Patent ID: 8546191

Claim:
A method of forming a multi-die semiconductor device, comprising: mounting a plurality of dice on a semiconductor substrate, each die of the plurality of dice forming a respective capillary region between the die and the semiconductor surface, and neighboring dice of the plurality of dice separated by a distance at which a first one of the neighboring dice will contact a meniscus of a flange of an underfill along a perimeter of a second one of the neighboring die during deposition of the underfill to form a capillary bridge between the respective capillary regions; reflowing solder bumps to electrically connect contact terminals of the plurality of dice to contact terminals on a top surface of the substrate; following the reflowing of the solder bumps, depositing the underfill along one or more edges of one or more of the plurality of dice; wherein the depositing of the underfill along the one or more edges includes depositing along an edge of one die of the plurality of dice a quantity of underfill that completely underfills the one die and a neighboring die of the plurality of dice, and the underfill having properties that induce capillary action causing the underfill to: flow between the bottom surfaces of the one or more dice of the plurality of dice and the top surface of the substrate; form the flange of the underfill along a perimeter of each of the one or more dice of the plurality of dice; and as a result of the capillary bridge formed between neighboring dice, flow between the bottom surfaces of the neighboring dice and the top surface of the substrate; and curing the dispensed underfill.