CN101053079A - 堆叠式封装的改进 - Google Patents

堆叠式封装的改进 Download PDF

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Publication number
CN101053079A
CN101053079A CNA2005800378141A CN200580037814A CN101053079A CN 101053079 A CN101053079 A CN 101053079A CN A2005800378141 A CNA2005800378141 A CN A2005800378141A CN 200580037814 A CN200580037814 A CN 200580037814A CN 101053079 A CN101053079 A CN 101053079A
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substrate
basal plate
unit
microelectronic element
microelectronic
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B·哈巴
C·S·米切尔
M·贝罗泽
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Adeia Semiconductor Solutions LLC
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Tessera LLC
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Abstract

通过切断加工过程中的单元制造多个微电子组件(60),该加工过程中的单元包括上部基板(40)和下部基板(20),使微电子元件(36)设置在基板之间。在另一实施例中,将引线框(452)连结到基板(440)上以使引线从该基板突出。引线框(452)连结到另一基板(470)上,使得一个或多个微电子元件(436,404,406)设置在两基板之间。

Description

堆叠式封装的改进
相关申请的交叉引用
本申请要求2004年11月3日提交的美国临时专利申请No.60/624,667的申请日的优先权,其内容援引于此以供参考。
技术领域
诸如半导体芯片的微电子元件通常被提供以对半导体芯片或其它电子元件提供物理和化学保护的封装。这种封装通常包括诸如由电介质形成且其上具有导电端子的小电路配电板之类的封装基板。芯片装在配电板上并电气连接到封装基板的端子上。通常芯片和基板的一部分由密封剂或上部模制件覆盖,使得仅露出基板的端子承载外表面。这种封装件可方便地运载、存储和处理。该封装件可使用标准安装技术,最通常是表面安装技术装到诸如电路板之类的较大电路配电板上。在本技术领域人们已经付出了很大的努力来使这种封装件变得更小,以使封装芯片在电路板上占据更小面积。例如,称为芯片比例封装件的封装件占据电路板上与芯片本身面积相同的面积,或仅稍大于芯片本身的面积。但是,即使用芯片比例封装件,几个封装芯片占据的总面积也大于或等于单个芯片的总面积。
人们已经提出一种“堆叠的”封装件,其中多个芯片一个在另一个上安装在共同封装件内。该共同封装件安装到电路配电板上的面积可等于或仅略大于通常安装包含单芯片的单个封装件需要的面积。
堆叠的封装方法节约了电路配电板上的空间。彼此功能相关联的芯片或其它元件可设置在共同的堆叠封装件内。该封装件可包含这些元件之间的相互连接。这样,封装件所安装的主电路配电板不需要包括用于这些相互连接的导体和其它元件。这又允许使用更简单的电路配电板,且在某些情况下,允许使用具有较少层金属连接的电路配电板,由此本质上降低电路配电板的成本。此外,堆叠的封装件内的相互连接可制成与装在电路金属板上单个封装件之间可比的相互连接相比具有较低的电阻和较短的信号传播延迟时间。这又可例如通过允许在这些元件之间的信号传输中使用较高的时钟脉冲速度,增加堆叠的封装件内微电子元件的运行速度。
