阅读说明：本技术 模制设备、模制半导体装置的制造方法及模制半导体装置 (Molding apparatus, method of manufacturing molded semiconductor device, and molded semiconductor device ) 是由 翁圣丰 谢静华 刘重希 林志伟 邱圣翔 赖耀东 林家民 于 2020-04-28 设计创作，主要内容包括：一种模制设备被配置成用于对半导体装置进行模制且所述模制设备包括下部模具及上部模具。所述下部模具被配置成承载所述半导体装置。所述上部模具设置在所述下部模具上方以接纳所述半导体装置且所述上部模具包括模具部件及动态部件。所述模具部件被配置成覆盖所述半导体装置的上表面。所述动态部件围绕所述上部模具的装置接纳区设置且被配置成相对于所述模具部件移动。另提供一种模制方法及一种模制半导体装置。(A molding apparatus is configured for molding a semiconductor device and includes a lower mold and an upper mold. The lower mold is configured to carry the semiconductor device. The upper mold is disposed above the lower mold to receive the semiconductor device and the upper mold includes a mold member and a dynamic member. The mold member is configured to cover an upper surface of the semiconductor device. The dynamic member is disposed about a device receiving area of the upper mold and is configured to move relative to the mold member. A molding method and a molded semiconductor device are also provided.)

1. A molding apparatus for molding a semiconductor device, comprising:

a lower mold configured to carry the semiconductor device; and

an upper mold disposed above the lower mold to receive the semiconductor device and including:

a mold member configured to cover an upper surface of the semiconductor device; and

a dynamic component disposed about the device receiving area of the upper mold and configured to move relative to the mold component.

Technical Field

Embodiments of the present invention relate to a semiconductor apparatus, a semiconductor device and a method of manufacturing the same, and more particularly, to a molding apparatus, a molded semiconductor device and a method of manufacturing the same.

Background

According to conventional semiconductor packaging techniques, a plurality of semiconductor chips are arranged in an array at a constant pitch and pitch on a substrate. After the electrical connection process between the chip and the substrate, a molding material is formed on top of the substrate to encapsulate the chip. The molding material is then cured and singulated by a dicing blade or by a laser to obtain a plurality of individual semiconductor devices.

When a molding material is injected to encapsulate the chip and fill the molding material into the gap between the substrate and the chip, a region (i.e., a void) in which the molding material is not formed may be formed in the gap between the substrate and the chip. This is due to the difference in flow rate of the molding material between the region where the bump electrode (conductive terminal) exists and the region where the bump electrode does not exist. In the region where the bump electrode is not present, the molding material flows faster downstream and enters the region where the bump electrode is present in a roundabout manner. Due to such flow of the molding material in a meandering manner, a space (i.e., a void) surrounded by the molding material may occur near the region where the bump electrode exists.

After filling the gap between the substrate and the chip with the molding material, a process for heat-setting (thermal setting) the molding material is performed, and thermal expansion and contraction cause stress in the package. The above-mentioned voids in the vicinity of the bump electrodes reduce the durability under thermal stress. Therefore, the bump electrode may be broken, and thus, the reliability of the semiconductor package may be lowered.

Disclosure of Invention

According to some embodiments of the present disclosure, a molding apparatus is configured for molding a semiconductor device and includes a lower mold and an upper mold. The lower mold is configured to carry the semiconductor device. The upper mold is disposed above the lower mold to receive the semiconductor device and the upper mold includes a mold member and a dynamic member. The mold member is configured to contact an upper surface of the semiconductor device. The dynamic member is disposed about a device receiving area of the upper mold and is configured to move relative to the mold member.

According to some embodiments of the present disclosure, a method of manufacturing a molded semiconductor device includes the following steps. A semiconductor device is mounted on a substrate. A lower mold is provided to carry the semiconductor device mounted on the substrate. An upper mold is provided above the lower mold. The upper mold includes a mold member covering an upper surface of the semiconductor device and a dynamic member disposed around a device receiving area of the upper mold. Moving the dynamic component in a first direction relative to the mold component. Injecting a molding material into the device-receiving region to encapsulate the semiconductor device. Moving the dynamic component relative to the mold component in a second direction, the second direction being opposite the first direction.

According to some embodiments of the present disclosure, a molded semiconductor device includes a semiconductor device and a molding material. The molding material encapsulates the semiconductor device, wherein an upper surface of the molding material is substantially coplanar with an upper surface of the semiconductor device and includes a groove at least partially surrounding the upper surface of the semiconductor device.

Drawings

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying drawing figures. It is noted that, in accordance with standard practice in the industry, the various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

Fig. 1 illustrates a cross-sectional view of a molding apparatus according to some exemplary embodiments of the present disclosure.

