MOLDING APPARATUS OF SEMICONDUCTOR PACKAGE

A molding apparatus for a semiconductor package includes a chamber including a lower mold configured to hold a substrate including a plurality of molding targets, an upper mold configured to move up and down with respect to the lower mold and define a cavity between the upper mold and the lower mold, and a port configured to provide a passage communicating with the cavity, a molding material supplier configured to supply a molding material to the port, a plunger configured to pressurize the molding material inside the port, a plunger actuator configured to apply a first pressure to the plunger such that the molding material provided in the port is supplied to the cavity, and a mold actuator configured to control actuation of the upper mold. The plunger actuator is configured to supply the molding material to the cavity by applying the first pressure to the plunger, and the mold actuator is configured to pressurize the molding material in the cavity by applying a second pressure to the upper mold. The mold apparatus further includes a controller configured to control the plunger actuator to reduce the first pressure applied to the plunger after the mold actuator begins applying the second pressure to the upper mold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 U.S.C. § 119 to Korean Patent Application Nos. 10-2022-0067701 filed on Jun. 2, 2022 and 10-2022-0100158 filed on Aug. 10, 2022, in the Korean Intellectual Property Office, the disclosures of which are incorporated by reference herein in their entireties.

BACKGROUND

Aspects of the inventive concept relate to a molding apparatus for a semiconductor package.

In order to prevent damage to a semiconductor chip due to external impact or light, a molding process of molding the semiconductor chip with a sealing resin, such as an epoxy molding compound (EMC), is performed. The recent trend of a semiconductor industry is to continuously achieve small, thin, lightweight, highly integrated and highly dense semiconductor products. Accordingly, the thickness of a semiconductor package is decreasing, and the thickness of the molding resin is also decreasing. As a result, using conventional molding techniques, undesired voids may be present in a completed product such as a semiconductor package. Example embodiments discussed herein address this issue and may help remove or decrease voids formed in a mold layer of a product.

SUMMARY

Aspects of the inventive concept provide a molding apparatus for a semiconductor package with a small thickness, reducing voids in a molding resin, and improving an unfilled molding resin, in relation to the apparatus for molding the semiconductor package.

According to an aspect of the inventive concept, a molding apparatus for a semiconductor package includes a chamber including a lower mold configured to hold a substrate including a plurality of molding targets, an upper mold configured to move up and down with respect to the lower mold and define a cavity between the upper mold and the lower mold, and a port configured to provide a passage communicating with the cavity, a molding material supplier configured to supply a molding material to the port, a plunger configured to pressurize the molding material inside the port, a plunger actuator configured to apply a first pressure to the plunger such that the molding material provided in the port is supplied to the cavity, and a mold actuator configured to control actuation of the upper mold. The plunger actuator is configured to supply the molding material to the cavity by applying the first pressure to the plunger, and the mold actuator is configured to pressurize the molding material in the cavity by applying a second pressure to the upper mold. The mold apparatus further includes a controller configured to control the plunger actuator to reduce the first pressure applied to the plunger after the mold actuator begins applying the second pressure to the upper mold.

According to another aspect of the inventive concept, a molding apparatus for a semiconductor package includes a cylindrical chamber including a lower mold configured to hold a substrate including a plurality of molding targets, and an upper mold configured to move up and down with respect to the lower mold and define a cavity between the upper mold and the lower mold, a first port formed on an inner sidewall of the chamber and configured to provide a passage communicating with the cavity, a second port formed in a top portion of the chamber and configured to provide a passage communicating with the cavity, a molding material supplier configured to supply a molding material to the second port, a plunger configured to pressurize the molding material inside the second port, a plunger actuator configured to apply a first pressure to the plunger such that the molding material provided in the second port is supplied to the cavity, and a mold actuator configured to control actuation of the upper mold. The plunger actuator is configured to supply the molding material to the cavity by applying the first pressure to the plunger, and the mold actuator is configured to pressurize the molding material in the cavity by applying a second pressure to the upper mold.

