Abstract:
Systems and methods disclose reduction of conductive paint overspray while maintaining paint thickness uniformity over the perimeter of a cap encapsulating at least one integrated circuit (IC) module on a panel of IC modules. The layer of conductive paint electrically couples with wirebonds on the panel to form at least part of an electromagnetic interference (EMI) or radio frequency interference (RFI) shield that attenuates EMI or RFI during operation of the IC module. Optimizing the spray nozzle diameter, fluid pressure, coaxial air pressure, spray heights, speeds, and spray pattern reduces paint waste and achieves edge uniformity. The reduction in paint overspray reduces paint waste, which in turn, reduces production costs. With the reduced amount of paint needed for coating a panel, the cost per unit can be significantly reduced.

Description:
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS 
       [0001]    Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. 
       BACKGROUND 
       [0002]    Conductive paint is widely used in the electronics industry for Electromagnetic Interference (EMI) shielding, Radio Frequency Interference (RFI) shielding, and electrostatic discharge (ESD) control. For conductivity, the paint contains metal particles or flakes, and for high conductivity, the metal particles can be copper, nickel, silver covered copper, silver or other expensive conductive materials. It is often sprayed, brushed, or rolled onto plastic parts which are then assembled into EMI or RFI shielded housings for sensitive electronic circuits or devices. 
       SUMMARY 
       [0003]    Conductive paint sprayed onto the surface of integrated circuit (IC) modules during the manufacturing process can provide at least part of a metal shield which reduces, attenuates or lessens EMI or RFI during the operation of the integrated circuits. 
         [0004]    To provide uniform coverage, conventional spray methods increase the distance between the paint applicator and the surface to be painted. This greatly increases the overspray, consuming almost twice the volume of paint that is actually required to cover a panel of IC modules, which greatly increases the price per unit for paint costs. To reduce overspray, conventional methods decrease the distance between the paint applicator and the surface to be painted. When this is done, track lines appear indicating there are hills and valleys in the paint surface. The overall paint thickness is not uniform, which does not provide a uniform EMI/RFI shield. 
         [0005]    Systems and methods disclose reduction of conductive paint overspray while maintaining approximate paint thickness uniformity over the surface including the edges of a panel of IC modules. In an embodiment, the surface is the surface of a cap encapsulating at least one integrated circuit (IC) on the panel of IC modules. Optimizing the spray nozzle diameter, fluid pressure, coaxial air pressure, spray heights, speeds, and spray pattern reduces paint overspray and achieves paint thickness control with edge uniformity. The reduction in paint overspray reduces paint waste, which in turn, reduces production costs. With the reduced amount of paint needed for coating the panel, the cost per IC module can be significantly reduced. A uniform coating of conductive paint provides at least part of a more effective EMI or RFI shield during the operation of the ICs. 
         [0006]    Certain embodiments relate to a method for of spraying a perimeter of a panel of integrated circuit (IC) modules with conductive paint to provide at least part of an electromagnetic interference (EMI) or radio frequency interference (RFI) shield that attenuates EMI or RFI during operation of the IC module. The method comprising spraying conductive paint including metal particles from a spray nozzle onto a perimeter of a panel including integrated circuit (IC) modules while controlling a height of the spray nozzle above the panel, a size of the metal particles, and a viscosity of the conductive paint until reaching a desired conductive paint thickness to provide an approximately uniform layer of the conductive paint over the perimeter of the panel with minimum overspray. The layer of conductive paint electrically couples with wirebonds on the panel to form at least part of an electromagnetic interference (EMI) or radio frequency interference (RFI) shield that attenuates EMI or RFI during operation of the IC module. 
         [0007]    According to a number of embodiments, the disclosure relates to a method of spraying a perimeter of a panel of integrated circuit (IC) modules with conductive paint to provide at least part of an electromagnetic interference (EMI) or radio frequency interference (RFI) shield that attenuates EMI or RFI during operation of the IC module. The method comprises controlling a first set of parameters including at least one of a height of a spray nozzle, a travel speed of the spray nozzle, a fluid on time, and a fluid off time, the first set of parameters based at least in part on viscosity of a conductive paint and a size of metal particles in the conductive paint, determining a second set of parameters including at least one of a start location of the spray nozzle for each side of a perimeter on a surface of a panel including at least one integrated circuit (IC) module, and an end location of the spray nozzle for each side of the perimeter, the second set of parameters based at least in part on at least one of the first set of parameters, and spraying the conductive paint from the spray nozzle onto a perimeter of the panel using the first and the second sets of parameters to form a layer of the conductive paint over the perimeter, the layer providing approximately uniform coverage of the metal particles on the perimeter without substantial paint overspray. The layer of conductive paint electrically couples with wirebonds on the panel to form at least part of an electromagnetic interference (EMI) or radio frequency interference (RFI) shield that attenuates EMI or RFI during operation of the IC module. 
         [0008]    For purposes of summarizing the disclosure, certain aspects, advantages and novel features of the inventions have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  shows individual packaged modules including a conductive layer formed over the overmold such that the conductive layer is in electrical contact with the exposed upper portions of the EM isolation wirebonds. 
           [0010]      FIG. 2  shows a process that can be implemented to fabricate a packaged module that includes an interconnected RF-shielding structure and/or shielded volume. 
           [0011]      FIG. 3  a show front side of an example laminate panel configured to receive a plurality of dies for formation of packaged modules. 
           [0012]      FIGS. 4 and 5  show various views of the die electrically connected to the laminate substrate by example wirebonds. 
           [0013]      FIGS. 6 and 7  show various views of wirebonds formed on the laminate substrate and configured to facilitate electromagnetic (EM) isolation between an area defined by the wirebonds and areas outside of the wirebonds. 
           [0014]      FIG. 8  shows a side view of molding configuration for introducing molding compound to a region above the laminate substrate. 
           [0015]      FIG. 9  shows a side view of an overmold formed via the molding configuration of  FIG. 8 . 
           [0016]      FIG. 10  shows the front side of a panel with the overmold. 
           [0017]      FIG. 11  shows a detail of a side view of how an upper portion of the overmold can be removed to expose upper portions of the EM isolation wirebonds. 
           [0018]      FIG. 12  shows a side view of how an upper portion of the overmold can be removed to expose upper portions of the EM isolation wirebonds. 
           [0019]      FIG. 13  shows a photograph of a portion of a panel where a portion of the overmold has its upper portion removed to better expose the upper portions of the EM isolation wirebonds. 
