PATENT DOCUMENT

Publication Number: US-10411329-B2
Application Number: US-201615002236-A
Country: US
Kind Code: B2

Title: Packaged devices with antennas

Abstract:
A packaged device may include electrical components such as integrated circuits that are mounted to a substrate such as a printed circuit substrate. Plastic may be molded to the printed circuit substrate over the integrated circuits. The molded plastic may include one or more shots of plastic and may include laser-sensitizable plastic material. Antenna structures may be supported by molded plastic such as molded plastic in a packaged device. The antenna structures may be formed from metal foil, flexible printed circuit substrate material with metal antenna traces, and metal traces that are formed on exposed surfaces of the plastic. The metal traces may be electroplated metal traces that are formed on regions of a laser-sensitizable plastic material that have been exposed to laser light. A package may have a protrusion that supports an antenna structure.

Claims:
What is claimed is: 
     
       1. A packaged device, comprising:
 a printed circuit substrate with metal traces; 
 an electrical component with contacts coupled to portions of the metal traces; 
 a first shot of molded plastic on the printed circuit that contacts and covers the electrical component; 
 a second shot of molded plastic on the first shot of molded plastic, wherein the first shot of molded plastic is interposed between the second shot of molded plastic and the printed circuit substrate; and 
 a metal antenna trace on the second shot of plastic. 
 
     
     
       2. The packaged device defined in  claim 1  wherein the second shot of molded plastic comprises laser-sensitizable plastic and wherein the metal antenna trace comprises electroplated metal on an activated portion of the laser-sensitizable plastic that has been exposed to laser light. 
     
     
       3. The packaged device defined in  claim 2  wherein the second shot of plastic forms a protrusion on the first shot of plastic and wherein the electroplated metal is formed on the protrusion. 
     
     
       4. The packaged device defined in  claim 1  wherein the electrical component comprises one of a plurality of electrical components that are coupled to portions of the metal traces. 
     
     
       5. The packaged device defined in  claim 4  wherein the first shot of molded plastic contacts and covers each of the plurality of electrical components. 
     
     
       6. The packaged device defined in  claim 5  wherein each of the plurality of electrical components comprises a semiconductor die and a plastic package in which the semiconductor die is packaged. 
     
     
       7. The packaged device defined in  claim 1  further comprising a third shot of molded plastic. 
     
     
       8. The packaged device defined in  claim 7  wherein the third shot of molded plastic comprises laser-sensitizable plastic and wherein the metal antenna trace comprises electroplated metal on an activated portion of the laser-sensitizable plastic that has been exposed to laser light. 
     
     
       9. The packaged device defined in  claim 1  wherein at least one of the metal traces on the printed circuit substrate comprises an antenna resonating element. 
     
     
       10. The packaged device defined in  claim 1  wherein the metal antenna trace is configured to form an inverted-F antenna resonating element. 
     
     
       11. The packaged device defined in  claim 10  wherein the packaged device has a periphery and wherein the inverted-F antenna resonating element runs along at least part of the periphery. 
     
     
       12. The packaged device defined in  claim 1  wherein the metal antenna trace is configured to form a patch antenna resonating element. 
     
     
       13. The packaged device defined in  claim 1  wherein the metal antenna trace is configured to form a loop antenna resonating element. 
     
     
       14. A system-in-package device, comprising:
 a printed circuit substrate with metal traces; 
 integrated circuits with contacts coupled to portions of the metal traces; 
 a first shot of molded plastic on the printed circuit that covers the integrated circuits; 
 a second shot of molded plastic on the first shot of molded plastic; 
 a third shot of molded plastic; 
 a first antenna structure on the third shot of plastic; 
 a second antenna structure that is electrically coupled to the first antenna structure; 
 a first metal post that is coupled between a contact formed from one of the metal traces on the printed circuit substrate and the second antenna structure through the first shot of molded plastic; and 
 a second metal post that is coupled between the second antenna structure and the first antenna structure on the third shot of molded plastic. 
 
     
     
       15. The system-in-package device defined in  claim 14  wherein the third shot of plastic is formed from a laser-sensitizable plastic and wherein the first antenna structure comprises an electroplated metal trace on a laser activated region of the third shot of plastic. 
     
     
       16. The system-in-package device defined in  claim 15  wherein the second antenna structure is a sheet metal antenna structure that is electrically coupled to the electroplated metal trace. 
     
     
       17. An electronic device, comprising:
 a housing; 
 a packaged device in the housing; 
 a display coupled to the housing; and 
 a metal antenna structure on the packaged device, wherein the metal antenna structure comprises a metal antenna trace that forms at least part of an antenna resonating element for an antenna, wherein the display has a transparent cover layer with a recess, and wherein the metal antenna trace is at least partly received within the recess. 
 
     
     
       18. The electronic device defined in  claim 17  wherein the packaged device has a printed circuit substrate and integrated circuits soldered to the printed circuit substrate, wherein the packaged device has thermoplastic material molded over the integrated circuits, and wherein the metal antenna trace is formed on a surface of the thermoplastic material. 
     
     
       19. The electronic device defined in  claim 17  wherein the transparent cover layer has a periphery and wherein the recess comprises a groove that runs along at least part of the periphery. 
     
