Integrated circuit packaging system with package underfill and method of manufacture thereof

1. A method of manufacturing an integrated circuit packaging system comprising:

providing a sacrificial carrier assembly having a stack interconnector thereover;

mounting an integrated circuit having a connector over the sacrificial carrier assembly with the connector over the stack interconnector;

dispensing an underfill material between the sacrificial carrier assembly and the integrated circuit with the underfill material substantially free of a void, the underfill material applied entirely over the sacrificial carrier assembly with a uniform distribution;

encapsulating the integrated circuit over the sacrificial carrier assembly and the underfill material with an encapsulating material, the encapsulating material having a different material composition than the underfill material;

exposing the stack interconnector by removing the sacrificial carrier assembly; and

forming a base array including a resistive circuit, a routing trace, and a film layer over the underfill material and the stack including:

layering the routing trace on the stack interconnector, and

applying the film layer over and surrounding the routing trace.

2. The method of claim 1 , wherein dispensing the underfill material between the sacrificial carrier assembly and the integrated circuit with the underfill material substantially free of the void includes:

dispensing an underfill material over the sacrificial carrier assembly; and

rotating the sacrificial carrier assembly with the underfill material and the integrated circuit.

3. The method of claim 1 , wherein dispensing the underfill material between the sacrificial carrier assembly and the integrated circuit with the underfill material substantially free of the void includes:

dispensing an underfill material along an interior area of the integrated circuit; and

surrounding the connector with the underfill material.

4. The method of claim 1 , wherein forming the base array including the resistive circuit over the underfill material and the stack interconnector includes building up a film inductor in the base array.

5. A method of manufacturing an integrated circuit packaging system comprising:

providing a sacrificial carrier assembly having a stack interconnector thereover;

mounting an integrated circuit having a connector over the sacrificial carrier assembly with the connector over the stack interconnector;

dispensing an underfill material between the sacrificial carrier assembly and the integrated circuit with the underfill material substantially free of a void, the underfill material applied entirely over the sacrificial carrier assembly with a uniform distribution;

encapsulating the integrated circuit over the sacrificial carrier assembly and the underfill material with an encapsulating material, the encapsulating material having a different material composition than the underfill material;

exposing the stack interconnector by removing the sacrificial carrier assembly;

forming a base array having a routing trace, a resistive circuit, and a film layer over the underfill material and the stack interconnector, including:

layering the routing trace on the stack interconnector, and

applying the film layer over and surrounding the routing trace;

forming a base by singulation of the base array; and

attaching a system interconnector to the routing trace or the film layer of the base.

6. The method of claim 5 , wherein encapsulating the integrated circuit over the sacrificial carrier assembly and the underfill material with the encapsulating material includes surrounding the integrated circuit and the underfill material with the encapsulating material.

7. The method of claim 5 , wherein encapsulating the integrated circuit over the sacrificial carrier assembly and the underfill material with the encapsulating material includes exposing the underfill material.

8. The method of claim 5 , wherein forming the base array having the routing trace, the resistive circuit, and the film layer over the underfill material and the stack interconnect includes forming a film inductor.

9. The method of claim 5 , wherein forming the base array having the routing trace, the resistive circuit, and the film layer over the underfill material and the stack interconnect includes forming a dielectric over the underfill material and the stack interconnector.

10. A method of manufacturing an integrated circuit packaging system, the method comprising:

(a) providing a stack interconnector;

(b) forming an integrated circuit having a connector over the stack interconnector;

(c) forming a base, having a first side, a second side, a routing trace, and a film layer on the stack interconnector, including:

layering the routing trace on the stack interconnector, and

applying the film layer over and surrounding the routing trace;

(d) dispensing an underfill material substantially free of void and with a substantially uniform distribution between the base and the integrated circuit;

(e) depositing an encapsulant material over the integrated circuit, the encapsulant material having a different material composition than the underfill material; and

(f) attaching a system interconnector to the second side of the base.

11. The method of claim 10 , wherein step (b) further includes forming a flip chip over the stack interconnector.

12. The method of claim 10 , wherein step (d) is operable to prevent delamination of the integrated circuit.

13. The method of claim 10 , wherein step (d) includes having at least a portion of the integrated circuit within the underfill material.

14. The method of claim 10 , wherein step (d) includes applying the underfill material across the entire first side of the base.

15. The method of claim 10 , wherein step (d) includes surrounding the connector with the underfill material.

16. The method of claim 10 , wherein step (e) includes surrounding the integrated circuit and the underfill material with the encapsulant material.

17. The method of claim 10 , wherein step (e) includes exposing the underfill material.

18. The method of claim 10 , wherein step (c) further includes forming the routing trace between the first side and the second side such that the underfill material surrounds the connector and the encapsulant material is over the first side.

19. The method of claim 18 , wherein step (d) includes dispensing the underfill material having an underfill non-horizontal side, and wherein step (e) includes depositing the encapsulant material having an encapsulant non-horizontal side, wherein the underfill non-horizontal side is coplanar with the encapsulant non-horizontal side.