Method of making a semiconductor chip assembly with a post/dielectric/post heat spreader
First Claim
1. A method of making a semiconductor chip assembly, comprising:
- providing a first post, a second post, a first adhesive, a second adhesive, a first conductive layer, a second conductive layer and a dielectric base, whereinthe first post extends vertically from the dielectric base in a first vertical direction, extends into a first opening in the first adhesive and is aligned with a first aperture in the first conductive layer,the second post extends vertically from the dielectric base in a second vertical direction opposite the first vertical direction, extends into a second opening in the second adhesive and is aligned with a second aperture in the second conductive layer,the first adhesive contacts the dielectric base, is sandwiched between the dielectric base and the first conductive layer, extends vertically beyond the dielectric base in the first vertical direction and is non-solidified,the second adhesive contacts the dielectric base, is sandwiched between the dielectric base and the second conductive layer, extends vertically beyond the dielectric base in the second vertical direction and is non-solidified,the first conductive layer extends vertically beyond the first adhesive in the first vertical direction,the second conductive layer extends vertically beyond the second adhesive in the second vertical direction, andthe dielectric base is a thermally conductive, electrically insulative material that contacts and is sandwiched between and thermally connects and electrically isolates and mechanically attaches the posts, covers the first post in the second vertical direction, covers the second post in the first vertical direction and extends laterally from the posts in lateral directions orthogonal to the vertical directions;
thenflowing the first adhesive in the first vertical direction into a first gap located in the first aperture between the first post and the first conductive layer;
flowing the second adhesive in the second vertical direction into a second gap located in the second aperture between the second post and the second conductive layer;
solidifying the adhesives, thereby mechanically attaching the first conductive layer to the first post and the dielectric base using the first adhesive and mechanically attaching the second conductive layer to the second post and the dielectric base using the second adhesive;
thenproviding a conductive trace that includes a pad, a terminal and an electrical interconnect, wherein the pad extends vertically beyond the dielectric base in the first vertical direction and includes a selected portion of the first conductive layer, the terminal extends vertically beyond the dielectric base in the second vertical direction and includes a selected portion of the second conductive layer and the electrical interconnect extends through the dielectric base and the adhesives in an electrically conductive path between the pad and the terminal;
providing a heat spreader that includes the posts and the dielectric base;
thenmounting a semiconductor device on the first post, wherein the semiconductor device extends vertically beyond the first post in the first vertical direction and extends laterally within peripheries of the posts and the posts are electrically isolated from one another;
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 first post, thereby thermally connecting the semiconductor device to the second post.
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Accused Products
Abstract
A method of making a semiconductor chip assembly includes providing first and second posts, first and second adhesives, first and second conductive layers and a dielectric base, wherein the first post extends from the dielectric base in a first vertical direction into a first opening in the first adhesive and is aligned with a first aperture in the first conductive layer, the second post extends from the dielectric base in a second vertical direction into a second opening in the second adhesive and is aligned with a second aperture in the second conductive layer and the dielectric base is sandwiched between and extends laterally from the posts, then flowing the first adhesive in the first vertical direction and the second adhesive in the second vertical direction, solidifying the adhesives, then providing a conductive trace that includes a pad, a terminal and selected portions of the conductive layers, wherein the pad extends beyond the dielectric base in the first vertical direction and the terminal extends beyond the dielectric base in the second vertical direction, providing a heat spreader that includes the posts and the dielectric base, then mounting a semiconductor device on the first post, electrically connecting the semiconductor device to the conductive trace and thermally connecting the semiconductor device to the heat spreader.
