WO1999028969A1 - Integrated circuit chip package and method of making the same - Google Patents

Integrated circuit chip package and method of making the same Download PDF

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Publication number
WO1999028969A1
WO1999028969A1 PCT/US1998/025673 US9825673W WO9928969A1 WO 1999028969 A1 WO1999028969 A1 WO 1999028969A1 US 9825673 W US9825673 W US 9825673W WO 9928969 A1 WO9928969 A1 WO 9928969A1
Authority
WO
WIPO (PCT)
Prior art keywords
inte
inteφoser
wirebond
åoser
die
Prior art date
Application number
PCT/US1998/025673
Other languages
French (fr)
Inventor
James Hayward
Quang Nguyen
Original Assignee
Advanced Micro Devices, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Advanced Micro Devices, Inc. filed Critical Advanced Micro Devices, Inc.
Publication of WO1999028969A1 publication Critical patent/WO1999028969A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
    • H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
    • H01L23/3107—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
    • H01L23/3121—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation
    • H01L23/3128—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation the substrate having spherical bumps for external connection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49833—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers the chip support structure consisting of a plurality of insulating substrates
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Definitions

  • the present invention relates to an integrated circuit chip package and a method of fabricating the same.
  • a conventional chip package is a flex/tape-BGA package, wliich includes a semiconductor die directly attached to an interposer.
  • the flex tape-BGA package allows for a constant package body and a constant solder ball pattern independent of the size of the die to some extent.
  • the flex/tape-BGA package requires a rigid connection between the die and the inte ⁇ oser, thereby resulting in a problem of decreased solder joint reliability.
  • Examples of the flex/tape-BGA package include Texas Instruments Microstar®, Fujitsu FBGA and Amkor FlexBGA® packages.
  • Another type of a conventional chip package is a microBGA® package, an example of wliich is developed by Tessera Inc.
  • the microBGA® package generally has an improved solder joint reliability compared to the flex/tape-BGA package.
  • the microBGA® package includes tab-like bonds for providing electrical connection between the semiconductor die and solder balls outside the inte ⁇ oser.
  • the design of the inte ⁇ oser in the microBGA® package is governed by the die size and the bond pad position, and is very sensitive to changes in the die size.
  • a different inte ⁇ oser design with a different tab bond and solder ball pattern is usually required for any change in die size.
  • an integrated circuit chip package generally comprises:
  • the chip package further includes a wirebond pad on the inside surface of the top inte ⁇ oser and a tab bond including a first portion in direct contact with the wirebond pad and a second portion in direct contact with the outside surface of the bottom inte ⁇ oser.
  • the wirebond is directly connected to the wirebond pad which establishes an electrically conductive path between the wirebond and the tab bond.
  • a solder ball is directly connected to the second portion of the tab bond
  • a spacer is provided on the inside surface of the bottom inte ⁇ oser to support the die, such that the die and the wirebond are spaced apart from the bottom inte ⁇ oser.
  • the step of attaching the first assembly includes providing a spacer between the first assembly and the bottom inte ⁇ oser to space the die and the wirebond apart from the bottom inte ⁇ oser.
  • an elastomeric material is flooded into the intermediate volume between the top and the bottom inte ⁇ osers to fill the volume.
  • the present invention provides an integrated circuit chip package that is expected to provide an improved solder joint reliability.
  • Mother advantage of the invention is that it is expected to allow a single inte ⁇ oser design with the same solder ball pattern to accommodate different die sizes and wirebond positions.
  • Fig. 1 is a sectional side view of an embodiment of an integrated circuit chip package with a first assembly including a plurality of wirebonds in accordance with the present invention
  • Fig. 2 is a sectional side view of the first assembly of Fig. 1;
  • Fig. 3 is a simplified top plan view of the first assembly of Fig. 2;
  • Fig. 4 is a sectional side view of another embodiment of an integrated circuit chip pacl age with a first assembly including a plurahty of flipchip connectors in accordance with the present invention;
  • Fig. 5 is a sectional side view of the first assembly of the integrated circuit chip package of Fig. 4;
  • Fig. 6 is a simplified top plan view of the first assembly of Fig. 5;
  • Fig. 7 is a block diagram showing an embodiment of the process of fabricating the integrated circuit chip package of Fig. 1 according to the present invention.
  • the present invention provides an integrated circuit chip package that is expected to improve the solder joint reliability without the need to customize the design of the inte ⁇ oser to accommodate different die sizes.
  • Fig. 1 is a section ⁇ side view of an integrated circuit chip package according to the present invention, with a top inte ⁇ oser 2 and a bottom inte ⁇ oser 4, both made of an insulating material, spaced apart from each other.
  • the top inte ⁇ oser 2 has an inside surface 6 and an outside surface 8
  • the bottom inte ⁇ oser 4 has an inside surface 10 and an outside surface 12.
  • ./M-hough Fig. 1 shows the top and bottom inte ⁇ osers 2 and 4 being of the same size, the top inte ⁇ oser 2 may be smaller than the bottom inte ⁇ oser 4.
  • the top and bottom inte ⁇ osers 2 and 4 are generally parallel to each other.
  • an example of which is a silicon die is suirounded by an encapsulant 16, such as one made of an elastomeric material, connected between the inside surface 6 of the top inte ⁇ oser 2 and the inside surface 10 of the bottom inte ⁇ oser 4.
  • the die 14 is positioned on the inside surface 6 of the top inte ⁇ oser 2.
  • a conductive wirebond 18, such as one made of a metal, is connected between the semiconductor die 14 and the top inte ⁇ oser 2. Connection of the wirebond 18 between the die 14 and the top inte ⁇ oser 2 can be made by using a conventional wirebonding method that is apparent to a person skilled in the art.
  • a plurahty of wirebonds are usually provided to connect the integrated circuit (not shown) embedded in the semiconductor die 14 and the inte ⁇ oser 2.