According to another aspect of the inventive concept, a molding apparatus for a semiconductor package includes a chamber including a lower mold configured to hold a substrate including a plurality of molding targets, and an upper mold configured to move and down with respect to the lower mold and define a cavity between the upper mold and the lower mold, a port formed on a sidewall of the chamber in a first direction, configured to provide a passage communicating with the cavity, and discharge a molding material to the cavity in a second direction perpendicular to the first direction, a molding material supplier configured to supply a molding material to the port, a plunger configured to pressurize the molding material inside the port, a plunger actuator configured to apply a first pressure to the plunger such that the molding material provided in the port is supplied to the cavity, and a mold actuator configured to control actuation of the upper mold. The plunger actuator is configured to supply the molding material to the cavity by applying a first pressure equal to or less than 5 MPa to the plunger, the mold actuator is configured to pressurize the molding material in the cavity by applying a second pressure higher than the first pressure to the upper mold. The molding apparatus further includes a controller configured to control the mold actuator to apply the first pressure to the plunger and apply the second pressure to the upper mold after the molding material molds the plurality of molding targets arranged at a farthest distance from the port, and to control the plunger actuator to reduce the first pressure applied to the plunger after the mold actuator begins applying the second pressure to the upper mold.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG.1is a perspective view schematically illustrating a molding apparatus10for a semiconductor package according to an embodiment.

Referring toFIG.1, a first direction (x direction) and a second direction (y direction) may cross each other among horizontal directions. For example, the first direction (x direction) and the second direction (y direction) may perpendicularly cross each other. A third direction (z direction) may cross both the first direction (x direction) and the second direction (y direction). For example, the third direction (z direction) may be perpendicularly orthogonal to the first direction (x direction) and the second direction (y direction). The third direction (z direction) may be a vertical direction. Accordingly, the first direction (x direction), the second direction (y direction), and the third direction (z direction) may be orthogonal to each other.

A quadrangular substrate230may include a plurality of molding targets250. Specifically, the plurality of molding targets250may be arranged on one surface of the substrate230at regular intervals. One surface of the substrate230may be a plane parallel to both the first direction (x direction) and the second direction (y direction). Terms such as “same,” “equal,” “planar,” “coplanar,” “parallel,” and “perpendicular,” as used herein encompass identicality or near identicality including variations that may occur, for example, due to manufacturing processes. The term “substantially” may be used herein to emphasize this meaning, unless the context or other statements indicate otherwise.

The substrate230may be a printed circuit board (PCB). For example, the substrate230may be a substrate in which an electronic circuit is configured by fixing electronic components, such as resistors, capacitors, and integrated circuits, to the surface of a printed wiring substrate, and connecting the electronic components to each other by a copper wiring.

According to an embodiment, although not shown, a wiring structure electrically connecting an upper surface of the substrate230to a lower surface of the substrate230may be inside the substrate230.

The molding target250may include electronic components, such as a semiconductor chip and a semiconductor package. For example, the molding targets250may be various semiconductor packages requiring molding, such as a Package On Package (POP) structure and an interposer-inserted POP (i-POP) structure.

A plurality of ports310may be arranged in the second direction (y direction) along the sidewall of a chamber (see100ofFIG.3). The ports310may be configured to discharge or supply a molding material in the first direction (x direction) perpendicular to the second direction through the sidewall of the chamber. For example, a hole in the sidewall of the chamber may be formed so that part of the sidewall is above the hole and part of the sidewall is below the hole. A detailed description of a process in which the port310discharges the molding material is given below. When the port supplying the molding material is disposed in the floor of the chamber100, the molding material is not smoothly supplied due to resistance of gravity, or greater energy is required for supplying the molding material. However, when the port for supplying the molding material is disposed on a part of the sidewall of the chamber100, the molding material can be uniformly and smoothly supplied toward the molding target due to the help of gravity. Ordinal numbers such as “first,” “second,” “third,” etc. may be used simply as labels of certain elements, steps, directions, etc., to distinguish such elements, steps, directions, etc. from one another. Terms that are not described using “first,” “second,” etc., in the specification, may still be referred to as “first” or “second” in a claim. In addition, a term that is referenced with a particular ordinal number (e.g., “first” in a particular claim) may be described elsewhere with a different ordinal number (e.g., “second” in the specification or another claim).

FIG.2is a perspective view schematically illustrating a molding apparatus20for a semiconductor package according to another embodiment.

Referring toFIG.2, a circular substrate240may include the plurality of molding targets250. Specifically, the plurality of molding targets250may be arranged on one surface of the substrate240at regular intervals. One surface of the substrate240may be a plane parallel to both the first direction (x direction) and the second direction (y direction).

