Abstract:
A semiconductor device manufacturing method includes the steps of filling a cavity and a resin reservoir hole in a lower metal mold with a liquid-state resin, holding a semiconductor element between the lower metal mold and an upper metal mold, injecting the resin in the resin reservoir hole into the cavity to seal the semiconductor device with the resin. Thus, the semiconductor device having almost no voids and less material loss is manufactured with high accuracy.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2006-032320 filed in Japan on 9 Feb. 2006 and Patent Application No. 2006-317300 filed in Japan on 24 Nov. 2006, the entire contents of which are incorporated herein by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a semiconductor device manufacturing method and a semiconductor device manufacturing apparatus. 
         [0003]    In general, according to a method for manufacturing a semiconductor device, as shown in  FIG. 15A , a semiconductor element  105  is manufactured by first bonding a semiconductor chip  102  to a lead frame  101  with an adhesive such as a silver paste. Then, as shown in  FIG. 15B , the semiconductor chip  102  is connected to the lead frame  101  with a gold wire  103 . Then, as shown in  FIG. 15C , a semiconductor device  106  is manufactured by sealing the semiconductor element  105  with a resin  104 . Subsequently, the semiconductor device  106  becomes a product after the steps of exterior plating, lead forming (lead frame processing), electrical characteristic inspection (measurement of various electric characteristics), marking, visual inspection and packing. 
         [0004]    It is general to use a thermosetting resin such as epoxy resin and silicone resin as the resin  104 . There are molding methods such as a transfer molding method and a casting molding method as a method for sealing with the resin  104 . 
         [0005]    In detail, when epoxy resin is used as the resin  104 , the most general method of sealing with the epoxy resin is the transfer molding method. The transfer molding method has the steps of inserting and melting an epoxy resin, which is compression molded into a tablet form or an epoxy resin in a powder form, in a resin reservoir section called a pot maintained at high temperature and thereafter injecting the epoxy resin into a cavity formed at a metal mold maintained at high temperature through a runner with a pressure. After injecting the epoxy resin, the resin is held in a metal mold until the resin is completely hardened. Thereafter, the semiconductor device is taken out by vertically opening the metal mold and transferred to the subsequent step (refer to JP 2004-311748 A and JP 2002-94124 A). 
         [0006]    As an example of a metal mold of the transfer molding, there is a one-pot type metal mold shown in  FIG. 16A . The metal mold has one round pot portion  111  into which a resin is inserted, and has runner portions  112  that extend from the pot portion  111 . 
         [0007]    As another example of a metal mold of the transfer molding, there is a multi-pot type metal mold shown in  FIG. 16B . The metal mold has a plurality of round pot portions  111  into which a resin is inserted, and has runner portions  112  that extend from the pot portions  111 . 
         [0008]    As still another example of a metal mold of the transfer molding, there is a cylindrical pot type metal mold shown in  FIG. 16C . The metal mold has one cylindrical pot portion  111  into which a resin is inserted, and has runner portions  112  that extend from the pot portion  111 . 
         [0009]    The multi-pot type metal mold of  FIG. 16B  and the cylindrical pot type metal mold of  FIG. 16C  have a shortened resin path after melting in comparison with the one-pot type metal mold of  FIG. 16A . Therefore they have an advantage that the molding conditions, such as a range of injection time in molding, become wider. 
         [0010]    However, the resin needs to be subjected to compression molding into a mini tablet or a rod-like shape in the case of  FIGS. 16B and 16C . Therefore, they have more faults in comparison with the normal tablet in the case of  FIG. 16A , which causes a need to decrease variation in weight of the mini tablet. Also, the rod-shaped tablet is easy to break after being subjected to compression molding, which needs more care during conveyance. 
         [0011]    When a liquid-state epoxy resin is used as the resin  104 , the casting method shown in  FIG. 17  or the potting method shown in  FIG. 18  is employed as a method for sealing with the liquid-state epoxy resin. 
         [0012]    In the casting method shown in  FIG. 17 , a semiconductor element  122  is set in a frame  121  prepared beforehand. The, a liquid-state resin  123  is injected into the frame  121 . Thereafter the liquid-state resin  123  is heated for hardening. 
         [0013]    In the potting method shown in  FIG. 18 , a semiconductor element  122  is set in a resin casing  124 . Then, a liquid-state resin  123  is injected into the resin casing  124 . Thereafter, the liquid-state resin  123  is heated for hardening. 
         [0014]    When silicone resin is used for the resin  104 , all the above-stated sealing methods can be considered as a method for sealing with the silicone resin. However, the potting method is most generally employed. 
         [0015]    In recent years, for example, car electronics has been remarkably progressed in the forms of digital information equipment, AV equipment, intra-car networks, hybrid engines, electric cars, sensors for safety driving and so on. Under these circumstances, semiconductor devices used therefor are required to have high reliability and capability of enduring onboard environments. Specifically, the semiconductor devices are needed to cope with an ambient temperature of −40 to 125° C. for example. 
         [0016]    In the case of using epoxy resin as a sealing resin, the epoxy resin has sufficiently tolerable characteristics in moisture resistance and so on. However, the epoxy resin has a disadvantage of being easily discolored by exposure to high temperature. In contrast to this, in the case of using silicone resin as a sealing resin, the silicone resin is hardly discolored even when it is exposed to high temperature. 
         [0017]    Thus, it is necessary to use silicone resin for resin sealing in order to cope with high ambient temperature as in the case of car-onboard-use, especially, in an optical semiconductor device that has a function to transmit and receive light. 
