Abstract:
An embedded die package includes a carrier with an electrical device in the cavity of the carrier, a first dielectric layer covering the sides and top of the electrical device except for vias over selected bonding pads of the electrical device, a plurality of metal conductors, each of which is in contact with at least one of the vias, one or more additional dielectric layers lying over the metal conductors and the first dielectric layer, wherein a top layer of the one or more dielectric layers has openings with metalization underneath coupled to at least one of the metal conductors, and solder bumps protruding from each of the openings.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to packaging for molded electrical device or multiple electrical devices. 
       BACKGROUND OF THE INVENTION 
       [0002]    In the past electrical devices such as semiconductor die have often been packaged by first mounting the device on a leadframe and then making connections to external leads, and then encapsulated. However, as miniaturization of electrical devices has advanced, new packaging techniques have been developed, and are still being developed, for shrinking the packaged semiconductor device or devices by such methods as putting multiple die in a package, and using solder bump interconnects with thin mold coverings. 
         [0003]    Although solder bumps and thin molding provide a small package, the semiconductor die is fragile and generally must be packaged with enough rigidity to protect the die and seal the die. Another constraint is that packaging methods, to be economically feasible for the commercial market, need to be versatile so that it can be used with different device sizes and geometries and still provide a package with foot prints which match de facto standards in the industry. 
       SUMMARY OF THE INVENTION 
       [0004]    The invention comprises, in one form thereof, a method of forming an embedded package. The method comprises the steps of forming a carrier having a first plurality of cavities, placing an electrical device in each of the first plurality of cavities, forming a first dielectric layer around and over each of the electrical devices and over the upper surfaces of the carriers, forming vias through the dielectric layer to selected bonding pads on each of the electrical devices, and forming a second plurality of metal conductors, each of which is in contact with one of the vias and extends a distance away from those vias. The method also includes forming one or more additional dielectric layers over each of the second plurality of metal conductors and exposed portions of the first dielectric layer, forming openings in one of the one or more additional dielectric layers over a metal conductor, forming a third plurality of solder bumps each of which is coupled to one of the second plurality of metal conductors; and singulating the first plurality of cavities. 
         [0005]    In another form, the invention comprises an embedded die package which includes a pre-molded carrier with a first electrical device in a first cavity of the carrier, a first dielectric layer covering the sides and top of the first electrical device except for vias over selected bonding pads of the electrical device, a first plurality of metal conductors, each of which is in contact with at least one of the vias, one or more additional dielectric layers lying over the metal conductors and the first dielectric layer, wherein a top layer of the one or more dielectric layers has openings over a portion of each of the metal conductors, and a second plurality of solder bumps protruding from each of the openings. 
         [0006]    In yet another form, the inventions comprises an embedded die package as described in the above forms, except that the pre-molded carrier is a flat horizontal surface rather than a pre-molded carrier with cavities. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The aforementioned and other features, characteristics, advantages, and the invention in general will be better understood from the following more detailed description taken in conjunction with the accompanying drawings, in which: 
           [0008]      FIG. 1A  is a diagrammatical cross sectional view of a pre-molded carrier according to an embodiment of the present invention; 
           [0009]      FIG. 1B  is a diagrammatical cross sectional view of the pre-molded carrier shown in  FIG. 1A  after two semiconductor die have been die attached in two cavities of the pre-molded carrier; 
           [0010]      FIG. 1C  is a diagrammatical cross sectional view of the pre-molded carrier shown in  FIG. 1B  after a first dielectric layer has been formed; 
           [0011]      FIG. 1D  is a diagrammatical cross sectional view of the pre-molded carrier shown in  FIG. 1C  after metal interconnects have been formed; 
           [0012]      FIG. 1E  is a diagrammatical cross sectional view of the pre-molded carrier shown in  FIG. 1D  after a second dielectric layer has been formed; 
           [0013]      FIG. 1F  is a diagrammatical cross sectional view of the pre-molded carrier shown in  FIG. 1E  after solder bumps have been formed; 
           [0014]      FIGS. 2A and 2B  show respective top and bottom perspective views of a packaged semiconductor die according to an embodiment of the present invention; 
           [0015]      FIGS. 3A ,  3 B,  3 C,  3 D,  3 E, and  3 F show various stages in the forming of embedded die packages according to an embodiment of the present invention; and 
           [0016]      FIGS. 4 ,  5 , and  6  are diagrammatical cross sectional views that show some of the embodiments possible in practicing the current invention. 
       
    
    
       [0017]    It will be appreciated that for purposes of clarity and where deemed appropriate, reference numerals have been repeated in the figures to indicate corresponding features. Also, the relative size of various objects in the drawings has in some cases been distorted to more clearly show the invention. 
       DETAILED DESCRIPTION 
       [0018]      FIG. 1A  is a diagrammatical cross sectional view of a pre-molded carrier  20  formed from encapsulating material such as epoxy molding compound. The carrier  20  shown in  FIG. 1  has two cavities  22  and  24  which have an exterior sidewall  26  for cavity  22  and an exterior sidewall  28  for cavity  24 . A thicker center wall  30  separates the two cavities  22 ,  24 , which represent two adjacent package sites on the pre-molded carrier. The cavities  22 ,  24  have a base  32 . 
         [0019]      FIG. 1B  shows the pre-molded carrier  20  after two semiconductor die  34  and  36  have been die attached in the cavities  22  and  24 , respectively. In  FIG. 1B  the semiconductor dies  34  and  36  extend above the side walls  26 ,  28  and the center wall  30  of the pre-molded carrier  20 . Each of the semiconductor dies  34  and  36  have bond pads  38 . The die attachment can be made with standard die-attach methods such as, but not limited to, epoxy or a die attach film  40 . In  FIG. 1C  dielectric material  42  fills the gaps between the semiconductor dies  34  and  36 , the sidewalls  26 ,  28 , and the center wall  30 , and extends above and on top of the semiconductor dies  34  and  36 . Vias  44  have been made through the dielectric material  42  to the bond pads  38 . 