The substrate240may be a disk, or wafer, formed by a single crystal pillar made by growing silicon (Si), gallium arsenide (GaAs), etc. being thinly sliced to a constant thickness.

The plurality of ports310may be disposed to be spaced apart from each other along the circumference of the circular substrate240. The ports310may be configured to discharge or supply molding materials toward the molding targets250arranged on one surface of the substrate240at regular intervals. The ports310may be configured to discharge or supply a molding material in a horizontal direction through the sidewall of the chamber. A detailed description of a process in which the ports310discharge molding materials is given below. An additional port320may also be formed at a center of the disk. A detailed description of this port320is given below.

A gas adjustor340may be disposed to face the port310(e.g., to be opposite the port310). The gas adjustor340may be configured to supply or discharge gas onto or away from the substrate240. A detailed description of a process in which the gas adjustor340supplies or discharges gas thereto is given below.

InFIG.2, the port310and the gas adjustor340are illustrated as being disposed two each, but the inventive concept is not limited thereto.

FIG.3is a cross-sectional view illustrating the molding apparatus10for a semiconductor package shown inFIG.1.

The molding apparatus10of the semiconductor package according to an embodiment includes a chamber100, an upper mold210, a lower mold220, the port310, a plunger312, a plunger actuator360, a molding material supplier410, a mold actuator630, and the gas adjustor340.

The chamber100may be a housing forming the exterior of the molding apparatus10for a semiconductor package of the inventive concept. The chamber100may include other components, such as the upper mold210or the lower mold220therein. The chamber100may be configured to isolate the inside and the outside, and when a molding process is performed inside the chamber100, the inside of the chamber100may be maintained in a vacuum unlike the outside. The chamber100may be a rectangular chamber in one embodiment, that matches the shape of the substrate230.

The chamber100may include an upper chamber110and a lower chamber120, also described as an upper housing and a lower housing. An upper mold210may be disposed in the upper chamber110, and a lower mold220may be disposed in the lower chamber120. The upper mold210may also be described as an upper mold plate, and the lower mold220may also be described as a lower mold plate. In a molding apparatus for a semiconductor package according to some embodiments, lower mold220may be fixed and the upper mold210may move up and down, or the upper mold210may be fixed and the lower mold220may move up and down, or both the upper mold210and the lower mold220may move up and down.

The lower mold220may be configured to fix and hold the substrate230including the plurality of molding targets250. For example, the lower mold220may include sidewalls, notches, or other devices to hold the substrate230in place. The lower mold220may define a cavity260between the lower mold220and the upper mold210with the molding targets250seated on the substrate230. The substrate may be fixed to the top surface of the lower mold220. This is described in more detail below.

The cavity260may be a space defined between the upper mold210and the lower mold220. The cavity260may be a space in which a molding material moves and is disposed on the plurality of molding targets250. According to some embodiments, the molding material is fluid when the temperature of the molding material increases, and thus, the molding material may be a mold film that fully fills the cavity260formed by the upper mold210and the lower mold220and is cured to cover the plurality of molding targets250.

The port310may provide a passage communicating with the cavity260formed between the upper chamber110and the lower chamber120. The port310may provide a flow path extending in the first direction (x direction) and the third direction (z direction). The plunger312may be located inside the port310, and may move up and down inside the port310. For example, the plunger312may elevate in the third direction (z direction) inside the port310. The plunger312may move up and down so that the molding material provided in the port310may flow. The plunger312may pressurize the molding material so that the molding material inside the port310is supplied to the cavity260through movement in the third direction (z direction) and first direction (x direction), and may perform molding on the plurality of molding targets250by using the molding material filled in the cavity260.

Referring toFIG.1together, the molding material supplier410may be configured to supply a molding material262to the port310. The molding material262may include epoxy mold compound (EMC), for example. However, the embodiments are not limited thereto. The molding material262may be, for example, a thermoplastic resin or a thermosetting resin. The resin, for example, may be made of any one of a granular resin, a powdery resin, a liquid resin, a plate-shaped resin, a sheet-shaped resin, a film-shaped resin, and a paste-shaped resin, or a combination thereof. In addition, the resin, for example, may be made of any one of a transparent resin, a translucent resin, and an opaque resin, or a combination thereof. The molding material262may be disposed in the port310in a solid state and may be liquefied when the temperature of the molding material262increases to be fluid. When the molding material262is fluid, the molding material262may be provided on the plurality of molding targets250by the plunger312, and then cured so that the plurality of molding targets250may be molded.

