High density interconnect structure including a spacer structure and a gap

Claim 2

In a high density interconnect structure of the type comprising an electronic component having contact pads on a first surface thereof, an interconnection structure thereover including a first layer of polymer dielectric material disposed over said electronic component, said layer of polymer dielectric material having apertures therein disposed in alignment with at least selected ones of said contact pads, a first patterned conductive layer overlying said first dielectric layer and extending into said apertures into ohmic contact with said selected ones of said contact pads, the improvement comprising: a spacer structure disposed on a portion of said first surface of said electronic component, leaving other portions of said first surface free of spacer structure; and said first layer of polymer dielectric material being bonded to said spacer structure and spaced from said first surface of said electronic component by said spacer structure.

Claim 3

The improvement recited in claim 1 wherein: said spacer structure comprises a polymer dielectric; and said surface of said electronic component is substantially free of polymer dielectric material except for said spacer structure.

Claim 4

The high density interconnect structure recited in claim 1 wherein: said spacer structure comprises an elongated ridge of dielectric material.

Claim 5

The high density interconnect structure recited in claim 3 wherein: said ridge is continuous, closed on itself and surrounds a portion of said first surface of said electronic component.

Claim 6

The high density interconnect structure recited in claim 4 wherein: said electronic component comprises a semiconductor chip and at least some of said contact pads are disposed along the periphery of said first surface of said semiconductor chip; and said ridge constitutes a wall around the periphery of said chip.

Claim 7

The high density interconnect structure recited in claim 5 wherein: those contact pads which are disposed in electrical contact with a conductor of said interconnection structure are referred to as a connected contact pads; and said connected contact pads have dielectric material of said ridge disposed thereon.

Claim 8

The high density interconnect structure recited in claim 1 wherein: said spacer structure comprises a plurality of spaced apart posts.

Claim 9

The high density interconnect structure recited in claim 7 wherein: each contact pad which is disposed in electrical contact with a conductor of said interconnection structure has a post disposed thereon and is referred to as a connected contact pad.

Claim 10

The improvement recited in claim 8 wherein: said posts comprise a polymer; each of said posts disposed on one of said connected contact pads has a via hole therein in which a conductor of said interconnection structure extends into electrical contact with the contact pad disposed thereunder.

Claim 11

The improvement recited in claim 7 wherein: said posts comprise a metal.

Claim 12

The improvement recited in claim 10 wherein: said posts are metallic.

Claim 13

The improvement recited in claim 7 wherein: said posts comprise a polymer.

Claim 14

The improvement recited in claim 12 wherein: said posts comprise at thermoplastic material.

Claim 15

The improvement recited in claim 12 wherein: said thermoplastic material is a polyetherimide.

Claim 16

The improvement recited in claim 12 wherein: said posts comprise a thermoset material.

Claim 17

The improvement recited in claim 15 wherein: said thermoset material is polyimide.

Claim 18

The improvement recited in claim 1 wherein: said first layer of polymer dielectric material is spaced from the surface of said electronic component by substantially the height of said spacer structure.

Claim 19

In a high density interconnect structure of the type comprising an electronic component having contact pads on a first surface thereof, an interconnection structure thereover including a first layer of polymer dielectric material disposed over said electronic component, said layer of polymer dielectric material having apertures therein disposed in alignment with at least first selected ones of said contact pads, a first patterned conductive layer overlying said first dielectric layer and extending into said apertures into ohmic contact with said selected ones of said contact pads, a second layer of polymer dielectric material disposed over said first layer of dielectric material, said second layer of polymer dielectric material having apertures therein disposed in alignment with second selected ones of said contact pads and/or selected portions of said first patterned conductive layer, a second patterned conductive layer overlying said second dielectric layer and extending into said apertures into ohmic contact with said second selected ones of said contact pads and/or selected portions of said first patterned conductive layer, the improvement comprising: a spacer structure disposed on a portion of said first layer of dielectric material, leaving other portions of said first layer free of spacer structure; and said second layer of polymer dielectric material being bonded to said spacer structure and spaced from the surface of said first patterned conductive layer elsewhere by said spacer structure.

