TWI651872B - 一種紫外線發光二極體晶片封裝結構 - Google Patents
一種紫外線發光二極體晶片封裝結構 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 claims abstract description 83
- 239000010949 copper Substances 0.000 claims abstract description 67
- 229910052802 copper Inorganic materials 0.000 claims abstract description 62
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 53
- 229910010272 inorganic material Inorganic materials 0.000 claims abstract description 50
- 239000011147 inorganic material Substances 0.000 claims abstract description 50
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 18
- 238000009792 diffusion process Methods 0.000 claims abstract description 13
- 239000010931 gold Substances 0.000 claims description 52
- 229910052737 gold Inorganic materials 0.000 claims description 38
- 238000000034 method Methods 0.000 claims description 37
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 29
- 229910052751 metal Inorganic materials 0.000 claims description 26
- 239000002184 metal Substances 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 23
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical group [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 19
- 229910052719 titanium Inorganic materials 0.000 claims description 19
- 239000010936 titanium Substances 0.000 claims description 19
- 229910045601 alloy Inorganic materials 0.000 claims description 11
- 239000000956 alloy Substances 0.000 claims description 11
- 150000001875 compounds Chemical group 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 238000005538 encapsulation Methods 0.000 claims description 7
- JVPLOXQKFGYFMN-UHFFFAOYSA-N gold tin Chemical compound [Sn].[Au] JVPLOXQKFGYFMN-UHFFFAOYSA-N 0.000 claims description 6
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 5
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 5
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 5
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 5
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 5
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 5
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 3
- KGWWEXORQXHJJQ-UHFFFAOYSA-N [Fe].[Co].[Ni] Chemical compound [Fe].[Co].[Ni] KGWWEXORQXHJJQ-UHFFFAOYSA-N 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- 150000002736 metal compounds Chemical class 0.000 claims 13
- MSNOMDLPLDYDME-UHFFFAOYSA-N gold nickel Chemical compound [Ni].[Au] MSNOMDLPLDYDME-UHFFFAOYSA-N 0.000 claims 3
