METHOD AND STRUCTURE FOR EFFECTING ENGINEERING CHANGES IN A MULTIPLE DEVICE MODULE PACKAGE

Abstract: In a semiconductor module with a substrate (10) having a plurality of semiconductor devices (12) mounted on the top surface, an internal metallurgy system interconnecting said devices, an auxiliary set of conductive lines with periodically occurring surface connecting terminals, a pattern (15) of engineering change terminals with electrical connections to the device terminals and to the internal metallurgy system, the improvement to provide engineering change devices (14) mounted on the top surface, having terminal means on the surface of the engineering change devices to establish electrical contact with the pattern (15) of engineering change terminals and the surface connecting terminals, and a tailorable metallurgy system which permits selective electrical contact between individual terminals of the terminal means, and a means on the substrate to selectively electrically isolate selective engineering change terminals from the internal metallurgy.

Description: Technical Field This invention relates to integrated circuit device carriers, commonly known as packages, on which devices can be bonded for electrical contact and mechanical support, in which permanent electrical connections of the circuits of the chip are made and which provide electrical connections to other circuits of a system such as computers and other electrical products. More particularly, this invention relates to the technique of and structure for making engineering changes in the device carrier to alter the original internal circuit design of the carrier or to correct wiring defects. Background Art In modern packaging technology, it is known to mount many integrated circuit devices on a substrate containing a printed circuit network that interconnects the devices with each other and to I/O's (inputs or outputs) on the end or opposite side of the substrate. A typical module embodying such a substrate is disclosed in U.S. Patent 4,245,273, and is also described in IBM Journal, Vol. 27, No. 1, Jan. 1983, pp. 11-19. Such substrates, normally made of ceramic material, are very complex containing 30 or more layers of green ceramic sheets with thousands of vias and printed lines that form the internal circuit network. After the substrate has been laminated and sintered, there is no practical method of changing the buried internal network. However, it becomes necessary quite frequently to modify the internal circuitry to (1) correct defective lines and/or vias, and (2) make changes to the basic circuitry to accommodate design changes, to upgrade the package or modify it by the use of different devices or the like. This contingency was provided for in the substrate described in the references previously cited by the use of engineering change (EC) pads interposed between the device terminals and the circuitry in the substrate. More specifically, fan-out metallurgy is provided in the top surface layers of the substrate that is joined to the solder pads of each device and also connected to surface EC pads that surround each device. The EC pads each have a deletable central portion with one end of the pad connected to a device pad and the other to buried circuitry in the substrate that interconnects the device with other devices and/or I/O pads on the opposite side of the substrate. To replace a defective buried metallurgy line in the substrate, or modify the circuitry by the addition of different lines, the proper EC pad is severed, thus electrically disconnecting the device terminal from the circuitry in the substrate. One end of a discrete wire is then joined to the portion of the pad joined to the device. The other end of the wire is joined to another EC pad that has been similarly severed. Thus, an electrical connection is made between any two terminals of any devices on the substrate, and the former electrical lines buried in the substrate disconnected. The same technique thus can be used to substitute defective electrical lines in the substrate, and also to change the internal electrical network of the substrate. While the EC structure works well, there are some notable disadvantages. The EC pads must be relatively large, compared to device pads in order to accommodate wire bonding, and therefore occupy a great deal of space on the top surface of the substrate. As the integrated circuit devices become more miniaturized with more circuits, and the number of required device pads also increases, the additional device pads require additional EC pads. With the size of the EC pads constrained to accommodate wire bonding, the total area required increases dramatically. The EC pads on the substrate surface have a different metallurgy than the pads that are joined to the devices. This requires that a different set of process steps be applied to the same surface which makes the substrate more costly than if a single