Patent Abstract:
A thermally enhanced three-dimensional (3D) package is disclosed. The package includes a heat sink having an opening and a stiffener ring inside the opening. The stiffener ring has a first surface and a second surface. A first substrate of a first package is disposed inside the opening and secured to the first surface of the stiffener ring. A second substrate of a second chip package is secured to the second surface of the stiffener ring. The first substrate is connected to the second substrate through a plurality of solder balls. The heat generated in the first chip package and the second chip package is dissipated by the heat sink. The first chip package and the second chip package are fixed by the stiffener ring to eliminate warpage of the first chip package and the second chip package, thereby assuring the electrical transmission of the product.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a division of U.S. application Ser. No. 11/164,819 filed Dec. 7, 2005, and incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The invention relates to a thermally enhanced three-dimensional package, and more particularly, to a three dimensional package utilizing a heat sink on a first chip package to position another chip package.  
         [0004]     2. Description of the Prior Art  
         [0005]     In conventional semiconductor packages, three dimensional packages fabricated by stacking a plurality of chip packages over one another are commonly utilized to achieve multi-functional purpose. However, as the chip packages generate large amounts of heat during operation, a heat sink is often installed to maintain the three dimensional package at a normal working temperature. Additionally, a boat is utilized to position the chip packages while stacking the chip packages over one another. This will unavoidably increase the overall cost. Moreover, a slight miscalculation in the size of the boat or the edge of the substrate of the chip packages will result in a cold joint issue and unsuccessful bonding of the chip package, and as the chip packages undergo numerous reflow processes, a warpage phenomenon will often result.  
         [0006]     Please refer to  FIG. 1 .  FIG. 1  is a perspective diagram showing a cross-section of a conventional three-dimensional package. As shown in  FIG. 1 , the three-dimensional package  100  includes a first chip package  110 , a second chip package  120 , a plurality of solder balls  130 , and a plurality of external conductive devices  140 . Preferably, the first chip package  110  includes a first substrate  111  and a first flip chip  112 , in which the first substrate  111  includes a top surface  113  and a bottom surface  114 . The flip chip  112  is connected to the bottom surface  114  of the first substrate  111  by utilizing a plurality of bumps  115 , in which the bumps  115  are sealed by an underfill layer  116 . Similarly, the second chip package  120  includes a second substrate  121  and a second flip chip  122 , in which the second substrate  121  includes a top surface  123  and a bottom surface  124 . The second flip chip  122  is connected to the top surface  123  of the second substrate  121  by utilizing a plurality of bumps  125 , in which the bumps  125  are sealed by an underfill layer  126 . Additionally, the solder balls  130  are formed between the top surface  113  of the first substrate  111  and the bottom surface  124  of the second substrate  121  to electrically connect the first chip package  110  and the second chip package  120 , and the external conductive devices  140  are disposed on the bottom surface  114  of the first substrate  111  for connecting to other electronic devices (not shown).  
         [0007]     Essentially, the first chip package  110  and the second chip package  120  of the three-dimensional package  100  often generate significant amounts of heat during operation thereto reducing the performance of the device as a result of overheating. Additionally, phenomenon such as warpage occurs frequently on the first chip package  110  and the second chip package  120  and influences the structural sturdiness and electrical transmission of the three-dimensional package  100 . Furthermore, when the first chip package  110  and the second chip package  120  are stacked over each other, a boat is commonly utilized to position the first chip package  110  and the second chip package  120 , thereby increasing cost and reducing over yield.  
       SUMMARY OF THE INVENTION  
       [0008]     It is therefore an objective of the present invention to provided a thermally enhanced three-dimensional package. Preferably, the thermally enhanced three-dimensional package includes a heat sink, a first chip package, and a second chip package, in which the heat sink includes an opening and a stiffener ring inside the opening. A first substrate of the first chip package is positioned in the opening and secured on a first surface of the stiffener ring, and a second substrate of the second chip package is secured on a second surface of the stiffener ring. By utilizing the stiffener ring to secure the first chip package and the second chip package, the present invention is able to prevent the warpage phenomenon of the first chip package and the second chip package.  