- BSIDXUHWUKTRQL-UHFFFAOYSA-N nickel palladium Chemical compound [Ni].[Pd] BSIDXUHWUKTRQL-UHFFFAOYSA-N 0.000 claims 3
- MOFOBJHOKRNACT-UHFFFAOYSA-N nickel silver Chemical compound [Ni].[Ag] MOFOBJHOKRNACT-UHFFFAOYSA-N 0.000 claims 3
- 239000010956 nickel silver Substances 0.000 claims 3
- 238000000059 patterning Methods 0.000 claims 1
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- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 30
- 229910052759 nickel Inorganic materials 0.000 description 15
- 239000012790 adhesive layer Substances 0.000 description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 7
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 4
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- 238000007747 plating Methods 0.000 description 4
- 239000002905 metal composite material Substances 0.000 description 3
- 229920006375 polyphtalamide Polymers 0.000 description 3
- 229910001020 Au alloy Inorganic materials 0.000 description 2
- 229910000846 In alloy Inorganic materials 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 229910001128 Sn alloy Inorganic materials 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
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- 230000017525 heat dissipation Effects 0.000 description 2
- 229910052738 indium Inorganic materials 0.000 description 2
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 2
- 239000011229 interlayer Substances 0.000 description 2
- 239000011368 organic material Substances 0.000 description 2
- 239000005022 packaging material Substances 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004954 Polyphthalamide Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 230000005611 electricity Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 229920006336 epoxy molding compound Polymers 0.000 description 1
- 239000006023 eutectic alloy Substances 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
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- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- 238000012858 packaging process Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
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- 229920005989 resin Polymers 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
- H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
- H10H20/80—Constructional details
- H10H20/85—Packages
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- 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
