WO2006061792A2 - Hermetically sealed integrated circuit package - Google Patents

Hermetically sealed integrated circuit package Download PDF

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Publication number
WO2006061792A2
WO2006061792A2 PCT/IB2005/054119 IB2005054119W WO2006061792A2 WO 2006061792 A2 WO2006061792 A2 WO 2006061792A2 IB 2005054119 W IB2005054119 W IB 2005054119W WO 2006061792 A2 WO2006061792 A2 WO 2006061792A2
Authority
WO
WIPO (PCT)
Prior art keywords
interconnection
major surface
substrate
recess
sealing ring
Prior art date
Application number
PCT/IB2005/054119
Other languages
French (fr)
Other versions
WO2006061792A3 (en
Inventor
Fabrice Verjus
Jean-Marc Yannou
David Chevrie
Francois Lecornec
Nicolaas J. A. Van Veen
Original Assignee
Koninklijke Philips Electronics N.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Koninklijke Philips Electronics N.V. filed Critical Koninklijke Philips Electronics N.V.
Publication of WO2006061792A2 publication Critical patent/WO2006061792A2/en
Publication of WO2006061792A3 publication Critical patent/WO2006061792A3/en
Priority to US12/702,041 priority Critical patent/US8237256B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B81—MICROSTRUCTURAL TECHNOLOGY
    • B81C—PROCESSES OR APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OR TREATMENT OF MICROSTRUCTURAL DEVICES OR SYSTEMS
    • B81C1/00—Manufacture or treatment of devices or systems in or on a substrate
    • B81C1/00015—Manufacture or treatment of devices or systems in or on a substrate for manufacturing microsystems
    • B81C1/00222—Integrating an electronic processing unit with a micromechanical structure
    • B81C1/0023—Packaging together an electronic processing unit die and a micromechanical structure die
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
    • H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/02—Containers; Seals
    • H01L23/04—Containers; Seals characterised by the shape of the container or parts, e.g. caps, walls
    • H01L23/053—Containers; Seals characterised by the shape of the container or parts, e.g. caps, walls the container being a hollow construction and having an insulating or insulated base as a mounting for the semiconductor body
    • H01L23/057—Containers; Seals characterised by the shape of the container or parts, e.g. caps, walls the container being a hollow construction and having an insulating or insulated base as a mounting for the semiconductor body the leads being parallel to the base
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/02—Containers; Seals
    • H01L23/10—Containers; Seals characterised by the material or arrangement of seals between parts, e.g. between cap and base of the container or between leads and walls of the container
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/12—Mountings, e.g. non-detachable insulating substrates
    • H01L23/13—Mountings, e.g. non-detachable insulating substrates characterised by the shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/12—Mountings, e.g. non-detachable insulating substrates
    • H01L23/14—Mountings, e.g. non-detachable insulating substrates characterised by the material or its electrical properties
    • H01L23/147—Semiconductor insulating substrates
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
    • H01L23/49816—Spherical bumps on the substrate for external connection, e.g. ball grid arrays [BGA]
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00—Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02—Details
    • H03H9/05—Holders; Supports
    • H03H9/058—Holders; Supports for surface acoustic wave devices
    • H03H9/059—Holders; Supports for surface acoustic wave devices consisting of mounting pads or bumps
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00—Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02—Details
    • H03H9/05—Holders; Supports
    • H03H9/10—Mounting in enclosures
    • H03H9/1057—Mounting in enclosures for microelectro-mechanical devices
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00—Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02—Details
    • H03H9/05—Holders; Supports
    • H03H9/10—Mounting in enclosures
    • H03H9/1064—Mounting in enclosures for surface acoustic wave [SAW] devices
    • H03H9/1071—Mounting in enclosures for surface acoustic wave [SAW] devices the enclosure being defined by a frame built on a substrate and a cap, the frame having no mechanical contact with the SAW device
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
    • H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
    • H01L2224/481—Disposition
    • H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/48225—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
    • H01L2224/48227—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation connecting the wire to a bond pad of the item
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/01—Chemical elements
    • H01L2924/01005—Boron [B]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/10—Details of semiconductor or other solid state devices to be connected
    • H01L2924/146—Mixed devices
    • H01L2924/1461—MEMS

Definitions

  • the invention relates to packaging of integrated circuits and in particular to packaging of integrated circuits including elements which are to be packaged in a hermetically sealed cavity.