         [0018]    However, the above-described conventional semiconductor device manufacturing methods, specifically, the casting method and the potting method have the disadvantages of the low dimensional accuracy of a package, a high manufacturing cost as a consequence of much time and/or labor necessary for the manufacturing, and the frequent occurrence of voids as a consequence of the entry of air into a package. 
         [0019]    In the transfer molding method, dimensional accuracy is improved. However, the transfer molding method has a disadvantage of increase in material cost due to superfluous resin generated in the runner portion and so on. Particularly, in the case where silicone resin is used as a sealing resin in order to manufacture a semiconductor device for the car-onboard use, the silicone resin is more expensive than the epoxy resin in unit price. Therefore, reduction in material loss is needed as much as possible. 
       BRIEF SUMMARY OF THE INVENTION 
       [0020]    An object of the present invention is to provide a semiconductor device manufacturing method with high accuracy, reduction in loss of material and less generation of voids in a way of sealing with liquid-state resin (particularly, silicone resin). 
         [0021]    To achieve the above-mentioned object, the present invention provides a semiconductor device manufacturing method comprising: 
         [0022]    a first step of filling a cavity formed in a lower metal mold and a resin reservoir hole formed in the lower metal mold and connected to the cavity with a liquid-state resin; 
         [0023]    a second step of holding a semiconductor element between the lower metal mold and an upper metal mold; and 
         [0024]    a third step of sealing the semiconductor element with the resin by injecting the resin of the resin reservoir hole into the cavity. 
         [0025]    According to the semiconductor device manufacturing method of the present invention, unlike the potting method and the transfer molding method, it is possible to manufacture a semiconductor device with a little loss of material and excellent quality at low cost. Particularly, the loss of material can be further reduced when silicone resin is used as the resin to manufacture the semiconductor device for the car-onboard use. This is because the cavity and the resin reservoir hole in the lower metal mold are filled with the liquid-state resin, the semiconductor element is held between the lower metal mold and the upper metal mold, and the resin in the resin reservoir hole is injected into the cavity, so as to seal the semiconductor element with the resin. 
         [0026]    In one embodiment of the present invention, the first step comprises placing a filling jig on the lower metal mold in such a way that a resin injection hole, which is formed in the filling jig and filled with the resin, is aligned with the cavity of the lower metal mold; and filling the cavity and the resin reservoir hole with the resin through the resin injection hole by opening a gate section formed in the filling jig to close or open the resin injection hole. 
         [0027]    According to the embodiment, the cavity and the resin reservoir hole can be filled simply and reliably with the liquid-state resin because the cavity and the resin reservoir hole are filled with the liquid-state resin from the filling jig. 
         [0028]    In one embodiment of the present invention, the first step comprises placing a tube extending from a resin feeder filled with the resin on the lower metal mold in such a way that an opening of the tube is aligned with the cavity of the lower metal mold; and filling the cavity and the resin reservoir hole with the resin through the opening of the tube via the tube from the resin feeder. 
         [0029]    According to the embodiment, the cavity and the resin reservoir hole can be filled simply and reliably with the liquid-state resin because the cavity and the resin reservoir hole are filled with the liquid-state resin from the resin feeder via the tube. 
         [0030]    In one embodiment of the present invention, the third step comprises injecting the resin of the resin reservoir hole into the cavity by extruding the resin into the cavity with use of an injection member moving in the resin reservoir hole; and pushing the semiconductor element sealed with the resin out of the lower metal mold with use of the injection member after the resin is hardened. 
         [0031]    According to the embodiment, the resin is injected into the cavity by being extruded into the cavity with use of the injection member, and also the semiconductor element sealed with the resin is pushed out of the lower metal mold with use of the injection member. Thus, the semiconductor device can be manufactured swiftly and efficiently because the injection member is used not only as a plunger that extrudes the resin from the resin reservoir hole, but also as an ejector pin that pushes the semiconductor element out of the lower metal mold. 
         [0032]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  1 , wherein 
         [0033]    the third step comprises: 
         [0034]    injecting the resin of the resin reservoir hole into the cavity by extruding the resin into the cavity with use of an injection member moving in the resin reservoir hole; and 
         [0035]    forming a lens portion of the hardened resin by pressurizing the resin during a hardening process with use of an end face formed in a lens-like shape of the injection member. 
         [0036]    According to the embodiment, the lens portion can be formed swiftly and simply out of the resin because the lens portion of the hardened resin is formed by pressurizing the resin during hardening the resin with use of the end face of the injection member, which face is formed into the lens-like shape. 
         [0037]    The present invention also provides a semiconductor device manufacturing apparatus comprising: 
         [0038]    a lower metal mold having a cavity and a resin reservoir hole directly connected to the cavity; 
         [0039]    an upper metal mold relatively coming close to or away from the lower metal mold and holding a semiconductor element together with the lower metal mold; 
         [0040]    a filling device filling the cavity and the resin reservoir hole in the lower metal mold with a liquid-state resin; and 
         [0041]    an injection member placed in the resin reservoir hole so as to reciprocate in the resin reservoir hole and injecting the resin of the resin reservoir hole into the cavity by extruding the resin into the cavity with use of the injection member. 
         [0042]    According to the semiconductor device manufacturing apparatus of the present invention, the apparatus includes the lower metal mold that has the cavity and the resin reservoir hole, the upper metal mold that holds the semiconductor element with the lower metal mold, the filling device that fills the cavity and the resin reservoir hole in the lower metal mold with the liquid-state resin, and the injection member that injects the resin in the resin reservoir hole into the cavity. Therefore, the semiconductor element is sealed with the resin by filling the cavity and the resin reservoir hole of the lower metal mold with the liquid-state resin, holding the semiconductor element by the lower and upper metal molds and then injecting the resin of the resin reservoir hole into the cavity by the injection member. 
