Self-aligning package for integrated circuits
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to integrated circuit packaging and more particularly to a self-aligning integrated circuit package. 
     2. Description of the Prior Art 
     Modern automated techniques for manufacturing integrated circuits have resulted in a substantial reduction in the cost of integrated circuit chips. A substantial portion of the cost of a completed integrated circuit device is attributable to packaging. The high cost of packaging integrated circuits primarily results from the difficulty encountered in making electrical contact to the integrated circuit chip. Some usuable form of lead must be brought out from the small contact pads of the integrated circuit. 
     The semiconductor industry has established standard lead configurations; however, these leads must be electrically connected to the contact pads on the circuit chip. Many schemes have been devised for connecting the leads to the contact pads; however, the practice of using fine interconnecting wires still prevails as the industry standard. 
     The standard practice was to bond fine gold or aluminum wire leads to the contact pads on the chip and to the individual leads of a standard lead configuration. This procedure required at least 28 separate bonding steps which resulted in high labor cost. The use of gold wire leads also resulted in high material cost and other technical difficulties such as the purple plague. 
     In an attempt to eliminate the need for wire leads, the contact frame leads were bonded directly to the contact pads on the chip. This procedure resulted in some success but required larger size contct pads and resulted in increased chip size. 
     Another solution described in U.S. Pat. No. 3,676,922 proposed the use of a conductive metal sheet spread over the chip and leads and bond thereto to interconnect the contact pads on the chip to the leads. Thereafter, the undesired portions of the conductive metal sheet were removed using a standard photo-resist and etching technique. This procedure allowed for the use of standard lead frames and contact pads; however, the interconnecting metal sheet was relatively thin and not strong enough for all applications. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a novel packaging technique for integrated circuits wherein the material cost is substantially reduced and assembly may be automated to significantly reduce the labor cost. Thus, the present invention results in a substantial reduction in the packaging cost of an integrated circuit. 
     The present invention contemplates the use of a standard integrated circuit die having raised bonding pads. The pads may be formed in a manner as described in a co-pending patent application of R. Scherrer, Ser. No. 601,856, filed August 4, 1975 or by a plating process for building up the bonding pads. An interconnecting die formed of an anodizable material is used to provide the interconnection between the contact pads on the standard integrated circuit die and the leads of a standard lead frame thereby eliminating the use of gold plated wire and a number of bonding steps. Self-alignment is achieved by selectively anodizing portions of the interconnecting die to form raised portions for guiding the integrated circuit die and the lead frame leads into position on the interconnecting die. 
     In one embodiment the interconnecting die is formed of silicon and has metalized conducting strips formed thereon for providing the connection between the contact pads of the integrated circuit die and the lead frame. 
     In another embodiment, the interconnecting die is formed of aluminum which is selectively anodized to form non-conducting regions which also functions as guide members for the integrated circuit die and the lead frame leads. 
     After the circuit die is bonded to the interconnecting die, a glass frit is applied over the circuit die and surrounding area which is thereafter fired to provide a hermetic seal about the integrated circuit. The circuit is encapsulated in epoxy to the desired form factor to provide the required strength. 
     The primary objective of the present invention is to provide a low cost package for an integrated circuit. 
     Another objective of the present invention is to provide a more reliable integrated circuit. 
     Another objective of the present invention is to provide an integrated circuit having heat sinks on both sides for providing for higher power dissipation. 
     Another objective of the present invention is to provide a package design wherein all alignment steps may be automated. 
     Another objective of the present invention is to provide an integrated circuit package having the hermeticity of a ceramic package combined with the ruggedness of a plastic package. p Another objective of the present invention is to provide an integrated circuit that does not require gold leads. 
     The foregoing and other objectives and advantages of the present invention will become more apparent from the following description and the accompanying drawings wherein two embodiments of the present invention are described. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a standard integrated circuit die. 
     FIG. 2 is a partial vertical section taken along line 2--2 of FIG. 1 showing a portion of the integrated circuit die. 
     FIG. 3 is a plan view of a sheet of anodizable material from which an interconnecting die may be formed. 
     FIG. 4 is a plan view of an interconnecting die constructed in accordance with the present invention. 
     FIGS. 5A through 5D are vertical sections taken along line 5--5 of FIG. 4 showing a portion of the interconnecting die during various stages of its fabrication. 
     FIGS. 6A through 6C are vertical sections taken along line 6--6 of FIG. 4 showing a portion of the interconnecting die during various stages of its fabrication. 
