Inorganic encapsulant for electronic component with adhesion promoter
11652012 · 2023-05-16
Assignee
Inventors
- Edmund Riedl (Wald, DE)
- Steffen Jordan (Pielenhofen, DE)
- Stefan Miethaner (Regensburg, DE)
- Stefan Schwab (Vienna, AT)
Cpc classification
H01L23/3142
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00012
ELECTRICITY
International classification
Abstract
A package includes an electronic component, an inorganic encapsulant encapsulating at least part of the electronic component, and an adhesion promoter between at least part of the electronic component and the encapsulant.
Claims
1. A package, comprising: an electronic component; an inorganic encapsulant encapsulating at least part of the electronic component; and an adhesion promoter that enhances adhesion between at least part of the electronic component and the encapsulant, wherein the adhesion promoter is a morphological adhesion promoter comprising a morphological structure having a plurality of openings.
2. The package of claim 1, wherein the encapsulant is a ceramic-based encapsulant or an inorganic polymer-based encapsulant.
3. The package of claim 1, wherein the encapsulant comprises at least one selected from the group consisting of: cement, concrete, gypsum, mortar, a silicon polymer, and an aluminum polymer.
4. The package claim 1, wherein the morphological adhesion promoter comprises at least one selected from the group consisting of: a metallic structure, an alloy structure, an alloy oxide structure, a chromium structure, a vanadium structure, a molybdenum structure, a zinc structure, a manganese structure, a cobalt structure, a nickel structure, a copper structure, a flame deposited structure, a roughened metal structure, and any alloy, alloy oxide, oxide, nitride, carbide, and selenide of said structures.
5. The package claim 1, wherein the plurality of openings comprises at least one selected from the group consisting of: pores, dendrites, and gaps between islands of a patterned structure.
6. The package of claim 1, wherein a material of the adhesion promoter is adapted for at least partially compensating a mismatch between the coefficients of thermal expansion of a material of the electronic component and a material of the encapsulant.
7. The package of claim 1, wherein the adhesion promoter forms an interlayer in an interface region between the encapsulant and the electronic component.
8. The package of claim 7, wherein at least one of: the interlayer provides a transition of porosity between the encapsulant and the electronic component; at least part of pores of the interlayer are at least partially filled with material of the encapsulant; and the interlayer has a thickness in a range between 30 nm and 500 nm.
9. The package of claim 1, further comprising a carrier on which the electronic component is mounted, wherein the carrier is at least partially encapsulated in the encapsulant, and wherein the carrier is at least partially covered by an adhesion promoter.
10. The package of claim 9, further comprising an electrically conductive contact element electrically coupling the electronic component with the carrier, wherein the electrically conductive contact element is at least partially encapsulated in the encapsulant, and wherein the electrically conductive contact element is at least partially covered by an adhesion promoter.
11. The package of claim 1, wherein the electronic component comprises at least one selected from the group consisting of: a semiconductor chip, a power semiconductor chip, an active electronic device, a passive electronic device, a sensor, an actuator, and a microelectromechanical system.
12. The package of claim 9, wherein the carrier is a leadframe made of copper.
13. The package of claim 10, wherein the electrically conductive contact element is a bond wire.
14. The package of claim 1, wherein the electronic component is a semiconductor chip having a metal pad.
15. The package of claim 14, wherein the metal pad is an aluminum or copper pad.
16. The package of claim 14, wherein along a vertical direction perpendicular to the metal pad, a coefficient of thermal expansion of the package is dominated by the encapsulant at a first vertical level, dominated by the metal pad at a second level, and dominated by the adhesion promoter at a third level between the first level and the second level.
17. The package of claim 14, wherein along a vertical direction perpendicular to the metal pad, an amount of material provided by the encapsulant continuously decreases and an amount of material provided by the adhesion promoter continuously increases between a first vertical level and a second vertical level, the second vertical level being closer to the metal pad than the first vertical level.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are included to provide a further understanding of exemplary embodiments and constitute a part of the specification, illustrate exemplary embodiments.
(2) In the drawings:
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DETAILED DESCRIPTION
(19) The illustration in the drawing is schematically and not to scale.
(20) Before exemplary embodiments will be described in more detail referring to the figures, some general considerations will be summarized based on which exemplary embodiments have been developed.
(21) According to exemplary embodiments, an encapsulant is provided comprising or consisting of an inorganic material—in particular ceramics (for example concrete)—combined with a—preferably morphological—adhesion promoter.
(22) Existing epoxy-based molding compounds have very high coefficients of thermal expansion (CTE) with limited yield strength. In addition, these thermosets may tend to crack along interfaces and in bulk. Furthermore, delamination at the interface may happen in such conventional approaches.