     
       20. A packaged device, comprising:
 a single printed circuit substrate having opposing first and second surfaces, wherein the first surface faces a first direction and the second surface faces a second direction that is opposite the first direction; 
 a plurality of integrated circuits soldered to contacts on the first surface of the printed circuit substrate; 
 plastic molded over the integrated circuits; and 
 a metal antenna trace on the second surface of the printed circuit substrate. 
 
     
     
       21. A packaged device, comprising:
 a printed circuit substrate with metal lines; 
 an electrical component with contacts coupled to portions of the metal lines; 
 a shot of molded plastic on the printed circuit that covers the electrical component, wherein the electrical component is embedded in the shot of molded plastic; 
 a metal trace on the shot of plastic; and 
 a metal post that extends through the shot of molded plastic and couples the metal lines of the printed circuit substrate to the metal trace. 
 
     
     
       22. The packaged device defined in  claim 21  wherein the shot of plastic forms a protrusion and wherein the metal trace comprises electroplated metal on the protrusion. 
     
     
       23. The packaged device defined in  claim 22  wherein the shot of molded plastic comprises laser-sensitizable plastic and wherein the electroplated metal comprises electroplated metal on an activated portion of the laser-sensitizable plastic that has been exposed to laser light. 
     
     
       24. The packaged device defined in  claim 23  wherein the electrical component comprises one of a plurality of electrical components that are coupled to portions of the metal lines. 
     
     
       25. The packaged device defined in  claim 24  wherein the shot of molded plastic covers each of the plurality of electrical components. 
     
     
       26. The packaged device defined in  claim 25  wherein each of the plurality of electrical components comprises a semiconductor die and a plastic package in which the semiconductor die is packaged. 
     
     
       27. The packaged device defined in  claim 26 , wherein the metal trace comprise a metal antenna trace, wherein the packaged device has a periphery, and wherein the metal antenna trace runs along at least part of the periphery.

