Alignment holder, testing apparatus and method for manufacturing a semiconductor package

An alignment holder for holding and testing a composite specimen includes a holder body, a supporter, and a positioning mechanism. The holder body is configured to clamp a first side of the composite specimen. The supporter is detachably connected to a lower part of the holder body for supporting a lower surface of the composite specimen. The positioning mechanism is configured to lean against a second side of the composite specimen and move relatively to the holder body for adjusting a clamping position of the composite specimen clamped by the holder body.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications, such as personal computers, cell phones, digital cameras, and other electronic equipment. Semiconductor devices are typically fabricated by sequentially depositing insulating or dielectric layers, conductive layers, and semiconductor layers of material over a semiconductor substrate, and patterning the various material layers using lithography to form circuit components and elements thereon. Many integrated circuits are typically manufactured on a single semiconductor wafer. The dies of the wafer may be processed and packaged at the wafer level, and various technologies have been developed for wafer level packaging.

In molded electronic and electric parts containing inserting components such as encapsulated semiconductor devices and resin insulating transformers, the interface between the resin and the inserting component subjected to high residual stress due to the cure shrinkage of the resin and the coefficient of the thermal expansion mismatch between the resin and the inserting components. These thermal stress sometimes causes delamination during operations of the components and reliability tests

Such a delamination at adhering interfaces not only results in corrosion of electric wiring materials and electric insulating degradation, but also causes a variety of other damages, such as cracking of the resin and wire breaking due to the stress concentration by the delamination. Therefore, the evaluation of bonding strength of a composite structure is therefore a critical issue in assuring the reliability of such composite structure.

DETAILED DESCRIPTION

FIG. 1illustrates a schematic view of a testing apparatus in accordance with some embodiments.FIG. 2illustrates a partial cross-sectional view of an alignment holder in accordance with some embodiments. With now reference toFIG. 1andFIG. 2, a testing apparatus100shown inFIG. 1is configured to test a bonding strength of a composite specimen10. In some embodiments, the composite specimen10may be a composite structure including multiple components bonding together, and the testing apparatus100is configured to test/measure the bonding strength between the components around interfaces thereof. In some embodiments, the composite specimen10may be a semiconductor package including a plurality of components (e.g. encapsulation materials, through vias, semiconductor devices, etc.) bonding with one another, such that the composite specimen10includes a plurality of bonding interfaces. The materials of the plurality of components may be different from one another. For example, the composite specimen10may include Integrated Fan Out (InFO) packages, Chip on Wafer on Substrate (CoWoS) packages, flip chip packages and other semiconductor packages.

In some embodiments, for example, the composite specimen10may be an encapsulated semiconductor device, which includes a semiconductor device11encapsulated by an encapsulating material12, and a plurality of through vias (conductive pillars)13surrounding the semiconductor device11and extending through the encapsulating material12as shown inFIG. 1andFIG. 2. The encapsulating material12reveals electrical terminals of the semiconductor device11and the end surfaces of the through vias13. In the embodiments of the composite specimen10being the encapsulated semiconductor device, the composite specimen10may be in a wafer form. In some embodiments, the testing apparatus100are provided to test/measure the bonding strength (i.e. delamination durability) of the composite specimen (encapsulated semiconductor device)10at the bonding interfaces (e.g. bonding interfaces between the encapsulation material12and the through vias13, bonding interfaces between encapsulation material12and the semiconductor device11, etc.) thereof.

In some embodiments, the materials of the components in the composite specimen10may be different from one another. For example, the material of the encapsulating material12may include epoxy or other suitable resins. In some embodiments, the encapsulating material12may be epoxy resin containing chemical filler. The material of a substrate of the semiconductor device11may include bulk silicon, doped or undoped, or an active layer of a silicon-on-insulator (SOI) substrate. Generally, an SOI substrate includes a layer of a semiconductor material such as silicon, germanium, silicon germanium, SOI, silicon germanium on insulator (SGOI), or combinations thereof. Other substrates that may be used include multi-layered substrates, gradient substrates, or hybrid orientation substrates. The material of the through vias13may include a copper (Cu) and/or a copper-based alloy, etc. In some embodiments, the materials of some components in the composite specimen10may be the same, and the testing apparatus100is also configured for testing the bonding strength between the components with the same materials.

