Semiconductor package

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A semiconductor package is a metal, plastic, glass, or ceramic casing containing one or more discrete semiconductor devices or integrated circuits. Individual components are fabricated on semiconductor wafers (commonly silicon) before being diced into die, tested, and packaged. The package provides a means for connecting the package to the external environment, such as printed circuit board, via leads such as lands, balls, or pins; and protection against threats such as mechanical impact, chemical contamination, and light exposure. Additionally, it helps dissipate heat produced by the device, with or without the aid of a heat spreader. There are thousands of package types in use. Some are defined by international, national, or industry standards, while others are particular to an individual manufacturer.

A semiconductor device is an electronic component that exploits the electronic properties of semiconductor material, principally silicon, germanium, and gallium arsenide, as well as organic semiconductors. Semiconductor devices have replaced vacuum tubes in most applications. They use electrical conduction in the solid state rather than the gaseous state or thermionic emission in a vacuum.

Integrated circuit electronic circuit manufactured by lithography; set of electronic circuits on one small flat piece (or "chip") of semiconductor material, normally silicon

An integrated circuit or monolithic integrated circuit is a set of electronic circuits on one small flat piece of semiconductor material that is normally silicon. The integration of large numbers of tiny MOS transistors into a small chip results in circuits that are orders of magnitude smaller, faster, and less expensive than those constructed of discrete electronic components. The IC's mass production capability, reliability, and building-block approach to circuit design has ensured the rapid adoption of standardized ICs in place of designs using discrete transistors. ICs are now used in virtually all electronic equipment and have revolutionized the world of electronics. Computers, mobile phones, and other digital home appliances are now inextricable parts of the structure of modern societies, made possible by the small size and low cost of ICs.

Semiconductor device fabrication manufacturing process used to create integrated circuits

Semiconductor device fabrication is the process used to manufacture semiconductor devices, particularly the metal-oxide-semiconductor (MOS) devices used in the integrated circuit (IC) chips that are present in everyday electrical and electronic devices. It is a multiple-step sequence of photolithographic and chemical processing steps during which electronic circuits are gradually created on a wafer made of pure semiconducting material. Silicon is almost always used, but various compound semiconductors are used for specialized applications.

Contents

Package functions

A semiconductor package may have as few as two leads or contacts for devices such as diodes, or in the case of advanced microprocessors, a package may have hundreds of connections. Very small packages may be supported only by their wire leads. Larger devices, intended for high-power applications, are installed in carefully designed heat sinks so that they can dissipate hundred or thousands of watts of waste heat.

Waste heat Waste heat is by necessity produced both by machines that do work and in other processes that use energy, for example in a refrigerator warming the room air or a combustion engine releasing heat into the environment.

Waste heat is heat that is produced by a machine, or other process that uses energy, as a byproduct of doing work. All such processes give off some waste heat as a fundamental result of the laws of thermodynamics. Waste heat has lower utility than the original energy source. Sources of waste heat include all manner of human activities, natural systems, and all organisms, for example, incandescent light bulbs get hot, a refrigerator warms the room air, an internal combustion engine generates high-temperature exhaust gases, and electronic components get warm when in operation.

In addition to providing connections to the semiconductor and handling waste heat, the semiconductor package must protect the "chip" from the environment, particularly the ingress of moisture. Stray particles or corrosion products inside the package may degrade performance of the device or cause failure. [1] A hermetic package allows essentially no gas exchange with the surroundings; such construction requires glass, ceramic or metal enclosures.

This replica of the first laboratory transistor shows connecting leads and a glass jar for protection; packaging the device was critical to its success. Replica-of-first-transistor.jpg
This replica of the first laboratory transistor shows connecting leads and a glass jar for protection; packaging the device was critical to its success.

Date code

Manufacturers usually print -- using ink or laser marking -- the manufacturer's logo and the manufacturer's part number on the package, to make it easier to distinguish the many different and incompatible devices packaged in relatively few kinds of packages. The markings often include a 4 digit date code, often represented as YYWW where YY is replaced by the last 2 digits of the calendar year and WW is replaced by the two-digit week number. [2]

Leads

To make connections between an integrated circuit and the leads of the package, wire bonds are used, with fine wires connected from the package leads and bonded to conductive pads on the semiconductor die. At the outside of the package, wire leads may be soldered to a printed circuit board or used to secure the device to a tag strip. Modern surface mount devices eliminate most of the drilled holes through circuit boards, and have short metal leads or pads on the package that can be secured by oven-reflow soldering. Aerospace devices in flat packs may use flat metal leads secured to a circuit board by spot welding, though this type of construction is now uncommon.

