Package structure and method for manufacturing package structure

Disclosed herein is a method for manufacturing a package structure. According to an exemplary embodiment of the present invention, the method for manufacturing a package structure includes: preparing a die having a metal pillar disposed on one surface thereof; bonding the die on the metal plate to allow the metal pillar to face the outside; forming an insulating film covering the metal plate and the die; buffing the insulating film so as to expose the metal pillar; and manufacturing a first package structure by forming a circuit structure electrically connected to the metal pillar on the insulating film.

This application claims the benefit under 35 U.S.C. Section 119 of Korean Patent Application Serial No. 10-2012-0111198 entitled “Package Structure And Method For Manufacturing Package Structure” filed on Oct. 8, 2012, which is hereby incorporated by reference in its entirety into this application.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a package structure and a method for manufacturing the same, and more particularly, to a package structure with improved manufacturing efficiency and a method for manufacturing the same.

2. Description of the Related Art

With the development of a high-density and high-performance semiconductor package, various package technologies have been developed. As the semiconductor package technologies, there is a package technology which bonds a die to a circuit board using a non-conductive paste (NCP). In more detail, the semiconductor package is manufactured by bonding a die to a circuit board while connecting a copper pillar and a metal bump to be aligned with each other, after the die having a copper (Cu) pillar disposed on one surface thereof and the circuit board having a metal bump disposed on one surface thereof are prepared and a non-conductive paste is interposed between the die and the circuit board.

However, in the case of the package technology using the non-conductive paste, a phenomenon that the non-conductive paste is not completely filled between the circuit board and the bump at the time of the packaging occurs. In this case, voids occur within the non-conductive paste, which is a cause of the occurrence of short between circuit patterns of the semiconductor package. Further, when a pitch between the metal pillars of the die is fine, it is difficult to match the metal pillars with the metal bumps, which causes the packaging defect.

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Patent Document

SUMMARY OF THE INVENTION

An object of the present invention is to provide a package structure with improved manufacturing efficiency and a method for manufacturing the same.

Another object of the present invention is to provide a package structure capable of solving problems occurring at the time of using a non-conductive paste and a method for manufacturing the same.

According to an exemplary embodiment of the present invention, there is provided a package structure, including: a metal plate; a die bonded to the metal plate to allow a metal pillar so as to face the outside; an insulating film covering the metal plate and the die so as to expose the metal pillar; and a metal pattern electrically connected to the metal pillar on the insulating film.

The circuit structure may be formed by performing a plating process on the insulating film.

The insulating film may be formed by directly laminating the insulating film on the metal plate and the die.

According to another exemplary embodiment of the present invention, there is provided a method for manufacturing a package structure, including: preparing a die having a metal pillar disposed on one surface thereof; bonding the die on the metal plate to allow the metal pillar to face the outside; forming an insulating film covering the metal plate and the die; buffing the insulating film so as to expose the metal pillar; and manufacturing a first package structure by forming a circuit structure electrically connected to the metal pillar on the insulating film.

The forming of the circuit structure includes: forming a metal seed layer covering the insulating film; forming an anti-plating pattern on the metal seed layer; forming a plating film on the metal seed layer by using the anti-plating pattern as an anti-plating film; and removing the anti-plating pattern.

The method for manufacturing a package structure may further include: forming a metal pattern by removing a part of the metal plate so as to expose the die; preparing a second package structure in which an external connection terminal is formed; and laminating the second package structure on the first package structure, while bonding the external connection terminal to the metal pattern.

The preparing of the die may include preparing a semiconductor integrated circuit chip having an inner via, and the method for manufacturing a package structure may further include: removing the metal plate so as to expose the die; and laminating an additional die on the exposed die.

The forming of the insulating film may include directly laminating the insulating film on the metal plate and the die.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Various advantages and features of the present invention and methods accomplishing thereof will become apparent from the following description of embodiments with reference to the accompanying drawings. However, the present invention may be modified in many different forms and it should not be limited to exemplary embodiments set forth herein. Rather, these embodiments may be provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals throughout the specification denote like elements.

Terms used in the present specification are for explaining the embodiments rather than limiting the present invention. Unless explicitly described to the contrary, a singular form includes a plural form in the present specification. The word “comprise” and variations such as “comprises” or “comprising,” will be understood to imply the inclusion of stated constituents, steps, operations and/or elements but not the exclusion of any other constituents, steps, operations and/or elements.

Further, the exemplary embodiments described in the specification will be described with reference to cross-sectional views and/or plan views that are ideal exemplification figures. In drawings, the thickness of layers and regions is exaggerated for efficient description of technical contents. Therefore, exemplified forms may be changed by manufacturing technologies and/or tolerance. Therefore, the exemplary embodiments of the present invention are not limited to specific forms but may include the change in forms generated according to the manufacturing processes For example, an etching region vertically shown may be rounded or may have a predetermined curvature.

