Support Assembly for Integrated Circuits

1. Field of the Invention

This invention relates to an integrated circuit package and in particular to a support assembly for integrated circuit chips.

2. Description of the Prior Art

Integrated circuits (IC) generally comprise a number of gates or flip-flops that are packaged in a single IC container. The IC package provides input and output pins, pads, or leads which are connected to plated strips on circuit boards or other means to form a complete circuit of which the IC is a part. The IC chips are packaged by die attachment to paddles of lead frames. The lead frames are either stamped or etched according to the quantity to be made. In the event that a large quantity is to be produced, then stamping techniques are employed. On the other hand, if only a small quantity of frames are needed, then they may be made by slower photolithography and etching techniques. The etching techniques allow finer tolerances than the stamping method. After die attachment, the bond pads of the device are connected to the leads of the lead frame by means of a fine metallic wire. Upon completion of the chip to frame interconnection, the chip and interconnections are encompassed by the IC package.

One problem that is encountered with stamped frames is the limitation of the space between the leads and components of the IC assembly imposed by the thickness of the metallic frame. The acceptable space between leads is approximately 1.5 times the thickness of the metal, which generally is a copper sheet of about 0.008 inches thick, for example.

Therefore, the spacing between leads that is required is at least 0.012 inches. If 25 leads, by way of example, are to be provided, then a total spacing of 0.300 inches is needed. This spacing creates too large a distance between the IC device, which is located centrally on the frame, and the leads at the periphery of the frame. Therefore a lower yield in production is obtained due to excessive length of the interconnecting wires. Also, the extra length required does not allow for a compact assembly with dimensions that are required by IC technology. The problem is compounded when the number of leads is increased thus necessitating a significant increase in space of the IC and the frame leads.

On the other hand, if a relatively thin tape-like support is used, such as an 0.001 inch thick metallic sheet, the spacing requirement is substantially reduced so that the leads can be located close to the IC device. However, such thin metal tapes of this type are too flexible and are not rigid enough for assembly.

An object of this invention is to provide an improved support assembly (lead frame) for integrated circuit chips.

Another object of the invention is to provide a composite IC support which provides a needed rigidity, and realizes proper alignment of the IC device and conductive leads

Another object is to provide a support assembly for an IC package that achieves high density of the conductive bond locations of the IC device and a high pin count.

According to this invention, an IC package includes a composite support assembly formed with a rigid lead frame and a thin flexible tape-like structure. The tape-like structure is configured, preferably by etching, with inner bonding fingers, and with outer lead fingers that connect to the inner lead fingers. The lead fingers on the tape-like structure are disposed in a short pitch, high density pattern that can be formed as a result of the very thin structure of the flexible tape material. The lead frame is formed with leads that connect to the outer lead fingers of the tape-like structure and external circuitry. The composite support assembly allows the wire lengths connecting the IC chip to be shortened. As a result, the support assembly can be made with a greater number of leads and a higher pin count employing a standard size frame. Fine line definition of the high density lead fingers is realized with resultant improved accuracy and proper alignment of the tape-like structure on the lead frame.

The invention will be described in greater detail with reference to the drawings in which:

FIG. 1 is a top plan view of a support assembly for an IC chip, made in accordance with this invention;

FIG. 2 is an enlarged sectional view of a portion of the assembly of FIG. 1 including the IC chip and package;

FIG. 3 is a side sectional view of a support assembly for an IC chip incorporating the flexible tape-like structure and rigid lead frame assembly of this invention with the IC chip and package; and

FIGS. 4A-4H illustrate the process steps of assembling the composite IC assembly.

Similar numerals refer to similar elements throughout the drawings.

With reference to FIG. 1, a composite support assembly (lead frame) for an IC chip 10 includes a flexible tape-like structure 14 that is joined to a rigid lead frame 12. The tape-like structure, which is preferably made of a thin copper sheet of about 0.001 inch in thickness and a dielectric film 30 of about 0.003 inch in thickness, is configured by well known photolithography and etching processes. The lead frame is preferably made as an integral piece that has been mass produced by stamping. The lead frame is formed from a rigid copper plate, about 0.008 inch in thickness.

As illustrated in FIGS. 2 and 3, the thin tape-like structure 14 is configured with inner lead fingers 16 that are electrically connected by bond wires 18 to bond pads 20 formed on an exposed surface of the IC chip 10. opposing surface of the IC chip is attached to the tape-like structure 14 through a die attach pad 22. The tape-like structure 14 is formed with outer lead fingers 24 that extend from the inner lead fingers 16 to make contact with coupling lead bonds 26, thereby providing a continuous conductive path from the integrated circuit to external package leads 28. The assembly including the structure 14 and frame 12 is housed in a package or module 32. As a result of the constricted geometry and the necessity for closely spaced patterned elements, including the lead fingers, manufacture of an IC package 32 with a relatively large number of lead fingers would be extremely difficult when employing conventional IC packaged designs. The use of a thin tape-like structure to enable the shaping of the closely spaced lead fingers with fine definition, in combination with the lead frame 12 to provide rigidity, overcomes the difficulties encountered in the prior art. Etching of a thin structure to obtain a desired pattern affords finer tolerances and better line delineation, which allows a short pitch, high density arrangement of the etched elements, including the conductive lead fingers.

During production, the flexible tape-like structure 14 and the rigid lead frame 12 are positioned in a bonder apparatus comprising a stripper 34, a thermode 36 and a punch 38 (FIGS. 4A, 4B). The outer lead fingers 24 of the tape-like structure are aligned with respective coupling lead bonds 26. The punch separates a tape unit 14A from the tape strip, and the tape unit is moved into contact with the frame 12 (FIG. 4C). The tape unit is welded to the frame by the application of heat from the thermode, i.e. thermocompression bonding or eutectic bonding. The thermode and the punch are then returned to the home position, and the assembly of the lead frame with the tape unit is advanced, enabling repetition of the assembly process (FIG. 4E).

An IC device 10 is then mounted on the composite frame and tape unit assembly 40 (FIG. 4F), and the IC device is wire bonded to the composite frame (FIG. 4G). Finally, the assembly of the bonded device and the frame 12 is encapsulated to form an IC package 32 (FIG. 4H).

The composite IC support assembly allows a high pin count with accurate definition of the connecting lead fingers. By virtue of the design of the assembly disclosed herein, production yield is significantly increased and manufacturing costs are reduced. Since the outer and inner lead fingers can be brought closer to the IC chip, the bond wires between the chip and the inner lead fingers are shortened. As a result, a relatively high number of leads can be incorporated in an IC package design. In successful implementations, packages having 68 leads and 132 leads were made employing a standard package mold. The support assembly design virtually eliminates losses of IC assemblies and production resulting from high temperature processing by mechanical forces, such as experienced in previous approaches to manufacture IC packages. It will be apparent to one skilled in the art that it is not necessary to employ the materials and thicknesses of the frame and tape-like structure given as examples herein. It is understood that various modifications may be made without departing from the spirit and scope of the instant invention.