         [0009]     It is another aspect of the present invention to provide a thermally enhanced three-dimensional package. Preferably, the thermally enhanced three-dimensional package includes a heat sink having an opening and a stiffener ring inside the opening, a first chip package disposed on a first surface of the stiffener ring, and a second chip package disposed on a second surface of the stiffener ring, such that the heat generated by the first chip package and the second chip package during operation can be dissipated via the heat sink.  
         [0010]     It is another aspect of the present invention to provide a thermally enhanced three-dimensional package. Preferably, the thermally enhanced three-dimensional package includes a heat sink having an opening and a stiffener ring inside the opening, a first chip package disposed on a first surface of the stiffener ring, and a second chip package disposed on a second surface of the stiffener ring, in which the stiffener ring is utilized to control the height of the solder balls between the first chip package and the second chip package, thereby preventing a solder failure or a broken circuit.  
         [0011]     It is another aspect of the present invention to provide a method of fabricating a thermally enhanced three dimensional package, the method includes: providing a first chip package, wherein the first chip package comprises a first substrate; disposing a heat sink having a first opening and a stiffener ring inside the first opening on the first chip package, wherein the stiffener ring comprises a first surface and a second surface and the first substrate of the first chip package is disposed in the opening of the heat sink and secured to the first surface of the stiffener ring; disposing a second chip package having a second substrate on the heat sink, wherein the second substrate is secured to the second surface of the stiffener ring; and performing a reflow process for forming a plurality of solder balls between the first substrate and the second substrate, wherein the solder balls are formed inside the stiffener ring for connecting the first substrate and the second substrate.  
         [0012]     According to the present invention, a thermally enhanced three dimensional package includes: a heat sink having a first opening and a stiffener ring inside the opening, in which the stiffener ring comprises a first surface and a second surface; a first chip package having a first substrate, in which the first substrate is disposed in the opening of the heat sink and secured to the first surface of the stiffener ring; a second chip package having a second substrate, in which the second substrate is secured to the second surface of the stiffener ring; and a plurality of solder balls disposed between the first substrate of the first chip package and the second substrate of the second chip package and inside the stiffener ring for connecting the first substrate and the second substrate. Preferably, the heat sink is utilized to position and facilitate the stacking of the first chip package and the second chip package, and the stiffener ring is utilized to secure the first chip package and the second chip package for preventing a warpage phenomenon and facilitating the heat dissipation of the two package structures.  
         [0013]     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  
       [0014]      FIG. 1  is a perspective diagram showing a cross-section of a conventional three-dimensional package.  
         [0015]      FIG. 2  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package according to the first embodiment of the present invention.  
         [0016]      FIG. 3  is a three-dimensional diagram showing the heat sink of  FIG. 2 .  
         [0017]      FIG. 4  through  FIG. 6  are perspective diagrams showing a means of fabricating the thermally enhanced three-dimensional package  200  according to the first embodiment of the present invention.  
         [0018]      FIG. 7  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package according to the second embodiment of the present invention.  
         [0019]      FIG. 8  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package according to the third embodiment of the present invention.  
         [0020]      FIG. 9  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package according to the fourth embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0021]     Please refer to  FIG. 2  and  FIG. 3 .  FIG. 2  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package according to the first embodiment of the present invention and  FIG. 3  is a three-dimensional diagram showing the heat sink from  FIG. 2 . As shown in  FIG. 2  and  FIG. 3 , a thermally enhanced three-dimensional package  200  includes a heat sink  210 , a first chip package  220 , a second chip package  230 , and a plurality of solder balls  240 . Preferably, the heat sink  210  includes an I-shaped cross-section, an opening  211 , and a stiffener ring  212  inside the opening  211 , in which the stiffener ring  212  is monolithically formed on the heat sink  210 . Additionally, the stiffener ring  212  includes a first surface  213  and a second surface  214 , such that the opening  211  exposes the first surface  213  and the second surface  214 . The first chip package  220  includes a first substrate  221  having a top surface  222  and a bottom surface  223 , in which the first substrate  221  is disposed in the opening  211  of the heat sink  210  and secured to the first surface  213  of the stiffener ring  212  by utilizing an adhesive  250 , thereby preventing the first substrate  221  of the first chip package  220  from suffering from the warpage phenomenon. The first chip package  220  also includes a first chip  224  and a plurality of bumps  225 . According to the present embodiment, the first chip  224  is connected to the bottom surface  223  of the first substrate  221  by a flip chip packaging process, the bumps  225  are electrically connected to the bottom surface  223  of the first substrate  221 , and an underfill layer  226  is formed to seal the bumps  225 . Additionally, the thermally enhanced three-dimensional package  230  includes a plurality of external conductive devices  260 , such as solder balls or pins, in which the external conductive devices  260  are disposed on the bottom surface  223  of the first substrate  221  and exposed from the opening  211  of the heat sink  210  to provide an external connection to other electronic devices (not shown).  
