Overmolded FC-SiP for miniaturized devices

The degree of integration of modern circuits has gone from singledie towards multi-die or even system partition integration. System-In-Package concepts allow to integrate in a hybrid form circuit components steming from different manufacturing processes e.g. CMOS, GaAs, MEMS as well as SMD chips. Combining Flip Chip technology, advanced PCB manufacturing, advanced assembly processes and large area overmolding, highly integrated and reliable sub-systems can be created. The paper describes the individual process steps for a GSM-Power Amplifier module, integrating the PA as a flip chip with the matching SMD components into a novel QFN concept featuring a laser structured bump-on-pad interconnect technology. Large area overmolding covers and protects the entire subsystem thus created. Manufacturing issues as well as specific fabrication details are highlighted and a reliability test shows the performance of the concept under harsh environmental load.