METHOD OF MANUFACTURING SEMICONDUCTOR PACKAGE USING DOUBLE ADHESIVE LAYERS
20250022830 ยท 2025-01-16
Assignee
Inventors
Cpc classification
H01L25/50
ELECTRICITY
H01L21/568
ELECTRICITY
H01L2224/32225
ELECTRICITY
International classification
H01L25/00
ELECTRICITY
Abstract
First and second layers of different adhesive materials are laminated to a carrier such that the second adhesive layer is attached to the carrier. The first adhesive layer is cured first. A semiconductor die is then placed on the cured first adhesive layer. An encapsulant layer is formed over at least a portion of the cured first adhesive layer while encapsulating the first semiconductor die. The second adhesive layer is cured after which the carrier is separated from the cured second adhesive layer.
Claims
1. A method of manufacturing a semiconductor package, the method comprising: laminating an adhesive sheet comprising first and second adhesive layers, to a carrier, wherein the second adhesive layer being coupled to the carrier; curing the first adhesive layer to produce a cured first adhesive layer; arranging a first semiconductor die on the cured first adhesive layer; forming an encapsulant layer on a portion of the first cured first adhesive layer, while encapsulating the first semiconductor die; curing the second adhesive layer to produce a cured second adhesive layer; and separating the carrier from the cured second adhesive layer.
2. The method of claim 1, wherein the first adhesive layer comprises a thermosetting adhesive, and wherein the second adhesive layer comprises a photocurable adhesive.
3. The method of claim 2, wherein the first adhesive layer further comprises a filler.
4. The method of claim 3, wherein the first adhesive layer further comprises a colorant.
5. The method of claim 2, wherein the second adhesive layer further comprises a filler.
6. The method of claim 5, wherein the second adhesive layer further comprises a colorant.
7. The method of claim 2, wherein the step of curing the first adhesive layer comprises heating the thermosetting adhesive and the photocurable adhesive.
8. The method of claim 2, wherein the step of curing the second adhesive layer comprises irradiating light for curing to the photocurable adhesive.
9. The method of claim 8, wherein the light for curing comprises ultraviolet (UV).
10. The method of claim 1, wherein the cured second adhesive layer has an adhesive strength less than an adhesive strength of the second adhesive layer before curing, while the second adhesive layer curing.
11. The method of claim 1, further comprising forming redistribution layers electrically connected to the first semiconductor die over the encapsulant layer.
12. The method of claim 11, further comprising forming outer terminals electrically connected to the redistribution layers.
13. The method of claim 1, further comprising forming a vertical connector, which is connected to the first semiconductor die before forming the encapsulant layer.
14. The method of claim 13, wherein the vertical connector is formed as a bonding wire that has one end coupled to the first semiconductor die and extends substantially vertically from the one end.
15. The method of claim 13, wherein the encapsulant layer is formed to substantially encapsulate the vertical connector.
16. The method of claim 1, further comprising stacking a second semiconductor die over the first semiconductor die before forming the encapsulant layer.
17. The method of claim 16, wherein the second semiconductor die is stacked over the first semiconductor die with a first off-set, a portion of the second semiconductor die protruding from the first semiconductor die in a first direction.
18. The method of claim 17, further comprising stacking a third semiconductor die over the second semiconductor die with a second off-set, a portion of the third semiconductor die protruding from the second semiconductor die in a second direction opposite to the first direction.
19. The method of claim 18, wherein the first semiconductor die is attached to the cured first adhesive layer by a third adhesive layer.
20. A method of manufacturing a semiconductor package, the method comprising: forming first and second adhesive layers on a carrier; first curing the first adhesive layer to produce a cured first adhesive layer; arranging a first semiconductor die on the cured first adhesive layer; forming an encapsulant layer on a portion of the cured first adhesive layer while encapsulating the first semiconductor die; curing the second adhesive layer to produce a cured second adhesive layer; and separating the carrier from the cured second adhesive layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0019] The terms used herein may correspond to words selected in consideration of their functions in presented embodiments, and the meanings of the terms may be construed to be different according to ordinary skill in the art to which the embodiments belong. If defined in detail, the terms may be construed according to the definitions. Unless otherwise defined, the terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiments belong.
[0020] In the description of the present disclosure, descriptions such as first and second, bottom, top, side, surface and lower are for distinguishing elements and are not used to limit the elements themselves or to imply a specific order. In the description of the present disclosure, descriptions such as on or under or beneath mean a relative positional relationship, but do not limit a specific case in which another member is further introduced into direct contact with the element or at an interface between them. The same interpretation can be applied to other expressions describing the relationship between components.
