Patent Publication Number: US-2023162991-A1

Title: Methods of forming packaged semiconductor devices, packaged semiconductor devices, and package molds for forming packaged semiconductor devices

Description:
FIELD 
     The disclosure relates to packaging structures and methods for semiconductor devices. 
     BACKGROUND 
     Semiconductor devices are often used in systems that are exposed to a variety of harsh environmental conditions. For example, semiconductor devices may be exposed to extreme temperature ranges, humidity ranges, and/or other environmental conditions that may negatively impact the semiconductor devices. Moreover, semiconductor devices are often required to operate at or near their rated currents and voltages over extended periods of time. Operating in extreme environmental conditions and/or at elevated levels may lead to failure of the devices and/or deterioration in semiconductor device performance. 
     To protect semiconductor devices during operation and to provide for enhanced heat removal, the devices may be packaged in packages including molded plastic bodies the provided mechanical and/or environmental protection to the semiconductor devices inside. 
     A conventional leadframe  10  is shown in  FIG.  1 A . The leadframe  10 , which may be formed of copper (Cu), includes a plurality of leads  12  connected to the leadframe  10  and to each other by tie bars  13 . The leadframe may include a die attach pad (not shown) on which one or more semiconductor devices (not shown) may be mounted. 
     During a manufacturing process, semiconductor devices are mounted onto the die attach pad, and wire bonds are formed to connect bond pads on the semiconductor devices to the leads  12 . A package body is then overmolded onto the lead frame  10 . The tie bars  13  are then trimmed away to separate the leads  12 . 
       FIG.  1 B  is a side cutaway illustration of the process of molding a package body onto a lead frame  10 . As shown in  FIG.  1 B , a package mold  30  includes an upper mold body  32  and a lower mold body  34  that together define a mold cavity  20 . A leadframe  10  is placed in the mold cavity  20 , and the package mold  30  is closed by bringing the upper mold body  32  and the lower mold body  34  into contact. 
     As further shown in  FIG.  1 B , the package mold  30  includes a gate  22  for allowing a liquid mold compound  38  to flow into the mold cavity  20  and an air vent  16  for allowing air in the mold cavity to escape. The liquid mold compound  38  is supplied to the gate  22  through a mold runner  14 , which is a passage from the source of the liquid mold compound through the mold body  30 . 
     As the liquid mold compound  38  fills the mold cavity  20 , air in the mold cavity is expelled through the air vent  16 . Once the liquid mold compound  38  has completely filled the mold cavity  20 , the liquid mold compound  38  is cured, for example, via heat or radiation, to form a solid package body  40  on the leadframe  10 . The package mold  30  is then opened, and the package body is removed from the mold cavity  20 . 
     SUMMARY 
     A method of forming a packaged semiconductor device according to some embodiments includes placing a leadframe in a mold cavity of a package mold. The package mold includes a first mold body and a second mold body, where the mold cavity is in the first mold body. The package mold further includes a gate in a first side of the mold cavity for supplying liquid mold compound into the mold cavity, a longitudinal vent for releasing gas from the mold cavity in a second side of the mold cavity opposite\e the first side of the mold cavity, and a transverse vent for releasing gas from the mold cavity in a third side of the mold cavity that extends between the first and second sides of the mold cavity. The method further includes placing a leadframe in the mold cavity, wherein the leadframe includes a lead extending away from the mold cavity on the third side of the mold cavity, and closing the mold by bringing the second mold body into contact with the first mold body. Liquid mold compound is flowed through the gate into the mold cavity, such that the liquid mold compound flows in a longitudinal direction from the first side of the mold cavity toward the second side of the cavity. Gas is released from the mold cavity through the longitudinal vent and the transverse vent as the mold cavity is filled with liquid mold compound. 
     In some embodiments, the transverse vent includes a first transverse vent, and the package mold further includes a second transverse vent in the third side of the mold cavity. The mold cavity may further include a fourth side opposite the third side and a second transverse vent in the fourth side of the mold cavity. The mold cavity may include a third transverse vent in the third side of the mold cavity and a fourth transverse vent in the fourth side of the mold cavity. 
     The lead may include a first lead, and the leadframe may include a second lead that extends away from the mold cavity on the second side of the mold cavity. 