         [0043]    Therefore, unlike the potting method and the transfer molding method, a semiconductor device can be manufactured with less loss of material and excellent quality at low cost. Particularly, the loss of material can be further reduced when silicone resin is used as the resin to manufacture the semiconductor device for the car-onboard use. 
         [0044]    In one embodiment of the present invention, The semiconductor device manufacturing apparatus as set forth in claim  6 , wherein 
         [0045]    an end face of the injection member, which end face is placed on a side of the cavity in the lower metal mold, is formed into a lens-like shape. 
         [0046]    According to the embodiment, since the end face of the injection member on the side of the cavity in the lower metal mold is formed into a lens-like shape, it is required to polish only the end face of the injection member but not the whole of the metal molds. This leads to cost reductions of the metal molds. Moreover, the dimensions of the lens can also be easily changed since the injection member can easily be replaced. 
         [0047]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  1 , wherein 
         [0048]    the first step comprises: 
         [0049]    placing the filling jig on the lower metal mold in such a way that a resin injection hole, which is formed in the filling jig and filled with the resin, is aligned with the cavity of the lower metal mold; and 
         [0050]    filling the cavity and the resin reservoir hole with the resin through the resin injection hole by opening a gate section formed in the filling jig to close or open the resin injection hole and by moving an injection member, which is placed in the upper metal mold, in the resin injection hole of the filling jig. 
         [0051]    According to the embodiment, the cavity and the resin reservoir hole can be filled simply and reliably with the liquid-state resin because the cavity and the resin reservoir hole are filled with the liquid-state resin from the filling jig by the injection member placed at the upper metal mold. 
         [0052]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  8 , wherein, 
         [0053]    a lens portion of the hardened resin is formed by pressurizing the resin during hardening the resin by using an end face of the injection member placed in the upper metal mold, which end face is formed into a lens-like shape. 
         [0054]    According to the embodiment, the lens portion can be formed swiftly and easily of the resin because the lens portion of the hardened resin is formed by pressurizing the resin during hardening the resin by using the end face of the injection member placed in the upper metal mold, which end face is formed in the lens-like shape. 
         [0055]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  8 , wherein 
         [0056]    the semiconductor element sealed with the resin is pushed out of the cavity formed in the lower metal mold by using the injection member placed in the upper metal mold after the resin is hardened. 
         [0057]    According to the embodiment, the semiconductor element sealed with the resin is pushed out of the cavity formed in the lower metal mold by using the injection member placed in the upper metal mold. Therefore, the semiconductor device can be manufactured swiftly and efficiently by using the injection member not only as a plunger for extruding the resin from the filling jig but also as an ejector pin for pushing the semiconductor element out of the lower metal mold. 
         [0058]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  2 , wherein 
         [0059]    a hole of the gate section of the filling jig, via which the resin passes when the lower metal mold is filled with the resin through the resin injection hole of the filling jig, is tapered in such a way that the hole gradually decreases in diameter toward the lower metal mold. 
         [0060]    According to the embodiment, the lower metal mold can be smoothly filled with the liquid-state resin since the hole of the gate section of the filling jig is tapered. 
         [0061]    In one embodiment of the present invention, The semiconductor device manufacturing method as set forth in claim  1 , wherein 
         [0062]    the third step comprises: 
         [0063]    injecting the resin of the resin reservoir hole into the cavity by extruding the resin into the cavity with use of an injection member moving in the resin reservoir hole; 
         [0064]    retreating the injection member from a side of the cavity after the resin is hardened; and 
         [0065]    pushing the semiconductor element sealed with the resin out of the lower metal mold by discharging air from the resin reservoir hole toward the cavity. 
         [0066]    According to the embodiment, the semiconductor device can easily be taken out of the lower metal mold because the semiconductor element sealed with the resin is pushed out of the lower metal mold by discharging air from the resin reservoir hole toward the cavity. 
         [0067]    In one embodiment of the present invention, The semiconductor device manufacturing apparatus as set forth in claim  6 , wherein 
         [0068]    an outer periphery of a bottom of the cavity coincides in shape with an inner periphery of the resin reservoir hole; and 
         [0069]    an outer periphery of an end face of the injection member on a side of the cavity coincides in shape with the inner periphery of the resin reservoir hole. 
         [0070]    According to the embodiment, the outer periphery of the bottom of the cavity coincides in shape with the inner periphery of the resin reservoir hole, and also the outer periphery of the end face of the injection member coincides in shape with the inner periphery of the resin reservoir hole. Therefore, the outer periphery of the bottom of the cavity coincides in shape with the outer periphery of the end face of the injection member. That is, the bottom of the cavity is formed by only the end face of the injection member. 
         [0071]    Therefore, the lower end face of the semiconductor device can be formed into a smooth shape without undulations by using a flat end face of the injection member. 
         [0072]    In one embodiment of the present invention, The semiconductor device manufacturing apparatus as set forth in claim  6 , wherein 
         [0073]    the lower metal mold has a plurality of the cavities, and 
         [0074]    communication passages, through which all the cavities communicate at least in series with one another, are formed on mutually facing surfaces of the upper and lower metal molds when the upper and lower metal molds contact with each other. 
         [0075]    According to the embodiment, when the upper and lower metal molds contact with each other, the communication passages is formed on the mutually facing surfaces of the upper and lower metal molds, so that through the communication passages all the cavities communicate with one another at least in series. Therefore, the resin of the cavity moves via the communication passages even if variation occurs in the amount of the resin to be charged in the cavities, and the variation in the amount of the resin of the cavities can be suppressed. Therefore, it is possible to manufacture a semiconductor device in a stable shape. 
