SEMICONDUCTOR PACKAGE AND METHOD FOR MANUFACTURING THE SAME

Provided is a method for manufacturing a semiconductor package, which includes providing a first substrate, providing, over the first substrate, a second substrate including an active region in which a semiconductor element is disposed and a periphery region surrounding the active region, providing an adhesive membrane between the first and second substrates, and mounting the second substrate on the first substrate, wherein the mounting of the second substrate includes aligning the second substrate on the first substrate by using an alignment member protruding from the periphery region of the second substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. non-provisional patent application claims priority under 35 U.S.C. §119 of Korean Patent Application No. 10-2015-0078681, filed on Jun. 3, 2015, the entire contents of which are hereby incorporated by reference.

BACKGROUND

The present disclosure herein relates to a semiconductor package and a method for manufacturing the same, and more particularly, to a semiconductor package for which a bonding process is performed for stacking a 3D semiconductor package and a method for manufacturing the same.

As a semiconductor device becomes high speed and high integration, the number of input and output pins rapidly increases, development of a connection technique using a through silicon via (TSV) electrode is enlarged, and development of a 3D semiconductor chip stacking structure using the same is enlarged. In particular, when a plurality of semiconductor chips are vertically stacked to realize high density chip stacking, semiconductor chips having various functions may be integrated on a small area. When semiconductor chips are stacked on an interposer or a wafer, bonding may be performed by using an adhesive film or underfill. When a bonding process is performed by using the adhesive film such as a non-conductive film (NCF), a thermal compression process is essentially accompanied. Accordingly, a processing time becomes longer and a processing efficiency may be lowered. When a bonding process using an underfill is proceeded, bubbles generated in the process may influence alignment of chips. When a compression process using a load is proceeded, the underfill may creep up to the top surface of the chip and contaminate a compression member. When a reflow process is proceeded without load, it is difficult to align the chips caused by bubble generation or an underfill flow.

SUMMARY

The present disclosure provides a semiconductor package which has a vertical stacking structure and in which semiconductor elements may be easily aligned, and a method for manufacturing the same.

The present disclosure also provides a semiconductor package which prevents semiconductor chips from tilting caused by an underfill flow or bubble generation at the time of stacking semiconductor chips, and a method for manufacturing the same.

The objectives of the present invention are not limited to the above-described. The objectives not mentioned in the above should be clearly understood by those skilled in the art from description below.

An embodiment of the inventive concept provides a method for manufacturing a semiconductor package including: providing a first substrate; providing, over the first substrate, a second substrate including an active region in which a semiconductor element is disposed and a periphery region surrounding the active region; providing an adhesive membrane between the first and second substrates; and mounting the second substrate on the first substrate, wherein the mounting of the second substrate includes aligning the second substrate on the first substrate by using an alignment member protruding from the periphery region of the second substrate.

In an embodiment, the second substrate may include a front surface facing a top surface of the first substrate and a rear surface facing the front surface, when mounted on the first substrate, and the aligning of the second substrate may include using a first alignment member protruding from the front surface.

In an embodiment, the aligning of the second substrate may include contacting the first alignment member and a base alignment member protruding from the top surface of the first substrate each other to be aligned.

In an embodiment, the contacting of the first alignment member and the base alignment member each other to be aligned may include fixing the second substrate on the first substrate to prevent tilting or misalignment caused by a flow of the adhesive membrane.

In an embodiment, the method may further include: mounting a third substrate on the second substrate, wherein the mounting of the third substrate may include aligning the third substrate by using a second alignment member protruding from the rear surface of the second substrate.

In an embodiment, the third substrate may include a front surface facing the rear surface of the second substrate and a rear surface facing the front surface, when mounted on the second substrate, and the aligning of the third substrate may include contacting the second alignment member and a third alignment member protruding from the front surface of the third substrate each other to be aligned.

In an embodiment, the method may further include: compressing the second substrate on the rear surface of the second substrate after mounting the second substrate.

In an embodiment, the adhesive membrane may be an underfill.

