Patent Description:
Conventional semiconductor device includes a substrate and an electronic component disposed on the substrate. However, the electronic component inevitably generates heat during operation. Thus, how to dissipate the heat from the electronic component has become a prominent task for the industries.

<CIT> relates to a semiconductor package that uses a convex-concave structure to improve heat flow from a semiconductor device via a liquid metal; the package is assembled using a vacuum. <CIT> relates to using solder compositions that have a solidus-liquidus temperature that encompasses an IC chip operating temperature. <CIT> relates to a semiconductor package that has a liquid metal and a single hole. <CIT> relates to a liquid metal thermal interface. <CIT> relates to a liquid solder thermal interface material contained within a cold-formed barrier.

In one embodiment of the invention, a semiconductor device as disclosed in claim <NUM> is provided.

In another embodiment of the invention, a semiconductor method as disclosed in claim <NUM> is provided.

Numerous objects, features and advantages of the invention will be readily apparent upon a reading of the following detailed description of embodiments of the invention when taken in conjunction with the accompanying drawings. However, the drawings employed herein are for the purpose of descriptions and should not be regarded as limiting.

The above objects and advantages of the invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:.

Referring to <FIG>, <FIG> illustrates a diagram view of a top view of a semiconductor device <NUM> according to an embodiment not falling under the present invention, <FIG> illustrates a cross-sectional views of the semiconductor device <NUM> of <FIG> along a direction 1B-1B', and <FIG> illustrates a diagram view of a bottom view of a cover <NUM> of <FIG>.

The semiconductor device <NUM> is, for example, a Flip Chip Ball Grid Array (FCBGA), such as a High Performance FCBGA; however, such exemplification is not meant to be for limiting.

As illustrated in <FIG> and <FIG>, the semiconductor device <NUM> includes a substrate <NUM>, an electronic component <NUM>, a cover <NUM>, a liquid metal <NUM>, a first adhesive layer <NUM>, a second adhesive layer <NUM>, a first seal <NUM>, a second seal <NUM> and at least one conductive portion <NUM>.

As illustrated in <FIG>, the electronic component <NUM> is disposed on the substrate <NUM>. The cover <NUM> is disposed on the substrate <NUM> and covers the electronic component <NUM>. The liquid metal <NUM> is formed between the cover <NUM> and the electronic component <NUM>. As a result, the heat generated by the electronic component <NUM> could be dissipated through the liquid metal <NUM> and the cover <NUM>.

The substrate <NUM> has, for example, single-layered structure or multilayered structure. Although not illustrated, the substrate <NUM> includes at least one conductive trace, at least one conductive via and /or at least one conductive pad, wherein the conductive traces are electrically connected with at least one conductive via. In an embodiment, the substrate <NUM> is, for example, a printed circuit board (PCB), an interposer, another semiconductor device or a semiconductor package.

The electronic component <NUM> is electrically connected with the conductive portion <NUM> through the substrate <NUM>. The electronic component <NUM> is, for example, the component capable of applying to (or disposed on) a package requiring high-power operation, such as Flip Chip BGA (FCBGA), Fan-out package, 3D (three-dimension) IC (Integrated Circuit) package, etc. The electronic component <NUM> includes at least one conductive portion <NUM>, wherein the conductive portion <NUM> is, for example, bump or solder ball. The electronic component <NUM> is bonded to the at least one conductive pad (not illustrated) of the substrate <NUM> through at least one conductive portion <NUM>.

The cover <NUM> is made by a material, for example, metal, such as copper, aluminum, iron or a combination thereof. The cover <NUM> conducts heat and increased strength of the semiconductor device <NUM> for reducing warpage.

As illustrated in <FIG> and <FIG>, the cover <NUM> includes a plate <NUM>, a first surrounding portion <NUM>, at least one pillar <NUM> and a second surrounding portion <NUM>. The plate <NUM> has a first surface 131s1 and a second surface 131s2 opposite to the first surface 131s1. The first surface 131s1 faces the electronic component <NUM>. The first surrounding portion <NUM>, the pillars <NUM> and the second surrounding portion <NUM> are disposed on the plate <NUM> and protrude with respect to (or relative to) the first surface 131s1. The first surrounding portion <NUM> is, for example, a closed-ring for surrounding the whole of the liquid metal <NUM>. Since the pillars <NUM> protrude with respect to the first surface 131s1, and accordingly it could increase heat conduction area of the cover <NUM>. The second surrounding portion <NUM> surrounds the first surrounding portion <NUM>, the pillars <NUM>, the electronic component <NUM> and the liquid metal <NUM>. The second surrounding portion <NUM> is a closed-ring for surrounding the whole of the first surrounding portion <NUM>, the pillars <NUM>, the electronic component <NUM> and the liquid metal <NUM>.

