Device structure

A device structure includes a first electronic structure and a plurality of first electric contacts. The first electronic structure has a surface and a center. The first electric contacts are exposed from the surface. The first electric contacts are spaced by a pitch that increases with increasing distance from the center.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates to a device structure, and to a device structure including a plurality of electric contacts.

2. Description of the Related Art

In the chip last process, a semiconductor die may be electrically connected to a plurality of pads of a redistribution layer (RDL) through a plurality of copper-pillar bumps. Since the coefficient of thermal expansion (CTE) of the redistribution layer is greater than the CTE of the semiconductor die, the peripheral pads of the RDL may generate a large outward displacement relative to the central pads due to thermal expansion in a solder reflow process, thereby causing a misalignment between the pads of the RDL and the copper-pillar bumps. Said misalignment may cause the cu-pillar bumps to crack during a reliability test. In a worst case, some of the copper-pillar bumps of the semiconductor die may be not bonded to the predetermined pads of the RDL.

SUMMARY

In some embodiments, a device structure includes a first electronic structure and a plurality of first electric contacts. The first electronic structure has a surface and a center. The first electric contacts are exposed from the surface. The first electric contacts are spaced by a pitch that increases with increasing distance from the center.

In some embodiments, a device structure includes a first electronic structure and a plurality of first electric contacts. The first electronic structure has a surface and a center. The first electric contacts are exposed from the surface. Each of the first electric contacts has a maximum length along a long axis thereof. The long axis extends through the center. The maximum length increases with increasing distance from the center.

In some embodiments, a device structure includes a first electronic structure, a plurality of first electric contacts and at least one alignment mark. The first electronic structure has a surface and a center. The first electric contacts are exposed from the surface. The alignment mark is disposed adjacent to at least one of the first electric contacts. The alignment mark is disposed at an axis extending through the center of the first electronic structure.

DETAILED DESCRIPTION

FIG. 1illustrates a perspective view of a device structure1according to some embodiments of the present disclosure.FIG. 2illustrates a top view ofFIG. 1.FIG. 3illustrates a cross-sectional view ofFIG. 1. Referring toFIG. 1throughFIG. 3, the device structure1includes a first electronic structure10and a plurality of first electric contacts20.

The first electronic structure10may be, for example, a substrate or a semiconductor die. The first electronic structure10has a surface15(e.g., a top surface), a central area16, a peripheral area18and a center C1. The central area16and the peripheral area18are defined on the surface15. The peripheral area18surrounds the central area16. The center C1is within the central area16. Further, the first electronic structure10may define a plurality of axes (including, for example, the axes R1, R2, R3) extending through the center C1. As shown inFIG. 2, there is an included angle θ between two nearest axes (e.g., the axes R1and R2).

As shown inFIG. 1andFIG. 3, the first electronic structure10may include a base11and a redistribution structure12. A material of the base11may be, for example, organic material or inorganic material. The redistribution structure12may be disposed on the base11(e.g., a top surface of the base11). The surface15may be a top surface of the redistribution structure12. In some embodiments, the redistribution structure12may include at least one dielectric layer121and at least one circuit layer122. The circuit layer122is embedded in the dielectric layer121.

The first electric contacts20are disposed on and electrically connected to the redistribution structure12of the first electronic structure10. The first electric contacts20may be metal pads or metal bumps. In some embodiments, the first electric contacts20may extend through the dielectric layer121and be electrically connected to the circuit layer122of the redistribution structure12. Further, the first electric contacts20are exposed from the surface15(e.g., the top surface of the redistribution structure12) of the first electronic structure10.