Hereinafter, a package structure and a method for manufacturing the same according to exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1is a flow chart showing a method for manufacturing a package structure according to an exemplary embodiment of the present invention andFIGS. 2 to 5are views describing a process of manufacturing a package structure according to the exemplary embodiment of the present invention.

Referring toFIGS. 1 and 2, a die110may be bonded on a metal plate120(S110). In detail, the die110may be prepared. In the preparing of the die110, a semiconductor integrated circuit chip112having one surface112aon which a metal pillar114is formed and the other surface112bwhich is an opposite surface to the one surface may be prepared. The metal pillar114may be made of a copper material. Meanwhile, the metal plate120may be prepared. As the metal plate120, a thin plate made of the copper material having relatively high thermal conductivity may be used. Further, the other surface112bof the die110may be bonded on the metal plate120to allow the metal pillar114to face the outside.

An insulating film130which covers the die110and the metal plate120may be formed (S120). The forming of the insulating film130may include laminating the insulating film covering the die110and the metal plate120, along with the metal pillar114and polishing or buffing the insulating film130so as to expose the metal pillar114and a part of the metal plate120. Herein, the directly laminating of the insulating film130may be defined as directly covering the insulating film130on the die110and the metal plate120, without using intermediate materials, such as a non-conductive paste (NCP). Therefore, the die110and the metal plate120are covered on the metal plate120, but the insulating film130having a via hole132through which the metal pillar114is exposed and at the same time, a part of the metal plate120is exposed may be formed.

Referring toFIGS. 1 and 3, a circuit structure140may be formed on the insulating film130(S130). The forming of the circuit structure140may include forming a metal seed layer (not illustrated) on the insulating film130, forming an anti-plating pattern (not illustrated) on the metal seed layer, forming a plating film by performing a plating process using the anti-plating pattern as an anti-plating film, and removing the anti-plating pattern. Therefore, a metal via142formed in the via hole132of the insulating film130may be formed on the insulating film130and a circuit pattern144electrically connected to the metal pillar114may be formed on the insulating film130.

Referring toFIGS. 1 and 4, a first package structure101may be manufactured (S140). The manufacturing of the first package structure101may be performed by further forming a circuit substrate layer150on results previously illustrated inFIG. 3. The forming of the circuit substrate layer150may include forming an outside layer152made of an insulating material on the results described above with reference toFIG. 3, forming a wiring structure154configured of a conductive via, a circuit pattern, and the like, on the outside layer152, forming a solder resist pattern156exposing the wiring structure154on the outside layer152, and bonding an external connection terminal158to the wiring structure154exposed by the solder resist pattern156. As the external connection terminal158, a solder ball may be used. By the above described process, the first package structure101in which the die110having the metal pillar114is packaged may be manufactured, without using the non-conductive paste (NCP).

Referring toFIGS. 1 and 5, a second package structure102may be laminated on the first package structure101(S150). For example, the second package structure102may be prepared. The second package structure102may include a circuit board on which the connection terminal102ais formed. A metal pattern121for electrical connection of the second package structure102may be formed by removing a part of the metal plate120ofFIG. 4so as to expose the other surface112bof the die110of the first package structure101. Further, the connection terminal102aof the second package structure102may be bonded to the metal pattern121of the first package structure101. Therefore, the package structure100in a package on package (POP) type may be manufactured.

As described above, a method for manufacturing a package structure according to the exemplary embodiment of the present invention may manufacture a package substrate by disposing the die110having the metal pillar114on the metal plate120. In this case, compared to a technology of packaging the die having the metal pillar by using the non-conductive paste, the occurrence problem of voids occurring at the time of using the non-conductive paste may be solved and a heat radiating effect of the die110may be improved. Therefore, according to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the packaging may be implemented by bonding the die having the metal pillar on the metal plate without using the non-conductive paste, thereby preventing the voids from occurring within the insulating film at the time of using the non-conductive paste and improving the heat radiating effect of the die.

The method for manufacturing a package structure according to the exemplary embodiment of the present invention may form the circuit structure140on the insulating layer130after the die110having the metal pillar114is disposed on the metal plate120and the insulating film130covering the metal pillar114and the die110is directly laminated. In this case, compared to the case of bonding the die to the substrate by interposing the non-conductive paste therebetween, the matching degree of the die110and the circuit structure140may increase, which may be very advantageous in the packaging of the die having the metal pillar of a pine pitch. Therefore, according to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the matching degree of the metal pillar and the circuit structure may be improved by forming the circuit structure electrically connected to the metal pillar after directly laminating the insulating film on the die having the metal pillar without using the non-conductive paste.

According to the method for manufacturing a package structure according to the exemplary embodiment of the present invention, the second package structure102may be laminated on the first package structure101in the state in which the other surface of the die110is exposed to the outside, without using a separate protective film, such as an epoxy molding compound (EMC). In this case, the package structure100may be manufactured without using the separate protective film, in the state in which the die110disposed in the first package structure101is exposed to the outside. Further, according to the method for manufacturing a package structure according to the exemplary embodiments of the present invention, the package structure in the package on package (POP) type may be manufactured without covering the die with the separate protective film, such as the epoxy molding compound, thereby more reducing the overall thickness of the package structure and more improving the heat radiating effect of the die as compared with the case of using the protective film. Further, according to the package structure and the method for manufacturing a package structure according to the exemplary embodiments of the present invention, the metal pillar of the die may be partially etched, thereby implementing the thinner package on package.