In some embodiments, the testing apparatus100includes an alignment holder105for holding the composite specimen10and a force applying bar140for applying a force to the composite specimen10. In some embodiments, the alignment holder105includes a holder body110and a positioning mechanism130. The holder body110is configured to clamp a first side (e.g. right side) of the composite specimen10. In one of the implementations, the holder body110may include an upper holder112and a lower holder114, and the first side of the composite specimen10is configured to be disposed between the upper holder112and the lower holder114. In some embodiments, the holder body110may further include a locking member118. The locking member118is coupled between the upper holder112and the lower holder114, and a distance G1between the upper holder112and the lower holder114can be adjusted by the locking member118. For instance, the locking member118can be a screw. The upper holder112and the lower holder114each has a threaded hole correspondingly. As such, the distance G1between the upper holder112and the lower holder114can be adjusted according to how deep the locking member118is screwed into the threaded holes of the upper holder112and the lower holder114.

FIG. 3illustrates a partial cross-sectional view of an alignment holder in accordance with some embodiments.FIG. 4illustrates a schematic top view of a lower holder of an alignment holder in accordance with some embodiments. With now reference toFIG. 3andFIG. 4, in some embodiments, the holder body110may further include a groove1141for receiving the composite specimen10. In accordance with some embodiments of the disclosure, the groove1141crosses over the lower holder114as shown inFIG. 3andFIG. 4, such that the composite specimen10is configured to be moved along a moving direction D1within the groove1141. In other words, the groove1141may be functioned as a sliding rail for the composite specimen10to slide relatively to the holder body along the groove1141. With such arrangement, the upper holder112and the lower holder114may be in contact with each other when clamping the composite specimen10. In other embodiments, the groove1141may be disposed on the upper holder112and/or the lower holder114to be functioned as the sliding rail for the composite specimen10. The depth of the groove1141can be adjusted according to actual requirements, such as the thickness of the composite specimen10, the configuration of the holder body110, etc.

FIG. 5illustrates a schematic view of an alignment holder in an intermediate stage of operation in accordance with some embodiments. With now reference toFIG. 1andFIG. 5, in some embodiments, the alignment holder105may further include a supporter120detachably connected to a lower part of the holder body110for supporting a lower surface of the composite specimen10. In some embodiments, the supporter120may be detachably connected to the lower holder114. In accordance with some embodiments of the disclosure, the supporter120is detachably connected to the lower holder114through mechanical engagement. For example, the supporter120may include at least one protrusion (e.g. the protrusion122illustrated in inFIG. 5), and the lower holder114may correspondingly include at least one concave (e.g. the concave1142illustrated in inFIG. 5). With such arrangement, the supporter120can be detachably connected to the lower holder114through the engagement of the protrusion122of the supporter120and the concave1142of the lower holder114, but the disclosure is not limited thereto. Any form of mechanical engagement or any suitable connections may be applied to the supporter120and the lower holder114. In alternative embodiments, the supporter120may be detachably connected to the lower holder114through magnetic force. For example, the supporter120and the lower holder114may each include a magnetic component, and the magnetic components in the supporter120and the lower holder114are configured to be attracted to each other.

In some embodiments, the supporter120can be firstly attached (connected) to the lower holder114when the composite specimen10is placed between the upper holder112and the lower holder114, so the lower surface of the composite specimen10can lean on the supporter120for holding and supporting the composite specimen10in place. Then, when the composite specimen10is adjusted to a desired clamping position, the distance G1between the upper holder112and the lower holder114can be adjusted (shortened) by, for example, screwing the locking member118into the threaded holes of the upper holder112and the lower holder114. That is to say, the tightness of the holder body110for clamping the composite specimen10can be controlled by the locking member118, so as to hold the composite specimen10in place.