As shown inFIG. 2andFIG. 3, the first electric contacts20are spaced by a pitch (including, for example, the pitch P, the pitch P1and the pitch P2) that increases with increasing distance from the center C1of the first electronic structure10. The first electric contacts20may be disposed at the axes (including, for example, the axes R1, R2, R3). In some embodiments, the centers of the first electric contacts20may be disposed at the axes (including, for example, the axes R1, R2, R3). That is, the axes (including, for example, the axes R1, R2, R3) extend through the centers of the first electric contacts20. As shown inFIG. 2andFIG. 3, the first electric contacts20are arranged in an array with a plurality of concentric loops. The loops of first electric contacts20are spaced by a pitch (including, for example, the pitch P, the pitch P1and the pitch P2) that increases with increasing distance from the center C1of the first electronic structure10.

The first electric contacts20may include at least one central electric contact21, a plurality of inner electric contacts22and a plurality of outer electric contacts23. The central electric contact21is disposed in the central area16of the first electronic structure10. For example, the central electric contact21may be disposed at the center C1. However, there may be a plurality of central electric contacts21disposed in the central area16. The inner electric contacts22are disposed in the peripheral area18and adjacent to the central area16. The outer electric contacts23are disposed in the peripheral area18and far away the central area16. In some embodiments, the pitch P1between the outer electric contact23and the inner electric contact22nearest to the outer electric contact23may be greater than the pitch P between the inner electric contact22and the central electric contact21nearest to the inner electric contact22. Further, the pitch P2between two adjacent outer electric contacts23may be greater than the pitch P1between the outer electric contact23and the inner electric contact22nearest to the outer electric contact23.

As shown in the embodiment illustrated inFIG. 1throughFIG. 3, the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) are spaced by the pitch (including, for example, the pitch P, the pitch P1and the pitch P2) that increases with increasing distance from the center C1of the first electronic structure10. The designed pitch (including, for example, the pitch P, the pitch P1and the pitch P2) between the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) may correct positional deviations of the first electric contacts20caused by the outward displacement of the first electric contacts20due to thermal expansion in a solder reflow process, thereby preventing the first electric contacts20from misalignment in the solder reflow process.

FIG. 4illustrates a top view of a device structure1aaccording to some embodiments of the present disclosure. The device structure1ais similar to the device structure1shown inFIG. 1throughFIG. 3, except for the configurations of the first electric contacts20. In some embodiments, the centers of some of the first electric contacts20may not be disposed at the axes (including, for example, the axes R1, R2, R3). That is, the axes (including, for example, the axes R1, R2, R3) may not extend through the centers of some of the first electric contacts20. There may be a shift between the axes (including, for example, the axes R1, R2, R3) and the centers of some of the first electric contacts20.

FIG. 5illustrates an exploded view of a device structure1baccording to some embodiments of the present disclosure.FIG. 6illustrates an assembled view ofFIG. 5.FIG. 7illustrates a top view ofFIG. 6.FIG. 8illustrates a cross-sectional view ofFIG. 6. Referring toFIG. 5throughFIG. 8, the device structure1bis similar to the device structure1shown inFIG. 1throughFIG. 3, except that the device structure1bfurther includes a second electronic structure30and a plurality of second electric contacts40.

The second electronic structure30may be, for example, a substrate or a semiconductor die. The second electronic structure30corresponds to the first electronic structure10. The second electronic structure30has a surface35(e.g., a bottom surface) and a center C2. The surface35faces the first electronic structure10. The center C2corresponds to the center C1of the first electronic structure10.

As shown inFIG. 5andFIG. 8, the second electronic structure30may include a base31and a circuit structure32. A material of the base31may be, for example, organic material or inorganic material. The circuit structure32may be disposed on the base31(e.g., a bottom surface of the base31). The surface35may be a bottom surface of the circuit structure32. In some embodiments, the circuit structure32may include at least one passivation layer321and at least one circuit layer322. The circuit layer322is embedded in the passivation layer321.

As shown inFIG. 7andFIG. 8, the second electric contacts40correspond to the first electric contacts20. The second electric contacts40are disposed on and electrically connected to the circuit structure32of the second electronic structure30. The second electric contacts40may be metal pads or metal bumps. In some embodiments, the second electric contacts40may extend through the passivation layer321and be electrically connected to the circuit layer322of the circuit structure32. Further, the second electric contacts40are exposed from the surface35(e.g., the bottom surface of the circuit structure32) of the second electronic structure30.

