STABLCOR Technology for Printed Circuit Board and Substrate

Transcription

1 STABLCOR Inc STABLCOR Technology for Printed Circuit Board and Substrate 1

2 Outline Electronics Challenges Today s Material and it s limitations Need for High Performance Material and Test data How to use STABLCOR in a PCB Benefits of STABLCOR in a PCB Supply Chain Case Study Design Guidelines Conclusion 2

3 Challenges of the Electronics The electronics Industry today is facing challenges such as HOT SPOT CTE mismatch, solder joint stress, thermal fatigue failure shock and vibration issues, SMALLER, FASTER, STRONGER 3

4 PCB material & It s limitations (Dielectric) DIELECTRIC MATERIAL Thermal Conductivity (W/m.K) IN-PLANE CTE (ppm/c) Tensile Modulus (Msi) Density (g/cc) FR-4/E-glass 0.3 to to to Polyimide/E-glass 0.2 to to to Aramid/Epoxy 0.2 to to 12 2 to PTFE Ceramic (RO3000) 0.5 to Non-PTFE Ceramic (R4000) 0.6 to to to

5 Current Material & It s limitations ELECTRICAL Property- Very Good THERMAL Property Poor MECHANICAL Property Poor Rigidity Co-efficient of Thermal Expansion (CTE) 5

6 Thermal & Thermo-mechanical material STABLCOR Material is used today in Printed Circuit Boards and Substrate to address THERMAL & MECHANICAL issues 6

7 What is STABLCOR Material? It is a Carbon Composite Laminate A thermally & Electrically Conductive Composite Material It has very good In-plane Thermal Conductivity It has low In-plane CTE (3-6 ppm/c) It can be used as a plane layer, Preferably GND plane Copper Copper Carbon Composite core C C L 7

8 STABLCOR material part number system Product Name ST10-EP387 ST10-LC909 ST325-EP387* Core Thickness (114um), (152um), (229um), (457um) (229um) (203um) Copper Thickness (oz) H/H, 1/1 H/H, 1/1 H/H, 1/1 Part Number System: ST325-EP H/H STABLCOR type Resin type Core thickness Copper thickness EP387 = EPOXY Grade STABLCOR LC909 = POLYIMIDE Grade STABLCOR *ST325 Material subject to have MICROCRACKS 8

9 STABLCOR Material - Part Number List Products Part Number Copper Weight Overall Thickness Inch (mm) Tg Epoxy STABLCOR Products ST10 ST10-EP H/H 1/2 oz over 1/2 oz " (0.150) 170 C ST10-EP /1 1oz over 1oz " (0.185) 170 C ST10-EP H/H 1/2 oz over 1/2 oz " (0.188) 170 C ST10-EP /1 1oz over 1oz " (0.224) 170 C ST10-EP H/H 1/2 oz over 1/2 oz " (0.264) 170 C ST10-EP /1 1oz over 1oz " (0.300) 170 C ST10-EP H/H 1/2 oz over 1/2 oz " (0.493) 170 C ST325* ST325-EP H/H 1/2 oz over 1/2 oz " (0.239) 170 C ST325-EP /1 1oz over 1oz " (0.274) 170 C Polyimide STABLCOR Products ST10 ST10-LC H/H 1/2 oz over 1/2 oz " (0.264) 240 C ST10-LC /1 1oz over 1oz " (0.300) 240 C *ST325 Material subject to have MICROCRACKS 9

10 STABLCOR Material COPPER CLAD CARBON COMPOSITE (STABLCOR ) Thermal, Low CTE, Stiff and Light Weight Material E.CONDUCTIVE MATERIAL FR-4/E-glass Polyimide/E-glass Thermal Conductivity (W/m.K) 0.3 to to 0.4 CTE (ppm/c) 16 to to 19 Tensile Modulus (Msi) 3.5 to to 4.5 Density (g/cc) Copper to CIC (Copper-Invar-Copper) to Stablcor Laminate-Unclad (X & Y) ST10~ 2* ST325~82* ST10~4.5to6 ST325~1to3 ST10~ 9 ST325~ to 1.65 STABLCOR Laminate-with 1oz Cu clad (X & Y) ST10~ 75* ST325~175* ST10~5to7 ST325~2to4 ST10~ 10 ST325~ to 1.7 * Theoretical calculated In-Plane values based on volume & Thermal conductivity of the composite materials 10

