Electronic package structure and fabrication method thereof

An electronic package structure is provided, including a substrate with an electronic component, an antenna element and a shielding element disposed on the substrate. The shielding element is positioned between the antenna element and the electronic component to prevent electromagnetic interference (EMI) from occurring between the antenna element and the electronic component. A method for fabricating the electronic package structure is also provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims under 35 U.S.C. § 119(a) the benefit of Taiwanese Patent Application No. 105131255, filed Sep. 29, 2016 and Taiwanese Patent Application No. 106105039, filed Feb. 16, 2017, the entire contents of which are incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to electronic package structures, and, more particularly, to an electronic package structure having an antenna structure.

2. Description of Related Art

Along with the rapid development of electronic industries, 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 compact in size and low in profile. For example, patch antennas have been widely applied in wireless communication modules of electronic products such as cell phones due to their advantages of small size, light weight and easy fabrication.

FIG. 1is a schematic perspective view of a wireless communication module1according to the prior art. The wireless communication module1has a substrate10, a plurality of electronic components11disposed on and electrically connected to the substrate10, an antenna structure12disposed on the substrate10, an encapsulant13, and a shielding structure14disposed on the encapsulant13. The substrate10is a rectangular circuit board. The antenna structure12is planar, and has an antenna body120and a conductive wire121electrically connecting the antenna body120and the electronic components11. The encapsulant13encapsulates the electronic components11and a portion of the conductive wire121.

However, during fabrication of the wireless communication module1, the antenna structure12and the shielding structure14are formed separately. In particular, the antenna structure12is formed before the formation of the encapsulant13, and the shielding structure14is formed after the formation of the encapsulant13, thus complicating the fabrication process of the wireless communication module1and increasing the fabrication cost.

Therefore, how to overcome the above-described drawbacks has become critical.

SUMMARY

In view of the above-described drawbacks, the present disclosure provides an electronic package structure, which comprises: a substrate; at least one electronic component disposed on the substrate; an antenna element disposed on and electrically connected to the substrate; and a shielding element disposed on the substrate between the antenna element and the electronic component, wherein the shielding element and the antenna element are arranged side by side in a horizontal direction relative to a surface of the substrate.

In an embodiment, the electronic package structure further comprises a connecting portion connecting the antenna element and the shielding element. In another embodiment, the connecting portion, the antenna element and the shielding element form an open or closed ring-shaped plane.

In an embodiment, the electronic package structure further comprises a supporting portion extending from the antenna element and the shielding element, wherein at least one assisting region is defined on the substrate around an outer periphery of the electronic component, the antenna element and the shielding element with the supporting portion located on the assisting region. In another embodiment, the shielding element is a metal cover to cover the electronic component and a portion of the surface of the substrate.

The present disclosure further provides a method for fabricating an electronic package structure, comprising: providing a substrate and a functional module, wherein the substrate has at least one electronic component disposed thereon, and the functional module comprises an antenna element, a shielding element, and a connecting portion connecting the antenna element and the shielding element; and disposing the functional module on the substrate with the antenna element and the shielding element vertically disposed on the substrate, wherein the shielding element is positioned between the antenna element and the electronic component, and the shielding element and the antenna element are arranged side by side in a horizontal direction relative to a surface of the substrate.

In an embodiment, the method further comprises removing the connecting portion after the functional module is disposed on the substrate.

In an embodiment, the functional module further comprises a supporting portion extending from the antenna element and the shielding element. When the functional module is disposed on the substrate, the supporting portion is positioned on an assisting region of the substrate. In another embodiment, after the functional module is disposed on the substrate, a singulation process is performed along the assisting region to remove the supporting portion.

In an embodiment, the substrate has a circuit electrically connected to the antenna element.

In an embodiment, the substrate has a grounding pad electrically connected to the shielding element.

In an embodiment, the antenna element is a metal frame.

In an embodiment, the shielding element is a metal frame or a metal cover.

In an embodiment, the shielding element is free from being electrically connected to the antenna element.

In an embodiment, the shielding element is electrically connected to the antenna element.

In an embodiment, the shielding element has a plurality of legs spaced apart from one another.

In an embodiment, the shielding element has a wall-shaped leg positioned between the antenna element and the electronic component.