In some embodiments, a pitch P3between two adjacent second electric contacts40may be greater than the pitch P between the inner electric contact22and the central electric contact21nearest to the inner electric contact22and the pitch P1between the outer electric contact23and the inner electric contact22nearest to the outer electric contact23. Further, the pitches P3between the second electric contacts40may be substantially the same.

In some embodiments, the first electronic structure10may be a substrate, thus, the first electric contacts20may be metal pads. The second electronic structure30may be a semiconductor die, thus, the second electric contacts40may be metal bumps. That is, the coefficient of thermal expansion (CTE) of the first electronic structure10may be greater than the CTE of the second electronic structure30, and the first electric contacts20(e.g., metal pads) may generate an outward displacement relative to the corresponding second electric contacts40(e.g., metal bumps) due to thermal expansion in the solder reflow process.

FIG. 9illustrates a cross-sectional view ofFIG. 6during a solder reflow process.FIG. 10illustrates a cross-sectional view ofFIG. 6after a solder reflow process. Referring toFIG. 9andFIG. 10, the second electric contacts40may be bonded to the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) through at least one solder material70. As shown inFIG. 9, during the solder reflow process, the solder material70are melted to join the second electric contacts40and the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23). As shown inFIG. 9, the first electric contacts20disposed in the peripheral area18(e.g., the inner electric contacts22and the outer electric contacts23) are misaligned with the corresponding second electric contacts40at the beginning of the solder reflow process. The misalignment may cause the solder material70, the first electric contacts20or the second electric contacts40to crack during a reliability test.

As shown inFIG. 10, the designed pitch (including, for example, the pitch P, the pitch P1and the pitch P2) between the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) may correct positional deviations of the first electric contacts20caused by the outward displacement of the first electric contacts20, thereby preventing the first electric contacts20from misalignment with the second electric contacts40in the solder reflow process. Thus, after the solder reflow process, the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) are aligned with the second electric contacts40.

FIG. 11illustrates a perspective view of a device structure1caccording to some embodiments of the present disclosure.FIG. 12illustrates a top view ofFIG. 11.FIG. 13illustrates a cross-sectional view ofFIG. 11. Referring toFIG. 11throughFIG. 13, the device structure1cis similar to the device structure1shown inFIG. 1throughFIG. 3, except for the structures of the first electric contacts20a. In some embodiments, each of the first electric contacts20ahas a maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) along a long axis (including, for example, the long axis X, the long axis X1and the long axis X2) thereof. The long axis (including, for example, the long axis X, the long axis X1and the long axis X2) extends through the center C1of the first electronic structure10. The maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) of each of the first electric contacts20aincreases with increasing distance from the center C1of the first electronic structure10.

The first electric contacts20amay include at least one central electric contact21a, a plurality of inner electric contacts22aand a plurality of outer electric contacts23a. The central electric contact21ais disposed in the central area16of the first electronic structure10. The inner electric contacts22aare disposed in the peripheral area18and adjacent to the central area16. The outer electric contacts23aare disposed in the peripheral area18and far away the central area16. In some embodiments, the maximum length L1of each of the inner electric contacts22amay be greater than the maximum length L of the central electric contact21a, and the maximum length L2of each of the outer electric contacts23amay greater than the maximum length L1of each of the inner electric contacts22a. In some embodiments, the first electric contacts20a(including, for example, the inner electric contacts22aand the outer electric contacts23a) may be in an oval shape.

As shown in the embodiment illustrated inFIG. 11throughFIG. 13, the maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) of each of the first electric contacts20aincreases with increasing distance from the center C1of the first electronic structure10. The designed maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) of each of the first electric contacts20amay compensate positional deviations of the first electric contacts20acaused by the outward displacement of the first electric contacts20adue to thermal expansion in the solder reflow process, thereby preventing the first electric contacts20afrom misalignment in the solder reflow process.

