Patent ID: 12261350

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

DETAILED DESCRIPTION

The following disclosure provides for many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below. These are, of course, merely examples and are not intended to be limiting. In the present disclosure, reference to the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Embodiments of the present disclosure are discussed in detail below. It should be appreciated, however, that the present disclosure provides many applicable concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative and do not limit the scope of the disclosure.

FIG.1Aillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package includes a substrate10, a support structure11, an antenna12, an electronic component14and electrical contacts15.

The substrate10may be, for example, a printed circuit board, such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated glass-fiber-based copper foil laminate. The substrate10may include opposite surfaces (e.g., a top surface and a bottom surface). The substrate10may include an interconnection structure (e.g., an electrical connection), such as a redistribution layer (RDL). The substrate10may include metal layers10m1and10m2respectively on its top surface and bottom surface. In some embodiments, the metal layer10m1is a grounding layer.

The support structure11disposed on the top surface of the substrate10. In some embodiments, the support structure11can be formed of or includes insulation materials. In some embodiments, the support structure11is formed of or includes photo sensitive materials, such as photo-imageable dielectric (PID).

In some embodiments, the support structure11is formed of or includes a dielectric material. For example, the support structure11may include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), Borophosphosilicate Glass (BPSG), silicon oxide, silicon nitride, silicon oxynitride, Undoped Silicate Glass (USG), any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets.

Referring toFIG.1A, the support structure11includes a step structure (or ladder structure) defined by surfaces11s1and11s2. The surfaces11s1and11s2are connected to each other. The surface11s1is spaced apart from the top surface of the substrate10by a distance. In some embodiments, the number of the step structures can be changed depending on design specifications. For example, there may be number of N step structures, wherein N is an integer equal to or greater than 1.

The antenna12may be disposed on the step structure of the support structure11. The antenna12is disposed on the surface11s1of the support structure11. In some embodiments, the antenna12includes an antenna pattern12aand an opening12o. In some embodiments, the antenna12can be integrated formed without any openings. In some embodiments, a lateral surface of the antenna12is in contact with the surface11s2of the step structure. In some embodiments, a lateral surface of the antenna12may be spaced apart from the surface11s2of the step structure by a gap (not shown). Referring toFIG.1A, the opening12openetrates from the top surface of the antenna12to the bottom surface of the antenna12. The opening12omay act as a passage for electromagnetic wave to transmit.

In some embodiments, a top surface and a bottom surface of the antenna pattern12aare exposed. In some embodiments, a top surface and a bottom surface of the antenna pattern12aare uncovered. In some embodiments, a top surface and a bottom surface of the antenna pattern12aare exposed to air. In some embodiments, a top surface and a bottom surface of the antenna pattern12aare in direct contact to air. In some embodiments, the semiconductor device package is disposed within a vacuum space or a vacuum cavity and thus a top surface and a bottom surface of the antenna pattern12ais exposed to vacuum.

In some embodiments, the antenna12is, or includes, a conductive material such as a metal or metal alloy. Examples of the conductive material include Au, Ag, Al, Cu, or an alloy thereof.

Referring toFIG.1A, the antenna12may be electrically connected to the metal layer10m1through a connection structure12fand a connection element16. In some embodiments, the connection structure12fmay function as a feeding element to provide signal to the antenna12. In some embodiments, the connection structure12fconnecting the antenna12to the ground with the help of the metal layer10m1. In some embodiments, the connection structure12fmay include, but not limited to, a metal pillar, a bonding wire or stacked vias. In some embodiments, the connection structure12fincludes Au, Ag, Al, Cu, or an alloy thereof. In some embodiments, the connection element16may include, but is not limited to, a solder ball or any other suitable electrical connection structures.

In some embodiments, the metal layer10m1electromagnetically couples with the antenna12. In some embodiments, the metal layer10m1electrically connected to the antenna12. In some embodiments, the metal layer10m1and the antenna12are referred to as an antenna structure.

Dielectric materials can be used in the manufacturing process of a semiconductor package device. Currently available dielectric materials may have a loss tangent or a dissipation factor (Df) that is greater than about 0.003 and a dielectric constant or a dissipation constant (Dk) that is greater than 3. Air or a vacuum can have a Df of approximately “0.” Air or a vacuum can have a Dk of approximately “1.” Dk and Df values of a dielectric layer may affect the performance of an antenna that is disposed adjacent to the dielectric layer.

Experiments may be conducted on two antennas, one antenna has a surface exposed to air (or a vacuum, with a Dk of approximately 1), and the other antenna has a surface covered by a dielectric material with a Dk of approximately 4. Experiment results show that the antenna having the surface exposed to air (or a vacuum, with a Dk of approximately 1) has a peak gain that is 2.3 times that of the other antenna having a surface covered by the dielectric material with a Dk of approximately 4.

Experiments may be conducted on two antennas, one antenna having a surface covered by a dielectric material with a Dk of approximately 2, and the other antenna having a surface covered by a dielectric material with a Dk of approximately 4. Experimental results show that under the condition that the thicknesses of the dielectric materials covering both antennas are the same, the antenna having a surface covered by the dielectric material with a Dk of approximately 2 has a peak gain that is 1.3 times that of the other antenna having a surface covered by the dielectric material with a Dk of approximately 4.

For example, as shown inFIG.1A, parts of the antenna12can be exposed to air (or a vacuum), and in that case the performance of the antenna12can be about 1.3 to about 2.3 times that of antennas that have a surface covered by dielectric materials in accordance with some comparative embodiments of the subject application.

FIG.1Billustrates a perspective view of a semiconductor device package in accordance with some embodiments of the present disclosure.

Referring toFIG.1B, the support structure11is disposed to surround or partially surround the antenna12to support the antenna12.FIG.1Acan be the cross-sectional view taken along the dotted line A-A′ as shown inFIG.1B. In the embodiment shown inFIG.1B, the opening12oincludes a substantial rectangle shape. However, it can be contemplated that the opening12omay include any other suitable shapes. In the embodiment shown inFIG.1B, the antenna12includes one or more openings12o. In some embodiments, it can be contemplated that the antenna12can be integrated formed without any openings.

Referring toFIG.1B, the support structure11is disposed at two opposite corners of the antenna12. The support structure11may be disposed at different corners or edges of the antenna12as long as the antenna12can be supported by the support structure11. For example, the support structure11can be disposed at three corners of the antenna12. For example, the support structure11can be disposed at four corners of the antenna12. For example, the support structure11can fully surround the antenna12.

FIG.2Aillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package shown inFIG.2Ais similar to that shown inFIG.1A, except for that the antenna12further includes a protection layer12m.

Referring toFIG.2A, the antenna12includes an antenna pattern12aand a protection layer12m. The protection layer12mcan be in direct contact with the antenna pattern12a. The protection layer12msurrounds the antenna pattern12a. For example, a lateral surface12s1of the antenna pattern12acan be covered or in contact with the protection layer12m. The antenna pattern12acan be embedded within the protection layer12m, wherein both surfaces of the antenna pattern12aare uncovered by the protection layer12m.

The antenna12includes an opening12openetrating from the top surface of the protection layer12mto the bottom surface of the protection layer12m. The opening12omay act as a passage for electromagnetic wave to transmit.

