Abstract:
The invention provides a warpage-proof circuit board structure, including: an inner layer circuit board; at least one dielectric layer formed on at least one surface of the inner layer circuit board; at least one first groove formed in the at least one dielectric layer corresponding in position thereto; a solder mask formed on the surface of the dielectric layer, a second groove formed in the solder mask and corresponding in position to the first groove formed in the dielectric layer; and a metal frame formed in the first and second grooves and protruding from the surface of the solder mask, thereby strengthening the circuit board to prevent it from warping in thermal processing and further using the metal frame as a heat-dissipating means for the package structure.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a warpage-proof circuit board structure, and more particularly, to a circuit board structure with support element. 
       BACKGROUND OF THE INVENTION 
       [0002]    As electronic industry evolves rapidly, multiple functions and high performance of electronic products are of interest. In order to meet packaging requirements of high integration and miniaturization, a single-layer circuit board that provides a plurality of active and passive components and interlayer connection has evolved to multi-layer boards, so as to expand the available circuit area on the circuit boards through interlayer connection under limited space. 
         [0003]    Currently, in most semiconductor packages, semiconductor devices (e.g. semiconductor chips and chip-type passive components etc.) are disposed on the surface of the circuit board. The circuit board that is used as the carrier for semiconductor devices is usually a core layer that can be an insulating board or double-side copper foil substrate (insulating material with copper coil on both sides). The insulating board can be made of resin material, e.g. epoxy resin, polyimide, BT (Bismaleimide Trazine) resin, FR4 resin etc. Circuits are formed on the top and bottom sides of the core layer and plated through holes are formed therein, wherein the plated through holes can be used as electrical paths for electrically conducting circuits on the top and bottom surfaces of the core layer. Dielectric layers are further formed on the surfaces on both sides of the core layer and vias formed in the dielectric layers. Then, circuit patterning processes are performed, including photoresist layer exposure and development and circuit formation, to form build-up layers, the number of build-up layers depends on design requirements. Thereafter, a solder mask made of an insulating material is formed on the outermost layer of the build-up layers. Openings are formed in the solder mask to expose circuits on the outermost layer and used as electrically connecting pads. Electrically connecting elements such as bumps are then formed on the electrically connecting pads for connecting to external electronic devices. 
         [0004]    As shown in  FIG. 1 , a cross-sectional schematic diagram depicts the structure of a circuit board used in traditional semiconductor packaging. The circuit board includes a core plate  10 ; circuit layers  11  and  11 ′ formed on the top and bottom surfaces of the core plate  10 , respectively; build-up structures  13  and  13 ′ formed on the circuit layers  11  and  11 ′, respectively; solder masks  14  and  14 ′ formed on the surface of the build-up structures  13  and  13 ′. The solder masks  14  and  14 ′ are formed with openings  140  which expose a portion of the outer most layers of the build-up structures  13  and  13 ′ so as to be electrically connecting pads  131  and  131 ′. 
         [0005]    When the above circuit board is applied in semiconductor packaging processes, the purposes of the top and bottom surfaces of the core plate  10  are different. The top surface of the core plate  10  is used for carrying and electrically connecting at least one semiconductor chip and passive component; while the bottom surface of the core plate  10  is implanted with a plurality of electrically connecting elements (e.g. solder balls). In addition, the circuit board is made up of different materials, i.e. the core plate  10 , the build-up structures  13  and  13 ′ (formed from dielectric layer and metal circuits) and solder masks  14  and  14 ′. Since the Coefficient of Thermal Expansion (CTE) of the metal circuit layers and the dielectric layer and the solder masks are quite different, warpage is caused by temperature variation of a manufacturing process of the circuit board structure. Owing to temperature variation during manufacturing processes of the circuit board structure, for example, during baking, curing, thermal cycling processes, the circuit board structure has thermal stress that results in different amounts of deformation between the different layers. The circuit board may deform or even delaminated, or worse, cause semiconductor chip to be damaged due to the detrimental compression stress. 
         [0006]    Along with the increase in the number of circuit layers and connecting element layout density, heat generated by highly integrated semiconductor chips in operation may significantly increase. Heat that is not efficiently dissipated may be adverse to the life of the semiconductor chips. 
