Patent ID: 7468886

Claim:
A method of improving thermal dissipation from a module assembly, the method comprising: attaching a first side of at least one chip to a multi ceramic chip carrier, to which a discrete device is mounted, the discrete device being selected from the group consisting of semiconductors, capacitors, resistors and thermistors, the at least one chip having a second side opposite of the first side; mounting a first side of at least one dummy device on the multi ceramic chip carrier, each dummy device having a second side opposite of the first side; dispensing a reworkable underfill at least one of around and under the at least one chip before the grinding; dry grinding and polishing the second side of the at least one chip and the second side of each dummy device to be in a coplanar configuration with one another; selectively thinning a selected portion of the second side of the at least one chip; conducting a reworking process to remove material from beneath and/or around the at least one chip and the dummy device; applying a thermal paste on at least one of a heat sink, including a protrusion positionally corresponding to the thinned selected portion of the second side of the at least one chip, and the second side of the at least one chip; and disposing the heat sink on the second side of the at least one chip with the thermal paste therebetween defining a gap between the heat sink and the second side of the at least one chip, wherein a dimension of the gap is controlled to improve heat transfer from the second side of the at least one chip to the heat sink.