- H01L23/055—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 having a passage through the base
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
- H01L23/3107—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
- H01L23/3121—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation
- H01L23/3128—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation the substrate having spherical bumps for external connection
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- 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 potential barriers, e.g. a 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 groups H01L21/18 - H01L21/326 or H10D48/04 - H10D48/07 e.g. sealing of a cap to a base of a container
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- 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 potential barriers, e.g. a 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 groups H01L21/18 - H01L21/326 or H10D48/04 - H10D48/07 e.g. sealing of a cap to a base of a container
- H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
- H01L21/563—Encapsulation of active face of flip-chip device, e.g. underfilling or underencapsulation of flip-chip, encapsulation preform on chip or mounting substrate
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- 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
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- 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
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- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
- H01L23/3107—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
- H01L23/3114—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed the device being a chip scale package, e.g. CSP
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- 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
- H01L23/49827—Via connections through the substrates, e.g. pins going through the substrate, coaxial cables
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- 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
- H01L23/49866—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers characterised by the materials
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- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K13/00—Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
- H05K13/04—Mounting of components, e.g. of leadless components
- H05K13/046—Surface mounting
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- 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
- H01L2224/10—Bump connectors; Manufacturing methods related thereto
- H01L2224/15—Structure, shape, material or disposition of the bump connectors after the connecting process
- H01L2224/16—Structure, shape, material or disposition of the bump connectors after the connecting process of an individual bump connector
- H01L2224/161—Disposition
- H01L2224/16151—Disposition the bump connector 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
- H01L2224/16221—Disposition the bump connector 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
- H01L2224/16225—Disposition the bump connector 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
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- Led Device Packages (AREA)
- Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
Abstract
一種紫外線發光二極體晶片封裝結構(SMD),包括一層陶瓷基板、一圖案化銅層、一無機材料上框及一石英玻璃,施以最低符合壓力介於0~8000kg,溫度介於數線y=-0.025x+300(壓力為x,溫度為y)與最高500℃之間的參數,透過ICH技術(Inorganic Ceramic Heterogeneity)其中包含改良自擴散焊(Diffusion Bonding)以及軟釺焊(Soldering)領域技術,並應用特定的共晶組成物(Eutectic Composition)做為熔填物,以達成封裝體(SMD)各部件緊密結合、氣密性高、高導熱的全無機封裝的紫外線發光二極體封裝結構;依照此方式完成的封裝結構,可以承受電子產業驗證最高標準-65℃~150℃的冷熱衝擊實驗,其中往返極限溫度搬運時間不超過20秒。
Description
本發明是有關於一種封裝結構,尤其是關於一種紫外線發光二極體晶片封裝結構。
發光二極體的封裝材料,幾乎都圍繞著成本在考量,傳統大多是PPA(Polyphthalamide,熱塑性塑膠)。近年來LED封裝廠逐漸採用耐熱性更高的EMC(Epoxy Molding Compound,環氧模壓樹脂)導線架,EMC導線逐漸站穩用在1-3瓦的中高功率LED的市場地位,但是EMC導線架受制於本身材料特性,無法再往更高功率的LED跨入。
然而,當發光二極體切入紫外線領域時,將會有60%~70%的光電效能轉換成熱能,甚至在深紫外線(UVC)領域僅只有不到10%電力轉換成光,90%都轉換成熱能,且目前發光二極體的製造廠商所製造出來的LED在功率皆小於100微瓦(mW)的領域,若未來持續往更高功率的紫外線發光二極體研發時,將會受限於散熱材料、後製加工、整體構裝的重重限制;而且熱能累積過多易造成光衰。傳統低溫共燒陶瓷(Low Temperature Co-fired Ceramic;LTCC)、高溫共燒多層陶瓷(High Temperature Co-fired Ceramic;HTCC)、以熱導率2~25W/mK的氧化鋁陶瓷元件來對應於30mW的深紫外線發光二極體元件應足以應付;但再往更高功率發展的未來,傳統LTCC、HTCC、氧化鋁陶瓷元件的散熱已經到達其極限,更不用說有機材質的EMC
等塑料材料是無法適用於此領域的,因此需要更高熱導率的陶瓷基板來對應紫外線領域。
另外,以現有的材料以及封裝製程用於紫外線發光二極體的領域而言,當整個封裝結構長期處於紫外線照射範圍內,無論是導線架本身材料,甚至連導線架上框與陶瓷電路載板間的黏合層,都可能在紫外線長期曝曬下,產生材料脆化或是黏合層剝離的狀況發生,尤其是本體採用有機材料(例如PPA或是EMC等有機物)或是採用有機膠體黏合上框與陶瓷電路載板的狀況下(市場上有黏合層採用UV膠,但即使是UV膠還是會脆化),是需要盡量避免的。
更進一步的說,LED封裝產業的固晶製程對於晶粒而言是屬於300℃左右的軟釺焊(Soldering)技術中的高溫製程,若無採用本案ICH技術(Inorganic Ceramic Heterogeneity)中改良自擴散焊(Diffusion Bonding)的應用來完成封裝結構的導線架製作,例如:GGI(Gold to Gold Integration)、CCI(Copper to Copper Integration),而用銦、銦合金、高溫錫等製程來施做的導線架,在封裝固晶製程往往會因為溫度高於銦、銦合金、高溫錫鍵合時的溫度,則容易造成後續生產穩定性不足以符合產業界的需求。
