Abstract:
A semiconductor device package assembly which increases production efficiency of semiconductor devices by enabling the number of semiconductor device packages held by a carrier to be increased. A predetermined area of a first housing molded of white-colored resin, which holds a plurality of bent contacts, is covered by a second housing molded of black-colored resin, and a plurality of second housings are supported by a secondary molding carrier in high density. A linking portion of each contact and one or both of the first and second housings are integrated by insert molding.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to a semiconductor device package assembly, a semiconductor device assembly, and a method of manufacturing a semiconductor device. 
     Description of the Related Art 
     Conventionally, there has been known a method of manufacturing a light emitting device, in which a plurality of packages are collectively manufactured (see Japanese Laid-Open Patent Publication (Kokai) No. 2011-138849, Paragraphs 0067, and 0072 to 0078, FIGS. 1, and 7 to 10). This manufacturing method will be described with reference to  FIGS. 28 to 32 . Note that  FIGS. 28 to 32  correspond to FIGS. 1, and 7 to 10 in Japanese Laid-Open Patent Publication (Kokai) No. 2011-138849, respectively. However, reference numerals in the drawings of the publication are changed, and part of reference numerals are deleted. 
     First, as shown in  FIGS. 32A and 32B , white-colored second resin material is filled into a cavity formed between an upper mold  931   a  and a lower mold  931   b  to thereby integrally mold a second molded resin  906  and a conductor portion  904  (primary molding). As a result, the plurality of second molded resins  906  are arranged at equally-spaced intervals on one substrate  911  (see  FIG. 29 ). The second molded resins  906  are each held by one set of conductor portions  904   a  to  904   h  of the substrate  911  (see  FIGS. 30A and 31A ). Note that the substrate  911  has a plate-like shape, formed by blanking one metal thin plate, and is formed by a plurality of sets of conductor portions  904   a  to  904   f  serving as leads of a light emitting device  901 , and a carrier  915  which supports the plurality of sets of conductor portions  904   a  to  904   f . Further, the conductor portions  904   a  to  904   f  each horizontally extend. 
     Next, as shown in  FIGS. 32C and 32D , black-colored first resin material is filled into a cavity formed between an upper mold  941   a  and a lower mold  941   b  to thereby integrally form a first molded resin  905 , the second molded resin  906 , and the conductor portions  904  ( 904   a  to  904   h ) into one molded piece (secondary molding). As a result, a package  902  is formed. 
     Then, light emitting devices  903  are arranged on a bottom surface  902   c  of a recess  902   a  of the package  902 , and portions of the conductor portions  904   a  to  904   f  which are exposed on the bottom surface  902   c  of the recess  902   a  and electrode terminals of the light emitting devices  903  are electrically connected by wires  907 , respectively. 
     Next, seal material is injected into the recess  902   a  of the package  902 , and is cured to thereby form a sealing member (not shown). 
     Thereafter, the packages  902  are cut out of the substrate  911  on which the packages  902  are arranged. 
     Finally, the conductor portions  904   a  to  904   f  which are horizontally exposed from side surfaces  902   e  of each package  902  are bent from the side surfaces  902   e  along an underside surface (bottom surface)  902   f  of the package  902  to thereby form terminal portions for external connection. 
     The light emitting device  901  manufactured according to the above-described manufacturing method is used as a component e.g. of a display device (not shown). In this case, a plurality of light emitting devices  901  are arranged on a substrate, not shown, in a matrix, and are soldered to the substrate. Further, black-colored resin is poured around the light emitting devices  901  arranged on the substrate to form a black resin layer (not shown), and the resin layer covers the conductor portions  904   a  to  904   f  exposed on the side surfaces  902   e  of each light emitting device  901 , whereby high contrast is ensured. 
     In a case where the above-described light emitting device  901  does not have a sufficiently large height (length from an upper surface  902   d  of the package  902  to the terminal portions of the conductor portions  904   a  to  904   f  for external connection), when black-colored resin is poured around the light emitting devices  901  in the manufacturing of a display device, the resin may adhere to a surface of the sealing member of the light emitting devices  901 . 
     To avoid this problem, it is only necessary to increase the height of the light emitting device  901  by increasing the length of the conductor portions  904   a  to  904   f . However, if the height of the light emitting device  901  is increased, this increases the arrangement pitch of the packages  902  on the substrate  911 , whereby the packages  902  held by the substrate  911  are reduced in density, which reduces production efficiency of the light emitting device  901 . 
