Abstract:
The present invention provides a connecting module having at least one passive component including a substrate, a connecting wire layout, at least one passive component and a chip-setting area, wherein the connecting wire layout is formed on the substrate, the passive components are formed on the connecting wire layout to electrically connect to the connecting wire layout. The chip-setting areas are formed in the substrate locating at different areas from the connecting wire layout, wherein the size of the passive components can be adjusted to match the needed impedance, and the numbers and the location of the chip-setting areas can be adjusted dynamically for reducing the dimension of the module.

Description:
FIELD OF INVENTION  
       [0001]     The invention relates to system with a multi-chip boarding package and a manufacturing method and structure of a connecting module, and more particularly to a method and structure for integrating the manufacturing process of the passive components and settling a chip by utilizing the space of the substrate to decrease the packaging difficulty.  
       DESCRIPTION OF RELATED ARTS  
       [0002]     Recently, the trend of the development of the electronic products is toward lightening, thinning, shortening, minifying, and high performance. And also the trend of the technology of the packaging market is toward high frequency, more I/O pins, and minification. With the progress of the IC manufacturing process, the sizes of the devices of an IC chip is getting smaller, the processing speed of data is getting faster, the required frequency is getting higher, and the requirement of the communication to the external for data is also getting more and more. In another word, the number of the pins of an IC chip is needed to be getting more and more. Therefore, the boarding package for providing high pins and high frequency becomes the main stream.  
         [0003]     Now the boarding package is classified as mono-chip and multi-chip package by the number of the chips. The mono-chip package includes ball grid array (BGA), flip chip (FC), chip scale package (CSP), pin grid array package (PGA), and column grid array (CGAQ). The multi-chip package includes system on package (SOP), such as stack IC package, multi-chip module (MCM), and multi-chip package memory (MCP).  
         [0004]     SOP refers to integrate at least two dies together by packaging. It is also called system-in-package (SiP). SOP can be classified as 3 main types, multi-chip package (MCP), multi-chip module (MCM), and integrated packaging (IP). MCP includes two main types, side-by-side, and stacked chip. The packaging methods and characteristics are described as the following: 
        1. referring to  FIG. 1 , it is the architecture of the side-by-side MCP  100 . The cost of the side-by-side architecture  100  is lower. But because there is no connecting, the pins of the side-by-side architecture  100  are almost the same as the individual package.     2. referring to  FIG. 2 , it is the architecture of the stacked MCP  200 . The required area of the stacked MCP can be reduced, but the manufacturing process of the stacked MCP needs to be more accurate.        
 
         [0007]     Besides, SOP is involved in whether the devices can be integrated in the same manufacturing process when manufacturing the chip. And even the devices can be integrated in the same manufacturing process, there are some problems needed to be considered, such as if the performance of the chip is reduced, if the yield can be maintained, and how much the cost is increased. In addition, for the reason not to complicate the packaging process and not to increase the area, the number of the dies to be integrated is limited. The more dies are packaged together, the lower yield of packaging is achieved.  
         [0008]     Therefore, the present invention provides a connecting module architecture with passive components and manufacturing process thereof to resolve the conventional packaging methods.  
       SUMMARY OF THE PRESENT INVENTION  
       [0009]     An object of the present invention is to provide a connecting module with passive components, comprising at least a device settling area and at least a passive component, wherein the size of the passive component can be adjusted to generate the required resistance of the connecting module. The connecting circuits, number and the layout of the device settling areas can be dynamically adjusted when needed to reduce the size of the module.  
         [0010]     Another object of the present invention is to provide a connecting module with passive components, comprising at least a device settling area and at least a passive component, the thickness of the architecture film of the connecting module with passive components and size of the wires can be adjusted in the needs of the resistances of different components.  
         [0011]     Another object of the present invention is to provide a connecting module with passive components, comprising at least a device settling area and at least a passive component, wherein the connecting circuits of the device settling areas are built in the electric connecting module to reduce the pin number of the package and to increase the reliability of the connecting module.  