  • Some devices include sensitive elements that need to be packaged in a hermetic enclosure. Such devices include micro electro-mechanical systems (MEMS) devices, acoustic wave filters and resonators. This requirement of a hermetic enclosure increases the thickness of these devices to be greater than regular pre-packaged devices or bare die circuits, which can make them difficult to include in a SIP.
  • MEMS micro electro-mechanical systems
  • CSP chip scale packaging
  • the device includes a substrate which carries the sensitive element.
  • the sensitive element is mounted in a package body which is sealed with a lid.
  • the package body is made of plastics material. This approach amounts to a small conventional package and the size and in particular the thickness of the device can often compromise its inclusion in a module.
  • WLP wafer level packaging
  • a substrate 2 has a sensitive element 4 on one surface 6.
  • a lid 8 is sealed to this surface 6 defining a cavity 10 containing the sensitive element.
  • Vias 12 through the lid 8 provide electrical connections to the substrate and flip chip bumps 14 are provided on the vias to allow the wafer lever package to be bonded within a module.
  • WLP package when mounted on a module substrate such a WLP package remains significantly thicker than a bare die.
  • an integrated semiconductor device including: a device substrate with a device major surface, a semiconductor element on the device major surface, and electrically conductive device connectors extending across the device major surface; and an interconnection substrate having an interconnection major surface, the interconnection substrate defining at least one sealing recess recessed from the interconnection major surface, the sealing recess being surrounded by a sealing ring; wherein the device substrate is mounted on the interconnection substrate with the interconnection major surface facing the device major surface, the sealing ring around the semiconductor element and with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element; the integrated semiconductor device further comprising: electrical interconnects across the interconnection major surface; and interconnection bumps outside the sealing ring, the interconnection bumps electrically connecting the device electrical connectors to the interconnects.
  • the invention provides a sealed electrical element in a thin arrangement.
  • the total thickness of the mounted device is no thicker than the sum of the device and interconnection substrate thicknesses.
  • a device substrate requiring hermetic sealing can be mounted in a way that results in no greater thickness than a simple bare die not requiring any such sealing.
  • the device preferably includes at least one bonding trench on the interconnect major surface around the sealing ring.
  • the bonding trench may accommodate one or more of the interconnection bumps.
  • the trench may conveniently be a trench completely surrounding the sealing ring, i.e. in the form of a ring trench concentrically around the sealing ring , or alternatively, there may be a plurality of bonding trenches around the sealing ring each to hold one or more of the interconnect bumps.
  • the interconnection substrate there is at least one additional semiconductor device mounted on the interconnection substrate.
  • the device substrate may be connected to the at least one additional semiconductor device by the electrical interconnects.
  • the integration substrate itself is the substrate interconnecting the various semiconductor components of a module.
  • the additional semiconductor devices may be mounted for hermetic sealing in the same way as the first semiconductor device or they may be mounted conventionally.
  • the interconnection substrate may define a device recess for holding the semiconductor device, the semiconductor device, the sealing ring and sealing recess being provided within the device recess. This reduces the overall thickness still further.
  • the semiconductor device does not extend beyond the interconnection major surface.
  • the thickness of the semiconductor device and integration substrate together does not exceed that of the integration substrate. In embodiments, this may be used to create an extremely thin device.
  • An additional semiconductor device may be mounted on the interconnection major surface extending above the device recess.
  • the integration substrate may be of silicon. Silicon represents a convenient material in which to form the sealing recess, the sealing ring and (if required) the bonding trench and the device recess.