因此,若封裝本體材料無法抵抗紫外線侵襲,黏合層強度不夠或是工藝未顧慮到後續製程,致使產品迅速劣化、損壞、妥善率低是可以想見的;然而,業界為能克服上述的各項缺失,在經過多次實驗後發覺了封裝材料理應採用無機材料,但仍苦於沒有讓無機材料結合的有效方法。
本發明之一目的在於提供一種紫外線發光二極體無機接合
封裝結構SMD(表面安裝元件;Surface Mount Device;SMD),採用ICH技術(Inorganic Ceramic Heterogeneity)其中包含改良自擴散焊(Diffusion Bonding)以及軟釺焊(Soldering)領域技術,並應用特定的共晶組成物(Eutectic Composition)做為熔填物,讓封裝接合結構強度達到10MPa~30MPa,足以抵抗使用本產品時熱能累積造成不同材料間的熱漲冷縮效應,解決金屬結合層剝離議題,進而提昇產品良率。
本發明再一目的在於提供一種紫外線發光二極體無機接合封裝結構,採用ICH技術(Inorganic Ceramic Heterogeneity),可讓此產品通過電子產業驗證最高標準-65℃~150℃的冷熱衝擊實驗,其中往返極限溫度搬運時間不超過20秒。
本發明又一目的在於提供一種紫外線發光二極體無機接合封裝結構,利用選定特定的無機物材料施做,讓整體產品長期在紫外線照射範圍內,也不會材料脆化與黏合層剝離。
本發明另一目的在於提供一種紫外線發光二極體無機接合封裝結構,採用ICH技術(Inorganic Ceramic Heterogeneity)提供發光二極體封裝產業一種對應高功率晶粒的氣密性封裝結構。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,其包括:一陶瓷基板;一金屬層,其係形成於該陶瓷基板之相對二面;一無機材料上框,其係形成於該金屬層一側;以及一石英玻璃,其係和該無機材料上框形成氣密結合,以將部份的金屬層以及紫外線發光二極體晶片密封於無機材料上框以及該陶瓷基板之間。
本發明再一目的是提供一種紫外線發光二極體無機接合封
裝結構,該陶瓷基板材料可由下列化合物群組中擇一:氧化鋁、氮化鋁、氮化矽、碳化矽。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,其中,該陶瓷基板與無機材料上框結合係採用ICH技術(Inorganic Ceramic Heterogeneity)以Au+Au、Cu+Cu或AuSn共晶組成的合金作為陶瓷基板與無機材料上框結合的熔填物材料。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,該無機材料上框可為銅或其合金、鋁或其合金、鐵鈷鎳合金、氮化鋁、氧化鋁、氮化矽或碳化矽。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,該金屬層包括了一鈦層、一銅層,其係形成於該鈦層的一側,以及形成於該銅層一側,且是由鎳、金或是鎳、銀或是鎳、鈀、金所組成的金屬複合層,且該金屬層之厚度範圍介於0.01μm~340μm。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,該陶瓷基板與無機材料上框結合係採用ICH技術(Inorganic Ceramic Heterogeneity)以Au+Au、Cu+Cu或AuSn共晶組成的合金作為熔填物材料的方式來完成,且其熔填物材料的厚度為0.01μm~50μm。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,其無機材料上框與石英玻璃結合係採用ICH技術(Inorganic Ceramic Heterogeneity)以Au+Au、Cu+Cu或AuSn共晶組成物作為熔填物的方式來完成,且其結合層厚度範圍介於0.01μm~50μm。
本發明再一目的是提供一種紫外線發光二極體無機接合封
裝結構,其中,該焊接製程係以y=-0.025x+300為溫度與壓力的關係方程式為之,壓力為x,溫度為y,最高溫為500℃。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,該陶瓷基板上係具有至少一通孔,且於該通孔內是具有一銅柱,以可和該圖案化銅層形成電性連接。
本發明再一目的是提供一種紫外線發光二極體無機接合封裝結構,其中,該金屬層包括了一鈦層、一銅層,其係形成於該鈦層的一側,以及形成於該銅層一側,且是由鎳、金或是鎳、銀或是鎳、鈀、金所組成的金屬複合層,且該金屬層之厚度範圍介於0.01μm~340μm。
為了達成上述目的,本案提供一種紫外線發光二極體無機接合封裝結構,運用半導體與微機電領域的背景技術結合焊接實務,透過ICH技術(Inorganic Ceramic Heterogeneity)其中包含改良自擴散焊(Diffusion Bonding)以及軟釺焊(Soldering)領域技術,並應用特定的共晶組成物(Eutectic Composition)做為熔填物,使其結構強度足以抵抗使用時造成的熱漲冷縮應力,且因為使用材料皆為無機物,可以長期曝曬於紫外線照射範圍而不被紫外線破壞,材料不會脆化且黏合層也不會剝離,因此可以避免掉目前產業所面臨議題。
10‧‧‧陶瓷基板
12‧‧‧鈦層
14‧‧‧銅層
16‧‧‧銅柱
20‧‧‧鎳層
22‧‧‧金層
30‧‧‧鋁框
32‧‧‧開孔
40‧‧‧陶瓷電路載板
42‧‧‧無機材料上框
44‧‧‧紫外線發光二極體晶片
46‧‧‧石英玻璃
第一A圖:陶瓷電路板含銅柱及結合層為銅的剖面示意圖;第一B圖:陶瓷電路板含銅柱及結合層為金的剖面示意圖;第二A圖:無機材料上框為鋁及結合層為金的剖面圖;第二B圖:無機材料上框為陶瓷及結合層為金的剖面圖;
第二C圖:無機材料上框為陶瓷,下結合層為銅,上結合層為金的剖面圖;第三圖:溫度與壓力關係圖
