Making electrical components in handle wafers of integrated circuit packages
09831302 ยท 2017-11-28
Assignee
Inventors
Cpc classification
H01L2224/73204
ELECTRICITY
H01L21/4853
ELECTRICITY
H01L2924/16153
ELECTRICITY
H01L2224/05009
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2224/73204
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L21/486
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L23/49833
ELECTRICITY
H01L25/11
ELECTRICITY
H01L2924/00
ELECTRICITY
International classification
H01L21/02
ELECTRICITY
H01L25/00
ELECTRICITY
H01L25/16
ELECTRICITY
H01L23/522
ELECTRICITY
H01L23/498
ELECTRICITY
Abstract
A method for making an integrated circuit package includes providing a handle wafer having a first region defining a cavity. A capacitor is formed in the first region. The capacitor has a pair of electrodes, each coupled to one of a pair of conductive pads, at least one of which is disposed on a lower surface of the handle wafer. An interposer having an upper surface with a conductive pad and at least one semiconductor die disposed thereon is also provided. The die has an integrated circuit that is electroconductively coupled to a redistribution layer (RDL) of the interposer. The lower surface of the handle wafer is bonded to the upper surface of the interposer such that the die is disposed below or within the cavity and the electroconductive pad of the handle wafer is bonded to the electroconductive pad of the interposer in a metal-to-metal bond.
Claims
1. An integrated circuit package comprising a first substrate and a second substrate bonded to the first substrate, with a plurality of cavities enclosed by the first and second substrates, the plurality of cavities comprising one or more first cavities and one or more second cavities; wherein the second substrate comprises circuitry with first electroconductive pads in the first and second cavities, each of the first and second cavities having at least one first electroconductive pad therein; and wherein the integrated circuit package further comprises: in each first cavity, at least one semiconductor die comprising an integrated circuit electroconductively coupled to at least one first electroconductive pad in the first cavity; and in each second cavity, at least one discrete electrical component electroconductively coupled to at least one first electroconductive pad in the second cavity and comprising a conductive layer such that at least one of the following is true: (i) the conductive layer is formed over a surface of the first substrate in the second cavity; (ii) the conductive layer comprises at least a part of the surface of the first substrate in the second cavity.
2. The integrated circuit package of claim 1 wherein the first substrate is a semiconductor substrate, and in at least one second cavity the conductive layer is a doped layer comprising at least said part of the surface of the first substrate.
3. The integrated circuit package of claim 1 wherein in at least one second cavity the conductive layer is formed over the surface of the first substrate.
4. The integrated circuit package of claim 1 wherein in at least one second cavity, at least one discrete electrical component is a capacitor, and the conductive layer is a first plate of the capacitor.
5. The integrated circuit package of claim 4 wherein in said at least one second cavity, the surface of the first substrate in the cavity comprises one or more rods or ridges increasing a capacitance of the capacitor.
6. The integrated circuit package of claim 5 wherein in said at least one second cavity: the capacitor comprises a second plate and a dielectric layer between the first and second plates; and the surface of the first substrate in the cavity comprises one or more rods or ridges increasing an area of each of the first and second plates.
7. The integrated circuit package of claim 4 wherein in at least one second cavity: the capacitor comprises a second plate and a dielectric layer between the first and second plates; and the surface of the first substrate in the cavity comprises one or more rods or ridges increasing an area of each of the first and second plates.
8. The integrated circuit package of claim 1 wherein the circuitry of the second substrate further comprises a second electroconductive pad not covered by the first substrate and comprises a conductive line connecting the second electroconductive pad to at least one first electroconductive pad in a second cavity.
9. The integrated circuit package of claim 1 wherein the circuitry of the second substrate comprises an electroconductive via connected to at least one first electroconductive pad and passing through the second substrate.
10. The integrated circuit package of claim 1 wherein at least one second cavity does not contain any integrated circuit.
