Semiconductor package device and method of manufacturing the same

The disclosure relates to an electronic module and a manufacturing method of the same. The electronic module includes a substrate, an electronic component, a first package body, a magnetic layer, a coil and a second package body. The electronic component is on the substrate. The first package body is on the substrate and covers the electronic component. The magnetic layer is on the first package body. The coil is on the magnetic layer. The coil includes a first section and a second section spaced from the first section. The first section and the second section are connected by a conductive material. The second package body is on the magnetic layer and covers the coil.

BACKGROUND

1. Technical Field

The present disclosure relates to a semiconductor package device and a method of manufacturing the same, and more particularly, to a semiconductor package device including a coil embedded therein and a method of manufacturing the same.

2. Description of the Related Art

Near-field communication (NFC) is a short-distance, high-frequency wireless communication technology and includes contact-free radio frequency identification (RFID) and interconnection technologies.

The NFC technology can be applied to products such as a credit card, an identification (ID) card, a smart phone or a wireless charger. It would be desirable to improve communication quality and to reduce a total package size of NFC devices.

SUMMARY

In accordance with some embodiments of the present disclosure, an electronic module includes a substrate, an electronic component, a first package body, a magnetic layer, a coil and a second package body. The electronic component is on the substrate. The first package body is on the substrate and covers the electronic component. The magnetic layer is on the first package body. The coil is on the magnetic layer. The coil includes a first section and a second section spaced from the first section. The first section and the second section are connected by a conductive material. The second package body is disposed on the magnetic layer and covers the coil.

In accordance with some embodiments of the present disclosure, an electronic module includes a substrate, an electronic component, a first package body, a magnetic layer, a plurality of pillars and a conductive wire. The electronic component is on the substrate. The first package body is on the substrate and covers the electronic component. The magnetic layer is on the first package body. The plurality of pillars are on the magnetic layer and are spaced from one another. The conductive wire connects each of the plurality of pillars.

In accordance with some embodiments of the present disclosure, an electronic module includes a substrate, an electronic component, a first package body, a magnetic layer, a plurality of conductive contacts and a plurality of conductive wires. The electronic component is on the substrate. The first package body is on the substrate and covers the electronic component. The magnetic layer is on the first package body. The plurality of conductive contacts are on the magnetic layer and are spaced from one another. Each of the plurality of conductive wires is connected between two conductive contacts.

DETAILED DESCRIPTION

In some embodiments of this disclosure, namely embodiments in which radio frequency identification (RFID) is used for near-field communication (NFC), an antenna structure is used for passive RFID, semi-passive RFID, or active RFID, each of which may benefit from improvements in communication quality and increased communication distance. Of these forms of RFID, in addition to challenges related to transmission through the antenna structure, passive RFID faces an additional challenge in that power to operate logic in a passive RFID device is received by way of an induced current from an associated antenna structure, and the received power should be sufficient to power the logic in the RFID device. Thus, in passive RFID devices, the antenna structure may be used both to receive a power transfer (the induced current) and to transmit information. Current may be induced in the antenna structure by passing the antenna through a magnetic field, such as a magnetic field generated by an RFID reader. The magnetic field is strongest closest to the source, and diminishes as a distance from the source increases. An improvement in the reception capability of the antenna structure may allow for an RFID device to receive sufficient power to operate the logic of the RFID device at an increased distance from a magnetic field source. Additionally, an improvement in the reception capability of the antenna may also improve the transmission capability of the antenna. Because of the additional challenges faced by passive RFID, this disclosure describes an antenna structure useful for improving a passive RFID device. However, an antenna structure according to some embodiments will also be useful for improving other NFC devices and non-NFC devices

FIG. 1Aillustrates a cross-sectional view of a semiconductor package device1in accordance with some embodiments of the present disclosure. The semiconductor package device1includes a substrate10, conductive pads18, electronic components11a,11b, package bodies12,16, a magnetically permeable layer (or magnetic layer)13, a coil15and an electrical connection17.

