PATENT DOCUMENT

Publication Number: US-10147685-B2
Application Number: US-201715403046-A
Country: US
Kind Code: B2

Title: System-in-package devices with magnetic shielding

Abstract:
Electrical components may be packaged using system-in-package configurations or other component packages. Integrated circuit dies and other electrical components may be soldered or otherwise mounted on printed circuits. A layer of encapsulant may be used to encapsulate the integrated circuits. A shielding layer may be formed on the encapsulant layer to shield the integrate circuits. The shielding layer may include a sputtered metal seed layer and an electroplated layer of magnetic material. The electroplated layer may be a magnetic material that has a high permeability such as permalloy or mu metal to provide magnetic shielding for the integrated circuits. Integrated circuits may be mounted on one or both sides of the printed circuit. A temporary carrier and sealant may be used to hold the encapsulated integrated circuits during electroplating.

Claims:
What is claimed is: 
     
       1. A magnetically shielded device, comprising:
 a substrate; 
 at least one electrical component mounted on the substrate; 
 an encapsulation layer having first and second opposing surfaces, wherein the first surface is coupled to the substrate covering the component; 
 a magnetic shielding layer on the encapsulation layer formed from a sputtered seed layer and an electroplated layer of magnetic material; 
 a shielding layer in the encapsulation layer, wherein the shielding layer comprises magnetic material; and 
 at least one shielding wall formed from a portion of the shielding layer, wherein the at least one shielding wall completely fills a groove in the encapsulation layer up to the second surface. 
 
     
     
       2. The magnetically shielded device defined in  claim 1  wherein the at least one electrical component comprises a plurality of integrated circuit dies soldered to the substrate and wherein the encapsulation layer covers the plurality of integrated circuit dies. 
     
     
       3. The magnetically shielded device defined in  claim 2  wherein the electroplated layer of magnetic material comprises an electroplated material selected from the group consisting of: NiFe, CoZrTa, Co, mu-metal, and permalloy. 
     
     
       4. The magnetically shielded device defined in  claim 3  wherein the substrate has a first surface to which the integrated circuit dies are soldered and an opposing second surface, wherein the substrate has metal traces that form a ground contact on the second surface, and wherein the electroplated layer of magnetic material is formed by passing electroplating current through the ground contact. 
     
     
       5. The magnetically shielded device defined in  claim 3  further comprising a coating layer of non-corrosive material on the electroplated layer of magnetic material. 
     
     
       6. The magnetically shielded device defined in  claim 3  wherein the substrate has opposing first and second sides and wherein some of the integrated circuit dies are mounted to the first side and some of the integrated circuit dies are mounted to the second side. 
     
     
       7. The magnetically shielded device defined in  claim 6  wherein the electroplated shielding layer shields the integrated circuit dies on the first side and the integrated circuit dies on the second side. 
     
     
       8. A magnetically shielded device, comprising:
 a substrate; 
 at least one electrical component mounted on the substrate; 
 an encapsulation layer having first and second opposing surfaces, wherein the first surface is coupled to the substrate covering the electrical component; 
 a magnetic shielding layer in the substrate, wherein the magnetic shielding layer comprises magnetic material; 
 a shielding layer on the encapsulation layer; and 
 at least one shielding wall formed from a portion of the shielding layer, wherein the at least one shielding wall completely fills a groove in the encapsulation layer up to the second surface. 
 
     
     
       9. The magnetically shielded device defined in  claim 8  wherein the shielding layer includes first, second, and third layers of material. 
     
     
       10. The magnetically shielded device defined in  claim 9  wherein the first and third layers of material comprise stainless steel and wherein the second layer of material is interposed between the first and third layers of material. 
     
     
       11. The magnetically shielded device defined in  claim 10  wherein the second layer of material comprises copper. 
     
     
       12. The magnetically shielded device defined in  claim 10  wherein the second layer of material comprises a magnetic material that serves as magnetic shielding. 
     
     
       13. The magnetically shielded device defined in  claim 12  wherein the second layer of material comprises a magnetic material with a relative permeability of at least 10000. 
     
     
       14. The magnetically shielded device defined in  claim 8  wherein the at least one electrical component comprises a plurality of integrated circuits, wherein the substrate comprises a printed circuit board having interconnects that interconnect the integrated circuits, and wherein the interconnects are interposed between the magnetic shielding layer and the interconnects. 
     
     
       15. The magnetically shielded device defined in  claim 14  wherein the shielding layer includes first, second, third, and fourth layers of material. 
     
     
       16. The magnetically shielded device defined in  claim 15  wherein the third layer of material comprises a magnetic material that serves as magnetic shielding. 
     
     
       17. The magnetically shielded device defined in  claim 16  wherein the second layer of material comprises a metal layer. 
     
     
       18. The magnetically shielded device defined in  claim 17  wherein the first layer of material is an inner layer formed on the encapsulation layer, wherein the fourth layer of material is an outer layer, wherein the inner layer comprises stainless steel, wherein the outer layer comprises stainless steel, wherein the third layer is interposed between the outer layer and the second layer of material, and wherein the second layer of material is interposed between the third layer of material and the inner layer. 
     