In an embodiments of the inventive concept, a semiconductor package includes: a first substrate; a second substrate mounted on the first substrate and including an active region in which a semiconductor element is disposed and a periphery region surrounding the active region; an adhesive membrane configured to fill between the first and second substrates; and an alignment member protruding from the periphery region of the second substrate and configured to align the second substrate on the first substrate.

In an embodiment, the second substrate may include a front surface facing a top surface of the first substrate and a rear surface facing the front surface, when mounted on the first substrate, and the alignment member may be provided to at least one of the front surface and the rear surface.

In an embodiment, the alignment member may include: a first alignment member protruding from the front surface; and a second alignment member protruding from the rear surface.

In an embodiment, the alignment member may further include a base alignment member protruding from a top surface of the first substrate to face the first alignment member and configured to contact the first alignment member.

In an embodiment, an inner surface of the first alignment member may contact an outer surface of the base alignment member.

In an embodiment, the semiconductor package may further include: a third substrate mounted on the second substrate and including a front surface facing the rear surface of the second substrate and a rear surface facing the front surface, wherein the third substrate may further include a third alignment member protruding from the front surface and configured to contact the second alignment member to align the third substrate.

In an embodiment, the adhesive membrane may be an underfill.

DETAILED DESCRIPTION

Advantages and features of the present invention, and methods for achieving the same will be cleared with reference to exemplary embodiments described later in detail together with the accompanying drawings. However, the present invention is not limited to the following exemplary embodiments, but realized in various forms. In other words, the present exemplary embodiments are provided just to complete disclosure the present invention and make a person having an ordinary skill in the art understand the scope of the invention. The present invention should be defined by only the scope of the accompanying claims. Throughout this specification, like numerals refer to like elements.

The terms and words used in the following description and claims are to describe embodiments but are not limited the inventive concept. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” used herein specify the presence of stated components, operations and/or elements but do not preclude the presence or addition of one or more other components, operations and/or elements.

Example embodiments are described herein with reference to cross-sectional views and/or plan views that are schematic illustrations of example embodiments. In the drawings, the thicknesses of layers and regions are exaggerated for clarity. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may be to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may, typically, have rounded or curved features. Thus, the regions illustrated in the figures are schematic in nature and their shapes may be not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of example embodiments.

FIGS. 1A to 4A, andFIGS. 5 to 8are cross-sectional views for explaining a method for manufacturing a semiconductor package according to an embodiment of the inventive concept.FIGS. 1B to 4Bare respective perspective views ofFIGS. 1A to 4A. Hereinafter, the method for manufacturing a semiconductor package according to an embodiment of the inventive concept will be described in detail with reference toFIGS. 1A to 4A,FIGS. 1B to 4B, andFIGS. 5 to 8.

Referring toFIGS. 1A and 1B, a semiconductor package may include a first substrate10and a second substrate20. The first substrate10may be mounted on the first substrate20. The first substrate10may include an active region (AR) on which memory elements are formed and a periphery region (PR) surrounding the AR. At least a part of the AR may include an integrated circuit (not illustrated). The first substrate10may be a semiconductor chip10. Hereinafter, the first substrate10will be exemplified and described as the semiconductor chip10. The semiconductor chip10may include a front surface10aon which an integrated circuit (not illustrated) is disposed and a rear surface10bwhich is an opposite surface thereto. The integrated circuit (not illustrated) may include a memory circuit, a logic circuit, or a combination thereof. When the semiconductor chip10is mounted on the second substrate20, the front surface10amay be a surface facing the top surface of the second substrate20. The semiconductor chip10may include through-electrodes12and bumps14. The through-electrodes12may be formed by using a via-first, via-middle, or via-last process. A via insulating film (not illustrated) may be provided to an external side of the plurality of through-electrodes12to prevent circuit elements included in the first semiconductor chip10from directly contacting the plurality of through-electrodes12. The bumps14are formed on a front surface of the semiconductor chip10to be electrically connected to the through-electrodes12. For example, the bumps14may electrically connect the through-electrodes12to bonding pads22on the second substrate20. The bumps14may be formed with a conductive material, for example, Cu, Al, Au, or solder, etc.

