Abstract:
A method and apparatus for applying packaging material to workpieces, with a high degree of precision, and resulting articles. A machine vision system including at least one camera is operably associated with a computer controlling a system for application of material so that the system may recognize the position and orientation of workpieces proximate to which the material is to be applied. The requirement for precise mechanical workpiece alignment is eliminated, and the ability of the machine vision system to recognize size, configuration and topography of different workpieces affords greater manufacturing flexibility. The method includes application of flowable material in separate volumes and draws formation of the material to at least a semisolid state for packaging electronic components, and the electronic components so packaged are also part of the invention.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation of application Ser. No. 10/293,160, filed Nov. 12, 2002, now U.S. Pat. No. 6,909,929, issued Jun. 21, 2005, which is a divisional of application Ser. No. 09/259,142, filed Feb. 26, 1999, now U.S. Pat. No. 6,549,821, issued Apr. 15, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates generally to stereolithography and, more specifically, to the use of stereolithography in the packaging of electronic components. Use of a machine vision system such as a pattern recognition system to facilitate application of stereolithographic techniques to fabrication of electronic components and other products is encompassed in the invention.  
         [0004]     2. State of the Art  
         [0005]     In the past decade, a manufacturing technique termed “stereolithography,” also known as “layered manufacturing,” has evolved to a degree where it is employed in many industries.  
         [0006]     Essentially, stereolithography, as conventionally practiced, involves utilizing a computer to generate a three-dimensional (3-D) mathematical simulation or model of an object to be fabricated, such generation usually effected with 3-D computer-aided design (CAD) software. The model or simulation is mathematically separated or “sliced” into a large number of relatively thin, parallel, usually vertically superimposed layers, each layer having defined boundaries and other features associated with the model (and thus the actual object to be fabricated) at the level of that layer within the exterior boundaries of the object. A complete assembly or stack of all of the layers defines the entire object, and surface resolution of the object is, in part, dependent upon the thickness of the layers.  
         [0007]     The mathematical simulation or model is then employed to generate an actual object by building the object, layer by superimposed layer. A wide variety of approaches to stereolithography by different companies has resulted in techniques for fabrication of objects from both metallic and non-metallic materials. Regardless of the material employed to fabricate an object, stereolithographic techniques usually involve disposition of a layer of unconsolidated or unfixed material corresponding to each layer within the object boundaries, followed by selective consolidation or fixation of the material to at least a semisolid state in those areas of a given layer corresponding to portions of the object, the consolidated or fixed material also at that time being substantially concurrently bonded to a lower layer. The unconsolidated material employed to build an object may be supplied in particulate or liquid form, and the material itself may be consolidated or fixed or a separate binder material may be employed to bond material particles to one another and to those of a previously formed layer. In some instances, thin sheets of material may be superimposed to build an object, each sheet being fixed to a next lower sheet and unwanted portions of each sheet removed, a stack of such sheets defining the completed object. When particulate materials are employed, resolution of object surfaces is highly dependent upon particle size, whereas when a liquid is employed, surface resolution is highly dependent upon the minimum surface area of the liquid which can be fixed and the minimum thickness of a layer which can be generated. Of course, in either case, resolution and accuracy of object reproduction from the CAD file is also dependent upon the ability of the apparatus used to fix the material to precisely track the mathematical instructions indicating solid areas and boundaries for each layer of material. Toward that end, and depending upon the layer being fixed, various fixation approaches have been employed, including particle bombardment (electron beams), disposing a binder or other fixative (such as by ink-jet printing techniques), or irradiation using heat or specific wavelength ranges.  
         [0008]     An early application of stereolithography was to enable rapid fabrication of molds and prototypes of objects from CAD files. Thus, either male or female forms on which mold material might be disposed might be rapidly generated. Prototypes of objects might be built to verify the accuracy of the CAD file defining the object and to detect any design deficiencies and possible fabrication problems before a design was committed to large-scale production.  
         [0009]     In more recent years, stereolithography has been employed to develop and refine object designs in relatively inexpensive materials, and has also been used to fabricate small quantities of objects where the cost of conventional fabrication techniques is prohibitive for same, such as in the case of plastic objects conventionally formed by injection molding. It is also known to employ stereolithography in the custom fabrication of products generally built in small quantities or where a product design is rendered only once. Finally, it has been appreciated in some industries that stereolithography provides a capability to fabricate products, such as those including closed interior chambers or convoluted passageways, which cannot be fabricated satisfactorily using conventional manufacturing techniques.  
         [0010]     However, to the inventors&#39; knowledge, stereolithography has yet to be applied to mass production of articles in volumes of thousands or millions, or employed to produce, augment or enhance products including other, pre-existing components in large quantities, where minute component sizes are involved, and where extremely high resolution and a high degree of reproducibility of results is required. Furthermore, conventional stereolithography apparatus and methods fail to address the difficulties of precisely locating and orienting a number of pre-existing components for stereolithographic application of material thereto without the use of mechanical alignment techniques or to otherwise assuring precise, repeatable placement of components.  
         [0011]     In the electronics industry, state-of-the-art packaging of semiconductor dice is an extremely capital-intensive proposition. In many cases, semiconductor dice carried on, and electrically connected to, lead frames are individually packaged with a filled-polymer material in a transfer molding process. A transfer molding apparatus is extremely expensive, costing at least hundreds of thousands of dollars in addition to the multi-hundred thousand dollar cost of the actual transfer molding dies in which strips of lead frames bearing semiconductor dice are disposed for encapsulation.  
         [0012]     So that the reader may more fully understand the present invention in the context of the prior art, it seems appropriate to provide a brief description of a transfer apparatus and method for forming a plastic package about an LOC die assembly. The term “transfer” molding is descriptive of this process as the molding compound, once melted, is transferred under pressure to a plurality of remotely-located mold cavities containing die assemblies to be encapsulated.  