     
       19. The magnetically shielded device defined in  claim 8  wherein the magnetic shielding layer comprises a sputtered magnetic shielding layer and wherein the shielding layer on the encapsulation comprises a sputtered shielding layer. 
     
     
       20. The magnetic shielding device defined in  claim 8  wherein the magnetic shielding layer comprises an electrolessly plated shielding layer and wherein the shielding layer on the encapsulation comprises an electrolessly plated shielding layer. 
     
     
       21. The magnetically shielded device defined in  claim 8  wherein the groove has a tapered profile. 
     
     
       22. The magnetically shielded device defined in  claim 8  further comprising a contact on the substrate, wherein the shield wall that completely fills the groove extends to the contact, wherein the contact comprises a solder pad. 
     
     
       23. The magnetically shielded device defined in  claim 8  wherein the shielding layer is formed from a sputter seed layer and an electroplated layer of magnetic material. 
     
     
       24. The magnetically shielded device defined in  claim 23  wherein the electroplated layer of magnetic material comprises an electroplated material selected from the group consisting of: CoZrTa, Co, mu-metal, and permalloy. 
     
     
       25. The magnetically shielded device defined in  claim 24  wherein the substrate has a first surface to which the electrical component is soldered and an opposing second surface, wherein the substrate has metal traces that form a ground contact on the second surface, and wherein the electroplated layer of magnetic material is formed by passing electroplating current through the ground contact. 
     
     
       26. The magnetically shielded device defined in  claim 24  further comprising a coating layer of non-corrosive material on the electroplated layer of magnetic material. 
     
     
       27. A magnetically shielded device, comprising:
 a printed circuit board substrate, wherein the printed circuit board substrate has first and second opposing sides and wherein the printed circuit board substrate has first and second opposing surfaces; 
 a plurality of integrated circuits mounted on the first surface of the substrate that are interconnected by interconnects in the printed circuit board substrate; 
 an encapsulation layer having first and second surfaces, wherein the first surface is coupled to the printed circuit board substrate, covering the integrated circuits; 
 a plurality of shielding layers in the substrate that extend completely from the first side of the substrate to the second side of the substrate; 
 a shielding layer on the encapsulation layer that includes a metal layer and a layer of magnetic material; and 
 at least one shielding wall formed from a portion of the shielding layer, wherein the at least one shielding wall penetrates into and completely fills a groove in the encapsulation layer, wherein the at least one shielding wall extends from the first to the second surface. 
 
     
     
       28. The magnetically shielded device defined in  claim 27  wherein the metal layer comprises a metal selected from the group consisting of: copper and aluminum and wherein the layer of magnetic material comprises a material having a relative permeability of at least 10000. 
     
     
       29. The magnetically shielded device defined in  claim 28  wherein the layer on the encapsulation layer comprises a first stainless steel layer interposed between the metal layer and the encapsulation layer and comprises a second stainless steel layer, wherein the layer of magnetic material is interposed between the second stainless steel layer and the metal layer. 
     
     
       30. The magnetically shielded device defined in  claim 27  wherein at least one of the shielding layers of the plurality of shielding layers comprises magnetic material.