Description:
FIELD 
     This relates generally to electronic devices and, more particularly, to system-in-package devices. 
     BACKGROUND 
     Electronic devices often include integrated circuits and other components that are mounted within semiconductor packages. System-in-package devices contain multiple integrated circuits mounted together in a single package. Use of this type of packaged device may be desirable in applications where space is at a premium. 
     In compact devices, it can be challenging to mount components efficiently. Signal routing paths and mounting structures can consume more space than desired and package layouts are often not sufficiently efficient to accommodate complex housing geometries. It can be difficult to incorporate antennas into a compact device without interfering with other electrical components. 
     SUMMARY 
     A packaged device may include electrical components such as integrated circuits that are mounted to a substrate such as a printed circuit substrate. The electrical components may include bare semiconductor die or packaged components such as packaged integrated circuits. Plastic may be molded to the printed circuit substrate over the integrated circuits to form a packaged device such as a system-in-package device. 
     The molded plastic of the packaged device may include one or more shots of plastic and may include laser-sensitizable plastic material. Antenna structures may be formed on molded plastic such as molded plastic in a packaged device. The antenna structures may be formed from metal foil, flexible printed circuit substrate material with metal antenna traces, and metal traces that are formed on exposed surfaces of the plastic material. The metal traces may be electroplated metal traces that are formed on regions of a laser-sensitizable plastic material that have been exposed to laser light. 
     A package may have a protruding plastic portion that supports an antenna structure such as an inverted-F antenna resonating element for an inverted-F antenna. The antenna structure on a package protrusion may be received within a groove in a display cover layer. The display cover layer may overlap display layers for a display. The display layers may display images in an active area of the display. The groove may run along the periphery of the package in an inactive area of the display. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device of the type that may be provided with electrical component package structures in accordance with an embodiment. 
         FIG. 2  is a schematic diagram of an illustrative electronic device with wireless circuitry in accordance with an embodiment. 
         FIG. 3  is a schematic diagram of an illustrative antenna in accordance with an embodiment. 
         FIG. 4  is a diagram showing illustrative equipment of the type that may be used in forming system-in-package structures in accordance with an embodiment. 
         FIG. 5  is a cross-sectional side view of an illustrative electrical component package with an antenna in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of an illustrative electrical component package with an antenna on a package protrusion in accordance with embodiment. 
         FIG. 7  is a cross-sectional side view of an illustrative electrical component package with an antenna formed within multiple shots of plastic in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of an illustrative electrical component package with an antenna formed from plated metal on a laser-activated region of a plastic package body in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of an illustrative electrical component package that has an antenna and that is formed from multiple shots of plastic in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative electrical component package that includes antenna traces formed on one side of a printed circuit substrate and electrical components formed on an opposing side of the printed circuit substrate in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative packaged device with a protrusion on which an antenna trace is formed in accordance with an embodiment. 
         FIGS. 12 and 13  are cross-sectional side view of illustrative electrical component package structures during fabrication in accordance with an embodiment. 
         FIG. 14  is a cross-sectional side view of an illustrative electrical component package having front and rear antenna structures in accordance with an embodiment. 
         FIG. 15  is a cross-sectional side view of an illustrative packaged electrical component in contact with a metal structure that forms an antenna in accordance with an embodiment. 
         FIG. 16  is a perspective view of an illustrative electrical component package with an antenna resonating element formed along a protrusion that runs along the periphery of the component package in accordance with an embodiment. 
         FIG. 17  is a cross-sectional side view of an illustrative electrical component package with a protrusion that supports an antenna trace that is received within a peripheral groove in a display cover layer in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with integrated circuits and other electrical components. These components may be mounted on a substrate such as a printed circuit board and embedded within molded plastic that forms an electrical component package. In configurations in which the circuitry of all or part of an electrical device or other system is mounted on the substrate, a packaged device with electrical components of this type may sometimes be referred to as a system-in-package device. To incorporate system-in-package devices and other packaged devices within a compact electronic device, one or more antennas may be formed from conductive antenna structures that are supported by the molded plastic of the packaged devices. 
       FIG. 1  is a perspective view of an illustrative electronic device of the type that may include an antenna or other conductive component that is supported by plastic in a packaged device such as a system-in-package device. 
     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. In the illustrative configuration of  FIG. 1 , device  10  is a portable device such as a wristwatch. Other configurations may be used for device  10  if desired. The example of  FIG. 1  is merely illustrative. 
     As shown in  FIG. 1 , device  10  may include display  14 . Display may be mounted in housing  12 . In the illustrative configuration of  FIG. 1 , display  14  has a rectangular outline and housing  12  has a correspondingly rectangular footprint. Other shapes may be used for display  14  and housing  12  if desired. 
     Housing  12 , which may sometimes be referred to as an enclosure or case, may be formed from 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.). Openings may be formed in housing  12  to form communications ports, holes for buttons, and other structures. 
     Display  14  may be a touch screen display that incorporates a layer of conductive capacitive touch sensor electrodes or other touch sensor components (e.g., resistive touch sensor components, acoustic touch sensor components, force-based touch sensor components, light-based touch sensor components, etc.) or may be a display that is not touch-sensitive. Capacitive touch sensor electrodes may be formed from an array of indium tin oxide pads or other transparent conductive structures. 