As illustrated in <FIG>, the cover <NUM> has a first through hole 131a1 and a second through hole 131a2. In the present embodiment, the first through hole 131a1 and the second through hole 131a2 are located at the plate <NUM>. For example, the first through hole 131a1 and the second through hole 131a2 both extend to the second surface 131s2 from the first surface 131s1. As a result, during injection of the liquid metal <NUM>, the liquid metal <NUM> flows into through the first through hole 131a1, and air (if any) could be discharged through the second through hole 131a2.

As illustrated in <FIG>, the first through hole 131a1 and the second through hole 131a2 are located adjacent to first surrounding portion <NUM>. The first through hole 131a1 and the second through hole 131a2 are located between the whole region 133R of the pillars <NUM> and the first surrounding portion <NUM>. In an embodiment not falling under the present invention, the first through hole 131a1 and the second through hole 131a2 are disposed at two opposite sides of the whole region 133R of the first surrounding portion <NUM>, and thus distance between the first through hole 131a1 and the second through hole 131a2 is long. As a result, during injection of the liquid metal <NUM>, the liquid metal <NUM> flows into through the first through hole 131a1, and most air could be discharged through the second through hole 131a2. In the embodiment of the present invention, the first through hole 131a1 and the second through hole 131a2 are disposed at two opposite corners of the whole region 133R of the first surrounding portion <NUM> (that is, at two end of the diagonal line of the whole region 133R of the first surrounding portion <NUM>). As a result, the distance between the first through hole 131a1 and the second through hole 131a2 is longest, and accordingly it is more conducive to exhausting the air. In another embodiment not falling under the present invention, the second through hole 131a2 could be omitted, and the first through hole 131a1 could be disposed at middle position of the second surface 131s2 of the plate <NUM> or other position of the plate <NUM>.

In terms of the property, the liquid metal <NUM> has melting point ranging between <NUM> to <NUM>, less or higher. During injection of the liquid metal <NUM>, the liquid metal <NUM> is pre-heated to be at flowable state, injected into space between the cover <NUM> and the electronic component <NUM> through the first through hole 131a1, and then solidified, without curing, by cooling or temperature drop. In addition, the liquid metal <NUM> has thermal conductivity ranging between the <NUM> W/m-K to <NUM> W/m-K, or higher. The thermal conductivity of the liquid metal <NUM> is higher than that of the thermal Interface Material (TIM). Generally, the TIM has thermal conductivity ranging between <NUM> W/m-K to <NUM> W/m-K.

As illustrated in <FIG>, the liquid metal <NUM> is formed among the cover <NUM> and the electronic component <NUM> as a heat transfer medium. Furthermore, there are a first receiving portion SP1 formed between adjacent two pillars <NUM>, a second receiving portion SP2 formed between a terminal 133b of each pillar <NUM> and the electronic component <NUM>, and a third receiving portion SP3 formed between the first surrounding portion <NUM>, the first surface 131s1, the outermost pillar <NUM> and the electronic component <NUM>. Viewed from top of the third receiving portion SP3, the third receiving portion SP3 has a ringed-shape, for example, a closed ringed-shape. The liquid metal <NUM> includes at least one first metal portion <NUM>, a second metal portion <NUM> and a third metal portion <NUM>. The first metal portion <NUM> fills up at least portion of each first receiving portion SP1, the second metal portion <NUM> fills up at least portion of the second receiving portion SP2, and the third metal portion <NUM> fills up at least portion of the third receiving portion SP3. As a result, even if the liquid metal <NUM> has at least one void (or air layer) 140a, the heat generated by the electronic component <NUM> still could be dissipated through other heat conduction part, such as the first metal portion <NUM>, the second metal portion <NUM> and the third metal portion <NUM> which connect the cover <NUM> and electronic component <NUM>.

In addition, as illustrated in <FIG>, there is space SP4 formed among the plate <NUM>, the first surrounding portion <NUM> and the second surrounding portion <NUM>. There is no physical material formed within the space SP4, for example.

As illustrated in <FIG>, the first adhesive layer <NUM> is disposed between a terminal 132b of the first surrounding portion <NUM> and the electronic component <NUM> for fixing relative position between the first surrounding portion <NUM> and the electronic component <NUM>. In an embodiment, viewed from top of the first adhesive layer <NUM>, the first adhesive layer <NUM> has a ringed-shape, for example, a closed ringed-shape for closing the gap (if any) between the first surrounding portion <NUM> and the electronic component <NUM>. As a result, the liquid metal <NUM> could be prevented from leaking through the first surrounding portion <NUM> and the electronic component <NUM>. In addition, the terminal 132b has a concave 132b1 for receiving a portion of the first adhesive layer <NUM>, and accordingly it could increase adhesion between the first surrounding portion <NUM> and the electronic component <NUM>.

