Patent ID: 7994636

Claim:
A flip chip semiconductor device, comprising: a semiconductor die having first interconnect members with substantially linear sidewalls and made with a deformable material; and a substrate having second interconnect members, the second interconnect members each having a plated surface with a plurality of asperities extending 1-25 micrometers from the plated surface, the first and second interconnect members being respectively permanently bonded together by compressing the first and second interconnect members to cause plastic flow of the first interconnect members into the asperities of the second interconnect members to electrically interconnect the semiconductor die and substrate, the first interconnect members undergoing plastic deformation of at least 25 micrometers to incorporate the asperities of the second interconnect members into the deformable material of the first interconnect members while maintaining the substantially linear sidewalls of the first interconnect members to reduce pitch between adjacent first interconnect members.