RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/698,801, filed on September 10, 2013 and entitled "MEMS MICROPHONE PACKAGE WITH MOLDED INTERCONNECT DEVICE," the entire contents of which are

incorporated herein by reference.

BACKGROUND

[0002] The present invention relates to a MEMS microphone package. In particular, the invention relates to mechanisms for electronic communication between components within a MEMS microphone package

SUMMARY

[0003] In one embodiment, the invention provides a microphone package including a plastic lid, a substrate base, and two electrical components. The plastic lid includes a first conductive lid trace and the substrate base includes a first conductive substrate trace. The plastic lid is sealably coupled to the substrate base to form a sealed cavity. The substrate trace and the lid trace are arranged such that, when the cavity is sealed, an electrical connection is formed between the substrate trace and the lid trace. The first component is mounted on the substrate base and electrically coupled to the substrate trace. The second component is mounted on the lid and is electrically coupled to the lid trace. The electrical connection between the substrate trace and the lid trace provides electrical coupling between the first component and the second component. At least one of the first component and the second component includes a MEMS microphone die.

[0004] In another embodiment, the invention provides a top-ported microphone package including a molded interconnect device lid, a base substrate, a MEMS microphone die, and an electrical contact pad. The MEMS microphone die is mounted on the molded interconnect device lid adjacent to an acoustic port opening that extends through the lid. The MEMS microphone die is electrically coupled to a conductive trace on the interior surface of the lid. The electrical contact pad is mounted on an exterior surface of the substrate base and is electrically coupled to a conductive substrate trace. The conductive substrate trace and the lid trace are arranged to form an electrical connection to provide for electrical coupling between the MEMS microphone die and the electrical contact pad.

[0005] In yet another embodiment, the invention provides a bottom-ported microphone package that includes a molded interconnect device lid, a base substrate, a MEMS microphone die, and an electrical contact pad. The MEMS microphone die is mounted on the base substrate adjacent to an acoustic port opening that extends through the base substrate. The MEMS microphone die is electrically coupled to a conductive trace on an interior surface of the base substrate. The electrical contact pad is mounted on an exterior surface of the lid and is electrically coupled to a conductive trace on an interior surface of the lid. The conductive substrate trace and the lid trace are arranged to form an electrical connection to provide for electrical coupling between the MEMS microphone die and the electrical contact pad.

[0006] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Fig. 1A is a top view of a top-ported MEMS microphone package.

[0008] Fig. IB is a cross-sectional elevation view of the top-ported MEMS microphone package of Fig. 1A from a first perspective.

[0009] Fig. 1C is another cross-sectional elevation view of the top-ported MEMS microphone package of Fig. 1A from a second perspective.

[0010] Fig. 2 is a cross-sectional elevation view of a bottom-ported MEMS microphone package.

[0011] Fig. 3A is a cross-sectional elevation view of a second example of bottom-ported MEMS microphone package.

[0012] Fig. 3B is a detailed view of the bottom-ported MEMS microphone package of Fig. 3A. [0013] Fig. 3C is a bottom-up cross-sectional view of the bottom-ported MEMS microphone package of Fig. 3 A.

[0014] Fig. 3D is a top-down cross-sectional view of the bottom-ported MEMS microphone package of Fig. 3 A.

[0015] Fig. 4 is a perspective view of an array of MEMS microphone package during assembly.

[0016] Fig. 5A is a bottom-up cross-sectional view of a third example of a bottom-ported MEMS microphone package.

[0017] Fig. 5B is a bottom-up view of the bottom surface of the bottom-ported MEMS microphone package of Fig. 5 A.

[0018] Fig. 5C is a cross-sectional elevation view of the bottom-ported MEMS microphone package of Fig. 5 A.

[0019] Fig. 5D is a side view of the bottom-ported MEMS microphone package of Fig. 5A.

[0020] Fig. 5E is a perspective view of the bottom-ported MEMS microphone package of Fig. 5A.

DETAILED DESCRIPTION

[0021] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

[0022] Acoustic performance of a microphone requires an acoustic chamber and an open port into the chamber to receive sound input. Depending upon the particular application, original equipment manufacturers (OEMs) that utilize microelectromechanical microphones (MEMS microphones) require MEMS microphone in both bottom-port and top-port configurations. In a bottom-port configuration, the acoustic input port is on the bottom of the microphone package while, in a top-port configuration, the acoustic input port is located on the top of the microphone package. Some bottom-port microphone packages include an acoustic input port formed as a hole through the substrate with the MEMS microphone die placed above the hole. A lid is then placed over the substrate to form an enclosed cavity.