11 In-Plane CTE CTE STABLCOR Material CTE vs Temperature Material: ST325-EP450 Unclad CTE (ppm/c) DIELECTRIC MATERIAL FR-4 / E-glass Polyimide/E-glass In Plane CTE (ppm/c) 16 to to 19 Temperature (C) Non Woven Aramid/Epoxy 9 to 12 X1 Direction X2 Direction Linear (X2 Direction) Linear (X1 Direction) Composite CTE (0-3 ppm) over Temp. range of -50C to +130C PTFE Ceramic (RO3000) Non-PTFE Ceramic (RO4000) to 16 11

12 Through Plane CTE CTE STABLCOR Material Sample: Tg and CTE test for CCL Size: mm Method: Ramp P/N: ST325-EP450 TMA File: C:\TA\Data\TMA\Stablcor substrate.008 Operator: BP Run Date: 12-Sep :38 Instrument: TMA Q400 V7.1 Build C Alpha=102µm/(m C) Run number 1 2 Z-CTE before Tg (ppm/ o C) Tg ( C) Dimension Change (mm) C Alpha=42.1µm/(m C) Tg C DIELECTRIC MATERIAL FR-4/E-glass Polyimide/E-glass Through Plane CTE (ppm/c) 55 to to Non Woven Aramid/Epoxy 110 to Temperature ( C) Universal V4.2E TA Instruments Z-axis CTE measurement by TMA method PTFE Ceramic (RO3000) Non-PTFE Ceramic (RO4000) 25 to to 55 12

13 How is STABLCOR used in a PCB? (<0.035 ) PCB/Substrate (<0.093 ) PCB (>0.093 ) PCB FR-4 FR-4 L1 L2/3 L4/5 STABLCOR FR-4 L1 L2* L3/4 FR-4 L1/2 STABLCOR FR-4 L3* L4/5 STABLCOR GND FR-4 L5/6 STABLCOR NF FR-4 L6/7 FR-4 L7/8 FR-4 L6/7 FR-4 L8/9 L10 STABLCOR L9* L10 STABLCOR FR-4 L8* L9/10 1-CORE 2-CORE 3-CORE 13

14 CROSS SECTIONS 3-layer PCB 6-layer PCB 12-layer PCB 1-CORE 2-CORE 4-CORE 14

15 The Benefits Of STABLCOR in a PCB / Substrate Thermal CTE (Co-efficient of Thermal Expansion) Rigidity / Stiffness Density / Weight 15

16 CARBON IN A PCB Thermal / HEAT 16

17 PCB Thermal Path - Schematic PCB Mounting Screw Heat source PCB Mounting Screw STABLCOR Chassis Ground Via Thermal Via Isolated via on Ground layer 17

18 VME - Wedge Lock MILLING STEP Wedge Lock Cu Edge Plating Ground Pin Ground Via Thermal Via Isolated via on Ground layer Wedge Lock Heat source Thermal Via STABLCOR HIGH LAYER VME CARD 18

19 THERMAL PATH 19

20 PCB acts as HEAT SPREADER STABLCOR PCB FR4 PCB STABLCOR PCB FR4 PCB 20

21 THERMAL PRODUCT LEVEL *>124.9 F NATURAL CONVECTION 40Watt FR4 PCB 1G module STABLCOR PCB 1G module *<68.0 F STABLCOR ST325+FR4 FR4 PCB 21