81 Citations
40 Claims
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1. A method of making a semiconductor chip assembly, comprising:
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providing a first post, a second post, a first adhesive, a second adhesive, a first conductive layer, a second conductive layer and a dielectric base, wherein the first post extends vertically from the dielectric base in a first vertical direction, extends into a first opening in the first adhesive and is aligned with a first aperture in the first conductive layer, the second post extends vertically from the dielectric base in a second vertical direction opposite the first vertical direction, extends into a second opening in the second adhesive and is aligned with a second aperture in the second conductive layer, the first adhesive contacts the dielectric base, is sandwiched between the dielectric base and the first conductive layer, extends vertically beyond the dielectric base in the first vertical direction and is non-solidified, the second adhesive contacts the dielectric base, is sandwiched between the dielectric base and the second conductive layer, extends vertically beyond the dielectric base in the second vertical direction and is non-solidified, the first conductive layer extends vertically beyond the first adhesive in the first vertical direction, the second conductive layer extends vertically beyond the second adhesive in the second vertical direction, and the dielectric base is a thermally conductive, electrically insulative material that contacts and is sandwiched between and thermally connects and electrically isolates and mechanically attaches the posts, covers the first post in the second vertical direction, covers the second post in the first vertical direction and extends laterally from the posts in lateral directions orthogonal to the vertical directions;
thenflowing the first adhesive in the first vertical direction into a first gap located in the first aperture between the first post and the first conductive layer; flowing the second adhesive in the second vertical direction into a second gap located in the second aperture between the second post and the second conductive layer; solidifying the adhesives, thereby mechanically attaching the first conductive layer to the first post and the dielectric base using the first adhesive and mechanically attaching the second conductive layer to the second post and the dielectric base using the second adhesive;
thenproviding a conductive trace that includes a pad, a terminal and an electrical interconnect, wherein the pad extends vertically beyond the dielectric base in the first vertical direction and includes a selected portion of the first conductive layer, the terminal extends vertically beyond the dielectric base in the second vertical direction and includes a selected portion of the second conductive layer and the electrical interconnect extends through the dielectric base and the adhesives in an electrically conductive path between the pad and the terminal; providing a heat spreader that includes the posts and the dielectric base;
thenmounting a semiconductor device on the first post, wherein the semiconductor device extends vertically beyond the first post in the first vertical direction and extends laterally within peripheries of the posts and the posts are electrically isolated from one another; 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 first post, thereby thermally connecting the semiconductor device to the second post. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of making a semiconductor chip assembly, comprising:
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providing a first post, a second post, a first adhesive, a second adhesive, a first conductive layer, a second conductive layer and a dielectric base, wherein the first post extends vertically from the dielectric base in a first vertical direction, extends into a first opening in the first adhesive and is aligned with a first aperture in the first conductive layer, the second post extends vertically from the dielectric base in a second vertical direction opposite the first vertical direction, extends into a second opening in the second adhesive and is aligned with a second aperture in the second conductive layer, the first adhesive contacts the dielectric base, is sandwiched between the dielectric base and the first conductive layer, extends vertically beyond the dielectric base in the first vertical direction and is non-solidified, the second adhesive contacts the dielectric base, is sandwiched between the dielectric base and the second conductive layer, extends vertically beyond the dielectric base in the second vertical direction and is non-solidified, the first conductive layer extends vertically beyond the first adhesive in the first vertical direction, the second conductive layer extends vertically beyond the second adhesive in the second vertical direction, and the dielectric base is a thermally conductive, electrically insulative material that contacts and is sandwiched between and thermally connects and electrically isolates and mechanically attaches the posts, covers the first post in the second vertical direction, covers the second post in the first vertical direction and extends laterally from the posts in lateral directions orthogonal to the vertical directions;
thenapplying heat to melt the adhesives; moving the conductive layers towards one another, thereby moving the first post in the first vertical direction in the first aperture, moving the second post in the second vertical direction in the second aperture, applying pressure to the molten first adhesive between the dielectric base and the first conductive layer and applying pressure to the molten second adhesive between the dielectric base and the second conductive layer, wherein the pressure between the dielectric base and the first conductive layer forces the molten first adhesive to flow in the first vertical direction into a first gap located in the first aperture between the first post and the first conductive layer and the pressure between the dielectric base and the second conductive layer forces the molten second adhesive to flow in the second vertical direction into a second gap located in the second aperture between the second post and the second conductive layer; applying heat to solidify the molten adhesives, thereby mechanically attaching the first conductive layer to the first post and the dielectric base using the first adhesive and mechanically attaching the second conductive layer to the second post and the dielectric base using the second adhesive;
