Metal core substrate packaging
First Claim
1. A method of making a rigid metal core carrier substrate, comprising:
- providing a metal core in the form of a metal sheet having a first side, an opposite second side, and at least one through hole, the metal core having a flexural modulus of elasticity of at least 20 GPa;
forming dielectric layers by depositing a dielectric material in a predetermined pattern on the first side, the second side, and each through hole forming a dielectric plug within the through hole;
forming a through hole in the dielectric plug having a diameter smaller than the core through hole forming a dielectric liner;
forming a conductive liner by depositing a conductive material on the dielectric liner defining a plated through hole, the conductive liner insulated from the metal core by the dielectric liner; and
depositing a conductive material in a predetermined pattern on the dielectric layers.
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Accused Products
Abstract
Apparatus and methods are provided for a rigid metal core carrier substrate. The metal core increases the modulus of elasticity of the carrier substrate to greater than 20 GPa to better resist bending loads and stresses encountered during assembly, testing and consumer handling. The carrier substrate negates the need to provide external stiffening members resulting in a microelectronic package of reduced size and complexity. The coefficient of thermal expansion of the carrier substrate can be adapted to more closely match that of the microelectronic die, providing a device more resistant to thermally-induced stresses. In one embodiment of the method in accordance with the invention, a metal sheet having a thickness in the range including 200-500 μm and a flexural modulus of elasticity of at least 20 GPa is laminated on both sides with dielectric and conductive materials using standard processing technologies to create a carrier substrate.
51 Citations
23 Claims
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1. A method of making a rigid metal core carrier substrate, comprising:
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providing a metal core in the form of a metal sheet having a first side, an opposite second side, and at least one through hole, the metal core having a flexural modulus of elasticity of at least 20 GPa;
forming dielectric layers by depositing a dielectric material in a predetermined pattern on the first side, the second side, and each through hole forming a dielectric plug within the through hole;
forming a through hole in the dielectric plug having a diameter smaller than the core through hole forming a dielectric liner;
forming a conductive liner by depositing a conductive material on the dielectric liner defining a plated through hole, the conductive liner insulated from the metal core by the dielectric liner; and
depositing a conductive material in a predetermined pattern on the dielectric layers. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of making a metal core substrate, comprising:
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providing a metal core in the form of a metal sheet having a first side, an opposite second side, and at least one through hole, the metal core having a flexural modulus of elasticity of at least 100 GPa;
covering the first and second side and each through hole with a laminate of dielectric material;
curing the laminate at elevated temperature forming a dielectric layer on the first and second side, a portion of the laminate flowing into and plugging the through holes;
forming dielectric through holes in the plug having a diameter smaller that the conductive through hole, and depositing a conductive layer on each dielectric liner forming a plated through hole, the conductive layer insulated from the metal core by the dielectric liner. - View Dependent Claims (8, 9, 10)
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11. A method of making a metal core carrier substrate, comprising:
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providing a metal core in the form of a metal sheet having a first side, an opposite second side, and at least one core through hole, the metal core having a flexural modulus of elasticity of at least 20 GPa;
depositing a dielectric material on the first side, the second side, and in each core through hole forming a dielectric layer on the first and second sides, and forming a dielectric plug in each core through hole;
forming a dielectric liner in each core through hole by providing a dielectric though hole in the dielectric plug and centered within the core through hole, the dielectric through hole having a diameter smaller than the core through hole; and
depositing a conductive material on each dielectric liner forming a conductive liner defining a plated through hole, the conductive liner insulated from the metal core by the dielectric liner. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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18. A rigid metal core carrier substrate, comprising:
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a metal core comprising a metal sheet having a first side and a second side, the metal sheet having a thickness in the range including 200-500 μ
m and a flexural modulus of elasticity of at least 20 GPa;
at least one dielectric layer covering the first side and the second side;
at least one conductive layer covering the dielectric layer on the first and second side; and
a plurality of plated through holes, the plated through holes comprising a tubular-shaped dielectric liner and a conductive liner lining the inside surface of the dielectric liner, the plated through holes extending through the metal sheet and the dielectric layers covering the first and second sides, the conductive liner in electrical communication with the conductive layer on the first and second side, the dielectric liner insulating the metal sheet from the conductive liner. - View Dependent Claims (19, 20)
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21. A high flexural modulus of elasticity microelectronic device, comprising:
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a metal core having at least one clearance formed there through, the metal core having a thickness in the range including 200-500 μ
m and a flexural modulus of elasticity of at least 20 GPa;
at least one dielectric layer disposed on each of top and bottom surfaces of the metal core;
at least one conductive layer disposed on each of the dielectric layers;
at least one conductive via electrically connecting the conductive layers, the conductive via electrically insulated from the metal core, the substrate adapted to electrically and mechanically interconnect with a microelectronic die; and
a microelectronic die electrically and mechanically interconnected to at least one of the at least one conductive layer. - View Dependent Claims (22, 23)
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Specification