HK1168195B - Connector assembly and method of manufacture - Google Patents

Description

Connector assembly and method of manufacture

Technical Field

The present invention relates generally to the field of electronics, and more particularly to connector assemblies.

Background

In the past, the semiconductor industry fabricated semiconductor parts that contained individual semiconductor dies within a protective structure (e.g., a molding compound). Various types of semiconductor components are mounted on printed circuit boards that contain interconnect structures that allow the semiconductor components to communicate with each other. As the demand for more functions in electronic devices increases, it is desirable to include more semiconductor components on printed circuit boards. Thus, semiconductor manufacturers are constantly striving to produce semiconductor components having smaller profiles and mounting footprints.

In some embodiments, the semiconductor dies are stacked vertically above each other with an intervening layer of adhesive material attached to the semiconductor dies for bonding the dies together to form a multi-chip or multi-die structure. The multi-chip structure is attached to a printed circuit board substrate of the glass resin type or other similar substrate. The semiconductor die is then wire bonded to the substrate to form an electrical interconnection between the substrate and the semiconductor die. One example of such a package structure is disclosed in U.S. patent No.6,650,019 to thomas b. glenn et al, at 18.11.2003. One example of an electronic assembly having stacked integrated circuit dies is disclosed in U.S. patent No.7,030,317 to toddp.oman, 2006, 4, 18.

Disadvantages of stacking semiconductor dies include forming electrical interconnections between semiconductor dies and removing heat from the stacked structure.

It would therefore be advantageous to have a connector assembly suitable for transmitting electrical signals between a semiconductor die and a semiconductor part and providing sufficient heat dissipation of the semiconductor die. It is advantageous that the electronic assembly and the method are cost and time efficient to implement.

Drawings

The present invention will be better understood from a reading of the following detailed description in conjunction with the drawings in which like reference designators refer to like elements, and in which:

FIG. 1 is a side view of a portion of a connector assembly according to an embodiment of the present invention;

FIG. 2 is a side view of a portion of a connector assembly according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view of a portion of a connector assembly according to an embodiment of the present invention;

FIG. 4 is a side view of a portion of a connector assembly according to an embodiment of the present invention;

FIG. 5 is a top view of a portion of the connector assembly of FIG. 4;

FIG. 6 is an isometric view of a connector assembly according to an embodiment of the present invention;

FIG. 7 is an isometric view of the connector assembly of FIG. 6 in an inverted orientation relative to that shown in FIG. 6;

FIG. 8 is a side view of the connector assembly of FIGS. 6 and 7;

fig. 9 is an isometric view of a connector assembly according to an embodiment of the present invention;

FIG. 10 is an isometric view of the connector assembly of FIG. 9 in an inverted orientation relative to the orientation shown in FIG. 9;

FIG. 11 is an isometric view of a connector assembly according to an embodiment of the present invention;

FIG. 12 is an isometric view of the connector assembly of FIG. 11 in an inverted orientation relative to the orientation shown in FIG. 11; and

fig. 13 is an isometric view of a connector assembly according to an embodiment of the present invention.

Detailed Description

Generally, the present invention provides connector assemblies and methods for manufacturing connector assemblies. According to an embodiment of the present invention, a connector assembly includes an electrical connector having opposing surfaces and opposing ends. The central region is located between the opposing ends. An electrically insulating material is formed on one surface in one end of the electrical connector. Alternatively, the electrically insulating material can be formed on opposing surfaces in the first and second end portions.

Fig. 1 is a side view of a connector assembly 400 according to an embodiment of the present invention. Shown in fig. 1 is a rectangular shaped electrical connector 402, the electrical connector 402 having opposing surfaces 404 and 406, end regions or portions 408 and 412, and a central region or portion 410. For example, the electrical connector 402 comprises copper. Other suitable materials for the electrical connector 402 include aluminum, tin, steel, noble metal coated metal clips, copper alloys, beryllium, gold, silver, aluminum alloys, brass alloys, and the like. The electrical connectors 402 may be etched or cut from, for example, a copper sheet having a thickness in the range of about 150 to about 250 micrometers (μm).

A layer of electrically insulating material 414 having a thickness in the range of about 50 to about 100 μm is formed on surface 404 in end region 412. Electrically insulating material 414 may be alumina, nitride, thermal insulating material, ceramic, or the like. Alternatively, the surface 404 in the region 412 may be anodized.

Fig. 2 is a side view of a connector assembly 416 according to another embodiment of the present invention. The connector assembly 416 is similar to the connector assembly 400, but includes a layer of electrically insulating material 418 formed on the surface 406 in the end region 412. Electrically insulating material 418 may be the same as electrically insulating material 414 or it may be different from electrically insulating material 414. Alternatively, the surfaces 404 and 406 in the end region 412 may be anodized.

