Patent Description:
<CIT> discloses a method and apparatus for mounting microelectronic chips to a thermal heat sink. The chips are arranged in a desired configuration with their active faces all facing a common direction and with their active faces defining a common planar surface for all of said chips. A metallic material is applied to the chip, preferably by electroplating to backsides of the chips, the metallic material being electro-formed thereon and making void-free contact with the backsides of the chips.

<CIT> discloses a semiconductor package and a method of fabricating the same. In one embodiment, to fabricate a semiconductor package, a wafer having semiconductor chips fabricated therein is provided. A heat sink layer is formed over the wafer. The heat sink layer contacts top surfaces of the semiconductor chips. Thereafter, the plurality of semiconductor chips are singulated from the wafer.

<CIT> discloses a semiconductor package including a substrate, a die, a first metal layer, a second metal layer and an optional seed layer. The package body at least partially encapsulates the die on the substrate. The seed layer is disposed on the package body and the first metal layer is disposed on the seed layer. The second metal layer is disposed on the first metal layer and the lateral surface of the substrate. The first metal layer and the second metal layer form an outer metal cap that provides thermal dissipation and electromagnetic interference (EMI) shielding.

<CIT> discloses semiconductor packages including: one or more die having a first side and a second side opposite the first side; the first side of the die may include one or more external connection points; a layer of one or more metals comprised on the second side of the one or more die; a second layer of one or more metals comprised on the first layer of one or more metals, wherein the second layer is thicker than the first layer; a molding compound encapsulating five sides of the one or more die and partially encapsulating the second layer of a metal; a plurality of interconnects coupled to the second layer of one or more metals; and two or more bumps coupled to the plurality of interconnects. At least a portion of each of the two or more bumps may be outside a perimeter of the one or more die.

Various electronic devices (e.g., high power regulators), due to various inefficiencies, generate heat that should be dissipated. Otherwise, the generated heat may degrade or limit the product performance. Accordingly, there is a continuing need for improved electronic devices with efficient solutions for dissipating the generated heat.

In one aspect, an integrated device package is provided in accordance with independent claim <NUM>.

In another aspect, a method of manufacturing an integrated device package is provided in accordance with independent claim <NUM>.

In another aspect, a method of manufacturing an integrated device package is disclosed. The method can include: partially embedding an electronic component within a protective material of an electronic component package, the electronic component package comprising a first surface and a second surface; and electroplating an integrated heat sink onto the first surface, wherein electroplating the integrated heat sink comprises adding a metal layer over the first surface and forming, by a photolithography process, the metal layer in a shape for dissipating heat, and connecting the integrated heat sink to the electronic component by at least one via, the at least one via disposed within the protective material and connecting the integrated heat sink and the electronic component at least thermally.

In some embodiments, the electronic component comprises a passive electronic device. In some embodiments, the electronic component comprises an integrated device die. In some embodiments, partially embedding the electronic component comprises partially embedding the electronic component within the protective material so as to expose at least a portion of the electronic component through the protective material. In some embodiments, electroplating the integrated heat sink comprises adding a metal layer over the first surface and plating the metal layer such that the metal layer directly contacts the electronic component.

In some embodiments, electroplating the integrated heat sink comprises adding a metal layer over the first surface and plating the metal layer such that the metal layer contacts an insulating layer over the protective material. In some embodiments, forming the metal layer in the shape for dissipating the heat comprises forming a plurality of projections extending in a direction away from the electronic component, the projections comprising fins spaced apart along one dimension of the first surface, wherein the space between the fins comprises a plurality of insulating portions. In some embodiments, forming the metal layer in the shape for dissipating the heat comprises forming a plurality of projections extending in a direction away from the electronic component, the projections comprising pins spaced apart in a two-dimensional (2D) array along a width and a length of the first surface, wherein the space between the pins comprises a plurality of insulating portions.

Embodiments of this disclosure will now be described, by way of non-limiting example, with reference to the accompanying drawings.