FIG. 14illustrates an exploded view of a device structure1daccording to some embodiments of the present disclosure.FIG. 15illustrates an assembled view ofFIG. 14.FIG. 16illustrates a top view ofFIG. 15.FIG. 17illustrates a cross-sectional view ofFIG. 15. Referring toFIG. 14throughFIG. 17, the device structure1dis similar to the device structure1cshown inFIG. 11throughFIG. 13, except that the device structure1dfurther includes a second electronic structure30aand a plurality of second electric contacts40a.

The second electronic structure30amay be, for example, a substrate or a semiconductor die. The second electronic structure30acorresponds to the first electronic structure10. The second electronic structure30ahas a surface35a(e.g., a bottom surface) and a center C2a. The surface35afaces the first electronic structure10. The center C2acorresponds to the center C1of the first electronic structure10.

As shown inFIG. 14andFIG. 17, the second electronic structure30amay include a base31aand a circuit structure32a. A material of the base31amay be, for example, organic material or inorganic material. The circuit structure32amay be disposed on the base31a(e.g., a bottom surface of the base31a). The surface35amay be a bottom surface of the circuit structure32a. In some embodiments, the circuit structure32amay include at least one passivation layer321aand at least one circuit layer322a. The circuit layer322ais embedded in the passivation layer321a.

As shown inFIG. 16andFIG. 17, the second electric contacts40acorrespond to the first electric contacts20a. The second electric contacts40aare disposed on and electrically connected to the circuit structure32aof the second electronic structure30a. In some embodiments, the second electric contacts40amay extend through the passivation layer321aand be electrically connected to the circuit layer322aof the circuit structure32a. Further, the second electric contacts40aare exposed from the surface35a(e.g., the bottom surface of the circuit structure32a) of the second electronic structure30a.

In some embodiments, the maximum length L1of each of the inner electric contacts22amay be greater than a maximum length L3of each of the second electric contacts40a, and the maximum length L2of each of the outer electric contacts23amay also be greater than the maximum length L3of each of the second electric contacts40a.

In some embodiments, the first electronic structure10may be a substrate, thus, the first electric contacts20amay be metal pads. The second electronic structure30amay be a semiconductor die, thus, the second electric contacts40amay be metal bumps. That is, the CTE of the first electronic structure10may be greater than the CTE of the second electronic structure30a, and the first electric contacts20a(e.g., metal pads) may generate an outward displacement relative to the corresponding second electric contacts40a(e.g., metal bumps) due to thermal expansion in the solder reflow process.

FIG. 18illustrates a cross-sectional view ofFIG. 15during a solder reflow process.FIG. 19illustrates a cross-sectional view ofFIG. 15after a solder reflow process. Referring toFIG. 18andFIG. 19, the second electric contacts40amay be bonded to the first electric contacts20a(including, for example, the central electric contact21a, the inner electric contacts22aand the outer electric contacts23a) through at least one solder material70a. As shown inFIG. 18, during the solder reflow process, the solder material70aare melted to join the second electric contacts40aand the first electric contacts20a(including, for example, the central electric contact21a, the inner electric contacts22aand the outer electric contacts23a). As shown inFIG. 19, the designed maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) of each of the first electric contacts20a(including, for example, the central electric contact21a, the inner electric contacts22aand the outer electric contacts23a) may compensate positional deviations of the first electric contacts20acaused by the outward displacement of the first electric contacts20a, thereby preventing the first electric contacts20afrom misalignment with the second electric contacts40ain the solder reflow process.

FIG. 20illustrates a perspective view of a device structure1eaccording to some embodiments of the present disclosure.FIG. 21illustrates a top view ofFIG. 20.FIG. 22illustrates a cross-sectional view ofFIG. 20. Referring toFIG. 20throughFIG. 22, the device structure1eis similar to the device structure1shown inFIG. 1throughFIG. 3, except that the device structure1efurther includes at least one alignment mark50. The alignment mark50may be disposed adjacent to at least one of the first electric contacts20. In some embodiments, the alignment mark50may be disposed adjacent to the outer electric contact23or the central electric contact21.

