Die package including encapsulated die and method of manufacturing the same

Disclosed herein is a die package including an encapsulated die, including: a die including pads on one side thereof; an encapsulation layer covering lateral sides of the die; a support layer covering the encapsulation layer and one side of the die; a passivation layer formed on the other side of the die such that the pads are exposed therethrough; and a redistribution layer formed on the passivation layer such that one part thereof is connected with the pad. Here, since one side of the die is supported by the support layer and the encapsulation layer is formed on only the lateral side of the die, the warpage of the die package due to the difference in thermal expansion coefficient can be minimized.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of Korean Patent Application No. 10-2009-0054396, filed Jun. 18, 2009, entitled “Die package having encapsulated die and method of manufacturing the same”, which is hereby incorporated by reference in its entirety into this application.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a die package including an encapsulated die and a method of manufacturing the same.

2. Description of the Related Art

With the advancement of the electronics industry, electronics parts have been gradually becoming highly-functionalized and miniaturized. Thus, next-generation multi-functional small-sized packages having more functions in a limited area have attracted considerable attention, and, particularly, the development of a die package provided therein with an electronic part (a die) has attracted considerable attention.

In particular, recently, a die package including a die encapsulated with a mold material has been being researched.

FIGS. 1 to 10are sectional views showing a conventional method of manufacturing a die package including an encapsulated die, in which the die is encapsulated using a porous ceramic plate. Hereinafter, a conventional method of manufacturing a die package including an encapsulated die will be described with reference toFIGS. 1 to 10.

First, as shown inFIG. 1, a porous ceramic plate12, which has pores through which a solvent can pass and is resistant to an encapsulation temperature (for example, 150° C. or more), is provided.

Subsequently, as shown inFIG. 2, an adhesive tape14for attaching dies is adhered to one side of the porous ceramic plate12.

Subsequently, as shown inFIG. 3, dies16are adhered to the adhesive tape12in a face-down state such that pads18formed in one side of each of the dies16are brought into contact with the adhesive tape14.

Subsequently, as shown inFIG. 4, an encapsulation layer20is formed on the adhesive tape14to cover the dies16.

Subsequently, as shown inFIG. 5, the porous ceramic plate12is immersed into an organic solvent22. In this case, the organic solvent22is absorbed in the porous ceramic plate by capillary action and then brought into contact with the adhesive tape14through the pores formed in the porous ceramic plate12to decrease the adhesion strength of the adhesive tape14. For example, when the organic solvent22is acetone and the adhesive tape14is made of silicon, the acetone softens the adhesive property of the silicon tape.

Subsequently, as shown inFIG. 6, the encapsulation layer20including the dies16is separated from the adhesive tape14and the porous ceramic plate12. That is, since the adhesion strength of the adhesive tape14is decreased by the organic solvent22in the afore-mentioned step, this step can be naturally performed.

Subsequently, as shown inFIG. 7, a passivation layer24is formed on one side of the dies16such that the pads18of the dies16are exposed, and then redistribution layers26are formed on the passivation layer24such that the redistribution layers26extend along the passivation layer24in a state in which one part of each of the redistribution layers26is connected with the pads18.

Subsequently, as shown inFIG. 8, a solder resist layer28having openings for exposing the other parts of the redistribution layers26is formed on the passivation layer24and the redistribution layers26.

Subsequently, as shown inFIG. 9, external connecting terminals32are respectively formed on the other parts of the redistribution layers26.

Finally, as shown inFIG. 10, the resulting structure is cut into package units, each including an individual die, through a singulation process, resulting in a die package10.

However, the conventional die package10is problematic in that the encapsulation layer20having a thermal expansion coefficient higher than those of other constituents is formed on both lateral sides and upper sides of the dies, so that the die package10warps due to the difference in thermal expansion coefficient between the encapsulation layer20and other constituents, thereby deteriorating the reliability of the die package10. Moreover, the conventional die package10is also problematic in that, since the encapsulation layer20is expensive, increasing the amount of material used to form the encapsulation layer20increases the production cost of the die package10.