The substrate10may be, for example, a printed circuit board, such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated glass-fiber-based copper foil laminate. The substrate10may include an interconnection structure, such as a redistribution layer (RDL) or a grounding element. In some embodiments, the grounding element is a via exposed from a lateral surface of the substrate10. In some embodiments, the grounding element is a metal layer exposed from the lateral surface of the substrate10. In some embodiments, the grounding element is a metal trace exposed from the lateral surface of the substrate10. The substrate10may include opposite surfaces101and102. In some embodiments, the surface101of the substrate10is referred to as a top surface or a first surface and the surface102of the substrate10is referred to as a bottom surface or a second surface.

The electronic components11a,11bare disposed on the surface101of the substrate10. The electronic component11amay be a passive electronic component, such as a capacitor, a resistor or an inductor. The electronic component11bmay be an active electronic component, such as an integrated circuit (IC) chip or a die. Each electronic component11a,11bmay be electrically connected to one or more other electronic components and to the substrate10(e.g., to the RDL), and electrical connection may be attained by way of flip-chip or wire-bond techniques.

The package body (e.g., a first package body)12is disposed on the surface101of the substrate10and encapsulates the electronic components11a,11b. In some embodiments, the package body12includes an epoxy resin having fillers dispersed therein.

The magnetically permeable layer13is disposed on the package body12. In some embodiments, the magnetically permeable layer13is attached to the package body12through an adhesive layer19. In some embodiments, the magnetically permeable layer13may include a magnetic layer and a conductive layer which is electrically connected to a grounding pad on the surface101of the substrate10. The magnetically permeable layer13is, or includes, a material with high permeability and low magnetic saturation. The magnetically permeable layer13can be, or can include, for example, molybdenum (Mo), nickel (Ni), cobalt (Co), iron (Fe), iron-cobalt alloy (FeCo), iron-nickel alloy (FeNi), nickel-vanadium alloy (NiV), ferric oxide (Fe2O3), iron-manganese-zinc-oxide (Fe—Mn—Zn—O) or iron-nickel-zinc-oxide Fe—Ni—Zn—O or an alloy thereof, another magnetically permeable metal or metal alloy (e.g., another nickel-containing or iron-containing material), or a combination thereof. One measure of magnetic permeability of a material is in terms of its relative permeability with respect to a permeability of free space. Examples of suitable magnetically permeable materials for the magnetically permeable layer13include those having a relative permeability greater than about 1, such as at least about 2, at least about 5, at least about 10, at least about 50, at least about 100, at least about 500, at least about 1000, at least about 5000, at least about 104, at least about 105, or at least about 106. Magnetic permeability of a material can be measured at room temperature and at a particular field strength, such as about 0.5 Tesla or about 0.002 Tesla. In some embodiments, the permeability of the magnetically permeable layer13is in a range from about 500 henries per meter (H/m) to about 3000 H/m.

The coil15is disposed on the magnetically permeable layer13. The coil15is, or includes, a conductive material such as a metal or metal alloy. Examples of the conductive material include gold (Au), silver (Ag), aluminum (Al), copper (Cu), or an alloy thereof. The coil15can be magnetically coupled to a magnetic field to induce a current within the coil15. Thus, the coil15performs a function of a wireless receiver (e.g., a charging coil). In some embodiments, a thickness of the coil15is at least about 10 micrometers (μm). In some embodiments, the coil15includes a first section15aof the coil15and a second section15bof the coil15.

The package body (e.g., a second package body)16is disposed on the magnetically permeable layer13and encapsulates the coil15. In some embodiments, the package body16includes an epoxy resin having fillers dispersed therein. In some embodiments, a filler of the second package body16is smaller than a filler of the first package body12.

The electrical connection17penetrates the package body16, the magnetically permeable layer13and the package body12to electrically connect the coil15with a conductive pad10pon the surface101of the substrate10. In some embodiments, the induced current is provided to the electronic components11a,11bthrough the electrical connection17and the interconnection structure (e.g., the RDL) within the substrate10, so as to power the electronic components11a,11bor other electronic components external to the semiconductor package device1.

