Process for manufacturing a surface-mount semiconductor device having exposed solder material
10211129 ยท 2019-02-19
Assignee
Inventors
Cpc classification
H01L2924/00012
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L24/97
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/83192
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/92247
ELECTRICITY
H01L2924/00
ELECTRICITY
International classification
H01L21/00
ELECTRICITY
Abstract
A process for manufacturing surface-mount semiconductor devices, in particular of the Quad-Flat No-Leads Multi-Row type, comprising providing a metal leadframe, in particular a copper leadframe, which includes a plurality of pads, each of which is designed to receive the body of the device, the pads being separated from adjacent pads by one or more rows of wire-bonding contacting areas, outermost rows from among the one or more rows of wire-bonding contacting areas identifying, together with outermost rows corresponding to the adjacent pads, separation regions.
Claims
1. A method comprising: depositing beads of conductive soldering material on portions of a plurality of leads and on joining regions of a leadframe so that each of the beads of conductive soldering material is on outer portions of adjacent leads and a joining region between two adjacent leads; coupling semiconductor devices to respective die pads of the leadframe; and carrying out a thermal process that sinters or reflows the beads of conductive soldering material to form soldered beads.
2. The method according to claim 1 further comprising: coupling ends of wires to the plurality of leads and ends of the wires to the semiconductor devices; etching a bottom surface of the leadframe and exposing a bottom surface of the soldered beads; forming a dielectric material on the leadframe and around the semiconductor devices and the wires; and dicing along through the soldered beads and the dielectric material to form individual packages, the dicing exposing lateral surfaces of the soldered beads on an outside surface of the individual packages.
3. The method according to claim 2, further comprising: mounting one of the individual packages on a board, the mounting including: depositing solder-paste beads on the board; and placing the individual packages on the solder-paste beads so that the soldered beads align with the solder-paste beads and bring about formation of a lateral meniscus of the solder-paste beads.
4. The method according to claim 1 wherein said conductive soldering material is sinterable Transient Liquid Phase Solder or solder paste with reflow-soldering temperature at or above 260 C.
5. The method according to claim 1 wherein the leadframe is a metal leadframe and the die pads and leads include a plated layer of one or more conductive materials.
6. The method according to claim 5 wherein the leadframe includes four rows of leads between adjacent die pads, wherein the four rows of leads includes two center rows that have first portions that are partially plated and second portions with the leadframe material exposed, and the second portions of the leads of the two center rows are proximate the joining regions.
7. The method according to claim 1 wherein the joining regions are at least 600 m in width.
8. A method, comprising: coupling a first die to a first die pad of a leadframe; forming a solder bead on an upper surface of a first lead of the leadframe; electrically coupling the first die to the solder bead using a wire, the wire having a first end on the first die and a second end on the upper surface of the first lead; forming molding material on the first die and the solder bead; and cutting through the molding material and the solder bead such that a surface of the solder bead is exposed from the molding material.
9. The method according to claim 8, further comprising: coupling a second die to a second die pad of the leadframe, the forming of the solder bead including forming the solder bead on a second lead of the leadframe.
10. The method according to claim 9, further comprising: electrically coupling the second die to the solder bead, the forming of the molding material including forming the molding material on the second die.
11. The method according to claim 8 wherein a second lead of the leadframe is physically coupled to the first lead by a coupling portion of the leadframe, the forming of the solder bead include forming the solder bead on the second lead and the coupling portion.
12. The method according to claim 11, further comprising: removing the coupling portion.
13. The method according to claim 11 wherein the coupling portion has a smaller thickness than the first lead and the second lead.
14. The method according to claim 8 wherein the first die is electrically coupled to the solder bead through a conductive layer on the first lead and the wire.
15. A method, comprising: coupling a first die to a first die pad of a leadframe, the leadframe including a first lead, the first lead including a surface having a first conductive layer on a first portion of the surface of the first lead, a second portion of the surface of the first lead remaining uncovered by the first conductive layer; forming a solder bead on the second portion of the surface of the first lead; electrically coupling the first die to the first conductive layer by a first wire; forming molding material on the first die, the first conductive layer, the solder bead, and the first wire; and cutting through the molding material and the solder bead such that a surface of the solder bead is exposed from the molding material.
