Semiconductor Lead Frame Lead Stabilization

This invention relates to semiconductor devices, and more particularly to a lead frame and method for stabilizing lead frame lead spacing and lead tip planarity.

In producing delicate, high pin count lead frames with closely spaced inner leads, polyimide or kapton tape is often applied to the leads to maintain lead-to-lead spacing and to stabilize lead tip planarity. This operation is typically done after stamping or etching the lead frame, and after the lead frame is plated. The process includes indexing and precisely locating the lead frame unit and applying heat and pressure to a piece or pieces of precisely cut and located polyimide tape to one or more strips to the lead frame. This procedure is expensive, time consuming and subjects the high value added plated lead frame to additional mechanical handling and heat treatment.

The invention is to a process and semiconductor device to which a plastic stabilizer has been applied on and between the inner leads fingers of a lead frame to stabilize lead frame spacing and planarity. The plastic stabilizer consists of a plastic preform on a support base. The plastic preform and support can be an individual preform, a strip of preforms, or a plurality of preforms on a continuous roll.

A heater block is mounted on a piston or press over an anvil type surface to apply heat and pressure to the non-preform surface of the plastic preform support base. The plastic preform is pressed onto the lead frame leads. The heat causes the plastic preform to melt onto the lead frame and between the lead frame leads, adherent to the lead frame. After the plastic preform has melted onto the lead frame and then cooled, the preform base material is peeled from the molded plastic.

The support base may have index holes, notches, or other indexing means to accurately locate the preform adjacent the lead frame prior to the application of heat and pressure.

The technical advance represented by the invention as well as the objects thereof will become apparent from the following description of a preferred embodiment of the invention when considered in conjunction with the accompanying drawings, and the novel features set forth in the appended claims.

FIG. 1 is an expanded view of the apparatus of the present invention.

FIG. 2 illustrates the lead frame leads on the preform stabilizer; and

FIG. 3 illustrates the lead frame leads and preform after the preform has been heated and the lead frame leads pressed into the preform.

FIG. 1 is an expanded view of the apparatus of the invention. A lead frame 10 having leads 11 attached to mounting pad 12. Lead frame 10 includes side rails 13 having index holes 14. Side rails with index holes permits indexing a strip or continuous roll of lead framed into position for processing.

A carrier or base material 20, having preforms 21 thereon, are positioned under the lead frames 10. Each preform 21 is shaped, for example, to under lie the leads 11 in a ring or square perimeter. The exact shape of preform 21 may vary according to the shape of the lead frame, and the portion of the lead frame to be partially embedded in the preform material. In FIG. 1, the preform has four sides 22 in a square pattern such that each side 22 under lies a set of lead frame leads 11. Carrier 20 has index holes 23 along two edges. These index holes correspond to the index holes 13 in lead frame side rails 13. The carrier/preform may be individually pieces, strips or continuous rolls to correspond to the format of the lead frames.

Positioned below the carrier base 20 and preforms 21 is a support base 30. Support base 30 has index pins 31 along two sides. These pins correspond to the index holes 23 in carrier 20 and holes 14 in lead frame 10.

At the top of FIG. 1, is a heater block 40 mounted on a piston 41. Heater block may be raised and lowered in the process of the invention. A heater block also may be in the support base and the piston used only to apply pressure.

The process of the invention is as follows. A individual, strip or continuous roll of lead frames 10 are moved adjacent an individual, strip or continuous roll of preforms 20 onto support base 30. The index holes in lead frame 10 and carrier 20, 14 and 23 respectively, are aligned on index pins 31 on support base 30. Heater block is moved against a lead frame, applying heat and pressure. The applied heat causes the preform material to melt into the lead frame leads. The preform material flows between the leads encapsulating three sides of the leads, bottom and two sides. When the heater block is removed, the preform material returns to a solid state, firmly hold the leads is a fixed relationship with each other and in a common plane.

Plastic materials such as nylon or polyester may be used. Heat in the range of 150 degree C. to 250 degree C. is applied. The use of plastic materials eliminates the use of adhesives, commonly used with polyimide tapes, which may introduce ionic contaminants.

FIG. 2 illustrates the plastic preform 22 adjacent lead fame leads 11 prior to the application of heat and pressure. FIG. 3 illustrates the flowed plastic 22a around lead frame leads 11 after the application of heat and pressure.

In the given example, the preform under lies a segment of the lead fame internal leads. In practice, the preform could under lie only part of the leads and mounting pad or only part of the leads.