Patent Description:
Today, there is an increasing trend to include radar systems in vehicles such as automobiles, trucks, buses, and the like in order to provide a driver with enhanced awareness of objects around the driver's vehicle. As the vehicle approaches objects (e.g., other cars, pedestrians, and obstacles) or as objects approach the vehicle, a driver cannot always detect the object and perform intervention actions needed to avoid a collision with the object. An automotive radar system mounted on a vehicle can detect the presence of objects including other vehicles in proximity to the vehicle and provide the driver with timely information so that the driver can perform possible intervention actions. However, such automotive radar system can significantly impact the cost of the vehicle.

<CIT>, <CIT> and <CIT> disclose semiconductor devices comprising a directing structure affixed to a device package.

According to the present invention, a semiconductor device is provided as set forth in claim <NUM> and a method of forming the same as set forth in claim <NUM>. Preferred embodiments are set forth in dependent claims.

Generally, there is provided, a semiconductor device having a radiating element and a directing structure. The semiconductor device includes a packaged semiconductor die interconnected to the radiating element integrated in the package. The directing structure is affixed over the radiating element by way of an adhesive material. The directing structure is formed as a low cost prefabricated multilayer laminate structure. For example, the directing structure includes a first set of directing elements arranged on a first conductive layer and a second set of directing elements arranged on a second conductive layer separated from the first conductive layer by way of a dielectric material. The radiating element and directing structure together are configured for propagation of radio frequency (RF) signals such as those in the mmWave frequency range (e.g., <NUM> - <NUM>). Because the directing structure is a prefabricated structure affixed to the package by way of an adhesive, an automated assembly process is employed to further improve reliability, accuracy, and overall device costs.

<FIG> illustrates, in a simplified top-side-up plan view, an example semiconductor device <NUM> at a stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes a semiconductor die <NUM>, a package substrate <NUM>, and radiating element structures <NUM> and <NUM> integrated in the package substrate <NUM>. In this embodiment, the semiconductor die, depicted as a dashed-outline for reference, is affixed at a bottom side of the package substrate <NUM>. Each of the radiating element structures <NUM> and <NUM> include a radiating element <NUM> and surrounding ring <NUM> embedded in the package substrate. For illustration purposes, the radiating element structures <NUM> and <NUM> are depicted as visible through a top side of the package substrate <NUM> even though the radiating element structures <NUM> and <NUM> are embedded within the package substrate. In this embodiment, the group of radiating element structures <NUM> may be characterized as receiver (RX) radiating structures and the group of radiating element structures <NUM> may be characterized as transmitter (TX) radiating structures.

<FIG> illustrates, in a simplified top-side-up plan view, the example semiconductor device <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes the semiconductor die <NUM> affixed at the bottom side of the package substrate <NUM> and example prefabricated directing structures <NUM> affixed at a top side of the package substrate <NUM>. Even though the semiconductor die <NUM> is not visible from the view depicted in <FIG>, the dashed-outline is provided to indicate the semiconductor die location for reference. In this embodiment, each of the directing structures <NUM> is affixed over a corresponding radiating element structure (<NUM>, <NUM>). For example, the directing structures <NUM> are arranged in a RX directing structure group <NUM> and a TX directing structure group <NUM> corresponding to the radiating element structures <NUM> and <NUM> respectively.

<FIG> illustrate, in simplified top-side-up cross-sectional views, the example semiconductor device <NUM> taken along line A-A of <FIG> at stages of manufacture in accordance with an embodiment. In the embodiments of <FIG>, an example ball grid array (BGA) package type is depicted having a package substrate characterized as a chip scale package (CSP) type package substrate. Even though the embodiments depicted in <FIG> exemplify BGA type package configurations, embodiments in other package configuration types (e.g., wafer-level packaging) are anticipated by this disclosure.

<FIG> illustrates, in a simplified cross-sectional view, the example semiconductor device <NUM> taken along line A-A at a stage of manufacture in accordance with an embodiment. At this stage, the device <NUM> includes the semiconductor die <NUM> affixed to the package substrate <NUM>. In this embodiment, the semiconductor die <NUM> affixed at the bottom side of the package substrate <NUM> by way of conductive die connectors <NUM> and underfilled with an epoxy material <NUM>. In some embodiments, the semiconductor die <NUM> may be affixed at the top side of the package substrate <NUM>. The die connectors <NUM> may be any suitable die connector structure such as solder bumps, gold studs, copper pillars, and the like. Features such as bond pads on the semiconductor die <NUM> and corresponding pads on the package substrate <NUM> are not shown for illustration purposes.

