Asymmetric Paste Via Structure for Reliable Component Carriers
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Solution Overview
Problem
The challenge of efficiently interconnecting multiple layers of component carriers with small spacing between contacts while ensuring mechanical robustness and electrical reliability, particularly in harsh conditions, is not adequately addressed by existing technologies.
Innovation Solution
A component carrier design featuring a stack with electrically insulating and conductive layer structures, utilizing an electrically conductive paste within a cavity that misaligns its vertical extremities to distribute mechanical tension, ensuring reliable electrical and mechanical connections through deformation and compression during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional paste interconnection methods are used between layers, then electrical connection is achieved, but mechanical robustness and electrical reliability are insufficient under harsh conditions
Solution Approach 1:
The conductive element is designed with asymmetric geometry where the first end has a larger cross-sectional area than the second end. This asymmetric design allows the conductive element to distribute mechanical tension asymmetrically, with the larger first end bearing more load, thereby improving both mechanical robustness and electrical reliability under harsh conditions while maintaining effective paste interconnection between layers.
2Productivity
If contact spacing is reduced to accommodate more components, then component density increases, but heat dissipation becomes more difficult
Solution Approach 1:
The conductive element employs local quality variation through its asymmetric cross-sectional design, where the first end has a larger area optimized for electrical connection and current distribution, while the second end has a smaller area suited for precise contact alignment. This localized differentiation enables effective heat dissipation at the connection interface while maintaining small contact spacing for high component density.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves robust and reliable electrical connections by distributing mechanical tension, enhancing the durability and conductivity of the interconnections between layers, even under stress, thus supporting efficient heat dissipation and electrical signal transmission.
Implementation Method 1
the center of gravity of one vertical extremity of the at least one electrically conductive element is misaligned with respect to the center of gravity of the opposed other vertical extremity
Implementation Method 2
enhancing the durability and conductivity of the interconnections between layers, even under stress
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5b
AI summary
The present invention relates to a component carrier (100, 200, 300, 400) a method for manufacturing thereof, wherein the component carrier (100, 200, 300, 400) comprises a stack (101) comprising at least one electrically insulating layer structure (30) and at least two electrically conductive layer structures (10, 20), at least one electrically conductive element (40), said at least one electrically conductive element (40) passing through said at least one electrically insulating layer structure (30), preferably in stacking direction (Z). Said at least one electrically conductive element (40) comprises an electrically conductive paste (42) provided in a cavity (41) being located at least partially within the at least one electrically insulating layer structure (30), said electrically conductive paste (42) being in contact with said at least two electrically conductive layer structures (10, 20), wherein the center of gravity (91) of one vertical extremity of the at least one electrically conductive element (40) is misaligned with respect to the center of gravity (92) of the opposed other vertical extremity of said at least one electrically conductive element (40).