22 THERMAL SIMULATION SOFTWARE STABLCOR material is listed in these software library 1. Ansys Inc. (TAS PCB Software) David Rosato Ph: (978) Canonsburg, PA Flomerics (Flotherm Software) Sherman Ikemoto Ph: (512) x 203 Sherman.Ikemoto@flowmerics.com Vista, California Fluent Inc. (Icepak Software) Dan Scharpf Ph: (603) x 617 dfs@fluent.com New Hampshire

23 CARBON IN A PCB Co-efficient of Thermal Expansion 23

24 CTE Associated with Package Type IC PACKAGE TYPE Organic Packages (CTE: 16-19ppm/C) Ceramic Packages (CTE: 6-8ppm/C) Flip Chip, DDA, WLP (2-4ppm/C) 24

25 CTE STABLCOR Material Sample ST10-EP /0 CTE, α x (x / o C) 4.88 CTE, α y (x / o C) 6.28 ST10-EP / ST325-EP / ST325-EP /

26 CTE STABLCOR PCB Layer, 80mil Thick, FR4+Stablcor PCB Temperature Dependent Coefficient of Thermal Expansion xxxxxx Board: EP3900B-A1 (STABLCOR+ FR4) α X1 = T T 2 α X2 = T T 2 CTE (ppm / o C) X1 direction X2 direction Layer, 80mil Thick, FR4+Stablcor PCB Temperature ( o C) 10.9 to 12.4ppm/C 26

27 CARBON IN A PCB RIGIDITY / STIFFNESS 27

28 Rigidity / Stiffness Rigidity of STABLCOR PCB v/s FR4 PCB at Room Temp Printed Wiring Board Bend Data Maximum Force at 15mm Deflection Applied force (N) Displacement (mm) Sample 1 (FR4) Sample 2 (FR4) Sample 3 (FR4 + STABLCOR) Sample 4 (FR4 + STABLCOR) Sample 5 (FR4 + STABLCOR) Sample 6 (FR4 + STABLCOR) Sample 7 (FR4 + STABLCOR) Maximum Applied Force (N) Sample 1 (FR4) Sample 2 (FR4) Sample 3 (FR4 + STABLCOR) Sample 4 (FR4 + STABLCOR) Sample Identification Sample 5 (FR4 + STABLCOR) Sample 6 (FR4 + STABLCOR) Sample 7 (FR4 + STABLCOR) This result shows the STABLCOR samples to be ~ 66.6% stiffer than the FR4 test samples 28

29 Rigidity / Stiffness Bend Test Over Temperature Range (40 o C to 250 o C) Sample: PCB Size: mm Method: Force Ramp Comment: Bend Test at various temperatures TMA File: C:\TA\Data\TMA\3 pt bend VLP FR4.003 Operator: BP Run Date: 07-Sep :19 Instrument: TMA Q400 V7.1 Build 89 Sample: PCB Size: mm Method: Force Ramp Comment: Bend Test at various temperatures TMA File: C:...\TMA\3 pt bend VLP Stablcor.002 Operator: BP Run Date: 06-Sep :55 Instrument: TMA Q400 V7.1 Build FR STABLCOR+FR4 Dimension Change (mm) Dimension Change (mm) Temperature ( C) Universal V4.2E TA Instruments Temperature ( C) Universal V4.2E TA Instruments Length of vertical lines represent the amount of Deflection 29

30 Rigidity / Stiffness Rigidity of thick STABLCOR PCB ( ) Bend Data Bend Data Samp le Num ber Sample Identification Maximum force at 6mm (N) Stiffness Improveme nt over Sample 5 Applied Force (N) Maximum 6mm Deflection ST10 board 1 ST10 board 2 ST325 board 1 ST325 board 2 Polyimide board Sample Identification ST10 board 1 ST10 board 2 ST325 board 1 ST325 board 2 Polyimide board ST10 board 1 ST10 board 2 ST325 board % 265.7% 423.5% ST325 board % Displacement (mm) 5 Polyimide board ST10 STABLCOR samples are ~ 275% stiffer than the Polyimide test samples ST325- STABLCOR samples are ~ 450% stiffer than the Polyimide test samples 30

