Electronic package and fabrication method thereof

An electronic package is disclosed, which includes: a substrate; at least an electronic element disposed on the substrate; an encapsulant formed on the substrate and encapsulating the electronic element; and an antenna body embedded in the encapsulant without contacting with the substrate and exposed from a surface of the encapsulant. Since the antenna body is not disposed on the substrate, the surface area of the substrate can be reduced to meet the miniaturization requirement of the electronic package.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims under 35 U.S.C. §119(a) the benefit of Taiwanese Application No. 102143399, filed Nov. 28, 2013, the entire contents of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to electronic packages, and more particularly, to an electronic package having an antenna structure.

2. Description of Related Art

Along with the rapid development of electronic industries, electronic products are developed toward the trend of multi-function and high performance. Wireless communication technologies have been widely applied in various kinds of consumer electronic products for receiving or transmitting various wireless signals. To meet the miniaturization requirement of consumer electronic products, wireless communication modules are becoming lighter, thinner, shorter and smaller. For example, patch antennas have been widely applied in wireless communication modules of electronic products such as cell phones and personal digital assistants (PDAs) due to their advantages of small size, light weight and easy fabrication.

FIG. 1is a schematic perspective view of a conventional wireless communication module. Referring toFIG. 1, the wireless communication module1has: a substrate10, a plurality of electronic elements11disposed on and electrically connected to the substrate10, an antenna structure12disposed on the substrate10, and an encapsulant13. The substrate10is a circuit board and has a rectangular shape. The antenna structure12is of a planar type. The antenna structure12has an antenna body120and a conductive wire121electrically connecting the antenna body120to the electronic elements11. The encapsulant13encapsulates the electronic elements11and a portion of the conductive wire121.

However, during the fabrication process of the wireless communication module1, based on the characteristic of electromagnetic radiation between the planar-type antenna structure12and the electronic elements11and limitation of the size of the planar-type antenna structure12, the antenna body120of the antenna structure12cannot be integrally processed with the electronic elements11. That is, only the electronic elements11are covered by the encapsulant13while the antenna body120of the antenna structure12is exposed from the encapsulant13. Therefore, the molding process for forming the encapsulant13needs to use a mold having a size corresponding to the mounting area of the electronic elements11instead of the overall substrate10, thus complicating the molding process.

Further, the planar-type antenna structure12occupies a large surface area of the substrate10and hinders miniaturization of the wireless communication module1.

Therefore, there is a need to provide an electronic package and a fabrication method thereof so as to overcome the above-described drawbacks.

SUMMARY OF THE INVENTION

In view of the above-described drawbacks, the present invention provides an electronic package, which comprises: a substrate; at least an electronic element disposed on the substrate; an encapsulant formed on the substrate and encapsulating the electronic element; and an antenna body embedded in the encapsulant without contacting with the substrate and exposed from a surface of the encapsulant.

The present invention further provides a method for fabricating an electronic package, which comprises the steps of: providing a substrate defined with an active area and a non-active area, wherein the active area has at least an electronic element disposed thereon; disposing an antenna structure on the substrate, wherein the antenna structure has an antenna body and a support portion connected to the antenna body for supporting the antenna body over the active area of the substrate, and the support portion is located on the non-active area of the substrate; forming an encapsulant on the active area of the substrate for encapsulating the electronic element and the antenna body; and removing the non-active area of the substrate and the support portion on the non-active area so as to expose a surface of the antenna body from a surface of the encapsulant.

In the above-described method, the encapsulant can further be formed on the non-active area of the substrate for encapsulating the support portion, and when removing the non-active area of the substrate, the encapsulant on the non-active area of the substrate is accordingly removed.

In the above-described package and method, the substrate can have a plurality of circuits electrically connected to the electronic element, and the substrate can be electrically connected to the antenna body, for example, through at least a bonding wire.

In the above-described package and method, the electronic element can be an active element or a passive element.

In the above-described package and method, the antenna body can be a metal frame. The antenna body can be such as a linear-shaped body, a bent-shaped body, a ring-shaped body or a ring-shaped body having an opening.

