SENSOR PACKAGE STRUCTURE AND MANUFACTURING METHOD THREROF

A sensor package structure and a manufacturing method thereof are provided. The sensor package structure includes a substrate, a fixing adhesive layer disposed on the substrate, a sensor chip adhered to the fixing adhesive layer, an annular adhering layer disposed on the sensor chip, a light-permeable sheet adhered to the annular adhering layer, and a plurality of metal wires that are electrically coupled to the substrate and the sensor chip. The size of the light-permeable sheet is smaller than that of the sensor chip.

FIELD OF THE DISCLOSURE

The present disclosure relates to a package structure, and more particularly to a sensor package structure and a manufacturing method thereof.

BACKGROUND OF THE DISCLOSURE

Based on an existing structural configuration of a conventional sensor package structure, the conventional sensor package structure is manufactured by fixing a sensor chip onto a substrate and then assembling a light-permeable sheet to the sensor chip. However, before the light-permeable sheet is assembled to the sensor chip, a sensing region of the sensor chip is easily contaminated or damaged in a manufacturing process or before a packaging process, thereby reducing the accuracy and yield rate of the sensing region.

SUMMARY OF THE DISCLOSURE

In response to the above-referenced technical inadequacies, the present disclosure provides a sensor package structure and a manufacturing method thereof for effectively improving on the issues associated with conventional sensor package structures and conventional manufacturing methods thereof.

In order to solve the above-mentioned problems, one of the technical aspects adopted by the present disclosure is to provide a manufacturing method of a sensor package structure, which includes a preparing step, a first bonding step, a slicing step, and a second bonding step. The preparing step is implemented by providing a wafer and a plurality of light-permeable sheets that are separate from each other. The wafer defines a plurality of sensor chips connected to each other, and a size of each of the sensor chips is greater than a size of any one of the light-permeable sheets. The first bonding step is implemented by adhering a top surface of each of the sensor chips with one of the light-permeable sheets by having an annular adhering layer sandwiched therebetween. Each of the sensor chips, the corresponding annular adhering layer, and the corresponding light-permeable sheet are jointly defined as a sensing module and jointly define an enclosed space therein. In any one of the sensing modules, a sensing region of the sensor chip is arranged in the enclosed space, and a plurality of connection pads of the sensor chip are arranged outside of the annular adhering layer. The slicing step is implemented by holding and slicing the wafer to separate the sensing modules from each other. The second bonding step is implemented by fixing one of the sensing modules onto an upper surface of a substrate and wire-bonding a plurality of bonding pads of the substrate and the connection pads of the one of the sensing modules through metal wires.

In order to solve the above-mentioned problems, another one of the technical aspects adopted by the present disclosure is to provide a sensor package structure, which includes a substrate, a fixing adhesive layer, a sensing module, and a plurality of metal wires. The substrate has a module-fixing region arranged on an upper surface thereof and a plurality of bonding pads that are arranged on the upper surface and that are located outside of the module-fixing region. The fixing adhesive layer is disposed on the module-fixing region of the substrate. The sensing module is fixed to the substrate through the fixing adhesive layer, and includes a sensor chip, an annular adhering layer, and a light-permeable sheet. The sensor chip is adhered to the fixing adhesive layer through a bottom surface thereof. The bottom surface of the sensor chip has a plurality of columnar microstructures embedded in the fixing adhesive layer, and a top surface of the sensor chip includes a sensing region and a plurality of connection pads that are arranged outside of the sensing region. The annular adhering layer is disposed on the top surface of the sensor chip. The annular adhering layer surrounds the sensing region, and the connection pads are located outside of the annular adhering layer. The light-permeable sheet is disposed on the annular adhering layer. The light-permeable sheet, the annular adhering layer, and the sensor chip jointly define an enclosed space, and a projection region defined by orthogonally projecting the light-permeable sheet onto the top surface of the sensor chip is located inside of the connection pads by a distance. The metal wires are respectively connected to the bonding pads of the substrate and the connection pads of the sensor chip so as to establish an electrical connection between the substrate and the sensor chip.

