Patent Publication Number: US-2020294827-A1

Title: Needle dispenser for dispensing and collecting an underfill encapsulant

Description:
BACKGROUND 
     Field 
     Embodiments described herein generally relate to substrates (e.g., semiconductor packages, printed circuit boards (PCB), etc.). More particularly, but not exclusively, embodiments described herein relate to a needle dispenser for dispensing and collecting underfill encapsulants. 
     Background Information 
     An underfill encapsulant is a material that provides mechanical support and protection for interconnects (e.g., solder balls, micro bumps, columns, etc.) that couple a target component (e.g., a die, etc.) to a substrate (e.g., an organic substrate, an inorganic substrate, a printed circuit board (PCB), a redistribution layer (RDL), etc.). The underfill encapsulant also minimizes mechanical stress that is due to a coefficient of thermal expansion (CTE) mismatch between the different materials. 
     When using an underfill encapsulant to encapsulate interconnects coupling a target component to a substrate, a keep-out zone around the target component may be required. The keep-out zone provides an area away from un-targeted components where the underfill encapsulant can reside on the substrate. In this way, the un-targeted components and interconnects coupling the un-targeted components to the substrate do not come in contact with the underfill encapsulant. The keep-out zone also provides an area to insert a needle dispenser used to dispense the underfill encapsulant. 
     One drawback of a keep-out zone is that it is unused space that takes up valuable real-estate on a substrate. Typically, the keep-out zone is a border around the target component. For example, a size (e.g., a perimeter, an area, etc.) of the keep-out zone around the target can range from 0.5 millimeters (mm) to 1 mm. This large keep-out zone can limit the size or number of components that can placed or manufactured on a substrate. 
     One alternative to using the keep-out zone is flooding the entire surface of a substrate with an underfill encapsulant such that the underfill encapsulant encapsulates interconnects associated with all components on the substrate. For example, a first component may be coupled to a substrate via a first set of interconnects and a second component that is adjacent to the first component may be coupled to the substrate via a second set of interconnects. In order to secure and protect the first set of interconnects, an underfill encapsulant may be dispensed on a surface of the substrate. More specifically, the underfill encapsulant is used to encapsulate the entire surface of the substrate, which includes the first and second interconnects thereon. Consequently, the first and second sets of interconnects are encapsulated by the underfill encapsulant, even though the aim was to encapsulate the first set of interconnects. One drawback of flooding the entire surface of the substrate  293  is that it results in wasting the underfill encapsulant and in unnecessarily encapsulating interconnects that do not necessarily need to be encapsulated by the underfill encapsulant. Wasting the underfill encapsulant and unnecessarily encapsulating interconnects that do not need to be encapsulated by the underfill encapsulant undesirably increase costs associated with semiconductor packaging and manufacturing. 
     Furthermore, current techniques of dispensing underfill encapsulants require use of needle dispensers with stiff metallic needles. One drawback of these stiff metallic needles is that they cannot be brought in contact with the substrate, components on the substrate, or interconnects coupling the components to the substrate. Such contact is undesired because the stiff metallic needles may damage the above-referenced objects. Additionally, because such contact is undesired, the stiff metallic needles cannot be used to dispense underfill encapsulants unless a large enough keep-out zone is provided. 
     In view of the description provided above, currently available techniques of dispensing an underfill encapsulant remain suboptimal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments described herein are illustrated by way of example and not a limitation in the figures of the accompanying drawings, in which like references indicate similar features. Furthermore, in the figures, some conventional details have been omitted so as not to obscure from the inventive concepts described herein. 
         FIGS. 1A-1B  are cross sectional side view illustrations of a needle dispenser used for dispensing and collecting an underfill encapsulant, according to one embodiment. 
         FIGS. 2A-2B  are cross sectional side view illustrations of a needle dispenser used for dispensing and collecting an underfill encapsulant, according to another embodiment. 
         FIGS. 3A-3B  are cross sectional side view illustrations of a needle dispenser used for dispensing and collecting an underfill encapsulant, according to yet another embodiment. 
         FIGS. 4A-4B  are cross sectional side view illustrations of a needle dispenser used for dispensing and collecting an underfill encapsulant, according to one more embodiment. 
         FIG. 5A  is a plan view illustration of a needle that is part of a needle dispenser, according to one embodiment. 
         FIGS. 5B-5C  are cross sectional side view illustrations of the needle in  FIG. 5A . 
         FIGS. 6A-6E  are cross sectional side view illustrations of a method of dispensing an underfill encapsulant on a substrate of a semiconductor package using a needle dispenser and of collecting the dispensed underfill encapsulant, according to one embodiment. 
         FIGS. 7A-7B  are plan view illustrations of a device on an underfill encapsulant after some portions of the dispensed underfill have been collected by a needle dispenser, according to one embodiment. 
         FIG. 8  is a cross sectional illustration of a packaged system, according to one embodiment. 
         FIG. 9  is a schematic illustration of a computer, according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, numerous specific details are set forth, such as specific material and structural regimes, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known features, such as techniques of using an underfill encapsulant to encapsulate a component, are not described in detail in order to not unnecessarily obscure embodiments of the present disclosure. Furthermore, it is to be understood that the various embodiments shown in the Figures are illustrative representations and are not necessarily drawn to scale. In some cases, various operations will be described as multiple discrete operations in a manner that is most helpful in understanding the present disclosure, however, the order of description should not be construed to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation. 
     Certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, “below,” “bottom,” and “top” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, and “side” describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. 
     Embodiments described herein are directed to a needle dispenser for dispensing and collecting an underfill encapsulant used to protect one or more interconnects (or other components) positioned on a substrate. The needle dispenser comprises a reservoir and a needle coupled to the reservoir. The needle directs an underfill encapsulant out of the reservoir. In an embodiment, the needle comprises: (i) a tip; (ii) a body coupled to the tip; (iii) a core; (iv) an outer surface; (v) one or more openings formed through the outer surface that expose the core; and (vi) one or more channels that run (e.g., extend, etc.) along the needle. In one embodiment, the needle&#39;s tip is formed from a first material while the needle&#39;s body is formed from a second material that differs from the first material. In one embodiment, the first material used to form the needle&#39;s tip is more compliant than the second material used to form the needle&#39;s body. In one embodiment, the entire needle (i.e., the body and the tip) are formed from the first material. 
     In one embodiment, the core of the needle is formed from a hydrophilic material and the outer surface of the needle is coated with or formed from a hydrophobic material. A solvent (e.g., acetone, isopropyl alcohol, any other suitable polar solvent, or any combination thereof) flows through at least one channel that runs (e.g., extends, etc.) along the needle to soak the needle&#39;s core to keep the hydrophilic core primed. At least one of openings that is formed through the needle&#39;s outer surface enables the core to collect (e.g., siphon, etc.) a material (e.g., an underfill encapsulant, etc.) on a substrate, a device on the substrate, or an interconnect coupling the device to the substrate. 
     Embodiments of the needle dispenser described herein have several advantages. One advantage is that the compliant material used to form the needle (or the tip of the needle) enables the needle to physically contact devices, interconnects coupling the devices to a substrate, and the substrate itself without damaging the devices, the interconnects, or the substrate. The ability of the needle to physically contact the devices, the interconnects, or the substrate assists with increasing yield by reducing or eliminating damage to the devices, the interconnects, and the substrate. Additionally, the use of a compliant material for the tip allows the tip to be displaced and extended below the target component. This allows for more precise and controllable dispensing of the underfill encapsulant. 
     Furthermore, the combination of the hydrophobic material used to form the core, the hydrophilic material used to form or coat the needle&#39;s outer surface, and the solvent that is infused into the core enables the needle to collect a material (e.g., an underfill encapsulant, etc.) on a substrate, a device on the substrate, or an interconnect coupling the device to the substrate. For example, embodiments of the needle described herein can clean up excess underfill encapsulant on a substrate by siphoning the excess underfill encapsulant back into the needle dispenser&#39;s core. Such embodiments can collect (e.g., siphon) an underfill encapsulant that is around or under a device, around or under an interconnect, or on a substrate. In this way, wasting of the underfill encapsulant can be minimized or eliminated. 
     Additionally, embodiments of the needle dispenser described herein can be used to dispense an underfill encapsulant to create a fillet under a device (e.g., a die, etc.) that is closer to the device than a fillet created using a stiff metallic needle. This is because the embodiments of the needle dispenser described herein enable the underfill encapsulant to be dispensed in any desired direction, unlike a stiff metallic needle that can only dispense an underfill encapsulant in a limited number of directions. This is also because the dispensed underfill encapsulant can be shaped by collecting a desired amount of the underfill encapsulant that is around or under a device coupled to a substrate by one or more interconnects. D 1 spensing an underfill encapsulant in a desired direction and shaping the dispensed underfill encapsulant assists with reducing waste and creating a fillet with a desired shape, size, or profile. Also, the ability of the embodiments of the needle dispenser described herein to create a fillet with a desired shape, size, or profile assists with minimizing the keep-out zone below what current manufacturing tolerances allow. For example, a size (e.g., a perimeter, an area, etc.) of the keep-out zone can be reduced from 1 millimeter (mm) to 0.5 mm or less (e.g., any value ranging from 0.125 mm to 0.5 mm, etc.). Furthermore, the ability of the embodiments of the needle dispenser described herein to dispense an underfill encapsulant in a desired direction and to shape the dispensed underfill encapsulant obviates the need to flood the entire surface of a substrate with the underfill encapsulant, as described above. Doing away with flooding the surface of the substrate assists with avoiding waste associated with performing underfill encapsulation operations. 
       FIGS. 1A-1B  are cross sectional side view illustrations of a needle dispenser  100  used for dispensing and collecting an underfill encapsulant, according to one embodiment. With regard now to  FIG. 1A , a needle dispenser  100  that is above a substrate  193  is shown. The substrate  193  can be any known substrate (e.g., an organic substrate, an inorganic substrate, a semiconductor package, a redistribution layer (RDL), a board (e.g., a printed circuit board, a motherboard, etc.), an interposer substrate, etc.). 
     The needle dispenser  100  comprises a reservoir  101  and a needle  103  coupled to the reservoir  101 . The reservoir  101  can house a material (e.g., an underfill encapsulant, etc.) to be dispensed through the needle  103 . The reservoir can be formed from metal, plastic, or any other suitable material(s) used to form reservoirs known in the art. 