As shown inFIG. 21, the alignment mark50may be disposed at an axis Y extending through the center C1of the first electronic structure10. Further, the axis Y may extend through a center of the first electric contact20(e.g., the outer electric contact23). In addition, the first electric contact20may be disposed between the center C1of the first electronic structure10and the alignment mark50. In some embodiments, the alignment mark50may be disposed between the center C1of the first electronic structure10and the first electric contact20(e.g., the inner electric contacts22).

In some embodiments, a pitch between the first electric contact20and the alignment mark50may be less than a pitch between two adjacent first electric contacts20.

As shown inFIG. 22, a position of the alignment mark50may be lower than a position of the first electric contacts20. For example, the alignment mark50may be embedded in the redistribution structure12of the first electronic structure10. In some embodiments, the alignment mark50may be embedded in the dielectric layer121and disposed adjacent to the circuit layer122. In some embodiments, the alignment mark50may be a portion of the circuit layer122. Further, a size of the alignment mark50may be less than a size of the first electric contact20.

FIG. 23illustrates an exploded view of a device structure if according to some embodiments of the present disclosure.FIG. 24illustrates an assembled view ofFIG. 23.FIG. 25illustrates a top view ofFIG. 24.FIG. 26illustrates a cross-sectional view ofFIG. 24. Referring toFIG. 23throughFIG. 26, the device structure if is similar to the device structure1eshown inFIG. 20throughFIG. 22, except that the device structure if further includes a second electronic structure30band a plurality of second electric contacts40b.

The second electronic structure30bmay be, for example, a substrate or a semiconductor die. The second electronic structure30bcorresponds to the first electronic structure10. The second electronic structure30bhas a surface35b(e.g., a bottom surface) and a center C2b. The surface35bfaces the first electronic structure10. The center C2bcorresponds to the center C1of the first electronic structure10.

As shown inFIG. 23andFIG. 26, the second electronic structure30bmay include a base31band a circuit structure32b. A material of the base31bmay be, for example, organic material or inorganic material. The circuit structure32bmay be disposed on the base31b(e.g., a bottom surface of the base31b). The surface35bmay be a bottom surface of the circuit structure32b. In some embodiments, the circuit structure32bmay include at least one passivation layer321band at least one circuit layer322b. The circuit layer322bis embedded in the passivation layer321b.

As shown inFIG. 25andFIG. 26, the second electric contacts40bcorrespond to the first electric contacts20. The second electric contacts40bare disposed on and electrically connected to the circuit structure32bof the second electronic structure30b. In some embodiments, the second electric contacts40bmay extend through the passivation layer321band be electrically connected to the circuit layer322bof the circuit structure32b. Further, the second electric contacts40bare exposed from the surface35b(e.g., the bottom surface of the circuit structure32b) of the second electronic structure30b.

In some embodiments, the alignment mark50may correspond to a portion of at least one of the second electric contacts40bto improve the alignment between the first electric contacts20and the second electric contacts40b. Further, a size of the alignment mark50may be less than a size of each of the second electric contacts40b.

Before the solder reflow process, the second electric contacts40bmay be aligned with the first electric contacts20through the alignment mark50. For example, the alignment mark50adjacent to the most peripheral outer electric contact23may correspond to a portion of the most peripheral second electric contact40bto achieve the alignment between the second electric contacts40band the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23).

In some embodiments, the first electronic structure10may be a substrate, thus, the first electric contacts20may be metal pads. The second electronic structure3bmay be a semiconductor die, thus, the second electric contacts40bmay be metal bumps.

FIG. 27illustrates a top view of a device structure1gaccording to some embodiments of the present disclosure.FIG. 28illustrates a cross-sectional view ofFIG. 27. Referring toFIG. 27throughFIG. 28, the device structure1gis similar to the device structure if shown inFIG. 23throughFIG. 26, except for the configuration of the alignment mark50a. In some embodiments, the alignment mark50amay be disposed adjacent to at least one of the second electric contacts40b.