     FIG. 7 is a plan view of the interconnecting die of FIG. 4 with the integrated circuit die of FIG. 1 positioned thereon. 
     FIG. 8 is a vertical section taken along line 8--8 of FIG. 7 showing a portion of the integrated circuit die and interconnecting die. 
     FIG. 9 is a plan view of the interconnecting die of FIG. 7 with leads attached thereto. 
     FIG. 10 is a vertical section taken along line 10--10 of FIG. 9 showing a portion of the interconnecting die with leads connected thereto. 
     FIG. 11 is a perspective view of an encapsulated integrated circuit. 
     FIG. 12 is a plan view of an interconnecting die constructed in accordance with a second embodiment of the present invention. 
     FIG. 13 is a vertical section taken along line 13--13 of FIG. 12. 
     FIG. 14 is a vertical section taken along line 14--14 of FIG. 12. 
     FIG. 15 is a plan view of the die of FIG. 12 shown at another stage of its fabrication. 
     FIGS. 16A through 16D are vertical sections taken along line 16--16 of FIG. 15 showing various stages and embodiments of die fabrication. 
     FIG. 17 is a plan view of the interconnecting die showing a lead frame attached thereto. FIGS. 18A to 18C are vertical sections taken along line 18--18 of FIG. 17 showing various stages fo fabrication of the integrated circuit. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, there is shown a typical integrated circuit chip or die 20 having contact pads 22 formed thereon. The circuit includes internal connections between the active parts of the circuit and said contact pads. The contact pads 22 may be formed in accordance with the teachings of a co-pending U.S. patent application Ser. No. 601,856 of Raymond Scherer entitled &#34;Contact Pad For A Semiconductor Device&#34;, or by a plating process. In the Scherrer application which is incorporated herein by reference, there is described how a raised contact pad may be easily formed on a semiconductive material using silicon anodization techniques. 
     Referring to FIG. 2, there is shown a vertical section through a typical contact pad formed in accordance with the method described in the Scherrer patent application. The surface of semiconductive material 24 is subjected to an oxidizing process to from a dielectric layer 26. While oxidizing the semiconductive material is the preferred method for providing the dielectric layer, the layer may be formed by depositon of silicon nitride or an oxide so long as the layer is a dielectric. 
     Using a conventional photo-resist process and etching, portions of layer 26 are removed from the areas under pads 22 to expose the semiconductive material in layer 24. The remaining portions of layer 26 form a mask for a subsequent anodization step. 
     The exposed semiconductive material 24 in the pad areas is anodized to form a dielectric material. During the anodization process, the semiconductive material in the pad area forms an anode when a positive potential is applied to material 24 while submerging the material into an anodizing solution containing an electolyte and a cathode. 
     The anodized semiconductive material 28 has increased size to form a raised pad area which should extend 1 to 2 mils above the surface of the die. In order to form anodized material of sufficient thickness, the anodized material must be porous so that anodization is not stopped by the insulating characteristic of the anodized material. A porous material is formed by using an electolyte of the type that etches the anodized material at an appreciable rate so as to form pores as the material is formed so that anodization continues. If the electrolyte does not have this characteristic, only a thin anodic film will be formed and the pad area will not be raised sufficiently. 
     In general, acidic electrolytes form porous anodic films that will develop to a sufficient thickness as shown in FIG. 2 if the proper conditions of acid concentration, electrolyte temperature and anodizing current level are provided. Electrolytes made of boric, sulfuric, nitric and phosphoric acids proved to be particularly useful. Generally speaking, hydrofluoric acid was found to be too strong in that it attacks the oxide layer 26 too rapidly. 
     A phosphoric acid type of electrolyte is preferred since it provides for rapid anodization at room temperatures and the V/I curve for the anodization is smooth and does not contain any disruptions between the slow and fast anodization modes thereby making it easy to induce the rapid exothermic type anodization as discussed in the Scherrer application. 
     After anodization, aluminum 30 is deposited on the pad area to form the contact pads 22. 
     If plating is to be used to build up the raised contact pads, openings to the desired contact areas are formed in the typical glass passivation layer and thereafter a layer of aluminum 1000 to 2000 A thick is evaporated over the surface of the die. A mask is then formed and opened over the contact pad areas which are then plated with zinc for making good contact with the aluminum, nickel for getting the desired height and then tin for providing a good soldering surface. A layer of solder may also be added depending upon the type of bonding that is to be subsequently used. the total height of the pads should be 1 to 2 mils. After pad formation, the mask and evaporated aluminum layer are removed which may be accomplished by etching. 
