Method for forming an encapsulation device

An improved die edge contacting socket incorporates particles of a thermally conducting material into an elastomeric compression pad disposed in the sealing cap of the socket. The elastomeric compression pad is preferably composed of an electrically insulating material, such as a silicone-based gel. The thermally conducting material is preferably either diamond, beryllium oxide, silicon nitride, or a like material.

FIELD OF THE INVENTION

The present invention relates to packaging of semiconductor integrated circuits and, more particularly, to a multi-die encapsulation device.

BACKGROUND OF THE INVENTION

Modern semiconductor computing systems have often utilized sets of individually packaged semiconductor dice mounted and interconnected on a circuit board. More recent designs have eliminated the numerous individual die packages in favor of a single package capable of housing several bare dice. The advantages of such systems are greater computing power per unit area of circuit board, and lower packaging cost.FIG. 1shows a portion of an example of such a conventional multi-dice package, illustrated in a cross-sectional view. The dice are initially formed in large groups on wafers. By cutting the wafer, the dice are individually segregated. The encapsulation device is typically molded plastic and has a chamber portion comprised of a plurality of die chambers5. Each chamber has at least one beveled edge10. A bare die is inserted by hand into a chamber5with the circuit side touching the beveled edge10The beveled edge10thus serves as a guide for the insertion of the bare die. However, since the circuit slides across the bevel, the circuitry may be damaged during insertion. The bare die is retained by a spring-retaining and contact assembly15located at the bottom of the chamber5. The retaining and contact assembly15holds the bare die in position in the encapsulation device, with a spring portion20electrically contacting the bare die.

A rigid foot portion25is provided for contacting a circuit board onto which the encapsulation device is mounted. Due to the rigidity of the foot portion25and inherent bowing of many circuit boards, the failure rate of electrical contact between the bare dice and the board is typically high. At times the failure rate runs as high as 80%.

Heat dissipation is a persistent problem in the packaging systems of virtually all semiconductor devices, including the encapsulation device shown in FIG.1. Long-term exposure to excessive temperatures may impede the operation of a die or lead to an electrical failure. There are various approaches available to lessen the problem of die heating that involve either redesigning the die circuitry or modifying the encapsulation device. For instance, designing circuits to operate at lower voltage levels may provide a partial solution. However, lower operating voltages may not be possible for a given die.

Alternatively, certain features may be incorporated into the encapsulation device itself to improve heat transfer. The encapsulation device shown inFIG. 1provides few pathways for the transfer of heat from the dice. This is due to the relatively small amount of physical contact between the encapsulation device and the dice and to the less than optimal thermoconductivity for molded plastic. Although there will be some minimal amount of natural convective heat transfer between the dice and the ambient, the amount is of little consequence. Further, radiative heat transfer does not ordinarily play a significant role because the temperatures required for significant radiative heat transfer from the dice are normally higher than the maximum permissible operating temperature of the dice.

To improve heat transfer from the dice, a cap, of the type to be described below, may be placed on the encapsulation device shown inFIG. 1, and may be modified in several ways, depending on the heat output of the dice. For a relatively low heat output combination of dice, the cap may be made of metal to improve conduction from the die chambers5. If additional heat transfer capacity is necessary, the cap may be fitted with slots, and possibly a forced air supply, to improve convection. The cap may be also be provided with fins to improve both the conduction and convection. The addition of fins, slots, and fans increases the complexity of the device, and space limitations may rule out their use. Furthermore, even with the aforementioned modifications, the predominant heat transfer mechanism will continue to be convection, which is less efficient than conduction.

In addition to these problems, solid caps secured over the chamber portion of the encapsulation device may not retain the dice in the correct position and often are a cause of dice damage subsequent to encapsulation of the dice.

Thus, a need exists for an encapsulation device for bare dice which provides reliable electrical contact between the dice and a mounting board and a need exists for a method for safely inserting the bare dice into the encapsulation device. In addition, there is a need to provide position retainment of the bare dice within the encapsulation device without fear of dice damage following encapsulation, and a need to incorporate conductive heat dissipation features into the encapsulation device without the need for space limiting heat sinks or circuit design changes to accommodate lower voltages.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an encapsulation device is provided. The encapsulation device has a chamber portion that includes a die chamber that is operable to accept one bare die. There is also a pad of elastomeric material containing particles of a thermally conducting material for biasing the bare dice in the die chamber.

