Patent ID: 8017449

Claim:
A method comprising: a) applying a silicone die attach adhesive composition to a substrate, b) curing the die attach adhesive composition to form a die attach adhesive, c) plasma treating a surface of the die attach adhesive, d) plasma treating a surface of a semiconductor die, e) contacting the plasma treated surface of the semiconductor die with the plasma treated surface of the die attach adhesive, f) wire bonding the semiconductor die to the substrate, g) injection molding a curable liquid silicone composition over the product of step f), where the silicone composition fills voids in the wire bonded semiconductor die and forms a hermetic seal over the substrate, thereby protecting it from environmental exposure, and optionally h) forming solder balls on a surface of the substrate opposite the die attach adhesive; where step g) comprises i) placing the product of step f) in an open mold, ii) closing the mold to form a mold cavity by applying a clamping force of 1 to 80 tonnes, iii) heating the mold cavity, iv) injection molding the curable liquid silicone composition into the mold cavity to overmold the semiconductor die on the substrate, wherein step iv) is carried out at an injection speed sufficient to provide a pressure in the mold cavity ranging from 0.3 to 7 megaPascals, v) opening the mold and removing the product of step iv), and optionally vi) post-curing the product of step v) wherein the silicone die attach adhesive composition and the curable liquid silicone composition for liquid injection molding have similar cure mechanisms such that groups reactive with the curable liquid silicone composition for liquid injection molding are present in the die attach adhesive.