         [0020]    The dielectric material  42  may be formed in any of several know methods, including using the process of vacuum film lamination with a material such as Ajinomoto Build-Up FILM (ABF) followed by laser drilling of the vias  44 . The vias  44  can also be formed by spin coating or spray coating of polyimide or photoresist followed by photolithography. 
         [0021]    Metallization is deposited, patterned and etched to form metal interconnects  48  from the bond pads  38  to locations not directly over the semiconductor dies  22  and  24 , as shown in  FIG. 1D . In one embodiment of the present invention, the metallization is formed by first coating the surface of the dielectric layer  42  and the exposed bond pads  38  with a thin metal seed layer through electroless Cu plating or Cu sputter deposition, putting down a patterned photoresist layer, and electroplating additional metal in the exposed areas of the thin metal layer. The photoresist is then removed and the metal seed layer is removed using acid etching. In another embodiment of the present invention, the metal interconnects are formed by Al sputter deposition to the desired final interconnect thickness. A photoresist layer is then deposited and patterned to match the interconnect routing. The Al metal is etched away followed by photoresist removal, which leaves the final interconnect pattern. 
         [0022]    With reference to  FIG. 1E , after the metal interconnects  48  are formed, a second dielectric layer  52  is then applied and patterned over the first level of dielectric material  42  and the metal interconnects  48 . This process for dielectric layer  52  application may match the process for the first dielectric layer  42  application. 
         [0023]    In  FIG. 1F  solder bumps  56  have been formed using one of several known processes such as, but not limited to, stencil printing or ball drop followed by a reflow cycle. Depending on the interconnect metal composition, a solderable under bump metallization (UBM) layer may be required. This can be achieved through electroless plating methods. The formation of the embedded die packages  58  are completed by the singulation of the two packages. 
         [0024]      FIGS. 2A and 2B  show respective top  60  and bottom  62  perspective views of a packaged semiconductor die  64  according to an embodiment of the present invention. The package shown in these figures have a pre-molded carrier  66 , a second dielectric layer  68  has the solder bumps  56  protruding through. 
         [0025]      FIGS. 3A-3F  show various stages in the forming of the embedded die packages  70  according to an embodiment of the present invention.  FIG. 3A  shows a pre-molded carrier  72  with a matrix of nine cavities  74 . Semiconductor dies  76  are placed in each of the six cavities  74  as shown in  FIG. 3B . 
         [0026]      FIG. 3C  shows the embedded die packages after a first dielectric layer  80  has been formed over the dies  76 , vias have been formed in the first dielectric layer  80 , and metal conductors  82  have been formed between each of the bond pads  78  and sites  84  where the solder bumps  56  will be placed. Then a second dielectric layer  86  is formed over the first dielectric layer  80  and the metal conductors  82 , and openings  88  are made in the second dielectric layer  86  to expose the sites  84  for the solder bumps  56  as shown in  FIG. 3D . 
         [0027]      FIG. 3E  shows the solder bumps  56  in place on the sites  84 , and  FIG. 3F  shows the individual die packages  70  after a singulation process. 
         [0028]      FIGS. 4 ,  5 , and  6  show some of the embodiments possible in practicing the current invention. In  FIG. 4  the semiconductor die  34  is in a cavity  22  which is next to a much deeper cavity  90  which contains a passive electrical element  92  such as an inductor, a resistor, or a capacitor. The semiconductor die  34  may have a height of about 20 μm and the electrical element  92  may have a height of 1 mm, but the height of each can vary with application requirements. In addition, the widths of the semiconductor die  34  and the electrical element  92  may be different as shown in  FIG. 4 . Thus the pre-molded carrier  94  is formed to accommodate the heights and widths of the semiconductor die  34  and the electrical element  92 . 
         [0029]      FIG. 5  is a diagrammatical cross sectional view of a pre-molded carrier according to another embodiment of the present invention with interconnection metalization made between the two semiconductor die  34  and  36 . Interconnections can be made at different vertical levels using general PC board or redistribution layer technology. In  FIG. 5  a metal interconnect  96  lies between a the first dielectric layer  42  and a second dielectric layer  94  that may be thicker than the second dielectric layer  52  shown in  FIG. 1E . The metal interconnect  96  connects together bonding pads  38  of semiconductor dies  34  and  36  as part of an embedded die package  98  which is a multi-chip package. A metal interconnect  100  forms a connection from a bonding pad  102  to a metal interconnect  104  which lies on the second dielectric layer  94  which extends to the metal interconnect  96 . Another metal interconnect  106  forms a connection from bonding pad  108  to a second metal interconnect  110  lying on the second dielectric layer  94 . A third dielectric layer  112  covers the metal interconnects  104  and  110  and the exposed regions of the second dielectric layer  94 . Also shown in  FIG. 5  are solder bumps  56  which extend through openings in the third dielectric layer  112  to the metal interconnects  104  and  110 . 
         [0030]    In  FIG. 6  the pre-molded carrier  114  does not have sidewalls  26 ,  28  or center walls  30 , but rather has a flat horizontal surface. The process described above with respect to  FIGS. 1A-F  is still applicable to forming the embodiment shown in  FIG. 6 . In applications in which a bonding pad  38  is not used, there may be no metal interconnect to the bonding pad in the embedded die package, an example of which is shown in  FIG. 6 . 
         [0031]    While the invention has been described with reference to particular embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope of the invention. 
         [0032]    Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope and spirit of the appended claims.