Patent US6521530B2 successfully refreshed from Google Patents.
US6521530B2
Expired / Lapsed
US
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Composite interposer and method for producing a composite interposer
Assignee: Fujitsu Ltd
•
Filing: 2001-05-23
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Granted: 2003-02-18
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Expires: 2021-05-23
Abstract
Abstract A composite interposer for providing power and signal connections between an integrated circuit chip or chips and a substrate. The interposer includes a signal core formed from a conductive power/ground plane positioned between two dielectric layers. A method for fabricating a composite interposer comprising disposing a silicon layer on a substrate, and selectively etching the silicon layer down to the substrate to develop silicon openings with a silicon profile, and to expose part of the substrate. Vias are formed through the exposed part of the substrate. The method additionally includes filling the vias and the silicon openings with a filler material (e.g., a high-aspect-ratio-capable photodefinable epoxy polymer) to form filled silicon openings and filled vias, forming first openings through the filled silicon openings and through the filled vias, forming second opening through filler material to expose semiconductor devices on the silicon layer, and interconnecting electrically, through the first openings and through the second openings, the exposed semiconductor devices with pads disposed against a bottom of the substrate.
Inventors
- 👤 Michael G. Peters
- 👤 Mark Thomas McCormack
- 👤 Aris Bernales
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 11:11
CPC Classifications
H; H05; H05K; H05K1/00; H05K1/02; H05K1/0213; H05K1/0216; H05K1/0218; H05K1/0219; H10; H10W; H10W42/00; H10W42/20; H10W42/261; H10W42/276; H10W70/00; H10W70/60; H10W70/611; H10W70/62; H10W70/65; H10W70/67; H10W70/68; H10W70/685; H10W72/00; H10W90/00; H10W90/401; H05K1/14; H05K1/141; H05K1/144; H05K2201/00; H05K2201/04; H05K2201/049; H05K2201/05; H05K2201/055; H05K2201/10; H05K2201/10227; H05K2201/10378; H05K3/00; H05K3/10; H05K3/20; H10W90/701; H10W90/721; H10W90/724
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
122 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a silicon layer on a substrate: (b) selectively etching the silicon layer down to the substrate to develop silicon openings with a silicon profile, and to expose part of the substrate; (c) forming vias through the exposed part of the substrate; (d) filling the vias and the silicon openings with a filler material to form filled silicon openings and filled vias; (e) forming first openings through the filled silicon openings and through the filled vias; (f) forming second openings through filler material to expose semiconductor devices on the silicon layer; and (g) interconnecting electrically, through the first openings and through the second openings, the exposed semiconductor devices with pads.
Claim 2
Independent Claim
122 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a silicon layer on a substrate: (b) selectively etching the silicon layer down to the substrate to develop silicon openings with a silicon profile, and to expose part of the substrate; (c) forming vias through the exposed part of the substrate; (d) filling the vias and the silicon openings with a filler material to form filled silicon openings and filled vias; (e) forming first openings through the filled silicon openings and through the filled vias; (f) forming second openings through filler material to expose semiconductor devices on the silicon layer; and (g) interconnecting electrically, through the first openings and through the second openings, the exposed semiconductor devices with pads.
Claim 3
Dependent Claim
26 words
The method of claim 1 wherein each of said pads is selected from the group of pads consisting of voltage pads, ground pads, and signal pads.
Claim 4
Dependent Claim
16 words
The method of claim 1 wherein said pads are coupled to the bottom of the substrate.
Claim 5
Dependent Claim
29 words
The method of claim 1 wherein said selectively etching the silicon layer down to the substrate additionally includes forming a plurality of spaced silicon layers supported by said substrate.
Claim 6
Dependent Claim
29 words
The method of claim 2 wherein said selectively etching the silicon layer down to the substrate additionally includes forming a plurality of spaced silicon layers supported by said substrate.
Claim 7
Dependent Claim
26 words
The method of claim 4 wherein said forming vias additionally includes forming a plurality of spaced substrates with each spaced substrate supporting a spaced silicon layer.
Claim 8
Dependent Claim
19 words
The method of claim 1 additionally comprising filling the first opening with a dielectric filler after said interconnecting electrically.
