Integrated circuit package system with interposer

An integrated circuit package system includes: providing a mountable integrated circuit system having an encapsulation with a cavity therein and a first interposer exposed by the cavity; mounting a second interposer over the first interposer for only stacking a discrete device thereover, and with the second interposer over the encapsulation and the cavity; and mounting an electrical component over the second interposer.

TECHNICAL FIELD

The present invention relates generally to an integrated circuit package system and more particularly to an integrated circuit package system with interposer.

BACKGROUND ART

Electronic devices such as smart phones, personal digital assistants, location based devices, digital cameras, music players, computers, or transportation, have become an integral part of many daily activities. Key components of these electronic devices are integrated circuit devices. These tiny integrated circuits must perform during daily activities including a wide variety of environmental conditions as well as potentially damaging forces. Many and varied types of packaging, intended for protection, interconnection or mounting, have been developed for integrated circuit devices.

Integrated circuit dies are conventionally enclosed in plastic packages that provide protection from hostile environments and enable electrical interconnection between the integrated circuit die and an underlying substrate such as a printed circuit board (PCB). The elements of such a package include: a lead frame or substrate, an integrated circuit die, bonding material to attach the integrated circuit die to the lead frame or substrate, bond wires or other connectors that electrically connect pads on the integrated circuit die to the lead frame or substrate. The package can also include a plastic or other insulating material that covers the components and forms the exterior of the package.

Wafer manufacturing strives to reduce transistor or capacitor feature size in order to increase circuit density and enhance functionality. Device geometries with sub-micron line widths are so common that individual chips routinely contain millions of electronic devices. Reduced feature size has been quite successful in improving electronic systems, and continuous development is expected in the future. However, significant obstacles to further reduction in feature size are being encountered. These obstacles include defect density control, optical system resolution limits, and availability of processing material and equipment. Attention has therefore increasingly shifted to semiconductor packaging as a means to fulfill the relentless demands for enhanced system performance.

Drawbacks of conventional designs include a relatively large footprint of the package on the mounting surface of motherboard. The footprint reflects dimensions that are typically the maximum of the package, namely, the maximum x-y dimensions of the package. In applications where mounting space is at a premium, such as pagers, portable telephones, and personal computers, among others, a large footprint is undesirable. With the goal of increasing the amount of circuitry in a package, but without increasing the area of the package so that the package does not take up any more space on the circuit board, manufacturers have been stacking two or more die within a single package. Unfortunately, sufficient overlap for electrical interconnect, large footprint top packages, increased device integration, pre-testing, and interconnect lengths have plagued previous package designs.

DISCLOSURE OF THE INVENTION

An integrated circuit package system includes: providing a mountable integrated circuit system having an encapsulation with a cavity therein and a first interposer exposed by the cavity; mounting a second interposer over the first interposer for only stacking a discrete device thereover, and with the second interposer over the encapsulation and the cavity; and mounting an electrical component over the second interposer.

BEST MODE FOR CARRYING OUT THE INVENTION

In the following description, numerous specific details are given to provide a thorough understanding of the invention. However, it will be apparent that the invention may be practiced without these specific details. In order to avoid obscuring the present invention, some well-known circuits, system configurations, and process steps are not disclosed in detail. Likewise, the drawings showing embodiments of the system are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown greatly exaggerated in the drawing FIGs. Generally, the invention can be operated in any orientation.

For expository purposes, the term “horizontal” as used herein is defined as a plane parallel to the plane or surface of the integrated circuit, regardless of its orientation. The term “vertical” refers to a direction perpendicular to the horizontal as just defined. Terms, such as “above”, “below”, “bottom”, “top”, “side” (as in “sidewall”), “higher”, “lower”, “upper”, “over”, and “under”, are defined with respect to the horizontal plane. The term “on” means there is direct contact among elements. The term “processing” as used herein includes deposition of material, patterning, exposure, development, etching, cleaning, molding, and/or removal of the material or as required in forming a described structure. The term “system” as used herein means and refers to the method and to the apparatus of the present invention in accordance with the context in which the term is used.

Referring now toFIG. 1, therein is shown a bottom view of an integrated circuit package system100in a first embodiment of the present invention. The bottom view depicts a base substrate102, such as a laminated substrate, and external interconnects104, such as solder balls, attached to the base substrate102.