     SUMMARY OF THE INVENTION 
     The present invention has been made in view of these circumstances, and an object thereof is to increase production efficiency of a semiconductor device by making it possible to increase the number of semiconductor device packages held by a carrier. 
     To attain the above object, in a first aspect of the present invention, there is provided semiconductor device package assembly comprising a plurality of semiconductor device packages each including a plurality of contacts each bent into a predetermined shape, a first housing which is molded of light-colored resin and holds the plurality of contacts, and a second housing which is molded of dark-colored resin and covers a predetermined area of the first housing, and a carrier which supports the plurality of semiconductor device packages in high density, wherein the contacts each include a first connection portion to which a semiconductor element is connected, a second connection portion which is connected to a substrate, and a linking portion which link the first connection portion and the second connection portion, wherein the first connection portion is exposed in an accommodation cavity formed in an upper portion of the first housing, for accommodating semiconductor elements, wherein the second connection portion is exposed outward from respective lower portions of the first housing and the second housing, and wherein the linking portion and at least the first housing are integrated by insert molding. 
     Preferably, the contact has a smaller thickness dimension than a thickness dimension of the carrier. 
     Preferably, the linking portion extends in a direction of height of the first housing, and the first connection portion and the second connection portion extend in a direction orthogonal to the direction of the height of the first housing. 
     Preferably, the predetermined area is an outer peripheral surface of the first housing and an inner wall surface of the first housing. 
     More preferably, the linking portion is sandwiched between the first housing and the second housing. 
     To attain the above object, in a second aspect of the present invention, there is provided a semiconductor device assembly wherein each semiconductor element connected to the first connection portion in the semiconductor device package assembly in the accommodation cavity by transparent resin filled in the accommodation cavity. 
     Preferably, the semiconductor element is a light emitting diode. 
     To attain the above object, in a third aspect of the present invention, there is provided a method of manufacturing a semiconductor device including a plurality of contacts each bent into a predetermined shape, a first housing which is molded of light-colored resin and holds the plurality of contacts, and a second housing which is molded of dark-colored resin and covers a predetermined area of the first housing, wherein the contacts each include a first connection portion to which a semiconductor element is connected, a second connection portion which is connected to a substrate, and a linking portion which link the first connection portion and the second connection portion, wherein the first connection portion is exposed in an accommodation cavity formed in an upper portion of the first housing, for accommodating semiconductor elements, wherein the second connection portion is exposed outward from respective lower portions of the first housing and the second housing, and wherein the linking portion and at least the first housing are integrated by insert molding, the method comprising a primary molding step of molding the linking portion of each contact of the light-colored resin by insert molding and causing the first housing to hold the linking portion, a primary molding carrier-removing step of removing a primary molding carrier which supports the plurality of contacts after the primary molding step, a secondary molding step of accommodating the first housings in a plurality of housing accommodation holes formed in a secondary molding carrier, respectively, after the primary molding carrier-removing step, and insert-molding the first housings and protrusions of the secondary molding carrier each of which protrudes toward the first housing in each housing accommodation hole with the dark-colored resin to thereby mold the second housings each of which covers the predetermined area of the first housing and links the first housing and the protrusions, a semiconductor element-mounting step of accommodating the semiconductor elements in an accommodation cavity of each first housing and connecting the semiconductor elements to the first connection portions, respectively, after the secondary molding step, and filling transparent resin in the accommodation cavity, and a secondary molding carrier-removing step of removing the secondary molding carrier from the second housings after the semiconductor element-mounting step. 
     According to this invention, it is possible to increase production efficiency of a semiconductor device by making it possible to increase the number of semiconductor device packages held by a carrier. 