With now reference toFIG. 1, in some embodiments, the positioning mechanism130is configured to lean against a second side (e.g. left side) of the composite specimen10and move relatively to the holder body110for adjusting a clamping position of the composite specimen10clamped by the holder body110. In some embodiments, the holder body110may further include a base116. The upper holder112and the lower holder114are disposed on the base116, and the positioning mechanism130is movably coupled to the base116. In accordance with some embodiments of the disclosure, the positioning mechanism130includes at least one positioning rod132(two positioning rods132are illustrated herein, but not limited thereto) and a positioning plate134coupled to the positioning rod132. Correspondingly, the base116includes at least one positioning hole1161(two positioning holes1161are illustrated herein, but not limited thereto), and the positioning rods132are movably engaged with the positioning holes1161respectively. The positioning plate134is configured to lean against a second side (e.g. left side) of the composite specimen10and move along with the positioning rod132. For example, the positioning holes1161may be threaded holes, and the positioning rods132may be threaded rods. As such, one end of the positioning rod132may penetrate the positioning plate134and another end of the positioning rod132is screwed into the positioning holes1161, so that the positioning rod132is configured to drive the positioning plate134to move toward or away from the holder body110. In some embodiments, a nub136may be disposed on a cantilever end of each positioning rod132to facilitate the operation of the positioning rod132.

With now reference toFIG. 2, in accordance with some embodiments of the disclosure, a length L1of the supporter120is substantially shorter than a length L2of the composite specimen10exposed by the upper holder112and the lower holder114of the holder body110. Accordingly, the positioning mechanism130is capable of pushing the second side of the composite specimen10toward the holder body110without interfering with the supporter120. In some embodiments, the positioning mechanism130is configured to lean against the second side of the composite specimen10, which is opposite to the first side of the composite specimen10where the upper holder112and the lower holder114are clamped.

FIG. 6illustrates a schematic view of a testing apparatus in a testing stage in accordance with some embodiments. With now reference toFIG. 1andFIG. 6, with such arrangement, when a user want to adjust the clamping position of the composite specimen10, the user may just simply rotate the nubs136along the rotating direction R1to screw the positioning rods132into the positioning holes1161. Accordingly, the positioning plate134is driven to move along with the positioning rods132, and pushes the composite specimen10to move toward the holder body110. When the composite specimen10is moved to a desired clamping position, the user just simply stops the rotation of the nub136and screws the locking member118further into the upper holder112and the lower holder114to lock the composite specimen10in place. Then, the positioning mechanism130may be removed by rotate the nub136conversely to unscrew the positioning rods132from the positioning holes1161. The supporter120may also be removed by, for example, disengaging the supporter120from the lower holder114. Then, a force may be applied to a part of the composite specimen10by a force applying bar140to test the bonding strength of the composite specimen10. In some embodiments, the force applying bar140may be a cantilever beam. In some embodiments, the cantilever end of the force applying bar140is configured for abutment with an upper surface of the composite specimen10to apply force thereon. Therefore, the positioning and the alignment of the composite specimen10can be well controlled by the upper holder112, the lower holder114and the positioning mechanism130, and manual error and false test result caused by shift or misalignment of the composite specimen10can be avoided.

With now reference toFIG. 2, in accordance with some embodiments of the disclosure, the upper holder112includes an inclined surface1121at a tip of the upper holder112for aligning with the first side of the composite specimen10. In some embodiments, the upper holder112may be a wedge block. With such arrangement, the view angle of the user would not be blocked by the upper edge of the upper holder112, so the user may have better observation on the composite specimen10during the adjusting of the clamping position of the composite specimen10.

In accordance with some embodiments of the disclosure, the force may be applied to an interface between two components of the composite specimen10by the force applying bar140. In some embodiments, the force applying bar140is configured to move toward the composite specimen10along a direction perpendicular to a surface (e.g. an upper surface) of the composite specimen10. For example, the force may be applied on an upper surface at the interface between the encapsulating material12and the semiconductor device11or the interface between the encapsulating material12and the through vias13. Accordingly, the bonding strength between the encapsulating material12and the semiconductor device11and the bonding strength between the encapsulating material12and the through vias13can be tested/measured. As such, bonding strength (delamination durability) can be determined by measuring the applied force during an increment of delamination growth at the interface. With the application of the alignment holder105, the clamping position can be well controlled to expose the interface to be tested without shifting, so the force can be applied to the interface of the composite specimen10precisely. For example, the composite specimen10is firstly clamped by the holder body110, and then pushed toward the holder body110by the positioning mechanism130to adjust the clamping position more precisely, so as to avoid or reduce misalignment (position shifting) of the composite specimen10resulting from manual placement of the composite specimen10. As such, accuracy of testing result of the testing apparatus100can be improved.