thenproviding a conductive trace that includes a pad, a terminal and an electrical interconnect, wherein the pad extends vertically beyond the first adhesive in the first vertical direction and includes a selected portion of the first conductive layer, the terminal extends vertically beyond the second adhesive in the second vertical direction and includes a selected portion of the second conductive layer and the electrical interconnect extends through the dielectric base and the adhesives in an electrically conductive path between the pad and the terminal; providing a heat spreader that includes the posts, the dielectric base, a first cap and a second cap, wherein the first cap is adjacent to the first post and the first adhesive, covers the first post in the first vertical direction, extends laterally from the first post, extends vertically beyond the first adhesive in the first vertical direction and includes a selected portion of the first conductive layer and the second cap is adjacent to the second post and the second adhesive, covers the second post in the second vertical direction, extends laterally from the second post, extends vertically beyond the second adhesive in the second vertical direction and includes a selected portion of the second conductive layer;
thenmounting a semiconductor device on the first cap, wherein the semiconductor device extends vertically beyond the first cap in the first vertical direction, extends laterally within peripheries of the posts and is located within peripheries of the caps, the first post is sandwiched between the first cap and the dielectric base, the second post is sandwiched between the second cap and the dielectric base, the posts are electrically isolated from one another and the caps are electrically isolated from one another; 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 first cap, thereby thermally connecting the semiconductor device to the second cap. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A method of making a semiconductor chip assembly, comprising:
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providing a first post, a second post, a first adhesive, a second adhesive, a first conductive layer, a second conductive layer and a dielectric base, wherein the first post extends vertically from the dielectric base in a first vertical direction, extends into a first opening in the first adhesive and is aligned with a first aperture in the first conductive layer, the second post extends vertically from the dielectric base in a second vertical direction opposite the first vertical direction, extends into a second opening in the second adhesive and is aligned with a second aperture in the second conductive layer, the first adhesive contacts the dielectric base, is sandwiched between the dielectric base and the first conductive layer, extends vertically beyond the dielectric base in the first vertical direction and is non-solidified, the second adhesive contacts the dielectric base, is sandwiched between the dielectric base and the second conductive layer, extends vertically beyond the dielectric base in the second vertical direction and is non-solidified, the first conductive layer extends vertically beyond the first adhesive in the first vertical direction, the second conductive layer extends vertically beyond the second adhesive in the second vertical direction, and the dielectric base is a thermally conductive, electrically insulative material that contacts and is sandwiched between and thermally connects and electrically isolates and mechanically attaches the posts, covers the first post in the second vertical direction, covers the second post in the first vertical direction and extends laterally from the posts in lateral directions orthogonal to the vertical directions;
thenapplying heat to melt the adhesives; moving the conductive layers towards one another, thereby moving the first post in the first vertical direction in the first aperture, moving the second post in the second vertical direction in the second aperture, applying pressure to the molten first adhesive between the dielectric base and the first conductive layer and applying pressure to the molten second adhesive between the dielectric base and the second conductive layer, wherein the pressure between the dielectric base and the first conductive layer forces the molten first adhesive to flow in the first vertical direction into a first gap located in the first aperture between the first post and the first conductive layer and the pressure between the dielectric base and the second conductive layer forces the molten second adhesive to flow in the second vertical direction into a second gap located in the second aperture between the second post and the second conductive layer; applying heat to solidify the molten adhesives, thereby mechanically attaching the first conductive layer to the first post and the dielectric base using the first adhesive and mechanically attaching the second conductive layer to the second post and the dielectric base using the second adhesive;
thenproviding first and second plated through-holes that extend through the dielectric base, the adhesives and the conductive layers;
thenproviding a conductive trace that includes a pad, a first terminal and the first plated through-hole, wherein the pad extends vertically beyond the first adhesive in the first vertical direction and includes a selected portion of the first conductive layer, the first terminal extends vertically beyond the second adhesive in the second vertical direction and includes a selected portion of the second conductive layer and the first plated through-hole is in an electrically conductive path between the pad and the first terminal; providing a heat spreader that includes the posts, the dielectric base, a first cap and a second cap, wherein the first cap is adjacent to the first post and the first adhesive, covers the first post in the first vertical direction, extends laterally from the first post, extends vertically beyond the first adhesive in the first vertical direction and includes a selected portion of the first conductive layer, the second cap is adjacent to the second post and the second adhesive, covers the second post in the second vertical direction, extends laterally from the second post, extends vertically beyond the second adhesive in the second vertical direction and includes a selected portion of the second conductive layer and the second plated through-hole is in an electrically conductive path between the first cap and a second terminal; providing the pad and the first cap including removing selected portions of the first conductive layer; providing the terminals and the second cap including removing selected portions of the second conductive layer;
thenmounting a semiconductor device on the first cap, wherein the semiconductor device extends vertically beyond the first cap in the first vertical direction, extends laterally within peripheries of the posts and is located within peripheries of the caps, the first post is sandwiched between the first cap and the dielectric base, the second post is sandwiched between the second cap and the dielectric base, the posts are electrically isolated from one another, the caps are electrically isolated from one another and the terminals are electrically isolated from one another; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the first terminal; electrically connecting the semiconductor device to the first cap, thereby electrically connecting the semiconductor device to the second terminal; and thermally connecting the semiconductor device to the first cap, thereby thermally connecting the semiconductor device to the second cap. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39, 40)
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Specification