           [0020]      FIG. 14  illustrates a schematic block diagram of a four section panel with an upper portion of the overmold removed to better expose the upper portions of the EM isolation wirebonds. 
           [0021]      FIG. 15  is a flow chart illustrating a process for forming a conductive layer on a panel of IC modules, according to an embodiment. 
           [0022]      FIG. 16A  is a schematic diagram illustrating a first perimeter spray pattern for the process of  FIG. 14 , according to an embodiment. 
           [0023]      FIG. 16B  is a schematic diagram illustrating a staggered flood spray pattern for the process of  FIG. 14 , according to an embodiment. 
           [0024]      FIG. 16C  illustrates is a schematic diagram illustrating a second perimeter spray pattern for the process of  FIG. 14 , according to an embodiment. 
           [0025]      FIG. 16D  is a schematic diagram illustrating a flood spray pattern for the process of  FIG. 4 , according to an embodiment. 
           [0026]      FIG. 17  is a partial cross-sectional view of a panel with modules after the process of  FIG. 14 , according to certain embodiments. 
           [0027]      FIG. 18  shows a photograph of a panel where the conductive layer can be a spray-on metallic paint. 
           [0028]      FIG. 19  is an exemplary table showing spray parameters, line parameters, and spray pattern parameters, according to an embodiment. 
           [0029]      FIG. 20  is an exemplary table showing spray parameters, line parameters, and spray pattern parameters, according to another embodiment. 
           [0030]      FIG. 21  shows a side view of a conductive layer formed over the overmold such that the conductive layer is in electrical contact with the exposed upper portions of the EM isolation wirebonds. 
           [0031]      FIG. 22  shows that one or more of modules that are mounted on a wireless phone board can include one or more features as described herein. 
           [0032]      FIG. 23  shows a process that can be implemented to install a packaged module having one or more features as described herein on a circuit board such as the phone board of  FIG. 22 . 
           [0033]      FIG. 24  schematically depicts the circuit board with the packaged module installed thereon. 
           [0034]      FIG. 25  schematically depicts a wireless device having the circuit board with the packaged module installed thereon. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0035]    The features of the systems and methods will now be described with reference to the drawings summarized above. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements. The drawings, associated descriptions, and specific implementation are provided to illustrate embodiments of the inventions and not to limit the scope of the disclosure. 
       Overview 
       [0036]      FIG. 2  shows a process  10  that can be implemented to fabricate a packaged module having an interconnected RF-shielding structure and/or shielded volume that attenuates EMI or RFI during operation of the IC module as described herein. FIGS.  1  and  3 - 21  show various parts and/or stages of various steps associated with the process  10  of  FIG. 2 . 
         [0037]    In block  12   i  of  FIG. 2 , the modules in a cookie section having a common conductive layer (e.g., a conductive paint layer) can be singulated into individual packaged modules. The conductive layer is in electrical contact with the upper portions of RF-shielding wirebonds adjacent to the IC module. Such a conductive layer can be formed by a number of different techniques, including methods such as spraying or printing. Spraying conductive paint to form the conductive layer is described below. 
         [0038]      FIG. 1  shows an example configuration  74  where a modular section  20  described herein has been singulated into a separated module  75 . The overmold portion is shown to include a side wall  77 ; and the module substrate portion is shown to include a side wall  76 . Collectively, the side walls  77  and  76  are shown to define a side wall  78  of the separated module  75 . The upper portion of the separated module  75  remains covered by the conductive layer  71 . Accordingly, the conductive layer  71  forms improved contacts with the RF-shielding wirebonds  51 . 
         [0039]    The lower surface  27  of the separated module  75  includes contact pads  28 ,  29  to facilitate electrical connections between the module  75  and a circuit board such as a phone board. As described herein, such a module includes RF-shielding structures encapsulated within the overmold structure and layered over the overmold structure; and in some implementations, the overall dimensions of the module  75  is not necessarily any larger than a module without the RF-shielding functionality. 
         [0040]    The RF-shielding wirebonds  51  and a ground plane  30  can yield an interconnected RF-shielding structure at sides and underside of the area defined by the RF-shielding wirebonds  51 . With the upper conductive layer  71  in electrical contact with the RF-shielding wirebonds  51 , the upper side above the area is now shielded as well, thereby yielding a shielded volume. Accordingly, modules having integrated RF-shielding functionality can advantageously yield a more compact assembled circuit board since external RF-shield structures are not needed. Further, the packaged modular form allows the modules to be handled easier during manipulation and assembly processes. 
         [0041]    In block  12   a  of  FIG. 2 , a packaging substrate and parts to be mounted on the packaging substrate can be provided. Such parts can include, for example, one or more surface-mount technology (SMT) components and one or more singulated dies having integrated circuits (ICs).  FIG. 3  shows that in some embodiments, the packaging substrate can include a laminate panel  16 .  FIG. 3  shows the example panel&#39;s front side. The panel  16  can include a plurality of individual module substrates  20  arranged in groups that are sometimes referred to as cookies  18 . 
         [0042]    In block  12   b  of  FIG. 2 , various steps can be performed to allow mounting of one or more SMT devices and one or more dies. The various steps can include but are not limited to applying solder paste on the module substrate to allow mounting of one or more SMT devices, positioning one or more SMT devices on the solder contacts having solder paste, performing a reflow operation to melt the solder paste to solder the one or more SMT devices on their respective contact pads, removing solder residue from the reflow operation, applying adhesive on one or more selected areas on the module substrate  20  to allow mounting of one or more dies, positioning one or more dies on the selected areas with adhesive applied thereon, curing the adhesive between the die and the die-mounting area, removing adhesive residue from the mounting operation, and the like. 
         [0043]    In block  12   c  of  FIG. 2 , electrical connections such as wirebonds can be formed between the mounted die(s) and corresponding contact pads on the module substrate  20 .  FIGS. 4 and 5  show an example configuration  48  where a number of wirebonds  49  are formed between the contact pads  37  of the die  36  and the contact pads  24  of the module substrate  20 . Such wirebonds can provide electrical connections for signals and/or power to and from one or more circuits of the die  36 . In some implementations, the formation of the foregoing wirebonds can be achieved by an automated wirebonding machine. 