In order to solve the above-mentioned problems, yet another one of the technical aspects adopted by the present disclosure is to provide a sensor package structure, which includes a substrate, a fixing adhesive layer, a sensing module, and a plurality of metal wires. The substrate has a module-fixing region arranged on an upper surface thereof and a plurality of bonding pads that are arranged on the upper surface and that are located outside of the module-fixing region. The fixing adhesive layer is disposed on the module-fixing region of the substrate. The sensing module is fixed to the substrate through the fixing adhesive layer, and includes a sensor chip, an annular adhering layer, and a light-permeable sheet. The sensor chip is adhered to the fixing adhesive layer through a bottom surface thereof. Moreover, a top surface of the sensor chip includes a sensing region and a plurality of connection pads that are arranged outside of the sensing region. The annular adhering layer is disposed on the top surface of the sensor chip. The annular adhering layer surrounds the sensing region, and the connection pads are located outside of the annular adhering layer. The light-permeable sheet is disposed on the annular adhering layer. The light-permeable sheet, the annular adhering layer, and the sensor chip jointly define an enclosed space, and a projection region defined by orthogonally projecting the light-permeable sheet onto the top surface of the sensor chip is located inside of the connection pads by a distance. The metal wires are respectively connected to the bonding pads of the substrate and the connection pads of the sensor chip so as to establish an electrical connection between the substrate and the sensor chip.

Therefore, the manufacturing method of the present disclosure can be implemented by adhering the light-permeable sheet having a smaller size onto the sensor chip to jointly form the sensing module (e.g., the light-permeable sheet and the annular adhering layer are used to surround the sensing region) so as to arrange the sensing region of the sensor chip in the enclosed space of the sensing module, and then fixing the sensing module onto the substrate, thereby effectively preventing the sensing region of the sensor chip from being contaminated or damaged in a manufacturing process of the sensor package structure.

Moreover, in the sensing module of the sensor package structure provided by the present disclosure, an expansion part generated from the annular adhering layer having a larger coefficient of thermal expansion (CTE) can be received in the enclosed space, thereby preventing the light-permeable sheet or the sensing region from being damaged and squeezed by the expansion part.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

First Embodiment

Referring toFIG.1toFIG.7, a first embodiment of the present disclosure is provided. As shown inFIG.1, the present embodiment provides a manufacturing method S100of a sensor package structure, which includes (or is implemented by) a preparing step S110, a first bonding step S120, a slicing step S130, a second bonding step S140, and a packaging step S150.

The present embodiment sequentially describes the steps S110-S150of the manufacturing method S100, but the present disclosure is not limited thereto. For example, in other embodiments of the present disclosure not shown in the drawings, any one of the steps S110-S150of the manufacturing method S100can be adjusted, added, or canceled (e.g., the packaging step S150can be omitted according to design requirements).

As shown inFIG.1toFIG.3, the preparing step S110is implemented by providing a wafer31aand a plurality of light-permeable sheets33that are separate from each other. The wafer31adefines a plurality of sensor chips31(integrally) connected to each other, and a size of each of the sensor chips31is greater than a size of any one of the light-permeable sheets33. The light-permeable sheets33are limited to being unconnected to each other, and any one of the light-permeable sheets33in the present embodiment is an individual component and can be a flat piece of glass, but the present disclosure is not limited thereto. In other words, any light-permeable sheet having a size greater than or equal to a size of the sensor chip31is different from the light-permeable sheet33of the present embodiment.

As shown inFIG.1andFIG.3, the first bonding step S120is implemented by adhering a top surface311of each of the sensor chips31with one of the light-permeable sheets33by having an annular adhering layer32sandwiched therebetween. Each of the sensor chips31, the corresponding annular adhering layer32, and the corresponding light-permeable sheet33are jointly defined as a sensing module3and jointly define an enclosed space S therein. Moreover, in any one of the sensing modules3, a sensing region3111of the sensor chip31is arranged in the enclosed space S, and a plurality of connection pads3113of the sensor chip31are arranged outside of the annular adhering layer32.