         [0022]     The second chip package  230  includes a second substrate  231  having a top surface  232  and a bottom surface  233 . Preferably, the second substrate  231  is disposed on the second surface  214  of the stiffener ring  212 , in which the second substrate  231  is secured to the second surface  214  by another adhesive  250  for preventing warpage of the second substrate  231 . The second chip package  230  also includes a second chip  234 , such as a flip chip and a plurality of bumps  235 , in which the second chip  234  is electrically connected to the top surface  232  of the second substrate  231  by utilizing the bumps  235 , and an underfill layer  236  is formed to seal the bumps  235  thereafter.  
         [0023]     The solder balls  240  are formed between the first substrate  221  of the first chip package  220  and the second substrate  231  of the second chip package  230  and inside the stiffener ring  212  of the heat sink  210 , such that the solder balls  240  are utilized to connect the first substrate  221  and the second substrate  231 , and facilitate the stacking of the first chip package  220  and the second chip package  230 . Preferably, the height of the solder balls  240  can be adjusted via the stiffener ring  212 , thereby preventing a solder failure or a broken circuit.  
         [0024]     By utilizing the heat sink  210  to position the first chip package  220  and the second chip package  230 , the present invention requires no additional boat as in the prior art. Additionally, the first chip package  220  and the second chip package  230  are secured on the stiffener ring  212  to prevent the warpage phenomenon. Furthermore, the heat generated by the first chip package  220  and the second chip package  230  during operation can be transmitted via the first substrate  221  of the first chip package  220 , the second substrate  231  of the second chip package  230 , and the stiffener ring  212  to the heat sink  210 , such that the heat will be dissipated by the heat sink  210 .  
         [0025]     Please refer to  FIG. 4  through  FIG. 6 .  FIG. 4  through  FIG. 6  are perspective diagrams showing a means of fabricating the thermally enhanced three-dimensional package  200  according to the first embodiment of the present invention. As shown in  FIG. 4 , a first chip package  220  having a first substrate  221  and a first chip  224  is first provided. Preferably, the first substrate  221  includes a top surface  222  and a bottom surface  223 , in which the first chip  224  is attached to the bottom surface  223  of the first substrate  221  by utilizing a plurality of bumps  225 . Next, a plurality of solder bumps  240   a  is formed on the top surface  222  of the first substrate  221 .  
         [0026]     As shown in  FIG. 5 , a heat sink  210 , such as the one shown in  FIG. 3 , is disposed on the top surface  222  of the first chip package  220 . Preferably, the heat sink  210  includes an opening  211  and a stiffener ring  212  inside the opening  211 , in which the stiffener ring  212  includes a first surface  213  and a second surface  214 . Subsequently, an adhesive  250  is applied on the stiffener ring  212  for attaching the first substrate  221  on the first surface  213  of the stiffener ring  212 .  