The first substrate10may be mounted on the second substrate20. For example, the second substrate20may be an interposer20. Hereinafter, the second substrate20will be exemplified and described as the interposer20. The interposer20may be a silicon interposer. The interposer20may have the same through-electrodes (not illustrated) as the semiconductor chip10. The interposer20may further include the bonding pads22electrically connected to the stacked semiconductor chip10. In addition, the interposer20may include at least one re-distribution layer (RDL) including interconnections. In addition, although not illustrated in the drawing, the interposer20may be connected to a carrier substrate (not illustrated) disposed therebelow. For example, the carrier substrate (not illustrated) may be a printed circuit board. At this point, the through-electrodes (not illustrated) of the interposer20may be electrically connected to the interconnections and bonding pads22to electrically connect the stacked semiconductor chip10and the carrier substrate (not illustrated). In addition, the through-electrodes may electrically connect a passive device such as an inductor, a capacitor, or a resistor included in the interposer20, or a logic device such as a processor, and the stacked semiconductor chip10and the carrier substrate (not illustrated).

When an adhesive membrane24may be provided between the first substrate10and the second substrate20. The adhesive membrane24may be provided on the second substrate20. The adhesive membrane24may connect the first substrate10onto the second substrate20. The adhesive membrane24may bond the semiconductor chip10onto the interposer20. The adhesive membrane24may include the underfill24. The underfill24may be a flowable underfill or non-flowable underfill. Hereinafter, a description will be provided about a case where the underfill24is exemplified as adhesive film24. For example, the underfill24may include at least one of epoxy, benzocyclobutene, polyimide, a silica filler, or flux. However, the adhesive membrane24is not limited thereto and may be a material having various compositions.

An alignment member30may be provided to the semiconductor chip10. The alignment member30may be disposed to protrude from the periphery region PR of the semiconductor chip10. The alignment member30may include first alignment members32and second alignment members34. The first alignment members32may protrude from the front surface10aof the semiconductor chip10. For example, the first alignment members32may vertically protrude from the front surface10aof the semiconductor chip10. The first alignment members32may be disposed on both sides of the periphery region PR. The second alignment members34may protrude from the rear surface10bof the semiconductor chip10. For example, the second alignment members34may vertically protrude from the front surface10bof the semiconductor chip10. The second alignment members34may be disposed on both sides of the periphery region PR. Alternatively, the alignment member30may further include third alignment members36provided on the second substrate20. The third alignment members36can be referred to as a base alignment member36. For example, the third alignment members36may protrude from the top surface of the interposer20. The third alignment members36may vertically protrude from the top surface of the semiconductor chip20. The third alignment members36may be disposed on both sides of the interposer20, which face the periphery region PR. The third alignment members36may be disposed to face the first alignment members32. For example, outer surfaces of the third alignment members36and inner surfaces of the first alignment members32contact each other, and the third alignment members36may be intervened and fixed between the first alignment members32. Unlike this, inner surfaces of the third alignment members36and outer surfaces of the first alignment members32contact each other, and the first alignment members32may be intervened and fixed between the third alignment members36.

The alignment members30may be manufactured in a silicon micro-fabrication process based on a semiconductor photolithography process. In other words, the alignment members30may be formed by applying a photoresist on a substrate, patterning with a mask pattern, and then proceeding a plating process. The alignment members30may be formed with a metal material. For example, the alignment members30may include Cu. However, the alignment members30are disposed on the periphery region PR or a region facing the periphery region PR on the second substrate20so as not to have an electrical influence on the semiconductor package. At this point, the alignment members30may have lower heights than the bumps14. Unlike this, the alignment members30may have equal to or higher heights than the bumps14. In order to adjust the heights of the alignment members30, the number of mask patterns may be variously provided at a process for manufacturing the alignment members30. In addition, the manufacturing method of the alignment members30is not limited thereto and the alignment members30may be formed in various methods.

