Methods of manufacture of bottom port surface mount silicon condenser microphone packages
First Claim
1. A method of manufacturing a plurality of solder reflow surface mount microelectromechanical system (MEMS) microphone devices, the method comprising:
- providing an unsingulated panel comprised of a plurality of individual substrates, each substrate having a planar upper surface and a planar lower surface, the upper surface having an interior region and a peripheral region that completely surrounds the interior region, each individual substrate further comprising;
a first plurality of metal pads formed on the upper surface of the individual substrate;
a second plurality of metal pads formed on the lower surface of the individual substrate and arranged within a perimeter of the lower surface of the individual substrate, wherein the second plurality of metal pads are configured to mechanically attach and electrically couple the surface mount MEMS microphone device to pads on a surface of an external printed circuit board;
one or more electrical pathways formed completely within the individual substrate, wherein the pathways electrically couple one or more of the first plurality of metal pads on the upper surface of the individual substrate to one or more of the second plurality of metal pads on the lower surface of the individual substrate; and
an acoustic port formed in the interior region of the individual substrate and passing completely through the individual substrate, wherein one of the second plurality of formed metal pads has an opening that completely surrounds the acoustic port in the substrate, the opening in the formed metal pad being larger than the acoustic port;
mounting a MEMS microphone die to the upper surface of each substrate in the unsingulated panel of substrates, each MEMS microphone die being arranged directly over the acoustic port in its respective substrate;
electrically coupling each MEMS microphone die to at least one of the first plurality of metal pads on the upper surface of its respective substrate;
providing an unsingulated panel comprised of a plurality of individual covers, each cover being a single-piece cover that has a top region and a sidewall region, the sidewall region adjoining the top region at a substantially perpendicular angle and having a predetermined height, an exterior surface, an interior surface, and a bottom surface;
attaching the unsingulated panel of covers to the unsingulated panel of substrates,wherein the bottom surface of the sidewall region of each single-piece cover is aligned with and attached to the peripheral region of the upper surface of its respective substrate, andwherein the predetermined height and interior surface of the sidewall region and interior surface of the top region of each cover, in cooperation with the interior region of the upper surface of its respective substrate, forms a protective enclosure for the MEMS microphone die that reduces electromagnetic interference and defines an acoustic chamber for its respective MEMS microphone die disposed on the upper surface of its respective substrate in the unsingulated panel of substrates; and
singulating the attached panels into a plurality of individual MEMS microphone devices.
1 Assignment
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Accused Products
Abstract
The present invention relates to a surface mount package for a silicon condenser microphone and methods for manufacturing the surface mount package. The surface mount package uses a limited number of components which simplifies manufacturing and lowers costs, and features a substrate that performs functions for which multiple components were traditionally required, including providing an interior surface on which the silicon condenser die is mechanically attached, providing an interior surface for making electrical connections between the silicon condenser die and the package, and providing an exterior surface for surface mounting the package to a device'"'"'s printed circuit board and for making electrical connections between package and the device'"'"'s printed circuit board.
169 Citations
30 Claims
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1. A method of manufacturing a plurality of solder reflow surface mount microelectromechanical system (MEMS) microphone devices, the method comprising:
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providing an unsingulated panel comprised of a plurality of individual substrates, each substrate having a planar upper surface and a planar lower surface, the upper surface having an interior region and a peripheral region that completely surrounds the interior region, each individual substrate further comprising; a first plurality of metal pads formed on the upper surface of the individual substrate; a second plurality of metal pads formed on the lower surface of the individual substrate and arranged within a perimeter of the lower surface of the individual substrate, wherein the second plurality of metal pads are configured to mechanically attach and electrically couple the surface mount MEMS microphone device to pads on a surface of an external printed circuit board; one or more electrical pathways formed completely within the individual substrate, wherein the pathways electrically couple one or more of the first plurality of metal pads on the upper surface of the individual substrate to one or more of the second plurality of metal pads on the lower surface of the individual substrate; and an acoustic port formed in the interior region of the individual substrate and passing completely through the individual substrate, wherein one of the second plurality of formed metal pads has an opening that completely surrounds the acoustic port in the substrate, the opening in the formed metal pad being larger than the acoustic port; mounting a MEMS microphone die to the upper surface of each substrate in the unsingulated panel of substrates, each MEMS microphone die being arranged directly over the acoustic port in its respective substrate; electrically coupling each MEMS microphone die to at