The plunger312may be configured to pressurize the molding material262inside the port310. Specifically, the plunger312may move up and down within the port310. The plunger312may move upward to push the molding material262into the cavity260. The plunger312may have almost the same size as that of the inner wall of the port310, but a gap may be between the outer surface of the plunger312and the inner wall of the port310.

Because air in the cavity260may leak through the gap, the plunger312may include a first ring314. The first ring314may be a ring made of a Teflon material, for example. The first ring314may completely block a space between the outer surface of the plunger312and the inner wall of the port310to prevent the air inside the cavity260from leaking.

Similar to the first ring314, a second ring316may also completely block the space between the outer surface of the plunger312and the inner wall of the port310to prevent the air inside the cavity260from leaking. The first ring314and the second ring316may maintain the vacuum of the cavity260by sealing between the port310and the plunger312. However, when the plunger312repeatedly moves up and down, a phenomenon may occur where the first ring314or the second ring316is worn, and undesired air flows into the cavity260through the gap between the plunger312and the port310.

The controller700may control the plunger actuator360and the mold actuator630. The controller700may be implemented in hardware, firmware, software, or any combination thereof. For example, the controller700may be a computer device, such as a workstation computer, a desktop computer, a laptop computer, or a tablet computer. For example, the controller700may include a memory device, such as read only memory (ROM) and random access memory (RAM), and a processor configured to perform certain operations and algorithms, for example, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), etc. The controller700may control the actions of the various devices described herein, such as the timing for exerting pressure, an amount of pressure, etc.

The plunger actuator360may be configured to apply a first pressure to the plunger312such that the molding material262provided in the port310is supplied to the cavity260. For example, the plunger actuator360may include a motor, a hydraulic cylinder, a pneumatic cylinder, etc. For example, the plunger actuator360may include a motor, and may control a pressure condition applied to the plunger312by adjusting a torque value of the motor. Alternatively, the plunger actuator360may control the pressure condition applied to the plunger312by inputting air into the port310. However, the embodiments are not necessarily limited to the above. A detailed description of a process in which the plunger actuator360applies the first pressure to the plunger312so that the molding material262is supplied to the cavity260is given below.

In addition, the controller700may adjust the rising speed of the plunger312in the port310. For example, the controller700may instantaneously cause high pressure to be applied to the plunger312in order to increase the flow rate of the molding material262in a specific part of the cavity260. To the contrary, in order to reduce the flow rate of the molding material262in a specific part of the cavity260, the controller700may instantaneously cause low pressure to be applied to the plunger312. It should be noted that one plunger and plunger actuator is described above, but the controller700may control the plurality of ports310, each including a plunger and plunger actuator as described above.

The mold actuator630may be configured to apply a second pressure to the upper mold210to pressurize the molding material262in the cavity260. For example, the mold actuator630may be connected to a driving motor620connected to a shaft610to control a pressure condition applied to the upper mold210by adjusting a torque value of the driving motor620, which thereby controls a movement pressure applied by the shaft610to the upper mold210. However, the embodiments are not necessarily limited to the above. A detailed description of a process in which the mold actuator630applies the second pressure to the upper mold210to mold the molding target250is given below.

The molding material supplier410may be connected to the port310. The molding material supplier410may supply the molding material262to the port310having a pipe shape. The molding material supplier410may include a molding material supply line412, a nozzle414, and a fluid supply pump416. The fluid supply pump416may supply the molding material262in a fluid state to the molding material supply line412. The nozzle414may be configured to adjust the flow rate of the molding material262in the fluid state supplied by the fluid supply pump416.

