Air cavity package

1. A method, comprising:

forming a leadframe from a strip conductive material, the leadframe including a plurality of conductive leads and a plurality of downset facets;

forming a plurality of slugs from conductive material;

arranging the plurality of slugs into respective positions relative to the plurality of downset facets of the leadframe;

fastening the plurality of slugs to the leadframe using the plurality of downset facets;

positioning the leadframe, with the plurality of slugs fastened to the leadframe, into a mold; and

forming a plurality of plastic packages around the leadframe, the plurality of downset facets, and the plurality of slugs, wherein each of the plurality of plastic packages comprises an air cavity in which at least a portion of a respective one of the plurality of slugs and at least a portion of a respective one of the plurality of conductive leads is exposed.

2. The method according to claim 1 , wherein fastening the plurality of slugs to the leadframe comprises inserting a plurality of fasteners through the plurality of downset facets of the leadframe and into the plurality of slugs.

3. The method according to claim 1 , wherein each of the plurality of slugs includes at least one interlocking edge.

4. The method according to claim 3 , wherein forming the plurality of plastic packages comprises injecting plastic into the mold and around the at least one interlocking edge of each of the plurality of slugs.

5. The method according to claim 4 , wherein the plastic comprises at least one of epoxy, liquid crystal polymer, silicone, or polymide resin.

6. The method according to claim 1 , further comprising:

repositioning the leadframe for wire-bonding;

placing at least one electrical component within the air cavity of each of the plurality of plastic packages; and

wire-bonding the at least one electrical component within the air cavity of each of the plurality of plastic packages to at least one of the plurality of conductive leads.

7. The method according to claim 6 , further comprising enclosing the air cavity of each of the plurality of plastic packages with a cover.

8. The method according to claim 6 , further comprising separating at least one of the plurality of plastic packages from the leadframe.

9. A method, comprising:

forming a leadframe from a strip conductive material, the leadframe including a plurality of conductive leads and a plurality of downset facets;

forming a plurality of slugs from conductive material;

fastening the plurality of slugs to the leadframe using the plurality of downset facets;

positioning the leadframe, with the plurality of slugs fastened to the leadframe, into a mold; and

forming a plurality of plastic packages around the leadframe, the plurality of downset facets, and the plurality of slugs, wherein each of the plurality of plastic packages comprises an air cavity in which at least a portion of a respective one of the plurality of slugs and at least a portion of a respective one of the plurality of conductive leads is exposed.

10. The method according to claim 9 , wherein fastening the plurality of slugs to the leadframe comprises inserting a plurality of fasteners through the plurality of downset facets of the leadframe and into the plurality of slugs.

11. The method according to claim 9 , wherein:

each of the plurality of slugs includes at least one interlocking edge; and

forming the plurality of plastic packages comprises injecting plastic into a mold and around the at least one interlocking edge of each of the plurality of slugs.

12. The method according to claim 11 , further comprising:

placing at least one electrical component within the air cavity of each of the plurality of plastic packages; and

wire-bonding the at least one electrical component within the air cavity of each of the plurality of plastic packages to at least one of the plurality of conductive leads.

13. The method according to claim 12 , further comprising enclosing the air cavity of each of the plurality of plastic packages with a cover.

14. The method according to claim 12 , further comprising separating at least one of the plurality of plastic packages from the leadframe.

15. A method, comprising:

forming a leadframe from a strip conductive material, the leadframe including a conductive lead and a downset facet;

forming a slug from conductive material;

inserting a fastener through the downset facet of the leadframe and into the slug to fasten the slug to the leadframe;

positioning the leadframe, with the slug fastened to the leadframe, into a mold; and

forming a plastic package around the leadframe, the downset facet, and the slug, wherein the plastic package comprises an air cavity in which at least a portion of the slug and at least a portion of the conductive lead is exposed.

16. The method according to claim 15 , wherein:

the slug includes at least one interlocking edge; and

forming the plastic package comprises injecting plastic into a mold and around the at least one interlocking edge of the slug.

17. The method according to claim 15 , further comprising:

placing at least one electrical component within the air cavity of the plastic package; and

wire-bonding the at least one electrical component to the conductive lead within the air cavity.

18. The method according to claim 17 , further comprising enclosing the air cavity of the plastic package with a cover.

19. The method according to claim 17 , further comprising separating the plastic package from the leadframe.

20. The method according to claim 1 , wherein each of the plurality of plastic packages comprises a first platform level within the air cavity at which the respective one of the plurality of conductive leads is exposed and a second platform level within the air cavity for enclosing the air cavity with a cover.