迄今已经提出一种形式的堆叠封装,有时称为“球形堆叠”。球形堆叠封装件包括两个或多个单个单元。每个单元包含的单元基板类似于单个封装件的封装基板,且一个或多个微电子元件安装到该单元基板上并连接到单元基板上的端子上。单个单元一个堆叠到另一个上,各单个单元基板上的端子通过诸如焊接球或插脚的导电元件连接到另一单位基板上的端子。底部单元基板的端子可组成封装件的端子,或者另外的基板可安装到封装件底部并可具有与各单元基板的端子连接的端子。例如美国公开专利申请2003/0107118和2004/0031972的某些优选实施例中描述了球形堆叠封装件,其内容援引于此以供参考。
在有时称为折叠堆叠封装件的另一类型的堆叠封装件中,在单个基板上装有两个或多个芯片或其它微电子元件。该单个基板通常具有电导体,其沿着基板延伸以与装在基板上的微电子元件彼此连接。该基板还具有导电端子,其连接到装在基板上的微电子元件中的一个或两个上。该基板在其自身上方折叠,使一部分上的微电子元件在另一部分的微电子元件上方,并使得封装基板的端子暴露在折叠封装件的底部,用于将封装件安装到电路配电板上。在折叠封装件的某些变体中,在基板被折叠成其最终构造之后,一个或多个微电子元件附连到基板上。美国专利6,121,676;美国专利申请No.10/077,388;美国专利申请No.10/655,952;美国临时专利申请No.60/403,939;美国临时专利申请No.60/408,664;和美国临时专利申请No.60/408,644的某些优选实施例示出了折叠堆叠的实例。折叠堆叠已用于各种目的,但已经发现在必须彼此通信的包装芯片中的特殊应用,例如在形成包含移动电话中基带信号处理芯片和射频功率放大器(“RFPA”)芯片的组件时,以形成紧凑的、自包含的组件。
除了本技术领域的所有这些努力,还需要进一步的改进。尤其是,需要提供可提供类似于折叠堆叠中实现的那些优点的封装件而不需实际将基板折叠。
发明内容
本发明一方面提供了一种制造多个微电子组件的方法。根据本发明该方面的方法,理想地包括以下步骤:提供加工过程中的(in-process)单元,该单元包括多个微电子元件、在微电子元件上方延伸的至少一个上部基板以及在微电子元件下方延伸的至少一个下部基板,基板中的至少一个包括多个区域;以及然后切割加工过程中的单元以形成单个单元,每个所述单元均包括所述基板中的所述至少一个和所述微电子元件中的至少一个中的每一个的一区域。
本发明的另一方面提供一种加工过程中的单元。根据本发明该方面的加工过程中的单元包括上部和下部基板以及设置在两基板之间的多个微电子元件。每个基板较佳地包括多个区域,上部基板的每个区域与下部基板的相应区域对齐,使得至少一个所述微电子单元设置在其间。较佳地,所述上部和下部基板的各区域均具有导电元件,上部基板的每个所述区域的至少一些所述导电元件电连接到所述下部基板相应区域的导电元件。
本发明的又另一方面提供了一种制造微电子组件的方法。根据本发明该方面的方法理想地包括将引线框附连到第一基板上,使得引线框的引线从该基板突出并将第一基板与第二基板组装使得至少一个微电子元件设置在第一和第二基板之间,并将所述引线连接到所述第二基板上。
附图说明
图1是示出了根据本发明一实施例过程中所利用元件的剖视图。
图2-6是类似于图1的图,但示出了该过程随后渐次的阶段的元件。
图7是示出用在根据本发明另一实施例过程中元件的剖视图。
图8是示出用在根据本发明又另一实施例过程中元件的剖视图。
图9是类似于图7和8的图,但示出了用在根据本发明另一实施例过程中的元件。
图10是示出了过程随后阶段的图9所示元件。
图11是示出了用在根据本发明另一实施例过程中基板和引线框的视图。
图12是示出了过程随后阶段的图11所示的基板和引线框。
图13是示出了在过程更后面阶段中的图11和12所示元件的视图。
图14是使用图11-13的元件制成的组件的剖视图。
具体实施方式
根据本发明一实施例的组装方法,利用方便起见在此称为下部基板20的基板,下部基板20包含限定上部表面22和下部表面24的电介质层21。下部基板20通常是具有大量的区域26的连续或半连续的条带或薄片的形式。如下文所解释的那样,每个区域26会在过程结束时组成单个封装件,且每个区域26包括如下所述会形成单个封装件的一部分的特征。
