Ball grid array to pin grid array conversion
View Patent ↗Ball grid array to pin grid array conversion methods are provided. An example method can include coupling a plurality of solder balls to a respective plurality of pin grid array contact pads. Each of the plurality of solder balls is encapsulated in a fixed material. A portion of the plurality of solder balls and a portion of the fixed material is removed to provide a plurality of exposed solder balls. The exposed solder balls are softened and each of a plurality of pin members is inserted in a softened, exposed, solder ball. The plurality of pin members forms a pin grid array package.
1. A method of making a pin grid array package, comprising:
affixing a solder ball to a contact pad of a ball grid array package;
encapsulating the solder ball within a fixed material;
forming a planar surface that includes a surface of each of the solder ball and a surface of the fixed material;
softening the solder ball;
inserting a pin member into the softened solder ball;
cooling the solder ball to rigidly affix the pin member to the solder ball to provide a pin grid array assembly; and
separating the pin grid array assembly into a plurality of individual pin grid array packages to provide discrete pin grid array packages.
2. The method of claim 1 wherein encapsulating the solder ball within the fixed material comprises:
disposing a thermosetting mold compound around the solder ball; and
curing the thermosetting mold compound to provide the fixed material encapsulating the solder ball.
3. The method of claim 1 wherein softening the solder ball comprises:
selectively heating the solder ball to increase a temperature of the solder ball to slightly less than a melting point of the solder ball.
4. The method of claim 1 wherein softening the solder ball comprises:
selectively heating the solder ball to increase a temperature of the solder ball to at least a melting point of the solder ball.
5. The method of claim 1 wherein inserting the pin member into the softened solder ball comprises:
increasing a temperature of at least a portion of the pin member to at least a melting point of the solder ball; and
inserting the increased temperature portion of the pin member into the softened solder ball.
6. The method of claim 1 wherein cooling the solder ball to rigidly affix the pin member to the solder ball comprises:
selectively cooling the pin member and the solder ball at a rate promoting the formation of a fillet between the solder ball and the pin member.
7. A pin grid array package, comprising:
an integrated circuit having a plurality of contact pads thereon;
an insulating layer adjacent the integrated circuit;
a plurality of solder balls formed as a ball grid array, each surrounded by a fixed material and coupled to a respective contact pad of the integrated circuit, a surface of the fixed material and a surface of each of the plurality of solder balls being coplanar;
a plurality of pin members having a first end inserted within each of the plurality of solder balls, respectively and a fillet formed between each of the plurality of pin members and the respective solder ball into which the pin member has been inserted.
8. The pin grid array package of claim 7 wherein the fixed material comprises:
a thermosetting mold compound bonded about the contact pads of the ball grid array.
9. A method of converting a ball grid array package to a pin grid array package, comprising:
encapsulating a plurality of solder balls of the ball grid array package with encapsulation material;
forming a planar surface that includes a surface of each of the plurality of solder balls and a surface of the encapsulation material;
softening the plurality of solder balls;
inserting a respective pin member into each of the plurality solder balls to form a pin grid array assembly; and
separating the pin grid array assembly into a plurality of individual pin grid array packages to provide discrete pin grid array packages.
10. The method of claim 9 wherein softening the plurality of solder balls comprises:
exposing the solder balls to a forced air convection heater or an infrared heater.
11. The method of claim 9 wherein softening the plurality of solder balls comprises:
increasing a temperature of the plurality of solder balls the temperature approximately equal to a melting temperature of the solder ball.
12. The method of claim 9 , further comprising:
increasing a temperature of the plurality of pin members to a temperature exceeding a melting temperature of the plurality of solder balls prior to inserting the respective pin member into each of the plurality of solder balls.