  • Fig. 1 shows an additional wirebond pad 28 on the inside surface 6 of the top inte ⁇ oser 2 and an additional wirebond 20 connected between a different portion of the semiconductor die 14 and the additional wirebond pad 28.
  • the integrated circuit chip package according to the present invention also includes a conductive tab bond 22, such as one made of a metal, connected between the top and bottom inte ⁇ osers 2 and 4.
  • the tab bond includes a first portion 22a that is in direct contact with the wirebond pad 26 on the inside surface 6 of the top inte ⁇ oser 2, and a second portion 22b that is in direct contact with the outside surface 12 of the bottom inte ⁇ oser 4.
  • the tab bond 24 may be attached to the top inte ⁇ oser 2 by thermosonic, ultrasonic, solder reflow or other means.
  • the tab bond 22 provides a structural support for the top and the bottom inte ⁇ osers 2 and 4, and an electrical connection from the wirebond pad 26 to outside the chip package.
  • a semiconductor chip package includes a plurality of tab bonds to provide structural integrity to the package assembly and a plurality of electrical connections.
  • Fig. 1 shows an additional tab bond 24 including a first portion 24a in direct contact with the additional wirebond pad 28 on the inside surface 6 of the top inte ⁇ oser 2 and a second portion 24b in direct contact with the outside surface 12 of the bottom inte ⁇ oser 4.
  • the wirebond pad 26 such as one made of a metallic material or a conductive polymer, is provided on the inside surface 6 of the top inte ⁇ oser 2 such that an electrically conductive path is established between the integrated circuit (not shown) on the die 14 and the second portion 22b outside the bottom inte ⁇ oser 4. Namely, the wirebond 18 is in direct contact with the integrated circuit and the wirebond pad 26, and the first portion 22a of the tab bond 22 is in direct contact with the wirebond pad 26 and the second portion 22b.
  • a plurality of wirebond pads are provided in the chip package.
  • a separate wirebond pad is provided for each wirebond, and a separate tab bond is directly connected to each wirebond pad.
  • Fig. 1 shows the additional wirebond pad 28 to which the wirebond 20 is directly connected, ⁇ n a manner similar to the connection of the tab bond 22, the first portion 24a of the tab bond 24 is in direct contact with the additional wirebond pad 28.
  • the integrated circuit chip package according to the present invention further includes a solder ball 30 directly connected to the second portion 22b of the tab bond 22 by soldeiing. In a similar manner, an additional solder ball 32 is directly soldered to the second portion 24b of the tab bond 24.
  • At least one additional solder ball 34 can be provided on the bottom inte ⁇ oser 4 to provide additional electrical connection and structural support for the chip package.
  • a metallic layer 36 with a thickness the same as that of the second portions 22b and 24b of the tab bonds 22 and 24 can be provided on the outside surface 12 of the bottom inte ⁇ oser 4, and the solder ball 34 may be directly soldered to the metallic layer 36.
  • Additional solder balls similar to the solder ball 34, which do not have any electrical contact with any of the wirebonds connected to the semiconductor die 14, may be provided for structural support; however, they are not critical to the present invention.
  • the solder balls 30 and 32 serve as electrical contacts because they are electrically connected to the wirebonds 18 and 20 through the tab bonds 22 and 24 and the wirebond pads 26 and 28, respectively.
  • the integrated circuit chip package according to the present invention further includes a spacer 38 of an insulating material, such as an elastomeric material, on the inside surface of one of the inte ⁇ osers or on the die surface.
  • a spacer 38 of an insulating material such as an elastomeric material
  • the integrated circuit chip package according to the present invention further includes a spacer 38 of an insulating material, such as an elastomeric material, on the inside surface of one of the inte ⁇ osers or on the die surface.
  • a spacer 38 of an insulating material, such as an elastomeric material, on the inside surface of one of the inte ⁇ osers or on the die surface.
  • the encapsulant 16 may be flooded into the intermediate volume 40 to fill the remaining space between the top and bottom inte ⁇ osers 2 and 4.
  • An elastomeric materi can be used as the encapsulant 16.
  • the spacer 38 can also be used to separate the semiconductor die 14 from the inside surface 10 of the bottom inte ⁇ oser 4 so that the wirebond 18 is spaced apart from the inside surface 10 of the bottom inte ⁇ oser 4. hi some applications, it is desirable to avoid a direct contact between the wirebond 18 and the inside surface 10 of the bottom inte ⁇ oser 4. As shown in Fig. 1, the wirebonds 18 and
  • the spacer 38 can be provided, for example, by attaching a plurality of columns of an elastomeric material onto the inside surface 10 of the bottom inte ⁇ oser 4 before attaching the die 14 to the spacer 38 or by using a pad of an elastomeric material on the surface of the die 14.
  • the present invention also provides a method of fabricating the integrated circuit chip package described above in accordance with the present invention. The method roughly comprises the steps of:
  • a wirebond pad 26 is attached to the inside surface 6 of the top inte ⁇ oser 2.
  • the assembly of the semiconductor die 14 to the top inte ⁇ oser 2 can be made by using a conventional die attachment method which is apparent to a person skilled in the art.
  • the wirebond 18 is then connected between the integrated circuit (not shown) embedded in the semiconductor die 14 and the wirebond pad 26.
  • the wirebond connections can be made by a conventional wirebond process which is apparent to a person skilled in the art.
  • the flipchip connections can be made by a conventional flipchip process wliich is known to a person skilled in the art.
  • a spacer 38 such as one made of an elastomeric material, is provided on the inside surface 10 of the bottom inte ⁇ oser 4 or on the surface of the die 14, and the first assembly 42 is then attached to the bottom inte ⁇ oser
  • the spacer 38 which spaces the top and bottom inte ⁇ osers 2 and 4 apart by an intermediate volume 40, also allows the wirebond 18 to be suspended from the semiconductor die 14 the wirebond pad 26 before the encapsulant 16 is injected such that there is no direct contact between the wirebond 18 and the inside surface 10 of the bottom inte ⁇ oser 4.