The protection layer12mmay be an insulation layer to protect the antenna pattern12aand to prevent the antenna pattern from being short. In some embodiments, the protection layer12mmay be formed of or includes a dielectric material. For example, the protection layer12mmay include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), BPS), silicon oxide, silicon nitride, silicon oxynitride, USG, any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets.

In some embodiments, a top surface and a bottom surface of the antenna pattern12aare exposed from the protection layer12m. In some embodiments, a top surface and a bottom surface of the antenna pattern12aare not covered by the protection layer12m.

In some embodiments, the top surface and the bottom surface of the antenna pattern12aare substantially coplanar with the top surface and the bottom surface of the protection layer12mrespectively. For example, a thickness of the antenna pattern12ais substantially the same as a thickness of the protection layer12m.

In some embodiments, the top surface of the antenna pattern12ais recessed from the top surface of the protection layer12mdue to the manufacturing process of the antenna12. In some embodiments, the bottom surface of the antenna pattern12ais recessed from the bottom surface of the protection layer12mdue to the manufacturing process of the antenna12. In some embodiments, the top surface of the antenna pattern12acan protrude beyond the top surface of the protection layer12m. In some embodiments, the bottom surface of the antenna pattern12acan protrude beyond the bottom surface of the protection layer12m.

In some embodiments, a metal finishing layer may be disposed on the top surface of the antenna pattern12a(not shown). In some embodiments, the metal finishing layer disposed on the antenna pattern12ais not coplanar with the top surface of the protection layer12m. In some embodiments, the metal finishing layer disposed on the antenna pattern12aprotrudes beyond the top surface of the protection layer12m. The metal finishing layer may include, but is not limited to Electroless Nickel Immersion Gold (ENIG) or any other suitable materials.

Referring toFIG.2A, a lateral surface of the protection layer12mis in contact with the surface11s2of the step structure. In some embodiments, a lateral surface of the protection layer12mmay be spaced apart from the surface11s2of the step structure by a gap (not shown).

FIG.2Billustrates a perspective view of a semiconductor device package in accordance with some embodiments of the present disclosure.

Referring toFIG.2B, the support structure11is disposed to surround or partially surround the antenna12to support the antenna12.FIG.2Acan be the cross-sectional view taken along the dotted line B-B′ as shown inFIG.2B.

Referring toFIG.2B, the support structure11is disposed at two opposite corners of the antenna12. The support structure11may be disposed at different corners or edges of the antenna12as long as the antenna12can be supported by the support structure11. For example, the support structure11can be disposed at three corners of the antenna12. For example, the support structure11can be disposed at four corners of the antenna12. For example, the support structure11can fully surround the antenna12.

FIG.3Aillustrates a cross-sectional view of an antenna in accordance with some embodiments of the present disclosure. Referring toFIG.3A, the antenna includes a carrier30, one or more of antenna patterns31and a protection layer32. The antenna further includes one or more connection structures33disposed on the antenna patterns31.

The protection layer32surrounds the antenna patterns31. The protection layer32encapsulates the carrier30. The protection layer32encapsulates the antenna patterns31.

The antenna ofFIG.3Aincludes an opening32openetrating the carrier30and the protection layer32. In some embodiments, a thickness of the antenna pattern31is substantially identical to a thickness of the protection layer. In some embodiments, a thickness of the antenna pattern31is different from a thickness of the protection layer. In some embodiments, a top surface of the antenna pattern31recessed from a top surface of the protection layer. In some embodiments, a top surface of the antenna pattern31protrudes beyond a top surface of the protection layer.

FIG.3Billustrates a cross-sectional view of an antenna in accordance with some embodiments of the present disclosure. Referring toFIG.3B, the antenna includes one or more antenna patterns31and a protection layer32. The antenna includes one or more connection structures33disposed on the antenna patterns31. The antenna further includes a protruding structure30t. The protruding structure30tis disposed on a surface of the antenna pattern31. The protruding structure30tis in contact with a surface of the antenna pattern31. The protruding structure30tis mechanically attached to the antenna pattern31. The protruding structure30tis electrically connected to the antenna pattern31.

The protruding structure30textends from the antenna pattern31into the protection layer32. A gap exists between two adjacent protruding structures30t. The bottom surface of the protruding structure30tis substantially coplanar with the bottom surface of the protection layer32. The protruding structure30tmay prevent the protection layer32from being stripped off the antenna patterns31.

FIG.3Cillustrates a cross-sectional view of an antenna in accordance with some embodiments of the present disclosure. Referring toFIG.3C, the antenna includes one or more antenna patterns31and a protection layer32. The antenna includes one or more connection structures33disposed on the antenna patterns31. The antenna further includes a protruding structure30t. The protruding structure30tis disposed between the top surface and the bottom surface of antenna pattern31. The protruding structure30tis disposed along a direction parallel to the top surface of the antenna pattern31.

The protruding structure30tis mechanically attached to the antenna pattern31. The protruding structure30tis electrically connected to the antenna pattern31. The protruding structure30textends from the antenna pattern31into the protection layer32. The protruding structure30tmay prevent the protection layer32from being stripped off the antenna patterns31.

FIG.4Aillustrates a cross-sectional view of support structures in accordance with some embodiments of the present disclosure. Referring toFIG.4A, the support structure11-1may be integrally-formed. In some embodiments, the support structure11-1may be formed by, for example, lithographic technique. In some embodiments, the support structure11-1may be formed by, for example, by three-dimensional printing technique.

Referring toFIG.4A, the support structure11-2may be composed of several distinct components. For example, the support structure11-2may include support structures11a,11band11c. The support structures11a,11band11care disposed on the substrate10and have different heights. The support structure11ais disposed adjacent to the support structure11b. The support structure11bis disposed adjacent to the support structure11c. The support structures11aand11bform a step structure. The support structures11band11cform a step structure.

FIG.4Billustrates a cross-sectional view of support structures in accordance with some embodiments of the present disclosure. Referring toFIG.4B, the support structure11-3may be formed by stacking a support structure11don a support structure11e. An adhesive layer21is disposed between the substrate10and the support structure11e. An adhesive layer21is disposed between the support structure11dand the support structure11e. In some embodiments, the adhesive layer21may include a gel type or film type adhesive layer. The adhesive layer21may include a thermoset resin. The adhesive layer21may include a thermoplastic resin. The adhesive layer21may include one or more of the following: a resin, a polyester resin, a polyether resin, an epoxy resin and/or a polyolefin composition.

Referring toFIG.4B, the support structure11-4may include multi-layers. In some embodiments, the support structure11-4includes a layer11f, a layer11gand a layer11h. The layer1if includes a protection layer22disposed on the top surface of the layer11f. The layer11gincludes a protection layer22disposed on the top surface of the layer11g. The layer11hincludes a protection layer22disposed on the top surface of the layer11h.

The protection layer22is disposed on each of the layers11f,11gand11hfor the purpose of forming the step structure of the support structure11-4. In some embodiments, the protection layer22may be removed from the layers11f,11gand11hafter the support structure11-4is formed. The process for forming the support structure11-4will be described in the subsequent paragraphs later.

FIG.5Aillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package shown inFIG.5Ais similar to the semiconductor device package shown inFIG.2A, except for that the semiconductor device package shown inFIG.5Afurther includes an antenna13. Referring toFIG.5A, the antenna13includes an antenna pattern13a, a protection layer13m, and an opening13o. The antenna13is disposed on a surface11s3of the support structure11. The support structure11includes a surface11s4connected to the surface11s3. The surfaces11s3and11s4form a step structure (or a ladder structure).