In an embodiment, an encapsulant is further formed on the substrate to encapsulate the electronic component, the antenna element and the shielding element. In an embodiment, the encapsulant is formed on the substrate to further encapsulate the connecting portion. In an embodiment, a portion of a surface of the antenna element is exposed from the encapsulant. In another embodiment, the portion of the surface of the antenna element is flush with a surface of the encapsulant. In an embodiment, a portion of a surface of the shielding element is exposed from the encapsulant. In another embodiment, the portion of the surface of the shielding element is flush with a surface of the encapsulant. In an embodiment, a portion of a surface of the connecting portion is exposed from the encapsulant. In another embodiment, the portion of the surface of the connecting portion is flush with a surface of the encapsulant. In an embodiment, a metal layer is formed on the encapsulant. In another embodiment, the metal layer is electrically connected to at least one of the antenna element and the shielding element. In an embodiment, the metal layer has separated first and second regions, the first region is electrically connected to the shielding element, and the second region is electrically connected to the antenna. In another embodiment, the second region is formed on the upper surface of the encapsulant and/or the side surface of the encapsulant.

In an embodiment, the substrate has a circuit layer exposed from the side surface thereof, and a metal layer electrically connected to the circuit layer is disposed on the side surface of the substrate and/or the side surface of the encapsulant.

According to the present disclosure, the antenna element and the shielding element form a functional module, and thus can be disposed together on the substrate. Therefore, the fabrication process is simplified, and the fabrication cost is greatly reduced.

Further, since the shielding element is positioned between the antenna element and the electronic component, the present disclosure prevents electromagnetic interference from occurring between the antenna element and the electronic component.

DETAILED DESCRIPTION OF EMBODIMENTS

The following illustrative embodiments are provided to illustrate the disclosure of the present disclosure, 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 disclosure. Various modifications and variations can be made without departing from the spirit of the present disclosure. Further, terms such as “first”, “second”, “on”, “a” etc. are merely for illustrative purposes and should not be construed to limit the scope of the present disclosure.

FIGS. 2A to 2Eare schematic perspective views showing a method for fabricating an electronic package structure2according to the present disclosure. In an embodiment, the electronic package structure2is a wireless communication module of a system in package (SiP).

Referring toFIGS. 2A and 2B, a substrate20and a functional module2aare provided. A plurality of electronic components21are disposed on the substrate20. The functional module2ahas an antenna element22, a shielding element23, a connecting portion24connecting the antenna element22and the shielding element23, and a plurality of supporting portions25extending from the antenna element22and the shielding element23(and the connecting portion24). The functional module2ais disposed on the substrate20in a manner that the antenna element22, the shielding element23and the supporting portions25are vertically disposed on the substrate20. The shielding element23is positioned between the antenna element22and the electronic components21, and the shielding element23and the antenna element22are arranged side by side in a horizontal direction relative to a surface of the substrate20.

In an embodiment, the substrate20is a lead frame, a fan-out redistribution layer (RDL) structure, a circuit board or a ceramic board, and is rectangular. In another embodiment, the substrate20has a plurality of circuits200and201and a plurality of grounding pads202disposed on the surface thereof. In yet another embodiment, the substrate20has a circuit layer formed therein (not shown). In further another embodiment, the substrate20is defined with an element mounting region for the electronic components21and the functional module2ato be mounted thereon, and an assisting region L around an outer periphery of the element mounting region are defined on the substrate20.

The electronic components21are electrically connected to the circuits200. At least one of the electronic components21is an active component such as a semiconductor chip, a passive component, such as a resistor, a capacitor or an inductor, or a combination thereof.

In an embodiment, the antenna element22is a metal frame having a base portion220and a foot portion221. The foot portion221is vertically disposed on the substrate20, and the base portion220is supported over the substrate20through the foot portion221. In another embodiment, the foot portion221is electrically connected to an input terminal of the circuit201. Alternatively, the foot portion221serves as an input terminal without being electrically connected to the circuit201. That is, it is not necessary form the circuit201to be disposed on the substrate20. According to the practical need, a plurality of foot portions221can be provided.

In an embodiment, the shielding element23is a metal frame having a plurality of legs230electrically connected to the grounding pads202. The legs230are spaced apart from one another at an interval231. In another embodiment, referring toFIG. 3A, the shielding element33is a metal cover covering the electronic components21and a portion of the surface of the substrate20, and the legs230are positioned between the antenna element22and the electronic components21. In a further embodiment, referring toFIG. 3B, the shielding element23only has a wall-shaped leg330positioned between the antenna element22and the electronic components21.

