Patent Publication Number: US-8110446-B2

Title: Method of making a semiconductor chip assembly with a post/base heat spreader and a conductive trace

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 12/616,775 filed Nov. 11, 2009. 
     U.S. application Ser. No. 12/616,775 is a continuation-in-part of U.S. application Ser. No. 12/557,540 filed Sep. 11, 2009, which is a continuation-in-part of U.S. application Ser. No. 12/406,510 filed Mar. 18, 2009, which claims the benefit of U.S. Provisional Application Ser. No. 61/071,589 filed May 7, 2008, U.S. Provisional Application Ser. No. 61/071,588 filed May 7, 2008, U.S. Provisional Application Ser. No. 61/071,072 filed Apr. 11, 2008, and U.S. Provisional Application Ser. No. 61/064,748 filed Mar. 25, 2008, each of which is incorporated by reference. U.S. application Ser. No. 12/557,540 also claims the benefit of U.S. Provisional Application Ser. No. 61/150,980 filed Feb. 9, 2009, which is incorporated by reference. 
     U.S. application Ser. No. 12/616,775 is also a continuation-in-part of U.S. application Ser. No. 12/557,541 filed Sep. 11, 2009, now U.S. Pat. No. 7,948,076 which is a continuation-in-part of U.S. application Ser. No. 12/406,510 filed Mar. 18, 2009, which claims the benefit of U.S. Provisional Application Ser. No. 61/071,589 filed May 7, 2008, U.S. Provisional Application Ser. No. 61/071,588 filed May 7, 2008, U.S. Provisional Application Ser. No. 61/071,072 filed Apr. 11, 2008, and U.S. Provisional Application Ser. No. 61/064,748 filed Mar. 25, 2008, each of which is incorporated by reference. U.S. application Ser. No. 12/557,541 also claims the benefit of U.S. Provisional Application Ser. No. 61/150,980 filed Feb. 9, 2009, which is incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to semiconductor chip assembly, and more particularly to a semiconductor chip assembly with a semiconductor device, a conductive trace, an adhesive and a heat spreader and its method of manufacture. 
     2. Description of the Related Art 
     Semiconductor devices such as packaged and unpackaged semiconductor chips have high voltage, high frequency and high performance applications that require substantial power to perform the specified functions. As the power increases, the semiconductor device generates more heat. Furthermore, the heat build-up is aggravated by higher packing density and smaller profile sizes which reduce the surface area to dissipate the heat. 
     Semiconductor devices are susceptible to performance degradation as well as short life span and immediate failure at high operating temperatures. The heat not only degrades the chip, but also imposes thermal stress on the chip and surrounding elements due to thermal expansion mismatch. As a result, the heat must be dissipated rapidly and efficiently from the chip to ensure effective and reliable operation. A high thermal conductivity path typically requires heat conduction and heat spreading to a much larger surface area than the chip or a die pad it is mounted on. 
     Light emitting diodes (LEDs) have recently become popular alternatives to incandescent, fluorescent and halogen light sources. LEDs provide energy efficient, cost effective, long term lighting for medical, military, signage, signal, aircraft, maritime, automotive, portable, commercial and residential applications. For instance, LEDs provide light sources for lamps, flashlights, headlights, flood lights, traffic lights and displays. 
     LEDs include high power chips that generate high light output and considerable heat. Unfortunately, LEDs exhibit color shifts and low light output as well as short lifetimes and immediate failure at high operating temperatures. Furthermore, LED light output and reliability are constrained by heat dissipation limits. LEDs underscore the critical need for providing high power chips with adequate heat dissipation. 
     LED packages usually include an LED chip, a submount, electrical contacts and a thermal contact. The submount is thermally connected to and mechanically supports the LED chip. The electrical contacts are electrically connected to the anode and cathode of the LED chip. The thermal contact is thermally connected to the LED chip by the submount but requires adequate heat dissipation by the underlying carrier to prevent the LED chip from overheating. 
     Packages and thermal boards for high power chips have been developed extensively in the industry with a wide variety of designs and manufacturing techniques in attempts to meet performance demands in an extremely cost-competitive environment. 
     Plastic ball grid array (PBGA) packages have a chip and a laminated substrate enclosed in a plastic housing and are attached to a printed circuit board (PCB) by solder balls. The laminated substrate includes a dielectric layer that often includes fiberglass. The heat from the chip flows through the plastic and the dielectric layer to the solder balls and then the PCB. However, since the plastic and the dielectric layer typically have low thermal conductivity, the PBGA provides poor heat dissipation. 
     Quad-Flat-No Lead (QFN) packages have the chip mounted on a copper die pad which is soldered to the PCB. The heat from the chip flows through the die pad to the PCB. However, since the lead frame type interposer has limited routing capability, the QFN package cannot accommodate high input/output (I/O) chips or passive elements. 
     Thermal boards provide electrical routing, thermal management and mechanical support for semiconductor devices. Thermal boards usually include a substrate for signal routing, a heat spreader or heat sink for heat removal, pads for electrical connection to the semiconductor device and terminals for electrical connection to the next level assembly. The substrate can be a laminated structure with single layer or multi-layer routing circuitry and one or more dielectric layers. The heat spreader can be a metal base, a metal slug or an embedded metal layer. 
     Thermal boards interface with the next level assembly. For instance, the next level assembly can be a light fixture with a printed circuit board and a heat sink. In this instance, an LED package is mounted on the thermal board, the thermal board is mounted on the heat sink, the thermal board/heat sink subassembly and the printed circuit board are mounted in the light fixture and the thermal board is electrically connected to the printed circuit board by wires. The substrate routes electrical signals to the LED package from the printed circuit board and the heat spreader spreads and transfers heat from the LED package to the heat sink. The thermal board thus provides a critical thermal path for the LED chip. 
     U.S. Pat. No. 6,507,102 to Juskey et al. discloses an assembly in which a composite substrate with fiberglass and cured thermosetting resin includes a central opening, a heat slug with a square or rectangular shape resembling the central opening is attached to the substrate at sidewalls of the central opening, top and bottom conductive layers are attached to the top and bottom of the substrate and electrically connected to one another by plated through-holes through the substrate, a chip is mounted on the heat slug and wire bonded to the top conductive layer, an encapsulant is molded on the chip and solder balls are placed on the bottom conductive layer. 
     During manufacture, the substrate is initially a prepreg with B-stage resin placed on the bottom conductive layer, the heat slug is inserted into the central opening and on the bottom conductive layer and spaced from the substrate by a gap, the top conductive layer is mounted on the substrate, the conductive layers are heated and pressed towards one another so that the resin melts, flows into the gap and solidifies, the conductive layers are patterned to form circuit traces on the substrate and expose the excess resin flash on the heat slug, and the excess resin flash is removed to expose the heat slug. The chip is then mounted on the heat slug, wire bonded and encapsulated. 
     The heat flows from the chip through the heat slug to the PCB. However, manually dropping the heat slug into the central opening is prohibitively cumbersome and expensive for high volume manufacture. Furthermore, since the heat slug is difficult to accurately position in the central opening due to tight lateral placement tolerance, voids and inconsistent bond lines arise between the substrate and the heat slug. The substrate is therefore partially attached to the heat slug, fragile due to inadequate support by the heat slug and prone to delamination. In addition, the wet chemical etch that removes portions of the conductive layers to expose the excess resin flash also removes portions of the heat slug exposed by the excess resin flash. The heat slug is therefore non-planar and difficult to bond to. As a result, the assembly suffers from high yield loss, poor reliability and excessive cost. 
     U.S. Pat. No. 6,528,882 to Ding et al. discloses a thermal enhanced ball grid array package in which the substrate includes a metal core layer. The chip is mounted on a die pad region at the top surface of the metal core layer, an insulating layer is formed on the bottom surface of the metal core layer, blind vias extend through the insulating layer to the metal core layer, thermal balls fill the blind vias and solder balls are placed on the substrate and aligned with the thermal balls. The heat from the chip flows through the metal core layer to the thermal balls to the PCB. However, the insulating layer sandwiched between the metal core layer and the PCB limits the heat flow to the PCB. 
     U.S. Pat. No. 6,670,219 to Lee et al. discloses a cavity down ball grid array (CDBGA) package in which a ground plate with a central opening is mounted on a heat spreader to form a thermal dissipating substrate. A substrate with a central opening is mounted on the ground plate using an adhesive with a central opening. A chip is mounted on the heat spreader in a cavity defined by the central opening in the ground plate and solder balls are placed on the substrate. However, since the solder balls extend above the substrate, the heat spreader does not contact the PCB. As a result, the heat spreader releases the heat by thermal convection rather than thermal conduction which severely limits the heat dissipation. 
     U.S. Pat. No. 7,038,311 to Woodall et al. discloses a thermal enhanced BGA package in which a heat sink with an inverted T-like shape includes a pedestal and an expanded base, a substrate with a window opening is mounted on the expanded base, an adhesive attaches the pedestal and the expanded base to the substrate, a chip is mounted on the pedestal and wire bonded to the substrate, an encapsulant is molded on the chip and solder balls are placed on the substrate. The pedestal extends through the window opening, the substrate is supported by the expanded base and the solder balls are located between the expanded base and the perimeter of the substrate. The heat from the chip flows through the pedestal to the expanded base to the PCB. However, since the expanded base must leave room for the solder balls, the expanded base protrudes below the substrate only between the central window and the innermost solder ball. Consequently, the substrate is unbalanced and wobbles and warps during manufacture. This creates enormous difficulties with chip mounting, wire bonding and encapsulant molding. Furthermore, the expanded base may be bent by the encapsulant molding and may impede soldering the package to the next level assembly as the solder balls collapse. As a result, the package suffers from high yield loss, poor reliability and excessive cost. 
     U.S. Patent Application Publication No. 2007/0267642 to Erchak et al. discloses a light emitting device assembly in which a base with an inverted T-like shape includes a substrate, a protrusion and an insulative layer with an aperture, electrical contacts are mounted on the insulative layer, a package with an aperture and a transparent lid is mounted on the electrical contacts and an LED chip is mounted on the protrusion and wire bonded to the substrate. The protrusion is adjacent to the substrate and extends through the apertures in the insulative layer and the package into the package, the insulative layer is mounted on the substrate, the electrical contacts are mounted on the insulative layer and the package is mounted on the electrical contacts and spaced from the insulative layer. The heat from the chip flows through the protrusion to the substrate to a heat sink. However, the electrical contacts are difficult to mount on the insulating layer, difficult to electrically connect to the next level assembly and fail to provide multi-layer routing. 
     Conventional packages and thermal boards thus have major deficiencies. For instance, dielectrics with low thermal conductivity such as epoxy limit heat dissipation, whereas dielectrics with higher thermal conductivity such as epoxy filled with ceramic or silicon carbide have low adhesion and are prohibitively expensive for high volume manufacture. The dielectric may delaminate during manufacture or prematurely during operation due to the heat. The substrate may have single layer circuitry with limited routing capability or multi-layer circuitry with thick dielectric layers which reduce heat dissipation. The heat spreader may be inefficient, cumbersome or difficult to thermally connect to the next level assembly. The manufacturing process may be unsuitable for low cost, high volume manufacture. 
