METHOD OF MAKING A SEMICONDUCTOR CHIP ASSEMBLY WITH A BUMP/BASE HEAT SPREADER AND A DUAL-ANGLE CAVITY IN THE BUMP
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Abstract
A method of making a semiconductor chip assembly includes providing a bump and a ledge, wherein the bump includes first, second and third bent corners that shape a cavity, mounting an adhesive on the ledge including inserting the bump into an opening in the adhesive, mounting a conductive layer on the adhesive including aligning the bump with an aperture in the conductive layer, then flowing the adhesive between the bump and the conductive layer, solidifying the adhesive, then providing a conductive trace that includes a pad, a terminal and a selected portion of the ledge, providing a heat spreader that includes the bump, then mounting a semiconductor device on the bump within the cavity, electrically connecting the semiconductor device to the conductive trace and thermally connecting the semiconductor device to the heat spreader.
123 Citations
100 Claims
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1-65. -65. (canceled)
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66. A method of making a semiconductor chip assembly, comprising:
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providing a bump, a ledge, an adhesive and a conductive layer, wherein the bump includes first, second and third bent corners with the second bent corner between the first and third bent corners, the bump defines a cavity that faces in a first vertical direction, has an entrance at the ledge, is shaped by the first, second and third bent corners and has a first angle between the first and second bent corners and a second angle between the second and third bent corners and the bump is adjacent to and integral with the ledge at the first bent corner, is spaced from the ledge at the second and third bent corners, extends vertically from the ledge in a second vertical direction opposite the first vertical direction, extends into an opening in the adhesive and is aligned with an aperture in the conductive layer, the ledge extends laterally from the bump in lateral directions orthogonal to the vertical directions, the adhesive is mounted on the ledge, is sandwiched between the ledge and the conductive layer and is non-solidified, and the conductive layer is mounted on the adhesive;
thenflowing the adhesive in the second vertical direction into a gap located in the aperture between the bump and the conductive layer; solidifying the adhesive;
thenproviding a conductive trace that includes a pad, a terminal and a selected portion of the ledge that is spaced from the bump; providing a heat spreader that includes the bump and a flange, wherein the bump is adjacent to the flange at the first bent corner and the flange includes a selected portion of the ledge that is adjacent to and integral with and extends laterally from the bump;
thenmounting a semiconductor device on the bump, wherein the semiconductor device is located within the cavity, extends beyond the first bent corner in the second vertical direction but not the first vertical direction, extends beyond the second bent corner in the first and second vertical directions and extends beyond the third bent corner in the first vertical direction but not the second vertical direction and the bump provides a recessed die paddle and a reflector for the semiconductor device; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal; and thermally connecting the semiconductor device to the bump. - View Dependent Claims (67, 68, 69, 70, 71, 72, 73, 74, 75)
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76. A method of making a semiconductor chip assembly, comprising:
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providing a bump and a ledge, wherein the bump includes first, second and third bent corners with the second bent corner between the first and third bent corners, the bump defines a cavity that faces in a first vertical direction, has an entrance at the ledge, is shaped by the first, second and third bent corners and has a first angle between the first and second bent corners and a second angle between the second and third bent corners, the bump is adjacent to and integral with the ledge at the first bent corner, is spaced from the ledge at the second and third bent corners and extends vertically from the ledge in a second vertical direction opposite the first vertical direction and the ledge extends laterally from the bump in lateral directions orthogonal to the vertical directions; providing an adhesive, wherein an opening extends through the adhesive; providing a conductive layer, wherein an aperture extends through the conductive layer; mounting the adhesive on the ledge, wherein the bump extends into the opening; mounting the conductive layer on the adhesive, including aligning the bump with the aperture, wherein the adhesive is sandwiched between the ledge and the conductive layer and is non-solidified;
thenapplying heat to melt the adhesive; moving the ledge and the conductive layer towards one another, thereby moving the bump in the second vertical direction in the aperture and applying pressure to the molten adhesive between the ledge and the conductive layer, wherein the pressure forces the molten adhesive to flow in the second vertical direction into a gap located in the aperture between the bump and the conductive layer; applying heat to solidify the molten adhesive, thereby mechanically attaching the bump and the ledge to the conductive layer;
thenproviding a conductive trace that includes a pad, a terminal and selected portions of the ledge and the conductive layer that are spaced from the bump; providing a heat spreader that includes the bump, a base and a flange, wherein the bump is adjacent to the flange at the first bent corner and is spaced from the flange at the second and third bent corners, is adjacent to the base at the third bent corner and is spaced from the base at the first and second bent corners and extends vertically from the base in the first vertical direction, the base extends vertically from the bump in the second vertical direction and extends laterally from the bump and the flange includes a selected portion of the ledge that is adjacent to and integral with and extends laterally from the bump;
thenmounting a semiconductor device on the bump, wherein the semiconductor device is located within the cavity, extends beyond the first bent corner in the second vertical direction but not the first vertical direction, extends beyond the second bent corner in the first and second vertical directions and extends beyond the third bent corner in the first vertical direction but not the second vertical direction and the bump provides a recessed die paddle and a reflector for the semiconductor device; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal; and thermally connecting the semiconductor device to the bump, thereby thermally connecting the semiconductor device to the base. - View Dependent Claims (77, 78, 79, 80, 81, 82, 83, 84, 85)
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86. A method of making a semiconductor chip assembly, comprising:
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providing a bump, a ledge, an adhesive and a substrate, wherein the bump includes first, second and third bent corners, first and second sidewalls and a floor, the second bent corner is between the first and third bent corners, the first sidewall extends between the first and second bent corners, the second sidewall extends between the second and third bent corners and the floor is adjacent to the third bent corner, the bump defines a cavity that faces in a first vertical direction, has an entrance at the ledge, is shaped by the first, second and third bent corners, the first and second sidewalls and the floor and has a first angle relative to the floor at the first sidewall and a second angle relative to the floor at the second sidewall and the bump is adjacent to and integral with the ledge at the first bent corner, is spaced from the ledge at the second and third bent corners, extends vertically from the ledge in a second vertical direction opposite the first vertical direction, extends into an opening in the adhesive and is aligned with an aperture in the substrate, the ledge extends laterally from the bump in lateral directions orthogonal to the vertical directions, the adhesive is mounted on the ledge, is sandwiched between the ledge and the substrate and is non-solidified, and the substrate is mounted on the adhesive, wherein the substrate includes a conductive layer and a dielectric layer and the dielectric layer is sandwiched between the conductive layer and the adhesive;
thenflowing the adhesive in the second vertical direction into a gap located in the aperture between the bump and the conductive layer; solidifying the adhesive;
thenproviding a conductive trace that includes a pad, a terminal, a plated through-hole, a selected portion of the ledge that is adjacent to the plated through-hole and spaced from the bump and a selected portion of the conductive layer that is adjacent to the plated through-hole and spaced from the bump, wherein the plated through-hole is in an electrically conductive path between the pad and the terminal; providing a heat spreader that includes the bump, a base and a flange, wherein the bump is adjacent to the flange at the first bent corner and is spaced from the flange at the second and third bent corners, is adjacent to the base at the third bent corner and the floor and is spaced from the base at the first and second bent corners and extends vertically from the base in the first vertical direction, the base covers the bump in the second vertical direction, extends laterally from the bump and includes a selected portion of the conductive layer that is spaced from the conductive trace and the flange includes a selected portion of the ledge that is adjacent to and integral with and extends laterally from the bump;
thenmounting a semiconductor device on the bump, wherein the semiconductor device is located within the cavity, extends beyond the first bent corner in the second vertical direction but not the first vertical direction, extends beyond the second bent corner in the first and second vertical directions and extends beyond the third bent corner in the first vertical direction but not the second vertical direction and the bump provides a recessed die paddle and a reflector for the semiconductor device; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal; and thermally connecting the semiconductor device to the bump, thereby thermally connecting the semiconductor device to the base. - View Dependent Claims (87, 88, 89, 90, 91, 92, 93, 94, 95)
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96. A method of making a semiconductor chip assembly, comprising:
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providing a bump and a ledge, wherein the bump includes first, second and third bent corners, first and second sidewalls and a floor, the second bent corner is between the first and third bent corners, the first sidewall extends between the first and second bent corners, the second sidewall extends between the second and third bent corners and the floor is adjacent to the third bent corner, the bump defines a cavity that faces in a first vertical direction, has an entrance at the ledge, is shaped by the first, second and third bent corners, the first and second sidewalls and the floor and has a first angle relative to the floor at the first sidewall and a second angle relative to the floor at the second sidewall, the bump is adjacent to and integral with the ledge at the first bent corner, is spaced from the ledge at the second and third bent corners and extends vertically from the ledge in a second vertical direction opposite the first vertical direction and the ledge extends laterally from the bump in lateral directions orthogonal to the vertical directions; providing an adhesive, wherein an opening extends through the adhesive; providing a substrate that includes a conductive layer and a dielectric layer, wherein an aperture extends through the substrate; mounting the adhesive on the ledge, including inserting the bump into the opening, wherein the bump extends through the opening; mounting the substrate on the adhesive, including inserting the bump into the aperture, wherein the bump extends into the aperture, the adhesive is sandwiched between the ledge and the dielectric layer and is non-solidified and the dielectric layer is sandwiched between the conductive layer and the adhesive;
thenapplying heat to melt the adhesive; moving the ledge and the substrate towards one another, thereby moving the bump in the second vertical direction in the aperture and applying pressure to the molten adhesive between the ledge and the substrate, wherein the pressure forces the molten adhesive to flow in the second vertical direction into a gap located in the aperture between the bump and the substrate; applying heat to solidify the molten adhesive, thereby mechanically attaching the bump and the ledge to the substrate;
thenproviding a plated through-hole that extends through the ledge, the adhesive, the dielectric layer and the conductive layer;
thenproviding a pad, a terminal, a base and a flange; providing a conductive trace that includes the pad, the terminal, the plated through-hole, a selected portion of the ledge that is adjacent to the plated through-hole and spaced from the bump and a selected portion of the conductive layer that is adjacent to the plated through-hole and spaced from the bump, wherein the plated through-hole is in an electrically conductive path between the pad and the terminal; providing a heat spreader that includes the bump, the base and the flange, wherein the bump is adjacent to the flange at the first bent corner and is spaced from the flange at the second and third bent corners, is adjacent to the base at the third bent corner and the floor and is spaced from the base at the first and second bent corners and extends vertically from the base in the first vertical direction, the base covers the bump in the second vertical direction, extends laterally from the bump in the lateral directions and includes a selected portion of the conductive layer that is spaced from the conductive trace and the flange includes a selected portion of the ledge that is adjacent to and integral with and extends laterally from the bump;
thenmounting a semiconductor device on the bump, wherein the semiconductor device is located within the cavity, extends beyond the first bent corner in the second vertical direction but not the first vertical direction, extends beyond the second bent corner in the first and second vertical directions and extends beyond the third bent corner in the first vertical direction but not the second vertical direction and the bump provides a recessed die paddle and a reflector for the semiconductor device; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal; and thermally connecting the semiconductor device to the bump, thereby thermally connecting the semiconductor device to the base. - View Dependent Claims (97, 98, 99, 100)
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Specification