Wafer fabrication process and devices with extended peripheral die area
12564019 ยท 2026-02-24
Assignee
Inventors
Cpc classification
H10P74/277
ELECTRICITY
H10P74/207
ELECTRICITY
H10P54/00
ELECTRICITY
International classification
Abstract
Semiconductor (SC) chip devices and associated methods of making are presented. The SC chips are designed to include enlarged extension semiconductor areas next to functional integrated circuit (IC) dies on these SC chips. Some variations include designing semiconductor wafers prior to fabrication so that the resultant IC dies are surrounded by the extension semiconductor areas. Other variations include processing post manufactured semiconductor wafers to expand the size of the available extension areas by including truncated pieces of IC dies that are immediately adjacent to functional working primary IC dies. These variations provide additional room for redistribution layers to fan-out from the IC dies outwards onto the extension areas.
Claims
1. A semiconductor (SC) chip comprising: an integrated circuit (IC) die formed on a semiconductor substrate; an extended semiconductor fan-out area, integral with the IC die and formed from the same semiconductor substrate material as the IC die, formed on the semiconductor substrate, immediately adjacent to the IC die, said extended semiconductor fan-out area extending laterally beyond a footprint defined by the IC die; and a redistribution layer (RDL) arrangement on the IC die and the extended semiconductor fan-out area, the RDL arrangement comprising an RDL conductor arm and an RDL contact platform, the RDL contact platform being mounted at the extended semiconductor fan-out area laterally outside the footprint defined by the IC die, wherein the RDL arrangement fans out from the IC die onto the extended semiconductor fan-out area, such that the RDL conductor arm electrically couples together the IC die to the RDL contact platform mounted at the extended semiconductor fan-out area.
2. The SC chip of claim 1, wherein the RDL arrangement comprises a plurality of RDLs that fan-out from the IC die onto the extended semiconductor fan-out area, such that the RDLs electrically couple together the IC die to a plurality of RDL contact platforms mounted at the extended semiconductor fan-out area.
3. The SC chip of claim 1, further comprising a seal ring, on the semiconductor substrate, surrounding the extended fan-out area and the IC die.
4. The SC chip of claim 1, further comprising a test structure, on the extended semiconductor fan-out area, which is electrically coupled to the IC die.
5. The SC chip of claim 1, wherein the RDL arrangement comprises: passivation layers around the RDL conductor arm that electrically insulate the RDL conductor arm.
6. The SC chip of claim 1, wherein the extended semiconductor fan-out area surrounds the IC die.
7. The SC chip of claim 1, wherein the semiconductor substrate comprises single crystalline silicon.
8. A semiconductor (SC) chip comprising: a primary integrated circuit (IC) die formed on a semiconductor substrate; an extended semiconductor fan-out area, formed on the semiconductor substrate, integral with the primary IC die and formed from the same semiconductor substrate material as the primary IC die, that comprises at least one truncated piece of a sacrificial IC die which is immediately adjacent to the primary IC die, said extended semiconductor fan-out area providing increased area for redistribution layer (RDL) fan-out; and at least one RDL arrangement, on the IC die and the extended semiconductor fan-out area, comprising an RDL conductor arm and an RDL contact platform, wherein the RDL contact platform is mounted on the truncated piece of the sacrificial IC die within said extended semiconductor fan-out area, the at least one RDL arrangement fanning out from the primary IC die onto the truncated piece of the sacrificial IC die within the extended semiconductor fan-out area, such that the RDL conductor arm electrically couples together the primary IC die to the RDL contact platform.
9. The SC chip of claim 8, wherein the RDL arrangement comprises: passivation layers around the RDL conductor arm that electrically insulate the RDL conductor arm.
10. The SC chip of claim 8, wherein: the at least one truncated piece of a sacrificial IC die are a plurality of truncated pieces of sacrificial IC dies, on the semiconductor substrate, that surround and are immediately adjacent to the primary IC die, and the at least one RDL arrangement are a plurality of RDL arrangements, on the semiconductor substrate, that fan-out from the primary IC die onto the plurality of truncated pieces of sacrificial IC dies.
