Semiconductor package and method of fabricating the same
11626393 · 2023-04-11
Assignee
Inventors
Cpc classification
H01L2221/68359
ELECTRICITY
H01L2224/73204
ELECTRICITY
H01L2224/0401
ELECTRICITY
H01L2224/12105
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/131
ELECTRICITY
H01L24/20
ELECTRICITY
H01L2224/73204
ELECTRICITY
H01L24/97
ELECTRICITY
H01L2224/0231
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L21/486
ELECTRICITY
H01L23/49816
ELECTRICITY
H01L2224/131
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2224/16227
ELECTRICITY
H01L2224/96
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/97
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2224/08235
ELECTRICITY
H01L2225/1041
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L23/3128
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L21/568
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L24/19
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2225/1058
ELECTRICITY
H01L24/96
ELECTRICITY
H01L2224/04105
ELECTRICITY
H01L2221/68345
ELECTRICITY
H01L2224/97
ELECTRICITY
H01L23/5226
ELECTRICITY
H01L2225/1035
ELECTRICITY
H01L24/73
ELECTRICITY
International classification
H01L21/44
ELECTRICITY
H01L23/522
ELECTRICITY
Abstract
A method of fabricating a semiconductor package includes providing a semiconductor chip, forming a redistribution substrate, and fabricating a package including the semiconductor chip disposed on the redistribution substrate. The forming of the redistribution substrate may include forming a first insulating layer on a substrate, the first insulating layer having a first opening formed therein, forming an integrally formed first redistribution pattern in the first opening and on the first insulating layer, forming a second insulating layer on the first insulating layer to cover the first redistribution pattern, and performing a planarization process on the second insulating layer to expose the first redistribution pattern.
Claims
1. A semiconductor package, comprising: a first redistribution substrate; a semiconductor chip on a top surface of the first redistribution substrate; a solder ball on a bottom surface of the redistribution substrate opposite the top surface; a bump provided between the first redistribution substrate and the semiconductor chip and electrically connected to the first redistribution substrate and the semiconductor chip; an interconnection structure provided on the top surface of the first redistribution substrate and laterally spaced apart from the semiconductor chip; and a second redistribution substrate on the semiconductor chip and the interconnection structure, wherein the first redistribution substrate comprises: a first redistribution pattern; a first seed pattern covering side surfaces of a lower portion of the first redistribution pattern; a second redistribution pattern disposed on the first redistribution pattern, the second redistribution pattern including a second via portion and a second interconnection portion connected to the second via portion; a second seed pattern disposed between the first redistribution pattern and the second via portion and extending to a lower surface of the second interconnection portion; a third redistribution pattern disposed on the second redistribution pattern, the third redistribution pattern including a third via portion and a third interconnection portion connected to the third via portion; and a third seed pattern disposed between the second redistribution pattern and the third via portion and extending to a lower surface of the third interconnection portion, wherein the first redistribution pattern is electrically connected to the bump through the second redistribution pattern and the third redistribution pattern, wherein a width of one surface of the second interconnection portion ranges from 100% to 120% of a width of another surface of the second interconnection portion, and wherein the first seed pattern is provided between the first redistribution pattern and the solder ball.
2. The semiconductor package of claim 1, wherein the first redistribution pattern further comprises an insulating layer, a bottom surface of the insulating layer exposed to an outside of the first redistribution substrate, wherein a maximum distance between the bottom surface of the insulating layer and an upper surface of the second redistribution pattern ranges from 100% to 120% of a minimum distance between the bottom surface of the insulating layer and the upper surface of the second redistribution pattern.
3. The semiconductor package of claim 1, wherein an upper surface of the second redistribution pattern has a surface roughness of 0.01 μm to 0.4 μm.
4. The semiconductor package of claim 1, wherein the first redistribution pattern includes the lower portion and a first interconnection portion on the lower portion, the first interconnection portion connected to the lower portion of the first redistribution pattern, and wherein the first interconnection portion has a width greater than a width of the lower portion of the first redistribution pattern.
5. The semiconductor package of claim 4, wherein the first seed pattern extends to a lower surface of the first interconnection portion.
6. The semiconductor package of claim 1, wherein the one surface and the other surface of the second interconnection portion are opposite to each other, and wherein one of the one surface and the other surface of the second interconnection portion is the lower surface of the second interconnection portion, wherein a width of one surface of the third interconnection portion ranges from 100% to 120% of a width of another surface of the third interconnection portion, and wherein the one surface and the other surface of the third interconnection portion are opposite to each other.
7. The semiconductor package of claim 1, wherein a width of the second via portion is smaller than the width of the one surface and the width of the other surface of the second interconnection portion.
8. The semiconductor package of claim 1, further comprising a molding layer covering the semiconductor chip and a sidewall of the interconnection structure and provided on the top surface of the first redistribution substrate.