         [0076]    In one embodiment of the present invention, The semiconductor device manufacturing apparatus as set forth in claim  6 , wherein 
         [0077]    a subcavity, which communicates with the cavity of the lower metal mold, is formed on mutually facing surfaces of the upper and lower metal molds when the upper and lower metal molds contact with each other. 
         [0078]    According to the embodiment, when the upper and lower metal molds contact with each other, the subcavity is formed on the mutually facing surfaces of the upper and lower metal molds and communicate with the cavity of the lower metal mold. Therefore, even if the resin is excessively injected into the cavity, the superfluous resin flows into the subcavity, and it is possible to manufacture a semiconductor device in a stable shape. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0079]    The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein: 
           [0080]      FIG. 1A  shows a schematic sectional view of a semiconductor device manufacturing apparatus according to a first embodiment of the present invention, and a first step of a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0081]      FIG. 1B  shows a schematic sectional view of a second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the first embodiment; 
           [0082]      FIG. 1C  shows a schematic sectional view of a third step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the first embodiment; 
           [0083]      FIG. 1D  shows a schematic sectional view of a fourth step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the first embodiment; 
           [0084]      FIG. 1E  shows a schematic sectional view of a fifth step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the first embodiment; 
           [0085]      FIG. 2A  shows a schematic sectional view of a semiconductor device manufacturing apparatus according to a second embodiment of the present invention; 
           [0086]      FIG. 2B  shows a schematic sectional view of a first step of a semiconductor device manufacturing method with use of the manufacturing apparatus of the second embodiment; 
           [0087]      FIG. 2C  shows a schematic sectional view of a second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the second embodiment; 
           [0088]      FIG. 3  shows a schematic sectional view of a semiconductor device manufacturing apparatus according to a third embodiment of the present invention and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0089]      FIG. 4A  shows a schematic sectional view of a semiconductor device manufacturing apparatus according to a fourth embodiment of the present invention and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0090]      FIG. 4B  shows a schematic sectional view of a semiconductor device manufactured by using the manufacturing apparatus and the manufacturing method of the fourth embodiment; 
           [0091]      FIG. 5A  shows a schematic sectional view of the semiconductor device manufacturing apparatus according to a fifth embodiment of the present invention and a first step of a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0092]      FIG. 5B  shows a schematic sectional view of the second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the fifth embodiment; 
           [0093]      FIG. 5C  shows a schematic sectional view of the third step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the fifth embodiment; 
           [0094]      FIG. 6A  shows a schematic sectional view of a sixth embodiment of the semiconductor device manufacturing apparatus and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0095]      FIG. 6B  shows a schematic sectional view of the semiconductor device manufactured with use of the manufacturing apparatus and the manufacturing method of the sixth embodiment; 
           [0096]      FIG. 7A  shows a schematic sectional view of a seventh embodiment of the semiconductor device manufacturing apparatus and the first step of a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0097]      FIG. 7B  shows a schematic sectional view of the second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the seventh embodiment; 
           [0098]      FIG. 8A  shows a schematic sectional view of an eighth embodiment of the semiconductor device manufacturing apparatus and the first step of a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0099]      FIG. 8B  shows a schematic sectional view of the second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the eighth embodiment; 
           [0100]      FIG. 9  shows a schematic sectional view of a ninth embodiment of the semiconductor device manufacturing apparatus and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0101]      FIG. 10A  shows a schematic sectional view of a tenth embodiment of the semiconductor device manufacturing apparatus and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0102]      FIG. 10B  shows a schematic sectional view of the semiconductor device manufactured with use of the manufacturing apparatus and the manufacturing method of the tenth embodiment; 
           [0103]      FIG. 11A  shows a schematic sectional view of a comparative example of the semiconductor device manufacturing apparatus and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0104]      FIG. 11B  shows a schematic sectional view of the semiconductor device manufactured with use of the manufacturing apparatus and the manufacturing method of the comparative example; 
           [0105]      FIG. 12A  shows a schematic sectional view of an eleventh embodiment of the semiconductor device manufacturing apparatus and the first step of a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0106]      FIG. 12B  shows a schematic sectional view of the second step of the semiconductor device manufacturing method with use of the manufacturing apparatus of the eleventh embodiment; 
           [0107]      FIG. 13  shows a schematic sectional view of a twelfth embodiment of the semiconductor device manufacturing apparatus and a semiconductor device manufacturing method with use of the manufacturing apparatus; 
           [0108]      FIG. 14A  shows a schematic sectional view of the semiconductor device manufactured with use of the manufacturing apparatus and the manufacturing method of the twelfth embodiment; 
           [0109]      FIG. 14B  shows a schematic sectional view of the semiconductor device manufactured with use of the manufacturing apparatus and the manufacturing method of the twelfth embodiment; 
           [0110]      FIG. 15A  shows a schematic sectional view of a first step of a general manufacturing method for a semiconductor device; 
           [0111]      FIG. 15B  shows a schematic sectional view of a second step of the general manufacturing method for the semiconductor device; 
           [0112]      FIG. 15C  shows a schematic sectional view of a third step of the general manufacturing method for the semiconductor device; 
           [0113]      FIG. 16A  shows a schematic sectional view of a metal mold in one-pot type transfer molding; 
           [0114]      FIG. 16B  shows a schematic sectional view of the metal mold in multi-pot type transfer molding; 
           [0115]      FIG. 16C  shows a schematic sectional view of the metal mold in cylindrical pot type transfer molding; 
           [0116]      FIG. 17  shows an explanatory view of a casting method; and 
           [0117]      FIG. 18  shows an explanatory view of a potting method. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0118]    The present invention will be described in detail below by embodiments with reference to the drawings. 