31 WEIGHT Material (Laminate) FR4 Polyimide STABLCOR (w/o Cu) Aluminum Copper Copper Invar Copper Density gm/cm

32 Current Supply Chain Factory: Millbury, Massachusetts, USA Lewcott / Carbon Core Laminates (STABLCOR material manufacturer / Distributor) Qualified PCB Manufacturer Dynamic Details Inc ** ELTEK - Israel Hunter Technologies ** CIREP Group France North Texas Circuit Board ** Stevenage Circuit - UK Murrietta Circuits ** Graphic PLC - UK Winonics ** Streamline Circuits- USA Cosmotronic ** Photochemie -Switzerland Cirtech ** Elvia PCB Group - France Unicircuit Harbor Electronics / ECT TTM Technologies Stafford & Chippewa Falls Plants 54,000 sq.ft facility End User / CUSTOMER 32

33 CASE STUDY CASE STUDY 33

34 CASE STUDY Thermal at 40W, ST10 NATURAL CONVECTION 40Watt Customer Quote: ST10 represented a 12% to 15% temperature reduction compared to FR4 dt between ST325 and ST10 PCBs are very close to each other FR4 PCB STABLCOR ST10+FR4 40Watt, Natural Convection, STABLCOR PCB running 11.2 o C Cooler Courtesy: CONTINENTAL Automotive France SAS, Mr. Loic Bertrand 34

35 CASE STUDY Thermal at 40W, ST325 NATURAL CONVECTION 40Watt Customer Quote: STABLCOR ST325+FR4 FR4 PCB With the STABLCOR we can say that hot spots are practically eliminated ST325 represented a 15% to 20% temperature reduction compared to FR4 40Watt, Natural Convection, STABLCOR PCB running 16.4 o C Cooler Courtesy: CONTINENTAL Automotive France SAS, Mr. Loic Bertrand 35

36 CASE STUDY Thermal at 40W 6-Layer PCB, thick, ~6.0 x 6.0, ST325 at L2 &L5 Thermal Resistance (at 40Watt), Natural Convection Without plate With plate FR4 PCB Stablcor PCB (ST325) Stablcor PCB (ST10) 6.7 o C/W 4.5 o C/W 4.8 o C/W 4.7 o C/W 2.5 o C/W Not Tested ST325: With the STABLCOR solution thermal resistance decreased by ~30% compared to the FR4 solution ST10: With the STABLCOR solution thermal resistance decreased by ~28% compared to the FR4 solution Courtesy: CONTINENTAL Automotive France SAS, Mr. Loic Bertrand 36

37 CASE STUDY SBC (Single Board Computer) 37

38 CASE STUDY SBC, Thermal & CTE 38

39 CASE STUDY - THERMAL Temp Rise Above Ambient in Celsius Heat Dissipation of PWB Materials with End Clamped in Vise R Vise Resistor Pos 1 Pos 2 Pos 3 Thermocouple Position FR4 STBLCore Difference The superior thermal conductivity is evident from the reduced temperature at the resistor. The power resistor was set up to heat up to about 100 C (ambient was about 24 C during the test), which required slightly over 6W into the resistor. Keeping the resistor power constant, the STABLCOR material lowered the resistor temperature by 12.8 C. The thermal resistivity of the resistor to ambient was 12.6 C/W with the FR-4 and 10.6 C/W with the STABLCOR indicating a 2.0W or 19% improvement in power handling capability with this configuration. 39

40 CASE STUDY Solar Panel, low CTE & Rigidity MATCHED CTE Eliminates thermal induced stress on the triple junction solar cells. Initial thermal cycle testing has shown no damage to solar cells due to matching thermal expansion AUTOMATED PRODUCTION Reduces cost in large volume production compared with traditional attachment methods RUGGED The rigidity of the CCL substrates reduces costs by eliminating need for additional supports to meet shock and vibration requirements 40

