Abstract:
A method of fabricating protective caps for protecting devices on wafer surface includes: (a) providing a non-metal cap substrate and forming a metal layer on the non-metal cap substrate; (b) forming a plurality of cavities on a surface of the metal layer, wherein the location of each cavity corresponds to each of the devices on the wafer surface; and (c) forming a protective cap in each cavity and forming a plurality of bonding media around the cavities.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a method of fabricating protective caps, and more particularly, to a method of fabricating protective caps for protecting elements on a wafer surface. 
   2. Description of the Prior Art 
   Currently, wafer level chip scale packages (WLCSP) have become one of the most popular packaging techniques. The wafer level chip scale packages are defined by having correspondingly equal or larger areas of the package structure than the area of the die. The area of the package structure is usually no larger than 25% of the die area. In general, the main difference between the wafer level chip scale package and the conventional package lies in the fact that the wafer level chip scale package first packages the wafer before the dicing process and then performs a dicing process after the packaging process to form a plurality of packaging structures. This in comparison to the conventional package wherein the wafer is diced first to form a plurality of dies and a packaging process is performed for each of the dies thereafter. 
   Since part of the wafer surface usually includes fragile structures, such as micro-electromechanical structures, special processes are often performed to protect the micro-electromechanical structures on the wafer surface during the packaging process of the wafer. Currently, protective caps made of metal or glass are commonly disposed on the fragile structures to protect the fragile structures from external damage. The fabrication of the protective caps can be divided into two categories. A first category and method of fabricating the protective caps involves dicing the wafer into a plurality of dies and fabricating protective caps on the surface of each die thereafter. However, this method is relatively complex and requires significantly long processing time. Hence, another wafer level package process has been introduced to fabricate the protective caps. 
   Please refer to  FIG. 1  through  FIG. 3 .  FIG. 1  through  FIG. 3  are perspective diagrams showing a wafer level package process according to the prior art. As shown in  FIG. 1 , a substrate  12  is provided, in which the surface of the substrate  12  includes a plurality of fragile structures  16 , such as micro-electromechanical structures. Next, a second category and method of fabricating the protective caps involves providing a cap substrate  14 , in which the surface of the cap substrate  14  includes a plurality of cavities  22 , such that the cavities  22  are located corresponding to the fragile structures  16 . Next, the cap substrate  14  is disposed on the substrate  12 , in which the cavities  22  of the cap substrate  14  are corresponding to the fragile structures  16 . Preferably, the cap substrate  14  also includes a plurality of bonding media  20  disposed on the periphery region surrounding the cavities  22 , and a plurality of sealed rings  18  corresponding to the substrate  12 , such that the bonding media  20  and the sealed rings  18  are utilized to bond the cap substrate  14  to the substrate  12 . 
   As shown in  FIG. 2 , the cap substrate  14  and the substrate  12  are diced along the direction I to form a plurality of dies  30 , in which the surface of each die  30  includes a protective cap  40  disposed on each of the fragile structures  16 . As shown in  FIG. 3 , since the surface of the substrate  12  also includes a plurality of bonding pads  24  and the bonding pads  24  are covered by the protective caps  40 , another dicing process must necessarily be performed along the direction II to dice the cap substrate  14  and expose the bonding pads  24  for facilitating electrical connection thereafter. 
   As a result, the two dicing processes utilized in the conventional packaging process will not only increase the possibility of misalignment, but also increase damage to the die resulting from pollution caused by micro-particles. Hence, if the number of dicing operations were to be reduced, damages resulted from the dicing process could be prevented and the yield of the package process could thereby be increased. 
   SUMMARY OF THE INVENTION 
   It is therefore an objective of the present invention to provide a package structure and package process for protecting devices on the wafer surface to solve the above-mentioned problems. 
   According to the present invention, a method of fabricating protective caps for protecting devices on wafer surface includes: (a) providing a non-metal cap substrate and forming a metal layer on the non-metal cap substrate; (b) forming a plurality of cavities on a surface of the metal layer, wherein the location of each cavity corresponds to each of the devices on the wafer surface; and (c) forming a protective cap in each cavity and forming a plurality of bonding media around the cavities. 