         [0007]    Thus, there is a need for a more robust circuit board structure that avoids warpage in large circuit boards due to thermal stress and increases heat dissipation efficiency for multi-layer circuit boards. 
       SUMMARY OF THE INVENTION 
       [0008]    In the light of forgoing drawbacks, an objective of the present invention is to provide a warpage-proof circuit board structure so as to avoid warpage in the circuit boards during thermal processes. 
         [0009]    Another objective of the present invention is to provide a warpage-proof circuit board structure that increases the strength of a support of the circuit board. 
         [0010]    Still another objective of the present invention is to provide a warpage-proof circuit board structure that efficiently dissipates heat generated by semiconductor devices. 
         [0011]    In accordance with the above and other objectives, The invention provides a warpage-proof circuit board structure, including: an inner layer circuit board; one or more dielectric layers formed on at least one surface of the inner layer circuit board and with a first groove formed at a position close to the periphery of the inner layer circuit board; a solder mask formed on the surface of the dielectric layer, a second groove corresponding in position to the first groove formed in the dielectric layer; and a metal frame formed in the first and second grooves and protruding from the surface of the solder mask. 
         [0012]    The inner layer circuit board is a two-layer or multi-layer circuit board with patterned circuit completed. 
         [0013]    The circuit board structure further includes a build-up circuit layer formed on the dielectric layer. Electrical conductive vias formed in the dielectric layer electrically connects the build-up circuit layer and the inner layer circuit board. A metal protecting layer is formed on the surface of the metal frame to protect it from oxidation. The metal frame includes a first metal frame formed in the dielectric layer and a second metal frame formed in the solder mask. The first metal frame or the second metal frame can be made of one selected from the group consisting of tin, silver, gold, bismuth, antimony, zinc, nickel, chromium, magnesium, indium, tellurium, and gallium. 
         [0014]    The above structure further includes an independent washer formed along the periphery of at least one surface of the inner layer circuit board and corresponding in position to the metal frame. A first electrical conductive layer is disposed between the dielectric layer and the first metal frame, and a second electrical conductive layer is disposed between the solder mask and the second metal frame. The first and second grooves are rectangular in shape. A portion of the build-up circuit layer is in the dielectric layer in the region surrounded by the first metal frame; openings are formed in the solder mask in the region surrounded by the second metal frame for exposing a portion of the build-up circuit layer so as to be electrically connecting pads. Metal posts are formed on the electrically connecting pads. 
         [0015]    In conclusion, the warpage-proof circuit board structure of the present invention provides a metal support element that may increase the strength of the circuit board structure, so to avoid warpage of the circuit board caused by temperature variation of the semiconductor substrate fabrication processes. At the same time, the rectangular metal frames surrounding on the surface of the circuit board can be used for heat dissipation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The present invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein: 
           [0017]      FIG. 1  is a cross-sectional schematic diagram depicting a traditional circuit board structure; 
           [0018]      FIGS. 2A to 2K  are schematic diagrams illustrating a first embodiment of a method for manufacturing a warpage-proof circuit board structure of the present invention; 
           [0019]    FIG.  2 E′ is a top view of  FIG. 2E ; 
           [0020]    FIG.  2 K′ is a top view of  FIG. 2K ; and 
           [0021]    FIG.  2 K″ is a bottom view of  FIG. 2K . 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0022]    The present invention is described by the following specific embodiments. Those with ordinary skills in the arts can readily understand the other advantages and functions of the present invention after reading the disclosure of this specification. The present invention can also be implemented with different embodiments. Various details described in this specification can be modified based on different viewpoints and applications without departing from the scope of the present invention. 
         [0023]    Referring to  FIGS. 2A to 2K , a schematic diagram shows the method for manufacturing a warpage-proof circuit board structure according to an embodiment of the present invention. 
         [0024]    Referring now to  FIG. 2A , first, an inner layer circuit board is provided. The inner layer circuit board  20  is a two-layer or multi-layer circuit board with patterned circuit completed. The circuit layer  201  is formed on at least one surface of the inner layer circuit board  20 , which has electrically connecting pads  202 . An independent washer  203  is formed along the periphery of the at least one surface of the inner layer circuit board  20 . 