     Display  14  may have an active area that includes an array of pixels. The array of pixels may be formed from liquid crystal display (LCD) components, an array of electrophoretic pixels, an array of plasma display pixels, an array of organic light-emitting diode pixels or other light-emitting diode pixels, an array of electrowetting pixels, or pixels based on other display technologies. 
     Display  14  may be protected using a display cover layer such as a layer of transparent glass, clear plastic, transparent ceramic, sapphire or other transparent crystalline material, or other transparent layer(s). The display cover layer may have a planar shape, a convex curved profile, a concave curved profile, a shape with planar and curved portions, a layout that includes a planar main area surrounded on one or more edges with a portion that is bent out of the plane of the planar main area, or other suitable shape. Openings may be formed in the display cover layer to accommodate buttons, speaker ports, and other components. 
     If desired, a strap such as wrist strap  15  may be attached to housing  12 . Strap  15  may be used to attach device  10  to the wrist of a user. Strap  15  may be formed from metal, plastic, leather, or other materials. If desired, strap  15  may be omitted (e.g., in configurations in which device  10  is too large to comfortably wear on a user&#39;s wrist). 
     A schematic diagram showing illustrative components that may be used in device  10  is shown in  FIG. 2 . As shown in  FIG. 2 , device  10  may include storage and processing circuitry such as control circuitry  30 . Circuitry  30  may include storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive), volatile memory (e.g., static or dynamic random-access-memory), etc. Processing circuitry in circuitry  30  may be used to control the operation of device  10 . This processing circuitry may be based on one or more microprocessors, microcontrollers, digital signal processors, baseband processor integrated circuits, application specific integrated circuits, etc. 
     Circuitry  30  may be used to run software on device  10 , such as internet browsing applications, voice-over-internet-protocol (VOIP) telephone call applications, email applications, media playback applications, operating system functions, etc. To support interactions with external equipment, circuitry  30  may be used in implementing communications protocols. Communications protocols that may be implemented using circuitry  30  include wireless local area network protocols (e.g., IEEE 802.11 protocols—sometimes referred to as WiFi®), protocols for other short-range wireless communications links such as the Bluetooth® protocol, cellular telephone protocols, near-field communications protocols, and other wireless communications protocols. 
     Device  10  may include input-output devices  32 . Input-output devices  32  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. Input-output devices  32  may include user interface devices, data port devices, and other input-output components. For example, input-output devices may include touch screens, displays without touch sensor capabilities, buttons, joysticks, scrolling wheels, touch pads, key pads, keyboards, microphones, cameras, speakers, status indicators, light sources, audio jacks and other audio port components, digital data port devices, light sensors, accelerometers, proximity sensors, and other sensors and input-output components. 
     Device  10  may include wireless communications circuitry  34  that allows control circuitry  30  of device  10  to communicate wirelessly with external equipment. The external equipment with which device  10  communicates wirelessly may be a computer (e.g., a laptop computer, a desktop computer, a tablet computer, etc.), a cellular telephone, a watch, a router or other wireless local area network equipment, a wireless base station in a cellular telephone network, a display, or other electronic equipment. Wireless communications circuitry  34  may include radio-frequency (RF) transceiver circuitry  90  and one or more antennas such as antenna  40 . Configurations in which device  10  contains a single antenna may sometimes be described herein as an example. 
     Radio-frequency transceiver circuitry  90  and antenna(s)  40  may be used to handle one or more radio-frequency communications bands. For example, circuitry  90  may include wireless local area network transceiver circuitry that may handle a 2.4 GHz band for WiFi® and/or Bluetooth® communications and, if desired, may include 5 GHz transceiver circuitry (e.g., for WiFi®). If desired, circuitry  90  and antenna(s)  40  may handle communications in other bands (e.g., cellular telephone bands between 700 MHz and 2700 MHz and other suitable frequencies), near field communications bands at 13.75 MHz and other near-field communications frequencies, bands at millimeter wave frequencies (e.g., extremely high frequency communications bands at 25 GHz, 60 GHz, etc.). 
     Antenna(s)  40  in wireless communications circuitry  34  may be formed using any suitable types of antenna. For example, an antenna for device  10  may include a resonating element that is formed from a loop antenna structure, a patch antenna structure, an inverted-F antenna structure, a slot antenna structure, a planar inverted-F antenna structure, a helical antenna structure, a hybrid of these structures, etc. If desired, device  10  may include cavity-backed antennas. Circuitry  30 , input-output devices  32 , wireless circuitry  34 , and other components of device  10  may be mounted in device housing  12 . 
     As shown in  FIG. 2 , transceiver circuitry  90  in wireless circuitry  34  may be coupled to antennas such as antenna  40  using paths such as transmission line path  92 . Transmission line paths in device  10  such as transmission line  92  may include coaxial cable paths, microstrip transmission lines, stripline transmission lines, edge-coupled microstrip transmission lines, edge-coupled stripline transmission lines, transmission lines formed from combinations of transmission lines of these types, etc. Transmission line  92  may be coupled to antenna feed  112 . Antenna  40  of  FIG. 2  may, for example, form an inverted-F antenna, a planar inverted-F antenna, a slot antenna, a hybrid inverted-F slot antenna, a monopole, a dipole, a patch antenna, or other antenna having an antenna feed such as feed  112  with a positive antenna feed terminal such as terminal  98  and a ground antenna feed terminal such as ground antenna feed terminal  100 . Positive transmission line conductor  94  may be coupled to positive antenna feed terminal  98  and ground transmission line conductor  96  may be coupled to ground antenna feed terminal  100 . Other types of antenna feed arrangements may be used and multiple antennas  40  may be provided in device  10 , if desired. The illustrative feeding configuration of  FIG. 2  is merely illustrative. 