9. A semiconductor package, comprising: a redistribution substrate having a bottom surface and a top surface opposite each other; a semiconductor chip on the top surface of the redistribution substrate; a solder ball on the bottom surface of the redistribution substrate, wherein the redistribution substrate comprises: a first redistribution pattern including a first via portion on the solder ball and a first interconnection portion connected to the first via portion, wherein the first via portion extends vertically and the first interconnection portion extends from the first via portion more in a horizontal direction than the first via portion; a first seed pattern covering a side surface of the first via portion and extending to a bottom surface of the first interconnection portion; a second redistribution pattern including a second via portion and a second interconnection portion connected to each other, the second via portion disposed between the first interconnection portion and the second interconnection portion, wherein the second via portion extends vertically and the second interconnection portion extends from the second via portion more in a horizontal direction than the second via portion; and a second seed pattern disposed between the first redistribution pattern and the second via portion and extending to a lower surface of the second interconnection portion, wherein the first interconnection portion is disposed between the first via portion and the second redistribution pattern, and wherein the solder ball is electrically connected to the semiconductor chip through the first redistribution pattern and the second redistribution pattern, wherein the first seed pattern is provided between the first via portion and the solder ball.
10. The semiconductor package of claim 9, wherein the redistribution substrate further comprises an insulating layer, wherein the second redistribution pattern includes a plurality of second redistribution patterns, wherein a maximum distance between a bottom surface of the insulating layer and upper surfaces of the plurality of second redistribution patterns ranges from 100% to 120% of a minimum distance between the bottom surface of the insulating layer and the upper surfaces of the plurality of second redistribution patterns, and wherein the bottom surface of the insulating layer is exposed to an outside of the redistribution substrate.
11. The semiconductor package of claim 9, wherein a width of the second via portion is smaller than a width of the second interconnection portion.
12. The semiconductor package of claim 9, wherein the redistribution substrate further comprises: a third conductive pattern including a third via portion and a third interconnection portion connected to each other, the third via portion disposed between the second interconnection portion and the third interconnection portion, wherein the third via portion extends vertically and the third interconnection portion extends from the third via portion more in a horizontal direction than the third via portion; and a third seed pattern disposed between the second redistribution pattern and the third via portion and extending to a lower surface of the third interconnection portion, wherein a width of the third via portion is smaller than a width of the third interconnection portion.
13. The semiconductor package of claim 12, wherein the second seed pattern covers side surfaces of the second via portion and does not cover side surfaces of the second interconnection portion, and wherein the third seed pattern covers side surfaces of the third via portion and does not cover side surfaces of the third interconnection portion.
14. The semiconductor package of claim 9, further comprising a molding layer covering the semiconductor chip and provided on the top surface of the redistribution substrate, wherein a sidewall of the molding layer is aligned with a sidewall of the redistribution substrate.
15. The semiconductor package of claim 9, further comprising a bump between the top surface of the redistribution substrate and a chip pad of the semiconductor chip, wherein the semiconductor chip is electrically connected to the second redistribution pattern through the bump.
16. A semiconductor package, comprising: a redistribution substrate having a first surface and a second surface opposite each other; a semiconductor chip on a first surface of the redistribution substrate; and a solder ball on the second surface of the redistribution substrate, wherein the redistribution substrate comprises: a first conductive pattern including a first lower portion on the solder ball and a first upper portion connected to the first lower portion; a first seed pattern covering a side surface of the first lower portion; a second conductive pattern disposed on the first conductive pattern, the second conductive pattern including a second via portion and a second interconnection portion connected to the second via portion, wherein the second via portion extends vertically and the second interconnection portion extends from the second via portion more in a horizontal direction than the second via portion; and a second seed pattern between the first conductive pattern and the second via portion and extending to a lower surface of the second interconnection portion, wherein the first upper portion is disposed between the first lower portion and the second conductive pattern, wherein the second via portion is disposed between the first conductive pattern and second interconnection portion, wherein the solder ball is electrically connected to the semiconductor chip through the first conductive pattern and the second conductive pattern, and wherein a first width of one surface of the second interconnection portion ranges from 100% to 120% of a second width of another surface of the second interconnection portion, wherein the first seed pattern is provided between the first via portion and the solder ball.
17. The semiconductor package of claim 16, wherein a width of the second via portion is smaller than the first width and the second width, wherein the one surface and the other surface of the second interconnection portion are opposite to each other, and wherein one of the one surface and the other surface of the second interconnection portion is the lower surface of the second interconnection portion.
18. The semiconductor package of claim 16, wherein the redistribution substrate further comprises: a third conductive pattern including a third via portion and a third interconnection portion connected to each other, the third via portion disposed between the second interconnection portion and the third interconnection portion; and a third seed pattern disposed between the second conductive pattern and the third via portion and extending to a lower surface of the third interconnection portion, wherein a width of one surface of the third interconnection portion ranges from 100% to 120% of a width of another surface of the third interconnection portion.
19. The semiconductor package of claim 16, wherein the first seed pattern extends to a bottom surface of the first upper portion, wherein a third width of one surface of the first upper portion ranges from 100% to 120% of a fourth width of another surface of the first upper portion, and wherein a width of the first lower portion is smaller than the third width and the fourth width.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The inventive concepts will become more apparent in view of the attached drawings and accompanying detailed description.
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DETAILED DESCRIPTION
(20) The same reference numerals or the same reference designators may denote the same elements or components throughout the specification. Semiconductor packages and methods of fabricating the same according to embodiments of the inventive concepts will be described hereinafter.