Electronic devices, including integrated circuit dies, can comprise devices that generate a significant amount of power. Heat generated from the dies can be dissipated in a variety of ways. With respect to electronic devices that generate heat, there are several ways in which the heat can be dissipated. An example heat dissipation pathway includes a pathway down into the system board (i.e., by a thermally-conductive pathway to the board). In many cases, the system boards are very dense and have many heat-generating components, and it is not feasible or desirable to pull all of the heat through the system board. Thus, other structures (e.g., heat sinks, cold plates, fans, etc.) are utilized with the electronic devices to improve the heat dissipation through the top of the components.

Some solutions typically add the other structures such as heat sinks as separate components. These increase cost (e.g., via added material and processes) and are not as efficient because of high thermally resistant polymers and adhesives used to attach, e.g., the heat sinks to the electronic devices.

Thus, as described herein, the package manufacturing process (e.g., to embed a die or component into a molding material) can be used to add an integrated heat sink into an electronic component package, which would not incur the increased costs discussed above. For example, a final top metal layer can be added and patterned to provide increased surface area to improve the convection cooling and heat dissipation characteristics of the package. The top metal pattern can mimic a heat sink (e.g., a pin-type or fin-type heat sink), but can be manufactured using plating technologies rather than being adhered to the package.

<FIG> is a schematic side sectional view of an electronic component package <NUM>, according to some implementations. The electronic component package <NUM> can be used in any suitable type of electronic system, and can be packaged in any suitable manner. The electronic component package <NUM> can include a first insulating layer <NUM>, a second insulating layer <NUM>, a plurality of first vias <NUM>, a plurality of second vias <NUM>, a plurality of laterally-extending traces <NUM>, a plurality of packaging terminations <NUM>, a protective material <NUM>, a second layer <NUM> of protective material, an electronic component <NUM> and a plurality of contact pads <NUM> that electrically connect the component <NUM> to the metallization <NUM>. The metallization <NUM> can comprise any suitable type of metal, such as, e.g., copper, as would be known to one of ordinary skill in the art. In various embodiments, the protective material can comprise an organic or polymer coating. For example, the protective material can comprise a molding compound in some embodiments. In other embodiments, the protective material can comprise a film, e.g., an organic epoxy resin which may include inorganic microparticle fillers, such as Ajinomoto Build-up Film (ABF), sold by Ajinomoto Group of Tokyo, Japan.

The electronic component <NUM> can comprise any suitable type of electronic component, such as an integrated device die (which can include active circuitry therein), a passive electronic device (such as a capacitor, an inductor, a resistor, a transformer, etc.), or any other suitable type of device. The component <NUM> can connect to the metallization <NUM> by way of the contact pads <NUM>.

As shown, the electronic component <NUM> is partially embedded within the protective material <NUM>, and coupled to the packaging terminations <NUM> through the contact pads <NUM> and the second vias <NUM>. The electronic component <NUM> can be placed between the first insulating layer <NUM> and the second insulating layer <NUM>, wherein the first insulating layer <NUM> and the second insulating layer <NUM> can be connected by the first vias <NUM>. The second insulating layer <NUM> can be placed over a substrate such as a system board, e.g., a PCB (printed circuit board) (not shown). The packaging terminations <NUM> can be, e.g., a BGA (Ball Grid Array) or an LGA (Land Grid Array), and provide electrical connection to the PCB. The metallization <NUM> can include the vias <NUM>, <NUM> which provide vertical communication through the protective material <NUM> and the second insulating layer <NUM>, respectively. The metallization <NUM> can also include the laterally-extending traces <NUM> that provide horizontal electrical communication within the package <NUM>.