第四圖:石英玻璃剖面圖
第五圖:SMD整體結構的立體示意圖
本案為一種紫外線發光二極體無機接合封裝結構,底層為一層陶瓷基板,堆疊數層金屬後形成陶瓷電路載板,其與無機材料上框結合後,完成導線架,再採用半導體固晶技術將紫外線發光二極體晶片與陶瓷電路載板結合,最後石英玻璃與無機材料上框結合,完成SMD封裝結構。
由於各部件有不同製法,且其效果亦都可達到本發明欲達到的目的,故而在後續段落中將分幾大部分論述;先描述陶瓷電路載板種類、無機材料上框種類及陶瓷電路載板與無機材料上框的接合法,再描述石英玻璃加工,紫外線發光二極體晶片及石英玻璃與無機材料上框的接合法種類。
陶瓷電路載板釋例一:請參閱第一A圖,準備一陶瓷基板10,先以雷射於基板上施打貫穿孔洞為通孔;由於一般雷射在形成通孔時,其進孔為直徑較大的孔,而出孔則因為能量消耗,致形成為直徑較小的孔。接著以濺鍍的方式在陶瓷基板10於形成通孔的側壁面以及上下表面處形成一鈦層12(厚度介於0.01μm~10μm)。其後,以黃光顯影製程,將欲形成電路線路的區域予以保留,爾後則施以電鍍方式電鍍一層銅層於所述的鈦層12上方,並填滿前述的通孔,以於所述的通孔處形成一銅柱16,再將位於鈦層12上
方的銅層予以圖案化以形成所需要的線路圖案;此時,位於鈦層12上方的銅層以及銅柱則是用以導通陶瓷基板10的雙面電路。至此,所形成的圖案化銅層14,厚度介於0.01μm~1,500μm,以銅做為金屬結合層。
陶瓷電路載板實施例二:請參閱第一B圖,製程前段與陶瓷電路載版釋例一相同,差異點為後續製程步驟;為了保護銅層電路避免與後續堆疊金屬產生反應,可再電鍍一隔離用的鎳層20,厚度介於0μm~10μm,鎳層20亦可視產品需求來決定是否必要設置,之後,再於其上方以電鍍方式設置一層金層22,以為金屬結合層的部分,其厚度介於0.01μm~20μm,至此,完成陶瓷電路載板,由下而上依照順序堆疊的金屬層分別為鈦、銅、鎳、金,因為堆疊了數層金屬複合層,電鍍技術的均勻性要求精度高為其重點。
陶瓷電路載板實施例三:在這一較佳實施例中,主要是以金錫共晶組成的合金取代在實施例二中的金層22;金錫比例有Au:Sn=80:20、Au:Sn=73:27和Au:Sn==10:90等不同比例,金錫共晶組成物厚度是介於0.01μm~50μm之間。
無機材料上框釋例一:請參閱第二A圖;在此釋例為準備一中心點具有一開孔32的鋁框30,並於鋁框上下及開孔側壁鍍上一鎳層20,厚度0.01μm~3μm作為中介層後再於鎳層20上鍍上金屬結合層,金22,其厚度為0.01μm~20μm,同樣電鍍技術的均勻性要求精度高為其重點,值得注意的是,該無機材料上框的材料可為:銅或其合金、鋁或其合金、鐵鈷鎳合金、氮化鋁、氧化鋁、氮化矽或碳化矽。
無機材料上框釋例二:製作方法與無機材料上框釋例一相
似,唯一的不同在於將金屬結合層金22換成金錫共晶組成的合金。
無機材料上框範例三:請參閱第二B圖,上框材料選擇與陶瓷電路載板相同的陶瓷材料10,陶瓷表面濺鍍一層中介鈦層12,厚度介於0.01μm~10μm,鈦層12主要為結合陶瓷與銅。其後,以黃光顯影製程,將欲形成電路線路的區域予以保留,爾後則施以電鍍方式電鍍一層銅層於所述的鈦層12上方,銅14厚度介於0.01μm~300μm,為了保護銅層避免與後續堆疊金屬產生反應,需再電鍍一隔離用的鎳層20,厚度介於0μm~10μm,鎳層是否必要端看產品需求,也可忽略直接電鍍金22,即為金屬結合層的部分,其厚度介於0.01μm~20μm,最後步驟為開孔32,以雷射貫穿陶瓷基板開洞。
無機材料上框範例四:製程與無機材料上框釋例三相似,唯一不同之處在於以金錫共晶組成的合金取代陶瓷上框釋例三的金層22,金錫比例有Au:Sn=80:20、Au:Sn=73:27和Au:Sn=10:90等不同比例,厚度介於0.01μm~50μm之間。
無機材料上框釋例五:請參閱第二C圖,上框材料選擇與陶瓷電路載板相同的陶瓷材料10,陶瓷表面濺鍍一層中介鈦層12,厚度介於0.01μm~10μm,鈦層12主要為結合陶瓷與銅,銅14厚度介於0.01μm~300μm,與陶瓷電路載板接觸面製作到銅層後即停止。另一面與石英玻璃結合的部分,為了保護銅層避免與後續堆疊金屬產生反應,需再電鍍一隔離用的鎳層20,厚度介於0μm~10μm,鎳層是否必要端看產品需求,也可忽略直接電鍍金22,即為金屬結合層的部分,其厚度介於0.01μm~20μm,最後步驟為開孔32,以雷射貫穿陶瓷基板開洞。
陶瓷電路載板與無機材料上框接合方法範例一:若選擇陶瓷
電路載板與無機材料上框的結合面都是金層,則透過ICH技術(Inorganic Ceramic Heterogeneity)中改良自擴散焊(Diffusion Bonding)製程完成GGI(Gold to Gold Integration)結合,施作方法是將無機材料上框與陶瓷電路載板接合面Au+Au對位貼合後,水平置入低溫高壓腔體內,溫度與壓力的關係圖請參閱第三圖所示,y=-0.025x+300為溫度與壓力的關係方程式(壓力為x,溫度為y),以數線0~8000kg為左右極限,最高溫為500℃,此梯形範圍內的面積,再搭配熱壓時間為30分鐘~90分鐘始可完成SMD封裝結構,上述三項製程參數依照需求的不同而有所調整,且因為在降溫過程中,壓力始終保持在最高壓狀態直到恢復常溫,依照此步驟所產生的鍵結力,可達到10MPa~30MPa不等,足以抵抗此產品在使用時,紫外線發光二極體產生的熱能造成產品不同材料結構層間的熱漲冷縮應力,而不會使產品產生翹曲甚至黏合層剝離。