Fig. 2-4 show cross-sectional views of intermediate stages in the manufacture of molded semiconductor devices according to some exemplary embodiments of the present disclosure.

Fig. 5-7 show cross-sectional views of intermediate stages in the manufacture of molded semiconductor devices according to some exemplary embodiments of the present disclosure.

Fig. 8 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure.

Fig. 9 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure.

Fig. 10 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure.

Fig. 11 illustrates a cross-sectional view of a molded semiconductor device according to some exemplary embodiments of the present disclosure.

Fig. 12 illustrates a top view of a molded semiconductor device according to some exemplary embodiments of the present disclosure.

Fig. 13 illustrates a top view of a molded semiconductor device according to some exemplary embodiments of the present disclosure.

Detailed Description

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are set forth below to simplify the present disclosure. Of course, these are merely examples and are not intended to be limiting. For example, in the following description, forming a first feature over or on a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. Additionally, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Additionally, spatially relative terms such as "below", "lower", "above", "upper", and the like may be used herein to describe one element or feature's relationship to another (other) element or feature as illustrated in the figures for ease of description. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may have other orientations (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly as such.

Embodiments of the present disclosure, which are now set forth in detail, provide a molding apparatus, a method of manufacturing a molded semiconductor device using the molding apparatus, and a molded semiconductor device formed by the manufacturing method to provide a molding material encapsulating the semiconductor device without a void occurring in a gap between the semiconductor device and a substrate. Release films may be used to facilitate the peeling of the finished device. In an embodiment, a dynamic part configured to move relative to the upper mold is used to provide accurate control of the flow of molding material. Voids in the molding material between the die and the substrate observed in prior known approaches are reduced or eliminated. The method embodiments are carried out without substantial changes to the molding material, the substrate, or the semiconductor device (integrated circuit die).

Fig. 1 illustrates a cross-sectional view of a molding apparatus according to some exemplary embodiments of the present disclosure. Fig. 2-4 show cross-sectional views of intermediate stages in the manufacture of molded semiconductor devices according to some exemplary embodiments of the present disclosure. Referring now to fig. 1 and 2, in some embodiments, a method of manufacturing a molded semiconductor device may include the following steps. First, for example, a semiconductor device 210 is mounted on a substrate 220, as shown in fig. 2. According to some embodiments of the present disclosure, the semiconductor device 210 may be, but is not limited to, an integrated circuit die. In some embodiments, semiconductor device 210 may be a logic device die in which logic circuitry is included. In some example embodiments, the semiconductor device 210 is a die designed for mobile applications and may include, for example, a Power Management Integrated Circuit (PMIC) die and a Transceiver (TRX) die. Although one semiconductor device 210 is shown, more semiconductor devices 210 may be placed over the substrate 220 and the more semiconductor devices 210 are flush with each other.

In some embodiments, the semiconductor device 210 may be mounted on the substrate 220 by, for example, a plurality of conductive terminals 230. In some embodiments, substrate 220 may be a semiconductor wafer or a portion of a wafer, in one non-limiting example. The wafer may be silicon, gallium arsenide, silicon on insulator ("SOI"), or other similar material. The wafer may include passive devices (e.g., resistors, capacitors, inductors, etc.) or active devices (e.g., transistors). In an exemplary embodiment, the semiconductor wafer substrate may include additional integrated circuits. However, in alternative embodiments, substrate 220 may be formed from other materials. For example, a multilayer circuit board may be used. In some embodiments, the substrate 220 may be Bismaleimide Triazine (BT) resin, FR4, ceramic, glass, plastic, tape, film, or other supporting material that may carry conductive pads or lands necessary to receive the conductive terminals 230 for mounting the semiconductor device 210 by, for example, flip chip bonding techniques.

The semiconductor device 210 shown in fig. 2 may be arranged as a flip-chip integrated circuit mounted on a substrate 220, according to some embodiments of the present disclosure. In flip-chip mounting of the semiconductor device 210, the substrate 220 receives connections (e.g., conductive terminals 230) on bond pad terminals of the semiconductor device 210. In a non-limiting example, the conductive terminals 230 may be solder bumps. The solder material of the solder bumps may be lead-based, or alternatively the solder material may be lead-free, such as a silver, copper, or tin composition. The conductive terminal 230 will be an eutectic (eutectic) with a common melting point (common) for reflow process. In some embodiments, the conductive terminals 230 may be plated using an electroplating or electroless plating technique, or may be formed using a screen printing (screen printing) technique or a jet printing (jet printing) technique. In some embodiments, the conductive terminals 230 may also be of other types, such as copper or gold pillars, conductive pillars, or controlled collapse chip connection (C4) pillars. The present disclosure is not so limited. It is noted that the flip-chip semiconductor device 210 mounted on the substrate 220 is illustrated for a molding process, but the present disclosure is not limited thereto. In other embodiments, the fabrication methods and molding apparatus described herein may also be applied to other packages, such as integrated fan-out (INFO) packages for molding processes.

