The components used in the method comprise a heat-dissipating base plate, one or more three-layer plates (the top layer consisting of copper plates and strips) and a one-piece frame designed to constitute the terminals. After the chips have been soldered onto the upper plates and connected to the strips, the inner ends of the frame are soldered to points of connection with the chips. This is followed by the encapsulation in resin and the shearing of the outer portions of the frame, which, during the process, serve to temporarily connect the terminals.
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20. A method for making a semiconductor package, comprising:
attaching a semiconductor device to a first surface of a substrate, said substrate having power leads on said first surface; electrically connecting said semiconductor device to said power leads; connecting selected leads of a lead frame with said power leads, said lead frame having a plurality of said leads temporarily attached to each other; and encapsulating at least portions of said selected leads and said semiconductor device.
32. A method for making a package containing at least one semiconductor device comprising:
fabricating a structure comprising an insulating layer and plural top conductive layers on said insulating layer; electrically coupling a semiconductor device to at least one of said top conductive layers so that at least some of said top conductive layers can supply power to said semiconductor device; electrically contacting plural leads to at least some of said top conductive layers; and encapsulating at least portions of said semiconductor device and said structure.
1. A method of manufacturing a modular semiconductor power device, comprising the steps of:
(a) welding semiconductor means including at least one attaching a semiconductor chip onto conductive-sheet means including at least one a sheet of an electrically conductive material; (b) forming a power-device body by fixing affixing said sheet to a member provided with a heat-dissipating metal plate for dissipating heat generated by the Joule effect and parallel to and close to said heat-dissipating plate ; (c) blanking from a single sheet of conductive material a one-piece forming a frame formed with strips adapted to form for signal and power terminals of for said device semiconductor chip, and with temporary connections between at least some of outer ends of said strips; (d) soldering selectively connecting inner ends of said strips selectively to points of said conductive sheet means connected with said semiconductor means or to said semiconductor means chip; (e) encapsulating at least active parts of said body semiconductor chip, said sheet of electrically conductive material, and said inner ends of said strips with an insulating resin and leaving said outer ends of said strips and an outer surface of said plate uncovered by said resin ; and (f) shearing removing said temporary connections from said strips.
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The use of a low-stress type of resin helps to limit the stress transmitted to the chips even in the case of chips of very large dimensions.
It is also clear that numerous modifications, adjustments, variations and substitutions may be made to the embodiments previously described by way of example, always remaining within the spirit of this invention and its scope. For example, the wires connecting the chips to the metal strips of the substrates can be by direct soldering between the inner terminal portions of the one-piece frame and the chips, whenever the latter have wettable metal coatings. These internal portions can then be soldered to points (P) of connection with the chips situated on the aforesaid plates 33 and strips 34, 35, 36 (as in the case illustrated in FIGS. 4 and 5), or situated on the same plates and on wettable metal coatings on the surface of the chips.
Likewise, the chip-supporting substrates could have a different structure from that previously described and the insulation between the chips and the dissipator could be achieved by means of a layer of the encapsulating resin itself--which in this case should be of high thermal conductivity--instead of by a layer of alumina.
Gandolfi, Luciano, Spatrisano, Antonio P., Minotti, Carlo, Di Cristina, Natale
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