PATENT DOCUMENT

Publication Number: US-8736080-B2
Application Number: US-201213632145-A
Country: US
Kind Code: B2

Title: Sensor array package

Abstract:
A sensor array package can include a sensor disposed on a first side of a substrate. Signal trenches can be formed along the edges of the substrate and a conductive layer can be deposited in the signal trench and can couple to sensor signal pads. Bond wires can be attached to the conductive layers and can be arranged to be below a surface plane of the sensor. The sensor array package can be embedded in a printed circuit board enabling the bond wires to terminate at other conductors within the printed circuit board.

Claims:
What is claimed is: 
     
       1. A low profile integrated circuit assembly, the assembly comprising:
 at least one integrated circuit; 
 a substrate including a first side, wherein the integrated circuit is disposed on the first side; 
 at least one signal trench formed on the first side of the substrate, the at least one signal trench proximate to an integrated circuit signal pad and extending to one edge of the substrate; 
 a conductive layer disposed in the signal trench and coupling to the integrated circuit signal pad; and 
 a bond wire configured to couple the conductive layer to an external pad, wherein:
 the bond wire, the at least one signal trench and the conductive layer are maintained below a surface plane of the integrated circuit, 
 the surface plane defines an interface between the integrated circuit and a user environment, and 
 the at least one signal trench is configured to have a ramp profile. 
 
 
     
     
       2. The assembly of  claim 1 , wherein the bond wire is further configured to attach to a slope portion of the ramp profile. 
     
     
       3. The assembly of  claim 1 , wherein the at least one integrated circuit is a sensor. 
     
     
       4. The assembly of  claim 1 , further comprising a flexible printed circuit assembly configured to bond to a second side of the substrate, the second side being disposed opposite the first side. 
     
     
       5. The assembly of  claim 1 , wherein the at least one signal trench includes at least two bond wires configured to couple conductive layers to external pads wherein the at least two bond wires, the at least one signal trench and the conductive layers are maintained below the surface plane of the integrated circuit. 
     
     
       6. A low profile circuit assembly, the assembly comprising:
 an integrated circuit; 
 a substrate including a first side, wherein the integrated circuit is disposed on the first side; 
 a shaped feature on a first edge of the substrate disposed proximate to an integrated circuit signal pad and arranged to support a wire bond ball below a surface plane of the integrated circuit; 
 a conductive layer disposed on the first side of the substrate and configured to couple the integrated circuit signal pad to the wire bond ball; and 
 a bond wire coupled to the wire bond ball and configured to remain below the surface plane of the integrated circuit, wherein:
 the surface plane defines an interface between the integrated circuit and a user environment, and 
 the shaped feature is configured to have a ramp profile. 
 
 
     
     
       7. The assembly of  claim 6 , wherein the bond wire is further configured to attach to a slope portion of the ramp profile. 
     
     
       8. The assembly of  claim 6 , wherein the integrated circuit is a sensor. 
     
     
       9. The assembly of  claim 6 , further comprising a flexible printed circuit assembly configured to bond to a second side of the substrate, the second side being disposed opposite the first side. 
     
     
       10. The assembly of  claim 6 , wherein the shaped feature includes at least two bond wires configured to couple conductive layers to external pads, wherein the at least two bond wires, the shaped feature, and the conductive layers are maintained below the surface plane of the integrated circuit. 
     
     
       11. A low profile assembly, comprising:
 a first substrate; 
 a second substrate, larger than the first substrate, wherein the first substrate is disposed on a first side of the second substrate; and 
 at least one signal trench disposed on the first side of the second substrate and configured to support bond wire connections to the first substrate below a surface plane of the first substrate, wherein:
 the surface plane defines an interface between the integrated circuit and a user environment, and 
 the at least one signal trench is configured to have a ramp profile. 
 
 
     
     
       12. The assembly of  claim 11 , wherein the bond wire connections are further configured to attach to a slope portion of the ramp profile. 
     
     
       13. The assembly of  claim 11 , further comprising at least one integrated circuit disposed on the first substrate. 
     
     
       14. The assembly of  claim 11 , further comprising a flexible printed circuit assembly configured to bond to a second side of the second substrate, the second side being disposed opposite the first side. 
     
     
       15. The assembly of  claim 11 , wherein the at least one signal trench can include at least two bond wires configured to couple conductive layers to external pads. 
     