For illustrative purposes, the integrated circuit package system100is shown with the external interconnects104equally spaced. Although, it is understood that the integrated circuit package system100may have some sites depopulated such that the integrated circuit package system100may have the external interconnects104not equally spaced.

Referring now toFIG. 2, therein is shown a cross-sectional view of the integrated circuit package system100along line2-2ofFIG. 1. The cross-sectional view depicts a mountable integrated circuit system206having an encapsulation208, such as a cover comprising an epoxy molding compound, with a cavity210and having a first interposer212exposed by the cavity210. A second interposer214, such as a laminated substrate, mounts over the encapsulation208and the cavity210. The second interposer214connects with the first interposer212. An electronic component216, such as a flip chip, is mounted over the second interposer214. The second interposer214, with the electronic component216thereover, is completely exposed from the encapsulation208or molding compound. An electrical attachment extent of the second interposer214includes a horizontal length greater than a horizontal length of an exposed extent of the first interposer212. The electrical attachment extent is an area at a top side of the second interposer214for electrically attaching electrical components, including the electronic component216, to the second interposer214. The exposed extent is exposed from the encapsulation208. The second interposer214has a side facing the cavity210and an opposite side having an electrical attachment area217directly over the cavity210.

The mountable integrated circuit system206, in this example, includes an integrated circuit package218and passive devices220over the base substrate102, such as a laminated substrate. First internal interconnects222, such as bond wires or ribbon bond wires, connect the first interposer212of the integrated circuit package218and the base substrate102. The encapsulation208is over the base substrate102covering the integrated circuit package218, the first internal interconnects222, and the passive devices220.

The integrated circuit package218includes an integrated circuit die224. The integrated circuit die224includes a non-active side226and an active side228, wherein the active side228includes active circuitry fabricated thereon. The non-active side226attaches with the first interposer212with an adhesive230, such as a die-attach adhesive. The first internal interconnects222, such as bond wires or ribbon bond wires, can connect the first interposer212of the integrated circuit package218and the base substrate102. The external interconnects104can attach below and to the base substrate102for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

The second interposer214includes electrical connectors232, such as solder balls. As an example, the second interposer214connects with the first interposer212with the electrical connectors232.

In this example, the electronic component216mounts over the second interposer214. The electronic component may be a Known Good Device (“KGD”) that has been functionally tested.

It has been discovered that the present invention provides an integrated circuit package on package system with reduced height by using the second interposer. The second interposer is configured to have redistribution layer and vias for bridging electrical connections between the integrated circuit below the second interposer and the electronic component above the second interposer.

It has also been discovered that in the present invention, the second interposer can be pre-attached to either the integrated circuit system or the electronic component in order to have them tested before final assembly. This feature can further reduce manufacturing cost and increase reliability.

Referring now toFIG. 3, therein is shown a cross-sectional view of an integrated circuit package system300along line2-2ofFIG. 1in a second embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system306having an encapsulation308, such as a cover comprising an epoxy molding compound, with a cavity310and having a first interposer312exposed by the cavity310. A second interposer314, such as a laminated substrate, mounts over the encapsulation308and the cavity310. The second interposer314connects with the first interposer312. An electronic component316, such as a flip chip, is mounted over the second interposer314.

The mountable integrated circuit system306, in this example, includes an integrated circuit package318and passive devices320over a base substrate302, such as a laminated substrate. First internal interconnects322, such as bond wires or ribbon bond wires, connect the first interposer312of the integrated circuit package318and the base substrate302. The encapsulation308is over the base substrate302covering the integrated circuit package318, the first internal interconnects322, and the passive devices320.

For example, the integrated circuit package318can be a Wafer Level Chip Scale Package (WLCSP), a Redistributed Layer (RDL) die or a flip chip. The integrated circuit package318includes the first interposer312. The integrated circuit package318attaches to the base substrate302with an adhesive330, such as a die-attach adhesive. The first internal interconnects322, such as bond wires or ribbon bond wires, can connect the first interposer312and the base substrate302. External interconnects304can attach below and to the base substrate302for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

The second interposer314includes electrical connectors332, such as solder balls. As an example, the second interposer314connects with the first interposer312with the electrical connectors332.

In this example, the electronic component316mounts over the second interposer314. The electronic component may be a Known Good Device (“KGD”) that has been functionally tested.