Referring toFIGS. 2A and 2B, a first semiconductor chip10A may be stacked on the interposer20. At this point, the third alignment members36on the interposer20and the first alignment members32of the first semiconductor chip10A may contact each other and be aligned. For example, when viewed from a top portion, the third alignment members36are formed at an inner side than the first alignment member32, and the outer surfaces of the third alignment members36and the inner surfaces of the first alignment members32may contact each other. Accordingly, it becomes a structure that the third alignment members36of the interposer20are forcibly intervened between the first alignment members32of the first semiconductor chip10A. Unlike this, the inner surfaces of the third alignment members36and the outer surfaces of the first alignment members32contact each other, which results that the first alignment members32may be intervened and fixed between the third alignment members36. Since the first semiconductor chip10A is aligned at a precise position on the interposer20, the bumps14of the first semiconductor chip10A may be electrically connected to the bonding pads22of the interposer20. The underfill24may cover sidewalls of the first semiconductor chip10A, while filling a space between the first semiconductor chip10A and the interposer20. Since the first alignment members32and the third alignment members36physically contact, misalignment of the semiconductor chip10caused by a flow of the underfill24may be prevented. In addition, tilting of the semiconductor caused by bubble generation during processes may be prevented.

Referring toFIGS. 3A and 3B, a third substrate10B may be mounted on the first semiconductor chip10A. The third substrate10B may include a semiconductor chip10B. Hereinafter, a description will be provided about a case where the third substrate10B is exemplified as the second semiconductor chip10B. The second semiconductor chip10B may have a shape and function broadly identical to or similar to the first semiconductor chip10A. Accordingly, a description about the second semiconductor chip10B which overlaps the foregoing will be omitted. When the second semiconductor chip10B is stacked on the first semiconductor chip10A, the second alignment members34of the first semiconductor chip10A and the first alignment members32of the second semiconductor chip10B may contact each other to align the second semiconductor chip10B. For example, the outer surfaces of the second alignment members34of the first semiconductor chip10A and the inner surfaces of the first alignment members32of the second semiconductor chip10B contact each other to align the second semiconductor10B. Accordingly, it becomes a structure that the second alignment members34of the first semiconductor chip10A are forcibly intervened between the first alignment members32of the second semiconductor chip10B. Since the second semiconductor chip10B is aligned at a precise position, the bumps14of the second semiconductor chip10B may be electrically connected to the through electrodes12of the first semiconductor chip10A. The underfill24may cover sidewalls of the second semiconductor chip10B while filling a space between the second semiconductor chip10B and the first semiconductor chip10A. The second alignment members34of the first semiconductor chip10A and the first alignment members32of the second semiconductor chip10B physically contact each other to prevent misalignment of the semiconductor chips10A and10B caused by a flow of the underfill24. In addition, tilting of the semiconductor caused by bubble generation during processes may be prevented.

ReferringFIGS. 4A and 4B, N first semiconductor chips10A,10B, . . . ,10(N−1), and lON are stacked to manufacture a semiconductor chip structure1. Accordingly, the stacked N first semiconductor chips10A,10B, . . . ,10(N−1), and lON may be interlocked and aligned. Since the N first semiconductor chips10A,10B, . . . ,10(N−1), and lON are aligned at precise positions, the semiconductor chip structure1may be electrically connected. For example, the outer surfaces of the second alignment members34of the (N−1)-th semiconductor chip10(N−1) and the inner surfaces of the first alignment members32of the N-th semiconductor chip lON contact each other to align the N-th semiconductor chip10N. The underfill24may cover sidewalls of the N-th semiconductor chip10N, while filling a space between the (N−1)-th semiconductor chip10(N−1) and the N-th semiconductor chip10N. The second alignment members34of the (N−1)-th semiconductor chip10(N−1) and the first alignment members32of the N-th semiconductor chip lON physically contact each other to prevent misalignment of the semiconductor chips10A,10B, . . . ,10(N−1), and lON caused by a flow of the underfill24. In addition, tilting of the semiconductor chips10A,10B, . . . ,10(N−1), and10N caused by bubble generation during processes may be prevented. At this point, the N-th semiconductor chip10N stacked on the top layer of the semiconductor chip structure1may not include only the first alignment members32.

FIGS. 5 to 8are cross-sectional views schematically illustrating a process for packaging semiconductor chip structures manufactured by using the method ofFIG. 4A, andFIGS. 1B to 4B.