   It is another aspect of the present invention to provide a wafer level package process, in which the process includes: (a) providing a device substrate, wherein one surface of the device substrate comprises a plurality of devices; (b) providing a non-metal cap substrate and forming a metal layer on the non-metal cap substrate; (c) forming a plurality of cavities on one surface of the metal layer, wherein the location of each cavity is corresponding to the location of each device of the devices substrate; (d) forming a protective cap in each cavity by utilizing the cavity as a mold; (e) aligning each cavity of the cap substrate to each device of the device substrate and connecting the protective caps on the device substrate, such that each of the protective caps covers each device; and (f) removing the metal layer from the protective caps. 
   By mass-producing the protective caps for devices on wafer surface and eliminating the extra dicing process for protective caps, the present invention is able to significantly reduce damage to the wafer and devices from the dicing process and thereby increase the overall yield. 
   These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  through  FIG. 3  are perspective diagrams showing a wafer level package process according to the prior art. 
       FIG. 4  through  FIG. 7  are perspective diagrams showing the means of fabricating protective caps according to a preferred embodiment of the present invention. 
       FIG. 8  and  FIG. 9  are perspective diagrams showing the means of fabricating protective caps and bonding media according another embodiment of the present invention. 
       FIG. 10  through  FIG. 12  are perspective diagrams showing a wafer level package process according to another embodiment of the present invention. 
       FIG. 13  is a perspective diagram showing a means of removing the non-metal cap substrate according to another embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
   Please refer to  FIG. 4  through  FIG. 7 .  FIG. 4  through  FIG. 7  are perspective diagrams showing the means of fabricating protective caps according to the preferred embodiment of the present invention. As shown in  FIG. 4 , a non-metal cap substrate  214 , such a semiconductor substrate is provided, in which the non-metal cap substrate  214  can be a silicon substrate, a glass substrate, a quartz substrate, or a plastic substrate. Next, a seed layer  216  is formed on the non-metal cap substrate  214 , in which the seed layer  216  is composed of titanium, copper or other materials commonly utilized for forming seed layers. Next, as shown in  FIG. 5 , a plating process is performed to form a metal layer  218  on the seed layer  216 , in which the metal layer  218  is composed of copper or other materials. 
   As shown in  FIG. 6 , a patterned mask  222  is disposed on the metal layer  218 , and an etching process is performed to etch the metal layer  218  not covered by the patterned mask  222  for forming a plurality of cavities  224 . Preferably, the cavities  224  are utilized to fabricate protective caps for protecting fragile devices on the wafer surface, and the location of the cavities  224  is adjusted corresponding to the location of the fragile structures or other devices on the surface of the wafer. 
   Next, as shown in  FIG. 7 , the patterned mask  222  is removed and another patterned mask  226  is formed on the surface of the metal layer  218 , in which the patterned mask  226  exposes the cavities  224  and the area surrounding the cavities  224 . Next, a plating process, such as an electroplating process, is performed to form a plurality of protective caps  236  on the exposed metal layer  218 , in which the protective caps  236  are composed of metal or other materials. For instance, if the devices to be protected are composed of light sensitive materials, the protective cap  236  can be made up of light-penetrating materials such as glass or quartz. Additionally, since the protective caps  236  will be detached from the metal layer  218  in a later process, the material utilized for fabricating the protective caps  236  should be selected accordingly. For instance, when copper is utilized to fabricate the metal layer  218 , nickel can be selected to fabricate the protective caps  236  to facilitate the removal of the metal layer  218  from the protective caps  236  during the etching process. 
   After the formation of the protective caps  236 , a plurality of bonding media  244  is formed on the protective caps  236 . According to the preferred embodiment of the present invention, the bonding media  244  is composed of a double layer structure having a tin layer  238  and a gold layer  240 . Nevertheless, other materials can also be utilized to form the bonding media  244 . The patterned mask  226  is removed thereafter. 