Claim 20

In a high density interconnect structure of the type comprising an electronic component having contact pads on a first surface thereof, an interconnection structure thereover including a first layer of polymer dielectric material disposed over said electronic component, said layer of polymer dielectric material having apertures therein disposed in alignment with at least first selected ones of said contact pads, a first patterned conductive layer overlying said first dielectric layer and extending into said apertures into ohmic contact with said selected ones of said contact pads, a second layer of polymer dielectric material disposed over said first layer of dielectric material, said second layer of polymer dielectric material having apertures therein disposed in alignment with second selected ones of said contact pads and/or selected portions of said first patterned conductive layer, a second patterned conductive layer overlying said second dielectric layer and extending into said apertures into ohmic contact with said second selected ones of said contact pads and/or selected portions of said first patterned conductive layer, the improvement comprising: a spacer structure disposed on a portion of said first layer of dielectric material, leaving other portions of said first layer free of spacer structure; and said second layer of polymer dielectric material being bonded to said spacer structure and spaced from the surface of said first patterned conductive layer elsewhere by said spacer structure.

Claim 21

The improvement recited in claim 18 wherein said improvement further comprises: a further spacer structure disposed on a portion of said first surface of said electronic component, leaving other portions of said first surface free of spacer structure; and wherein said first layer of polymer dielectric material is bonded to said spacer structure and spaced from said first surface of said electronic component elsewhere by substantially the height of said spacer structure.

Claim 22

In a high density interconnect structure of the type comprising an electronic component having contact pads thereon, one or more polymer dielectric material layers disposed thereover and having apertures therein, one or more patterned conductive layers overlying selected ones of said dielectric layers and extending into selected ones of said apertures into ohmic contact with selected contact pads or other conductive layers, the improvement comprising: a plurality of posts disposed on said electronic component, each contact pad which is disposed in electrical contact with a conductor of said patterned conductive layers having a post disposed thereon and being referred to as a connected contact pad; and the one of said polymer dielectric material layers disposed nearest said electronic component being bonded to said posts and spaced from the surface of said electronic component elsewhere by substantially the height of said posts.

Claim 23

In a high density interconnect structure of the type comprising an electronic component having contact pads thereon, one or more polymer dielectric material layers disposed thereover and having apertures therein, one or more patterned conductive layers overlying selected ones of said dielectric layers and extending into selected ones of said apertures into ohmic contact with selected contact pads or other conductive layers, the improvement comprising: a plurality of posts disposed on said electronic component, each contact pad which is disposed in electrical contact with a conductor of said patterned conductive layers having a post disposed thereon and being referred to as a connected contact pad; and the one of said polymer dielectric material layers disposed nearest said electronic component being bonded to said posts and spaced from the surface of said electronic component elsewhere by substantially the height of said posts.

Claim 24

The improvement recited in claim 20 wherein: said posts comprise a polymer; each of said posts which is disposed on one of said connected contact pads having a via hole therein through which a conductor of one of said conductor layers extends into electrical contact with the contact pad disposed thereunder.

Claim 25

The improvement recited in claim 20 wherein: said posts comprise a metal.

Claim 26

The improvement recited in claim 20 wherein: said posts comprise a polymer.

Claim 27

A semiconductor chip comprising: a body of semiconductor material having a major surface; a plurality of contact pads disposed on said major surface of said body; a patterned spacer structure disposed on said major surface of said body and said at least selected ones of said contact pads, said spacer structure including a raised portion and a gap.

Claim 28

A semiconductor chip comprising: a body of semiconductor material having a major surface; a plurality of contact pads disposed on said major surface of said body; a patterned spacer structure disposed on said major surface of said body and said at least selected ones of said contact pads, said spacer structure including a raised portion and a gap.

Claim 29

The semiconductor chip recited in claim 24 wherein: said spacer structure is a polymer dielectric material.

Claim 30

The semiconductor chip recited in claim 24 wherein: said spacer structure is conductive.

Claim 31

A semiconductor chip comprising: a body of semiconductor material having a major surface; a patterned spacer structure disposed on said major surface of said body and including a raised portion and a gap; a plurality of contact pads disposed on said raised portion of said spacer structure whereby, said contact pads are spaced above said major surface of said body.

Claim 32

A semiconductor chip comprising: a body of semiconductor material having a major surface; a patterned spacer structure disposed on said major surface of said body and including a raised portion and a gap; a plurality of contact pads disposed on said raised portion of said spacer structure whereby, said contact pads are spaced above said major surface of said body.

Claim 33

The semiconductor chip recited in claim 27 wherein: said spacer structure is an inorganic dielectric material.

Claim 34

The semiconductor chip recited in claim 27 wherein: said spacer structure is an polymer dielectric material.