Semiconductor device package and method of manufacturing the same

A semiconductor device package includes a substrate, a first antenna pattern and a second antenna pattern. The substrate has a first surface and a second surface opposite to the first surface. The first antenna pattern is disposed over the first surface of the substrate. The first antenna pattern has a first bandwidth. The second antenna pattern is disposed over the first antenna pattern. The second antenna pattern has a second bandwidth different from the first bandwidth. The first antenna pattern and the second antenna pattern are at least partially overlapping in a direction perpendicular to the first surface of the substrate.

BACKGROUND

1. Technical Field

The present disclosure relates to a semiconductor device package and a method of manufacturing the same, and to a semiconductor device package including an antenna and a method of manufacturing the same.

2. Description of the Related Art

Wireless communication devices, such as cell phones, typically include antennas for transmitting and receiving radio frequency (RF) signals. In recent years, with the continuous development of mobile communication and the pressing demand for high data rate and stable communication quality, relatively high frequency wireless transmission (e.g., 28 GHz or 60 GHz) has become one of the most important topics in the mobile communication industry. However, signal attenuation and inference are some of the problems at relatively high frequency (or relatively short wavelength) wireless transmission.

SUMMARY

In accordance with some embodiments of the present disclosure, a semiconductor device package includes a substrate, a first antenna pattern and a second antenna pattern. The substrate has a first surface and a second surface opposite to the first surface. The first antenna pattern is disposed over the first surface of the substrate. The first antenna pattern has a first bandwidth. The second antenna pattern is disposed over the first antenna pattern. The second antenna pattern has a second bandwidth different from the first bandwidth. The first antenna pattern and the second antenna pattern are at least partially overlapping in a direction perpendicular to the first surface of the substrate.

In accordance with some embodiments of the present disclosure, a semiconductor device package includes a substrate, a first antenna pattern and a second antenna pattern. The substrate has a first surface and a second surface opposite to the first surface. The first antenna pattern is disposed over the first surface of the substrate. The first antenna pattern has a feeding point. The second antenna pattern is disposed over the first antenna pattern. The second antenna pattern has a feeding point. The feeding point of the first antenna pattern is coupled to the feeding point of the second antenna pattern.

Common reference numerals are used throughout the drawings and the detailed description to indicate the same or similar components. The present disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

FIG. 1Aillustrates a top view of a semiconductor device package1in accordance with some embodiments of the present disclosure.FIG. 1Billustrates a perspective view of the semiconductor device package1illustrated inFIG. 1Ain accordance with some embodiments of the present disclosure (for clarity, some of the components inFIG. 1Aare omitted inFIG. 1B). The semiconductor device package1includes a substrate10, dielectric layers11a,11b,11cand11d, antenna patterns12,13and14.

The substrate10may be, for example, a printed circuit board, such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated glass-fiber-based copper foil laminate. The substrate10may include an interconnection structure (or electrical connection), such as a redistribution layer (RDL) or a grounding element. The substrate10has a surface101and a surface102opposite to the surface101. In some embodiments, one or more electronic components (not shown in the drawing) are disposed on the surface102of the substrate10and electrically connected to the substrate10. In some embodiments, the electronic components may be active electronic components, such as integrated circuit (IC) chips or dies. The electronic components may be electrically connected to the substrate10(e.g., to the RDL) by way of flip-chip or wire-bond techniques.

A conductive layer10ais disposed on the surface101of the substrate10. In some embodiments, the conductive layer10ais formed of or includes gold (Au), silver (Ag), aluminum (Al), copper (Cu), or an alloy thereof. In some embodiments, the conductive layer10aacts as a ground layer or a RF layer for the antenna pattern12,13or14. An isolation layer10b(e.g., solder mask or solder resist) is disposed on the surface101of the substrate10to protect the conductive layer10a.

The dielectric layers11a,11b,11cand11dare arranged in a stacked structure. For example, as shown inFIG. 1A, the dielectric layer11ais disposed on the isolation layer10b, the dielectric layer11bis disposed on the dielectric layer11a, the dielectric layer11cis disposed on the dielectric layer11b, and the dielectric layer11dis disposed on the dielectric layer11c. In some embodiments, the dielectric layer11aand11bare used to increase a distance (e.g., a clearance area) between the antenna pattern12and the conductive layer10a(e.g., ground plane or RF plane), which would improve the performance of the antenna pattern12. In some embodiments, the number of the dielectric layers can be adjusted depending on different specifications.

In some embodiments, the dielectric layers11a,11b,11cand11dmay include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), Borophosphosilicate Glass (BPSG), silicon oxide, silicon nitride, silicon oxynitride, Undoped Silicate Glass (USG), any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets. The dielectric layers11a,11b,11cand11dmay include the same or different materials depending on different specifications.

