Abstract:
The present invention discloses an electronic device package and a method of the package. In particular, an electronic device package and a method of the package suitable for a bumpless electronic device package with enhanced electrical performance and heat-dissipation efficiency are disclosed. The method comprises: providing a substrate having a plurality of vias and a plurality of electronic devices; forming a gluing layer on a surface of the substrate and fixing the electronic devices on the gluing layer, wherein the electronic devices have I/O units aligned with the vias respectively; forming a plurality of fixing layers in the gaps between the electronic devices; trenching a plurality of openings aligned with the vias respectively in the fixing layer; forming a plurality of metallic conductive units in the vias, the openings and part of the surface of the substrate; and forming a passivation layer over the other surface of the substrate.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an electronic device package and a method of manufacturing the package, and more particularly, to an electronic device package and a method of manufacturing the package suitable for a bumpless electronic device package with enhanced electrical performance and heat-dissipation efficiency. 
     2. Description of Related Art 
     A prior electronic device packaging process is described as follows. At the beginning, as shown in  FIG. 1   a , a plurality of through-holes (not shown) is trenched in the substrate  11  by mechanical drilling or laser drilling, and the fixing tape  12  is then adhered to the surface of the substrate  11 . Next, a quantity of dice  13  is placed into the plurality of through-holes, being held with the aforesaid fixing tape  12 . Even so, the dice mounted with the fixing tape  12  are not held in a completely secure manner. Therefore, glue  14  is generally injected into the though-holes to further fix the position of the dice  13 . After all, as shown in  FIG. 1   b , the passivation layer  15  made from a dielectric material is formed over a surface of the substrate opposing to the surface covered with the fixing tape  12  by spin coating or other manners. 
     It can be easily understood that the dice  13  need to be fully accommodated and fixed in the through-holes of the aforesaid substrate  11 . Consequently, the size of each of the through-holes must be accurate and be slightly larger than that of the die. When a plurality of dice with different sizes is packaged on a single substrate, it will be necessary to have the through-holes with various widths and lengths each of which corresponding to the size of dice respectively. As such, the packaging process will become much complicated. 
     Besides, due to the size of the aforesaid through-hole are just slightly larger than that of the die  13  accommodated therein. The die  13  may get stuck obliquely somewhere within the through-hole so that the die  13  fails to be mounted on the fixing tape  12  disposed at the bottom of the through-hole as desired. The deviation of the position of the die will cause the subsequent process being unable to execute, such as formation of metal contacts. Thus, the yield of the electronic device packages is adversely affected. Furthermore, since the dice  13  are fully enclosed with the glue  14  in the through-holes, the heat generated during operation of the dice  13  cannot be efficiently dissipated to the external environment. Thus, the package tends to be overheated, shorten the lifetime of the dice  13 . 
     Although the electrical performance of the electronic device package can be satisfactory, the yield of the electronic device package formed by the prior process is low. Therefore, a dire need exists for the industry to provide an improved method of electronic device packages capable of solving the disadvantages of the aforesaid prior electronic device packaging process, simplifying the process of electronic device packages and increasing the yield of such packages. 
     SUMMARY OF THE INVENTION 
     A manufacturing method of an electronic device package according to the present invention comprises: providing a substrate having a plurality of first vias and a plurality of electronic devices each of which having a plurality of I/O units; forming a gluing layer on a first surface of the substrate; fixing the electronic devices on the gluing layer, wherein the I/O units of the electronic devices are aligned with the first vias respectively; forming a plurality of fixing layers in the gaps between the electronic devices; trenching a plurality of first openings aligned with the first vias in the fixing layer respectively; forming a plurality of first metallic conductive units in the first vias, the first openings and part of a second surface of the substrate, wherein the first metallic conductive units are connected to the I/O units respectively; and forming a passivation layer over the second surface of the substrate, wherein the second surface is remote from the electronic devices. 
     A manufacturing method of an electronic device package according to the present invention comprises: providing a substrate having a first surface on which a gluing layer is formed and a plurality of electronic devices each of which having a plurality of I/O units; fixing the electronic devices on the gluing layer; forming a plurality of fixing layers in the gaps between the electronic devices; trenching a plurality of first vias in the substrate and a plurality of first openings in the gluing layer, wherein the first openings are aligned with the I/O units while the first vias are aligned with the first openings; forming a plurality of first metallic conductive units in the first vias, the first openings and part of a second surface of the substrate, wherein the first metallic conductive units are connected to the I/O units respectively; and forming a passivation layer over the second surface of the substrate, wherein the second surface is remote from the electronic devices. 
