Substrate Metal Wall Structure for Stable Resin Molding
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Solution Overview
Problem
In high frequency modules, the metal wall can collapse due to pressure from resin fluidity during resin molding, leading to potential falling of the metal member.
Innovation Solution
A module design featuring a metal member with a plate-shaped portion and foot portions that extend backward, connected to a substrate via mounting electrodes, and a sealing resin layer that covers the metal member and electronic components, with specific surface treatments to enhance solder adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a groove is provided in the upper part of the metal wall to allow resin flow, then the resin molding portion can be formed properly, but the metal wall may collapse due to pressure from the resin
Solution Approach 1:
The metal member is divided into a plate-shaped portion and multiple foot portions that extend backward. This segmentation allows the foot portions to be positioned at different locations to provide distributed support against resin pressure, preventing collapse while allowing the plate-shaped portion to accommodate resin flow.
Solution Approach 2:
The foot portions extend backward from the plate-shaped portion in the depth direction, utilizing the third dimension to provide support structure. This dimensional extension allows the metal member to resist resin pressure from the front while maintaining structural integrity through the backward-extending feet.
2Reliability
If the metal member is made taller to improve shielding effect, then electromagnetic shielding is enhanced, but the metal member becomes more prone to falling during resin molding
Solution Approach 1:
The foot portions are designed to extend backward and make contact with the substrate before the resin molding process begins. This preliminary positioning establishes a stable base that prevents the tall plate-shaped portion from falling during subsequent resin injection, allowing the metal member to maintain its height for effective shielding.
Solution Approach 2:
The foot portions act as an intermediary between the tall plate-shaped portion and the substrate. They transfer the load and provide mechanical support, enabling the plate-shaped portion to maintain its height for shielding purposes without directly contacting the substrate, thus preventing falling during resin molding.
3Device complexity
If the metal member structure is simplified to reduce manufacturing complexity, then production is easier, but the metal member cannot resist resin pressure effectively
Solution Approach 1:
The metal member is segmented into a plate-shaped portion and multiple foot portions. This segmentation provides effective pressure resistance through distributed support points while maintaining relatively simple manufacturing processes. Each segment serves a specific function, balancing structural effectiveness with manufacturing simplicity.
Data Source
AI summary
A substrate has an upper main surface and a lower main surface arranged in an up-down direction. The metal member is provided on the upper main surface of the substrate. The metal member includes a plate-shaped portion and one or more foot portions. The plate-shaped portion has a front main surface and a back main surface arranged in a front-back direction when viewed in the up-down direction. The one or more foot portions extend backward from the lower side by bending the metal member at the lower side of the plate-shaped portion. A line extending in a predetermined direction is provided on the front main surface, the back main surface, the outer surface of the portion where the metal member is bent, and the inner surface of the portion where the metal member is bent.