     As shown, the needle  103  comprises a body  109  and a tip  111 . The body  109  has sidewalls  105  that couple the tip  111  to the reservoir  101 . In one embodiment, the tip  111  includes an exit opening  107 . The material (e.g., an underfill encapsulant, etc.) housed in the reservoir  101  can flow out of the needle  103  through the exit opening  107 . In one embodiment, the needle  103  is a micro machined needle. 
     In one embodiment, the needle  103  is constructed to have an outer surface  113  formed from a hydrophobic material (or coated with a hydrophobic material) and a core  191  (partially shown) that is formed from a hydrophilic material. The core  191  is exposed via openings  189 , which allow for a material (e.g., an underfill encapsulant, etc.) to be collected (e.g., siphoned, etc.) by the core  191 . In one embodiment, one or more channels (not shown in  FIG. 1A ) run (e.g., extend, etc.) along the needle  103 . In this embodiment, a solvent (not shown) flows through at least one channel that runs (e.g., extends, etc.) along the needle to soak the core  191 . Soaking the core  191  with the solvent (not shown) primes the core and enables the core  191  to collect a material (e.g., an underfill encapsulant, etc.) on the substrate  193 . Examples of a solvent include, but are not limited to, acetone, isopropyl alcohol, any other polar solvent, and any combination thereof. 
     As illustrated in  FIG. 1A , the needle  103  extends downwards from the reservoir  101 . In one embodiment, the needle  103  is aligned with the reservoir  101 . A center line L 199  is aligned with center lines L 197  and L 195 . More specifically, a center line L 199  of the reservoir  101  is parallel and coincident to a center line L 197  of the body  109  and a center line L 195  of the tip  111 . 
     In one embodiment, a material used to form the tip  111  differs from a material used to form the body  109 . In one embodiment, the material used to form the tip  111  is more compliant than the material used to form the body  109 . Examples of the material used to form the tip  111  are a rubber, a compliant polymer, or a combination thereof. Examples of the material used to form the body  109  are stiff metals, stiff metal alloys, stiff plastics, or a combination thereof. In one embodiment, the entire needle  103  is formed from a compliant material (e.g., a rubber, a compliant polymer, a combination thereof, etc.). That is, there may be no discernible boundary between the body  109  and the tip  111 . 
     Moving on to  FIG. 1B , the needle dispenser  100  is brought in contact with the substrate  193 . As shown, the tip  111  of the needle  103  is displaced (e.g., by deforming, bending, etc.) when brought in contact with substrate  193  such that the center line L 195  of the tip  111  is no longer parallel with center lines L 199  and L 197 . In one embodiment, the displacement of the tip  111  causes the center line L 195  to intersect the center line L 197 . In one embodiment, the center line L 195 in  FIG. 1B  is substantially perpendicular to the center lines L 199  and L 197 . The displacement of the tip  111  enables a material (e.g., an underfill encapsulant, etc.) to be dispensed onto the substrate  193  in a direction that substantially aligns with the center line L 195 . One advantage of the displacement property of the tip  111  is that it enables a material (e.g., an underfill encapsulant, etc.) to be dispensed on or collected from the substrate  193  in a more precise manner than was previously available (e.g., when compared to an unbending needle whose tip is formed from a stiff material like metal, etc.). Furthermore, because the tip  111  is formed from a compliant material (e.g., rubber, compliant polymer, a combination thereof, etc.), the tip  111  does not damage the substrate  193  when the tip  111  is in contact with the substrate  193 . 
       FIGS. 2A-2B  are cross sectional side view illustrations of an additional embodiment of a needle dispenser  200  that can dispense or collect a material (e.g., an underfill encapsulant, etc.) onto or from a substrate  293 , respectively. The needle dispenser  200  includes parts or components that are similar to those described above in connection with  FIGS. 1A-1B . For brevity, these similar parts or components are not described again in connection with  FIG. 2A or 2B  unless the description is necessary. 
     Referring now to  FIG. 2A , a needle dispenser  200  above a substrate  293  is shown. The needle dispenser  200  is similar to the needle dispenser  100  described above in connection with  FIGS. 1A-1B , with the exception that the tip  211  of the needle dispenser  200  differs from the tip  111  of the needle dispenser  100 . More specifically, the tip  211  is not parallel to the body  209  and the reservoir  201 . That is, a center line L 295  of the tip  211  is not parallel to a center line L 297  of the body  209  and a center line L 299  of the reservoir  201 . For example, in  FIG. 2B , the center line L 295  of the tip  211  is substantially orthogonal to the center line L 297  of the body  209  and the center line L 299  of the reservoir  201 . In some scenarios, because the tip  211  has an angled center line L 295  relative to the center lines of the body  209  and the reservoir  201 , there is no need to bring the tip  211  into contact with the substrate  293  in order to dispense a material (e.g., an underfill encapsulant, etc.) in a desired direction. It is, however, to be appreciated that the tip  211  may be brought in contact with the substrate  293 . 