The conductive pads18are disposed on the surface102of the substrate10. The conductive pads18are used to provide electrical connections between the semiconductor package device1and external circuits. For example, the conductive pads18can be attached to a circuit board to be electrically connected with other electronic components on the circuit board.

FIG. 1Billustrates a top view of the semiconductor package device1in accordance with some embodiments of the present disclosure.

As shown inFIG. 1B, the coil15can be divided into two sections or parts15a1,15b1, which can be referred to as a first section or a first part15a1of the coil15and a second section or a second part15b1of the coil15. One terminal or a first terminal of each segment of the section15a1is connected to a corresponding segment of the section15b1, while another or second terminal of each segment of the section15a1is separated or spaced from a corresponding segment of the section15b1. The separated terminal of each segment of the section15a1is electrically connected to a corresponding terminal of a segment of the section15b1through a conductive material15p1to form the coil15. In some embodiments, the conductive material15p1is a same material as that of the coil15. Alternatively, the conductive material15p1and the coil15are formed from different materials. As shown inFIG. 1B, a separation is formed at a middle portion of the coil15. In other embodiments, the separation can be formed at any section of the coil (such as at a corner of the coil15) depending on specifications for designing circuits.

FIG. 1Cillustrates a top view of the semiconductor package device1in accordance with some embodiments of the present disclosure.

As shown inFIG. 1C, the coil15can be divided into two sections or parts15a2,15b2, which can be referred to as a first section or a first part15a2of the coil15and a second section or a second part15b2of the coil15. Two terminals of each segment of the section15a2are separated from corresponding segments of the section15b2. At both separated terminals of each segment, the section15a2is electrically connected to a corresponding segment of the section15b2through a conductive material15p2to form the coil15. In some embodiments, the conductive material15p2is made from a same material as that of the coil15. Alternatively, the conductive material15p2and the coil15are formed from different materials. As shown inFIG. 1C, a separation is formed at a middle portion of the coil15. In other embodiments, the separation can be formed at any portion of the coil (such as at a corner of the coil15) depending on specifications for designing circuits.

FIG. 1Dillustrates a top view of the semiconductor package device1in accordance with some embodiments of the present disclosure.

As shown inFIG. 1D, the coil15can be divided into four sections or parts15a3,15b3,15c3and15d3. The section15a3is electrically connected to the section15b3through a conductive material15p31. The section15b3is electrically connected to the section15c3through a conductive material15p32. The section15c3is electrically connected to the portion15d3through a conductive material15p33. The portion15d3is electrically connected to the portion15a3through a conductive material15p34. In some embodiments, the conductive materials15p31,15p32,15p33and15p34are a same material as that of the coil15. Alternatively, the conductive materials15p31,15p32,15p33and15p34and the coil15are formed from different materials. As shown inFIG. 1D, a separation is formed at a middle portion of the coil15. In other embodiments, the separation can be formed at any portion of the coil (such as at a corner of the coil15) depending on specifications for designing circuits. As shown inFIG. 1D, the coil15includes a single spiral inductor coil that includes a plurality of turns. Each turn of the plurality of turns includes at least one portion including at least one conductive material (e.g., the conductive material15p31,15p32,15p33, or15p34). The conductive material of a first turn of the plurality of turns is co-aligned with the conductive material of a second turn of the plurality of turns that is adjacent to the first turn.

To reduce a total size or area of a chip, a coil and other electronic components may be integrated into a single package. In some other approaches, a pitch of the coil is scaled down to miniaturize an inductor coil while keeping or improving performance. However, a stencil to make such a fine-pitched coil may not support a weight of the coil and may lead to deformation, which may cause various problems (e.g., turns of the coil may be shorted due to the deformation). In accordance with some embodiments (e.g., as shown inFIGS. 1B-1D), the coil15is divided into at least two sections and the separated sections are connected through a conductive material. Therefore, each segment of the separated portions of the coil15is much shorter than a total length of the coil without separation, so as to avoid deformation of the coil15.