Description:
This application claims the benefit of provisional patent application No. 62/306,302, filed Mar. 10, 2016, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD 
     This relates generally to shielding and, more particularly, magnetic shielding for devices such as system-in-package devices. 
     BACKGROUND 
     Electronic equipment often contains components that are subject to signal interference. Metal shield cans may be used to cover integrated circuits and other components and thereby help to suppress electromagnetic interference. Magnetic materials may be used to form shield cans that help suppress magnetic fields. An example of a magnetic material that can be used in forming magnetic shielding cans is the high permeability nickel-iron magnetic alloy that is sometimes referred to as mu-metal. 
     It can be challenging to design effective shielding for portable electronic devices and other environments in which components are mounted in close proximity to each other. If care is not taken, shielding structures will be more bulky than desired, will not be as effective at shielding components from each other as desired, and will be difficult to manufacture. 
     SUMMARY 
     System-in-package devices and other packaged electrical components may be provided with shielding. The shielding may include high conductivity metal layers that serve as radio-frequency shielding and magnetic material layers that serve as magnetic shielding. The shielding may be formed on the surface of the devices and may extend into grooves within encapsulation layers in the devices. Shielding may also be formed within substrate layers for the devices. 
     Integrated circuit dies and other electrical components may be soldered or otherwise mounted on printed circuits that serve as package substrates. A layer of encapsulant may be used to encapsulate the integrated circuits. 
     A shielding layer may be formed on the encapsulant layer to shield the integrated circuits. The shielding layer may include a sputtered metal seed layer and an electroplated layer of magnetic material. The electroplated layer may be a magnetic material that has a high permeability such as permalloy or mu metal. Layers of shielding material may also be deposited using spraying, printing, and other techniques. For example, electroless plating techniques may be used. With electroless plating, a seed layer need not be used. If desired, the shielding layer may be formed by sputtering only. Combinations of these approaches may also be used (e.g., electroless plating in combination with electroplating and/or sputtering, printing, and/or other techniques). 
     Integrated circuits may be mounted on one or both sides of the printed circuit and may be covered with a magnetic shielding layer on one or both sides of the printed circuit. A temporary carrier and sealant may be used to hold encapsulated integrated circuits during electroplating. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional side view of an illustrative electronic device in accordance with an embodiment. 
         FIG. 2  is a cross-sectional side view of a portion of an illustrative packaged device of the type that may be used in the electronic device of  FIG. 1  in accordance with an embodiment. 
         FIG. 3  is a cross-sectional side view of an illustrative packaged device with a shielding layer that covers a top surface and side surfaces of an encapsulation layer in accordance with an embodiment. 
         FIG. 4  is a cross-sectional side view of an illustrative packaged device with a shielding layer that covers top, side, and rear device surfaces in accordance with an embodiment. 
         FIG. 5  is a cross-sectional side view of an illustrative packaged device with a shielding layer that penetrates into grooves in an encapsulant layer to form shielding walls between components in the package in accordance with an embodiment. 
         FIG. 6  is a top view of an interior portion of an illustrative packaged device of the type shown in  FIG. 5  in accordance with an embodiment. 
         FIG. 7  is a diagram of illustrative equipment of the type that may be used in fabricating packaged devices with shielding and assembling these devices to form a finished electronic device in accordance with an embodiment. 
         FIG. 8  is a diagram of equipment and operations involved in forming shielded system-in-package devices and other shielded components in accordance with an embodiment. 
         FIG. 9  is a side view of an illustrative electroplating system of the type that may be used in forming shielding for packaged electrical components in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative system-in-package device having double-sided shielding in accordance with an embodiment. 
         FIG. 11  is a flow chart of illustrative steps involved in forming devices such as system-in-package devices with shielding in accordance with an embodiment. 
         FIGS. 12, 13, and 14  are cross-sectional side views of illustrative packaged devices with magnetic shielding in accordance with embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with electrical components such as integrated circuits, discrete electrical components such as inductors, capacitors, and resistors, and other electrical components. Shielding may be used to prevent interference between components. In some scenarios, components may be packaged in multi-component packages using system-in-package technology. Arrangements in which shielding is provided in the context of system-in-package devices may sometimes be described herein as an example. In general, any suitable electrical component may be provided with shielding. The use of system-in-package devices is merely illustrative. 
     A cross-sectional side view of an illustrative electronic device of the type that may include shielded electrical components 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, an accessory (e.g., earbuds, a remote control, a wireless trackpad, etc.), or other electronic equipment. 
     As shown in  FIG. 1 , device  10  may include components such as display  14 . Display  14  may be 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. Display  14  may be protected using a display cover layer such as display cover layer  16 . A liquid crystal display module, organic light-emitting diode display, or other display structures (shown as display module  18  in the example of  FIG. 1 ) may be mounted below display cover layer  16 . In some configurations for device  10 , display  14  may be omitted. The arrangement of  FIG. 1  in which device  10  includes display  14  is merely illustrative. 