metallurgy could be used throughout the entire surface area. It also detracts from the yield of the substrate fabrication. As the number of EC pads increases, the number of lines required for making changes also increases. At some point the volume of wires becomes prohibitive. In addition, the wires, particularly longer wires, present problems with inductive coupling. This factor in a computer application is very serious. Still further, the EC wires reduce the speed of operation. The length of the engineering change wires can be reduced by the technique and structure described in U.S. Patent 4,489,364. In this structure, describing the state of the art according to the preambles of claims 1 and 9, buried EC lines in the X and Y directions are provided in the substrate. The buried lines periodically surface on the substrate with the line segments joined by a deletable engineering change pad. With these buried lines electrical lines can be formed from or to any location on the substrate. The EC connections thus consist of very short wires on the substrate. However this technique fails to alleviate the large area requirement for EC pads discussed previously. A similar technique, using EC lines on the top surface of the substrate, is described in the European Patent 18,489. Summary of the Invention An object of this invention is to provide a new and improved method and structure for modifying an inaccessible circuit network in a module substrate that supports and interconnects a plurality of integrated circuit devices. Another object of this invention is to provide a new method and structure for making circuit changes in a module substrate for a plurality of devices, wherein the area dedicated to engineering change pads is reduced. Yet another object of this invention is to provide an engineering change method and structure wherein the surface metallurgy pad structure on the module substrate is of uniform design. Another object of this invention is to provide an engineering change method and structure wherein the conventional bonded wires are replaced with "tailored" engineering change devices. In accordance with the aforementioned objectives of the invention, there is provided a module for an array of integrated circuit semiconductor devices according to claim 1. A method, according to this invention is given by claim 9. The subject-matter of the dependent claims gives preferred embodiments of the invention. Brief Description of the Drawings In the accompanying drawings forming a material part of this disclosure. FIG. 1 is a top plan view in broken section of a portion of a module substrate illustrating the placement of integrated circuit devices, EC devices, and EC lines. FIG. 2 is a schematic view in perspective that illustrates buried EC lines in the substrate and their relationship to deletable EC pads and integrated circuit devices. FIGS. 3 and 4 are detailed views of structures for interconnecting X and Y lines on EC devices. FIG. 5 is a schematic view of a portion of X-Y lines on an EC device illustrating their relationship to the EC pads and deletable links for tailoring the EC device. FIG. 6 is a schematic view of buried EC lines in the substrate between devices, which illustrates an EC line connection between two spaced devices. FIG. 7 is a plan view, in enlarged scale, of a surface metallurgy pattern on the substrate, similar to the pattern in FIG. 1. Detailed Description of the Invention Referring now to the drawings, and FIG. 1 in particular, there is illustrated a top view of a module substrate 10 including integrated circuit devices 12, engineering change devices 14 and a typical fan-out pattern 15 terminating in EC pads (FIG. 7). The substrate 10 is typically a multilayer ceramic (MLC) substrate of the type described in the above-cited U.S. Patent 4,245,273. Substrate 10 is formed of a plurality of laminated green ceramic sheets that have been punched to form via holes and a conductive metal line pattern formed thereon. The conductive lines collectively form an internal metallurgy system that interconnects the devices 12 with each other and to a plurality of I/O terminals on the opposite side, not shown. The laminated sheet assembly is subsequently sintered forming a unitary body. The substrate is provided with a fan-out pattern 15, also shown in FIG. 7, which can be either formed as a separate surface metallization layer with an overlying dielectric layer, as illustrated in FIG. 1, or in the top surface layers of the substrate (not illustrated). The fan-out layer consists basically of conductive lines 13 that connect the solder pads on the surface of substrate 10 joined to the terminals of the device 12 with EC pads 16 on the top surface of the substrate, located in the area between the devices 12. The end of each line 13 terminates in an EC pad 16 and a short deletable line portion 17 wherein the fan-out line can be disconnected from the internal