     
       16. The assembly of  claim 1 , further comprising a printed circuit board (PCB) on a second side of the substrate, the external pad disposed on the PCB. 
     
     
       17. The assembly of  claim 1 , further comprising:
 a printed circuit board (PCB) on a second side of the substrate; and 
 a second device adjacent to the substrate and embedded in the PCB, wherein the external pad is disposed on the second device. 
 
     
     
       18. The assembly of  claim 1 , further comprising a plurality of trenches, wherein at least one of the plurality of trenches comprises more than one conductive layer coupled to more than one signal pad. 
     
     
       19. The assembly of  claim 1 , further wherein the at least one signal trench is configured to have one of a substantially rectilinear profile, a curved profile, and a bowl shaped profile. 
     
     
       20. The assembly of  claim 6 , further comprising a printed circuit board (PCB) on a second side of the substrate. 
     
     
       21. The assembly of  claim 6 , further comprising:
 a printed circuit board (PCB) on a second side of the substrate; and 
 a second device adjacent to the substrate and embedded in the PCB. 
 
     
     
       22. The assembly of  claim 6 , wherein the shaped feature on the first edge is configured to have a vertical section. 
     
     
       23. The assembly of  claim 11 , wherein a second device adjacent to the first substrate is disposed on the first side of the second substrate, and wherein at least one of the bond wire connections to the first substrate is coupled with the second device.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/640,589, filed Apr. 30, 2012 and entitled “SENSOR ARRAY PACKAGE” by ARNOLD et al., which is incorporated by reference in its entirety for all purposes. 
    