       First Embodiment 
       [0119]      FIG. 1A  shows a longitudinal sectional view of a semiconductor device manufacturing apparatus according to one embodiment of the present invention. The manufacturing apparatus has an upper metal mold  11 , a lower metal mold  12  that relatively moves close to and away from the upper metal mold  11 , and a filling device  20  that fills a space between the upper metal mold  11  and the lower metal mold  12  with a liquid-state resin  17 . 
         [0120]    The upper metal mold  11  has a plurality of cavities  13 . The lower metal mold  12  has a plurality of cavities  14  and a resin reservoir hole  15  connected directly to each of the cavities  14 . An injection member  16  is placed in the resin reservoir hole  15  so as to reciprocate therein. 
         [0121]    The filling device  20  fills the cavities  14  and the resin reservoir hole  15  in the lower metal mold  12  with use of the liquid-state resin  17 . The resin  17  is, for example, epoxy resin or silicone resin. 
         [0122]    The upper metal mold  11  and the lower metal mold  12  cooperate to hold the semiconductor element  30  shown in  FIG. 1B . The semiconductor element  30  has a lead frame  31  and a semiconductor chip  32  bonded to the lead frame  31 . 
         [0123]    The injection member  16  has a rod-like shape and extrudes the resin  17  in the resin reservoir hole  15 , so that the resin  17  is injected into the cavity  14 . 
         [0124]    That is, the manufacturing apparatus manufactures the semiconductor device  35  shown in  FIG. 1E  by sealing the semiconductor element  30  with the liquid-state resin  17 . The semiconductor device  35  has the semiconductor element  30  and a hardened resin  18  that seals at least part of the semiconductor element  30 . Specifically, the hardened resin  18  seals at least the semiconductor chip  32  of the semiconductor element  30 . 
         [0125]    Next, a semiconductor device manufacturing method with use of the manufacturing apparatus of the construction is described. 
         [0126]    As shown in  FIG. 1A , the cavities  14  and the resin reservoir holes  15  of the lower metal mold  12  are filled with the liquid-state resin  17  from the filling device  20 . This is conducted under a state that the upper metal mold  11  and the lower metal mold  12  are separated from each other. 
         [0127]    Then, as shown in  FIG. 1B , the semiconductor element  30  is held by the upper metal mold  11  and the lower metal mold  12 . At this time, the lead frame  31  is fixed by using the upper metal mold  11  and the lower metal mold  12  in the state that the semiconductor chip  32  faces the resin reservoir hole  15 . 
         [0128]    After clamping of the upper metal mold  11  and the metal mold  12 , as shown in  FIG. 1C , the resin  17  in the resin reservoir holes  15  has been injected into the cavities  13  and  14  as the result of extruding the resin  17  in the resin reservoir hole  15  toward the cavities  13  and  14  by using the injection member  16 . In other words, the cavities  13  and  14  are sealed with resin to which pressure is applied by the injection member  16 . In addition, the volume of the resin  17  is roughly equal to a value obtained by subtracting the volume of the semiconductor element  30  from the volume of the cavities  13  and  14 . 
         [0129]    After curing the resin  17 , the metal molds  11  and  12  are separated from each other as shown in  FIG. 1D . The semiconductor device  35  is pushed out of the lower metal mold  12  by the injection member  16 , as shown in  FIG. 1E . 
         [0130]    In the manufacturing apparatus having the above construction and the manufacturing method thereof, as stated above, the cavities  14  and the resin reservoir holes  15  of the lower metal mold  12  are filled with the liquid-state resin  17 . Next, the semiconductor element  30  is held by the lower metal mold  12  and the upper metal mold  11 . Then the resin  17  of the resin reservoir holes  15  is injected into the cavities  13  and  14  so as to seal the semiconductor element  30  with the resin  17 . Therefore, unlike the potting method and the transfer molding method, it is possible to manufacture a semiconductor device having excellent quality with a little loss of material at low cost. The reduction in loss of material become further apparent, in particular, when silicone resin is used as the resin  17  in order to manufacture the semiconductor devices for automobiles. 
         [0131]    In the manufacturing apparatus and method of the embodiment, the injection member  16  extrudes the resin  17  toward the cavities  13  and  14  so that the resin  17  is injected into the cavities  13  and  14 . Also, the injection member  16  pushes the semiconductor element  30 , which is sealed with the resin  17 , out of the lower metal mold  12 . Therefore, the injection member  16  is concurrently used as a plunger that extrudes the resin  17  from the resin reservoir hole  15  and as an ejector pin that pushes the semiconductor element  30  out of the lower metal mold  12 . Thus the semiconductor device can be manufactured swiftly and efficiently. 
         [0132]    Although not shown in the drawings, an air vent for letting air out is provided in the metal molds  11  and  12  in the manufacturing apparatus. In the manufacturing method, vacuum molding may be used concurrently so that the product is improved in quality. 
       Second Embodiment 
       [0133]      FIG. 2A  shows a semiconductor device manufacturing apparatus according to a second embodiment of the present invention. The second embodiment is different from the first embodiment in construction of the filling device. 