  • the tab bond 22 between the top and bottom inte ⁇ osers 2 and 4 is then made with the first portion 22a of the tab bond 22 in direct contact with the wirebond pad 26 and the second portion 22b in direct contact with the outside surface 12 of the bottom inte ⁇ oser 4.
  • the tab bond 22 is formed and assembled to penetrate through the bottom inte ⁇ oser 4 such that an electrical connection is established by the tab bond 22 from the wirebond 18 through the wirebond pad 26 to an electrical contact outside the chip package, such as the solder ball 30.
  • the tab bonds 22 and 24 can be fabricated by using a conventional tab bonding method that is apparent to a person skilled in the art.
  • the remaining intermediate volume 40 between the inside surfaces 6 and 10 of the top and bottom inte ⁇ osers 2 and 4 is filled with an encapsulant 16, for example, by flooding the intermediate volume 40 with an elastromeric material.
  • Fig. 2 shows a sectional side view of the first assembly 42 of Fig. 1 before it is assembled with the bottom inte ⁇ oser 4.
  • the sectional view of Fig. 2 is opposite the view of the first assembly 42 in Fig. 1 with respect to the top and bottom.
  • the inside surface 6 of the top inte ⁇ oser 2 is usually positioned upward when the wirebond pads 26 and 28 and the silicon die 14 are attached to the inside surface 6 of the top inte ⁇ oser 2.
  • the wirebonds 18 and 20 are connected between the semiconductor die 14 and the wirebond pads 26 and 28, respectively, when the inside surface 6 of the top inte ⁇ oser 2 is positioned to face upward.
  • Fig.3 is a simplified top plan view of the first assembly 42 of Fig. 2 showing the silicon die 14 on the inside surface 6 of the top inte ⁇ oser 2, wirebond pads 26 and 28 on the surface 6, and wirebonds 18 and 20 connected between the semiconductor die 14 and the wirebond pads 26 and 28, respectively.
  • a plurality of conductive tab pads 44 and 46 which have direct electrical connections with the wirebond pads 26 and 28, respectively, can be provided on the inside surface 6 of the top inte ⁇ oser 2 to which the first portions 22a and 24 a of the tab bonds 22 and 24 of Fig. 1 can be directly attached, respectively.
  • a typical integrated circuit chip assembly usually includes more wirebonds and wirebonds pads than those which are shown in Fig. 3, and the wirebond and tab pads may have a variety of patterns on the inside surface 6 of the top inte ⁇ oser 2.
  • Fig. 3 shows the wirebond connections from two sides of the semiconductor die 14, wirebond connections can also be made from all four sides of the die 14. They are nonetheless within the scope of the present invention.
  • FIG. 4 shows a sectional side view of another embodiment of the present invention in which a plurality of flipchip connectors 52 and 54 are provided between the semiconductor die 14 and the conductive pads 26 and 28, respectively, instead of the wirebond connections 18 and 20 of Fig. 1.
  • the semiconductor die 14 is not directly attached to the inside surface 6 of the top inte ⁇ oser 2.
  • the flipchip connectors 52 and 54 provide direct electrical connections between the integrated circuit embedded on the semiconductor die 14 and the pads 26 and 28, respectively.
  • Flipchip connectors 52 and 54 are usually solder ball connectors but may also be metal-coated polymer balls or electrically conductive adhesives.
  • the tab bonds 22 and 24 are assembled to provide electrical connections between the pads 26 and 28 and the solder balls 30 and 32, respectively, outside the bottom inte ⁇ oser 4, in a manner similar to that which is shown in
  • a plurality of spacers 38 may be provided to space the semiconductor die 14 apart from the inside surface 10 of the bottom inte ⁇ oser 4, although the spacers 38 are optional and are used to provide structural support to the first assembly 42 when the encapsulant 16 is flooded to fill the intermediate volume 40 between the top and the bottom inte ⁇ osers 2 and 4 during the assembly process.
  • Fig. 5 shows a sectional side view of the first assembly 42 of Fig. 4 with the flipchip connectors 52 and 54 before the first assembly 42 is attached to the bottom inte ⁇ oser 4.
  • the orientation of the first assembly 42 in Fig. 5 is opposite that of the first assembly 42 in Fig.4 with respect to the top and bottom.
  • the inside surface 6 of the top inte ⁇ oser 2 is usually positioned upward when the conductive pads 26 and 28 are attached to the inside surface 6.
  • the flipchip connectors 52 and 54 are then positioned on the conductive pads 26 and 28, respectively, and the silicon die 14 is attached to the flipchip connectors 52 and 54, such that proper electrical connections are made between the integrated circuit embedded on the semiconductor die 14 and the conductive pads 26 and 28.
  • the flipchip connectors 52 and 54 can be provided on the die 14 prior to attachment to the conductive pads 26 and 28.
  • the first assembly 42 is made according to Fig. 5, it is attached to the bottom inte ⁇ oser 4 with the tab bonds 22 and 24 and the encapsulant 16 to foim the integrated circuit chip package as shown in Fig. 4.
  • the first assembly 42 is usually positioned on top of the bottom inte ⁇ oser 4 when the assembly process is finished.
  • Fig. 6 is a simplified top plan view of the first assembly 42 of Fig. 5, with the semiconductor die 14 shown in a dashed rectangle as if it is transparent to expose the flipchip connectors 52 and 54.
  • the flipchip connectors 52 and 54 are directly attached to the conductive pads 26 and 28 and the die 14, respectively.
  • a plurality of tab pads 44 and 46 are usually provided on the inside surface 6 of the top inte ⁇ oser 2 with direct electrical connections to the conductive pads 26 and 28, respectively.
  • a plurality of pads more than those which are shown in Fig. 6 may be provided in an integrated circuit package, and a variety of conductive pad patterns may be provided on the inside surface 6 of the top inte ⁇ oser 2.
  • Fig. 6 shows the flipchip connections from two sides of the semiconductor die 14, flipchip connections can also be made from all four sides of the die
  • FIG. 7 An embodiment of a method of making the integrated chip package of Fig. 1 according to the present invention is illustrated by the flowchart of Fig. 7. The method includes the steps of:
  • the spacer 38 and the encapsulant 16 both comprise an elastomeric material.