The gas adjustor340may be disposed on the sidewall of the chamber100to face the port310. The gas adjustor340may include a vent hole341, a sealing member342, a gas pipe343, a sensor344, a gas nozzle345, and a gas pump346. The sealing member342may be between the upper chamber110and the lower chamber120. The sealing member342may be disposed where the upper chamber110and the lower chamber120are engaged with each other. The sealing member342may perform sealing on a part where the lower chamber120and the upper chamber110are engaged with each other, except for the vent hole341. The volume of the sealing member342may increase or decrease according to a force applied thereto. The sealing member342may be configured to expand or contract according to the force applied thereto. Accordingly, the sealing member342may efficiently perform sealing and venting. The sealing member342may be, for example, a flexible rubber or plastic material that can expand and contract while maintaining a seal. For example the sealing member342may have an accordion-shaped configuration. Also, though only one vent hole341is shown, a plurality of vent holes341may be formed, and may be connected to a plurality of respective gas pipes343. In this case, a plurality of sensors344, gas nozzles345, and/or gas pumps346may also be used.

The vent hole341may be formed adjacent to the sealing member342(e.g., it may be a hole in the sealing member342). The vent hole341may be disposed between the upper chamber110and the lower chamber120, where the upper chamber110and the lower chamber120are engaged with each other. The vent hole341may be opposite the port310within the chamber100. The air in the cavity260may be removed through the vent hole341. For example, the vent hole341may be connected to the gas pump346to discharge the air inside the cavity260to the outside. The gas pipe343may serve as a connection passage between the vent hole341and the gas pump346. The gas nozzle345may be configured to adjust the flow rate of introduced or discharged gas through the gas pump346.

The sensor344may be connected to the vent hole341. The sensor344may detect whether the air in the cavity260leaks by sensing the pressure of the vent hole341. Accordingly, the sensor344may maintain the vacuum of the cavity260.

FIG.4is a cross-sectional view illustrating the molding apparatus20for a semiconductor package shown inFIG.2.

Specifically, the molding apparatus20for a semiconductor package may be substantially the same as the molding apparatus10for a semiconductor package ofFIGS.1and3except that the molding apparatus20for the semiconductor package includes the substrate240instead of the substrate230and further includes different arrangements of first ports310and includes a second port320and a second molding material supplier420. The same reference numerals as inFIGS.1and3denote the same members. InFIG.4, the same descriptions as those ofFIGS.1to3are briefly given or omitted.

The molding apparatus20of a semiconductor package according to an embodiment includes the chamber100, the upper mold210, the lower mold220, the first port310, the first plunger312, the second port320, a second plunger322, the plunger actuator360, the molding material supplier410, the mold actuator630, and the gas adjustor340. The chamber100may be a cylindrical chamber, for example, that matches the shape of the substrate240.

The lower mold220may be configured to fix and hold the substrate240including the plurality of molding targets250. Unlike the substrate230ofFIG.3, the substrate240may be in the form of a disk having a circular cross-section. The lower mold220may have sidewalls, notches, or other devices to hold the substrate240in place. The substrate240may be a semiconductor wafer, for example. The cavity260may be formed between the lower mold220and the upper mold210with the molding target250seated on the substrate240when the upper chamber110is coupled to the lower chamber120. This is described in more detail below.

The second port320may be formed on the upper portion of the chamber100(e.g., on a ceiling, or top surface, of the chamber) to provide a passage communicating with the cavity260. The second port320may be aligned in the third direction (z direction) at the center of the circular cross-section of the substrate240. The second port320may discharge the molding material262toward the substrate240. The second port320may provide the passage extending in the third direction (z direction). The second plunger322may be positioned inside the second port320, and the second plunger322may move up and down inside the second port320. As the second plunger322moves up and down, a molding material previously disposed on the second plunger322inside the second port320may be filled into the cavity260so that molding may be performed on the plurality of molding targets250.

The first port310may be formed between the upper chamber110and the lower chamber120, and thus may be formed in a sidewall of the chamber100, to provide a passage communicating with the cavity260. The first port310may provide the passage extending in the first direction (x direction) and the third direction (z direction). The first plunger312may be positioned inside the first port310, and the first plunger312may move up and down inside the first port310. The first plunger312may supply the molding material inside the first port310to the cavity260by moving up and down, and may perform molding on the plurality of molding targets250by using the molding material filled in the cavity260.