Wire bonding

Wire bonding is the method of making interconnections (ATJ) between an integrated circuit (IC) or other semiconductor device and its packaging during semiconductor device fabrication. Although less common, wire bonding can be used to connect an IC to other electronics or to connect from one printed circuit board (PCB) to another. Wire bonding is generally considered the most cost-effective and flexible interconnect technology and is used to assemble the vast majority of semiconductor packages. Wire bonding can be used at frequencies above 100 GHz.

Printed circuit board Board to support and connect electronic components

A printed circuit board (PCB) mechanically supports and electrically connects electronic components or electrical components using conductive tracks, pads and other features etched from one or more sheet layers of copper laminated onto and/or between sheet layers of a non-conductive substrate. Components are generally soldered onto the PCB to both electrically connect and mechanically fasten them to it.

Flatpack (electronics) flat integrated circuit package

Flatpack is a US military standardized printed-circuit-board surface-mount-component package. The military standard MIL-STD-1835C defines: Flat package (FP). A rectangular or square package with leads parallel to base plane attached on two opposing sides of the package periphery.

Sockets

Early semiconductor devices were often inserted in sockets, like vacuum tubes. As devices improved, eventually sockets proved unnecessary for reliability, and devices were directly soldered to printed circuit boards. The package must handle the high temperature gradients of soldering without putting stress on the semiconductor die or its leads.

Solder metal alloy used to join together metal pieces with higher melting points

Solder is a fusible metal alloy used to create a permanent bond between metal workpieces. The word solder comes from the Middle English word soudur, via Old French solduree and soulder, from the Latin solidare, meaning "to make solid". In fact, solder must first be melted in order to adhere to and connect the pieces together after cooling, which requires that an alloy suitable for use as solder have a lower melting point than the pieces being joined. The solder should also be resistant to oxidative and corrosive effects that would degrade the joint over time. Solder used in making electrical connections also needs to have favorable electrical characteristics.

Sockets are still used for experimental, prototype, or educational applications, for testing of devices, for high-value chips such as microprocessors where replacement is still more economical than discarding the product, and for applications where the chip contains firmware or unique data that might be replaced or refreshed during the life of the product. Devices with hundreds of leads may be inserted in zero insertion force sockets, which are also used on test equipment or device programmers.

Package materials

Many devices are molded out of an epoxy plastic that provides adequate protection of the semiconductor devices, and mechanical strength to support the leads and handling of the package. Some devices, intended for high-reliability or aerospace or radiation environments, use ceramic packages, with metal lids that are brazed on after assembly, or a glass frit seal. All-metal packages are often used with high power (several watts or more) devices, since they conduct heat well and allow for easy assembly to a heat sink. Often the package forms one contact for the semiconductor device. Lead materials must be chosen with a thermal coefficient of expansion to match the package material.

A very few early semiconductors were packed in miniature evacuated glass envelopes, like flashlight bulbs; such expensive packaging was made obsolete when surface passivation and improved manufacturing techniques were available. [1] Glass packages are still commonly used with diodes, and glass seals are used in metal transistor packages.

Package materials for high-density dynamic memory must be selected for low background radiation; a single alpha particle emitted by package material can cause a single event upset and transient memory errors (soft errors).

Spaceflight and military applications traditionally used hermetically packaged microcircuits (HPMs). However, most modern integrated circuits are only available as plastic encapsulated microcircuits (PEMs). Proper fabrication practices using properly qualified PEMs can be used for spaceflight. [3]

Hybrid integrated circuits

A hybrid integrated circuit IntegratedCircuit1966.JPG
A hybrid integrated circuit

Multiple semiconductor dies and discrete components can be assembled on a ceramic substrate and interconnected with wire bonds. The substrate bears leads for connection to an external circuit, and the whole is covered with a welded or frit cover. Such devices are used when requirements exceed the performance (heat dissipation, noise, voltage rating, leakage current, or other properties) available in a single-die integrated circuit, or for mixing analog and digital functions in the same package. Such packages are relatively expensive to manufacture, but provide most of the other benefits of integrated circuits.

A modern example of multi-chip integrated circuit packages would be certain models of microprocessor, which may include separate dies for such things as cache memory within the same package. In a technique called flip chip, digital integrated circuit dies are inverted and soldered to a module carrier, for assembly into large systems. [4] The technnique was applied by IBM in their System/360 computers. [5]

Special packages

Semiconductor packages may include special features. Light-emitting or light-sensing devices must have a transparent window in the package; other devices such as transistors may be disturbed by stray light and require an opaque package. [1] An ultraviolet erasable programmable read-only memory device needs a quartz window to allow ultraviolet light to enter and erase the memory. Pressure-sensing integrated circuits require a port on the package that can be connected to a gas or liquid pressure source.