  • the encapsulant 16 can be provided to fill the intermediate volume 40 between the top and bottom inte ⁇ osers 2 and 4 by flooding the elastomeric material into the remaimng intermediate volume 40 after the first assembly 42 is attached to the bottom inte ⁇ oser 4 and the tab bonds 22 and 24 are made.
  • a flipchip connector 52 is used to connect the die 14 with the pad 26 as shown in Figs. 4-6, instead of the wirebond 18 as shown in Figs. 1-3.
  • the method of fabrication described above and illustrated in the flowchart of Fig. 7 is only one of several embodiments of fabricating the chip package.
  • the integrated circuit chip package according to the present invention is not limited to that which is fabricated by using the method described above; it will be appreciated that other methods of fabrication are also possible to produce the chip package according to the present invention.
  • An advantage of the chip package according to the present invention is that the design of the tab bonds 22 and 24 and the pattern of the solder balls 30, 32 and 34 can be made constant and independent of the size of the semiconductor die 14 as long as adequate space is provided for the semiconductor die 14 -and the wirebonds 18 and 20. Since the size of the chip package is mainly determined by the tab bonds and the solder ball pattern, a chip package with a fixed overall dimension can accommodate a variety of different die sizes.
  • a fiirther advantage of using two inte ⁇ osers 2 and 4 is that one inte ⁇ oser, such as the top inte ⁇ oser 2, can be used for direct attachment of the die 14 while a second inte ⁇ oser, such as the bottom inte ⁇ oser 4, can be used for supporting solder joint connections, such as the solder balls 30 and 32, through the second portions 22b and 24b of the tab bonds 22 and 24.
  • This configuration avoids the necessity for a rigid connection between the semiconductor die 14 and the bottom inte ⁇ oser 4. Therefore, solder joint reliability of the solder balls 30 and 32 is improved.
  • the integrated circuit chip pac.kage according to the present invention is applicable for the packaging of a wide variety of semiconductor integrated circuits, and more particularly, for the packaging of semiconductor dies with a variety of die sizes.
  • the chip package is believed to be superior to the flex/tape-BGA packages in that it is expected to provide an improved solder joint reliability by avoiding a rigid connection between the die and the inte ⁇ oser to which the solder balls are connected.
  • the chip package according to the present invention is believed to be superior to the microBGA package in that a single package design with the same tab bond and solder ball pattern can accommodate a variety of die sizes.
  • the method according to the present invention is applicable for the fabrication of the semiconductor chip package of the present invention.
  • the chip package according to the present invention is not limited by the method of fabrication described in the Modes for Carrying Out the Invention; other methods of fabrication are also possible.

Abstract

A semiconductor integrated circuit chip package includes top and bottom interposers (2) and (4), a semiconductor die (14) attached to the top interposer (2), a wirebond (18) or a flipchip connector (52) connected between the die (14) and the top interposer (2), and a tab bond (22) providing an electrical connection from the wirebond (18) or the flipchip connector (52) to outside the bottom interposer (4). A method of making the chip package includes providing top and bottom interposers (2) and (4), attaching a semiconductor die (14) to the top interposer (2), providing a wirebond (18) or a flipchip connector (52) between the die (14) and the top interposer (2), providing a tab bond (22) between the top and bottom interposers (2) and (4), and providing an encapsulant (16) to fill the intermediate volume (40) between the top and bottom interposers (2) and (4).

Description

INTEGRATED CIRCUIT CHIP PACKAGE AND METHOD OF MAKING THE SAME
TECHNICAL FIELD
The present invention relates to an integrated circuit chip package and a method of fabricating the same.
BACKGROUND ART The semiconductor chip industry has developed "chip scale" packages for protecting an integrated circuit on a semiconductor die and for providing wire connections from the integrated circuit to other circuits outside the chip. ^ example of a conventional chip package is a flex/tape-BGA package, wliich includes a semiconductor die directly attached to an interposer. The flex tape-BGA package allows for a constant package body and a constant solder ball pattern independent of the size of the die to some extent.
However, the flex/tape-BGA package requires a rigid connection between the die and the inteφoser, thereby resulting in a problem of decreased solder joint reliability. Examples of the flex/tape-BGA package include Texas Instruments Microstar®, Fujitsu FBGA and Amkor FlexBGA® packages. Another type of a conventional chip package is a microBGA® package, an example of wliich is developed by Tessera Inc. The microBGA® package generally has an improved solder joint reliability compared to the flex/tape-BGA package. The microBGA® package includes tab-like bonds for providing electrical connection between the semiconductor die and solder balls outside the inteφoser. However, the design of the inteφoser in the microBGA® package is governed by the die size and the bond pad position, and is very sensitive to changes in the die size. In a conventional microBGA® package, a different inteφoser design with a different tab bond and solder ball pattern is usually required for any change in die size.
Therefore, there is a need for an integrated circuit chip package that simultaneously provides both a good solder joint reliability and a single inteφoser design with a constant tab bond and solder ball pattern that can accommodate a variety of die sizes. DISCLOSURE OF THE INVENTION
The present invention satisfies these needs. In accordance with the present invention, an integrated circuit chip package generally comprises:
(a) a bottom inteφoser having an inside surface and an outside surface;
(b) a top inteφoser spaced apart from the bottom inteφoser, the top inteφoser having an inside surface and an outside surface;
(c) an encapsulant connected between the inside suifaces of the top and bottom inteφosers;
(d) a die surrounded by the encapsulant and one of the inteφosers; and
(e) a wirebond connected between the die and one of the inteφosers.
In an embodiment, the chip package further includes a wirebond pad on the inside surface of the top inteφoser and a tab bond including a first portion in direct contact with the wirebond pad and a second portion in direct contact with the outside surface of the bottom inteφoser. The wirebond is directly connected to the wirebond pad which establishes an electrically conductive path between the wirebond and the tab bond.