metallization circuity of substrate 10. Both the device terminal pads and the EC pads are preferably solder wettable pads which are joined to the terminals of the integrated circuit devices 12 and the terminals of EC devices 14 by solder connections, as described in U.S. Patent 3,429,040. Also included in substrate 10 is a plurality of buried engineering change (EC) lines 18 in the X direction and a plurality of buried EC lines 20 in the Y direction, as illustrated schematically in FIG. 2. As indicated, both X lines 18 and Y lines 20 surface periodically on the surface of the substrate 10 as pairs of solder pads 26 and 22. Deletable links 23 and 24 join the adjacent pads 22 and 26 thus forming continuous metal stripes. Pads 22 and 26 are solder wettable. Links 23 and 24 can be either covered with a thin dielectric layer or have a top surface layer that is not solder wettable. This will constrain the solder to the pads 22 and 26 when the solder mass used to make the solder connections is heated to a molten state. The buried EC lines are described in the cited U.S. Patent 4,489,364. The fan-out pattern 15, as illustrated in FIG. 1, is repeated on each side of devices 12. In general, it is symmetrical about a center line with one-half of the fan-out pattern associated with one device 12, and the other side associated with the adjacent device 12. Preferably the pads 22 and 26 joined to the buried EC lines are located in the center area as shown. The fan-out pattern is preferably a single layer of metallurgy which can be deposited using conventional deposition and etching techniques. The pads are formed with a solder-wettable top metal layer, such as copper. The link portion can be formed with at least the top layer of a metal that is not solder wettable. Alternately, the link portion can be covered with a thin dielectric layer. The stripes of the fan-out layer can be severed with a laser beam to isolate the stripe from the internal metallurgy of the substrate. Adjacent sets of pads 22 and 26 can also be electrically isolated by severing portion 23 or 24. Preferably solder pads to buried EC lines in both the X and Y directions will be accessible in each fan-out pattern 15. Using conventional MLC technology, the lines in the X direction can be made to surface in a short stripe 24 which can be severed. Surface lead lines 25 (FIG. 7) joined to the ends of link 24 are joined to pads 26. The use of these pads will become apparent in the following explanation. Engineering change (EC) devices 14 are each provided with a solder pad configuration that is the mirror image of the solder pad configuration of fan-out pattern 15. Devices 14 have a tailorable metallurgy system 30, 32, 34, 36 that will permit making electrical connections between the various solder pads of the fan-out pattern 15. In practice, the substrate 10 is tested to determine if any of the internal buried lines are defective, the appropriate lines are severed in pattern 15 on substrate 10, the metallurgy of device is tailored to make the required electrical connections between the various pads to correct the substrate defects, and the device 14 is joined to the substrate using solder joining techniques to join the respective solder pads. The same technique can be used to alter the circuit arrangement of the substrate, i.e. make engineering and design changes. EC devices 14 are each provided with a solder pad configuration that is the mirror image of the solder pad configuration of fan-out pattern 15. Devices 14 have a tailorable metallurgy system that will permit making electrical connections between the various solder pads of fan-out pattern 15. Referring to FIG. 5 of the drawings, there is illustrated a schematic circuit diagram of a representative portion of the circuit of an EC device 14. There is a plurality of solder pads 16′ arranged in a mirror image grid of the solder pads 16 on substrate 10. Each pad 16′ is connected to a single stripe 30 that extends in the X direction. Preferably stripes 30 are all on a single metallurgy level. A similar set of stripes 30 and pads 16′ (not shown) can be provided beneath the set of stripes 30 of FIG. 5. The row of pads 16′ associated with each set of stripes 30 is related to a similar row of EC pads 16 on substrate 10. A plurality of pads 22′ are joined to stripes 32 that extend in the Y direction. A set of pads 26′ joined to stripes 34 are located between stripes 32. Pads 22′ and 26′ correspond in placement and spacing to pads 22 and 26 on substrate 10. The stripes 32 and 34 are preferably formed in the same metallurgy layer which is electrically isolated from stripes 30 by a suitable dielectric layer. Surface pads 22′ and 26′ are solder wettable. At each juncture of stripes 30, and 32 and 34, there is provided a deletable connection 36. Connection 36 can be a connection 36A, as illustrated in FIG. 3 or a connection 36B, as illustrated in FIG. 4. Connection 36A is a personalized