    
     FIELD OF THE DESCRIBED EMBODIMENTS 
     The described embodiments relate generally to packaging for sensors, and more particularly, to low profile sensor array packages. 
     BACKGROUND 
     Sensors and sensor arrays can be formed from customized integrated circuits. Sensor arrays are often used to sense environmental characteristics or can act as a user input for computing devices. Sensor arrays are often formed on a silicon wafer, using similar processing techniques to those used to fabricate other integrated circuits, such as memories, processors, field programmable gate arrays (FPGAs) and the like. 
     Sensors, unlike some general purpose integrated circuits, can have unique packaging and mounting requirements. Typical integrated circuits, for example, can have related silicon bonded out, and then packaged. The bonding out steps can couple signals on the silicon to pins or balls on the package. The packaging step can include encapsulating the silicon die in a package (typically plastic or ceramic). The packing can support and protect the otherwise fragile silicon die. However, since sensors are meant to interface with the environment, the packaging steps are often different. 
     Sensors are often outward facing, and generally exposed to a user environment. Instead of having the silicon die protected by a package, the die is often times exposed on the surface of a supporting element. While such configurations permit the sensor to function, these configurations can be bulky and can take up a relatively large amount of volume, increasing the size of a user device in which the sensor is ultimately used. 
     Therefore, what is needed is a sensor, sensors, and/or sensor arrays which overcome these and other drawbacks. 
     SUMMARY OF THE DESCRIBED EMBODIMENTS 
     One embodiment of a low profile sensor array assembly can include a sensor disposed on a first side of a substrate. Signal trenches can also be formed on the first side of the substrate and can be near sensor signal pads and extend to one edge of the substrate. A conductive layer can be deposited in the signal trench and couple to sensor signal pads. Bond wires can attach to the conductive layer and can couple signals from the sensor to external pads. 
     Another embodiment of a low profile sensor array assembly can include a sensor disposed on a first side of a substrate. The substrate can include a shaped feature on a first edge positioned near a signal pad of the sensor. The shaped feature can be configured to support a wire bond ball below a surface plane relative to the sensor. A conductive layer can be deposited on the substrate coupling the signal pad and the wire bond ball. A bond wire can be coupled to the wire bond ball and be arranged to remain below the surface plane relative to the sensor. 
     According to another embodiment of the invention, a low profile integrated circuit assembly includes at least one integrated circuit, a substrate including a first side, wherein the integrated circuit is disposed on the first side, at least one signal trench, formed on the first side of the substrate, proximate to an integrated circuit signal pad and extending to one edge of the substrate, a conductive layer disposed in the signal trench and coupling to the integrated circuit signal pad, and a bond wire configured to couple the conductive layer to an external pad wherein the bond wire, signal trench and conductive layer are maintained below a surface plane of the integrated circuit. 
     According to another embodiment of the invention, a low profile circuit assembly includes an integrated circuit, a substrate including a first side, wherein the integrated circuit is disposed on the first side, a shaped feature on a first edge of the substrate disposed proximate to an integrated circuit signal pad and arranged to support a wire bond ball below a surface plane of the integrated circuit, a conductive layer disposed on the first side of the substrate and configured to couple the integrated circuit signal pad to the wire bond ball, and a bond wire coupled to the wire bond ball and configured to remain below the surface plane of the integrated circuit. 
     According to another embodiment of the invention, a low profile assembly includes a first substrate, a second substrate, larger than the first substrate, wherein the first substrate is disposed on a first side of the second substrate, and at least one signal trench disposed on the first side of the second substrate and configured to support bond wire connections to the first substrate below a surface plane of the first substrate. 
     According to another embodiment of the invention, a method of forming a low profile assembly includes forming at least one signal trench in a substrate, depositing a barrier layer over the substrate proximate the at least one signal trench, depositing a seed layer of metal in the at least one signal trench, masking the substrate, barrier layer, and at least one signal trench, depositing additional metal over the masked substrate, and removing the mask and seed layer to form a final conductive layer in the at least one signal trench. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The described embodiments and the advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings. These drawings in no way limit any changes in form and detail that may be made to the described embodiments by one skilled in the art without departing from the spirit and scope of the described embodiments. 
         FIGS. 1A and 1B  are simplified diagrams of a low profile sensor, in accordance with one embodiment. 
         FIGS. 2A-2D  illustrate side views of exemplary embodiments of a low profile sensor. 
         FIGS. 3A-3D  illustrate possible shape profiles for signal trenches. 
         FIGS. 4A-4G  illustrate steps that can be used to form a signal trench. 
         FIG. 5  is a flow chart of method steps for forming signal trenches in a substrate. 
         FIG. 6  is a side view of signal trench, in accordance with one embodiment of the specification. 
         FIG. 7  shows another embodiment of a low profile sensor. 