     In view of the various development stages and limitations in currently available packages and thermal boards for high power semiconductor devices, there is a need for a semiconductor chip assembly that is cost effective, reliable, manufacturable, versatile, provides flexible signal routing and has excellent heat spreading and dissipation. 
     SUMMARY OF THE INVENTION 
     The present invention provides a semiconductor chip assembly that includes a semiconductor device, a heat spreader, a conductive trace and an adhesive. The semiconductor device is electrically connected to the conductive trace and thermally connected to the heat spreader. The heat spreader includes a post and a base. The post extends upwardly from the base into an opening in the adhesive, and the base extends laterally from the post. The adhesive extends between the post and the conductive trace and between the base and the conductive trace. The conductive trace provides signal routing between a pad and a terminal. 
     In accordance with an aspect of the present invention, a semiconductor chip assembly includes a semiconductor device, an adhesive, a heat spreader and a conductive trace. The adhesive includes an opening. The heat spreader includes a post and a base, wherein the post is adjacent to the base and extends above the base in an upward direction, and the base extends below the post in a downward direction opposite the upward direction and extends laterally from the post in lateral directions orthogonal to the upward and downward directions. The conductive trace includes a pad and a terminal. 
     The semiconductor device is above and overlaps the post, is electrically connected to the pad and thereby electrically connected to the terminal, and is thermally connected to the post and thereby thermally connected to the base. 
     The adhesive is mounted on and extends above the base, extends into a gap between the post and the pad, extends laterally from the post to or beyond the terminal and is sandwiched between the base and the pad. 
     The pad is mounted on the adhesive and extends above the base. 
     The post extends into the opening, and the base extends below the semiconductor device, the adhesive and the pad. 
     The heat spreader can include a cap that is above and adjacent to and covers in the upward direction and extends laterally in the lateral directions from a top of the post. For instance, the cap can have a rectangular or square shape and the top of the post can have a circular shape. In this instance, the cap can be sized and shaped to accommodate a thermal contact surface of the semiconductor device whereas the top of the post is not sized and shaped to accommodate the thermal contact surface of the semiconductor device. The cap can also contact and cover a portion of the adhesive that is coplanar with and adjacent to the post. The cap can also be coplanar with the pad and/or the terminal above the adhesive. In addition, the post can thermally connect the base and the cap. The heat spreader can consist of the post and the base or the post, the base and the cap. The heat spreader can also consist of copper, aluminum or copper/nickel/aluminum. In any case, the heat spreader provides heat dissipation and spreading from the semiconductor device to the next level assembly. 
     The semiconductor device can be mounted on the heat spreader. For instance, the semiconductor device can be mounted on the heat spreader and the conductive trace, overlap the post and the pad, be electrically connected to the pad using a first solder joint and be thermally connected to the heat spreader using a second solder joint. Alternatively, the semiconductor device can be mounted on the heat spreader but not the conductive trace, overlap the post but not the conductive trace, be electrically connected to the pad using a wire bond and be thermally connected to the heat spreader using a die attach. 
     The semiconductor device can be a packaged or unpackaged semiconductor chip. For instance, the semiconductor device can be an LED package that includes an LED chip, is mounted on the heat spreader and the conductive trace, overlaps the post and the pad, is electrically connected to the pad using a first solder joint and is thermally connected to the heat spreader using a second solder joint. Alternatively, the semiconductor device can be a semiconductor chip that is mounted on the heat spreader but not the conductive trace, overlaps the post but not the conductive trace, is electrically connected to the pad using a wire bond and is thermally connected to the heat spreader using a die attach. 
     The adhesive can contact the post in the gap and contact the base, the pad and the terminal outside the gap. The adhesive can also cover the conductive trace in the downward direction, cover and surround the post in the lateral directions and cover the base outside the post in the upward direction. The adhesive can also conformally coat the sidewalls of the post and a top surface of the base outside the post. The adhesive can also be coplanar with a top of the post. The adhesive can also fill the space between the base and the conductive trace and be contained in the space between the heat spreader and the conductive trace. 
     The adhesive can extend laterally from the post to or beyond the terminal. For instance, the adhesive and the terminal can extend to peripheral edges of the assembly. In this instance, the adhesive extends laterally from the post to the terminal. Alternatively, the adhesive can extend to peripheral edges of the assembly and the terminal can be spaced from the peripheral edges of the assembly. In this instance, the adhesive extends laterally from the post beyond the terminal. 
     The adhesive can overlap or be overlapped by the terminal. For instance, the terminal can extend above and overlap the adhesive and be coplanar with the pad and the cap. In this instance, the adhesive is overlapped by the terminal and the assembly provides horizontal signal routing between the pad and the terminal. Alternatively, the terminal can be extend below and be overlapped by the adhesive and be coplanar with the base. In this instance, the adhesive overlaps the terminal and the assembly provides vertical signal routing between the pad and the terminal. 
     The post can be integral with the base. For instance, the post and the base can be a single-piece metal or include a single-piece metal at their interface, and the single-piece metal can be copper. The post can also extend through the opening. The post can also be coplanar with the adhesive above a bottom surface of the pad. The post can also have a cut-off conical shape in which its diameter decreases as it extends upwardly from the base to its flat top adjacent to the cap. 
     The base can cover the semiconductor device, the post, the cap, the adhesive and the conductive trace in the downward direction, support the adhesive and the conductive trace and extend to peripheral edges of the assembly. 
     The conductive trace can be spaced from the post and the base. The conductive trace can also be a single-level continuous trace that is mounted on and contacts and overlaps and extends above the adhesive. The conductive trace can also include the pad, the terminal and a routing line, wherein an electrically conductive path between the pad and the terminal includes the routing line. In any case, the conductive trace provides signal routing between the pad and the terminal. 
     The pad can be an electrical contact for the semiconductor device, the terminal can be an electrical contact for the next level assembly, and the pad and the terminal can provide signal routing between the semiconductor device and the next level assembly. 
     The assembly can be a first-level or second-level single-chip or multi-chip device. For instance, the assembly can be a first-level package that contains a single chip or multiple chips. Alternatively, the assembly can be a second-level module that contains a single LED package or multiple LED packages, and each LED package can contain a single LED chip or multiple LED chips. 
     The present invention provides a method of making a semiconductor chip assembly that includes providing a post and a base, mounting an adhesive on the base including inserting the post into an opening in the adhesive, mounting a conductive layer on the adhesive including aligning the post with an aperture in the conductive layer, then flowing the adhesive into and upward in a gap located in the aperture between the post and the conductive layer, solidifying the adhesive, then providing a conductive trace that includes a pad, a terminal and a selected portion of the conductive layer, mounting a semiconductor device on a heat spreader that includes the post and the base, electrically connecting the semiconductor device to the conductive trace and thermally connecting the semiconductor device to the heat spreader. 
     In accordance with an aspect of the present invention, a method of making a semiconductor chip assembly includes (1) providing a post, a base, an adhesive and a conductive layer, wherein (a) the post is adjacent to the base, extends above the base in an upward direction, extends into an opening in the adhesive and is aligned with an aperture in the conductive layer, (b) the base extends below the post in a downward direction opposite the upward direction and extends laterally from the post in lateral directions orthogonal to the upward and downward directions, (c) the adhesive is mounted on and extends above the base, is sandwiched between the base and the conductive layer and is non-solidified, and (d) the conductive layer is mounted on and extends above the adhesive, then (2) flowing the adhesive into and upward in a gap located in the aperture between the post and the conductive layer, (3) solidifying the adhesive, then (4) providing a conductive trace that includes a pad, a terminal and a selected portion of the conductive layer, (5) mounting a semiconductor device on a heat spreader that includes the post and the base, wherein the semiconductor device overlaps the post, (6) electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal, and (7) thermally connecting the semiconductor device to the post, thereby thermally connecting the semiconductor device to the base. 
     In accordance with another aspect of the present invention, a method of making a semiconductor chip assembly includes (1) providing a post and a base, wherein the post is adjacent to and integral with the base and extends above the base in an upward direction, and the base extends below the post in a downward direction opposite the upward direction and extends laterally from the post in lateral directions orthogonal to the upward and downward directions, (2) providing an adhesive, wherein an opening extends through the adhesive, (3) providing a conductive layer, wherein an aperture extends through the conductive layer, (4) mounting the adhesive on the base, including inserting the post into the opening, wherein the adhesive extends above the base and the post extends into the opening, (5) mounting the conductive layer on the adhesive, including aligning the post with the aperture, wherein the conductive layer extends above the adhesive and the adhesive is sandwiched between the base and the conductive layer and is non-solidified, then (6) applying heat to melt the adhesive, (7) moving the base and the conductive layer towards one another, thereby moving the post upward in the aperture and applying pressure to the molten adhesive between the base and the conductive layer, wherein the pressure forces the molten adhesive to flow into and upward in a gap located in the aperture between the post and the conductive layer, (8) applying heat to solidify the molten adhesive, thereby mechanically attaching the post and the base to the conductive layer, then (9) providing a conductive trace that includes a pad and a terminal, wherein the conductive trace includes selected portions of the conductive layer and an electrically conductive path is between the pad and the terminal, (10) mounting a semiconductor device on a heat spreader that includes the post and the base, wherein the semiconductor device overlaps the post, (11) electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal, and (12) thermally connecting the semiconductor device to the post, thereby thermally connecting the semiconductor device to the base. 
     Providing the post and the base can include providing a metal plate, forming an etch mask on the metal plate that selectively exposes the metal plate, etching the metal plate in a pattern defined by the etch mask, thereby forming a recess in the metal plate that extends into but not through the metal plate, and then removing the etch mask, wherein the post includes an unetched portion of the metal plate that protrudes above the base and is laterally surrounded by the recess, and the base includes an unetched portion of the metal plate below the post and the recess. 
     Providing the adhesive can include providing a prepreg with uncured epoxy, flowing the adhesive can include melting the uncured epoxy and compressing the uncured epoxy between the base and the conductive layer, and solidifying the adhesive can include curing the molten uncured epoxy. 
     Providing the heat spreader can include providing a cap on the post that is above and adjacent to and covers in the upward direction and extends laterally in the lateral directions from a top of the post after solidifying the adhesive and before mounting the semiconductor device. 
     Providing the pad, the terminal and the routing line can include removing selected portions of the conductive layer after solidifying the adhesive. 
     Providing the pad, the terminal and the routing line can also include grinding the post, the adhesive and the conductive layer after solidifying the adhesive such that the post, the adhesive and the conductive layer are laterally aligned with one another at a top lateral surface that faces in the upward direction, and then removing selected portions of the conductive layer such that the pad, the terminal and the routing line include selected portions of the conductive layer. The grinding can include grinding the adhesive without grinding the post and then grinding the post, the adhesive and the conductive layer. The removing can include applying a wet chemical etch to the conductive layer using an etch mask that defines the pad, the terminal and the routing line. 