     The integrated circuit die 20 is connected to a lead frame through the use of an intermediate interconnecting die 32 as shown in FIG. 4. A plurality of interconnecting dice 32 may be formed from a sheet 34 of anodizable material such as silicon as shown in FIG. 3. After the dice 32 are completely formed sheet 34 may be broken into the individual die 32 using standard techniques. Referring to FIGS. 4 and 5A-5D, sheet 34 is subjected to an oxidizing process to form a dielectric layer 36 in a manner similar to that described for forming the dielectric layer 26 shown in FIG. 2. Using conventional photo-resist and etching methods, portions of the dielectric layer 36 are removed from selected contact regions 38 which correspond in position to the contact pads 22 of the integrated circuit die 20. Sheet 34 is thereafter subjected to an anodizing process as previously described to form anodized silicon 40 in regions 38. Anodized silicon 40 is thereafter removed using a 10% solution of hydrofluroic acid so as to provide depressions in regions 38 as shown in FIG. 5C. The entire surface of sheet 34 is again oxidized to reform the dielectric layer 36. Portions 42, 44 and 46 of the dielectric layer 36 are removed using a photo-resist process to form openings as shown in FIGS. 4 and 6a. the sheet 34 is again subjected to an anodizing process to form anodized silicon 43 and 47 in regions 42, 44 and 46 as shown in FIG. 6b. It is to be noted that in the larger areas such as regions 46 a greater bulk of anodized silicon is formed that extends higher than the anodized silicon in the smaller areas 42. It is desirable that the anodized silicon in regions 46 be grown to a height slightly lower than the top of the leads which are to be positioned in regions 42. 
     Aluminum 48 is deposited on selected regions of sheet 34 to provide electrical contact between regions 38 and 42. Thus, the deposited aluminum lines the depressions 38 as shown in FIG. 5D and covers the anodized silicon 43 in regions 42. 
     At this point in the fabrication process, it may be desirable to scribe sheet 34 to separate the individual die; however, the scribing could take place after attaching the integrated circuit die 20 to the interconnecting die 32. 
     The integrated circuit die 20 is attached to the interconnecting die 32 as shown in FIGS. 7 and 8. Die 20 is guided into position by raised portions 44 so that the raised contact pads 22 mate with the depression 38 on the interconnecting die. Thermo compression bonding may be used to permanently connect the contact pads 22 to regions 38 if the aluminum coated pads of Scherrer are used, or bonding may be by soldering or brazing in a chain furnace if plated pads are used. 
     A glass frit 50 is applied over the integrated circuit die 20 in the surrounding area of the die 32 and is thereafter fired to provide a hermetic seal equivalent to that of a ceramic package. 
     Referring to FIG. 9, there is shown how a standard lead frame having leads 52 formed of Kovar aluminum is positioned over the interconnecting die 32. The leads 52 are guided into position to contact regions 42 by the anodized silicon material 47 in regions 46 as clearly shown in FIG. 10. The leads 52 of the lead frame are then bonded to regions 42 of the interconnecting die 32 by any of the accepted bonding methods such as thermo-compression soldering or welding. The assembly is ready for encapsulation in a package 54 which is preferably formed of epoxy molded to a standard form factor as shown in FIG. 11. The epoxy provides additional strength to the package to complement the excellent hermeticity of the glass seal. 
     In a second and preferred embodiment of the present invention the interconnecting die is formed of aluminum rather than silicon. Aluminum is preferred since it reduces the cost to about 1/2 of the cost of the silicon die. An aluminum sheet 12 inches square and having a thickness of 12 mils may be used to form about 7,200 interconnecting dice. The interconnecting dice are formed on a sheet of aluminum in a manner similar to that shown in FIG. 3 so that the individual die may later be separated by standard techniques such as scribing and braking or by sawing. 
     Referring to FIG. 12, there is shown an aluminum interconnecting die 56 which represents a portion of a sheet of aluminum as shown in FIG. 3. 
     Interconnecting die 56 is masked using a Vapox layer and a photo-resist to provide masking over regions 60 that are to ultimately be conducting regions. The Vapox layer is used because it stands up better during subsequent anodization. A preferred photo-resist for aluminum is XP-7310 which has a high J and is sold by Shipley of Nutley, N.J. After regions 60 are masked, the aluminum sheet is anodized in a manner similar to that previously described using an acidic electrolyte containing sulfuric, phosphoric, oxalic or chromic acid. The preferred electrolyte contains 660 milliliters of sulfuric acid, 56 grams of oxalic acid crystal and 4,228 mililiters of deionized water. The electrolyte temperature is preferably 0 to 10° C and the applied potential is between 10 to 50 volts pulsed at about 30 Hz with a 10 percent duty cycle to provide a current density of about 600 milliamps average per square inch. 