       FIGS. 3A-3B  are cross sectional side view illustrations of another embodiment of a needle dispenser  300  that can dispense or collect a material (e.g., an underfill encapsulant, etc.) onto or from a substrate  393 , respectively. The needle dispenser  300  includes parts or components that are similar to those described above in connection with  FIGS. 1A-1B . For brevity, these similar parts or components are not described again in connection with  FIG. 3A or 3B  unless the description is necessary. 
     With regard now to  FIG. 3A , a needle dispenser  300  above a substrate  393  is shown. The needle dispenser  300  is similar to the needle dispenser  100  described above in connection with  FIGS. 1A-1B , with the exception that the tip  311  of the needle dispenser  300  differs from the tip  111  of the needle dispenser  100 . More specifically, the tip  311  is tapered. 
     Moving on to  FIG. 3B , the needle dispenser  300  is brought in contact with the substrate  393 . As shown, the tip  311  of the needle  303  is displaced (e.g., deformed, bent, etc.) when brought in contact with substrate  393 . Stated differently, when the needle dispenser  300  is brought in contact with substrate  393 , the center line L 395  of the tip  311 , which was previously parallel to the center lines L 399  and L 397 , is no longer substantially parallel to the center lines L 399  and L 397 . The advantages that accrue from the needle dispenser  300  are similar to or the same as the advantages described above in connection with  FIGS. 1A-1B . 
       FIGS. 4A-4B  are cross sectional side view illustrations of a needle dispenser  400  that can dispense or collect a material (e.g., an underfill encapsulant, etc.) onto or from a substrate  493 , respectively. The needle dispenser  400  includes parts or components that are similar to those described above in connection with  FIGS. 1A-1B . For brevity, these similar parts or components are not described again in connection with  FIG. 4A or 4B  unless the description is necessary. 
     With regard now to  FIG. 4A , a needle dispenser  400  above a substrate  493  is shown. The needle dispenser  400  is similar to the needle dispenser  100  described above in connection with  FIGS. 1A-1B , with the exception that the tip  411  of the needle dispenser  400  differs from the tip  111  of the needle dispenser  100 . More specifically, the tip  411  is flared. 
     Moving on to  FIG. 4B , the needle dispenser  400  is brought in contact with the substrate  493 . As shown, the tip  411  of the needle  403  is displaced (e.g., deformed, bent, etc.) when brought in contact with substrate  493 . Stated differently, when the needle dispenser  401  is brought in contact with substrate  493 , the center line L 495  of the tip  411 , which was previously parallel to the center lines L 499  and L 497 , is no longer substantially parallel to the center lines L 499  and L 497 . The advantages that accrue from the needle dispenser  400  are similar to or the same as the advantages described above in connection with  FIGS. 1A-1B . 
       FIG. 5A  is a cross sectional plan view illustration of a needle  500 , according to one embodiment. The needle  500  can be similar to or the same as any of the needles (e.g., needles  103 ,  203 ,  303 ,  403 , etc.) described above in connection with  FIGS. 1A-4B . The needle  500  may be viewed from two points of view (POVs)  525  and  550 . The needle  500 , as viewed from the POVs  525  and  550 , is described in more detail below in connection with  FIGS. 5B and 5C . 
     With regard now to  FIG. 5A , a cross sectional plan view illustration of the needle  500  is shown. As shown, the needle  500  comprises: (i) a core  501  formed from a hydrophilic material; (ii) an inner surface  511 ; (iii) an outer surface  505  formed from or coated with a hydrophobic material; (iv) multiple channels  503  between the inner surface  511  and the outer surface  505 ; (v) multiple openings  507  formed through the inner surface  511  and the outer surface  505  to expose the core  511 ; and (vi) a solvent  509  passing through the channels  503  that soaks the core  501 . It is be appreciated that only one channel  503  may be formed in the needle  500 . It is also to be appreciated that only one opening  507  may be formed in the needle  500 . 
     The core  501  can be used to collect a material (e.g., an underfill encapsulant, etc.) by siphoning the material. The needle  500 &#39;s outer surface  505  is hydrophobic to keep the needle  500  clean, and the inner core  501  is made of a hydrophilic absorbent material soaked in a solvent  509  passing through the channels  503  to help reduce the viscosity of the material (e.g., an underfill encapsulant, etc.) and increase the core  501 &#39;s ability to collect material. 
     Moving on  FIG. 5B , the needle  500  illustrated in  FIG. 5A  is shown from a POV  525 . More specifically,  FIG. 5B  is a side view illustration of the needle  500  shown in  FIG. 5A . As shown, the channels  503  run (e.g., extend, etc.) along the length of the needle  500 . In this way, the solvent  509  can be used to soak the entire length of the core  501 . In one embodiment, the channels  503  are formed between the outer surface  505  (shown in  FIG. 5A ) and the inner surface  511  (shown in  FIG. 5A ). In one embodiment, the channels  503  are formed on the inner surface  511  (shown in  FIG. 5A ) and do not pass through the outer surface  505  (shown in  FIG. 5A ). 