     Providing the pad, the terminal and the routing line can also include depositing a second conductive layer on the post, the adhesive and the conductive layer after the grinding and then removing selected portions of the conductive layers such that the pad, the terminal and the routing line include selected portions of the conductive layers. Depositing the second conductive layer can include electrolessly plating a first plated layer on the post, the adhesive and the conductive layer and then electroplating a second plated layer on the first plated layer. The removing can include applying the wet chemical etch to the conductive layers using the etch mask to define the pad, the terminal and the routing line. 
     Providing the cap can include removing selected portions of the second conductive layer. Providing the cap can also include the grinding and then removing selected portions of the second conductive layer using the etch mask to define the cap such that the cap includes selected portions of the second conductive layer. Thus, the pad, the terminal, the routing line and the cap can be formed simultaneously using the same grinding, wet chemical etch and etch mask. 
     Flowing the adhesive can include filling the gap with the adhesive. Flowing the adhesive can also include squeezing the adhesive through the gap, above the post and the conductive layer and on top surface portions of the post and the conductive layer adjacent to the gap. 
     Solidifying the adhesive can include mechanically bonding the post and the base to the conductive layer. 
     Mounting the conductive layer can include mounting the conductive layer alone on the adhesive, or alternatively, attaching the conductive layer to a carrier, then mounting the conductive layer and the carrier on the adhesive such that the carrier overlaps the conductive layer and the conductive layer contacts the adhesive and is sandwiched between the adhesive and the carrier, and then, after solidifying the adhesive, removing the carrier and then providing the conductive trace. 
     Mounting the semiconductor device can include mounting the semiconductor device on the cap. Mounting the semiconductor device can also include positioning the semiconductor device above and overlapping the post, the cap and the opening. 
     Mounting the semiconductor device can include providing a first solder joint between an LED package that includes an LED chip and the pad and a second solder joint between the LED package and the cap, electrically connecting the semiconductor device can include providing the first solder joint between the LED package and the pad, and thermally connecting the semiconductor device can include providing the second solder joint between the LED package and the cap. 
     Mounting the semiconductor device can include providing a die attach between a semiconductor chip and the cap, electrically connecting the semiconductor device can include providing a wire bond between the chip and the pad, and thermally connecting the semiconductor device can include providing the die attach between the chip and the cap. 
     The adhesive can contact the post, the base, the cap, the pad, the terminal and the routing line, cover the conductive trace in the downward direction, cover and surround the post in the lateral directions, cover the base outside the post in the upward direction and extend to peripheral edges of the assembly after the assembly is manufactured and detached from other assemblies in a batch. 
     The base can cover the semiconductor device, the post, the cap, the adhesive and the conductive trace in the downward direction, support the adhesive and the conductive trace and extend to peripheral edges of the assembly after the assembly is manufactured and detached from other assemblies in a batch. 
     The present invention has numerous advantages. The heat spreader can provide excellent heat spreading and heat dissipation without heat flow through the adhesive. As a result, the adhesive can be a low cost dielectric with low thermal conductivity and not prone to delamination. The post and the base can be integral with one another, thereby enhancing reliability. The cap can be customized for the semiconductor device, thereby enhancing the thermal connection. The adhesive can be sandwiched between the base and the conductive trace, thereby providing a robust mechanical bond between the heat spreader and the conductive trace. The conductive trace can provide horizontal single-layer signal routing with simple circuitry patterns to reduce cost. The base can provide mechanical support for the conductive trace, thereby preventing warping. The assembly can be manufactured using low temperature processes which reduces stress and improves reliability. The assembly can also be manufactured using well-controlled processes which can be easily implemented by circuit board, lead frame and tape manufacturers. 
     These and other features and advantages of the present invention will be further described and more readily apparent from a review of the detailed description of the preferred embodiments which follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description of the preferred embodiments of the present invention can best be understood when read in conjunction with the following drawings, in which: 
         FIGS. 1A-1D  are cross-sectional views showing a method of making a post and a base in accordance with an embodiment of the present invention; 
         FIGS. 1E and 1F  are top and bottom views, respectively, corresponding to  FIG. 1D ; 
         FIGS. 2A and 2B  are cross-sectional views showing a method of making an adhesive in accordance with an embodiment of the present invention; 
         FIGS. 2C and 2D  are top and bottom views, respectively, corresponding to  FIG. 2B ; 
         FIGS. 3A-3D  are cross-sectional views showing a method of making a conductive layer in accordance with an embodiment of the present invention; 
         FIGS. 3E and 3F  are top and bottom views, respectively, corresponding to  FIG. 3D ; 
         FIGS. 4A-4L  are cross-sectional views showing a method of making a thermal board in accordance with an embodiment of the present invention; 
         FIGS. 4M and 4N  are top and bottom views, respectively, corresponding to  FIG. 4L ; 
         FIGS. 5A ,  5 B and  5 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes the thermal board and an LED package with backside contacts accordance with an embodiment of the present invention; 
         FIGS. 6A ,  6 B and  6 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes the thermal board and an LED package with lateral leads in accordance with an embodiment of the present invention; 
         FIGS. 7A ,  7 B and  7 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes the thermal board and a semiconductor chip in accordance with an embodiment of the present invention; and 
         FIGS. 8A ,  8 B and  8 C are cross-sectional, top and bottom views, respectively, of a light source subassembly that includes the semiconductor chip assembly in  FIGS. 5A-5C  and a heat sink in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1A-1D  are cross-sectional views showing a method of making a post and a base in accordance with an embodiment of the present invention, and  FIGS. 1E and 1F  are top and bottom views, respectively, corresponding to  FIG. 1D . 
       FIG. 1A . is a cross-sectional view of metal plate  10  which includes opposing major surfaces  12  and  14 . Metal plate  10  is illustrated as a copper plate with a thickness of 500 microns. Copper has high thermal conductivity, good bondability and low cost. Metal plate  10  can be various metals such as copper, aluminum, alloy 42, iron, nickel, silver, gold, combinations thereof, and alloys thereof. 
       FIG. 1B  is a cross-sectional view of etch mask  16  and cover mask  18  formed on metal plate  10 . Etch mask  16  and cover mask  18  are illustrated as photoresist layers which are deposited on metal plate  10  using dry film lamination in which hot rolls simultaneously press photoresist layers  16  and  18  onto surfaces  12  and  14 , respectively. Wet spin coating and curtain coating are also suitable deposition techniques. A reticle (not shown) is positioned proximate to photoresist layer  16 . Thereafter, photoresist layer  16  is patterned by selectively applying light through the reticle so that the photoresist portions exposed to the light are rendered insoluble, applying a developer solution to remove the photoresist portions that are unexposed to the light and remain soluble and then hard baking, as is conventional. As a result, photoresist layer  16  has a pattern that selectively exposes surface  12 , and photoresist layer  18  remains unpatterned and covers surface  14 . 
       FIG. 1C  is a cross-sectional view of recess  20  formed into but not through metal plate  10  by etching metal plate  10  in the pattern defined by etch mask  16 . The etching is illustrated as a front-side wet chemical etch. For instance, the structure can be inverted so that etch mask  16  faces downward and cover mask  18  faces upward as a bottom spray nozzle (not shown) that faces etch mask  16  upwardly sprays the wet chemical etch on metal plate  10  and etch mask  16  while a top spray nozzle (not shown) that faces cover mask  18  is deactivated so that gravity assists with removing the etched byproducts. Alternatively, the structure can be dipped in the wet chemical etch since cover mask  18  provides back-side protection. The wet chemical etch is highly selective of copper and etches 200 microns into metal plate  10 . As a result, recess  20  extends from surface  12  into but not through metal plate  10 , is spaced from surface  14  by 300 microns and has a depth of 200 microns. The wet chemical etch also laterally undercuts metal plate  10  beneath etch mask  16 . A suitable wet chemical etch can be provided by a solution containing alkaline ammonia or a dilute mixture of nitric and hydrochloric acid. Likewise, the wet chemical etch can be acidic or alkaline. The optimal etch time for forming recess  20  without excessively exposing metal plate  10  to the wet chemical etch can be established through trial and error. 
       FIGS. 1D ,  1 E and  1 F are cross-sectional, top and bottom views, respectively, of metal plate  10  after etch mask  16  and cover mask  18  are removed. The photoresist layers are stripped using a solvent, such as a strong alkaline solution containing potassium hydroxide with a pH of 14, that is highly selective of photoresist with respect to copper. 
     Metal plate  10  as etched includes post  22  and base  24 . 
     Post  22  is an unetched portion of metal plate  10  defined by etch mask  16 . Post  22  is adjacent to and integral with and protrudes above base  24  and is laterally surrounded by recess  20 . Post  22  has a height of 200 microns (recess  20  depth), a diameter at its top surface (circular portion of surface  12 ) of 1000 microns and a diameter at its bottom (circular portion adjacent to base  24 ) of 1100 microns. Thus, post  22  has a cut-off conical shape (resembling a frustum) with tapered sidewalls in which its diameter decreases as it extends upwardly from base  24  to its flat circular top surface. The tapered sidewalls arise from the lateral undercutting by the wet chemical etch beneath etch mask  16 . The top surface is concentrically disposed within a periphery of the bottom (shown in phantom in  FIG. 1E ). 
     Base  24  is an unetched portion of metal plate  10  that is below post  22 , extends laterally from post  22  in a lateral plane (with lateral directions such as left and right) and has a thickness of 300 microns (500-200). 
     Post  22  and base  24  can be treated to improve bondability to epoxy and solder. For instance, post  22  and base  24  can be chemically oxidized or microetched to provide rougher surfaces. 
     Post  22  and base  24  are illustrated as a subtractively formed single-piece metal (copper). Post  22  and base  24  can also be a stamped single-piece metal formed by stamping metal plate  10  with a contact piece with a recess or hole that defines post  22 . Post  22  can also be formed additively by depositing post  22  on base  24  using electroplating, chemical vapor deposition (CVD), physical vapor deposition (PVD) and so on, for instance by electroplating a solder post  22  on a copper base  24 , in which case post  22  and base  24  have a metallurgical interface and are adjacent to but not integral with one another. Post  22  can also be formed semi-additively, for instance by depositing an upper portion of post  22  on an etch-defined lower portion of post  22 . Post  22  and base  24  can also be formed semi-additively by depositing a conformal upper portion of post  22  and base  24  on an etch-defined lower portion of post  22  and base  24 . Post  22  can also be sintered to base  24 . 
       FIGS. 2A and 2B  are cross-sectional views showing a method of making an adhesive in accordance with an embodiment of the present invention, and  FIGS. 2C and 2D  are top and bottom views, respectively, corresponding to  FIG. 2B . 
       FIG. 2A  is a cross-sectional view of adhesive  26 . Adhesive  26  is illustrated as a prepreg with B-stage uncured epoxy provided as a non-solidified unpatterned sheet with a thickness of 125 microns. 