Fig. 3 is a cross-sectional view of a connector assembly 420 according to another embodiment of the present invention. Shown in fig. 3 is a substrate 422 having opposing surfaces 424 and 426, end regions or portions 428 and 432, and a central region or portion 430. The substrate 422 is preferably formed of a resin (e.g., epoxy, polyimide, triazine, or phenolic resin), Bismaleimide Triazine (BT) resin, epoxy glass composite, Printed Circuit Board (PCB) material, FR-4, ceramic, or the like. Alternatively, substrate 22 may comprise a flexible sheet material or a selectively anodized aluminum substrate. A conductive interconnect layer 434 is formed in the substrate 422. A conductive contact 436 is formed in contact with a portion of the interconnect layer 434 in the end region 428 and a conductive contact 438 is formed in contact with a portion of the interconnect layer 434 in the end region 432. The conductive contacts 436 and 438 can be formed by patterning conductive platinum using photolithographic techniques, screen printing, deposition on portions of the interconnect layer 434 in the end regions 428 and 432, and the like.

Although connector assembly 420 is shown with conductive contacts 436 and 438 in end regions 428 and 432, respectively, the invention is not so limited. Alternatively, the conductive contact 438 may not be present in the end region 432 or the conductive contact 436 may not be present in the end region 428.

Fig. 4 is a side view of a connector assembly 440 according to another embodiment of the present invention. Shown in fig. 4 is a rectangular shaped electrical connector 442 having opposing surfaces 444 and 446, end regions or portions 448 and 452, and a central region or portion 450. For example, the electrical connector 442 comprises copper. Other suitable materials for electrical connector 442 include aluminum, tin, steel, noble metal coated metal clips, copper alloys, beryllium, gold, silver, aluminum alloys, brass alloys, and the like. The electrical connector 442 may be etched or cut from, for example, a copper sheet having a thickness ranging from about 150 to about 200 μm and stamped or embossed such that the end region 448 is at the level identified by dashed line 456 and the end region 452 is at the level identified by dashed line 457. Preferably, the horizontal planes 456 and 458 are vertically spaced apart from each other.

A layer of electrically insulating material 454 having a thickness in the range of about 50 to about 100 μm is formed on a portion of surface 446 in end region 452. Alternatively, the layer of electrically insulating material 454 can be formed on substantially all portions of the surface 446 in the end region 452. Electrically insulating material 454 may be alumina, nitride, thermal insulating material, ceramic, or the like. Alternatively, the surface 446 in the region 452 may be anodized.

Fig. 5 is a top view of the embodiment of the connector assembly 440 shown in fig. 4. Shown in fig. 5 is an electrical connector 442 having a surface 444 and end regions 448 and 452 interconnected by a central region 450. A notch 460 extends into the end region 452 from the terminus of the end region 452. The portion of electrical connector 442 into which recess 460 extends may be referred to as a body region. The area where the end region 448 meets the central region 450 is identified by dashed line 462 and the area where the end region 450 meets the end region 452 is identified by dashed line 464.

It should be noted that the notch 460 is optional and may not be present in the electrical connector 440.

Fig. 6-8 illustrate a connector assembly 470 according to another embodiment of the present invention. Fig. 6 and 7 are isometric views of the connector assembly 470 and fig. 8 is a side view of the connector assembly 470. For clarity, fig. 6-8 will be described together. Shown in fig. 6-8 is a connector assembly 470 including an electrical connector 472, the electrical connector 472 having opposing surfaces 474 and 476, end regions or portions 478 and 482, and a central region or portion 480. For example, the electrical connector 472 comprises copper. Other suitable materials for electrical connector 472 include aluminum, tin, steel, noble metal coated metal clips, copper alloys, beryllium, gold, silver, aluminum alloys, brass alloys, and the like. Electrical connector 472 can be etched or cut from, for example, a copper sheet having a thickness in the range of about 150 to about 200 micrometers (μm) and stamped or embossed such that end region 478 is at a level identified by dashed line 486 and end region 482 is at a level identified by dashed line 488. Preferably, the horizontal planes in which dashed lines 486 and 488 are located are vertically spaced from each other.

The central region 480 includes end sub-regions 490 and 494 connected together by a central sub-region 492. The end 496 of the sub-region 490 meets the end region 478 and the end 498 of the sub-region 490 meets the end 500 of the central sub-region 492. The end 502 of the central sub-region 492 meets the end 504 of the sub-region 494 and the end 506 of the sub-region 494 meets the end 508 of the end region 482. The central sub-region 492 is located at a horizontal plane identified by the dashed line 510. Preferably, the dashed horizontal plane in which the central sub-region 492 is located is between and spaced from the horizontal planes in which the dashed lines 486 and 488 are located, i.e., the horizontal plane in which the central sub-region 492 is located is between and spaced vertically from the horizontal plane dashed lines 486 and 488 in which the end regions are located.

A layer of electrically insulating material 512 having a thickness in the range of about 50 to about 100 μm is formed on a portion of surface 474 in end region 482. Alternatively, the layer of electrically insulating material 512 may be formed on substantially all of surface 474 in end region 482. Electrically insulating material 512 may be alumina, nitride, thermal insulation material, ceramic, or the like. Alternatively, electrically insulating layer 512 may not be present and may anodize a portion or all of surface 474 in region 482.

The notch 514 extends into the end region 482. The portion of electrical connector 472 into which recess 514 extends may be referred to as a body region.