In an additional embodiment, a solder ball is directly connected to the second portion of the tab bond, in a further embodiment, a spacer is provided on the inside surface of the bottom inteφoser to support the die, such that the die and the wirebond are spaced apart from the bottom inteφoser. The present invention further provides a method of fabricating the integrated circuit chip package, the method generally comprising the steps of:
(a) providing a top inteφoser;
(b) attaching a semiconductor die to the top inteφoser; (c) providing a wirebond or a flipchip connector between the silicon die and the top inteφoser, the top inteφoser and the silicon die forming a first assembly;
(d) providing a bottom inteφoser;
(e) attaching the first assembly to the bottom inteφoser, the top and bottom inteφosers spaced apart by an intermediate volume;
(f) providing a tab bond between the top and bottom inteφoser; and
(g) providing an encapsulant to fill the intermediate volume between the top and the bottom inteφosers.
In an embodiment, the step of attaching the first assembly includes providing a spacer between the first assembly and the bottom inteφoser to space the die and the wirebond apart from the bottom inteφoser. In a fiirther embodiment, an elastomeric material is flooded into the intermediate volume between the top and the bottom inteφosers to fill the volume.
Advantageously, the present invention provides an integrated circuit chip package that is expected to provide an improved solder joint reliability. Mother advantage of the invention is that it is expected to allow a single inteφoser design with the same solder ball pattern to accommodate different die sizes and wirebond positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with respect to particular embodiments thereof, and references will be made to the drawings in which:
Fig. 1 is a sectional side view of an embodiment of an integrated circuit chip package with a first assembly including a plurality of wirebonds in accordance with the present invention;
Fig. 2 is a sectional side view of the first assembly of Fig. 1; Fig. 3 is a simplified top plan view of the first assembly of Fig. 2; Fig. 4 is a sectional side view of another embodiment of an integrated circuit chip pacl age with a first assembly including a plurahty of flipchip connectors in accordance with the present invention;
Fig. 5 is a sectional side view of the first assembly of the integrated circuit chip package of Fig. 4;
Fig. 6 is a simplified top plan view of the first assembly of Fig. 5; and
Fig. 7 is a block diagram showing an embodiment of the process of fabricating the integrated circuit chip package of Fig. 1 according to the present invention.
MODES FOR CARRYING OUT THE INVENTION
The present invention provides an integrated circuit chip package that is expected to improve the solder joint reliability without the need to customize the design of the inteφoser to accommodate different die sizes.
Fig. 1 is a section^ side view of an integrated circuit chip package according to the present invention, with a top inteφoser 2 and a bottom inteφoser 4, both made of an insulating material, spaced apart from each other. The top inteφoser 2 has an inside surface 6 and an outside surface 8, and the bottom inteφoser 4 has an inside surface 10 and an outside surface 12. ./M-hough Fig. 1 shows the top and bottom inteφosers 2 and 4 being of the same size, the top inteφoser 2 may be smaller than the bottom inteφoser 4. The top and bottom inteφosers 2 and 4 are generally parallel to each other. A semiconductor die
14, an example of which is a silicon die, is suirounded by an encapsulant 16, such as one made of an elastomeric material, connected between the inside surface 6 of the top inteφoser 2 and the inside surface 10 of the bottom inteφoser 4. The die 14 is positioned on the inside surface 6 of the top inteφoser 2. A conductive wirebond 18, such as one made of a metal, is connected between the semiconductor die 14 and the top inteφoser 2. Connection of the wirebond 18 between the die 14 and the top inteφoser 2 can be made by using a conventional wirebonding method that is apparent to a person skilled in the art. A conductive wirebond pad 26, such as a metallic pad, is usually provided on the inside surface 6 of the top inteφoser 2, and the wirebond 18 is directly connected to the wirebond pad 26. In a semiconductor chip pacl<-age, a plurahty of wirebonds are usually provided to connect the integrated circuit (not shown) embedded in the semiconductor die 14 and the inteφoser 2. As an illustrative example, Fig. 1 shows an additional wirebond pad 28 on the inside surface 6 of the top inteφoser 2 and an additional wirebond 20 connected between a different portion of the semiconductor die 14 and the additional wirebond pad 28. The integrated circuit chip package according to the present invention also includes a conductive tab bond 22, such as one made of a metal, connected between the top and bottom inteφosers 2 and 4. In an embodiment, the tab bond includes a first portion 22a that is in direct contact with the wirebond pad 26 on the inside surface 6 of the top inteφoser 2, and a second portion 22b that is in direct contact with the outside surface 12 of the bottom inteφoser 4. The tab bond 24 may be attached to the top inteφoser 2 by thermosonic, ultrasonic, solder reflow or other means.
The tab bond 22 provides a structural support for the top and the bottom inteφosers 2 and 4, and an electrical connection from the wirebond pad 26 to outside the chip package. In general, a semiconductor chip package includes a plurality of tab bonds to provide structural integrity to the package assembly and a plurality of electrical connections. As an illustrative example, Fig. 1 shows an additional tab bond 24 including a first portion 24a in direct contact with the additional wirebond pad 28 on the inside surface 6 of the top inteφoser 2 and a second portion 24b in direct contact with the outside surface 12 of the bottom inteφoser 4. The wirebond pad 26, such as one made of a metallic material or a conductive polymer, is provided on the inside surface 6 of the top inteφoser 2 such that an electrically conductive path is established between the integrated circuit (not shown) on the die 14 and the second portion 22b outside the bottom inteφoser 4. Namely, the wirebond 18 is in direct contact with the integrated circuit and the wirebond pad 26, and the first portion 22a of the tab bond 22 is in direct contact with the wirebond pad 26 and the second portion 22b.
