Patent ID: 12255159

DETAILED DESCRIPTION

Implementations of the present disclosure are described as follows through specific embodiments, and a person skilled in the art may easily understand other advantages and effects of the present disclosure from the content disclosed in this specification. The present disclosure may also be implemented or applied through another different specific implementation, and any modification or variation may be made to each detail in this specification based on different opinions and applications without departing from the spirit of the present disclosure.

Referring toFIG.1toFIG.18. It is to be noted that the drawings provided in these embodiments only illustrate the basic ideas of the present disclosure in a schematic manner. The drawings only show components related to the present disclosure, instead of drawing according to the numbers, shapes, and sizes of the components in actual implementation. In actual implementation, the type, quantity, and ratio of each component may be changed as needed, and the layout of the components may also be more complex.

Embodiment 1

Referring toFIG.1toFIG.17, the present disclosure provides a method for preparing an antenna chip packaging structure. The method comprises the following steps:1): Provide a first support substrate101, and form a redistribution layer102on the first support substrate101.2): Sequentially form, above the redistribution layer102, a first antenna layer103electrically connected to the redistribution layer102, a first connection structure104connected to the first antenna layer103, and a first packaging layer105which covers the redistribution layer102, the first antenna layer103, and the first connection structure104; then polish the first packaging layer105to expose the top of the first connection structure104.3): Sequentially form, above the first packaging layer105, a second antenna layer106electrically connected to the first connection structure104, a second connection structure107connected to the second antenna layer106, and a second packaging layer108covering the first packaging layer105, the second antenna layer106, and the second connection structure107; parts of the second antenna layer106are aligned to parts of the first antenna layer respectively and the second connection structure is aligned to the first connection structure. However, a part of the second antenna layer can be smaller in size than the aligned-to part of the first antenna layer. Then polish the second packaging layer108to expose the top of the second connection structure107.4): Form, above the second packaging layer108, a third antenna layer109electrically connected to the second connection structure107.5): Provide a second support substrate110above the second packaging layer108and the third antenna layer109, and bond the second support substrate110to the second packaging layer108and the third antenna layer109.6): Remove the first support substrate101, and form an under-bump-metal (UBM) layer111below the redistribution layer102.7): Form a solder ball112on the UBM layer111and connect a chip113to the UBM layer.

In step 1), referring to step S1inFIG.1andFIG.2, the first support substrate101is first provided, and then the redistribution layer102is formed on the first support substrate101.

As an example, as shown inFIG.2, a first release layer101ais further coated on the first support substrate101. The redistribution layer102is adhered to the first support substrate101by the first release layer101a. The first release layer101acomprises a light to heat conversion (LTHC) layer. The LTHC layer is heated by a laser, so that the LTHC layer loses its viscosity and then the redistribution layer102can be separated from the first support substrate101at the LTHC layer.

As an example, the redistribution layer102comprises at least one metal distribution layer102aand a dielectric layer102bwrapped around the metal distribution layer102. Optionally, a material of the metal distribution layer102acomprises one or more of copper, aluminum, nickel, gold, silver, and titanium. A material of the dielectric layer102bcomprises one or more of epoxy resin, silica gel, polyimide, piperonyl butoxide (PBO), benzocylobutene (BCB), silicon oxide, phosphosilicate glass, and fluorine-containing glass. A process for depositing the metal distribution layer102acomprises a chemical vapor deposition process, an evaporation process, a sputtering process, an electroplating process, or a chemical plating process. After deposition, the metal distribution layer102ais patterned by lithography and etching processes. A process for forming the dielectric layer102bcomprises a chemical vapor deposition process or a physical vapor deposition process. By repeatedly forming a metal distribution layer102aand a dielectric layer102b, a redistribution layer102having a multilayer structure can be obtained. In one embodiment, there are two layers of metal distribution layers102a.

In step 2), referring to S2 inFIG.1, andFIGS.3-6, the first antenna layer103connected to the redistribution layer102, the first connection structure104connected to the first antenna layer103, and the first packaging layer105that covers the redistribution layer102, the first antenna layer103and the first connection structure104, are successively formed above the redistribution layer102.

As shown inFIG.3, the first antenna layer103connected to the metal distribution layer in the redistribution layer102is formed above the redistribution layer102. A material of the antenna layer comprises one or more of copper, aluminum, nickel, gold, silver, and titanium, and it can be formed by one or more of chemical vapor deposition and physical vapor deposition. After deposition, the antenna layer is patterned by lithography and etching processes.

As shown inFIG.4, one end of a metal connecting wire is welded to an area between two parts of the first antenna layer103by a wire bonding process, and the other end extends upward to form the first connection structure104. Optionally, the welding process comprises one of a hot-pressing wire bonding process, an ultrasonic wire bonding process, and a hot-pressing ultrasonic wire bonding process. A material of the metal connecting wire comprises gold, silver, copper, or aluminum. After one end of the metal connecting wire is welded to the first antenna layer103, the metal connecting wire is extended upward and cut at the other end. In one embodiment, there is a plurality of such metal connecting wires and the other ends of the plurality of metal connecting wires obtained after cutting are on a same horizontal plane.