Fig. 9 is an isometric view of a connector assembly 470A in which the notch 514 is not present. Reference numeral "a" has been appended to reference numeral 470 to distinguish a connector assembly having a notch from a connector assembly without a notch.

Fig. 10 is an isometric view of connector assembly 470A in which a layer of electrically insulative material 512A is formed on surface 474 in end region 482. Alternatively, the layer of electrically insulating material 512 may not be present in the connector assembly 470A shown in fig. 9 and 10 and the surface 474 in the end region 482 is anodized.

Fig. 11 and 12 are isometric views of a connector assembly 520 including an electrical connector 522 according to another embodiment of the present invention. The electrical connector 522 has opposite surfaces 524 and 526, end regions or portions 528 and 532, and a central region or portion 530 and comprises aluminum. The surface 526 in the end region 532 is anodized to form an aluminum oxide layer 534 having a thickness in the range of about 50 to about 100 μm. It should be noted that a portion of surface 526 in end region 532 may be anodized or substantially the entire surface 526 in end region 532 may be anodized.

Fig. 13 is an isometric view of a connector assembly 550 according to another embodiment of the invention. Shown in fig. 12 is a connector assembly 550 including an electrical connector 472, the electrical connector 472 having opposing surfaces 474 and 476, end regions or portions 478 and 482, and a central region or portion 480. The electrical connector 472 has been described with reference to fig. 6-8.

A layer of electrically insulating material 552 having a thickness in the range of about 50 to about 100 μm is formed on surface 476 in end region 482. Electrically insulating material 552 may be alumina, nitride, thermal insulating material, ceramic, or the like. Alternatively, surface 474 in region 482 may be anodized. According to an embodiment in which the electrical connector 472 is aluminum, the anodized surface 474 is formed of aluminum oxide from the surface 474.

Electrical connector 472A is coupled with electrical insulation 552 to form connector assembly 550. More particularly, surface 474 is in end region 482. Reference numeral "a" has been appended to reference numeral 472 to distinguish the two electrical connectors forming the connector assembly 550. The present invention is not limited to the number of electrical connectors 472 stacked on top of each other to form a connector assembly.

It should be appreciated that there has thus been provided a connector assembly and a method for manufacturing a connector assembly. According to an embodiment of the present invention, a connector assembly includes an electrical connector having opposing ends and opposing surfaces. The electrically insulating material may be formed on portions of one or both surfaces in one or both ends of the electrical connector. The connector assembly may be used to form a semiconductor part having stacked semiconductor dies. The connector assembly enables the stacking of semiconductor dies thereby reducing the footprint on the printed circuit board and allowing for efficient heat removal from the semiconductor parts.

Although specific embodiments have been disclosed herein, it is not intended that the invention be limited to the disclosed embodiments. Those skilled in the art will appreciate that modifications and variations can be made without departing from the spirit of the invention. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims (9)

1. A connector assembly comprising:

a first electrical connector having first and second ends and first and second surfaces;

a first electrically insulating material on the first surface of the first end, wherein the first electrically insulating material is an electrically insulating material selected from the group of electrically insulating materials comprising ceramics, nitrides, and metal-based oxides; and

a second electrically insulating material on the second surface of the first end.

2. The connector assembly of claim 1, wherein the first electrical connector comprises a conductive material.

3. The connector assembly of claim 1, wherein the first electrically insulative material is a metal-based oxide.

4. The connector assembly of claim 1, wherein the first electrical connector has first, second, and third portions, the first portion being coupled to the third portion by the second portion, and wherein the first portion is located at a first horizontal plane and the third portion is located at a second horizontal plane.

5. The connector assembly of claim 4, wherein the second portion comprises:

first, second, and third sub-portions, the first sub-portion being coupled to the third sub-portion through the second sub-portion, the second sub-portion being located at a third horizontal plane, the third horizontal plane being vertically located between the first and second horizontal planes.

6. The connector assembly of claim 1, wherein the first electrical connector has first, second, and third portions, the first portion being coupled with the third portion by the second portion, and wherein the third portion is planar, has a body portion, an end portion, and a notch extending into the body portion from the end portion, and further comprising: a second electrical connector coupled with the first electrically insulating material over the first surface of the first end of the first electrical connector.

7. A method for manufacturing a connector assembly, comprising:

providing a first electrical connector having first and second surfaces and first and second ends, wherein providing the first electrical connector comprises: forming the first electrical connector to have a first end at a first level and a second end at a second level;

forming a first electrically insulating material over a portion of the first surface of the first end, wherein the first electrically insulating material is an electrically insulating material selected from the group of electrically insulating materials comprising ceramics, nitrides, and oxides; and

a second electrically insulative material is formed over a portion of the second surface of the first end.

8. The method of claim 7, wherein providing the first electrical connector comprises:

the first electrical connector is formed such that the first end is located at a first level and the second end is located at a second level.

9. The method of claim 8, wherein providing the first electrical connector comprises: forming the first electrical connector such that a central region is located between the first and second ends, wherein the central region includes a portion at a third level, the third level being located between the first and second levels, and the method further comprises: coupling a second electrical connector with the electrically insulating material over the portion of the first surface of the first end of the first electrical connector.