The semiconductor die <NUM> has an active side (e.g., major side having circuitry, bond pads) and a backside (e.g., major side opposite of the active side). In this embodiment, the semiconductor die <NUM> is configured in a flip-chip orientation having the active side mounted on the bottom side of the package substrate <NUM>. The semiconductor die <NUM> may be formed from any suitable semiconductor material, such as silicon, germanium, gallium arsenide, gallium nitride, and the like. The semiconductor die <NUM> may further include any digital circuits, analog circuits, RF circuits, memory, processor, the like, and combinations thereof at the active surface.

The package substrate <NUM> has a top side and a bottom side (e.g., major side opposite of the top side). In this embodiment, the package substrate <NUM> is formed as a multilayer laminate structure having conductive (e.g., metal) layers patterned to form traces <NUM> and <NUM>-<NUM>, portion <NUM>, and radiating element <NUM>. The radiating element <NUM> may be formed as a monopole, loop, patch, or other suitable structure. In this embodiment, the radiating element <NUM> may be characterized as a signal launcher configured for propagation of radio frequency (RF) signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example. The conductive layers are separated from each another by a non-conductive material <NUM> (e.g., FR-<NUM>). The package substate <NUM> further includes connector pads <NUM> located at the bottom side and configured for connection to a printed circuit board (PCB) by way of conductive connectors, for example. Contacts <NUM> and vias <NUM>-<NUM> provide conductive connections between the semiconductor die <NUM> and the conductive traces <NUM>, <NUM>-<NUM>, portion <NUM>, and radiating element <NUM>.

In this embodiment, the semiconductor die <NUM> is interconnected with the radiating element <NUM> by way of conductive features of the package substrate <NUM> such as contact <NUM> and via <NUM>, for example. The portion <NUM> is a conductive layer portion located below the radiating element and separated from the radiating element <NUM> by way of the non-conductive material <NUM>. In this embodiment, the conductive layer portion <NUM> is configured and arranged to serve as a signal reflector. The package substate <NUM> further includes conductive vias <NUM> and trace <NUM> configured and arranged to form a vertical conductive structure (e.g., wall, fence) connected around a perimeter of the conductive layer portion <NUM>. The vertical conductive structure configured and arranged to serve as a sidewall of the signal reflector substantially surrounding the radiating element <NUM>. In some embodiments, it may be desirable to connect the conductive layer portion <NUM> and the vertical conductive structure to a ground supply terminal or other suitable supply terminal.

<FIG> illustrates, in a simplified cross-sectional view, the example semiconductor device <NUM> taken along line A-A at a subsequent stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes the example directing structure <NUM> affixed at the top side of the package substrate <NUM> by way of an adhesive material <NUM>. In this embodiment, the directing structure <NUM> is positioned over the radiating element <NUM> and affixed by way of the adhesive material <NUM>.

The adhesive material <NUM> may be any suitable adhesive (e.g., paste, film) configured for joining electronic components and packaging materials (e.g., die stacking). The adhesive material <NUM> may be dispensed or applied in a manner suitable for attachment of the directing structure <NUM> in a process consistent with component pick-and-place assembly processes or automated die attach processes, for example. The adhesive material <NUM> may be a polymer (e.g., polyimide, epoxy, Teflon) based adhesive in the form of a non-conductive adhesive or a conductive adhesive. For example, a non-conductive adhesive material <NUM> may be applied across a partial or entire interface between the radiating element <NUM> and the directing structure <NUM>. Whereas a conductive adhesive material <NUM> may be applied (e.g., around a perimeter) such that a radiated signal path between the radiating element <NUM> and the directing structure <NUM> is not obstructed by the conductive adhesive. Because the directing structure <NUM> is a prefabricated structure affixed to the package by way of the adhesive material <NUM>, an automated assembly process may be employed for a variety of package types (e.g., ball grid array packaging, wafer-level and strip-level packaging).