(21)
(22) As described herein, a semiconductor package includes a package substrate, which in some embodiments disclosed herein is a redistribution substrate, one or more semiconductor chips mounted on the package substrate, and an encapsulant or molding layer covering the package substrate and the one or more semiconductor chips. A “redistribution substrate,” or “redistribution package substrate” as discussed herein, is different from a PCB package substrate in both its structure and its formation. For example, it may be formed of redistribution layers, which may be formed initially as one or more layers on a dummy substrate or carrier substrate. The dummy substrate or carrier substrate, also described as a temporary or sacrificial substrate or carrier substrate, is removed from the redistribution substrate prior to the semiconductor package being completed.
(23) Referring to
(24) The first insulating layer 111 may be patterned to form a first opening 191 in the first insulating layer 111. The first opening 191 may expose the carrier substrate 900 or the carrier adhesive layer. A bottom surface of the first opening 191 may correspond to a top surface of the carrier substrate 900 or a top surface of the carrier adhesive layer. The process of patterning the first insulating layer 111 may be performed by exposure and development processes. The development process may be a positive tone development process or a negative tone development process. Thereafter, a process of hardening the first insulating layer 111 may be performed.
(25) The first seed layer 121 may be formed in the first opening 191 and on a top surface of the first insulating layer 111. The first seed layer 121 may conformally cover the bottom surface and a sidewall of the first opening 191 and the top surface of the first insulating layer 111. The first seed layer 121 may cover the carrier substrate 900 or the carrier adhesive layer exposed through the first opening 191. The first seed layer 121 may include a conductive material. For example, the first seed layer 121 may include at least one of copper (Cu) or titanium (Ti).
(26) The first resist pattern 171 may be formed on the first seed layer 121. The first resist pattern 171, which may be a photoresist pattern formed by performing photolithography on a photoresist material, may have a first guide opening 181 penetrating the first resist pattern 171. The first guide opening 181 may expose a top surface of the first seed layer 121. At least a portion of the first guide opening 181 may overlap with the first opening 191 when viewed in a plan view. Thus, these openings may together form a single opening having two portions: a bottom portion having a first area and volume, and a top portion, which may have a second area and volume greater than the first area and volume. A sidewall of the first guide opening 181 may be substantially perpendicular.
(27) Referring to
(28) Referring to
(29) Referring to
(30) Referring to
(31) Referring to
(32) The planarization process may include removing the second insulating layer 112 disposed on the surface 131a of the first redistribution pattern 131 to expose the surface 131a of the first redistribution pattern 131, and planarizing the exposed surface 131a of the first redistribution pattern 131. The second insulating layer 112 may be disposed locally between the first redistribution patterns 131 by the removal of the second insulating layer 112 disposed on the surface 131a of the first redistribution pattern 131. Thereafter, the second insulating layer 112 may also be planarized during the planarization of the exposed surface 131a of the first redistribution pattern 131. After the planarization process, the planarized surface 131a of the first redistribution pattern 131 may be substantially coplanar with a surface 112a of the second insulating layer 112. The surface 112a of the second insulating layer 112 may correspond to a top surface of the second insulating layer 112. The planarized surface 131a of the first redistribution pattern 131 may be substantially flat. The planarized surface 131a of the first redistribution pattern 131 may have a surface roughness, for example, of 0.01 μm to 0.4 μm. Terms such as “same,” “equal,” “planar,” “coplanar,” “parallel,” or “perpendicular,” as used herein when referring to orientation, layout, location, shapes, sizes, amounts, or other measures do not necessarily mean an exactly identical orientation, layout, location, shape, size, amount, or other measure, but are intended to encompass nearly identical orientation, layout, location, shapes, sizes, amounts, or other measures within acceptable variations that may occur, for example, due to manufacturing processes. The term “substantially” may be used herein to emphasize this meaning, unless the context or other statements indicate otherwise. For example, items described as “substantially the same,” “substantially equal,” or “substantially flat,” may be exactly the same, equal, or flat, or may be the same, equal, or planar within acceptable variations that may occur, for example, due to manufacturing processes.
(33) The first redistribution pattern 131 may be provided in plurality. By the planarization process, the planarized surfaces 131a of the first redistribution patterns 131 may be disposed at substantially the same level. A difference between a maximum distance between a bottom surface 111b of the first insulating layer 111 and the surfaces 131a of the first redistribution patterns 131 and a minimum distance between a bottom surface 111b of the first insulating layer 111 and the surfaces 131a of the first redistribution patterns 131 may be reduced. For example, the maximum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 131a of the first redistribution patterns 131 may range from 100% to 120% of the minimum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 131a of the first redistribution patterns 131. Here, the maximum distance may be a distance between the bottom surface 111b of the first insulating layer 111 and an uppermost one of the surfaces 131a of the first redistribution patterns 131. The minimum distance may be a distance between the bottom surface 111b of the first insulating layer 111 and a lowermost one of the surfaces 131a of the first redistribution patterns 131.
(34) The first seed layer 121 may not be exposed by the planarization process.