     Referring now to  FIG. 5C , the needle  500  illustrated in  FIG. 5A  is shown from a POV  550 . More specifically,  FIG. 5C  is another side view illustration of the needle  500  shown in  FIG. 5A . As shown, the openings  507  are formed through the outer surface  505  (shown in  FIG. 5A ) and the inner surface  511  (shown in  FIG. 5A ) to expose the core  501 . In this way, the core  501  can be used to collect a material (e.g., an underfill encapsulant, etc.). 
     It is to be appreciated that the locations, sizes, and/or shapes of the channels  503  and the openings  507  shown in  FIGS. 5A-5C  are exemplary in nature. For example, channels  503  may be located at any location around the needle  500  (i.e., the channels are not limited to be formed along one side of the needle  500 ). In some embodiments, channels  503  may be equally or unequally spaced around a perimeter of the needle  500 . Additionally, in some embodiments, the openings  509  may have uniform or non-uniform sizes. For example, the openings  509  proximate to the tip of the needle  500  may be smaller or larger than openings  509  proximate to the beginning of the needle  500 . 
     Moving on to  FIGS. 6A-6E , a method of dispensing an underfill encapsulant  625  under a device (e.g., a die, etc.)  617  is shown. With regard now to  FIG. 6A , a first device  617  that is coupled to a substrate  621  using interconnects (e.g., solder bumps, micro bumps, pillars, etc.)  619  is shown. Additionally, a second device  615  (e.g., a die, etc.) is adjacently located on the substrate  621  near the first device  617 . The second device  615  is coupled to the substrate  621  using interconnects  613 , which may be solder bumps, micro bumps, or pillars. Next, and as shown in  FIG. 6A , a needle dispenser  600  is placed in the gap between the first device  617  and the second device  615 . In one embodiment, the needle dispenser  600  is similar to or the same as any of the needle dispensers described above in connection with  FIGS. 1A-5C . The needle dispenser  600  comprises a reservoir  601  and a needle  603  coupled to the reservoir  601 . In one embodiment, the needle  603  is a micro machined needle. The needle  603  comprises a body  609  and a tip  611 . The body  609  has sidewalls  605  that couple the tip  611  to the reservoir  601 . In one embodiment, the tip  611  includes an exit opening  607 . The needle  603  also includes openings  689  that expose a core  691  of the needle  603 . Furthermore, the needle  603  includes one or more channels (not shown) that run (e.g., extend, etc.) along the length of the needle  603 . An underfill encapsulant  625 , which is described below in connection with  FIGS. 6C-6E , is housed in the reservoir  601 . In one embodiment, the underfill encapsulant  625  can flow out of the needle  603  through the exit opening  607 . 
     Moving on  FIG. 6B , the needle  603  of the needle dispenser  600  is brought in contact with a surface of the substrate  621 . More specifically, the needle  603  is placed under the device  617  in a location that is adjacent to one of the interconnects  619 . That is, the tip  611  of the needle  603  is under the device  617  and within an outer perimeter of the device  617 . 
     In one embodiment, the needle  603  (or the tip  607 ) is formed from a compliant material. This compliant material enables the needle  603  to be displaced (e.g., deformed, bent, etc.) and maneuvered underneath the device  617  when the needle  603  is in contact with the substrate  621 . That is, the tip  607  of the needle  603  is within an outer perimeter of the device  617 . One advantage of forming the needle  603  (or the tip  607 ) from a compliant material is that the needle  603  (or the tip  607 ) can physically contact the devices  617  and  615 , interconnects  619  and  613  coupling the devices  617  and  615  to the substrate  621 , and the substrate  621  itself without damaging the devices  617  and  615 , the interconnects  619  and  613 , or the substrate  621 . The ability of the needle  603  to physically contact the devices  617  and  615 , interconnects  619  and  613  coupling the devices  617  and  615  to the substrate  621 , and the substrate  621  assists with increasing yield associated with performing an underfill encapsulation operation by reducing or eliminating damage to the devices  617  and  615 , interconnects  619  and  613  coupling the devices  617  and  615  to the substrate  621 , and the substrate  621 . When the needle  603  is in contact with the substrate  621  and under the device  617 , the underfill encapsulant  625  is dispensed in a direction  651 . 
     Moving on to  FIG. 6C , the underfill encapsulant  625  under the device  617  and encapsulating the interconnects  619  is shown. In one embodiment, an outer perimeter of the device  617  is smaller than an outer perimeter of the underfill encapsulant  625  that is encapsulating the interconnects  619 . In one embodiment, a keep-out zone  699  is around the underfill encapsulant  625  encapsulating the interconnects  619 . For example, the keep-out zone  699  extends from a sidewall of the device  617  to a sidewall of the device  615 , as shown in  FIG. 6C . Furthermore, since dispensing of the underfill encapsulant  625  is controlled, an edge of the underfill encapsulant  625  may extend out from under the device  617  a distance D 1  or D 2  that is less than the width of the keep-out zone  699 . For example, the width of the keep-out zone  699  may be 0.5 mm or less (e.g., any value ranging from 0.125 mm to 0.5 mm, etc.), and the distances D 1  and D 2  may be less than Z. For example, one or both of the distances D 1  and D 2  may range from 25% of the keep-out zone  699  to 50% of the keep-out zone  699 . It is to be appreciated that the keep-out zone  699  may be larger than the distances D 1  and D 2  in order to accommodate the needle  603 . However, due to the use of a needle  603  with a compliant tip (or a compliant tip and body), the keep-out zone  699  in embodiments disclosed herein is still smaller than existing manufacturing tolerances allow. 