least one of the first plurality of metal pads on the upper surface of its respective substrate; providing an unsingulated panel comprised of a plurality of individual covers, each cover being a single-piece cover that has a top region and a sidewall region, the sidewall region adjoining the top region at a substantially perpendicular angle and having a predetermined height, an exterior surface, an interior surface, and a bottom surface; attaching the unsingulated panel of covers to the unsingulated panel of substrates, wherein the bottom surface of the sidewall region of each single-piece cover is aligned with and attached to the peripheral region of the upper surface of its respective substrate, and wherein the predetermined height and interior surface of the sidewall region and interior surface of the top region of each cover, in cooperation with the interior region of the upper surface of its respective substrate, forms a protective enclosure for the MEMS microphone die that reduces electromagnetic interference and defines an acoustic chamber for its respective MEMS microphone die disposed on the upper surface of its respective substrate in the unsingulated panel of substrates; and singulating the attached panels into a plurality of individual MEMS microphone devices. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of manufacturing a plurality of solder reflow surface mount microelectromechanical system (MEMS) microphone devices, the method comprising:
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providing an unsingulated panel comprised of a plurality of individual printed circuit boards, each printed circuit board comprising multiple layers of non-conductive material and having a planar upper surface and a planar lower surface, the upper surface having an interior region and a peripheral region that completely surrounds the interior region, each individual printed circuit board further comprising; a first plurality of metal pads formed on the upper surface of the individual printed circuit board; a second plurality of metal pads formed on the lower surface of the individual printed circuit board and arranged within a perimeter of the lower surface of the printed circuit board, wherein the second plurality of metal pads are configured to mechanically attach and electrically couple the surface mount MEMS microphone device to pads on a surface of an external printed circuit board; one or more electrical pathways formed completely within the individual printed circuit board, wherein the pathways electrically couple one or more of the first plurality of metal pads on the upper surface of the individual printed circuit board to one or more of the second plurality of metal pads on the lower surface of the individual printed circuit board; and an acoustic port formed in the interior region of the individual printed circuit board and passing completely through the individual printed circuit board, wherein one of the second plurality of formed metal pads has an opening that completely surrounds the acoustic port in the printed circuit board, the opening in the formed metal pad being larger than the acoustic port; mounting a MEMS microphone die to the upper surface of each printed circuit board in the unsingulated panel of printed circuit board, each MEMS microphone die being arranged directly over the acoustic port in its respective printed circuit board; electrically coupling each MEMS microphone die to at least one of the first plurality of metal pads on the upper surface of its respective printed circuit board; providing an unsingulated panel comprised of a plurality of individual covers, each cover being a single-piece cover that has a top region and a sidewall region, the sidewall region adjoining the top region at a substantially perpendicular angle and having a predetermined height, an exterior surface, an interior surface, and a bottom surface, wherein each cover has a first length and a first width, and its respective printed circuit board has a second length and a second width, and wherein the first length of each cover and second length of its respective printed circuit board are substantially equal, and the first width of each cover and second width of its respective printed circuit board are substantially equal; mechanically attaching the unsingulated panel of covers to the unsingulated panel of printed circuit boards, wherein the bottom surface of the sidewall region of each single-piece cover is aligned with and mechanically attached to the peripheral region of the upper surface of its respective printed circuit board, and wherein the predetermined height and interior surface of the sidewall region and interior surface of the top region of each cover, in cooperation with the interior region of the upper surface of its respective substrate, forms a protective enclosure for the MEMS microphone die that reduces electromagnetic interference and that defines an acoustic chamber for its respective MEMS microphone die disposed on the upper surface of its respective substrate in the unsingulated panel of substrates; and singulating the attached panels into a plurality of individual MEMS microphone devices. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A method of manufacturing a plurality of solder reflow surface mount microelectromechanical system (MEMS) microphone devices, the method comprising:
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providing an unsingulated panel comprised of a plurality of individual substrates, each substrate comprising multiple layers of non-conductive material and having a planar upper surface and a planar lower surface, the upper surface having an interior region and a peripheral region that completely surrounds the interior region, each individual substrate further comprising; a first plurality of metal pads formed on the upper surface of the individual substrate; a second plurality of metal pads formed on the lower surface of the individual substrate and arranged within a perimeter of the lower surface of the individual substrate, wherein the second plurality of metal pads are configured to mechanically couple and electrically couple the surface mount MEMS microphone device to pads on a surface of an external printed circuit board; and one or more electrical pathways formed completely within the individual substrate, wherein the pathways electrically couple one or more of the first plurality of metal pads on the upper surface of the individual substrate to one or more of the second plurality of metal pads on the lower surface of the individual substrate; and an acoustic port formed in the interior region of the individual substrate and passing completely through the individual substrate, wherein one of the second plurality of formed metal pads has an opening that completely surrounds the acoustic port in the substrate, the opening in the formed metal pad being larger than the acoustic port; a MEMS microphone die physically coupled to the upper surface of the substrate and electrically coupled to at least one of the first plurality of metal pads on the upper surface of the substrate, the MEMS microphone die being disposed directly over the acoustic port in the substrate; and providing an unsingulated panel comprised of a plurality of individual covers, each cover being a single-piece cover that has a top region and a sidewall region, the sidewall region adjoining the top region at a substantially perpendicular angle and having a predetermined height, an exterior surface, an interior surface, and a bottom surface; physically coupling the unsingulated panel of covers to the unsingulated panel of substrates, wherein the bottom surface of the sidewall region of each single-piece cover is aligned with and physically coupled to the peripheral region of the upper surface of its respective substrate, thereby forming a protective enclosure for the MEMS microphone die that reduces electromagnetic interference, and wherein the interior of each protective enclosure is an acoustic chamber having a volume defined by the predetermined height of the sidewall region of its respective cover, and the width and length of the top region of its respective cover; and singulating the coupled panels into a plurality of individual MEMS microphone devices. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 29, 30)
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25. A method of manufacturing a plurality of solder reflow surface mount microelectromechanical system (MEMS) microphone devices, the method comprising:
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providing an unsingulated panel comprised of a plurality of individual printed circuit boards, each printed circuit board having a multi-layer core of conductive and non-conductive materials, wherein the printed circuit board has a planar upper surface and a planar lower surface, the upper surface having an interior region and a peripheral region that completely surrounds the interior region, each individual printed circuit board further comprising; a first metal layer formed on the upper surface of the individual printed circuit board and patterned into a first plurality of metal pads, wherein at least one pad of the first plurality of metal pads is formed in the peripheral region of the upper surface of the individual printed circuit board; a second metal layer formed on the lower surface of the individual printed circuit board and patterned into a second plurality of metal pads, the second plurality of metal pads arranged within a perimeter of the lower surface of the individual printed circuit board, wherein the second plurality of metal pads are configured to mechanically couple and electrically couple the surface mount MEMS microphone device to pads on a surface of an external printed circuit board; one or more electrical pathways formed completely within the individual printed circuit board, wherein the pathways electrically couple one or more of the first plurality of metal pads on the upper surface of the individual printed circuit board to one or more of the second plurality of metal pads on the lower surface of the individual printed circuit board; and an acoustic port formed in the interior region of the individual printed circuit board and passing completely through the individual printed circuit board, wherein one of the second plurality of formed metal pads has an opening that completely surrounds the acoustic port in the printed circuit board, the opening in the formed metal pad being larger than the acoustic port; physically coupling a MEMS microphone die to the upper surface of each printed circuit board in the unsingulated panel of printed circuit boards, each MEMS microphone die being arranged directly over the acoustic port in its respective printed circuit board; electrically coupling each MEMS microphone die to at least one of the first plurality of metal pads on the upper surface of its respective printed circuit board; providing an unsingulated panel comprised of a plurality of individual covers, each individual cover being a single-piece cover that has a top region and a sidewall region, the sidewall region adjoining the top region at a substantially perpendicular angle and having a predetermined height, an exterior sidewall surface, an interior sidewall surface, and a bottom surface; physically coupling the unsingulated panel of covers to the unsingulated panel of printed circuit boards, wherein the bottom surface of the sidewall region of each single-piece cover is aligned with and physically coupled to the peripheral region of the upper surface of its respective printed circuit board, thereby forming a protective enclosure for the MEMS microphone die that reduces electromagnetic interference, and wherein the interior of each protective enclosure is an acoustic chamber having a volume defined by the predetermined height of the sidewall region of its respective cover, and the width and length of the top region of its respective cover; and singulating the coupled panels into a plurality of individual MEMS microphone devices. - View Dependent Claims (26, 27, 28)
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Specification