As shown inFIG.5, the first packaging layer105is formed on the first antennal layer103, and covers the redistribution layer102, the first antenna layer103, and the first connection structure104. A material of the first packaging layer105comprises one of polyimide, silica gel, and epoxy resin and is formed by one of compression molding, transfer molding, liquid sealing, vacuum lamination, and spin coating.

As shown inFIG.6, excessive parts of the first packaging layer105and the first connection structure104are removed by polishing, and a top surface of the first connection structure104is exposed.

In step 3), referring to step S3inFIG.1andFIG.7toFIG.10, these layers are sequentially formed above the first packaging layer105: the second antenna layer106is connected to the first connection structure104, the second connection structure107is connected to the second antenna layer106, and the second packaging layer108covers the first packaging layer105, the second antenna layer106, and the second connection structure107.

As shown inFIG.7, the second antenna layer106is formed above the first packaging layer105, wherein the second antenna layer106has a part connected to the first connection structure104. The second antenna layer includes parts which are aligned to the first antenna layer but are not connected to the first connection structure104. In one embodiment, the second antenna layer is made of the same materials as the first antenna layer103, and is also made by the same process as the first antenna layer103.

As shown inFIG.8, the second connection structure107connected to the second antenna layer106is formed on the second antenna layer106. In one embodiment, the second connection structure is made of the same materials as the first connection structure104is, and made by the same technique as the first connection structure104is.

As shown inFIG.9toFIG.10, the second packaging layer108is formed and covers the first packaging layer105, the second antenna layer106, and the second connection structure107. In one embodiment, the second packaging layer is made of the same materials as the first packaging layer105is, and made by the same method as the first packaging layer105. Optionally, a buffer layer108ais formed between the second packaging layer108and the first packaging layer105. The buffer layer108acan relieve the inter-layer stress between the two layers and protect the antenna layer structure from deformation and damage by the stress.

In step 4), referring to step S4inFIG.1andFIG.11, the third antenna layer109connected to the second connection structure107is formed above the second packaging layer108.

As shown inFIG.11, the third antenna layer109connected to the second connection structure107is formed above the second packaging layer108. In one embodiment, the third antenna layer is made of the same materials as the first antenna layer103is, and is formed by the same technique as the first antenna layer103.

In step 5), referring to S5 inFIG.1andFIG.12, the second support substrate110is formed above the second packaging layer108and the third antenna layer109.

As an example, as shown inFIG.12, the second support substrate110also comprises a second release layer110awhich can be an LTHC layer. The second release layer at the second support substrate110has the same function as the first release layer on the first support substrate. According to the present disclosure, the second support substrate110introduced as a temporary bonding substrate. The second support substrate110provides an additional fixing and supporting mechanism in the subsequent process, prevents abnormal warping of the packaging structure in the subsequent process, and can improve the performance of the packaging structure from stress induced abnormal warping.

In step 6), referring to S6 inFIG.1andFIG.12toFIG.15, the first support substrate101is removed, and the UBM layer111is formed below the redistribution layer102.

As shown inFIG.12toFIG.13, the first release layer101ais peeled off by laser irradiation, thereby removing the first support substrate101.

As shown inFIG.13, after the first support substrate101is removed, the method further comprises a step of forming, in the redistribution layer102, via holes111awhich are connected at bottom with the metal distribution layer102a. Optionally, a method for forming the via111acomprises a laser drilling process. Forming the via structure by a laser drilling process has significant advantages such as high precision and low costs. The metal distribution layer102ais exposed from the bottom of the via111aafter the via is formed.

As shown inFIG.14, the UBM layer111is formed below the redistribution layer102in a region where the via111ais formed. The UBM layer111may be composed of a plurality of metal layers. The UBM layer can improve electrical connection between the solder ball and the chip, and has a desirable soldering effect in the reflow soldering process, thereby enhancing the reliability of the chip packaging structure.

As shown inFIG.15, after the UBM layer111is formed, the method further comprises a step of removing the second support substrate110in a way similar to that of the first support substrate101.

In step 7), referring to step S7inFIG.1andFIG.16toFIG.17, the solder ball112is formed on the UBM layer111, and the chip113is connected to the UBM layer111.

As shown inFIG.16, the solder ball112is formed on the UBM layer111. Optionally, the step of forming the solder ball112on the UBM layer111comprises a bumping process and a soldering reflow process.

As shown inFIG.17, the chip113is connected to the UBM layer111. Optionally, the chip113is a 5G chip.

In this embodiment, the first support substrate and the second support substrate are introduced, to ensure that the packaging structure is supported and held tight by the support substrates during the packaging, thereby preventing abnormal warping. The multi-antenna layer structure is introduced, reducing the size of the packaging structure; the laser drilling is used, improving the precision and reducing the cost of via formation; the UBM layer is introduced and is connected to the solder ball and the chip, achieving a desirable soldering effect and high reliability.