     In some embodiments, the leadframe may include a plurality of first leads extending away from the mold cavity on the third side of the mold cavity. 
     The leadframe may include a vent support that extends away from the mold cavity at a location of the transverse vent. The vent support may include a metal tab having a hole therethough where the metal tab crosses the third side of the mold cavity. 
     A package mold according to some embodiments includes a first mold body and a second mold body, a mold cavity in the first mold body, a gate in a first side of the mold cavity for supplying liquid mold compound into the mold cavity, a longitudinal vent for releasing gas from the mold cavity in a second side of the mold cavity opposite the first side of the mold cavity, and a transverse vent for releasing gas from the mold cavity in a third side of the mold cavity that extends between the first and second sides of the mold cavity. 
     The transverse vent may include a first transverse vent, and the package mold may further include a second transverse vent in the third side of the mold cavity. 
     The transverse vent may include a first transverse vent, and wherein the mold cavity further may include a fourth side opposite the third side and a second transverse vent in the fourth side of the mold cavity. 
     The mold cavity may include a third transverse vent in the third side of the mold cavity and a fourth transverse vent in the fourth side of the mold cavity. 
     A packaged semiconductor device according to some embodiments includes a leadframe having a lead, a semiconductor device on the leadframe, and a molded package body on the leadframe, the molded package body covering the semiconductor device, wherein the lead extends from a first side of the molded package body. The leadframe includes a vent support that extends to the first side of the molded package body. The vent support may include a metal tab having a hole therethough at the first side of the molded package body. 
     In some embodiments, the vent support may include a first vent support, and the packaged semiconductor device may further include a second vent support at the first side of the molded package body. 
     In some embodiments, the packaged semiconductor device may further include a second vent support that extends to a second side of the molded package body opposite the first side. 
     In some embodiments, the packaged semiconductor may further include a third vent support at the first side of the package body and a fourth vent support at the second side of the package body. 
     In some embodiments, the packaged semiconductor may further include a fifth vent support at a third side of the package body that extends between the first and second sides of the package body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate aspects of the disclosure and together with the detailed description serve to explain the principles of the disclosure. No attempt is made to show structural details of the disclosure in more detail than may be necessary for a fundamental understanding of the disclosure and the various ways in which it may be practiced. In the drawings: 
         FIGS.  1 A and  1 B  illustrate conventional mold arrangements and packaging methods. 
         FIG.  2    illustrates a TO248 leadframe that may be included in a package according to some embodiments described herein. 
         FIG.  3    illustrates a leadframe and a mold cavity superimposed thereon. 
         FIG.  4    illustrates a mold arrangement according to some embodiments. 
         FIG.  5    illustrates a process of forming a package body on a leadframe according to some embodiments. 
         FIGS.  6  and  7    are images of a leadframe onto which a package body has been molded. 
         FIG.  8    is a flowchart that illustrates a method of forming a packaged semiconductor device according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Embodiments of the inventive concepts are explained more fully with reference to the non-limiting aspects and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of some embodiments may be employed with other aspects as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the aspects of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the aspects of the disclosure. Accordingly, the examples and aspects herein should not be construed as limiting the scope of the disclosure, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings. 
     It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the disclosure. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     It will be understood that when an element such as a layer, region, or substrate is referred to as being “on” or extending “onto” another element, it can be directly on or extend directly onto the another element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or extending “directly onto” another element, there are no intervening elements present. Likewise, it will be understood that when an element such as a layer, region, or substrate is referred to as being “over” or extending “over” another element, it can be directly over or extend directly over the another element or intervening elements may also be present. In contrast, when an element is referred to as being “directly over” or extending “directly over” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the another element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. 
     Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. 
     The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     As noted above, in a conventional packaging method for semiconductor devices, liquid mold compound is supplied via a mold runner through a gate into a mold cavity in which a leadframe has been placed. As the mold compound fills the mold cavity, air in the mold cavity escapes through an air vent. The gate and air vent are typically on opposite ends of the mold cavity, so that the liquid mold compound enters the mold cavity through the gate at a first end and flows across the mold cavity toward the air vent  16  at a second end of the mold cavity opposite the first end. Typically, the gate and air vent are positioned at opposite ends of the mold cavity, while the package leads extend in a transverse direction from sides of the mold cavity. That is, the liquid mold compound flows in a direction parallel to the orientation of the sides of the mold cavity from which the package leads extend. 
