Abstract:
A dual flat non-leaded semiconductor package is disclosed. A method of making a dual flat non-leaded semiconductor package includes forming a leadframe having a die bonding area with an integral drain lead, a gate lead bonding area and a source lead bonding area, the gate lead bonding area and a source lead bonding area being of increased area; bonding a die to the die bonding area; coupling a die source bonding area to the source lead bonding area; coupling a die gate bonding area to the gate lead bonding area; and partially encapsulating the die, the drain lead, the gate lead and the source lead to form the dual flat non-leaded semiconductor package.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present invention is a divisional application of commonly assigned application Ser. No. 11/150,489, filed on Jun. 10, 2005 entitled “DFN Semiconductor Package Having Reduced Electrical Resistance”, which is a continuation in part application of commonly assigned application Ser. No. 11/029,653, filed on Jan. 5, 2005 entitled “Dual Flat Non-Leaded Semiconductor Package”, the disclosures of which are incorporated herein in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention generally relates to semiconductor packages and more particularly to semiconductor packages and methods of making Dual Flat Non-Leaded (DFN) semiconductor packages having reduced electrical resistance and improved thermal properties. 
         [0003]    Quad Flat Non-Leaded (QFN) semiconductor packages are well known in the art. QFN semiconductor packages are widely used in high pin out IC package applications; For example, a QFN semiconductor package is disclosed in U.S. Patent Application Publication 2002/0177254 entitled “Semiconductor Package and Method for Making the Same”. The disclosed semiconductor package includes a plurality of connection pads and an embedded die. The connection pads at least partially enclose a die receiving area. An insulator is disposed in the die receiving area and the die is attached to the insulator. The die has a plurality of die bond pads. A plurality of connectors connect the die bond pads to respective connection pads. An encapsulant at least partially encapsulates the connection pads, insulator and die. The connection pads and insulator have exposed surfaces on an outer surface of the encapsulant. The exposed surfaces are substantially co-planar with the outer surface of the encapsulant. A resulting semiconductor package is shown in  FIG. 1A  and  FIG. 1B . 
         [0004]    It has been proposed to use DFN semiconductor packages in power MOSFET applications. In power MOSFET applications a major concern relates to thermal and electrical performance. The total electrical resistance Rds(on) of an electrical component includes chip resistance and package resistance. Chip resistance depends upon the wafer process technology used to fabricate the chip and die size while package resistance depends upon the quantity, diameter and length of bond wires used to bond internal chip bonding areas to external package leads. By increasing the amount of bond wires and/or their diameters, total Rds(on) can be reduced dramatically. QFN and DFN packages of the prior art suffer from the disadvantage of having high Rds(on). A prior art 6×5 mm DFN package  700  is shown in  FIG. 7 . A leadframe  710  includes a narrow source bonding area  720  and a narrow gate bonding area  730 . The narrow source bonding area  720  of DFN package  700  allows for only 11 narrow and short bonding wires  760  for connecting source leads  735  to a semiconductor die  750  and consequently does not provide reduced Rds(on). 
         [0005]    There is therefore a need in the art for a DFN semiconductor package having improved electrical performance and thermal properties. Preferably such a DFN semiconductor package provides for reduced electrical resistance and inductance and improved thermal dissipation. 
       SUMMARY OF THE INVENTION 
       [0006]    In accordance with one aspect of the invention, a DFN semiconductor package includes a leadframe having a die bonding pad formed integrally with a drain lead, a source lead bonding area and a gate lead bonding area, the source lead bonding area and the gate lead bonding area being of increased area, a die coupled to the die bonding pad, a die source bonding area coupled to the source lead bonding area and a die gate bonding area coupled to the gate lead bonding area, and an encapsulant at least partially covering the die, drain lead, gate lead bonding area and source lead bonding area 
         [0007]    In accordance with yet another aspect of the invention, a method of making a DFN semiconductor package includes the steps of forming a leadframe having a die bonding area with an integral drain lead, a gate lead bonding area and a source lead bonding area, the gate lead bonding area and a source lead bonding area being of increased area, bonding a die to the die bonding area, coupling a die source bonding area to the source lead bonding area, coupling a die gate bonding area to the gate lead bonding area, and at least partially encapsulating the die, the drain lead, the gate lead and the source lead to form the dual flat non-leaded semiconductor package. 