陶瓷電路載板與無機材料上框接合方法釋例二:若選擇陶瓷電路載板與無機材料上框的結合面都是銅層,透過ICH技術(Inorganic Ceramic Heterogeneity)中改良自擴散焊(Diffusion Bonding)製程完成CCI(Copper to Copper Integration)接合,施作方法是將無機材料上框與陶瓷電路載板接合面Cu+Cu對位貼合後,進入低溫高壓製程,同樣可以產出具有高鍵結力的黏合層。
陶瓷電路載板與無機上框接合方法範例三:若選擇陶瓷電路載板與無機材料上框的結合面,至少一層為金錫共晶組成的合金時,透過ICH技術(Inorganic Ceramic Heterogeneity)中改良自軟釺焊(Soldering)製程,並應用特定的金錫共晶組成的合金(Eutectic Composition)做為熔填物的材料,
將無機上框與陶瓷電路載板對位貼合後,進入低溫高壓製程,同樣可以產出具有高鍵結力的黏合層。
紫外線發光二極體晶片與陶瓷電路載板結合範例:因紫外線發光二極體晶片的固晶金屬結合層為金錫共晶組成物於潔淨環境下施以280℃~320℃的溫度及適當壓力,將發光二極體晶片與陶瓷電路載板結合。
石英玻璃釋例一:請參閱第四圖;石英玻璃40切割尺寸對應無機玻璃上框需求,於接合面濺鍍一層鈦層12,厚度10Å~1000Å後,再電鍍上一層金22,厚度500Å~5μm,即為金屬結合層。
石英玻璃與無機材料上框接合法釋例:若選擇無機材料上框與石英玻璃的金屬結合層至少一為金錫共晶組成的合金,於潔淨環境下施以280℃~320℃的溫度及適當壓力,將石英玻璃與無機材料上框結合。值得注意的是,石英玻璃可為一凸透鏡,並設置在前述的無機材料上框之內;也可為一平面型石英玻璃,而設置在前述無機材料上框之上。
請參閱第五圖;以上各部件所使用材料種類排列組合繁多,僅為完成一種紫外線發光二極體無機接合SMD封裝結構的各部件及結合製法,其整體結構為陶瓷電路載板40為底層,紫外線發光二極體晶片44單顆或數顆貼覆在陶瓷電路載板40上,而無機材料上框42結合下方的陶瓷電路載板與上方的石英玻璃46完成完整的封裝結構。
當不能以此限定本發明之實施範圍,即依照本發明申請專利範圍及發明說明書內容所做的等效果修飾與變化,仍應屬於本發明專利涵蓋範圍之內。
Claims (20)
- 一種紫外線發光二極體無機接合封裝結構,其包括:一陶瓷基板;一金屬化合物層,其係形成於前述陶瓷基板之相對二面;一圖案化銅層,其係形成於前述金屬化合物層之一面;一第二金屬化合物層,其係形成於前述圖案化銅層相對於和前述金屬化合物層結合面之相對一側;一無機材料上框,其係形成於前述第二金屬化合物層的一自由面;以及一石英玻璃,其係和前述無機材料上框結合,並其間夾合一金屬層,以將前述圖案化銅層密封於無機材料上框以及前述陶瓷基板之間。
- 如申請專利範圍第1項所述的紫外線發光二極體無機接合封裝結構,前述陶瓷基板材料可由下列化合物群組中擇一:氧化鋁、氮化鋁、氮化矽、碳化矽。
- 如申請專利範圍第1項所述的紫外線發光二極體無機接合封裝結構,其中,前述陶瓷基板與無機材料上框結合係採用為ICH技術(Inorganic Ceramic Heterogeneity),其係包括了金屬擴散效應或金錫共晶製程(Au+Au、Cu+Cu或Au+Sn)。
- 如申請專利範圍第1、2或3項所述的紫外線發光二極體無機接合封裝結構,前述無機材料上框可為銅或其合金、鋁或其合金、鐵鈷鎳合金、氮化鋁、氧化鋁、氮化矽或碳化矽。
- 如申請專利範圍第3項所述的紫外線發光二極體無機接合封裝結構,前述金屬化合物層以及前述第二金屬化合物層之厚度範圍介於0μm~10μm。
- 如申請專利範圍第1、2或3項所述的紫外線發光二極體無機接合封裝結構,前述陶瓷基板與無機材料上框結合採用共晶製程的厚度範圍為介於0.05μm~50μm。
- 如申請專利範圍第1或3項所述的紫外線發光二極體無機接合封裝結構,其無機材料上框與石英玻璃結合時,所夾合的金屬層為Au+Au、Cu+Cu或Au+Sn,且其厚度範圍介於0.05μm~50μm。
- 如申請專利範圍第1或3項所述的紫外線發光二極體無機接合封裝結構,其無機材料上框與石英玻璃結合為ICH技術(Inorganic Ceramic Heterogeneity)改良之金屬擴散效應或金錫共晶製程(Au+Au、Cu+Cu或Au+Sn)。
- 如申請專利範圍第1項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第2項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第4項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第6項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第7項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第11項所述的紫外線發光二極體無機接合SMD封裝結構,前述陶瓷基板上係具有至少一通孔,且於前述通孔內是具有一銅柱,以可和前述圖案化銅層形成電性連接。
- 如申請專利範圍第1項所述的紫外線發光二極體無機接合SMD封裝結構,其中,前述金屬化合物層係含鈦之化合物層以及前述第二金屬化合物層是由下列化合物所形成的群組中擇一:鎳銀、鎳金以及鎳鈀金。
- 如申請專利範圍第6項所述的紫外線發光二極體無機接合SMD封裝結構,其中,前述金屬化合物層係含鈦之化合物層以及前述第二金屬化合物層是由下列化合物所形成的群組中擇一:鎳銀、鎳金以及鎳鈀金。
- 如申請專利範圍第11項所述的紫外線發光二極體無機接合SMD封裝結構,其中,前述金屬化合物層係含鈦之化合物層以及前述第二金屬化合物層是由下列化合物所形成的群組中擇一:鎳銀、鎳金以及鎳鈀金。
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