     Filter circuitry, switching circuitry, impedance matching circuitry, and other circuitry may be interposed within transmission line  92  or other portions of wireless circuitry  34 , if desired. Control circuitry  30  may be coupled to transceiver circuitry  90  and input-output devices  32 . During operation, input-output devices  32  may supply output from device  10  and may receive input from sources that are external to device  10 . Control circuitry  30  may use wireless circuitry  34  to transmit and receive wireless signals. Control circuitry  30  may control adjustable components  70  over control paths such as path  72 . Adjustable components  70  may be coupled to conductive structures associated with antenna  40  and may be used in tuning antenna  40 . Adjustable components  70  may include tunable inductors, tunable capacitors, and other adjustable circuitry. Adjustable components  70  may include discrete components that are coupled to adjustable circuits such as switches. With this type of arrangement a switch may be used to switch a desired component into use in antenna  40 , thereby tuning antenna  40 . If desired, adjustable components  70  may also include continuously adjustable circuitry (e.g., continuously adjustable inductors, capacitors, etc.). 
       FIG. 3  is a schematic diagram of an illustrative antenna for device  10 . In the example of  FIG. 3 , antenna  40  is an inverted-F antenna having inverted-F antenna resonating element  106  and antenna ground  104 . Resonating element  106  may have a main resonating element arm such as arm  108 . If desired, element  106  may have multiple branches (e.g., a first branch formed from arm  108 , a second arm formed from branch  108 ′, etc.). The lengths of each of the branches of element  106  may be selected to support communications band resonances at desired frequencies (e.g., a high band resonance may be supported using a shorter branch and a low band resonance may be supported using a longer branch). Antenna resonances may also be produced from resonating element harmonics and/or from using parasitic antenna resonating elements. 
     As shown in  FIG. 3 , antenna resonating element  106  (e.g., arm  108 ) may be coupled to ground by return path  110 . Antenna feed  112  may be coupled between antenna resonating element arm  108  and ground  104  in parallel with return path  110 . Antenna feed  112  may be formed from antenna feed terminals  98  and  100 . Antenna feed terminal  100  may be coupled to antenna ground  104 . Ground  104  may be formed from metal portions of housing  12  (e.g., portions of housing  12 B), metal traces on a printed circuit or other carrier (e.g., a main logic board in device  10 , a printed circuit in a packaged device, etc.), internal metal bracket members, sheet metal members, and other conductive structures in device  10 . 
     In the illustrative configuration of  FIG. 3 , adjustable component  70  has been coupled between the tip of antenna resonating element arm  108  and ground  104 . If desired, adjustable components for antenna  40  may be located at other portions of antenna resonating element  106  (see, e.g., illustrative adjustable components  70 ′). Adjustable components may also be incorporated into impedance matching circuits, filter circuits, and other circuitry associated with the operation of antenna  40 . 
     A diagram of a system with illustrative equipment for forming antennas on electrical component package structures such as system-in-package structures  120  or other packaged devices is shown in  FIG. 4 . Metal deposition tools  122  may include equipment for depositing metal layers. Tools  122  may include physical vapor deposition equipment, chemical vapor deposition equipment, atomic layer deposition equipment, equipment for printing conductive inks and other conductive materials (e.g., ink-jet printing equipment, pad printing equipment, screen printing equipment), and other deposition equipment. Tools  122  may be used to deposit layers of metal on dielectric structures (e.g., plastic) and other structures in system-in-package structures  120 . 
     Molding tools  124  may include equipment for molding thermoplastic polymers (e.g., plastic for forming the body of an electrical component package or other structures  120 ) and other polymers. Molding tools  124  may have heated dies for molding plastic into desired shapes under heat and pressure. Plastic may be injection molded, may be compression molded, or may be molded using other molding techniques. Metal structures (e.g., metal posts, sheet metal members, and other metal structures) may be insert molded into plastic using tools  124 . Insert-molded metal structures may be completely embedded within plastic or may have exposed conductive portions (e.g., exposed conductive surfaces, exposed protruding portions, etc.). 
     Laser tool  126  may include a laser for applying laser light to selective portions of a plastic substrate or other portions of structures  120 . The laser may emit light at any suitable wavelength (ultraviolet, visible, and/or infrared). Laser light may be continuous wave laser light and/or pulsed laser light and may be focused to increase the intensity of the laser light where the laser light is illuminating structures  120 . Laser tool  126  may be used to selectively activate structures such as laser-sensitizable plastic structures in system-in-package structures  120 . Laser-sensitizable plastic suitable for laser activation may be filled with additives that render the plastic sensitive to laser light exposure. Following selective application of laser light to the plastic in this way, the plastic may be electroplated using electrodeposition equipment  128 . During plating operations, metal will selectively electroplate onto the areas of structures  120  that were selectively illuminated using laser light from tool  126 . Laser tool  126  may also be used for laser drilling of holes in metal and plastic structures, laser welding, soldering, etc. 
     Patterning equipment  130  may include photolithographic patterning equipment (e.g., equipment for patterning metal layers and other layers by photomasking and etching techniques and/or other processing techniques). 
     Soldering tool and other equipment  132  may also be used in processing system-in-package structures  120 . Equipment  132  may be used in soldering metal structures together (e.g., equipment  132  may include equipment such as a hot bar soldering tool, a reflow oven, a laser soldering tool, or other soldering equipment), equipment  132  may include machining equipment, equipment for welding metal structures together, equipment for joining conductive structures using crimping or conductive adhesive, computer-controlled equipment for assembling structures to form structures  120  and to form finished electronic devices, and other equipment. 
     Using equipment of the type shown in  FIG. 4 , electrical component packages may be formed that include antennas. As an example, components may be mounted on a printed circuit. The components may then be overmolded using one or more shots of plastic. Metal structures may be incorporated into the packaged electrical components to form metal components such as one or more antennas. 