  • a method of mounting a device substrate having a device major surface, a semiconductor element on the device major surface, and device electrical connectors on the device major surface comprising: providing an interconnection substrate having an interconnection major surface and electrical interconnects across the interconnection major surface, the interconnection substrate defining at least one sealing recess recessed from the interconnection major surface, the sealing recess being surrounded by a sealing ring; forming interconnection bumps on the electrical interconnects or the electrical connection pads; aligning the device substrate with the interconnection substrate with the interconnection major surface facing the device major surface, with the sealing ring around the semiconductor element; and with the interconnection bumps aligned between the device electrical connectors and the interconnects; and bonding the device substrate to the interconnection substrate with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element and with the interconnection bumps connect the device electrical connectors and the electrical interconnects.
  • the step of providing an interconnection substrate includes: etching the sealing recess and at least one bonding trench around the sealing recess in the interconnection major surface of a substrate; and depositing the electrical interconnect on the interconnection major surface including in the at least one bonding trench.
  • the invention in another aspect, relates to an interconnection substrate for mounting a device substrate having a device major surface, a semiconductor element on the device major surface, and device electrical connectors on the device major surface
  • the interconnection substrate comprises: an interconnection major surface; electrical interconnects extending across the interconnection major surface; at least one sealing recess recessed from the interconnection major surface; a sealing ring surrounding the sealing recess; bonding pads around and outside the sealing ring for connecting through interconnection bumps to the device electrical connectors on the device major surface so that the device substrate may be mounted on the interconnection substrate with the interconnection major surface facing the device major surface, with the sealing ring around the semiconductor element and with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element.
  • Figure 1 shows a prior art package
  • Figure 2 shows a side section of a first embodiment of the invention
  • Figure 3 shows a top view of a first embodiment of the invention.
  • FIG. 4 shows a side section of a second embodiment of the invention.
  • Like components are given like reference numerals in the different figures, which are purely schematic and not to scale.
  • a silicon semiconductor device substrate 2 has a surface acoustic wave (SAW) filter device element 4 on a first major surface 6 which will be referred to as a device major surface below.
  • the device major surface 6 of the silicon substrate has device electrical connectors 16 running along it which are connected to the device element 4 by bond wires 18.
  • connection may be made by means of an underlying conductive layer, or layers, within the device substrate 2.
  • Another semiconductor substrate 20 acts as a passive interconnection substrate. This interconnection substrate 20 may be seen in side view in
  • the interconnection substrate 20 has a first major surface 21 which will be referred to as the interconnection major surface 21 to avoid confusion with the device major surface 6.
  • a recess 24 is formed in the interconnection major surface.
  • another recess 26 in the form of a ring around the recess 24 which will be referred to as a bonding trench 26 for reasons which will be come apparent later.
  • the sealing ring 22 extends around the whole of the recess 24.
  • the sealing ring 22 in the embodiment is thus at the level of the second major surface 21 , and is accordingly raised with respect to the recess 24.
  • Metallic interconnections 30 are provided on the interconnection substrate 20 extending into the bonding trench 26. As shown in Figure 3, the ends of these interconnections 30 are broadened to provide bonding pads 32.
  • the interconnection substrate is conveniently of silicon which makes it straightforward to fabricate the recess 24, trench 26 and sealing ring 22, as well as to deposit the interconnect 30. In use, to mount the silicon substrate 2 on the interconnection substrate
  • bonding "bumps" 28 are formed on the interconnections 16 on the device major surface. Any suitable material may be used to form these bumps and the skilled person will be aware of a number of such single materials or material combinations.
  • the silicon substrate is arranged so that the device major surface 6 faces the interconnection major surface 21 with the MEMS element 4 facing the recess 24.
  • the device substrate 2 and interconnection substrate 20 are then brought together so that the device major surface contacts the sealing ring 22, the recess 24 thus forming a hermetically sealed cavity 24 sealing the device element 4.
  • the bonding bumps 28 contact the bonding pads 32. Bonding of the bonding bumps may follow using techniques known to those skilled in the art, for example by reflowing the bonding bumps 28 in the case that the bumps are solder bumps or by the simple application of pressure or heat and pressure. It will be noted that the bumps 28 end up in the bonding trench 26 and so any extra thickness caused by the bumps does not increase the thickness of the finished device.