         [0013]      FIG. 9  is a flow chart of a typical process sequence for plastic package molding. It should be noted that the solder dip/plate operation has been shown as one step for brevity; normally, plating would occur prior to trim and form.  FIGS. 10A and 10B  show pre-molding and post-molding positions of encapsulant during a transfer molding operation using a typical mold apparatus comprising upper and lower mold halves  410  and  412 , each mold half including a platen  414  or  416  with its associated chase  418  or  420 . Heating elements  422  are employed in the platens to maintain an elevated and relatively uniform temperature in the runners and mold cavities during the molding operation.  FIG. 11  shows a top view of one side of the transfer mold apparatus of  FIGS. 10A and 10B .  
         [0014]     In operation, a heated pellet of resin mold compound  430  is disposed beneath ram or plunger  432  in pot  434 . The plunger descends, melting the pellet and forcing the melted encapsulant down through sprue  436  and into primary runner  438 , from which it travels to transversely-oriented secondary runners  440  and across gates  442  into and through the mold cavities  444 , wherein die assemblies  500  comprising dice  100  with attached lead frames  502  are disposed (usually in strips so that a strip of six lead frames, for example, would be cut and placed in and across the six cavities  444  shown in  FIG. 11 ). Air in the runners  438  and  440  and mold cavities  444  is vented to the atmosphere through vents  446  and  448 . At the end of the molding operation, the encapsulant is “packed” by application of a higher pressure to eliminate voids and reduce nonuniformities of the encapsulant in the mold cavities  444 . After molding, the encapsulated die assemblies are ejected from the cavities  444  by ejector pins  450 , after which they are post-cured at an elevated temperature to complete cross-linking of the resin mold compound  430 , followed by other operations as known in the art and set forth in  FIG. 9  by way of example. It will be appreciated that other transfer molding apparatus configurations, as well as variations in the details of the described method are known in the art. However, none of such are pertinent to the invention, and so will not be discussed herein.  
         [0015]     Encapsulant flow in the mold cavities  444  is demonstrably non-uniform. The presence of the die assembly  500  comprising a die  100  with lead frame  502  disposed across the mid-section of a cavity  444  splits the viscous encapsulant flow front into upper and lower components. Further, the presence of the (relatively) large die  100  with its relatively lower temperature in the middle of a cavity  444  permits the flow front on each side of the die  100  to advance ahead of the front which passes over and under the die  100 .  
         [0016]     Encapsulant filler particles may become lodged between lead ends and the underlying die surfaces. The non-uniform flow characteristics of the viscous encapsulant flow may cause particles to be more forcefully driven between the lead ends and the die  100  and wedged or jammed in place in low-clearance areas. As the encapsulant flow front advances and the mold operation is completed by packing the cavities, pressure in substantially all portions of the mold cavities reaches hydrostatic. With LOC arrangements where lead ends extending over the active surface of a die  100  are bonded thereto by adhesive-coated tape or an adhesive material patterned on the active surface, the relative inflexibility of the tightly-constrained (adhered) lead ends maintains the point stresses of any particles trapped under the lead ends. These residual stresses are carried forward in the fabrication process to post-cure and beyond. When mechanical, thermal or electrical stresses attendant to post-encapsulation processing are added to the residual point stresses associated with the lodged filler particles, cracking or perforation of the die coat may occur, with the adverse effects previously noted. It has been observed that filler particle-induced damage occurs more frequently in close proximity to the adhesive, where lead flexure potential is at its minimum. In addition to damage by filler particles, transfer molding also results in the problem of bond wire sweep, wherein bond wires may be damaged, broken, loosened from their connections to bond pads or lead ends or swept into shorting contact with an adjacent bond wire under the impetus of the flow front of molten resin encapsulant as it flows through a mold cavity.  
         [0017]     In addition to end-product deficiencies as noted above due to the phenomena of particulate die coat penetration and bond wire sweep, the capital-intensive nature of the transfer molding apparatus, including the requirement for different, multi-hundred thousand dollar molds for each die and lead frame arrangement as well as the high cost of the encapsulant resin and waste of same which is not used in the mold cavities, renders the transfer molding process an extremely expensive one. Mold damage and refurbishment is an additional, ongoing cost. Further, the elevated temperatures used in the molding process as well as in the post cure of the resin encapsulant is detrimental to the circuitry of the die as well as to the electrical connections to the lead ends.  
       BRIEF SUMMARY OF THE INVENTION  
       [0018]     The present invention provides a method of applying material to a preformed structure such as an electronic component with a high degree of precision to create a package therefor. For example, a semiconductor die may be provided with a protective structure in the form of a layer of dielectric material having a controlled thickness or depth over or adjacent one or more surfaces thereof. As used herein, the term “package” as employed with reference to electrical components includes partial as well as full covering of a given semiconductor die surface with a dielectric material, and specifically includes a semiconductor die configured in a so-called “chip scale” package, wherein the package itself, including the die, is of substantially the same dimensions as, or only slightly larger than, the die itself.  
         [0019]     The packaging method of the present invention may be applied, by way of example and not limitation, to a die mounted to a lead frame (having a die mounting paddle or in a paddle-less leads-over-chip (LOC) or in a leads-under-chip (LUC) configuration), mounted to a carrier substrate in a chip-on-board (COB) or board-on-chip (BOC) arrangement, or in other packaging designs, as desired.  