Claim 9
Dependent Claim
19 words
The method of claim 7 additionally comprising filling the first opening with a dielectric filler after said interconnecting electrically.
Claim 10
Independent Claim
131 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a silicon layer on a substrate; (b) selectively etching the silicon layer down to the substrate to develop silicon openings with a silicon profile, and to expose part of the substrate; (c) forming vias through the exposed part of the substrate; (d) filling the vias and the silicon openings with a filler material comprising a photodefinable epoxy polymer having an aspect ratio to form filled silicon openings and filled vias; (e) forming first openings through the filled silicon openings and through the filled vias; (f) forming second openings through filler material to expose semiconductor devices on the silicon layer; and (g) interconnecting electrically, through the first openings and through the second openings, the exposed semiconductor devices with pads.
Claim 11
Independent Claim
131 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a silicon layer on a substrate; (b) selectively etching the silicon layer down to the substrate to develop silicon openings with a silicon profile, and to expose part of the substrate; (c) forming vias through the exposed part of the substrate; (d) filling the vias and the silicon openings with a filler material comprising a photodefinable epoxy polymer having an aspect ratio to form filled silicon openings and filled vias; (e) forming first openings through the filled silicon openings and through the filled vias; (f) forming second openings through filler material to expose semiconductor devices on the silicon layer; and (g) interconnecting electrically, through the first openings and through the second openings, the exposed semiconductor devices with pads.
Claim 12
Dependent Claim
26 words
The method of claim 9 wherein each of said pads is selected from the group of pads consisting of voltage pads, ground pads, and signal pads.
Claim 13
Dependent Claim
16 words
The method of claim 9 wherein said pads are coupled to the bottom of the substrate.
Claim 14
Dependent Claim
29 words
The method of claim 9 wherein said selectively etching the silicon layer down to the substrate additionally includes forming a plurality of spaced silicon layers supported by said substrate.
Claim 15
Dependent Claim
29 words
The method of claim 10 wherein said selectively etching the silicon layer down to the substrate additionally includes forming a plurality of spaced silicon layers supported by said substrate.
Claim 16
Dependent Claim
19 words
The method of claim 9 additionally comprising filling the first opening with a dielectric filler after said interconnecting electrically.
Claim 17
Dependent Claim
19 words
The method of claim 12 additionally comprising filling the first opening with a dielectric filler after said interconnecting electrically.
Claim 18
Dependent Claim
16 words
The method of claim 9 wherein said aspect ratio ranges from about 2:1 to about 40:1.
Claim 19
Dependent Claim
16 words
The method of claim 15 wherein said aspect ratio ranges from about 6:1 to about 8:1.
Claim 20
Independent Claim
145 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a plurality of conductive elements on a top of a silicon layer, leaving part of a top of the silicon layer exposed; (b) disposing dielectric material over the conductive elements and the exposed top of the silicon layer; (c) selectively removing dielectric material from over the conductive elements to expose conductive elements; (d) forming a voltage plane and a ground plane; (e) selectively removing silicon from a bottom of the silicon layer to form silicon openings and to expose part of the dielectric material; (f) filling the silicon openings with a polymer filler, leaving a polymer filler layer on the bottom of the silicon layer; (g) securing a substrate to the polymer filler layer; (h) forming vias through the substrate, the polymer filler, and the dielectric material; and (i) plating the vias.
Claim 21
Independent Claim
145 words
A method for fabricating a composite interposer comprising the steps of: (a) disposing a plurality of conductive elements on a top of a silicon layer, leaving part of a top of the silicon layer exposed; (b) disposing dielectric material over the conductive elements and the exposed top of the silicon layer; (c) selectively removing dielectric material from over the conductive elements to expose conductive elements; (d) forming a voltage plane and a ground plane; (e) selectively removing silicon from a bottom of the silicon layer to form silicon openings and to expose part of the dielectric material; (f) filling the silicon openings with a polymer filler, leaving a polymer filler layer on the bottom of the silicon layer; (g) securing a substrate to the polymer filler layer; (h) forming vias through the substrate, the polymer filler, and the dielectric material; and (i) plating the vias.
Claim 22
Dependent Claim
32 words
The method of claim 18 additionally comprising testing, prior to said selectively removing dielectric material, the silicon layer including the conductive elements to determine if any of the conductive elements are defective.