The alignment mark50amay be embedded in the circuit structure32bof the second electronic structure30b. In some embodiments, the alignment mark50amay be embedded in the passivation layer321band disposed adjacent to the circuit layer322b. Further, the alignment mark50amay correspond to a portion of at least one of the first electric contacts20(e.g., the outer electric contact23) to improve the alignment between the first electric contacts20and the second electric contacts40b.

FIG. 29illustrates a cross-sectional view of a device structure1haccording to some embodiments of the present disclosure. The device structure1his similar to the device structure1bshown inFIG. 5throughFIG. 8, except for the configurations of the first electronic structure10, the first electric contacts20, the second electronic structure30and the second electric contacts40. In some embodiments, the first electronic structure10may be a semiconductor die, thus, the first electric contacts20may be metal bumps. The second electronic structure30may be a substrate, thus, the second electric contacts40may be metal pads. That is, the CTE of the second electronic structure30may be greater than the CTE of the first electronic structure10, and the second electric contacts40(e.g., metal pads) may generate an outward displacement relative to the corresponding first electric contacts20(e.g., metal bumps) due to thermal expansion in the solder reflow process. However, the designed pitch (including, for example, the pitch P, the pitch P1and the pitch P2) between the first electric contacts20(including, for example, the central electric contact21, the inner electric contacts22and the outer electric contacts23) may compensate positional deviations of the second electric contacts40caused by the outward displacement of the second electric contacts40, thereby preventing the second electric contacts40from misalignment with the first electric contacts20in the solder reflow process.

FIG. 30illustrates a cross-sectional view of a device structure1iaccording to some embodiments of the present disclosure. The device structure1iis similar to the device structure1dshown inFIG. 14throughFIG. 17, except for the configurations of the first electronic structure10, the first electric contacts20a, the second electronic structure30aand the second electric contacts40a. In some embodiments, the first electronic structure10may be a semiconductor die, thus, the first electric contacts20amay be metal bumps. The second electronic structure30amay be a substrate, thus, the second electric contacts40amay be metal pads. That is, the CTE of the second electronic structure30amay be greater than the CTE of the first electronic structure10, and the second electric contacts40a(e.g., metal pads) may generate an outward displacement relative to the corresponding first electric contacts20a(e.g., metal bumps) due to thermal expansion in the solder reflow process. However, the designed maximum length (including, for example, the maximum length L, the maximum length L1and the maximum length L2) of each of the first electric contacts20a(including, for example, the central electric contact21a, the inner electric contacts22aand the outer electric contacts23a) may compensate positional deviations of the second electric contacts40acaused by the outward displacement of the second electric contacts40a, thereby preventing the second electric contacts40afrom misalignment with the first electric contacts20ain the solder reflow process.

FIG. 31illustrates a schematic view of a first electric contact20baccording to some embodiments of the present disclosure. The first electric contact20bofFIG. 31includes a contact portion201band an alignment portion202bconnected to the contact portion201b. In some embodiments, a size of the alignment portion202bmay be less than a size of the contact portion201b.

FIG. 32illustrates a schematic view of a first electric contact20caccording to some embodiments of the present disclosure. The first electric contact20cofFIG. 32includes a first contact portion201c, a second contact portion202copposite to the first contact portion201cand an intermediate contact portion203cbetween the first contact portion201cand the second contact portion202c. The intermediate contact portion203cmay be connected to the first contact portion201cand the second contact portion202c. In some embodiments, a shape of the first contact portion201cmay be the same or similar to a shape of the second contact portion202c.

FIG. 33illustrates a schematic view of a first electric contact20daccording to some embodiments of the present disclosure. The first electric contact20dofFIG. 33is similar to the first electric contact20cofFIG. 32, except that the shapes of the first contact portion201c, the second contact portion202cand the intermediate contact portion203c.