The present invention relates to a sound producing package structure and a method for packaging a sound producing package structure, and more particularly, to a sound producing package structure and a method for packaging a sound producing package structure where a surface mount technology (SMT) is used.
Nowadays, a surface mount technology (SMT) is widely used in a package structure, wherein the surface mount technology is an assembly technology in which electronic components are directly connected onto a surface of a substrate (e.g., a circuit board) with printed conductive elements (e.g. solders). The surface mount technology has the following advantages: 1) The electronic components in the package structure can be disposed in high density, such that the size of the package structure can be decreased (e.g., the package structure can be miniaturized); 2) The surface mount technology has the high reliability; 3) The highly automatized formation of the package structure can be achieved by the surface mount technology, so as to decrease the cost of the package structure and enhance the productivity of the package structure.
However, the surface mount technology cannot be used in a conventional speaker because the conventional speaker cannot tolerate the process temperature of the surface mount technology. For example, if the surface mount technology is used in the conventional speaker, the electronic component(s) and/or structure(s) of the conventional speaker can be damaged due to the process temperature of the surface mount technology, such that the conventional speaker cannot be normally operated after processing the surface mount technology.
It is therefore a primary objective of the present invention to provide a sound producing package structure and a method for packaging a sound producing package structure where a surface mount technology is used.
An embodiment of the present invention provides a sound producing package structure configured to produce sound, wherein the sound producing package structure includes a substrate, a sound producing component and a conductive adhesive layer. The sound producing component is disposed on the substrate, and the sound producing component is configured to generate an acoustic wave corresponding to an input audio signal. The conductive adhesive layer is disposed between the substrate and the sound producing component by a surface mount technology.
An embodiment of the present invention further provides a method for packaging a sound producing package structure. The method includes: providing a substrate; forming a sound producing component, wherein the sound producing component is configured to generate an acoustic wave corresponding to an input audio signal; and disposing the sound producing component on the substrate via a conductive adhesive layer by using a surface mount technology.
In the present invention, according to the present invention, the surface mount technology is used to manufacture the sound producing package structure, the highly automatized formation of the sound producing package structure can be achieved, and/or the sound producing package structure can be miniaturized more.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
To provide a better understanding of the present invention to those skilled in the art, preferred embodiments and typical material or range parameters for key components will be detailed in the follow description. These preferred embodiments of the present invention are illustrated in the accompanying drawings with numbered elements to elaborate on the contents and effects to be achieved. It should be noted that the drawings are simplified schematics, and the material and parameter ranges of key components are illustrative based on the present day technology, and therefore show only the components and combinations associated with the present invention, so as to provide a clearer description for the basic structure, implementing or operation method of the present invention. The components would be more complex in reality and the ranges of parameters or material used may evolve as technology progresses in the future. In addition, for ease of explanation, the components shown in the drawings may not represent their actual number, shape, and dimensions; details may be adjusted according to design requirements.
In the following description and in the claims, the terms “include”, “comprise” and “have” are used in an open-ended fashion, and thus should be interpreted to mean “include, but not limited to . . . ”. Thus, when the terms “include”, “comprise” and/or “have” are used in the description of the present invention, the corresponding features, areas, steps, operations and/or components would be pointed to existence, but not limited to the existence of one or a plurality of the corresponding features, areas, steps, operations and/or components.
When the corresponding component such as layer or area is referred to “on another component (or the variant thereof)”, it may be directly on another component, or other component may exist between them. On the other hand, when the component is referred to “directly on another component (or the variant thereof)”, any component does not exist between them. Furthermore, when a component A1 is disposed on a component A2, the component A1 may be situated on upper side, lower side, left side, right side or any other suitable side of the component A2.
It will be understood that when an element or layer is referred to as being “connected to” or “contact with” another element or layer, it can be directly connected to (or directly contact with) the other element or layer, or intervening elements or layers may be presented. In contrast, when an element is referred to as being “directly connected to” or “directly contact with” another element or layer, there are no intervening elements or layers presented.
In the following description and in the claims, when “a B1 component is formed by/of B2”, B2 exist in the formation of B1 component or B2 is used in the formation of B1 component, and the existence and use of one or a plurality of other features, areas, steps, operations and/or components are not excluded in the formation of B1 component.
Although terms such as first, second, third, etc., may be used to describe diverse constituent elements, such constituent elements are not limited by the terms. The terms are used only to discriminate a constituent element from other constituent elements in the specification, and the terms do not relate to the sequence of the manufacture if the specification do not describe. The claims may not use the same terms, but instead may use the terms first, second, third, etc. with respect to the order in which an element is claimed. Accordingly, in the following description, a first constituent element may be a second constituent element in a claim.