电介质层21可以是单层,或可以是包括几个内层的叠层。电介质层理想地主要由诸如聚酰亚胺、BT树脂、环氧化物或其它电介质聚合体形成,并可包括加强纤维,例如玻璃纤维。电介质层21可以是柔性或刚性的。下部基板20包括在电介质层的下表面24上露出的安装端子28、和随后的相互连接端子29以及在上部表面22上露出的传导连接元件30。在所示的具体实施例中,端子28和29形成在与连接元件30分开的一层,这些层通过电介质层21彼此分开并通过诸如延伸穿过电介质层的通路(vias)32的传导元件彼此电连接。这种设置通常称为“双金属”结构。但是,下部基板20可形成为带有传导连接构件30以及端子28和29构成的单金属层的单金属结构。例如,这种层可以设置在电介质层的底部表面24上,传导连接元件30通过电介质层上的孔(未示出)露出在顶部表面22。同样,这样的金属层可设置在上部表面22上,端子28和29通过电介质层上的孔(未示出)露出在下部表面24上。在又另一替代形式中,组成传导安装元件的一个或多个金属层、端子或两者设置在电介质层的厚度内并通过孔到适当的表面。
下部基板20具有从上部表面到下部表面延伸穿过电介质层的小孔34。小孔34可以是单个孔或细长狭槽的形式。小孔34设置在层间连接端子29附近。微电子元件36安装在下部基板20的上表面22上。每个区域26具有安装在其上的一个或多个微电子元件。在所示具体实施例中,下部基板的每个区域26承载一个微电子元件。所示微电子元件为面向下定向安装的半导体芯片,使得芯片的触点(未示出)例如用诸如焊料的粘结材料通过将触点粘结到传导安装元件而连接到基板的传导连接元件30。但是,也可采用其它技术。例如,每个微电子元件36可以是包含有端子在上面的封装基板(未示出)的封装微电子元件,这些端子连接到下部基板上的传导连接元件30。在又另一变体中,可采用诸如非均质传导粘结剂的技术。上部模制件38覆盖每个微电子元件36露出的表面。在其它实施例中,省略了上部模制件38。下部基板的每个区域26内的微电子元件36通过该区域的传导连接元件30电连接到该区域的安装端子28的至少一些上、连接到该区域的层间连接端子29的至少一些上或连接到两者上。微电子元件36可用常规技术安装在下部基板上,或者作为在此描述的组装过程的一部分或这在分开的操作中用于准备下部基板20。
根据本发明该实施例的过程还使用包括电介质层41的上部基板40,其可由上述相同材料形成,连接下部电介质层,限定上部表面42和下部表面44。上部基板具有在下部表面44上露出的层间连接端子49和在上部表面露出的传导安装端子50。在这里,这些特征示出为双层结构,但是可由单层或多层形成,这些特征通过电介质层上的孔露出在两表面中的一个或两个上。上部基板40还具有多个区域46,每个这种区域包括一系列层间连接端子49和一系列安装端子50,至少一些安装端子50电连接到该区域的至少一些层间连接端子49上。
在组装过程中,上面有微电子元件36的下部基板20与上部基板40结合成一体,使得上部基板40的下部表面44搁在微电子元件36上并面向下部基板。这样,微电子元件36设置在两基板之间。粘结剂52涂敷在上部基板的下部表面44上,该上部基板在微电子元件36的远离下部基板的表面上,这些表面可以是环绕每个微电子元件的密封剂38限定的表面。将基板彼此组装的过程最佳地在两基板保持包含多个区域26和46的大基板的形式的同时进行。例如,在基板是细长带或条形式时,基板可通过一对轧辊或通过挤压改进,以使上部基板与下部基板上的微电子元件36的表面啮合。或者,在两基板都是诸如大圆形或方形薄片之类的大薄片形式时,组装过程可进通过将一个薄片放置在另一薄片上进行,以将基板彼此组装。该基板彼此组装使得上部基板的每个区域46与下部基板20的相应区域26对齐。
在将基板彼此组装后,下部基板每个区域的层互连端子29与上部基板相应区域的层互连端子49连接。该连接通过在层互连端子之间应用丝焊形成。丝焊延伸穿过下部基板上的小孔34。在丝焊之后,与每个下部区域相关联的至少一些下部安装端子28,或者芯片36上的至少一些触点,通过丝焊和层互连端子连接到上部基板相应区域的至少一些安装端子50。