Referring now toFIG. 4, therein is shown a cross-sectional view of an integrated circuit package system400along line2-2ofFIG. 1in a third embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system406having an encapsulation408, such as a cover comprising an epoxy molding compound, with a cavity410and having a first interposer412exposed by the cavity410. A second interposer414, such as a laminated substrate, mounts over the encapsulation408and the cavity410. The second interposer414connects with the first interposer412. An electronic component416, such as a flip chip, is mounted over the second interposer414.

The mountable integrated circuit system406, in this example, includes an integrated circuit package418and passive devices420over a base substrate402, such as a laminated substrate. First internal interconnects422, such as bond wires or ribbon bond wires, connect the first interposer412of the integrated circuit package418and the base substrate402. The encapsulation408is over the base substrate402covering the integrated circuit package418, the first internal interconnects422, and the passive devices420.

The integrated circuit package418includes an integrated circuit die424. The integrated circuit die424includes a non-active side426and an active side428, wherein the active side428includes active circuitry fabricated thereon. The non-active side426attaches with the base substrate402with an adhesive430, such as a die-attach adhesive. Second internal interconnects434, such as bond wires or ribbon bond wires, can connect the active side428and the base substrate402. An inner encapsulation436, such as a cover comprising an epoxy molding compound, is over the base substrate402covering the integrated circuit die424and the second internal interconnects434.

The first interposer412mounts over the inner encapsulation436of the integrated circuit package418with a second adhesive439. The second interposer414includes electrical connectors432, such as solder balls. As an example, the second interposer414connects with the first interposer412with the electrical connectors432. In this example, the electronic component416mounts over the second interposer414. External interconnects404can attach below and to the base substrate402for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

Referring now toFIG. 5, therein is shown a cross-sectional view of an integrated circuit package system500along line2-2ofFIG. 1in a fourth embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system506having an encapsulation508, such as a cover comprising an epoxy molding compound, with a cavity510and having a first interposer512exposed by the cavity510. A second interposer514, such as a laminated substrate, mounts over the encapsulation508and the cavity510. The second interposer514connects with the first interposer512. An electronic component516, such as a flip chip, is mounted over the second interposer514.

The mountable integrated circuit system506, in this example, includes a first integrated circuit package518, a second integrated circuit package538, and passive devices520over a base substrate502, such as a laminated substrate. The second integrated circuit package538is over the first integrated circuit package518.

First internal interconnects522, such as bond wires or ribbon bond wires, connect the first interposer512of the second integrated circuit package538and the base substrate502. The encapsulation508is over the base substrate502covering the first integrated circuit package518, the second integrated circuit package538, the first internal interconnects522, and the passive devices520.

The first integrated circuit package518includes an integrated circuit die524. The integrated circuit die524includes a first non-active side526and a first active side528, wherein the first active side528includes active circuitry fabricated thereon. The first non-active side526attaches to the base substrate502with a first adhesive530, such as a die-attach adhesive. Second internal interconnects534, such as bond wires or ribbon bond wires, can connect the first active side528and the base substrate502. An inner encapsulation536, such as a cover comprising an epoxy molding compound, is over the base substrate502covering the integrated circuit die524and the second internal interconnects534.

The second integrated circuit package538mounts over the first integrated circuit package518with a second adhesive539. The second integrated circuit package538includes a second integrated circuit die540. The second integrated circuit die540includes a second non-active side542and a second active side544wherein the second active side544includes active circuitry fabricated thereon. The second non-active side542attaches with the first interposer512with a third adhesive546. The second active side544can connect with the first interposer512with third internal interconnects548.

The second interposer514includes electrical connectors532, such as solder balls. As an example, the second interposer514connects with the first interposer512with the electrical connectors532. External interconnects504can attach below and to the base substrate502for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

Referring now toFIG. 6, therein is shown a cross-sectional view of an integrated circuit package system600along line2-2ofFIG. 1in a fifth embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system606having an encapsulation608, such as a cover comprising an epoxy molding compound, with a cavity610and having a first interposer612exposed by the cavity610. A second interposer614, such as a laminated substrate, mounts over the encapsulation608and the cavity610. The second interposer614connects with the first interposer612. An electronic component616, such as a flip chip or a packaged integrated circuit device, is mounted over the second interposer614.

For illustrative purposes, the integrated circuit package system600is shown with the electronic component as a single device, although it is understood that the integrated circuit package system600may have electronic components over the second interposer614in a different configuration. For example, the electronic component616may represent a number of components.