  • the sealing of the sealing ring is essentially independent of the electrical interconnects.
  • the capillary action of the melted bonding bumps will tend to urge the substrates together thus assisting a good seal.
  • the interconnection substrate includes a number of recesses 24, each used to bond a separate substrate 2. For clarity, only one such substrate 2 is shown in a dotted line in Figure 3.
  • the same interconnection substrate may also be used to mount conventional chips 38 that do not require hermetic sealing. These chips may be mounted on additional chip mounting points 36 which have a plurality of bonding pads 34 connected to interconnects 30.
  • the additional chip mounting points 36 in this embodiment do not have recesses or bonding trenches and may conveniently be flat to avoid the need for excessive processing.
  • all additional chips may be mounted in like manner to the device substrate 2 needing to be hermetically sealed.
  • Figure 4 shows a second embodiment in which device recesses 40 are provided in the interconnection substrate 20. These recesses are large enough to accommodate the device substrate 2.
  • the device element is a MEMS element 4.
  • the sealing ring 22, the recess 24 and the bonding trench 26 are provided at the base of the device recess.
  • the device substrate 2 is wholly contained in the device recess 40 and does not extend beyond the interconnection major surface 21.
  • interconnection substrate 20 and device substrate 2 are not greater than that of the interconnection substrate 20.
  • an additional device 42 may be mounted over the device recess 40, using additional bumps 44 to connect to bonding pads 34 which in turn are connected to interconnects 30 which in the example shown connect through bonding pads 32, bonding bumps 28, interconnections 16 and bonding wires 18 to the MEMS device element 4.
  • the additional device 42 effectively overlaps the device 2 thus saving area of interconnection substrate 20.
  • Both the first and second embodiments can readily be implemented without excessive processing cost. Various modifications of these embodiments are possible.
  • the mounting technique described is not just useful for bonding SAW or MEMS devices, but may be used for any device, especially those with sensitive elements requiring a hermetically sealed cavity.
  • the substrate 2 need not be of silicon, but may be another semiconductor such as GaAs or InP, or insulator such as quartz or sapphire or any other substrate material as will be appreciated by those skilled in the art.
  • the interconnection substrate 20 need not necessarily be made of silicon but other materials including ceramics or plastics may also be used.
  • additional sealing material may be provided, especially on the sealing ring 22, if required to improve the seal. However, this is not usually required.
  • the interconnection substrate is passive active substrates including active devices may be used if required.
  • the device substrate may in embodiments extend above the level of the interconnection major surface.
  • the additional devices in the described embodiments are attached using bump technology.

Abstract

A device substrate (2) has a device major surface (6), a semiconductor element (4) on the device major surface (6), and electrically conductive device connectors (16) extending across the device major surface (4). An interconnection substrate has an interconnection substrate (20) having an interconnection major surface (21 ), the interconnection substrate (20) defining at least one sealing recess (24) recessed from the interconnection major surface (21 ) , the sealing recess (24) being surrounded by a sealing ring (22). The device substrate (2) is mounted on the interconnection substrate (20) with the interconnection major surface (21 ) facing the device major surface (6), the sealing ring (22) around the semiconductor element (4) and with the device major surface (6) sealed against the sealing ring (22) so that the recess (24) forms a sealed cavity containing the semiconductor element (4). Electrical interconnects (30) extend across the interconnection major surface (21 ). Interconnection bumps (28) are provided outside the sealing ring (22) to electrically connect the device (2) to the interconnect substrate (20).

Description

DESCRIPTION
INTEGRATED PACKAGE
The invention relates to packaging of integrated circuits and in particular to packaging of integrated circuits including elements which are to be packaged in a hermetically sealed cavity.
There is an increasing demand for thinner packages. Further, there is an increasing demand for combining more than one device, in a single package, often known as a "system in package" (SIP). This packaged device may be a complete module. Thus, there is a need for thinner devices.
Some devices include sensitive elements that need to be packaged in a hermetic enclosure. Such devices include micro electro-mechanical systems (MEMS) devices, acoustic wave filters and resonators. This requirement of a hermetic enclosure increases the thickness of these devices to be greater than regular pre-packaged devices or bare die circuits, which can make them difficult to include in a SIP.