     An electronic device package associated with a plurality of electronic devices each of which having a plurality of I/O units according to the present invention comprises: a substrate having a plurality of first vias; a gluing layer having a plurality of first openings, wherein the electronic devices are fixed to a first surface of the substrate with the gluing layer, the first vias correspond to the first openings corresponding to the I/O units respectively; a plurality of fixing layers being disposed on the first surface of the substrate and in the gaps between the electronic devices; a plurality of metallic conductive units mounted in the first vias, the first openings and part of a second surface of the substrate, respectively, wherein the first metallic conductive units are connected to the I/O units respectively; a passivation layer covering part of a surface of the first metallic conductive units; and a plurality of conducting members formed on part of the surface of the first metallic conductive units which is not covered with the passivation layer. 
     Accordingly, the electronic device package and the manufacturing method of the package provided by the present invention can solve the disadvantages of the prior electronic device packaging process, simplify the process of electronic device packages and increase the yield of such packages. 
     The substrate of the present invention is not specifically defined, preferably glass fiber, polyimide, copper, aluminum or a non-conductive plastic material. The electronic devices of the present invention is not specifically defined, preferably a dice. The method for forming the first vias of the substrate of the present invention is not specifically defined, preferably by laser drilling or mechanical drilling. The method for forming the first openings of the present invention is not specifically defined, preferably by mechanical drilling or laser drilling. 
     The form of the gluing layer of the present invention is not specifically defined, preferably a liquid-state glue or a thin-film glue. 
     The method for forming the gluing layer of the present invention is not specifically defined, preferably by a sol-gel method, a bonding method, a printing method or a pressing method. The method for forming the fixing layers in the gaps between the electronic devices of the present invention is not specifically defined, preferably by a spin coating method, a sol-gel method or a screen printing method. The first metallic conductive units of the present invention can be made from any kind of conducting material, preferably copper or gold. The method for forming the passivation layer of the present invention is not specifically defined, preferably by a sol-gel method, a spin coating method or a screen printing method. The method for forming second vias of the present invention in the substrate is not specifically defined, preferably by laser drilling or mechanical drilling. The method for forming second openings of the present invention in the gluing layer is not specifically defined, preferably by mechanical drilling or laser drilling. The method for forming through-holes of the present invention in the fixing layers is not specifically defined, preferably by mechanical drilling or laser drilling. The second metallic conductive units of the present invention can be made from any kind of conducting material, preferably copper or gold. 
     Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a  is a schematic view of a substrate used in a prior electronic device packaging process. 
         FIG. 1   b  is a schematic view of an electronic device package formed by a prior electronic device packaging process. 
         FIG. 2  is a flowchart of a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 3  is a schematic view of a substrate used in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 4  is a schematic view illustrating the position of dice on a substrate when the dice are attached to the surface of the substrate in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 5  is a schematic view of an electronic device package having a number of dice held on a substrate surface in a manufacturing method for packaging electronic devices according to a first preferred embodiment of the present invention. 
         FIG. 6  is a schematic view of an electronic device package having a plurality of openings formed in a gluing layer in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 7  is a schematic view of an electronic device package having a plurality of metal contacts and a passivation layer formed in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 8  is a schematic view of an electronic device package having a plurality of projections formed on a surface of a passivation layer in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 9  is a schematic view of an electronic device package having a plurality of solder balls formed between projections in a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. 
         FIG. 10  is a flowchart of a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 11  is a schematic view of a substrate used in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 12  is a schematic view of an electronic device package having dice mounted on a substrate surface in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 13  is a schematic view of an electronic device package having dice mounted on a substrate surface and a plurality of fixing protective layers formed in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 14  is a schematic view of an electronic device package having a plurality of openings formed in a gluing layer in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 15  is a schematic view of an electronic device package having a plurality of metal contacts and a passivation layer formed in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 16  is a schematic view of an electronic device package having a plurality of projections formed on a surface of a passivation layer in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 17  is a schematic view of an electronic device package having a plurality of solder balls formed between projections in a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. 
         FIG. 18  is a schematic view of an electronic device package having a plurality of vias, a plurality of openings, a plurality of through-holes and a plurality of grooves in a manufacturing method for packaging electronic devices according to the third preferred embodiment of the present invention. 
         FIG. 19  is a schematic view of an electronic device package having a plurality of metal contacts, a plurality of bottom metal contacts and a passivation layer formed in a manufacturing method for packaging electronic devices according to the third preferred embodiment of the present invention. 