         [0044]    In block  12   d  of  FIG. 2 , a plurality of RF-shielding wirebonds can be formed about a selected area on the module substrate  20 .  FIGS. 6 and 7  show an example configuration  50  where a plurality of RF-shielding wirebonds  51  is formed on wirebond pads  26 . The wirebond pads  26  are schematically depicted as being electrically connected (dotted lines  31 ) with one or more reference planes such as a ground plane  30 . In some embodiments, such a ground plane can be disposed within the module substrate  20 . The foregoing electrical connections between the RF-shielding wirebonds  51  and the ground plane  30  can yield an interconnected RF-shielding structure at sides and underside of the area defined by the RF-shielding wirebonds  51 . As described herein, a conductive layer can be formed above such an area and connected to upper portions of the RF-shielding wirebonds  51  to thereby form an RF-shielded volume. 
         [0045]    In the example configuration  50 , the RF-shielding wirebonds  51  are shown to form a perimeter around the area where the die ( 36 ) and the SMT devices ( 43 ) are located. Other perimeter configurations are also possible. For example, a perimeter can be formed with RF-wirebonds around the die, around one or more of the SMT devices, or any combination thereof. In some implementations, an RF-wirebond-based perimeter can be formed around any circuit, device, component or area where RF-isolation is desired. For the purpose of description, it will be understood that RF-isolation can include keeping RF signals or noise from entering or leaving a given shielded area. 
         [0046]    In the example configuration  50 , the RF-shielding wirebonds  51  are shown to have an asymmetrical side profile configured to facilitate controlled deformation during a molding process as described herein. Additional details concerning such wirebonds can be found in, for example, PCT Publication No. WO 2010/014103 titled “SEMICONDUCTOR PACKAGE WITH INTEGRATED INTERFERENCE SHIELDING AND METHOD OF MANUFACTURE THEREOF.” In some embodiments, other shaped RF-shielding wirebonds can also be utilized. For example, generally symmetric arch-shaped wirebonds as described in U.S. Pat. No. 8,071,431, titled “OVERMOLDED SEMICONDUCTOR PACKAGE WITH A WIREBOND CAGE FOR EMI SHIELDING,” can be used as RF-shielding wirebonds in place of or in combination with the shown asymmetric wirebonds. In some embodiments, RF-shielding wirebonds do not necessarily need to form a loop shape and have both ends on the surface of the module substrate. For example, wire extensions with one end on the surface of the module substrate and the other end positioned above the surface (for connecting to an upper conductive layer) can also be utilized. 
         [0047]    In the example configuration  50  of  FIGS. 6 and 7 , the RF-shielding wirebonds  51  are shown to have similar heights that are generally higher than heights of the die-connecting wirebonds ( 49 ). Such a configuration allows the die-connecting wirebonds ( 49 ) to be encapsulated by molding compound as described herein, and be isolated from an upper conductive layer to be formed after the molding process. 
         [0048]    In block  12   e  of  FIG. 2 , an overmold can be formed over the SMT component(s), die(s), and RF-shielding wirebonds.  FIG. 8  shows an example configuration  52  that can facilitate formation of such an overmold. A mold cap  53  is shown to be positioned above the module substrate  20  so that the lower surface  54  of the mold cap  53  and the upper surface  21  of the module substrate  20  define a volume  55  where molding compound can be introduced. 
         [0049]    In some implementations, the mold cap  53  can be positioned so that its lower surface  54  engages and pushes down on the upper portions of the RF-shielding wirebonds  51 . Such a configuration allows whatever height variations in the RF-shielding wirebonds  51  to be removed so that the upper portions touching the lower surface  54  of the mold cap  53  are at substantially the same height. When the mold compound is introduced and an overmold structure is formed, the foregoing technique maintains the upper portions of the encapsulated RF-shielding wirebonds  51  at or close to the resulting upper surface of the overmold structure. 
         [0050]    In the example molding configuration  52  of  FIG. 8 , molding compound can be introduced from one or more sides of the molding volume  55  as indicated by arrows  56 . In some implementations, such an introduction of molding compound can be performed under heated and vacuum condition to facilitate easier flow of the heated molding compound into the volume  55 . 
         [0051]      FIG. 9  shows an example configuration  58  where molding compound has been introduced into the volume  55  as described in reference to  FIG. 8  and the molding cap removed to yield an overmold structure  59  that encapsulates the various parts (e.g., die, die-connecting wirebonds, and SMT devices). The RF-shielding wirebonds are also shown to be substantially encapsulated by the overmold structure  59 . The upper portions of the RF-shielding wirebonds are shown to be at or close to the upper surface  60  of the overmold structure  59 . 
         [0052]      FIG. 10  shows an example panel  62  that has overmold structures  59  formed over the multiple cookie sections. Each cookie section&#39;s overmold structure can be formed as described herein in reference to  FIGS. 8 and 9 . The resulting overmold structure  59  is shown to define a common upper surface  60  that covers the multiple modules of a given cookie section. 
         [0053]    The molding process described herein in reference to  FIGS. 8-10  can yield a configuration where upper portions of the encapsulated RF-shielding wirebonds are at or close to the upper surface of the overmold structure. Such a configuration may or may not result in the RF-shielding wirebonds forming a reliable electrical connection with an upper conductor layer to be formed thereon. 
         [0054]    In block  12   f  of  FIG. 2 , a top portion of the overmold structure can be removed to better expose upper portions of the RF-shielding wirebonds.  FIG. 12  shows an example configuration  64  where such a removal has been performed.  FIG. 11  shows an enlarged detail of the example configuration  64 . In the example, the upper portion of the overmold structure  59  is shown to be removed to yield a new upper surface  65  that is lower than the original upper surface  60  (from the molding process). Such a removal of material is shown to better expose the upper portions  66  of the RF-shielding wirebonds  51 . 
         [0055]    The foregoing removal of material from the upper portion of the overmold structure  59  can be achieved in a number of ways.  FIG. 13  shows an example configuration  68  where such removal of material is achieved by sand-blasting. In the example, the lighter-shaded portion is where material has been removed to yield the new upper surface  65  and better exposed upper portions  66  of the RF-shielding wirebonds. The darker-shaded portion is where material has not been removed, so that the original upper surface  60  still remains. The region indicated as  69  is where the material-removal is being performed. 
         [0056]    In the example shown in  FIG. 13 , a modular structure corresponding to the underlying module substrate  20  (depicted with a dotted box  22 ) is readily shown. Such modules will be separated after a conductive layer is formed over the newly formed upper surface  65 . 
         [0057]    In block  12   g  of  FIG. 2 , the new exposed upper surface resulting from the removal of material can be cleaned to yield a cleaner surface to facilitate improved adhesion of a conductive layer formed thereon. 