         FIG. 8  shows a side view of one embodiment of a way of forming multiple low profile sensors. 
         FIG. 9  illustrates optional features that can be applied to a low profile sensor assembly embedded in a PCB. 
         FIGS. 10A and 10B  illustrate another embodiment of a low profile sensor. 
         FIGS. 11A-11E  illustrate steps that can be used to mount a low profile sensor on a substrate. 
         FIG. 12  is a flow chart of method steps for mounting a low profile sensor on a substrate. 
         FIG. 13  is a top view of yet another embodiment of a low profile sensor. 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     Sensors and sensor arrays are often fabricated on a silicon die and then supported with a structure underneath the die. To protect the surface of the sensor, often a clear cover is applied. However, some embodiments require little if any cover over the sensor, to increase sensor sensitivity. Furthermore, the support structure can be bulky and in turn increase the size of a product design including the sensor. 
     One embodiment of a low profile sensor can include a sensor disposed on a silicon die. The silicon die, in turn, can be embedded in a printed circuit board (PCB) structure. The low profile sensor can include signal trenches formed in the silicon to allow bond wires to couple to the sensor, while remaining substantially below a surface plane of the sensor. Bond wires can couple the sensor directly to other embedded devices, or to one or more conductive layers in the PCB. 
     Signal trenches can be formed by removing substrate material such as with a saw or grinder, or signal trenches can be formed by selectively etching the substrate. After forming the signal trench, a conductive material can be deposited into the trench forming a conductive path between a sensor pad and the trench. Finally, a bond wire can be attached to the conductive material and can be used to couple signals from the sensor to external devices or other components. 
       FIGS. 1A and 1B  are simplified diagrams of a low profile sensor  100 , in accordance with one embodiment of the specification.  FIG. 1A  shows a top view of the low profile sensor  100 . Low profile sensor  100  can include a substrate  102  and a sensor  104  disposed on a first surface of substrate  102 . Substrate  102  can be silicon or any other technically feasible material such as gallium arsenide, gallium nitride or the like. Sensor  104  can be a single sensor or an array of sensors. Sensor  104  can be used to detect user input such a touch (pressure), heat or capacitive sensor. In other embodiments, sensor  104  can be any other feasible integrated circuit. Such integrated circuits can be formed on any technically feasible substrate such as silicon, gallium arsenide or the like. In other words, the mounting techniques described herein can be applied equally to any integrated circuit, not only sensors. Throughout this specification, reference will be made to a sensor in the description, but it is understood that any integrated circuit can be substituted for the sensor. Also disposed on the first surface are pads  106  that can be electrically coupled to signals in sensor  104 .  FIG. 1A  also shows a top view of a signal trench  108 . A layer of metal  110  (or other conductor) can be deposited in signal trench  108  and couple to pad  106 . This is described in greater detail below in conjunction with  FIG. 4 .  FIG. 1B  is a side view of low profile sensor  100 . This view shows some detail of a possible shape of signal trench  108  within substrate  102 . The shape of the signal trench  108  is indicated with dashed lines. 
       FIGS. 2A-2D  illustrate side views of exemplary embodiments of a low profile sensor.  FIGS. 2A and 2B  shown low profile sensor  100  embedded in a PCB.  FIGS. 2C and 2D  show low profile sensor  100  mounted on thin substrate, such as a flex circuit. These figures are not drawn to scale, but are meant to show relationships between low profile sensor  100  and PCB or low profile sensor  100  and thin substrate. These figures are not meant to be exhaustive and show every possible configuration, but rather illustrate exemplary approaches. Persons skilled in the art can appreciate that other approaches exist.  FIG. 2A  illustrates a first bonding approach  200  between substrate  102  and PCB  204 . Substrate  102  can include a sensor  104  disposed on a first side. Signal trenches  215  are shown in side view. Metal layer  110  can be formed in signal trenches  215  and can couple to pad  106 . Bond wire  208  can couple metal layer  110  to a pad  210  that can be on any layer within PCB  204 . Bond wire  208  can be implemented to be below the surface plane  220  of sensor  104 . A surface plane can be an imaginary plane that extends in all directions and is co-planar with the highest surface of sensor  104 . Surface plane  220  is denoted with a dashed line. 
       FIG. 2B  illustrates a second bonding approach  250  between substrate  102  and PCB  204 . Sensor  104  is mounted on substrate  102  and includes pad  106 . Signal trenches  215  can be formed in substrate  102  and can include metal layer  110  coupled to pad  106 . Substrate  102  and separate device  252  can be embedded together in PCB  204 . In some embodiments, two or more separate devices  252  can be embedded in PCB  204 . Device  252  can be a separate integrated circuit that can be used to provide additional functionality to sensor  104 . For example, device  252  can be a signal processing device used to preprocess signals from sensor  104 . Device  252  can include at least one pad  254  to couple to signals within device  252 . Bond wire  208  can couple metal layer  110  to device  252 . Bond wire  208  can be maintained below surface plane  220 . 
       FIG. 2C  illustrates a third bonding approach  260  between substrate  102  and thin substrate  225 . In one embodiment, thin substrate  225  can be a flexible circuit (flex circuit). Substrate  102  can be affixed to thin substrate  225  with an adhesive, such as a glue, epoxy or tape adhesive. Sensor  104  can be disposed on substrate  102 . Signal trenches  215  can be formed on substrate  102  and can support metal layer  110  over pad  106 . A bond wire  208  can couple metal layer  110  to a pad  210 . In this embodiment, bond wire  208  can be maintained below surface plane  220 . 