The mountable integrated circuit system606, in this example, includes an integrated circuit package618and passive devices620over a base substrate602, such as a laminated substrate. First internal interconnects622, such as bond wires or ribbon bond wires, connect the first interposer612of the integrated circuit package618and the base substrate602.

The encapsulation608is over the base substrate602covering the integrated circuit package618, the first internal interconnects622, and the passive devices620. For illustrative purposes, the integrated circuit package system600is shown with the encapsulation608having vertical sidewalls over the top side of the base substrate602, although it is understood that the integrated circuit package system600may have a different configuration for the encapsulation608. For example, the encapsulation608can partially cover the top side of the base substrate602with non-vertical sidewalls.

The integrated circuit package618includes an integrated circuit die624. The integrated circuit die624includes a non-active side626and an active side628, wherein the active side628includes active circuitry fabricated thereon. The non-active side626attaches with the first interposer612with an adhesive630, such as a die-attach adhesive. Second internal interconnects634, such as bond wires or ribbon bond wires, can connect the active side628and the base substrate602. External interconnects604can attach below and to the base substrate602for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

The second interposer614includes electrical connectors632, such as solder balls. For example, the second interposer614connects with the first interposer612with the electrical connectors632. Also for example, the second interposer614extends the length of a top side of the encapsulation608and further passive devices646mount over or directly on the second interposer614.

Referring now toFIG. 7, therein is shown a cross-sectional view of an integrated circuit package system700along line2-2ofFIG. 1in a sixth embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system706having an encapsulation708, such as a cover comprising an epoxy molding compound, with a cavity710and having a first interposer712exposed by the cavity710. A second interposer714, such as a laminated substrate, mounts over the encapsulation708and the cavity710. The second interposer714includes a slot740over the cavity710. The second interposer714connects with the first interposer712. An electronic component716, such as a packaged integrated circuit device, is mounted over the second interposer714.

The mountable integrated circuit system706, in this example, includes an integrated circuit package718and passive devices720over a base substrate702, such as a laminated substrate. First internal interconnects722, such as bond wires or ribbon bond wires, connect the first interposer712of the integrated circuit package718and the base substrate702. The encapsulation708is over the base substrate702covering the integrated circuit package718, the first internal interconnects722, and the passive devices720.

The integrated circuit package718includes an integrated circuit die724. The integrated circuit die724includes a non-active side726and an active side728, wherein the active side728includes active circuitry fabricated thereon. The non-active side726attaches with the first interposer712with an adhesive730, such as a die-attach adhesive. Second internal interconnects734, such as bond wires or ribbon bond wires, can connect the active side728and the first interposer712. External interconnects704can attach below and to the base substrate702for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

The second interposer714includes electrical connectors732, such as solder balls. As an example, the second interposer714connects with the first interposer712with the electrical connectors732. An underfill742surrounds the electrical connectors732, fills the cavity710, and surrounds component connectors744of the electronic component716. The underfill742also fills the slot740. The slot740can be used for flow of the underfill742. Further passive devices746also mount over the second interposer714.

Referring now toFIG. 8, therein is shown a cross-sectional view of an integrated circuit package system800along line2-2ofFIG. 1in a seventh embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system806having an encapsulation808, such as a cover comprising an epoxy molding compound, with a cavity810and having a first interposer812exposed by the cavity810. A second interposer814, such as a laminated substrate, mounts over the encapsulation808and the cavity810. The second interposer814includes a slot840over the cavity810and along a side wall of the cavity810. The second interposer814connects with the first interposer812. An electronic component816, such as a flip chip, is mounted over the second interposer814.

The mountable integrated circuit system806, in this example, includes an integrated circuit package818and passive devices820over a base substrate802, such as a laminated substrate. First internal interconnects822, such as bond wires or ribbon bond wires, connect the first interposer812of the integrated circuit package818and the base substrate802. The encapsulation808is over the base substrate802covering the integrated circuit package818, the first internal interconnects822, and the passive devices820.

The integrated circuit package818includes an integrated circuit die824. The integrated circuit die824includes a non-active side826and an active side828, wherein the active side828includes active circuitry fabricated thereon. The non-active side826attaches with the first interposer812with an adhesive830, such as a die-attach adhesive. Second internal interconnects834, such as bond wires or ribbon bond wires, can connect the active side828and the first interposer812. External interconnects804can attach below and to the base substrate802for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

The second interposer814includes electrical connectors832, such as solder balls. As an example, the second interposer814connects with the first interposer812with the electrical connectors832. An underfill842surrounds the electrical connectors832, fills the cavity810, and surrounds component connectors844of the electronic component816. The underfill842includes low viscosity material such that it cannot be used as an encapsulation, such as the encapsulation808. The slot840can be used for flow of the underfill842. Further passive devices846also mount over the second interposer814.