         [0058]    In block  12   h  of  FIG. 2 , an electrically conductive layer can be formed on the new exposed upper surface of the overmold structure, so that the conductive layer is in electrical contact with the upper portions of the RF-shielding wirebonds. Such a conductive layer can be formed by a number of different techniques, including methods such as spraying or printing. 
         [0059]    Spraying conductive paint on the surface of an IC panel to form the conductive layer as at least part of an EMI/RF shield is described in further detail below. Although certain embodiments are described herein with respect to the exemplary panel  1400  illustrated in  FIG. 14 , it is understood that in other embodiments, the panel of IC modules can have different dimensions, a different number of cookies, and each cookie can include different quantities of IC modules than the illustrated panel  1400 . 
         [0060]      FIG. 14  illustrates a schematic block diagram of an embodiment of a four section panel  1400  formed after completion of block  12   f  of  FIG. 2 . In the illustrated embodiment, panel  1400  comprises a module substrate  1402  and four abraded encapsulated sections or cookies  1404 . Each cookie  1404  comprises at least one integrated circuit  1406  mounted to the substrate  1402 , a cap or overmold  1408 , and at least one RF-shielding wirebond  51 . 
         [0061]    The panel  1400  has a cookie length, L, along the longitudinal axis of the substrate  1402  of approximately 7.10 inches and a cookie height, H, along the vertical axis of the substrate  1402  of approximately 2.05 inches. In other embodiments, the panel dimensions can be other values. Typically, each cookie  1404  can comprise between approximately 4 and approximately 300 integrated circuits. In another embodiments, the panel  1400  can comprise less than or more than four cookies  1404 . In further embodiments, each cookie  1404  can comprise less than 4 or more than 300 IC modules  1406 . 
         [0062]    In an embodiment, forming the conductive layer comprises covering the surface of the overmold  1408  with an approximately uniform or nearly uniform layer of conductive paint using a spray process. In an embodiment, the conductive paint is sprayed onto the surfaces  1408  of the panel  1400  during module manufacturing as at least part of an RFI or EMI shield for the IC modules  1406 . Unlike conventional spray paint, the conductive paint includes metal particles or flakes and can be much more expensive. A conductive paint can contain flakes with an average size or a range of sizes. Flake sizes can vary from less than approximately 1 micron, approximately 1 micron to approximately 10 microns, approximately 10 microns to approximately 60 microns, and greater than approximately 60 microns. While in some embodiments, the flakes or particles are uniform in shape, in other embodiments, the flakes or particles are irregularly shaped. When the conductive paint is applied, a more efficient RFI or EMI shield is created for the IC modules  1406  if the flakes overlap to provide coverage of the surfaces  1408  without gaps or with small gaps between the flakes. 
         [0063]    For example, a thin layer of corn flakes on a table surface where none of the flakes overlap does not cover the table surface. There are many gaps between the flakes where the table shows. Whereas a layer of corn flakes with an approximately uniform thickness such that the flakes overlap one another can provide total coverage, effective total coverage, or coverage that approximates total coverage of the table surface. While corn flakes are not conductive metal particles, the coverage analogy is applicable to the conductive paint. A layer of conductive paint including metal flakes where the conductive paint is applied with an approximate uniform thickness such that the metal flakes overlap one another can provide total coverage, effective total coverage, or coverage that approximates total coverage of the surface of the IC module  1406 . This in turn provides a conductive surface in electrical contact with the wirebonds  51  for each IC module  1406 , forming at least part of an EMI/RFI shield structure or volume for each IC module  1406 . 
         [0064]    Another quality of the conductive paint which affects the paint coverage is the paint viscosity. This may be an inherent quality of the paint or may be user adjustable with the addition of a suitable paint thinner. A more viscous paint will flow more slowly than a less viscous paint and may increase manufacturing throughput time, which in turn increases manufacturing costs. The less viscous paint may flow more quickly than the more viscous paint, but may provide spotty paint and/or spotty conductive particle coverage, which may provide poor EMI or RFI shielding. 
         [0065]    Due to the expense of the conductive paint, it is desirable to reduce the overspray. Overspray is the application of the conductive paint to any surface other than the surfaces  1408  on the panel  1400 . The conventional method of reducing the overspray is to apply the paint closer to the surface to be painted such that the spread of the spray is reduced. This also creates a non-uniform surface with peaks and valleys in the applied paint. 
         [0066]    Due to the use of the conductive paint as an EMI or RFI shield, it is desirable to form a uniform or approximately uniform layer of conductive metal particles over the IC modules  1406  with no or small gaps between the metal particles as described above. The conventional method of applying a uniform layer of a sprayed material is to apply the paint farther from the surface to be painted such that the spread of the spray is increased. This also increases the overspray. 
         [0067]    In one embodiment, a paint sprayer comprising a spray head and a paint delivery system delivers the conductive paint to the IC panel  1400 . Examples of paint sprayer spray heads are standard flux material spray heads, automated spray booths, jetting systems, and the like. Examples of paint delivery systems are an air atomization delivery system, an ultrasonic atomization paint delivery system, a regular air spray paint delivery system, automotive spray systems, and the like. In an embodiment, the paint sprayer is computer controlled and user programmable, where the user program is executed by the paint sprayer computer. The spray head comprises a spray nozzle and the spray nozzle includes a needle from which the paint enters the delivery system. Needles of various sizes can be used. The size of the needle depends at least in part on the size of the conductive particles in the paint and/or at least in part on the viscosity of the paint. If the needle is too small, the particles will clog the needle. The size of the needle also depends in part on the desired rate at which the paint exits the needle. A larger needle provides a greater rate of paint flow than a smaller needle. In one embodiment, needle sizes range from approximately 14 gauge to approximately 32 gauge. In other embodiments, larger or smaller needles can be used. 
         [0068]    Paint sprayers include additional factors that may be an inherent quality of the type of paint sprayer, or may be user settable. For example, in a paint sprayer with an air atomizer paint delivery system, in addition to choosing the needle size, the user may vary factors, such as, for example, the valve pressure, the air cap, the fluid pressure, the air assist pressure, and the like. The valve pressure controls the rate in which the seat valve opens and closes to allow the paint to flow to the nozzle. The air cap is measured in degrees and varies the angle of the cavity used to atomize the paint. The fluid pressure is the pressure applied to the paint reservoir to control the rate the conductive paint is pushed through the nozzle when the seat valve is opened and the air assist pressure is the pressure applied to the air cap to atomize the paint to apply it to the IC panel  1400 . 