As illustrated in <FIG>, the second adhesive layer <NUM> is disposed between a terminal 134b of the second surrounding portion <NUM> and the substrate <NUM> for fixing relative position between the cover <NUM> and the substrate <NUM>. In an embodiment, viewed from top of the second adhesive layer <NUM>, the second adhesive layer <NUM> has a ringed-shape, for example, a closed ringed-shape for closing the gap (if any) between the second surrounding portion <NUM> and the substrate <NUM>. As a result, an external impurity is prevented from invading interior of the semiconductor device <NUM> through the second surrounding portion <NUM> and the substrate <NUM>.

As illustrated in <FIG>, the first seal <NUM> closes or seals the first through hole 131a1. As a result, the liquid metal <NUM> is prevented from leaking through the first through hole 131a1, and an external impurity is prevented from invading an interior of the semiconductor device <NUM> through the first through hole 131a1. In addition, there is space between the first seal <NUM> and the third metal portion <NUM> of the liquid metal <NUM>, and there is no physical material formed within the space, and thus the space could receive the thermal expansion of the third metal portion <NUM>.

As illustrated in <FIG>, the second seal <NUM> closes the second through hole 131a2. As a result, the liquid metal <NUM> is prevented from leaking through the second through hole 131a2, and an external impurity is prevented from invading an interior of the semiconductor device <NUM> through the second through hole 131a2. In addition, there is space between the second seal <NUM> and the third metal portion <NUM> of the liquid metal <NUM>, and there is no physical material formed within the space, and thus the space could receive the thermal expansion of the third metal portion <NUM>.

As illustrated in <FIG>, the first adhesive layer <NUM>, the second adhesive layer <NUM>, the first seal <NUM> and the second seal <NUM> seal the receiving portions among the cover <NUM> and the electronic component <NUM> within.

As illustrated in <FIG>, the conductive portions <NUM> are formed on a lower surface 110b of the substrate <NUM>. Any one of the conductive portions <NUM> is, for example, bump, solder ball, etc. The semiconductor device <NUM> is bonded to and electrically connected with an external electronic device (for example, PCB, etc.) through the conductive portions <NUM> of the semiconductor device <NUM>.

Referring to <FIG> illustrate manufacturing processes of the semiconductor device <NUM> of <FIG>.

As illustrated in <FIG>, the electronic component <NUM> is disposed on the substrate <NUM>, wherein the electronic component <NUM> includes at least one conductive portion <NUM>, wherein the electronic component <NUM> is bonded to the substrate <NUM> through at least one conductive portion <NUM>. In addition, an underfill <NUM> is formed between a lower surface 120b of the electronic component <NUM> and an upper surface 110u of the substrate <NUM> to encapsulate the conductive portions <NUM>.

As illustrated in <FIG>, the first adhesive layer <NUM> is formed on an upper surface 120u of the electronic component <NUM>, wherein the first adhesive layer <NUM> is formed on an peripheral zone of the upper surface 120u. Viewed from top of the first adhesive layer <NUM>, the first adhesive layer <NUM> has a ringed-shape, for example, a closed ringed-shape.

As illustrated in <FIG>, the second adhesive layer <NUM> is formed on the upper surface 110u of the substrate <NUM>, wherein the second adhesive layer <NUM> is formed on an peripheral zone of the upper surface 110u. Viewed from top of the second adhesive layer <NUM>, the second adhesive layer <NUM> has a ringed-shape, for example, a closed ringed-shape.

In addition, the embodiment of the present invention does not limit the order of forming the first adhesive layer <NUM> and the second adhesive layer <NUM>.

As illustrated in <FIG>, the cover <NUM> is disposed on the substrate <NUM> to cover the electronic component <NUM>. The cover <NUM> includes the plate <NUM>, the first surrounding portion <NUM>, at least one pillar <NUM> and the second surrounding portion <NUM>. The cover <NUM> has the first through hole 131a1 and the second through hole 131a2, wherein the first through hole 131a1 and the second through hole 131a2 both extend to the second surface 131s2 of the plate <NUM> from the first surface 131s1 of the plate <NUM>.