In a further embodiment, a plurality of wirebond pads are provided in the chip package. In general, a separate wirebond pad is provided for each wirebond, and a separate tab bond is directly connected to each wirebond pad. As an illustrative example, Fig. 1 shows the additional wirebond pad 28 to which the wirebond 20 is directly connected, ϊn a manner similar to the connection of the tab bond 22, the first portion 24a of the tab bond 24 is in direct contact with the additional wirebond pad 28. In an additional embodiment, the integrated circuit chip package according to the present invention further includes a solder ball 30 directly connected to the second portion 22b of the tab bond 22 by soldeiing. In a similar manner, an additional solder ball 32 is directly soldered to the second portion 24b of the tab bond 24. Furthermore, at least one additional solder ball 34 can be provided on the bottom inteφoser 4 to provide additional electrical connection and structural support for the chip package. For example, a metallic layer 36 with a thickness the same as that of the second portions 22b and 24b of the tab bonds 22 and 24 can be provided on the outside surface 12 of the bottom inteφoser 4, and the solder ball 34 may be directly soldered to the metallic layer 36. Additional solder balls similar to the solder ball 34, which do not have any electrical contact with any of the wirebonds connected to the semiconductor die 14, may be provided for structural support; however, they are not critical to the present invention. On the other hand, the solder balls 30 and 32 serve as electrical contacts because they are electrically connected to the wirebonds 18 and 20 through the tab bonds 22 and 24 and the wirebond pads 26 and 28, respectively.
In a further embodiment, the integrated circuit chip package according to the present invention further includes a spacer 38 of an insulating material, such as an elastomeric material, on the inside surface of one of the inteφosers or on the die surface. For example, in the chip package wherein the semiconductor die 14 is directly attached to the inside surface 6 of the top inteφoser 2, a plurality of spacers 38 can be connected between the semiconductor die 14 and the inside surface 10 of the bottom inteφoser 4, as shown in Fig. 1. The spacer 38 provides structural support for the semiconductor die 14 and leaves an intermediate volume 40 between the inside surfaces 6 and 10 of the top and bottom inteφosers 2 and 4. The encapsulant 16 may be flooded into the intermediate volume 40 to fill the remaining space between the top and bottom inteφosers 2 and 4. An elastomeric materi can be used as the encapsulant 16. The spacer 38 can also be used to separate the semiconductor die 14 from the inside surface 10 of the bottom inteφoser 4 so that the wirebond 18 is spaced apart from the inside surface 10 of the bottom inteφoser 4. hi some applications, it is desirable to avoid a direct contact between the wirebond 18 and the inside surface 10 of the bottom inteφoser 4. As shown in Fig. 1, the wirebonds 18 and
20, which are suspended from the semiconductor die 14, are spaced apart from the bottom inteφoser 4. The spacer 38 can be provided, for example, by attaching a plurality of columns of an elastomeric material onto the inside surface 10 of the bottom inteφoser 4 before attaching the die 14 to the spacer 38 or by using a pad of an elastomeric material on the surface of the die 14. The present invention also provides a method of fabricating the integrated circuit chip package described above in accordance with the present invention. The method roughly comprises the steps of:
• providing a top inteφoser 2;
• attaching a semiconductor die 14 to the top inteφoser 2;
• providing a wirebond 18 or a flipchip connector 52 between the semiconductor die 14 and the top inteφoser 2 to form a first assembly 42;
• attaching the first assembly 42 to the bottom inteφoser 4, the top and bottom inteφosers 2 and 4 spaced apart by an intermediate volume 40;
• providing a tab bond 22 between the top and bottom inteφosers 2 and 4; and
• providing an encapsulant 16 to fill the intermediate volume 40 between the top and bottom inteφosers 2 and 4.
Furthermore, a wirebond pad 26 is attached to the inside surface 6 of the top inteφoser 2. The assembly of the semiconductor die 14 to the top inteφoser 2 can be made by using a conventional die attachment method which is apparent to a person skilled in the art. The wirebond 18 is then connected between the integrated circuit (not shown) embedded in the semiconductor die 14 and the wirebond pad 26. The wirebond connections can be made by a conventional wirebond process which is apparent to a person skilled in the art. hi another embodiment in which flipchip connections are used, the flipchip connections can be made by a conventional flipchip process wliich is known to a person skilled in the art.
.After the first assembly 42 is made, a spacer 38, such as one made of an elastomeric material, is provided on the inside surface 10 of the bottom inteφoser 4 or on the surface of the die 14, and the first assembly 42 is then attached to the bottom inteφoser
4 by attaching the semiconductor die 14 directly to the spacer 38. The spacer 38, which spaces the top and bottom inteφosers 2 and 4 apart by an intermediate volume 40, also allows the wirebond 18 to be suspended from the semiconductor die 14 the wirebond pad 26 before the encapsulant 16 is injected such that there is no direct contact between the wirebond 18 and the inside surface 10 of the bottom inteφoser 4.
The tab bond 22 between the top and bottom inteφosers 2 and 4 is then made with the first portion 22a of the tab bond 22 in direct contact with the wirebond pad 26 and the second portion 22b in direct contact with the outside surface 12 of the bottom inteφoser 4. The tab bond 22 is formed and assembled to penetrate through the bottom inteφoser 4 such that an electrical connection is established by the tab bond 22 from the wirebond 18 through the wirebond pad 26 to an electrical contact outside the chip package, such as the solder ball 30. The tab bonds 22 and 24 can be fabricated by using a conventional tab bonding method that is apparent to a person skilled in the art. Subsequently, the remaining intermediate volume 40 between the inside surfaces 6 and 10 of the top and bottom inteφosers 2 and 4 is filled with an encapsulant 16, for example, by flooding the intermediate volume 40 with an elastromeric material.