         [0012]     Another object of the present invention is to provide a connecting module with passive components, comprising at least a device settling area and at least a passive component, wherein the device settling areas are grooves, capable of being inserted at least a device not to increase the height of the electric connecting module after being inserted the device, to reduce the manufacturing difficulty when proceeding the stacked semiconductor manufacturing process.  
         [0013]     Another object of the present invention is to provide a connecting module with passive components in wafer class packaging manufacturing process, comprising at least a device settling area and at least a passive component, wherein the connecting module can be segmented after being packaged and tested.  
         [0014]     Another object of the present invention is to provide a semiconductor manufacturing process to form a connecting module with passive components, wherein the surface of the connecting module with passive components employs the photo sensitive material with the electric isolating ability to protect the module and define at least a device settling area.  
         [0015]     Another object of the present invention is to provide a chip module with passive components, comprising at least a device settling area, at least a passive component, and at least a chip, wherein the sizes of the passive components can be adjusted to generate the required resistances of the connecting module, the connecting circuits, number, and the layout of the device settling area can be dynamically adjusted in need to reduce the size of the module, and the chips are settled in the device settling areas to increase the reliability of the semiconductor module.  
         [0016]     Accordingly, in order to accomplish the one or some or all above objects, the present invention provides a connecting module with passive components, comprising:  
         [0017]     a substrate;  
         [0018]     a connecting wire layout, comprising at least a connecting wire formed on the substrate to provide the required electric connecting for operating the chip module;  
         [0019]     a passive component layout, comprising at least a passive component formed on the connecting wire layout and connected to the connecting wire layout to provide the required resistances for operating the chip module;  
         [0020]     at least a chip-setting area, the chip-setting areas are formed by etch the substrate and locating in the different area from the connecting wire layout and the passive component layout; and  
         [0021]     at least a chip, settled in the chip-setting area and connected to the connecting wire layout.  
         [0022]     Accordingly, in order to accomplish the one or some or all above objects, the present invention provides a semiconductor manufacturing process to form the chip module with passive components, comprising the following steps: 
        (a) forming a connecting wire layout on a substrate, wherein the connecting wire layout comprises at least a connecting wire to provide the required electric connecting for operating the chip module;     (b) forming a passive component layout on the connecting wire layout, wherein the passive component layout comprises at least a passive component, electrically connected to the connecting wire layout, to provide the required resistances for operating the chip module;     (c) etching the substrate to generate a chip-setting layout, wherein the chip-setting layout comprises at least a chip-setting groove locating at the different area from the connecting wire layout on the substrate;     (d) settling at least a chip from the external in the chip-setting groove;     (e) electrically connecting the chip from the external and the connecting wire layout.        
 
         [0028]     One or part or all of these and other features and advantages of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of different embodiments, and its several details are capable of modifications in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0029]      FIG. 1  illustrates the side-by-side multi-chip packaging structure.  
         [0030]      FIG. 2  illustrates the stacked multi-chip packaging structure.  
         [0031]      FIG. 3A-3E  illustrate the manufacturing process of the connecting wire layout in accordance with the present invention.  
         [0032]      FIG. 3F-3H  illustrate the manufacturing process of the passive component in accordance with the present invention.  
         [0033]      FIG. 3I-3K  illustrate the manufacturing process of the chip-setting area in accordance with the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0034]     Referring to the  FIG. 3 , it is a semiconductor manufacturing process disclosed by the preferred embodiment of the present invention to form a connecting module with passive components. In the embodiment, a connecting wire layout is formed on a wafer first.  
         [0035]     Referring to  FIG. 3A-3E , they are the manufacturing process of the connecting wire layout in accordance with the preferred embodiment of the present invention. Referring to  FIG. 3A , the first silicon dioxide layer  321  is formed on a wafer  310  first, and then an aluminum-copper alloy layer  322  is deposited on the silicon dioxide layer  321 . In the embodiment, the first silicon dioxide layer  321  is formed in the thermal diffusion method, and the aluminum-copper alloy layer  322  is formed in the physics deposition method, but not restricted.  