One existing solution for the hermetic packaging of devices is known as chip scale packaging (CSP). In this approach, the device includes a substrate which carries the sensitive element. The sensitive element is mounted in a package body which is sealed with a lid. Normally the package body is made of plastics material. This approach amounts to a small conventional package and the size and in particular the thickness of the device can often compromise its inclusion in a module.
An alternative approach is wafer level packaging (WLP). In this approach, illustrated in Figure 1 , a substrate 2 has a sensitive element 4 on one surface 6. A lid 8 is sealed to this surface 6 defining a cavity 10 containing the sensitive element. Vias 12 through the lid 8 provide electrical connections to the substrate and flip chip bumps 14 are provided on the vias to allow the wafer lever package to be bonded within a module. However, when mounted on a module substrate such a WLP package remains significantly thicker than a bare die.
According to the invention, there is provided an integrated semiconductor device including: a device substrate with a device major surface, a semiconductor element on the device major surface, and electrically conductive device connectors extending across the device major surface; and an interconnection substrate having an interconnection major surface, the interconnection substrate defining at least one sealing recess recessed from the interconnection major surface, the sealing recess being surrounded by a sealing ring; wherein the device substrate is mounted on the interconnection substrate with the interconnection major surface facing the device major surface, the sealing ring around the semiconductor element and with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element; the integrated semiconductor device further comprising: electrical interconnects across the interconnection major surface; and interconnection bumps outside the sealing ring, the interconnection bumps electrically connecting the device electrical connectors to the interconnects.
By using this approach a semiconductor element that requires hermetic sealing can be mounted as a bare die on the integration substrate, the sealing ring sealing the semiconductor element as required. Thus, the invention provides a sealed electrical element in a thin arrangement. The total thickness of the mounted device is no thicker than the sum of the device and interconnection substrate thicknesses. Thus, a device substrate requiring hermetic sealing can be mounted in a way that results in no greater thickness than a simple bare die not requiring any such sealing.
The device preferably includes at least one bonding trench on the interconnect major surface around the sealing ring. The bonding trench may accommodate one or more of the interconnection bumps. The trench may conveniently be a trench completely surrounding the sealing ring, i.e. in the form of a ring trench concentrically around the sealing ring , or alternatively, there may be a plurality of bonding trenches around the sealing ring each to hold one or more of the interconnect bumps.
In this way conventional bump bonding of the device and interconnection substrates may be provided without interfering with the sealing of the sealing ring or increasing the thickness of the substrate.
In preferred embodiments there is at least one additional semiconductor device mounted on the interconnection substrate. The device substrate may be connected to the at least one additional semiconductor device by the electrical interconnects. Thus, the integration substrate itself is the substrate interconnecting the various semiconductor components of a module. It should be noted that the additional semiconductor devices may be mounted for hermetic sealing in the same way as the first semiconductor device or they may be mounted conventionally.
The interconnection substrate may define a device recess for holding the semiconductor device, the semiconductor device, the sealing ring and sealing recess being provided within the device recess. This reduces the overall thickness still further.
Preferably, the semiconductor device does not extend beyond the interconnection major surface. In this way, the thickness of the semiconductor device and integration substrate together does not exceed that of the integration substrate. In embodiments, this may be used to create an extremely thin device.
An additional semiconductor device may be mounted on the interconnection major surface extending above the device recess. Thus, the use of a device recess allows the additional device to overlap the device in the device recess, saving space. The integration substrate may be of silicon. Silicon represents a convenient material in which to form the sealing recess, the sealing ring and (if required) the bonding trench and the device recess. In another aspect there is provided a method of mounting a device substrate having a device major surface, a semiconductor element on the device major surface, and device electrical connectors on the device major surface, the method comprising: providing an interconnection substrate having an interconnection major surface and electrical interconnects across the interconnection major surface, the interconnection substrate defining at least one sealing recess recessed from the interconnection major surface, the sealing recess being surrounded by a sealing ring; forming interconnection bumps on the electrical interconnects or the electrical connection pads; aligning the device substrate with the interconnection substrate with the interconnection major surface facing the device major surface, with the sealing ring around the semiconductor element; and with the interconnection bumps aligned between the device electrical connectors and the interconnects; and bonding the device substrate to the interconnection substrate with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element and with the interconnection bumps connect the device electrical connectors and the electrical interconnects.
