Method of fabricating a microelectronic device package with an integral window
First Claim
1. A method of fabricating a microelectronic package having an integral window, comprising:
- forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising applying a surface treatment to a mating surface to improve wettability and adhesion to said corresponding mating surface.
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Accused Products
Abstract
A method of fabricating a microelectronic device package with an integral window for providing optical access through an aperture in the package. The package is made of a multilayered insulating material, e.g., a low-temperature cofired ceramic (LTCC) or high-temperature cofired ceramic (HTCC). The window is inserted in-between personalized layers of ceramic green tape during stackup and registration. Then, during baking and firing, the integral window is simultaneously bonded to the sintered ceramic layers of the densified package. Next, the microelectronic device is flip-chip bonded to cofired thick-film metallized traces on the package, where the light-sensitive side is optically accessible through the window. Finally, a cover lid is attached to the opposite side of the package. The result is a compact, low-profile package, flip-chip bonded, hermetically-sealed package having an integral window.
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Citations
63 Claims
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1. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising applying a surface treatment to a mating surface to improve wettability and adhesion to said corresponding mating surface.
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2. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising applying an anti-reflection coating to said window.
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3. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
attaching said first plate to said second plate by joining said second surface to said third surface;
wherein forming said package comprises laminating a plurality of electrically insulating sheets; and
wherein said laminating step comprises;
personalizing said sheets;
stacking and registering said personalized sheets to form a stack of personalized sheets;
holding said stack of personalized sheets as a rigid assembly; and
baking and firing said rigid assembly, whereby said stacked sheets are cofired and laminated together to form a unitized, monolithic package. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
fabricating a second electrically conductive metallized trace disposed on said fourth surface of said second plate;
forming a third plate, having a third aperture disposed through said third plate, wherein said third aperture is larger than said second aperture; and
attaching said third plate to said fourth surface of said second plate.
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15. The method of claim 14, wherein said third aperture is substantially aligned with said second aperture.
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16. The method of claim 3, wherein said second aperture is substantially aligned with said first aperture.
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17. The method of claim 3, further comprising:
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providing a microelectronic device;
mounting said microelectronic device within said package; and
attaching a cover lid to said package, whereby said device is housed inside of a package having an integral window.
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18. The method of claim 12, wherein said microelectronic device comprises a light-sensitive side.
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19. The method of claim 18, further comprising orienting said light-sensitive side facing said window.
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20. The method of claim 17, further comprising flip-chip mounting said microelectronic device to said electrically conductive metallized trace disposed on said second surface.
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21. The method of claim 20, wherein flip-chip mounting further comprises using a process selected from the group consisting of brazing, reflow soldering, plasma-assisted dry soldering, thermocompression without vibration, thermocompression with vibration, and attachment with a conductive adhesive.
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22. The method of claim 17, wherein said microelectronic device comprises a CCD chip.
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23. The method of claim 17, wherein said microelectronic device comprises a MEMS or IMEMS device.
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24. The method of claim 17, further comprising applying a seal in-between said microelectronic device and said second surface.
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25. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising attaching a cover lid to said package, thereby forming a sealed package; and
further comprising substantially removing ambient air from inside said package; and
then replacing it with at least one gas other than air, before attaching said cover lid to said package.
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26. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture;
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising fabricating said window with an integral lens. - View Dependent Claims (27, 28)
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29. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture;
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising attaching a lens to said window.
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30. A method of fabricating a microelectronic package having an integral window, comprising:
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forming a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
fabricating an electrically conductive metallized trace on said second surface of said first plate;
attaching a window to said first plate;
forming a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture;
attaching said first plate to said second plate by joining said second surface to said third surface; and
further comprising attaching an electrically-switched optical modulator to said package, for modulating light passing through an aperture. - View Dependent Claims (31)
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32. A method for packaging at least one microelectronic device in a package having an integral window, comprising:
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providing a package comprising;
a first electrically insulating plate having a first surface, an opposing second surface, and a first aperture disposed through said first plate;
a first electrically conductive metallized trace on said second surface of said first plate;
an integral window attached to said first plate;
a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
wherein said second surface of said first plate is attached to said third surface of said second plate; and
further comprising;
a second electrically conductive metallized trace disposed on said fourth surface of said second plate;
a third electrically insulating plate, having a third aperture disposed through said third plate, wherein said third aperture is larger than said second aperture; and
wherein said third plate is attached to said fourth surface of said second plate;
providing a first microelectronic device;
flip-chip mounting said first microelectronic device to said first electrically conductive metallized trace disposed on said second surface;
providing a second microelectronic device;
mounting and electrically interconnecting said second microelectronic device to said second electrically conductive metallized trace disposed on said fourth surface; and
attaching a cover lid to said package. - View Dependent Claims (33, 34, 35, 36)
bonding together back-to-back said first microelectronic device and said second microelectronic device; and
thenwirebonding said second microelectronic device to said second electrically conductive metallized trace disposed on said fourth surface, before attaching said cover lid to said package.
