US-12618818-B2 - Arrays of gas sensor device packages, and related methods

Abstract

An array of gas sensor device packages comprises a plurality of gas sensor device packages, each gas sensor device package comprising a lead frame including bond pads and at least one gas sensor die in electrical communication with the bond pads. The array further comprises a protective covering over the plurality of gas sensor device packages. Related gas sensor device packages and arrays and methods of forming the arrays are also disclosed.

Inventors

• Vijay Mohan Sajja
• Steven W. Malekos
• Dean A. Hopkins
• Ronald J. Mack

Assignees

• NEVADA NANOTECH SYSTEMS INC.

Dates

Publication Date

20260505

Application Date

20210825

Claims (20)

1. 1 . An array of gas sensor device packages, the array comprising: a plurality of gas sensor device packages, each gas sensor device package comprising a leadframe including bond pads and at least one gas sensor die in electrical communication with the bond pads, the gas sensor device packages each comprising at least one vent; a protective covering over the plurality of gas sensor device packages; and a flame arrestor overlying the plurality of gas sensor device packages and bonded to the leadframe at sidewalls of the leadframe, a material of the sidewalls disposed within and surrounding the flame arrestor.
2. 2 . The array of gas sensor device packages of claim 1 , wherein the flame arrestor comprises a unitary material disposed over the plurality of gas sensor device packages.
3. 3 . The array of gas sensor device packages of claim 1 , wherein the flame arrestor is coupled to the at least one of the protective covering or sidewalls of at least one gas sensor device package of the plurality of gas sensor device packages with glue, epoxy, or is integral with a thermoplastic material defining the sidewalls.
4. 4 . The array of gas sensor device packages of claim 1 , wherein the protective covering comprises a temporary protective covering over the vent of at least one gas sensor device package.
5. 5 . The array of gas sensor device packages of claim 1 , wherein the protective covering comprises a continuous material over the array of gas sensor device packages.
6. 6 . The array of gas sensor device packages of claim 1 , further comprising saw streets defining individual gas sensor device packages of the array of gas sensor device packages.
7. 7 . The array of gas sensor device packages of claim 1 , wherein the protective covering covers one or more vents in the plurality of gas sensor device packages.
8. 8 . The array of gas sensor device packages of claim 1 , wherein the protective covering comprises nitrocellulose.
9. 9 . The array of gas sensor device packages of claim 1 , wherein the protective covering comprises a protuberance extending in a direction away from the leadframe, each gas sensor device package of the array of gas sensor device packages including a protuberance.
10. 10 . The array of gas sensor device packages of claim 1 , further comprising one or more filters attached to at least one of the protective covering, sidewalls of at least one gas sensor device package of the plurality of gas sensor device packages, or a flame arrestor.
11. 11 . The array of gas sensor device packages of claim 10 , wherein the one or more filters comprises a unitary material over an upper surface the array of gas sensor device packages.
12. 12 . The array of gas sensor device packages of claim 11 , wherein the one or more filters comprises at least one dust filter and at least one gas filter.
13. 13 . The array of gas sensor device packages of claim 1 , wherein the at least one gas sensor device package comprises a thermoplastic polymer formulated and configured not to outgas volatile organic compounds responsive to exposure to a temperature greater than about 200° C.
14. 14 . An array of gas sensor device packages, the array comprising: a plurality of gas sensor device packages within a package material, the package material defining a leadframe for each gas sensor device package of the plurality of gas sensor device packages; each gas sensor device package of the plurality of gas sensor device packages electrically connected to its respective leadframe, each gas sensor device package comprising at least one gas sensor die and a vent through which the gas sensor die is exposed; a protective material over the vents of the plurality of gas sensor device packages; and a flame arrestor overlying and contacting the leadframe of the respective gas sensor device package.
15. 15 . The array of claim 14 , wherein the flame arrestor is embedded in a material of sidewalls of the at least one gas sensor device package.
16. 16 . The array of claim 14 , wherein the flame arrestor is clipped over the at least one gas sensor device package with removable clips.
17. 17 . The array of claim 14 , further comprising a metal ring disposed between the at least one gas sensor device package and the flame arrestor.
18. 18 . The array of claim 14 , wherein the protective material comprises at least one vent over each gas sensor device package of the array of gas sensor device packages.
19. 19 . The array of claim 14 , wherein the protective material comprises a lid, wherein the lid comprises at least one protuberance over each gas sensor device package of the array of gas sensor device packages.