Embodiment II

As shown inFIG.18, embodiment II provides a method for manufacturing an antenna chip packaging structure, and its difference from Embodiment I is as follows. In step 3), in Embodiment II, stacked up antenna structure can be formed. The stacked up antenna structure comprises what are in the Embodiment I, i.e. the first antenna layer, the first connection structure, and the first packaging layer, the second antenna layer, the second connection structure, and the second packaging layer; the third antenna layer, the third connection structure, and the third packaging layer. In addition, the Embodiment II further adds more antenna structures stacked up in sequence. The size and alignment geometry of the upper stacked up antenna layers are similar to the second and the third antenna layers, and all of which are not necessarily the same as the first antenna layer.

Each of the stacked up antenna layers above the second packaging layer covers a lower antenna layer and connects to the lower antenna layer's connection structure, similarly like how the third antenna layer connects to the second antenna layer.

The lowest stacked up antenna layer, the second antenna layer, is connected to the first connection structure, and the top one of the stacked up antenna connection structure is connected to the second support substrate.

As an example, inFIG.18, a multi-layer stacked structure is formed between the first packaging layer205and the top antenna layer209and comprises multiple antenna layers206, all of which are similar-to-the-second antenna layers from the second connection structure207, and second packaging layer208. A buffer layer208ais further formed between two adjacent packaging layers to ease the interlayer stress. The lowest antenna layer206of the stacked up antenna layers (second and above) is connected to the first connection structure204. The first connection structure204is connected to the first antenna layer203. The top one of connection structures207is connected to the highest antenna layer209. In other embodiments of the present disclosure, the stacked up antenna structures may comprise three or more layers.

Other implementations of this embodiment are the same as those of Embodiment I, and therefore relevant details are not repeated herein.

Embodiment III

As shown inFIG.17, this embodiment provides an antenna chip packaging structure. The antenna chip packaging structure comprises:a redistribution layer102;a first antenna layer103connected to the redistribution layer102, a first connection structure104connected to the first antenna layer103, and a first packaging layer105covering the redistribution layer102, the first antenna layer103, and the first connection structure104, wherein the first antenna layer, the first connection structure, and the first packaging layer are located above the redistribution layer102;a second antenna layer106connected to the first connection structure104, a second connection structure107connected to the second antenna layer106, and a second packaging layer108covering the first packaging layer105, the second antenna layer106, and the second connection structure107, wherein the second antenna layer, the second connection structure, and the second packaging layer are located above the first packaging layer105;a UBM layer111, located below the redistribution layer102; anda solder ball112and a chip113, connected to the UBM layer111.

As an example, as shown inFIG.17, the redistribution layer102comprises at least one metal distribution layer102aand a dielectric layer102bwrapped around the metal distribution layer102a. As shown inFIG.13, a via111aconnected to the metal distribution layer102ais further formed in the redistribution layer102.

As an example, as shown inFIG.18, a stacked structure is formed above the first packaging layer205and comprises a plurality of second antenna layers206, a plurality of second connection structures207, and a plurality of second packaging layers208. The plurality of second packaging layers208is stacked in sequence and each covers a corresponding second antenna layer206and second connection structure207. The plurality of second antenna layers206are connected to each other by the plurality of second connection structures207. The bottommost one of the plurality of second antenna layers206is connected to the first connection structure204, and the topmost one of the plurality of second connection structures207is connected to the third antenna layer209. The connection structures at all antenna layers overlap vertically. The parts of the first antenna layer not connected with the first connection structure align to and are larger than the parts of the other antenna layers not connected with the corresponding connection structures.

In conclusion, the present disclosure provides an antenna chip packaging structure and a method for preparing the same. The method for preparing an antenna chip packaging structure comprises the following steps: 1) Provide a first support substrate, and form a redistribution layer on the first support substrate; 2) Successively form, above the redistribution layer, a first antenna layer connected to the redistribution layer, a first connection structure connected to the first antenna layer, and a first packaging layer covering the redistribution layer, the first antenna layer, and the first connection structure; 3) Successively form, above the first packaging layer, a second antenna layer connected to the first connection structure, a second connection structure connected to the second antenna layer, and a second packaging layer covering the first packaging layer, the second antenna layer, and the second connection structure; 4) Form, above the second packaging layer, a third antenna layer connected to the second connection structure; 5) Bond a second support substrate above the second packaging layer and the third antenna layer; 6) Remove the first support substrate, and form a UBM layer below the redistribution layer; 7) Form a solder ball on the UBM layer and connect a chip to the UBM layer. A structure with multiple antenna layers is introduced, thereby reducing the size of the packaging structure; laser drilling is used, thereby improving the precision and reducing the cost of via formation processes; a UBM layer is introduced and is connected to a solder ball and a chip, achieving a desirable soldering effect and high reliability; and a second support substrate is introduced, thereby alleviating warpage of the packaging structure.

The above embodiments merely exemplarily describe the principles and effects of the present disclosure, and are not intended to limit the present disclosure. Any person familiar with this technology all may make modifications or variations to the above embodiments without departing from the spirit and scope of the present disclosure. Therefore, all equivalent modifications or changes made by a person of ordinary skill in the art without departing from the spirit and technical ideas disclosed in the present disclosure shall still fall within the scope of the claims of the present disclosure.