Method for fabricating an integrated circuit module
First Claim
1. A method of fabricating an integrated circuit module substrate on a base, comprising the steps of:
- applying an insulative base sheet over said base, said base sheet comprising a polymer film having an adhesive coating situated on the side of the polymer film opposite said base;
placing a plurality of chips having contact pads face down on said base sheet;
positioning a mold form around said chips;
adding substrate molding material within said mold form;
hardening said substrate molding material;
separating said base from said base sheet;
forming a plurality of vias through said base sheet, some of said plurality of vias being aligned with predetermined ones of said contact pads; and
providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said base sheet to form an integrated circuit module.
3 Assignments
0 Petitions
Accused Products
Abstract
Substrate material is molded directly to semiconductor chips and other electrical components that are positioned for integrated circuit module fabrication. Chips having contact pads are placed face down on a layer of adhesive supported by a base. A mold form is positioned around the chips. Substrate molding material is added within the mold form, and the substrate molding material is then hardened. A dielectric layer having vias aligned with predetermined ones of the contact pads and having an electrical conductor extending through the vias is situated on the hardened substrate molding material and the faces of the chips. A thermal plug may be affixed to the backside of a chip before substrate molding material is added. A connector frame may be placed on the adhesive layer before substrate molding material is added. A dielectric layer may be placed over the backsides of the chips before the substrate molding material is added to enhance repairability. A portion of the chips and substrate molding material may be removed after the substrate molding material is hardened.
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Citations
46 Claims
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1. A method of fabricating an integrated circuit module substrate on a base, comprising the steps of:
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applying an insulative base sheet over said base, said base sheet comprising a polymer film having an adhesive coating situated on the side of the polymer film opposite said base; placing a plurality of chips having contact pads face down on said base sheet; positioning a mold form around said chips; adding substrate molding material within said mold form; hardening said substrate molding material; separating said base from said base sheet; forming a plurality of vias through said base sheet, some of said plurality of vias being aligned with predetermined ones of said contact pads; and providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said base sheet to form an integrated circuit module. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method of fabricating an integrated circuit module substrate on a base, comprising the steps of:
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applying an insulative base sheet over said base, said base sheet comprising a polymer film having an adhesive coating situated on the side of the polymer film opposite said base; placing a plurality of chips having contact pads face down on said base sheet; positioning a mold form around said chips; adding substrate molding material within said mold form; hardening said substrate molding material; separating said substrate molding material and said chips from said base sheet and base; applying a dielectric layer over said chips and said substrate molding material; forming a plurality of vias through said dielectric layer, some of said plurality of vias being aligned with predetermined ones of said contact pads; and providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said dielectric layer to form an integrated circuit module. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32)
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33. A method of fabricating an integrated circuit module substrate on a base, comprising the steps of:
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applying an insulative base sheet over said base, said base sheet comprising an adhesive layer; placing a plurality of chips having contact pads face down on said base sheet; positioning a mold form around said chips; adding substrate molding material within said mold form; hardening said substrate molding material; separating said substrate molding material and said adhesive layer from said base; applying a dielectric layer over said adhesive layer; forming a plurality of vias through said dielectric layer, some of said plurality of vias being aligned with predetermined ones of said contact pads; and providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said dielectric layer to form an integrated circuit module. - View Dependent Claims (34, 35, 36, 37, 38, 39)
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40. A method of fabricating an integrated circuit module substrate on a base, comprising the steps of:
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applying an insulative base sheet over said base, said base sheet comprising a polymer film having an adhesive coating situated on the side of the polymer film opposite said base; placing a chip having contact pads face down on said base sheet; positioning a mold form around said chip; adding substrate molding material within said mold form; hardening said substrate molding material; separating said base sheet from said base; forming a plurality of vias through said base sheet, some of said plurality of vias being aligned with predetermined ones of said contact pads; and providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said base sheet.
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41. A method of fabricating an integrated circuit module substrate, comprising the steps of:
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placing a plurality of chips having contact pads face down on a vacuum plate; applying a continuous vacuum to said vacuum plate; positioning a mold form around said chips; adding substrate molding material within said mold form; hardening said substrate molding material; separating said substrate molding material and said chips from said vacuum plate; applying a dielectric layer over said chips and said substrate molding material; forming a plurality of vias through said dielectric layer, some of said plurality of vias being aligned with predetermined ones of said contact pads; and providing a pattern of electrical conductors extending through selected ones of said plurality of vias in said dielectric layer to form an integrated circuit module. - View Dependent Claims (42, 43, 44, 45, 46)
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Specification