         [0008]    In accordance with another aspect of the invention, a DFN common-drain die semiconductor package includes a leadframe having a die bonding pad formed integrally with a drain lead, first and second source lead bonding areas and first and second gate lead bonding areas, the first and source lead bonding areas and the first and second gate lead bonding areas being of increased area, a pair of common-drain die coupled to the die bonding pad, a first die source bonding area coupled to the first source lead bonding area, a second die source bonding area coupled to the second source lead bonding area, a first die gate bonding area coupled to the first gate lead bonding area, and a second die gate bonding area coupled to the second gate lead bonding area, and an encapsulant at least partially covering the pair of common-drain dies, drain lead, first and second gate lead bonding areas and first and second source lead bonding areas. 
         [0009]    In accordance with another still aspect of the invention, a DFN common-drain die semiconductor package includes a leadframe having first and second die bonding pads formed integrally with first and second drain leads, first and second source lead bonding areas and first and second gate lead bonding areas, the first and source lead bonding areas and the first and second gate lead bonding areas being of increased area, a first common-drain die coupled to the first die bonding pad, a second common-drain die coupled to the second die bonding pad, a first die source bonding area coupled to the first source lead bonding area, a second die source bonding area coupled to the second source lead bonding area, a first die gate bonding area coupled to the first gate lead bonding area, and a second die gate bonding area coupled to the second gate lead bonding area, and an encapsulant at least partially covering the first and second common-drain dies, first and second drain leads, first and second gate lead bonding areas and first and second source lead bonding areas. 
         [0010]    There has been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended herein. 
         [0011]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
         [0012]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
         [0013]    These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1A  is a cross sectional view of a semiconductor package of the prior art; 
           [0015]      FIG. 1B  is a perspective view of the semiconductor package of  FIG. 1A ; 
           [0016]      FIG. 2A  is a perspective view of a leadframe for a single die package having a die attached and wire bonded thereto in accordance with the invention; 
           [0017]      FIG. 2B  is a bottom perspective view of a molded leadframe for a single die package in accordance with the invention; 
           [0018]      FIG. 3A  is a schematic representation of a leadframe for a single die package in accordance with the invention; 
           [0019]      FIG. 3B  is a schematic representation of a leadframe for a dual die in accordance with the invention; 
           [0020]      FIG. 4  is a perspective of an alternative embodiment of a leadframe for single die package having a die attached and wire bonded in accordance with the invention; 
           [0021]      FIG. 5A  is a schematic representation of a molded leadframe for a single die package in accordance with the invention; 
           [0022]      FIG. 5B  is a cross sectional view of a power MOSFET package having the molded leadframe of  FIG. 5A  in accordance with the present invention; 
           [0023]      FIG. 6  is a plan view of a printed circuit board land pattern in accordance with the invention; 
           [0024]      FIG. 7  is a schematic representation of a prior art 6×5 mm DFN semiconductor package; 
           [0025]      FIG. 8  is a schematic representation of a 6×5 mm DFN semiconductor package in accordance with the invention; 
           [0026]      FIG. 9  is a schematic representation of a 2×4 mm DFN semiconductor package in accordance with the invention; 
           [0027]      FIG. 10  is a schematic representation of a 3×3 mm DFN semiconductor package in accordance with the invention; 
           [0028]      FIG. 11  is a schematic representation of another 3×3 mm DFN semiconductor package in accordance with the invention; and 
           [0029]      FIG. 12  is a schematic representation of a 2×3 mm DFN semiconductor package in accordance with the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    The present invention generally provides a power MOSFET DFN semiconductor package exhibiting improved electrical characteristics. An increased source bonding area provides for an increased number of source bonding wires having a 2 mil diameter. Improved thermal performance is also provided by an increased contact area between the encapsulant and the source bonding area and source bonding wires. 
         [0031]    In a first aspect of the invention and with reference to  FIG. 2A , a DFN semiconductor package generally designated  200  may include a leadframe  210  fabricated of copper, aluminum, nickel or other good electrical and thermal conductive material. Leadframe  210  may be fabricated using metal plating or general manufacturing techniques. Leadframe  210  may include a drain portion  220  fused to drain leads  260 , a source portion or lead  230  and a gate portion or lead  240 . A power MOSFET die  250  may be attached to a die bonding pad  300  ( FIG. 3A ). Drain portion  220  may include four drain leads  260  to provide a six lead package. 