         [0027]     As shown in  FIG. 6 , a second chip package  230  having a second substrate  231  and a second chip  234  is disposed on the stiffener ring  212  of the heat sink  210 . Preferably, the second chip package  230  includes a second substrate  231  and a second chip  234 , in which the second chip  234  is connected to the top surface  232  of the second substrate  231  by utilizing the plurality of bumps  235 . Additionally, an adhesive  250  is formed to attach the second chip package  230  on the second surface  214  of the stiffener ring  212 , and a plurality of second solder bumps  240   b  is formed on the bottom surface  233  of the second substrate  231 . Preferably, the heat sink  210  is utilized to position the first chip package  220  and the second chip package  230 , such that the second solder bumps  240   b  of the second chip package  230  can be aligned corresponding to the first solder bumps  240   a  of the first chip package  220 . Subsequently, a soldering flux  270  is formed on the first solder bumps  240   a  or the second solder bumps  240   b  to facilitate the melting of the first solder bumps  240   a  and the second solder bumps  240   b  during a reflow process for producing a plurality of solder balls  240  (as shown in  FIG. 2 ). Preferably, the height of the stiffener ring  212  of the heat sink  210  is controlled corresponding to the height of the solder balls  240  between the first chip package  220  and the second chip package  230  to prevent a solder failure or a broken circuit. Subsequently, a plurality of external conducting devices  260  is disposed on the bottom surface  223  of the first substrate  221  and exposed from the opening  211  of the heat sink  210  for forming a thermally enhanced three-dimensional package  200  (as shown in  FIG. 2 ).  
         [0028]     Please refer to  FIG. 7 .  FIG. 7  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package  300  according to the second embodiment of the present invention. As shown in  FIG. 7 , the thermally enhanced three-dimensional package  300  includes a heat sink  310 , a first chip package  320 , a second chip package  330 , and a plurality of solder balls  340 , in which the heat sink  310  includes an opening  311  and a stiffener ring  312  inside the opening  311 . According to the present embodiment, the stiffener ring  312  is step-shaped, in which the stiffener ring  312  also includes a first surface  313  and a second surface  314 , and both the first surface  313  and the second surface  314  expose the opening  311 . Preferably, the first chip package  320  is disposed in the opening  311 , in which the first chip package  320  includes a first substrate  321  and a first chip  324 . Additionally, the first substrate includes a top surface  322  and a bottom surface  323 , in which the first substrate  321  is positioned in the opening  311  of the heat sink  310  and secured on the first surface  313  of the stiffener ring  310 . The first chip  322  is connected to the bottom surface  323  of the first substrate  321  by utilizing a plurality of bumps  325 , and an underfill layer  326  is formed to seal the bumps  325 .  
         [0029]     The second chip package  330  includes a second substrate  331  and a second chip  334 . Preferably, the second substrate  331  includes a top surface  332  and a bottom surface  333 , in which the second substrate  331  is disposed in the opening  311  of the heat sink  310  and secured on the second surface  314  of the stiffener ring  312 . The second chip  334  is attached to the top surface  332  of the second substrate  314  by utilizing a plurality of bumps  335 , and an underfill layer  336  is formed to seal the bumps  335 . The solder balls  340  are disposed between the top surface  322  of the first substrate  321  and the bottom surface  333  of the second substrate  331 , the first chip package  320  is secured on the first surface  313  of the stiffener ring  312 , and the second chip package  330  is secured on the second surface  314  of the stiffener ring  312  to facilitate the alignment of the first chip package  320  and the second chip package  330  while stacking the packages over each other. Preferably, the present invention is able to utilize the stiffener ring  313  to secure the first chip package  320  and the second chip package  330  to prevent warpage of the two packages, utilize the heat sink  310  of the stiffener ring  312  to dissipate heat, and utilize the step-shaped stiffener ring  312  to control the height of the solder balls  340  between the first chip package  320  and the second chip package  330  for preventing a solder failure or a broken circuit.  
         [0030]     Please refer to  FIG. 8 .  FIG. 8  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package  400  according to the third embodiment of the present invention. As shown in  FIG. 8 , the thermally enhanced three-dimensional package  400  includes a heat sink  410 , a first chip package  420 , a second chip package  430 , and a plurality of solder balls  440 . Preferably, the heat sink  410  includes an opening  411  and a stiffener ring  412  inside the opening  411 , in which the stiffener ring  412  includes a first surface  413  and a second surface  414 , such that the first surface  413  and the second surface  414  expose the opening  411 .  