         [0020]     The present invention employs computer-controlled, 3-D CAD initiated, stereolithographic techniques to form structures comprising one or more layers of material abutting a workpiece such as an electronic component and, more specifically, a semiconductor die. A dielectric layer, or layer segments, may be formed over or adjacent a single die or substantially simultaneously over or adjacent a large number of dice or die locations on a semiconductor wafer or other large-scale semiconductor substrate, individual dice or groups of dice then being singulated therefrom. As used herein, the term “semiconductor die” may be taken to encompass all of the aforementioned semiconductor substrate-based elements and the term “electronic component” may be taken in its broadest sense to encompass both active and passive components, combinations thereof and assemblies of components as well as individual components.  
         [0021]     Precise mechanical alignment of workpieces, including singulated semiconductor dice or larger semiconductor substrates having multiple die locations, is not required to practice the method of the present invention, which includes the use of machine vision to locate workpieces, their orientation and features. Specifically, and in a preferred embodiment, semiconductor dice, dimensions thereof and features or other components thereon or associated therewith (such as lead frames, bond wires, solder bumps, etc.), or features on a larger semiconductor substrate, may be identified by a machine vision system for alignment and material disposition purposes by an associated stereolithographic apparatus.  
         [0022]     In a preferred embodiment, packaging for electronic components according to the invention is fabricated using precisely focused electromagnetic radiation in the form of an ultraviolet (UV) wavelength laser under control of a computer and responsive to input from a machine vision system such as a pattern recognition system to fix or cure a liquid material in the form of a photopolymer.  
         [0023]     It should be understood that the invention is not so limited to stereolithographic techniques employing a UV-curable photopolymer, but may be employed with other techniques employing alternative materials. Furthermore, the apparatus of the present invention, insofar as it employs a machine vision system, encompasses any and all stereolithographic apparatus and the application of any and all materials thereby, including both metallic and non-metallic materials applied in any state and cured or otherwise fixed to at least a semisolid state to define a three-dimensional structure having identifiable boundaries. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0024]      FIG. 1  is a schematic side elevation of an exemplary stereolithography apparatus suitable for use in practicing the method of the present invention;  
         [0025]      FIG. 2  is a schematic top elevation of a plurality of workpieces in the form of semiconductor dice disposed on a platform of the stereolithographic apparatus of  FIG. 1 ;  
         [0026]      FIG. 3  is a schematic side elevation of a plurality of workpieces in the form of semiconductor dice disposed on a platform of the stereolithographic apparatus of  FIG. 1  and depicting a stereolithographic sequence for packaging the dice according to the present invention;  
         [0027]      FIG. 4  is a schematic side elevation of one embodiment of a stereolithographic sequence of packaging a semiconductor die, including a package bottom, according to the present invention;  
         [0028]      FIG. 5  is a schematic side elevation of another embodiment of a stereolithographic sequence of packaging a semiconductor die, including a package bottom, according to the present invention;  
         [0029]      FIGS. 6A and 6B  are schematic side elevations of yet another embodiment of a stereolithographic sequence of packaging a die, including a package bottom, according to the present invention;  
         [0030]      FIG. 7  is a schematic side elevation of a multi-chip module packaged according to the present invention;  
         [0031]      FIG. 8  is a schematic side elevation of a semiconductor die mounted to a carrier substrate in a board-on-chip configuration and packaged according to the present invention;  
         [0032]      FIG. 9  is a flow chart of an exemplary process sequence for a conventional transfer molding operation employed for packaging lead frame-mounted semiconductor dice;  
         [0033]      FIGS. 10A and 10B  are side schematic elevations of a conventional transfer molding apparatus, showing pre-molding and post-molding encapsulant positions;  
         [0034]      FIG. 11  is a top schematic elevation of one side of a transfer mold of  FIGS. 10A and 10B , depicting encapsulant flow and venting of the primary mold runner and the mold cavities wherein die assemblies are contained for encapsulation; and  
         [0035]      FIG. 12  is a side, partial sectional elevation of another embodiment of a semiconductor die packaged according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]      FIG. 1  depicts schematically various components, and operation, of an exemplary stereolithography apparatus  10  to facilitate the reader&#39;s understanding of the technology employed in implementation of the present invention, although those of ordinary skill in the art will understand and appreciate that apparatus of other designs and manufacture may be employed in practicing the method of the present invention. The preferred, basic stereolithography apparatus for implementation of the present invention as well as operation of such apparatus are described in great detail in United States Patents assigned to 3D Systems, Inc. of Valencia, Calif., such patents including, without limitation, U.S. Pat. Nos. 4,575,330; 4,929,402; 4,996,010; 4,999,143; 5,015,424; 5,058,988; 5,059,021; 5,096,530; 5,104,592; 5,123,734; 5,130,064; 5,133,987; 5,141,680; 5,143,663; 5,164,128; 5,174,931; 5,174,943; 5,182,055; 5,182,056; 5,182,715; 5,184,307; 5,192,469; 5,192,559; 5,209,878; 5,234,636; 5,236,637; 5,238,639; 5,248,456; 5,256,340; 5,258,146; 5,267,013; 5,273,691; 5,321,622; 5,344,298; 5,345,391; 5,358,673; 5,447,822; 5,481,470; 5,495,328; 5,501,824; 5,554,336; 5,556,590; 5,569,349; 5,569,431; 5,571,471; 5,573,722; 5,609,812; 5,609,813; 5,610,824; 5,630,981; 5,637,169; 5,651,934; 5,667,820; 5,672,312; 5,676,904; 5,688,464; 5,693,144; 5,695,707; 5,711,911; 5,776,409; 5,779,967; 5,814,265; 5,840,239; 5,854,748; 5,855,718; and 5,855,836. The disclosure of each of the foregoing patents is hereby incorporated herein by this reference. As noted in more detail below, however, a significant modification is made to conventional stereolithographic apparatus, such as those offered by 3D Systems, Inc., in the context of initiation and control of the stereolithographic disposition and fixation of materials. Specifically, the apparatus of the present invention employs a so-called “machine vision” system, in combination with suitable programming of the computer controlling the stereolithographic process, to eliminate the need for accurate positioning or mechanical alignment of workpieces to which material is stereolithographically applied. Thus, the present invention expands the use of conventional stereolithographic apparatus and methods to application of materials to large numbers of workpieces which may differ in orientation, size, thickness, configuration and surface topography. While the workpieces employed in the practice of the preferred embodiment of the method of the invention may be, by way of example only, semiconductor dice, wafers, partial wafers, other substrates of semiconductor material or carrier substrates bearing integrated circuits on dice or other semiconductor structures, the method and apparatus of the invention are applicable to fabrication of other products wherein adaptability for rapidly fabricating large numbers of parts having the aforementioned variations in orientation, size, thickness and surface topography is desired.  
