The invention relates to a method for utilizing one or more B-stageable or pre-formed
underfill encapsulant compositions in the application of electronic components,
most commonly chip scale packages (CSP's) to substrates. One such composition comprises
a thermoplastic resin system comprising a phenoxy resin, an expandable polymer
sphere or thermosetting composition, optionally an epoxy resin such as higher molecular
weight epoxy resin, a solvent, an imidazole-anhydride catalyst or comparable latent
catalyst, and optionally, fluxing agents and/or wetting agents. The underfill encapsulant
may be B-stageable to provide a coating on the substrate or component that is smooth
and non-tacky. In an alternative embodiment, the underfill encapsulant is a pre-formed
film. In both embodiments the expandable filler material expands upon the application
of higher temperatures to form a closed-cell foam structure in the desired portion
of the assembly. The method of applying the underfill application of the underfill
to a component or substrate, attachment of the component and substrate, and heating
of the assembly to a temperature sufficient to cause the expandable thermoplastic
or thermosetting composition to foam. A second pre-applied underfill composition
containing an epoxy resin, an anhydride curing agent, and catalyst may also be
applied, either separately or in conjunction with the foamable underfill. The second
composition acts as a pressure sensitive adhesive and may be applied selectively
to parts of the CSP, for example to the solder bumps. The pressure sensitive adhesive
property of the composition provides sufficient tack in order to hold the electronic
assembly together during the assembly process.