     Adhesive  26  can be various dielectric films or prepregs formed from numerous organic or inorganic electrical insulators. For instance, adhesive  26  can initially be a prepreg in which thermosetting epoxy in resin form impregnates a reinforcement and is partially cured to an intermediate stage. The epoxy can be FR-4 although other epoxies such as polyfunctional and bismaleimide triazine (BT) are suitable. For specific applications, cyanate esters, polyimide and PTFE are also suitable. The reinforcement can be E-glass although other reinforcements such as S-glass, D-glass, quartz, Kevlar aramid and paper are suitable. The reinforcement can also be woven, non-woven or random microfiber. A filler such as silica (powdered fused quartz) can be added to the prepreg to improve thermal conductivity, thermal shock resistance and thermal expansion matching. Commercially available prepregs such as SPEEDBOARD C prepreg by W.L. Gore &amp; Associates of Eau Claire, Wis. are suitable. 
       FIGS. 2B ,  2 C and  2 D are cross-sectional, top and bottom views, respectively, of adhesive  26  with opening  28 . Opening  28  is a central window that extends through adhesive  26 . Opening  28  is formed by mechanical drilling through the prepreg and has a diameter of 1150 microns. Opening  28  can be formed by other techniques such as punching and stamping. 
       FIGS. 3A-3D  are cross-sectional views showing a method of making a conductive layer in accordance with an embodiment of the present invention, and  FIGS. 3E and 3F  are top and bottom views, respectively, corresponding to  FIG. 3D . 
       FIG. 3A  is a cross-sectional view of conductive layer  30 . Conductive layer  30  is an electrical conductor. For instance, conductive layer  30  is an unpatterned copper sheet with a thickness of 125 microns. 
       FIG. 3B  is a cross-sectional view of conductive layer  30  with etch masks  32  and  34  formed on the top and bottom surfaces, respectively, of conductive layer  30 . Etch masks  32  and  34  are illustrated as photoresist layers similar to photoresist layer  16 . Photoresist layer  32  has a pattern that selectively exposes conductive layer  30  at its top surface, and photoresist layer  34  has an identical pattern that selectively exposes conductive layer  30  at its bottom surface. 
       FIG. 3C  is a cross-sectional view of conductive layer  30  with aperture  36  formed by etching conductive layer  30  in the pattern defined by etch masks  32  and  34 . The etching is illustrated as a front-side and back-side wet chemical etch. For instance, a top spray nozzle (not shown) that faces etch mask  32  can downwardly spray the wet chemical etch on conductive layer  30  and etch mask  32  while a top spray nozzle (not shown) that faces etch mask  34  can upwardly spray the wet chemical etch on conductive layer  30  and etch mask  34 . Alternatively, the structure can be dipped in the wet chemical etch. The wet chemical etch is highly selective of copper and etches through conductive layer  30 . As a result, aperture  36  extends through conductive layer  30 . A suitable wet chemical etch can be provided by a solution containing alkaline ammonia or a dilute mixture of nitric and hydrochloric acid. Likewise, the wet chemical etch can be acidic or alkaline. The optimal etch time for forming aperture  36  without excessively exposing conductive layer  30  to the wet chemical etch can be established through trial and error. 
       FIGS. 3D ,  3 E and  3 F are cross-sectional, top and bottom views, respectively, of conductive layer  30  with aperture  36  after etch masks  32  and  34  are removed. Photoresist layers  30  and  34  can be stripped in the same manner as photoresist layers  16  and  18 . 
     Aperture  36  is a central window that extends through conductive layer  30  and has a diameter of 1150 microns. Aperture  36  can be formed with other techniques such as mechanical drilling, punching and stamping. Preferably, opening  28  and aperture  36  have the same diameter. 
       FIGS. 4A-4L  are cross-sectional views showing a method of making a thermal board that includes post  22 , base  24 , adhesive  26  and conductive layer  30  in accordance with an embodiment of the present invention, and  FIGS. 4M and 4N  are top and bottom views, respectively, corresponding to  FIG. 4L . 
       FIG. 4A  is a cross-sectional view of the structure with adhesive  26  mounted on base  24 . Adhesive  26  is mounted by lowering it onto base  24  as post  22  is inserted into and through and upwards in opening  28 . Adhesive  26  eventually contacts and rests on base  24 . Preferably, post  22  is inserted into and extends through opening  28  without contacting adhesive  26  and is aligned with and centrally located within opening  28 . 
       FIG. 4B  is a cross-sectional view of the structure with conductive layer  30  mounted on adhesive  26 . Conductive layer  30  is mounted by lowering it onto adhesive  26  as post  22  is inserted into and upwards in aperture  36 . Conductive layer  30  eventually contacts and rests on adhesive  26 . Preferably, post  22  is inserted into but not through aperture  36  without contacting conductive layer  30  and is aligned with and centrally located within aperture  36 . As a result, gap  38  is located in aperture  36  between post  22  and conductive layer  30 . Gap  38  laterally surrounds post  22  and is laterally surrounded by conductive layer  30 . In addition, opening  28  and aperture  36  are precisely aligned with one another and have the same diameter. 
     At this stage, conductive layer  30  is mounted on and contacts and extends above adhesive  26 . Post  22  extends through opening  28  into aperture  36 , is 50 microns below the top surface of conductive layer  30  and is exposed through aperture  36  in the upward direction. Adhesive  26  contacts and is sandwiched between base  24  and conductive layer  30  and remains a non-solidified prepreg with B-stage uncured epoxy, and gap  38  is filled with air. 
       FIG. 4C  is a cross-sectional view of the structure with adhesive  26  in gap  38 . Adhesive  26  is flowed into gap  38  by applying heat and pressure. In this illustration, adhesive  26  is forced into gap  38  by applying downward pressure to conductive layer  30  and/or upward pressure to base  24 , thereby moving base  24  and conductive layer  30  towards one another and applying pressure to adhesive  26  while simultaneously applying heat to adhesive  26 . Adhesive  26  becomes compliant enough under the heat and pressure to conform to virtually any shape. As a result, adhesive  26  sandwiched between base  24  and conductive layer  30  is compressed, forced out of its original shape and flows into and upward in gap  38 . Base  24  and conductive layer  30  continue to move towards one another and adhesive  26  eventually fills gap  38 . Moreover, adhesive  26  remains sandwiched between and continues to fill the reduced space between base  24  and conductive layer  30 . 
     For instance, base  24  and conductive layer  30  can be disposed between top and bottom platens (not shown) of a press. In addition, a top cull plate and top buffer paper (not shown) can be sandwiched between conductive layer  30  and the top platen, and a bottom cull plate and bottom buffer paper (not shown) can be sandwiched between base  24  and the bottom platen. The stack includes the top platen, top cull plate, top buffer paper, conductive layer  30 , adhesive  26 , base  24 , bottom buffer paper, bottom cull plate and bottom platen in descending order. Furthermore, the stack may be positioned on the bottom platen by tooling pins (not shown) that extend upward from the bottom platen through registration holes (not shown) in base  24 . 
     The platens are heated and move towards one another, thereby applying heat and pressure to adhesive  26 . The cull plates disperse the heat from the platens so that it is more uniformly applied to base  24  and conductive layer  30  and thus adhesive  26 , and the buffer papers disperse the pressure from the platens so that it is more uniformly applied to base  24  and conductive layer  30  and thus adhesive  26 . Initially, conductive layer  30  contacts and presses down on adhesive  26 . As the platen motion and heat continue, adhesive  26  between base  24  and conductive layer  30  is compressed, melted and flows into and upward in gap  38  and across conductive layer  30 . For instance, the uncured epoxy is melted by the heat and the molten uncured epoxy is squeezed by the pressure into gap  38 , however the reinforcement and the filler remain between base  24  and conductive layer  30 . Adhesive  26  elevates more rapidly than post  22  in aperture  36  and fills gap  38 . Adhesive  26  also rises slightly above gap  38  and overflows onto the top surfaces of post  22  and conductive layer  30  adjacent to gap  38  before the platen motion stops. This may occur due to the prepreg being slightly thicker than necessary. As a result, adhesive  26  creates a thin coating on the top surface of post  22 . The platen motion is eventually blocked by post  22  and the platens become stationary but continue to apply heat to adhesive  26 . 
     The upward flow of adhesive  26  in gap  38  is shown by the thick upward arrows, the upward motion of post  22  and base  24  relative to conductive layer  30  is shown by the thin upward arrows, and the downward motion of conductive layer  30  relative to post  22  and base  24  is shown by the thin downward arrows. 
       FIG. 4D  is a cross-sectional view of the structure with adhesive  26  solidified. 
     For instance, the platens continue to clamp post  22  and base  24  and apply heat after the platen motion stops, thereby converting the B-stage molten uncured epoxy into C-stage cured or hardened epoxy. Thus, the epoxy is cured in a manner similar to conventional multi-layer lamination. After the epoxy is cured, the platens move away from one another and the structure is released from the press. 
     Adhesive  26  as solidified provides a secure robust mechanical bond between post  22  and conductive layer  30  as well as between base  24  and conductive layer  30 . Adhesive  26  can withstand normal operating pressure without distortion or damage and is only temporarily distorted under unusually high pressure. Furthermore, adhesive  26  can absorb thermal expansion mismatch between post  22  and conductive layer  30  and between base  24  and conductive layer  30 . 
     At this stage, post  22  and conductive layer  30  are essentially coplanar with one another and adhesive  26  and conductive layer  30  extend to a top surface that faces in the upward direction. For instance, adhesive  26  between base  24  and conductive layer  30  has a thickness of 75 microns which is 50 microns less than its initial thickness of 125 microns, post  22  ascends 50 microns in aperture  36  and conductive layer  30  descends 50 microns relative to post  22 . The 200 micron height of post  22  is essentially the same as the combined height of conductive layer  30  (125 microns) and the underlying adhesive  26  (75 microns). Furthermore, post  22  continues to be centrally located in opening  28  and aperture  36  and spaced from conductive layer  30 , and adhesive  26  fills the space between base  24  and conductive layer  30  and fills gap  38 . For instance, gap  38  (as well as adhesive  26  between post  22  and conductive layer  30 ) has a width of 75 microns ((1150−1000)/2) at the top surface of post  22 . Adhesive  26  extends across conductive layer  30  in gap  38 . That is, adhesive  26  in gap  38  extends in the upward and downward directions across the thickness of conductive layer  30  at the outer sidewall of gap  38 . Adhesive  26  also includes a thin top portion above gap  38  that contacts the top surfaces of post  22  and conductive layer  30  and extends above post  22  by 10 microns. 
       FIG. 4E  is a cross-sectional view of the structure after upper portions of post  22 , adhesive  26  and conductive layer  30  are removed. 
     Post  22 , adhesive  26  and conductive layer  30  have their upper portions removed by grinding. For instance, a rotating diamond sand wheel and distilled water are applied to the top of the structure. Initially, the diamond sand wheel grinds only adhesive  26 . As the grinding continues, adhesive  26  becomes thinner as its grinded surface migrates downwardly. Eventually the diamond sand wheel contacts post  22  and conductive layer  30  (not necessarily at the same time), and as a result, begins to grind post  22  and conductive layer  30  as well. As the grinding continues, post  22 , adhesive  26  and conductive layer  30  become thinner as their grinded surfaces migrate downwardly. The grinding continues until the desired thickness has been removed. Thereafter, the structure is rinsed in distilled water to remove contaminants. 