         [0134]    As shown in  FIG. 2A , a filling device  21  of the second embodiment has a filling jig  22  and an opening and shutting device  25 . The filling jig  22  has a jig main body  23  and a gate section  24 . In the jig main body  23 , resin injection holes  23   a  are formed. The gate section  24  openably closes the resin injection holes  23   a . The resin injection holes  23   a  are filled with the liquid-state resin  17 . Holes  24   a  are formed in the gate section  24 . The opening and shutting device  25  moves the gate section  24  so that the holes  24   a  of the gate section  24  are aligned with the resin injection holes  23   a  of the jig main body  23 , so as to open the resin injection holes  23   a.    
         [0135]    A method for filling the resin  17  by the filling device  21  is described next. 
         [0136]    As shown in  FIG. 2B , the filling jig  22  is placed on the lower metal mold  12  so that the resin injection holes  23   a , which are filled with the resin  17 , are aligned with the cavities  14  of the lower metal mold  12 . At this time, the filling jig  22  is inserted and fixed between the upper metal mold  11  and the lower metal mold  12 . 
         [0137]    Then, as shown in  FIG. 2C , the gate section  24  is slid to open, so that the resin reservoir holes  15  and the cavities  14  are filled with the resin  17  moved from the resin injection holes  23   a  through the holes  24   a.    
         [0138]    Thus, the cavities  14  and the resin reservoir holes  15  are filled with the liquid-state resin  17  from the filling jig  22 , and therefore it is possible to simply and reliably fill the cavities  14  and the resin reservoir holes  15  with the liquid-state resin  17 . 
       Third Embodiment 
       [0139]      FIG. 3  shows a semiconductor device manufacturing apparatus according to a third embodiment of the present invention. The third embodiment is different from the first embodiment in construction of the filling device. 
         [0140]    As shown in  FIG. 3 , a filling device  26  of the third embodiment has a syringe-shaped resin feeder  27  and a tube  28  that extends from the resin feeder  27 . The resin feeder  27  is filled with the liquid-state resin  17 . Openings  28   a  are formed in the tube  28 . 
         [0141]    A method for filling the resin  17  by the filling device  26  is described next. 
         [0142]    The tube  28  is placed on the lower metal mold  12  in such a way that the openings  28   a  of the tube  28  are aligned with the cavities  14  of the lower metal mold  12 . At this time, the tube  28  is inserted and fixed between the upper metal mold  11  and the lower metal mold  12 . 
         [0143]    Then, the cavities  14  and the resin reservoir holes  15  are filled with the resin  17  through the openings  28   a  of the tube  28  from the resin feeder  27 . 
         [0144]    Thus, the cavities  14  and the resin reservoir holes  15  are filled with the liquid-state resin  17  from the resin feeder  27  via the tube  28 , and therefore it is possible to simply and reliably fill the cavities  14  and the resin reservoir holes  15  with the liquid-state resin  17 . 
       Fourth Embodiment 
       [0145]      FIG. 4A  shows a semiconductor device manufacturing apparatus according to a fourth embodiment of the present invention. The fourth embodiment is different from the first embodiment in construction of the injection member. 
         [0146]    In the fourth embodiment, as shown in  FIG. 4A , the injection member  40  has an end face  41  is formed into a lens-like shape. Specifically, the end face  41  of the injection member  40  is formed into a concave lens-like shape as shown on the side of the cavity  14  of the lower metal mold  12  in  FIG. 4A . 
         [0147]    Then, a method for manufacturing the semiconductor device by using the injection member  40  is explained. The resin  17  of the resin reservoir holes  15  is extruded into the cavity  14  by the injection member  40  so that the resin  17  is injected into the cavity  14 . A lens portion  19  of the resin  18  is formed by the end face  41  of the injection member  40  while the resin  17  is pressurized and hardened. 
         [0148]    That is to say, as shown in  FIG. 4B , the convex lens-shaped lens portion  19  is formed on the outer surface of the hardened resin  18 , which outer surface is facing the semiconductor chip  32  of the semiconductor element  30 , in the semiconductor device  35  manufactured by the injection member  40 . 
         [0149]    Thus, since the end face  41  of the injection member  40  is formed into a lens-like shape, it is required to polish only the end face  41  of the injection member  40  but not the whole of the metal molds  11  and  12 . This therefore leads to cost reductions of the metal molds  11  and  12 . Moreover, it is possible to easily change dimensions of the lens because the injection member  40  can easily be replaced. 
         [0150]    Moreover, it is possible to swiftly and easily form the lens portion  19  on the hardened resin  18  because the lens portion  19  is formed by pressurizing the resin  17  during the hardening process of the resin  17  with use of the end face  41  of the injection member  40  formed into a lens-like shape. 
       Fifth Embodiment 
       [0151]      FIG. 5A  shows a semiconductor device manufacturing apparatus according to a fifth embodiment of the present invention. The fifth embodiment is different from the second embodiment ( FIG. 2B ) in construction of the upper metal mold. The other structures are the same as those of the second embodiment, and description thereof is omitted. 
         [0152]    In the fifth embodiment, as shown in  FIG. 5A , the upper metal mold  11  has a guide hole  55  connected directly to each cavity  13 . An injection member  56  is provided so that it reciprocates in the guide hole  55 . The injection member  56  has a rod shape similar to that of the injection member  16  placed in the lower metal mold  12 . 
         [0153]    A semiconductor device manufacturing method with use of the manufacturing apparatus is described next. 
         [0154]    As shown in  FIG. 5A , the filling jig  22  is placed on the lower metal mold  12  in such a way that the resin injection holes  23   a  filled with the resin  17  are aligned with the cavities  14  of the lower metal mold  12 . At this time, the filling jig  22  is inserted and fixed between the upper metal mold  11  and the lower metal mold  12 . 