在应用丝焊之后,在下部基板20和上部基板10之间引入密封剂54(图4)。密封剂可以是任何与构造材料兼容的易流动的密封剂。最理想地,密封剂54是可定位材料,其在未处理状态下是粘度相对低的液体,且其可处理成固体或半固体状态。这种材料的实例包括环氧化物、硅树脂以及在微电子封装中通常采用作为密封剂的其它材料。这些材料通过化学反应处理,通常通过加热改进。可使用加热液化并通过冷却处理成固体状态的诸如热塑材料的其它密封剂。该密封剂可通过任何适当过程注入基板之间。在注射密封剂时,一些密封剂可通过下部基板上的小孔34(图3)逸出。这些基板可在密封剂注入时约束在模子或其它固定设备的构件之间,且这些构件可密封下部基板上的开口34。替代地或另外地,下部基板上的开口34可由诸如在丝焊后涂敷在开口上方的焊料掩模之类的电介质膜覆盖。可在该步骤采用共同转让的美国专利6,329,224和5,766,987中讲授的该技术,其内容援引于此以供参考。密封剂诸如步骤理想地也在基板40和20保持在它们初始形式的同时进行,使得每个基板的各区域在该阶段保持彼此连接。密封剂环绕丝焊53(图3)并理想地基本上或完全填充出了微电子元件本身粘结的空间之外的上部和下部基板之间的空间。
在密封剂注入和处理之后,将一个或多个附加微电子元件56安装在上部基板40露出的顶部表面42上,并与上部基板的安装端子50电连接。这里,微电子元件56安装在上部基板的各区域46上。诸如焊球58之类的导电粘结材料可涂敷在下部基板的安装端子28上。附加微电子元件56可以是“裸的”或未封装的半导体芯片或其它微电子元件,或者可以是诸如封装的半导体芯片之类的封装微电子元件。在所示实施例中,每个附加微电子元件通过直接将微电子元件上的触点粘结到上部基板的安装元件50上安装。但是,也可使用其它安装和连接技术。例如,在一变体中,附加微电子元件56可以以面向上的配置安装在上部基板上并通过丝焊连接到安装元件50上。同样,密封剂和其它覆盖物可涂敷到附加微电子元件上方。
在安装附加微电子元件56和导电粘结材料58之后,上部和下部基板用于形成单个单元60(图6)。每个这样的单元包括下部基板的一个区域26和上部基板的相应区域46,以及下部基板上的微电子元件36和上部基板上附加微电子元件56。每个这样的单元是自包含堆叠封装。每个单元60形成完全堆叠封装,有一个或多个附加电子元件56连接到一个或多个微电子元件36。这样的封装可以与基本上常规单元件微电子封装件相同的方式安装在电路板上或其它较大基板上。
在上述过程的变体中,切断后,附加的微电子元件26、连接粘结材料58或两者都可安装到基板上。组装的基板或微电子元件36,有或没有粘结材料58,在未切断状态或分开的、切断的单元,可作为商业半成品进行处理、运载和存储。这种设置可用于例如同样的微电子元件36包含进大量的封装件,但不同的附加元件56用于不同的封装件的情况。
在又另一变体中,可省略密封剂54。在该变体中,微电子元件36设置在基板之间提供结构支撑。附加结构支撑可通过提供在电子元件之间未被微电子元件36或丝焊53占据的位置延伸的间隔件而设置在基板之间。
根据本发明又一实施例的过程使用参照图1-6与上述类似的下部基板120和上部基板140。但是,安装在下部基板120上的微电子元件136面向上布置安装,而没有上部模制件。在上部基板140组装之前,微电子元件136上的触点通过丝焊102电连接到下部基板120的上部表面上的导电安装元件130。间隔件104设置在微电子元件136面向上的表面上或在上部基板140的下部表面上,以将上部基板保持在丝焊102上方。间隔件104理想地由电介质材料形成,且可包括或由粘合层组成。这里,下部基板的层间连接端子129通过丝焊152连接到上部基板的层间连接衬垫149上。在丝焊之后,如图7所示的组件可与参照图4-6上述同样的方式进行处理和操作。