In one exemplary embodiment, solder bumps are used as the conductive terminals 230, and the semiconductor device 210 is flipped over, aligned and placed on the substrate 220 to place the conductive terminals 230 in contact with the landing pads on the substrate 220. The semiconductor device 210 and the conductive terminals 230 may then be subjected to a thermal solder reflow step to make the conductive terminals 230 electrically and physically connected to the substrate 220. However, other methods may be used to assemble the embodiment shown in FIG. 2 and the embodiment is not limited by these examples.

With this arrangement, the substrate 220 and the semiconductor device 210 are now ready for a molding step to encapsulate the semiconductor device 210. Thus, for example, the molding apparatus 100 of FIG. 1 is provided to perform the molding step. According to some embodiments of the present disclosure, the molding apparatus 100 may include a lower mold 110 and an upper mold 120. In some embodiments, the lower mold 110 is configured to carry a semiconductor device 210. Specifically, the lower mold 110 is configured to carry a substrate 220 on which the semiconductor device 210 is mounted. In some embodiments, the lower mold 110 may include a mold cavity (mold cavity) for receiving the substrate 220, and the mold cavity is designed according to the size and number and arrangement of the mold regions and the thickness of the substrate 220. However, in other embodiments, the lower mold 110 may be a substantially flat plate on which the substrate 220 rests. The present disclosure does not limit the arrangement of the lower mold 110.

According to some embodiments of the present disclosure, the upper mold 120 is disposed (mounted) above the lower mold 110 for receiving the semiconductor device 210. The upper mold 120 and the lower mold 110 may be made of metal or other suitable material. The present disclosure is not so limited. In some embodiments, the upper mold 120 may include a device receiving region R1, the device receiving region R1 for receiving the semiconductor device 210 and receiving a molding material to be injected into the device receiving region R1. In some embodiments, the upper mold 120 includes a mold member 122 and a dynamic member 124. The mold member 122 is configured to cover the upper surface of the semiconductor device 210. The dynamic member 124 is disposed about the device receiving region R1 of the upper mold 120 and is configured to move relative to the mold member 122 to control the flow direction of the molding material. In some embodiments, the mold member 122 and the dynamic member 124 together define a device receiving region R1.

According to some embodiments of the present disclosure, the mold member 122 includes a cover portion 1221 and a sidewall portion 1222. The side wall portion 1222 surrounds the cover portion 1221 and the dynamic component 124 is disposed between the cover portion 1221 and the side wall portion 1222. The cover 1221, dynamic member 124, and sidewall 1222 collectively define a mold cavity, which is a device receiving area R1. In some embodiments, the thickness of the cover 1221 is substantially less than the thickness of the sidewall portions 1222. In some embodiments, the sidewall portions 1222 may contact the upper surface of the lower mold 110 to define a device receiving area R1 during the molding process, the device receiving area R1 being for receiving the semiconductor device 210 and receiving a molding material to be injected into the device receiving area R1.

According to some embodiments of the present disclosure, the cover 1221 may include a contact surface S1, the contact surface S1 being configured to cover an upper surface of the semiconductor device 210. In some embodiments, the contact surface S1 of the cover 1221 is configured to contact the upper surface of the semiconductor device 210 during a molding process. In some embodiments, the contact surface S1 of the cover 1221 may be substantially higher than the upper surface of the semiconductor device 210. That is, there may be a gap between the contact surface S1 of the cover 1221 and the upper surface of the semiconductor device 210, and the contact surface S1 may contact the molding material to be injected into the device receiving region R1 during the molding process.

Referring now to fig. 1 and 2, prior to performing the molding process (i.e., prior to injecting molding material into the device receiving region R1), the dynamic member 124 is moved relative to the mold member 122 in the first direction D1. In some embodiments, the first direction D1 is a (downward) direction toward the lower mold 110. Accordingly, the dynamic component 124 moves to a first position, as shown in fig. 2, where the lower surface of the dynamic component 124 is substantially below the contact surface S1 of the mold component 122 (i.e., the cover 1221). In detail, the lower surface of the dynamic member 124 is substantially lower than the contact surface S1 of the cover 1221 and substantially higher than the lower surface of the side wall portion 1222.