         [0036]     Referring to  FIG. 3B , the aluminum-copper alloy layer  322  is etched to form the first wiring layout  323  next. In the embodiment, the etching process defines the wiring for the aluminum-copper alloy layer  322  by exposing and developing, then the area not to be defined as the wiring in the aluminum-copper alloy layer  322  is etched to form the first wiring layout  323 , and the photo sensitive material is removed last.  
         [0037]     Referring to  FIG. 3C , the second silicon dioxide layer  324  is formed on the first wiring layout, the first electric connecting opening layout  324 A is defined on the second silicon dioxide layer  324  by exposing and developing next, and the second silicon dioxide layer  324  is etched to be defined as the connecting opening to expose the area which is for electric connecting in the first wiring layout  323 . At last, the photo sensitive material is removed. The first wiring layout  323  exposed out of the first electric connecting opening layout  324 A is the electric connecting nodes of the first wiring layout  323 , and is the contact area as the electric connecting for the first wiring layout  323 .  
         [0038]     Referring to  FIG. 3D , the second aluminum-copper alloy layer  325  is deposited on the second silicon dioxide layer  324  and connected to the first wiring layout  323  via the electric connecting opening layout to achieve the electric connecting with the first wiring layout  323 . Next, the second aluminum-copper alloy layer  325  is etched to form the second wiring layout  326 . In the embodiment, the second aluminum-copper alloy layer  325  is defined for the wiring by exposing and developing in the etching process, and then the area not to be defined as the wiring in the second aluminum-copper alloy layer  325  is etched to form the second wiring layout  326 . At last, the photo sensitive material is removed.  
         [0039]     Referring to  FIG. 3E , the third silicon dioxide layer  327  is formed on the second wiring layout  326 . Next, the second connecting opening layout  328  is defined on the third silicon dioxide  327  by exposing and developing, and the area defined as the opening in the third silicon dioxide layer  327  is etched to expose the area for electric connecting in the second wiring layout  326 . At last, the photo sensitive material is removed. The second wiring layout  326  exposed out of the second connecting opening layout  328  is the electric connecting nodes of the second wiring layout  326 .  
         [0040]     The manufacturing process is employed in forming a connecting wire layout on a specific substrate, wherein there are two connecting wire layers in the connecting wire layout, but not restricted. The required number of the layers, materials, and manufacturing methods for achieving the wire connecting layout of the module are intended to be disclosed by the present invention.  
         [0041]     Referring to  FIG. 3F-3H , they are the manufacturing process of passive components in accordance with the preferred embodiment of the present invention. Referring to  FIG. 3F , a barrier layer  331  and a seed layer  332  the third silicon dioxide layer  327  are formed on the third silicon dioxide layer  327  in order, wherein the barrier layer  331  is connected to the second wiring layout  326  via the second connecting opening layout  328 , and the seed layer  332  is formed on the barrier layer  331 .  
         [0042]     The barrier layer  331  is the buffering layer between the second aluminum-copper alloy layer  325  and the seed layer  332 . By employing the barrier layer  331 , the problem due to the high diffusion coefficient of the copper and the electricity degeneration of the device when forming deep energy levels in the silicon substrate can be resolved, even the problem of the low adherent ability for the copper to the dielectrics. The conventional material employed in the barrier layer  331  is tungsten (W), titanium-tungsten (TiW), Ta/TaN, Ti/TiN, or the combination thereof, but not restricted. The seed layer  332  provides the required seed for forming the metal layer and avoid the peeling problem due to the large stress. The employed material in the seed layer  332  depends on the metal layer. The conventional material is copper or gold, but not restricted.  
         [0043]     Referring to  3 G, the first photo resist layer  333  is form on the seed layer  332 . The material of the first photo resist layer  333  is the photo sensitive material capable of defining patterns by exposing and developing. In the embodiment, the first photo resist layer  333  comprises photosensitive BCB, and polyimide, but not restricted. The epoxy and UV glue are also the conventional gluing material. And the processing the exposing and developing, the passive component connecting opening layout  334  is defined on the first photo resist layer  333 , and the area defined as the passive component connecting opening in the first photo resist layer  333  is etched. The seed layer  332  exposed out of the passive component connecting opening layout  334  are the electric connecting nodes of the seed layer  332 , and are the contact area for electric connecting for the seed layer  332 .  