       FIG. 2D  illustrates a fourth bonding approach  270  between multiple substrates and thin substrate  225 . As shown, a first substrate  102 A and a second substrate  102 B are affixed to thin substrate  225 . Bond wire  208  can be used to couple metal layers  110  from two or more substrates. In  FIG. 2D , bond wire  208  can couple signals from first substrate  102 A to second substrate  102 B. In this manner, two or more substrates  102 A,  102 B can be linked together. 
       FIGS. 3A-3D  illustrate possible shape profiles for signal trench  215 . In one embodiment, the shape profile of the signal trench can affect signal integrity of the signals carried within the signal trenches  215 . For example, some common metal deposition techniques (i.e., filament evaporation or electron beam evaporation) can have poor coverage on vertical or near vertical surfaces Other metal deposition techniques can have improved coverage on vertical or near vertical surfaces, but may have other associated costs (i.e., sputter deposition). In other words, certain shape profiles can be preferred over others depending on a selected metal deposition method. Other shape profiles can be possible beyond the exemplary shapes described below. 
       FIG. 3A  illustrates a vertical profile  301  for signal trench  215 . In this embodiment, signal trench  215  can have a substantially rectilinear profile  301 . The rectilinear profile  310  can be formed by many methods, including saw blade and deep reactive ion etch techniques. In some embodiments, two or more shaping methods can be combined to create vertical profile  301 . As shown, vertical profile  301  can include at least one substantially vertical section  302 . In some embodiments, vertical or near vertical sections may not have relatively even metal coverage. An uneven metal layer can include voids or other irregularities that could result in a discontinuity in the metal. 
       FIG. 3B  illustrates a ramp profile  303  for signal trench  215 . The ramp profile  303  can be formed a number of ways. In one embodiment a saw blade can be used to form and shape signal trench  215 . In another embodiment, ramp profile  303  can be formed, at least in part, by wet etching with potassium hydroxide (KOH). Etching with potassium hydroxide can have the advantage that, by virtue of the reactant, a ramp angle is naturally produced. One advantage of ramp profile  303  is that the profile includes no substantially vertical portions. Thus, the shape of the profile can enable the deposition of relatively even metal layers  110 . 
       FIG. 3C  illustrates an engineered curve profile  305  for signal trench  215 . Engineered curve profile  305  can be formed with a shaped saw blade, or by etching. In some embodiments, two or more shaping methods can be combined to create engineered curve profile  305 . One advantage of engineered curve profile  305  is that the profile does not include any sharp bends or curves. Sharp bends or curves can become stress points within the substrate  102 . These stress points can become starting points for fractures and cracks. Another advantage of engineered curve profile  305  is that the profile does not include any substantially vertical portions, therefore the profile can support the formation of relatively even metal layers. 
       FIG. 3D  illustrates a bowl shaped profile  307  for signal trench  215 . This profile can be formed with a saw or with etching methods. One advantage of the bowl shaped profile  307  is the inherent strength of the profile. Substrate area near bowl shaped profile  307  can be relatively stronger when compared to areas near other profiles such as rectilinear profile  303 . A drawback of the bowl shaped profile  307  it that it can include a relatively vertical region  308 . As described above, vertical regions can develop discontinuities and voids when certain metal deposition techniques are used. 
       FIGS. 4A-4G  illustrate steps that can be used to form signal trench  215 . These illustrations are cross sectional views of the trench, with the surrounding areas not drawn to clarify the drawing.  FIG. 4A  shows a possible beginning state including substrate  102 . Pad  106  and sensor  104  are disposed on a first side of substrate  102 .  FIG. 4B  shows substrate  102  with signal trench  215  formed into the substrate  102 . Sensor  104  and pad  106  remain on the surface of substrate  102 . Signal trench  215  can be formed in the shape of any technically feasible profile. Exemplary profiles are described above in  FIGS. 3A-3D . A ramp profile (shown in  FIG. 3B ) is selected as the exemplary profile in this figure. A ramp profile can be formed using a potassium hydroxide etch process, for example.  FIG. 4C  shows a barrier layer  405  deposited on the substrate  102 . In one embodiment, barrier layer  405  can be formed with techniques similar to forming passivation layers. In one embodiment, barrier layer  405  can help protect sensor  104 . 
       FIG. 4D  shows substrate  102 , pad  106  and sensor  104 . In this view, a metal seed layer  410  has been deposited over the substrate  102 , barrier layer  405  and pad  106 . As shown, seed layer  410  can be deposited in the regions of the signal trench  215  where a final conductive channel is desired. In one embodiment, seed layer  410  can be deposited by sputtering a conductive metal, such as aluminum.  FIG. 4E  shows substrate  102 , pad  106  and sensor  104  with a mask  415  selectively applied to the first surface. Mask  415  can be used to define regions where additional metal can be deposited over the seed layer  410 . In one embodiment mask  415  can be a liquid photoimageable mask.  FIG. 4F  shows metal  420  deposited over substrate  102 , pad  106 , seed layer  410  and mask  415 . During the metal deposition process, metal can be non-selectively deposited over the entire substrate  102 . In  FIG. 4G  shows substrate  102  after the mask  415  and excess metal seed layer  410  is removed. In one embodiment, metal seed layer  410  can be removed with a wet etch process. Removal of the mask  415  and metal seed layer  410  can define the final shape of the metal layer  420  in signal trench  215 . 