         [0025]    Referring to  FIG. 2B , a dielectric layer  21  is formed on the at least one surface of the inner layer circuit board  20 . A rectangular shaped first groove  210  corresponding in position to the independent washer  203  is formed along the periphery of the dielectric layer  21 . The independent washer provides a barrier that shields laser beam used when producing the first groove  210  from the inner layer circuit board. A plurality of vias  211  are formed in the dielectric layer  21  within the area surrounded by the first groove  210  for exposing the electrically connecting pads  202  of the inner layer circuit board  20 . The dielectric layer  21  can be made of an insulating material, such as FR-4 resin, FR-5 resin, epoxy resin, polyesters, cyanate ester, polyimide, BT (Bismaleimide Trazine) or glass fiber mixed with epoxy resin. 
         [0026]    Referring to  FIG. 2C , a first electrical conductive layer  22  is formed on the dielectric layer  21 , the first groove  210  and the vias  211 . The first electrical conductive layer  22  is used as a electrical current conducting path for electroplated metal materials, as will be mentioned later. The first electrical conductive layer  22  can be made up of metal, alloy, deposited multi-layer metal frame, for example one selected from the group consisting of copper, tin, nickel, chromium, titanium or copper-chromium alloy, or conductive polymer such as polyacetylene, polyaniline or organic sulfuric polymer. 
         [0027]    Referring to  FIG. 2D , a resist layer  23  is formed on the first electrical conductive layer  22 . The resist layer  23  includes a groove  230  for exposing the portions of the first electrical conductive layer  22  in the first groove  210  of the dielectric layer and a plurality of openings  231  for exposing the portions of the first electrical conductive layer  22  in the vias  211  of the dielectric layer  21 . The resist layer  23  can be a dry film or liquid photoresist that can be formed on the first electrical conductive layer  22  by printing, spin coating or adhesion. The resist layer  23  can be patterned by steps such as exposure and development etc. 
         [0028]    Referring to  FIG. 2E , electroplating is performed, wherein the first electrical conductive layer  22  is used as the electrical current conducting path, so as to form a first metal frame  24 ′ in the first groove  210  of the dielectric layer  21  and the resist groove  230  through electroplating. A build-up circuit layer  240  is formed by electroplating in the vias  211  of the dielectric layer  21  and on the portions of the first electrical conductive layer  22  in the resist openings  231 . Electrical conductive vias  241  are formed in the dielectric layer  21  to electrically connect to the circuit layer  201  of the inner layer circuit board  20 . The first metal frame  24 ′, the build-up circuit layer  240  and the conductive vias  241  are preferably made from copper, but the present invention is not limited to this. FIG.  2 E′ is a top view of  FIG. 2E , wherein the build-up circuit layer  240  is surrounded by the first metal frame  24 ′. 
         [0029]    Referring to  FIG. 2F , the resist layer  23  and a portion of the first electrical conductive layer  22  covered by the resist layer  23  are removed using, for example, solvent and etchant, respectively. As a result, the first metal frame  24 ′ and the build-up circuit layer  240  protrude from the surface of the dielectric layer  21 . The process for removing the resist layer  23  and the portion of the first electrical conductive layer  22  are well known in the art, and therefore further description is omitted. 
         [0030]    Referring to  FIG. 2G , the processes in  FIG. 2B  to  FIG. 2F  are repeated to form another dielectric layer  21   a , a build-up circuit layer  240   a  and a first metal frame  24   a ′. However, the present invention is not limited to the two build-up circuit layers as shown, more build-up circuit layers can be formed by repeating the above steps when necessary. The build-up circuit layer  240 ,  240   a  are connected to one another. The first metal frame  24 ′,  24   a ′ are connected to one another. 
         [0031]    As shown in  FIG. 2H , a solder mask  25  is formed on the outer most layer of the dielectric layer  21   a . A rectangular second groove  250  is formed in the solder mask  25  for exposing the first metal frame  24   a ′. A plurality of openings  251  are also formed in the solder mask  25  for exposing the electrically connecting pads  242  in the underlying build-up circuit layer  240   a.    
         [0032]    As shown in  FIG. 2I , a second electrical conductive layer  22 ′ is formed on the solder mask  25  and in the second groove  250  of the solder mask  25 . Another resist layer  23 ′ is formed on the second electrical conductive layer  22 ′. A groove  230 ′ and openings  231 ′ corresponding in position to the first metal frame  24   a ′ and the electrically connecting pads  242  are formed in the resist layer  23 ′, so as to expose the second electrical conductive layer  22 ′ on the first metal frame  24   a ′ and the electrically connecting pads  242 . 
