Method for making semiconductor device with lead frame made from top and bottom components and related devices

1. A method for making a semiconductor device comprising:

providing a top lead frame component having a first major surface and a second major surface opposite to the first major surface, the top lead frame component having a plurality of holes extending completely through the top lead frame component from the first major surface to the second major surface;

directly bonding the top lead frame component with a bottom lead frame component to form a lead frame, the top and bottom lead frame components each comprising metal;

mounting at least one integrated circuit (IC) on the lead frame;

encapsulating, with encapsulation material, the at least one IC and the lead frame, wherein each of the plurality of holes defines mold anchoring tabs extending laterally inwardly at an upper region of the top lead frame component and into the encapsulation material, wherein the forming of the top lead frame component comprises etching to define the plurality of holes; and

removing portions of the bottom lead frame component to define a plurality of contacts for the at least one IC.

2. The method of claim 1 , wherein each of the plurality of holes extends through the top lead frame component.

3. The method of claim 1 , wherein the bonding comprises bonding the top and bottom lead frame components together without an adhesive.

4. The method of claim 1 , wherein the bonding comprises at least one of hot rolling and press bonding.

5. The method of claim 1 , wherein the metal comprises copper.

6. The method of claim 1 , wherein the removing of the bottom lead frame component comprises etching so that each contact extends past the encapsulation material.

7. A method for making a semiconductor device comprising:

forming a top lead frame component to have a plurality of holes and with each hole defining mold anchoring tabs extending laterally inwardly at an upper region of the top lead frame component, the top lead frame component having a first major surface and a second major surface opposite to the first major surface, the plurality of holes extending completely through the top lead frame component from the first major surface to the second major surface;

after the forming, directly bonding the top lead frame component with a bottom lead frame component to form a lead frame, the top and bottom lead frame components each comprising copper, the bottom lead frame component forming a bottom surface of the plurality of holes, the top lead frame component forming sidewalls of the plurality of holes, the top lead frame component physically contacting the bottom lead frame component;

mounting at least one integrated circuit (IC) on the lead frame, the IC coupled to pads on a major surface of the top lead frame;

encapsulating, with encapsulation material, the at least one IC and the lead frame, the mold anchoring tabs extending laterally inwardly into the encapsulation material; and

removing portions of the bottom lead frame component to define a plurality of contacts for the at least one IC, the plurality of contacts extending vertically past a bottom surface of the encapsulation material.

8. The method of claim 7 , wherein the forming of the top lead frame component comprises partial etching to define the plurality of holes.

9. The method of claim 7 , wherein each of the plurality of holes extends through the top lead frame component.

10. The method of claim 7 , wherein the bonding comprises bonding the top and bottom lead frame components together without an adhesive.

11. The method of claim 7 , wherein the bonding comprises at least one of hot rolling and press bonding.

12. The method of claim 7 , wherein the removing of the bottom lead frame component comprises etching so that each contact extends past the encapsulation material.

13. The method of claim 1 , wherein each mold anchoring tab comprises:

a curved sidewall;

a lowermost region; and

an upper region extending in a lateral direction into the encapsulation material, the curved sidewall extending between the lowermost region and the upper region, the lateral direction being parallel to a major surface of the top lead frame component, the upper region extending beyond the lowermost region along the lateral direction.

14. The method of claim 7 , wherein each mold anchoring tab comprises:

a curved sidewall;

a lowermost region; and

an upper region extending n a lateral direction into the encapsulation material, the curved sidewall extending between the lowermost region and the upper region, the lateral direction being parallel to a major surface of the top lead frame component, the upper region extending beyond the lowermost region along the lateral direction.

15. The method of claim 1 , wherein the etching is performed before the direct bonding of the top lead frame component and the bottom lead frame component.

16. The method of claim 8 , wherein the etching is performed before the direct bonding of the top lead frame component and the bottom lead frame component.

17. The method of claim 1 , further comprising mounting the lead frame on a printed circuit board.

18. The method of claim 7 , further comprising mounting the lead frame on a printed circuit board.

19. The method of claim 7 , wherein the forming of the top lead frame component comprises partial etching to define the plurality of holes.