[0023] To obtain equivalent performance in a top-port microphone package, the acoustic input port can be formed as a hole through the lid with a MEMS microphone die placed directly underneath the hole. However, in such constructions, mechanisms must be provided for electronic communication between the top surface of a microphone package (i.e., the lid) and the bottom surface of the microphone package (i.e., the substrate). One option would be to construct the MEMS microphone package as a stack of laminate substrates with a cavity formed by the inner substrate. Electronic routing between the top surface and the bottom surface can be accomplished by vias positioned in the sidewalls of the inner substrate.

Alternatively, "flip-chip" design technology could be used to place the MEMS microphone die on the substrate upside-down. An additional sealing to the lid of the microphone package would then be required to ensure proper acoustic performance.

[0024] Figs. 1 A - 1C illustrate an example of a top-ported MEMS microphone package that provides for communication between the top surface (i.e., the lid) and the bottom surface (i.e., the substrate) of a microphone using a lid that operates as a molded interconnect device (MID). Fig. 1A shows the top surface of the package 100. From this perspective, the lid component 101 is visible as well as the acoustic input port 103 formed through the lid 101. The lid 101 is an injection-molded thermoplastic component with integrated electronic circuit traces as described in further detail below.

[0025] Fig. IB provides a cross-sectional view of the microphone package 100 along the A-A line of Fig. 1A. It is noted that, although Figs. 1A - 1C illustrate a top-ported microphone package, Fig. IB shows the microphone package 100 oriented with the acoustic port 103 on the bottom of the package 100. As illustrated in Fig. IB, the thermoplastic lid 101 is formed with a hollow cavity inside. The thermoplastic lid 101 is coupled to a substrate layer 105 to form a sealed cavity. A MEMS microphone die 107 is mounted to the lid 101 adjacent to the acoustic port opening 103 such that acoustic pressures (e.g., sounds) entering the microphone package 100 through the acoustic input port 103 encounter the MEMS microphone die 107. [0026] Conductive traces 109 (e.g., metal) are deposited on the interior surface of the MID lid 101. When the substrate 105 is sealed to the lid 101, the conductive traces are electronically coupled with corresponding traces formed on the substrate 105. In the example of Fig. IB, the circuit traces 11 1 on the substrate 105 are coupled to one or more electric vias 113 which, in turn, are coupled to one or more electrical contact pads 1 15 on the bottom surface of the substrate 105.

[0027] In the example of Fig. IB, the MEMS microphone die 107 is a monolithically integrate MEMS die which includes both application specific integrated circuit (ASIC) components and the micro-mechanical electric microphone diaphragm within a single die. Wires 117 extend from the MEMS microphone die 107 to couple the MEMS microphone die 107 to the conductive traces 109 on the interior surface of the lid 101. As such, the MEMS microphone die 107 is in electronic communication with one or more devices mounted on the substrate 105 - including, in this example, the electric contact pads 1 15 on the exterior surface of the microphone package 100.

[0028] Fig. 1C provides another cross-sectional view of the microphone package - this time along the B-B line of Fig. 1A. Fig. 1C provides a more detail view of the interior surface of the lid 101. As noted above, conductive traces 109 deposited on the interior walls of the lid 101 provide for electrical routing between the lid 101 and the substrate 105.

However, in this example, interior surfaces of the lid 101 that are not used for electrical routing are covered with a conductive layer 1 19 that is grounded to the substrate. The lined surfaces 119 of the cavity, together with the substrate 105 (which may also include a conductive ground plate) forms a Faraday's cage and provide for improved electromagnetic shielding of the MEMS microphone device.