     With regard again to  FIG. 6A , the needle dispenser  600  can be used to control the size, shape, or profile of the fillets  627  and  629 . In a further embodiment, and as explained below in connection with  FIGS. 7A-7B , the needle dispenser  600  can be used to collect portions of the underfill encapsulant  625  so that the fillets  627  and  629  have a desired size, shape, or profile. In one embodiment, using the needle dispenser  600  to dispense the underfill encapsulant  625  enables different types of fillets to be formed under the device  617 . For example, and as shown in  FIGS. 6C and 6E , a first fillet  627  has a sloped profile. For another example, and as shown in  FIGS. 6C and 6D , a second fillet  629  has a concave profile. It is to be appreciated that the fillet  627  can also have a concave profile, as shown in  FIG. 6D . It is also to be appreciated that the fillet  629  can have a sloped profile, as shown in  FIG. 6E . Additionally, it is to be appreciated that the fillets  627 ,  629  can have any profile known in the art (e.g., a convex profile, etc.). 
       FIGS. 7A-7B  are plan view illustrations of a device on an underfill encapsulant after at least some portions of the dispensed underfill have been collected by a needle dispenser, according to one embodiment. Referring now to  FIG. 7A , a device  701  that is on an underfill encapsulant  719  is illustrated. As shown, portions of the underfill encapsulant  719  have been collected by a needle dispenser, for example, the needle dispenser described above in connection with  FIGS. 5A-5C . In one embodiment, the needle dispenser (not shown in  FIGS. 7A-7B ) can be used to create desired voids  711 ,  709 ,  707  having any shape or size in the underfill encapsulant  719  by collecting portions of the underfill encapsulant  719 . For example, the void  711  is shown as a chevron, the void  709  is a circle, and the void  707  is a star. In yet another embodiment, portions of edges of the underfill encapsulant  719  can be removed to prevent the underfill encapsulant  719  from bleeding onto a substrate, interconnects not associated with the device  701 , or other devices on the substrate. In one embodiment, the outer perimeter of the underfill encapsulant  719  has edges that have non-linear shapes after portions of the edges have been collected by an embodiment of a needle dispenser described herein. For example, an edge  723  can have a wavy shape  713 , an edge  727  can have notches  703  formed therein, and an edge  725  can have notches  705  formed therein. It is to be appreciated that the edges of the underfill encapsulant  719  can have any known shape, size, or profile. 
     Moving on to  FIG. 7B , a device  713  that is on an underfill encapsulant  721  is illustrated. As shown, portions of the underfill encapsulant  721  have been collected by a needle dispenser, for example, the needle dispenser described above in connection with  FIGS. 5A-5C . In one embodiment, the needle dispenser (not shown in  FIGS. 7A-7B ) can be used to create voids  717 ,  715  with desired shapes or sizes in the underfill encapsulant  719  by collecting portions of the underfill encapsulant  719 . 
       FIG. 8  illustrates a cross sectional side view illustration of packaged system  800  that comprises a semiconductor package  825 , where the semiconductor package  825  comprises an device  801  coupled to a substrate  803  that is coupled to a board (e.g., a printed circuit board, motherboard, etc.), according to one embodiment. The semiconductor package  825  comprises device  801  coupled to a substrate  803  via interconnects  807  that are encapsulated in an underfill encapsulant  815 . As shown, the underfill encapsulant  815  has two fillets  817  and  821 , where the fillet  821  has a concave profile and the fillet  817  has a sloped profile. It is to be appreciated that each of the fillets  821 ,  817  may have any known profile (e.g., a convex profile, a sloped profile, a concave profile, etc.). The semiconductor package further comprises a substrate  803  coupled to a board  805  via interconnects  809  that are encapsulated in an underfill encapsulant  813 . As shown, the underfill encapsulant  813  has two fillets  823  and  819 , where the fillet  823  has a concave profile and the fillet  819  has a sloped profile. It is to be appreciated that each of the fillets  823 ,  819  may have any known profile (e.g., a convex profile, a sloped profile, a concave profile, etc.). The semiconductor package  825  further comprises interconnects  811  formed on a surface of the board  805 . In one embodiment, the semiconductor package  825  is similar to or the same as any one of the semiconductor packages described above in connection with one or more of  FIGS. 1A-7B . 
       FIG. 9  illustrates a schematic of computer system  900  according to an embodiment. The computer system  900  (also referred to as an electronic system  900 ) can include a semiconductor package comprising an underfill encapsulant that has been dispensed or collected in accordance with any of the embodiments and their equivalents as set forth in this disclosure. The computer system  900  may be a mobile device, a netbook computer, a wireless smart phone, a desktop computer, a hand-held reader, a server system, a supercomputer, or a high-performance computing system. 
     The system  900  can be a computer system that includes a system bus  920  to electrically couple the various components of the electronic system  900 . The system bus  920  is a single bus or any combination of busses according to various embodiments. The electronic system  900  includes a voltage source  930  that provides power to the integrated circuit  910 . In one embodiment, the voltage source  930  supplies current to the integrated circuit  910  through the system bus  920 . 