Preferably, the step of providing an interconnection substrate includes: etching the sealing recess and at least one bonding trench around the sealing recess in the interconnection major surface of a substrate; and depositing the electrical interconnect on the interconnection major surface including in the at least one bonding trench.
In another aspect, the invention relates to an interconnection substrate for mounting a device substrate having a device major surface, a semiconductor element on the device major surface, and device electrical connectors on the device major surface, wherein the interconnection substrate comprises: an interconnection major surface; electrical interconnects extending across the interconnection major surface; at least one sealing recess recessed from the interconnection major surface; a sealing ring surrounding the sealing recess; bonding pads around and outside the sealing ring for connecting through interconnection bumps to the device electrical connectors on the device major surface so that the device substrate may be mounted on the interconnection substrate with the interconnection major surface facing the device major surface, with the sealing ring around the semiconductor element and with the device major surface sealed against the sealing ring so that the recess forms a sealed cavity containing the semiconductor element.
Embodiments of the invention will now be described, purely by way of example, with reference to the accompanying drawings in which:
Figure 1 shows a prior art package;
Figure 2 shows a side section of a first embodiment of the invention;
Figure 3 shows a top view of a first embodiment of the invention; and
Figure 4 shows a side section of a second embodiment of the invention. Like components are given like reference numerals in the different figures, which are purely schematic and not to scale.
Referring to Figure 2, a silicon semiconductor device substrate 2 has a surface acoustic wave (SAW) filter device element 4 on a first major surface 6 which will be referred to as a device major surface below. The device major surface 6 of the silicon substrate has device electrical connectors 16 running along it which are connected to the device element 4 by bond wires 18.
Alternatively, connection may be made by means of an underlying conductive layer, or layers, within the device substrate 2. Another semiconductor substrate 20 acts as a passive interconnection substrate. This interconnection substrate 20 may be seen in side view in
Figure 2 and in top view in Figure 3. The interconnection substrate 20 has a first major surface 21 which will be referred to as the interconnection major surface 21 to avoid confusion with the device major surface 6.
To provide a mounting point for a device, a recess 24 is formed in the interconnection major surface. Around the recess 24, there is provided another recess 26 in the form of a ring around the recess 24 which will be referred to as a bonding trench 26 for reasons which will be come apparent later.
Between the recess 24 and bonding trench 26 there is a ring shaped portion of the interconnection substrate which will be referred to as the sealing ring 22. The sealing ring 22 extends around the whole of the recess 24. The sealing ring 22 in the embodiment is thus at the level of the second major surface 21 , and is accordingly raised with respect to the recess 24.
Metallic interconnections 30 are provided on the interconnection substrate 20 extending into the bonding trench 26. As shown in Figure 3, the ends of these interconnections 30 are broadened to provide bonding pads 32.
The interconnection substrate is conveniently of silicon which makes it straightforward to fabricate the recess 24, trench 26 and sealing ring 22, as well as to deposit the interconnect 30. In use, to mount the silicon substrate 2 on the interconnection substrate
20, bonding "bumps" 28 are formed on the interconnections 16 on the device major surface. Any suitable material may be used to form these bumps and the skilled person will be aware of a number of such single materials or material combinations. The silicon substrate is arranged so that the device major surface 6 faces the interconnection major surface 21 with the MEMS element 4 facing the recess 24.
The device substrate 2 and interconnection substrate 20 are then brought together so that the device major surface contacts the sealing ring 22, the recess 24 thus forming a hermetically sealed cavity 24 sealing the device element 4.