In this embodiment, the directing structure <NUM> is a prefabricated structure and includes a first plurality of directing elements <NUM> arranged on a first conductive layer, a second plurality of directing elements <NUM> arranged on a second conductive layer, and a third plurality of directing elements <NUM> arranged on a third conductive layer. Each of the three conductive layers are separated from each other by way of a dielectric material <NUM> (e.g., prepreg, epoxy, polyimide, FR-<NUM>). The first conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on a desired frequency of operation. Likewise, the second conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on the desired frequency of operation. The third conductive layer is patterned to form directing elements <NUM> as a slot in a conductive (e.g., copper) plane. The dimensions of the slot are predetermined based on the desired frequency of operation. In this embodiment, the directing structure <NUM> is formed as a laminate structure including three conductive layers separated by non-conductive material. In other embodiments, the directing structure <NUM> may be formed with any suitable number of conductive layers and directing elements. In this embodiment, the directing structure <NUM> may be characterized as an antenna configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example. In other embodiments, the directing structure <NUM> may serve as a coupler configured to receive a radiated signal from the radiating element <NUM> and propagate the signal by way of a conductive trace to a connector (e.g., for an antenna) at the top surface of the directing structure <NUM>. A simplified example manufacturing flow is depicted in <FIG>.

<FIG> illustrates, in a simplified cross-sectional view, the example semiconductor device <NUM> taken along line A-A at a subsequent stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes conductive connectors <NUM> affixed at the bottom side of the package substrate <NUM>. In this embodiment, after the directing structure <NUM> is affixed at the top side of the package substrate <NUM>, the conductive connectors <NUM> are affixed to respective connector pads <NUM> located at the bottom side. In this embodiment, the conductive connectors <NUM> may be characterized as input/output and power supply connectors coupled to provide input/output signals and power to the semiconductor die <NUM> by way of the connector pads <NUM>, for example. The conductive connectors <NUM> may be formed in any suitable conductive connector structures such as solder balls, gold studs, copper pillars, and the like. In this embodiment, the conductive connectors <NUM> are formed as ball connectors, for example, and arranged in a ball grid array (BGA). After conductive connectors <NUM> are affixed, individual semiconductor device units may be singulated from a panel or strip in a subsequent manufacturing process, for example.

<FIG> and <FIG> illustrate, in simplified cross-sectional views, the example semiconductor device <NUM> taken along line A-A at alternative stages of manufacture in accordance with an embodiment. The embodiments depicted in <FIG> and <FIG> are subsequent to the stage of manufacture depicted in <FIG> and are alternatives to the embodiments depicted in <FIG> and <FIG>.

<FIG> illustrates, in a simplified cross-sectional view, the example semiconductor device <NUM> taken along line A-A at an alternative stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes conductive connectors <NUM> affixed at the bottom side of the package substrate <NUM>. In this embodiment, the conductive connectors <NUM> are affixed to respective connector pads <NUM> located at the bottom side. In this embodiment, the conductive connectors <NUM> may be characterized as input/output and power supply connectors coupled to provide input/output signals and power to the semiconductor die <NUM> by way of the connector pads <NUM>, for example. The conductive connectors <NUM> may be formed in any suitable conductive connector structures such as solder balls, gold studs, copper pillars, and the like.

<FIG> illustrates, in a simplified cross-sectional view, the example semiconductor device <NUM> taken along line A-A at an alternative stage of manufacture in accordance with an embodiment. At this stage of manufacture, the device <NUM> includes the example directing structure <NUM> affixed at the top side of the package substrate <NUM> by way of an adhesive material <NUM>. In this embodiment, the directing structure <NUM> is positioned over the radiating element <NUM> and affixed by way of the adhesive material <NUM>. The adhesive material <NUM> may be any suitable adhesive (e.g., paste, film) configured for joining electronic components and packaging materials (e.g., die stacking). The adhesive material <NUM> may be dispensed or applied in a manner suitable for attachment of the directing structure <NUM> in a process consistent with component pick-and-place assembly processes or automated die attach processes, for example. The adhesive material <NUM> may be a polymer (e.g., polyimide, epoxy, Teflon) based adhesive in the form of a non-conductive adhesive or a conductive adhesive, for example. After the directing structure <NUM> is affixed at the top side of the package substrate <NUM>, individual semiconductor device units may be singulated from a panel or strip in a subsequent manufacturing process, for example. In some embodiments, singulated semiconductor device units may be subsequently attached to a PCB before affixing the directing structure <NUM> at the top side of the package substrate <NUM>.

