PATENT ABSTRACT
An apparatus package for high-temperature thermal applications for ball grid array semiconductor devices and a method of packaging ball grid array semiconductor devices.

PATENT DESCRIPTION
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation of application Ser. No. 09/344,279, filed Jun. 30, 1999, pending, which claims the benefit of U.S. Provisional Application No. 60/091,205 filed Jun. 30, 1998. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    Statement of the Invention: The present invention relates to an apparatus for high-temperature thermal applications for ball grid array semiconductor devices and a method of packaging ball grid array semiconductor devices.  
           [0003]    State of the Art: Integrated semiconductor devices are typically constructed in wafer form with each device having the form of an integrated circuit die which is typically attached to a lead frame with gold wires. The die and lead frame are then encapsulated in a plastic or ceramic package, which is then commonly referred to as an integrated circuit (IC). ICs come in a variety of forms, such as a dynamic random access memory (DRAM), static random access memory (SRAM), read only memory (ROM), gate arrays, etc. The ICs are interconnected in many combinations on printed circuit boards by a number of techniques, such as socketing and soldering. Interconnection among ICs arrayed on a printed circuit board are typically made by conductive traces formed by photolithography and etching processes.  
           [0004]    Such semiconductor devices typically take the form of the semiconductor die therein. The die is generally electrically attached to a lead frame within a package. The lead frame physically supports the die and provides electrical connections between the die and its operating environment. The die is generally electrically attached to the lead frame by means of fine gold wires. These fine gold wires function to connect the die to the lead frame so that the gold wires are connected electrically in series with the lead frame leads. The lead frame and die are then encapsulated. The packaged chip is then able to be installed on a circuit board by any desired manner, such as soldering, socketing, etc.  
           [0005]    However, as the speed of the semiconductor die increases, the heat generated during operation increases. Additionally, it becomes necessary to shorten the leads between the printed circuit board on which the IC is located and the IC device itself in order to keep the impedance of the circuit from affecting the response speed of the IC device.  
           [0006]    The wires connecting the leads of the lead frame to the bond pads on the active surface of the semiconductor die in an IC package are not an effective connection for high operating speed semiconductor dice as the wires slow down the response of the semiconductor die.  
           [0007]    Therefore, a packaging is required for semiconductor dice which have high operating speeds and generate heat associated therewith while minimizing the lead length between the semiconductor dice and the printed circuit boards on which they are mounted.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention comprises an apparatus package for high-temperature thermal applications for ball grid array semiconductor devices and a method of packaging ball grid array semiconductor devices. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 is a cross-sectional view of a stack of a first embodiment of the packaged semiconductor dice of the present invention on a printed circuit board;  
         [0010]    [0010]FIG. 2 is a top view of a packaged semiconductor die of the present invention;  
         [0011]    [0011]FIG. 3 is a bottom view of a packaged semiconductor die of the present invention;  
         [0012]    [0012]FIG. 4 is a cross-sectional view of stacks of the packaged semiconductor dice of the present invention on both sides of a printed circuit board;  
         [0013]    [0013]FIG. 5 is a cross-sectional view of a stack of a second embodiment of the packaged semiconductor die of the present invention on a printed circuit board; and  
         [0014]    [0014]FIG. 6 is a cross-sectional view of stacks of the second embodiment of the present invention on both sides of a print circuit board. 
     
    
       [0015]    The present invention will be better understood when the drawings are taken in conjunction with the description of the invention.  
       DESCRIPTION OF THE INVENTION  
       [0016]    Referring to drawing FIG. 1, a plurality of assemblies  10  comprising a carrier  12  and a semiconductor device  14  located therein is illustrated installed on a substrate  2 . Each carrier  12  comprises a member having a cavity  16  therein. As illustrated, the cavity  16  may be a single-level or multi-level cavity having any desired number of levels therein. The carrier  12  is formed having a plurality of contact pads  18  located on the upper surface  20  and lower surface  22  thereof which is connected by circuits  24  (not shown) and by wire bonds  26  to the bond pads  28  located on the active surface  30  of the semiconductor die or device  14 . The semiconductor die or device  14  is initially retained within the cavity  16  by any suitable means, such as adhesive, etc. The circuits  24  (not shown) are formed on the upper surface  20  of the carrier  12  and portions of the walls or surfaces of the cavity  16  by any suitable well-known means, such as deposition and etching processes. The wire bonds connecting the bond pads  28  of the semiconductor die or device  14  to the circuits  24  (not shown) are made using any suitable commercially available wire bonder. After the wire bonds  26  are formed, the cavity  16  is filled with suitable encapsulant material  32  covering and sealing the semiconductor die  14  in the cavity  16  and sealing the wire bonds  26  in position therein.  