It should be noted that the technical features in different embodiments described in the following can be replaced, recombined, or mixed with one another to constitute another embodiment without departing from the spirit of the present invention.
Referring to
In the present invention, since the surface mount technology is performed, the sound producing component PC needs to be designed for being capable of tolerating a highest process temperature of the surface mount technology. As the result, the sound producing component PC has a heat resistant temperature which has an upper bound higher than the highest process temperature of the surface mount technology, such that the breakdown of the sound producing component PC would not occur and the sound producing component PC would maintain its normal operation after performing the surface mount technology. In some embodiments, the highest process temperature of the surface mount technology may range from 240° C. to 250° C., and therefore, the upper bound of the heat resistant temperature of the sound producing component PC may be higher than 240° C. or higher than 250° C., but not limited thereto. Moreover, in some embodiments, each material contained in the sound producing component PC has a heat resistant temperature which has an upper bound higher than the highest process temperature of the surface mount technology, so as to ensure that the sound producing component PC would not be damaged during surface mounting technology. For example, each material contained in the sound producing component PC has the heat resistant temperature which has the upper bound higher than 240° C. or higher than 250° C., but not limited thereto. Note that “the operation of the sound producing component PC” described in the present invention represents that the sound producing component PC can normally generate the acoustic wave.
Regarding the sound producing component PC, as shown in
The membrane 120 and the anchor structure 130 are disposed on the base 110, and the anchor structure 130 is connected to outer edge(s) of the membrane 120, wherein the membrane 120 is configured to be actuated to have a movement based on driving signal(s) correspondingly generated according to the input audio signal, the acoustic wave is produced due to the movement of the membrane 120, and the outer edge(s) of the membrane 120 may define a boundary of the membrane 120. Note that the anchor structure 130 may be a fixed end (or fixed edge) respecting the membrane 120 during the operation of the sound producing component PC. In other words, the anchor structure 130 is immobilized during the operation of the sound producing component PC. The present invention can use any suitable method to make the membrane 120 be disposed on the base 110. For example, in
Since the surface mount technology is performed in the present invention, the membrane 120 needs to be designed for being capable of tolerating the highest process temperature of the surface mount technology. In some embodiments, the membrane 120 may include silicon (e.g., single crystalline silicon or poly-crystalline silicon), silicon compound (e.g., silicon carbide), germanium, germanium compound (e.g., gallium nitride or gallium arsenide), gallium, gallium compound, any other suitable material or a combination thereof, but not limited thereto. Furthermore, in some embodiments, the material of the anchor structure 130 may be the same as the material of the membrane 120, but not limited thereto. In some embodiments, the material of the anchor structure 130 may include the material of the membrane 120 and any other suitable material, but not limited thereto.
In addition, the top-view shape of the membrane 120 may be such as a rectangle, a circle, a polygon or any other suitable shape (in
In
The actuator 140 is disposed on the membrane 120 and configured to actuate the membrane 120 to move based on the received driving signal(s). For instance, in
Furthermore, the actuator 140 may be electrically connected to the conductive layer (e.g., the upper conductive layer 114b) of the base 110, such that the driving signal(s) may be transmitted to the actuator 140, so as to actuate the membrane 120 for producing the acoustic wave. As an example (as shown in
The disposition of the actuator 140 may be designed based on requirement(s). The actuator 140 may overlap the partial membrane 120 or the complete membrane 120. For example, in
In particular, in some embodiments, the membrane(s) 120, the anchor structure 130 and the actuator 140 may be components in a chip. Namely, in some embodiments, the sound producing component PC may include a chip disposed on the base 110, and the chip includes the membrane(s) 120, the anchor structure 130 and the actuator 140. Specifically, the chip is formed by any suitable manufacturing process. In this embodiment, the chip may be formed by at least one semiconductor process, wherein the semiconductor process(es) may be performed on a wafer to form the chip, and the wafer may contain silicon (e.g., single crystalline silicon or poly-crystalline silicon), silicon compound (e.g., silicon carbide), germanium, germanium compound (e.g., gallium nitride or gallium arsenide), gallium, gallium compound, any other suitable material or a combination thereof. For example, the wafer may be a silicon wafer, a silicon on insulator (SOI) wafer, a polysilicon on insulator (POI) wafer, an epitaxial silicon on insulator wafer, or a germanium on insulator (GOI) wafer, but not limited thereto. Moreover, since the membrane(s) 120 may be formed by the semiconductor process(es), the chip may be a micro electro mechanical system (MEMS) structure, but not limited thereto. For example, an etching process may be performed on the chip to release the membrane 120 and form the anchor structure 130, but not limited thereto. More precisely, if the chip is the MEMS structure, the sound producing component PC may be a package structure of the MEMS structure (i.e., the chip), but not limited thereto. Therefore, due to the semiconductor process, the size of the chip (i.e., thickness and/or the lateral dimension) may be decreased. Note that, in the present invention, the chip is the MEMS structure capable of tolerating the highest process temperature of the surface mount technology.