         [0037]     With reference again to  FIG. 1  and as noted above, a 3-D CAD drawing of an object to be fabricated in the form of a data file is placed in the memory of a computer  12  controlling the operation of apparatus  10  if computer  12  is not a CAD computer in which the original object design is effected. In other words, an object design may be effected in a first computer in an engineering or research facility and the data files transferred via wide or local area network, tape, disc, CD-ROM or otherwise as known in the art to computer  12  of apparatus  10  for object fabrication.  
         [0038]     The data is preferably formatted in an STL (for StereoLithography) file, STL being a standardized format employed by a majority of manufacturers of stereolithography equipment. Fortunately, the format has been adopted for use in many solid-modeling CAD programs, so often translation from another internal geometric database format is unnecessary. In an STL file, the boundary surfaces of an object are defined as a mesh of interconnected triangles.  
         [0039]     Apparatus  10  also includes a reservoir  14  (which may comprise a removable reservoir interchangeable with others containing different materials) of liquid material  16  to be employed in fabricating the intended object. In the currently preferred embodiment, the liquid is a photo-curable polymer (hereinafter “photopolymer”) responsive to light in the UV wavelength range. The surface level  18  of the liquid material  16  is automatically maintained at an extremely precise, constant magnitude by devices known in the art responsive to the output of sensors within the apparatus and preferably under control of computer  12 . A support platform or elevator  20 , precisely vertically movable in fine, repeatable increments responsive to control of computer  12 , is located for movement downward into and upward out of liquid material  16  in reservoir  14 . A UV wavelength range laser plus associated optics and galvanometers (collectively identified as laser  22 ) for controlling the scan of laser beam  26  in the X-Y plane across platform  20  has associated therewith mirror  24  to reflect beam  26  downwardly as beam  28  toward surface  30  of platform  20 . Beam  28  is traversed in a selected pattern in the X-Y plane, that is to say, in a plane parallel to surface  30 , by initiation of the galvanometers under control of computer  12  to at least partially cure, by impingement thereon, selected portions of liquid material  16  disposed over surface  30  to at least a semisolid state. The use of mirror  24  lengthens the path of the laser beam, effectively doubling same, and provides a more vertical beam  28  than would be possible if the laser  22  itself were mounted directly above platform surface  30 , thus enhancing resolution.  
         [0040]     Data from the STL files resident in computer  12  is manipulated to build an object  50  one layer at a time. Accordingly, the data mathematically representing object  50  is divided into subsets, each subset representing a slice or layer of object  50 . This is effected by mathematically sectioning the 3-D CAD model into a plurality of horizontal layers, a “stack” of such layers representing object  50 . Each slice or layer may be from about 0.0001 to 0.0300 inch thick. As mentioned previously, a thinner slice promotes higher resolution by enabling better reproduction of fine vertical surface features of object  50 . In some instances, a base support or supports  52  for an object  50  may also be programmed as a separate STL file, such supports  52  being fabricated before the overlying object  50  in the same manner, and facilitating fabrication of an object  50  with reference to a perfectly horizontal plane and removal of object  50  from surface  30  of elevator  20 . Where a “recoater” blade  32  is employed as described below, the interposition of base supports  52  precludes inadvertent contact of blade  32  with surface  30 .  
         [0041]     Before fabrication of object  50  is initiated with apparatus  10 , the primary STL file for object  50  and the file for base support(s)  52  are merged. It should be recognized that, while reference has been made to a single object  50 , multiple objects may be concurrently fabricated on surface  30  of platform  20 . In such an instance, the STL files for the various objects and supports, if any, are merged. Operational parameters for apparatus  10  are then set, for example, to adjust the size (diameter, if circular) of the laser light beam used to cure material  16 .  
         [0042]     Before initiation of a first layer for a support  52  or object  50  is commenced, computer  10  automatically checks and, if necessary, adjusts by means known in the art the surface level  18  of liquid material  16  in reservoir  14  to maintain same at an appropriate focal length for laser beam  28 . U.S. Pat. No. 5,174,931, referenced above and previously incorporated herein by reference, discloses one suitable level control system. Alternatively, the height of mirror  24  may be adjusted responsive to a detected surface level  18  to cause the focal point of laser beam  28  to be located precisely at the surface of liquid material  16  at surface level  18  if level  18  is permitted to vary, although this approach is somewhat more complex. The platform  20  may then be submerged in liquid material  16  in reservoir  14  to a depth equal to the thickness of one layer or slice of the object  50 , and the liquid surface level  18  readjusted as required to accommodate liquid material  16  displaced by submergence of platform  20 . Laser  22  is then activated so that laser beam  28  will scan liquid material  16  over surface  30  of platform  20  to at least partially cure (e.g., at least partially polymerize) liquid material  16  at selective locations, defining the boundaries of a first layer  60  (of object  50  or support  52 , as the case may be) and filling in solid portions thereof. Platform  20  is then lowered by a distance equal to the thickness of a layer  60 , and the laser beam  28  scanned to define and fill in the second layer  60  while simultaneously bonding the second layer to the first. The process is then repeated, layer by layer, until object  50  is completed.  