根据本发明的又另一实施例的过程,同样利用与上述的类似的下部基板220和上部基板240。微电子元件236安装在下部基板220的上部表面222上。理想地,这些微电子元件通过环绕每个微电子元件的上部模制件238覆盖。这里,微电子元件236可以是封装件或未封装元件。但是,在图8的实施例中,下部基板的层间连接端子229露出在基板的上部表面222,然而上部基板的层间连接端子249露出在上部基板的下部表面244。这些基板以与上述类似的方式彼此组装。但是,诸如焊球之类的导电间隔件设置在基板之间下部基板层间连接端子229上或上部基板的层间连接端子249上。当基板彼此组装时,传导元件与相对基板上的层间连接端子啮合并粘结到其上。这样,传导元件202提供基板之间的电连接并提供基板之间的物理间隔。附加微电子元件256可在组装之前或之后安装到上部基板上。如上述其它实施例那样,组装步骤可在单次操作中用于将上部基板的无数区域与下部基板的无数区域相互连接。如上述实施例中那样,互连的基板可用于形成单个单元。密封剂(未示出)可以可选地以上述方式注入基板之间,理想地在切断基板之前。在另一变体(图9)中,下部基板320上的微电子元件336是未用密封剂的“裸的”半导体芯片。这些芯片用类似于参照图7的上述丝焊丝焊到下部基板的传导安装部件330上。上部基板340组装到下部基板上并通过类似于参照图8上述的传导元件304连接到下部基板上。理想地,在用基板形成单个单元之前,密封剂354(图10)注入基板之间。可在各实施例中采用除了焊球之外的传导元件。例如,如PCT公开国际专利申请WO2004/077525揭示的那样,其内容援引于此以供参考,细长隆起或插脚形式的金属传导元件可用作堆叠封装件中的单元件连接件。
如2004年6月25日提交的美国临时专利申请第60/583,066,号所阐述的那样,其内容也援引于此,同于2003年12月30日提交的共同待审查、共同转让的美国临时专利申请60/533,210、60/533,393和60/533,437(其内容援引于此以供参考)所揭示类型的插脚可用作堆叠封装件内的单元间连接。这些和其它类型的插脚可用在上述组件中。两基板中的一个或两个可在组装前设以这些插脚,使得插脚与相对基板上的层间连接端子啮合。
根据本发明又另一实施例的过程利用包含电介质层421的单金属条形式的上部基板440,有由条的下部表面上的单层金属特征限定的上部安装端子450和层间连接端子449,安装端子450通过电介质层上的孔451暴露于上部基板的上部表面422。包括无数引线452的引线框附连到上部基板440上以使得每根引线452从层间连接端子449之一延伸,如图12所示。尽管图中仅示出两根引线452,应当理解,引线框包括无数引线,并还可包括总线杆或其它元件以将引线相对于彼此保持在位置上。可在引线框装到上部基板之后将总线杆或其它保持元件移除。可使用2003年12月24日提交的共同待审查、共同转让的美国专利申请第10/746,810号中讲授的那种类型的引线框,其内容援引于此以供参考。引线框可通过诸如焊料粘结、扩散粘结、热压缩粘结等粘结到上部基板的层间连接端子449上。或者,层间连接端子449可制成条自动粘结(tape-automated bonding)(″TAB″)引线,且这些引线可用使用类似于通常用于将TAB引线粘结到诸如半导体芯片上的元件的处理粘结到引线框上。如图12所清楚示出的,引线框的引线452从上部基板440向下突出。该过程还利用下部基板420,其在其下部表面424有露出的下部安装端子428,并在其上部表面有露出的电子连接件430和也在其上部表面442露出的层间连接端子429。这里,在图13所示的特别实施例中,下部基板示出为“双金属”结构,但可以是单金属结构,该单金属结构具有通过下部基板的电介质元件421上的孔露出的各种特征。半导体芯片或其它微电子元件436装在下部基板420上。在所示实施例中,半导体芯片436面向上布置安装并通过丝焊402连接到连接端子430。但是,芯片436也可面向下安装。在另一变体中,芯片436可以是封装芯片或其它封装微电子元件。在图13所示的特别实施例中,芯片436通过间隔件404支撑在下部基板的电介质元件421上方。在另一变体中,间隔件404可用另一可面向下或面向上安装的半导体芯片或其它微电子元件替代。理想地由电介质材料形成的间隔件406设置在远离下部基板420的微电子元件436的表面上。
