Semiconductor device having improved contact interface reliability and method therefor

1. A semiconductor package assembly comprising:

a first semiconductor package;

a plurality of first solder balls attached to a first surface of the first semiconductor package;

a circuit board having a plurality of mounting pads that is electrically connected to the plurality of first solder balls;

a plurality of vias formed through the circuit board;

a first underfill disposed between gaps of each of the plurality of first solder balls creating a void between at least two adjacent first solder balls;

a plurality of second solder balls attached to a second surface of the first semiconductor package; and

a second underfill disposed between gaps of each of the plurality of second solder balls creating a void between at least two adjacent second solder balls;

wherein the first semiconductor package comprises:

a first substrate having a first surface and a second surface, wherein a plurality of first conductive patterns is formed on the first surface of the first substrate and a plurality of second conductive patterns is formed on the second surface of the first substrate;

a first semiconductor die attached to the first surface of the substrate;

at least one first electrically conductive wire connecting at least one first conductive pattern and the first semiconductor die;

a first encapsulant surrounding a periphery of the first electrically conductive wire and the first semiconductor die;

wherein the plurality of first solder balls is electrically connected to at least one second conductive pattern;

at least one third conductive pattern being formed on a periphery of the first encapsulant on the first surface of the first substrate;

a second semiconductor package electrically connected to the third conductive pattern, wherein the second semiconductor package comprises:

a second substrate having a first surface and a second surface, wherein a plurality of fourth conductive patterns is formed on the first surface and a plurality of fifth conductive patterns is formed on the second surface of the second substrate;

a second semiconductor die attached to the first surface of the second substrate;

at least one second electrically conductive wire electrically connecting at least one fourth conductive pattern and the second semiconductor die; and

a second encapsulant being surrounding a periphery of the second electrically conductive wire and the second semiconductor die;

wherein the plurality of second solder balls is electrically connected to at least one third conductive pattern, and at least one fifth conductive pattern;

wherein the first underfill has been removed above a first group of the plurality of vias.

2. A semiconductor package assembly in accordance with claim 1 , wherein the first underfill comprises:

a first region formed between the surface of each first solder ball and the first substrate;

a second region formed between the surface of each first solder ball and the circuit board; and

a third region formed between the first region and the second region that covers an approximately central portion of the surface of each first solder ball;

wherein the first region and the second region are formed to have a wider vertical cross-sectional than the third region.

3. A semiconductor package assembly in accordance with claim 1 , wherein the first underfill forms an approximate sandglass shape on each of the plurality of first solder balls.

4. A semiconductor package assembly in accordance with claim 3 , wherein the first underfill comprises one of: an epoxy resin, a thermosetting resin, a polymer, or combinations thereof.

5. A semiconductor package assembly in accordance with claim 1 , further comprising at least one through via formed through the circuit board.

6. A semiconductor package assembly in accordance with claim 1 , wherein the second underfill comprises:

a first region formed between each of the plurality of second solder balls and the second substrate;

a second region formed between each of the plurality of second solder balls and the first substrate; and

a third region formed between the first region and the second region and covers an approximately central portion of the surface of each of the plurality of second solder balls;

wherein the first region and the second region are formed to have a relatively wider vertical cross-sectional area than the third region.

7. A semiconductor package assembly in accordance with claim 1 , wherein the second underfill forms an approximate sandglass shape on each of the plurality of second solder balls.

8. A semiconductor package assembly in accordance with claim 1 , wherein the second underfill comprises one of: an epoxy resin, a thermosetting resin, a polymer, or combinations thereof.

9. A semiconductor package assembly in accordance with claim 1 , wherein the first semiconductor package is a wafer level chip scale package.

10. A semiconductor package assembly in accordance with claim 1 , wherein the first group of the plurality of vias is positioned under the first semiconductor package and are suction vias to remove the first underfill from above the first group of the plurality of vias.

11. A semiconductor package assembly in accordance with claim 10 , wherein a second group of the plurality of vias is positioned on an outer perimeter of the circuit board outside a width of the first semiconductor package and the second semiconductor package.