     The grinding removes a 25 micron thick upper portion of adhesive  26 , a 15 micron thick upper portion of post  22  and a 15 micron thick upper portion of conductive layer  30 . The decreased thickness does not appreciably affect post  22 , adhesive  26  or conductive layer  30 . 
     At this stage, post  22 , adhesive  26  and conductive layer  30  are coplanar with one another at a smoothed lapped lateral top surface that is above base  24  and faces in the upward direction. 
       FIG. 4F  is a cross-sectional view of the structure with conductive layer  40  deposited on post  22 , adhesive  26  and conductive layer  30 . 
     Conductive layer  40  contacts post  22 , adhesive  26  and conductive layer  30  and covers them in the upward direction. For instance, the structure is dipped in an activator solution to render adhesive  26  catalytic to electroless copper, then a first copper layer is electrolessly plated on post  22 , adhesive  26  and conductive layer  30 , and then a second copper layer is electroplated on the first copper layer. The first copper layer has a thickness of 2 microns, the second copper layer has a thickness of 13 microns, and conductive layer  40  has a thickness of 15 microns. As a result, conductive layer  30  essentially grows and has a thickness of 125 microns (110+15). Thus, conductive layer  40  serves as a cover layer for post  22  and a build-up layer for conductive layer  30 . Post  22  and conductive layer  40 , and conductive layers  30  and  40  are shown as a single layer for convenience of illustration. The boundary (shown in phantom) between post  22  and conductive layer  40  and between conductive layers  30  and  40  may be difficult or impossible to detect since copper is plated on copper. However, the boundary between adhesive  26  and conductive layer  40  is clear. 
       FIG. 4G  is a cross-sectional view of the structure with etch mask  42  and cover mask  44  formed on the top and bottom surfaces, respectively, of the structure. Etch mask  42  and cover mask  44  are illustrated as photoresist layers similar to photoresist layers  16  and  18 , respectively. Photoresist layer  42  has a pattern that selectively exposes conductive layer  40 , and photoresist layer  44  remains unpatterned and covers base  24 . 
       FIG. 4H  is a cross-sectional view of the structure with selected portions of conductive layers  30  and  40  removed by etching conductive layers  30  and  40  in the pattern defined by etch mask  42 . The etching is a front-side wet chemical etch similar to the etch applied to metal plate  10 . The wet chemical etch etches through conductive layers  30  and  40  to expose adhesive  26  and converts conductive layers  30  and  40  from unpatterned into patterned layers, and base  24  remains unpatterned. 
       FIG. 4I  is a cross-sectional view of the structure after etch mask  42  and cover mask  44  are removed. Photoresist layers  42  and  44  can be stripped in the same manner as photoresist layers  16  and  18 . 
     Conductive layers  30  and  40  as etched include pad  46 , routing line  48  and terminal  50 , and conductive layer  40  as etched includes cap  52 . Pad  46 , routing line  48  and terminal  50  are unetched portions of conductive layers  30  and  40  defined by etch mask  42 , and cap  52  is an unetched portion of conductive layer  40  defined by etch mask  42 . Thus, conductive layers  30  and  40  are a patterned layer that includes pad  46 , routing line  48  and terminal  50  and excludes cap  52 . Furthermore, routing line  48  is a copper trace that contacts and extends above adhesive  26  and is adjacent to and electrically connects pad  46  and terminal  50 . 
     Conductive trace  54  is provided by pad  46 , routing line  48  and terminal  50 . Similarly, an electrically conductive path between pad  46  and terminal  50  is routing line  48 . Conductive trace  54  provides horizontal (lateral) fan-out routing from pad  46  to terminal  50 . Conductive trace  54  is not be limited to this configuration. For instance, the electrically conductive path can include passive components such as resistors and capacitors mounted on additional pads. 
     Heat spreader  56  includes post  22 , base  24  and cap  52 . Post  22  and base  24  are integral with one another. Cap  52  is above and adjacent to and covers in the upward direction and extends laterally in the lateral directions from the top of post  22 . Cap  52  is positioned so that post  22  is centrally located within its periphery. Cap  52  also contacts the underlying portion of adhesive  26  that is coplanar with and adjacent to and laterally surrounds post  22  and covers this portion in the upward direction. 
     Heat spreader  56  is essentially a heat slug with an inverted T-like shape that includes a pedestal (post  22 ), wings (base  24  portions that extend laterally from the pedestal) and a thermal pad (cap  52 ). 
       FIG. 4J  is a cross-sectional view of the structure with solder mask  58  formed on adhesive  26 , conductive layer  40  and cap  52 . 
     Solder mask  58  is an electrically insulative layer that is selectively patterned to expose pad  46 , terminal  50  and cap  52  and cover routing line  48  and the exposed portions of adhesive  26  in the upward direction. Solder mask  58  has a thickness of 25 microns above pad  46  and terminal  50  and extends 150 microns (125+25) above adhesive  26 . 
     Solder mask  58  can initially be a photoimageable liquid resin that is dispensed on the structure. Thereafter, solder mask  58  is patterned by selectively applying light through a reticle (not shown) so that the solder mask portions exposed to the light are rendered insoluble, applying a developer solution to remove the solder mask portions that are unexposed to the light and remain soluble and then hard baking, as is conventional. 
       FIG. 4K  is a cross-sectional view of the structure with plated contacts  60  formed on base  24 , pad  46 , terminal  50  and cap  52 . 
     Plated contacts  60  are thin spot plated metal coatings that contact base  24  and cover it in the downward direction and contact pad  46 , terminal  50  and cap  52  and cover their exposed portions in the upward direction. For instance, a nickel layer is electrolessly plated on base  24 , pad  46 , terminal  50  and cap  52 , and then a gold layer is electrolessly plated on the nickel layer. The buried nickel layer has a thickness of 3 microns, the gold surface layer has a thickness of 0.5 microns, and plated contacts  60  have a thickness of 3.5 microns. 
     Base  24 , pad  46 , terminal  50  and cap  52  treated with plated contacts  60  as a surface finish have several advantages. The buried nickel layer provides the primary mechanical and electrical and/or thermal connection, and the gold surface layer provides a wettable surface to facilitate solder reflow. Plated contacts  60  also protect base  24 , pad  46 , terminal  50  and cap  52  from corrosion. Plated contacts  60  can include a wide variety of metals to accommodate the external connection media. For instance, a silver surface layer plated on a buried nickel layer can accommodate a solder joint or a wire bond. 
     Base  24 , pad  46 , terminal  50  and cap  52  treated with plated contacts  60  are shown as single layers for convenience of illustration. The boundary (not shown) with plated contacts  60  in base  24 , pad  46 , terminal  50  and cap  52  occurs at the copper/nickel interface. 
     At this stage, the manufacture of thermal board  62  can be considered complete. 
       FIGS. 4L ,  4 M and  4 N are cross-sectional, top and bottom views, respectively, of thermal board  62  after it is detached at peripheral edges along cut lines from a support frame and/or adjacent thermal boards in a batch. 
     Thermal board  62  includes adhesive  26 , conductive trace  54 , heat spreader  56  and solder mask  58 . Conductive trace  54  includes pad  46 , routing line  48  and terminal  50 . Heat spreader  56  includes post  22 , base  24  and cap  52 . 
     Post  22  extends through opening  28 , remains centrally located within opening  28  and is coplanar with an adjacent portion of adhesive  26  above a bottom surface of pad  46 . Post  22  retains its cut-off conical shape with tapered sidewalls in which its diameter decreases as it extends upwardly from base  24  to its flat circular top adjacent to cap  52 . Base  24  covers post  22 , adhesive  26 , cap  52 , conductive trace  54  and solder mask  58  in the downward direction and extends to the peripheral edges of thermal board  62 . Cap  52  is above and adjacent to and thermally connected to post  22 , covers the top of post  22  in the upward direction and laterally extends from the top of post  22  in the lateral directions. Cap  52  also contacts and covers in the upward direction a portion of adhesive  26  that is coplanar with and adjacent to and laterally surrounds post  22 . Cap  52  is also coplanar with pad  46  and terminal  50  above adhesive  26 . 
     Adhesive  26  is mounted on and extends above base  24 , extends between post  22  and pad  46  in gap  38 , contacts and is sandwiched between and fills the space between base  24  and conductive trace  54  outside gap  38 , extends laterally from post  22  beyond and is overlapped by terminal  50 , covers base  24  outside the periphery of post  22  in the upward direction, covers conductive trace  54  in the downward direction, contacts and covers and surrounds post  22  in the lateral directions, is contained in and fills most of the space between conductive trace  54  and heat spreader  56  and is solidified. 
     Conductive trace  54  (as well as pad  46 , routing line  48  and terminal  50 ) is mounted on and contacts and overlaps and extends above adhesive  26 . 
     Post  22 , base  24  and cap  52  remain spaced from conductive trace  54 . As a result, conductive trace  54  and heat spreader  56  are mechanically attached and electrically isolated from one another. 
     Base  24 , adhesive  26  and solder mask  58  extend to straight vertical peripheral edges of thermal board  62  after it is detached or singulated from a batch of identical simultaneously manufactured thermal boards. 
     Pad  46  is customized as an electrical interface for a semiconductor device such as an LED package or a semiconductor chip that is subsequently mounted on cap  52 , terminal  50  is customized as an electrical interface for the next level assembly such as a solderable wire from a printed circuit board, cap  52  is customized as a thermal interface for the semiconductor device, and base  24  is customized as a thermal interface for the next level assembly such as a heat sink for an electronic device. Furthermore, cap  52  is thermally connected to base  24  by post  22 . 
     Pad  46  and terminal  50  are laterally offset from one another and exposed at the top surface of thermal board  62 , thereby providing horizontal fan-out routing between the semiconductor device and the next level assembly. 
     Pad  46 , terminal  50  and cap  52  are coplanar with one another at their top surfaces above adhesive  26 . 
     Conductive trace  54  is shown in cross-section as a continuous circuit trace for convenience of illustration. However, conductive trace  54  typically provides horizontal signal routing in both the X and Y directions. That is, pad  46  and terminal  50  are laterally offset from one another in the X and Y directions, and routing line  48  routes in the X and Y directions. 
     Heat spreader  56  provides heat spreading and heat dissipation from a semiconductor device that is subsequently mounted on cap  52  to the next level assembly that thermal board  62  is subsequently mounted on. The semiconductor device generates heat that flows into cap  52 , from cap  52  into post  22  and through post  22  into base  24  where it is spread out and dissipated in the downward direction, for instance to an underlying heat sink. 
     Thermal board  62  does not expose post  22  or routing line  48 . Post  22  is covered by cap  52 , routing line  48  is covered by solder mask  58 , and adhesive  26  at its top surface is covered by cap  52  and solder mask  58 . Post  22  and routing line  48  are shown in phantom in  FIG. 4M  for convenience of illustration. 