         [0044]     Referring to  3 H, at least a passive component  350  is formed by electro-plating copper in the area of the seed layer  332  exposed out of the passive component connecting opening layout  334 , such as the inductor, resistor, capacitor, and so on. The characteristics of the passive component can be controlled by the size of the opening of the connecting opening layout, shape, thickness, and the state of the surface.  
         [0045]     Next, the first photo resist layer  333  is removed by the photo resistance remover, and the passive component, the seed layer  332 , and the barrier layer  331  are etched separately to have the size of the passive component matches the required resistance. The area of the seed layer  332  not to be covered by the passive component and the barrier layer  331  are removed to expose the third silicon dioxide layer  327  out.  
         [0046]     The mentioned manufacturing process is employed to form at least a passive component in the connecting wire layout. Any implementation of the modified order of the manufacturing process, etching method, and manufacturing materials in accordance with the mentioned above is intended to be disclosed by the present invention.  
         [0047]     Referring to  FIG. 31-3K , they are the manufacturing process of the chip-setting in accordance with the preferred embodiment of the present invention. Referring to  FIG. 31 , the second photo resist layer  341  is coated by spin-coating first. Next, a connecting pad opening layout  342  and a chip-setting opening layout  343  are defined on the second photo resist layer  341 , the areas defined as the connecting pad opening and chip-setting opening in the second photo resist layer  341  are etched, and the second photo resist layer  341  is processed by curing so that the second photo resist layer  341  can achieve the result of protecting the connecting module.  
         [0048]     Referring to  FIG. 3J , And then the second photo resist layer  341  is etched to expose the area, for electric connecting, of the passive component  350 , and also the connection structure is etched by the active plasma etching apparatus to form at least a chip-setting area  344 .  
         [0049]     Referring to  FIG. 3K , at least a chip is placed in the chip  345  settling area  344 . In the embodiment, resin is employed to glue the chip  345  in the bottom of the chip-setting area  344 . Next, the chip  345  is electrically connected to the electric connecting area of the specific passive component by wire bonding, but not restricted. Any method suitable for electrically connecting the chip  345  and the passive component can be alternate to implement.  
         [0050]     The present invention is the manufacturing process for manufacturing a connecting module employing the wafer packaging structure instead of the electric connecting function of a part of the printed circuit board by integrating the passive component, connecting wire layout, and the chip-setting area to produce a connecting module. First, the required time and complexity of the manufacturing process are reduced by integrating the wafer packaging and manufacturing process of the passive component. In the meanwhile, the yields of the wafer and the passive components are increased by reducing the packaging time, signal degeneration of the external passive components, and indifferent effect to the system caused by the noise, and also by employing of the passivation layer. When the defects are generated in the manufacturing process, it is easy to recover. The chip-setting area is generated in the wafer itself so that the thickness of the connecting structure that the wafer is included is more uniform. The thickness of the packaging structure is not uniform due to the height of the chip to increase the complexity of the following stacked type manufacturing process. The reduction of the reliability caused by the complicate wiring between the passive components and the chip can be decreased by integrating the passive components with the chip. Also the cured photo resist layer is employed to increase the strength of the packaging structure.  
         [0051]     One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.  
         [0052]     The foregoing description of the preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or to exemplary embodiments disclosed. Accordingly, the foregoing description should be regarded as illustrative rather than restrictive. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. The embodiments are chosen and described in order to best explain the principles of the invention and its best mode practical application, thereby to enable persons skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use or implementation contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents in which all terms are meant in their broadest reasonable sense unless otherwise indicated. It should be appreciated that variations may be made in the embodiments described by persons skilled in the art without departing from the scope of the present invention as defined by the following claims. Moreover, no element and component in the present disclosure is intended to be dedicated to the public regardless of whether the element or component is explicitly recited in the following claims.