<FIG> is a schematic side sectional view showing an example of an integrated device package <NUM> including an integrated heat sink <NUM>, according to an embodiment. The integrated device package <NUM> can also be used in any suitable type of electronic system. For example, the integrated device package <NUM> can be utilized for a high power application (e.g., a high power regulator). The integrated device package <NUM> can include an electronic component package <NUM> and the integrated heat sink <NUM>. The electronic component package <NUM> can include a first insulating layer <NUM>, a second insulating layer <NUM>, a plurality of first vias <NUM>, a plurality of second vias <NUM>, a plurality of laterally-extending traces <NUM>, a plurality of packaging terminations <NUM>, a protective material <NUM>, a second layer <NUM> of protective material, an electronic component <NUM> and a plurality of contact pads <NUM> (which electrically connect the electronic component <NUM> to the metallization <NUM>), as well as a first surface <NUM> and a second surface <NUM>. The metallization <NUM> can include the vias <NUM>, <NUM> which provide vertical communication through the protective material <NUM> and the second insulating layer <NUM>, respectively. Furthermore, the metallization <NUM> can also include the laterally-extending traces <NUM> that provide horizontal electrical communication within the integrated device package <NUM>. In some embodiments, the metallization <NUM> can comprise any suitable type of metal, such as, e.g., copper, as would be known to one of ordinary skill in the art. The heat sink <NUM> can include a plurality of projections <NUM> and a plurality of insulating portions <NUM> between corresponding projections <NUM>. The insulating portions <NUM> can comprise a gas (e.g., air) in some embodiments, such that the gas is provided between the projections <NUM>. In other embodiments, however, a solid state insulating materials (such as an organic or inorganic dielectric) can serve as the insulating portions <NUM> between adjacent projections <NUM>.

The electronic component <NUM> can comprise any suitable type of electronic component, such as an integrated device die (which can include active circuitry therein), a passive electronic device (such as a capacitor, an inductor, a resistor, a transformer, etc.), or any other suitable type of device. The electronic component <NUM> can connect to the metallization <NUM> by way of the contact pads <NUM>.

As shown, the electronic component <NUM> is partially embedded within the protective material <NUM>, and coupled to packaging terminations <NUM> through the contact pads <NUM> and the second vias <NUM>. The electronic component <NUM> can be placed between the first insulating layer <NUM> and the second insulating layer <NUM>, wherein the first insulating layer <NUM> and the second insulating layer <NUM> can be connected by the first vias <NUM>. The second insulating layer <NUM> can be placed over a substrate such as a system board, e.g., a PCB (not shown) and coupled to the PCB, for example, by way of solder bumps (not shown). The packaging terminations <NUM> can be, e.g., a BGA or an LGA. The packaging terminations <NUM> are disposed over the PCB and spaced apart along the second surface <NUM> in a pattern corresponding to, e.g., the BGA or the LGA, and provide electrical connection between the electronic component <NUM> and the PCB.

While not shown, in one embodiment, the electronic component <NUM> can comprise a die of one or more layers. In another embodiment, there can be more than one electronic component <NUM> partially embedded within the molding material <NUM>.

In some high power applications, the foregoing structure of the electronic component package <NUM> can generate power of at least <NUM> W, at least <NUM> W, at least <NUM> kW, or at least <NUM> kW. In some embodiments, it can generate power in a range of <NUM> W to <NUM> kW, in a range of <NUM> W to <NUM> kW, in a range of <NUM> kW to <NUM> kW, or in a range of <NUM> kW to <NUM> kW. In some applications, it can operate at one or more frequencies in a range of <NUM> to <NUM>, in a range of <NUM> to <NUM>, or in a range of <NUM> to <NUM>. It can also accommodate high relative currents, including current in a range of <NUM> A to <NUM> A, in a range of <NUM> A to <NUM> A, or in a range of <NUM> A to <NUM> A. In some embodiments, it can comprise a passive device, such as an inductor or transformer. In embodiments that include an inductor, the inductance can be at least <NUM>µH, at least <NUM>µH, or at least <NUM>µH, for example, in a range of <NUM>µH to <NUM>µH.