         [0069]    In addition, the user can adjust the speed at which the spray head travels and the distance of the spray head above the surface to be painted. As described above, when the spray head is too far above the surface to be painted, the paint spreads and oversprays. When the spray head is too close to the surface to be painted, the spray is less uniform. There are tradeoffs with the speed also. The faster the spray head travels, the throughput of modules during manufacturing increases, but a thinner paint line is laid down, creating non-uniform paint and conductive particle coverage. 
         [0070]    Further factors include line parameters, such as a fluid on time, a fluid off time, an air assist on time, and an air assist off time. The fluid on time is the amount of time from the start of the spray head travel and to the start of the spray. The fluid off time is the time from the stop of the spray to the stop of the spray head travel. Similarly, the air assist on time is the time from the start of the spray head travel to the start of the flow of the air providing the atomization, and the air assist off time is the time from the stop of the flow of air providing the atomization to the stop of the spray head travel. 
         [0071]    Once the above parameters are chosen for a desired paint line, taking into account the line width, overspray width, thickness, and uniformity of coverage for the line, the process in  FIG. 2  block  12   h  can achieve a tight spray pattern that minimizes overspray and maintains acceptable paint thickness uniformity for the painted surfaces  1408 . In an embodiment, the above parameters are chosen to optimize overspray reduction and uniform paint coverage for a perimeter paint spray pattern and surface area spray patterns, such as, a flood paint spray pattern and a staggered flood paint spray pattern, respectively for the panel  1400  of IC modules  1406 . 
         [0072]      FIG. 2  block  12   h  illustrates forming a conductive layer on the exposed surfaces  1408  of a panel  1400  of IC modules  1406  during the module fabrication process.  FIG. 15  is a flow chart illustrating an embodiment of  FIG. 2  block  12   h  in further detail.  FIG. 15  illustrates the process used to spray conductive paint in spray patterns which form a uniform or nearly uniform or substantially uniform conductive layer having little or no overspray. 
         [0073]      FIGS. 16A-16D  are schematic diagrams illustrating embodiments of the spray patterns for the panel  1400  of  FIG. 14 .  FIG. 16A  is a schematic diagram illustrating an embodiment of a first perimeter spray  1600 .  FIG. 16B  is a schematic diagram illustrating an embodiment of a staggered flood spray  1620 .  FIG. 16C  illustrates is a schematic diagram illustrating an embodiment of a second perimeter spray  1640  and  FIG. 16D  is a schematic diagram illustrating an embodiment of a flood spray  1660 . 
         [0074]    Referring to  FIGS. 14 ,  15  and  16 A, the process  12   h  at block  1500  sprays conductive paint in a perimeter spray pattern  1600  over the surfaces  1408  of the panel  1400 . The spray paint apparatus sprays a first horizontal band of paint  1602  having a width W1 from approximately point A (0, 0) to approximately point B (L, 0). The first horizontal band  602  is approximately parallel to the longitudinal or horizontal axis of the panel  1400 . 
         [0075]    The beginning of the band  1602  is approximately at point A and the end of the band  1602  is approximately at point B because the actual beginning and ending points of the band  1602  are adjusted upward along the vertical axis toward points D and C, respectively, at least a portion of the width W1. Further, the actual beginning point of the band  1602  is adjusted outward along the longitudinal axis toward point B at least a portion of the width W1 and the actual ending point of the band  1602  is further adjusted inward along the longitudinal axis toward point A at least a portion of the width W1. 
         [0076]    The spray paint apparatus then sprays a first vertical band of paint  1604  having about width W1 from approximately point B (L,0) to approximately point C (L,H). The first vertical band  1604  is approximately parallel to the vertical axis of the panel  1400  and approximately perpendicular to the longitudinal or horizontal axis of the panel  1400 . 
         [0077]    The beginning of the band  1602  is approximately at point B and the end of the band  1602  is approximately at point C because the actual beginning and ending points of the band  1602  are adjusted inward along the longitudinal axis toward points A and D, respectively, at least a portion of the width W1. Further, the actual beginning point of the band  1604  is adjusted upward along the vertical axis toward point C at least a portion of the width W1 and the actual ending point of the band  1604  is further adjusted downward along the vertical axis toward point B at least a portion of the width W1. 
         [0078]    The spray paint apparatus then sprays a second horizontal band of paint  1606  having about width W1 from approximately point C (L,H) to approximately point D (0,H). The second horizontal band  1606  is approximately parallel to the longitudinal or horizontal axis of the panel  1400 . 
         [0079]    The beginning of the band  1606  is approximately at point C and the end of the band  1606  is approximately at point D because the actual beginning and ending points of the band  1606  are adjusted downward along the vertical axis toward points B and A, respectively, at least a portion of the width W1. Further, the actual beginning point of the band  1606  is adjusted inward along the longitudinal axis toward point D at least a portion of the width W1 and the actual ending point of the band  1606  is further adjusted inward along the longitudinal axis toward point A at least a portion of the width W1. 
         [0080]    The spray paint apparatus then sprays a second vertical band of paint  1608  having about width W1 from approximately point D (0,H) to approximately point A (0,0). The second vertical band  1608  is approximately parallel to the vertical axis of the panel  1400  and approximately perpendicular to the longitudinal or horizontal axis of the panel  1400 . 
         [0081]    The beginning of the band  1608  is approximately at point D and the end of the band  1608  is approximately at point A because the actual beginning and ending points of the band  1608  are adjusted outward along the longitudinal axis toward points C and B at least a portion of the width W1. Further, the actual beginning point of the band  1608  is adjusted downward along the vertical axis toward point A at least a portion of the width W1 and the actual ending point of the band  608  is further adjusted upward along the vertical axis toward point D at least a portion of the width W1. 
         [0082]    The adjustments of the beginning and ending locations of the bands  1602 ,  1604 ,  1606 ,  1608  reduce or in some embodiments eliminate overspray along the perimeter of the group of cookies  1404 . In addition, these adjustments prevent the perimeter bands of paint  1602 ,  1604 ,  1606 ,  1608  from overlapping, which would cause an additional layer of paint to be applied at the corners A, B, C, D of the group of cookies  1404 . 
         [0083]    In the described embodiment, the width W1 of the bands  1602 ,  1604 ,  1606 ,  1608  is approximately the same. In other embodiments, each band  1602 ,  1604 ,  1606 ,  1608  can have a differing width. In some embodiments, the width W1 is based at least in part on the height Z of the spray head above IC panel  1400 . Although the order of spraying of the perimeter bands in the described embodiment occurs with band  1602  being sprayed first, followed by band  1604 , which is then followed by band  1606  and ending with band  1608 , the order of the spraying of the bands  1602 ,  1604 ,  1606 ,  1608  can be different in other embodiments. 
