Advanced 3D eWLB-PoP (Embedded Wafer Level Ball Grid Array - Package on Package) Technology

The emergence and evolution of any package technology is driven by market trends as experienced by the end application. With the maturation of the mobile market, the trends for Smartphone and other mobile devices are more than ever for lower cost. Meanwhile, a higher degree of functionality and performance, thinner profile, and longer battery life are some of the additional market drivers seen in these devices. The implications of these market drivers on the packaging content of mobile devices are, higher performance designs, lower cost, smaller form factor, and higher level of integration. The advancement of silicon scaling to 14/16 nanometer (nm) in support of higher performance, higher bandwidth and lower power consumption in portable and mobile devices is pushing the boundaries of emerging packaging technologies to smaller fan-out packaging designs with finer line/spacing as well as improved electrical performance and passive embedded technology capabilities. Advanced embedded Wafer Level Ball Grid Array (eWLB) technology provides a versatile platform for the semiconductor industry's technology evolution from single or multi-die 2D package designs to 2.5D interposers and 3D System-in-Package (SiP) configurations. Earlier in 2012, eWLB Package-on-Package (eWLB-PoP) technology delivered a 30% height reduction in PoP, reducing the overall stacked package height from the industry standard 1.4mm to 1.0mm. Through further innovations in eWLB technology, a 40% height reduction in the bottom PoP architecture has been achieved. An ultra thin z-height of 0.3mm was realized in 2013, thereby providing the advantage of having an overall PoP package height as low as 0.8mm with proven board level reliability. While traditional PoP solutions are widely used in the high-end mobility market, demand is accelerating for ultra thin, cost effective packages that have the flexibility to serve a range of applications from mid-range to low-end mobile phones as well as tablets that require significantly higher processor speeds. While printed circuit board (PCB) substrate technology limits the interconnection density of a PoP package to 200-300 input/output (I/O), eWLB-based PoP solutions can deliver beyond 500 I/O in an overall thinner package with a dense vertical interconnection and wider interface to stack memory packages on the top. This paper reports developments that extend 3D PoP and 3D SiP applications with eWLB technology, including ultra thin devices or/and with an interposer substrate attachment. Various test vehicles have been designed and fabricated to demonstrate these low profile solutions for mobile, portable and wearable electronics. The test vehicles have ranged from medium to large sizes up to ~230mm2 and 0.4mm ball pitch. Assembly process details including embedded Bar (eBar), laser ablation, interconnect processes and mechanical characterizations are to be discussed with component and board level reliability results. In addition, warpage behavior and the PoP stacking process will also be presented. Innovative structure optimization that provides dual advantages of both height reduction and enhanced package reliability are reported. To enable higher interconnection density and signal routing, packages with multiple redistribution layers (RDL) and fine line/width spacing are fabricated and implemented on the eWLB platform. Successful reliability and electrical characterization results on 3D eWLB-PoP / eWLB-SiP configurations are reported as an enabling technology for highly integrated, miniaturized, low profile and cost effective solutions.