PATENT DOCUMENT

Publication Number: US-9888561-B2
Application Number: US-201514804486-A
Country: US
Kind Code: B2

Title: Packaged electrical components with supplemental conductive structures

Abstract:
Electrical components such as integrated circuits and other components may be mounted on a substrate such as a printed circuit substrate. A molded plastic cap may cover the components and a portion of the printed circuit substrate to form a packaged electrical device. Metal structures such as springs, posts, and other metal members may be insert molded within the plastic cap. A metal layer on the surface of the cap may be patterned to from electromagnetic shielding, signal paths, contact pads, sensor electrodes, antennas, and other structures. Multiple substrates each with a respective set of mounted electrical components may be joined using a flexible printed circuit. The flexible printed circuit may be covered with a rigid cap portion or an elastomeric material or may be left uncovered.

Claims:
What is claimed is: 
     
       1. A packaged electrical device, comprising:
 a substrate; 
 electrical components mounted to the substrate; 
 a single, molded cap that covers the electrical components and that has a first exterior surface and a second exterior surface, wherein the second exterior surface extends from the first exterior surface at a nonzero angle and wherein the molded cap directly contacts the electrical components; and 
 signal lines formed from metal traces on the first and second exterior surfaces of the molded cap. 
 
     
     
       2. The packaged electrical device defined in  claim 1  wherein the signal lines include parallel metal traces that form a signal bus. 
     
     
       3. The packaged electrical device defined in  claim 2  wherein the signal lines include contact pads and wherein the electrical components include silicon integrated circuit die. 
     
     
       4. The packaged electrical device defined in  claim 3  wherein the signal lines comprise electroplated signal lines. 
     
     
       5. The packaged electrical device defined in  claim 4  wherein the molded cap comprises laser activated areas under the electroplated signal lines. 
     
     
       6. The packaged electrical device defined in  claim 5  wherein the signal lines are electrically isolated from the electrical components. 
     
     
       7. The packaged electrical device defined in  claim 3  wherein the molded cap comprises molded plastic, the packaged electrical device further comprising a metal structure embedded within the molded cap. 
     
     
       8. The packaged electrical device defined in  claim 7  wherein the metal structure has a first portion that is mounted to the substrate and has a second portion that protrudes from the molded cap. 
     
     
       9. The packaged electrical device defined in  claim 8  further comprising a shield layer on the surface of the molded cap, wherein the shield layer has an opening through which the second portion passes. 
     
     
       10. A packaged electrical device, comprising:
 a printed circuit substrate; 
 integrated circuits mounted to the substrate; 
 molded plastic that overlaps the integrated circuits and that has first and second exterior surfaces, wherein the second exterior surface extends from the first exterior surface at a nonzero angle and the molded plastic directly contacts the printed circuit substrate and the integrated circuits; and 
 a patterned metal layer on the first and second exterior surfaces. 
 
     
     
       11. The packaged electrical device defined in  claim 10  wherein the patterned metal layer is configured to form an antenna. 
     
     
       12. The packaged electrical device defined in  claim 10  wherein the patterned metal layer is configured to form a strain gauge resistor. 
     
     
       13. The packaged electrical device defined in  claim 12  wherein the patterned metal layer is configured to moisture sensor electrodes. 
     
     
       14. The packaged electrical device defined in  claim 10  further comprising a spring contact that protrudes from the molded plastic. 
     
     
       15. The packaged electrical device defined in  claim 10  wherein the molded plastic has a bend. 
     
     
       16. The packaged electrical device defined in  claim 15  further comprising:
 a flexible printed circuit; and 
 an electrical component that is not mounted on the printed circuit substrate, wherein the flexible printed circuit is coupled between the printed circuit substrate and the electrical component. 
 
     
     
       17. A packaged electrical device, comprising:
 a substrate; 
 electrical components mounted to the substrate; 
 a cap that covers the electrical components and that has a first exterior surface and a second exterior surface that extends perpendicularly from the first exterior surface; 
 signal lines formed from metal traces on the first and second exterior surfaces of the cap; and 
 a unitary metal structure embedded within the cap, wherein the metal structure has a first portion that is mounted to the substrate and a second portion that protrudes from the cap. 
 
     
     
       18. The packaged electrical device defined in  claim 17  wherein the cap further comprises a third exterior surface that extends perpendicularly from the first exterior surface. 
     