11. A fabrication method comprising: obtaining a first substrate; forming one or more features each of which comprises a conductive layer such that at least one of the following is true: (i) the conductive layer is formed over a surface of the first substrate; (ii) the conductive layer comprises a part of the surface of the first substrate; providing a second substrate comprising circuitry comprising one or more first electroconductive pads; obtaining one or more semiconductor dies each of which comprises an integrated circuit; attaching together the first substrate, the second substrate, and the one or more semiconductor dies to obtain a structure with a plurality of cavities enclosed by the first and second substrates, the plurality of cavities comprising one or more first cavities and one or more second cavities, each of the first and second cavities having at least one first electroconductive pad therein, such that each first cavity contains at least one said semiconductor die comprising the integrated circuit electroconductively coupled to at least one first electroconductive pad in the first cavity, and each second cavity contains at least one discrete electrical component comprising at least one said feature and electroconductively coupled to at least one first electroconductive pad in the first cavity.
12. A fabrication method comprising: obtaining a first substrate; forming one or more features each of which comprises a conductive layer such that at least one of the following is true: (i) the conductive layer is formed over a surface of the first substrate; (ii) the conductive layer comprises a part of the surface of the first substrate; providing a second substrate comprising circuitry comprising one or more first electroconductive pads; obtaining one or more semiconductor dies each of which comprises an integrated circuit; attaching together the first substrate, the second substrate, and the one or more semiconductor dies to obtain a structure with a plurality of cavities enclosed by the first and second substrates, the plurality of cavities comprising one or more first cavities and one or more second cavities, each of the first and second cavities having at least one first electroconductive pad therein, such that each first cavity contains at least one said semiconductor die comprising the integrated circuit electroconductively coupled to at least one first electroconductive pad in the first cavity, and each second cavity contains at least one discrete electrical component comprising at least one said feature and electroconductively coupled to at least one first electroconductive pad in the second cavity; wherein in at least one second cavity, at least one discrete electrical component is a capacitor, and the conductive layer is a first plate of the capacitor.
13. The method of claim 12 wherein the first substrate is a semiconductor substrate, and in at least one said discrete electrical component at least one said feature comprises a doped part of the surface of the first substrate.
14. The method of claim 13 wherein in at least one said feature of at least one said discrete electrical component, the conductive layer is formed over the surface of the first substrate.
15. The method of claim 12 wherein in said at least one second cavity, the surface of the first substrate in the cavity comprises one or more rods or ridges increasing a capacitance of the capacitor.
16. The method of claim 12 wherein in said at least one second cavity, the capacitor comprises a second plate and a dielectric layer between the first and second plates; and the surface of the first substrate in the cavity comprises one or more rods or ridges increasing an area of each of the first and second plates.
17. The method of claim 12 wherein in said at least one second cavity, the capacitor comprises a second plate and a dielectric layer between the first and second plates; and the surface of the first substrate in the cavity comprises one or more rods or ridges increasing an area of each of the first and second plates.
18. A fabrication method comprising: obtaining a first substrate; forming one or more features each of which comprises a conductive layer such that at least one of the following is true: (i) the conductive layer is formed over a surface of the first substrate; (ii) the conductive layer comprises a part of the surface of the first substrate; providing a second substrate comprising circuitry comprising one or more first electroconductive pads; obtaining one or more semiconductor dies each of which comprises an integrated circuit; attaching together the first substrate, the second substrate, and the one or more semiconductor dies to obtain a structure with a plurality of cavities enclosed by the first and second substrates, the plurality of cavities comprising one or more first cavities and one or more second cavities, each of the first and second cavities having at least one first electroconductive pad therein, such that each first cavity contains at least one said semiconductor die comprising the integrated circuit electroconductively coupled to at least one first electroconductive pad in the first cavity, and each second cavity contains at least one discrete electrical component comprising at least one said feature and electroconductively coupled to at least one first electroconductive pad in the second cavity; wherein the circuitry of the second substrate further comprises a second electroconductive pad not covered by the first substrate and comprises a conductive line connecting the first electroconductive pad to at least one first electroconductive pad in a second cavity.
