Patent ID: 8034645

Claim:
A method of making a semiconductor chip assembly, comprising: providing a post, a base, an adhesive and a conductive layer, wherein 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, 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 post and the base include a copper surface layer and an aluminum core, the copper surface layer conformally coats and extends above the aluminum core, and the aluminum core of the post extends above the copper surface layer of the base, the adhesive is mounted on and extends above the base, is sandwiched between the base and the conductive layer and is non-solidified, and the conductive layer is mounted on and extends above the adhesive; 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; providing a heat spreader that includes the post and the base, wherein providing the heat spreader includes grinding the post, the adhesive and the conductive layer such that the post, the adhesive and the conductive layer are laterally aligned with one another at a top lateral surface that includes the copper surface layer, excludes the aluminum core and faces in the upward direction; mounting a semiconductor device on the heat spreader, wherein the semiconductor device overlaps the post; electrically connecting the semiconductor device to the pad, thereby electrically connecting the semiconductor device to the terminal; and thermally connecting the semiconductor device to the post, thereby thermally connecting the semiconductor device to the base.