         FIG. 20  is a schematic view of an electronic device package having a plurality of projections formed in a manufacturing method for packaging electronic devices according to the third preferred embodiment of the present invention. 
         FIG. 21  is a schematic view of an electronic device package having a plurality of solder balls formed between projections in a manufacturing method for packaging electronic devices according to the third preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention is now described step by step with reference to the flowchart ( FIG. 2 ) and the diagrams of the packaging structure in the respective processing steps ( FIG. 3  to  FIG. 9 ). 
     Referring to  FIG. 3 , a substrate  21  having a plurality of vias  22  formed therein by mechanical drilling or laser drilling is provided, the vias  22  being arranged in accordance with I/O ports of a die to be incorporated. Referring to  FIGS. 4 and 5 , a gluing layer  23  is formed over the surface of the substrate  21  by spin coating. Two dice  24  each of which having a plurality of I/O ports  241  are mounted on the surface of the gluing layer  23  in an aligned manner by a pressing method. (Although only two dice are shown in the related drawings, it is not intended to limit the scope of the present invention with respect to the quantity of the die, but serving as an example for the descriptions which follow.) The I/O ports  241  of each of the two dice  24  are aligned with the vias  22  of the substrate  21 , respectively. After the two dice  24  are fixedly attached to the surface of the gluing layer  23 , a plurality of fixing protective layers  25  is formed in the gap between the two dice  24  and the gaps between either of the two dice  24  and any other die (not shown) by a screen printing method. It is noted that the fixing protective layers  25  can also be formed over the surface (not shown) of the two dice  24  by a screen printing method. 
     Referring to  FIG. 6 , a plurality of openings  221  is formed in the gluing layer  23  by laser drilling, wherein the openings  221  are aligned with the plurality of vias  22  of the substrate  21  respectively. Referring to  FIG. 7 , a plurality of metal contacts  26  is formed in the aforesaid vias  22 , the openings  221  and part of the surface of the substrate  21 , being electrical connecting to the I/O ports  241  of the two dice  24 . The metal contacts  26  are formed by plating. Then, a water-resisting layer  27  is formed over a surface of the substrate  21  by a sol-gel method, wherein the surface is remote from the two dice  24 . The water-resisting layer  27  may cover the metal contacts  26  formed on part of the surface of the substrate  21 . After the water-resisting layer  27  is formed, the water-resisting layer  27  is etched to form a desired pattern by employing the widely adopted technique, such as dry etching or wet etching. As such, a plurality of projections  271  is formed as shown in  FIG. 8 . Referring to  FIG. 9 , a step of solder ball implantation proceeds, in which a plurality of solder balls  28  is implanted into the gaps between the projections  271 . Consequently, an electronic device package is formed by employing a manufacturing method for packaging electronic devices according to the first preferred embodiment of the present invention. It is noted that the dice  24  of different types may have various quantities of I/O ports  241 . Thus, the manufacturing method for packaging electronic devices of the present invention may further comprise a step forming a multi-layer wiring structure having a build-up layer over the surface of the substrate  21  to generate at least one isolation layer and corresponding wirings. Hence, the respective I/O ports  241  of each of the dice  24  can be laid out as a whole corresponding to the position of the solder balls to be implanted. 
       FIG. 10  is the flowchart of a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. Similarly, this preferred embodiment is now described step by step with reference to the flowchart ( FIG. 10 ) and the diagrams of the packaging structure in the respective processing steps ( FIG. 11  to  FIG. 17 ). 
     Referring to  FIG. 11 , a substrate  31  having a gluing layer  32  formed over the surface thereof is provided. The gluing layer  32  is formed on the surface of the substrate  31  by an appropriate method such as pressing. Referring to  FIGS. 12 and 13 , two dice  33  each of which having a plurality of I/O ports  331  are mounted on the surface of the gluing layer  32  by pressing. (Although only two dice are shown in the related drawings, it is not intended to limit the scope of the present invention with respect to the number of the die, but serves as an example for the descriptions which follow.) A plurality of fixing protective layers  34  is formed in the gap between the two dice  33  and the gaps between either of the two dice  33  and any other die (not shown) by a screen printing method. It is noted that the fixing protective layers  34  can also be formed over the surface (not shown) of the two dice  33 . 