19. The method of claim 18 wherein the circuitry of the second substrate comprises an electroconductive via connected to at least one first electroconductive pad and passing through the second substrate.
20. The method of claim 18 wherein after said attaching, at least one second cavity does not contain any integrated circuit.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1)
(2)
(3)
(4)
DETAILED DESCRIPTION
(5) This disclosure provides embodiments of methods for making semiconductor packages in which electrical components, viz., metal-insulator-metal (MIM) capacitors, are fabricated within selected regions of a first substrate, such as a handle wafer, that contains cavities for housing integrated circuit dies or packages mounted on a second, associated substrate, e.g., an interposer wafer. The methods result in a more efficient use of package volume, and hence, semiconductor packages of a reduced size and/or enhanced functionality.
(6)
(7) In the particular example IC package 10 of
(8) In the particular example embodiment of
(9) The solder bumps 32 can be used to mount the IC packages 10 and electroconductively connect the ICs of the dies 24 therein to, for example, the conductive traces of an underlying printed circuit board (PCBnot illustrated) in a conventional IC package mounting arrangement. In addition, selected conductive traces within the RDL 28 can be coupled to electroconductive pads 36 disposed on the upper surface 22 of the interposer 14, which can be used, for example, as contact pads for the application of, e.g., test probes for testing the functionality of the IC dies 24. Of course, other known electroconductive coupling and mounting mechanisms, such as pin grid arrays (PGAs) and corresponding sockets, can be used both to couple and mount the IC dies 24 to the inter poser 14, and/or to couple and mount the interposer 14 to an associated PCB (not illustrated.)
(10) The first substrate or handle wafer 12 and the second substrate or interposer 14 can each be made of a variety of suitable materials, including a semiconductor material, such as silicon (Si), germanium (Ge), and gallium arsenide (GaAs), many types of glass or ceramics, many types of polymers, such as epoxy, or a composite material, which if desired, can be reinforced with fibers, such as fiberglass.
(11) The sandwiching of the IC package 10 is effected during the fabrication of the package by bonding a lower surface 38 of the handle wafer 12 to the upper surface 22 of the interposer 14. This can be effected in a variety of ways, including adhesive bonding and by making metal-to-metal bonds that are achieved by compressing the handle wafer 12 and the interposer 14 together under relatively large forces and at relatively high temperatures.
(12) As discussed above, in some cases, it is desirable to fabricate discrete electrical components, for example, capacitors, on or within the interposer 14, i.e., on its upper surface 22 or within a recess disposed therein. For example, a conventional two-dimensional (2D) metal-insulator-metal (MIM) capacitor can be formed on the upper surface of the interposer 14 by disposing alternating layers of a suitable metal and a dielectric material thereon and electroconductively coupling the metal layers to conductive pads to define the electrodes or plates of the capacitor. A similar arrangement can be effected in a blind trench or recess formed in the upper surface 22 of the interposer 14, and such capacitors are sometimes referred to 2D capacitors because, all other factors being equal, their capacitance is generally a function of the area of their MIM layers, i.e., their length times their width.
(13) Similarly, so-called 3D capacitors can be fabricated on or in the interposer 14 by including a third dimension, viz., height, in the definition of the capacitors by constructing one or more upstanding structures, such as rods or ridges, on the upper surface 22 of the interposer 14, or alternatively, on the floor of a recess disposed therein, then disposing the alternating MIM layers over the surfaces of the upstanding structures as above. All other factors being equal, the capacitance of such 3D capacitors is a function of their length times their width times their height. That is, the upstanding structures upon which the MIM layers are disposed serve to substantially increase the area of the layers, and hence, the capacitance of such devices, relative to those of 2D capacitors.
(14) However, as can be seen in
(15) It has been discovered that it is both feasible and advantageous to fabricate discrete electrical components, e.g., resistors, inductors, light emitting diodes (LEADS), detectors, sensors, actuators, microelectromechanical (MEMS) devices, and particularly, the capacitors described above, in the otherwise wasted volume of the first regions 16 of the handle wafer 12, and then electroconductively coupling them to, e.g., the RDL 28 of the interposer 14 during the bonding of the two wafers.