The antenna pattern12is disposed on the dielectric layer11band covered by the dielectric layer11c. In some embodiments, as shown inFIG. 1AandFIG. 1B, the antenna pattern12has a portion12aand a portion12b. The portion12ais electrically connected to the conductive layer10athrough a conductive via12v. In some embodiments, the portion12aacts as a feeding point of the antenna pattern12. For example, the portion12ais arranged to transmit or receive signal from the conductive layer10athrough the conductive via12v. The portion12bis spaced apart from the portion12a. For example, there is a gap between the portion12aand the portion12b. In some embodiments, the portion12bmay surround the portion12a. In some embodiments, the signal transmission between the portion12aand the portion12bmay be achieved by coupling. In some embodiments, the antenna pattern12is, or includes, a conductive material such as a metal or metal alloy. Examples of the conductive material include Au, Ag, Al, Cu, or an alloy thereof.

In some embodiments, the antenna pattern12may include a single antenna element. In some embodiments, the antenna pattern12may include multiple antenna elements. For example, the antenna pattern12may include an array including patch antennas. In some embodiments, the antenna pattern12may include an M×N array of antenna elements, where M or N is an integer greater than 1. In some embodiments, M can be the same as or different from N depending on design specifications. For example, as shown inFIGS. 2-5, which illustrate top views of the semiconductor device package1in various embodiments (for clarity, some of the components of the semiconductor device package1are omitted, such as the antenna pattern14, dielectric layers11a,11b,11c,11dand the substrate10), the antenna pattern12may include a 1×4 array of antenna elements. For example, as shown inFIG. 6, which illustrate a top view of the semiconductor device package1in some embodiments, the antenna pattern12may include a 3×8 array of antenna elements. In some embodiments, the antenna pattern12is or includes a patch antenna or a patch antenna array operating in a frequency of 28 GHz. For example, a bandwidth of the antenna pattern12is in a range from about 27.5 GHz to about 28.35 GHz.

As shown inFIG. 1AandFIG. 1B, the antenna pattern13is disposed on the dielectric layer11cand covered by the dielectric layer11d. The antenna pattern13is electrically connected to the portion12aof the antenna pattern12through a conductive via13v. For example, the signal transmission between the antenna pattern12and the antenna pattern13may be achieved by the direct feed. In other embodiments, the signal transmission between the antenna pattern12and the antenna pattern13may be achieved by magnetically coupling. In some embodiments, the antenna pattern13is, or includes, a conductive material such as a metal or metal alloy. Examples of the conductive material include Au, Ag, Al, Cu, or an alloy thereof.

In some embodiments, the antenna pattern13is disposed over the antenna pattern12, and the number, the location and the shape of the antenna pattern13may be corresponding to those of the antenna pattern12. For example, as shown inFIGS. 2-5, the antenna pattern13may include a 1×4 array of antenna elements located corresponding to the antenna pattern12. For example, as shown inFIG. 6, the antenna pattern12may include a 3×8 array of antenna elements located corresponding to the antenna pattern12. In some embodiments, the antenna pattern13is or includes a patch antenna or a patch antenna array operating in a frequency of 38 GHz. For example, a bandwidth of the antenna pattern13is in a range from about 37 GHz to about 40 GHz.

As shown inFIG. 1AandFIG. 1B, the antenna pattern14is disposed on the dielectric layer11dand may be covered by a protection layer (now shown). The antenna pattern14is spaced apart from the antenna pattern13and is coupled to the antenna pattern13for signal transmission therebetween. For example, the signal transmission between the antenna pattern13and the antenna pattern14may be achieved by coupling. In some embodiments, the antenna pattern14is, or includes, a conductive material such as a metal or metal alloy. Examples of the conductive material include Au, Ag, Al, Cu, or an alloy thereof.

In some embodiments, the antenna pattern14is disposed over the antenna pattern13, and the number and the location of the antenna pattern14correspond to those of the antenna pattern13. In some embodiments, the area of the antenna pattern14is substantially the same as that of the antenna pattern13. In some embodiments, the area of the antenna pattern14may be greater or less than that of the antenna pattern13depending on different specifications. In some embodiments, the antenna pattern14is or includes a patch antenna or a patch antenna array operating in a frequency of 38 GHz. For example, a bandwidth of the antenna pattern14is in a range from about 37 GHz to about 40 GHz. By stacking two antenna patterns (e.g., the antenna patterns13and14) with the same or similar bandwidth, the bandwidth can further increase.