     The integrated circuit  910  is electrically coupled to the system bus  920  and includes any circuit, or combination of circuits according to an embodiment. In an embodiment, the integrated circuit  910  includes a processor  912 . As used herein, the processor  912  may mean any type of circuit such as, but not limited to, a microprocessor, a microcontroller, a graphics processor, a digital signal processor, or another processor. In an embodiment, the processor  912  includes, or is coupled with, a semiconductor package. In one embodiment, the integrated circuit  910  or the processor  912  is part of a semiconductor package that comprises an underfill encapsulant that has been dispensed or collected in accordance with any of the embodiments and their equivalents as set forth in this disclosure. In an embodiment, SRAM embodiments are found in memory caches of the processor. Other types of circuits that can be included in the integrated circuit  910  are a custom circuit or an application-specific integrated circuit (ASIC), such as a communications circuit  914  for use in wireless devices such as cellular telephones, smart phones, pagers, portable computers, two-way radios, and similar electronic systems, or a communications circuit for servers. In an embodiment, the integrated circuit  910  includes on-die memory  916  such as static random-access memory (SRAM). In an embodiment, the integrated circuit  910  includes embedded on-die memory  916  such as embedded dynamic random-access memory (eDRAM). In one embodiment, the on-die memory  916  may be packaged with a suitable packaging process to form a semiconductor package comprising an underfill encapsulant that has been dispensed or collected in accordance with any of the embodiments and their equivalents as set forth in this disclosure. 
     In an embodiment, the integrated circuit  910  is complemented with a subsequent integrated circuit  911 . Useful embodiments include a dual processor  913  and a dual communications circuit  915  and dual on-die memory  917  such as SRAM. In an embodiment, the dual integrated circuit  910  includes embedded on-die memory  917  such as eDRAM. 
     In an embodiment, the electronic system  900  also includes an external memory  940  that may include one or more memory elements suitable to the particular application, such as a main memory  942  in the form of RAM, one or more hard drives  944 , and/or one or more drives that handle removable media  946 , such as diskettes, compact disks (CDs), digital variable disks (DVDs), flash memory drives, and other removable media known in the art. The external memory  940  may also include embedded memory  948  such as the first die in a die stack, according to an embodiment. In one embodiment, the embedded memory  948  part of a semiconductor package that comprises an underfill encapsulant that has been dispensed or collected in accordance with any of the embodiments and their equivalents as set forth in this disclosure. 
     In an embodiment, the electronic system  900  also includes a display device  950  and an audio output  960 . In an embodiment, the electronic system  900  includes an input device such as a controller  970  that may be a keyboard, mouse, trackball, game controller, microphone, voice-recognition device, or any other input device that inputs information into the electronic system  900 . In an embodiment, an input device  970  is a camera. In an embodiment, an input device  970  is a digital sound recorder. In an embodiment, an input device  970  is a camera and a digital sound recorder. 
     At least one of the integrated circuits  910  or  911  can be implemented in a number of different embodiments, including a semiconductor package, an electronic system, a computer system, one or more methods of fabricating an integrated circuit, and one or more methods of fabricating a semiconductor package. In one embodiment, at least one of the integrated circuits is part of a semiconductor package that comprises an underfill encapsulant that has been dispensed or collected in accordance with any of the embodiments and their equivalents as set forth in this disclosure. The elements, materials, geometries, dimensions, and sequence of operations can all be varied to suit particular I/O coupling requirements including array contact count, array contact configuration for a microelectronic die embedded in a processor mounting substrate. A foundation substrate may be included, as represented by the dashed line of  FIG. 9 . Passive devices may also be included, as is also depicted in  FIG. 9 . 
     Reference throughout this specification to “one embodiment,” “an embodiment,” “another embodiment” and their variations means that a particular feature, structure, configuration, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “for one embodiment,” “In an embodiment,” “for another embodiment,” “in one embodiment,” “in an embodiment,” “in another embodiment,” or their variations in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     The terms “over,” “to,” “between,” “onto,” and “on” as used in the foregoing specification refer to a relative position of one layer with respect to other layers. One layer “over” or “on” another layer or bonded “to” or in “contact” with another layer may be directly in contact with the other layer or may have one or more intervening layers. One layer “between” layers may be directly in contact with the layers or may have one or more intervening layers. 
     The description provided above in connection with one or more embodiments as described herein that is included as part of a process of forming semiconductor packages may also be used for other types of IC packages and mixed logic-memory package stacks. In addition, the processing sequences may be compatible with both wafer level packages (WLP), and integration with surface mount substrates such as LGA, QFN, and ceramic substrates. 
     In the foregoing specification, abstract, and/or figures, numerous specific details are set forth, such as specific materials and processing operations, in order to provide a thorough understanding of embodiments described herein. It will, however, be evident that any of the embodiments described herein may be practiced without these specific details. In other instances, well-known features, such as the integrated circuitry of semiconductive dies, are not described in detail in order to not unnecessarily obscure embodiments described herein. Furthermore, it is to be understood that the various embodiments shown in the Figures and described in connection with the Figures are illustrative representations and are not necessarily drawn to scale. Thus, various modifications and/or changes may be made without departing form the broader spirit and scope of the embodiments described in connection with the foregoing specification, abstract, and/or Figures. As used herein, the phrases “A or B”, “A and/or B”, “one or more of A and B”, and “at least one of A or B” means (A), (B), or (A and B). 