         [0084]    Referring again to  FIGS. 14 ,  15  and  16 B, the process  12   h  at block  1502  performs a staggered flood spray pattern  1620 . The staggered flood spray pattern  1620  comprises n lines of paint which are sprayed in alternating left to right and right to left bands which are approximately parallel to each other and the longitudinal axis of the panel  1400 . In an embodiment, the spray head sprays the first band of the staggered flood spray pattern  1620  near the lower edge of the panel  400  and subsequent bands advance upward over the surface of the panel  1400 . In other embodiments, the spray begins near the top, the middle, or any other point of the panel  1400  and travels so as to cover the surfaces  1408  of the panel  1400 . 
         [0085]    In the embodiment illustrated in  FIG. 16B , n=9, or in other words, the staggered flood spray pattern  1620  comprises 9 paint bands. In other embodiments, n can be more or less than 9. The number of bands, n, of the staggered flood spray pattern  1620  depends at least in part on the height, H, of the panel  1400  and/or on the width of the spray line. 
         [0086]    Referring to  FIG. 16B , the spray paint apparatus sprays a first horizontal band of paint  1622  having a width W2 from approximately point B (L,0) to approximately point A (0,0). The first horizontal band  1622  is approximately parallel to the longitudinal or horizontal axis of the panel  1400 . 
         [0087]    The beginning of the band  1622  is approximately at point B and the end of the band  1622  is approximately at point A because the actual beginning and ending points of the band  1622  are adjusted upward along the vertical axis toward points D and C, respectively, to take into account the width W1 of the perimeter spray, the width W2 of the staggered flood spray bands, and line spacing LS1 of the staggered spray pattern  1620 . Further, the actual beginning point of the band  1622  is adjusted inward along the longitudinal axis toward point A and the actual ending point of the band  1622  is adjusted outward along the longitudinal axis toward point B to take into account the width W1 of the perimeter spray. 
         [0088]    In the illustrated embodiment, the first band  1622  begins at approximately (L−W1, 0.08+W1+½LS1), where L is the length of the panel, W1 is the width of the perimeter spray band of paint, and LS1 is the line spacing of the staggered flood spray pattern  1620 . The starting point coordinates may vary depending on the (0, 0) coordinates of the spray paint apparatus and the IC panel  1400  being painted. The first band  1622  ends at approximately (W1, 0.08+W1+½LS1). The spray head advances upward along the vertical axis of the panel  1400  to spray the next band in the staggered flood spray pattern  1620 . The spray head moves upward a distance approximately equal to the line spacing, LS1, and sprays a band of paint approximately parallel to the longitudinal axis of the panel  1400  ending at the beginning of the previous band but offset by the line spacing, LS1, above the previous line  1622 . 
         [0089]    This process repeats until the spray head applies n bands of paint to the surface of the panel  1400 , where each band of paint in the staggered flood spray pattern  1620  is offset from the previous band of paint by the line spacing, LS1. 
         [0090]    In the illustrated embodiment, the bands of paint in the staggered flood spray pattern  1640  are sprayed in an alternating left to right and right to left pattern. In another embodiment, the bands can be sprayed in an alternating right to left and left to right pattern. In yet other embodiments, each band can be sprayed from left to right, from right to left, or in any combination of left to right or right to left spray patterns. 
         [0091]    Referring again to  FIGS. 14 ,  15  and  16 C, the process  12   h  at block  1504  performs a second perimeter spray pattern  1640 . In an embodiment, the second perimeter spray pattern  1640  is the same as the first perimeter spray pattern  1600  described above. In other embodiments, the second perimeter spray pattern  1640  can have different beginning and ending points, a different order of application, wider or narrower band widths, or the like, than the first perimeter spray pattern  1600 . 
         [0092]    In the embodiment illustrated in  FIG. 16C , the second perimeter spray pattern  1640  comprises four perimeter bands of paint,  1642 ,  1644 ,  1646 , 1648 . The second perimeter bands  1642 ,  1644 ,  1646 ,  1648  correspond to the bands  1602 ,  1604 ,  1606 ,  1608  of the first perimeter spray pattern  1600 , respectively, and are applied as described above with respect to the first perimeter spray pattern  1600 . The processes of spraying the first and second perimeter spray patterns  1600 ,  1640  provide spray edge control that facilitates high volume manufacturing and reduces paint overspray. The reduction in paint overspray reduces paint waste, which provides cost savings. 
         [0093]    Referring again to  FIGS. 14 ,  15  and  16 D, the process  12   h  at block  1506  performs a flood spray pattern  1660 . The flood spray pattern  1640  comprises n+1 lines of paint which are sprayed in alternating left to right and right to left which are approximately parallel to each other and the longitudinal axis of the panel  1400  and have a width W3. The n+1 bands of the flood spray pattern  1660  interleave before, after, and between the n bands of the staggered flood spray pattern  620  to provide near uniform coverage of the panel  1400 . 
         [0094]    In the embodiment illustrated in  FIG. 6D , n=9, or in other words, the flood spray pattern  1660  comprises n+1=10 paint bands. While in other embodiments, n can be greater or less than 9, the relationship between the number of bands in the staggered flood spray pattern  1620  and the number in bands in the flood spray pattern  1660  is n:n+1. The number of bands, n+1, of the flood spray pattern  1660  depends at least in part on the height H of the panel  1400  and/or on the width of the spray line W3. 
         [0095]    The number of bands or paint lines, n+1, in the flood spray pattern is determined by rounding up to the next integer value the result of [H−2W1]/W3 where H is the height of the panel  400 , W1 is the width of the perimeter spray bands  1602 ,  1604 ,  1606 ,  1608 ,  1642 ,  1644 ,  1646 ,  1648 , and W3 is the width of bands in the flood spray pattern  1660 . The line spacing, LS2, between the bands of the flood spray pattern  1660  is [H−2W1]/[n+1]. 
         [0096]    In an embodiment, the spray head sprays the first band of the staggered flood spray pattern  1660  near the lower edge of the panel  1400  and subsequent bands advance upward over the surface of the panel  1400 . In other embodiments, the spray begins near the top, the middle, or any other point of the panel  1400  and travels so as to cover the surface of the panel  1400 . In an embodiment, the bands of paint in the flood spray pattern  1660  are sprayed in an alternating left to right and right to left pattern. In another embodiment, the bands can be sprayed in an alternating right to left and left to right pattern. In yet other embodiments, each band can be sprayed from left to right from right to left, or in any combination of left to right or right to left spray patterns. 