(16) An example embodiment of an integrated circuit package 100 incorporating a plurality of capacitors 140 in the first regions 116 of a handle wafer 112 is illustrated in the vertical cross-sectional view of
(17) The particular handle wafer 112 illustrated in
(18) The example second substrate or interposer 114 comprises an upper surface 122 with two semiconductor dies, chips or packages 124 disposed thereon, and as above, the dies 124 each have at least one IC formed in a surface thereof. The example interposer 114 also includes an
(19) RDL 128, to which the dies 124 are variously electroconductively coupled, and which, in turn, is electroconductively interconnected to solder bumps 132 disposed on the lower surface 130 of the interposer 114 by corresponding vias 134, and/or to electroconductive pads 136 disposed on the upper surface 122 of the interposer 114 by conductive traces of the RDL 128.
(20) As above, during fabrication, the lower surface 138 of the handle wafer 112 is bonded to the upper surface 122 of the interposer 114 such that the dies 124 are disposed below or within corresponding ones of the cavities 120. However, in the example IC package 100 of
(21) In one possible embodiment, the forming of the capacitor 140 can begin with making a recess 142 having an interior surface in the lower surface 138 of a selected one of the first regions 116 of the handle wafer 112. As discussed above, in some embodiments, the recess 142 can be made to include at least one vertical structure, e.g., an upstanding rod or ridge 144, or alternatively, an array of such rods or ridges 144, formed on the floor of the recess 142 in order to substantially increase the area of the MIM layers of the capacitor 140. The rods or ridges 144 can have a relatively high aspect ratio, and can have, e.g., rectangular horizontal cross-sections. In some embodiments, the recess 142 and the rods or ridges 144 can be made simultaneously by patterning the lower surface 138 of the selected first region 116 and then etching the recess 142, together with the upstanding rods or ridges 144 therein, into the lower surface of the first region 116 using well-known photolithography techniques.
(22) A first electroconductive layer is then created on or in the interior surface of the recess 142, including on or in the upstanding rods or ridges 144, to define a first electrode or plate of the capacitor 140. In the case of a handle wafer 112 made of a semiconductor, such as silicon (Si), the first electroconductive layer 144 can be created by doping the entire first region 116 within which the recess is formed with an appropriate dopant. For example, if the handle wafer 112 comprises monocrystalline or lightly p-doped silicon, then the entire selected first region 116 can be doped with an n-type dopant to render it, and hence, the interior surface of the recess 142 and the upstanding rods or ridges 144 therein, electrically conductive. Alternatively, only a thin layer of doped material can be formed in the respective surfaces of the interior of the recess 142 and the upstanding rods or ridges 144 to render them electrically conductive, and thereby form a first electrode or plate of the capacitor 140. In either case, the doping can be effected using, e.g., known diffusion doping or ion implant doping techniques.
(23) In another possible embodiment, the first electrode of the capacitor 140 can be created by depositing a first layer of a metal on the interior surface of the recess 142 and on the surfaces of the upstanding rods or ridges 144. The metal can comprise, for example, one or more of tantalum
(24) (Ta), copper (Cu), titanium (Ti), titanium nitride (TiN), silver (Ag), gold (Au), aluminum (Al), chromium (Cr), palladium (Pd), platinum (Pt), Ruthenium (Ru), osmium (Os), and/or rhodium (Rh), and can be deposited on those surfaces using, for example, one or more of atomic layer deposition (ALD), chemical vapor deposition (CVD), electroless plating and/or sputtering techniques.
(25) After the first electroconductive layer, i.e., the first electrode or plate 144 of the capacitor 140, is created, its entire surface is coated with a layer 146 of a dielectric material, to form the I, or insulator, of the MIM capacitor 140. The dielectric layer 146 can comprise, for example, Parylene, silicon oxide (SiO.sub.2), hafnium oxide (HfO.sub.2), tantalum pentoxide (Ta.sub.2O.sub.5), zirconium dioxide (ZrO.sub.2), yttrium oxide (Y.sub.2O.sub.3), lanthanum oxide (La.sub.2O.sub.3), titanium dioxide (TiO.sub.2), or strontium titanate (SrTiO.sub.3), and can be deposited in a layer on the first electrode or plate 144 by atomic layer deposition (ALD), chemical vapor deposition (CVD), electroless plating and/or sputtering techniques.