Fig. 2 shows a sectional side view of the first assembly 42 of Fig. 1 before it is assembled with the bottom inteφoser 4. The sectional view of Fig. 2 is opposite the view of the first assembly 42 in Fig. 1 with respect to the top and bottom. During the process of malcing the first assembly 42, the inside surface 6 of the top inteφoser 2 is usually positioned upward when the wirebond pads 26 and 28 and the silicon die 14 are attached to the inside surface 6 of the top inteφoser 2. The wirebonds 18 and 20 are connected between the semiconductor die 14 and the wirebond pads 26 and 28, respectively, when the inside surface 6 of the top inteφoser 2 is positioned to face upward. .After the first assembly 42 is completed, it is attached to the bottom inteφoser 4 with the encapsulant 16 and the tab bonds 22 and 24, thereby resulting in an integrated circuit chip package with the fϊr.st assembly 42 on top of the bottom inteφoser 4 as shown in Fig. 1 and described above. Fig.3 is a simplified top plan view of the first assembly 42 of Fig. 2 showing the silicon die 14 on the inside surface 6 of the top inteφoser 2, wirebond pads 26 and 28 on the surface 6, and wirebonds 18 and 20 connected between the semiconductor die 14 and the wirebond pads 26 and 28, respectively. A plurality of conductive tab pads 44 and 46, which have direct electrical connections with the wirebond pads 26 and 28, respectively, can be provided on the inside surface 6 of the top inteφoser 2 to which the first portions 22a and 24 a of the tab bonds 22 and 24 of Fig. 1 can be directly attached, respectively. A typical integrated circuit chip assembly usually includes more wirebonds and wirebonds pads than those which are shown in Fig. 3, and the wirebond and tab pads may have a variety of patterns on the inside surface 6 of the top inteφoser 2. For example, whereas Fig. 3 shows the wirebond connections from two sides of the semiconductor die 14, wirebond connections can also be made from all four sides of the die 14. They are nonetheless within the scope of the present invention. Fig. 4 shows a sectional side view of another embodiment of the present invention in which a plurality of flipchip connectors 52 and 54 are provided between the semiconductor die 14 and the conductive pads 26 and 28, respectively, instead of the wirebond connections 18 and 20 of Fig. 1. m this embodiment, the semiconductor die 14 is not directly attached to the inside surface 6 of the top inteφoser 2. The flipchip connectors 52 and 54 provide direct electrical connections between the integrated circuit embedded on the semiconductor die 14 and the pads 26 and 28, respectively. Flipchip connectors 52 and 54 are usually solder ball connectors but may also be metal-coated polymer balls or electrically conductive adhesives. The tab bonds 22 and 24 are assembled to provide electrical connections between the pads 26 and 28 and the solder balls 30 and 32, respectively, outside the bottom inteφoser 4, in a manner similar to that which is shown in
Fig. 1 and described above. A plurality of spacers 38 may be provided to space the semiconductor die 14 apart from the inside surface 10 of the bottom inteφoser 4, although the spacers 38 are optional and are used to provide structural support to the first assembly 42 when the encapsulant 16 is flooded to fill the intermediate volume 40 between the top and the bottom inteφosers 2 and 4 during the assembly process.
Fig. 5 shows a sectional side view of the first assembly 42 of Fig. 4 with the flipchip connectors 52 and 54 before the first assembly 42 is attached to the bottom inteφoser 4. The orientation of the first assembly 42 in Fig. 5 is opposite that of the first assembly 42 in Fig.4 with respect to the top and bottom. During the process of making the first assembly 42, the inside surface 6 of the top inteφoser 2 is usually positioned upward when the conductive pads 26 and 28 are attached to the inside surface 6. The flipchip connectors 52 and 54 are then positioned on the conductive pads 26 and 28, respectively, and the silicon die 14 is attached to the flipchip connectors 52 and 54, such that proper electrical connections are made between the integrated circuit embedded on the semiconductor die 14 and the conductive pads 26 and 28. Alternatively, the flipchip connectors 52 and 54 can be provided on the die 14 prior to attachment to the conductive pads 26 and 28. After the first assembly 42 is made according to Fig. 5, it is attached to the bottom inteφoser 4 with the tab bonds 22 and 24 and the encapsulant 16 to foim the integrated circuit chip package as shown in Fig. 4. The first assembly 42 is usually positioned on top of the bottom inteφoser 4 when the assembly process is finished. Fig. 6 is a simplified top plan view of the first assembly 42 of Fig. 5, with the semiconductor die 14 shown in a dashed rectangle as if it is transparent to expose the flipchip connectors 52 and 54. The flipchip connectors 52 and 54 are directly attached to the conductive pads 26 and 28 and the die 14, respectively. .In a manner similar to that which is shown in Fig. 3 and described above, a plurality of tab pads 44 and 46 are usually provided on the inside surface 6 of the top inteφoser 2 with direct electrical connections to the conductive pads 26 and 28, respectively. In general, a plurality of pads more than those which are shown in Fig. 6 may be provided in an integrated circuit package, and a variety of conductive pad patterns may be provided on the inside surface 6 of the top inteφoser 2. For example, whereas Fig. 6 shows the flipchip connections from two sides of the semiconductor die 14, flipchip connections can also be made from all four sides of the die
14. They are nonetheless within the scope of the present invention.
An embodiment of a method of making the integrated chip package of Fig. 1 according to the present invention is illustrated by the flowchart of Fig. 7. The method includes the steps of:
• providing a top inteφoser 2; • providing a wirebond pad 26 on the top inteφoser 2;
• attaching a semiconductor die 14 to the top inteφoser 2;
• providing a wirebond 18 between the semiconductor die 14 and the wirebond pad 26, the top inteφoser 2, the wirebond pad 26, the semiconductor die 14 and the wirebond 18 forming a first assembly 42;
• providing a bottom inteφoser 4;
• attaching the first assembly 42 to the bottom inteφoser 4 with a spacer 38 spacing the semiconductor die 14 and the wirebond 18 apart from the bottom inteφoser 4, the top and bottom inteφosers 2 and 4 substantially parallel to each other and spaced apart by an intermediate volume 40;
• providing a tab bond 22 between the top and bottom inteφosers 2 and 4, the tab bond 22 including a first portion 22a in direct contact with the wirebond pad 26 and a second portion 22b in direct contact with the bottom inteφoser 4 ;
• providing an encapsulant 16 to fill the intermediate volume 40 between the top and bottom inteφosers 2 and 4; and
• providing a solder ball 30 directly connected to the second portion 22b of the tab bond 22.