In accordance with some embodiments of the disclosure, for a bending test, the force applying bar140is moved along a direction from the upper holder112toward the lower holder114to apply a bending force toward the composite specimen10. In some embodiments, a longitudinal axis A1of the force applying bar140is substantially perpendicular to an applying surface (e.g. the upper surface) of the composite specimen10, and the bending force is applied by the tip of the force applying bar140as it is shown inFIG. 6.

FIG. 7illustrates a schematic view of a testing apparatus in a testing stage in accordance with some embodiments. With now reference toFIG. 7, in accordance with some embodiments of the disclosure, for a shear test, after the positioning mechanism130and the supporter120are removed, the holder body110can be placed in an upright position as it is shown inFIG. 7. As such, the composite specimen10clamped by the holder body110is also in an upright position. Accordingly, the longitudinal axis A1of the force applying bar140is substantially parallel to an applying surface (e.g. lower surface) of the composite specimen10, and the shear stress is applied by the side surface of the force applying bar140as it is shown inFIG. 7. In the embodiments of performing the shear test, the force applying bar140is moved along a direction from the lower holder114toward the upper holder112to apply a shear stress toward the composite specimen10. Therefore, the alignment holder105provides the testing apparatus100more precision in alignment and more flexibility in operation of tests. With such arrangement, the alignment holder105and the testing apparatus100having the alignment holder105are capable of performing a bending test, a shear test, a scratch test, an indent test, or any other suitable tests that includes alignment and force application. Therefore, the application of the testing apparatus100having the alignment holder105is more versatile and the alignment of the composite specimen10and the testing result can be more precise.

In accordance with some embodiments of the disclosure, the composite specimen10′ may be an encapsulated semiconductor device, which includes a first semiconductor device11, a second semiconductor device14, a first encapsulating material12a, and a second encapsulating material12b. In some embodiments, the first semiconductor device11is encapsulated by the first encapsulating material12a, and the second semiconductor device14is encapsulated by the second encapsulating material12b. The first encapsulating material12aand the second encapsulating material12bare bonded with each other. In some embodiments, the structure of the first semiconductor device11encapsulated by the first encapsulating material12a, and the structure of the second semiconductor device14encapsulated by the second encapsulating material12bmay be formed in separate steps.

For example, the structure of the first semiconductor device11encapsulated by the first encapsulating material12amay be pre-formed and provided, and the second encapsulating material12bis then formed to encapsulate the second semiconductor device14and bonding with the first encapsulating material12a. In some embodiments, the first encapsulating material12aand the second encapsulating material12bmay be over molding to cover the first semiconductor device11and the second semiconductor device14. Then, a planarizing process may be performed on the first encapsulating material12aand the second encapsulating material12bto reveal the first semiconductor device11and the second semiconductor device14. The planarizing process may include mechanical grinding or chemical mechanical polishing (CMP), for example. After the grinding process, a cleaning step may be optionally performed, for example, to clean and remove the residue generated from the grinding step. However, the disclosure is not limited thereto, and the planarizing step may be performed through any other suitable method.

With such arrangement, the force may be applied to the interface between the first semiconductor device11and the first encapsulating material12a, the interface between the second semiconductor device14and the second encapsulating material12b, and the interface between the first encapsulating material12aand the second encapsulating material12bto test the bonding strength thereof. In some embodiments, the materials of the first encapsulating material12aand the second encapsulating material12bmay be the same. For example, the material of the first encapsulating material12aand the second encapsulating material12bmay include epoxy or other suitable resins. In some embodiments, the first encapsulating material12aand the second encapsulating material12bmay be epoxy resin containing chemical filler. In alternative embodiments, the materials of the first encapsulating material12aand the second encapsulating material12bmay be different from each other. The first semiconductor device11and/or the second semiconductor device14may be high bandwidth memory (HBM) dies, or any other suitable semiconductor devices. In some embodiments, at least one of the first semiconductor device11and the second semiconductor device14may be a dummy die merely for testing purpose, so as to further reduce the cost for testing.