         [0033]    As shown in  FIG. 2J , a second metal frame  24 ″ and a metal protecting layer  26  are sequentially formed on a portion of the second electrical conductive layer  22 ′ in the groove  230 ′ of the resist layer  23 ′ through electroplating. Accordingly, the second metal frame  24 ″ is formed on the first metal frame  24 ′, so the first metal frames  24 ′,  24   a ′ and second metal frame  24 ″ constitutes a metal frame  24 , which increases the strength of the inner layer circuit board  20 , thus avoiding warpage. Metal posts  243  and the metal protecting layer  26  are formed on the electrically connecting pads  242  located in the openings  231 ′ of the resist layer  23 ′ and the openings  251  of the solder mask  25  by electroplating. The metal frame  24 , the metal posts  243  and the electrically connecting pads  242  are preferably copper. The metal protecting layer  26  can be one selected from the group consisting of lead, tin, silver, gold, bismuth, antimony, zinc, nickel, chromium, magnesium, indium, tellurium, and gallium. 
         [0034]    As shown in  FIG. 2K , the resist layer  23 ′ and the portion of the second electrical conductive layer  22 ′ covered by the resist layer  23 ′ are removed, so the second metal frame  24 ″ protrudes from the surface of the solder mask  25 , thereby avoiding warpage and dissipating heat through the exposed second metal frame  24 ″. Additionally, FIGS.  2 K′ and  2 K″ are top views of two sides of the circuit board, respectively. As can be seen, the metal frames  24  surround the metal posts  243  on solder ball disposed side (as shown in FIG.  2 K′) and the metal posts  243  on chip disposed side (as shown in FIG.  2 K″). 
         [0035]    The metal protecting layer  26  is formed on the second metal frame  24 ″ and the metal posts  243  so as to protect the second metal frame  24 ″ and the metal posts  243  from oxidation. 
         [0036]    Furthermore, electrically connecting elements (not shown), such as solder balls, can be formed on the metal posts  243  for electrically connecting to other electronic devices. 
         [0037]    The present invention further provides a warpage-proof circuit board structure, including: an inner layer circuit board  20 ; one or more dielectric layers  21  formed on at least one surface of the inner layer circuit board  20  and with a first groove  210  formed at a position close to the periphery of the inner layer circuit board  20 ; a solder mask  25  formed on the surface of the dielectric layer  21  and with a second groove  250  corresponding in position to the first groove  210  formed in the dielectric layer  21 ; and a metal frame  24  formed in the first and second grooves  210  and  250  and protruding from the surface of the solder mask  25 . 
         [0038]    The metal frame  24  is consisted of a first metal frame  24 ′ and  24   a ′ and a second metal frame  24 ″. The circuit board structure further includes a build-up circuit layer  240  on the dielectric layer  21 . Electrical conductive vias  241  formed in the dielectric layer  21  electrically connects the build-up circuit layer  240  and the inner layer circuit board  20 . The build-up circuit layer  240  or  240   a  in the dielectric layer  21  is surrounded by the first metal frame  24 ′ or  24   a ′. Openings  251  are formed in the solder mask  25  surrounded by the second metal frame  24 ″ for exposing a portion of the build-up circuit layer  240   a  so as to be electrically connecting pads  242 . Metal posts are formed on the electrically connecting pads  242 . 
         [0039]    A metal protecting layer  26  is formed on the second metal frame  24 ″ and the metal posts  243  to protect them from oxidation. 
         [0040]    In conclusion, the warpage-proof circuit board structure of the present invention provides a metal frame consisted of first and second metal frames to increase the strength of the circuit board structure, but the present invention is not limited to this, a metal frame can be formed at any layer in the inner layer circuit board depending on the need to avoid warpage and delamination. At the same time, the metal frames positioned on the surface of the circuit board can be used for heat dissipation. The above embodiments are only used to illustrate the principles of the present invention, and they should not be construed as to limit the present invention in any way. The above embodiments can be modified by those with ordinary skills in the arts without departing from the scope of the present invention as defined in the following appended claims.