     As shown in the cross-sectional side view of electronic device  10  of  FIG. 1 , electronic device  10  may include internal device components such as devices  22 . Devices  22  may include sensors, integrated circuits, buttons, connectors, and other circuitry. If desired, one or more components such as devices  22  may be a system-in-package (SiP) device. A component formed using system-in-package technology includes multiple integrated circuits packaged in a common package. 
     In the interior of electronic device  10 , devices  22  may be mounted on one or more substrates such as substrate  20 . Substrate  20  may be a dielectric carrier such as a molded plastic carrier or a printed circuit. For example, substrate  20  may be a printed circuit such as a rigid printed circuit formed from a material such as fiberglass-filled epoxy or may be a flexible printed circuit formed from a sheet of polyimide or other flexible polymer layer. 
     A cross-sectional side view of a portion of an illustrative system-in-package device (sometimes referred to as a system-in-package or system-in-package component) is shown in  FIG. 2 . As shown in  FIG. 2 , system-in-package device  22  may include a substrate such as substrate  30 . Substrate  30  may be a printed circuit or other package substrate that includes one or more layers of signal interconnects  32  (e.g., one or more layers of patterned metal traces). Interconnects  32  may include contacts such as solder pads  32 P. Pads  32 P may be formed on the upper surface of substrate  30  (as an example). Contacts formed from interconnects  32  may also be located on the lower surface of substrate  30  (e.g., to facilitate mounting of device  22  to printed circuit  20 ). 
     Integrated circuits  34  (i.e., silicon integrated circuit dies) may have contacts such as solder pads  34 P that mate with contacts  32 P on the upper surface of printed circuit  30 . A soldering tool or other equipment may use solder  36  or other conductive material (e.g., conductive adhesive, etc.) to mount integrated circuits  34 , discrete components, and other circuitry to pads  32 P on substrate  30 . After integrated circuits (integrated circuit dies)  34  have been mounted to substrate  30 , integrated circuits  34  may be encapsulated using dielectric encapsulant such as encapsulant (encapsulation) layer  38 . Layer  38  may be a polymer such as a thermoset or thermoplastic polymer and may sometimes be referred to as a mold cap (e.g., when layer  38  is formed by molding plastic over integrated circuits  34 ). Device  22  may have a land-grid-array (LGA) form factor, a ball-grid-array (BGA) form factor, or any other suitable form factor. The configuration of  FIG. 2  is merely illustrative. 
     Shielding layer  40  may be formed on one or more of the surfaces of system-in-package device  22 . As shown in  FIG. 2 , shielding layer  40  may, if desired, include multiple sublayers of material such as layers  42 . Layers  42  may include metal, non-metallic materials, magnetic materials, dielectric, and/or other layers of material. Electromagnetic shielding layers may be formed, for example, from a first layer of stainless steel (e.g., an inner layer), a second layer of stainless steel (e.g., an outer layer), and an interposed conductive layer such as a layer of copper or other conductive metal. 
     To help suppress magnetic fields, shielding layer  40  preferably includes one or more magnetic shielding layers. For example, shielding layer  40  may include one or more layers of soft magnetic materials such as NiFe (e.g., Ni80Fe20, Ni45Fe55, Ni82Fe18, Ni55Fe45, etc.), CZT (CoZrTa), Co, CoNiFe, Ni, CoNi, Co, Cobalt-based amorphous alloys (e.g., CoZrTa alloy), and mu-metal (e.g., an alloy of Ni, Fe, Cu, and a metal such as Cr or Mo such as Ni80Mo5Fe15), ferrites (e.g., a ferrimagnetic ceramic formed from iron oxide with metallic elements), nickel-iron alloys such as permalloy, other nickel iron alloys, or other high permeability material. Non-corrosive coating layers may, if desired, by incorporated into layer  40  (e.g., a stainless steel coating layer may be formed on a high permeability magnetic shielding layer such as a mu-metal layer to help prevent corrosion). The relative permeability of the layer(s) of magnetic material in layer  40  may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, or may have any other suitable value that allows the layer(s) to serve as magnetic shielding for device  22 . 
     A cross-sectional side view of an illustrative configuration for incorporating shielding layer  40  onto the sides and upper (outer) surface of device  22  is shown in  FIG. 3 . As shown in  FIG. 3 , interconnects  32  (e.g., ground traces in interconnects  32 ) may contact portions of shielding layer  40  along the edges of device  22 . In the example of  FIG. 4 , shielding layer  40  has been formed on the upper surface of encapsulation layer  38  and extends over the edge surfaces of encapsulation layer  38  and the exposed ground lines (interconnects  32 ) on the edges of substrate  30  (i.e., layer  40  covers the upper surface of device  22 ). If desired, shielding layer  40  may cover the opposing lower (rear) surface of device  22 , as shown in the illustrative configuration of device  22  in  FIG. 4 . 
     If desired, shielding layer  40  may be used to form dividing walls such as shielding wall  40 W of  FIG. 5 . As shown in  FIG. 5 , shielding wall  40 W may be formed from a portion of shielding layer  40  that penetrates into a groove in encapsulant  38 . Shielding wall  40 W may be interposed between one or more integrated circuits in a first set of electrical components (see, e.g., component  34 - 1 ) and one or more integrated circuits in a second set of electrical components (see, e.g., components  34 - 2 ). This type of arrangement may be used, for example, to help shield components  34 - 2  from a noisy component such as component  34 - 1 . Shielding wall  40 W may be formed from shielding layer material that penetrates to the surface of substrate  30  and that contacts a ground trace such as ground contact (pad)  32 P in interconnects  32 . 