In some embodiment, a lateral surface of the protection layer13mis in contact with the surface11s4of the step structure. In some embodiments, a lateral surface of the protection layer13mmay be spaced apart from the surface11s4of the step structure by a gap (not shown).

Referring toFIG.5A, the antenna12is disposed between the antenna13and the substrate10. The antenna12includes an antenna pattern12a. In some embodiments, the antenna pattern12ais aligned with the antenna pattern13ain the direction perpendicular to the top surface of the antenna12. In some embodiments, the antenna pattern12aelectromagnetically couples with the antenna pattern13a.

As shown inFIG.5A, the signal can be coupled from the metal layer10m1to the antenna pattern13aof the antenna13through the opening12oof the antenna12, and vice versa. The signal can be radiated from the antenna12upwardly through the opening13oof the antenna13. Since the signal can be transmitted between the metal layer10m1and the antennas12or13by coupling, no interconnection structure within the support structure11is included. In other embodiments, the support structure11may also include the interconnection structure as shown inFIG.5Bdepending on different design specifications.

FIG.5Billustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package inFIG.5Bis similar to the semiconductor device package inFIG.5Aexcept that the semiconductor device package inFIG.5Bfurther includes an interconnection structure11v. The interconnection structure11vis disposed within the support structure11. The interconnection structure11vis encapsulated or covered by the support structure11. The interconnection structure11vprovides an electrical connection between the antenna package13and the substrate10and/or between the antenna package12and the substrate10. In some embodiments, the interconnection structure11vis a through via or a copper pillar. The signal can be transmitted from the metal plate10m1to the antenna package13through the interconnection structure11v, and vice versa.

FIG.5Cillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package inFIG.5Cis similar to the semiconductor device package inFIG.5Bexcept that the connection structure12fshown inFIG.5Bis replaced by a support structure18. Referring toFIG.5C, the support structure18includes a metal layer18mand an interconnection structure18v. The support structure18surrounds the metal layer18mand the interconnection structure18v. The support structure18encapsulates the metal layer18mand the interconnection structure18v. The metal layer18mand the interconnection structure18vare embedded within the support structure18.

The metal layer18mmay be referred to as a feeding element in the present disclosure. The antenna12is electrically connected to the metal layer10m1through the metal layer18m, the interconnection structure18vand the connection element16. In some embodiments, the interconnection structure18vis a through via or a copper pillar. Signal can be transmitted from the metal plate10m1to the antenna package12through the metal layer18m, the interconnection structure18vand the connection element16, and vice versa.

FIG.5Dillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package inFIG.5Dis similar to the semiconductor device package inFIG.5Cexcept that the semiconductor device package inFIG.5Dfurther includes a connection structure13f. The connection structure13fis disposed between the antenna pattern12aand the antenna pattern13a. The connection structure13fis electrically connected the antenna12to the antenna13.

In some embodiments, the connection structure13fis electrically connected the antenna13through a connection element16. In some embodiments, the connection structure13fmay include, but not limited to, a metal pillar, a bonding wire or stacked vias. Signal can be transmitted from the antenna12to the antenna13through the connection structure13fand the connection element16, and vice versa.

FIG.5Eillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package ofFIG.5Eincludes a substrate10and support structures11-1,11-2and11-2disposed above the substrate10.

The semiconductor device package includes an antenna12disposed between the support structures11-1and11-2. The semiconductor device package includes an antenna13disposed between the support structures11-2and11-3. The antenna12is disposed on a step structure of the support structure11-1. The antenna12is disposed on a step structure of the support structure11-2. The antenna13is disposed on a step structure of the support structure11-2. The antenna13is disposed on a step structure of the support structure11-3.

The semiconductor device package further includes an electronic component14and electrical contacts15.

The antenna12is spaced apart from the top surface of the substrate10by a distance D1. The antenna13is spaced apart from the top surface of the substrate10by a distance D2. Referring toFIG.5E, D2is greater than D1.

The antenna12is electrically connected to the metal layer10m1through the support structure18-1. The antenna13is electrically connected to the metal layer10m1through the support structure18-2. The support structure18-1has a structure similar to or identical to the support structure18shown inFIG.5C. The support structure18-2has a structure similar to the support structure18shown inFIG.5C.

FIG.5Fillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package ofFIG.5Fincludes a substrate10and support structures11-1,11-2,11-3and11-4disposed above the substrate10.

Referring toFIG.5F, the semiconductor device package includes an antenna12disposed between the support structures11-1and11-2. The semiconductor device package includes an antenna13disposed on the support structures11-1,11-3and11-4. The antenna12is disposed on a step structure of the support structure11-1. The antenna12is disposed on a step structure of the support structure11-2. The antenna13is disposed on a step structure of the support structure11-1. The antenna13is disposed on the top surface of the support structure11-3. The antenna13is disposed on a step structure of the support structure11-4. The top surface of the support structure11-3is in contact with the protection layer13mof the antenna13.

In some embodiments, the support structures11-1,11-2,11-3and11-4are formed of or include the same material. In some embodiments, the support structures11-1,11-2,11-3and11-4are formed of or include different materials.

The antenna12is electrically connected to the metal layer10m1through the support structure18-1. The antenna13is electrically connected to the metal layer10m1through the support structure18-2. The support structure18-1has a structure similar to or identical to the support structure18shown inFIG.5C. The support structure18-2has a structure similar to the support structure18shown inFIG.5C.

FIG.5Gillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package inFIG.5Gis similar to the semiconductor device package inFIG.5Fexcept that the support structure11-3ofFIG.5Fis replaced by a shielding structure11-5.

In some embodiments, the shielding structure11-5is a conductive component, and may include, for example, aluminum (Al), copper (Cu), chromium (Cr), tin (Sn), gold (Au), silver (Ag), nickel (Ni) or stainless steel, or a mixture, an alloy, or other combination thereof. The shielding structure11-5can prevent the electromagnetic signal emitted by the antenna12from adversely affecting the antenna13, and vice versa.

FIG.5Hillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure. The semiconductor device package inFIG.5His similar to the semiconductor device package inFIG.5Fexcept that the antenna13includes an opening13openetrating from the top surface of the antenna13to the bottom surface of the antenna13. Referring toFIG.5H, the antenna pattern13aof the antenna13includes surfaces13s1,13s2and13s3. In some embodiments, the surfaces13s1,13s2and13s3are not covered by the protection layer13m. In some embodiments, the surfaces13s1,13s2and13s3are exposed to air. In some embodiments, the surfaces13s1,13s2and13s3are exposed to a vacuum.

In the embodiment shown inFIG.5H, the antenna pattern13ais not aligned with the antenna pattern12a. In some embodiments, it can be contemplated that the antenna pattern13acan be aligned with the antenna pattern12ain a direction parallel to the surface13s1. In some embodiments, the antenna pattern13acan be aligned with the antenna pattern12ain a direction perpendicular to the surface13s2. In the condition that the antenna pattern13ais not aligned with the antenna pattern12a, signals can be transmitted between the antenna13and the metal layer10m1through coupling. In the condition that the antenna pattern13ais aligned with the antenna pattern12a, signals can be transmitted between the antenna13and the antenna pattern12athrough coupling.

FIG.5Iillustrates a cross-sectional view of a semiconductor device package in accordance with some embodiments of the present disclosure.