     The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a semiconductor device package assembly according to an embodiment of the present invention; 
         FIG. 2  is a side view of the semiconductor device package assembly shown in  FIG. 1 ; 
         FIG. 3  is an enlarged perspective view of part A of the semiconductor device package assembly shown in  FIG. 1 ; 
         FIG. 4  is a cross-sectional view taken along IV-IV of  FIG. 1 ; 
         FIG. 5  is a cross-sectional view taken along V-V of  FIG. 4 ; 
         FIG. 6  is a cross-sectional view taken along VI-VI of  FIG. 4 ; 
         FIG. 7  is a perspective view of contacts supported by a primary molding carrier; 
         FIG. 8  is a perspective view of contacts supported by the primary molding carrier, which are combined with the contacts shown in  FIG. 7 ; 
         FIG. 9  is a perspective view showing a state in which the contacts shown in  FIG. 7  and the contacts shown in  FIG. 8  are opposed to each other; 
         FIG. 10  is a perspective view of package intermediates each formed by integrating the contacts and a first housing by insert molding; 
         FIG. 11  is a side view of the package intermediates; 
         FIG. 12  is a cross-sectional view taken along XII-XII of  FIG. 11 ; 
         FIG. 13  is a perspective view of each package intermediate separated from the primary molding carrier appearing in  FIG. 10 ; 
         FIG. 14  is a front view of the package intermediate shown in  FIG. 13 ; 
         FIG. 15  is a plan view of the package intermediate shown in  FIG. 13 ; 
         FIG. 16  is a bottom view of the package intermediate shown in  FIG. 13 ; 
         FIG. 17  is a side view of the package intermediate shown in  FIG. 13 ; 
         FIG. 18  is a cross-sectional view of the package intermediate taken along XVIII-XVIII of  FIG. 14 ; 
         FIG. 19  is a perspective view showing a state before the package intermediates are accommodated in housing accommodation holes of a secondary molding carrier; 
         FIG. 20  is a perspective view showing a state in which the package intermediates are accommodated in the housing accommodation holes of the secondary molding carrier; 
         FIG. 21  is a plan view showing the state in which the package intermediates are accommodated in the housing accommodation holes of the secondary molding carrier; 
         FIG. 22  is an enlarged perspective view of part B in  FIG. 21 ; 
         FIG. 23  is a cross-sectional view taken along XXIII-XXIII of  FIG. 21 ; 
         FIG. 24  is a perspective view showing a state in which transparent resin is filled into cavities for accommodating semiconductor device packages after mounting light emitting diodes on each semiconductor device package shown in  FIG. 3 ; 
         FIG. 25  is a perspective view of a light emitting device removed from the secondary molding carrier appearing in  FIG. 24 ; 
         FIG. 26  is a perspective view showing a state in which the plurality of light emitting devices are mounted on a printed board; 
         FIG. 27  is a perspective view showing a state in which black-colored resin is filled around the plurality of light emitting devices shown in  FIG. 26 ; 
         FIG. 28  is a perspective view of a conventional light emitting device; 
         FIG. 29  is a plan view of an example of a package assembly during a process of manufacturing the conventional light emitting devices; 
         FIGS. 30A and 30B  are perspective views showing shapes of a bottom side of the package during the process for manufacturing the conventional light emitting device, in which  FIG. 30A  shows a shape at the time of completion of primary molding, and  FIG. 30B  shows a shape at the time of completion of secondary molding; 
         FIGS. 31A and 31B  are a perspective views showing shapes of an upper portion side of the package during the process of manufacturing the conventional light emitting device, in which  FIG. 31A  shows a shape at the time of completion of the primary molding, and  FIG. 31B  shows a shape at the time of completion of the secondary molding; and 
         FIGS. 32A to 32D  are cross-sectional views schematically showing the process of manufacturing the conventional light emitting device, in which  FIG. 32A  shows an example of molds for the primary molding,  FIG. 32B  shows the primary molding process,  FIG. 32C  shows an example of molds for the secondary molding, and  FIG. 32D  shows the secondary molding process. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention will now be described in detail with reference to the drawings showing preferred embodiments thereof. 
     Referring to  FIGS. 1 to 6 , a semiconductor device package assembly  80  according to an embodiment of the present invention comprises a plurality of semiconductor device packages  70 , and a secondary molding carrier  60 . 
     Each semiconductor device package  70  is formed by a plurality of contacts  10 , a first housing  20 , and a second housing  30 . 
     As shown in  FIG. 6 , each contact  10  includes a first connection portion  11 , a second connection portion  12 , and a linking portion  13 . For example, each contact  10  is silver-plated. The contact  10  has a thickness dimension (e.g. 0.15 mm) which is smaller than that (e.g. 0.2 mm) of the secondary molding carrier  60 , referred to hereinafter. Although the plurality of contacts  10  include six types of contacts  10  (see  FIGS. 7 and 8 ), these are mainly different from each other only in the shape of the first connection portion  11 , and hence description of the contact  10  on a type basis is omitted. 
     A light emitting diode (semiconductor device)  100  (see  FIG. 25 ) is mounted on the first connection portion  11 . The light emitting diode  100  is electrically connected to the first connection portion  11  by a bonding wire (not shown). The light emitting diode  100  includes three types, i.e. red, green, and blue light emitting diodes. The first connection portion  11  is exposed in an accommodation cavity  21 , referred to hereinafter. The second connection portion  12  is electrically connected to a printed board (substrate)  200  (see  FIG. 26 ) by soldering. The second connection portion  12  is exposed outward from respective lower portions of the first and second housings  20  and  30 . The linking portion  13  links the first connection portion  11  and the second connection portion  12 . 