     A top view of an interior portion of an illustrative system-in-package device  22  in which shielding wall  40 W is present is shown in  FIG. 6 . As shown in  FIG. 6 , electrical components  34  may include a component (component D 1 ) that is being shielded from three additional components (D 2 , D 3 , and D 4 ) by shielding wall  40 W. Shielding wall  40 W may have a rectangular ring shape, may be joined to sidewall portions of shielding layer  40  (as shown in the example of  FIG. 6 ), may have the shape of a straight interior partition that divides a rectangular device  22  into first and second portions, or may have any other suitable shape. The arrangement of  FIG. 6  is merely illustrative. 
     Illustrative equipment of the type that may be used in fabricating an electronic device having shielded system-in-package devices  22  and other packaged devices is shown in  FIG. 7 . As shown in  FIG. 7 , structures  62  (e.g., partly and/or completely formed devices  22  and other components of electrical device  10 ) may be processed using the tools of system  60  to form a completed device (e.g., a cellular telephone, watch, portable computer, or other electronic device  10 ). 
     Physical vapor deposition tool  64  may include evaporation equipment, sputtering equipment, or other tools for depositing metal or other materials. Tool  64  may, for example, include a sputtering tool for depositing a thin metal seed layer onto device  22  to facilitate subsequent electrochemical deposition operations. The seed layer may be formed from gold, stainless steel, silver, or a layer of other metal through which current may pass to initiate electrochemical deposition operations (e.g., electroplating). 
     Electrochemical deposition equipment  66  may be used to deposit layers of material (e.g., one or more layers  42  for layer  40  or other layers) for forming device  22 . Equipment  66  may include electroless deposition equipment, electroplating equipment, or other suitable electrochemical deposition equipment. Magnetic materials (e.g., magnetic shielding layers) and other materials may be deposited to form layers  42  using tool  64 , equipment  66 , and other suitable deposition tools. 
     Packaging equipment  74  may include a soldering tool (e.g., a pick and place tool or other equipment for soldering integrated circuits and other components to a printed circuit board or other substrate  30 ). Equipment  74  may also include injection molding equipment or other equipment for molding or otherwise forming desired encapsulation layer structures (mold caps) such as encapsulant layer  38  on device  22 . Equipment  74  may, for example, include equipment for depositing liquid polymer material that forms a solid encapsulation layer after cooling and/or curing. 
     A temporary carrier such as a printed circuit carrier or other carrier may be used to support devices  22  during the formation of shielding layer  40 . Carrier mounting equipment  68  may be used to temporarily mount devices  22  on the carrier substrate. Equipment  68  may include, for example, equipment for depositing a sealant (e.g. a liquid polymer sealant), equipment for curing the sealant (e.g., an ultraviolet light for ultraviolet-light-curing the sealant), computer-controlled positioners for attaching and removing devices  22  from the carrier, and other equipment. 
     Laser equipment  70  may include one or more lasers and associated computer-controlled positioners. Using a laser processing tool of this type, a beam of focused laser light may be scanned across the surface of each of devices  22 , thereby drilling (i.e., cutting by thermal dissociation, ablation, etc.) one or more grooves through encapsulant  38 . A portion of shielding layer  40  may then be formed in the groove(s) to form shielding walls such as shielding wall portion  40 W of layer  40  in  FIGS. 5 and 6 . 
     If desired, layers of soft magnetic material for magnetic shielding, high conductivity metals such as copper and aluminum for radio-frequency shielding, and/or other layers of material may be deposited using equipment  65 . Equipment  65  may include tools for depositing liquids (e.g., thin polymer resins) that contain particles of soft magnetic material. Equipment  65  may, for example, include spraying equipment, ink-jet printing equipment, pad printing equipment, screen printing equipment, other tools for depositing soft magnetic materials by printing, or may include other deposition equipment. Soft magnetic material may also be deposited by lamination (e.g., lamination of soft magnetic foils with other layers), and/or other deposition techniques. The illustrative equipment of  FIG. 7  is merely illustrative. 
     Assembly equipment  72  may be used to complete assembly operations for device  10 . In particular, after forming shielded electrical components such as shielded system-in-package device  22  using other equipment in system  60 , equipment  72  (e.g., robotic assembly equipment) may be used in soldering devices  22  to substrates such as substrate  20  of  FIG. 1 , may be used in coupling substrates such as substrate  20  of  FIG. 1  to display  14  and other components, and may be used in mounting devices  22  and other circuitry for device  10  within housing  12  to complete assembly of electronic device  10 . 
     Illustrative equipment and operations for forming shielding on components such as system-in-package device  22  are shown in  FIG. 8 . 
     Initially a pick-and-place tool, other soldering tool, or other mounting equipment  74 A may be used in soldering or otherwise mounting integrated circuits  34  and/or other circuit components on substrate  30 . Encapsulation tool  74 B may be used to encapsulate mounted components  34  with encapsulant (i.e., encapsulant layer  38 ). 
     If desired, optional grooves for shielding walls  40 W may be formed in encapsulation layer  38 . For example, laser drilling tool  70  or other groove formation equipment may be used to cut through encapsulation layer  38  and remove the material in groove  80 , thereby forming partially completed system-in-package device structures  22 P. To facilitate subsequent deposition of a sputtered metal seed layer into groove  80 , the sidewalls of groove  80  may be provided with a tapered profile, as shown by illustrative outwardly flared groove sidewall surfaces  82  in partially completed devices  22 P. 
