the second component; and optionally covering the second component with a second coating material, the first coating material spatially extending to the lower surface of the layer stack; wherein in particular the second coating material is a second filler material, with which voids existing between the second component and the second frame structure are filled.
5. The method as set forth in claim 3, further comprising: after covering the first component with the first coating material and before mounting the second component, attaching a further temporary carrier at an upper surface of the first component and/or at an upper surface of the first frame structure; and, after mounting the second component, removing the further temporary carrier.
6. The method as set forth in claim 3, further comprising: planarizing the upper surface of the first component and the upper surface of the first frame structure; and/or planarizing the lower surface of the second component and the lower surface of the second frame structure.
7. The method as set forth in claim 3, further comprising: mounting a further first component at the upper surface of the layer stack; placing a further first frame structure at the upper surface of the layer stack, the further first frame structure surrounding at least partially the further first component; and mounting a further second component at the lower surface of the layer stack; wherein in particular the method further comprises placing a further second frame structure at the lower surface of the layer stack, the further second frame structure surrounding at least partially the further second component.
8. The method as set forth in claim 7, further comprising: filling voids existing between the further first component and the further first frame structure with the first filler material; and/or filling voids existing between the further second component and the further second frame structure with the second filler material.
9. The method as set forth in claim 7: further comprising: performing at least on singularization process, such that the manufactured electronic package is separated into at least (i) an individual electronic package comprising a portion of the layer stack, the first component, the second component, the first frame structure, and the second frame structure; and (ii) a further individual electronic package comprising a further portion of the layer stack, the further first component, the further second component, the further first frame structure, and the further second frame structure.
10. An electronic package, comprising: a layer stack comprising at least one electrically insulating layer structure and at least one patterned electrically conductive layer structure forming at least partially a plurality of layer stack through connections extending at least partially from an upper surface of the layer stack to a lower surface of the layer stack, wherein the layer stack through connections are spatially arranged with a layer stack density; a first component mounted at the upper surface of the layer stack; and a first frame structure placed at the upper surface of the layer stack, the first frame structure surrounding at least partially the first component, wherein the first frame structure comprises a plurality of first frame through connections extending at least partially through the first frame structure, wherein the first frame through connections are spatially arranged with a first density being smaller than the layer stack density; wherein the first component is covered with a first coating material, which spatially extends at least partially into voids at or within the first frame structure as well as into voids at or within the layer stack; and wherein the lower surface of the layer stack is an even surface and the opposite upper surface of the layer stack is an uneven surface.
11. The electronic package as set forth in claim 10, wherein the density is a geometric property which relates to the spatial arrangement of the respective through connections within planes being parallel to the planar extension of the layers of the layer stack.
12. The electronic package as set forth in claim 10, further comprising: an electric interface connecting at least one of the layer stack through connections with at least one of the first frame through connections.
13. The electronic package as set forth in claim 10, further comprising: a second component mounted at the lower surface of the layer stack.
14. The electronic package as set forth in claim 10, wherein the first component is surrounded by a first filler material forming a first protection layer and a region of a first cavity between the first component and the layer stack is a first void, wherein in particular the first protection layer forms both a part of the layer stack and a part of the first frame structure; and/or wherein the second component is surrounded by a second filler material forming a second protection layer and a region of the second cavity between the second component and the layer stack is a second void.
15. The electronic package as set forth in claim 10, further comprising: a further layer stack, which is formed at the first frame structure and which comprises at least one further electrically insulating layer structure and at least one further patterned electrically conductive layer structure forming at least partially a plurality of further layer stack through connections extending from an upper surface of the further layer stack to a lower surface of the further layer stack, wherein the further layer stack through connections are spatially arranged with a further layer stack density being higher than the first density.
16. The electronic package as set forth in claim 10, further comprising: a third component mounted at the first frame structure and being electrically connected with the first frame through connections.
17. The electronic package as set forth in claim 13, further comprising: a second frame structure placed at the lower surface of the layer stack, the second frame structure surrounding at least partially the second component, wherein the second frame structure comprises a plurality of second frame through connections extending at least partially through the second frame structure, wherein the second frame through connections are spatially arranged with a second density being smaller than the layer stack density and/or wherein the second component is accommodated within a second cavity formed at least partially by the second frame structure, wherein voids existing within the second cavity are filled at least partially and preferably completely with a second filler material.
18. The electronic package as set forth in claim 17, wherein the second filler material forms both a part of the layer stack and a part of the second frame structure.
19. The electronic package as set forth in claim 10, wherein the layer stack through connections and/or the further layer stack through connections have a line spacing being smaller than 8 μm and the first frame through connections are arranged with a line spacing larger than 15 μm and in particular larger than 25 μm.
20. The electronic package as set forth in claim 10, further comprising: a first build-up structure formed above the first component and the first frame structure and/or a second build-up structure formed below the second component and the second frame structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0102] 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.
[0103] 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 another element(s) 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.
[0104]
[0105] As can be taken from
[0106] Next, an electrically insulating layer structure 124 is formed on the upper surface of the temporary carrier 110a in between the patterned pieces of the electrically conductive layer structure 122. The result is denominated with “(a2)”.
[0107] In next per se known process steps there are formed additional electrically insulating layer structures and electrically conductive layer structures resulting in a layer stack 120. As can be taken from the bottom image of
[0108] Within a main surface of the layer stack 120 the layer stack through connections 126 are spatially arranged close to each other, e.g., with an (average) Fine Line Spacing (FLS) of less than 10 μm. Hence, the (average) integration density of the layer stack through connections 126 within a (horizontal) plane being parallel to the main surface of the layer stack 120 is comparatively high.