20. A method for making a semiconductor device comprising:

providing a top lead frame component and a bottom lead frame component physically separate from the top lead frame component;

forming through holes in the top lead frame component, wherein each of the through holes comprises a first sidewall, an opposite second sidewall;

after forming the through holes, attaching the top lead frame component with the bottom lead frame component to form a lead frame, the bottom lead frame component forming a bottom surface of the through holes after the attaching;

mounting an integrated circuit (IC) on the lead frame;

encapsulating the IC and the lead frame, the encapsulating completely filling the through holes with an encapsulant material; and

removing portions of the bottom lead frame component to form contacts of the lead frame for the IC, wherein the removing is stopped after removing the bottom surface of the through holes to expose the encapsulant material.

21. The method of claim 20 , wherein the through holes comprise a first opening size at a first surface, wherein the through holes comprise a second opening size at the bottom surface, wherein the first opening size is smaller than the second opening size.

22. The method of claim 20 , wherein the attaching the top lead frame component with the bottom lead frame component comprises bonding the top and bottom lead frame components together without an adhesive.

23. The method of claim 20 , wherein the attaching the top lead frame component with the bottom lead frame component comprises at least one of hot rolling and press bonding.

24. The method of claim 20 , wherein the attaching the top lead frame component with the bottom lead frame component comprises diffusion bonding.

25. The method of claim 20 , wherein the removing of the bottom lead frame component comprises etching so that each contact extends past the encapsulation material.

26. The method of claim 20 , wherein the top lead frame component comprises copper and the bottom lead frame component comprises copper.

27. The method of claim 20 , wherein the contacts of the lead frame comprise a first thickness in a central region of each of the contacts, wherein the contacts protrude out past the encapsulation material to a first distance from a major surface of the encapsulation material, wherein the first distance is 45-55% of the first thickness.

28. The method of claim 20 , further comprising mounting the lead frame onto a printed circuit board.

29. A method for making a semiconductor device comprising:

providing a top lead frame component and a bottom lead frame component physically separate from the top lead frame component;

forming through holes in the top lead frame component, wherein each of the through holes comprises a first sidewall, an opposite second sidewall;

after forming the through holes, attaching the top lead frame with the bottom lead frame component to form a lead frame, the bottom lead frame component forming a bottom surface of the through holes after the attaching;

mounting an integrated circuit (IC) on the lead frame;

encapsulating the IC and the lead frame, the encapsulating completely filling the through holes with an encapsulant material to form mold anchor points; and

removing portions of the bottom lead frame to form T-shaped insulated columns supported by the mold anchor points, wherein the T-shaped insulated columns provide contacts to the lead frame, wherein, in a top sectional view parallel to a major surface of the IC, the IC is mounted onto one of the T-shaped columns, wherein the one of the T-shaped insulated columns comprises a first upper portion that extends past a corresponding exposed surface of the contacts away from the IC, wherein the remaining T-shaped insulated columns comprise an upper portion that extends past a corresponding exposed surface of the contacts towards the IC, wherein the removing is stopped after removing the bottom surface of the through holes to expose the encapsulant material.

30. The method of claim 29 , wherein the through holes comprise a first opening size at a first surface, wherein the through holes comprise a second opening size at the bottom surface, wherein the first opening size is smaller than the second opening size.

31. The method of claim 29 , wherein the attaching the top lead frame component with the bottom lead frame component comprises bonding the top and bottom lead frame components together without an adhesive.

32. The method of claim 29 , wherein the attaching the top lead frame component with the bottom lead frame component comprises at least one of hot rolling and press bonding.

33. The method of claim 29 , wherein the attaching the top lead frame component with the bottom lead frame component comprises diffusion bonding.

34. The method of claim 29 , wherein the removing of the bottom lead frame component comprises etching so that each contact extends past the encapsulation material.

35. The method of claim 29 , wherein the top lead frame component comprises copper and the bottom lead frame component comprises copper.

36. The method of claim 29 , wherein the contacts of the lead frame comprise a first thickness in a central region of each of the contacts, wherein the contacts protrude out past the encapsulation material to a first distance from a major surface of the encapsulation material, wherein the first distance is 45-55% of the first thickness.

37. The method of claim 29 , further comprising mounting the lead frame onto a printed circuit board.