In this embodiment, the directing structure <NUM> includes a first plurality of directing elements <NUM> arranged on a first conductive layer, a second plurality of directing elements <NUM> arranged on a second conductive layer, and a third plurality of directing elements <NUM> arranged on a third conductive layer. Each of the three conductive layers are separated from each other by way of a dielectric material <NUM>. The first conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on a desired frequency of operation. Likewise, the second conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on the desired frequency of operation. The third conductive layer is patterned to form directing elements <NUM> as a slot in a conductive (e.g., copper) plane. The dimensions of the slot are predetermined based on the desired frequency of operation. In this embodiment, the directing structure <NUM> is formed as a laminate structure including three conductive layers separated by non-conductive material. In other embodiments, the directing structure <NUM> may be formed with any suitable number of conductive layers and directing elements.

<FIG> illustrates, in a simplified cross-sectional view, an alternative example semiconductor device <NUM> with a directing structure <NUM> attached at a stage of manufacture in accordance with an example not forming part of the claimed invention but is nonetheless useful for the understanding of the invention. At this stage, the device <NUM> includes a semiconductor die <NUM> affixed at a bottom side of a package substrate <NUM> and a directing structure <NUM> affixed at a top side of the package substrate <NUM>. The semiconductor die <NUM> is affixed at a bottom side of a package substrate <NUM> by way of conductive die connectors <NUM> and underfilled with an epoxy material <NUM>. The die connectors <NUM> may be any suitable die connector structure such as solder bumps, gold studs, copper pillars, and the like. Features such as bond pads on the semiconductor die <NUM> and corresponding pads on the package substrate <NUM> are not shown for illustration purposes.

The package substrate <NUM> has a top side and a bottom side (e.g., major side opposite of the top side). In this embodiment, the package substrate <NUM> is formed as a multilayer laminate structure having conductive (e.g., metal) layers patterned to form traces <NUM>-<NUM>, slot <NUM>, and radiating element <NUM>. The conductive layers are separated from each another by way of a non-conductive material <NUM>. The package substate <NUM> further includes connector pads <NUM> located at the bottom side. Conductive connectors <NUM> are affixed to respective connector pads <NUM> located at the bottom side and configured for connection to a PCB, for example. The conductive connectors <NUM> may be formed in any suitable conductive connector structures such as solder balls, gold studs, copper pillars, and the like. Contacts <NUM> and vias <NUM>-<NUM> provide conductive connections between the semiconductor die <NUM> and the conductive traces <NUM>-<NUM> and radiating element <NUM>, for example.

The radiating element <NUM> is interconnected with the semiconductor die <NUM> by way of contact <NUM> in this embodiment. The radiating element <NUM> may be formed as a monopole, loop, patch, or other suitable structure. In this embodiment, the radiating element <NUM> may be characterized as a signal launcher configured for propagation of RF signals. In this embodiment, the radiating element <NUM> and the slot <NUM> are formed in separate conductive layers (e.g., copper) of the package substrate <NUM>. The slot <NUM> formed in a predetermined location over the radiating element <NUM>. The slot <NUM> may serve as an antenna when RF signals are propagated. The dimensions of the slot are predetermined based on a desired frequency of operation.

The directing structure <NUM> is affixed at a top side of the package substrate <NUM> by way of an adhesive. In this embodiment, the directing structure <NUM> is positioned over the slot <NUM> and affixed by way of the adhesive material <NUM>. The adhesive material <NUM> may be any suitable adhesive configured for joining electronic components and packaging materials. The adhesive material <NUM> may be dispensed or applied in a manner suitable for attachment of the directing structure <NUM> in a process consistent with component pick-and-place assembly processes or automated die attach processes, for example.

In this embodiment, the directing structure <NUM> includes a first plurality of directing elements <NUM> arranged on a first conductive layer and a second plurality of directing elements <NUM> arranged on a second conductive layer separated from the first conductive layer by way of a dielectric material <NUM>. The first conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on the desired frequency of operation. Likewise, the second conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on the desired frequency of operation. In this embodiment, the directing structure <NUM> may be characterized as an antenna configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example.