41 CASE STUDY Flip Chip RELIABILITY Liquid to Liquid Thermal Shock Reliability STABLCOR With no underfill, the characteristic (63.2%) life of the FR-4/NELCO is about 20 cycles. The STABLCOR board is about 173 cycles For no underfill test, the chips on STABLCOR substrate remain attached at 353 cycles. Most of the chips detached from the other test boards at 353 cycles 41

42 CASE STUDY Ceramic BGA Reliability Thermal Cycle Reliability Thick PCB Unreliability, (% failure) FR4 PCB STABLCOR PCB Cycles (-40 to +125 C) W C W F C W F FR h/h 2ply 44N106 ST325-EP H/H 2ply 44N106 FR h/h 1ply 2313 FR h/h 1 ply 2313 FR h/h 1ply 2313 FR h/h 2ply 44N106 ST325-EP H/H 2ply 44N106 FR h/h L1 L2 L3- STABLCOR (GND plane) L4 L5 L6 L7 L8 L9 L10 L11 L12- STABLCOR (GND plane) L13 L14 The characteristic life of the CBGA on the STABLCOR PWB is roughly 2X better than on the regular PWB 42

43 Case Study Thermount vs. Stablcor PCB CTE 14-Layer, 80mil Thick, 85NT Thermount PCB 14-Layer, 80mil Thick, FR4+Stablcor PCB 43

44 Case Study Thermount vs. Stablcor PCB CTE Layer, 80mil Thick, 85NT Thermount PCB Temperature Dependent Coefficient of Thermal Expansion xxxxxxx Board: EP3900B-C1 (Thermount) α X1 = T T 2 α X2 = T T Layer, 80mil Thick, FR4+Stablcor PCB Temperature Dependent Coefficient of Thermal Expansion xxxxxx Board: EP3900B-A1 (STABLCOR+ FR4) α X1 = T T 2 α X2 = T T 2 CTE (ppm / o C) CTE (ppm / o C) X1 direction X2 direction 4 2 X1 direction X2 direction Temperature ( o C) Temperature ( o C) 10.3 to 12.1ppm/C 10.9 to 12.4ppm/C 44

45 CASE STUDY 45 Technology Presentation JPL Study for Multifunctional Spacecraft Structure

46 DESIGN GUIDELINES DESIGN GUIDELINES 46

47 DESIGN GUIDELINES STABLCOR Laminate is an Electrically Conductive Material 47

48 DESIGN GUIDELINES Thus,.. It is used as a PLANE layer, preferably GROUND plane layer within a multilayer PCB 48

49 BEST WAY TO USE STABLCOR? USE AS A GROUND PLANE USE ALL STABLCOR LAYERS AS SAME GROUND DO NOT USE AS SPLIT GROUND PLANE DO NOT USE AS A POWER PLANE DO NOT USE AS A MIX PLANE LAYER 49

50 OPTIMIZE CLEARANCE PAD SIZES ON GND Plane Plated Through Hole (PTH) pattern Rule to optimize anti-pad size: PTH size + 20mil (minimum) PTH size + 28mil (maximum) ** stay towards minimum side Anti-pad size TOO BIG Optimized Anti-pad sizes DESIGNER MUST OPTIMIZE ANTI-PAD SIZES ON A STABLCOR GROUND PLANE DATA 50

51 STABLCOR must be symmetrical in a stack-up FR-4 FR-4 STABLCOR FR-4 FR-4 L1 L2/3 L4/5 GND L6/7 L8/9 L10 STABLCOR FR-4 FR-4 FR-4 STABLCOR 1-CORE 2-CORE 3-CORE L1 L2* L3/4 L5/6 L7/8 L9* L10 FR-4 L1/2 STABLCOR FR-4 STABLCOR FR-4 STABLCOR FR-4 L3* L4/5 NF L6/7 L8* L9/10 STABLCOR LAYERS MUST BE PLACED SYMMETRICALLY ALONG THE THICKNESS OF A PCB 51