     The linking portion  13  extends in a height direction H of the first housing  20 , and the first and second connection portions  11  and  12  extend in a direction C orthogonal to the height direction H. 
     The linking portion  13  is sandwiched between the first housing  20  and the second housing  30 . 
     As shown in  FIGS. 3, 4, 5, and 6 , the first housing  20  is casing-shaped, and defines a space therein (see  FIG. 18 ). Further, the first housing  20  has an upper portion formed with the accommodation cavity  21  for accommodating the light emitting diodes  100 . The first housing  20  is molded of light-colored resin, such as white resin. The second housing  30  covers an outer peripheral surface (predetermined area) of the first housing  20  and an inner wall surface (predetermined area) of the first housing  20 . The outer peripheral surface of the first housing  20  includes a front surface  20   a , a rear surface  20   b , and opposite side surfaces  20   c  of the first housing  20  (see  FIG. 15 ). The inner wall surface of the first housing  20  includes an inner peripheral surface  20   d  and a ceiling surface  20   e  of the first housing  20  (see  FIG. 18 ). The second housing  30  is molded of dark-colored resin, such as black resin. The contacts  10  are integrated with the first housing  20  and the second housing  30  by insert molding. 
     The secondary molding carrier  60  has housing accommodation holes  61  and protrusions  62 . Each housing accommodation hole  61  accommodates the first housing  20  and the second housing  30 . Each pair of opposed ones of the protrusions  62  support the second housing  30 . 
     The secondary molding carrier  60  is formed by blanking a metal plate. The secondary molding carrier  60  is not plated. 
     Next, a description will be given of a method of manufacturing a light emitting device (semiconductor device)  120 . 
     First, the plurality of contacts  10  shown in  FIGS. 7 and 8  are formed by blanking and bending a metal plate (not shown). At this time, the plurality of contacts  10  and a primary molding carrier  40  are integrally connected. The primary molding carrier  40  continues to the second connection portion  12  of each contact  10 . 
     Next, as shown in  FIG. 9 , the plurality of contacts  10  supported by the primary molding carrier  40  are arranged on a lower mold of a mold for primary molding (not shown), an upper mold is combined with the lower mold, and resin in a fluid state is filled in a cavity formed by the lower mold and the upper mold and is cured to thereby form the first housings  20  appearing in  FIGS. 10, 11, and 12  (primary molding process). One package intermediate  50  is formed by six contacts  10  and one first housing  20 . 
     Then, the primary molding carrier  40  supporting the contacts  10  of the package intermediates  50  is cut off (primary molding carrier-removing process). As a result, there are obtained the package intermediates  50  each in a single state shown in  FIGS. 13 to 18 . 
     Next, the process is shifted to a secondary molding process, and a plurality of package intermediates  50  are arrayed in a lower mold of a mold for secondary molding (not shown) (see  FIG. 19 ). 
     Thereafter, as shown in  FIG. 19 , the secondary molding carrier  60  is placed over the arrayed package intermediates  50  from above to accommodate the package intermediates  50  in the plurality of housing accommodation holes  61  of the secondary molding carrier  60 , respectively, as shown in  FIGS. 20, 21, 22, and 23 . 
     Next, an upper mold of the mold for secondary molding is combined with the lower mold, and black-colored resin in a fluid state is filled in a cavity formed by the lower mold and the upper mold and is cured to thereby form the second housings  30  appearing in  FIG. 4 . At this time, the outer peripheral surface and the inner wall surface of each first housing  20  is covered with the black-colored resin. The plurality of semiconductor device packages  70  (see  FIG. 3 ) which are supported by the secondary molding carrier  60  in high density are thus formed, and the secondary molding process is terminated. 
     By execution of the above-described processes, the semiconductor device package assembly  80  comprising the secondary molding carrier  60  and the plurality of semiconductor device packages  70  is completed (see  FIGS. 1 to 4 ). 
     Next, the light emitting diodes  100  (see  FIGS. 24 and 25 ) are connected to the first connection portions  11  exposed in the accommodation cavity  21  using a mounter, not shown, and transparent resin  110  in a fluid state is filled in the accommodation cavity  21 , and is cured to thereby seal the light emitting diodes  100  in the accommodation cavity  21 , as shown in  FIG. 24  (semiconductor element-mounting process). As a result, as shown in  FIG. 24 , an assembly of the light emitting devices  120  supported by the secondary molding carrier  60  is completed. 