Furthermore, the conventional die package10is problematic in that, since the carrier type porous ceramic plate12is used, its manufacturing process is complicated, and its production cost is increased.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made to solve the above-mentioned problems, and the present invention provides a die package including an encapsulated die, which can improve reliability by minimizing the occurrence of warpage due to the difference of thermal expansion coefficient, and a method of manufacturing the same

Further, the present invention provides a die package including an encapsulated die, the manufacturing process of which is simple, and the production cost of which is low, and a method of manufacturing the same.

An aspect of the present invention provides a die package including an encapsulated die, including: a die including pads on one side thereof; an encapsulation layer covering lateral sides of the die; a support layer covering the encapsulation layer and the other side of the die; a passivation layer formed on the one side of the die such that the pads are exposed therethrough; and a redistribution layer formed on the passivation layer such that one part thereof is connected with the pad.

In the die package, the encapsulation layer may be formed such that its thickness is less than that of the die.

Further, the encapsulation layer may be formed such that its thickness is 10˜90% of that of the die.

Further, the support layer may have a thermal expansion coefficient lower than that of the encapsulation layer.

Further, the support layer may be made of a prepreg or a liquid crystalline polymer.

Further, the die package further may include: a solder resist layer which is formed on the passivation layer and the redistribution layer and which has an opening for exposing the other part of the redistribution layer; and an external connecting terminal formed on the other part of the redistribution layer exposed by the opening.

Another aspect of the present invention provides a method of manufacturing a die package including an encapsulated die, including: adhering dies provided on one side thereof with pads to a tape in a face-down state; forming an encapsulation layer to cover lateral sides of the dies; forming a support layer to cover the encapsulation layer and the other side of the dies; removing the tape and then forming a passivation layer for exposing the pads therethrough; and forming a redistribution layer on the passivation layer such that one part thereof is connected with the pad.

In the method, in the forming of the encapsulation layer, the encapsulation layer may be formed through a printing process or a dispensing process.

Further, in the forming of the support layer, the support layer may have a thermal expansion coefficient lower than that of the encapsulation layer.

Further, in the forming of the support layer, the support layer may be made of a prepreg or a liquid crystalline polymer.

Further, in the forming of the encapsulation layer, the encapsulation layer may be formed such that its thickness is less than that of the die.

Further, the encapsulation layer may be formed such that its thickness is 10˜90% of that of the die.

Further, The method may further include, after the forming of the redistribution layer: forming a solder resist layer having an opening for exposing the other part of the redistribution layer on the passivation layer and the redistribution layer; forming an external connecting terminal on the other part of the redistribution layer exposed by the opening; and cutting the resulting structure into respective package units along a scribing line by performing a singulation process.

Various objects, advantages and features of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The objects, features and advantages of the present invention will be more clearly understood from the following detailed description and preferred embodiments taken in conjunction with the accompanying drawings. Throughout the accompanying drawings, the same reference numerals are used to designate the same or similar components, and redundant descriptions thereof are omitted. In the following description, the terms “first”, “second” and the like are used to differentiate a certain component from other components, but the configuration of such components should not be construed to be limited by the terms. Further, in the description of the present invention, when it is assumed that the detailed description of the related art would obscure the gist of the present invention, the description thereof will be omitted.

Structure of a Die Package Including an Encapsulated Die

FIG. 11is a sectional view showing a die package including an encapsulated die according to an embodiment of the present invention. Hereinafter, a die package including an encapsulated die according to an embodiment of the present invention will be described with reference toFIG. 11.

As shown inFIG. 11, a die package100including an encapsulated die according to an embodiment of the present invention includes a die104, an encapsulation layer108, a support layer110, a passivation layer112, and a redistribution layer114.

The die104includes pads106electrically connected with an integrated circuit (not shown) on one side of a die body which is made of silicon and in which the integrated circuit is embedded. Here, the pads106are made of a metal such as aluminum.