Referring toFIG.5I, the semiconductor device package includes a substrate10, one or more support structures11, an antenna12, an antenna13and an electronic component14. A metal layer10m1can be disposed on the substrate10. The metal layer10m1can include several patterns. Some of the patterns of the metal layer10m1may act as a conductive pad. Some of the patterns of the metal layer10m1may act as a feeding element for transmitting/receiving signals to/from the antenna12. Some of the patterns of the metal layer10m1may act as a feeding element for transmitting/receiving signals to/from the antenna13.

The semiconductor device package may include a solder resist layer10rdisposed on the top surface of the substrate10. The solder resist layer10rmay cover a sidewall of the metal layer10m1. The solder resist layer10rmay cover at least a portion of the top surface of the metal layer10m1. The solder resist layer10rmay cover the entire top surface of the metal layer10m1. The solder resist layer10rmay expose a portion of the top surface of the metal layer10m1. The solder resist layer10rmay form an opening on the top surface of the metal layer10m1.

The antenna12includes one or more antenna patterns12a. The antenna12includes a protection layer12msurrounds the one or more antenna patterns12a. The antenna12includes a protection layer12mcovers the one or more antenna patterns12a. The antenna13includes one or more antenna patterns13a. The antenna13includes a protection layer13msurrounds the one or more antenna patterns13a. The antenna13includes a protection layer13mcovers the one or more antenna patterns13a.

The antenna12may include a solder resist layer12rdisposed on a surface of the protection layer12m. In some embodiments, the solder resist layer12rmay have a thickness of about 15 micrometers. In some embodiments, the solder resist layer12rmay include an edge that is aligned with an edge of the protection layer12m. In some embodiments, the solder resist layer12rmay include two edges that are aligned with two edges of the protection layer12m. In some embodiments, the solder resist layer12rmay include an edge that is not aligned with an edge of the protection layer12m.

The solder resist layer12rmay expose a portion of a surface of the antenna pattern12a. The solder resist layer12rmay expose a surface of the antenna pattern12a. The solder resist layer12rmay form an opening on a surface of the antenna pattern12a.

In some embodiments, the solder resist layer12rmay extend beyond an edge of the protection layer12mand cover at least a portion of the antenna pattern12a. In some embodiments, both surfaces of the antenna pattern12amay include a protection layer12m. The solder resist layer12r, when disposed on a portion of a surface of the antenna pattern12a, may prevent oxidation (for example, getting rusty or corrosion) on the portion of the antenna pattern12a.

The antenna13may include a solder resist layer13rdisposed on a surface of the protection layer13m. In some embodiments, the solder resist layer13rmay have a thickness of about 15 micrometers. In some embodiments, the solder resist layer13rmay include an edge that is aligned with an edge of the protection layer13m. In some embodiments, the solder resist layer13rmay include two edges that are aligned with two edges of the protection layer13m. In some embodiments, the solder resist layer13rmay include an edge that is not aligned with an edge of the protection layer13m.

In some embodiments, the solder resist layer13rmay extend beyond an edge of the protection layer13mand cover at least a portion of the antenna pattern13a. In some embodiments, the solder resist layer13rmay extend beyond an edge of the protection layer13mand completely cover a surface of the antenna pattern13a. In some embodiments, both surfaces of the antenna pattern13amay include a protection layer13m. The solder resist layer13r, when disposed on a portion of a surface of the antenna pattern13a, may prevent oxidation (for example, getting rusty or corrosion) on the portion of the antenna pattern13a.

The solder resist layer13rmay expose a portion of a surface of the antenna pattern13a. The solder resist layer13rmay expose a surface of the antenna pattern13a. The solder resist layer13rmay form an opening on a surface of the antenna pattern13a.

Referring toFIG.5I, the antenna12can be supported by two support structures11. The antenna12can be disposed on the surface11s1of the support structure11. The antenna12can be spaced apart from the substrate10by the support structures11. In some embodiments, the support structure11may include, but is not limited to, a solder ball or any other suitable electrical connection structures. In some embodiments, the antenna12can be electrically connected to the metal layer10m1through the support structure11. In some embodiments, the support structure11can be in direct contact with one or more of the antenna patterns12a. In some embodiments, the support structure11can be in direct contact with the metal layer10m1. In some embodiments, the antenna12can be mechanically attached to the metal layer10m1through the support structure11.

In some embodiments, the support structure11can be disposed within the opening defined by the solder resist layer10r. In some embodiments, the support structure11can be disposed within the opening defined by the solder resist layer12r. In some embodiments, the support structure11can be disposed within the opening defined by the solder resist layer13r. The support structure11can be limited by the opening defined by the solder resist layer10r. The support structure11can be limited by the opening defined by the solder resist layer12r. The support structure11can be limited by the opening defined by the solder resist layer13r.

The opening defined by the solder resist layer10rcan provide a better positioning to the support structure11. The opening defined by the solder resist layer12rcan provide a better positioning to the support structure11. The opening defined by the solder resist layer13rcan provide a better positioning to the support structure11. The opening defined by the solder resist layer10rcan prevent undesired leakages of the support structure11during the reflow procedure. The opening defined by the solder resist layer12rcan prevent undesired leakages of the support structure11during the reflow procedure. The opening defined by the solder resist layer13rcan prevent undesired leakages of the support structure11during the reflow procedure.

The antenna13can be supported by one or more support structures11. The antenna13can be disposed on the surface11s2of the support structure11. In some embodiments, the antenna13can be supported by one support structure11disposed between the substrate10and the antenna13. In some embodiments, the antenna13can be supported by one support structure11disposed between the antenna12and the antenna13.

In some embodiments, the antenna13can be electrically connected to the metal layer10m1through the support structure11. In some embodiments, the support structure11can be in direct contact with one or more of the antenna patterns13aand the metal layer10m1. In some embodiments, the antenna13can be mechanically attached to the metal layer10m1through the support structure11.

In some embodiments, the antenna13can be electrically connected to the antenna12through the support structure11. In some embodiments, the support structure11can be in direct contact with one or more of the antenna patterns12aand one or more of the antenna patterns13a. In some embodiments, the antenna13can be mechanically attached to the antenna12through the support structure11.

The antenna pattern12acan be aligned with the antenna pattern13athrough one or more support structures11. The antenna pattern12aand the antenna pattern13acan be aligned in a direction perpendicular to the top surface of the substrate10through one or more support structures11.

FIG.6Aillustrates a top view of a semiconductor device package in accordance with some embodiments of the present disclosure. For simplicity, the substrate10and the support structure11are depicted while the other components are omitted. Referring toFIG.6A, the support structure11fully surrounds the edges of the substrate10. Referring toFIG.6A, the surface11s3and the surface11s1is not coplanar. The antenna11as illustrated in accordance withFIGS.1A and2Amay be disposed on the surface11s1of the support structure11.

FIG.6Billustrates a top view of a semiconductor device package in accordance with some embodiments of the present disclosure. For simplicity, the substrate10and the support structure11are depicted while the other components are omitted. Referring toFIG.6B, support structures11-1,11-2,11-3and11-4are disposed around the four corners of the substrate10. In some embodiments, the support structure11-1and the support structure11-2are separated by a gap11G. In some embodiments, the support structure11-1and the support structure11-3are separated by a gap11G. In some embodiments, the support structure11-2and the support structure11-4are separated by a gap11G. In some embodiments, the support structure11-3and the support structure11-4are separated by a gap11G.