11. The SC chip of claim 8, wherein the semiconductor substrate comprises single crystalline silicon.
12. The SC chip of claim 8, wherein the at least one RDL arrangement is over a plurality of seal rings.
13. The SC chip of claim 8, wherein the at least one RDL arrangement is over a test structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present disclosure is best understood from the following detailed description when with the accompanying figures. Various features may be not drawn to scale and used for illustration purposes only. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
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(16) The same reference numerals refer to the same parts throughout the various figures.
DETAILED DISCLOSURE
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(19) Other variations of this embodiment provide that the extended fan-out area (90) need not surround completely the initial IC die (30) as long as the extended fan-out areas (90) are immediately adjacent to the initial IC die (30).
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(21) With continued reference to
(22) The SC chip (15) may additionally include a plurality of RDL arrangements (100) that fan-out from the IC die (30) onto the extended fan-out area (90), such that the RDL arrangements (100) electrically couple together the initial IC die (30) in the SC chip (15) to a plurality of solder bumps (110) mounted at the extended fan-out areas (90).
(23) A person skilled in the art would recognize that the SC chip (15) comprises the initial IC die (30), the extended fan-out area (90) and the RDL arrangements (100) illustrated in
(24) According to a preferred embodiment, the integrated circuit for the initial IC die (30) of the SC chip (15) is designed, before fabrication on the SC wafer (10), in a way that the extended fan-out area (90) is already taken into consideration at the mask-generation step.
(25) Referring now to
(26) The receiving (210) operational procedure of the SC chip (15) manufacturing fabrication method (200) includes receiving a semiconductor wafer (10) having a design layout that comprises: initial IC dies (30), on a semiconductor substrate (130) of the semiconductor wafer (10), with adjoined extended fan-out areas (90) as shown and described in
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(28) After the semiconductor wafer (10) passes wafer testing, a depositing (230) operational procedure of the SC chip (15) is envisioned, to include depositing, patterning and etching redistribution (RDL) arrangements (100), and optionally including solder bumps (110), on the SC chips (15) while on the semiconductor wafer (10).
(29) After depositing (230) the RDL arrangements (100) and optionally providing the solder bumps (110), the SC chip (15) performance is again evaluated by implementing an inspecting (240) operational procedure of the SC chip (15). This may include inspecting the semiconductor wafer (10) using automatic optical inspection (AOI).
(30) After inspecting (240), a separating (250) operational procedure of the SC chip (15) manufacturing method (200) is included that separates the semiconductor wafer along the initial scribe streets (60) to singulate SC chips (15) from the semiconductor wafer (10) using, for example, backside griding (BSG) and dicing procedures. The dicing process can be accomplished by scribing and breaking, by mechanical sawing (e.g., with a dicing saw) or by laser cutting.
(31) After separating (250), the mounting (260) operational procedure of the SC chip (15) manufacturing method is intended to include mounting the SC chips (15) for shipment by, for example, carrying out tape and reel operations, or pick and place operations, or plate some of the SC chips as a waffle pack or other containers.
(32) An optional additional procedure of shipping (270) the assembled SC chip (15) can also be included.
(33) It is understood that the above-described fabrication method of making SC chips is simply an example embodiment, and that alternative embodiments, additional and/or different operational procedures may be included.
(34) Reference will now be made to
(35) As shown in
(36) Differently from the previous disclosed embodiment, here
(37) Similarly to the previous embodiment, the substrate (130) may be a silicon substrate (e.g. made of single crystalline silicon) or other proper substrate having material layers formed thereon. Other proper substrate materials include suitable elementary semiconductors, such as diamond or germanium; a suitable compound semiconductor, such as gallium arsenide, silicon carbide, indium arsenide, or indium phosphide; or a suitable alloy semiconductor, such as silicon germanium carbide, gallium arsenic phosphide, or gallium indium phosphide.
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(40) Reference will now be made to
(41) The obtaining (290) operational procedure of the SC chip manufacturing method (280) includes obtaining a semiconductor wafer (10) that comprises initial IC dies (30) between initial scribe streets (40).