Referring toFIG. 5, a plurality of semiconductor chip structures1may be formed on one interposer20. Then, referring toFIG. 6, a compression process may be proceeded by using a compression member40. The compression member40may be provided to top portions of the semiconductor chip structures1to compress the rear surfaces10bof the N-th semiconductor chips10N. The compression member40may deliver a load to the semiconductor chip structures1and discharge heat to expedite a bonding process. When a process for stacking the semiconductor chip structures1, each of which has N layers, is proceeded, the compression process using the compression member40may be selectively proceeded. The N-layered semiconductor chip structures1are entirely stacked and then the compression process may be proceeded. Alternatively, every time each semiconductor chip of the N-layered semiconductor chip structures1is stacked, the compression process may be proceeded. However, since the semiconductor chip structures1according to an embodiment of the inventive concept prevent tilting and misalignment of the semiconductor chips by the alignment members30, a thermo-compression process is not essential and as illustrated inFIG. 6, may be simultaneously proceeded after the N-layered semiconductor chip structures1are entirely stacked. In addition, at the same time, a reflow process may be proceeded. Accordingly, the number of essential bonding processes is reduced to improve a throughput. Referring toFIG. 7, an encapsulation process may be proceeded for the semiconductor chip structures1. An encapsulation50may include an epoxy molding compound. After the encapsulation process is completed and the encapsulation50is cured, as illustrated inFIG. 8, a dicing process for separating the cured encapsulation into each package may be proceeded. According, semiconductor packages may be completed.

FIGS. 9 and 10illustrate a first semiconductor chip10having alignment members according to different embodiments.FIGS. 9 and 10illustrate the first semiconductor chip10viewed from the rear surface10bthereof. Referring toFIG. 9, the first semiconductor chip10may include the first alignment member32aand the second alignment member34a.The first alignment member32aand the second alignment member34amay be formed on the periphery region PR. The first alignment member32ais formed on the front surface10aof the first semiconductor chip10and the second alignment member34amay be formed on the rear surface10bof the first semiconductor chip10. At this point, the first alignment member32aand the second alignment member34amay be provided in plurality to be separated from each other. The first alignment member32aand the second alignment member34amay be separated from each other to assist smooth diffusion of the underfill24. A plural number of the first alignment members32aand the second alignment members34amay be provided in a zigzag type to be deviated from a straight line. Referring toFIG. 10, the first semiconductor chip10may include a first alignment member32band a second alignment member34b.The first alignment member32aand the second alignment member34amay be formed on the periphery region PR. At this point, the first alignment member32band the second alignment member34bmay be formed on corner sides of the periphery region PR. For example, the first alignment member32band the second alignment member34bmay be formed in a type to enclose the corner sides of the periphery region PR. The first alignment member32bis formed on the front surface10aof the first semiconductor chip10and the second alignment member34bmay be formed on the rear surface10bof the first semiconductor chip10. Since the first alignment member32band the second alignment member34bare formed only on a part of the periphery region PR, the area of the periphery region PR may be reduced and accordingly a process margin may increase. Unlike this, the alignment members may have various shapes and arrangements.

In the above-described embodiments, a semiconductor package is exemplified which has the structure in which the plurality of semiconductor chips10are stacked on the interposer20. However, the semiconductor package is not limited thereto and the interposer20may be mounted on a carrier wafer. In addition, the first substrate10may be various semiconductor elements other than the semiconductor chip10, and the second substrate20may include various semiconductor elements other then the interposer20. In addition, the alignment members are exemplified as formed on both sides of the semiconductor chip10, but may be formed on only one side of the semiconductor chip10.

In addition, in the above-described embodiments, the alignment members are exemplified as provided in a rod type, but may have various shapes.

In addition, in the above-described embodiments, a die-to-wafer (D2W) manner in which a plurality of chips are bonded on a wafer is exemplified, but the embodiments may also be applied to a wafer-to-wafer (W2W) manner in which a plurality of chips in a wafer state are boned to another wafer and to a die-to-die manner in which a chip and another chip are bonded.

According to embodiments of the inventive concept, a semiconductor package and a method for manufacturing the same may be provided which may physically support and align a plurality of semiconductor chips to prevent miss-alignment and tilting caused by bubble generation or a underfill flow, etc. during a process, when the plurality of semiconductor chips are vertically stacked.