FIG.6Cillustrates a top view of a semiconductor device package in accordance with some embodiments of the present disclosure. For simplicity, the substrate10and the support structure11are depicted while the other components are omitted. The semiconductor device package ofFIG.6Cincludes a support structure11-5and a support structure11-6. The support structure11-5includes a top surface11s1. The support structure11-6includes a surface11s1and a surface11s3. The surface11s1of the support structure11-5is in the same level as the surface11s1of the support structure11-6. The surface11s3of the support structure11-6is in a level higher than the surface11s1of the support structure11-6. The surface11s3of the support structure11-6is spaced apart from the top surface of the substrate10by a first distance and the surface11s1of the support structure11-6is spaced apart from the top surface of the substrate10by a second distance. The first distance is greater than the second distance.

In some embodiments, the antenna12is disposed on the surface11s1of the support structure11-5. In some embodiments, the antenna12is disposed on the surface11s1of the support structure11-6. In some embodiments, the antenna12is disposed on the surface11s1of the support structures11-5and11-6.

FIG.6Dillustrates a top view of an antenna in accordance with some embodiments of the present disclosure.

In some embodiments,FIG.6Dcan be a top view of an antenna that is similar to the antenna13shown inFIG.5H. In some embodiments,FIG.6Dcan be a top view of an antenna that is different to the antenna13shown inFIG.5H. In some embodiments,FIG.6Dcan be a top view of the antenna13as shown inFIG.5H.

Referring toFIG.6D, the antenna13may include one or more antenna patterns13a. The antenna13includes a protection layer13m. The antenna13may include one or more openings13o. The protection layer13mcovers at least a portion of the antenna pattern13a. The protection layer13msurrounds at least a portion of the antenna pattern13a. The protection layer13mexposes at least a portion of the antenna pattern13a.

Referring toFIG.6D, the antenna pattern13amay include one or more surfaces that are not covered by the protection layer13m. The antenna pattern13amay include one or more surfaces that are exposed by the protection layer13m. The antenna pattern13amay include one or more surfaces exposed to air. The antenna pattern13amay include one or more surfaces exposed to vacuum.

In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cthat are not covered by the protection layer13m. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cthat are exposed by the protection layer13m. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cexposed to air. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cexposed to vacuum.

FIG.6Eillustrates a top view of an antenna in accordance with some embodiments of the present disclosure.

In some embodiments,FIG.6Ecan be a top view of an antenna that is similar to the antenna13shown inFIG.5H. In some embodiments,FIG.6Ecan be a top view of an antenna that is different to the antenna13shown inFIG.5H. In some embodiments,FIG.6Ecan be a top view of the antenna13as shown inFIG.5H.

Referring toFIG.6E, the antenna13may include one or more antenna patterns13a. The antenna13includes a protection layer13m. The antenna13may include a patterned conductive layer13c.

The protection layer13mcovers at least a portion of the antenna pattern13a. The protection layer13msurrounds at least a portion of the antenna pattern13a. The protection layer13mexposes at least a portion of the antenna pattern13a.

Referring toFIG.6E, the antenna pattern13amay include one or more surfaces that are not covered by the protection layer13m. The antenna pattern13amay include one or more surfaces that are exposed by the protection layer13m. The antenna pattern13amay include one or more surfaces exposed to air. The antenna pattern13amay include one or more surfaces exposed to vacuum.

In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cthat are not covered by the protection layer13m. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cthat are exposed by the protection layer13m. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cexposed to air. In some embodiments, the antenna pattern13aincludes surfaces13s1_a,13s1_band13s1_cexposed to vacuum.

Referring toFIG.6E, the patterned conductive layer13cmay include diamond-shaped patterns, as shown in the dotted-circle C. In some embodiments, the patterned conductive layer13cmay include patterns of any other suitable shapes. Some of the patterns of the patterned conductive layer13cmay act as a conductive pad. Some of the patterns of the patterned conductive layer13cmay act as a feeding element for transmitting/receiving signals to/from the antenna13.

Referring toFIG.6E, the patterned conductive layer13cmay surround four edges of the antenna13. The patterned conductive layer13cmay include a portion13c_1passing across the antenna13from the top to the bottom. The patterned conductive layer13cmay include a portion13c_2passing across the antenna13from the left side to the right side.

In some embodiments, the diamond-shaped patterns of the patterned conductive layer13cmay prevent a warpage produced in the manufacturing process of the antenna13. In some embodiments, the patterned conductive layer13cmay prevent a warpage produced in the manufacturing process of the antenna13by surrounding the four edges of the antenna13. In some embodiments, the portion13c_1of the patterned conductive layer13cmay prevent a warpage produced in the manufacturing process of the antenna13. In some embodiments, the portion13c_2of the patterned conductive layer13cmay prevent a warpage produced in the manufacturing process of the antenna13.

FIGS.7A,7B,7C,7D,7E and7Fare cross-sectional views of an antenna fabricated at various stages, in accordance with some embodiments of the present disclosure. Various figures have been simplified for a better understanding of the aspects of the present disclosure. In some embodiments, the operations shown inFIGS.7A,7B,7C,7D,7E and7Fare a method for manufacturing the antennas12or13shown inFIG.2A,3AorFIG.5A. Alternatively, the operations shown inFIGS.7A,7B,7C,7D,7E and7Fare a method for manufacturing other antennas.

Referring toFIG.7A, a carrier30is provided. The carrier30may be a metal plate, such as a copper plate. An antenna pattern31is formed on the carrier30. In some embodiments, the antenna pattern31is formed by, for example, sputtering, coating, electroplating or any other suitable operations.

Referring toFIG.7B, a protection layer32is formed on the carrier30to cover or encapsulate the antenna pattern31. The protection layer32fully covers or encapsulates the antenna pattern31. For example, the protection layer32is formed on exterior surfaces of the antenna pattern31and within gaps defined by the antenna pattern31.

The protection layer32is an insulation layer formed of or includes a dielectric material. For example, the protection layer32may include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), BPS), silicon oxide, silicon nitride, silicon oxynitride, USG, any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets. In some embodiments, the protection layer32can be formed by molding, lamination, screening or any other suitable techniques.

Referring toFIG.7C, a portion of the protection layer32is removed to expose a top surface of the antenna pattern31. In some embodiments, the top surface of the antenna pattern31is substantially coplanar with a top surface of the protection layer32. In some embodiments, the top surface of the antenna pattern31recesses from a top surface of the protection layer32. In some embodiments, the top surface of the antenna pattern31protrudes beyond a top surface of the protection layer32.

In some embodiments, the portion of the protection layer32is removed by, for example, etching, grinding, laser or any other suitable operations. In other embodiments, the carrier30can be removed after the operation illustrated inFIG.7C.

Referring toFIG.7D, a portion of the antenna pattern31and a portion of the carrier30are removed to form an opening32o. The opening32openetrates the protection layer32and the carrier30. The opening32openetrates from the top surface of the protection layer32to the bottom surface of the carrier30. The opening32ois formed by, for example, etching, grinding, laser or any other suitable operations.

Referring toFIG.7E, one or more connection structures33are formed on the antenna pattern31by, for example, electroplating, wire bonding or any other suitable operations. The connection structures33may include, but not limited to, Cu pillars, bonding wires or any other suitable connection elements.