(35) If a guide opening is formed in the second insulating layer 112 in place of the first resist pattern 171 unlike the descriptions of
(36) However, according to embodiments described herein, the first redistribution pattern 131 may be formed in the first guide opening 181 defined in the first resist pattern 171 before the formation of the second insulating layer 112, as described with reference to
(37) Referring to
(38) The third insulating layer 113 may be patterned to form a second opening 192 in the third insulating layer 113. The second opening 192 may expose the surface 131a of the first redistribution pattern 131. The surface 131a of the first redistribution pattern 131 may be the planarized top surface of the first redistribution pattern 131. The process of patterning the third insulating layer 113 may be performed by exposure and development processes. Thereafter, a process of hardening the third insulating layer 113 may be performed.
(39) The second seed layer 122 may be formed in the second opening 192 and on a top surface of the third insulating layer 113. The second seed layer 122 may conformally cover a bottom surface and a sidewall of the second opening 192 and the top surface of the third insulating layer 113. The second seed layer 122 may contact the surface 131a of the first redistribution pattern 131 exposed by the second opening 192. The surface 131a of the first redistribution pattern 131 may have a relatively small surface roughness. Thus, a contact resistance between the first redistribution pattern 131 and the second seed layer 122 may be reduced. The second seed layer 122 may include a conductive material. For example, the second seed layer 122 may include at least one of copper (Cu) or titanium (Ti).
(40) The second resist pattern 172 may be formed on the second seed layer 122. The second resist pattern 172 may have a second guide opening 182 formed therein by a patterning process (e.g., where a second resist layer such as a photoresist material is patterned using photolithography). The second guide opening 182 may expose at least a portion of a top surface of the second seed layer 122. The second guide opening 182 may have a substantially perpendicular sidewall. A separate hardening process may not be performed in the process of forming the second resist pattern 172.
(41) A second redistribution pattern 132 may be formed in the second opening 192 and the second guide opening 182. The second redistribution pattern 132 may be formed by performing an electroplating process using the second seed layer 122 as an electrode. The second redistribution pattern 132 may include a metal such as copper.
(42) According to the embodiments described herein, since the surface 131a of the first redistribution pattern 131 and the surface 112a of the second insulating layer 112 are planarized as described with reference to
(43) Each of the second opening 192, the second guide opening 182 and the second redistribution pattern 132 may be formed in plurality. If the surfaces 131a of the first redistribution patterns 131 are provided at greatly different levels, it may be difficult for at least one of the second openings 192 to expose a corresponding one of the first redistribution patterns 131. However, according to the embodiments described herein, the surfaces 131a of the first redistribution patterns 131 may be provided at substantially the same or similar levels, and thus the second openings 192 may be formed well. For example, the second openings 192 may expose the first redistribution patterns 131, respectively. Thus, the second redistribution patterns 132 may be electrically connected to the first redistribution patterns 131 through the second seed layer 122, respectively. The second redistribution patterns 132 may have substantially uniform resistances, and thus electrical characteristics of the second redistribution patterns 132 may be improved.
(44) The second redistribution pattern 132 may include a second via portion 132V and a second interconnection portion 132W. The second via portion 132V may be provided in the second opening 192. The second interconnection portion 132W may be provided in the second guide opening 182. The second interconnection portion 132W may be connected to the second via portion 132V. A width and a pitch of the second interconnection portion 132W will be described later in detail with reference to
(45) Thereafter, the second resist pattern 172 may be removed to expose a portion of the second seed layer 122 and a sidewall of the second interconnection portion 132W of the second redistribution pattern 132.
(46) Referring to
(47) Referring to
(48) Referring to
(49) The second redistribution pattern 132 may be provided in plurality as described above. By the planarization process, the planarized surfaces 132a of the second redistribution patterns 132 may be disposed at substantially the same level. A difference between a maximum distance and a minimum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 132a of the second redistribution patterns 132 may be reduced. For example, the maximum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 132a of the second redistribution patterns 132 may range from 100% to 120% of the minimum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 132a of the second redistribution patterns 132. Here, the maximum distance may be a distance between the bottom surface 111b of the first insulating layer 111 and an uppermost one of the surfaces 132a of the second redistribution patterns 132. The minimum distance may be a distance between the bottom surface 111b of the first insulating layer 111 and a lowermost one of the surfaces 132a of the second redistribution patterns 132.
(50) The second interconnection portions 132W may have a fine pitch. For example, a horizontal distance between the second interconnection portions 132W may range from 0.1 μm to 10 μm, in particular, from 0.1 μm to 5 μm. A minimum width of the second interconnection portions 132W may be relatively narrow. For example, the minimum width of the second interconnection portions 132W may range from 0.1 μm to 10 μm, in particular, from 0.1 μm to 5 μm.
(51) Since each of the second interconnection portions 132W is formed in the second guide opening 182 defined by the second resist pattern 172, each of the second interconnection portions 132W may have a relatively uniform width. For example, a width W11 of the second interconnection portion 132W at the surface 132a of the second redistribution pattern 132 (i.e., at one surface of the second interconnection portion 132W) may range from 100% to 120% of a width W21 of the second interconnection portion 132W at another surface 132b of the second interconnection portion 132W. The other surface 132b of the second interconnection portion 132W may face the first insulating layer 111 and may be opposite to the surface 132a of the second redistribution pattern 132. The other surface 132b of the second interconnection portion 132W may be in contact with the second seed layer 122. Different surfaces described herein may be described using the naming convention of “first,” “second,” etc. Furthermore, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. Unless the context indicates otherwise, these terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section, for example as a naming convention. The second seed layer 122 may not be exposed by the planarization process.