         [0031]     The first chip package  420  includes a first substrate  421 , a first chip  422 , a plurality of wires  423 , and a sealing compound  424 , in which the first substrate  421  includes a top surface  425  and a bottom surface  426 . The first chip  422  is disposed on the top surface  425 , in which the first chip  422  is electrically connected to the first substrate  421  via the wires  423 , and the sealing compound  424  is utilized to seal the first chip  422  and the wires  425 . Preferably, the first substrate  421  is contained in the opening  411  of the heat sink  410  and secured to the first surface  413  of the stiffener ring  412 , in which an adhesive  450  is disposed to secure the bonding of the stiffener ring  412  and the first substrate  421  and prevent warpage of the first substrate  421 . Additionally, the thermally enhanced three-dimensional package  400  includes a plurality of external conductive devices  460 , such as solder balls. As shown in  FIG. 8 , the external conductive devices  460  are disposed on the bottom surface  426  of the first substrate  421  and exposed from the opening  411  of the heat sink  410 .  
         [0032]     The second chip package  430  includes a second substrate  431 , a second chip  432 , a plurality of wires  433 , and a sealing compound  434 , in which the second substrate  431  includes a top surface  435  and a bottom surface  436 . The second chip  432  is disposed on the top surface  435  of the second substrate  431  and electrically connected to the second substrate  431  via the wires  433 , and the sealing compound  434  is formed on the top surface  435  of the second substrate  431  to seal and protect the second chip  432  and the wires  433 . The second substrate  431  is secured on the second surface  414  of the stiffener ring  412 , in which an adhesive  450  is disposed on the second surface  414  of the stiffener ring  412  to prevent the second substrate  431  of the second chip package  430  from suffering from the warpage phenomenon.  
         [0033]     The solder balls  440  are formed between the top surface  425  of the first substrate  421  and the bottom surface  436  of the second substrate  431  and on the periphery of the first chip  422 , in which the solder balls  440  are utilized to electrically connect the first substrate  421  and the second substrate  431 . Preferably, the thermally enhanced three-dimensional package  400  is able to utilize the stiffener ring  412  to control the height of the solder balls  440  to prevent a solder failure or a broken circuit, and utilize the heat sink  410  to dissipate the heat generated during the operation of the first chip package  420  and the second chip package  430 .  
         [0034]     Please refer to  FIG. 9 .  FIG. 9  is a perspective diagram showing the cross-section of a thermally enhanced three-dimensional package  500  according to the fourth embodiment of the present invention. As shown in  FIG. 9 , the thermally enhanced three-dimensional package  500  includes a heat sink  510 , a first chip package  520 , a second chip package  530 , and a plurality of solder balls  540 , in which the heat sink  510  includes an opening  511  and a first surface  512  and a second surface  513  inside the opening  511 . According to the present embodiment, the opening  511  exposes the first surface  512  and the second surface  513  and forms a step shape.  
         [0035]     The first chip package  520  includes a first substrate  521 , a first chip  522 , a plurality of wires  523 , and a sealing compound  524 , in which the firs substrate  521  includes a top surface  525  and a bottom surface  526 . The first chip  522  is disposed on the top surface  525  of the first substrate  521  and electrically connected to the first substrate  521  via the wires  523 , in which the sealing compound  524  is utilized to seal the first chip  521  and the wires  523 . When the first chip package  520  is bonded to the heat sink  510 , the first substrate  521  is positioned on the first surface  512  of the heat sink  510 . Additionally, a plurality of external conductive devices  550  is disposed on the bottom surface  526  of the first substrate  521  and exposed from the opening  511  of the heat sink  510  for connecting to other electronic devices (not shown).  
         [0036]     The second chip package  530  includes a second substrate  531 , a second chip  532 , a plurality of wires  533 , and a sealing compound  534 . The second chip  532  is disposed on a top surface  535  of the second substrate  531 , the wires  533  are utilized to electrically connect the second substrate  531  and the second chip  532 , and the sealing compound  534  is formed to seal the second chip  532  and the wires  533 . When the second chip package  530  is bonded to the heat sink  510 , the second substrate  531  is disposed on the second surface  513  of the heat sink  510 . Since the first chip package  520  is secured to the first surface  512  of the heat sink  510  and the second chip package  530  is secured to the second surface  513  of the heat sink  510 , the present invention is able to accurately align and stack the packages over each other, thereby preventing the warpage phenomenon and utilizing the heat sink effectively. Additionally, by controlling the height of the heat sink  510  corresponding to the height of the solder balls  540  between the first chip package  520  and the second chip package  530 , the present invention is able to prevent a solder failure or a broken circuit.  
         [0037]     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.

Technology Classification (CPC): 7