connection that is selectively formed on substrate 14 after it has been determined which connections must be made to form the proper EC changes. The printed connection 36A is made to connect vias 38 and 40 by suitable deposition and subtractive etching techniques that are well-known in the art. If the top stripe is not covered by a dielectric layer, the connection is made directly to the exposed stripe, without the need for a via. Device 14 is formed without connections 36A, and tailored by adding the needed connections after they have been determined. In contrast, the fusible link stripes 36B are formed during the metallization of the device 14. Link 36B has a thin portion which can be blown by applying a suitable electrical current across the connection, using pads 16′, 22′ and 26′ as terminals. After it has been determined which connections are needed to make the EC changes, the remaining links are broken. Links 36B can also be broken with a laser pulse. The aforedescribed metallurgy lines can be used to interconnect any solder pad 16 to any EC pad 22 or 26 on substrate 10. Stripes 39 which extend in the X direction and are preferably in the same metallurgy layer as stripes 30 can be used to join EC pads 22, associated with EC lines in the Y direction, to EC pads 26, associated with EC lines 18 in the X direction in substrate 10. Lines are each joined to a pad 41′ which can be joined to similarly placed solder pads 41 on substrate 10. The primary use, however, of pad 41′ is to provide an electrical connection to blow out the unneeded links 36. For example, in FIG. 5, a pad 26′ can be connected to a pad 22′ by leaving or forming the link connections 36 at the juncture of the associated stripe 34 and stripe 39, and the juncture of stripe 39 and the associated stripe 32. All of the remaining links on stripe 39 are severed or never formed, depending on the type of link. The same connection described could be formed between stripes 34 or 32 with stripe 30. These stripes 30 are associated with EC pads 16 connected to fan-out stripe connections, in turn connected to active I/O's on the device 12. In order to illustrate how an engineering change is made for connecting I/O's from two different spaced integrated circuit devices 12 on substrate 10, a specific description of the steps involved will now be presented. At each of the two selected integrated circuit devices, the fan-out line 50 (FIG. 7) is electrically isolated from the internal electrical network of substrate 10 by severing the stripe portion 52. The metallurgy pattern on device 14 is then tailored to connect the substrate solder pad 50 to 51. The method of making a connection in the device metallurgy between an I/O fan-out pad and an engineering change line pad was described previously. A similar procedure is used to join the I/O terminal of the integrated circuit device 12 to an engineering change line connection 53 (FIG. 6). In order to make an electrical connection between the points 53 and 55, a connection 44 between pads 22 and 26, under a different EC device pad 14 located at the intersection of the chosen X and Y EC lines 18 and 20 respectively must be established in EC device 14 overlying the intersecting lines. The procedure for tailoring the metallurgy system of device 14 to interconnect EC pads from an X and Y EC lines, i.e. pads 22′ and 26′ was described previously. The delete stripes 52 and 54 are severed to isolate a segment of EC line 18. Delete stripes 56 and 58 are severed to electrically isolate a segment of EC line 20. After the respective metallurgy systems of the EC devices have been properly tailored, the devices are joined to the solder pads associated with the respective pads of the fan-out patterns 15. This establishes an engineering change, connecting lead points 53 to 55 which are each connected in turn to selected I/O terminals under different separated integrated circuit devices 12 as previously described in connecting solder pads 16 to 22. An alternate method of forming an electrical connection between buried EC lines in the X direction, and EC lines in the Y directions is presented. A row of solder pads 41 (FIG. 7) can be provided along the edge of fan-out pattern 15 on substrate 10. Lines, either on the surface or buried, join these pads to similar placed pads under the adjacent EC devices which pads are connected to EC lines that extend in the X direction. Pads 41′ (FIG. 5) are connected to pads 41 (FIG. 7) of device 10. Thus, a link connection 36 can be made on EC device metallurgy to join solder pads 22, which are connected to the EC lines that extend in the Y direction to solder pads 26 in the adjacent pattern that are joined to EC lines 18 in the X direction. While the invention has been illustrated and described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the precise construction herein disclosed and the right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.