     Although this approach may be useful for packaging conventional leadframes, problems may arise when an unconventional leadframe design is used, such as a leadframe that has leads that extend from the ends of the mold cavity in addition to the sides of the mold cavity. 
     For example, a TO248 package leadframe  80  as shown in  FIG.  2    may be used for high-frequency applications. The package leadframe  80  shown in  FIG.  2    has so-called “smart leads”  12 A,  12 C that extend from opposite ends of the package leadframe  80  in addition to conventional leads  12 B,  12 D that extend from the sides of the package leadframe  80 . The smart leads  12 A,  12 C are able to extend the resonance frequency of a device formed on the package leadframe  80  to achieve a wider video bandwidth. However, the presence of such “smart leads”  12 A,  12 C at the ends of the package leadframe  80  may create a risk of mold flash accumulation when a standard air vent position is used. “Mold flash” refers to excess material attached to a molded product. Mold flash is typically caused by leakage of the liquid mold compound between the two surfaces of a mold or between the base material and the mold in the case of overmolding. Such material is typically trimmed away as part of the manufacturing process. 
     If mold flash blocks the air vent, wire sweep may occur and/or internal void defects may be formed in the package body. That is, mold flash blocking the vent may cause the flow of liquid molding compound to be unbalanced, which may result in air becoming trapped inside the mold cavity. This can lead to mold voids and/or wire sweep in the finished device. As is known in the art, wire sweep occurs when bonded wires within the package are not correctly aligned in the horizontal plane (as opposed to wire sag, which is in the vertical orientation). 
     This problem is illustrated in more detail in  FIG.  3   , which illustrates a leadframe  10  and a mold cavity  20  superimposed thereon. The mold cavity  20  has opposing ends  20 A,  20 C, that are separated in a longitudinal direction and sides  20 B,  20 D that extend in the longitudinal direction between the opposing ends  20 A,  20 C. The leadframe  10  includes leads  12 B,  12 D that extend from sides  20 B,  20 D of the mold cavity  20  and “smart leads”  12 A,  12 C that extend from opposite ends  20 A,  20 C of the mold cavity. A gate  22  connected to a mold runner  14  is provided at the first end  20 A of the mold cavity  20 , and an air vent  16  is provided at the second end  20 C of the mold cavity  20 . When liquid mold compound is supplied into the mold cavity  20  from the runner  14  via the gate  22 , mold flashing may build up near the second end  20 C of the mold cavity  20 , which may fully or partially block the air vent  16  formed at the second end  20 C of the mold cavity  20 . As noted above, the mold flashing may interfere with the venting of air from the mold cavity, which may cause voids to form in the package body and/or may cause wire sweep, both of which are undesirable. 
     Some embodiments described herein provide package molds with multiple air vents that are arranged in a transverse direction to the direction of flow of liquid mold compound through the mold cavity. Such an arrangement may allow air to be more efficiently expelled from the mold cavity when it becomes pressurized as liquid mold compound is introduced into the cavity. This may reduce the trapping of air inside the mold cavity that could lead to the formation of internal mold voids. Such an arrangement may be particularly useful in applications that are not appropriate for the use of vacuum venting. 
     A mold arrangement according to some embodiments is shown in  FIG.  4   , which illustrates a leadframe  100  and a mold cavity  120  superimposed thereon. The mold cavity  120  has opposing ends  120 A,  120 C, that are separated in a longitudinal direction (i.e., the horizontal direction relative to the orientation of  FIG.  4   ) and sides  120 B,  120 D that extend in the longitudinal direction between the opposing ends  120 A,  120 C. The leadframe  100  includes leads  12 B,  12 D that extend from top and bottom sides  120 B,  120 D of the mold cavity  120  and leads  12 A,  12 C that extend from opposite ends  120 A,  120 C of the mold cavity. A gate  22  connected to a mold runner  14  is provided at the first end  120 A of the mold cavity  120 , and a longitudinal air vent  16  is provided at the second end  120 C of the mold cavity  120  to vent air longitudinally as liquid mold compound fills the mold cavity  120 . 