(23) Moreover, besides mechanical and thermomechanical limitations, existing polymer based encapsulation may have a limitation regarding thermal degradation and may start to degrade already at very low temperature of 200° C. Specific semiconductor materials (such as GaN, SiC or modern MOSFET generations) may however require much higher temperature stability of the respective package of up to 300° C. which cannot be achieved with conventional encapsulation materials, for example epoxy-based polymeric encapsulants.
(24) Conventional epoxy mold compounds may have inorganic fillers (for example SiO.sub.2) with high filler contents to reduce the CTE value of the bulk material. To increase the adhesion of the mold compound towards a semiconductor chip, leadframe and other interfaces, various adhesion promoter molecules may be added. In addition to the adhesion promoters, these mold compounds may comprise various different chemicals, such as flame-retardants. However, possible reactions between the different components at higher temperatures may lead to additional chemical species that may be dangerous for the package.
(25) Limitations of conventional encapsulants based on hydrocarbon-based encapsulation materials (epoxy, etc.) include their limited yield strength, high CTE and low temperature resistance, as such materials may decompose quickly at higher temperature.
(26) In order to overcome at least part of the above-mentioned and/or other shortcomings, an exemplary embodiment uses an inorganic encapsulation material, in particular a ceramic encapsulation material. Using ceramic-based inorganic materials (for example concrete) may offer a much lower CTE at much higher yield strength. Since concrete materials may be non-flammable non-polymers, additives such as flame retardants can be omitted, thus reducing the complexity of the encapsulation material. Additionally, concrete offers a far broader stability when it comes to higher temperatures of more than 300° C. Conventional mold compounds already show stability weakness at 200° C. Details of ceramic formulations of encapsulants used according to an exemplary embodiments and their solidification mechanism are shown in Table 1 below.
(27) TABLE-US-00001 TABLE 1 Table 1: Overview of ceramic formulations and inorganic polymer formulations and their different phases to interact with any of the adhesion promoters described in Table 3 Solid phase Liquid matrix Solidification Material phase in bulk of liquid phase Additives Concrete Soluble Al.sub.2O.sub.3, Formation of Concrete Ca-oxide SiO.sub.2, hydrates of 23iquefier, and Si-oxde Fe.sub.2O.sub.3 Ca-oxide, Super- phases Ca- plasticizer, (for example Aluminates, Stabilizer, Ca(OH).sub.2; Ca-Silicates Airtrap maximum former, concentration Accelerator 1.7 g/L in for water at solidifica- 20° C.) (*1) tion: CaCl.sub.2, carbonate, Na.sub.2CO.sub.3, aluminate, Tricalcium- aluminate, Inhibitor, Sealing agents Gypsum Soluble Ca- Formation of Ca-sulfate sulfate Ca-sulfate and its hydrates hydrates hydrates (for example CaSO.sub.4; maximum concentration 2 g/L in water) (*1) Mortar Soluble CaCO.sub.3, Formation of Ca-oxide CaOH hydrates of and Si-oxide and Ca-oxide, phases its further (for example hydrides solidifycation Ca (OH) .sub.2; with absorption maximum of CO.sub.2: concentration Ca(OH).sub.2 + 1.7 g/L in CO.sub.2 −> CaCO.sub.3 + water at H.sub.2O 20° C.) (*1) Silicon Silicate polymer Aluminum Aluminate polymer ((*1): Solvents: Besides water also alcohols and/or other solvents may be used)
(28) Table 2 shows different types of cements which may be used as ceramic-based encapsulant of a package of an exemplary embodiment.
(29) TABLE-US-00002 TABLE 2 Table 2: Examples for cement components used for concrete formulations Portland Siliceous Calcareous Slag Silica Property cement fly ash fly ash cement fume Silicon 21.9 52 35 35 85 to 97 oxide content (%) Aluminum 6.9 23 18 12 oxide (%) Iron 3 11 6 1 oxide (%) Calcium 63 5 21 40 <1 oxide (%) Magnesium 2.5 oxide (%) SO.sub.3 (%) 1.7
(30) Using a morphological adhesion promoter as a base for the ceramic encapsulation material may allow for efficiently improving intra-package adhesion within a package according to an exemplary embodiment.
(31) In embodiments, the ceramic based materials may be manufactured and processed as a mixture of solution and particles to encapsulate the electronic component(s). To ensure a proper interaction between the encapsulation material and a morphological adhesion promoter, the morphological adhesion promoter may be preferably applied before the application of the encapsulation material.
(32) At the time when the liquid encapsulation material is getting contact to the morphological adhesion promoter, the liquid part of the mixture, during application on the electronic component, may be able to penetrate into pores of the adhesion promoter layer. Possible morphological adhesion promoters which may be used according to exemplary embodiments are shown in Table 3. For all these morphological adhesion promoters the given pore sizes and layer thickness can be adapted to the respective encapsulation material by correspondingly adjusting deposition process parameters.