   Preferably, the protective caps  236  are utilized to protect the devices on the surface of the wafer and the bonding media  244  are utilized to connect to the sealed rings fabricated in the later stage of the fabrication process and fix the protective caps  236  on the devices. Depending on the functionality of each component, the fabrication of the protective caps  236  and the bonding media  244  is not limited to the process described previously. Please refer to  FIG. 8  and  FIG. 9 .  FIG. 8  and  FIG. 9  are perspective diagrams showing the means of fabricating protective caps and bonding media according another embodiment of the present invention. In order to compare to the embodiment discussed previously, same labels will be carried forward through  FIG. 8  and  FIG. 9 . As shown in  FIG. 8 , the plurality of protective caps  236  is formed in the cavities  224  while maintaining the patterned mask  222  after the formation of the cavities  224 . As shown in  FIG. 9 , the patterned mask  222  is removed and another patterned mask  226  is formed on the non-metal cap substrate  214 , in which the patterned mask  226  only exposes the surrounding area of the cavities  224 . Next, a plating process is performed to form the bonding media  224  around the cavities  224 , in which the bonding media  224  is composed of a tin layer  238  and a gold layer  240 . The patterned mask  226  is removed thereafter. 
   According to another embodiment of the present invention, a wafer level package process is introduced to package the protective caps discussed previously onto the fragile structures or other devices on the wafer surface. Please refer to  FIG. 10  through  FIG. 12 .  FIG. 10  through  FIG. 12  are perspective diagrams showing a wafer level package process according to another embodiment of the present invention. As shown in  FIG. 10 , a device substrate  212  is provided, in which the surface of the device substrate  212  includes a plurality of devices  246 . Preferably, the devices  246  are micro-electromechanical devices, light sensitive devices, or other devices. Additionally, a plurality of sealed rings  248  is disposed around the devices  246  for protecting the devices  246  in the later process. Furthermore, the surface of the device substrate  212  includes a plurality of bonding pads  250  for electrically connecting to other devices. 
   Next, as shown in  FIG. 11 , the protective caps  236  fabricated on the non-metal cap substrate  214  are disposed on the device substrate  212 , such that each protective cap  236  covers each device  246 , and the protective caps  236  are fixed on the sealed rings  248  by utilizing the bonding media  244 . Next, as shown in  FIG. 12 , the non-metal cap substrate  214  and the metal layer  218  are removed, in which the removal of the non-metal cap substrate  214  may involve the utilization of a mechanical polishing process or an etching process. After the non-metal cap substrate  214  is detached from the metal layer  218 , the metal layer  218  will be removed from the protective caps  236 . According to the preferred embodiment of the present invention, the metal layer  218  is composed of copper whereas the protective caps  236  are composed of nickel. Since copper exhibits a higher etching selectivity relative to nickel, an etching process is then performed to remove the metal layer  218 . Nevertheless, other process can also be utilized to achieve the same goal. 
   Please refer to  FIG. 13 .  FIG. 13  is a perspective diagram showing a means of removing the non-metal cap substrate  214  according to another embodiment of the present invention. As shown in  FIG. 13 , an adhesive layer  215  is formed over the surface of the non-metal cap substrate  214  and a plurality of through holes  217  is formed within the non-metal cap substrate  214  before the deposition of the seed layer  216 . Hence, if the non-metal cap substrate  214  were to be removed, the present invention is able to inject a releasing agent into the through holes  217  to quickly release the non-metal cap substrate  214  from the metal layer  218 . By utilizing this method, the non-metal cap substrate  214  can be used repeatedly thereby saving resources. 
   By utilizing the protective caps  236  to cover only the devices  246  on the device substrate  212  but not the bonding pads  250 , the present invention requires no additional dicing process for exposing the bonding pads  250 , results in no influence on the electrical connection of the device substrate  212 , thereby significantly reducing the damage to the wafer and the devices resulted from the dicing process and increasing the overall yield. 
   Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.