     Thermal board  62  includes other conductive traces  54  that typically include pad  46 , routing line  48  and terminal  50 . A single conductive trace  54  is described and labeled for convenience of illustration. In conductive traces  54 , pads  46  and terminals  50  generally have identical shapes and sizes whereas routing lines  48  generally have different routing configurations. For instance, some conductive traces  54  may be spaced and separated and electrically isolated from one another whereas other conductive traces  54  can intersect or route to the same pad  46 , routing line  48  or terminal  50  and be electrically connected to one another. Likewise, some pads  46  may receive independent signals whereas other pads  46  share a common signal, power or ground. 
     Thermal board  62  can be adapted for an LED package with blue, green and red LED chips, with each LED chip including an anode and a cathode and each LED package including a corresponding anode terminal and cathode terminal. In this instance, thermal board  62  can include six pads  46  and four terminals  50  so that each anode is routed from a separate pad  46  to a separate terminal  50  whereas each cathode is routed from a separate pad  46  to a common ground terminal  50 . 
     A brief cleaning step can be applied to the structure at various manufacturing stages to remove oxides and debris that may be present on the exposed metal. For instance, a brief oxygen plasma cleaning step can be applied to the structure. Alternatively, a brief wet chemical cleaning step using a solution containing potassium permanganate can be applied to the structure. Likewise, the structure can be rinsed in distilled water to remove contaminants. The cleaning step cleans the desired surfaces without appreciably affecting or damaging the structure. 
     Advantageously, there is no plating bus or related circuitry that need be disconnected or severed from conductive traces  54  after they are formed. A plating bus can be disconnected during the wet chemical etch that forms pad  46 , routing line  48 , terminal  50  and cap  52 . 
     Thermal board  62  can include registration holes (not shown) that are drilled or sliced through base  24 , adhesive  26  and solder mask  58  so that thermal board  62  can be positioned by inserting tooling pins through the registration holes when it is subsequently mounted on an underlying carrier. 
     Thermal board  62  can omit cap  52 . This can be accomplished by adjusting etch mask  42  to expose conductive layer  40  above all of aperture  36  to the wet chemical etch that forms pad  46 , routing line  48  and terminal  50 . This can also be accomplished by omitting conductive layer  40 . 
     Thermal board  62  can accommodate multiple semiconductor devices rather than one. This can be accomplished by adjusting etch mask  16  to define additional posts  22 , adjusting adhesive  26  to include additional openings  28 , adjusting conductive layer  30  to include additional apertures  36 , adjusting etch mask  42  to define additional pads  46 , routing lines  48 , terminals  50  and caps  52  and adjusting solder mask  58  to contain additional openings. The elements except for terminals  50  can be laterally repositioned to provide a 2×2 array for four semiconductor devices. In addition, the topography (lateral shape) can be adjusted for some but not all of the elements. For instance, pads  46 , terminals  50  and caps  52  can retain the same topography whereas routing lines  48  have different routing configurations. 
       FIGS. 5A ,  5 B and  5 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes a thermal board and an LED package with backside contacts in accordance with an embodiment of the present invention. 
     Semiconductor chip assembly  100  includes thermal board  62 , LED package  102  and solder joints  104  and  106 . LED package  102  includes LED chip  108 , submount  110 , wire bond  112 , electrical contact  114 , thermal contact  116  and transparent encapsulant  118 . LED chip  108  includes an electrode (not shown) electrically connected to a via (not shown) in submount  110  by wire bond  112 , thereby electrically connecting LED chip  108  to electrical contact  114 . LED chip  108  is mounted on and thermally connected to and mechanically attached to submount  110  by a die attach (not shown), thereby thermally connecting LED chip  108  to thermal contact  116 . Submount  110  is a ceramic block with low electrical conductivity and high thermal conductivity, and contacts  114  and  116  are plated on and protrude downwardly from the backside of submount  110 . 
     LED package  102  is mounted on conductive trace  54  and heat spreader  56 , electrically connected to conductive trace  54  and thermally connected to heat spreader  56 . In particular, LED package  102  is mounted on pad  46  and cap  52 , overlaps post  22 , is electrically connected to conductive trace  54  by solder joint  104  and is thermally connected to heat spreader  56  by solder joint  106 . For instance, solder joint  104  contacts and is sandwiched between and electrically connects and mechanically attaches pad  46  and electrical contact  114 , thereby electrically connecting LED chip  108  to terminal  50 . Likewise, solder joint  106  contacts and is sandwiched between and thermally connects and mechanically attaches cap  52  and thermal contact  116 , thereby thermally connecting LED chip  108  to base  24 . Pad  46  is spot plated with nickel/gold to bond well with solder joint  104  and is shaped and sized to match electrical contact  114 , thereby improving signal transfer from conductive trace  54  to LED package  102 . Likewise, cap  52  is spot plated with nickel/gold to bond well with solder joint  106  and is shaped and sized to match thermal contact  116 , thereby improving heat transfer from LED package  102  to heat spreader  56 . Furthermore, post  22  is not and need not be shaped and sized to match thermal contact  116 . 
     Transparent encapsulant  118  is a solid adherent electrically insulative protective plastic enclosure that provides environmental protection such as moisture resistance and particle protection for LED chip  108  and wire bond  112 . LED chip  108  and wire bond  112  are embedded in transparent encapsulant  118 . 
     Semiconductor chip assembly  100  can be manufactured by depositing a solder material on pad  46  and cap  52 , then placing contacts  114  and  116  on the solder material over pad  46  and cap  52 , respectively, and then reflowing the solder material to provide solder joints  104  and  106 . 
     For instance, solder paste is selectively screen printed on pad  46  and cap  52 , then LED package  102  is positioned over thermal board  62  using a pick-up head and an automated pattern recognition system in step-and-repeat fashion. The pick-up head places contacts  114  and  116  on the solder paste over pad  46  and cap  52 , respectively. Next, the solder paste is heated and reflowed at a relatively low temperature such as 190° C. and then the heat is removed and the solder paste cools and solidifies to form hardened solder joints  104  and  106 . Alternatively, solder balls are placed on pad  46  and cap  52 , then contacts  114  and  116  are placed on the solder balls over pad  46  and cap  52 , respectively, and then the solder balls are heated and reflowed to form solder joints  104  and  106 . 
     The solder material can be initially deposited on thermal board  62  or LED package  102  by plating or printing or placement techniques, then sandwiched between thermal board  62  and LED package  102  and then reflowed. The solder material can also be deposited on terminal  50  if required for the next level assembly. Furthermore, a conductive adhesive such as silver-filled epoxy or other connection media can be used instead of solder, and the connection media on pad  46 , terminal  50  and cap  52  need not be the same. 
     Semiconductor chip assembly  100  is a second-level single-chip module. 
       FIGS. 6A ,  6 B and  6 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes a thermal board and an LED package with lateral leads in accordance with an embodiment of the present invention. 
     In this embodiment, the LED package has lateral leads rather than backside contacts. For purposes of brevity, any description of assembly  100  is incorporated herein insofar as the same is applicable, and the same description need not be repeated. Likewise, elements of the assembly similar to those in assembly  100  have corresponding reference numerals indexed at two-hundred rather than one-hundred. For instance, LED chip  208  corresponds to LED chip  108 , submount  210  corresponds to submount  110 , etc. 
     Semiconductor chip assembly  200  includes thermal board  62 , LED package  202  and solder joints  204  and  206 . LED package  202  includes LED chip  208 , submount  210 , wire bond  212 , lead  214  and transparent encapsulant  218 . LED chip  208  is electrically connected to lead  214  by wire bond  212 . Submount  210  includes thermal contact surface  216  at its backside, is narrower than submount  110  and has the same lateral size and shape as thermal contact  116 . LED chip  208  is mounted on and thermally connected to and mechanically attached to submount  210  by a die attach (not shown), thereby thermally connecting LED chip  208  to thermal contact surface  216 . Lead  214  extends laterally from submount  210  and thermal contact surface  216  faces downward. 
     LED package  202  is mounted on conductive trace  54  and heat spreader  56 , electrically connected to conductive trace  54  and thermally connected to heat spreader  56 . In particular, LED package  202  is mounted on pad  46  and cap  52 , overlaps post  22 , is electrically connected to conductive trace  54  by solder joint  204  and is thermally connected to heat spreader  56  by solder joint  206 . For instance, solder joint  204  contacts and is sandwiched between and electrically connects and mechanically attaches pad  46  and lead  214 , thereby electrically connecting LED chip  208  to terminal  50 . Likewise, solder joint  206  contacts and is sandwiched between and thermally connects and mechanically attaches cap  52  and thermal contact surface  216 , thereby thermally connecting LED chip  208  to base  24 . 
     Semiconductor chip assembly  200  can be manufactured by depositing a solder material on pad  46  and cap  52 , then placing lead  214  and thermal contact surface  216  on the solder material over pad  46  and cap  52 , respectively, and then reflowing the solder material to provide solder joints  204  and  206 . 
     Semiconductor chip assembly  200  is a second-level single-chip module. 
       FIGS. 7A ,  7 B and  7 C are cross-sectional, top and bottom views, respectively, of a semiconductor chip assembly that includes a thermal board and a semiconductor chip in accordance with an embodiment of the present invention. 
     In this embodiment, the semiconductor device is a chip rather than a package and the chip is mounted on the heat spreader but not the conductive trace. Furthermore, the chip overlaps the post but not the conductive trace, is electrically connected to the pad using a wire bond and is thermally connected to the cap using a die attach. 
     Semiconductor chip assembly  300  includes thermal board  62 , chip  302 , wire bond  304 , die attach  306  and encapsulant  308 . Chip  302  includes top surface  310 , bottom surface  312  and bond pad  314 . Top surface  310  is the active surface and includes bond pad  314  and bottom surface  312  is the thermal contact surface. 
     Chip  302  is mounted on heat spreader  56 , electrically connected to conductive trace  54  and thermally connected to heat spreader  56 . In particular, chip  302  is mounted on cap  52 , is within the periphery of cap  52 , overlaps post  22  but does not overlap conductive trace  54 , is electrically connected to conductive trace  54  by wire bond  304  and is thermally connected to and mechanically attached to heat spreader  56  by die attach  306 . For instance, wire bond  304  is bonded to and electrically connects pads  46  and  314 , thereby electrically connecting chip  302  to terminal  50 . Likewise, die attach  306  contacts and is sandwiched between and thermally connects and mechanically attaches cap  52  and thermal contact surface  312 , thereby thermally connecting chip  302  to base  24 . Pad  46  is spot plated with nickel/silver to bond well with wire bond  304 , thereby improving signal transfer from conductive trace  54  to chip  302 , and cap  52  is shaped and sized to match thermal contact surface  312 , thereby improving heat transfer from chip  302  to heat spreader  56 . Furthermore, post  22  is not and need not be shaped and sized to match thermal contact surface  312 . 
     Encapsulant  308  is a solid adherent electrically insulative protective plastic enclosure that provides environmental protection such as moisture resistance and particle protection for chip  302  and wire bond  304 . Chip  302  and wire bond  304  are embedded in encapsulant  308 . Furthermore, encapsulant  308  can be transparent if chip  302  is an optical chip such as an LED. Encapsulant  308  is transparent in  FIG. 7B  for convenience of illustration. 