Claims: A module for an array of integrated circuit semiconductor devices, said module comprising a substrate (10) of insulating material having an upper surface and sets of device solder pads thereon for connection to pads of integrated circuit semiconductor devices (12), an internal metallization circuitry inside said substrate (10) for electrically interconnecting said integrated circuit devices (12) mounted on said surface, engineering change solder pads (16) on said surface adjacent to said devices (12) deletably connected to said internal metallization circuitry, fan-out metallization lines (13) on said substrate (10) joining said device solder pads to respective engineering change solder pads (16), embedded engineering change lines (18, 20) in said substrate (10) including a plurality of periodically spaced breaks, connection vias extending to said surface from the ends of said breaks ending in engineering change line solder pads (22, 26) over said connection vias, and a deletable line (23, 24) joining each pair of said engineering change line solder pads (22, 26), characterized by: engineering change devices (14) having solder pads (16′, 22′, 26′) arranged to match said engineering change solder pads (16) and engineering change line solder pads (22, 26) on said substrate (10), and a tailorable metallurgy system (30, 32, 34, 36) on each said engineering change device (14) adapted to selectively join said solder pads (16', 22', 26') thereon, said engineering change device (14) when bonded to said substrate (10) is adapted to selectively join engineering change solder pads (16) to associated adjacent engineering change line solder pads (22, 26) to thereby modify said internal metallization circuitry of said substrate (10). The module of claim 1 wherein said substrate (10) is a multilayer ceramic substrate, and wherein said engineering change solder pads (16) are connected to said internal metallization circuitry by a deletable metallurgy line portion (17) on said surface. The module of claim 1 or 2 wherein said fan-out metallization lines (13) are located in a single layer on said surface of said substrate (10) and are covered with a layer of dielectric material. The module of a preceding claim wherein said embedded engineering change lines are comprised of a first set of parallel lines (18) in the X direction, and a second set of parallel lines (20) in the Y direction. The module of a preceding claim wherein said engineering change solder pads (16) and engineering change line solder pads (22, 26) are located between said device solder pads for adjacent devices (12). The module of a preceding claim wherein all electrical connections between said integrated circuit devices (12) and said device solder pads are solder reflow connections, and all electrical connections between said solder pads (16', 22', 26') on said engineering change devices (14), and said engineering change solder pads (16) and engineering change line solder pads (22, 26) are solder reflow connections. The module of a preceding claim wherein said tailorable metallurgy system on said engineering change device (14) is comprised of a plurality of parallel conductive stripes (30, 39) in the X direction, a plurality of parallel conductive stripes (32, 34) in the Y direction, a layer of dielectric material separating said pluralities of conductive X and Y lines, a deletable electrical connection (36) adjacent to each of the intersections of said conductive X and Y stripes that electrically joins the respective stripes, said solder pads (16′, 22′, 26′, 41′) being joined to respective stripes of each of said X and Y stripes. The module of claim 7 wherein said deletable electrical connections are each comprised of a thin fusable conductive line (36B). A method of modifying the electrical interconnection of a plurality of integrated circuit devices (12) mounted on an upper surface of the substrate (10) of a module and electrically interconnected by an internal metallization circuitry within the substrate (10) comprising: providing on said surface adjacent to said devices (12) engineering change solder pads (16) which are electrically connected by fan-out metallization lines (13) to terminals of said integrated circuit devices (12) and are deletably connected to said internal metalization circuitry, providing embedded engineering change lines (18, 20) in said substrate (10), and providing periodically spaced breaks in said engineering change lines (18, 20) and connection vias at the ends of said breaks which vias extend to said surface of said substrate (10), engineering change line solder pads (22, 26) over each via, and deletable surface lines (23, 24) joining each pair of adjacent engineering change line solder pads (22, 26), characterized by: providing engineering change devices (14) with a set of solder pads (16′, 22′, 26′) arranged in a pattern to match said engineering change solder pads (16) and engineering change line solder pads (22, 26) and with a tailorable metallurgy system (30, 32, 34, 36) for selectively electrically connecting said solder pads (16', 22', 26') on said engineering change device (14), tailoring said metallurgy system (30, 32, 34, 36) of said engineering change device (14) to achieve the desired change in said internal metallization circuitry of said substrate (10), and joining the solder pads (16', 22', 26') on said engineering change device (14) to the engineering change solder pads (16) and engineering change line solder pads (22, 26) on said substrate (10) by solder reflow techniques. The method of claim 9 wherein said engineering change device (14) is provided with fusible metal link stripes (36B) that electrically connect all of said solder pads (16', 22', 26'), comprising the step of selectively deleting said fusible metal link stripes (36B) with the selected application of electrical currents, leaving such connections as to effect only the desired changes said internal in metallization circuitry of the substrate (10).

Inventors: RYAN, CHARLES T.
Applicants: INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1986
Main classification: H01L23
IPC codes: H05K1, H05K3, H01L23, H01L21