         [0032]    Power MOSFET die  250  may include a patterned active area including a source bonding area  270  and a gate bonding area  280 . A bottom portion of the power MOSFET die  250  (not shown) may include a drain bonding area. 
         [0033]    With reference to  FIG. 3A , the drain portion  220  includes the die bonding pad  300  integrally formed or fused with the drain leads  260 . When the drain bonding area of the power MOSFET die  250  is attached to the die bonding pad  300  using a conductive epoxy or solder, and considering that the drain portion  220  includes an exposed bottom portion  720  ( FIG. 2B ), a thermal dissipation path is provided. 
         [0034]    The source lead  230  ( FIG. 2A ) may be larger than in conventional semiconductor packages to enable the use of an increased number of source wires  285  which preferably are formed from gold or copper. Increasing the number of source wires  285  advantageously decreases the semiconductor package  200  resistance significantly. Additionally, as the DFN semiconductor package  200  has no external leads, the overall size of the package is reduced allowing for the use of shorter source lead  230 , drain leads  260  and gate lead  240  thereby reducing package resistance and inductance. 
         [0035]    The leadframe  210 , power MOSFET die  250  and source wires  285  and gate wire  290  may be encapsulated by an encapsulant  500  formed of resin or other suitable material as shown in  FIG. 5A  and  FIG. 5B . Drain leads  260 , the gate lead  240  and the source lead  230  are shown disposed a distance internally of the encapsulant  500  edges. With reference to  FIG. 6 , a land pattern  600  for a PCB to which the DFN semiconductor package  200  may be mounted includes a standard pitch between drain lead mounting portions  610  and a standard dimension  620 . Disposing the drain leads  260 , the gate lead  240  and the source lead  230  a distance from an edge of the encapsulant  500  ( FIG. 5A  and  FIG. 5B ) provides for reduced short circuiting between devices and for higher device density. 
         [0036]    In another aspect of the invention and with reference to  FIG. 2B , a DFN semiconductor package generally designated  700  may include the source lead  230 , the gate lead  240  and the drain leads  260  disposed at an edge of an encapsulant  710 . 
         [0037]    In another aspect of the invention and with reference to  FIG. 4 , a DFN semiconductor package generally designated  400  includes a leadframe  410  having an expanded drain portion  420 . Expanded drain portion  420  provides for an eight lead DFN semiconductor package  400  having six drain leads  440 . 
         [0038]    In another aspect of the invention and with reference to  FIG. 3B , a DFN semiconductor package generally designated  800  may include a first drain portion  810  and a second drain portion  815  having drain leads  820  and  825  respectively. First drain portion  810  may include a first die bonding pad  830  integrally formed with the drain lead  820  and the second drain portion  815  may include a second die bonding pad  835  integrally formed with the drain lead  825 . First drain portion  810  may have associated therewith a first gate lead  840  and a first source lead  845 . First source lead  845  may include an expanded surface area to accommodate more source bonding wires. Second drain portion  815  may have associated therewith a second gate lead  850  and a second source lead  855 . Second source lead  855  may include an expanded surface area to accommodate more source bonding wires. The first drain portion  810  and the second drain portion  815  may be fused together to provide a common drain device (not shown). 
         [0039]    In yet another aspect of the invention, a 6×5 mm DFN semiconductor package generally designated  890  ( FIG. 8 ) may include a leadframe  891  having a source bonding area  892  of increased area. A gate bonding area  893  may also be of an increased area. The source bonding area  892  allows for the use of 21 source bonding wires of 2 mil diameter rather than the conventional package which allows for the use of 11 source bonding wires. 
         [0040]    In another aspect of the invention, a 2×5 mm DFN semiconductor package generally designated  900  ( FIG. 9 ) may include a leadframe  910  having a pair of source bonding areas  920   a  and  920   b  of increased area. Gate bonding areas  930   a  and  930   b  may also be of an increased area. Source bonding area  920   a  and gate bonding area  930   a  may be disposed along a first shorter length of the leadframe  910 . Source bonding area  920   b  and gate bonding area  930   b  may be disposed along a second shorter length of the leadframe  910 . Leadframe  910  may be used for a common-drain die package where the drains of two MOSFET devices  940   a  and  940   b  may be connected internally either through the semiconductor substrate or through the die bonding pad  950  of the leadframe  910 . Source bonding area  920   a  may be connected to a source pad of a first MOSFET by wire bonding and source bonding area  920   b  may be connected to the source pad of a second MOSFET by wire bonding. Similarly, gate bonding area  930   a  and  930   b  may be connected to the gate bonding pads of first and second MOSFETs respectively by wire bonding. 