The controller700may control the plunger actuator360and the mold actuator630. The plunger actuator360may be configured to cause a first pressure to be applied to the first plunger312and the second plunger322so that the molding material262provided in the first port310and the second port320is supplied to the cavity260. For example, the plunger actuator360may be connected to a motor to control a pressure condition applied to the first plunger312and the second plunger322by adjusting a torque value of the motor. Alternatively, the plunger actuator360may control the pressure condition applied to the first plunger312and the second plunger322by inputting air into the first port310and the second port320. Accordingly, the plunger actuator360may be connected to both the first port310and the second port320. However, the embodiments are not necessarily limited to the above. A detailed description of a process in which the plunger actuator360applies the first pressure to the first plunger312and the second plunger322so that the molding material262is supplied to the cavity260is given below.

The plunger322may be configured to pressurize the molding material inside the second port320. Specifically, the plunger322may move up and down within the second port320. The plunger322may move downward to push the molding material into the cavity260. The plunger322may have almost the same size as that of the inner wall of the second port320, but a gap may be between the outer surface of the plunger322and the inner wall of the second port320.

The plunger actuator360may perform the steps described above in connection with the first plunger312, and may also control the second plunger322in a similar manner. Because air in the cavity260may leak through the gap between the second plunger322and the inner wall of the second port320, the second plunger322may include a first ring324. The first ring324may be a ring made of a Teflon material, for example. The first ring324may completely block a space between the outer surface of the second plunger322and the inner wall of the second port320to prevent the air inside the cavity260from leaking.

Similar to the first ring324, a second ring326may also completely block the space between the outer surface of the second plunger322and the inner wall of the second port320to prevent the air inside the cavity260from leaking. The first ring324and the second ring326may maintain the vacuum of the cavity260by sealing between the second port320and the second plunger322. However, when the second plunger322repeatedly moves up and down, a phenomenon may occur where the first ring324or the second ring326is worn, and undesired air flows into the cavity260through the gap between the second plunger322and the second port320.

FIG.5is a cross-sectional view illustrating a molding apparatus30for a semiconductor package according to another embodiment.

Specifically, the molding apparatus30for a semiconductor package may be substantially the same as the molding apparatus10ofFIGS.2and4except that the molding apparatus30ofFIG.5includes a second gas adjustor350(and may include a plurality of gas adjustors350arranged around the circumference of the chamber100), and does not include the ports310along the sidewalls of the chamber100. The same reference numerals as inFIGS.2and4denote the same members. InFIG.5, the same descriptions as those ofFIGS.2to4are briefly given or omitted.

The first gas adjustor340and the second gas adjustor350may be disposed on the sidewalls of the chamber100. The first gas adjustor340may include a first vent hole341, a first sealing member342, a first gas pipe343, a first sensor344, a first gas nozzle345, and a first gas pump346. The second gas adjustor350may include a second vent hole351, a second sealing member352, a second gas pipe343, a second sensor354, a second gas nozzle355, and a second gas pump356. The second gas adjustor350may be configured to perform the same function as the first gas adjustor340.

According to an embodiment, the molding apparatus30for a semiconductor package may include only the second port320vertically spaced apart from the center of the circular cross-section of a substrate, differently from the molding apparatus20of the semiconductor package shown inFIG.4. That is, the molding apparatus30of a semiconductor package may not include the first ports310(seeFIG.4) formed on the inner sidewall of a chamber.

FIGS.6A to6Dare cross-sectional views illustrating an operation process of the molding apparatus10of the semiconductor package shown inFIG.1.

Referring toFIGS.6A and6B, the molding material262may be supplied from the molding material supplier410and accumulated in the port310. After the molding material262is supplied to the port310, the plunger actuator360may apply a first pressure to the plunger312. The first pressure may be a pressure applied to the plunger312to allow the plunger312to move along the inner sidewall of the port310. When the first pressure increases, the plunger312may more quickly move along the inner sidewall of the port310, and the molding material262may be supplied to the cavity260more quickly.

Although not shown in the drawings, an empty space may be between the molding target250and the substrate230. The molding material262may be supplied through the empty space. The empty space may be formed, for example, between solder balls or bumps connecting the molding target250to the substrate230. When the molding material262is supplied to the cavity260, the flow of a fluid in a direction without an obstacle (e.g., above the molding targets250) may be relatively fast, and the flow of the fluid in a direction with the obstacle (e.g., below the molding targets250) may be relatively slow. Therefore, there is a possibility that a void may be generated in the space between the molding target250and the substrate230due to a difference in the speed of the molding material262for each region. In some embodiments, the molding material262may be supplied to the cavity260without generating a void by maintaining the first pressure applied to the plunger312to move the plunger312along the inner sidewall of the port310to be equal to or less than 5 MPa.