In some embodiments, the cover 1221 covers the semiconductor device 210, and the dynamic component 124 surrounds the periphery of the device receiving region R1. With this arrangement, when the dynamic component 124 moves to the first position shown in fig. 2, the dynamic component 124 surrounds the side surface of the semiconductor device 210. That is, the dynamic member 124 is arranged to correspond to the region filled with the molding material in the device receiving region R1. In some embodiments, the contact surface S1 of the cover 1221 that contacts the upper surface of the semiconductor device 210 is substantially larger than the upper surface of the semiconductor device 210 to allow for tolerances (to avoid damage to the semiconductor device 210). In some embodiments, a distance d1 is maintained between the boundary of the contact surface S1 of the cover 1221 and the upper surface of the semiconductor device 210. For example, the distance d1 may be in the range of 200 μm to 2000 μm.

Referring now to fig. 3, in some embodiments, a molding process may now be performed. According to some embodiments of the present disclosure, the molding apparatus 100 may further include an injection port (injection port)130, and the injection port 130 may be disposed at the lower mold 110 to inject the molding material 240 into the device receiving region R1, but the present disclosure is not limited thereto. For example, the injection ports 130 may be provided at the lower mold 110 and/or the upper mold 120 for injecting the molding material 240 into the device receiving region R1. In some embodiments, the molding material 240 may comprise a molding compound, an epoxy, a resin, or the like, although the disclosure is not so limited. In some embodiments, the upper mold 120 (e.g., sidewall 1222) may include an injection channel 128 and an injection port (injioninlet) 126. The injection channel 128 is in fluid communication with the injection port 130 for flowing the molding material 240 provided through the injection port 130. The injection channel 128 is connected to the injection port 126 such that the molding material 240 in the injection channel 128 may be injected into the device receiving region R1 through the injection port 126 to encapsulate the semiconductor device 210.

Generally, the space between the semiconductor device 210 and the substrate 220 is relatively narrow. In addition, since there is a difference in flow velocity of the molding material 240 between a region where the conductive terminals 230 exist and a region where the conductive terminals 230 do not exist, it is difficult for the molding material 240 to be completely filled, and thus a void may occur. During the heating process and the cooling process of the molding process, the solid or paste molding material 240 melts and solidifies during the solidification process. Thus, voids in the cured molding material 240 will reduce the mechanical strength or product weight of the customer-specified product. In addition, when voids are formed in the molding material 240, delamination (delamination) or popping particles (popcorp) easily occur between the semiconductor device 210 and the substrate 220 during thermal cycling, resulting in a product reliability problem. Therefore, it is desirable to have the molding material 240 completely fill between the surface of the semiconductor device 210 and the surface of the substrate 220 without forming any voids therein.

Accordingly, in some embodiments, the dynamic member 124 is moved relative to the mold member 122 to a first position where the lower surface of the dynamic member 124 is substantially below the contact surface S1 of the cap portion 1221 prior to injection of molding material into the device receiving region R1. Thus, the molding material 240 injected through the injection port 126 will be forced to flow into the space between the semiconductor device 210 and the substrate 220. In other words, with this arrangement, the molding material 240 is first forced to fill the lower portion of the device-receiving region R1. It is noted that the lower portion of the device receiving area R1 is a cavity defined by the cover 1221, sidewall 1222, and dynamic component 124 in the first position, as shown in fig. 3. Therefore, the molding material 240 will not flow to any other more spacious position (e.g., a space around the side surface of the semiconductor device 210) first, and will not leave a void in the defined space between the semiconductor device 210 and the substrate 220.

Referring now to fig. 3 and 4, in some embodiments, after the molding material 240 completely fills the lower portion of the device receiving region R1, the dynamic member 124 is moved relative to the mold member 122 in a second direction D2, the second direction D2 being opposite the first direction D1. Accordingly, the dynamic member 124 moves to the second position, as shown in fig. 4, where the lower surface of the dynamic member 124 is substantially coplanar with the contact surface S1 of the cover 1221. In some embodiments, the molding material 240 is injected into the device-receiving region R1 while the dynamic member 124 is moved in the second direction D2 relative to the mold member 122, so the molding material 240 may gradually fill the space around the side surface of the semiconductor device 210. That is, as the dynamic component 124 moves from the first position shown in fig. 3 to the second position shown in fig. 4, the molding material 240 is continuously injected into the device receiving region R1.

In other embodiments, the injection of the molding material 240 may be performed in two separate stages. For example, the first stage is when the dynamic member 124 moves to the first position shown in FIG. 3, injecting the molding material 240 until the molding material 240 completely fills the lower portion of the device receiving area R1. Then, the injection of the molding material 240 is stopped. Then, when the dynamic component 124 moves to the second position (as shown in fig. 4), the second stage of injection of the molding material 240 is initiated such that the molding material 240 may fill the remainder of the device receiving area R1.