     The applied voltage and current density may be varied considerably and the highest rate of anodization is preferred provided breakdown of the Vapox does not occur. 
     Anodization is continued at a controlled rate until approximately 6 mils of anodized aluminum 58 is developed. 
     Referring to FIGS. 13 and 14, there is shown how the anodized aluminum 58 extends above the unanodized surface 60 of the aluminum 62 of sheet 56. Die 56 is again masked so that only a central portion 64 is exposed as shown in FIG. 15. Portion 64 corresponds in shape to and is a little larger in size than the integrated circuit chip 20 which is to be mounted on die 56. The anodized aluminum in central portion 64 is partially removed using a hydrofluroic acid zinc sulfate solution in a plating bath which acts to both etch the anodized aluminum and plate zinc to aluminum surfaces 60. 
     The preferred solution contains approximately 30 ounces of zinc sulfate crystals (Z n  SO y  . 7H 2  O) per gallon of deionized water and 3.5 percent by volume of 18 percent hydrofluoric acid. Plating could be electroless but the application of a potential is preferred since it speeds up the process and allows for the use of a more dilute solution. The plating and etching are continued till about 1 mil of anodized aluminum remains above surface 60. After removal of a portion of the anodized aluminum and the simultaneous zinc plating the central portion 64 is depressed as shown in FIG. 16 having a level surface 65 and side walls 59. Surface 65 of anodized aluminum is provided for supporting the integrated circuit die 20 when it is mounted in the interconnecting die 56 and a layer 66 of zinc is provided on the aluminum surfaces 60 within portion 65. As is most clearly shown in FIG. 16, layer 66 is at a lower level than the surface 65 thereby forming depressions in the surface for receiving the raised contact pads of the die 20 and providing for alignment of the die 20 on the interconnecting die 56. Depending upon the type of bonding to be used additional plating steps may be desired to add a layer of tin or nickel and tin on layer 66. 
     The interconnecting die 56 is now sufficiently prepared for mounting of the integrated circuit die 20 as shown in FIG. 16B. The integrated circuit die 20 is roughly guided by the side walls 59 of anodized aluminum 58 so that it slides into central portion 64 and the raised contact pads 22 of the primary die 20 mate with the depressions formed by portions of layer 66 in central portion 64 of the of the interconnecting die. The contact pads 22 are bonded to layer 66 using standard bonding techniques such as brazing or soldering in a chain furnace and thereafter the integrated circuit die and the surrounding area of the interconnecting die are glazed with a glass frit 70 and fired to provide a heremetic seal for the integrated circuit. 
     At this point in the manufacturing process, the alluminum sheet must be divided to form individual interconnecting dice 56 if this was not done prior to mounting the circuit die 20. A lead frame having leads 72 is positioned so that leads 72 are guided to positions over aluminum contact areas 68 of die 56 as shown in FIGS. 17 and 18A. The leads 72 are guided into position by the anodized aluminum 58 as shown in FIG. 18A and are thereafter bonded to the aluminum contact areas 68 using a welding technique wherein the Kovar lead is welded to the aluminum. Nickel could be plated to the alumunum prior to welding if desired. 
     The interconnecting die may be then further anodized to provide anodized aluminum on the reverse side of the die. Anodization would be continued until the unanodized aluminum 62 in conducting regions 60 are isolated by anodized aluminum 58 as shown in FIGS. 16C and 18B. 
     Preferably, the aluminum on the reverse side is removed by etching in a mixture of Hydrochloric acid and Hydrogen Peroxide until sufficient aluminum is removed so that the aluminum 62 in conducting regions 60 is isolated as shown in FIGS. 16D and 18C. 
     The completed device is then encapsulated in an integrated circuit package 54 is shown in FIG. 11 preferably by molding epoxy about the device. 
     Thus, the present invention provides a self-aligning package for integrated circuits that is substantially lower in cost than those of the prior art. The package provides the hemeticity of a ceramic package by using a glass seal and additional strength is provided by the epoxy encapsulation. The use of an interconnecting die also provides a substantial heat sink so that high power dissipation may be tolerated. The fabrication of the device may be completely automated through the unique use of guides formed of anodized material for both the integrated circuit die and the lead frame.