Hereinafter, a method for manufacturing a package structure according to a modified example of the present invention will be described in detail. Herein, a description of overlapping portions with the method for manufacturing a package structure according to the exemplary embodiment of the present invention described above will be omitted or simplified.

FIG. 6is a flow chart illustrating a package structure according to a modified example of the present invention andFIGS. 7 to 8are views describing a process of manufacturing a package structure according to a modified example of the present invention.

Referring toFIGS. 6 and 7, a reserved package structure illustrated inFIG. 3may be prepared (S210). The preparing of the reserved package structure may be similar to one described above with reference toFIGS. 2 and 3. However, the die110ato be packaged may have an inner via116electrically connected to the metal pillar114on the one surface112athereof, while penetrating through the one surface112aand the other surface112bof the die110a.The die110ahaving the above-mentioned structure may be the semiconductor integrated circuit chip having a through silicon via (TSA) structure. The inner via116may be manufactured during the process of manufacturing the die110a.As another example, the inner via116may be directly formed on the die110aafter the metal plate120is removed as described above.

Further, the package structure101amay be manufactured by removing the metal plate of the reserved package structure (S220). The removing of the metal plate may be performed by performing a predetermined etching process on the metal plate120so as to expose the other surface112bof the die110aand the metal via144of the circuit structure140. Therefore, the package structure101ain which the inner via116of the die110ais exposed to the outside may be manufactured.

Referring toFIGS. 6 and 8, the additional die110bmay be bonded to the package structure101a(S230). The bonding of the additional die110bmay include performing an electrical inspection on the die110a, preparing a semiconductor integrated circuit chip having a connection terminal110b′ disposed on one surface thereof, and bonding the additional die110bto the die110aso that the connection terminal110b′ is electrically connected to the inner via116of the die110a.When the defect of the die110aoccurs during the performing of the electrical inspection on the die110a, a new die may be replaced or a performance of a subsequent process may be retained. Therefore, the package structure101ahaving a structure in which the two dies110aand110bare laminated may be manufactured.

By the above-mentioned process, the package structure100ahaving a structure in which the plurality of dies110aand110bare laminated may be manufactured. The package structure100amay solve a part of the known good die (KGD) which is a disadvantage of the through silicon via, by mounting the additional die after manufacturing the package using the through silicon via (STA) die and completing the electrical inspection thereon. Further, according to the method for manufacturing a package structure according to the exemplary embodiments of the present invention, the semiconductor package using the die having the through silicon via (TSV) structure can be implemented without using the non-conductive paste to solve the problem of the known good die (KGD) which is a disadvantage of the through silicon via package, thereby improving the manufacturing yield and the reducing the manufacturing costs.

According to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the packaging can be implemented by bonding the die having the metal pillar on the metal plate without using the non-conductive paste, thereby preventing the voids from occurring within the insulating film at the time of using the non-conductive paste and improving the heat radiating effect of the die.

Further, according to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the matching degree of the metal pillar and the circuit structure can be improved by forming the circuit structure electrically connected to the metal pillar after directly laminating the insulating film on the die having the metal pillar without using the non-conductive paste.

Further, according to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the package structure in the package on package (POP) type can be manufactured without covering the die with the separate protective film, such as the epoxy molding compound, thereby more reducing the overall thickness of the package structure and more improving the heat radiating effect of the die as compared to the case of using the protective film. Further, according to the method for manufacturing a package structure according to the exemplary embodiments of the present invention, the metal pillar of the die can be partially etched, thereby implementing the thinner package on package.

Further, according to the package structure and the method for manufacturing the same according to the exemplary embodiments of the present invention, the semiconductor package using the die having the through silicon via (TSV) structure can be implemented without using the non-conductive paste to solve the problem of the known good die (KGD) which is a disadvantage of the through silicon via package, thereby improving the manufacturing yield and the reducing the manufacturing costs.

The present invention has been described in connection with what is presently considered to be practical exemplary embodiments. In addition, the above-mentioned description discloses only the exemplary embodiments of the present invention. Therefore, it is to be appreciated that modifications and alterations may be made by those skilled in the art without departing from the scope of the present invention disclosed in the present specification and an equivalent thereof. The exemplary embodiments described above have been provided to explain the best state in carrying out the present invention. Therefore, they may be carried out in other states known to the field to which the present invention pertains in using other inventions such as the present invention and also be modified in various forms required in specific application fields and usages of the invention. Therefore, it is to be understood that the invention is not limited to the disclosed embodiments. It is to be understood that other embodiments are also included within the spirit and scope of the appended claims.