Packages for microwave frequency devices are arranged to have minimal parasitic inductance and capacitance in their leads. Very-high-impedance devices with ultralow leakage current require packages that do not allow stray current to flow, and may also have guard rings around input terminals. Special isolation amplifier devices include high-voltage insulating barriers between input and output, allowing connection to circuits energized at 1 kV or more.

The very first point-contact transistors used metal cartridge-style packages with an opening that allowed adjustment of the whisker used to make contact with the germanium crystal; such devices were common for only a brief time since more reliable, less labor-intensive types were developed. [1]

Standards

Just like vacuum tubes, semiconductor packages standards may be defined by national or international industry associations such as JEDEC, Pro Electron, or EIAJ, or may be proprietary to a single manufacturer.

See also

Related Research Articles

Dual in-line package Type of electronic component package

In microelectronics, a dual in-line package, or dual in-line pin package (DIPP) is an electronic component package with a rectangular housing and two parallel rows of electrical connecting pins. The package may be through-hole mounted to a printed circuit board (PCB) or inserted in a socket. The dual-inline format was invented by Don Forbes, Rex Rice and Bryant Rogers at Fairchild R&D in 1964, when the restricted number of leads available on circular transistor-style packages became a limitation in the use of integrated circuits. Increasingly complex circuits required more signal and power supply leads ; eventually microprocessors and similar complex devices required more leads than could be put on a DIP package, leading to development of higher-density chip carriers. Furthermore, square and rectangular packages made it easier to route printed-circuit traces beneath the packages.

CMOS Technology for constructing integrated circuits

Complementary metal–oxide–semiconductor (CMOS), also known as complementary-symmetry metal–oxide–semiconductor (COS-MOS), is a type of MOSFET fabrication process that uses complementary and symmetrical pairs of p-type and n-type MOSFETs for logic functions. CMOS technology is used for constructing integrated circuits (ICs), including microprocessors, microcontrollers, memory chips, and other digital logic circuits. CMOS technology is also used for analog circuits such as image sensors, data converters, RF circuits, and highly integrated transceivers for many types of communication.

Programmable logic device reprogrammable computer hardware technology

A programmable logic device (PLD) is an electronic component used to build reconfigurable digital circuits. Unlike integrated circuits (IC) which consist of logic gates and have a fixed function, a PLD has an undefined function at the time of manufacture. Before the PLD can be used in a circuit it must be programmed (reconfigured) by using a specialized program.

Ball grid array

A ball grid array (BGA) is a type of surface-mount packaging used for integrated circuits. BGA packages are used to permanently mount devices such as microprocessors. A BGA can provide more interconnection pins than can be put on a dual in-line or flat package. The whole bottom surface of the device can be used, instead of just the perimeter. The traces connecting the package's leads to the wires or balls which connect the die to package are also on average shorter than with a perimeter-only type, leading to better performance at high speeds.

Surface-mount technology method for producing electronic circuits

Surface-mount technology (SMT) is a method for producing electronic circuits in which the components are mounted or placed directly onto the surface of printed circuit boards (PCBs). An electronic device so made is called a surface-mount device (SMD). In industry, it has largely replaced the through-hole technology construction method of fitting components with wire leads into holes in the circuit board. Both technologies can be used on the same board, with the through-hole technology used for components not suitable for surface mounting such as large transformers and heat-sinked power semiconductors.

Pin grid array type of integrated circuit packaging. In a PGA, the package is square or rectangular, and the pins are arranged in a regular array on the underside of the package

A pin grid array (PGA) is a type of integrated circuit packaging. In a PGA, the package is square or rectangular, and the pins are arranged in a regular array on the underside of the package. The pins are commonly spaced 2.54 mm (0.1") apart, and may or may not cover the entire underside of the package.

Integrated circuit packaging Final stage of semiconductor device fabrication

In electronics manufacturing, integrated circuit packaging is the final stage of semiconductor device fabrication, in which the block of semiconductor material is encapsulated in a supporting case that prevents physical damage and corrosion. The case, known as a "package", supports the electrical contacts which connect the device to a circuit board.