Furthermore, in any one of the sensing modules3, the annular adhering layer32can be adhered to the top surface311of the sensor chips31, and then the light-permeable sheets33is adhered to the annular adhering layer32; or, the annular adhering layer32can be adhered to the light-permeable sheets33, and then the light-permeable sheets33is adhered to the top surface311of the sensor chips31through the annular adhering layer32; or, a glass board and a glue layer formed thereon are sliced to form the light-permeable sheets33and the annular adhering layers32respectively adhered thereon (e.g., before the first bonding step S120, the light-permeable sheets33can be provided by the glass board that is not sliced yet), and then any one of the light-permeable sheets33is adhered to the top surface311of one of the sensor chips31through the annular adhering layer32, but the present disclosure is not limited thereto.

Specifically, in each of the sensing modules3, a projection region defined by orthogonally projecting the light-permeable sheet33onto the top surface311of the sensor chip31is located inside of the connection pads3113and is spaced apart from each of the connection pads3113by a distance G (shown inFIG.7). In other words, any configuration not meeting the above connection relationship of the light-permeable sheet33and the sensor chip31is different from the sensing module3of the present embodiment.

As shown inFIG.1,FIG.3, andFIG.4, the slicing step S130is implemented by holding and slicing the wafer31ato separate the sensing modules3from each other. In the present embodiment, the light-permeable sheets33are spaced from each other through a checkerboard-like channel, so that a slicing tool or a laser beam (not shown in the drawings) can pass through and move along the checkerboard-like channel to slice the wafer31a. In other words, the light-permeable sheets33in the slicing step S130are not in contact with the slicing tool.

It should be noted that the slicing step S130in the present embodiment is limited to be implemented by slicing a single component (e.g., the wafer31a), thereby preventing the relative position between the components of each of the sensing modules3from being affected due to more than one of the components of each of the sensing modules3being sliced. Accordingly, any slicing process implemented by slicing at least two components is different from the slicing step S130of the present embodiment.

As shown inFIG.1andFIG.5, the second bonding step S140is implemented by fixing one of the sensing modules3onto an upper surface11of a substrate1and wire-bonding a plurality of bonding pads112of the substrate1and the connection pads3113of the one of the sensing modules3through metal wires4. In the present embodiment, the one of the sensing modules3is fixed onto the upper surface11of the substrate1through a fixing adhesive layer2.

Specifically, in the one of the sensing modules3, a bottom surface312of the sensor chip31is not grinded and is fixed onto the upper surface11of the substrate1, and a thickness T31of the sensor chip31has a maximum acceptable value of 700 μm. Accordingly, since the sensor chip31does not need to be grinded to reduce the thickness thereof, the sensor chip31can have a higher heat capacity for allowing the sensor chip31to slowly increase in temperature during operation, thereby effectively increasing a signal-to-noise ratio (SNR) of the sensor chip31.

As shown inFIG.1,FIG.6, andFIG.7, the packaging step S150is implemented by forming an encapsulant5on the upper surface11of the substrate1. Moreover, the metal wires4and the one of the sensing modules3are embedded in the encapsulant5, and an outer surface331of the light-permeable sheets33of the one of the sensing modules3is at least partially exposed from the encapsulant5. Accordingly, after the packaging step S150is implemented, a sensor package structure100provided by the present embodiment can be obtained. Furthermore, the substrate1is provided without any solder ball disposed on a lower surface12thereof, thereby reducing a thickness of the sensor package structure100.

In summary, the manufacturing method S100of the present embodiment can be implemented by adhering the light-permeable sheet33having a smaller size onto the sensor chip31to jointly form the sensing module3so as to arrange the sensing region3111of the sensor chip31in the enclosed space S of the sensing module3, and then fixing the sensing module3onto the substrate1, thereby effectively preventing the sensing region3111of the sensor chip31from being contaminated or damaged in a manufacturing process of the sensor package structure100.

In addition, the above description substantially describes the manufacturing method S100of the present embodiment, and the following description substantially describes a specific configuration of the sensor package structure100provided by the present embodiment. The sensor package structure100is preferably prepared by implementing the manufacturing method S100of the present embodiment, but the present disclosure is not limited thereto.

As shown inFIG.6andFIG.7, the sensor package structure100in the present embodiment includes a substrate1, a fixing adhesive layer2disposed on the substrate1, a sensing module3fixed to the substrate1through the fixing adhesive layer2, a plurality of metal wires4electrically coupled to the substrate1and the sensing module3, and an encapsulant5that is formed on the substrate1, but the present disclosure is not limited thereto.