20. 20 . The array of claim 14 , further comprising one or more filters attached to at least one of the protective material, sidewalls of at least one gas sensor device package of the plurality of gas sensor device packages, or a flame arrestor over the plurality of gas sensor device packages.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a national phase entry under 35 U.S.C. § 371 of International Patent Application PCT/US2021/071279, filed Aug. 25, 2021, designating the United States of America and published as International Patent Publication WO 2022/051743 A1 on Mar. 10, 2022, which claims the benefit under Article 8 of the Patent Cooperation Treaty to U.S. Patent Application Ser. No. 62/706,670, filed Sep. 2, 2020. TECHNICAL FIELD Embodiments of the disclosure relate generally to arrays of gas sensor device packages, and to related methods. More particularly, embodiments of the disclosure relate to arrays of gas sensor device packages including a plurality of individual gas sensor device packages, at least one gas sensor device package including at least one protective material over at least a portion thereof, and to related methods of fabricating the arrays of gas sensor device packages. BACKGROUND Electronic gas sensors are electrical devices that are exposed to air to accurately sense chemicals in the air. Such chemicals may include volatile organic compounds (VOCs), water, semi-volatile chemicals, volatile chemicals, aerosols, spores, and other chemicals. Gas sensors may include a variety of different heating elements. For example, microhotplates are used with catalytic and metal oxide semiconductor (MOS) coatings and also used to measure thermal conductivity of a sampled gas. A resonant gas sensor may include a heater used to desorb absorbed materials from the surface of the sensor. A gas pre-concentrator may have a heating element to affect the release of absorbed material. The gas sensors may be used to detect a presence of one or more gases, at least some of which may be flammable. However, in the presence of such heated components used for detection of gases, the flammable gases to which the gas sensor is exposed may ignite. To prevent the flames from travelling from the sensor to the location of the source of the flammable gases and causing an explosion, some sensors include a mechanism to arrest the flame. Accordingly, gas sensor device packages including gas sensors may include a so-called flame arrestor located in a region between the gas sensing component (e.g., the gas sensor) and the external environment to which the gas sensor is exposed. The flame arrestor is formulated and configured to absorb the heat required for ignition and, therefore, may prevent an explosion. The flame arrestor of a conventional gas sensor device package may be located proximate the sensing material and may be configured to prevent an ignition source from escaping a cavity in which the gas sensor is disposed. The flame arrestor may allow gases to diffuse therethrough to the gas sensor, while preventing a potential flame (such as by quenching flames by absorbing heat from a potential ignition source) from propagating from the sensor cavity to the outside environment. However, use of a flame arrestor in a gas sensor may require separate manufacturing and assembly of the flame arrestor and the gas sensor device package, and may result in a large gap between the gas sensor and the flame arrestor. Further, the flame arrestor and gas sensor may become separated from each other after use and operation of the gas sensor (e.g., after multiple ignitions of a flammable gas), rendering the gas sensor unsafe for operation. BRIEF SUMMARY Embodiments disclosed herein include assemblies including gas sensor device packages, arrays of gas sensor device packages, and related methods of forming the gas sensor device packages and the arrays of gas sensor device packages. For example, in accordance with one embodiment, an array of gas sensor device packages comprises a plurality of gas sensor device packages, each gas sensor device package comprising a lead frame including bond pads and at least one gas sensor die in electrical communication with the bond pads, the gas sensor device packages each comprising at least one vent, and a protective covering over the plurality of gas sensor device packages. Additional embodiments include an array of gas sensor device packages, the array comprising a plurality of gas sensor device packages within a package material, the package material defining a lead frame for each gas sensor device package of the plurality of gas sensor device packages, each gas sensor device package of the plurality of gas sensor device packages electrically connected to its respective lead frame, each gas sensor device package comprising at least one gas sensor die and a vent through which the gas sensor die is exposed, and a protective material over the vents of the plurality of gas sensor device packages. In yet additional embodiments, a gas sensor device package comprises a lead frame, a thermoplastic material disposed around at least a portion of the lead frame and defining a cavity, at least one gas sensor die in the cavity at least partially defined by sidewalls and electrically connect