With this arrangement, the molding apparatus 100 utilizes the dynamic member 124 configured to move relative to the mold member 122 to more precisely control the flow of the molding material 240 and reduce voids present in the molding material 240. According to some embodiments of the present disclosure, the dynamic member 124 moves to a first position where the dynamic member 124 is substantially lower than the cover portion 1221 prior to injecting the molding material into the device receiving region R1. Thus, the molding material 240 injected through the sprue 126 will be forced to first fill the lower portion of the device receiving area R1. Thus, the molding material 240 will not flow to any other more spacious location first and leave voids in the defined space between the semiconductor device 210 and the substrate 220. Therefore, the mechanical strength of a molded semiconductor device (e.g., the molded semiconductor device 200 shown in fig. 11) formed by the molding apparatus 100 and the above-described manufacturing method can be improved. Furthermore, since no void is formed in the molding material 240, a delamination or a burst particle effect between the semiconductor device 210 and the substrate 220 may be avoided.

Fig. 5-7 show cross-sectional views of intermediate stages in the manufacture of molded semiconductor devices according to some exemplary embodiments of the present disclosure. It is noted that the method of manufacturing the molded semiconductor device shown in fig. 5-7 includes many features that are the same as or similar to the method of manufacturing the molded semiconductor device disclosed above in connection with fig. 2 and 4. For clarity and conciseness, the same or similar features are not repeated and the same or similar reference numerals denote the same or similar components. The following describes the main differences between the method of manufacturing the molded semiconductor device shown in fig. 5 to 7 and the method of manufacturing the molded semiconductor device disclosed in connection with fig. 2 and 4 described above.

Referring now to fig. 5, in some embodiments, the dynamic member 124 is moved relative to the mold member 122 in the first direction D1' prior to injecting the molding material 240 into the device receiving area R1. In some embodiments, the first direction D1' is the (upward) direction of movement away from the lower mold 110. Thus, the dynamic component 124 moves to a first position, as shown in fig. 5, where the lower surface of the dynamic component 124 is substantially higher than the lower surface of the mold component 122 (i.e., the lid 1221). In detail, the lower surface of the dynamic member 124 is substantially higher than the contact surface S1 of the cover 1221.

Referring now to fig. 3, in some embodiments, a molding process may now be performed. According to some embodiments of the present disclosure, the molding apparatus 100 may further include an injection port 130, and the injection port 130 may be disposed at the lower mold 110 and/or the upper mold 120 to inject the molding material 240 into the device receiving region R1. In some embodiments, the molding material 240 may comprise a molding compound, an epoxy, a resin, or the like, although the disclosure is not so limited. In some embodiments, the upper mold 120 (e.g., sidewall 1222) may include an injection channel 128 and an injection port 126. The injection channel 128 is connected to the injection port 126 such that the molding material 240 in the injection channel 128 may be injected into the device receiving region R1 through the injection port 126 to encapsulate the semiconductor device 210.

According to some embodiments of the present disclosure, after the dynamic member 124 is moved to a first position relative to the mold member 122 (where the lower surface of the dynamic member 124 is substantially higher than the contact surface S1 of the lid 1221), the molding material 240 is then injected into the device receiving zone R1. In some embodiments, the molding material 240 may flow first to some other more spacious location (e.g., the space around the side surfaces of the semiconductor device 210) and leave a void in the defined space between the semiconductor device 210 and the substrate 220, as shown in fig. 6. The molding material 240 may be continuously injected into the device receiving region R1 until the space around the side surface of the semiconductor device 210 is substantially filled with the molding material 240, but the present disclosure does not limit the timing of stopping the injection of the molding material 240.

Referring now to fig. 6 and 7, in some embodiments, after the molding material 240 substantially fills the space around the side surfaces of the semiconductor device 210, the dynamic member 124 is moved relative to the mold member 122 in a second direction D2 ', the second direction D2 ' being opposite to the first direction D1 '. Accordingly, the dynamic member 124 moves to the second position, as shown in fig. 7, where the lower surface of the dynamic member 124 is substantially coplanar with the contact surface S1 of the cover 1221. Thus, the molding material 240 in the device receiving region R1 will be pressed by the dynamic component 124 and forced to flow into the space between the semiconductor device 210 and the substrate 220. In other words, with this arrangement, the molding material 240 is pushed and the molding material 240 is forced to completely fill the space between the semiconductor device 210 and the substrate 220.

In some embodiments, the molding material 240 is injected into the device-receiving region R1 while the dynamic member 124 is moved in the second direction D2' relative to the mold member 122, so the molding material 240 may gradually fill the space between the semiconductor device 210 and the substrate 220. That is, as the dynamic component 124 moves from the first position shown in fig. 6 to the second position shown in fig. 7, the molding material 240 is continuously injected into the device receiving region R1.