The substrate1of the present embodiment has a square shape or a rectangular shape, but the present disclosure is not limited thereto. An upper surface11of the substrate1includes a module-fixing region111arranged approximately on a center portion thereof, and the substrate1includes a plurality of bonding pads112arranged outside of the module-fixing region111. The bonding pads112in the present embodiment are in a ring-shaped arrangement, but the present disclosure is not limited thereto. For example, in other embodiments of the present disclosure not shown in the drawings, the bonding pads112can be arranged in two rows respectively at two opposite sides of the module-fixing region111.

In addition, the substrate1can be provided without any solder ball disposed on a lower surface12thereof. In other words, the sensor package structure100can be soldered onto an electronic component (not shown in the drawings) through the lower surface12of the substrate1, but the present disclosure is not limited thereto. For example, in other embodiments of the present disclosure not shown in the drawings, the substrate1can be further provided with solder balls disposed on the lower surface12thereof according to design requirements.

The fixing adhesive layer2is disposed on the module-fixing region111of the substrate1. In other words, the fixing adhesive layer2is located inside of the bonding pads112, so that the sensing module3can be fixed to the module-fixing region111of the substrate1along a predetermined direction D through the fixing adhesive layer2. It should be noted that the sensing module3in the present embodiment is entirely adhered to the substrate1, which is different from a configuration formed by sequentially assembling multiple components to the substrate1.

Specifically, the sensing module3includes a sensor chip31, an annular adhering layer32disposed on the sensor chip31, and a light-permeable sheet33that is disposed on the annular adhering layer32. Moreover, a size of the light-permeable sheet33(e.g., an area that is surrounded by an outer contour of the light-permeable sheet33) is greater than a size of the annular adhering layer32, and is smaller than a size of the sensor chip31, so that an outer lateral edge of the annular adhering layer32, the sensor chip31, and the light-permeable sheet33jointly define an annular groove34.

The sensor chip31in the present embodiment has a square shape or a rectangular shape and is an image sensor chip, and a thickness T31of the sensor chip31has a maximum acceptable value of 700 μm, but the present disclosure is not limited thereto. Moreover, a bottom surface312of the sensor chip31is fixed onto the fixing adhesive layer2. In other words, the sensor chip31is arranged to be surrounded on the inside of the bonding pads112. Moreover, a top surface311of the sensor chip31has a sensing region3111and a carrying region3112that has a ring shape arranged around the sensing region3111.

The sensor chip31includes a plurality of connection pads3113arranged on the carrying surface3112. In other words, the carrying surface3112are arranged outside of the sensing region3111. The number and positions of the connection pads3113of the sensor chip31in the present embodiment correspond to those of the bonding pads112of the substrate1. In other words, the connection pads3113in the present embodiment are substantially in a ring-shaped arrangement.

The annular adhering layer32is disposed on the top surface311of the sensor chip31(e.g., the carrying region3112), the annular adhering layer32surrounds the sensing region3111, and the connection pads3113are located outside of the annular adhering layer32. The annular adhering layer32is spaced apart from the sensing region3111by an interval, and is spaced apart from any one of the connection pads3113by another interval.

The light-permeable sheet33in the present embodiment is a transparent and flat glass board, but the present disclosure is not limited thereto. The light-permeable sheet33has an outer surface331and an inner surface332that is opposite to the outer surface331. The inner surface332of the light-permeable sheet33is disposed on the annular adhering layer32, so that the light-permeable sheet33, the annular adhering layer32, and the sensor chip31jointly define an enclosed space S. Moreover, the sensing region3111of the sensor chip31is located in the enclosed space S, and a projection region defined by orthogonally projecting the light-permeable sheet33along the predetermined direction D onto the top surface311of the sensor chip31is located inside of the connection pads3113by a distance G.

In summary, in the sensing module3of the sensor package structure100(e.g., the light-permeable sheet33, the sensor chip31, and the annular adhering layer32sandwiched therebetween) provided by the present embodiment, an expansion part generated from the annular adhering layer32having a larger coefficient of thermal expansion (CTE) can be received in the enclosed space S, thereby preventing the light-permeable sheet33or the sensing region3111from being damaged and squeezed by the expansion part.

