Patent ID: 7736950
Filing Date: 2010-06-15
Classification: H01L

Abstract:
1. A method for forming flip chip interconnection between a semiconductor die and a substrate, comprising: mounting the substrate to a carrier, the substrate having a plurality of interconnect sites on conductive traces formed on a die attach surface of the substrate; forming a plurality of bumps on an active surface of the semiconductor die, the bumps containing fusible material; mounting a backside of the semiconductor die, opposite the active surface, to a thermode placement tool which generates thermal energy under control of a temperature controller; depositing a resin material between the semiconductor die and substrate sufficient to cover the interconnect sites; aligning the bumps of the semiconductor die to the interconnect sites of the substrate; bringing the bumps into contact with the resin material; applying a force with the thermode placement tool to bring the bumps into contact with the interconnect sites, the force being sufficient to displace the resin material and deform the bumps against the interconnect sites; after deforming the bumps against the interconnect sites using the force of the thermode placement tool, employing the thermode placement tool to heat the semiconductor die and bring the resin material to a gel stage; selecting a first temperature of the thermode placement tool to partially cure without completely curing the resin material and stabilize the semiconductor die to the substrate; after partially curing the resin material, removing the force applied to the semiconductor die; after removing the force applied to the semiconductor die, heating an entirety of the fusible material of the bumps to a molten state using the thermal energy from the thermode placement tool, wherein the partially cured resin material prevents flow of the fusible material to adjacent interconnect sites and conductive traces; re-solidifying the fusible material to form metallurgical bond between the bumps and interconnect sites; and after re-solidifying the fusible material, substantially curing the resin material.