     Optional conductive filling tool  67  may be used to fill groove  80  with conductive epoxy or other conductive fill. After curing, the conductive fill may form shielding walls such as wall  40 W of  FIG. 6 . With this type of arrangement, sputtering and plating operations to form shielding walls  40 W can be omitted. 
     After forming groove  80  with laser tool  70 , singulation tool  69  may be used to dice or laser cut a panel or strip of system-in-package device structures  22 P into individual system-in-package devices. 
     To enhance throughput when forming shielding layer  40  on system-in-package devices, multiple devices may be supported by a common carrier structure. For example, carrier mounting equipment  68  may mount multiple partially completed system-in-package devices  22 P on carrier layer  84 . Carrier layer  84  may be a plastic support structure or a rigid or flexible printed circuit. Illustrative configurations in which carrier layer  84  is a rigid printed circuit may sometimes be described herein as an example. Carrier mounting equipment  68  may include sealant dispensing equipment such as a needle dispenser, screen printing equipment, inkjet printing equipment, or other equipment for dispensing a ring of adhesive or other sealant around the base of each component  34  when mounting components  34  to carrier  84 . The ring of sealant may hold devices  22 P to carrier  84 . Carrier  84  may contain metal traces for carrying plating current and contacts that mate with corresponding contact(s) on devices  22 P. The contacts on carrier  84  may be used to applying current to a seed layer on the outside of devices  22 P during electroplating operations. The ring of sealant that is interposed between the periphery of each device  22 P and carrier  84  may prevent electroplating solution from contacting potentially sensitive components on devices  22 P such as exposed contact pads. 
     After attaching devices  22 P to carrier  84  and using sealant to prevent liquid intrusion under devices  22 P when carrier  84  is immersed in liquid, equipment  86  may be used to form shielding layer  40 . With one suitable arrangement, at least one sputter-deposited layer of material is formed on devices  22 P such as a sputtered seed layer of metal. The seed layer may be a relatively thin layer (e.g., a layer of less than 1 micron in thickness, a layer of less than 0.5 microns in thickness, etc.). Due to the tapered profile of groove  80 , the seed layer may be deposited onto the inner sidewalls of groove  80  (i.e., onto curved groove surfaces  82 ) and onto the metal contacts at the bottom of groove  80 . Once the seed layer has been deposited, current may be applied to the seed layer through signal paths in carrier  84  while carrier  84  and devices  22 P are submerged within a liquid electroplating bath using a signal source (current source). This electroplating process may be used to grow (electroplate) relatively thick layers of material (e.g., layers with thicknesses of 1-5 microns, 1-20 microns, 2-10 microns, less than 30 microns, more than 2 microns, or other suitable thicknesses). The plated material may be, for example, one or more layers  42  such as magnetic material layers (magnetic shielding layers), anti-corrosion coating layers, adhesion layers, conductive electromagnetic shielding layers, etc. If desired, layers  42  may include a combination of multiple layers formed using different deposition techniques (e.g., sputtering or other physical vapor deposition techniques, electroplating, electroless deposition (e.g., electroless plating without using a seed layer, electroless plating in combination with electroplating and/or sputtering, etc.), chemical vapor deposition, atomic layer deposition, etc.). 
     In scenarios in which grooves  80  are not formed in encapsulant layer  38 , layer  40  may form a planar surface layer that covers the surface of encapsulant  38  (and, if desired, the rear surface of substrate  20 , as shown in  FIG. 4 ). In scenarios in which grooves  80  were formed in encapsulant  38 , the deposited material of layer  40  (i.e., the sputtered seed layer and the one or more subsequently deposited layers such as one or more electroplated layers of magnetic material, etc.) may be deposited in groove  80  to form shielding walls  40 W. 
       FIG. 9  is a diagram showing an illustrative electroplating arrangement for forming shielding layer  40  onto device  22 . As shown in  FIG. 9 , electroplating tool  66 P may have an electroplating bath  92  in receptacle  98  in which devices  22  and carrier  84  are immersed. Tool  66 P may apply current to electrodes  94  and  96  during electroplating operations. Electrode  96  may be in contact with electroplating bath  92 . Electrode  94  may be shorted to pad  84 PT on carrier  84 . Carrier traces such as path  100  may short contact  84 PT and therefore electrode (terminal)  94  to contacts such as pads  84 P on carrier  84 . 
     Equipment  68  ( FIG. 8 ) may apply a ring of adhesive such as sealant  90  between devices  22  and carrier  84 . Sealant  90  may, for example, be a reworkable elastomeric adhesive such as an ultraviolet light cured liquid adhesive. Equipment  68  may include a dispensing tool that deposits sealant  90  in a ring shape that is interposed between the lower surface of substrate  30  of device  22  and the opposing upper surface of carrier  84 . Equipment  68  may also include an ultraviolet light source that applies ultraviolet light to sealant  90  to cure sealant  90 . Devices  22  may have exposed lower surface contacts such as solder pads  32 P′. During normal use in device  10 , contacts  32 P′ may allow devices  22  to be soldered to substrates such as printed circuit  20  ( FIG. 1 ). During electroplating operations, contacts  32 P′ on the outer surface of system-in-package substrate  30  serve as back (outer surface) ground contacts for completing a plating circuit in electroplating bath  92  and may mate with corresponding contacts  84 P on the upper surface of carrier  84 . The ring of sealant  90  between substrate  30  and carrier  84  may surround contacts  32 P′ and  84 P and thereby prevent liquid bath  92  from penetrating under devices  22  and reaching contacts  34 P′ and  84 P. 