Furthermore, the spacer 38 and the encapsulant 16 both comprise an elastomeric material. The encapsulant 16 can be provided to fill the intermediate volume 40 between the top and bottom inteφosers 2 and 4 by flooding the elastomeric material into the remaimng intermediate volume 40 after the first assembly 42 is attached to the bottom inteφoser 4 and the tab bonds 22 and 24 are made. In another embodiment, a flipchip connector 52 is used to connect the die 14 with the pad 26 as shown in Figs. 4-6, instead of the wirebond 18 as shown in Figs. 1-3.
The method of fabrication described above and illustrated in the flowchart of Fig. 7 is only one of several embodiments of fabricating the chip package. The integrated circuit chip package according to the present invention is not limited to that which is fabricated by using the method described above; it will be appreciated that other methods of fabrication are also possible to produce the chip package according to the present invention.
An advantage of the chip package according to the present invention is that the design of the tab bonds 22 and 24 and the pattern of the solder balls 30, 32 and 34 can be made constant and independent of the size of the semiconductor die 14 as long as adequate space is provided for the semiconductor die 14 -and the wirebonds 18 and 20. Since the size of the chip package is mainly determined by the tab bonds and the solder ball pattern, a chip package with a fixed overall dimension can accommodate a variety of different die sizes. A fiirther advantage of using two inteφosers 2 and 4 is that one inteφoser, such as the top inteφoser 2, can be used for direct attachment of the die 14 while a second inteφoser, such as the bottom inteφoser 4, can be used for supporting solder joint connections, such as the solder balls 30 and 32, through the second portions 22b and 24b of the tab bonds 22 and 24. This configuration avoids the necessity for a rigid connection between the semiconductor die 14 and the bottom inteφoser 4. Therefore, solder joint reliability of the solder balls 30 and 32 is improved.
INDUSTRIAL APPLICABILITY
The integrated circuit chip pac.kage according to the present invention is applicable for the packaging of a wide variety of semiconductor integrated circuits, and more particularly, for the packaging of semiconductor dies with a variety of die sizes. The chip package is believed to be superior to the flex/tape-BGA packages in that it is expected to provide an improved solder joint reliability by avoiding a rigid connection between the die and the inteφoser to which the solder balls are connected. Moreover, the chip package according to the present invention is believed to be superior to the microBGA package in that a single package design with the same tab bond and solder ball pattern can accommodate a variety of die sizes.
The method according to the present invention is applicable for the fabrication of the semiconductor chip package of the present invention. However, the chip package according to the present invention is not limited by the method of fabrication described in the Modes for Carrying Out the Invention; other methods of fabrication are also possible.
The invention has been described with respect to particular embodiments thereof, and numerous modifications can be made which are within the scope of the invention as set forth in the claims.

Claims

CLAIMSWhat is claimed is:
1. An integrated circuit chip package, comprising:
(a) a first inteφoser (4) having an inside surface (10) and an outside surface (12);
(b) a second inteφoser (2) spaced apart from the first inteφoser (4), the second inteφoser (2) having an inside surface (6) and an outside surface (8);
(c) an encapsulant (16) connected between the inside surfaces (10, 6) of the first and second inteφosers (4, 2);
(d) a die (14) surrounded by the encapsulant (16); and
(e) a wirebond (18) connected between the die (14) and one of the inteφosers (2, 4).
2. The package of claim 1, further comprising a wirebond pad (26) on the inside surface (6) of the second inteφoser (2).
3. A package as in one of claims 1-2, further comprising a tab bond (22) connected between the first and second inteφosers (4, 2).
4. The package of claim 3, wherein the tab bond (22) includes a first portion
(22a) in direct contact with the wirebond pad (26) and a second portion (22b) in direct contact with the outside surface (12) of the first inteφoser (4).
5. A package as in one of claims 1-4, further comprising a solder ball (30) directly connected to the second portion (22b) of the tab bond (22).
6. A package as in one of claims 1-5, further including a spacer (38) on the inside surface (6, 10) of one of the inteφosers (2, 4).
7. ni integrated circuit chip package, comprising:
(a) a bottom inteφoser (4) having an inside surface (10) and an outside surface (12);
(b) a top inteφoser (2) spaced apart from the bottom inteφoser (4), the top inteφoser (2) having an inside surface (6) and an outside surface (8);
(c) an encapsulant (16) connected between the inside surfaces (6, 10) of the top and bottom inteφosers (2, 4);
(d) a semiconductor die (14) suirounded by the encapsulant (16);
(e) a flipchip connector (52) connected between the semiconductor die (14) and one of the inteφosers (2, 4); and
(f) a tab bond (22) connected between the top and bottom inteφosers (2, 4).
8. The package of claim 7, further comprising a conductive pad (26) on the inside surface (6) of the top inteφoser (2).
9. The package of claim 8, wherein the tab bond (22) includes a first portion (22a) directly connected to the pad (26) and a second portion (22b) in direct contact with the outside surface (12) of the bottom inteφoser (4).
10. A method of making an integrated circuit chip package, comprising the steps of:
(a) providing a top inteφoser (2);
(b) attaching a semiconductor die (14) to the top inteφoser (2);
(c) providing a wirebond (18) between the semiconductor die (14) and the top inteφoser (2), the top inteφoser (2), the semiconductor die (14) and the wirebond (18) foiming a first assembly (42);
(d) providing a bottom inteφoser (4);
(e) attaching the first assembly (42) to the bottom inteφoser (4), the top and bottom inteφosers (2, 4) spaced apart by an intermediate volume (40);
(f.) providing a tab bond (22) between the top and bottom inteφosers (2, 4); and
(g) providing an encapsulant (16) to fill the intermediate volume (40) between the top and bottom inteφosers (2, 4).
PCT/US1998/025673 1997-12-03 1998-12-03 Integrated circuit chip package and method of making the same WO1999028969A1 (en)

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