     An illustrative packaged device is shown in  FIG. 5 . Packaged device  140  of  FIG. 5 , which may sometimes be referred to as a system-in-package, system-in-package device, or electrical component package, may include one or more electrical components such as components  142 . Components  142  may include integrated circuits (e.g., transceiver circuitry  90 , control circuitry  30 , etc.), may include discrete components (e.g., capacitors, inductors, resistors), may include switches, and may include other circuitry. There may, in general, be any suitable number of components  142  in device  140  (e.g., one or more, two or more, five or more, ten or more, 2-20, fewer than 40, more than twenty, or other suitable number of components). 
     Plastic (e.g., a thermoplastic material) such as plastic  156  may be molded over components  142  and substrate  154 . There may be one or more shots of plastic (i.e., separately molded portions of plastic) in packaged device  140 . The example of  FIG. 5  in which a single shot of plastic is molded over components  142  is merely illustrative. 
     Substrate  154  may be a flexible printed circuit (e.g. a printed circuit formed from a sheet of polyimide or other flexible polymer layer) or may be a rigid printed circuit (e.g., a printed circuit formed from a rigid printed circuit board material such as fiberglass-filled epoxy). If desired, substrate  154  may be formed from a ceramic or other dielectric substrate material. Substrate  154  may include patterned metal traces  152  for forming electrical signal paths and contact pads such as contacts  150 . 
     Components  142  may be packaged integrated circuits or other packaged electrical components that each include a semiconductor die (see, e.g., silicon integrated circuit die  144  in the example of  FIG. 5 ). In this type of arrangement, each die  144  is bonded to a substrate and embedded within a plastic package body to form a respective component  142 . If desired, components  142  may include one or more bare semiconductor dies. Configurations in which components  142  are packaged components are sometimes described herein as an example. 
     Components  142  may have solder pads or other contacts such as contacts  146  (e.g., contacts associated with substrates within the packages of components  142 ). Components  142  may be mounted to contacts  150  on substrate  154  using conductive material  148 . Conductive material  148  may be, for example solder that is coupled between component contacts  146  and substrate contacts  150  of device  10 . 
     Substrate  154  may have one or more layers of interconnects formed from patterned metal traces  152  (e.g., signal lines, vias, contacts  150 , etc.). Solder or other conductive material  148  may be used to couple conductive structures such as metal member  158  to contacts  150 . Metal member  158  may be, for example, a metal post for carrying signals through plastic  156 . 
     As shown in the illustrative configuration of  FIG. 5 , metal member  158  may have one end that is coupled to one of contacts  150  and an opposing end that is exposed at surface  162  of plastic  156 . Metal traces  160  or other conductive structures may be coupled to the exposed portion of metal member  158  on surface  162 . Metal traces  160  may be patterned to form an antenna such as antenna  40  of  FIG. 2  or may be patterned to form other metal structures (e.g., a strain gauge, a temperature sensor, or other sensor or electrical component). Illustrative arrangements in which traces  160  are used in forming antennas may sometimes be described herein as an example. 
     Plastic  156  may be formed in a single shot (e.g., a single injection molding operation using a single type of plastic material) or may be formed using two or more successive shots of plastic material of one or more types. As shown in  FIG. 6 , plastic  156  may have protruding portions. For example, plastic  156  may have a main portion  156 M that is characterized by planar upper surface  162  and that is molded over one or more components  142  in a planar shape (i.e., a shape that lies in the X-Y plane of  FIG. 6  and that is characterized by a rectangular footprint or other suitable outline shape) and may have a protruding portion  156 P that protrudes outwardly from main portion  156 M (i.e., upwardly in direction Z in the example of  FIG. 6 ). Antenna traces  160  may be formed on elevated surface  162 P of protrusion  156 P and may form an antenna resonating element. This may help to vertically separate antenna traces  160  from antenna ground traces formed from traces  152  in substrate  154 , to separate antenna traces  160  from an antenna ground formed from metal portions of housing  12 , or to help separate antenna traces  160  from other ground structures within device  10 . 
     There may be one or more protrusions such as protrusion  156 P in plastic  156  and the protrusions of plastic  156  may extend in any desired direction (vertically up, vertically down, horizontally, diagonally, etc.). Protrusions may have flat exterior surfaces, curved surfaces, and/or textured surfaces. Configurations in which plastic  156  has recessed portions (see, e.g., illustrative recess  156 R of  FIG. 6 ) may also be used. Metal antenna traces  160  may, if desired, overlap recesses, protrusions, and/or other portions of the surface of plastic  156 . Some or all of the metal structures for antenna  40  may also be formed from metal that is embedded fully or partly within plastic  156 . 
     In the examples of  FIGS. 5 and 6 , metal member  158  has the shape of a vertically extending metal post. This is merely illustrative. Embedded conductive structures such as members  158  of  FIGS. 5 and 6  may, in general, be formed from curved metal structure, from flexible printed circuit structures, from brackets, posts, or other metal members, from stamped sheet metal parts, or from other conductive structures. 
       FIG. 7  is a cross-sectional side view of packaged device  140  in an illustrative configuration in which plastic  156  includes two shots of plastic material: first plastic shot  156 - 1  and second plastic shot  156 - 2 . Plastic shot  156 - 1  may be molded over components  142  and a first (lower) portion of metal structure  158 . Metal structure  158  may be a sheet metal member or other metal member that is soldered or otherwise coupled to a contact on substrate  154 . A portion of metal structure  158  may protrude out of plastic shot  156 - 1  and may be coupled to metal antenna structure  160 ′ using conductive connections  164  (e.g., solder joints, welds, conductive adhesive, etc.). Metal antenna structure  160 ′ may be formed from a stamped sheet metal layer (i.e., patterned metal foil), may be formed from patterned metal traces on a flexible printed circuit or other substrate, or may be metal traces deposited using physical vapor deposition, printing, or other deposition techniques. 