     
       19. The packaged device defined in  claim 18  wherein the signal lines are formed from metal traces on the first, second, and third exterior surfaces of the cap. 
     
     
       20. The packaged device defined in  claim 19  wherein the third exterior surface is parallel to the second exterior surface. 
     
     
       21. The packaged device defined in  claim 17  wherein the entire metal structure is completely surrounded by the cap except at the first and second portions.

Description:
BACKGROUND 
     This relates generally to electronic devices, and, more particularly, to packaging for circuitry in electronic devices. 
     Electronic devices often include integrated circuits and other components that are mounted within semiconductor packages. System-in-package devices may contain multiple integrated circuits mounted together a single package. Use of this type of packaged device may be desirable in applications where space is at a premium. 
     In compact devices, it can be challenging to mount components efficiently. Signal routing paths and mounting structures can consume more space than desired and package layouts are often not sufficiently efficient to accommodate complex housing geometries. In view of these challenges, it would be desirable to be able to provide improved packaging for electronic components in electronic devices. 
     SUMMARY 
     Electrical components such as integrated circuits and other components may be mounted on a substrate such as a printed circuit substrate. A molded plastic cap may cover the components and a portion of the printed circuit substrate to form a packaged electrical device. 
     Metal structures such as springs, posts, and other metal members may be insert molded within the plastic cap. When installed within an electronic device, the metal structures may contact external components to make electrical contact with these external components. 
     A metal layer on the surface of the cap may be patterned to from electromagnetic shielding, signal paths, contact pads, sensor electrodes, antennas, and other structures. Electrical components can be soldered to the metal layer or may form electrical contact with the metal layer using springs or other coupling arrangements. 
     Multiple substrates each with a respective set of mounted electrical components may be joined using a flexible printed circuit. The flexible printed circuit may be covered with a rigid cap portion or an elastomeric material or may be left uncovered. The substrates may be angled at a non-zero angle with respect to each other, may be oriented at right angles with respect to each other, or may be parallel to each other. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device that may include packaged circuitry in accordance with an embodiment. 
         FIG. 2  is a schematic diagram of an illustrative electronic device that may include packaged circuitry in accordance with an embodiment. 
         FIG. 3A  is a cross-sectional side view of an illustrative electronic device that may include packaged circuitry in accordance with an embodiment. 
         FIG. 3B  is a cross-sectional side view of an illustrative packaged electrical device in accordance with an embodiment. 
         FIG. 4  is a diagram showing equipment and techniques of the type that may be involved in forming packages and devices in accordance with an embodiment. 
         FIG. 5  is a perspective view of an illustrative packaged device with surface metal traces that can serve as signal busses and other signal paths for external components in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of an illustrative package with a metal structure such as a metal post to which an electrical connection with an external component may be made in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of an illustrative packaged device with multiple components and a metal member mounted on a common package substrate in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of an illustrative packaged device with an insert-molded spring that protrudes from the device in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of an illustrative packaged device with surface metal traces that serve as signal paths to which one or more external components may be mounted using solder joints or other coupling mechanisms in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative packaged device showing how multiple external components may be coupled to metal traces on the surface of the device using connections based on springs in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative packaged device having surface metal traces for forming interconnect paths for external components in accordance with an embodiment. 
         FIG. 12  is a perspective view of an illustrative packaged device having surface metal traces that form an antenna such as an inverted-F antenna in accordance with an embodiment. 
         FIG. 13  is a perspective view of an illustrative packaged device having surface metal traces that form a multi-turn near-field communications loop antenna in accordance with an embodiment. 
         FIG. 14  is a perspective view of an illustrative packaged device having a meandering surface metal trace for forming a strain gauge sensor in accordance with an embodiment. 
         FIG. 15  is a circuit diagram of an illustrative strain gauge bridge circuit in accordance with an embodiment. 