The encapsulation layer108serves to impart the property of mechanical strength to the die package100, to protect the die104from pollutants and to provide a surface area allowing for formation of the redistribution layer114and the build-up thereon. Here, in order to minimize the occurrence of warpage due to the high thermal expansion coefficient of the encapsulation layer108, the encapsulation layer108is formed on the lateral side of the die104such that its thickness is smaller than the thickness of the die104, preferably, such that its thickness is 10˜100% of the thickness of the die104. The encapsulation layer may be made of an epoxy molding compound (EMC).

The support layer110, which serves to support the encapsulated die104, is formed to cover the encapsulation layer108formed on the lateral side of the die104and the other side of the die104. Further, the support layer110serves to protect the other side of the die104, i.e. the side on which the encapsulation108is not formed, from pollutants. In this case, the support layer110is made of a material having a thermal expansion coefficient lower than that of the encapsulation layer108, for example, a prepreg or a liquid crystalline polymer.

The passivation layer112, which serves to protect the die104from the external environment, is formed of a laminate including first and second insulation films (not shown) made of silicon oxide (SiO2) and a third insulation film (not shown) made of silicon nitride (SiN), and has high heat resistance and electrical insulation. The surface of the passivation layer112functions as the surface of the die104.

The redistribution layer114serves to connect the pads106formed on the die104to larger connection pads located at other positions, and is formed such that it extends from the pads106to the passivation layer112. Here, one part of the redistribution layer114is connected with the pad106, and a connection pad (not shown) connected with an external connecting terminal is formed on the other part thereof. Further, the redistribution layer114is made of a conductive metal, such as aluminum (Al), copper (Cu), nickel (Ni), gold (Au) or the like.

Meanwhile, a solder resist layer116having an opening118for exposing the other part of the redistribution layer114is formed on the passivation layer112and the redistribution layer114, and an external connecting terminal120for connecting the die104with an external system, such as a solder ball, may be formed on the other part of the redistribution layer114.

Method of Manufacturing a Die Package Including an Encapsulated Die

FIGS. 12 to 19are sectional views showing a method of manufacturing a die package including an encapsulated die according to an embodiment of the present invention. Hereinafter, a method of manufacturing a die package including an encapsulated die according to an embodiment of the present invention will be described with the reference toFIGS. 12 to 19.

First, as shown inFIG. 12, dies104, each of which is provided on one side thereof with pads106, are adhered onto a tape102in a face-down state.

In this case, the dies104are adhered onto the tape102at regular intervals, and are adhered onto the tape102such that the pads106are brought into contact with the tape102. Here, the tape102serves to support the dies104and to use adhesivity to prevent the dies104from moving during an ensuing encapsulation process. A silicon rubber adhesive tape or a polyimide (PI) adhesive tape may be used as the tape102.

Subsequently, as shown inFIG. 13, an encapsulation layer108is formed on the tape102to cover the lateral sides of the dies104.

In this case, the encapsulation layer108is made of a molding material, such as plastic, resin, epoxy molding compound or the like, and serves to impart the property of mechanical strength to the die package100, to protect the dies104from pollutants and to provide a surface area allowing for formation of the redistribution layer and the build-up thereon. Since the thermal expansion coefficient (CTE) of the encapsulation layer108is much higher than those of other components constituting the die package100, the die package100warps due to the difference in thermal expansion coefficient therebetween, so that it is preferred that the encapsulation layer108be used in the minimal amount necessary to achieve the original function of encapsulating the dies104. Therefore, in this step, unlike in the conventional technology, it is preferred that the encapsulation layer108be formed to cover only the lateral sides of the dies104, and that the thickness of the encapsulation layer108be less than that of each of the dies104. Even in this case, since one side of the encapsulation layer108is flush with the one side of each of the dies104on which the pads6are formed, the encapsulation layer108may serve to provide a surface area for build-up.

In this step, in order to form the encapsulation layer108only on the lateral sides of the dies104, a printing process or a dispensing process may be employed.