     Semiconductor chip assembly  300  can be manufactured by mounting chip  302  on cap  52  using die attach  306 , then wire bonding pads  46  and  314  and then forming encapsulant  308 . 
     For instance, die attach  306  is initially a silver-filled epoxy paste with high thermal conductivity that is selectively screen printed on cap  52  and then chip  302  placed on the epoxy paste using a pick-up head and an automated pattern recognition system in step-and-repeat fashion. Thereafter, the epoxy paste is heated and hardened at a relatively low temperature such as 190° C. to form die attach  306 . Next, wire bond  304  is a gold wire that is thermosonically ball bonded to pads  46  and  314  and then encapsulant  308  is transfer molded on the structure. 
     Chip  302  can be electrically connected to pad  46  by a wide variety of connection media, thermally connected to and mechanically attached to heat spreader  56  by a wide variety of thermal adhesives and encapsulated by a wide variety of encapsulants. 
     Semiconductor chip assembly  300  is a first-level single-chip package. 
       FIGS. 8A ,  8 B and  8 C are cross-sectional, top and bottom views, respectively, of a light source subassembly that includes a semiconductor chip assembly and a heat sink in accordance with an embodiment of the present invention. 
     Light source subassembly  400  includes semiconductor chip assembly  100  and heat sink  402 . Heat sink  402  includes thermal contact surface  404 , fins  406  and fan  408 . Assembly  100  is mounted on heat sink  402  and mechanically fastened to heat sink  402 , for instance by screws (not shown). As a result, base  24  is clamped against and thermally connected to thermal contact surface  404 , thereby thermally connecting heat spreader  56  to heat sink  402 . Heat spreader  56  spreads the heat from LED chip  108  and transfers the spread heat to heat sink  402 , which in turn dissipates the heat into the exterior environment using fins  406  and fan  408 . 
     Light source subassembly  400  is designed for a light fixture (not shown) that is interchangeable with a standard incandescent light bulb. The light fixture includes subassembly  400 , a glass cap, a threaded base, a control board, wiring and a housing. Subassembly  400 , the control board and the wiring are enclosed within the housing. The wiring extends from the control board and is soldered to terminals  50 . The glass cap and the threaded base protrude from opposite ends of the housing. The glass cap exposes LED chip  108 , the threaded base is configured to screw into a light socket and the control board is electrically connected to terminals  50  by the wiring. The housing is a two-piece plastic shell with top and bottom pieces. The glass cap is attached to and protrudes above the top piece, the threaded base is attached to and protrudes below the bottom piece, and subassembly  400  and the control board are mounted on the bottom piece and extend into the top piece. 
     During operation, the threaded base transfers AC from a light socket to the control board, which converts the AC to modulated DC and the wiring transmits the modulated DC to terminal  50  and grounds another terminal  50 . As a result, LED chip  108  illuminates bright light through the glass cap. LED chip  108  also generates intense localized heat that flows into and is spread by heat spreader  56  and flows from heat spreader  56  into heat sink  402  where fins  406  heat the air, and fan  408  blows the hot air radially outward through slots in the housing into the external environment. 
     The semiconductor chip assemblies and thermal boards described above are merely exemplary. Numerous other embodiments are contemplated. In addition, the embodiments described above can be mixed-and-matched with one another and with other embodiments depending on design and reliability considerations. For instance, the semiconductor device can be an LED package that is wire bonded to the conductive trace. The semiconductor device can be a semiconductor chip that overlaps the conductive trace. The thermal board can include multiple posts arranged in an array for multiple semiconductor devices and can include additional conductive traces to accommodate the additional semiconductor devices. Likewise, the semiconductor device can be an LED package with multiple LED chips and the thermal board can include additional conductive traces to accommodate the additional LED chips. 
     The semiconductor device can share or not share the heat spreader with other semiconductor devices. For instance, a single semiconductor device can be mounted on the heat spreader. Alternatively, numerous semiconductor devices can mounted on the heat spreader. For instance, four small chips in a 2×2 array can be attached to the post and the thermal board can include additional conductive traces to receive and route additional wire bonds to the chips. This may be more cost effective than providing a miniature post for each chip. 
     The semiconductor chip can be optical or non-optical. For instance, the chip can be an LED, a solar cell, a microprocessor, a controller or an RF power amplifier. Likewise, the semiconductor package can be an LED package or an RF module. Thus, the semiconductor device can be a packaged or unpackaged optical or non-optical chip. Furthermore, the semiconductor device can be mechanically, electrically and thermally connected to the thermal board using a wide variety of connection media including solder and electrically and/or thermally conductive adhesive. 
     The heat spreader can provide rapid, efficient and essentially uniform heat spreading and dissipation for the semiconductor device to the next level assembly without heat flow through the adhesive, the conductive trace or elsewhere in the thermal board. As a result, the adhesive can have low thermal conductivity which drastically reduces cost. The heat spreader can include a post and base that are integral with one another and a cap that is metallurgically bonded and thermally connected to the post, thereby enhancing reliability and reducing cost. The cap can be coplanar with the pad, thereby facilitating the electrical, thermal and mechanical connections with the semiconductor device. Furthermore, the cap can be customized for the semiconductor device and the base can be customized for the next level assembly, thereby enhancing the thermal connection from the semiconductor device to the next level assembly. For instance, the post can have a circular shape in a lateral plane and the cap can have a square or rectangular shape in a lateral plane with the same or similar topography as the thermal contact of the semiconductor device. 
     The heat spreader can be electrically connected to or isolated from the semiconductor device and the conductive trace. For instance, the second conductive layer on the grinded surface can include a routing line that extends across the adhesive between the conductive trace and the cap and electrically connects the semiconductor device to the heat spreader. Thereafter, the heat spreader can be electrically connected to ground, thereby electrically connecting the semiconductor device to ground. 
     The heat spreader can be copper, aluminum, copper/nickel/aluminum or other thermally conductive metallic structures. 
     The post can be deposited on or integral with the base. The post can be integral with the base when they are a single-piece metal such as copper or aluminum. The post can also be integral with the base when they include a single-piece metal such as copper at their interface as well as additional metal elsewhere such as a solder upper post portion and a copper lower post portion and base. The post can also be integral with the base when they share single-piece metals at their interface such as a copper coating on a nickel buffer layer on an aluminum core. 
     The post can include a flat top surface that is coplanar with the adhesive. For instance, the post can be coplanar with the adhesive or the post can be etched after the adhesive is solidified to provide a cavity in the adhesive over the post. The post can also be selectively etched to provide a cavity in the post that extends below its top surface. In any case, the semiconductor device can be mounted on the post and located in the cavity, and the wire bond can extend from the semiconductor device in the cavity to the pad outside the cavity. In this instance, the semiconductor device can be an LED chip and the cavity can focus the LED light in the upward direction. 
     The base can provide mechanical support for the conductive trace. For instance, the base can prevent the conductive layer from warping during metal grinding and prevent the conductive trace from warping during chip mounting, wire bonding and encapsulant molding. The base can also cover the assembly in the downward direction. Furthermore, the base can include fins at its backside that protrude in the downward direction. For instance, the base can be cut at its bottom surface by a routing machine to form lateral grooves that define the fins. In this instance, the base can have a thickness of 700 microns, the grooves can have a depth of 500 microns and the fins can have a height of 500 microns. The fins can increase the surface area of the base, thereby increasing the thermal conductivity of the base by thermal convection when it remains exposed to the air rather than mounted on a heat sink. 
     The cap can be formed by numerous deposition techniques including electroplating, electroless plating, evaporating and sputtering as a single layer or multiple layers after the adhesive is solidified, either before, during or after the pad and/or the terminal is formed. The cap can be the same metal as the post or the adjacent top of the post. In any case, the cap extends laterally from the top of the post in the lateral directions. 
     The adhesive can provide a robust mechanical bond between the heat spreader and the conductive trace. For instance, the adhesive can extend laterally from the post beyond the conductive trace to the peripheral edges of the assembly, the adhesive can fill the space between the base and the conductive trace, the adhesive can be located in the space between the heat spreader and the conductive trace and the adhesive can be void-free with consistent bond lines. The adhesive can also absorb thermal expansion mismatch between the heat spreader and the conductive trace. Furthermore, the adhesive can be a low cost dielectric that need not have high thermal conductivity. Moreover, the adhesive is not prone to delamination. 
     The adhesive thickness can be adjusted so that the adhesive essentially fills the gap and essentially all the adhesive is within structure once it is solidified and/or grinded. For instance, the optimal prepreg thickness can be established through trial and error. Likewise, the conductive layer thickness can be adjusted to achieve this result. 
     The conductive layer alone can be mounted on the adhesive. For instance, the aperture can be formed in the conductive layer and then the conductive layer and nothing else can be mounted on the adhesive so that the conductive layer contacts the adhesive and is exposed in the upward direction and the post extends into and is exposed in the upward direction by the aperture. In this instance, the conductive layer can have a thickness of 100 to 200 microns such as 125 microns which is thick enough to handle without warping and wobbling and to accommodate high drive current yet thin enough to pattern without excessive etching. 
     The conductive layer and a carrier can be mounted on the adhesive. For instance, the conductive layer can be attached to a carrier such biaxially-oriented polyethylene terephthalate polyester (Mylar) by a thin film, then the aperture can be formed in the conductive layer but not the carrier, then the conductive layer and the carrier can be mounted on the adhesive so that the carrier covers the conductive layer and is exposed in the upward direction, the thin film contacts and is sandwiched between the carrier and the conductive layer, the conductive layer contacts and is sandwiched between the thin film and the adhesive, and the post is aligned with the aperture and covered in the upward direction by the carrier. After the adhesive is solidified, the thin film can be decomposed by UV light so that the carrier can be peeled off the conductive layer, thereby exposing the conductive layer in the upward direction, and then the conductive layer can be grinded and patterned to provide the conductive trace. In this instance, the conductive layer can have a thickness of 10 to 50 microns such as 30 microns which is thick enough for reliable signal transfer yet thin enough to reduce weight and cost, and the carrier can have a thickness of 300 to 500 microns which is thick enough to handle without warping and wobbling yet thin enough to reduce weight and cost. Furthermore, the carrier is a temporary fixture and not a permanent part of the thermal board. 
     The pad and the terminal can have a wide variety of packaging formats as required by the semiconductor device and the next level assembly. 
     The pad and the cap can be coplanar at their top surfaces, thereby enhancing solder joints between the semiconductor device and the thermal board by controlling solder ball collapse. 
     The pad, the terminal and the routing line can be formed by numerous deposition techniques including electroplating, electroless plating, evaporating and sputtering as a single layer or multiple layers, either before or after the conductive layer or the conductive trace is mounted on the adhesive. For instance, the conductive layer can be patterned on a carrier before it is mounted on the adhesive. Alternatively, the conductive layer can be patterned after it is attached to the post and the base by the adhesive. 