(52) Referring to
(53) The third seed layer 123 may be formed in the third openings 193 and on a top surface of the fifth insulating layer 115. The third seed layer 123 may conformally cover bottom surfaces and sidewalls of the third openings 193 and the top surface of the fifth insulating layer 115. The third seed layer 123 may contact the surfaces 132a of the second redistribution patterns 132 exposed by the third openings 193. The surfaces 132a of the second redistribution patterns 132 may have relatively small surface roughnesses, and thus a contact resistance between the third seed layer 123 and the second redistribution patterns 132 may be reduced. The third seed layer 123 may include a conductive material. For example, the third seed layer 123 may include at least one of copper (Cu) or titanium (Ti).
(54) The third resist pattern 173 may be formed on the third seed layer 123. The third resist pattern 173 may have third guide openings 183. Each of the third guide openings 183 may expose a portion of the third seed layer 123. A separate hardening process may not be performed in the process of forming the third resist pattern 173. The third guide openings 183 may have substantially perpendicular sidewalls.
(55) The third redistribution patterns 133 may be formed in the third openings 193 and the third guide openings 183 to cover the third seed layer 123. The third redistribution patterns 133 may be formed by performing an electroplating process using the third seed layer 123 as an electrode. The third redistribution patterns 133 may include a metal such as copper. Each of the third redistribution patterns 133 may include a third via portion 133V and a third interconnection portion 133W. The third via portion 133V may be provided in one of the third openings 193. The third interconnection portion 133W may be provided in one of the third guide openings 183. The third interconnection portion 133W may be connected to the third via portion 133V. A width and a pitch of the third interconnection portion 133W will be described later in detail with reference to
(56) Since the surface 132a of the second redistribution pattern 132 and the surface 114a of the fourth insulating layer 114 are planarized as described with reference to
(57) By the planarization process, the surfaces 132a of the second redistribution patterns 132 may be provided at substantially the same or similar levels. Thus, the third openings 193 may be formed well. For example, each of the third openings 193 may expose the second redistribution pattern 132. Thus, the third redistribution patterns 133 may be electrically connected to the second redistribution patterns 132, respectively. The third redistribution patterns 133 may have substantially uniform resistances, and thus electrical characteristics of the third redistribution patterns 133 may be improved. Thereafter, the third resist pattern 173 may be removed to expose a portion of the third seed layer 123 and a sidewall of the third interconnection portion 133W.
(58) Referring to
(59) A sixth insulating layer 116 may be formed on the fifth insulating layer 115. For example, the sixth insulating layer 116 may cover surfaces 133a of the third redistribution patterns 133 and the top surface of the fifth insulating layer 115. The sixth insulating layer 116 may contact sidewalls of the third interconnection portions 133W. The third seed layer 123 may not extend between the sixth insulating layer 116 and the third redistribution patterns 133. The sixth insulating layer 116 may include a photosensitive polymer.
(60) Referring to
(61) By the planarization process, the planarized surfaces 133a of the third redistribution patterns 133 may be disposed at substantially the same level. For example, a maximum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 133a of the third redistribution patterns 133 may range from 100% to 120% of a minimum distance between the bottom surface 111b of the first insulating layer 111 and the surfaces 133a of the third redistribution patterns 133.
(62) The third interconnection portion 133W of each of the third redistribution patterns 133 may have a relatively or substantially uniform width. For example, a width of the third interconnection portion 133W at the surface 133a of one of the third redistribution patterns 133 (i.e., at one surface of the third interconnection portion 133W) may range from 100% to 120% of a width of the third interconnection portion 133W at another surface 133b of the third interconnection portion 133W. The other surface 133b of the third interconnection portion 133W may be opposite to the surface 133a of the third redistribution pattern 133. The other surface 133b of the third interconnection portion 133W may contact the third seed layer 123. Thus, the third redistribution patterns 133 may have a fine pitch. For example, a distance between the third interconnection portions 133W may range from 0.1 μm to 10 μm, in particular, from 0.1 μm to 5 μm. A minimum width of the third interconnection portions 133W may range from 0.1 μm to 10 μm, in particular, from 0.1 μm to 5 μm.
