Patent ID: RE39426

Claim:
A method of forming a flip chip package, comprising: providing a substrate member having a plurality of electrical contacts disposed thereon; providing a flip chip having a plurality of electrical contacts disposed on a lower surface, a planar upper surface, and a plurality of edge surfaces extending between said lower and said upper surfaces; connecting the electrical contacts of said flip chip with selected ones of the electrical contacts on a top surface of said substrate; providing a thermally conductive planar member having a plurality of peripherally disposed edge surfaces; placing said thermally conductive planar member in thermally conductive communication with said upper surface of the flip chip; placing said thermally conductive planar member, said flip chip, and said substrate member in a mold cavity wherein a predefined portion of said substrate member cooperates with said mold cavity to define a sealable cavity; injecting a moldable dielectric material into said sealable cavity; curing said moldable dielectric material and thereby forming a sealed rigid dielectric covering about the edge surfaces of said thermally conductive planar member, so that said moldable dielectric material is prevented from extending below said substrate member, the edge surfaces of said flip chip, and said predefined portion of said substrate member and forming an encapsulated flip chip package comprising said thermally conductive planar member, said flip chip, and said predefined portion of said substrate member, and removing said flip chip package from said sealed covering mold cavity .