16. The method of claim 15, further comprising: coupling a second die to a second die pad of the leadframe, the leadframe including a second lead, the second lead including a second conductive layer on a first portion of the surface of the second lead, a second portion of the surface of the second lead remaining uncovered by the second conductive layer; forming the solder bead on the second portion of the surface of the second lead; electrically coupling the second die to the second conductive layer by a second wire; and forming the molding material on the second die, the second conductive layer, and the second wire.
17. The method of claim 16, further comprising: removing a portion of the leadframe that physically couples the first lead to second lead such that another surface of the solder bead is exposed from the molding material.
18. The method according to claim 17 wherein the portion of the leadframe has a smaller thickness than the first lead and the second lead.
19. The method of claim 15 wherein the exposed surface of the solder bead is coplanar with a surface of the molding material.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) Various embodiments will now be described, purely by way of example, with reference to the annexed drawings, wherein:
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DETAILED DESCRIPTION
(19) In the ensuing description, numerous specific details are provided aimed at enabling maximum understanding of the embodiments provided by way of example. The embodiments may be implemented with or without specific details, or else with other processes, components, materials, etc. In other circumstances, well-known structures, materials, or operations are not illustrated or described in detail so that aspects of the embodiments will not be obscured. Reference, in the course of this description, to an embodiment or one embodiment is meant to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is comprised in at least one embodiment. Hence, phrases such as in an embodiment or in one embodiment or the like that may be present in various points of the present description do not necessarily refer to one and the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any convenient way in one or more embodiments.
(20) The references are provided herein merely for convenience of the reader and do not define the scope or the meaning of the embodiments.
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(22) The pads 12a and the areas 12 are plated with contact layers 14 using materials such as NiPd or else NiPdAu or else Ag in order to define the areas where the bonding wires 13 are to be applied. The contact layers 14 are preferably plated before providing the leadframe 11, according to the known PPF technique (leadframe pre-plated with an electrochemical process).
(23) As has been mentioned, each pad 12a is separated from another by four areas 12. As may be noted more clearly from
(24) On a bottom surface 11d of the leadframe 11 there are obtained, once again by plating, solderable bottom contacts 16, in the position corresponding to the areas 12, and in a position corresponding to the top pad 12a a bottom pad 16a is provided, the bottom contacts 16 and the bottom pad 16a being plated directly on the bottom copper surface 11d of the leadframe 11, which is substantially planar and without any reliefs.
(25) Illustrated in
(26) Basically, a device area AD may be identified that ranges from one half of the length S of the separation regions 23 and includes inside it the rows R2 and R1 and the pad 12a. As illustrated in
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(28) To return to the process illustrated in
(29) In variant embodiments, the conductive soldering material 15 may be a conductive alloy with a reflow-soldering temperature higher than 260 C., and hence higher than that of SAC (tin-silver-copper) alloys used for soldering devices on PCBs, which is also resistant to the process of etching of the copper leadframe. For instance, a silver-bismuth alloy, for example the material BiAgX produced by Indium, is here used, or else a solder paste at a reflow-soldering temperature higher than 260 C.
(30) Application, in step 120, of the conductive soldering material 15 is performed using a dispensing needle, which is moved from one contact to another to form the bead, or else by hot rolling plus application of pressure, or else by transfer with silk-screen printing technique. The TLPS material may preferably be applied by needle dispensing or with silk-screen printing techniques, whereas the paste with conductive alloy may preferably be applied just with silk-screen printing technique.
(31) The conductive soldering material 15 is applied in such a way as to cover also approximately 50% of the contiguous surface on the wire-bonding area 12, i.e., substantially the surface left without plating 14, for a length of not less than 10050 m. There is thus created a bead of conductive material 15, of oblong shape, the total length S of which, in the direction that joins two areas 12 corresponding to two adjacent pads, is greater than 80050 m, the width is 25050 m, and the thickness is greater than 20050 m.
(32) The part of the area 12 that is to receive the bonding wire 13 is plated in order to create a discontinuity with respect to the contiguous surface of the area 12 itself on which the conductive material 15 is applied, this surface being, instead, left exposed, and hence being a copper surface. In this way, the degree of overstepping of the margins by the conductive material 15 is controlled, thus preventing the material from contaminating the portion of the area 12 provided with the plating 14, where the bonding wires 13 are effectively to be applied.
(33) Where it is desired to use rough copper as surface finishing of the part of the area 12 designed for wire bonding, the contiguous surface is once again made of copper, but with a standard roughness.