         [0043]     If a recoater blade  32  is employed, the process sequence is somewhat different. In this instance, the surface  30  of platform  20  is lowered into liquid material  16  below surface level  18 , then raised thereabove until it is precisely one layer&#39;s thickness below blade  32 . Blade  32  then sweeps horizontally over surface  30 , or (to save time) at least over a portion thereof on which object  50  is to be fabricated, to remove excess liquid material  16  and leave a film thereof of the precise, desired thickness on surface  30 . Platform  20  is then lowered so that the surface of the film and material level  18  are coplanar and the surface of the material  16  is still. Laser  22  is then initiated to scan with laser beam  28  and define the first layer  60 . The process is repeated, layer by layer, to define each succeeding layer  60  and simultaneously bond same to the next lower layer  60  until object  50  is completed. A more detailed discussion of this sequence and apparatus for performing same is disclosed in U.S. Pat. No. 5,174,931, previously incorporated herein by reference.  
         [0044]     As an alternative to the above approach to preparing a layer of liquid material  16  for scanning with laser beam  28 , a layer of liquid material  16  may be formed on surface  30  by lowering platform  20  to flood material over surface  30  or over the highest completed layer  60  of object  50 , then raising platform  20  and horizontally traversing a so-called “meniscus” blade across the platform (or just the formed portion of object  50 ) one layer thickness thereabove, followed by initiation of laser  22  and scanning of beam  28  to define the next higher layer  60 .  
         [0045]     Another alternative to layer preparation of liquid material  16  is to merely lower platform  20  to a depth equal to that of a layer of liquid material  16  to be scanned and then traverse a combination flood bar and meniscus bar assembly horizontally over platform  20  (or merely over object  50 ) to substantially concurrently flood liquid material  16  over platform  20  and define a precise layer thickness of liquid material  16  for scanning.  
         [0046]     All of the foregoing approaches to liquid material flooding and layer definition and apparatus for initiation thereof are known in the art and are not material to practice of the present invention, so no further details relating thereto will be provided herein.  
         [0047]     Each layer  60  of object  50  is preferably built by first defining any internal and external object boundaries of that layer with laser beam  28 , then hatching solid areas of object  50  with laser beam  28 . If a particular part of a particular layer  60  is to form a boundary of a void in the object above or below that layer  60 , then the laser beam  28  is scanned in a series of closely-spaced, parallel vectors so as to develop a continuous surface, or skin, with improved strength and resolution. The time it takes to form each layer  60  depends upon its geometry, surface tension and viscosity of material, and thickness of the layer.  
         [0048]     Once object  50  is completed, platform  20  is elevated above surface level  18  of liquid material  16 , and the platform  20  with object  50  may be removed from apparatus  10 . Excess, uncured liquid material  16  on the surface of object  50  may be manually removed, and object  50  then solvent-cleaned and removed from platform  20 , usually by cutting it free of base supports  52 . Object  50  may then require postcuring, as material  16  may be only partially polymerized and exhibit only a portion (typically 40% to 60%) of its fully cured strength. Postcuring to completely harden object  50  may be effected in another apparatus projecting UV radiation in a continuous manner over object  50  and/or by thermal completion of the initial, UV-initiated partial cure.  
         [0049]     In practicing the present invention, a commercially available stereolithography apparatus operating generally in the manner as that described with respect to apparatus  10  of  FIG. 1  is preferably employed. For example and not by way of limitation, the SLA-250/50HR, SLA-5000 and SLA-7000 stereolithography systems, each offered by 3D Systems, Inc. of Valencia, Calif., are suitable for practice of the present invention. Photopolymers believed to be suitable for use in practicing the present invention include Cibatool SL 5170 and SL 5210 resins for the SLA-250/50HR system, Cibatool SL 5530 resin for the SLA-5000 and Cibatool SL 7510 resin for the SLA-7000 system. All of these resins are available from Ciba Specialty Chemicals. By way of example and not limitation, the layer thickness of material  16  to be formed, for purposes of the invention, may be on the order of 0.001 to 0.020 inch, with a high degree of uniformity over a field on a surface  30  of a platform  20 . It should be noted that different material layers may be of different heights, so as to form a structure of a precise, intended total height or to provide different material thicknesses for different portions of a structure. The size of the laser beam “spot” impinging on the surface of liquid material  16  to cure same may be on the order of 0.002 inch to 0.008 inch. Resolution is preferably ± 0.0003 inch in the X-Y plane (parallel to surface  30 ) over at least a 0.5 inch ×0.25 inch field from a center point, permitting a high resolution scan effectively across a 1.0 inch ×0.5 inch area. Of course, it is desirable to have substantially this high a resolution across the entirety of surface  30  of platform  20  to be scanned by laser beam  28 , which area may be termed the “field of exposure,” such area being substantially coextensive with the vision field of a machine vision system employed in the apparatus of the invention as explained in more detail below. The longer and more effectively vertical the path of laser beam  26 / 28 , the greater the achievable resolution.  
         [0050]     Referring again to  FIG. 1  of the drawings, it should be noted that apparatus  10  of the present invention includes a camera  70  which is in communication with computer  12  and preferably located, as shown, in close proximity to mirror  24  located above surface  30  of platform  20 . Camera  70  may be any one of a number of commercially available cameras, such as capacitive-coupled discharge (CCD) cameras available from a number of vendors. Suitable circuitry as required for adapting the output of camera  70  for use by computer  12  may be incorporated in a board  72  installed in computer  12 , which is programmed as known in the art to respond to images generated by camera  70  and processed by board  72 . Camera  70  and board  72  may together comprise a so-called “machine vision system,” and specifically a “pattern recognition system” (PRS), the operation of which will be described briefly below for a better understanding of the present invention. Alternatively, a self-contained machine vision system available from a commercial vendor of such equipment may be employed. For example, and without limitation, such systems are available from Cognex Corporation of Natick, Mass. For example, the apparatus of the Cognex BGA Inspection Package™ or the SMD Placement Guidance Package™ may be adapted to the present invention, although it is believed that the MVS-8000™ product family and the Checkpoint® product line, the latter employed in combination with Cognex PatMax™ software, may be especially suitable for use in the present invention.  