(63) The planarization process of the third redistribution patterns 133 and the sixth insulating layer 116 may be completed to fabricate a redistribution substrate 100. The redistribution substrate 100 may include the first to sixth insulating layers 111, 112, 113, 114, 115 and 116, the first to third seed layers 121, 122 and 123, and the first to third redistribution patterns 131, 132 and 133. However, embodiments of the inventive concepts are not limited thereto. In certain embodiments, the number of the insulating layers 111, 112, 113, 114, 115 and 116, the number of the seed layers 121, 122 and 123, and the number of the redistribution patterns 131, 132 and 133 may be variously modified or changed. As discussed above, the redistribution substrate 100 includes different types of openings in different insulating layers—e.g., a first-type opening such as the opening in insulating layers 111, 113, and 115, where a via portion of a redistribution pattern is formed, and a second-type opening such as the opening in insulating layers 112, 114, and 116, where a redistribution portion of a redistribution pattern is formed. The first-type openings in the insulating layers where the via portions are formed may have relatively tapered sidewall shapes (so that the via portions have relatively tapered sidewalls) compared to the second-type openings in the insulating layers where the redistribution patterns are formed, which may have relatively vertical sidewalls compared to the tapered sidewalls of the first-type openings. Referring to
(64) Conductive pads 140 may be formed on the exposed portions of the surfaces 133a of the third redistribution patterns 133 and may be electrically connected to the third redistribution patterns 133, respectively. The surfaces 133a of the third redistribution patterns 133 may have the small surface roughnesses, and thus contact resistances between the third redistribution patterns 133 and the conductive pads 140 may be reduced. The conductive pads 140 may include a metal such as copper and/or aluminum. At least one of the conductive pads 140 may not be aligned with the first via portion 131V of the first redistribution pattern 131, electrically connected thereto, in a vertical direction. The vertical direction may be a direction vertical to the bottom surface 111b of the first insulating layer 111. The conductive pads 140 may serve as or may form part of interconnection terminals that electrically connect the redistribution substrate 100 to a semiconductor chip. The conductive pads 140 may, for example, have a substantially flat surface exposed to an outside of the redistribution substrate 100. The conductive pads 140 may be referred to as redistribution substrate pads.
(65) Referring to
(66) The semiconductor chip 200 may be disposed on the redistribution substrate 100 in such a way that the chip pads 205 of the semiconductor chip 200 face the redistribution substrate 100. A first connection part 251 may be provided between one of the conductive pads 140 and one of the chip pads 205 so as to be electrically connected to the chip pad 205 and the conductive pad 140. The semiconductor chip 200 may be electrically connected to the redistribution substrate 100 through the first connection part 251. In the present specification, it may be understood that when a component is referred to as being electrically connected to the redistribution substrate 100, it may be electrically connected to at least one of the first to third redistribution patterns 131, 132 and 133. The first connection part 251 may include at least one of solder, a pillar, or a bump. The first connection part 251 may include a conductive material such as a metal, and may be described as an interconnection terminal. Though one semiconductor chip 200 is shown, a plurality of semiconductor chips may be stacked on each other and connected to the redistribution substrate 100, where the semiconductor chip 200 depicted is the bottom semiconductor chip in the stack.
(67) A molding layer 300 may be formed on the redistribution substrate 100 to cover the semiconductor chip 200. The molding layer 300 may cover the protective layer 117. The molding layer 300 may extend into a gap between the semiconductor chip 200 and the protective layer 117 to surround or seal the first connection part 251. The molding layer 300 may include an insulating polymer such as an epoxy molding compound (EMC). In certain embodiments, an underfill pattern (not shown) may be provided in the gap between the redistribution substrate 100 and the semiconductor chip 200. Thereafter, the carrier substrate 900 may be removed to expose a bottom surface of the redistribution substrate 100, for example, the first insulating layer 111. At this time, a portion of the first seed layer 121 may also be exposed.
(68) Referring to
(69)
(70) Referring to
(71) A semiconductor chip 200 may be provided on the redistribution substrate 100 in such a way that chip pads 205 of the semiconductor chip 200 face the redistribution substrate 100. A first connection part 251 may be formed between one of the conductive pads 140 and one of the chip pads 205. At this time, the semiconductor chip 200 may be provided in plurality on the redistribution substrate 100. A molding layer 300 may be provided on a top surface of the redistribution substrate 100 to cover the semiconductor chips 200. Thereafter, the carrier substrate 900 may be removed to expose the first insulating layer 111 and the first seed layer 121.
(72) Referring to
(73) The molding layer 300 and the redistribution substrate 100 may be sawed along one-dot chain lines to separate semiconductor packages 10 from each other. In the present specification, the semiconductor packages 10 may be fabricated in a chip level, a panel level, or a wafer level. Hereinafter, a single semiconductor package 10 will be described and illustrated for the purpose of ease and convenience in explanation. However, embodiments of the inventive concepts are not limited to the fabrication of a semiconductor package in the chip level.
(74)
(75) Referring to
(76)
(77) Referring to
(78) Referring to
(79) Referring to
(80) Referring to
(81) Referring to
(82) A terminal pad 410 may be formed on the third redistribution pattern 133 exposed by the protective layer 117. The terminal pad 410 may include a metal. An external connection terminal 420 may be formed on the terminal pad 410. Thus, a semiconductor package 12 may be fabricated.
(83) Referring to
(84) In certain embodiments, like
(85)
(86) Referring to
(87) A semiconductor chip 200 may be provided on the redistribution substrate 100. The semiconductor chip 200 may be disposed on a central region of the redistribution substrate 100 when viewed in a plan view. A first connection part 251 may be formed between one of the conductive pads 140 and one of the chip pads 205. A first underfill pattern 261 may be formed between the redistribution substrate 100 and the semiconductor chip 200 to surround or seal the first connection part 251.