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(36) With reference to
(37) The conductive material 15 is then sintered in a step 140 (illustrated in
(38) The oxygen content of the oven is monitored in order to provide complete sintering or reflow. This condition is obtained by getting the ovens to work in a nitrogen atmosphere. In the embodiment of a low-temperature sinterable material (TLPS), it is possible to improve sintering further by getting the oven to work in a reducing atmosphere. This condition is obtained by getting the ovens to work with a mixture of nitrogen N.sub.2 and hydrogen H.sub.2 (with a percentage of H.sub.2 of less than 5%). As illustrated in
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(42) A step 160 of wire bonding is then carried out, which is made using gold, copper, or silver wire 13 on the plated surfaces 14 (or else on the rough copper surfaces) of the areas 12 and pads 12a. Wires 13 are connected between each area 12 of the rows R1 and R2 and the pad 12a that the areas 12 enclose in their perimeter.
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(44) The next step 170 (illustrated in
(45) The molding step 170 may be followed by a thermal treatment, for example, at the curing temperature of 175 C., this treatment being known as post-molding curing (PMC).
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(47) In this step, of chemical back etching, a chemical etch of the bottom surface 11d of the leadframe 11 is carried out to remove the layer of copper where it is not protected by the plating 14, namely on the contacts 16 and on the pad 16a of the bottom surface 11d. In particular, the back-etching step 180 removes the copper of the leadframe 11, but does not remove the SnCu inter-metal composite that is obtained by sintering of the TPLS and of which the sintered soldered bead 15s is made. Consequently, the soldered bead 15s, after step 180, gives out, with a bottom surface 15d of its own onto the bottom surface 11d of the leadframe 11, set in the non-masked part between the plated contacts 16, where the copper has been removed. The chemical etch 180 hence exposes also the bottom surface 15d of the soldered bead 15s for a length E of 700 m and a width of 250 m.
(48) The next step, step 190, of the process is illustrated in
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(51) To sum up, following upon the cutting operation 190, the dielectric region 40 forms the package 41 that covers the device 20, this package 41 being delimited underneath by the portion of leadframe 11 of the area of the device 20. The cutting operation 190 causes each soldered bead 15s, after it has in turn been cut substantially in half thus forming a cut soldered bead 15m, identifies a terminal 50 of sintered material, which comprises a bottom surface 15d, which gives out onto the bottom surface 11d of the package 41, and a lateral surface 15a, which is in turn exposed outwards and hence be solderable. This lateral surface 15a is coplanar with the lateral surface of the package P, which has a substantially parallelepipedal shape with top and bottom surfaces corresponding to those of the device area AD. Extending along the edge formed by the lateral surface 411 of the package 41 and by the bottom surface 11d are at least part of the contact terminals 50. Hence, the cutting operations (step 190) bring about formation of a device with a package of a quad-flat no-leads (QFN) type.
(52) Hence, as has just been discussed, basically, after the singulation step 190, the soldered bead 15s has the lateral surface 15a and the bottom surface 15d exposed. This makes it possible, during a step 200 of soldering on the PCB 60 (illustrated in
(53) Illustrated in
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(56) Hence, the advantages of the solution disclosed emerge clearly from the foregoing description.
(57) Advantageously, the process described enables, for a QFN_mr package, a lateral meniscus to be obtained, which is visible in a PCB inspection of the outer row, this being a characteristic that is specified in systems for automatic positioning of components.
(58) Furthermore, advantageously, the process can use a simple mixed technology of etched leadframe and conductor screen printing. No plating line is necessary.
(59) The process described advantageously provides that the sinterable material is applied directly on the copper leadframe, not requiring removable insulating means, or more in general temporary substrates. For this reason, the sintered material can be replaced by a high-temperature (up to 300 C.) solder paste in so far as the process, by using a metal leadframe, can enable reflow temperatures (over 250 C.) to be reached.
(60) The device obtained via the process advantageously does not have sintered material connected to the die, i.e., to the semiconductor body, but the sintered material is applied on the contacts of the leadframe, which in turn are wire-bonded to the die.
(61) The process is advantageously compatible with ASE, STATS, and UTAC technologies.
(62) Of course, without prejudice to the principle of the solution described, the details and the embodiments may vary, even significantly, with respect to what has been described herein purely by way of example, without departing from the sphere of protection.
(63) The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.