         FIG. 16  is a perspective view of an illustrative packaged device having electrodes with interleaved fingers for forming a moisture sensor in accordance with an embodiment. 
         FIG. 17  is a cross-sectional side view of a packaged device having two package substrates joined by a flexible printed circuit that is embedded within an elastomeric layer in accordance with an embodiment. 
         FIG. 18  is a cross-sectional side view of a packaged device having two package substrates joined by a flexible printed circuit that has not been embedded within a package material in accordance with an embodiment. 
         FIG. 19  is a cross-sectional side view of an illustrative packaged device having an engagement feature such as a snap that engages a mating engagement feature in a housing structure of an electronic device in accordance with an embodiment. 
         FIG. 20  is a cross-sectional side view of an illustrative packaged device having a locally thinned portion to accommodate a screw in accordance with an embodiment. 
         FIG. 21  is a cross-sectional side view of an illustrative L-shaped packaged device with an integral component such as a dome switch for forming a button in an electronic device in accordance with an embodiment. 
         FIG. 22  is a cross-sectional side view of an illustrative L-shaped packaged device containing a pair of package substrates that have been populated with electronic components and joined by a flexible printed circuit that is embedded within the packaged device in accordance with an embodiment. 
         FIG. 23  is a cross-sectional side view of an illustrative packaged device having stacked package substrates joined by an external flexible printed circuit in accordance with an embodiment. 
         FIG. 24  is a cross-sectional side view of an illustrative packaged device having stacked package substrates joined by an internal flexible printed circuit in accordance with an embodiment. 
         FIG. 25  is a cross-sectional side view of an illustrative packaged device with a bent portion and a flexible printed circuit that couples a component on an end of the device to a substrate within the device in accordance with an embodiment. 
         FIG. 26  is a cross-sectional side view of an illustrative packaged device that has a bent portion and a flexible printed circuit that couples a component on an end of the device to a substrate within the device and that has a portion to accommodate a fastener such as a screw in accordance with an embodiment. 
         FIG. 27  is a cross-sectional side view of an illustrative packaged device having a portion that forms an electromagnetic shield in accordance with an embodiment. 
         FIG. 28  is a cross-sectional side view of an illustrative packaged device having integral strengthening features such as a set of parallel ridges that prevent bending of the packaged device in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     An illustrative electronic device of the type that may be provided with integrated circuits and other packaged electrical devices is shown in  FIG. 1 . Electronic device  10  may be a computing device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, a device embedded in eyeglasses or other equipment worn on a user&#39;s head, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, equipment that implements the functionality of two or more of these devices, or other electronic equipment. In the illustrative configuration of  FIG. 1 , device  10  is a portable device such as a cellular telephone, media player, tablet computer, wrist device, or other portable computing device. Other configurations may be used for device  10  if desired. The example of  FIG. 1  is merely illustrative. 
     In the example of  FIG. 1 , device  10  includes a display such as display  14  mounted in housing  12 . Housing  12 , which may sometimes be referred to as an enclosure or case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of any two or more of these materials. Housing  12  may be formed using a unibody configuration in which some or all of housing  12  is machined or molded as a single structure or may be formed using multiple structures (e.g., an internal frame structure, one or more structures that form exterior housing surfaces, etc.). 
     Display  14  may be a touch screen display that incorporates a layer of conductive capacitive touch sensor electrodes or other touch sensor components (e.g., resistive touch sensor components, acoustic touch sensor components, force-based touch sensor components, light-based touch sensor components, etc.) or may be a display that is not touch-sensitive. Capacitive touch screen electrodes may be formed from an array of indium tin oxide pads or other transparent conductive structures. A touch sensor may be formed using electrodes or other structures on a display layer that contains a pixel array or on a separate touch panel layer that is attached to the pixel array (e.g., using adhesive). 
     Display  14  may include an array of pixels formed from liquid crystal display (LCD) components, an array of electrophoretic pixels, an array of plasma pixels, an array of organic light-emitting diode pixels or other light-emitting diodes, an array of electrowetting pixels, or pixels based on other display technologies. 