     Following formation of metal antenna structure  160 ′, second plastic shot  156 - 2  may be formed. Plastic shot  156 - 2  may cover some or all of metal antenna structure  160 ′. In the example of  FIG. 7 , plastic shot  156 - 2  covers all of metal antenna structure  160 ′ so that metal antenna structure  160 ′ is embedded within plastic  156 . If desired, plastic  156  of  FIG. 7  may have protrusions, recesses, and other non-planar features, as described in connection with  FIG. 6 . Antenna structure  160  may lie on the boundary between first shot  156 - 1  and  156 - 2  (i.e., on the upper surface of shot  156 - 1 ) or the boundary between first shot  156 - 1  and  156 - 2  may lie below antenna structure  160  so that antenna structure  160 , as shown by illustrative boundary  157  of  FIG. 7 . If desired, one or more metal shielding layers may be included in packaged devices. For example, device  140  of  FIG. 7  may include a metal shielding layer formed along boundary  157 . 
     In general, any suitable technique may be used in forming antenna structures for antenna  40  such as machining, cutting, stamping, printing, photolithography, etc. With one suitable arrangement, laser patterning may be used in forming antenna structures for antenna  40 . Laser patterning processes may use thermoplastic materials that can be locally sensitized by exposure to laser light. These materials may sometimes be referred to as laser-sensitizable plastic. Once sensitized, electroplating may be used to deposit additional metal and thereby form a desired pattern of conductive antenna traces. When forming packaged device  140 , one or more shots of plastic  156  may be formed from laser-sensitizable plastic. 
       FIG. 8  is a cross-sectional side view of packaged device  140  in an illustrative configuration in which plastic  156  has been formed using laser-sensitizable material. Laser-sensitizable plastic  156  may be molded over components  142  on substrate  154 . Metal member  158  (e.g., a metal post or other signal path structure) may be mounted to a contact on substrate  154  and may be molded within plastic  156  so that portion  158 P of member  158  is accessible on the surface of plastic  156 . Plastic  156  may be selectively exposed to laser light (e.g., in the desired shape of an antenna resonating element or other antenna structure). Following electroplating operations, metal antenna trace  160  may contact and be electrically shorted to metal member portion  158 P. 
     Another illustrative configuration for packaged device  140  is shown in  FIG. 9 . In the example of  FIG. 9 , plastic  156  includes three shots of plastic: first plastic shot  156 - 1 , second plastic shot  156 - 2 , and third plastic shot  156 - 3 . First plastic shot  156 - 1  may be used to cover components  142  and substrate  154 . Metal structure  158 - 1  may be a metal post, a spring, or other metal member that serves as a signal path through plastic  156 - 1 . Metal structure  158 - 1  may be soldered or otherwise connected to a contact on substrate  154  and may be partly or fully embedded in plastic  156 - 1 . 
     Metal antenna structure  160 ′ may be coupled to a portion of metal structure  158 - 1 . Metal antenna structure  160 ′ may be a sheet metal member (e.g., stamped metal foil), may be a flexible printed circuit with patterned antenna traces, or may be a metal structure that is deposited and patterned on layer  156 - 1  using other techniques. Metal antenna structure  160 ′ may be coupled to structure  158 - 1  using conductive connections  164  (e.g., solder, welds, conductive adhesive, etc.). 
     Second plastic shot  156 - 2  may be used to cover metal antenna structure  160 ′ and thereby help hold structure  160 ′ within packaged device  140 . Metal structure  158 - 2  (e.g., a metal post or other metal member) may be coupled to metal antenna structure  160 ′ (e.g., using solder  170 , welds, conductive adhesive, etc.). Plastic shots  156 - 1  and  156 - 2  may be insensitive to laser light or may be formed form laser-sensitizable plastic. 
     Third plastic shot  156 - 3  may be formed over some or all of structure  158 - 2 . Structure  158 - 2  may be a metal post or other structure that is used to route signals through third plastic shot  156 - 3 . Metal structure  158 - 2  may have an exposed portion to which metal antenna traces  160  may be connected. Third plastic shot  156 - 3  may be formed from laser-sensitizable plastic and metal antenna trace  160  may be formed by electroplating metal onto the surface of plastic  156 - 3  after activating selected regions of plastic  156 - 3  by exposing these regions of plastic  156 - 3  to laser light. If desired, portions of plastic  156  (e.g., the portion under antenna trace  160  and/or under antenna structure  160 ′ may include protrusions and/or recesses. Antenna  40  (e.g., an inverted-F antenna resonating element or other antenna structure) may be formed from antenna structure  160 ′ and/or antenna structure  160 . 
     In the example of  FIG. 10 , packaged device  140  has components  142  that are mounted on the lower surface of substrate  154  and has an antenna structure that is formed from patterned metal traces  160 ″ on the opposing upper surface of substrate  154 . Plastic  156  may be molded over components  142  and, if desired, may be molded over some or all of antenna traces  160 ″ on the upper surface of substrate  154 . If desired, antenna traces for antenna  40  may be formed from portions of metal traces  152  embedded within substrate  154  and/or may be formed on plastic  156  in addition to substrate  154  (see, e.g., metal trace  160 B). 
     In the example of  FIG. 11 , first plastic shot  156 - 1  of plastic  156  covers component(s)  142  on substrate  154 . Metal structure  158  protrudes through shot  156 - 1 . Second plastic shot  156 - 2  of plastic  156  covers remaining portions of metal structure  158 , but leaves a surface portion of metal structure  158  exposed so that metal antenna trace  160  can contact structure  158 . Second plastic shot  156 - 2  may be formed from laser-sensitizable plastic and may have a protruding portion such as protruding portion  156 - 2 P. Antenna trace  160  may be formed by electroplating metal onto the activated portions of plastic  156 - 2  so that trace  160  is coupled to structure  158 . 
       FIGS. 12 and 13  are cross-sectional side views of packaged device  140  during and after fabrication using a film-assist molding technique. In the illustrative configuration of  FIG. 12 , device  140  is being formed by molding plastic  156  over components  142  and metal structures  158 . A soft polymer film such as flexible film  172  may be used to cover the surfaces of metal structures  158  and thereby ensure that plastic  156  does not adhere to these surfaces. While plastic film  172  is in place within a plastic mold formed from die structure such as upper mold die  174  and lower mold die  176 , plastic  156  may be injection molded into the mold cavity formed between dies  174  and  176 , thereby covering components  142  and substrate  154  and surrounding metal structures  158 . Plastic  156  may be formed from laser-sensitizable plastic. 