(42) The selecting (300) operational procedure of the SC chip manufacturing method (280) includes selecting some of the initial IC dies (30) as primary IC dies (50) and some of the initial IC dies (30) as sacrificial IC dies (70).
(43) The laying out (310) operational procedure of the SC chip (15) manufacturing method (280) includes laying out new scribe streets (40) across the semiconductor wafer (10) to define extended fan-out areas (90) adjacent to the primary IC dies (50), such that the extended fan-out areas (90) comprise portions of the initial scribe streets (40) that are next to the primary IC dies (50) and portions of the sacrificial IC dies (70) that are adjacent to the primary IC dies (50).
(44) The forming (320) operational procedure of the SC chip (15) manufacturing method includes forming RDL arrangements (100) and optionally forming solder bumps (110) on the semiconductor wafer (10) that electrically couple together the primary IC dies (50) to the solder bumps (110) mounted at the extended fan-out areas (90), wherein the RDL arrangements (100) fan-out from the primary IC dies (50) onto the extended fan-out areas (90).
(45) The operational procedures of obtaining (290), selecting (300), laying out (310), and forming (320) are usually processed at a single facility.
(46) An additional optional set of procedures of performing (330), singulating (340), and carrying out (350) can also be included in the manufacturing method (280). The optional performing (330) operational procedure of the SC chip (15) manufacturing method includes performing automatic optical inspection (AOI) of the semiconductor wafer (10). The optional singulating (340) operational procedure of the SC chip (15) manufacturing method includes singulating the semiconductor wafer (10) along the new scribe streets (60) into SC chips (15) that comprise the primary IC dies (50) adjoining the extended fan-out areas (90) by using backside griding (BSG) and dicing procedures. The optional carrying out (350) operational procedure of the SC chip (15) manufacturing method can include carrying out tape and reel (TnR) operations to mount the SC chips (15) for shipment. The operational procedures of performing 330, singulating 340, and carrying out 350 may be performed at single facility.
(47) Reference will now be made to
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(51) With continued reference to
(52) With reference now to
(53) In practicing the above described fabrication methods (200) and (280) according to the embodiments of the present disclosure, a substantial time saving advantage can be realized when implementing the SC chip according to the teachings of
(54) When the time saving advantage is high, the teachings of the present disclosure will be well suited not only for a sampling operation (where a single or small number of sample(s) is shipped to the customer) but also for the production stage of the final product. By way of example, the embodiment of
(55) Circuits and devices in accordance with the present invention may be used alone or in combination with other components, circuits, and devices. Embodiments of the present invention may be fabricated as integrated circuits (ICs), which may be encased in IC packages and/or in modules for case of handling, manufacture, and/or improved performance. In particular, IC embodiments of this invention are often used in modules in which one or more of such ICs are combined with other circuit blocks (e.g., filters, amplifiers, passive components, and possibly additional ICs) into one package. The ICs and/or modules are then typically combined with other components, often on a printed circuit board, to form part of an end product such as a cellular telephone, laptop computer, or electronic tablet, or to form a higher-level module which may be used in a wide variety of products, such as vehicles, test equipment, medical devices, etc. Through various configurations of modules and assemblies, such ICs typically enable various applications including signal, data, and power transmission; power management; wireless communications; data conversions; data processing; and other such applications.
(56) A number of embodiments of the invention have been described. It is to be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, some of the steps described above may be order independent, and thus can be performed in an order different from that described. Further, some of the steps described above may be optional. Various activities described with respect to the methods identified above can be executed in repetitive, serial, and/or parallel fashion.
(57) It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the following claims, and that other embodiments are within the scope of the claims. In particular, the scope of the invention includes any and all feasible combinations of one or more of the processes, machines, manufactures, or compositions of matter set forth in the claims below. (Note that the parenthetical labels for claim elements are for ease of referring to such elements, and do not in themselves indicate a particular required ordering or enumeration of elements; further, such labels may be reused in dependent claims as references to additional elements without being regarded as starting a conflicting labeling sequence).