MEMS direct chip attach packaging methodologies and apparatuses for harsh environments
First Claim
1. A method of bulk packaging sensors, comprising the steps of:
- placing a bottom substrate having an array of sensor housings in a holding device to receive sensors, each of said sensor housings having an aperture therein;
inserting a sensor having contact pads in each housing of said bottom substrate;
and, placing a top substrate having an array of covers onto each respective sensor.
1 Assignment
0 Petitions
Accused Products
Abstract
Methods of bulk manufacturing high temperature sensor sub-assembly packages are disclosed and claimed. Sensors are sandwiched between a top cover and a bottom cover so as to enable the peripheries of the top covers, sensors and bottom covers to be sealed and bound securely together are disclosed and claimed. Sensors are placed on the bottom covers leaving the periphery of the bottom cover exposed. Likewise, top covers are placed on the sensors leaving the periphery of the sensor exposed. Individual sensor sub-assemblies are inserted into final packaging elements which are also disclosed and claimed. Methods of directly attaching wires or pins to contact pads on the sensors are disclosed and claimed. Sensors, such as pressure sensors and accelerometers, and headers made out of silicon carbide and aluminum nitride are disclosed and claimed. Reference cavities are formed in some embodiments disclosed and claimed herein where top covers are not employed.
-
Citations
76 Claims
-
1. A method of bulk packaging sensors, comprising the steps of:
-
placing a bottom substrate having an array of sensor housings in a holding device to receive sensors, each of said sensor housings having an aperture therein;
inserting a sensor having contact pads in each housing of said bottom substrate;
and, placing a top substrate having an array of covers onto each respective sensor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A plurality of packaged sensors comprising:
-
a bottom substrate having a plurality of housings;
each of said housings has a perimeter;
a plurality of sensors each of which resides in a respective housing;
each of said sensors has a perimeter;
a top substrate having a plurality of covers;
each of said covers has a perimeter; and
,said sensors being sandwiched together between said housings and said covers with the perimeters of each sensor, housing and cover sealed by glass. - View Dependent Claims (11, 12, 13)
-
-
14. A plurality of packaged sensors comprising:
-
a plurality of housings defined by walls;
a plurality of sensors each having perimeters which fit within said walls of said housings;
a plurality of top covers residing on top of said plurality of sensors such that each of said top covers resides on top of a respective sensor, each of said top covers having a shorter perimeter than its respective sensor, each said top cover has the same shape but is proportionally smaller than its respective sensor such that when said covers are mounted on top said each respective sensors said perimeters of said sensors are not covered. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23)
-
-
24. A method of direct contact attachment of a pin to a contact pad on a sensor, said sensor covered with a top cover having a through hole aligned with said contact pad, said top cover having a periphery, said sensor having a periphery, and, glass binding and sealing said periphery of said top cover and said periphery of said sensor together, comprising the steps of:
-
dipping one end of the pin into a high temperature conductive paste that cures at a temperature less than the softening point of said glass used for sealing;
inserting said pin coated with conductive paste until it engages said contact pad;
firing said assembly to a temperature to cure said conductive paste;
cooling said assembly;
applying glass to said pin and said top cover to secure said pin to said cover; and
,firing said assembly to the glass curing temperature. - View Dependent Claims (25, 26, 27, 28, 29)
-
-
30. A packaged sensor sub-assembly comprising:
-
a bottom housing;
said sensor having contact pads and a perimeter, said sensor residing in said bottom housing;
a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor;
pins;
conductive paste;
said pins residing in said through holes and engaging said contact pads of said sensors;
said conductive paste securing said pins to said through holes;
glass securing said top cover, sensor, and bottom housing together; and
,glass securing said pins to said top cover. - View Dependent Claims (31, 32, 33)
-
-
34. A packaged sensor sub-assembly comprising:
-
a sensor having contact pads and a perimeter;
a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor;
pins;
conductive paste;
said pins residing in said through holes and engaging said contact pads of said sensors;
said conductive paste securing said pins to said through holes;
glass securing said top cover and sensor together; and
,glass securing said pins to said top cover. - View Dependent Claims (35, 36, 37, 38, 39, 40)
-
-
41. A method for packaging a sensor sub-assembly, said sensor sub-assembly comprising a bottom housing, said sensor having contact pads and a perimeter, said sensor residing in said bottom housing, a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor, pins, conductive paste, said pins residing in said through holes and engaging said contact pads of said sensors, said conductive paste securing said pins to said through holes, glass securing and sealing said top cover, sensor, and bottom housing together, and, glass securing said pins to said top cover, comprising the steps of:
-
attaching a Kovar header to a stainless steel housing;
inserting said sensor sub-assembly into said Kovar header, and, glassing said sensor sub-assembly to said Kovar header. - View Dependent Claims (42)
-
-
43. A method for packaging a sensor sub-assembly, said sensor sub-assembly comprising a sensor having contact pads and a perimeter, said sensor residing in said bottom housing, a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor, pins, conductive paste, said pins residing in said through holes and engaging said contact pads of said sensors, said conductive paste securing said pins to said through holes, glass securing said top cover and sensor together, and, glass securing said pins to said top cover, comprising the steps of:
-
inserting said sensor sub-assembly into a stainless steel housing having threads on the interior of said housing; and
,sealing said threads, said sensor sub-assembly and said pins within said housing. - View Dependent Claims (44, 45, 46)
-
- 47. A sensor sub-assembly in combination with a stainless steel housing having an interior and an exterior, said interior includes threads thereon, comprising a sensor having contact pads and a perimeter, said sensor residing in said bottom housing, a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor, pins, conductive paste, said pins residing in said through holes and engaging said contact pads of said sensors, said conductive paste securing said pins to said through holes and to said contact pads, glass securing said top cover and sensor together, and, glass securing said pins to said top cover in combination with a stainless steel housing having an interior and an exterior, sealing glass residing in said interior of said of said stainless steel housing seals said threads, said sensor sub-assembly and said pins within said housing.