52 Proposed stack-up to Optimize RIGIDITY Benefit Non-Optimized Stack-up for Rigidity FR-4 FR-4 STABLCOR 9to18mil core FR-4 FR-4 STABLCOR along the Neutral Axis L1 L2/3 L4/5 GND L6/7 L8/9 L10 Optimized Stack-up for Rigidity Principle: Use STABLCOR layers away from Neutral Axis Two thin STABLCOR layers as arranged below would give higher stiffness than single thick core in a center L1 STABLCOR 4.5 to 9mil core L2 Gnd FR-4 L3/4 FR-4 L5/6 FR-4 L7/8 STABLCOR 4.5 to 9mil core L9 Gnd L10 STABLCOR near the surface and away from the Neutral Axis 52

53 Do s & Don ts Do s and Don ts 53

54 Do s & Don t Don t Do s Thick Dielectric Core STABLCOR L1 L2 L3 L4 GND STABLCOR Thick Dielectric Core L1 L2 GND L3 L4 STABLCOR NF STABLCOR NF STABLCOR Thick Dielectric Core L5 GND L6 L7 L8 Thick Dielectric Core STABLCOR L5 L6 L7 GND L8 DISTRIBUTE THE STABLCOR MATERIAL ACROSS THE THICKNESS OF A PCB 54

55 Do s & Don t Don t Do s L1 3ply 106 min. 8mil STABLCOR L2 GND 16mil STABLCOR L3 GND 3ply 106 min. 8mil STABLCOR Dielectric Core L4 Dielectric Core L5 Dielectric Core L6 Dielectric Core L7 Dielectric Core 8mil STABLCOR L8 GND 3ply 106 min. 8mil STABLCOR L9 GND 16mil STABLCOR L10 3ply 106 min. USE THICK CORE INSTEAD OF USING TWO THIN CORE NEXT TO EACH OTHER L1 L2 GND L3 L4 L5 L6 L7 L8 L9 GND L10 55

56 Do s & Don t Don ts SINGLE CORE, SINGLE PLY STACK-UP Do s SINGLE CORE, DOUBLE PLY STACK-UP Top to Top NF, STABLCOR (CTE control layer) Bottom NF, STABLCOR (CTE control layer) Bottom DOUBLE PLY, UNCLAD, STABLCOR LAMINATE SINGLE PLY, UNCLAD, STABLCOR LAMINATE Single ply Stablcor in a Single Core, Thin PCB stack-up will cause warpage. That is why it is recommended to use Double ply Stablcor in a Single Core, thin PCB Top NF, STABLCOR (CTE control layer) DOUBLE PLY, Copper CLAD, STABLCOR LAMINATE DO NOT USE SINGLE PLY STABLCOR IF THERE IS ONLY ONE CORE STACK-UP Bottom 56

57 LIMITATIONS IT IS NOT A DIELECTRIC MATERIAL IN SOME CASES IT CAN INCREASE FINISH PCB THICKNESS STABLCOR CORE WILL BE EXPOSED AROUND THE PERIMETER OF THE FINISHED PCB AVAILABLE FROM AUTHORIZED MANUFACTURERS ONLY IT IS NOT RECOMMENDED TO USE HOT AIR SOLDER LEVEL (HASL) SURFACE FINISH FOR ST325 PRODUCTS 57

58 CONCLUSION Operates Cooler Reduces Hot Spot PCB acts as a Heat Sink Reduces Thermal Stress on Components Matches CTE Attach Ceramic packages more reliably Attach Flip Chip more reliably Stiffness Prevents Warpage Increased Yields for Component Placement All above benefits at almost no weight premium Benefits for lead free PCBA processing lower reflow oven temperatures 58

59 STABLCOR Inc For more info 59