At the same time, the bonding bumps 28 contact the bonding pads 32. Bonding of the bonding bumps may follow using techniques known to those skilled in the art, for example by reflowing the bonding bumps 28 in the case that the bumps are solder bumps or by the simple application of pressure or heat and pressure. It will be noted that the bumps 28 end up in the bonding trench 26 and so any extra thickness caused by the bumps does not increase the thickness of the finished device.
By arranging the bonding bumps outside the sealing ring the sealing of the sealing ring is essentially independent of the electrical interconnects.
Moreover, if a reflow process is used to melt the bonding bumps, the capillary action of the melted bonding bumps will tend to urge the substrates together thus assisting a good seal.
As may be seen in Figure 3, the interconnection substrate includes a number of recesses 24, each used to bond a separate substrate 2. For clarity, only one such substrate 2 is shown in a dotted line in Figure 3.
The same interconnection substrate may also be used to mount conventional chips 38 that do not require hermetic sealing. These chips may be mounted on additional chip mounting points 36 which have a plurality of bonding pads 34 connected to interconnects 30. The additional chip mounting points 36 in this embodiment do not have recesses or bonding trenches and may conveniently be flat to avoid the need for excessive processing. However, in alternative embodiments all additional chips may be mounted in like manner to the device substrate 2 needing to be hermetically sealed.
Figure 4 shows a second embodiment in which device recesses 40 are provided in the interconnection substrate 20. These recesses are large enough to accommodate the device substrate 2. In this embodiment, the device element is a MEMS element 4.
The sealing ring 22, the recess 24 and the bonding trench 26 are provided at the base of the device recess. When the device substrate 2 is mounted as in the embodiment of Figure 1 the device substrate 2 is wholly contained in the device recess 40 and does not extend beyond the interconnection major surface 21.
This means that the total thickness of interconnection substrate 20 and device substrate 2 is not greater than that of the interconnection substrate 20. A further benefit of this approach is that an additional device 42 may be mounted over the device recess 40, using additional bumps 44 to connect to bonding pads 34 which in turn are connected to interconnects 30 which in the example shown connect through bonding pads 32, bonding bumps 28, interconnections 16 and bonding wires 18 to the MEMS device element 4.
Thus, in this embodiment the additional device 42 effectively overlaps the device 2 thus saving area of interconnection substrate 20.
Both the first and second embodiments can readily be implemented without excessive processing cost. Various modifications of these embodiments are possible.
The mounting technique described is not just useful for bonding SAW or MEMS devices, but may be used for any device, especially those with sensitive elements requiring a hermetically sealed cavity. The substrate 2 need not be of silicon, but may be another semiconductor such as GaAs or InP, or insulator such as quartz or sapphire or any other substrate material as will be appreciated by those skilled in the art.
The interconnection substrate 20 need not necessarily be made of silicon but other materials including ceramics or plastics may also be used.
Optionally, additional sealing material may be provided, especially on the sealing ring 22, if required to improve the seal. However, this is not usually required.
Although in the above embodiments the interconnection substrate is passive active substrates including active devices may be used if required.
If a device recess in the interconnection substrate is used, the device substrate may in embodiments extend above the level of the interconnection major surface.
The additional devices in the described embodiments are attached using bump technology. However, it is also possible to mount additional devices on the interconnection substrate in any known way, including for example by attaching them with the inactive side facing the substrate and then using wire bonding to electrically connect them to the interconnects.

Claims

1. An integrated semiconductor device including: a device substrate (2) with a device major surface (6), a semiconductor element (4) on the device major surface (6), and electrically conductive device connectors (16) extending across the device major surface (4); and an interconnection substrate (20) having an interconnection major surface (21 ), the interconnection substrate (20) defining at least one sealing recess (24) recessed from the interconnection major surface (21 ) , the sealing recess (24) being surrounded by a sealing ring (22); wherein the device substrate (2) is mounted on the interconnection substrate (20) with the interconnection major surface (21) facing the device major surface (6), the sealing ring (22) around the semiconductor element (4) and with the device major surface (6) sealed against the sealing ring (22) so that the recess (24) forms a sealed cavity containing the semiconductor element (4); the integrated semiconductor device further comprising: electrical interconnects (30) across the interconnection major surface (21 ); and interconnection bumps (28) outside the sealing ring (22), the interconnection bumps (28) electrically connecting the device electrical connectors (16) to the interconnects (30).