- 50. A sensor sub-assembly housing comprising a stainless steel housing having an interior and an exterior, said interior includes threads thereon, a ceramic tube resides in said interior of said stainless steel housing, brazing resides intermediate said interior threads of said stainless steel housing and said ceramic tube, and, said brazing secures said ceramic tube and said stainless steel housing together upon heating said brazing.
-
56. A packaged sensor sub-assembly comprising:
-
a bottom housing;
said sensor having contact pads and a perimeter, metal bumps formed on said contact pads, said sensor residing in said bottom housing;
a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor;
said through holes being filled with nickel so as to form a transconnect;
said transconnect engaging said bumps;
conductive paste; and
,glass securing said top cover, sensor, transconnect and bottom housing together forming a reference cavity bounded by said top cover, said sensor and said glass. - View Dependent Claims (57, 58, 59)
-
- 60. A sensor sub-assembly housing comprising a stainless steel tube, a ceramic tube having through holes, a reference cavity, and an opening therein, said ceramic tube being partially brazed to said stainless steel tube, said ceramic tube extending outside said stainless steel tube a sufficient length to thermally decouple said stainless steel tube from said sensor.
- 62. A packaged sensor sub-assembly comprising a sensor sub-assembly inserted into and glassed to a kovar header brazed to a stainless steel housing, said sensor sub-assembly comprising a bottom housing, said sensor having contact pads and a perimeter, said sensor residing in said bottom housing, a top cover having through holes therethrough, said through holes being aligned with said contact pads of said sensor, pins and conductive paste, said pins residing in said through holes and engaging said contact pads of said sensors, said conductive paste securing said pins to said through holes, glass securing and sealing said top cover, sensor, and bottom housing together, and, glass securing said pins to said top cover.
-
64. A method of packaging a sensor sub-assembly comprising the steps of:
-
inserting a ceramic tube inside a stainless steel housing, said ceramic tube having through holes, and said stainless steel housing includes an interior having threads thereon;
inserting brazing material in the gap intermediate said stainless steel housing and said ceramic tube such that said brazing material is conformal to said interior threads;
heating said brazing material and securing said ceramic tube to said stainless steel housing;
inserting a sensor sub-assembly having contact pads into said stainless steel housing in alignment with said through holes of said ceramic tube and in proximity to said ceramic tube; and
,inserting and heating glass to secure said sensor sub-assembly to said ceramic tube and said stainless steel housing forming a reference cavity. - View Dependent Claims (65, 66, 67, 68, 69)
-
-
70. A method of packaging a sensor sub-assembly in a stainless steel housing having an interior and an exterior, comprising the steps of:
-
coating pins with paste;
inserting said coated pins into a ceramic tube having through holes;
placing said coated pins inside said through holes in said ceramic tube and heating said paste to secure said pins to said ceramic tube;
smoothening one end of said ceramic tube and said pins located therein such that said end of said pins are coplanar with said ceramic tube;
attaching said pins to bumps on contact pads of a sensor;
heating said ceramic tube and said sensor and bumps on said contact pads;
prewetting the interior of a stainless steel housing with a glass paste;
inserting said ceramic tube and sensor in said interior of said prewet stainless steel housing;
inserting additional glass to secure said sensor to said ceramic tube and said stainless steel housing to form a reference cavity;
firing said ceramic tube, said sensor and said stainless steel housing to cure said glass. - View Dependent Claims (71, 72)
-
-
73. A method of packaging a sensor sub-assembly in an aluminum nitride header partially secured within a stainless steel housing having an interior, an exterior and a reference cavity formed therein, said sensor sub-assembly including contact pads, comprising the steps of:
-
coating said aluminum nitride header with a metallic material;
inserting said aluminum nitride header having four through holes therein into said stainless steel housing;
attaching said metallic material to said stainless steel housing;
coating through hole openings with conductive paste;
inserting conductive pins in said through holes coating said holes with conductive paste;
heating said header, said stainless steel housing, said pins and said conductive paste so as to cure and harden said conductive paste;
reapplying said conductive paste on said cured and hardened conductive paste which is proximate said reference cavity;
inserting said sensor sub-assembly in said reference cavity such that said sensor contact pads are aligned with said through holes of said aluminum nitride header;
heating and bonding said sensor sub-assembly to said reference cavity such that electrical conductivity may be established between said contact pads and said pins; and
,sealing between said aluminum nitride header and said sensor locking air between said reference cavity and said sensor. - View Dependent Claims (74, 75, 76)
-
Specification