     In addition to the longitudinal air vent  16 , a plurality of transverse air vents  46  are provided in the mold to vent air in a transverse direction relative to the direction of flow of mold compound in the mold cavity  120  (i.e., in the vertical direction relative to the orientation of  FIG.  4   ). The transverse air vents  46  may be provided adjacent to or between respective leads  12 B,  12 D that extend from the top and bottom sides  120 B,  120 D of the mold cavity  120 . In the embodiment illustrated in  FIG.  4   , two transverse air vents  46  are provided in each of the top and bottom sides  120 B,  120 D of the mold cavity  120 . However, more or fewer transverse air vents  46  may be provided depending on the implementation. For example, some embodiments may only include a single transverse air vent  46  extending from each side  120 B,  12 D of the mold cavity  120 . In some embodiments, there may be no transverse air vent  46  extending from one of the sides  120 B,  12 D of the mold cavity  120 . In some embodiments, there may be more than two transverse air vents  46  extending from one of the sides  120 B,  12 D of the mold cavity  120 . 
     As further illustrated in  FIG.  4   , the leadframe  100  may include a vent support structure  48  aligned with each of the transverse air vents  46 . The vent support structure  48  may include a metal tab in which a hole  44  is provided therethrough where the metal tab crosses the side of the mold cavity  120 . 
       FIG.  5    illustrates a process of forming a package body  40  on a leadframe  100  according to some embodiments. A mold (not shown) includes a gate  22  through which liquid mold compound is supplied into a mold cavity  120  from a mold runner  14 . The mold includes a longitudinal air vent  16  at an opposite end of the mold cavity  120  from the gate  22  and four transverse air vents  46  arranged on the sides of the mold cavity  120 . As the liquid mold compound  38  is pushed through the mold runner  14  into the mold cavity  120 , pressure increases within the mold cavity  120 , causing air in the mold cavity  120  to vent out through all of the air vents  16 ,  46 . The transverse air vents  46  allow the liquid mold compound  38  to flow evenly to the sides of the mold cavity  120 . As the liquid mold compound  38  fills the mold cavity  120 , the transverse air vents  46  nearest the gate  22  become blocked, cutting off the flow of air therethrough. However, air continues to flow out of the mold cavity  120  through the remaining air vents  16 ,  46  until the mold cavity  120  is completely filled with liquid mold compound  38 . The liquid mold compound  38  is then cured to form a hardened package body  40 , at which time the mold may be opened. 
       FIG.  6    is a picture of a leadframe  100  onto which a package body  40  has been molded, but before the external structure of the leadframe  100  has been trimmed away. The vent support structures  48  including the holes  44  therethrough are still present in the structure. 
       FIG.  7    is a picture of a completed package  200  including a molded package body  40  from which a plurality of metal leads  12  extend after the leadframe  100  has been trimmed. Trimmed ends of the vent support structures  48  may still be evident where the vent support structures  48  were trimmed from the package. 
       FIG.  8    is a flowchart of operations for forming a packaged semiconductor device according to some embodiments. 
     Referring to  FIG.  8   , a method of forming a packaged semiconductor device includes providing a package mold (block  802 ) and placing (block  804 ) a leadframe in a mold cavity of the package mold. The package mold includes a first mold body and a second mold body, where the mold cavity is in the first mold body. The package mold further includes a gate in a first side of the mold cavity for supplying liquid mold compound into the mold cavity, a longitudinal vent for releasing gas from the mold cavity in a second side of the mold cavity opposite the first side of the mold cavity, and a transverse vent for releasing gas from the mold cavity in a third side of the mold cavity that extends between the first and second sides of the mold cavity. The leadframe includes a lead extending away from the mold cavity on the third side of the mold cavity. The method further includes closing the mold (block  806 ) by bringing the second mold body into contact with the first mold body. Liquid mold compound is then flowed (block  808 ) through the gate into the mold cavity, such that the liquid mold compound flows in a longitudinal direction from the first side of the mold cavity toward the second side of the cavity. Gas is released from the mold cavity through the longitudinal vent and the transverse vent as the mold cavity is filled with liquid mold compound. 
     Although embodiments of the inventive concepts have been described in considerable detail with reference to certain configurations thereof, other versions are possible. The field plates and gates can also have many different shapes and can be connected to the source contact in many different ways. Accordingly, the spirit and scope of the invention should not be limited to the specific embodiments described above.