In other embodiments, the molding material 240 may not be injected into the device receiving region R1 while the dynamic member 124 is moved in the second direction D2' relative to the mold member 122. For example, the first stage is to inject the molding material 240 into the device receiving area R1 when the dynamic member 124 is moved to the first position shown in fig. 6. The injection of the molding material 240 may be stopped until the molding material 240 substantially fills the space around the side surfaces of the semiconductor device 210 (or until the top surface of the molding material 240 contacts the lower surface of the dynamic component 124). The dynamic component 124 is then moved to a second position, as shown in fig. 7, to push the molding material 240 to fill the space between the semiconductor device 210 and the substrate 220. Then, if the molding material 240 does not completely fill the device receiving region R1, a second stage of injection of the molding material 240 may be selectively performed.

With this arrangement, the molding apparatus 100 utilizes the dynamic member 124 configured to move relative to the mold member 122 to more precisely control the flow of the molding material 240 and reduce voids present in the molding material 240. According to some embodiments of the present disclosure, the dynamic component 124 is moved to a first position where the dynamic component 124 is substantially higher than the cover 1221 prior to injecting the molding material into the device receiving region R1. As such, the molding material 240 may substantially fill the device receiving region R1 (at least the space around the side surfaces of the semiconductor device 210). Next, the dynamic component 124 is moved relative to the mold component 122 to a second position, as shown in fig. 7, where the lower surface of the dynamic component 124 is substantially coplanar with the contact surface S1 of the cover 1221. Thus, the molding material 240 in the device receiving region R1 will be pushed and the molding material 240 in the device receiving region R1 will be forced to completely fill the space between the semiconductor device 210 and the substrate 220. Therefore, the mechanical strength of the molded semiconductor device (e.g., the molded semiconductor device 200 shown in fig. 11) formed by the molding apparatus 100 and the above-described manufacturing method can be improved. Furthermore, since no void is formed in the molding material 240, a delamination or a burst particle effect between the semiconductor device 210 and the substrate 220 may be avoided.

Fig. 8 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure. Referring now to fig. 8, the cover 1221 is spaced apart from the sidewall portion 1222 by the dynamic member 124, according to some embodiments of the present disclosure. In this embodiment, the dynamic component 124 is arranged in a closed loop that completely surrounds the cover 1221 and isolates the cover 1221 from the sidewall portions 1222. With this arrangement, the molding material 240 is injected into the device receiving region R1 through the injection port 130, and the molding material 240 is forced to fill the space between the semiconductor device 210 and the substrate 220 by the dynamic member 124 completely surrounding the cover 1221. Of course, the exemplary embodiments herein are merely for illustration and are not intended to limit the scope of the present disclosure.

Fig. 9 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure. It is noted that the molding apparatus 100a shown in FIG. 9 includes many features that are the same as or similar to the molding apparatus 100 disclosed above in connection with FIG. 8. For clarity and conciseness, the same or similar features are not repeated and the same or similar reference numerals denote the same or similar components. The main differences between the molding apparatus 100a shown in fig. 9 and the molding apparatus 100 disclosed above in connection with fig. 8 are set forth below.

Referring now to fig. 9, the dynamic component 124a partially surrounds the cover 1221 and the cover 1221 is partially connected to the sidewall portion 1222 according to some embodiments of the present disclosure. In some exemplary embodiments, the shape of the cover 1221 may be substantially the same as the shape of a semiconductor device (e.g., the semiconductor device 210 shown in fig. 2). In one of the embodiments, both the contact surface S1 of the cover 1221 and the upper surface of the semiconductor device 210 are rectangular in shape, while the size of the cover 1221 is slightly larger than the size of the semiconductor device 210 to cover the upper surface of the semiconductor device 210. Thus, the dynamic component 124a is arranged as an open loop surrounding at least three sides of the rectangular cover 1221, and the injection port 130 is provided at the opening of the loop (i.e., the side of the rectangular cover 1221 not surrounded by the dynamic component 124 a). With this arrangement, the molding material 240 is injected into the device receiving region R1 through the injection port 130 through the side not surrounded by the dynamic component 124a, and the molding material 240 is forced to fill the space between the semiconductor device 210 and the substrate 220 through the dynamic component 124a surrounding the rest of the lid 1221. Of course, the exemplary embodiments herein are merely for illustration and are not intended to limit the scope of the present disclosure.

Fig. 10 illustrates a top view of a molding apparatus according to some exemplary embodiments of the present disclosure. It is noted that the molding apparatus 100b shown in FIG. 10 includes many features that are the same as or similar to the molding apparatus 100 disclosed above in connection with FIG. 8. For clarity and conciseness, the same or similar features are not repeated and the same or similar reference numerals denote the same or similar components. The following sets forth the main differences between the molding apparatus 100b shown in FIG. 10 and the molding apparatus 100 disclosed above in connection with FIG. 8.