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35. The method of claim 34, wherein said second microelectronic device comprises a light-sensitive side facing towards said cover lid;
- and further wherein said cover lid comprises a transparent material.
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36. The method of claim 34, wherein bonding together back-to-back said first microelectronic device and said second microelectronic device comprises using a process selected from the group consisting of anodic bonding, eutectic bonding, soldering, and adhesive attachment.
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37. A method of fabricating a microelectronic package having an integral window, comprising:
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a) laminating together a plurality of individual layers of an electrically insulating material to form a first electrically insulating plate comprising a multilayered material, a first surface, an opposing second surface, and a first aperture disposed through said first plate;
b) fabricating a first electrically conductive metallized trace on said second surface of said first plate;
c) joining a window, disposed across said first aperture, to said first plate;
d) providing a second electrically insulating plate having a third surface, an opposing fourth surface, and a second aperture disposed through said second plate;
wherein said second aperture is larger than said first aperture; and
e) joining the second surface of said first plate to said third surface of said second plate. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 51, 52, 53)
49.The method of claim 48, said window is joined to said first plate without using a separate sealing material disposed in-between said window and said plate. -
49. The method of;
- claim 37, wherein said window substantially fills said first aperture.
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51. The method of claim 37, wherein said window is a material selected from the group consisting of borosilicate glass, quartz glass, fused silica, optical quality glass, a transparent ceramic, sapphire, an optically transparent polymer, an UV transparent polymer, PMMA, an IR transparent material, silicon, a metal, a metal alloy, a material that switches from being optically transparent to being opaque at voltages around 5-6 volts, and lithium niobate.
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52. The method of claim 37, further comprising flip-chip mounting a first microelectronic device to said first electrically conductive metallized trace after said window has been joined to said first plate.
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53. The method of claim 37, further comprising:
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f) providing an unreleased MEMS device;
g) mounting said MEMS device to said third surface of said second plate;
h) electrically interconnecting said MEMS device to said first electrically conductive metallized trace; and
i) releasing said MEMS device after mounting said MEMS device in step h).
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50. The method of claim 50, wherein joining said window to said first plate comprises casting a castable window material directly into said first aperture;
- wherein the castable window material is selected from the group consisting of a molten glass that solidifies after casting and a liquid polymer that hardens after casting.
- 54. The method of claim 54, wherein joining said window in step c) is performed after releasing said MEMS device in step i).
- 56. The method of claim 56, wherein attaching said cover lid in step j) is performed after releasing said MEMS device in step i).
- 59. The method of claim 59, wherein said sacrificial protective coating comprises a vacuum-deposited conformal coating.
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60. The method of claim 60, wherein releasing said MEMS device in step i) comprises using a dry plasma etching process to remove said vacuum-deposited conformal coating.
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62. A method of fabricating a package with an integral window for housing a microelectronic device, comprising:
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a) personalizing a first set of individual layers of an electrically insulating multilayer material by removing a cutout shape from each layer;
wherein removal of said cutout shape from each layer of said first set of individual layers defines a first aperture; and
wherein said first set of individual layers comprises a top layer;
b) personalizing a second set of individual layers of an electrically insulating multilayer material by removing a cutout shape from each layer;
wherein removal of said cutout shape from each layer of said second set of individual layers defines a second aperture; and
further wherein said second aperture is wider than said first aperture;
c) depositing a first electrical conductor on said top layer of said first set of individual layers;
d) stacking and registering said second set of individually personalized layers on top of said first set of individually personalized layers, including placing a window at a specified location in said first set;
thereby making an assembled stack of said first and second sets including said window;
wherein said window is disposed across said first aperture; and
e) processing said assembled stack of said first and second sets including said window by applying sufficient pressure and temperature to said assembled stack for sufficient time to form a consolidated monolithic multilayered body having an integral window;
wherein said window is bonded directly to said consolidated monolithic multilayered body without having a separate layer of sealing material disposed in-between said window and said body.
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63. The method of claim 63, further comprising:
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f) providing an unreleased MEMS device;
g) mounting said MEMS device to said top layer of said first set of individual layers;
h) electrically interconnecting said MEMS device to said first electrical conductor; and
i) releasing said MEMS device after mounting said MEMS device in step g).
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Specification