     Display  14  may be protected using a display cover layer such as a layer of transparent glass or clear plastic. Openings may be formed in the display cover layer. For example, an opening may be formed in the display cover layer to accommodate a button, a speaker port, or other component. Openings may be formed in housing  12  to form communications ports (e.g., an audio jack port, a digital data port, etc.), to form openings for buttons, etc. 
       FIG. 2  is a schematic diagram of device  10 . As shown in  FIG. 2 , electronic device  10  may have control circuitry  16 . Control circuitry  16  may include storage and processing circuitry for supporting the operation of device  10 . The storage and processing circuitry may include storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive), volatile memory (e.g., static or dynamic random-access-memory), etc. Processing circuitry in control circuitry  16  may be used to control the operation of device  10 . The processing circuitry may be based on one or more microprocessors, microcontrollers, digital signal processors, baseband processors, power management units, audio chips, application specific integrated circuits, etc. 
     Input-output circuitry in device  10  such as input-output devices  18  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. Input-output devices  18  may include display  14 , buttons, joysticks, scrolling wheels, touch pads, key pads, keyboards, audio components  20  such as microphones and speakers, tone generators, vibrators, cameras, sensors  22 , light-emitting diodes and other status indicators, data ports, etc. Wireless circuitry  21  may be used to transmit and receive radio-frequency wireless signals. Wireless circuitry  21  may include antennas and radio-frequency transmitters and receivers operating in wireless local area network bands, cellular telephone bands, and other wireless communications bands. 
     A user can control the operation of device  10  by supplying commands through input-output devices  18  and may receive status information and other output from device  10  using the output resources of input-output devices  18 . Input-output devices  18  may include one or more displays such as display  14 . 
     Control circuitry  16  may be used to run software on device  10  such as operating system code and applications. During operation of device  10 , the software running on control circuitry  16  may display images on display  14  using an array of pixels in display  14 . The software of device  10  may also be used in controlling wireless transmission and reception of communications signals, sensor data gathering and processing operations, input-output device operation, and other device operations. 
     Display  14  may have a rectangular shape (i.e., display  14  may have a rectangular footprint and a rectangular peripheral edge that runs around the rectangular footprint) or may have other suitable shapes. Display  14  may be planar or may have a curved profile. 
     A cross-sectional side view of an illustrative electronic device of the type that may include packaged integrated circuits and other packaged electrical devices is shown in  FIG. 3A . As shown in  FIG. 3A , device  10  may include a housing such as housing  12  in which display  14  is mounted. Display  14  may have a transparent cover layer such as display cover layer  24 . Display layers  25  (e.g., liquid crystal display layers, organic light-emitting diode display layers, etc.) may be mounted below display cover layer  24 . Packaged electrical devices  28  may be mounted in the interior of device  10  on one or more substrates such as substrate  30 . Substrate  30  may be, for example, a printed circuit (e.g., a rigid printed circuit having a substrate formed from a rigid printed circuit board material such as fiberglass-filled epoxy or a flexible printed circuit formed from a flexible polymer substrate such as a sheet of polyimide). Signal path structures such as signal path structure  26  may be used to couple circuitry on substrates such as substrate  30  to other substrates and to components such as display  14  (e.g., display layers  25 ). Signal path structure  26  may be formed from a flexible printed circuit bus, cables, wires, or other signal path structures. 
     A cross-sectional side view of an illustrative packaged electrical device is shown in  FIG. 3B . Packaged electrical device  28  may include integrated circuits, inductors, capacitors, resistors, and other discrete electronic components, microelectromechanical systems (MEMs) components, switches, connectors, sensors, and other electrical components  32 . As shown in  FIG. 3B , packaged device  28  may include a substrate such as substrate  44  (e.g., a printed circuit, a ceramic layer, a layer of glass, or other dielectric substrate layer). Substrate  44  may have metal traces for forming lower pads  42  and upper pads  38  and may have traces that form interconnects  40  (e.g., interconnects that couple pads  42  and/or pads  38 ). 
     One or more components  32  may be mounted to substrate  44 . Components  32  (e.g., silicon integrated circuit die, etc.) may have component pads  34  that are coupled to substrate pads  38  using wire bonds, solder  36 , or other conductive structures. Components  32  may be protected using an encapsulating material that covers components  32 . The encapsulating material may be a polymer (e.g., a thermoset or thermoplastic polymer) or other dielectric. As an example, the encapsulating material may be molded plastic. The encapsulating material may include adhesive that flows under components  32  and molded plastic or other material to form a cap such as cap  46  that prevents environmental contaminants from interfering with the desired operation of components  32 . 