     The plated contact surface finish can be formed before or after the pad and the terminal are formed. For instance, the plated layer can be deposited on the second conductive layer and then patterned using the etch mask that defines the pad, the terminal and the routing line. 
     The conductive trace can include additional pads, terminals and routing lines as well as passive components and have different configurations. The conductive trace can function as a signal, power or ground layer depending on the purpose of the corresponding semiconductor device pad. The conductive trace can also include various conductive metals such as copper, gold, nickel, silver, palladium, tin, combinations thereof, and alloys thereof. The preferred composition will depend on the nature of the external connection media as well as design and reliability considerations. Furthermore, those skilled in the art will understand that in the context of a semiconductor chip assembly, the copper material can be pure elemental copper but is typically a copper alloy that is mostly copper such as copper-zirconium (99.9% copper), copper-silver-phosphorus-magnesium (99.7% copper) and copper-tin-iron-phosphorus (99.7% copper) to improve mechanical properties such as tensile strength and elongation. 
     The cap, solder mask, plated contacts and second conductive layer on the grinded surface are generally desirable but may be omitted in some embodiments. For instance, if the opening and aperture are punched rather than drilled so that the top of the post is shaped and sized to accommodate a thermal contact surface of the semiconductor device then the cap and the second conductive layer may be omitted to reduce cost. 
     The thermal board can include a thermal via that is spaced from the post, extends through the adhesive outside the opening and is adjacent to and thermally connects the base and the cap to improve heat dissipation from the cap to the base and heat spreading in the base. 
     The working format for the thermal board can be a single thermal board or multiple thermal boards based on the manufacturing design. For instance, a single thermal board can be manufactured individually. Alternatively, numerous thermal boards can be simultaneously batch manufactured using a single metal plate, a single adhesive, a single conductive layer and a single solder mask and then separated from one another. Likewise, numerous sets of heat spreaders and conductive traces that are each dedicated to a single semiconductor device can be simultaneously batch manufactured for each thermal board in the batch using a single metal plate, a single adhesive, a single conductive layer and a single solder mask. 
     For example, multiple recesses can be etched in the metal plate to form multiple posts and the base, then the non-solidified adhesive with openings corresponding to the posts can be mounted on the base such that each post extends through an opening, then the conductive layer with apertures corresponding to the posts can be mounted on the adhesive such that each post extends through an opening into an aperture, then the base and the conductive layer can be moved towards one another by platens to force the adhesive into the gaps in the apertures between the posts and the conductive layer, then the adhesive can be cured and solidified, then the posts, the adhesive and the conductive layer can be grinded to form a lateral top surface, then the second conductive layer can be plated on the posts, the adhesive and the conductive layer, then the conductive layers can be etched to form the pads, the terminals and the routing lines corresponding to the posts and the second conductive layer can be etched to form the caps corresponding to the posts, then the solder mask can be deposited on the structure and patterned to expose the pads, the terminals and the caps, then the plated contact surface finish can be formed on the base, the pads, the terminals and the caps and then the base, the adhesive and the solder mask can be cut or cracked at the desired locations of the peripheral edges of the thermal boards, thereby separating the individual thermal boards from one another. 
     The working format for the semiconductor chip assembly can be a single assembly or multiple assemblies based on the manufacturing design. For instance, a single assembly can be manufactured individually. Alternatively, numerous assemblies can be simultaneously batch manufactured before the thermal boards are separated from one another. Likewise, multiple semiconductor devices can be electrically, thermally and mechanically connected to each thermal board in the batch. 
     For example, solder paste portions can be deposited on the pads and the caps, then the LED packages can be placed on the solder paste portions, then the solder paste portions can be simultaneously heated, reflowed and hardened to provide the solder joints, and then the thermal boards can be separated from one another. 
     As another example, die attach paste portions can be deposited on the caps, then the chips can be placed on the die attach paste portions, then the die attach paste portions can be simultaneously heated and hardened to provide the die attaches, then the chips can be wired bonded to the corresponding pads, then the encapsulants can be formed over the chips and the wire bonds, and then the thermal boards can be separated from one another. 
     The thermal boards can be detached from one another in a single step or multiple steps. For instance, the thermal boards can be batch manufactured as a panel, then the semiconductor devices can be mounted on the panel and then the semiconductor chip assemblies of the panel can be detached from one another. Alternatively, the thermal boards can be batch manufactured as a panel, then the thermal boards of the panel can be singulated into strips of multiple thermal boards, then the semiconductor devices can be mounted on the thermal boards of a strip and then the semiconductor chip assemblies of the strip can be detached from one another. Furthermore, the thermal boards can be detached by mechanical sawing, laser sawing, cleaving or other suitable techniques. 
     The term “adjacent” refers to elements that are integral (single-piece) or in contact (not spaced or separated from) with one another. For instance, the post is adjacent to the base regardless of whether the post is formed additively or subtractively. 
     The term “overlap” refers to above and extending within a periphery of an underlying element. Overlap includes extending inside and outside the periphery or residing within the periphery. For instance, the semiconductor device overlaps the post since an imaginary vertical line intersects the semiconductor device and the post, regardless of whether another element such as the cap is between the semiconductor device and the post and is intersected by the line, and regardless of whether another imaginary vertical line intersects the semiconductor device but not the post (outside the periphery of the post). Likewise, the adhesive overlaps the base and is overlapped by the pad, and the base is overlapped by the post. Likewise, the post overlaps and is within a periphery of the base. Moreover, overlap is synonymous with over and overlapped by is synonymous with under or beneath. 
     The term “contact” refers to direct contact. For instance, the conductive trace contacts the adhesive but does not contact the post or the base. 
     The term “cover” refers to complete coverage in the upward, downward and/or lateral directions. For instance, the base covers the post in the downward direction but the post does not cover the base in the upward direction. 
     The term “layer” refers to patterned and unpatterned layers. For instance, the conductive layer can be an unpatterned blanket sheet when the conductive layer is mounted on the non-solidified adhesive, and the conductive layer can be a patterned circuit with spaced conductive traces on the solidified adhesive when the semiconductor device is mounted on the heat spreader. Furthermore, a layer can include stacked layers. 
     The term “pad” in conjunction with the conductive trace refers to a connection region that is adapted to contact and/or bond to external connection media (such as solder or a wire bond) that electrically connects the conductive trace to the semiconductor device. 
     The term “terminal” in conjunction with the conductive trace refers to a connection region that is adapted to contact and/or bond to external connection media (such as solder or a wire bond) that electrically connects the conductive trace to an external device (such as a PCB or a wire thereto) associated with the next level assembly. 
     The term “cap” in conjunction with the heat spreader refers to a contact region that is adapted to contact and/or bond to external connection media (such as solder or thermally conductive adhesive) that thermally connects the heat spreader to the semiconductor device. 
     The terms “opening” and “aperture” refer to a through-hole and are synonymous. For instance, the post is exposed by the adhesive in the upward direction when it is inserted into the opening in the adhesive. Likewise, the post is exposed by the conductive layer in the upward direction when it is inserted into the aperture in the conductive layer. 
     The term “inserted” refers to relative motion between elements. For instance, the post is inserted into the aperture regardless of whether the post is stationary and the conductive layer moves towards the base, the conductive layer is stationary and the post moves towards the conductive layer or the post and the conductive layer both approach the other. Furthermore, the post is inserted (or extends) into the aperture regardless of whether it goes through (enters and exits) or does not go through (enters without exiting) the aperture. 
     The phrase “move towards one another” also refers to relative motion between elements. For instance, the base and the conductive layer move towards one another regardless of whether the base is stationary and the conductive layer moves towards the base, the conductive layer is stationary and the base moves towards the conductive layer or the base and the conductive layer both approach the other. 
     The phrase “aligned with” refers to relative position between elements. For instance, the post is aligned with the aperture when the adhesive is mounted on the base, the conductive layer is mounted on the adhesive, the post is inserted into and aligned with the opening and the aperture is aligned with the opening regardless of whether the post is inserted into the aperture or the post is below and spaced from the aperture. 
     The phrase “mounted on” includes contact and non-contact with a single or multiple support element(s). For instance, the semiconductor device is mounted on the heat spreader regardless of whether it contacts the heat spreader or is separated from the heat spreader by a die attach. Likewise, the semiconductor device is mounted on the heat spreader regardless of whether it is mounted on the heat spreader alone or the heat spreader and the conductive trace. 
     The phrase “adhesive . . . in the gap” refers to the adhesive in the gap. For instance, adhesive that extends across the conductive layer in the gap refers to the adhesive in the gap that extends across the conductive layer. Likewise, adhesive that contacts and is sandwiched between the post and the conductive layer in the gap refers to the adhesive in the gap that contacts and is sandwiched between the post at the inner sidewall of the gap and the conductive layer at the outer sidewall of the gap. 
     The term “above” refers to upward extension and includes adjacent and non-adjacent elements as well as overlapping and non-overlapping elements. For instance, the post extends above, is adjacent to, overlaps and protrudes from the base. Likewise, the conductive trace extends above the base even though it is not adjacent to the base. 
     The term “below” refers to downward extension and includes adjacent and non-adjacent elements as well as overlapping and non-overlapping elements. For instance, the base extends below, is adjacent to, is overlapped by and protrudes from the post. Likewise, the post extends below the conductive trace even though it is not adjacent to or overlapped by the conductive trace. 
     The “upward” and “downward” vertical directions do not depend on the orientation of the semiconductor chip assembly (or the thermal board), as will be readily apparent to those skilled in the art. For instance, the post extends vertically above the base in the upward direction and the adhesive extends vertically below the pad in the downward direction regardless of whether the assembly is inverted and/or mounted on a heat sink. Likewise, the base extends “laterally” from the post in a lateral plane regardless of whether the assembly is inverted, rotated or slanted. Thus, the upward and downward directions are opposite one another and orthogonal to the lateral directions, and laterally aligned elements are coplanar with one another at a lateral plane orthogonal to the upward and downward directions. 
     The semiconductor chip assembly of the present invention has numerous advantages. The assembly is reliable, inexpensive and well-suited for high volume manufacture. The assembly is especially well-suited for high power semiconductor devices such as LED packages and large semiconductor chips as well as multiple semiconductor devices such as small semiconductor chips in arrays which generate considerable heat and require excellent heat dissipation in order to operate effectively and reliably. 
     The manufacturing process is highly versatile and permits a wide variety of mature electrical, thermal and mechanical connection technologies to be used in a unique and improved manner. The manufacturing process can also be performed without expensive tooling. As a result, the manufacturing process significantly enhances throughput, yield, performance and cost effectiveness compared to conventional packaging techniques. Moreover, the assembly is well-suited for copper chip and lead-free environmental requirements. 
     The embodiments described herein are exemplary and may simplify or omit elements or steps well-known to those skilled in the art to prevent obscuring the present invention. Likewise, the drawings may omit duplicative or unnecessary elements and reference labels to improve clarity. 
     Various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. For instance, the materials, dimensions, shapes, sizes, steps and arrangement of steps described above are merely exemplary. Such changes, modifications and equivalents may be made without departing from the spirit and scope of the present invention as defined in the appended claims.