(33) Again referring to Table 3, the chromium, vanadium and molybdenum-based adhesion promoters may be formed by galvanic deposition of the corresponding inorganic material. Thus, the three mentioned adhesion promoters are all an inorganic morphological adhesion promoters with a sponge-like pore structure. A flame deposited adhesion promoter may be a porous silicon oxide layer deposited from a gas phase, for instance using a flame, and is also a morphological adhesion promoter. Rough copper can be created by a corresponding copper etching procedure of a copper layer which causes porosity of the surface of the etched copper layer, thereby producing this morphological copper-based adhesion promoter. In a similar way, aluminum oxide may be roughened. Such an aluminum oxide material may be formed by thermal oxidation of aluminum or by ALD (atomic layer deposition). What concerns a wet chemical etching process for an ALD layer, it should be mentioned that this is only an exemplary way of getting the layer porous. For instance, water vapor can be already enough to get the porous layer. In addition, aluminium oxide may be formed porous by Chemical Vapor Deposition (CVD) with specific gas composition of aluminium organyl in the chamber. Apart from this, also silicon nitride can be deposited porous with a specific ratio between TEOS (tetraethylsilane) and ammonia (NH.sub.3) and specific deposition conditions regarding concentration and temperature. By a subsequent wet etching procedure, the created aluminum oxide may be rendered porous, wherein the pores may for instance have a substantially columnar and/or substantially spherical shape.
(34) As an alternative to the mentioned inorganic morphological adhesion promoters, it is also possible to use an organic adhesion promoter, for instance silane.
(35) A liquid precursor or a liquid part of the encapsulation material may crystalize in a sponge layer or in pores of a morphological adhesion promoter through formation of a solid phase, for example for concrete formation of crystalline hydrates.
(36) During this solidification of the liquid phase in the porous morphological adhesion promoter sponge, the morphological adhesion promoter and the encapsulation material may form a mixture of fiber/encapsulation interlayer. Besides a strong adhesion, this interlayer enables a CTE adaption from the electronic component, carrier or substrate to the encapsulation material. The ratio between adhesion promoter volume fraction and encapsulation material volume fraction may continuously change within the formed interlayer. The average CTE of the nano-structured layer may change from CTE (electronic component, carrier or substrate) to CTE (encapsulation material) continuously, depending on the pore size and the porosity. Therefore, the formed interlayer (which may be composed of material of the morphological adhesion promoter and material of the encapsulant, with spatially varying percentages) may form a layer with a continuous change of the CTE value from the electronic component or device substrate to the encapsulation material. A CTE mismatch between electronic component or device substrate on the one hand and encapsulation material on the other hand, which may generate stress (in particular thermomechanical stress), may be partially or even entirely compensated. Together with the advantageously low-CTE characteristic of a ceramic encapsulation, this may lead to stress reduction or even minimization in the package.
(37) Besides adhesion promotion and stress reduction, the morphological adhesion promoter may also act as a corrosion barrier. Especially together with the ceramic encapsulation, the formed interlayer may act as a protection from water and oxygen.
(38) In particular in case of a morphological adhesion promoter using Cr, V, or Mo, the adhesion to the device surface can be made also via a seed layer of the actual adhesion promoter layer as a metallurgical contact. Such a seed layer may also act as a corrosion barrier.
(39) Table 3 shows an overview of morphological adhesion promoters which may be used according to exemplary embodiments:
(40) TABLE-US-00003 TABLE 3 Table 3: Overview of morphological adhesion promoters that may interact with liquid-phase encapsulation materials (other materials are possible in other embodiments, in particular: a metallic structure, an alloy structure, a chromium structure, a vanadium structure, a molybdenum structure, a zinc structure, a manganese structure, a cobalt structure, a nickel structure, a copper structure, a flame deposited structure, a roughened metal structure, in particular a roughened copper structure or a roughened aluminum oxide structure, and any oxide, nitride, carbide, and selenide of said structures) Adhesion Material Pore Layer Preparation/deposition promoter of layer size thickness process Cr ZnCr-oxide 1-500 nm 1-500 nm Galvanic and and ZnCr- electroless alloy deposition with including pulse plating and seed layer plating, or V ZnV-oxide 1-500 nm 1-500 nm constant current and ZnV- alloy including seed layer Mo ZnMo-oxide 1-500 nm 1-500 nm and ZnMo- alloy including seed layer Flame SiO.sub.2, 1-500 nm 1-500 nm Flame or plasma deposited Si—O—C deposition with precursors (*1) Rough Cu Etched Cu 1-500 nm 1-500 nm Anisotropic etching surface of Cu or its alloys at from grain boundaries (*2) various Cu alloys Al.sub.2O.sub.3 Al.sub.2O.sub.3 1-500 nm 1-500 nm Thermal oxidation rough of aluminum or deposition of Al.sub.2O.sub.3 from, gas phase (atom layer deposition); treatment with aqueous solutions to form sponge and dendrites (*1): Precursors: Tetraethylsilane, Hexamethyldisiloxane, Hexamethyldisilane, Ti-organyls (*2): Example Cu roughening with H.sub.2SO.sub.4/H.sub.2O.sub.2 etching with benzotriazole additive to enhance selectivity of etching to grain boundaries
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(42) The mounting structure 132 comprises an electric contact 134 embodied as a plating in a through hole of the mounting structure 132. When the package 100 is mounted on the mounting structure 132, an electronic component 104 of the package 100 is electrically connected to the electric contact 134 via an electrically conductive carrier 102, here embodied as a leadframe made of copper, of the package 100.