         [0051]     It is noted that a variety of machine vision systems are in existence, examples of which and their various structures and uses are described, without limitation, in U.S. Pat. Nos. 4,526,646; 4,543,659; 4,736,437; 4,899,921; 5,059,559; 5,113,565; 5,145,099; 5,238,174; 5,463,227; 5,288,698; 5,471,310; 5,506,684; 5,516,023; 5,516,026; and 5,644,245. The disclosure of each of the immediately foregoing patents is hereby incorporated by this reference.  
         [0052]     In order to facilitate practice of the present invention with apparatus  10 , a data file representative of at least one physical parameter, such as (for example) the size, configuration, thickness and surface topography of, for example, a particular type and design of semiconductor die  100  to be packaged, is placed in the memory of computer  12 . If the die  100  is to be packaged with a lead frame, data representative of the die with attached and electrically connected lead frame is provided. If packaging material in the form of the aforementioned photopolymer is to be applied only to an upper surface of a die  100 , or to the upper surface and portions or all of the side surfaces of a die  100 , a large plurality of such dice  100  may be placed on surface  30  of platform  20  for packaging, as depicted in  FIGS. 2 and 3 .  FIG. 3  depicts dice  100  in various stages of package formation to completion, the packaging being shown as substantially transparent as results if the aforementioned photopolymers are employed. If package sidewalls are to be formed, it is desirable that the surface  30  of platform  20  comprise, or be coated or covered with, a material from which the at least partially cured material  16  defining the lowermost layers of the package sidewalls may be easily released to prevent damage to the packaging. Alternatively, a solvent may be employed to release the package sidewalls from platform  20  after packaging is completed. Such release and solvent materials are known in the art. See, for example, U.S. Pat. No. 5,447,822 referenced above and previously incorporated herein by reference. Camera  70  is then activated to locate the position and orientation of each die  100  to be packaged by scanning platform  20  and comparing the features of the dice  100  with those in the data file residing in memory, the locational and orientational data for each die  100  then also being stored in memory. It should be noted that the data file representing the design size, shape and topography for the dice may be used at this juncture to detect physically defective or damaged dice  100  prior to packaging and to automatically delete such dice  100  from the packaging operation. It should also be noted that data files for more than one type (size, thickness, configuration, surface topography) of die  100  may be placed in computer memory and computer  12  programmed to recognize not only die locations and orientations, but which type of die  100  is at each location so that material  16  may be cured by laser beam  28  in the correct pattern and to the height required to define package sidewalls and to provide a package top at the correct level and of the correct size and shape over each die  100 .  
         [0053]     Continuing with reference to  FIG. 3  of the drawings, dice  100  on platform  20  may then be submerged partially below the surface level  18  of liquid material  16  to a depth the same as, or greater than, the thickness of a first layer of material  16  to be at least partially cured to a semisolid state to form the lowest layer  60  of a package sidewall  102  about each of dice  100 , and then raised to a depth equal to the layer thickness if lowered to a greater depth than a layer thickness, the surface of liquid material  16  being allowed to settle. The material  16  selected for use in packaging dice  100  may be one of the above-referenced resins from Ciba Specialty Chemicals which exhibits a desirable dielectric constant, is of sufficient (semiconductor grade) purity, and is of sufficiently similar coefficient of thermal expansion (CTE) to that of the die so that the package and the die itself are not unduly stressed during thermal cycling in testing and subsequent normal operation.  
         [0054]     Laser  22  is then activated and scanned to direct beam  28 , under control of computer  12 , about the periphery of each die  100  to effect the aforementioned partial cure of material  16  to form a first layer  60 . The platform  20  is then lowered into reservoir  14  and raised to another sidewall layer thickness-equaling depth increment and the laser  22  activated to add another sidewall layer  60 . This sequence continues, layer  60  by layer  60 , until the package sidewalls  102  are built up about dice  100 . As noted below with regard to  FIG. 12 , the sidewalls  102  may comprise only a single layer  60  of material  16 . At this point, platform  20  is again lowered to submerge the upwardly-facing active surfaces  104  of dice  100  below surface level  18  and then positioned a desired additional depth increment below the surface of material  16 , which may be lesser or greater than the sidewall layer thickness, depending upon the thickness required for the top  106  of the package. For example, a greater thickness of material  16  may be required to cover a die  100  having wire bonds protruding upwardly therefrom than if a die  100  is covered before connection to a lead frame. It should also be noted that the thickness of material  16  over a selected portion of a given die  100  may be altered die by die, again responsive to output of camera  70  or one or more additional cameras  74 ,  76  or  78 , shown in broken lines in  FIG. 1 , detecting the protrusion of unusually high wire bond loops or other features projecting above the active surface  104  of a given die  100  which should be, but is not, covered by the “design” or pre-programmed thickness of material  16  disposed over and at least partially cured on active surface  104 . In any case, laser  22  is again activated to at least partially cure material  16  residing over each die  100  to form a package top  106  of one or more layers  60 , top  106  being substantially contiguous with package sidewalls  102 , laser beam  26  being controlled as desired to avoid certain surface features on dice  100 , such as bond pads  108  intended to be exposed for connection to higher-level packaging as by wire bonding, TAB bonding using flex circuits, or use of projecting conductive connectors in a “flip chip” configuration. It should also be noted (see  FIG. 4 ) that the package top may be formed within an outer boundary defined by sidewalls  102  extending above active surface  104  and forming a dam  102   d  thereabout. In this instance, the platform  20  may be submerged so that material  16  enters the area within the dam  102   d , raised above surface level  18 , and then laser beam  28  activated and scanned to at least partially cure material  16  residing within the dam or, alternatively, to merely cure a “skin”  106   a  over the top of the dice  100  which may also bound bond pads  108 , the final cure of the remaining, underlying material  106   b  of the package top  106  being effected subsequently by broad-source UV radiation in a chamber, or by thermal cure in an oven. In this manner, an extremely thick protective package top of material  16  may be formed in minimal time within apparatus  10 .  