The vent hole341may be connected to the gas pump346to discharge air inside the cavity260to the outside. When the molding material262is supplied to the cavity260, the vent hole341may discharge the air inside the cavity260to the outside to make the cavity260be in a vacuum state. The cavity260in the vacuum state may prevent generation of a void. To this end, the gas pump346may suck air through the vent hole341. Specifically, the gas pump346may suck air through the vent hole341before the mold actuator630applies the first pressure to the upper mold210. The gas pump346may also suck air through the vent hole341before the plunger actuator360applies the first pressure to the plunger312. As the gas pump346sucks air through the vent hole341, the cavity260may be in the vacuum state. The vacuum state referred to herein refers to a state where the pressure of the cavity260is equal to or less than 1 Torr. The gas pump346may suck air until the pressure of the cavity260is equal to or less than 1 Torr.

Referring toFIGS.6C and6D, the mold actuator630may operate after the molding material262is sufficiently supplied to the cavity260to cover the plurality of molding targets250. The mold actuator630may be configured to apply a second pressure to the upper mold210to pressurize the molding material262in the cavity260. Specifically, the mold actuator630may apply the second pressure to the upper mold210after the molding material262molds (e.g., covers) the molding target250arranged at the farthest distance from the port310. In one embodiment, this may be before the molding material262completely covers an entire top surface of the substrate or completely fills the cavity260. For example, a sensor may detect when this occurs. In this regard, the second pressure may be higher than the first pressure in order for the molding material262to sufficiently cover and mold the molding targets250.

The plunger actuator360may reduce the first pressure applied to the plunger312after the mold actuator630applies the second pressure to the upper mold210and pressurizes the molding material262in the cavity260. For example, in some embodiments, the first pressure applied to the plunger312may be applied at the same time as the second pressure applied to the upper mold210, after which the first pressure applied to the plunger312is reduced while the second pressure is continued to be applied to the upper mold210. Therefore, while molding material262is still being supplied to the cavity260, the second pressure may be initially applied by the mold actuator630, and thereafter, while the second pressure continues to be applied by the mold actuator630, the first pressure applied by the plunger actuator360may be decreased.

The vent hole341may be connected to the gas pump346to have external air introduced into the cavity270. To this end, the gas pump346may supply air to the cavity270through the vent hole341. The gas pump346may make the pressure of the cavity270be equal to atmospheric pressure by supplying air to the cavity270. Atmospheric pressure here refers to a state where pressure is equal to or greater than 760 torr. Accordingly, the gas pump346may supply air until the pressure of the cavity270is equal to or greater than 760 torr. According to an embodiment, the gas pump346may supply air through the vent hole341after the mold actuator630applies the second pressure to the upper mold210.

According to an embodiment, the molding apparatus10of the semiconductor package may perform a molding process primarily by supplying the molding material262to the cavity260through the port310, and then may perform a molding process secondarily by driving the upper mold210and pressurizing the molding material262. The molding apparatus10of a semiconductor package may continuously perform a primary molding process and a secondary molding process, thereby preventing the generation of a void. Specifically, the first pressure applied to the plunger312to move the plunger312along the inner sidewall of the port310may remain to be equal to or less than 5 MPa, and thus, the generation of a void in the molding material262may be prevented. Subsequently, at first while the first pressure is still applied to the plunger312, and then after the first pressure applied to the plunger312is reduced and released, the mold actuator630may minimize the generation of a void by applying the second pressure to the upper mold210and pressurizing the molding material262in the cavity260.

FIGS.7A to7Dare cross-sectional views illustrating an operation process of the molding apparatus of the semiconductor package shown inFIG.2.

Specifically, the molding apparatus20of a semiconductor package may be substantially the same as the molding apparatus10of a semiconductor package shown inFIGS.6A to6Dexcept that the molding apparatus20ofFIGS.7A-7Dincludes the substrate240instead of the substrate230, and further includes the second port320and the second molding material supplier420. The same reference numerals as inFIGS.6A to6Ddenote the same members. InFIGS.7A to7D, the same descriptions as inFIGS.6A to6Dare briefly given or omitted.