     After removal of device  140  from the mold, selected regions of plastic  156  may be exposed to laser light and electroplating operations may be performed so that metal traces  160  are formed on the surface of plastic  156  and metal structures  158 , as shown in  FIG. 13 . If desired, electrical components such as component  178  (e.g., adjustable components  70  of  FIG. 2 ) or other circuitry may be soldered or otherwise coupled to exterior portions of device  140  of  FIG. 13  and/or other packaged devices  140 . Additional plastic may be molded over component  178  to protect component  178 . 
     As shown in the illustrative configuration of  FIG. 14 , antenna traces  160 T may be formed on one or more sides of packaged device  140 . For example, antenna traces  160 T may include upper surface traces  160 T- 1  and side traces  160 T- 2  formed using laser activation of laser-sensitizable plastic followed by electroplating and may include lower surface traces  160 T- 3 . Traces  160 T- 3  may be metal traces such as traces  152  on the lower surface of substrate  154  and/or metal traces  152  that are embedded within substrate  154 . With this type of arrangement, an antenna resonating element may be formed from traces  160 T- 1  and an antenna ground may be formed from traces  160 T- 3  (as an example). 
       FIG. 15  shows how antenna structure  160 ′ may have a portion such as portion  180  that serves as a spring. Portion  180  may impart force in the downwards direction (in the orientation of  FIG. 15 ) so that antenna structure  160 ′ is electrically connected to member  158 . 
     If desired, antenna  40  may be formed from antenna traces that run along the periphery of packaged device  140  as shown in  FIG. 16 . In the example of  FIG. 16 , components  142  have been mounted on substrate  154  and covered with plastic  156 . Plastic  156  may contain one or more shots of plastic. As an example, plastic  156  may contain a first shot of plastic such as shot  156 - 1  that has a planar shape and that covers components  142  and substrate  154  and may have a second shot of plastic such as shot  156 - 2  that protrudes upwardly from shot  156 - 1  around some or all of the periphery of shot  156 - 1 . Shot  156 - 1  may be formed from a plastic that is insensitive to laser exposure and shot  156 - 2  may be formed from laser-sensitizable plastic material (as an example). If desired, plastic  156  may be formed from a single shot that forms protrusions. 
     Antenna  40  may be formed from metal structure that are supported by protruding peripheral portions  156 - 2 . For example, antenna  40  may contain metal  184  and metal  182 . Metal  182  may be coupled to traces  152  in substrate  154  using metal member  158  in plastic  156 . Metal  182  and/or metal  184  may be formed from an electroplated layer of metal traces formed in laser activated regions of shot  156 - 2  or may be formed from stamped metal foil, machined metal, a flexible printed circuit containing metal traces, or other metal antenna structures. 
     A cross-sectional side view of device  10  in an illustrative configuration in which an antenna has been formed on a packaged device such as device  140  of  FIG. 16  is shown in  FIG. 17 . As shown in  FIG. 17 , device  10  may include a display such as display  14 . Display  14  may have an active area AA in which display layers  190  are used to display images for a user. Display layers  190  may include an array of pixels that form a liquid crystal display, an organic light-emitting diode display, or other suitable display. Display  14  may also have border regions such as inactive areas IA that are free of pixels and that do not display images. Display  14  may have a cover layer such as cover layer  192  that is formed from a transparent material such as glass, plastic, ceramic, sapphire or other crystalline materials, and/or other transparent layers. Display cover layer  192  may overlap and protect display layers  190 . 
     Antenna  40  may be formed from metal antenna structures  184  on packaged device  140 . Metal antenna structures  184  may form an antenna resonating element (e.g., an inverted-F antenna resonating element, a patch antenna resonating element, a loop antenna resonating element, a monopole antenna resonating element, a dipole antenna resonating element, a slot antenna resonating element, or other suitable antenna resonating element), a parasitic antenna resonating element, antenna ground structures, or other portions of antenna  40 . In the example of  FIG. 17 , metal antenna structures  184  form part of antenna resonating element  106  of  FIG. 3  (e.g., an inverted-F antenna resonating element). Housing  12  (e.g., a metal housing) and ground traces  152  in substrate  154  may form antenna ground  104  of  FIG. 3 . 
     As shown in  FIG. 17 , display cover layer  192  may have recess such as groove  192 G that runs along some or all of the periphery of layer  192  and device  10 . Antenna structure  184  may be received within groove  192 G. Packaged device  140  may have a protrusion such as plastic protrusion  156 P that supports antenna structure  184 . Protrusion  156 P may be formed from laser-sensitizable plastic such as plastic  156 - 2  of  FIG. 16  and structure  184  may be formed from metal traces on activated portions of protrusion  156 P that have been exposed to laser light and/or structure  184  may be formed from metal foil, traces in a flexible printed circuit, or other conductive structures. 
     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: 20160120
Publication Date: 20190910
Grant Date: 20190910
Priority Date: 20160120
Inventors: CARDINALI, STEVEN P.
HORIUCHI, JAMES G.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2203/1469", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1322", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/186", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q9/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2223/6677", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16227", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/15192", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L2224/16227", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q9/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1322", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1469", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/15192", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/186", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2223/6677", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/15192", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q9/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10098", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16227", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1469", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2223/6677", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1322", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K3/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/186", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/1815", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/3025", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 59314749