In accordance with some embodiments of the disclosure, for a bending test, the force applying bar140can be moved along a direction from the upper holder112toward the lower holder114to apply a bending force toward the composite specimen10. In some embodiments, the longitudinal axis of the force applying bar140is substantially perpendicular to an applying surface (e.g. the upper surface) of the composite specimen10′, and the bending force is applied by the tip of the force applying bar140as it is shown inFIG. 8.

FIG. 9illustrates a schematic view of a testing apparatus in a testing stage in accordance with some embodiments. With now reference toFIG. 9, in accordance with some embodiments of the disclosure, for a shear test, after the positioning mechanism130and the supporter120are removed, the holder body110can be placed in an upright position as it is shown inFIG. 9. As such, the composite specimen10′ clamped by the holder body110is also in an upright position. Accordingly, the longitudinal axis of the force applying bar140is substantially parallel to an applying surface (e.g. lower surface) of the composite specimen10′, and the shear stress is applied by the side surface of the force applying bar140as it is shown inFIG. 9. In the embodiments of performing the shear test, the force applying bar140is moved along a direction from the lower holder114toward the upper holder112to apply a shear stress toward the composite specimen10′. In general, the composite specimen10′ including the first encapsulating material12aand the second encapsulating material12bbonding with each other is easily to crack at the lower surface of the composite specimen10′ when subjected to high residual stress due to, for example, cure shrinkage of the encapsulating materials12a,12b. Therefore, the shear test as it is shown inFIG. 9is inevitable for the composite specimen10′.

In accordance with some embodiments of the disclosure, the alignment holder105provides the testing apparatus100more precision in alignment and more flexibility in operation of tests. With such arrangement, the alignment holder105and the testing apparatus100having the alignment holder105are capable of performing a bending test, a shear test, a scratch test, an indent test, or any other suitable tests that includes alignment and force application.

With now reference toFIG. 1,FIG. 10andFIG. 11, in accordance with some embodiments of the disclosure, the method for manufacturing a semiconductor package50as shown inFIG. 11may include the following steps. It is noted that the following description is illustrated regarding the embodiment of the method is applied to the composite specimen (encapsulated semiconductor device)10shown inFIG. 1, but the disclosure is not limited thereto. It should be understood that the method and the testing apparatus100might also be applied to any suitable specimens.

First, performing step S110, an encapsulated semiconductor device10including an encapsulating material12and a semiconductor device11encapsulated by the encapsulating material12is provided. In some embodiments, the encapsulated semiconductor device10is formed by a semiconductor process. Such semiconductor process may include providing a semiconductor device11and a plurality of through vias (conductive pillars)13and then providing an encapsulating material12to encapsulate the semiconductor device11and the conductive pillars13. In some embodiments, the semiconductor device11and the through vias (conductive pillars)13may be provided on a carrier (not shown), and the carrier may be removed during the sequential testing process. In some embodiments, the carrier may be a glass carrier, a ceramic carrier, or the like. The conductive pillars13may be pre-formed, and are then placed on the carrier. In alternative embodiments, the conductive pillars13may be formed by, for example, plating process. The plating of the conductive pillars130may be performed before the placement of the semiconductor device11. In some embodiments, the encapsulating material12may include a molding compound, an epoxy, or a resin, etc. In some embodiments, a thinning process, which may be a grinding process, may be optionally performed to thin the encapsulating material12for revealing the through vias13and electrical terminals of the semiconductor device11.

Then, performing step S120, a testing apparatus100including a holder body110, a positioning mechanism130and a force applying bar140as it is shown inFIG. 1is provided. The testing apparatus100is provided to test/measure the bonding strength (i.e. delamination durability) of the encapsulated semiconductor device10at the bonding interfaces (e.g. bonding interfaces between the encapsulation material12and the through vias13, bonding interfaces between encapsulation material12and the semiconductor device11, etc.) thereof.

Then, performing step S130, a first side of the encapsulated semiconductor device (composite specimen)10is clamped by the holder body110. In some embodiments, the first side (e.g. the right side) of the encapsulated semiconductor device10is placed between the upper holder112and the lower holder114of the holder body110. In the embodiments of the testing apparatus100having a stopper120shown inFIG. 1, the supporter120can be firstly attached (connected) to the lower holder114before the encapsulated semiconductor device10is placed between the upper holder112and the lower holder114. Thereby, the lower surface of the encapsulated semiconductor device10can lean on the supporter120for holding and supporting the encapsulated semiconductor device10in place. In some embodiments, the supporter120can be detachably connected to the lower holder114by mechanical engagement, magnetic force, or any suitable means.