     Carrier  84  may have metal traces that form interconnect lines such as path  100 . Path  100  may short contact  84 PT to one or more of contacts  84 P. Contacts  84 P mate with corresponding contacts  32 P′ on the lower surfaces of devices  22  and are therefore shorted to contacts  32 P′. Contacts  32 P′, in turn, are shorted to sputter deposited seed layer  40 - 1  by paths  32  in substrate  30 . Layer  40 - 1  may be deposited using physical vapor deposition equipment  64  of  FIG. 7  such as sputtering equipment (see, e.g., equipment  86  of  FIG. 8 ) prior to immersion of carrier  84  in bath  92 . The presence of layer  40 - 1  and the current applied using signal source  102  causes one or more layers of magnetic material or other material to plate from bath  92  onto the outer surface of sputtered layer  40 - 1 , as shown by electroplated layer  40 - 2  of  FIG. 9 . Following electroplating operations to form one or more layers  42  for shield layer  40  in this way, devices  22  may be removed from temporary carrier  84  and sealant  90  may be peeled away from devices  22 . Devices  22  may then be mounted on printed circuit boards such as printed circuit  20  of  FIG. 1 . 
     If desired, electroplating operations with system  66 P may be used to electroplate metal layer  40 - 2  onto both sides of devices  22 , as shown in the illustrative configuration for device  22  of  FIG. 10 . In the illustrative arrangement of  FIG. 10 , substrate  30  has been provided with a protruding portion  30 P onto which contacts  32 P″ have been formed. Contacts  32 P″ may be shorted to seed layer  40 - 1  so that current can be applied to seed layer  40 - 1  to help electroplate layer  40 - 2  onto the outer surface of device  22  when device  22  is mounted on a carrier in bath  92 . The carrier used for processing multisided devices such as device  22  of  FIG. 10  may be the same as carrier  84  of  FIG. 9  or may have other structures for forming temporary electrical connections between carrier contacts  84 P and system-in-package substrate contacts  32 P′. 
       FIG. 11  is a flow chart of illustrative steps involved in forming shielded devices such as magnetically shielded system-in-package devices  22  for electronic device  10 . 
     At step  120 , electrical components such as integrated circuits  34  or other electrical components may be soldered or otherwise mounted on system-in-package substrates such as printed circuit substrates  30  using mounting tool  74 A of  FIG. 8  (see, e.g., packaging equipment  74  of  FIG. 7 ). 
     At step  122 , encapsulation tool  74 B of  FIG. 8  (see, e.g., packaging equipment  74  of  FIG. 7 ) may be used to form dielectric encapsulation layer  38  over integrated circuits  34 . Integrated circuits  34  and encapsulant  38  may be located on one or both sides of substrate  30 . 
     If it is desired to form shielding walls  40 W, groove formation equipment such as laser equipment  70  may be used to form grooves  80  in encapsulant  38  (e.g., to form a groove for a shielding wall to shield separate sets of integrated circuits  34  from each other). 
     At step  125 , optional conductive epoxy or other conductive fill may be used to fill grooves  80  (e.g., to create shield wall  40 W without need for sputtering, plating, etc.). 
     At step  127 , strips or panels of system-in-package devices  22  may be diced or laser cut into individual system-in-package devices  22  (i.e., devices  22  may be singulated). 
     At step  126 , mounting equipment  68  may be used to mount devices  22  on temporary carrier  84  (e.g., a printed circuit). When mounting devices  22 , sealant  90  may be used to attach devices  22  to carrier  84  and to protect exposed contacts on devices  22 , while the contacts on devices  22  mate with corresponding contacts on carrier  84 . 
     At step  128 , after mounting devices  22  on carrier  84 , sputter deposition equipment (see, e.g., physical vapor deposition equipment  64  of  FIG. 7  and tools  86  of  FIG. 8 ) may be used to deposited a layer of metal onto the surface of encapsulant  38  (and thereby into grooves  80 ) to serve as an electroplating seed layer (layer  40 - 1 ). 
     Electroplating equipment  66 P may then be used to electroplate layer  40 - 2  onto layer  40 - 1  at step  130 . If desired, electroless deposition techniques may be used to plate layers of magnetic material, metal, and other layers onto device  22  (alone or in combination with electroplating and/or sputtering, etc). Moreover, one or more additional layers of material may be deposited (i.e., one or more layers of material other than seed layer  40 - 1  and electroplated layer  40 - 2 ), as illustrated by the multiple layers  42  of shield layer  40  of  FIG. 2 . The configuration of  FIG. 11  is merely illustrative. 
     Following formation of shield layer  40  by electroplating layer  40 - 2  (or, if desired, using electroless deposition) and following formation of any desired additional layers for shielding layer  40  by sputtering, electroplating, electroless deposition, or other deposition techniques (see, e.g., layers  42  of  FIG. 2 ), devices  22  may be removed from temporary carrier  84  (step  132 ). 
     At step  134 , devices  22  may be mounted on printed circuits such as printed circuit  20  of  FIG. 1  and printed circuit  20  and other electrical components for device  10  may be assembled using equipment  72  to form electronic device  10 . 
     During operation of device  10 , the magnetic shielding layer on system-in-package device  22  may help prevent undesired wireless interference between noise-generating components and sensitive components in device  10 . 
     If desired, packaged devices such as device  22  may be formed using arrangements of the types shown in  FIGS. 12, 13, and 14  and/or may be formed using combinations of these arrangements and the arrangement of  FIGS. 3 and 4 , and/or other suitable configurations. In the illustrative arrangements of  FIGS. 12, 13, and 14 , electrical components such as integrated circuits  34  may be soldered to the surface of printed circuit board substrate  30  and interconnected using patterned metal traces that form interconnects  32  in substrate  30 . Substrate  30  may also have one or more embedded shielding layers  31  (e.g., a single shielding layer, two shielding layers, three shielding layers, four shielding layers, etc.). Shielding layers  31  may include high-conductivity metal that serves as radio-frequency shielding and/or magnetic material that serves as magnetic shielding. In the examples of  FIGS. 12 and 13 , there are two shielding layers  31  in each substrate  30  and in the example of  FIG. 14  there is a single shielding layer  31  in substrate  30 . This is merely illustrative. Substrates  30  of  FIGS. 12 and 13  may have fewer than two layers  31  or more than two layers  31  and substrate  30  of  FIG. 14  may have two or more layers  31 . 