         [0041]    In yet another aspect of the invention and with reference to  FIG. 10 , a 3×3 mm DFN semiconductor package generally designated  1000  may include a leadframe  1010  having a pair of source bonding areas  1020   a  and  1020   b  of increased area. Gate bonding areas  1030   a  and  1030   b  may also be of an increased area. Source bonding areas  1020   a  and  1020   b  may be disposed along one side of the leadframe  1010  and gate bonding areas  1030   a  and  1030   b  may be disposed along an opposite side of the leadframe  1010 . Leadframe  1010  may be used for a common-drain die package where the drains of two MOSFET devices may be connected internally either through the semiconductor substrate or through the die bonding pad  1040  of the leadframe  1010 . Source bonding area  1020   a  may be connected to a source pad of a first MOSFET by wire bonding and source bonding area  1020   b  may be connected to the source pad of a second MOSFET by wire bonding. Similarly, gate bonding area  1030   a  and  1030   b  may be connected to the gate bonding pads of the first and second MOSFETs respectively by wire bonding. 
         [0042]    In another aspect of the invention and with reference to  FIG. 11 , a 3×3 mm DFN semiconductor package generally designated  1100  may include a leadframe  1110  having a pair of source bonding areas  1120   a  and  1120   b  of increased area. Gate bonding areas  1130   a  and  1130   b  may also be of an increased area. Source bonding areas  1120   a  and  1120   b  may be disposed along a first side of the leadframe  1110  on either side of the gate bonding area  1130   a . Gate bonding area  1130   b  may be disposed along an opposite side. Leadframe  1110  may also include drain leads  1140   a  and  1140   b  disposed on the opposite side on either side of the gate bonding area  1130   b . Leadframe  1110  may be used for a common-drain die package where the drains of two MOSFET devices are connected internally either through the semiconductor substrate or through the die bonding pad of the leadframe  1110 . Source bonding area  1120   a  may be connected to a source pad of a first MOSFET by wire bonding and source bonding area  1120   b  may be connected to a source pad of a second MOSFET by wire bonding. Similarly, gate bonding area  1130   a  and  1130   b  may be connected to the gate bonding pads of first and second MOSFETs respectively by wire bonding. 
         [0043]    In yet another aspect of the invention and with reference to  FIG. 12 , a 2×3 mm DFN semiconductor package generally designated  1200  may include a leadframe  1210  having a pair of drain pads  1250   a  and  1250   b  and a pair of corresponding source bonding areas  1220   a  and  1220   b  of increased area. Gate bonding areas  1230   a  and  1230   b  may also be of an increased area. Leadframe  1210  may also include drain leads  1240   a  and  1240   b  fused to drain pad  1250   a  and drain leads  1240   c  and  1240   d  fused to drain pad  1250   b . Source bonding areas  1220   a  and  1220   b  and gate bonding areas  1230   a  and  1230   b  may be disposed along a longer side of the leadframe  1210  while the drain leads  1240   a ,  1240   b ,  1240   c  and  1240   d  may be disposed along an opposite side of the leadframe  1210 . Leadframe  1210  may be used for a common-drain die package where the drains of two MOSFET devices are connected internally either through the semiconductor substrate or through the die bonding pad of the leadframe  1210 . Source bonding area  1220   a  may be connected to a source pad of a first MOSFET by wire bonding and source bonding area  1220   b  may be connected to a source pad of a second MOSFET by wire bonding. Similarly, gate bonding area  1230   a  and  1230   b  may be connected to the gate bonding pads of first and second MOSFETs respectively by wire bonding. 
         [0044]    The DFN semiconductor package of the invention provides for a non-leaded semiconductor package having reduced resistance and inductance and improved thermal conductivity. By providing a source lead having an expanded surface area, an increased number of source wires may be used to reduce package resistance and inductance. Integrally forming the drain bonding pad with the drain leads provides a thermal dissipation path through the bottom of the DFN semiconductor package. 
         [0045]    It should be understood, of course, that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.