Referring toFIG.7F, the carrier30is removed from the antenna pattern31and the protection layer32to expose a bottom surface of the antenna pattern31. In some embodiments, the carrier30may be removed completely. In some embodiments, a portion of the carrier30remains on the bottom surface of the protection layer32. In some embodiments, a portion of the carrier30remains on the bottom surface of the antenna pattern31. In some embodiments, a pattern30premains on the bottom surface of the protection layer32. The pattern30pmay be used, but not limited to, signal transmission, electromagnetic wave transmission or electricity transmission.

FIGS.8A,8B,8C,8D,8E and8Fare cross-sectional views of an antenna fabricated at various stages, in accordance with some embodiments of the present disclosure. Various figures have been simplified for a better understanding of the aspects of the present disclosure. In some embodiments, the operations shown inFIGS.8A,8B,8C,8D,8E and8Fare a method for manufacturing the antennas12or13shown inFIG.2A,3AorFIG.5A. Alternatively, the operations shown inFIGS.8A,8B,8C,8D,8E and8Fare a method for manufacturing other antennas.

Referring toFIG.8A, a carrier30is provided. The carrier30may be a metal plate, such as a copper plate. A patterned conductive layer30tis formed on the carrier. A portion of an antenna pattern31is formed on the patterned conductive layer30t. A portion of the antenna pattern31is formed on the carrier30. The patterned conductive layer30tis also referred to as a protruding structure30tin the previous paragraphs.

In some embodiments, the patterned conductive layer30tis formed by, for example, sputtering, coating, electroplating or any other suitable operations. In some embodiments, the antenna pattern31is formed by, for example, sputtering, coating, electroplating or any other suitable operations.

The protruding structure30tis mechanically attached to the antenna pattern31. The protruding structure30tis electrically connected to the antenna pattern31. In some embodiments, a thickness of the antenna pattern31is greater than a thickness of the patterned conductive layer30t. In some embodiments, a thickness of the antenna pattern31is substantially identical to a thickness of the patterned conductive layer30t. In some embodiments, a thickness of the antenna pattern31is less than a thickness of the patterned conductive layer30t.

Referring toFIG.8B, a protection layer32is formed on the carrier30to cover or encapsulate the antenna pattern31and the patterned conductive layer30t. The protection layer32fully covers or encapsulates the antenna pattern31. The protection layer32fully covers or encapsulates the patterned conductive layer30t. For example, the protection layer32is formed on exterior surfaces of the antenna pattern31and within gaps defined by the antenna pattern31. The protection layer32is formed on exterior surfaces of the patterned conductive layer30tand within gaps defined by the patterned conductive layer30t.

The protection layer32is an insulation layer formed of or includes a dielectric material. For example, the protection layer32may include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), BPS), silicon oxide, silicon nitride, silicon oxynitride, USG, any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets. In some embodiments, the protection layer32can be formed by molding, lamination, screening or any other suitable techniques.

Referring toFIG.8C, a portion of the protection layer32is removed to expose a top surface of the antenna pattern31. In some embodiments, the top surface of the antenna pattern31is substantially coplanar with a top surface of the protection layer32. In some embodiments, the top surface of the antenna pattern31recesses from a top surface of the protection layer32. In some embodiments, the top surface of the antenna pattern31protrudes beyond a top surface of the protection layer32.

In some embodiments, the portion of the protection layer32is removed by, for example, etching, grinding, laser or any other suitable operations. In other embodiments, the carrier30can be removed after the operation illustrated inFIG.8C.

Referring toFIG.8D, a portion of the antenna pattern31and a portion of the carrier30are removed to form an opening32o. The opening32openetrates the protection layer32and the carrier30. The opening32openetrates from the top surface of the protection layer32to the bottom surface of the carrier30. The opening32ois formed by, for example, etching, grinding, laser or any other suitable operations.

Referring toFIG.8E, one or more connection structures33are formed on the antenna pattern31by, for example, electroplating, wire bonding or any other suitable operations. The connection structures33may include, but not limited to, Cu pillars, bonding wires or any other suitable connection elements.

Referring toFIG.8F, the carrier30is removed from the antenna pattern31and the protection layer32to expose a bottom surface of the pattern conductive layer30t. In some embodiments, the carrier30may be removed completely. In some embodiments, a portion of the carrier30remains on the bottom surface of the protection layer32(not shown). In some embodiments, a portion of the carrier30remains on the bottom surface of the pattern conductive layer30t(not shown).

FIGS.9A,9B,9C,9D and9Eare cross-sectional views of an antenna fabricated at various stages, in accordance with some embodiments of the present disclosure. Various figures have been simplified for a better understanding of the aspects of the present disclosure. In some embodiments, the operations shown inFIGS.9A,9B,9C,9D and9Eare a method for manufacturing the antennas12or13shown inFIG.2A,3AorFIG.3C. Alternatively, the operations shown inFIGS.9A,9B,9C,9D and9Eare a method for manufacturing other antennas.

Referring toFIG.9A, a carrier30is provided. The carrier30may be a metal plate, such as a copper plate. An antenna pattern31ais formed on the carrier30. In some embodiments, the antenna pattern31ais formed by, for example, sputtering, coating, electroplating or any other suitable operations.

Referring toFIG.9B, a protection layer32is formed on the carrier30to cover or encapsulate the antenna pattern31aand the patterned conductive layer30t. The protection layer32fully covers or encapsulates the antenna pattern31a. For example, the protection layer32is formed on exterior surfaces of the antenna pattern31aand within gaps defined by the antenna pattern31a.

Referring toFIG.9B, a patterned conductive layer30tis formed on the antenna pattern31a. A portion of the antenna pattern31ais covered by the patterned conductive layer30t. A portion of the antenna pattern31ais exposed by the patterned conductive layer30t. The patterned conductive layer30tis also referred to as a protruding structure30tin the previous paragraphs.

Referring toFIG.9C, an antenna pattern31bis formed on the antenna pattern31a. In some embodiments, the antenna pattern31bis aligned with the antenna pattern31ain a direction parallel to the top surface of the carrier30. In some embodiments, the antenna pattern31bmay be shifted with respect to the antenna pattern31aby a distance in a direction parallel to the top surface of the carrier30.

Referring toFIG.9C, a protection layer32is formed to cover or encapsulate the antenna pattern31band the patterned conductive layer30t. The protection layer32fully covers or encapsulates the lateral surfaces of the antenna pattern31b. For example, the protection layer32is formed on lateral surfaces of the antenna pattern31band within gaps defined by the antenna pattern31b. The protection layer32exposes the top surface of the antenna pattern31b.

Referring toFIG.9C, the patterned conductive layer30textends from the lateral surfaces of the antenna patterns31binto the protection layer32. The patterned conductive layer30tis spaced apart from the bottom surface of the antenna pattern31aby a distance d1. The patterned conductive layer30tis spaced apart from the top surface of the antenna pattern31bby a distance d2. In some embodiments, the distance d1is substantially identical to the distance d2. In some embodiments, the distance d1is less than the distance d2. In some embodiments, the distance d1is greater than the distance d2.

The antenna pattern31aand the antenna pattern31bcan be collectively referred to as antenna pattern31.