Quad Flat Package surface mount integrated circuit package

A QFP or Quad Flat Package is a surface-mounted integrated circuit package with "gull wing" leads extending from each of the four sides. Socketing such packages is rare and through-hole mounting is not possible. Versions ranging from 32 to 304 pins with a pitch ranging from 0.4 to 1.0 mm are common. Other special variants include low-profile QFP (LQFP) and thin QFP (TQFP).

Electronic component basic discrete device or physical entity in an electronic system used to affect electrons or their associated fields

An electronic component is any basic discrete device or physical entity in an electronic system used to affect electrons or their associated fields. Electronic components are mostly industrial products, available in a singular form and are not to be confused with electrical elements, which are conceptual abstractions representing idealized electronic components.

Hybrid integrated circuit miniaturized electronic circuit combining different semiconductor devices and passive components on a substrate

A hybrid integrated circuit (HIC), hybrid microcircuit, hybrid circuit or simply hybrid is a miniaturized electronic circuit constructed of individual devices, such as semiconductor devices and passive components, bonded to a substrate or printed circuit board (PCB). A PCB having components on a Printed Wiring Board (PWB) is not considered a hybrid circuit according to the definition of MIL-PRF-38534.

Electronic packaging is the design and production of enclosures for electronic devices ranging from individual semiconductor devices up to complete systems such as a mainframe computer. Packaging of an electronic system must consider protection from mechanical damage, cooling, radio frequency noise emission and electrostatic discharge. Product safety standards may dictate particular features of a consumer product, for example, external case temperature or grounding of exposed metal parts. Prototypes and industrial equipment made in small quantities may use standardized commercially available enclosures such as card cages or prefabricated boxes. Mass-market consumer devices may have highly specialized packaging to increase consumer appeal. Electronic packaging is a major discipline within the field of mechanical engineering.

TO-3

In electronics, TO-3 is a designation for a standardized metal semiconductor package used for power semiconductors, including transistors, silicon controlled rectifiers, and, integrated circuits. TO stands for "Transistor Outline" and relates to a series of technical drawings produced by JEDEC.

Thermal copper pillar bump

The thermal copper pillar bump, also known as the "thermal bump", is a thermoelectric device made from thin-film thermoelectric material embedded in flip chip interconnects for use in electronics and optoelectronic packaging, including: flip chip packaging of CPU and GPU integrated circuits (chips), laser diodes, and semiconductor optical amplifiers (SOA). Unlike conventional solder bumps that provide an electrical path and a mechanical connection to the package, thermal bumps act as solid-state heat pumps and add thermal management functionality locally on the surface of a chip or to another electrical component. The diameter of a thermal bump is 238 μm and 60 μm high.

Failure of electronic components Ways electronic elements fail and prevention measures

Electronic components have a wide range of failure modes. These can be classified in various ways, such as by time or cause. Failures can be caused by excess temperature, excess current or voltage, ionizing radiation, mechanical shock, stress or impact, and many other causes. In semiconductor devices, problems in the device package may cause failures due to contamination, mechanical stress of the device, or open or short circuits.

Chip carrier one of several kinds of surface mount technology packages for integrated circuits

In electronics, a chip carrier is one of several kinds of surface-mount technology packages for integrated circuits. Connections are made on all four edges of a square package; Compared to the internal cavity for mounting the integrated circuit, the package overall size is large.

Chip on board Circuit board manufacturing technique

Chip on board (COB) is the method of manufacturing where integrated circuits are wired and bonded directly to a printed circuit board. By eliminating the packaging of individual semiconductor devices, the completed product can be more compact, lighter, and less costly. In some cases chip on board construction improves the operation of radio frequency systems by reducing the inductance and capacitance of integrated circuit leads. Chip on board effectively merges two levels of electronic packaging, level 1 (components) and level 2, and may be referred to as a "level 1.5"

References

  1. 1 2 3 4 Lloyd P.Hunter (ed.), Handbook of Semiconductor Electronics, McGraw Hill, 1956 ,Library of Congress catalog 56-6869, no ISBN chapter 9
  2. Texas Instruments. “Quality & Lead-free (Pb-free): Marking Convention.” Retrieved August 6, 2015.
  3. Ronald K. Burek, Johns Hopkins APL Technical Digest. “The NEAR Solid-State Data Recorders.” 1998. Retrieved August 6, 2015.
  4. Keyan Bennaceur, Nature.com. “Mechanical Flip-Chip for Ultra-High Electron Mobility Devices.” September 22, 2015. April 23, 2015.
  5. Michael Pecht (ed) Integrated circuit, hybrid, and multichip module package design guidelines: a focus on reliability, Wiley-IEEE, 1994 ISBN   0-471-59446-6, page 183