包括上部基板440和引线框的引线452的子组件通过将子组件朝向下部基板推进和使用任何上述技术将引线452远离上部基板441的下端粘结到下部基板的层间连接端子429而安装到下部基板上。在上部和下部基板组装后,形成的单元包括下部基板420、上部基板440、微电子元件436和连接上部和下部基板的引线452,该单元例如通过环绕微电子元件436和在基板420和440之间引入的易流动密封剂而被密封。进行密封过程以使上部安装端子450和下部安装端子露出并不被密封剂454覆盖。参照图11-14的上述所有步骤可使用单个上部和下部基板和/或单个引线框进行,或可在上部基板、下部基板和引线框或这些的任意组合在诸如包含无数基板和/或无数引线框的带或条之类的较大组件形式的同时进行。这种情况下,较大元件如上所述切断,以形成单个单元,各包括下部基板、上部基板以及一个或多个微电子元件436。这里,较大单元在切断之前可作为商业产品处理、运载和存储。同样,单个单元也可这样处理。这里,封装或未封装附加电子元件456可例如通过如图14所示的焊料粘结,或通过丝焊安装到上部安装端子上。下部安装端子428可设有诸如焊球408之类的导电粘结材料并可用于将完成的组件安装到电路配电板上。
在上述的每个实施例中,上部和下部基板的位置可翻转。例如,如图14所示的上部安装端子450可用于将组件安装到电路配电板上,而下部安装端子428可用于将另一微电子元件安装到该组件上。同样,引线框的引线452可组装到下部基板上而不是上部基板上。在又另一实施例中,整个上部基板可仅由引线框组成。用于互连各引线并形成自支撑引线框的引线框的总线杆或其它部分可在密封后移除。反之,下部基板420可用引线框的元件替代。在一变体中,引线框远离上部基板的端部露出以使这些端部用作组件的下部安装端子。
如本文中所使用的诸如“上部”、“下部”、“向上”以及“向下”之类的术语以及类似表示方向的术语,指部件本身的参照系,而不是重力参照系。用重力参照系中定向的部件在图中所示的方向中,重力参照系中图的顶部是上而图的底部是下,上部基板实际上在重力参照系中在下部基板的上方。但是当部件翻转时,图的顶部在重力参照系中面向下,重力参照系中上部基板在下部基板下方。
优选实施例中的前述说明意味着说明而不是限制本发明。
由于可使用上述特征的这些和其它变体以及组合而不偏离权利要求书限定的本发明,应当通过说明的方式而不是限制权利要求书限定的本发明的方式采用优选实施例的前述说明。

Claims (10)

1.一种制造多个微电子组件的方法,包括以下步骤:
(a)提供加工过程中的单元,该单元包括多个微电子元件、在所述微电子元件上方延伸的至少一个上部基板以及在所述微电子元件下方延伸的至少一个下部基板,所述基板中的至少一个包括多个区域;以及然后
(b)切割所述加工过程中的单元以形成单独的单元,每个所述单元均包括所述基板中的所述至少一个和所述微电子元件中的至少一个中的每一个的一区域。
2.如权利要求1所述的方法,其特征在于,所述上部基板和所述下部基板都包括多个区域,且进行所述切割使得每个所述单元包括所述上部基板的一部分、所述下部基板的一部分和设置在所述基板之间的多个微电子元件中的一个。
3.如权利要求2所述的方法,其特征在于,还包括将所述上部和下部基板上的传导元件相互电连接的步骤。
4.如权利要求3所述的方法,其特征在于,所述电连接的步骤在所述切割步骤之前进行。
5.如权利要求4所述的方法,其特征在于,还包括在所述切断步骤之前将密封剂注入所述上部和下部基板之间的步骤。
6.一种加工过程中的单元,包括上部和下部基板以及设置在所述上部和下部基板之间的多个微电子元件,每个所述基板包括多个区域,所述上部基板的每个区域与所述下部基板的相应区域对齐,使得至少一个所述微电子单元设置在其间,所述上部和下部基板的所述区域各具有导电元件,所述上部基板的每个所述区域的至少一些所述导电元件电连接到所述下部基板相应区域的导电元件。
7.如权利要求6所述的加工过程中的单元,其特征在于,还包括设置在所述上部和下部基板之间的密封剂。
8.一种制造微电子组件的方法,包括将引线框附连到第一基板上,使得所述引线框的引线从所述基板突出并将所述第一基板与第二基板组装使得至少一个微电子元件设置在所述第一和第二基板之间,并将所述引线连接到所述第二基板上。
9.如权利要求8所述的方法,其特征在于,还包括在所述组装步骤之前将所述至少一个微电子元件电连接到所述基板之一的步骤。
10.如权利要求9所述的方法,其特征在于,在所述组装步骤之前进行所述电连接步骤,以将所述至少一个微电子元件连接到所述第二基板。
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