         [0155]    Then, as shown in  FIG. 5B , the gate section  24  is slid to open, and then the injection members  56  placed in the upper metal mold  11  is moved along the resin injection holes  23   a  of the filling jig  22  so as to extrude the resin  17  from the resin injection holes  23   a  through holes  24   a . As the result, as shown in  FIG. 5C , the cavities  14  and the resin reservoir holes  15  are filled with the resin  17 . 
         [0156]    By the injection members  56  placed at the upper metal mold  11 , the cavities  14  and the resin reservoir holes  15  are filled with the liquid-state resin  17  from the filling jig  22 . Therefore, it is possible to simply and reliably fill the cavities  14  and the resin reservoir holes  15  with the liquid-state resin  17 . 
       Sixth Embodiment 
       [0157]      FIG. 6A  shows a semiconductor device manufacturing apparatus according to a sixth embodiment of the present invention. The sixth embodiment is different from the fifth embodiment ( FIG. 5A ) in construction of the injection member placed at the upper metal mold. 
         [0158]    In the sixth embodiment, as shown in  FIG. 6A , an end face  61  of an injection member  60  is formed into a lens-like shape as shown on the side of the cavity  13  of the upper metal mold  11 . In other words, the end face  61  is formed into a concave lens-like shape. 
         [0159]    Then, a method for manufacturing the semiconductor device is described. The injection member  16  on the lower side extrudes the resin  17  within the resin reservoir hole  15  into the cavity  14 , so that the resin  17  is injected into the cavity  14 . A lens portion  19  is formed on the resin  18  during the process of hardening the resin  17  by pressurizing the resin  17  with use of the end face  61  of the injection member  60  on the upper side. It is noted that the semiconductor element  30  is arranged so that the semiconductor chip  32  faces the injection member  60  on the upper side. 
         [0160]    That is to say, as shown in  FIG. 6B , a convex lens-shaped lens portion  19  is formed on the outer surface of the hardened resin  18  in the semiconductor device  35 , which outer surface is facing the semiconductor chip  32  of the semiconductor element  30 . 
         [0161]    The end face  61  of the injection member  60  on the upper side is formed into a lens-like shape, and therefore it is required to polish only the end face  61  of the injection member  60  but not the whole of the metal molds  11  and  12 . This leads to cost reductions of the metal molds  11  and  12 . Moreover, the injection member  60  on the upper side can easily be replaced, so that the dimensions of the lens can also be easily changed. 
         [0162]    Moreover, the lens portion  19  can be swiftly and easily formed on the hardened resin  18  since the lens portion  19  is formed by pressurizing the resin  17  during the hardening process of the resin  17  with use of the end face  61  of the injection member  60 , which is formed into a lens-like shape on the upper side. 
       Seventh Embodiment 
       [0163]      FIG. 7A  shows a semiconductor device manufacturing apparatus according to a seventh embodiment of the present invention. The seventh embodiment is different from the fifth embodiment ( FIG. 5A ) in that the injection members  56  placed in the upper metal mold  11  are used for pushing the semiconductor devices  35  out of the cavities  13  of the upper metal mold  11 . 
         [0164]    Specifically, as shown in  FIG. 7A , after clamping of the upper metal mold  11  and the lower metal mold  12 , the resin  17  of the resin reservoir holes  15  is extruded into the cavities  13  and  14  by suing the injection member  16  on the lower side, so that the resin  17  is injected into the cavities  13  and  14 . Then, resin sealing in the cavities  13  and  14  is performed by applying pressure to the resin  17  with use of both the injection members  56  on the upper side and the injection members  16  on the lower side. 
         [0165]    Then, after the resin  17  is hardened, as shown in  FIG. 7B , the upper metal mold  11  and the lower metal mold  12  are relatively separated from each other while the injection member  56  on the upper side pushes the semiconductor devices  35  out of the cavities  13  formed in the upper metal mold  11 . 
         [0166]    Therefore, the semiconductor devices  35  can be manufactured swiftly and efficiently because the injection member  56  on the upper side is served as not only a plunger that extrudes the resin  17  from the filling jig  22  (as in the case of the fifth embodiment) but also an ejector pin that pushes the semiconductor device  35  out of the upper metal mold  11 . 
       Eighth Embodiment 
       [0167]      FIG. 8A  shows a semiconductor device manufacturing apparatus according to an eighth embodiment of the present invention. The eighth embodiment is different from the second embodiment ( FIG. 2A ) in the shape of a hole  24   b  in the gate section  24  of the filling jig  22 . 
         [0168]    Specifically, the hole  24   b  of the gate section  24  in the filling jig  22  is tapered so that the diameter thereof gradually decreases toward the lower metal mold  12 , wherein the resin  17  passes through the hole  24   b  from the resin injection holes  23   a  of the filling jig  22  when the lower metal mold  12  is filled with the resin  17 . 
         [0169]    Therefore, as shown in  FIG. 8B , the holes  24   b  of the gate section  24  allows the resin  17  existing in the resin injection holes  23   a  to smoothly fill the cavity  14  of the lower metal mold  12 . 
       Ninth Embodiment 
       [0170]      FIG. 9  shows a semiconductor device manufacturing apparatus according to a ninth embodiment of the present invention. The ninth embodiment is different from the first embodiment ( FIG. 1E ) in that the semiconductor devices  35  are pushed out of the lower metal mold  12  by air from the resin reservoir holes  15  of the lower metal mold  12 . 