       FIG. 4  is a diagram showing illustrative equipment and techniques that may be used in forming packaged devices  28 . As shown in  FIG. 4 , equipment  50  may be used in mounting components  32  on substrate  44 . Equipment  50  may include pick-and-place equipment, hot-bar tools, reflow ovens, and other soldering equipment. 
     After components  32  have been mounted on substrate  44 , cap formation equipment such as plastic molding tool  52  and other equipment may be used to encapsulate components  32  within cap  46 . Cap  46  may be molded in a planar shape or a non-planar shape. If desired, metal structures may be insert molded within cap  46 . Openings and other features may also be formed in cap  46  during the process of forming packaged device  28 . 
     If desired, deposition equipment  54  may be used to deposit metal  60  (e.g., a blanket metal film, a metal coating that is patterned using a shadow mask during deposition, or other metal layer). Deposition equipment  54  may include physical vapor deposition equipment, chemical vapor deposition equipment, equipment for printing metal paint, etc. 
     Layer  60  may serve as an electromagnetic shield and/or may be used in forming signal paths and other metal structures (e.g., sensor structures, etc.). Patterning equipment  58  may be used to pattern metal  60  to form signal lines, regions of shielding, and other patterned metal structures. Patterning equipment  58  may include photolithographic equipment (e.g., equipment for depositing and patterning photoresist, etching equipment, etc.). Patterning equipment  58  may also include mechanical patterning tools, lasers, and other equipment for patterning metal  60 . 
     If desired, metal  60  may be patterned using laser-based patterning and electroplating techniques. As shown in  FIG. 4 , for example, laser-based equipment  62  may be used to apply laser light  66  to desired areas such as area  68  on the surface of cap  46 , thereby laser activating these areas. Equipment  62  may include lasers such as laser  64  for producing laser light  66  and may include computer-controlled positioners such as computer-controlled positioner  70  for controlling the position of laser  64 . Cap  46  may be formed from a polymer or other material with additives that sensitize cap  46  to exposure to laser light  66 . As a result, exposed areas  68  promote growth of patterned metal  60  during subsequent electroplating operations using electroplating equipment  72 . Laser-based patterning techniques may be used for patterning metal  60  alone or in combination with using other patterned metal formation techniques (e.g., deposition through a shadow mask, deposition of a blanket film by deposition equipment  54  followed by patterning with patterning equipment  58 , etc.). 
     By patterning metal  60 , signal paths may be formed on the surface of cap  46 , as shown in the perspective view of illustrative packaged device  28  of  FIG. 5 . Signal paths formed from metal traces such as the metal traces of  FIG. 5  may be used in forming signal busses (i.e., groups of signal paths that carry corresponding sets of signals), contacts (e.g., contact pads such as solder pads, contact pads for forming electrical connections with springs, etc.), shielding, and other metal structures. As shown in  FIG. 5 , the ends of the signal paths formed from the metal traces may be enlarged to form contact pads such as solder pads. 
     If desired, metal structures may be incorporated in cap  46  (e.g., using insert molding techniques). A cross-sectional side view of packaged device  28  in an illustrative configuration in which device  28  includes an embedded metal structure is shown in  FIG. 6 . In the example of  FIG. 6 , metal post  74  has been soldered to a pad on the surface of substrate  44  adjacent to components  32  so that post  74  is electrically connected to interconnects in substrate  44  and thereby is electrically connected to circuitry in components  32 . Cap  46  has been formed over components  32  so that post  74  passes through cap  46  and has protruding portion with exposed surface  76  to which electrical contact may be formed using spring  78  of component  80  when component  80  is moved in direction  82 . Metal  60  may be patterned to form an opening that accommodates surface  76  of metal post  74 . Metal  60  may, as an example, form a shield layer. 
       FIG. 7  is a cross-sectional side view of an illustrative packaged device with a metal member. As shown in  FIG. 7 , packaged device  28  may include components  32  that are mounted to substrate  44 . Metal members such as metal member  84  may be mounted to substrate  44  adjacent to components  32 . Cap  46  may cover some of metal member  84 . Some surfaces of member  84  such as surface  86  may protrude from cap  46  and may remain exposed to form contacts with external components (see, e.g.,  FIG. 6 ). Metal  60  may be patterned to form an opening to accommodate metal member  84  or may be shorted to metal member  84 . Metal member  84  may be a metal block (e.g., a rectangular bar) or may have other suitable shapes. Components  32  and member  84  may be interconnected using interconnects in substrate  44 . 
