Patent ID: 7547582

Claim:
A method for fabricating a semiconductor chip assembly including a surface adapting cap with an integrated adapting thermally conductive material, comprising the steps of: (a) forming a cap including a mechanically deformable membrane having a high thermal conductivity, a sealing structure, and an adaptive material, the adaptive material enclosed within a space defined by the membrane and the sealing structure, the adaptive material having a high thermal conductivity and that either has a softening or liquidus temperature at least slightly above the operating temperature of the at least one chip, or which initially exists in form of a paste or liquid and then is subject to harden above a curing temperature by a curing process; (b) preassembling said cap onto a rear face of the at least one chip under pressure at a temperature above the softening or liquidus temperature sufficient for the adaptive material to do at least one of the softening or change to liquidus, or sufficient for the adaptive material to begin hardening in the curing process, causing said membrane and adaptive material to conform to the surface profile of the at least one chip under influence of the hydrostatic pressure developed by the compression and produce surface adaptation in said membrane and adaptive material, and then lowering the temperature, whereby said adaptive material solidifies and stores said surface adaptation; and (c) then assembling said cap having said stored surface adaptation with the at least one chip and a thermally conductive interface material between the cap and the at least one chip to form said semiconductor chip assembly by compressing again without causing the adaptive material to soften.