       FIG. 5  is a flow chart  500  of method steps for forming signal trenches in a substrate. The method begins in step  502  where the trench profile is formed in the substrate. The trench profile can be selected from one of the profiles described in  FIGS. 3A-3D , or any other technically feasible profile. In step  504 , a barrier layer can be formed and deposited over the substrate. The barrier layer can help protect the substrate after trenches are formed in substrate. In step  506 , a seed layer of metal can be deposited in the formed trench and can couple to the pad. In step  508 , a mask can be selectively placed on the substrate. In one embodiment, the mask can be a liquid photoimageable mask. The mask can be used to determine the areas on the substrate where the metal within the signal trench will be positioned. In step  510 , additional metal can be deposited over the substrate. In one embodiment, metal can be sputtered. In step  512 , the mask and excess seed layer can be removed, forming the final conductive layer in the signal trench and the method ends. 
     Formation of the signal trenches can provide access to signals from sensor while maintaining connections below the surface plane of sensor  104 . In order to fan out the signals to other devices, wires can be bonded to the metal deposited in the signal trenches. After a wire is bonded, the wire can be routed to a pad or other conductor. Care can be taken to maintain the path of the wire to be below the surface plane of sensor, thereby allowing a low profile mounting of the sensor and substrate. In one embodiment, a bond wire  208  can be formed by depositing a wire bond ball in the signal trench on metal layer. The bond wire can be guided within the signal trench. 
       FIG. 6  is a side view  600  of signal trench  215 , in accordance with one embodiment of the specification. The side view  600  includes substrate  102 , pad  106  and metal layer  110 . Depth  602  of signal trench  205  can be a function of the elements that can be included within signal trench  215 . Wire bond ball  604  can be bonded to metal layer  110  in the bottom of signal trench  215 . The height  606  of wire bond ball  604  can vary. Common heights can range from 5-15 μm. Diameter  608  of wire can vary by application; current carrying wires (power) can be thicker than wires only carrying signals. A typical wire diameter  608  can be 25 μm. Finally, bend radius  610  can affect the depth  602 . In one embodiment depth  602  can be determined, at least in part by the sum of the wire bond ball height  606  plus wire diameter  608  plus bend radius  610 . 
     The width  612  of the bottom of signal trench  215  can be determined, at least in part, by elements that are included in the bottom of the signal trench  215 . A typical diameter  615  of wire bond ball  604  can be 50 μm. The distance  617  from the wire bond ball to the edge of the substrate  102  can be 20 μm. This distance can be reduced, however, since edge chipping can occur, yield of the device can be reduced if the distance is reduced too much. The distance  618  from the wire bond ball to the inside edge of the bottom of signal trench  15  can be between 5 to 10 μm. In some embodiments, the distance  618  can be influenced by a tool used for wire bonding. Thus, in one embodiment, width  612  can be determined, at least in part, by the sum of wire bond ball diameter  615 , plus distance to substrate edge  617  plus distance to inside edge  618 . 
       FIG. 7  shows another embodiment of a low profile sensor  700 . In this embodiment, signal trenches can be replaced by shaped features disposed on the edge of the substrate. Substrate  702  includes pad  106  disposed on a first side of substrate  702 . Shaped feature  706  can be formed on one corner of substrate  702 . Metal layer  704  can be disposed on pad  106  and can also be disposed on shaped feature  706 . Wire bond ball  604  can be positioned on shaped feature  706  such that wire  708  can be maintained below surface plane  220  of sensor  104 . 
       FIG. 8  shows a side view  800  of one embodiment of a way of forming multiple low profile sensors. Multiple low profile sensors can be formed on a silicon wafer with each individual low profile sensor formed on an individual die on the wafer. Prior to separating the individual dice, a grinding wheel  802  or shaped saw blade can form signal trenches  215  across two or more dice, with a relatively continuous grind or cut. In the example shown in  FIG. 8 , grinding wheel  802  can form signal trenches  215  in first and second low profile sensors  805  and  807  respectively. In a later operation, a saw can separate the dice forming a saw cut  810 . 
       FIG. 9  illustrates optional features that can be applied to a low profile sensor assembly  901  embedded in a PCB  204 . The low profile sensor assembly  901  can include sensor  104  and substrate  102 . After the low profile sensor assembly  901  is embedded in PCB  204 , empty voids  902 , especially in the areas of signal trench  215 , can be filled with an epoxy, resin or other like material to strengthen the bond between low profile sensor assembly  901  and PCB  204  and form a relatively planar surface. In another embodiment, components  904  can be disposed on PCB  204 , on the side facing away from sensor  104 . Components  904  can be passive components such as resistors, inductors, capacitors or the like. Components  904  can be coupled to sensor  104  or other devices. 
       FIGS. 10A and 10B  illustrate another embodiment of a low profile sensor  1000 . 