     As shown in  FIG. 8 , metal structures such as structure  88  may be embedded within cap  46 . Structure  88  may be a spring member that is partly embedded within cap  46  so that protruding spring portion  90  may form a spring contact. When configured so that spring  90  makes contact with an external component, structure  88  may form an electrical path that allows the external component to be coupled to circuitry in components  32  (via structure  88  and interconnects in substrate  44 ). 
       FIG. 9  is a cross-sectional side view of an illustrative packaged device with surface metal traces that serve as signal paths. As shown in  FIG. 9 , external components such as component  92  (e.g., a component such as a packaged integrated circuit or other component such as one of devices  28 ) may be coupled to metal traces formed from metal  60 . Solder  94  or other conductive material may be used to mount external component  92  to signal paths formed from metal  60 . Portions of metal  60  may also be used in forming shielding. 
       FIG. 10  is a cross-sectional side view of an illustrative packaged device showing how multiple external components may be coupled to metal traces on the surface of the device using connections based on springs. As shown in  FIG. 10 , metal  60  on the surface of cap  46  may serve as a signal path that couples spring  98 A of component  96 A to spring  98 B of component  96 B, thereby electrically connecting components  96 A and  96 B. 
       FIG. 11  is a cross-sectional side view of an illustrative packaged device having surface metal traces for forming interconnect paths for external components. In the example of  FIG. 11 , packaged device  28  has components  32  mounted to substrate  44  and covered with cap  46 . One or more flexible printed circuits  104  may be coupled to pads  106  on the underside of substrate  44 . One or more flexible printed circuits  104  (e.g., flexible printed circuits that are entirely flexible or flexible printed circuits of the type sometimes referred to as “rigid flex” that contain flexible printed circuit tails extending from rigid printed circuit board areas) may also be coupled to metal traces  60  on the upper surface of cap  46  (e.g., using solder  108 ). Connectors such as connectors  110  may be used to couple flexible printed circuits  104  together (as an example). Flexible printed circuits  104  may also be coupled to components such as display module  25 . External components such as electrical component  100  (e.g., a packaged device such as one of devices  28 ) may be coupled to metal  60  using solder, springs such as spring  102 , or other conductive structures. 
     If desired, metal  60  may be patterned to form antenna structures. As shown in the perspective view of illustrative packaged device  28  of  FIG. 12 , metal  60  may be patterned to form an antenna such as an inverted-F antenna (e.g., an inverted-F antenna having a feed formed from positive feed terminal TP and ground antenna feed terminal TN). Metal  60  may be used to from a loop antenna, a slot antenna, a planar inverted-F antenna, a patch antenna, a monopole antenna, a dipole, near-field communications antennas, or other suitable antennas. 
       FIG. 13  is a perspective view of an illustrative configuration for packaged device  28  in which metal  60  has been patterned to form a loop antenna for supporting near-field communications (NFC) at a frequency of 13.56 MHz or other suitable communications frequency. The antenna of  FIG. 13  is a loop antenna that includes multiple turns of metal traces forming an inductor. During operation, the antenna of  FIG. 13  may be coupled to another NFC antenna through near-field electromagnetic coupling. The antenna of  FIG. 13  may be fed using antenna feed terminals such as feed terminals TP and TN. 
       FIG. 14  is a perspective view of packaged device  28  in an illustrative configuration in which metal  60  has been patterned to form a meandering surface trace that may serve as a variable resistor in a strain gauge (strain sensor). The variable resistor formed from patterned metal  60  may have a resistance that increases when device  28  is bent about axis  113 , thereby stretching and thinning metal  60 . The resistor of  FIG. 14  may be placed in a bridge circuit such as Wheatstone bridge circuit  114  of  FIG. 15 . In this type of circuit, resistor RS (and/or other resistors) may be formed from a variable resistor structure of the type shown by metal resistor  60  of  FIG. 14  and the other resistors R of the bridge may be formed from structures that do not deform with device  28  and that therefore serve as reference resistors. Bridge circuits with two variable resistors RS and two reference resistors R may also be used. Power may be applied to bridge circuit  114  using positive power supply terminal V+ and ground power supply terminal V−. Amplifier  112  may supply an output signal on output line  116  that is proportional to the amount of strain experienced by strain gauge resistor RS (see, e.g., the resistor formed from the serpentine metal path of metal  60  on the surface of cap  46  in device  28  of  FIG. 14 ). The strain sensor formed from metal  60  may be used to make strain measurements for device  28  (e.g., to determine whether device  28  is being subjected to excess stress, to allow device  28  to serve as a button or other input device, etc.). 