In <FIG>, the first surrounding portion <NUM> of the cover <NUM> adheres to the electronic component <NUM> through the first adhesive layer <NUM>, and the second surrounding portion <NUM> of the cover <NUM> adheres to the substrate <NUM> through the second adhesive layer <NUM> for fixing the relative position between the substrate <NUM> and the cover <NUM>. The first adhesive layer <NUM> could close the gap (if any) between the first surrounding portion <NUM> and the electronic component <NUM>, and the second adhesive layer <NUM> could close the gap (if any) between the second surrounding portion <NUM> and the substrate <NUM>.

In <FIG>, there are the first receiving portion SP1 formed between adjacent two pillars <NUM>, the second receiving portion SP2 formed between the terminal 133b of each pillar <NUM> and the electronic component <NUM>, and the third receiving portion SP3 formed between the first surrounding portion <NUM>, the first surface 131s1, the outermost pillar <NUM> and the electronic component <NUM>. Viewed from top of the third receiving portion SP3, the third receiving portion SP3 has a ringed-shape, for example, a closed ringed-shape.

As illustrated in <FIG>, at least one conductive portion <NUM> is formed on the lower 110b of the substrate <NUM>.

As illustrated in <FIG>, the liquid metal <NUM> is formed between the cover <NUM> and the electronic component <NUM> by using injector <NUM>. For example, the liquid metal <NUM> is injected into the first receiving portion SP1, the second receiving portion SP2 and the third receiving portion SP3 through the first through hole 131a1, and gas (for example, air) A1 is discharged through the second through hole 131a2.

In <FIG>, the liquid metal <NUM> includes at least one first metal portion <NUM>, the second metal portion <NUM> and the third metal portion <NUM>. The first metal portion <NUM> fills up at least portion of each first receiving portion SP1, the second metal portion <NUM> fills up at least portion of the second receiving portion SP2, and the third metal portion <NUM> fills up at least portion of the third receiving portion SP3. Due to many portions (for example, the first metal portions <NUM>, the second metal portion <NUM> and the third metal portion <NUM>) connecting the cover <NUM> and electronic component <NUM>, even if the liquid metal <NUM> has at least one void (or air layer) 140a, the heat generated by the electronic component <NUM> still could be dissipated through other heat conduction part, such as the first metal portion <NUM>, the second metal portion <NUM> and the third metal portion <NUM> which connect the cover <NUM> and electronic component <NUM>.

Then, the first seal <NUM> is formed within the first through hole 131a1 to seal the first through hole 131a1, as illustrated in <FIG>. As a result, the liquid metal <NUM> is prevented from leaking through the first through hole 131a1, and an external impurity is prevented from invading an interior of the semiconductor device <NUM> through the first through hole 131a1. In addition, there is space between the first seal <NUM> and the third metal portion <NUM> of the liquid metal <NUM>, and there is no physical material formed within the space, and thus the space could receive the thermal expansion of the third metal portion <NUM>.

Then, the second seal <NUM> is formed within the second through hole 131a2 to seal the second through hole 131a2, as illustrated in <FIG>. As a result, the liquid metal <NUM> is prevented from leaking through the second through hole 131a2, and an external impurity is prevented from invading an interior of the semiconductor device <NUM> through the second through hole 131a2. In addition, there is space between the second seal <NUM> and the third metal portion <NUM> of the liquid metal <NUM>, and there is no physical material formed within the space, and thus the space could receive the thermal expansion of the third metal portion <NUM>.

Claim 1:
A semiconductor device (<NUM>), wherein the semiconductor device (<NUM>) comprises:
a substrate (<NUM>);
an electronic component (<NUM>) disposed on the substrate (<NUM>);
a cover (<NUM>) disposed on the substrate (<NUM>) and covering the electronic component (<NUM>); and
a liquid metal (<NUM>) formed between the cover (<NUM>) and the electronic component (<NUM>),
wherein the cover (<NUM>) has a first through hole (131a1) and a second through hole (131a2), wherein the first through hole (131a1) is sealed by a first seal (<NUM>), and wherein the second through hole (131a2) is sealed by a second seal (<NUM>),
wherein the cover (<NUM>) comprises:
a plate (<NUM>) having a first surface (131s1) facing the electronic component (<NUM>); and
a first surrounding portion (<NUM>) disposed on the plate (<NUM>) and protruding with respect to the first surface (131s1);
wherein the liquid metal (<NUM>) is formed between the plate (<NUM>) and the electronic component (<NUM>),
wherein the first surrounding portion (<NUM>) is a closed-ring, having four corners, for surrounding the whole of the liquid metal (<NUM>),
characterized in that
the first through hole (131a1) and the second through hole (131a2) are disposed at two diagonally opposite corners adjacent the first surrounding portion (<NUM>).