(26) The MIM sandwich of the capacitor 140 is completed by depositing a second electroconductive layer 148 on the surface of the dielectric layer 146. The second electroconductive layer 148 comprises a second electrode or plate of the capacitor 140, and like the first electroconductive layer 144, can comprise a metal, such as tantalum (Ta), copper (Cu), titanium (Ti), titanium nitride (TiN), silver (Ag), gold (Au), aluminum (Al), chromium (Cr), palladium (Pd), platinum (Pt), Ruthenium (Ru), osmium (Os), and/or rhodium (Rh), and can be deposited on the surface of the dielectric layer 146 using, for example, atomic layer deposition (ALD), chemical vapor deposition (CVD), electroless plating and/or sputtering techniques.
(27) As those of some skill will understand, the MIM sandwich of the capacitor 140 is not limited to one insulator layer 146 and two electroconductive layers 144, 148, but rather, can have multiple alternating dielectric and electroconductive layers that serve to increase the capacitance of the capacitor 140. As a practical matter, the number of these additional alternating layers depends mainly on the spacing between, or pitch, of the upstanding rods or ridges 144 in the recess 142.
(28) In most applications, it is desirable to electroconductively couple each of the electrodes or plates 144, 148 of the capacitor 140 to a corresponding electroconductive pad that is disposed on the lower surface 138 of the handle wafer 112 such that, when the handle wafer 112 is bonded to the interposer 114, each of the pads is simultaneously electroconductively bonded to a corresponding electroconductive pad in the RDL 128 of the interposer 114, thereby electrically coupling the capacitor 140 to one or more circuits, such as the ICs of the semiconductor dies 124, that are also electroconductively coupled to the RDL 128. For example, the electroconductive pads of the capacitor 140 on the lower surface 138 of the handle wafer 112 and the corresponding pads on the upper surface 122 of the interposer 114 can confected of or plated with the same metal, for example, aluminum (AL), gold (Au) or copper (Cu), such that, when the handle wafer 112 is bonded to the interposer 114 at elevated temperatures and pressures, the electroconductive pads of the capacitor 140 are electroconductively coupled to the corresponding pads of the interposer 114 in an aluminum-to-aluminum (AL-to-AL), a gold-to-gold (Au-Au), or a copper-to-copper (Cu-Cu) metal bond.
(29) However, in some embodiments, it may be desirable to electroconductively couple at least one of the electrodes or plates 144, 148 of the capacitor 140 to an upper surface 150 of the handle wafer 112, there to participate in, for example, a stacking arrangement of the type discussed in more detail below.
(30) In the particular example embodiment of
(31) In some embodiments, a headspace or empty volume 158 can be defined between the interior surfaces of the cavities 120 and the exterior surfaces of the semiconductor dies or die packages 124 when they are disposed therein. As illustrated in
(32) As illustrated in
(33) In the example IC package 300 of
(34) As above, an I or dielectric layer 346 can be formed over the interior surface of the first electroconductive layer 344, and the hollow space inside the dielectric layer 346 can then be filled with, e.g., a copper (Cu) filling to form a second electroconductive layer 348 comprising a second electrode or plate of the capacitor 340.
(35) In a manner similar to that of the IC package 100 of
(36) In light of the foregoing detailed description, it should be clear to those of some skill in this art that many modifications, substitutions and variations can be made in and to the methods and materials of the IC packages of the present disclosure, and accordingly, that the scope of the present disclosure should not be limited to that of the particular embodiments illustrated and described herein, as they are merely by way of some examples thereof, but rather, should be fully commensurate with that of the claims appended hereafter and their functional equivalents.