     Finally, the light emitting devices  120  are each removed from the associated protrusions  62  of the secondary molding carrier  60  (secondary molding carrier-removing process). By execution of the above-described processes, the light emitting devices  120  each in a single state shown in  FIG. 25  are obtained. 
     Next, a description will be given of a method of manufacturing a display device  300  using the light emitting devices  120 . 
     First, as shown in  FIG. 26 , the light emitting devices  120  are arranged on the printed board  200  in a matrix, and are solder-mounted. 
     Then, as shown in  FIG. 27 , dark-colored resin, such as black resin, in fluid state is filled around the light emitting devices  120  arranged on the printed board  200 , and is cured to thereby form a black resin layer  210 . Each light emitting device  120  has a large height dimension, and hence an operation error causing unintended attachment of black-colored resin to upper surfaces of the light emitting devices  120  is less liable to occur. By forming the black resin layer  210 , it is possible to obtain high contrast when an image is displayed. 
     By execution of the above-described process, the display device  300  is completed. 
     The following advantageous effect is obtained by the present embodiment. 
     Since the plurality of contacts  10  each bent into a predetermined shape are supported by the first housing  20  (see  FIG. 12 ), and the second housings  30  each covering the first housing  20  are supported by the secondary molding carrier  60  on which the semiconductor device packages  70  can be arranged in high density (see  FIGS. 21 and 24 ) as described above, it is possible to manufacture the semiconductor device package  70  having a large height dimension, and in turn, the light emitting device  120  having a large height dimension, whereby it is possible to reduce an operation error in the manufacturing of the display device  300  (unintended attachment of black-colored resin to the upper surfaces of the light emitting devices  120 ), and further it is possible to mount the light emitting diodes  100  to the semiconductor device packages  70  arranged in high density. Therefore, it is possible to more efficiently manufacture the light emitting device  120  than the conventional technique (see  FIGS. 29 and 31B ) in which the conductor portions  904   a  to  904   f  are supported by the carrier  915  in a horizontally extending state, and the packages  902  are supported by the carrier  915  in low density. 
     Further, the dedicated carrier (secondary molding carrier  60 ) is employed for supporting the semiconductor device packages  70 , and hence it is possible to make the thickness dimension of each contact  10  smaller than that of the secondary molding carrier  60 . Therefore, it is possible to comply with complication of the shape of each contact, and ensure strength of the secondary molding carrier  60  which has effects on the operation of mounting the light emitting diodes  100  and the secondary molding operation. 
     Further, since the linking portion  13  of each contact  10  (contact  10  in a bent state) and the first housing  20  are integrated by insert molding, the linking portion  13  of each contact  10  is less liable to be removed from the first housing  20 , whereby the location accuracy of the second connection portion  12  is ensured. Therefore, during manufacturing of the display device  300 , when the light emitting devices  120  are mounted onto the printed board  200 , the light emitting devices  120  are hardly inclined with respect to the mounting surface of the printed board  200 , and hence the screen on the display device  300  is less liable to have unevenness. In the present embodiment, since the linking portion  13  of each contact  10  is sandwiched between the first housing  20  and the second housing  30 , the linking portion  13  of each contact  10  is further less liable to be removed from the first housing  20 . 
     Although in the above-described embodiment, the thickness dimension of each contact  10  is made smaller than that of the secondary molding carrier  60 , each contact  10  may be formed to have the same thickness dimension as the thickness dimension of the secondary molding carrier  60 , or may be formed to have a larger thickness dimension than the thickness dimension of the secondary molding carrier  60 . 
     Further, although in the present embodiment, the second housing  30  covers the outer peripheral surface of the first housing  20  and inner wall surface of the first housing  20 , the predetermined areas of the first housing  20  to be covered by the second housing  30  are not limited to these. 
     Although in the present embodiment, the linking portion  13  of each contact  10  is sandwiched between the first housing  20  and the second housing  30 , the linking portion  13  is not be necessarily required to be sandwiched between the first housing  20  and the second housing  30 . 
     Further, although in the present embodiment, the first housing  20  is molded of white-colored resin, and the second housing  30  is molded of black-colored resin, the color of first housing  20  is not limited to white, but is only required to be molded of light-colored resin, and the color of the second housing  30  is not limited to black, but is only required to be molded of dark-colored resin. 
     Note that the semiconductor element is not limited to the light emitting diode  100 . 
     It is further understood by those skilled in the art that the foregoing are the preferred embodiments of the present invention, and that various changes and modification may be made thereto without departing from the spirit and scope thereof.