         [0055]     Referring to  FIGS. 4, 5 ,  6 A and  6 B of the drawings by way of example and not limitation, it will be evident that a die  100  requiring a package bottom  110  so as to effect substantially complete semi-hermetic sealing of die  100  within the confines of a package may have such package formed thereabout in several ways, depending on its configuration and how it is to be connected to higher-level packaging.  
         [0056]     For example, as shown in  FIG. 4 , die  100  may be placed, active surface  104  up, on a sheet of material  120  on surface  30  of platform  20  with which material  16  is compatible and to which material  16  bonds when at least partially cured. In practice, a plurality of dice  100  would be placed on sheet  120 . Laser  22  would then be activated and laser beam  26  scanned to build package sidewalls  102  layer by layer, bonding the lowest sidewall layer  60  to the material of sheet  120  under die  100  and defining package bottom  110  so that die  100  is substantially encapsulated after sidewalls  102  and top  106  are completed. Die  100  with material  120  adhered to the bottom thereof may then be severed from the sheet immediately as shown in broken lines  122 , or carried thereon with a plurality of dice  100  for further handling, fabrication or testing operations.  
         [0057]     An alternative approach, shown in  FIG. 5 , which may be more economical from a material wastage standpoint, depending upon the cost of material  120 , is to literally “build” package bottom  110  in one or more layers  60  on surface  30  of platform  20  or on a precisely-dimensioned (in terms of thickness) carrier sheet  124  from which material  16  may be subsequently released after cure through use of a release layer or coating, solvent, or other techniques known in the art. The package bottom  110  may include a peripheral lip or rim  126  comprising one or more layers  60  to form a receptacle into which die  100  is inserted, the package then being completed as described above with respect to  FIG. 4 .  
         [0058]     Yet another approach, shown in  FIGS. 6A and 6B , which may be suitable for lead frame-mounted dice  100 , involves the use of a lead frame strip  130  carrying a plurality of dice  100  secured and electrically connected (as by wire bonding, thermocompression bonding, TAB or otherwise as known in the art) to lead frames  132  of the strip  130 . In this instance (see  FIG. 6A ), the dice  100  are first presented for packaging face down, the lead frame strip  130  carrying dice  100  partially submerged, and material  16  is at least partially cured, layer  60  by layer  60 , from a level where lead fingers  134  are located to first fix a discontinuous layer  60 a of material intermediate the lead fingers  134  and around the lead finger-devoid periphery of the dice  100  at that level, and then to build the lower portion package sidewalls  102   a  and package bottom  110  layer  60  by layer  60 . The lead frame strip  130  is then inverted (see  FIG. 6B ) and the upper portion package sidewalls (if any, such as might be required for a package housing a paddle-type lead frame wherein the lead fingers  134  may extend laterally below the upper, active surface of the die or if a dam is built about the active surface of the die as dam  102 d in  FIG. 4 ) is built layer  60  by layer  60 , after which the package top  106  is formed. Again, it should be noted that adequate dielectric coverage of unusually large or high projecting surface features of a given die  100  such as wire bonds  150  with a package top or top portion  106   c  of enhanced thickness may be ensured through the use of one or more additional cameras  74 ,  76 ,  78 . Thus, unlike a conventional, transfer molding packaging process, the stereolithographic process of the present invention is adaptable to ensure adequate encapsulation of semiconductor die assemblies with dimensions outside a conventional tolerance range. Further, it is also contemplated that the upper portion sidewalls, if any, may first be formed, then the package top  106 , the die  100  then being inverted for formation of the lower portion sidewalls  102   a  and the package bottom  110 , the exact sequence being immaterial to the practice of the invention.  
         [0059]     It is also notable that the method depicted and described with respect to  FIGS. 6A and 6B  has utility with a variety of lead frame configurations, including conventional lead frames having a die mounting paddle, or paddle-less leads-over-chip (LOC) lead frames or leads-under-chip (LUC) lead frames. The present invention is adaptable to various arrangements of lead fingers, whether extending from a single side of a package as in a zig-zag in-line package (ZIP), single in-line package (SIP) arrangements, from both sides as in a dual in-line package (DIP) arrangement or a more modem thin small outline package (TSOP), from four sides as in a quad flat pack (QFP) arrangement, a direct die connect package (DDC), or otherwise.  
         [0060]     Referring now to  FIG. 7  of the drawings, it will be understood and appreciated that a plurality of dice  100  secured and electrically connected to a carrier substrate  200  to create a multi-chip module  1000 , such as, without limitation, a single in-line memory module (SIMM), dual in-line memory module (DIMM) or triple in-line memory module (TRIMM), may be encapsulated in place on the carrier substrate in the same manner as described above with respect to individual dice  100 . Specifically, sidewalls  102  comprising multiple layers  60  may be built up around the lateral peripheries of dice  100 , and package tops  106  formed thereafter. If wire bonds, TAB bonds or other upwardly-projecting conductive connectors are employed to connect dice  100  to traces on carrier substrate  200 , such structures may be detected by camera  70  (and  74 ,  76  or  78 , if employed) so that the wire bonds may be individually covered with material  16  only to a required depth. Thus, in contrast to the use of excessive material in a conventional “glob top” of silicone gel, each die  100  may be encapsulated using a minimal volume of material  16 .  