Referring now to fig. 10, the dynamic component 124b partially surrounds the cover 1221 and the cover 1221 is partially connected to the sidewall portion 1222 according to some embodiments of the present disclosure. In some exemplary embodiments, both the contact surface S1 of the cover 1221 and the upper surface of the semiconductor device 210 are rectangular in shape, while the size of the cover 1221 is slightly larger than the size of the semiconductor device 210 to cover the upper surface of the semiconductor device 210. Thus, the dynamic component 124b is arranged as an open loop surrounding at least three sides of the rectangular cover 1221, and the injection port 130 is provided at a side of the rectangular cover 1221 opposite to the opening of the loop. With this arrangement, the molding material 240 is injected into the device receiving region R1 through the injection port 130, and the molding material 240 is forced to fill the space between the semiconductor device 210 and the substrate 220 by partially surrounding the dynamic part 124b of the cover 1221. Of course, the exemplary embodiments herein are merely for illustration and are not intended to limit the scope of the present disclosure.

Fig. 11 illustrates a cross-sectional view of a molded semiconductor device according to some exemplary embodiments of the present disclosure. Fig. 12 illustrates a top view of a molded semiconductor device according to some exemplary embodiments of the present disclosure. Referring now to fig. 11 and 12, a molded semiconductor device 200 manufactured by the above-described manufacturing method and molding apparatus may include a semiconductor device 210 and a molding material 240, according to some embodiments of the present disclosure. In some embodiments, the molding material 240 encapsulates the semiconductor device 210 and an upper surface of the molding material 240 is substantially coplanar with an upper surface of the semiconductor device 210. In some embodiments, the molded semiconductor device 200 may also include a substrate 220 and a plurality of conductive terminals 230. The semiconductor device 210 is mounted on the substrate 220 through the plurality of conductive terminals 230.

According to some embodiments of the present disclosure, the molding material 240 includes a groove 242, the groove 242 at least partially surrounding an upper surface of the semiconductor device 210. Referring now to fig. 8 and 12, in the present embodiment, a molding process of molding the semiconductor device 200 shown in fig. 12 may be performed by the molding apparatus 100 shown in fig. 8. In detail, the dynamic component 124 of the molding apparatus 100 is arranged in a closed loop that completely surrounds the cover 1221 and isolates the cover 1221 from the sidewall 1222. In some embodiments, the contact surface S1 of the cover 1221 is substantially larger than the upper surface of the semiconductor device 210 to allow for tolerances (to avoid damage to the semiconductor device 210). Thus, during the molding process, the boundary between the cap 1221 and the dynamic component 124 will leave a mark (i.e., the groove 242) on the molding material 240. Thus, the molded semiconductor device 200 formed by such a molding apparatus 100 shown in fig. 8 includes a groove 242, the groove 242 being a closed loop and completely surrounding the upper surface of the semiconductor device 210, as shown in fig. 11 and 12. In addition, the groove 242 maintains a distance d1 from the boundary BD between the semiconductor device 210 and the molding material 240. For example, the distance d1 may be in the range of 200 μm to 2000 μm.

It is noted that the flip-chip semiconductor device 210 is shown herein mounted to a substrate 220, but the disclosure is not so limited. In other embodiments, other packages (e.g., Integrated fan-out (InFO) packages) suitable for use with the above-described fabrication methods and molding apparatus may also have the same or similar structural features (e.g., the recess 242 at least partially surrounding the upper surface of the semiconductor device 210).

Fig. 13 illustrates a top view of a molded semiconductor device according to some exemplary embodiments of the present disclosure. It is noted that the molded semiconductor device 200' shown in fig. 13 includes many features that are the same as or similar to the molded semiconductor device 200 disclosed above in connection with fig. 12. For clarity and conciseness, the same or similar features are not repeated and the same or similar reference numerals denote the same or similar components. The main differences between the molded semiconductor device 200' shown in fig. 13 and the molded semiconductor device 200 disclosed above in connection with fig. 12 are described below.

According to some embodiments of the present disclosure, the molding material 240 ' includes a groove 242 ', the groove 242 ' partially surrounding the upper surface of the semiconductor device 210. Referring now to fig. 9 and 13, in the present embodiment, a molding process of molding the semiconductor device 200' shown in fig. 13 may be performed by the molding apparatus 100a shown in fig. 9. In detail, the dynamic component 124a of the molding apparatus 100a is arranged in an open loop that partially surrounds the cap portion 1221. In some embodiments, the contact surface S1 of the cover 1221 is substantially larger than the upper surface of the semiconductor device 210 to allow for tolerances (to avoid damage to the semiconductor device 210). Thus, during the molding process, the boundary between the cap 1221 and the dynamic component 124a will leave a mark (i.e., the groove 242 ') on the molding material 240'. Thus, a molded semiconductor device 200 ' formed by such a molding apparatus 100a shown in fig. 9 includes a groove 242 ', the groove 242 ' being open-loop and partially surrounding the upper surface of the semiconductor device 210, as shown in fig. 13. In addition, the groove 242 'maintains a distance d1 from the boundary BD between the semiconductor device 210 and the molding material 240'. For example, the distance d1 may be in the range of 200 μm to 2000 μm. Of course, the grooves may vary depending on the configuration of the dynamic component. The present disclosure is not so limited.