     Integrated circuits  34  may be encapsulated with encapsulation layer  38  and covered with shielding layers  40 . Each layer  40  may include multiple sublayers, as described in connection with sublayers  42  of  FIG. 2 . To provide device  22  with satisfactory electromagnetic shielding, layer  40  may contain high-conductivity materials and/or magnetic materials. The resistivity of a high-conductivity metal layer in layer  40  and/or in layer  31  may be less than 2×10 −8  ohm-m, less than 3×10 −8  ohm-m, or other suitable amount. The relative permeability of the layer(s) of magnetic material in layer  40  and/or layer  31  may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, be less than 100,000, or may have any other suitable value that allows the layer(s) to serve as magnetic shielding for device  22 . The layers of material in layer  40  and/or layer(s)  31  may be deposited by sputtering or other physical vapor deposition processes, electroplating, spraying, printing, or other deposition techniques. 
     In the example of  FIG. 12 , layer  40  includes outer layer  150 , inner layer  154 , and intermediate layer  152 . Additional layers may be provided or fewer layers may be provided in layer  40  if desired. Layer  40  of  FIG. 12  may provide radio-frequency shielding for device  22  and may sometimes be referred to as a radio-frequency shielding layer. Layers  150  and  154  may be formed from a material such as stainless steel. Layer  152  may be a high conductivity layer such as a layer of copper or aluminum. Layer  154  may serve as an adhesion layer for layer  152 . Layer  150  may serve as a corrosion protection layer. 
     Layer(s)  31  in substrate  30  of  FIG. 12  may include copper layers or other high conductivity layers that serve as grounding and may, if desired, be shorted to the conductive materials in layer  40  to form a closed circuit for radio-frequency shielding. If desired, layer(s)  31  in substrate  30  of  FIG. 12  may include one or more layers of magnetic material. The magnetic material may have high permeability (e.g., the relative permeability of the layer(s)  31  of magnetic material in layer  40  may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, or may have any other suitable value that allows layer(s)  31  to serve as magnetic shielding for device  22 ), may have high saturation magnetic induction flux (flux density), and may have low coercivity. 
     In the example of  FIG. 13 , layer  40  includes inner layer  156 , intermediate layers  158  and  160 , and outer layer  162 . Layer  156  may be a stainless steel layer that covers encapsulant layer  38  and that serves as an adhesion layer for layer  158 . Outer layer  162  may be formed from stainless steel or other material that provides corrosion protection for layer  40 . Layer  158  may be a metal with a high conductivity such as copper or aluminum that serves a radio-frequency shielding for components  34 . Layer  158  may be interposed between layer  156  and layer  160 . Layer  160  may be formed from a magnetic material that forms a magnetic shield (e.g., a soft magnetic material with a relative permeability that may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, etc.). The placement of copper layer  158  under magnetic shield layer  160  may help ensure that there is a low resistance path between copper layers or other conductive layer(s)  31  in substrate  30  and layer  158 , thereby ensuring that components  34  are enclosed within a sealed radio-frequency copper shield. 
     If desired, one or more of layers  31  in substrate  30  of  FIG. 13  may be formed from magnetic material for forming a magnetic shield (i.e., in addition to or instead of forming layer(s)  31  from copper to form a radio-frequency shield, one or more of layers  31  may be formed from magnetic material with a relative permeability that may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, etc.). 
     In the illustrative configuration of  FIG. 14 , layer  40  includes a single layer of material such as a single layer of magnetic material for magnetic shielding (e.g., a single layer of material with a relative permeability that may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, etc.). There may be one or more layers such as layer  31  in substrate  30  that serve as shielding (e.g., one or more copper or aluminum layers or other layers with a high conductivity to serve as radio-frequency shielding, one or more layers of magnetic material for magnetic shielding, etc.). Layer  31  may, for example, be a magnetic material with a relative permeability that may be 2000 or more, may be 5000 or more, may be 10,000 or more, may be 20,000 or more, may be 80,000 or more, may be 5,000-100,000, may be 50,000-100,000, may be less than 100,000, etc. 
     Layer  40  of  FIG. 14  and the sublayers in layers  40  of  FIGS. 12 and 13  may be formed using sputtering, plating, spraying, printing, and/or other suitable deposition techniques. If desired, sputtered layers of stainless steel and/or copper or other material may serve as seed layers for plated material (e.g., plated magnetic material, etc.). Layers  31  and the layers of material in layers  40  may include high-conductivity metals (copper, aluminum, etc.) and/or may include magnetic materials. Each layer  31  may include a single material or, if desired, one or more of the layers of material embedded in substrate  30  may include multiple stacked layers of material (e.g., two or more sublayers). In arrangements of the type shown in  FIG. 14 , the soft magnetic material that is used in forming layer  40  may have a both high permeability and good conductivity, thereby allowing layer  40  to serve as a broad-band (large frequency range) shielding layer. In this type of configuration, a magnetic material layer (in layer  40  and/or layer  31 ) may serve as both radio-frequency and magnetic shielding. 
     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: 20170110
Publication Date: 20181204
Grant Date: 20181204
Priority Date: 20160310
Inventors: SOMMER, PHILLIP R.
PENNATHUR, Shankar
LEE, MENG CHI
CHAUHAN, Shakti S.
CHEN, YANFENG
Assignee: APPLE INC
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Family ID: 59787086