     Examples of the embodiments described herein are set forth below. It is to be appreciated that the examples are illustrative examples not exhaustive examples. 
     Example embodiment 1: A needle dispenser comprises a reservoir and a needle coupled to the reservoir. A tip of the needle is comprised of a first material and a body of the needle that comprises a second material is coupled to the tip of the needle. The first and second materials differ from each other. The needle comprises a plurality of channels extending along a length of the needle. 
     Example embodiment 2: The needle dispenser of example embodiment 1, wherein the first material is more compliant than the second material. 
     Example embodiment 3: The needle dispenser of any one of example embodiments 1-2, wherein the first material comprises a rubber, a compliant polymer, or a combination thereof. 
     Example embodiment 4: The needle dispenser of any one of example embodiments 1-3, wherein a core of the needle comprises a hydrophilic material. 
     Example embodiment 5: The needle dispenser of any one of example embodiments 1-4, further comprising: a plurality of openings through sidewall surfaces of the needle, wherein the plurality of openings expose portions of the core. 
     Example embodiment 6: The needle dispenser of any one of example embodiments 1-5, wherein an outer surface of the needle comprises a hydrophobic material. 
     Example embodiment 7: The needle dispenser of any one of example embodiments 1-6, wherein a center line of the body of the needle is parallel to a center line of the body of the reservoir. 
     Example embodiment 8: The needle dispenser of any one of example embodiments 1-7, wherein a center line of the tip of the needle intersects the center of line of the body of the needle. 
     Example embodiment 9: The needle dispenser of any one of example embodiments 1-7, wherein a center of line of the tip of the needle is parallel to the center line of the body of the needle. 
     Example embodiment 10: The needle dispenser of any one of example embodiments 1-9, wherein the tip of the needle is tapered or flared. 
     Example embodiment 11: A semiconductor package comprises: a substrate; a device positioned on the substrate; one or more interconnects coupling the device to the substrate; and an underfill encapsulant encapsulating the one or more interconnects. The underfill encapsulant has a plurality of sides that extend outward from under the device. A side of the plurality of sides has a concave profile. 
     Example embodiment 12: The semiconductor package of example embodiment 11, wherein a distance between an edge of the device and an adjacent edge of the side of the underfill encapsulant that has the concave profile ranges from 0.125 millimeters (mm) to 0.5 mm. 
     Example embodiment 13: The semiconductor package of any one of example embodiments 11-12, wherein the underfill encapsulant comprises a void therein. 
     Example embodiment 14: The semiconductor package of any one of example embodiments 11-13, wherein a second side of the underfill encapsulant has a sloped profile. 
     Example embodiment 15: A method comprises dispensing, using a needle dispenser, an underfill encapsulant under a device coupled to a substrate using one or more interconnects. The needle dispenser comprises a reservoir and a needle coupled to the reservoir. A tip of the needle comprises a first material. A body of the needle that is coupled to the tip of the needle comprises a second material that differs from the first material. The needle comprises a plurality of channels extending along the needle. 
     Example embodiment 16: The method of example embodiment 15, further comprising contacting the tip of the needle with a surface of the substrate during the dispensing of the underfill encapsulant. 
     Example embodiment 17: The method of any one of example embodiments 15-16, wherein the tip of the needle is under the device and within an outer perimeter of the device during the dispensing. 
     Example embodiment 18: The method of any one of example embodiments 15-17, wherein the first material is more compliant than the second material. 
     Example embodiment 19: The method of any one of example embodiments 15-18, wherein an outer perimeter of the dispensed underfill encapsulant is larger than an outer perimeter of the device and wherein at least one sidewall surface defining the outer perimeter of the dispensed underfill encapsulant has a concave profile. 
     Example embodiment 20: The method of any one of any one of example embodiments 15-19, further comprising: collecting, using the needle dispenser, at least some of the dispensed underfill encapsulant under the device such that a sidewall surface defining at least one part of an outer perimeter of the dispensed underfill encapsulant has a desired profile. 
     Example embodiment 21: A packaged system comprises: a motherboard; a semiconductor package; one or more interconnects coupling the semiconductor package to the motherboard; and an underfill encapsulant encapsulating the one or more interconnects. The underfill encapsulant has first and second sides that extend outward from under the semiconductor package. The first side has a concave profile. 
     Example embodiment 22: The packaged system of example embodiment 21, wherein a distance between an edge of a keep-out zone and a corresponding edge of the first device that is parallel to the edge of the keep-out zone is less than or equal to 0.5 millimeters (mm). 
     Example embodiment 23: The packaged system of any one of example embodiments 21-22, wherein the first side of the plurality of sides has a non-linear shape. 
     Example embodiment 24: The packaged system of any one of example embodiments 21-23, wherein a second side of the plurality of sides has a sloped profile. 
     Example embodiment 25: The packaged system of any one of example embodiments 21-24, wherein the second side of the plurality of sides comprises notches.