The connecting portion24connects the antenna element22and the shielding element23at one end. As such, the connecting portion24, the antenna element22and the shielding element23form an open ring-shaped plane, i.e., a ring shape having an opening, such as a substantially C-shape or U-shape. Alternatively, the connecting portion24connects the antenna element22and the shielding element23at any position between the two opposite ends so as to form an H-shaped plane. In another embodiment, referring toFIG. 3C, the connecting portion34connects the antenna element22and the shielding element23at the two opposite ends so as to form a closed ring-shaped plane (for example, a rectangular shape), thus increasing mechanical strength and avoiding stress deformation.

The supporting portions25are disposed on contact pads203on the assisting region L of the substrate20.

Referring toFIG. 2C, an encapsulant26is formed on the substrate20except the assisting region L. As such, the encapsulant26encapsulates the electronic components21, the antenna element22and the shielding element23, with the supporting portions25exposed.

In an embodiment, the interval231between the legs230of the shielding element23serves as a passageway for the encapsulant26to flow therethrough, thereby facilitating the encapsulant26to be uniformly formed on the substrate20.

In an embodiment, the encapsulant26does not encapsulate the connecting portion24. In another embodiment, the encapsulant26encapsulates a portion of the connecting portion24. In a further embodiment, the encapsulant26completely encapsulates the electronic components21and the functional module2a(including the antenna element22, the shielding element23and the connecting portion24). In still another embodiment, as shown inFIG. 5A, the encapsulant26encapsulates the electronic components21and a portion of the functional module2a, and a portion of a surface of the functional module2a(including the antenna element22, the shielding element23and the connecting portion24) is exposed from an upper surface26aof the encapsulant26.

In another embodiment, the encapsulant26is also formed on the assisting region L to encapsulate the supporting portions25.

Referring toFIG. 2D, following the process ofFIG. 2C, a singulation process is performed along the assisting region L (which is used as a cutting path) to remove the supporting portions25and the connecting portion24. As such, the shielding element23is not electrically connected to the antenna element22.

In an embodiment, a portion of a surface of the antenna element22and a portion of a surface of the shielding element23are exposed from the encapsulant26. In another embodiment, the exposed surface of the antenna element22and the exposed surface of the shielding element23are flush with the side surface26cof the encapsulant26. In another embodiment, the encapsulant26encapsulates the connecting portion24, and the singulation process is performed to expose a portion of a surface of the connecting portion24from the encapsulant26. Referring toFIGS. 4A and 4B, the exposed surface of the connecting portion24is flush with the side surface26cof the encapsulant26. As such, the shielding element23is electrically connected to the antenna element22.

Further, the singulation process can be performed on the electronic package structure2, without the encapsulant26formed.

In another embodiment, the assisting region L does not serve as a cutting path, and thus the assisting region L and the supporting portions25are not removed.

In an embodiment, as shown inFIG. 2D′, the circuit layer200′ of the substrate20is also exposed from the side surface20cof the substrate20.

Referring toFIG. 2E, following the process ofFIG. 2D, a metal layer27is formed on the surface of the encapsulant26to encapsulate a portion of the surface of the encapsulant26and a portion of the side surface of the substrate20.

In an embodiment, the metal layer27is used for heat dissipating or EMI shielding. The metal layer27is formed by sputtering, plating, coating or others, or by disposing a frame, and encapsulates a portion of a surface of the encapsulant26and a portion of a side surface of the substrate20(and, optionally, is electrically connected to the circuit layer of the substrate20exposed from the side surface of the substrate20). In another embodiment, the metal layer27encapsulates the entire surface of the encapsulant26and the entire side surface of the substrate20.

Further, referring toFIG. 2E, the metal layer27is electrically connected to the shielding element23exposed from the encapsulant26, or, as shown inFIGS. 5B, 6A and 6B, the metal layer57is electrically connected to functional module2a, such as the antenna element22and the shielding element23. In an embodiment, the metal layer57has separated first region57aand second region57b. The first region57ais electrically connected to the shielding element23, and the second region57bis electrically connected to the antenna element22.