         [0097]    In the embodiment illustrated in  FIG. 16D , the spray head begins traveling left to right. A first band  1662  begins at approximately (0, 0.08+W1+½LS2) and ends at approximately (L−W1, 0.08+W1+½LS2) where W1 is the width of bands in the perimeter spray  1600 ,  1620 , LS2 is the line spacing of the flood spray pattern  1660 , and L is the length of the panel  1400 . The spray head advances upward along the vertical axis of the panel  1400  to spray the next band in the flood spray pattern  1660 . The spray head moves upward a distance approximately equal to the line spacing, LS2, and sprays a band of paint approximately parallel to the longitudinal axis of the panel  1400  ending at the beginning of the previous band but offset by the line spacing, LS2, above the previous line  1662 . 
         [0098]    This process repeats until the spray head applies n+1 bands of paint to the surface of the panel  1400 , where each band of paint in the flood spray pattern  660  is offset from the previous band of paint by the line spacing, LS2. 
         [0099]    In the illustrated embodiment, the width W2 of the paint band in the staggered flood spray  1640  is approximately the same as the width W3 of the paint bands in the flood spray  1660 . In other embodiments, the widths W2, W3 are not the same. In some embodiments, the widths W2, W3 are based at least in part on the height Z of the spray head above IC panel  1400 . In a preferred embodiment, the staggered flood spray  1640  precedes the flood spray  1660 . In other embodiments, the order of the perimeter sprays  1600 ,  1640 , the staggered flood spray  1620 , and the flood spray  1660  can vary. 
         [0100]    Referring to  FIG. 5 , in block  1508  the process  12   h  determines whether the desired paint thickness has been reached. If the desired paint thickness has not been reached, the process returns to block  1500 , where blocks  1502 - 1506  are repeated until the desired paint thickness has been reached. If the desired paint thickness has been reached, the process  12   h  ends at block  1510 . 
         [0101]      FIG. 17  is an exemplary cross-sectional view of the panel  1400  after the process of  FIG. 15 . The panel  1400  comprises the mold cap  1408  encasing the IC modules  1406  and the wirebonds  51  on the substrate  1402 . The panel  1400  further comprises the bands of paint from the first perimeter spray  1600 , the staggered flood spray  1620 , the second perimeter spray  1640 , and the flood spray  1660 . The bands of perimeter spray pattern  1640  are over the bands of perimeter spray pattern  1600 . The perimeter sprays  1600 ,  1640  provide little or no overspray. 
         [0102]    In the embodiment illustrated in  FIG. 17 , n=9. The 9 bands of the staggered flood spray pattern  1620  are next to the overmold  1408 , while the 10 bands of the flood spray pattern  1660  are above the staggered flood spray bands and cover any gaps in created by the irregular metal particles or flakes in the conductive paint. The 9 bands of conductive paint in the staggered flood spray pattern  1620  and the 10 bands of conductive paint in the flood spray pattern  1660  interleave to provide a nearly or approximately or substantially uniform paint thickness over the surface of the caps  1408 . The nearly or approximately or substantially uniform paint thickness provides a nearly or approximately uniform conductive layer  71  over the panel  1400 . 
         [0103]    As illustrated if  FIG. 17 , the thickness of each of the bands  1600 ,  1620 ,  1640 ,  1660  of conductive paint is greater toward the middle of the band and tapers off toward the sides of the band. As a result, the conductive paint forms a layer on the surfaces  1408  of the panel  1400  that is approximately uniform or approximately flat within a tolerance that accounts for the variations in the thickness of the band of paint. The flatness tolerance is the distance between two parallel planes within which the surface of the layer of conductive paint lies. In an embodiment, the conductive layer  71  has a thickness of approximately 30 microns±15 microns. In another embodiment, the conductive layer  71  has a thickness of approximately 5 microns to approximately 50 microns and a flatness of approximately 5 microns. In other words, the conductive paint layer  71  is between approximately 5 microns and 50 microns thick and the surface of the layer of paint lies within two parallel planes spaced approximately 5 microns apart. More preferably the thickness of the conductive layer  71  is approximately 20 microns to approximately 30 microns with a flatness of approximately 1 micron, and most preferably, the thickness of the conductive layer  71  is approximately 25 microns with a flatness of approximately 0.25 micron. In an embodiment, the flatness of the conductive layer ranges between approximately 0.25 micron and approximately 5 microns. In another embodiment, the flatness is approximately 1% of the thickness of the conductive paint layer  71 . 
         [0104]      FIG. 18  is an exemplary table showing spray parameters, line parameters, and spray pattern parameters, according to one embodiment. The paint sprayer has a valve pressure of approximately 75 psi, a 21 gauge needle, and an air gap of approximately 22.5°. The paint reservoir is pressurized to approximately 2.5 psi and the air assist is pressurized to approximately 4 psi. In this embodiment, n=9, such that the staggered flood spray pattern  1640  comprises 9 bands of paint and the flood spray pattern comprises 10 bands of paint. 
         [0105]    The spray parameters and the line parameters are set for each spray pattern,  1600 ,  1620 ,  1640 ,  1660 . Here, the first and the second perimeter spray patterns  1600 ,  1640  are the same. For each perimeter spray pattern  1600 ,  1640 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.25 inches above the panel  1400 . For each perimeter spray pattern  1600 ,  1640 , the paint spray is enabled 10 msec after the spray head begins to travel and is disabled approximately 7.5 msec before the end of the spray head travel. The air assist is enabled 10 msec after the spray head begins to travel and disabled 7.5 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the perimeter bands,  1602 ,  1604 ,  1606 ,  1608 ,  1642 ,  1644 ,  1646 ,  1648 . For example, the first perimeter band  602  begins at approximately (0.09, 0.18) and ends at approximately (7.15, 0.18). 
         [0106]    For the staggered flood spray pattern  1620 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.4 inches above the panel  1400 . The paint spray is enabled 5 msec after the spray head begins to travel and is disabled approximately 8 msec before the end of the spray head travel. The air assist is enabled 5 msec after the spray head begins to travel and disabled 8 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the 9 staggered flood spray pattern bands. For example, the first staggered flood spray band  1622  begins at approximately (7.1, 0.37) and ends at approximately (0.1, 0.37). 