     If desired, a moisture sensor may be formed by patterning metal  60  on the surface of cap  46  of packaged device  28 , as shown in  FIG. 16 . In the example of  FIG. 16 , metal  60  has been patterned to form two moisture sensor electrodes. Electrodes  60 - 1  and  60 - 2  have interdigitated sets of fingers that are separated by gaps. When moisture is present, some of the gaps will be bridged by moisture and a corresponding change in resistance and/or capacitance between the electrodes can be measured by device  10 . By patterning metal  60  to form a moisture sensor of the type shown in  FIG. 16 , device  10  can monitor for undesired moisture intrusion into housing  12 . Moisture detection circuitry may be formed from components  32  within a packaged device having an external moisture sensor or from other circuitry in device  10 . 
       FIG. 17  is a cross-sectional side view of packaged device  28  in an illustrative configuration in which device  28  has two packaged device portions. Portion  28 A has substrate  44 A, components  32 A on substrate  44 A, and cap  46 A that covers components  32 A. Portion  28 B has substrate  44 B, components  32 B on substrate  44 B, and cap  46 B that covers components  32 B. Flexible printed circuit  118  may have one end mounted to substrate  44 A and an opposing end mounted to substrate  44 B (e.g., using solder). Flexible printed circuit  118  may couple interconnects within respective substrates  44 A and  44 B together, thereby coupling the circuitry of components  32 A and  32 B. 
     Flexible printed circuit  118  may be used to accommodate a bend in device  28 . This may allow device  28  to be mounted in a confined interior space within housing  12 . The bend may be a right angle bend or other bend (i.e., a non-right-angle bend) that allows substrates  44 A and  44 B to lie in planes that are not parallel to each other (i.e., the surface normal for the plane of portion  28 A may lie perpendicular to the surface normal for the plane of portion  28 B or may otherwise not be parallel to the surface normal for the plane of portion  28 B). A flexible polymer or other elastomeric material such as material  120  may cover flexible printed circuit  118  and may help protect flexible printed circuit  118  from exposure to moisture (as shown in  FIG. 17 ) or elastomeric material  120  may be omitted (as shown in  FIG. 18 ). 
     As shown in  FIG. 19 , cap  46  may be provided with an engagement feature that helps mount device  28  within housing  12 . In the example of  FIG. 19 , cap  46  has been provided with protrusion  46 P. Protrusion  46 P may have the shape of a flexible snap structure that engages with a mating engagement feature in device  10  such as protrusion  12 P of housing  12 . Cap  46  may be provided with multiple protrusions  46 P (e.g., multiple snaps) or other engagement features. The arrangement of  FIG. 19  is merely illustrative. 
       FIG. 20  is a cross-sectional side view of packaged device  28  in an illustrative configuration in which device  28  has a locally thinned portion to accommodate a screw. As shown in  FIG. 20 , components  32  may be mounted on substrate  44  and covered with cap  46 . Cap  46  may have thinned portion  122  to accommodate the head of screw  126 . Portion  122  of cap  46  may have an opening such as opening  124  to allow the shaft of screw  126  (or other suitable threaded fastener) to pass though cap  46 . Screws such as screw  126  may be used to attach device  28  to structures such as structure  128  (e.g., a portion of housing  12 , an internal support structure in device  10 , etc.). 
       FIG. 21  is a cross-sectional side view of device  28  in an illustrative configuration in which cap  46  of device  28  is L-shaped. Device  28  may be an L-shaped packaged device or other device with an integral component such as dome switch  138 . This may allow device  28  to form a switch module for a button such as button  130 . In the example of  FIG. 21 , button  130  has movable button member  132 . During operation, button member  132  moves in directions  136 . When pressed, button member  132  contacts dome switch  138  and actuates switch  138 . Switch  138  may be mounted to one of substrates  44 . Components  32  may be mounted to an opposing side of the substrate. L-shaped cap  46  may cover components  32  and substrates  44 . Cap  46  may have an opening to accommodate screw  126 . Screw  126  may be used to mount device  28  to housing  12 . Flexible printed circuit  118  may be embedded within cap  46  and may be used to couple substrates  44  together. In the example of  FIG. 22 , device  28  has an L-shaped cap  46  with an opening to accommodate screw  126  while screw  126  attaches device  28  to housing  12  and does not include a dome switch. 
     If desired, multiple substrates in device  28  may be stacked on top of each other. For example, substrates  44 A and  44 B of packaged device  28  of  FIG. 23  may be stacked on top of each other. Components  32  may be mounted on the sides of the substrates that face each other. Cap  46  may cover components  32  and substrates  44 A and  44 B. Flexible printed circuit  118  may be coupled to the outer surfaces of substrates  44 A and  44 B as shown in  FIG. 23 , or may be coupled to the inner surfaces of substrates  44 A and  44 B as shown in the example of  FIG. 24 . Flexible printed circuit  118  of  FIG. 24  may be embedded within cap  46 . 