In another aspect of the present invention, a cap for mating with and sealing an encapsulation device that is operable to house bare die is provided. The cap includes an elastomeric compression pad for biasing the bare die in a correct orientation when the bare die is inserted into a chamber in the encapsulation device. The elastomeric material contains particles of a thermally conducting material.

In still another aspect of the present invention, an encapsulation device is provided. The encapsulation device includes a chamber portion comprising a plurality of parallel die chambers. Each of the plurality of die chambers is operable to accept one bare die of a plurality of bare die. A cap portion for mating with and sealing a top portion of the chamber portion is provided. The cap portion comprises an elastomeric compression pad for biasing the bare die in a correct orientation when the bare die is inserted into a chamber. The elastomeric compression pad contains particles of a thermally conducting material.

In a further aspect of the present invention, a method of forming an encapsulation device is provided. In the method, a chamber portion is provided that includes a plurality of die chambers. Each of the plurality of die chambers is operable to accept one bare die. A cap portion is provided for mating with and sealing a top portion of the chamber portion. The cap portion is provided with a thermally conducting elastomeric compression pad for biasing the bare die in a given orientation when the bare die is inserted into a chamber.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2is a three-dimensional view of the encapsulation device45of the invention prior to insertion of bare die into the encapsulation device. A chamber portion50comprises a plurality of chambers55for accepting and retaining the bare dice. The exact number of chambers55may vary depending on design considerations. Each chamber55comprises retaining edges60which define a chamber void65. The chamber void65accepts a bare die insertion tool during the process of inserting the bare die into each chamber55.

When the bare dice have been inserted into the chambers55, a cap70is sealed to the chamber portion. The cap70rests on lip75of the chamber portion50. The final locking seal between the cap70and the lip75is typically an epoxy which when heated allows the cap70to be removed and resealed, thereby allowing for the removal and the replacement of faulty dice. However, other locking seals, such as a snap seal, a grooved seal, or a pressure seal, may work equally well. The chamber portion50and the cap70are typically a molded plastic, such as, for example, glass filled polysulfone, polyethersulfone (sometimes referred to alternatively as “PES”), polyamidimide (sometime referred to alternatively as “PAI” or Porlon®), polyphenyline-sulfide, high temperature PCT polyester, or a like plastic.

FIG. 3is representative of a single bare die76designed to fit into the encapsulation device45. In this case the single die76has eight die pads77, although it is possible for the bare dice to have any number of die pads.

FIG. 4is a cross-sectional view of a single die chamber55having parallel walls78. A bare die76inserted into the die chamber55is retained against the retaining edges60by retaining contact85. The retaining contact85electrically contacts one of the die pad77of bare die76(seeFIG. 3) at a spring portion86and electrically contacts a circuit board90with a compliant foot portion95when the bare die76is seated in the die chamber55. Thus, the retaining contact85protrudes through a bottom portion96of the chamber portion50. The compliant contact foot95provides reliable contact to the circuit board90even though the circuit board90may be bowed. It can be seen fromFIG. 4that the compliant foot95has a vertical displacement d. Therefore, as long as the distance between the reference foot100and the circuit board90is less than d, and the distance accommodates a width of the compliant foot95, the compliant foot95makes contact with the circuit board90. The number of retaining contacts85is equal to the number of die pads77on the bare die76. Therefore, for the bare die ofFIG. 2, there would be eight retaining contacts85in a die chamber55.

FIG. 5is a top view of a single die chamber55. In addition to elements previously named, a pair of opposed parallel walls101is shown in FIG.5. Preferably, the chamber portion50shown inFIG. 1is oriented during bare die insertion, such that the chambers55are stacked. This orientation allows for a simplified insertion process which can best be understood with reference toFIGS. 3,4,5,6, and7.

A bare die76is placed on an insertion tool105, shown three dimensionally in FIG.6and cross-sectionally inFIG. 7, with the circuit side of the bare die76up, thereby preventing damage to the circuitry of the bare die76. The insertion tool105is then inserted into the chamber void65between the two retaining edges60. The guide edge110of the insertion tool105is used to mechanically force the bare die76into the retaining contact85(see FIG.4). The bare die76is held in a correct orientation on the insertion tool105with a vacuum provided by a vacuum source (not shown). The vacuum source is connected to the insertion tool105at vacuum connection115through a means such as a plastic hose (not shown). Internal passages120connected to the vacuum connection115directs the vacuum to suction depressions125. Thus the die insertion tool105allows for insertion of the bare die76into chamber55without damage to die circuitry.