To increase a bandwidth and a stability of the transmission rate of a wireless device, a dual-band (or multi-band) antenna module having two (or more) antennas with different operating bandwidths can be implemented. In some embodiments, the dual-band antenna module may include a one antenna (e.g., a dual-polarization patch antenna) having a first bandwidth (e.g., 28 GHz) and the other antenna (e.g., another dual-polarization patch antenna) having a second bandwidth (e.g., 38 GHz) arranged alternatively in the same plane or level. However, the polarized wave/radiation (e.g., magnetic field and/or electric field) emitted by one antenna may pass through the other antenna, which would adversely affect the performance of the other antenna, and vice versa.

In accordance with the embodiments as shown inFIGS. 1A and 1B, the antenna pattern13is disposed over the antenna pattern12. For example, the antenna pattern13and the antenna pattern12are disposed on different planes or levels. Hence, the polarized wave/radiation (e.g., magnetic field and/or electric field) emitted by the antenna pattern13would not pass through the antenna pattern12, and vice versa. For example, as shown inFIG. 2, the antenna pattern12or13include a 1×4 array of patch antennas, each has a pair of polarized ports (e.g., “p1and p2,” “p3and p4,” “p5and p6,” “p7and p8”). Take the topmost patch antenna for an example, the port p1would generate two polarized radiations/waves, such as a magnetic field) M1and an electric field E1(the magnetic field M1and the electric field E1are orthogonal). Similarly, the port p2would also generate two polarized radiations/waves, such as a magnetic field M2and an electric field E2(the magnetic field M1and the electric field E1are orthogonal). As shown inFIG. 2, the magnetic field M1and the magnetic field M2are orthogonal, and the electric field M1and the electric field M2are orthogonal. If the antenna patterns12and13are arranged alternatively on the same plane or level, the polarized radiation M2generated by the antenna pattern13(e.g., the port p2of the antenna pattern13) and/or the polarized radiation E1generated by the antenna pattern13(e.g., the port p1of the antenna pattern13) would pass through the antenna pattern12, which would adversely affect the performance of the antenna pattern12, and vice versa. As shown inFIG. 2, since the antenna pattern13and the antenna pattern12are disposed on different planes or levels, the polarized wave M2or E1emitted by the topmost patch antenna selectively passes through the patch antennas having the same bandwidth (e.g., other patch antennas of the antenna pattern13), but would not pass through the patch antennas having different bandwidth (e.g., the patch antennas of the antenna pattern12), and vice versa. This would avoid the interference between the antenna patterns12and13, and improve the performance of the antenna patterns12and13.

The structure illustrated inFIG. 3is similar to that inFIG. 2, except that inFIG. 3, the antenna patterns12and13rotate counterclockwise by 45°. As shown inFIG. 3, both the polarized radiations E1, E2, M1and M2generated by the topmost patch antenna would not pass through either the patch antennas having different bandwidth (e.g., the patch antennas of the antenna pattern12) or the patch antennas having the same bandwidth (e.g., other patch antennas of the antenna pattern13). Therefore, the inference can be further eliminated or reduced, which would increase the gain of the antenna patterns12and13.

In some embodiments, the antenna pattern12or13may have different shapes. For example, as shown inFIG. 2, the antenna pattern12or13is rectangular. For example, as shown inFIGS. 3 and 6, the antenna pattern12or13may be shaped like a rhombus. For example, as shown inFIG. 4, the antenna pattern12or13may be shaped like a cross. For example, as shown inFIG. 5, the antenna pattern12or13may be shaped like an “X”. The shapes of the antenna patterns12and13can be changed or adjusted depending on different design specifications. For example, the antenna patterns12and13can be shaped like a polygon having N edges (or sides), where N is an integer equal to or greater than 3.

As used herein, the terms “substantially,” “substantial,” “approximately,” and “about” are used to denote and account for small variations. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation of less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. As another example, a thickness of a film or a layer being “substantially uniform” can refer to a standard deviation of less than or equal to ±10% of an average thickness of the film or the layer, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. The term “substantially coplanar” can refer to two surfaces within micrometers of lying along a same plane, such as within 40 within 30 within 20 within 10 or within 1 μm of lying along the same plane. Two surfaces or components can be deemed to be “substantially perpendicular” if an angle therebetween is, for example, 90°±10°, such as ±5°, ±4°, ±3°, ±2°, ±1°, ±0.5°, ±0.1°, or ±0.05°. When used in conjunction with an event or circumstance, the terms “substantially,” “substantial,” “approximately,” and “about” can refer to instances in which the event or circumstance occurs precisely, as well as instances in which the event or circumstance occurs to a close approximation.

Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It can be understood that such range formats are used for convenience and brevity, and should be understood flexibly to include not only numerical values explicitly specified as limits of a range, but also all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.