         [0017]    The carriers  12  may be of any desired geometric shape. The carrier  12  is formed having internal circuits  34  extending between the contact pads  18  on the upper surface  20  and lower surface  22  of the carrier  12 . The carrier  12  is formed having frustoconical recess surfaces  36 , lips  38 , and frustoconical surfaces  40  on the upper surface  20 . The surfaces  36  and  40  are formed having complementary angles so that the surfaces  36  and lips  38  of an adjacent carrier  12  mate or nest with an adjacent carrier  12  having surfaces  40  thereon, thereby forming a stable, self-aligning stack of carriers  12 . If desired, the carriers  12  may be formed having a plurality of heat transfer fins  42  thereon. The carrier  12  may be formed of any desired suitable material, such as ceramic material, high-temperature plastic material, etc. The carrier  12  may be formed by any suitable method, such as molding, extrusion, etc.  
         [0018]    Once a plurality of carriers  12  having semiconductor die or devices  14  therein is formed as an assembly, the assembly is connected to the substrate  2  using a plurality of reflowed solder balls  50 . The substrate  2  includes circuitry thereon, on either the upper surface or lower surface or both, and therein, as well as conductive vias, if desired. The substrate  2  may be any suitable substrate, such as a printed circuit board, FR-4 board, etc. Any desired number of carriers  12  may be stacked to form an assembly on the substrate  2 . As illustrated, the reflowed solder balls  50  are located in alignment with the contact pads  18  and the connecting internal circuits  34  extending between the contact pads  18  on the upper surface  20  and lower surface  22  of a carrier  12 .  
         [0019]    Referring to drawing FIG. 2, a carrier  12  having circuits  24  thereon extending between contact pads  18  on the upper surface  20  of the carrier  12  is illustrated. For purposes of clarity, only a portion of the circuits  24  extending on the surface  20  of the carrier  12  is illustrated.  
         [0020]    Referring to drawing FIG. 3, the bottom surface  22  of a carrier  12  is illustrated having a plurality of contact pads  18  located thereon. [ 0021 ] Referring to drawing FIG. 4, a plurality of assemblies  10  is illustrated located on both sides of a substrate  2  being connected to the circuitry thereon by a plurality of reflowed solder balls  50 .  
         [0021]    Referring to drawing FIG. 5, a second embodiment of the present invention is illustrated. A plurality of assemblies  100  is stacked on a substrate  2 , being electrically and mechanically connected thereto by reflowed solder balls  150 . Each assembly  100  comprises a carrier  112  having a cavity  116  therein containing a semiconductor die or device  114  therein. The semiconductor die or device  114  is electrically connected to the circuits  134  of the carrier  112  by reflowed solder balls  126 . Each carrier  112  is formed having apertures  160  therethrough connecting with circuits  134 . Each carrier  112  is formed with surfaces  136  and  140  as well as lips  138  as described hereinbefore with respect to carrier  12 . To connect each carrier  112  to an adjacent carrier  112 , a conductive material  162 , such as conductive epoxy, solder, etc., is used to fill the apertures  160  in the carriers and contact the conductive material  162  in adjacent carriers  112 .  
         [0022]    The carriers  112  are similar in construction to the carriers  12  as described hereinbefore, except for the apertures  160 , conductive material  162 , circuits  134 , and reflowed solder balls  126  between the semiconductor die or device  114  and the circuits  134 .  
         [0023]    The substrate  2  is the same as described hereinbefore.  
         [0024]    Referring to drawing FIG. 6, a plurality of assemblies  100  is illustrated stacked on both sides of a substrate  2 , being electrically and mechanically connected thereto by reflowed solder balls  150 .  
         [0025]    The present invention includes additions, deletions, modifications, and alterations which are within the scope of the claims.