Based on the above discussion, it can be seen that the present disclosure provides various advantages. However, it is to be understood that not necessarily all advantages may be discussed herein and that other embodiments may provide different advantages and that no particular advantage is required for all embodiments.

According to some embodiments of the present disclosure, a molding apparatus is configured for molding a semiconductor device and includes a lower mold and an upper mold. The lower mold is configured to carry the semiconductor device. The upper mold is disposed above the lower mold to receive the semiconductor device and the upper mold includes a mold member and a dynamic member. The mold member is configured to contact an upper surface of the semiconductor device. The dynamic member is disposed about a device receiving area of the upper mold and is configured to move relative to the mold member.

In some embodiments, a contact surface of the mold member for covering the upper surface of the semiconductor device is substantially larger than the upper surface of the semiconductor device. In some embodiments, the molding apparatus further includes an injection port disposed at the lower mold to inject molding material into the device receiving area. In some embodiments, the mold member includes a cover portion having a contact surface covering the upper surface of the semiconductor device and a sidewall portion surrounding the cover portion to define the device receiving area. In some embodiments, the cover portion is spaced apart from the sidewall portion by the dynamic component. In some embodiments, the dynamic component partially surrounds the cover portion, and the cover portion is partially connected to the sidewall portion. In some embodiments, the dynamic component is configured to move to a first position in which a lower surface of the dynamic component is substantially below a contact surface of the mold component. In some embodiments, the dynamic component is configured to move to a first position where a lower surface of the dynamic component is substantially higher than a lower surface of the mold component covering the upper surface of the semiconductor device. In some embodiments, the dynamic component is configured to move to a second position in which a lower surface of the dynamic component is substantially coplanar with a contact surface of the mold component. In some embodiments, the semiconductor device is mounted on a substrate carried by the lower mold.

According to some embodiments of the present disclosure, a method of manufacturing a molded semiconductor device includes the following steps. A semiconductor device is mounted on a substrate. A lower mold is provided to carry the semiconductor device mounted on the substrate. An upper mold is provided above the lower mold. The upper mold includes a mold member covering an upper surface of the semiconductor device and a dynamic member disposed around a device receiving area of the upper mold. Moving the dynamic component in a first direction relative to the mold component. Injecting a molding material into the device-receiving region to encapsulate the semiconductor device. Moving the dynamic component relative to the mold component in a second direction, the second direction being opposite the first direction.

In some embodiments, the dynamic component is moved in the first direction to a first position where a lower surface of the dynamic component is substantially below a contact surface of the mold member covering the upper surface of the semiconductor device. In some embodiments, the dynamic component is moved in the first direction to a first position where a lower surface of the dynamic component is substantially higher than a lower surface of the mold component covering the upper surface of the semiconductor device. In some embodiments, the dynamic component moves in the second direction to a second position where a lower surface of the dynamic component is substantially coplanar with a contact surface of the mold component. In some embodiments, the molding material is injected into the device receiving area while the dynamic member moves in the second direction relative to the mold member.

According to some embodiments of the present disclosure, a molded semiconductor device includes a semiconductor device and a molding material. The molding material encapsulates the semiconductor device, wherein an upper surface of the molding material is substantially coplanar with an upper surface of the semiconductor device and includes a groove at least partially surrounding the upper surface of the semiconductor device.

In some embodiments, the recess maintains a distance from a boundary between the semiconductor device and the molding material. In some embodiments, the molded semiconductor device further comprises a substrate and a plurality of conductive terminals, wherein the semiconductor device is mounted on the substrate by the plurality of conductive terminals. In some embodiments, the recess is a closed loop to surround the upper surface of the semiconductor device. In some embodiments, the recess is an open loop to partially surround the upper surface of the semiconductor device.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

[ description of symbols ]

100. 100a, 100 b: moulding apparatus

110: lower die

120: upper mold

122: mould part

124. 124 a: dynamic component

126: injection port

128: injection channel

130: injection port

240. 240': molding material

200. 200': molded semiconductor device

210: semiconductor device with a plurality of semiconductor chips

220: substrate

230: conductive terminal

242. 242': groove

1221: cover part

1222: side wall part

BD: boundary of

d 1: distance between two adjacent plates

D1, D1': a first direction

D2, D2': second direction

R1: device receiving area

S1: a contact surface.