         [0107]    For the flood spray pattern  1660 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.4 inches above the panel  1400 . The paint spray is enabled 5 msec after the spray head begins to travel and is disabled approximately 8 msec before the end of the spray head travel. The air assist is enabled 5 msec after the spray head begins to travel and disabled 8 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the 10 flood spray pattern bands. For example, the first flood spray band  1662  begins at approximately (0.1. 0.275) and ends at approximately (7.1, 0.275). 
         [0108]      FIG. 19  is another exemplary table showing spray parameters, line parameters, and spray pattern parameters, according to another embodiment. The paint sprayer has a valve pressure of approximately 75 psi, a 21 gauge needle, and an air gap of approximately 22.5°. The paint reservoir is pressurized to approximately 2 psi and the air assist is pressurized to approximately 3 psi. In this embodiment, n=9, such that the staggered flood spray pattern  640  comprises 9 bands of paint and the flood spray pattern comprises 10 bands of paint. 
         [0109]    The spray parameters and the line parameters are set for each spray pattern,  1600 ,  1620 ,  1640 ,  1660 . Here, the first and the second perimeter spray patterns  1600 ,  1640  are the same. For each perimeter spray pattern  1600 ,  1640 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.25 inches above the panel  1400 . For each perimeter spray pattern  1600 ,  1640 , the paint spray is enabled approximately 6.37 msec after the spray head begins to travel and is disabled approximately 8.25 msec before the end of the spray head travel. The air assist is enabled approximately 6.37 msec after the spray head begins to travel and disabled approximately 6.25 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the perimeter bands,  1602 ,  1604 ,  1606 ,  1608 ,  1642 ,  1644 ,  1646 ,  1648 . For example, the first perimeter band  1602  begins at approximately (0.080, 0.200) and ends at approximately (7.160, 0.200). 
         [0110]    For the staggered flood spray pattern  1620 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.4 inches above the panel  1400 . The paint spray is enabled 5.26 msec after the spray head begins to travel and is disabled approximately 10.0 msec before the end of the spray head travel. The air assist is enabled 5.26 msec after the spray head begins to travel and disabled 7 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the 9 staggered flood spray pattern bands. For example, the first staggered flood spray band  1622  begins at approximately (7.055, 0.370) and ends at approximately (0.170, 0.370). 
         [0111]    For the flood spray pattern  1660 , the spray speed is approximately 30 inches per second and the spray head is approximately 0.4 inches above the panel  1400 . The paint spray is enabled approximately 5.26 msec after the spray head begins to travel and is disabled approximately 10.0 msec before the end of the spray head travel. The air assist is enabled approximately 5.26 msec after the spray head begins to travel and disabled approximately 7 msec before the end of the spray head travel. The table further lists the coordinates of the beginning and ending points for the 10 flood spray pattern bands. For example, the first flood spray band  1662  begins at approximately (0.170, 0.275) and ends at approximately (7.055, 0.275). 
         [0112]      FIG. 20  shows an example panel  72  that has been sprayed with conductive paint to yield the electrically conductive layer  71  that covers multiple cookie sections. As described in reference to  FIG. 10 , each cookie section includes multiple modules that will be separated. 
         [0113]      FIG. 21  shows an example configuration  70  where the electrically conductive layer  71  has been formed over an upper surface  65  of the overmold structure  59  encapsulating components of IC modules on the substrate  20  having the ground plane  30 . As described herein, the upper surface  65  better exposes upper portions  66  of RF-shielding wirebonds  51 . Accordingly, the formed conductive layer  71  forms improved contacts with the upper portions  66  of the RF-shielding wirebonds  51 . 
         [0114]    The RF-shielding wirebonds  51  and the ground plane  30  can yield an interconnected RF-shielding structure at sides and underside of the area defined by the RF-shielding wirebonds  51 . Connections between the components and the ground plane  30  are depicted as dotted lines  31 . With the upper conductive layer  71  in electrical contact with the RF-shielding wirebonds  51 , the upper side above the area is now shielded as well, thereby yielding a shielded volume. 
         [0115]    In block  12   i  of  FIG. 2 , the modules in a cookie section having a common conductive layer (e.g., a conductive paint layer) can be singulated into individual packaged modules. The singulated modules can be tested for proper functionality and the modular form allows such testing to be performed easier. Further, the module&#39;s internal EMI/RFI-shielding functionality allows such testing to be performed without external EMI/RFI-shielding devices. 
         [0116]      FIG. 22  shows that in some embodiments, one or more modules included in a circuit board such as a wireless phone board can be configured with one or more packaging features as described herein. Non-limiting examples of modules that can benefit from such packaging features include, but are not limited to, a controller module, an application processor module, an audio module, a display interface module, a memory module, a digital baseband processor module, GPS module, an accelerometer module, a power management module, a transceiver module, a switching module, and a power amplifier module. 
         [0117]      FIG. 23  shows a process  80  that can be implemented to assemble a packaged module having one or more features as described herein on a circuit board. In block  82   a,  a packaged module can be provided. In some embodiments, the packaged module can represent a module described in reference to  FIG. 22 . In block  82   b,  the packaged module can be mounted on a circuit board (e.g., a phone board).  FIG. 24  schematically depicts a resulting circuit board  90  having module  91  mounted thereon. The circuit board can also include other features such as a plurality of connections  92  to facilitate operations of various modules mounted thereon. 
         [0118]    In block  82   c,  a circuit board having modules mounted thereon can be installed in a wireless device.  FIG. 25  schematically depicts a wireless device  94  (e.g., a cellular phone) having a circuit board  90  (e.g., a phone board). The circuit board  90  is shown to include a module  91  having one or more features as described herein. The wireless device is shown to further include other components, such as an antenna  95 , a user interface  96 , and a power supply  97 . 
         [0119]    While embodiments have been described with respect to applying conductive spray paint to a panel of integrated circuit modules, the disclosed systems and methods apply to spray painting any surface with edge control to reduce overspray while maintaining paint thickness uniformity. 
         [0120]    The panel  1400  in the illustrated embodiment is a four sided rectangular shape. In other embodiments, the process  12   h  of  FIG. 15  can be adapted for other shapes with more or less than four sides, such as ovals, circles, squares, triangles, trapezoids, and the like. 
         [0121]    Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” The words “coupled” or connected”, as generally used herein, refer to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. 
         [0122]    Moreover, conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” “for example,” “such as” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment. 
         [0123]    The above detailed description of certain embodiments is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those ordinary skilled in the relevant art will recognize. For example, while processes or blocks are presented in a given order, alternative embodiments may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times. 
         [0124]    The teachings of the invention provided herein can be applied to other systems, not necessarily the systems described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments. 
         [0125]    While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.