Referring toFIGS.7A and7B, the molding material262may be supplied from the first molding material supplier410and the second molding material supplier420and respectively accumulated in the second port320formed in the upper portion of a chamber and the first port310formed in the side portion of the chamber. After the molding material262is supplied to the second port320and the first port310, the plunger actuator360may apply a first pressure to the first plunger312and the second plunger322. The first pressure may be a pressure applied to respectively move the first plunger312and the second plunger322along the inner sidewalls of the second port320and the first port310. When the first pressure increases, the first plunger312and the second plunger322may more quickly move along the inner sidewalls of the second port320and the first port310, respectively, and the molding material262may also be supplied to the cavity260more quickly.

Referring toFIGS.7C and7D, after the molding material262is sufficiently supplied to the cavity260, and in some embodiments, while the molding material262is still being supplied to the cavity260, the mold actuator630may operate. The mold actuator630may be configured to apply a second pressure to the upper mold210and pressurize the molding material262in the cavity260. Specifically, the mold actuator630may mold the molding target250after the molding material262is arranged at the farthest distance from the center of the substrate240, and then apply the second pressure to the upper mold210. In this regard, the second pressure may be higher than the first pressure in order for the molding material262to sufficiently mold the molding target250.

The plunger actuator360may reduce the first pressure applied to the first plunger312and/or the second plunger322after the mold actuator630has already begun to apply the second pressure to the upper mold210to pressurize the molding material262in the cavity260.

The vent hole341formed in the sidewall of the chamber may be connected to the gas pump346and have external air introduced into the cavity270, now formed above the upper mold210. To this end, the gas pump346may supply air to the cavity260through the vent hole341. According to an embodiment, the gas pump346may supply air into the cavity260through the vent hole341after the mold actuator630applies the second pressure to the upper mold210.

According to an embodiment, the molding apparatus20of the semiconductor package may perform a molding process primarily by supplying the molding material262to the cavity260through the second port320and the first port310and then may perform a molding process secondarily by driving the upper mold210and pressurizing the molding material262. In this regard, the second port320is vertically spaced apart from the center of a circular cross-section of a substrate, thereby uniformly supplying the molding material262onto the substrate. According to an embodiment, the molding apparatus20of a semiconductor package may continuously, and for a particular time period simultaneously, perform a primary molding process and a secondary molding process, thereby preventing the generation of a void. Specifically, the first pressure applied to move the plunger312along the inner sidewall of the port310may remain to be equal to or less than 5 MPa, and thus, the generation of a void may be prevented, and the molding material262may be supplied. Subsequently, and with some overlap with the first pressure, the mold actuator630may minimize the generation of a void by applying the second pressure to the upper mold210and pressurizing the molding material262in the cavity260.

FIG.8is a flow chart diagram showing an example method800of manufacturing a semiconductor device using an example molding apparatus, according to an embodiment. As can be seen inFIG.8, in step801, a substrate including a plurality of molding targets arranged in an array pattern is provided. The substrate may be, for example, a package substrate for a semiconductor package, which may be a package-on-package device. The molding targets may be, for example semiconductor chips, or semiconductor packages, including conductive bumps or balls formed on a bottom surface and connected to the substrate. The substrate may be formed of an insulating material, or a semiconductor material.

In step802, the substrate including the molding targets is disposed on a lower mold of a chamber, such as lower mold220depicted in the previous figures. In step803, molding material may be introduced to a cavity in the chamber, for example, as depicted and described inFIGS.6A and6B, or7A and7B, by applying pressure to a plunger312and/or322. In step804, a pressure may be applied to the molding material using pressure applied between the lower mold220and the upper mold210to compact and fill the mold to cover the plurality of molding targets, including spaces between each of the plurality of molding targets and the substrate. The pressure applied in step804may be applied at the same time as introducing molding material to the cavity, e.g., at the end portion of step803. Then, in step805, the molding material may be hardened. For example, in some embodiments, a temperature of the molding material may be adjusted to cure the molding material.

Next, after the molding material is completely hardened, in step806, the substrate may be removed from the chamber, and may be placed in a chamber that performs further processing. For example, the substrate may be moved to a chamber where dicing of the substrate is performed, to singulate semiconductor devices (e.g., packages) from each other, resulting in a plurality of separated, completed semiconductor devices.