[0029] The examples discussed above in reference to Figs. 1A-1C illustrate a top-ported microphone package that provides for electrical communication between the substrate 105 and devices (such as a MEMS microphone die 107) mounted on the top surface of the lid. Fig. 2 illustrates an example of a bottom-ported microphone package that also provides for electrical communication between the top surface of the microphone package and the bottom surface. The microphone package 200 of Fig. 2 includes a thermoplastic lid 201 sealably coupled to a substrate 203. Because the microphone package 200 is a bottom-ported configuration, the MEMS microphone die 205 is mounted on the substrate 203 adjacent to an acoustic input port 207 formed through the substrate 205. [0030] Like the example of Figs. 1A-1C, conductive metal traces 209 are deposited on the interior surface of the lid 201. The conductive traces 209 on the lid 201 align with corresponding traces 21 1 on the substrate and extend to a conductive "via" 213 formed through the top surface of the lid 201. One or more electrical contact pads 215 are mounted on the exterior of the top surface of the lid 201. When the MEMS microphone die 205 is coupled to the conductive traces 21 1 on the substrate 203 by one or more wires 217, the conductive traces 209 on the interior surface of the lid 201 couple the MEMS microphone die 205 to the electrical contact pads 215 on the exterior top surface of the lid 201.

[0031] Fig. 3A illustrates yet another example of a bottom-ported microphone package 300. In this example, the MEMS microphone die 301 is again mounted adjacent to an acoustic input port 303 formed through the substrate 305. The substrate 305 is sealably coupled to a thermoplastic molded lid 307. However, in this example, additional electronic components - i.e., an ASIC 309 - is also mounted to the substrate 305. The conductive traces 311 on the substrate align with the corresponding conductive traces 313 on the interior surface of the lid 307 and extend to a conductive "via" 315 formed through the top surface of the lid. One or more electrical contact pads 317 are mounted on the exterior of the top surface of the lid 307. A first wire bond electronically couples the MEMS microphone die 301 to the ASIC 309 while a second wire bond 321 couples the ASIC 309 to the contact pad 317 on the exterior surface of the lid 307 through the traces 313 deposited on the interior surface of the lid 307. In this way, the ASIC 309 monitors and controls the operation of the MEMS microphone die 301 and also facilitates electrical communication with exterior systems through the contact pads 317.

[0032] Fig. 3B illustrates additional features of the bottom-ported configuration of Fig. 3 A by providing a detailed view of inset "D" from Fig. 3A. As shown in Fig. 3B, an isolating layer 323 provides a solder mask with openings 325 where conductive traces 313 on the lid 307 can be electronically coupled with traces 311 on the substrate 305. When solder (or another conductive material) is deposited at 325 to seal the lid 307 to the substrate 305, an electrical connection 327 is formed between the lid traces 313 and the corresponding substrate traces 31 1.

[0033] As shown in Fig. 3B, an electrically isolated trace 329 forms a conductive ring around the outer edge of the substrate that is used to acoustically seal the cavity and to also provide a conductive connection between a conductive shielding layer on the lid 307 to the grounding of the substrate 305. This conductive ring and the shielding arrangement is more clearly illustrated in Figs. 3C and 3D. Fig. 3C shows a cross-section of the lid 307 from the bottom at the point where the lid 307 is coupled to the substrate 305. The dotted line represents the interior surface of the lid 307 where the electronic traces are deposited for electronic communication. A conductive shielding layer extends through the lid above the conductive trace ring 329. The conductive shielding layer can be formed on the interior surface of the lid 307 as illustrated in Fig. 1C above or can be deposited on the exterior surface of the molded lid 307. Electrical communication between the active electronics and the conductive traces of the lid is provide at point 327 whereas ground of the shielding is provided at contact pad 331.

[0034] Fig. 3D shows the corresponding conductive contact arrangement on the substrate 305. Again, the conductive ring trace 329 provides electrical coupling between the shielding layer of the lid 307 and the grounding of the substrate 305 at contact pad 331. The conductive traces 311 on the surface of the substrate 305 are more visible in Fig. 3D and align with the traces on the interior surface of the lid 307 at electrical connection 327. Wire bonds 321 connect the ASIC 309 to the electrical traces 31 1 of the substrate 305.

[0035] Although the discussion above focuses primarily on a single path of electronic communication between the components mounted on the substrate and components mounted on the opposite surface of the lid, it is to be understood that the concepts discussed above can be used to provide multiple avenues for electronic communication between the two surface and, in some cases, between the substrate and devices mounted on the side surfaces of the lid. For example, in Fig. 3D, a total of three wire bonds 321 are each used to connect the ASIC 309 to a different trace 31 1. Each trace extends to a point where it contacts the lid - and the corresponding traces formed on the interior of the lid - at a different location. As such, the example of Fig. 3D provides for three different, electrically isolated paths for electrical communication between the ASIC 309 mounted on the substrate 305 and components (e.g., electrical contact pads) mounted on the top surface of the lid.