In the above-described package and method, the antenna body can be located over an edge of the substrate and surround the electronic element. The exposed surface of the antenna body can be flush with the surface of the encapsulant.

In the above-described package and method, at least a support portion can be located on the active area of the substrate and encapsulated by the encapsulant. Therein, the support portion on the active area is not removed when the non-active area of the substrate is removed. Further, the support portion on the active area of the substrate can be electrically connected to the substrate.

According to the present invention, since the antenna body is located over the substrate, both the antenna body and the electronic element can be encapsulated by the encapsulant. As such, the present invention can use a mold having a size corresponding to the substrate so as to facilitate the molding process for forming the encapsulant.

Further, since the antenna body is supported over a region of the substrate where the electronic element is disposed (i.e., where the encapsulant is to be formed, for example, the active area) instead of being directly disposed on the substrate, the invention saves the surface area of the substrate. Therefore, compared with the prior art, the invention can effectively reduce the size of the substrate so as to meet the miniaturization requirement of the electronic package.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The following illustrative embodiments are provided to illustrate the disclosure of the present invention, these and other advantages and effects can be apparent to those in the art after reading this specification.

It should be noted that all the drawings are not intended to limit the present invention. Various modifications and variations can be made without departing from the spirit of the present invention. Further, terms such as “upper”, “lower”, “first”, “second”, “a” etc. are merely for illustrative purposes and should not be construed to limit the scope of the present invention.

FIGS. 2A to 2Care schematic perspective views showing a method for fabricating an electronic package2according to a first embodiment of the present invention. In the present embodiment, the electronic package2is a SiP (system in package) wireless communication module.

Referring toFIGS. 2A and 2A′, a substrate20having opposite first and second surfaces20a,20bis provided. The first surface20aof the substrate20is defined with a rectangular-shaped active area A and a non-active area B around an outer periphery of the active area A, and a plurality of electronic elements21are disposed on the active area A. Then, an antenna structure22is disposed on the first surface20of the substrate20.

In the present embodiment, the substrate20is a circuit board or a ceramic board and has a rectangular shape. A plurality of circuits200are formed on the first surface of the substrate20. Further, a circuit layer (not shown) can be formed inside the substrate20.

The electronic elements21can be active or passive elements. The electronic elements21are electrically connected to the circuits200through a plurality of bonding wires210.

Further, the antenna structure22is a metal frame. The antenna structure22has an antenna body220, and a plurality of bent-shaped support portions221vertically disposed on the non-active area B of the substrate20for supporting the antenna body220over the active area A of the substrate20. As such, the antenna body220of the antenna structure22is located at a position higher than the electronic elements21. In particular, the antenna body220is located over side edges of the active area A of the substrate20and correspondingly extends to surround the electronic elements21.

Furthermore, the substrate20is electrically connected to the antenna body220of the antenna structure22through, for example, at least a bonding wire201. The antenna body220,220′ can be a ring-shaped body having an opening, for example, a substantially C-shaped body ofFIG. 2Aor a substantially n-shaped body ofFIGS. 3A and 3A′. In other embodiments, the antenna body220can be a linear-shaped body, such as an I-shaped body, a bent-shaped body, such as an L-shaped body, or a ring-shaped body, such as a rectangular-shaped body.

Referring toFIG. 2B, an encapsulant23is formed on the active area A of the first surface20aof the substrate20to encapsulate the electronic elements21and the antenna body220of the antenna structure22.

In the present embodiment, the antenna body220is buried adjacent to an upper side of the encapsulant23and the support portions221protrude from side surfaces23cof the encapsulant23.

Referring toFIGS. 2C and 2C′, a cutting process is performed to remove the non-active area B of the substrate20and the support portions221on the non-active area B, thereby exposing surfaces220aof the antenna body220(i.e., interfaces between the support portions221and the antenna body220) from the side surfaces23cof the encapsulant23. The antenna body220does not contact with the first surface20aor the second surface20bof the substrate20. In the present embodiment, the exposed surfaces220aof the antenna body220are flush with the side surfaces23cof the encapsulant23.

In other embodiments, the encapsulant23can further be formed on the non-active area B for encapsulating the support portions221. As such, when the non-active area B of the substrate20is removed, the encapsulant23on the non-active area B is also removed.