<FIG> illustrates, in a simplified cross-sectional view, an alternative example semiconductor device <NUM> with a directing structure <NUM> attached at a stage of manufacture in accordance with an embodiment. At this stage, the device <NUM> includes a semiconductor die <NUM> encapsulated with an encapsulant <NUM> (e.g., epoxy) and the directing structure <NUM> affixed at a top side of the encapsulant <NUM>. A redistribution layer (RDL) including conductive trace <NUM> and connector pads <NUM> is formed at a bottom side of the encapsulant <NUM> and exposed side of the semiconductor die <NUM>. In the embodiment of <FIG>, an example fan-out wafer-level package (FOWLP) type is depicted. A conductive (e.g., copper) radiating element <NUM> is formed at the top side of the encapsulant <NUM>. Conductive connectors <NUM> are affixed to respective connector pads <NUM> located at the bottom side and configured for connection to a PCB, for example. The conductive connectors <NUM> may be formed in any suitable conductive connector structures such as solder balls, gold studs, copper pillars, and the like.

The semiconductor die <NUM> has an active side (e.g., major side having circuitry, bond pads) and a backside (e.g., major side opposite of the active side). In this embodiment, the semiconductor die <NUM> is configured in the active side exposed at the bottom side of the encapsulant <NUM>. The semiconductor die <NUM> may be formed from any suitable semiconductor material, such as silicon, germanium, gallium arsenide, gallium nitride, and the like. The semiconductor die <NUM> may further include any digital circuits, analog circuits, RF circuits, memory, processor, the like, and combinations thereof at the active surface. Features such as bond pads on the semiconductor die <NUM> are not shown for illustration purposes.

The radiating element <NUM> is interconnected with the semiconductor die <NUM> by way of the trace <NUM> and a through-package via <NUM>, in this embodiment. The radiating element <NUM> may be formed as a monopole, loop, patch, or other suitable structure. The radiating element <NUM> shape and dimensions are predetermined based on a desired frequency of operation. In this embodiment, the radiating element <NUM> may be characterized as a signal launcher configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example.

The directing structure <NUM> is affixed at the top side of the encapsulant <NUM> by way of an adhesive. In this embodiment, the directing structure <NUM> is positioned over the radiating element <NUM> and affixed by way of the adhesive material <NUM>. The adhesive material <NUM> may be any suitable adhesive configured for joining electronic components and packaging materials. The adhesive material <NUM> may be dispensed or applied in a manner suitable for attachment of the directing structure <NUM> in a process consistent with component pick-and-place assembly processes or automated die attach processes, for example.

In this embodiment, the directing structure <NUM> includes a first plurality of directing elements <NUM> arranged on a first conductive layer, a second plurality of directing elements <NUM> arranged on a second conductive layer, and a third plurality of directing elements <NUM> arranged on a third conductive layer. Each of the three conductive layers are separated from each other by way of a dielectric material <NUM>. The first conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on a desired frequency of operation. Likewise, the second conductive layer is patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The number, size, and location of the directing elements <NUM> are predetermined based on the desired frequency of operation. The third conductive layer is patterned to form directing elements <NUM> as a slot in a conductive (e.g., copper) plane. The dimensions of the slot are predetermined based on the desired frequency of operation. In this embodiment, the directing structure <NUM> is formed as a laminate structure including three conductive layers separated by non-conductive material. In other embodiments, the directing structure <NUM> may be formed with any suitable number of conductive layers and directing elements. In this embodiment, the directing structure <NUM> may be characterized as an antenna configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example.