Accordingly, high power devices like those disclosed herein can generate significant heat. Thus, it can be important to effectively remove the generated heat from, e.g., the electronic component <NUM>. As shown in <FIG>, the heat sink <NUM> can be added to the first surface <NUM> of the electronic component package <NUM>, to dissipate the generated heat. For example, based on the heat sink <NUM> directly contacting the first vias <NUM>, most heat can be pulled away.

In one embodiment, the heat sink <NUM> can include the projections <NUM>, which can be spaced apart by the insulating portions <NUM>. The projections <NUM> can extend from a base portion that contacts the first surface <NUM>, and away from the electronic component package <NUM>. The first vias <NUM> can provide a thermal connection to the electronic component <NUM>, and provide, e.g., a thermal pathway for the generated heat discussed herein to be dissipated from the component <NUM> through the heat sink <NUM>. By providing a continuous connection between the vias <NUM>, <NUM> and the heat sink <NUM> (i.e., without any added adhesive which may be highly thermally-resistant), the integrated device package <NUM> can achieve a more efficient heat dissipating characteristics than adding a heat sink with an adhesive.

In one embodiment, the heat sink <NUM> can comprise a metal layer that is added on the first surface <NUM> of the electronic component package <NUM>. For example, the heat sink <NUM> can be added by, e.g., electroplating the heat sink <NUM> onto (e.g., directly onto) the first insulating layer <NUM> and the upper pads <NUM> of the metallization <NUM>. In one embodiment, the dry film patterning or photolithography can allow the metal layer to be patterned to mimic a shape of a heat sink. For example, the metal layer can be plated with pins or fins. Electroplating the heat sink <NUM> onto the surface <NUM> of the electronic component package <NUM> can accordingly be performed without an adhesive between the electronic component package <NUM> and the heat sink <NUM>. Accordingly, in the illustrated embodiment, the electroplated metallic portion of the heat sink <NUM> can directly contact the portions of the insulating layer <NUM> and the portions of the metallization <NUM> over which the heat sink is deposited. The patterned metal layer (i.e., the heat sink <NUM>), with its increased surface area, can provide an improved heat dissipation for the integrated device package <NUM> with convective cooling. As shown, for example, the projections <NUM> can be spaced apart by the insulating portions <NUM>, which can comprise a gas such as air or a solid-state insulating material, such that heat can be conveyed away from the integrated device package <NUM>.

Various embodiments utilizing the plating and photolithography processes developed as part of a partially embedded die manufacturing process can employ an inductor/ferrite manufacturing process to provide a thermally enhanced integrated device package <NUM> (e.g., high power inductors and transformers). This can be achieved by manufacturing inductors using the different metal layers in the structure to create parallel inductor windings between the metal layers, and can be further improved by incorporating ferrous dielectric layers between the metal layers to increase the inductance. Because the plating and photolithography process are used to provide the heat sink <NUM>, manufacturing of the integrated device package <NUM> provides a solution that does not add significantly to the material and process costs. By comparison, other solutions may experience increased material and processing costs, and may not be as efficient due to high thermally resistant polymers and adhesives used to attach separate components. In the embodiments disclosed herein, the integrated device package <NUM> with the integrated heat sink <NUM> can be integrated into a manufacturing process with little to no impact to pricing. Further, as explained above, increasing the available surface area of the heat sink by proper design of the heat sinks pins and fins for improved convective thermal dissipative properties can provide the ability to operate the finished module at high dissipative power densities.

In various embodiments, the heat sink <NUM> can be added onto (e.g., plated directly onto and contacting) the electronic component package <NUM> wherein the first surface <NUM> (<FIG>) is the first insulating layer <NUM> and the exposed upper surface of the electronic component <NUM> (<FIG>).