[0021] The same reference numbers throughout the specification may refer to the same elements. The same reference numerals or similar reference numerals may be described with reference to other drawings, even if not mentioned or described in the drawings. In addition, even if reference numerals are not indicated, description may be made with reference to other drawings.
[0022]
[0023] As used herein, the word layer may refer to a sheet of a material, which covers a surface or a body. As used herein, laminate means uniting or combining of two or more superposed layers to form a single structure.
[0024]
[0025] As shown in
[0026] The release layer 130 and the base layer 140 may be layers, films, or sheets that cover and protect opposite surfaces 150, 160 of the adhesive sheet 100. The base layer 140 may cover and protect the top surface 160 of the first adhesive layer 110. The release layer 130 may cover and protect the bottom surface 150 of the second adhesive layer 120.
[0027] The first adhesive layer 110 may have a thickness of several micrometers (m) up to several tens of micrometers (m). In the preferred embodiment, the first adhesive layer 110 may have a thickness of about 10 micrometers (m).
[0028] The second adhesive layer 120 may also have a thickness of several micrometers (m) to several tens of micrometers (m). In the preferred embodiment, the second adhesive layer 120 may have a thickness of 10 micrometers (m). The second adhesive layer 120 may thus have the same thickness as the first adhesive layer 110. The adhesive sheet 100 may therefore have a thickness of several tens of micrometers (m). In the preferred embodiment, the adhesive sheet 100 may have a thickness of 20 micrometers (m).
[0029] The first adhesive layer 110 may be a thermosetting adhesive, i.e., an adhesive which is cured by heat or thermal energy. The thermosetting adhesive may be a thermosetting resin, examples of which include epoxy resin and/or a phenol resin. The thermosetting adhesive may also be a crosslinking agent that induces a thermosetting reaction. The first adhesive layer 110 may further include a filler dispersed in the thermosetting adhesive. The filler may be composed of inorganic materials. The first adhesive layer 110 may further include a colorant additionally dispersed in the thermosetting adhesive. The colorant may improve the visibility of the first adhesive layer 110. The colorant may include carbon black or carbon powder. The first adhesive layer 110 may include an epoxy molding compound (EMC).
[0030] The second adhesive layer 120 may include an adhesive, which is cured by a method other than thermosetting. The second adhesive layer 120 may be an adhesive layer in which adhesive strength is reduced while the adhesive is cured by irradiation of light such as ultraviolet (UV) rays. The second adhesive layer 120 may thus be a photocurable adhesive layer containing a photocurable adhesive. The photocurable adhesive may be an adhesive that is cured by light. The photocurable adhesive may be an adhesive that is cured by ultraviolet (UV) rays. The photocurable adhesive may include a photopolymerizable compound. The photocurable adhesive may include an ultraviolet polymerizable compound. The photocurable adhesive may contain a compound having an ultraviolet curable functional group such as a carbon-carbon double bond and exhibiting adhesive properties. The photocurable adhesive may include an acrylic polymer. The photocurable adhesive may further include a photopolymerization initiator.
[0031] The second adhesive layer 120 may further include a filler in addition to the photocurable adhesive. The filler may be composed of an inorganic material. The second adhesive layer 120 may further include a colorant additionally dispersed in the photocurable adhesive. The colorant may improve the visibility of the second adhesive layer 120. The colorant may include carbon black or carbon powder.
[0032]
[0033] Referring to
[0034] The process steps for manufacturing the semiconductor package may be performed on the carrier 200. The carrier 200 may act as a worktable, a handling station, or a supporting substrate, which is detachable from the second adhesive layer 120. The carrier 200 may be made of a more rigid material than the adhesive sheet 100, such as a glass, silicon, or a metal. The carrier 200 may have a shape of a semiconductor wafer.
[0035]
[0036] Referring to
[0037] In
[0038] Radiant thermal energy 940 may be provided to the first adhesive layer 110 by an infrared lamp. As the first adhesive layer 110 is cured thermally, a first cured first adhesive layer 110C may be formed. The uncured first adhesive layer 110 may be a viscous liquid. After curing, however, the cured first adhesive layer 110C may be solid or may have a much greater viscosity similar to glass.