The cap 160 is disposed on the base 110, and the membrane 120, the actuator 140 and the cap 160 are on a same side of the base 110, wherein the membrane 120 and the actuator 140 are situated inside the cap 160 (i.e., the membrane 120 and the actuator 140 are situated between the base 110 and the cap 160), such that the cap 160 can protect the membrane 120 and the actuator 140. In addition, the cap 160 may include any suitable material, such as metal, glass, silicon, germanium, plastic and/or polymer, but not limited thereto. In an embodiment, the cap 160 may be adhered to/on the base 110 by using the surface mount technology. In this case, the cap 160 also needs to be capable of tolerating the highest process temperature of the surface mount technology.
Moreover, the cap 160 has at least one cap opening 160a, and the cap opening 160a may be any suitable shape, such that the acoustic wave may outwards propagate from the cap opening 160a of the sound producing component PC. As an example, the cap 160 shown in
Regarding the operation of the sound producing component PC, the actuator 140 receives the driving signal to correspondingly actuate the membrane 120 to have the membrane 120 move upwardly movement or downwardly, such that the acoustic wave is produced due to the movement of the membrane 120. Note that, in the present invention, the terms “upwardly” and “downwardly” are substantially along a direction parallel to a normal direction Dn of the membrane 120, and the terms “upwardly” and “downwardly” are based on the
As shown in
In some embodiments, the first chamber CH1 and the second chamber CH2 may need to be isolated well, so as to decrease the SPL drop of the acoustic wave due to the leak of the air between the first chamber CH1 and the second chamber CH2. Thus, in the sound producing component PC, the membrane 120 of this embodiment may cover (or overlap) each base opening 110a in top view, wherein a top view direction may be parallel to a normal direction of the substrate SB, a normal direction of the base 110 and/or a normal direction Dn of the membrane 120 (as shown in
Each membrane 120 may correspond to one base opening 110a or a plurality of base openings 110a, and the number of the base opening(s) 110a corresponding to one membrane 120 may be the same or different from the number of the base opening(s) 110a corresponding to another membrane 120. More precisely, in
As shown in
The surface mount technology may use the conductive adhesive layer CAL to adhere to the sound producing component PC and the substrate SB. In detail, the conductive adhesive layer CAL includes at least one conductive structure CCS, the sound producing component PC is electrically connected to the substrate conductive pad SBp of the substrate SB through the conductive structure CCS, and each conductive structure CCS is directly in contact with the sound producing component PC and one substrate conductive pad SBp. More precisely, each conductive structure CCS is directly in contact with one base conductive pad 114ap of the sound producing component PC and one substrate conductive pad SBp of the substrate SB. That is to say, each conductive structure CCS is between one base conductive pad 114ap and one substrate conductive pad SBp. In addition, the conductive adhesive layer CAL may include any suitable conductive material which can be used in the surface mount technology. For example, the conductive adhesive layer CAL may include a solder material, but not limited thereto.
The surface mount technology used in the method for packaging the sound producing package structure PAS will be described in the following, and the following surface mount technology is an example, and some steps are omits for making the description of the surface mount technology clear.
In the process of the surface mount technology, the substrate SB having the substrate conductive pad(s) SBp and the substrate opening(s) SBa may be provided firstly, wherein the substrate conductive pad(s) SBp and the substrate opening(s) SBa may be formed before performing the surface mount technology. In some embodiments, the substrate SB may further have at least one conductive trace. Then, the conductive adhesive layer CAL having the conductive structure(s) CCS is disposed on substrate conductive pad(s) SBp of the substrate SB. For example, the conductive adhesive layer CAL may be printed on the substrate SB, but not limited thereto. Next, the electronic component such as the sound producing component PC is put on the conductive adhesive layer CAL to be in contact with the conductive structure CCS, wherein the base conductive pad 114ap of the sound producing component PC is in contact with the conductive structure CCS. Namely, the sound producing component PC is formed before the sound producing component PC is put on the conductive adhesive layer CAL (e.g., the sound producing component PC is formed before the surface mount technology is performed). In the formation of the sound producing component PC, the base opening(s) 110a is formed (e.g., by an etching process), the membrane 120, the anchor structure 130 and the actuator 140 are formed on the base 110, and the cap 160 is formed on the base 110 (e.g., the cap 160 is adhered on the base 110). Then, a temperature increasing step (e.g., a reflow step) is performed to make the process temperature increase, such that the conductive structure CCS of the conductive adhesive layer CAL melt to adhere to the substrate conductive pad SBp of the substrate SB and the base conductive pad 114ap of the sound producing component PC. As the result, by using the surface mount technology, the sound producing component PC is disposed on the substrate SB and electrically connected to the substrate conductive pad SBp through the conductive structure CCS of the conductive adhesive layer CAL.