     In this embodiment, individual signal trenches can be replaced with a single trench  1010  that can be formed on edge of substrate  102 . Sensor  104  can be disposed on one surface of substrate  102 . Pad  106  can be disposed on the same planar surface as sensor  104 . Metal layer  1015  can couple pad  106  to at least one region of single trench  1010 . In another embodiment, pads can be positioned within single trench  1010  region as shown with pad  1020 . Metal layer  1025  can be deposited over pad  1020  and be positioned in single trench  1010 .  FIG. 10B  shows a side view of low profile sensor  1000 . Metal layer  1015  can be deposited on pad  106  and into single trench  1010 . In another embodiment, pad  1020  can be positioned in single trench  1010 . Metal layer  1025  can be deposited on pad  1020  and into single trench  1010 . 
       FIGS. 11A-11E  illustrate steps that can be used to mount a low profile sensor on a substrate. In one embodiment, the substrate can be a thin substrate  1110 , such as a flexible cable.  FIG. 11A  shows an initial state of thin substrate  1110  and pads  1120 . Adhesive  1130  can be deposited on thin substrate  1110 . Adhesive  1130  can be an epoxy, glue, adhesive tape or other similar article. In  FIG. 11B , substrate  1140  including sensor  1145  can be positioned on adhesive  1130 . In  FIG. 11C , wire bond balls  1150  can be attached to substrate  1140  in preparation for bond wire attachment. In  FIG. 11D , bond wires  1160  can be attached to wire bond balls  1150  and can couple signals from sensor  1145  to pad  1120 . In one embodiment, optional wire bond balls  1165  can be coupled to pad  1120 . In  FIG. 11E  bond wires  1160  can be encapsulated to protect them in an epoxy  1170 , resin or similar material. 
       FIG. 12  is a flow chart of method steps for mounting a low profile sensor on a substrate. In one embodiment, the substrate can be a thin substrate such as a flexible circuit. The method begins in step  1210  where an adhesive is applied to a substrate. The adhesive can be a liquid adhesive such as an epoxy or can be a tape based adhesive. In step  1220 , the sensor/substrate combination can be bonded to the substrate. In step  1230 , bond wire balls can be attached to the substrate. In one embodiment, the bond wire balls can be coupled to metal layers on the substrate enabling access to the signals in the sensor. In step  1240 , bond wires can be attached to bond wire balls and pads disposed on the substrate. In step  1250 , bond wires can be encapsulated. Encapsulation can help protect fragile bond wires from damage. 
       FIG. 13  is a top view of yet another embodiment of a low profile sensor  1300 . This embodiment can include both individual single trenches as described in  FIG. 1  and multiple signal trenches that can include more than one signal as described in  FIG. 10 . Low profile sensor  1300  can include substrate  102  and sensor  104 . Pads  106  can be disposed outside of a trench. For example, pad  106  is disposed beyond multiple signal trench  1310  and beyond single signal trench  1311 . In another embodiment, the pad can be disposed inside the trench region. For example, pad  1020  can be disposed within multiple signal trench  1310  or within single trench  1311 . Metal layers  1015  can couple to pads  106  beyond signal trenches  1310  and  1311 . Alternatively, metal layers  1025  can couple to pads  1020  within signal trenches  1310  and  1311 . In some embodiments, multiple signal trenches  1310  can provide greater signal densities, while in some embodiments, single signal trenches  1311  can provide greater strength to substrate  102 . Low profile sensor  1300  can posses advantages of both the signal and multiple signal trench systems. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20120930
Publication Date: 20140527
Grant Date: 20140527
Priority Date: 20120430
Inventors: ARNOLD SHAWN X.
GILTON TERRY L.
LAST MATTHEW E.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01L2224/48091", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/48091", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/81", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2224/43", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10151", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/45015", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/45015", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/85", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/10155", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/48137", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/10253", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/85186", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/45", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/85", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/43", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/00014", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/11", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2924/10253", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/48479", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/00014", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/48", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/183", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2924/10155", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/451", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/85", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2224/85051", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/451", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/43", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L24/45", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F3/041", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/111", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10D62/117", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10D62/117", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06V40/1329", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06V40/1329", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2224/85051", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/48479", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/85186", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/48137", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L24/48", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 49476579