Referring toFIG.9D, a portion of the antenna pattern31and a portion of the carrier30are removed to form an opening32o. The opening32openetrates the protection layer32and the carrier30. The opening32openetrates from the top surface of the protection layer32to the bottom surface of the carrier30. The opening32ois formed by, for example, etching, grinding, laser or any other suitable operations.

Referring toFIG.9D, one or more connection structures33are formed on the antenna pattern31by, for example, electroplating, wire bonding or any other suitable operations. The connection structures33may include, but not limited to, Cu pillars, bonding wires or any other suitable connection elements.

Referring toFIG.9E, the carrier30is removed from the antenna pattern31and the protection layer32to expose a bottom surface of the antenna pattern31. In some embodiments, the carrier30may be removed completely. In some embodiments, a portion of the carrier30remains on the bottom surface of the protection layer32(not shown). In some embodiments, a portion of the carrier30remains on the bottom surface of the antenna pattern31(not shown).

FIGS.11A,11B,11C,11D,11E,11F,11G,11H,11I,11J and11Kare cross-sectional views of a semiconductor device package fabricated at various stages, in accordance with some embodiments of the present disclosure. Various figures have been simplified for a better understanding of the aspects of the present disclosure. In some embodiments, the operations shown inFIGS.11A,11B,11C,11D,11E,11F,11G,11H,11I,11J and11Kare a method for manufacturing the semiconductor device package shown inFIG.4A or4B. Alternatively, the operations shown inFIGS.11A,11B,11C,11D,11E,11F,11G,11H,11I,11J and11Kare a method for manufacturing other semiconductor device package.

Referring toFIG.11A, a semiconductor device package is provided. The semiconductor device package includes a substrate50and a package body52disposed above or covers the substrate50. In some embodiments, the substrate50is a single-layered substrate. In some embodiments, the substrate50is a multi-layered substrate.

The substrate50may be, for example, a printed circuit board, such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated glass-fiber-based copper foil laminate. The substrate50may include an interconnection structure, such as a redistribution layer (RDL) or a grounding element.

In some embodiments, the package body52includes an epoxy resin having fillers, a molding compound (e.g., an epoxy molding compound or other molding compound), a polyimide, a phenolic compound or material, a material with a silicone dispersed therein, or a combination thereof. The package body52may include an interconnection structure56, such as a redistribution layer (RDL) disposed within or above the package body52. The package body52may include a conducting element54, such as a conductive via disposed within or above the package body52.

Referring toFIG.11B, a protection layer58is provided above the package body52. The protection layer58covers or encapsulates the package body52. The protection layer58covers or encapsulates the interconnection structure56. In some embodiments, the protection layer58may include insulation materials. In some embodiments, the protection layer58may include photo sensitive materials, such as photo-imageable dielectric (PID). In some embodiments, the protection layer58includes a dielectric material. For example, the protection layer58may include molding compounds, pre-impregnated composite fibers (e.g., pre-preg), Borophosphosilicate Glass (BPSG), silicon oxide, silicon nitride, silicon oxynitride, Undoped Silicate Glass (USG), any combination thereof, or the like. Examples of molding compounds may include, but are not limited to, an epoxy resin including fillers dispersed therein. Examples of a pre-preg may include, but are not limited to, a multi-layer structure formed by stacking or laminating a number of pre-impregnated materials/sheets.

Referring toFIG.11C, a metal layer60is provided above the protection layer58. The metal layer60may include an interconnection structure60vsurrounded by the protection layer58. The metal layer60may include an interconnection structure60vembedded within the protection layer58. The metal layer60may include, for example, aluminum (Al), copper (Cu), chromium (Cr), tin (Sn), gold (Au), silver (Ag), nickel (Ni) or stainless steel, or a mixture, an alloy, or other combination thereof.

Referring toFIG.11D, an opening60ois formed on the metal layer60. In some embodiments, the opening60omay be formed by a process that includes the following operations: (i) forming a photoresist or mask on the metal layer60; (ii) defining a predetermined pattern on the photoresist or mask by, for example, lithographic technique; (iii) plating or etching conductive material to form the opening60o; and (iv) removing the photoresist or mask.

Referring toFIG.11E, a protection layer58′ is provided above the metal layer60. The protection layer58′ covers or encapsulates the metal layer60. The protection layer58covers or encapsulates the interconnection structure60v. In some embodiments, the protection layer58′ includes material similar to that of the protection layer58. In some embodiments, the protection layer58′ includes material identical to that of the protection layer58. In some embodiments, the protection layer58′ includes material different from that of the protection layer58.

Referring toFIG.11F, a metal layer60′ is provided above the protection layer58′. The metal layer60′ may include an interconnection structure60v′ surrounded by the protection layer58′. The metal layer60′ may include an interconnection structure60v′ embedded within the protection layer58′. In some embodiments, the metal layer60′ includes material similar to that of the metal layer60. In some embodiments, the metal layer60′ includes material identical to that of the metal layer60. In some embodiments, the metal layer60′ includes material different from that of the metal layer60.

Referring toFIG.11F, an opening60o′ is formed on the metal layer60′. In some embodiments, the opening60o′ may be formed by a process that includes the following operations: (i) forming a photoresist or mask on the metal layer60′; (ii) defining a predetermined pattern on the photoresist or mask by, for example, lithographic technique; (iii) plating or etching conductive material to form the opening60o′; and (iv) removing the photoresist or mask.

Referring toFIG.11G, a protection layer58″ is provided above the metal layer60′. The protection layer58″ covers or encapsulates the metal layer60′. The protection layer58″ covers or encapsulates the interconnection structure60v′. In some embodiments, the protection layer58″ includes material similar to that of the protection layer58. In some embodiments, the protection layer58″ includes material identical to that of the protection layer58. In some embodiments, the protection layer58″ includes material different from that of the protection layer58.

Referring toFIG.11H, a metal layer60″ is provided above the protection layer58″. In some embodiments, the metal layer60″ includes material similar to that of the metal layer60. In some embodiments, the metal layer60″ includes material identical to that of the metal layer60. In some embodiments, the metal layer60″ includes material different from that of the metal layer60.

Referring toFIG.11H, an opening60o″ is formed on the metal layer60″. In some embodiments, the opening60o″ may be formed by a process that includes the following operations: (i) forming a photoresist or mask on the metal layer60″; (ii) defining a predetermined pattern on the photoresist or mask by, for example, lithographic technique; (iii) plating or etching conductive material to form the opening60o″; and (iv) removing the photoresist or mask.

Referring toFIG.11I, a portion of the protection layer58″ is removed. In some embodiment, a portion of the protection layer58″ which is not covered by the metal layer60″ is removed. In some embodiment, a portion of the protection layer58″ exposed by the opening60o″ is removed. The portion of the protection layer58″ may be removed using, for example, laser, grinding, etching or any other suitable operations. After a portion of the protection layer58″ is removed, a step structure or a ladder structure62is formed.

Referring toFIG.11J, a portion of the protection layer58′ is removed. In some embodiment, a portion of the protection layer58′ which is not covered by the metal layer60′ is removed. In some embodiment, a portion of the protection layer58′ exposed by the opening60o′ is removed. The portion of the protection layer58′ may be removed using, for example, laser, grinding, etching or any other suitable operations. After a portion of the protection layer58′ is removed, a step structure or a ladder structure64is formed.