In an embodiment, as shown inFIG. 5B, following the process ofFIG. 5A, the second region57bis formed on the supper surface26aof the encapsulant26and electrically connected to the antenna element22. In another embodiment, as shown inFIG. 6A, following the process ofFIG. 2D, the second region57bis formed on the adjacent sides surfaces26cand26dof the encapsulant26and electrically connected to the antenna element22. In yet another embodiment, as shown inFIG. 6B, following the process ofFIG. 2D, the second region57bis disposed on the upper surface26aand the side surfaces26cand26dof the encapsulant26and electrically connected to the antenna element22. In an embodiment, as shown inFIG. 6C, following the process ofFIG. 2D′, the circuit layer200′ is electrically connected to a second region67bon the side surface20cof the substrate20(or the side surfaces26cand26dof the encapsulant26), and the antenna element22is electrically connected to the second region57bon the upper surface26aof the encapsulant26.

In an embodiment, the projection location of the second region57band the circuits201of the substrate20are staggered, to avoid the degradation of efficiency of the antenna element22due to the overlapping of the second region57bwith the circuit201.

In another embodiment, the metal layer27is not electrically connected to the antenna element22or the shielding element23(or the connecting portion24).

Furthermore, if the electronic package structure2does not have the encapsulant26and the shielding element23is a metal frame instead of a metal cover, the metal layer27can be frame-disposed over the substrate20to cover the electronic components21.

In an embodiment, after the singulation process shown inFIG. 2D, a portion of surfaces of the antenna element22and the shielding element23can be exposed from the upper surface26of the encapsulant26by polishing, laser or cutting knife, to form the metal layer57shown inFIG. 5B.

In another embodiment, the metal layer27,57is arranged corresponding to the shape of the encapsulant26so as to minimize the volume of the electronic package structure2and protect the electronic components21and the antenna element22against external EMI.

According to the present disclosure, a metal sheet is bent into a3D functional module2a. As such, the antenna element22and the shielding element23of the functional module2acan be disposed together on the substrate20so as to simplify the fabrication process and greatly reduce the fabrication cost.

Further, since the shielding element23is positioned between the antenna element22and the electronic components21, the present disclosure prevents electromagnetic interference from occurring between the antenna element22and the electronic components21.

The antenna element22can be extended to a region outside of the encapsulant26through the second region57bof the metal layer57, and thus has an antenna length sufficient to satisfy the electric length required by antenna resonance.

The present disclosure further provides an electronic package structure2, which has a substrate20, and a plurality of electronic components21, an antenna element22and a shielding element23,33disposed on the substrate20.

The substrate20has a plurality of circuits200,201and a plurality of grounding pads202.

At least one of the electronic components21is an active component or a passive component. The electronic components21are electrically connected to the circuits200of the substrate20.

The antenna element22is metal frame and optionally electrically connected to the circuit201of the substrate20.

The shielding element23,33is a metal frame or a metal cover. The shielding element23,33is electrically connected to the grounding pads202of the substrate20.

In an embodiment, the shielding element23,33is not electrically connected to the antenna element22. In an embodiment, the shielding element23,33is electrically connected to the antenna element22through a connecting portion24,34. In another embodiment, the connecting portion24,34, the antenna element22and the shielding element23,33form an open or closed ring-shaped plane.

In an embodiment, the shielding element23has a plurality of legs230spaced apart from one another at an interval231.

In an embodiment, the shielding element23has a wall-shaped leg330positioned between the antenna element22and the electronic components21.

The electronic package structure2further has an encapsulant26formed on the substrate20to encapsulate the electronic components21, the antenna element22and the shielding element23,33(and the connecting portion24,34).

In an embodiment, a portion of a surface of the antenna element22is exposed from the encapsulant26. In another embodiment, a portion of a surface of the shielding element23,33is exposed from the encapsulant26. In a further embodiment, a portion of a surface of the connecting portion24,34is exposed from the encapsulant26.

In an embodiment, the electronic package structure2further comprises the metal layer27,57formed on the encapsulant26, and the metal layer27,57is electrically connected to the antenna element22and/or the shielding element23.

According to the present disclosure, the functional module allows the antenna element and the shielding element to be disposed together on the substrate so as to simplify the fabrication process and greatly reduce the fabrication cost.

Further, since the shielding element is positioned between the antenna element and the electronic components, the present disclosure prevents electromagnetic interference from occurring between the antenna element and the electronic components.

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