The metal wires4are respectively connected to the bonding pads112of the substrate1and the connection pads3113of the sensor chip31(e.g., two ends of any one of the metal wires4are respectively connected to one of the bonding pads112and a corresponding one of the connection pads3113) so as to establish an electrical connection between the substrate1and the sensor chip31.

In the present embodiment, a bending point (e.g., a highest point) of any one of the metal wires4and the upper surface11of the substrate1have a largest distance H4therebetween that is greater than an interval distance F33between the light-permeable sheet33and (the upper surface11of) the substrate1. In other words, the configuration of the sensing module3does not affect the following the wire-bonding process of any one of the metal wires4.

The encapsulant5of the present embodiment is opaque for blocking a visible light from passing therethrough. The encapsulant5is a liquid encapsulation and is formed on the upper surface11of the substrate1, and edges of the encapsulant5are flush with edges of the substrate1. The sensing module3and the metal wires4are embedded in the encapsulant5, and the outer surface331of the light-permeable sheet3is at least partially exposed from the encapsulant5, but the present disclosure is not limited thereto. Moreover, the connection strength of the sensing module3and the encapsulant5in the present embodiment can be effectively increased through the configuration of the sensing module3(e.g., the annular groove34is fully filled with the encapsulant5).

Second Embodiment

Referring toFIG.8toFIG.10, a second embodiment of the present disclosure, which is similar to the first embodiment of the present disclosure, is provided. For the sake of brevity, descriptions of the same components in the first and second embodiments of the present disclosure will be omitted herein, and the following description only discloses different features between the first and second embodiments.

In the present embodiment, the bottom surface312of the sensor chip31has a plurality of columnar microstructures3121. Moreover, in the second bonding step, the columnar microstructures3121of the sensor chip31are embedded in the fixing adhesive layer2and each can be adjusted or changed according to design requirements, but the present disclosure is not limited thereto. For example, each of the columnar microstructures3121can be a triangular column shown inFIG.8, a circular column (or a rectangular column) shown inFIG.9, or a spherical column shown inFIG.10. Furthermore, a thickness T2of the fixing adhesive layer2is greater than a thickness T3121of any one of the columnar microstructures3121, so that each of the columnar microstructures3121is entirely embedded in the fixing adhesive layer2and is not in contact with the substrate1.

In summary, the sensor package structure100of the present embodiment is provided with the sensor chip31having the columnar microstructures3121embedded in the fixing adhesive layer2, thereby further effectively increasing the connection strength of the sensing module3and the encapsulant5.

Third Embodiment

Referring toFIG.11andFIG.12, a third embodiment of the present disclosure, which is similar to the first and second embodiments of the present disclosure, is provided. For the sake of brevity, descriptions of the same components in the first to third embodiments of the present disclosure will be omitted herein, and the following description only discloses different features among the first to third embodiments.

In the present embodiment, the manufacturing method S100can be provided without the packaging step according to design requirements. In other words, the sensor package structure100in the present embodiment does not have the encapsulant provided by the above embodiments according to design requirements. In addition, the encapsulant can be adjusted or changed according to design requirements. For example, in other embodiments of the present disclosure not shown in the drawings, the encapsulant can surround lateral sides of the light-permeable sheet33and does not cover any one of the metal wires4or only cover a part of any one of the metal wires4.

Beneficial Effects of the Embodiments

In conclusion, the manufacturing method of the present disclosure can be implemented by adhering the light-permeable sheet having a smaller size onto the sensor chip to jointly form the sensing module so as to arrange the sensing region of the sensor chip in the enclosed space of the sensing module, and then fixing the sensing module onto the substrate, thereby effectively preventing the sensing region of the sensor chip from being contaminated or damaged in a manufacturing process of the sensor package structure.

Moreover, in the sensing module of the sensor package structure provided by the present disclosure, an expansion part generated from the annular adhering layer having a larger coefficient of thermal expansion (CTE) can be received in the enclosed space, thereby preventing the light-permeable sheet or the sensing region from being damaged and squeezed by the expansion part.