[0039]
[0040] Referring to
[0041] The first semiconductor die 410 may be a device in which integrated circuits (ICs) are integrated on a semiconductor substrate. The integrated circuits may include memory elements such as dynamic random access memory (DRAM), static random access memory (SRAM), NAND-type flash memory, NOR-type flash memory, magnetic random access memory (MRAM), resistive random access memory (ReRAM), ferroelectric random access memory (FeRAM), or phase change random access memory (PCRAM). Alternatively, the integrated circuits may constitute a logic circuit, an application processor (AP), a graphic processing unit (GPU), or a central processing unit (CPU).
[0042] The first semiconductor die 410 may include a first connecting terminal 411 or first connecting terminals 411 on a first surface 410T. The first connecting terminal 411 may be formed in a shape of a conductive pattern or a conductive pad. The first connecting terminal 411 may be electrically and signally connected to the integrated circuits integrated in the first semiconductor die 410. The first semiconductor die 410 may be located over the carrier 200 such that a second surface 410B of the first semiconductor die 410 is bonded to the third adhesive layer 310. The second surface 410B may be a surface opposite to the first surface 410T where the first connecting terminal 411 is disposed.
[0043] A fifth semiconductor die 450 may be located over the carrier 200 at a position spaced apart from the first semiconductor die 410. The fifth semiconductor die 450 may be laterally spaced apart from the first semiconductor die 410. The fifth semiconductor die 450 may be substantially the same as the first semiconductor die 410.
[0044]
[0045] Referring to
[0046] The fourth semiconductor die 440 may be attached to the first semiconductor die 410 by a sixth adhesive layer 340. The sixth adhesive layer 340 may be a DAF or a WBL tape. The second semiconductor die 420 may be attached to the fourth semiconductor die 440 by a fourth adhesive layer 320. The fourth adhesive layer 320 may be a DAF or a WBL tape. The third semiconductor die 430 may be attached to the second semiconductor die 420 by a fifth adhesive layer 330. The fifth adhesive layer 330 may be a DAF or a WBL tape.
[0047] The fourth semiconductor die 440 may be located over the first semiconductor die 410 to expose the first connecting terminal 411 of the first semiconductor die 410. The second semiconductor die 420 may be located over the fourth semiconductor die 440 to expose a fourth connecting terminal 441 of the fourth semiconductor die 440. The second semiconductor die 420 may be located over the fourth semiconductor die 440 to expose the connecting terminal 411 of the first semiconductor die 410. The third semiconductor die 430 may be located over the second semiconductor die 420 to expose a second connecting terminal 421 of the second semiconductor die 420. The third semiconductor die 430 may include a third connecting terminal 431. Similarly, semiconductor dies may also be stacked over the fifth semiconductor die (450 in
[0048] Because the third semiconductor die 430 is stacked with the second off-set in the second direction that is opposite to the off-set directions of the underlaying second and fourth semiconductor dies 420 and 440, it is possible to reduce a width of the stack structure in which the semiconductor dies 410, 440, 420, and 430 are stacked.
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[0050] Referring to
[0051] Each of the vertical connectors 510, 520, and 540 may include a conductive metal material such as gold (Au) or copper (Cu). The conductive bump 530 may include a conductive metal material such as copper (Cu). The vertical connectors 510, 520, and 540 and the conductive bumps 530 may be formed as interconnection members that extend substantially vertically or stand substantially vertically from the semiconductor dies 410, 420, 440, and 430, respectively. The vertical connectors 510, 520, and 540 and the conductive bumps 530 may provide paths through which electrical signals are connected to the semiconductor dies 410, 420, 440, and 430, respectively.
[0052]
[0053] Referring to
[0054] The encapsulant layer 601 may be formed by a molding process using a liquid encapsulant material. The encapsulant layer 601 may be molded using a liquid epoxy molding compound (EMC). Both the encapsulant layer 601 and the cured first adhesive layer 110C may be formed of an epoxy molding compound (EMC).
[0055]
[0056] Referring to
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[0060] Referring to
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[0062] Referring to
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[0064] Referring to
[0065] A laser marking process may be performed on the cured first adhesive layer 110C and/or the cured second adhesive layer 120C of the package structure 10A separated from the carrier 200.
[0066]
[0067] Referring to
[0068] As shown in
[0069] The inventive concept has been disclosed in conjunction with some embodiments as described above. Those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure. Accordingly, the embodiments disclosed in the present specification should be considered from not a restrictive standpoint but an illustrative standpoint. The scope of the inventive concept is not limited to the above descriptions but defined by the accompanying claims, and all of distinctive features in the equivalent scope should be construed as being included in the inventive concept.