         [0171]    Specifically, as in the case of the first embodiment ( FIG. 1C ), the resin  17  in the resin reservoir holes  15  is extruded into the cavities  13  and  14  by the injection members  16  so that the resin  17  is injected into the cavities  13  and  14   
         [0172]    Subsequently, after the resin  17  is hardened, the injection members  16  are retreated from the cavity  14  as shown in  FIG. 9 . Then, the semiconductor devices  35  are pushed out of the lower metal mold  12  by discharging air from the resin reservoir holes  15  toward the cavities  14  (as indicated by the arrows A in  FIG. 9 ). 
         [0173]    Therefore, the semiconductor devices  35  can easily be taken out of the lower metal mold  12  since the semiconductor devices  35  are pushed out of the lower metal mold  12  by air from the resin reservoir holes  15 . 
       Tenth Embodiment 
       [0174]      FIG. 10A  shows a semiconductor device manufacturing apparatus according to a tenth embodiment of the present invention. The tenth embodiment is different from the first embodiment ( FIG. 1C ) in that the bottom of the cavity  14  of the lower metal mold  12  is formed by only the end face  66  of the injection member  65  on the lower side. 
         [0175]    In detail, the outer periphery of the bottom of the cavity  14  coincides in shape with the inner periphery of the resin reservoir hole  75 . The outer periphery of the end face  66  of the injection member  65  on the side of cavity  14  coincides in shape with the inner periphery of the resin reservoir hole  75 . 
         [0176]    Therefore, as shown in  FIG. 10B , the lower end face  36  of the semiconductor device  35  is formed by only the end face  66  of the injection member  65 , so that the lower end face  36  of the semiconductor device  35  can be formed into a smooth shape without undulations by using the flat end face  66 . 
         [0177]    In contrast to this, as shown in  FIG. 11A  as a comparative example, when the shape of the bottom of the cavity  14  is not coincident with but larger than the shape of the resin reservoir hole  15 , the end face  68  of the injection member  67  on the side of the cavity  14  forms a portion of the bottom of the cavity  14 . 
         [0178]    In this case, the end face  68  of the injection member  67  is located in a position lower than the other portion of the bottom of the cavity  14 . When resin  17  is charged in the cavities  13  and  14 , as shown in  FIG. 11B , a protrusion  37  is formed on the lower end face  36  of the semiconductor device  35  by using the end face  68  of the injection member  67 . 
       Eleventh Embodiment 
       [0179]      FIGS. 12A and 12B  show a semiconductor device manufacturing apparatus according to an eleventh embodiment of the present invention. The eleventh embodiment is different from the first embodiment ( FIG. 1B ) in that communication passages  70  are provided between the upper metal mold  11  and the lower metal mold  12  so that a plurality of cavities  13  and  14  communicate with one another through the communication passages. It is noted that the semiconductor element  30  of  FIG. 1B  is omitted from the illustrations of  FIGS. 12A and 12B . 
         [0180]    Specifically, the upper metal mold  11  and the lower metal mold  12  have a plurality of the cavities  13  and  14 , respectively. When the upper and lower metal molds  11  and  12  contact with each other, the communication passages  70  are formed on the mutually facing surfaces of the upper metal mold  11  and the lower metal mold  12 , so that all the cavities  13  and  14  communicate at least in series with one another through he communication passages  70 . The communication passages  70  may be formed in such a way that all the cavities  13  and  14  mutually communicate with one another. 
         [0181]    When variation occurs in the amounts of the resin  17  charged into the cavities  14 , specifically, when the amount of the resin  17  charged in the central cavity  14  is smaller than the amount of the resin  17  charged in the both end cavities  14  as shown in  FIG. 12A , the resin  17  in the both end cavities  14  move into the central cavity  14  via the communication passages  70  as indicated by the arrows B as shown in  FIG. 12B  after the clamping of the upper metal mold  11  and the lower metal mold  12 . As the result, the variation in the amount of the resin  17  in the cavities  13  and  14  can be suppressed, and therefore, semiconductor devices  35  of a stable shape can be manufactured. 
       Twelfth Embodiment 
       [0182]      FIG. 13  shows a semiconductor device manufacturing apparatus according to a twelfth embodiment of the present invention. The twelfth embodiment is different from the first embodiment ( FIG. 1B ) in that subcavities  80  are formed in the upper metal mold  11  and the lower metal mold  12  so as to communicate with the cavities  13  and  14 . It is noted that the semiconductor element  30  of  FIG. 1B  is omitted from the illustration of  FIG. 13 . 
         [0183]    Specifically, when the upper metal mold  11  and the lower metal mold  12  contact with each other, the subcavities  80  for communicating with the cavities  13  and  14  are formed on the mutually facing surfaces of the upper and lower metal molds  11  and  12 . The cavities  13 ,  14  and the subcavities  80  communicate with each other via a communication passage  81  that is formed therebetween on the mutually facing surfaces of the upper metal mold  11  and the lower metal mold  12 . 
         [0184]    Then, if the resin  17  is excessively injected into the cavity  14 , the superfluous resin  17  flows from the cavity  14  into the subcavity  80 , and therefore a semiconductor device  35  of a stable shape can be manufactured. Moreover, superfluous air in the cavities  13  and  14  can be sent into the subcavities  80 . 
         [0185]    That is, the redundant portion  38  formed of the superfluous resin in the subcavity  80  is attached to the semiconductor device  35  taken out of the upper and lower metal molds  11  and  12 , as shown in  FIG. 14A . Therefore, the redundant portion  38  is removed from the semiconductor device  35  in a subsequent process. It is noted that the semiconductor element  30  of  FIG. 1B  is omitted from the illustrations of  FIGS. 14A and 14B . 
         [0186]    The invention being thus described, it will be obvious that the invention may be varied in many ways. Such variations are not be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.