(88) A connection substrate 500 may be provided on the redistribution substrate 100. The connection substrate 500 may be provided before or after providing the semiconductor chip 200. The connection substrate 500 may have a hole 590 penetrating the connection substrate 500. For example, the hole 590 may be formed in a printed circuit board to fabricate the connection substrate 500. The hole 590 may overlap with the central region of the redistribution substrate 100 when viewed in a plan view. The hole 590 may expose the redistribution substrate 100. The semiconductor chip 200 may be provided in the hole 590 of the connection substrate 500. The connection substrate 500 may include a base layer 510 and a conductive structure 520. The base layer 510 may include a plurality of base layers 510 sequentially stacked. The base layers 510 may include an insulating material. For example, the base layers 510 may include a carbon-based material, a ceramic, or a polymer. The hole 590 may penetrate the base layers 510. The conductive structure 520 may be provided in the base layers 510. As illustrated in
(89) As illustrated in
(90) The third redistribution pattern 133 may include a plurality of third redistribution patterns 133. One of the third redistribution patterns 133 may be electrically connected to the chip pad 205 through the first connection part 251, and another of the third redistribution patterns 133 may be electrically connected to the first pad 521 through the second connection part 252. The semiconductor chip 200 may be electrically connected to the conductive structure 520 through at least one of the redistribution patterns 131, 132 and 133.
(91) A molding layer 300 may be formed on the semiconductor chip 200 and the connection substrate 500. The molding layer 300 may extend into a gap between the semiconductor chip 200 and the connection substrate 500 to fill the gap. The molding layer 300 may include an insulating polymer such as an epoxy-based polymer. In certain embodiments, an adhesive insulating film may be adhered onto the connection substrate 500 and the semiconductor chip 200 to form the molding layer 300. For example, the Ajinomoto build-up film (ABF) may be used as the adhesive insulating film. In certain embodiments, the first underfill pattern 261 may be omitted, the molding layer 300 may further extend into a gap between the redistribution substrate 100 and the semiconductor chip 200. In certain embodiments, the second underfill pattern 262 may be omitted, the molding layer 300 may further extend into a gap between the redistribution substrate 100 and the connection substrate 500. Thereafter, the carrier substrate 900 may be removed to expose a bottom surface of the redistribution substrate 100. For example, the first insulating layer 111 and the first seed layer 121 may be exposed.
(92) Referring to
(93)
(94) Referring to
(95) The upper redistribution layer 600 may be provided on a top surface of the molding layer 300. The upper redistribution layer 600 may include first to fourth upper insulating layers 611, 612, 613 and 614, a first upper seed layer 621, a second upper seed layer 622, a first upper redistribution pattern 631, a second upper redistribution pattern 632, and an upper protective layer 617.
(96) The first upper insulating layer 611 may be provided on the molding layer 300. The first upper insulating layer 611 may include a photosensitive polymer. The first upper insulating layer 611 may have an upper opening which exposes the conductive portion 395. The first upper redistribution pattern 631 may be provided on the first upper insulating layer 611 and in the upper opening. The first upper redistribution pattern 631 may include a metal such as copper. The first upper seed layer 621 may be disposed between the first upper redistribution pattern 631 and the first upper insulating layer 611 and between the first upper redistribution pattern 631 and the conductive portion 395. The first upper redistribution pattern 631 may be electrically connected to the conductive portion 395 through the first upper seed layer 621.
(97) The second upper insulating layer 612 may be provided on the first upper insulating layer 611. The second upper insulating layer 612 may contact a sidewall of the first upper redistribution pattern 631. The first upper seed layer 621 may not extend between the first upper redistribution pattern 631 and the second upper insulating layer 612.
(98) The first upper insulating layer 611, the first upper seed layer 621, the first upper redistribution pattern 631, the second upper insulating layer 612, the third upper insulating layer 613, the second upper seed layer 622, the second upper redistribution pattern 632, and the fourth upper insulating layer 614 may be formed by substantially the same methods as the first insulating layer 111, the first seed layer 121, the first redistribution pattern 131, the second insulating layer 112, the third insulating layer 113, the second seed layer 122, the second redistribution pattern 132, and the fourth insulating layer 114 described above with reference to
(99) Likewise, a planarization process may be performed on a top surface 632a of the second upper redistribution pattern 632 and a top surface of the fourth upper insulating layer 614. Thus, the top surface 632a of the second upper redistribution pattern 632 may be substantially coplanar with the top surface of the fourth upper insulating layer 614. The top surface 632a of the second upper redistribution pattern 632 may have a surface roughness, for example, of 0.01 μm to 0.4 μm. A maximum distance between the bottom surface 611b of the first upper insulating layer 611 and the top surfaces 632a of the second upper redistribution patterns 632 may range from 100% to 120% of a minimum distance between the bottom surface 611b of the first upper insulating layer 611 and the top surfaces 632a of the second upper redistribution patterns 632. The second upper seed layer 622 may be disposed between the second upper redistribution pattern 632 and the second upper insulating layer 612. The second upper seed layer 622 may not extend between the second upper redistribution pattern 632 and the fourth upper insulating layer 614.