     Referring to  FIG. 14 , a plurality of vias  351  and a plurality of openings  352  are trenched in the substrate  31  and the gluing layer  32  respectively by laser drilling. The vias  351  and the openings  352  are aligned with the I/O ports  331  of the two dice  33  respectively. Referring to  FIG. 15 , a plurality of metallic conductive portions  36  is formed in the aforesaid vias  351 , the openings  352  and part of the surface of the substrate  31 , being electrical connecting to the I/O ports  331  of the two dice  33 . Then, a water-resisting layer  37  is formed over a surface of the substrate  33  by a sol-gel method, wherein the surface is remote from the two dice  33 . The water-resisting layer  33  may cover the metallic conductive portions  36  formed on part of the surface of the substrate  31 . After the water-resisting layer  37  is formed, the water-resisting layer  37  is etched to form a desired pattern by employing the widely adopted technique, such as dry etching or wet etching. As such, a plurality of projections  371  is formed as shown in  FIG. 16 . Referring to  FIG. 17 , a step of solder ball implant proceeds, in which a plurality of solder balls  38  is implanted into the gaps between the projections  371 . Consequently, an electronic device package is formed by employing a manufacturing method for packaging electronic devices according to the second preferred embodiment of the present invention. It is noted that the dice  33  of different types may have various quantities of I/O ports  331 . Thus, the manufacturing method for packaging electronic devices of the present invention may further comprise a step for forming a multi-layer wiring structure having a build-up layer over the surface of the substrate  31  to generate at least one isolation layer and corresponding wirings. Hence, the respective I/O ports  331  of each of the dice  33  can be laid out as a whole corresponding to the position of the solder balls to be implanted. 
     A manufacturing method for packaging electronic devices according to the third embodiment of the present invention is described below. 
     Referring to  FIGS. 18 through 21 , a manufacturing method for packaging electronic devices according to the third embodiment of the present invention includes the formation of a plurality of additional metal contacts such as bottom metal contacts  361  as shown in  FIG. 19  at the end close to the aforesaid two dice of an electronic device package. 
     It is noted that some preceding steps of the manufacturing method for packaging electronic devices according to the third embodiment of the present invention are substantially similar to those of the first or the second embodiment of the present invention, except that a plurality of through-holes  353  is trenched in the fixing protective layers  25  ( 34 ), the gluing layer  23  ( 32 ) and the substrate  21  ( 31 ) in the step of either forming the openings  221  in the gluing layer  23  by of mechanical drilling or laser drilling (as illustrated in  FIG. 6  for the first embodiment) or forming the vias  351  and the openings  352  in the substrate  31  and the gluing layer  32  respectively by mechanical drilling or laser drilling (as illustrate in  FIG. 14  for the second embodiment). In addition to the through-holes  353 , grooves  354  can also be trenched at the bottom of the fixing protective layers  34 , as shown in  FIG. 18 . 
     Referring to  FIG. 19 , a plurality of metallic conductive portions  36  is formed in the aforesaid vias  351 , the openings  352 , the through-holes  353  and part of the surface of the substrate  31 , being electrical connecting to the I/O ports  331  of the two dice  33 . In addition, the bottom metal contacts  361  are formed in the grooves  354 . Then, a water-resisting layer  37  is formed over a surface of the substrate  33  by a sol-gel method, wherein the surface is remote from the two dice  33 . The water-resisting layer  33  may cover the metallic conductive portions  36  formed on part of the surface of the substrate  31 . After the water-resisting layer  37  is formed, the water-resisting layer  37  is then etched to form a desired pattern by employing the widely adopted technique, such as dry etching or wet etching. As such, a plurality of projections  371  is formed as shown in  FIG. 20 . Referring to  FIG. 21 , a step of solder ball implant proceeds, in which a plurality of solder balls  38  is implanted into the gaps between the projections  371 . It is noted that the dice  33  of different types may have various quantities of I/O ports  331 . Thus, the manufacturing method for packaging electronic devices of the present invention may further comprise a step forming a multi-layer wiring structure having a build-up layer over the surface of the substrate  31  to generate at least one isolation layer and corresponding wirings. Hence, the respective I/O ports  331  of each of the dice  33  can be laid out as a whole corresponding to the position of the solder balls to be implanted. Consequently an electronic device package having additional bottom metal contacts  361  is formed by employing a manufacturing method for packaging electronic devices according to the third embodiment of the present invention. 
     It is noted that a manufacturing method for packaging electronic devices according to the third embodiment of the present invention can be illustrated by referring to the electronic device package formed by employing a manufacturing method for packaging electronic devices according to the first embodiment of the preset invention, though the related descriptions and the reference numbers as illustrated from  FIG. 18  to  FIG. 21  refer to the electronic device package formed by employing a manufacturing method for packaging electronic devices according to the second embodiment of the present invention. 
     Although the present invention has been explained in relation to its preferred embodiments, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.