Not only does the process and encapsulation device of the invention prevent damage to die circuitry, but there is also a space savings over the beveled wall chamber of the related art shown in FIG.1. It should also be noted that the exact orientation of the parallel chamber walls is unimportant. For example, they may be at an angle of less than 90 degrees to the circuit board to which the encapsulated device attaches. In this case, the chambers55may be slanted to form a low profile encapsulation device.

After the bare dice76have been inserted into the desired chambers55, the cap70is seated on lip75(seeFIG. 1) and retained and sealed to the chamber portion50with a sealant glue. The cap contains a compression pad130which provides a flexible bias to the bare dice76. Various substances may be used for the compression pad, including a variety of springs, gels, or foams. Because of the flexible bias, the compression pad130biases the bare dice firmly into the retaining contact. Therefore, the compression pad130of the cap70helps to eliminate breakage of the bare dice, even with jarring. The seating of the cap70on the lip75completes the encapsulation process.

The skilled artisan will appreciate that the compression pad130not only serves die-retaining and shock-absorbing functions, but also has the potential to provide a significant capability to transfer heat away from the dice76. In the absence of some structure to contact the top of the dice76, the paths for conductive heat transfer will be limited to those areas of contact between the chamber55and the dice76, at the surfaces135and140, and at the interface between the spring portion86and the dice76as shown inFIGS. 4 and 5. However, the biasing contact between the elastomeric compression pad130and the top of the tie76may provide a significant conductive heat transfer pathway, depending upon the materials selected for the compression pad130and the cap70.

In an embodiment, the compression pad130may be advantageously formed from an electrically-insulating, elastomeric material, such as a silicone-based jell that is impregnated with particles of a thermally conducting material, such as diamond, beryllium oxide, silicon nitride, or like materials. The silicone-based elastomeric material is typically a three-part mixture of a base material, a hardening material, and a diluent material. The Shore-A or Durometer value for the elastomeric material is influenced by the amount of hardening material—a higher amount of hardening material results in a higher Shore-A or Durometer value. The diluent material influences the viscosity of the mixture. Silicone-based materials are preferred due to their high elasticity and desirable electrical insulating properties If relatively high temperatures are anticipated, the compression pad130may be fabricated from a polyamide silicone-based material. The mean size of the relatively small conducting particles, as well as their concentration in the elastomeric material, is a matter of discretion on the part of the designer. Relatively smaller sized particles in the range of 5 to 10 microns are preferred since the thermal conductivity of the conducting particles normally does not diminish with particle size, and relatively larger particles may damage the dice76.

Depending upon the amount of heat dissipation required, different combinations of materials for the compression pad130and the cap70may be selected. For example, the cap70may be fabricated from molded plastic, and the compression pad130may be fashioned from a silicone-based jell with a Shore-A value of about45that is impregnated with diamond particles. If higher heat dissipation is necessary, the cap70may be fabricated from a material with a higher thermoconductivity, such as aluminum or other metallic material. A metallic cap70ordinarily would be undesirable due to the potential for short-circuiting between the cap70and the dice76. However, the excellent insulating properties of the elastomeric material permit the use of a metallic material for the cap70. In addition, if space and power consumption are not unduly limited, other heat sink devices, such as fins, may be incorporated into the cap70to provide additional material available for heat conduction and to provide a larger available surface area for convective heat transfer. In addition, a fan may be used to provide forced convection.

Alternatively, the compression pad130may be potted, that is, poured directly over the dice76and into the slots55, thereby sealing the slots55. Tis alternative provides the aforementioned die-retaining, shock-absorbing and heat dissipation advantages, however, it does render the installation of the dice76permanent.

The exact dimensions of the encapsulation device45will depend on the size of the dice. In a preferred embodiment the encapsulation device45is approximately 600 mils long, approximately 630 mils wide, and approximately 270 mils high with the cap70in place, the cap70itself, being approximately 70 mils high. In this preferred embodiment, each chamber55is approximately 570 mils long, slightly more than approximately 18 mils wide at its widest point, and approximately 215 mils deep at its deepest point.

Although the invention has been described with respect to specific embodiments, the invention is limited only as claimed.