<FIG> illustrate, in simplified cross-sectional views, an example directing structure <NUM> at stages of manufacture in accordance with an embodiment. In this embodiment, the directing structure <NUM> is formed as a laminate structure including three conductive layers separated by non-conductive material layers. In other embodiments, the directing structure <NUM> may be formed with other suitable number of conductive layers.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a stage of manufacture in accordance with an embodiment. At this stage, the directing structure <NUM> includes a first non-conductive layer <NUM> formed on a carrier substrate <NUM>. The first non-conductive layer may be characterized as a dielectric material such as prepeg, epoxy, polyimide, and the like, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, a first conductive layer is formed on the first non-conducting layer <NUM>. In this embodiment, after forming the first non-conductive layer <NUM>, the first conductive layer is deposited and patterned to form directing elements <NUM> as a slot <NUM> formed in a conductive (e.g., copper) plane. The slot <NUM> may be configured as an antenna for propagation of RF signals. The dimensions of the slot may be chosen based on a desired frequency of operation, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, the directing structure <NUM> includes a second non-conductive layer <NUM> formed over the directing elements <NUM> and slot <NUM>. The second non-conductive layer may be characterized as a dielectric material formed from a similar material as the first non-conducting layer <NUM>, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, a second conductive layer is formed on the second non-conducting layer <NUM>. In this embodiment, after forming the second non-conductive layer <NUM>, the second conductive layer is deposited and patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The directing elements <NUM> may be configured as an artificial dielectric layer for propagation of RF signals. The number, size, and location of the directing elements <NUM> may be chosen based on the desired frequency of operation, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, the directing structure <NUM> includes a third non-conductive layer <NUM> formed over the directing elements <NUM>. The third non-conductive layer may be characterized as a dielectric material formed from a similar material as the first and second non-conducting layers <NUM> and <NUM>, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, a third conductive layer is formed on the third non-conducting layer <NUM>. In this embodiment, after forming the third non-conductive layer <NUM>, the third conductive layer is deposited and patterned to form directing elements <NUM> as an array of conductive (e.g., copper) patches. The directing elements <NUM> may be configured as an artificial dielectric layer for propagation of RF signals. The number, size, and location of the directing elements <NUM> may be chosen based on the desired frequency of operation, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, the carrier substrate <NUM> and the first non-conducting layer <NUM> are removed. In this embodiment, after forming the directing elements <NUM>, the carrier substrate <NUM> is removed. The first non-conducting layer <NUM> is removed after the carrier substrate <NUM> is removed. After the carrier substrate <NUM> and the first non-conducting layer <NUM> are removed, individual directing structure units may be singulated from a panel or strip in a subsequent manufacturing process, for example. At this stage, the singulated directing structure <NUM> may be supplied or provided as a prefabricated directing structure. At a subsequent stage, the directing structure <NUM> may be affixed to a semiconductor device package by way of an adhesive. In this embodiment, the directing structure <NUM> may be characterized as an antenna configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example.

<FIG> illustrates, in a simplified cross-sectional view, the example directing structure <NUM> at a subsequent stage of manufacture in accordance with an embodiment. At this stage, a conductive (e.g., copper) vertical sidewall <NUM> is formed around an outer perimeter of the directing structure <NUM>. In this embodiment, the vertical sidewall <NUM> is configured to provide shielding and noise isolation from adjacent directing structures or other sources, for example. At this stage, the singulated directing structure <NUM> may be supplied or provided as a prefabricated directing structure. At a subsequent stage, the directing structure <NUM> may be affixed to a semiconductor device package by way of an adhesive. In this embodiment, the directing structure <NUM> may be characterized as an antenna configured for propagation of RF signals such as radar, Wi-Fi, UWB, <NUM> and <NUM> signals, for example.

By now, it should be appreciated that there has been provided a semiconductor device having a radiating element and a directing structure. The semiconductor device includes a packaged semiconductor die interconnected to the radiating element integrated in the package. The directing structure is affixed over the radiating element by way of an adhesive material. The directing structure is formed as a low cost prefabricated multilayer laminate structure. For example, the directing structure includes a first set of directing elements arranged on a first conductive layer and a second set of directing elements arranged on a second conductive layer separated from the first conductive layer by way of a dielectric material. The radiating element and directing structure together are configured for propagation of radio frequency (RF) signals such as those in the mmWave frequency range (e.g., <NUM> - <NUM>). Because the directing structure is a prefabricated structure affixed to the package by way of an adhesive, an automated assembly process is employed to further improve reliability, accuracy, and overall device costs.

The terms "front," "back," "top," "bottom," "over," "under" and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

Claim 1:
A semiconductor device comprising:
a device package including a semiconductor die (<NUM>, <NUM>, <NUM>) coupled to a radiating element (<NUM>, <NUM>, <NUM>), the radiating element (<NUM>, <NUM>, <NUM>) integrated in the device package; and
a directing structure (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) affixed to the device package by way of an adhesive material (<NUM>), the directing structure (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) located over the radiating element (<NUM>, <NUM>, <NUM>) and configured for propagation of radio frequency, RF, signals,
wherein the directing structure (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) includes a first plurality of directing elements formed as an array of conductive patches (<NUM>, <NUM>, <NUM>, <NUM>) arranged on a first conductive layer, a second plurality of directing elements formed as an array of conductive patches (<NUM>, <NUM>, <NUM>, <NUM>) arranged on a second conductive layer, and a third plurality of directing elements (<NUM>, <NUM>, <NUM>, <NUM>) arranged on a third conductive layer and formed as a slot (<NUM>) in a conductive plane, wherein each of the first, second and third conductive layers are separated from each other by way of a dielectric material (<NUM>).