(100) The upper protective layer 617 may be formed on the fourth upper insulating layer 614 to cover at least a portion of the top surface 632a of the second upper redistribution pattern 632. The upper protective layer 617 may include an insulating polymer.
(101) An upper conductive pad 640 may be formed on the top surface 632a of the second upper redistribution pattern 632 so as to be connected to the second upper redistribution pattern 632. The upper conductive pad 640 may be electrically connected to the conductive structure 520 through the first and second upper redistribution patterns 631 and 632 and the conductive portion 395. The upper conductive pad 640 may not be vertically aligned with the conductive portion 395.
(102)
(103) Referring to
(104) Referring to
(105) An upper hole 390 may be formed in the molding layer 300 to expose the second pad 522 of the conductive structure 520. In certain embodiments, the conductive portion 395 and the upper redistribution layer 600 may further be formed on the molding layer 300, as described with reference to
(106)
(107) Referring to
(108) The second semiconductor package 30 may be disposed on the first semiconductor package 13′. The second semiconductor package 30 may include a package substrate 710, an upper semiconductor chip 720, and an upper molding layer 730. The package substrate 710 may be a printed circuit board (PCB). Alternatively, the redistribution substrate 100 fabricated according to the embodiments of
(109) The upper semiconductor chip 720 may be disposed on the package substrate 710. The upper semiconductor chip 720 may include integrated circuits, and the integrated circuits may include a memory circuit, a logic circuit, or a combination thereof. The upper semiconductor chip 720 may be electrically connected to the metal pad 705 through an interconnection line 715 disposed in the package substrate 710. The interconnection line 715 is schematically illustrated in
(110) A connection terminal 750 may be provided in the upper hole 390 of the molding layer 300. The connection terminal 750 may be disposed between the second pad 522 and the metal pad 705 to electrically connect the second pad 522 and the metal pad 705. Thus, the second semiconductor package 30 may be electrically connected to the semiconductor chip 200 and the external connection terminal 420 through the connection terminal 750. Electrical connection of the second semiconductor package 30 may include electrical connection to the integrated circuits of the upper semiconductor chip 720. According to certain embodiments, since the connection substrate 500 is provided, the connection terminal 750 may be disposed freely. It should be noted that the number and arrangement of the connection terminal(s) 750 is not limited to the number and arrangement of the first pad(s) 521. Thus, the interconnection lines 715 in the package substrate 710 and the integrated circuits and interconnection lines in the upper semiconductor chip 720 may be designed freely.
(111) In certain embodiments, the semiconductor package 15 described with reference to
(112)
(113) Referring to
(114) The connection substrate 500 of
(115) A molding layer 300 may be formed on the redistribution substrate 100 to cover the semiconductor chip 200. The molding layer 300 may cover a sidewall of the conductive structure 520′ but may expose a top surface 520a of the conductive structure 520′. Thereafter, the carrier substrate 900 may be removed to expose a bottom surface of the redistribution substrate 100.
(116) Referring to
(117)
(118) Referring to
(119)
(120) Referring to
(121) Thereafter, the carrier substrate 900 may be removed to expose a surface 200b of the semiconductor chip 200, a surface 300b of the molding layer 300, and a bottom surface of the conductive structure 520′.
(122) Referring to
(123) A terminal pad 410 and an external connection terminal 420 may be provided on the bottom surface of the redistribution substrate 100 so as to be electrically connected to one of the third redistribution patterns 133. For example, one of the external connection terminals 420 may be electrically connected to the semiconductor chip 200 through the redistribution patterns 131, 132 and 133, and another of the external connection terminals 420 may be electrically connected to the conductive structure 520′ through the redistribution patterns 131, 132 and 133. Thus, a semiconductor package 20 may be fabricated. In certain embodiments, the upper redistribution layer 600 described with reference to
(124)
(125) Referring to
(126) The second semiconductor package 30 may be disposed on the first semiconductor package 19′. The second semiconductor package 30 may be substantially the same as the second semiconductor package 30 of
(127) The connection terminal 750 may be disposed between the upper conductive pad 640 and the metal pad 705 to electrically connect the upper conductive pad 640 and the metal pad 705. The upper semiconductor chip 720 may be electrically connected to the redistribution substrate 100 through the connection terminal 750, the upper redistribution patterns 631 and 632, and the conductive structure 520′.
(128) In certain embodiments, the semiconductor package 18 fabricated in
(129) According to the embodiments of the inventive concepts, the surfaces of the first redistribution patterns may be planarized and thus may be disposed at substantially the same or similar levels. The second redistribution patterns may be formed on the surfaces of the first redistribution patterns. Thus, the patterning accuracy may be improved in the process of forming the second redistribution patterns. As a result, a distance between the second redistribution patterns may be reduced, and the second redistribution patterns may have a fine pitch. The redistribution patterns may be formed in the guide openings defined by the resist pattern. Thus, each of the redistribution patterns may have a relatively uniform width.
(130) While the inventive concepts have been described with reference to example embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the inventive concepts. Therefore, it should be understood that the above embodiments are not limiting, but illustrative. Thus, the scope of the invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing description.