[0036] MEMS microphone packages such as those described above can be manufactured in arrays and singulated from a single substrate. As illustrated in Fig. 4, a single substrate layer 401 is manufactured to include a plurality of MEMS microphone dies, associated circuitry, and necessary conductive traces (collectives shown as 403) arranged in an array. An array 405 of thermoplastic molded lids - each with the appropriate conductive traces - is aligned with the array of substrate packages 403, lowered into place, and sealably coupled to the substrate. Fig. 4 shows a first array of lids 405 aligned above the substrate array 401 and another array of lids 407 lowered into place. The individual packages are then singulated from the array.

[0037] Some constructions of the MEMS microphone package are specifically designed to benefit from the array-based manufacturing technique and the singulation process such as described above. For example, instead of metalizing the interior surface of the lid for shielding purposes, one or more metalized electric vias can be formed as part of the lid array positioned along the saw-street of the array.

[0038] Fig. 5 A illustrates an example of one such construction of a top-ported MEMS microphone package 500 (the substrate is omitted to better illustrate the arrangement and component of the lid of the package). The reference measurements provide the relative dimensions of the components in this example. A lid 501 is provides with both a MEMS microphone die 503 and an ASIC 505 mounted thereto. A series of conductive traces 507 are positioned within the material of the lid 501 and provide for electrical connection with the substrate when the cavity is sealed. As noted above, a conductive layer 509 is positioned around the exterior surface of the lid 501. This conductive layer 509 is coupled to the grounding of the substrate and provides for electromagnetic shielding of the MEMS microphone die 503 as discussed above.

[0039] The conductive layer 509 in this example is not deposited on the exterior surface of the lid 501. Instead, the array of lids (i.e., array 405 of Fig. 4) is manufactured to includes one or more vias arranges along the saw-streets of the array of lids. When the individual packages are singulated from the array, the vias are partially cut away. The remaining portion of the conductive via on the exterior surface of the lid forms the conductive shielding layer 509 of Fig. 5 A.

[0040] Fig. 5B shows the top exterior surface of the lid 501 of the top-ported microphone package 500. The acoustic port opening 51 1 is visible through the top surface of the lid 500. As shown in Fig. 5C, the MEMS microphone die 503 is mounted to the lid 501 adjacent to the acoustic port opening 511. The ASIC 505 is also mounted to the surface of the lid. As noted above, the conductive shielding layer 509 extends along the exterior surface of each singulated package 500. [0041] Alternatively, instead of utilizing vias placed at the saw-street of the array to form a substantially uniform conductive layer on the exterior surface of the lid, cylindrical conductive vias can be positioned at periodic intervals along the saw-street in the array. When the individual microphone packages 500 are singulated, the cylindrical vias are halved. The remaining portion - illustrated in Fig. 5B as the semicircular structures 513 - are coupled to the substrate grounding and provide shielding for the microphone device.

[0042] In yet another construction, an isolating layer 515 is deposited on the exterior surface of the conductive shielding layer 509 after the microphone packages are singulated. To provide for electrical contact points to the shielding layer 509, semi-cylindrical cut-outs 513 are formed at intervals around the perimeter of the lid 501. As shown in Fig. 5D, the cylindrical cutouts 513 cut through the isolating layer 515 so that the conductive shielding layer 5009 is partially exposed on the exterior of the microphone package. The layout and construction of the package 500 is also illustrated in perspective view in Fig. 5E.

[0043] The specific layouts, components, and manufacturing techniques described above are exemplary and are capable of different implementations. For example, in addition to using an injection moldable thermoplastic material to form the MID lid, transfer moldable thermosetting plastic materials can be used. Although this material is not typically used for MID technology, it may be implemented in some microphone package constructions by utilizing plating methods for metallization.

[0044] Thus, the invention provides, among other things, a MEMS microphone package including a substrate and a molded lid that provides for electrical coupling between one or more components mounted on a substrate and one or more components mounted on the lid. Various features and advantages of the invention are set forth in the following claims.