         [0061]     In yet another, board-on-chip (BOC) embodiment of the present invention shown in  FIG. 8 , a single die  100  or multiple dice  100  may be mounted active-surface facing a carrier substrate  300  having a slot or slots  302  therethrough (the number corresponding to the number of dice  100  to be carried thereon). In such a configuration, a single or double row of bond pads  108  running down the center of a die  100  is wire bonded as at  150  to ends  306  of circuit traces  304  adjacent slot  302  and on the opposite side of carrier substrate  300  from that to which die  100  is secured. Such an arrangement may be employed to use dice  100  configured for an LOC lead frame in a multi-chip module or to convert such dice to provide solder bumps or other conductive connective elements  310  (conductive epoxy, conductor-filled epoxy, anisotropically-conductive adhesive elements, etc.) projecting in an array for connection in a flip-chip configuration to higher level packaging. As shown in  FIG. 8 , the sides and back of a die  100  may be packaged with layered sidewalls  102  (again, which may comprise only a single, relatively thick layer  60 ) and a bottom  110  and (after inversion of carrier substrate  300 ) the wire bonds  150  projecting through slot  302  and extending from bond pads  108  to trace ends  306  covered with one or more layers  60  of at least partially cured material  16  comprising package top  106 . Desirably, the entire slot may be filled and the wire bonds  150  covered to beyond the laterally outer peripheries of trace ends  306  so that the wires and bond points to trace ends  306  are covered.  
         [0062]     Referring now to  FIG. 12  of the drawings, an extremely simple and effective packaging approach according to the invention is illustrated. Semiconductor die  100 , residing on surface  30  (or alternatively on a release layer or on a package bottom as discussed above) is packaged using only two layers  60  of material  16 . The first layer  60   a  forms the entire height of the sidewalls  102 , while the second layer  60   b  forms the entire package top  106  extending over the tops of sidewalls  102 . Of course, layer  60   a  may be formed high enough so as to extend over active surface  104  of semiconductor die  100  to define a dam thereabout to contain liquid material  16 , the upper surface of which may be skin-cured and the underlying material  16  subsequently completely cured by a broad-source UV radiation or by heat cure. Thus, it is possible to effect the complete packaging of a semiconductor die or other electronic component using no more than three layers  60  of material  16  or, if no package bottom is required (such as in a multi-chip module), only two layers  60 .  
         [0063]     It is notable that the method of the present invention, in addition to eliminating the capital equipment expense of transfer molding processes, is extremely frugal in its use of dielectric encapsulant material  16 , since all such material in which cure is not initiated by laser beam  26  remains in a liquid state in reservoir  14  for use in packaging the next plurality of dice  100  or modules  1000 . Further, since it is no longer necessary to encapsulate dice with packaging of sufficient wall thickness to accommodate relatively large dimensional variations such as those which may be exhibited by wire bond loop heights, the overall volume of packaging material may be smaller in some cases. Also, surprisingly, the package dimensional tolerances achievable through use of the present invention are more precise, e.g., three times more precise, than those of which a transfer molding system is capable, and there is no need for an inclined mold sidewall (and thus extra packaging material) to provide a release angle to facilitate removal of a packaged die from a mold cavity. Moreover, there is no potential for mold damage, mold wear, or requirement for mold refurbishment. Finally, the extended cure times at elevated temperatures, on the order of, for example, four hours at 175° C., required after removal of batches of dice from the transfer mold cavities are eliminated. Post-cure of die packages formed according to the present invention may be effected with broad-source UV radiation emanating from, for example, flood lights in a chamber through which dice are moved on a conveyor, or in large batches. Additionally, if some portion of a package is shadowed by a portion of a die or lead frame, cure of material  16  in that area may be completed in an oven at a relatively low temperature such as, for example, 160° C.  
         [0064]     It should also be noted that the packaging method of the present invention is conducted at substantially ambient temperature, the small beam spot size and rapid traverse of laser beam  28  around and over the semiconductor dice  100  resulting in negligible thermal stress thereon. Physical stress on the semiconductor dice and associated lead frames and bond wires is also significantly reduced, in that material  16  is fixed in place and not moved over the dice in a viscous, high-pressure wave front as in transfer molding, followed by cooling-induced stressing of the package. Bond wire sweep is eliminated, as is any tendency to drive particulates in the polymer encapsulant between lead fingers and an underlying portion of the active surface of the die with consequent damage to the integrity of the active surface.  
         [0065]     It should be specifically noted that packaging electronic components in accordance with the invention may be effected with the use of a liquid material, such as the aforementioned polymers, which is “filled” with particulates of silicon or other materials. By such an approach, the cost of the liquid material may be lowered in appropriate instances where the filler does not adversely alter the coefficient of thermal expansion (CTE) of the packaging material. Further, the CTE of the packaging material may be tailored to be similar to, or even closely match in some instances, the CTE of the substrate onto, or adjacent, which the packaging material is applied by appropriate selection of the volume and type of filler material. Thus, whether the substrate to which the packaging material is applied comprises a plastic, a ceramic, or silicon (or other material), the packaging filler mixture may be adjusted as desired or required.  
         [0066]     While the present invention has been disclosed in terms of certain preferred embodiments, those of ordinary skill in the art will recognize and appreciate that the invention is not so limited. Additions, deletions and modifications to the disclosed embodiments may be effected without departing from the scope of the invention as claimed herein. Similarly, features from one embodiment may be combined with those of another while remaining within the scope of the invention.