2. An integrated semiconductor device according to claim 1 further comprising at least one bonding trench (26) around the sealing ring (22) on the interconnect major surface for accommodating one or more of the interconnection bumps (28).
3. An integrated semiconductor device according to claim 1 or 2 further comprising at least one additional semiconductor device (38) mounted on the interconnection substrate (20); wherein the device substrate (2) is connected to the at least one additional semiconductor device (38) by the interconnects (30).
4. An integrated semiconductor device according to claim 1 , 2 or 3 wherein the interconnection substrate (20) defines a device recess (40) for holding the device substrate(2), wherein the sealing ring (22) and sealing recess (24) are provided within the device recess (40).
5. An integrated semiconductor device according to claim 4 further comprising an additional semiconductor device (42) mounted on the interconnection substrate (20); wherein the additional semiconductor device (42) is mounted on the interconnection major surface (21) and extends across the device recess.
6. An integrated semiconductor device according to any preceding claim wherein the interconnection substrate (20) is of silicon.
7. An interconnection substrate for mounting a device substrate (2) having a device major surface (6), a semiconductor element (4) on the device major surface, and device electrical connectors (16) on the device major surface (6), wherein the interconnection substrate comprises: an interconnection major surface (21); electrical interconnects (30) extending across the interconnection major surface (21 ); at least one sealing recess (24) recessed from the interconnection major surface; a sealing ring (22) surrounding the sealing recess; bonding pads (32) around and outside the sealing ring (22) for connecting through interconnection bumps (28) to the device electrical connectors (16) on the device major surface (6) so that the device substrate
(2) may be mounted on the interconnection substrate (20) with the interconnection major surface (21) facing the device major surface (6), with the sealing ring (22) around the semiconductor element (4) and with the device major surface sealed (6) against the sealing ring (22) so that the recess (24) forms a sealed cavity containing the semiconductor element (4).
8. An interconnection substrate according to claim 7 further comprising at least one bonding trench (26) for accommodating one or more interconnection bumps (28) around the sealing ring (22).
9. A method of mounting a device substrate (2) having a device major surface (6), a semiconductor element (4) on the device major surface
(6), and device electrical connectors (16) on the device major surface (6), the method comprising: providing an interconnection substrate (20) having an interconnection major surface (21) and electrical interconnects (30) across the interconnection major surface, the interconnection substrate (20) defining at least one sealing recess (24) recessed from the interconnection major surface (21 ), the sealing recess being surrounded by a sealing ring (22); forming interconnection bumps (28) on the electrical interconnects (30) or the electrical connection pads (16); aligning the device substrate (2) with the interconnection substrate (20) with the interconnection major surface (21) facing the device major surface (6), with the sealing ring (22) around the semiconductor element (4); and with the interconnection bumps (28) aligned between the device electrical connectors
(16) and the interconnects (30); and bonding the device substrate (2) to the interconnection substrate (20) with the device major surface (6) sealed against the sealing ring (22) so that the recess (24) forms a sealed cavity containing the semiconductor element
(4) and with the interconnection bumps (28) connect the device electrical connectors (16) and the electrical interconnects (30).
10. A method according to claim 9 wherein the step of providing an interconnection substrate includes: etching the sealing recess and at least one bonding trench around the sealing recess in the interconnection major surface; and depositing the electrical interconnect on the interconnection major surface including in the at least one bonding trench.
11. A method according to claim 9 or 10 wherein the step of bonding the device substrate (2) to the interconnection substrate (20) includes melting the interconnection bumps (28) and allowing the melted interconnection bumps (28) to solidify.
PCT/IB2005/054119 2004-12-10 2005-12-08 Hermetically sealed integrated circuit package WO2006061792A2 (en)

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EP04300878.8 2004-12-10

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TWI449134B (en) 2014-08-11
TW200639983A (en) 2006-11-16

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