Patent ID: 6984545

Claim:
A method of encapsulating intermediate conductive elements electrically connecting at least one bond pad of a semiconductor die to a corresponding contact area of a carrier substrate, comprising: providing a carrier substrate comprising at least one contact area on a surface thereof adjacent a central slot formed therethrough; forming or placing a solder mask having a central opening on the surface of the carrier substrate to a thickness in excess of a predicted height of protrusion above the surface of at least one intermediate conductive element to be connected to the at least one contact area, including aligning the solder mask over at least a portion of thesurface of the carrier substrate such that the central opening thereof is aligned with the central slot of the carrier substrate and the at least one contact area of the carrier substrate is exposed through the central opening; securing a semiconductor die including at least one bond pad to an opposite surface of the carrier substrate with the at least one bond pad exposed through the central opening of the solder mask and the central slot of the carrier substrate; forming or positioning the at least one intermediate conductive element between the at least one bond pad and the at least one first contact area; positioning a coverlet over the central opening of the solder mask to substantially cover the central opening of the solder mask while leaving each end of the central opening of the solder mask open; and introducing an encapsulant material only through an open end of the central opening of the solder mask such that the encapsulant material flows into the central slot of the carrier substrate towards the other open end of the central opening of the solder mask, and to a level at least above the surface of the carrier substrate and at least partially confining the encapsulant material within the central opening using the solder mask.