FIG. 2Aillustrates a cross-sectional view of a semiconductor package device2in accordance with some embodiments of the present disclosure. The semiconductor package device2is similar to the semiconductor package device1shown inFIG. 1Aexcept that a coil25of the semiconductor package device2is different from the coil15of the semiconductor package device1.

As shown inFIG. 2A, a plurality of pillars25pare disposed on the magnetically permeable layer13. In some embodiments, the pillars25pare made of non-conductive material, such as non-conductive adhesive or epoxy resin.

A conductive wire251is disposed over the magnetically permeable layer13and connects one pillar to another pillar to form the coil25.

FIG. 2Billustrates a top view of the semiconductor package device2in accordance with some embodiments of the present disclosure.

As shown inFIG. 2B, the pillars25pare separated from each other and are arranged in a matrix structure. In other embodiments, the pillars25pcan be arranged in a circle or other shapes depending on specifications for designing circuits. The conductive wire251winds around the pillars25pand connects one pillar to another pillar to form the coil25. The conductive wire251contacts any one of the pillars once.

Conductive pads25c1and25c2are disposed on the magnetically permeable layer13. The conductive pads25c1and25c2are disposed at both terminals of the coil25to provide an electrical connection between the coil25and other electronic components.

FIG. 2Cillustrates a top view of the semiconductor package device2in accordance with some embodiments of the present disclosure. The top view of the semiconductor package device2shown inFIG. 2Cis similar to that shown inFIG. 2B, except that inFIG. 2C, the pillars25pare replaced by a plurality of conductive contacts25c.

As shown inFIG. 2C, the conductive contacts25care separated from each other and are arranged in a matrix structure. In other embodiments, the conductive contacts25ccan be arranged in a circle or other shapes depending on specifications for designing circuits. The conductive wire251winds around the conductive contacts25cand connects one conductive contact to another conductive contact to form the coil25. The conductive wire251contacts any one of the conductive contacts once. Each conductive contact25ccontacts no more than two segments of the conductive wire251(e.g., each conductive contact25ccontacts one segment or two segments).

In some other wireless devices, a coil may be built using electroplating. However, the use of electroplating may increase manufacturing cost. In addition, a thickness of the coil may be limited by electroplating time, which might lead to uneven thickness of the coil. As shown inFIGS. 2B and 2C, the coil25is formed by using a conductive wire251to wind around the pillars25por the conductive contacts25c, which may reduce manufacturing cost. In addition, since the thickness of the coil25can be easily determined by selecting the thickness of the conductive wire251, a trace number of the coil25can be increased. Therefore, the coil25shown inFIGS. 2B and 2Cmay have smaller resistance and higher Q factor, which may in turn increase a charging efficiency of the coil25.

FIG. 3illustrates a cross-sectional view of a semiconductor package device3in accordance with some embodiments of the present disclosure. The semiconductor package device3is similar to the semiconductor package device1shown inFIG. 1Aexcept that a coil35of the semiconductor package device3is different from the coil15of the semiconductor package device1and that the semiconductor package device3includes two electrical connections37a,37b.

The coil35is disposed over the magnetically permeable layer13. A surface351of the coil35is substantially coplanar with a surface161of the package body16. In other words, the surface351of the coil35is exposed from the package body16.

The electrical connection37apenetrates the package body16, the magnetically permeable layer13and the package body12to contact the conductive pad10p1of the substrate10. The electrical connection37bpenetrates the package body16, the magnetically permeable layer13and the package body12to contact a conductive pad10p2of the substrate10. The electrical connection37ais electrically connected to one terminal (e.g., a first terminal) of the coil35while the electrical connection37bis electrically connected with another terminal (e.g., a second terminal) of the coil35. The electrical connections37aand37bare used to electrically connect the coil35with the conductive pads10p1and10p2, respectively, so that induced current generated by the coil35can be provided to the electronic components11a,11bthrough the electrical connections37a,37band the interconnection structure (e.g., the RDL) within the substrate10. In some embodiments, the electrical connections37aand37bcan be applied to the semiconductor package device1or2shown inFIG. 1AorFIG. 2A. Similarly, the coil35shown inFIG. 3can be replaced by any of the coils shown inFIGS. 1A-1D, 2B and 2C, depending on specifications for designing circuits.