     In L-shaped package configurations for device  28 , cap  46  may have a right angle bend. If desired, cap  46  may have non-right-angle bends (e.g., bends at angles of 0-90°, 10-80°, 30-60°, etc.). This type of arrangement is shown in  FIGS. 25 and 26 . In the examples of  FIGS. 25 and 26 , cap  46  has bend  142 . Flexible printed circuit  118  may be coupled between substrate  44  and component  140 , so that the circuitry of components  32  may be interconnected with component  140 . Component  140  may be an electrical component such as a microphone, sensor, or other input-output device (as an example). Flexible printed circuit  118  may be coupled to the upper or lower surface of substrate  44  and may be coupled to the upper or lower surface of components  140 . 
     Cap  46  may cover components  32  while flexible printed circuit  118  is uncovered by cap  46  as shown in  FIG. 25  or cap  46  may cover both components  32  and a portion of flexible printed circuit  118  as shown in  FIG. 26 . As shown in  FIG. 26 , portions of cap  46  may be provided with openings to accommodate screws such as illustrative screw  126  of  FIG. 26 , thereby facilitating the mounting of device  28  to housing  12  or other support structures. 
       FIG. 27  is a cross-sectional side view of packaged device  28  in an illustrative configuration in which device  28  has a portion that forms an electromagnetic shield. As shown in  FIG. 27 , components  32  may be mounted on substrate  44 . Cap  46  may cover components  32  and substrate  44 . Metal  60  may be formed on one or more surfaces of cap  46  at a location between external electrical component  146  and components  32 . In this position, metal  60  may serve as an electromagnetic shield that reduces interference between component  146  and components  32 . If desired, device  28  may be provided with support structures such as feet  144 . Feet  144  may be formed from a sticky material (e.g., an elastomeric substance such as a soft polymer) to help secure device  28  to a support structure. 
       FIG. 28  is a cross-sectional side view of device  28  in an illustrative configuration in which device  28  has strengthening features. Strengthening features for device  28  may be formed as integral molded structures in cap  46 . In the example of  FIG. 28 , device  28  has parallel ridges  46 R that help prevent undesired flexing of device  28  about axis  148 . Strengthening features may be provided in the form of ridges or other protrusions and may be provided on one or more sides of cap  46 . The configuration of  FIG. 28  in which strengthening ribs  46 R have been formed on the upper surface of cap  46  is merely illustrative. 
     The features of the illustrative packaged devices  28  of  FIGS. 3A, 3B, and 4-28  may be used alone or in combination with any other features of devices  28  of  FIGS. 3A, 3B, and 4-28 . For example, device  28  may have any or all of the features of the structural features of  FIGS. 3A, 3B, and 4-28 , any or all of the electrical features of  FIGS. 3A, 3B, and 4-28 , and/or any other features from  FIGS. 3A, 3B, and 4-28 . The examples of  FIGS. 3A, 3B, and 4-28  and the other drawings are merely illustrative. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20150721
Publication Date: 20180206
Grant Date: 20180206
Priority Date: 20150721
Inventors: PERKINS RYAN C.
NESS TREVOR J.
BUSHNELL TYLER S.
Cardinali Steven P.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/0218", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K9/0022", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/167", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2223/6677", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/181", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16225", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10977", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/564", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0707", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10371", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/0218", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/167", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10151", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0133", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0133", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10151", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0133", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0707", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10371", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L31/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/0218", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L23/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/167", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K9/0022", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/564", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10977", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10151", "inventive": false, "first": false, "tree": "[]"}, {"code": "H10F19/80", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2223/6677", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/181", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16225", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 57837583