In conventional speakers or conventional sound producing devices, since some components (such as a rubber suspension and/or an adhesive material adhere to a coil) cannot tolerate the highest process temperature of the surface mount technology, the surface mount technology cannot be used in the conventional speakers (or conventional sound producing devices). In comparison, in the present invention, since the sound producing component PC is designed to be capable of tolerating the highest process temperature of the surface mount technology, the breakdown of the sound producing component PC would not occur and the sound producing component PC can normally operate after performing the surface mount technology. Moreover, since the surface mount technology is applied in the present invention, there is no need to perform a wire bonding method/process (a method/process using a conductive wire for being electrically connected between the electronic component and the substrate SB), such that the lateral size of the sound producing package structure PAS may be reduced significantly.
Moreover, the sound producing package structure PAS may include an outer casing OC, and the substrate SB, the sound producing component PC and the conductive adhesive layer CAL are disposed inside the outer casing OC. Optionally, the outer casing OC of this embodiment may clamp the substrate SB and the sound producing component PC (e.g., the outer casing OC may be in contact with the sidewalls of the substrate SB and the sidewalls of the sound producing component PC), so as to further fix the substrate SB and the sound producing component PC, but not limited thereto. In addition, the outer casing OC may have at least one outlet opening OCa, the outlet opening OCa may be any suitable shape, and the acoustic wave generated by the sound producing component PC may propagate through the outlet opening OCa. As shown in
Furthermore, as shown in
As mentioned earlier, the first chamber CH1 and the second chamber CH2 needs to be isolated well, so as to decrease the SPL drop of the acoustic wave due to the leak of the air between the first chamber CH1 and the second chamber CH2 (for example, some air may leak from the first chamber CH1 to the second chamber CH2 through a small gap between the sidewalls of the substrate SB and the outer casing OC). Thus, as shown in
The sound producing package structure and the method for packaging the sound producing package structure of the present invention is not limited by the above embodiments. Other embodiments of the present invention are described below. For ease of comparison, same components will be labeled with the same symbol in the following. The following descriptions relate the differences between each of the embodiments, and repeated parts will not be redundantly described.
Referring to
In particular, in order to reduce the resonance phenomenon occurring in the sound producing package structure PAS (e.g., the base 110) when the sound producing package structure PAS (or the sound producing component PC) operates to generate the acoustic wave, the arrangement of the first base openings 110a_1 may not be completely the same as the arrangement of the second base openings 110a_2. Optionally, in some embodiments, in the top view, a row of the first array may extend along a first row direction D1r, a row of the second array may extend along a second row direction D2r, and the first row direction D1r is not parallel to the second row direction D2r, such that the arrangement of the first base openings 110a_1 may not be the same as the arrangement of the second base openings 110a_2. For instance, in
Optionally, if the base openings 110a are arranged with a special distance respecting to the side-edge of the membrane 120, the resonance phenomenon occurring in the sound producing package structure PAS may be further reduced due to the asymmetric arrangement of the base openings 110a. More precisely, in
Referring to
In some embodiments, the sound producing package structure PAS may include the gasket GK disposed between the sound producing component PC and the outer casing OC, and the conductive adhesive layer CAL may include the enclosing ring structure(s) ER directly in contact with the substrate SB and the base 110 (the content of the enclosing ring structure(s) ER can be referred to the first embodiment). In this case, the first chamber CH1 and the second chamber CH2 may be isolated well to decrease the SPL drop of the acoustic wave.
Furthermore, in this embodiment shown in
In summary, according to the present invention, the surface mount technology is used to manufacture the sound producing package structure PAS, the highly automatized formation of the sound producing package structure PAS can be achieved, and/or the sound producing package structure PAS can be miniaturized more.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
This application claims the benefit of U.S. provisional application No. 63/012,089, filed on Apr. 18, 2020, which is incorporated herein by reference in its entirety.
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