In some other wireless devices, electrical connections are located at an edge of a package. Therefore, a terminal at a center of a coil may be connected to the electrical connections through a long wire, which may cause a short circuit. By connecting the terminal at the center of the coil35to the substrate10through the adjacent electrical connection37b, as shown inFIG. 3, a short circuit can be avoided.

FIG. 4illustrates a cross-sectional view of a semiconductor package device4in accordance with some embodiments of the present disclosure. The semiconductor package device4is similar to the semiconductor package device1shown inFIG. 1Aexcept that the semiconductor package device4further includes an insulating layer44and that a magnetically permeable layer43is completely encapsulated by the package body12.

The insulating layer44is disposed over the package body12. In some embodiments, the insulating layer44and the package bodies12and16include a same material. Alternatively, the insulting layer44and the package bodies12and16are formed of different materials. The insulating layer44can be used to prevent a short circuit between the magnetically permeable layer43and the coil15.

The magnetically permeable layer43is disposed within the package body12. Accordingly, a lateral or side surface of the magnetically permeable layer43is not exposed from a lateral or side surface of the package body12. An area of the magnetically permeable layer43is less than that of the insulating layer44. In some embodiments, the area of the magnetically permeable layer43is substantially at least 95% of the area of the insulating layer44. Encapsulating the magnetically permeable layer43within the package body12may prevent the magnetically permeable layer43from oxidization.

In some embodiments, a width of the magnetically permeable layer43is greater than a diameter D2of the coil15. Therefore, the magnetically permeable layer43can prevent the electronic components11a,11bon the surface101of the substrate10from being interfered with by undesired magnetic fields passing through the coil15. The coil15shown inFIG. 4can be replaced by any of the coils shown inFIGS. 1A-1D, 2B, 2C and 3, depending on specifications for designing circuits.

FIGS. 5A-5Billustrate a semiconductor manufacturing method in accordance with some embodiments of the present disclosure.

Referring toFIG. 5A, a first section of conductive lines55aand a second section of conductive lines55bare disposed on the magnetically permeable layer13. The first section of conductive lines55aincludes segments55a1,55a2,55a3,55a4,55a5,55a6,55a7and55a8, and the segments55a1,55a2,55a3,55a4,55a5,55a6,55a7and55a8are separated from each other by respective gaps55g2. The second section of conductive lines55bincludes segments55b1,55b2,55b3,55b4,55b5,55b6,55b7and55b8, and the segments55b1,55b2,55b3,55b4,55b5,55b6,55b7and55b8are separated from each other by the respective gaps55g2. The first section of conductive lines55aand the second section of conductive lines55bare separated by a plurality of gaps55g1. For example, the segment55a1of the first section of conductive lines55ais separated from the segment55b1of the second section of conductive lines55bby the gap55g1. In some embodiments, the sections of conductive lines55aand55bcan be formed by printing a conductive material on the magnetically permeable layer13.

Referring toFIG. 5B, the gaps55g1are filled by a conductive material55p(e.g., a conductive adhesive) to electrically connect each segment of the first section of the conductive lines55awith a corresponding segment of the second section of the conductive lines55b. For example, the segment55a1is electrically connected to the segment55b1, the segment55a2is electrically connected to the segments55b1and55b2, the segment55a3is electrically connected to the segments55b2and55b3, and so on. In some embodiments, the conductive material55pis the same as a material of the sections of the conductive lines55aand55b. Alternatively, the conductive material55pand the sections of the conductive lines55aand55bare formed from different materials.

The gaps55g2are then filled by a non-conductive material to form the coil as shown inFIG. 1C. The non-conductive material can include, for example, a molding compound. In some embodiments, the non-conductive material and the package body12are formed from the same material. Alternatively, the non-conductive material and the package body12are formed from different materials. That is, a filler of the non-conductive material is smaller than that of the package body12. In some embodiments, after filling the gaps55g2, the package body16is formed to cover the coil, and the semiconductor package device1as shown inFIG. 1Ais formed.