Then, performing step S140, the clamping position of the encapsulated semiconductor device10is adjusted by the positioning mechanism130. For example, in some embodiments, a second side of the encapsulated semiconductor device10is pushed toward the holder body110by the positioning mechanism130for adjusting the clamping position of the encapsulated semiconductor device10. In some embodiments, the positioning mechanism130leans against the second side (e.g. left side) of the encapsulated semiconductor device10opposite to the first side where the holder body110is clamped, and configured to pushes the second side of the encapsulated semiconductor device10toward the holder body110in a controllable way. When the encapsulated semiconductor device10is pushed and adjusted to a desired clamping position, the upper holder112and the lower holder114can be locked by, for example, screwing the locking member118into the threaded holes of the upper holder112and the lower holder114. That is to say, the tightness of the holder body110for clamping the encapsulated semiconductor device10can be controlled by the locking member118, so as to hold the encapsulated semiconductor device10in place. In other embodiments, the upper holder112and the lower holder114can be connected by an elastic piece, so as to clamp the encapsulated semiconductor device10in place.

Then, performing step S150, the positioning mechanism130may be removed. In some embodiments, the positioning mechanism130may be removed from the holder body by, for example, unscrewing the positioning rods132of the positioning mechanism130from the positioning holes1161of the holder body. In the embodiments of the testing apparatus100having the supporter120, the supporter120may also be removed by, for example, disengaging the supporter120from the lower holder114.

Then, performing step S160, a predetermined force may be applied to a part of the encapsulated semiconductor device10by a force applying bar140to test the bonding strength of the encapsulated semiconductor device10. In some embodiments, the force may be applied to an interface between two bonding components of the encapsulated semiconductor device10by the force applying bar140. For example, the predetermined force may be applied at the interface between the encapsulating material12and the semiconductor device11or the interface between the encapsulating material12and the through vias13. Accordingly, the bonding strength between the encapsulating material12and the semiconductor device11and the bonding strength between the encapsulating material12and the through vias13can be tested and measured. With the application of the alignment holder105, the alignment holder105can be well controlled to hold the encapsulated semiconductor device10and expose the interface to be tested, so the force can be applied to the interface of the encapsulated semiconductor device10precisely without shifting. Accordingly, the positioning and the alignment of the encapsulated semiconductor device10can be well controlled by the upper holder112, the lower holder114and the positioning mechanism130, and manual error and false test result caused by shift or misalignment of the encapsulated semiconductor device10can be avoided.

Then, performing step S160, if the encapsulated semiconductor device10is failed by the predetermined force applied by the force applying bar140, a process parameter of the semiconductor process is modified to form a modified encapsulated semiconductor device10a. In some embodiments, if the bonding strength between the interfaces of the encapsulated semiconductor device10does not meet the requirement, when the predetermined force is applied onto the encapsulated semiconductor device10by the force applying bar140, the encapsulated semiconductor device10may fail (e.g. crack, or deform, etc.) around the interfaces. As such, process parameters of the semiconductor process for forming the encapsulated semiconductor device10may be modified to form the modified encapsulated semiconductor device10a. For example, process parameters may include curing temperature of the encapsulating material12, reactant concentrations of plating process for forming the conductive pillars13and/or conductors of the semiconductor device11, etc. The testing process may be repeated until the bonding strength of the modified encapsulated semiconductor device meets the requirement, and then sequential process (e.g. forming a redistribution structure20over the modified encapsulated semiconductor device10a, etc.) may be performed on the modified encapsulated semiconductor device to form the semiconductor package50. Certainly, if the bonding strength of the encapsulated semiconductor device10meets the requirement in the first place, the sequential process (e.g. forming a redistribution structure20over the encapsulated semiconductor device10, etc.) may be performed on the encapsulated semiconductor device10to form the semiconductor package50without modifying any process parameters.