Referring now toFIG. 9, therein is shown a cross-sectional view of an integrated circuit package system900along line2-2ofFIG. 1in an eighth embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system906having an encapsulation908, such as a cover comprising an epoxy molding compound, with a cavity910and having a first interposer912exposed by the cavity910. A second interposer914, such as a laminated substrate, mounts over the encapsulation908and the cavity910. The second interposer914connects with the first interposer912. An electronic component916, such as a flip chip, is mounted over the second interposer914.

The mountable integrated circuit system906, in this example, includes an integrated circuit package918and passive devices920over a base substrate902, such as a laminated substrate. First internal interconnects922, such as bond wires or ribbon bond wires, connect the first interposer912of the integrated circuit package918and the base substrate902.

The integrated circuit package918includes an integrated circuit die924. The integrated circuit die924includes a non-active side926and an active side928, wherein the active side928includes active circuitry fabricated thereon. The non-active side926attaches with a carrier952, such as a laminated substrate, with an adhesive930, such as a die-attach adhesive.

The first interposer912, such as a laminated substrate, mounts over the integrated circuit package918and connects with the integrated circuit package918with internal connectors948, such as solder balls. Further passive devices946also mount to and below the first interposer912.

The second interposer914includes electrical connectors932, such as solder balls. As an example, the second interposer914connects with the first interposer912with the electrical connectors932. The second interposer914can extend the length of a top side of the encapsulation908. Yet further passive devices950mounts over the second interposer914.

The encapsulation908is over the base substrate902covering the integrated circuit package918, the first internal interconnects922, the passive devices920, and the further passive devices946. External interconnects904can attach below and to the base substrate902for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

Referring now toFIG. 10, therein is shown a cross-sectional view of an integrated circuit package system1000along line2-2ofFIG. 1in a ninth embodiment of the present invention. The cross-sectional view depicts a mountable integrated circuit system1006having an encapsulation1008, such as a cover comprising an epoxy molding compound, with a cavity1010and having a first interposer1012exposed by the cavity1010.

A second interposer1014, such as a laminated substrate, mounts over the encapsulation1008with an adhesive1030and over the cavity1010. The second interposer1014includes a slot1040over the cavity1010. An electronic component1016, such as a packaged integrated circuit device, is mounted over the second interposer1014.

The mountable integrated circuit system1006, in this example, includes an integrated circuit package1018and passive devices1020over a base substrate1002, such as a laminated substrate. First internal interconnects1022, such as bond wires or ribbon bond wires, connect the first interposer1012of the integrated circuit package1018and the base substrate1002. Second internal interconnects1034, through the slot1040, connect the center bond pads of the first interposer1012and the second interposer1014. The encapsulation1008, such as cover comprising an epoxy molding compound, is over the base substrate1002covering the integrated circuit package1018, the first internal interconnects1022, and the passive devices1020. A cavity cover1048, such as a cover comprising a glob top material, fills the slot1040and the cavity1010covering the second internal interconnects1034.

Further passive devices1046also mount over the second interposer1014. External interconnects1004can attach below and to the base substrate1002for connection to the next system level (not shown), such as a printed circuit board or another integrated circuit package system.

Referring now toFIG. 11, therein is shown a flow chart of an integrated circuit package system1100for manufacturing of the integrated circuit package system100in an embodiment of the present invention. The system1100includes providing a mountable integrated circuit system having an encapsulation with a cavity therein and a first interposer exposed by the cavity in a block1102; mounting a second interposer over the first interposer for only stacking a discrete device thereover, and with the second interposer over the encapsulation and the cavity in a block1104; and mounting an electrical component over the second interposer in a block1106.

Thus, it has been discovered that the integrated circuit package system of the present invention furnishes important and heretofore unknown and unavailable solutions, capabilities, and functional aspects for improving yield, increasing reliability, and reducing cost of circuit system. The resulting processes and configurations are straightforward, cost-effective, uncomplicated, highly versatile, accurate, sensitive, and effective, and can be implemented by adapting known components for ready, efficient, and economical manufacturing, application, and utilization.