Claim 23
Dependent Claim
29 words
The method of claim 18 wherein said forming a voltage plane includes depositing a metal voltage layer on said dielectric material and coupling same to said exposed conductive elements.
Claim 24
Dependent Claim
47 words
The method of claim 20 additionally comprising selectively removing at least one portion of the metal voltage layer to produce a residual voltage layer and to expose metal-filled conductive elements; and disposing a second dielectric layer over the residual voltage layer and the exposed metal-filled conductive elements.
Claim 25
Dependent Claim
69 words
The method of claim 21 wherein said forming a ground plane comprises forming a plurality of vias in said second dielectric layer to produce a residual second dielectric layer and to reexpose the exposed metal-filled conductive elements; and depositing a metal ground metal on said residual second dielectric layer and in said vias in said second dielectric layer to couple said metal-filled conductive elements to said metal ground metal.
Claim 26
Dependent Claim
21 words
The method of claim 22 additionally comprising removing a portion of the metal ground layer to produce exposed second dielectric layer.
Claim 27
Dependent Claim
19 words
The method of claim 23 wherein said forming vias includes forming vias through said produced exposed second dielectric layer.
Claim 28
Dependent Claim
11 words
The method of claim 24 additionally comprising filling the plated vias.
Claim 29
Dependent Claim
12 words
The method of claim 25 additionally comprising capping the filled plated vias.
Claim 30
Dependent Claim
13 words
The method of claim 26 wherein said conductive element is a metal pad.
Claim 31
Dependent Claim
13 words
The method of claim 18 wherein said conductive element is a semiconductor device.
Claim 32
Independent Claim
131 words
A method for fabricating a composite interposer comprising the steps: (a) disposing a plurality of conductive elements on top of a silicon layer, leaving part of a top of the silicon layer exposed; (b) disposing dielectric material over the conductive elements and the exposed top of the silicon layer; (c) selectively removing silicon from a bottom of the silicon layer to form silicon openings and to expose part of the dielectric material; (d) filling the silicon openings with a polymer filler, leaving a polymer filler layer on the bottom of the silicon layer; (e) securing a substrate to the polymer filler layer; (f) selectively removing dielectric material from over the conductive elements; (g) forming vias through the substrate, the polymer filler layer, and the dielectric material; and (h) plating the vias.
Claim 33
Independent Claim
131 words
A method for fabricating a composite interposer comprising the steps: (a) disposing a plurality of conductive elements on top of a silicon layer, leaving part of a top of the silicon layer exposed; (b) disposing dielectric material over the conductive elements and the exposed top of the silicon layer; (c) selectively removing silicon from a bottom of the silicon layer to form silicon openings and to expose part of the dielectric material; (d) filling the silicon openings with a polymer filler, leaving a polymer filler layer on the bottom of the silicon layer; (e) securing a substrate to the polymer filler layer; (f) selectively removing dielectric material from over the conductive elements; (g) forming vias through the substrate, the polymer filler layer, and the dielectric material; and (h) plating the vias.
Claim 34
Dependent Claim
13 words
The method of claim 1 additionally comprising testing the semiconductor devices for defectiveness.
Claim 35
Dependent Claim
13 words
The method of claim 9 additionally comprising testing the semiconductor devices for defectiveness.
Claim 36
Dependent Claim
13 words
The method of claim 18 additionally comprising testing the conductive elements for defectiveness.
Claim 37
Dependent Claim
13 words
The method of claim 29 additionally comprising testing the conductive elements for defectiveness.
Claim 38
Dependent Claim
13 words
A composite interposer produced in accordance with the method of claim 1 .
Claim 39
Dependent Claim
13 words
A composite interposer produced in accordance with the method of claim 9 .
Claim 40
Dependent Claim
13 words
A composite interposer produced in accordance with the method of claim 18 .
Claim 41
Dependent Claim
13 words
A composite interposer produced in accordance with the method of claim 29 .
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2006-02-17 | 2006-08-19 | 2007-02-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2010-02-17 | 2010-08-19 | 2011-02-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2014-02-17 | 2014-08-19 | 2015-02-18 | $7700.00 | Window Closed / Lapsed |