In some embodiments, for the sequential process, the redistribution structure20may be formed over the encapsulating material12and the semiconductor device11and electrically connected to the semiconductor device11and the through vias13of the encapsulated semiconductor device10/10a. The redistribution structure140may be formed by, for example, depositing conductive layers, patterning the conductive layers to form redistribution circuits21, partially covering the redistribution circuits21and filling the gaps between the redistribution circuits21with dielectric layers22, etc. The material of the redistribution circuits21may include a metal or a metal alloy including aluminum, copper, tungsten, and/or alloys thereof. The dielectric layers22may be formed of dielectric materials such as oxides, nitrides, carbides, carbon nitrides, combinations thereof, and/or multi-layers thereof. The redistribution circuits21are formed in the dielectric layers22and electrically connected to the semiconductor device11and the through vias13. In addition, an Under Bump Metallurgy (UBM) layer23may be formed on the redistribution structure20by sputtering, evaporation, or electroless plating, etc.

Then, a plurality of electrical connectors30and at least one Integrated Passive Device (IPD)32are disposed on the redistribution structure20in accordance with some exemplary embodiments. The formation of the electrical connectors30may include placing solder balls on the UBM layer23(or on the redistribution structure20), and then reflowing the solder balls. In alternative embodiments, the formation of the electrical connectors30may include performing a plating process to form solder regions on the UBM layer23(or on the redistribution structure20), and then reflowing the solder regions. The electrical connectors30may also include conductive pillars, or conductive pillars with solder caps, which may also be formed through plating. The IPD32may be fabricated using standard wafer fabrication technologies such as thin film and photolithography processing, and may be mounted on the redistribution structure20through, for example, flip-chip bonding or wire bonding, etc.

In accordance with some embodiments of the disclosure, the method and the testing apparatus for testing the bonding strength of the encapsulated semiconductor device10can be applied once the encapsulating material12is formed (i.e. molding process). In other words, the delamination durability of the encapsulated semiconductor device10can be obtained once the molding process is performed instead of waiting until the whole semiconductor package process is finished. That is to say, the testing method and the testing apparatus can be applied to the encapsulated semiconductor device10instead of being applied to the semiconductor package, which may include the encapsulated semiconductor device, and redistribution structure, etc. Thereby, the delamination durability of the encapsulated semiconductor device10can be obtained more instantaneously, so as to modify recipe of the encapsulated semiconductor device10to prevent the risk of delamination immediately rather than having to wait until the whole semiconductor package process is finished. Therefore, the product cost can be reduced and the process efficiency can be improved.

Based on the above discussions, it can be seen that the present disclosure offers various advantages. It is understood, however, that not all advantages are necessarily discussed herein, and other embodiments may offer different advantages, and that no particular advantage is required for all embodiments.

In accordance with some embodiments of the disclosure, an alignment holder for holding a composite specimen includes a holder body, a supporter, and a positioning mechanism. The holder body is configured to clamp a first side of the composite specimen. The supporter is detachably connected to a lower part of the holder body for supporting a lower surface of the composite specimen. The positioning mechanism is configured to lean against a second side of the composite specimen and move relatively to the holder body for adjusting a clamping position of the composite specimen clamped by the holder body.

In accordance with some embodiments of the disclosure, a testing apparatus for testing a bonding strength of a composite specimen includes a holder body, a positioning mechanism, and a force applying bar. The holder body is configured to clamp a first side of the composite specimen. The positioning mechanism is movably coupled to the holder body, wherein the positioning mechanism is configured to lean against a second side of the composite specimen and move relatively to the holder body for adjusting a clamping position of the composite specimen clamped by the holder body. The force applying bar is configured to apply a force to a part of the composite specimen exposed by the holder body.

In accordance with some embodiments of the disclosure, a method for manufacturing a semiconductor package includes the following steps. A semiconductor process is performed to form an encapsulated semiconductor device, wherein the encapsulated semiconductor device comprises an encapsulating material and a semiconductor device encapsulated by the encapsulating material. A testing apparatus including a holder body, a positioning mechanism and a force applying bar is provided. The encapsulated semiconductor device is clamped by the holder body. A clamping position of the encapsulated semiconductor device is adjusted by the positioning mechanism. The positioning mechanism is removed. A predetermined force is applied to a part of the encapsulated semiconductor device exposed by the holder body by the force applying bar. If the encapsulated semiconductor device is failed by the predetermined force, a process parameter of the semiconductor process is modified to form a modified encapsulated semiconductor device.