According to the method of the present invention, a metal sheet is formed into the 3D antenna structure22and then the antenna body220of the antenna structure22is disposed over the substrate20to surround the electronic elements21. As such, the antenna body220and the electronic elements21can be integrally processed. That is, both the antenna body220and the electronic elements21can be encapsulated by the encapsulant23. Therefore, the present invention can use a mold having a size corresponding to the substrate20so as to facilitate the molding process for forming the encapsulant23.

Further, the antenna body220can be stably fixed at a certain height by the encapsulant23even after the support portions221are removed. Furthermore, the dielectric constant of the encapsulant23can reduce the required electrical length of the antenna structure.

Moreover, since the antenna body220is supported over a region of the substrate20where the electronic elements21are disposed (i.e., the active area A) instead of being directly disposed on the substrate20as in the prior art, the present invention saves the surface area of the substrate20. Therefore, compared with the prior art, the present invention can effectively reduce the size of the substrate20so as to meet the miniaturization requirement of the electronic package2.

Also, by disposing the antenna body220over the substrate20, a receiving space is formed between the antenna body220and the substrate20, which can receive other electrical structures therein.

FIGS. 3A and 3Bshow a method for fabricating an electronic package3according to a second embodiment of the present invention.

Referring toFIGS. 3A and 3A′, the antenna structure22has an antenna body220′ and a plurality of support portions221,221′ connected to the antenna body200′. The support portions221are vertically disposed on the non-active area B of the substrate20, and the support portions221′ are vertically disposed on the active area A of the substrate20.

The substrate20can be electrically connected (for example, grounded) to the antenna body220′ through the support portions221′. Alternatively, the substrate20can be electrically connected to the antenna body220′ through a plurality of bonding wires201. In other embodiments, the support portions221′ can be used only for supporting the antenna body220′ and have no electrical function.

Referring toFIG. 3B, an encapsulant23is formed on the active area A of the first surface20aof the substrate20for encapsulating the electronic elements21, the antenna body220′ and the support portions221′.

Then, a cutting process is performed to remove the non-active area B and the support portions221thereon such that surfaces220aof the antenna body220′ are exposed from side surfaces23cof the encapsulant23while the support portions221′ are not exposed from the encapsulant23.

According to the method of the present embodiment, the support portions221′ facilitate to stably fix the antenna body220′ at a certain height.

The invention further provides an electronic package2, which has: a substrate20, at least an electronic element21disposed on the substrate20, an encapsulant23formed on the substrate20and encapsulating the electronic element21, and an antenna body220,220′ embedded in the encapsulant23without contacting with the substrate20and exposed from side surfaces23cof the encapsulant23.

The substrate20can have a plurality of circuits200. The electronic element21can be an active element or a passive element and electrically connected to the circuits200.

The antenna body220,220′ can be a metal frame. The antenna body220,220′ can be a ring-shaped body having an opening, a linear-shaped body, a bent-shaped body or a ring-shaped body.

In an embodiment, the circuits200or an inner circuit layer of the substrate200is electrically connected to the antenna body220,220′ through at least a bonding wire201.

In an embodiment, the exposed surfaces220aof the antenna body220are flush with the side surfaces23cof the encapsulant23.

In an embodiment, the antenna body220,220′ is located over side edges of the substrate20and correspondingly extends to surround the electronic elements21.

In an embodiment, the electronic package3further has at least a support portion221′ connected to the antenna body220′, vertically disposed on the substrate20and embedded in the encapsulant23. Further, the support portion221′ can be electrically connected to the substrate20.

Therefore, by providing an antenna body that can be supported over a region of the substrate where the electronic elements are disposed, the present invention dispenses with the conventional planar-type antenna structure to facilitate the molding process and reduce the size of the substrate to meet the miniaturization requirement of the electronic package.

The above-described descriptions of the detailed embodiments are only to illustrate the preferred implementation according to the present invention, and it is not to limit the scope of the present invention. Accordingly, all modifications and variations completed by those with ordinary skill in the art should fall within the scope of present invention defined by the appended claims.