(43) The package 100 thus comprises the electrically conductive carrier 102, the electronic component 104 (which is here embodied as a power semiconductor chip) adhesively (see reference numeral 136) mounted on the carrier 102, and an encapsulant 106 encapsulating part of the carrier 102 and part of the electronic component 104. As can be taken from
(44) During operation of the power package or package 100, the power semiconductor chip in form of the electronic component 104 generates a considerable amount of heat. At the same time, it shall be ensured that any undesired current flow between a bottom surface of the package 100 and an environment is reliably avoided.
(45) For ensuring electrical insulation of the electronic component 104 and removing heat from an interior of the electronic component 104 towards an environment, an electrically insulating and thermally conductive interface structure 108 may be provided which covers an exposed surface portion of the carrier 102 and a connected surface portion of the encapsulant 106 at the bottom of the package 100. The electrically insulating property of the interface structure 108 prevents undesired current flow even in the presence of high voltages between an interior and an exterior of the package 100. The thermally conductive property of the interface structure 108 promotes a removal of heat from the electronic component 104, via the electrically conductive carrier 102 (of thermally properly conductive copper), through the interface structure 108 and towards a heat dissipation body 112. The heat dissipation body 112, which may be made of a highly thermally conductive material such as copper or aluminum, has a base body 114 directly connected to the interface structure 108 and has a plurality of cooling fins 116 extending from the base body 114 and in parallel to one another so as to remove the heat towards the environment.
(46) Although
(47) As will be described below referring to
(48) As indicated schematically by reference numeral 150′ in
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(50) As already mentioned above, the encapsulant 106 may comprise cement, concrete, or alternatively gypsum or mortar. Such a ceramic-based inorganic encapsulant 106 may have inherently non-flammable properties, so that the addition of non-flammable additives may be dispensable. This renders the encapsulant 106 simple in manufacture. In particular, the combination of a morphological adhesion promoter 150 and a ceramic encapsulant 106 may be highly advantageous. This ensures proper adhesion, keeps thermomechanical stress small, enables efficient heat removal, prevents corrosion, and ensures thermal stability in the presence of very high temperatures.
(51) For instance, the schematically illustrated morphological adhesion promoter 150 may be a roughened copper structure or a porous Zn/Cr layer having pores into which material of the encapsulant 106 (which may be at least partially liquid or flowable during manufacture) may penetrate. Roughening of a copper material may be accomplished for instance by a plasma treatment, by wet etching, and/or by a mechanical treatment.
(52) As shown in
(53) Adhesion promoting interlayer 152 forms an interface between the encapsulant 106 and the adhesion promoter 150. For instance, a vertical thickness, d, of the interlayer 152 can be 100 nm. The interlayer 152 constitutes a continuous transient between material of the encapsulant 106 and material of the adhesion promoter 150, as will be described in the following in further detail: For manufacturing the structure shown in
(54) With the structure shown in
(55) Still referring to
(56) The cement of the ceramic-based encapsulant 106 may reduce thermomechanical stress due to its highly advantageous CTE properties. Furthermore, the cement material with its crystalline structure may enhance mechanical stability of the package 100. Even more important, thermal stability of cement increases manufacturing and operation temperatures of the package 100 compared to conventional approaches. Moreover, cement material has an excellent thermal conductivity, as compared to other encapsulation materials.
(57) In particular in combination with the morphological adhesion promoter 150, an improved adhesion and a reduced tendency of delamination, as well as an increased tensile strength of the package 100 may be obtained.
(58) A skilled person will understand that the illustration of the pore structure in
(59) In the following, different embodiments of deposition layer porosity will be compared:
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(66) The simulated morphological adhesion promoter 150 shows that the configuration of
(67) It should be noted that the term “comprising” does not exclude other elements or features and the “a” or “an” does not exclude a plurality. Also, elements described in association with different embodiments may be combined. It should also be noted that reference signs shall not be construed as limiting the scope of the claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.