Referring toFIG.11K, a portion of the protection layer58is removed. In some embodiment, a portion of the protection layer58which is not covered by the metal layer60is removed. In some embodiment, a portion of the protection layer58exposed by the opening60ois removed. The portion of the protection layer58may be removed using, for example, laser, grinding, etching or any other suitable operations. After a portion of the protection layer58is removed, a step structure or a ladder structure66is formed.

FIGS.10A,10B,10C,10D,10E,10F and10Gare cross-sectional views of a semiconductor device package or a portion of the semiconductor device package fabricated at various stages, in accordance with some embodiments of the present disclosure. Various figures have been simplified for a better understanding of the aspects of the present disclosure. In some embodiments, the operations shown inFIGS.10A,10B,10C,10D,10E,10F and10Gare a method for manufacturing the semiconductor device package shown inFIG.1AorFIG.2A. Alternatively, the operations shown inFIGS.10A,10B,10C,10D,10E,10F and10Gare a method for manufacturing other semiconductor device packages.

Referring toFIG.10A, a substrate40is provided. The substrate40may include interconnection structures (RDL)40rcovered or encapsulate by dielectric layers. The substrate40may include a conductive layer40m1and a conductive pad40m2on a top surface of the substrate40. In some embodiments, the conductive layer40m1is grounded. In some embodiments, the conductive layer40m1is an antenna. In some embodiments, the conductive layer40m1is part of an antenna structure. In some embodiment, the conductive pad40m2acts as a feeding element for providing signals to an antenna structure. In some embodiment, the conductive pad40m2acts as a feeding element for receiving signals from an antenna structure.

Referring toFIG.10B, an insulation layer41is formed on the top surface of the substrate40to cover the conductive layer40m1, the conductive pad40m2and the top surface of the substrate40. In some embodiments, the insulation layer41is formed of or includes PID, polyimide (PI) or solder resist. In some embodiments, the insulation layer41can be formed by, for example, lamination or other suitable operations.

Referring toFIG.10C, a portion of the insulation layer41is removed to form one or more openings (or cavities)41h1and41h2to expose the conductive layer40m1and the conductive pad40m2. In some embodiments, the insulation layer41is removed by, for example, etching or other suitable operations.

Referring toFIG.10D, a conductive material is filled within the opening41h2to form a conductive via41v1. In some embodiments, the conductive via41v1is formed by plating or other suitable operations. The conductive via41v1is in contact with the conductive pad40m2on the top surface of the substrate40. In some embodiments, the conductive via41v1and the conductive pad40m2are collectively referred to as a feeding element.

Referring toFIG.10E, an insulation layer42is formed on the insulation layer41to cover the conductive via41v1and the conductive layer40m1. In some embodiments, the insulation layer42can be formed of or includes PID, PI or solder resist. In some embodiments, the insulation layer42can be formed by, for example, lamination or other suitable operations. The insulation layer42and the insulation layer41can be formed of the same or different materials depending on design specifications.

Referring toFIG.10F, a portion of the insulation layer42is removed to form a step structure42s1(or ladder structure) and to expose the conductive via41v1and the conductive layer40m1. In some embodiments, the insulation layer42can be removed by, for example, etching or other suitable operations.

Referring toFIG.10G, an antenna43is placed on the step structure42s1of the insulation layer42through an adhesive (e.g., conductive adhesive or non-conductive adhesive). The antenna43is electrically connected to the conductive via41v1through an electrical contact41s(e.g., a solder ball). In some embodiments, the conductive via41v1may act as a feeding point of the antenna43. In some embodiments, the antenna43is similar to the antenna12or13illustrated inFIG.2AorFIG.5A. In some embodiments, the antenna43can be formed by the operations illustrated inFIGS.7A,7B,7C,7D,7E and7F. In some embodiments, the antenna43can be formed by the operations illustrated inFIGS.8A,8B,8C,8D,8E and8F. In some embodiments, the antenna43can be formed by the operations illustrated inFIGS.9A,9B,9C,9D and9E.

In some embodiments, the conductive via41v1and the electrical contact41scan be omitted, and the antenna as shown inFIG.7Eis placed on the step structure42s1of the insulation layer42with the connection structure33directly connecting to the conductive pad40m2.

As used herein, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” “lower,” “left,” “right” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. It should be understood that when an element is referred to as being “connected to” or “coupled to” another element, it may be directly connected to or coupled to the other element, or intervening elements may be present.

Ranges can be expressed herein as from one endpoint to another endpoint or between two endpoints. All ranges disclosed herein are inclusive of the endpoints, unless specified otherwise.

As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, two numerical values can be deemed to be “substantially” or “about” the same if a difference between the values is less than or equal to ±10% of an average of the values, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, “substantially” parallel can refer to a range of angular variation relative to 0° that is less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1, less than or equal to ±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°. For example, “substantially” perpendicular can refer to a range of angular variation relative to 90° that is less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1, less than or equal to ±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°.

For example, two surfaces can be deemed to be coplanar or substantially coplanar if a displacement between the two surfaces is equal to or less than 5 μm, equal to or less than 2 μm, equal to or less than 1 μm, or equal to or less than 0.5 μm. A surface can be deemed to be planar or substantially planar if a displacement of the surface relative to a flat plane between any two points on the surface is equal to or less than 5 μm, equal to or less than 2 μm, equal to or less than 1 μm, or equal to or less than 0.5 μm.

As used herein, the terms “conductive,” “electrically conductive” and “electrical conductivity” refer to an ability to transport an electric current. Electrically conductive materials typically indicate those materials that exhibit little or no opposition to the flow of an electric current. One measure of electrical conductivity is Siemens per meter (S/m). Typically, an electrically conductive material is one having a conductivity greater than approximately 104S/m, such as at least 105S/m or at least 106S/m. The electrical conductivity of a material can sometimes vary with temperature. Unless otherwise specified, the electrical conductivity of a material is measured at room temperature.

As used herein, the singular terms “a,” “an,” and “the” may include plural referents unless the context clearly dictates otherwise. In the description of some embodiments, a component provided “on” or “over” another component can encompass cases where the former component is directly on (e.g., in physical contact with) the latter component, as well as cases where one or more intervening components are located between the former component and the latter component.

Spatial descriptions, such as “above,” “below,” “up,” “left,” “right,” “down,” “top,” “bottom,” “vertical,” “horizontal,” “side,” “higher,” “lower,” “upper,” “over,” “under,” “downward,” and so forth, are indicated with respect to the orientation shown in the figures unless otherwise specified. It should be understood that the spatial descriptions used herein are for purposes of illustration only, and that practical implementations of the structures described herein can be spatially arranged in any orientation or manner, provided that the merits of embodiments of this disclosure are not deviated from by such arrangement

While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations do not limit the present disclosure. It can be clearly understood by those skilled in the art that various changes may be made, and equivalent components may be substituted within the embodiments without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not necessarily be drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus, due to variables in manufacturing processes and such. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it can be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Therefore, unless specifically indicated herein, the order and grouping of the operations are not limitations of the present disclosure.

The foregoing outlines features of several embodiments and detailed aspects of the present disclosure. The embodiments described in the present disclosure may be readily used as a basis for designing or modifying other processes and structures for carrying out the same or similar purposes and/or achieving the same or similar advantages of the embodiments introduced herein. Such equivalent constructions do not depart from the spirit and scope of the present disclosure, and various changes, substitutions, and alterations may be made without departing from the spirit and scope of the present disclosure.