Moreover, in various embodiments, the shape of the heat sink <NUM> can be formed or modified so as to include the heat-dissipating projections <NUM> as, e.g., a fin-type (<FIG>) or pin-type (<FIG>) heat sink. As illustrated herein in <FIG>, for example, the projections <NUM> can comprise a plurality of elongated fins. The fins in <FIG> can extend across a width of the first surface <NUM>. The fins in <FIG> can be spaced along a length of the first surface <NUM> in a one-dimensional (1D) array of projections <NUM>. In other embodiments, as shown in <FIG>, the projections <NUM> can comprise a plurality of pins disposed in an array over the first surface <NUM>. The pins of <FIG> can be disposed in a two-dimensional (2D) array in which pins are spaced apart along the width and length of the first surface <NUM>. Beneficially, the integrated device package <NUM> may not include a separate heat sink structure that is adhered with an adhesive.

As explained herein, the integrated device package <NUM> can include any suitable type of electronic component <NUM>. For example, the electronic component <NUM> can comprise a semiconductor die, such as a processor die, a memory die, a sensor die, a microelectromechanical systems die, etc. The packaging terminations <NUM> can connect to any suitable carrier. In the illustrated embodiment, the packaging terminations <NUM> are disposed on the second surface <NUM> of the electronic component package <NUM>.

<FIG> is a flow chart showing a method <NUM> of manufacturing an integrated device package <NUM> including an integrated heat sink <NUM>, according to an embodiment.

In step <NUM>, the method <NUM> comprises partially embedding an electronic component <NUM> within a protective material <NUM>. The electronic component <NUM> is only partially embedded within the protective material <NUM>. For example, the electronic component <NUM> is exposed through the protective material <NUM> embodiments (see <FIG>). In some embodiments, the integrated device package <NUM> can have additional vias (e.g., through the protective material <NUM>) to at least thermally connect the electronic component <NUM> to the heat sink <NUM>.

In step <NUM>, the method <NUM> comprises electroplating a heat sink <NUM> on a first surface of an electronic component package <NUM>. In one embodiment, as discussed herein, electroplating the heat sink <NUM> can include utilizing the plating and photolithography processes developed as part of a partially embedded die manufacturing process to provide a thermally enhanced integrated device package <NUM> (e.g., high power inductors and transformers). In the embodiments disclosed herein, the integrated device package <NUM> with the embedded heat sink <NUM> can be economically integrated into a molded packaging process. Further, as explained above, increasing the available surface area for improved convective thermal dissipative properties can provide the ability to operate the finished module at high dissipative power densities. Thus, while electroplating the heat sink <NUM> can comprise forming the projections <NUM> that are fin-type (<FIG>) or pin-type (<FIG>), it can also include forming the projections <NUM> in any other way so as to increase the available surface area of the heat sink <NUM> for heat dissipation.

Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise," "comprising," "include," "including" and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to. " The word "coupled", as generally used herein, refers to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Likewise, the word "connected", as generally used herein, refers to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words "herein," "above," "below," and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Moreover, as used herein, when a first element is described as being "on" or "over" a second element, the first element may be directly on or over the second element, such that the first and second elements directly contact, or the first element may be indirectly on or over the second element such that one or more elements intervene between the first and second elements. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. Regarding the word "or" in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

Claim 1:
An integrated device package (<NUM>) comprising:
an electronic component package (<NUM>) comprising:
an electronic component (<NUM>); and
a protective material (<NUM>) in which the electronic component is at least partially embedded;
wherein the electronic component package comprises a first surface (<NUM>) and a second surface (<NUM>), wherein the first surface comprises an exposed surface of the electronic component (<NUM>);
an integrated heat sink (<NUM>) electroplated onto the first surface;
at least one via (<NUM>) connecting the integrated heat sink (<NUM>) to the electronic component (<NUM>) by a continuous connection; and
one or more packaging terminations (<NUM>) disposed on the second surface (<NUM>) of the electronic component package (<NUM>), the electronic component (<NUM>) being coupled to the one or more packaging terminations (<NUM>).