That is, in this step, a printing process used to apply an encapsulation material using a mask having openings for exposing the lateral sides of the dies104and a dispensing process used to apply an encapsulation material using a dispenser are used, thus forming the encapsulation layer108covering the lateral sides of the dies104without an additional process, such that the encapsulation layer108is thinner than each of the dies104. For example, when the encapsulation layer108is formed using conventional transfer molding or compression molding, since the encapsulation layer108is formed even on other sides of the dies104in addition to the lateral side thereof, there is a problem in that an additional process, such as a polishing process, is required. However, as in this step, when a printing process or a dispensing process is used, the encapsulation layer108can be formed only on the lateral sides of the dies104.

Subsequently, as shown inFIG. 14, a support layer110is formed on the encapsulation layer108and the dies104to cover the encapsulation layer108and the other sides of the dies104.

Here, the support layer110serves to support the encapsulated dies104, and is formed to cover the other sides of the dies104and the encapsulation layer formed on the lateral side of the dies104. The support layer110further serves to protect the other sides of the dies104, i.e. those sides on which the encapsulation layer108are not formed, from pollutants.

In this case, the support layer110is made of a material having a thermal expansion coefficient lower than that of the encapsulation layer108, for example, prepreg or liquid crystalline polymer. That is, owing to the low thermal expansion coefficient of the support layer110, the high thermal expansion coefficient of the encapsulation layer108is attenuated, thus minimizing the occurrence of the warpage of the die package.

Subsequently, as shown inFIG. 16, the encapsulated dies104are turned over, and then a passivation layer112is formed on one side of the encapsulated dies104such that the pads106are exposed, and then redistribution layers114are formed on the passivation layer112in a state in which one part of each of the redistribution layers114is connected to the pad106. Here, when a passivation layer is collectively formed on dies in a FAB process, a process of forming a passivation layer may be omitted.

In this case, the redistribution layers114serve to direct the pads106formed in the dies104to other positions, and may be provided with additional connection pads. One part of each of the redistribution layers114is connected with the pad106, and each of the redistribution layers114is made of a conductive metal, such as aluminum (Al), copper (Cu), nickel (Ni), gold (Au) or the like. Further, an auxiliary adhesion layer (UBM) may be selectively formed on the other part of each of the redistribution layers114in order to improve the adhesive force between the redistribution layer114and an external connecting terminal.

Subsequently, as shown inFIG. 17, a solder resist layer116having openings118for exposing the other parts of the redistribution layers114is formed on the passivation layer112and the redistribution layers114.

Here, the other parts of the redistribution layers114serve as connection pads. The solder resist layer116is formed in order to protect the redistribution layers excluding the other parts thereof and the passivation layer112.

Subsequently, as shown inFIG. 18, external connecting terminals120, such as solder balls, are formed on the other parts of the redistribution layers114, which are exposed through the openings118formed in the solder resist layer116.

Finally, as shown inFIG. 19, the resulting structure is cut into respective package units along a scribing line by performing a singulation process using a dicing apparatus, thus manufacturing a die package100shown inFIG. 11.

As described above, according to the present invention, an encapsulation layer having a thermal expansion coefficient higher than that of other constituents is formed on only the lateral side of a die, and the other side of the die is covered with a cheap support layer, so that the occurrence of the warpage of a die package due to the difference in thermal expansion coefficient between the encapsulation layer and other constituents is minimized, thereby improving the reliability of the die package and decreasing the production cost thereof.

Further, according to the present invention, an encapsulation layer is formed through a printing process or a dispensing process, so that the pressure applied to a die is minimized, with the result that the encapsulation layer can be formed without an additional process.

Further, according to the present invention, a support layer for supporting one side of a die is used after a manufacturing process as well as during the manufacturing process, so that an additional carrier member is not required, thereby simplifying the manufacturing process and decreasing the production cost of a die package.

Simple modifications, additions and substitutions of the present invention belong to the scope of the present invention, and the specific scope of the present invention will be clearly defined by the appended claims.