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[0110] According to the embodiment described here together with the first component 130a there is (surface) mounted a further first component 130a′ at the upper surface of the layer stack 120. Thereby, the first component 130a and the further first component 130a′ are placed next to each other with a certain spacing in between. Also, the further first component 130a′ is electrically connected in an appropriate manner with the upper patterned electrically conductive layer structure 122. In
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[0112] It is mentioned that the insulating layer 144 may also be or comprise a stack including (copper) conductor structures. However, as mentioned already above, compared to layer stack 120 the conductor density is lower.
[0113] As can be seen from the middle figure portion “(c2)”, a first frame through connections 146 are formed in between two conductive pieces, one of the upper electrically conductive layer 142 and the other one from the lower electrically conductive layer 142.
[0114] Next, as can be taken from the lower figure portion “(c3)”, an opening 148 is formed within an insulating layer 144. This can be done, e.g., by means of laser cutting or any appropriate etching process, wherein a proper mask is applied in order to realize a spatially selective etching.
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[0116] As can be taken from
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[0118] Next, as can be seen from
[0119] It is pointed out that in reality the so far manufactured structure is flipped by 180° such that the further temporary carrier 110b is again located at the bottom. Thereby, the following manufacturing steps can be carried out (with the help of gravity) much easier. However, for these, ease of illustration, such a beneficial flipping is not shown here.
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[0123] Next, as can be taken from
[0124] Next, as can be taken from
[0125] Next, as can be taken from
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[0128] It is mentioned that of course the voids around the third components 130c, 130c′ which can be seen in
[0129] An important aspect of the embodiment described here is that structure of the temporary carrier 110a shown already in
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[0133] In the electronic package 200b the upper connection pads 272 may be used for electrically connecting the third component 130c with external circuitry. However, in some embodiments where the third component 130c is a Radio Frequency (RF) component, these pads are used as antenna elements 272.
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[0137] As can best be seen from
[0138] This approach, which works without any filler material, may result in a significant reduction of mechanical stress. Further, thermal conduction towards a neighboring component can be blocked or can be reduced at least significantly. This holds true, in particular, for vertically neighboring components accommodated within stacked layer structures.
[0139] Such a vertically neighboring component is provided in the electronic package shown in
[0140] Electric connections 489 are formed within the insulating layer 484 in order to electrically connect connection terminals 132 of the embedded component 488 from the upper side. In some RF applications the electric connections 489 may be used as antenna elements.
[0141] As can be seen from
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[0144] In the electronic package 500a the second component 130b is not surrounded by a frame structure. Instead, there is provided a bulk filler material 552 surrounding and protecting the second component 130b.
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[0146] It is mentioned that the electronic package comprises a not depicted structure which surrounds at least partially the third component in order to provide for a mechanic stability. This surrounding structure may be a known mold or a layer build-up, preferably with an appropriate filling material in order to stabilize the third component 530c in a smooth manner.
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[0150] It should be noted that the term “comprising” does not exclude other elements or steps and the article “a” or “an” does not exclude a plurality. Also, elements described in association with different embodiments may be combined.
[0151] Implementation of the invention is not limited to the preferred embodiments shown in the figures and described above. Instead, a multiplicity of variants are possible which variants use the solutions shown and the principle according to the invention even in the case of fundamentally different embodiments.
LIST OF REFERENCE SIGNS
[0152] 100 electronic package [0153] 110a temporary carrier [0154] 110b further temporary carrier [0155] 110c temporary carrier [0156] 120 layer stack [0157] 122 (patterned) electrically conductive layer structure [0158] 124 electrically insulating layer structure [0159] 126 layer stack through connections [0160] 128 electric interface [0161] 130a first component [0162] 130a′ further first component [0163] 130b second component [0164] 130b′ further second component [0165] 130c third component [0166] 130c′ further third component [0167] 132 connection terminal [0168] 140a first frame structure [0169] 140a′ further first frame structure [0170] 140b second frame structure [0171] 140b′ further second frame structure [0172] 140c third frame structure [0173] 140c′ further third frame structure [0174] 142 (patterned) conductive layer [0175] 144 insulating layer [0176] 146 first frame through connections/metallized via [0177] 148 opening [0178] 150a first filler material [0179] 150b second filler material [0180] 160 further layer stack [0181] 162 (patterned) electrically conductive layer structure [0182] 164 electrically insulating layer structure [0183] 166 layer stack through connections [0184] 200a stacked electronic package [0185] 200b singularized stacked electronic package [0186] 200c shielded singularized stacked electronic package [0187] 270 additional layer stack [0188] 272 connection pad/antenna element [0189] 274 shielding layer [0190] 300 stacked electronic package [0191] 349 inner frame region [0192] 370 additional layer stack [0193] 400 electronic package [0194] 475 open cavity [0195] 476 component cover/coating material/protection layer [0196] 477 voids [0197] 480 build-up structure [0198] 482 (patterned) conductive layer [0199] 484 insulating layer [0200] 486 first frame through connections/metallized via [0201] 487 air gap/gas gap [0202] 488 embedded component [0203] 489 electric connection/antenna element [0204] 500a-e electronic package [0205] 530b second component [0206] 530c third component [0207] 552 bulk filler material [0208] 576 component cover/coating material [0209] SB solder ball