FIGS. 6A-6Cillustrate a semiconductor manufacturing method in accordance with some embodiments of the present disclosure.

Referring toFIG. 6A, a substrate10is provided. The substrate10includes conductive pads10p1and10p2on its surface101. The substrate10may include an interconnection structure, such as an RDL or a grounding element. In some embodiments, the grounding element is a via exposed from a lateral or side surface of the substrate10. In some embodiments, the grounding element is a metal layer exposed from the lateral surface of the substrate10.

Electronic components11a,11bare disposed on the surface101of the substrate10. The electronic component11amay be a passive electronic component, such as a capacitor, a resistor or an inductor. The electronic component11bmay be an active electronic component, such as an IC chip or a die. The electronic component11a,11bmay be connected to the substrate10by flip-chip or wire-bond techniques.

The package body12is formed on the surface101of the substrate10and encapsulates the electronic components11a,11b. In some embodiments, the package body12includes an epoxy resin having fillers dispersed therein.

A magnetically permeable layer13is formed on the package body12. In some embodiments, the magnetically permeable layer13is attached to the package body12through an adhesive layer19. In some embodiments, the magnetically permeable layer13may include a magnetic layer and a conductive layer which is electrically connected to a grounding pad on the surface101of the substrate10.

The package body16is formed on the magnetically permeable layer13. In some embodiments, the package body16includes an epoxy resin having fillers dispersed therein.

Referring toFIG. 6B, a plurality of cavities60g1are formed from the surface161of the package body16into the package body16without completely penetrating the package body16. A through hole60g2is formed to penetrate the package body16, the magnetically permeable layer13and the package body12to expose the conductive pad10p2of the substrate10. A through hole60g3is formed to penetrate the package body16, the magnetically permeable layer13and the package body12to expose the conductive pad10p1of the substrate10. The cavities60g1and the through holes60g2and60g3can be formed by, for example, laser drilling, etching or other suitable processes.

Referring toFIG. 6C, the cavities60g1are filled with a conductive material to form a coil65. The through hole60g2is filled with a conductive material to form an electrical connection67aand the through hole60g3is filled with a conductive material to form an electrical connection67b. The electrical connection67ais electrically connected to one terminal of the coil65while the electrical connection67bis electrically connected to another terminal of the coil65. The electrical connections67aand67bare used to electrically connect the coil65with the conductive pads10p1and10p2, respectively, so that induced current generated by the coil65can be provided to the electronic components11a,11bthrough the electrical connections67a,67band the interconnection structure (e.g., the RDL) within the substrate10.

As used herein, the terms “substantially,” “substantial,” “approximately,” and “about” are used to denote and account for small variations. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation of less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. As another example, a thickness of a film or a layer being “substantially uniform” can refer to a standard deviation of less than or equal to ±10% of an average thickness of the film or the layer, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. The term “substantially coplanar” can refer to two surfaces within micrometers of lying along a same plane, such as within 40 within 30 within 20 within 10 or within 1 μm of lying along the same plane. Two surfaces or components can be deemed to be “substantially perpendicular” if an angle therebetween is, for example, 90°±10°, such as ±5°, ±4°, ±3°, ±2°, ±1°, ±0.5°, ±0.1°, or ±0.05°. When used in conjunction with an event or circumstance, the terms “substantially,” “substantial,” “approximately,” and “about” can refer to instances in which the event or circumstance occurs precisely, as well as instances in which the event or circumstance occurs to a close approximation.

In the description of some embodiments, a component provided “on” another component can encompass cases where the former component is directly on (e.g., in physical contact with) the latter component, as well as cases where one or more intervening components are located between the former component and the latter component.

Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It can be understood that such range formats are used for convenience and brevity, and should be understood flexibly to include not only numerical values explicitly specified as limits of a range, but also all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.