Component Carrier Cavity Geometry for Uniform Insulating Coating
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Solution Overview
Problem
Manufacturing component carriers with precise and uniform cavity dimensions is challenging due to the non-constant thickness of electrically insulating coating material on sidewalls, leading to variations in the final profile of the cavity.
Innovation Solution
A component carrier design with a change in cavity width at an intermediate portion of the sidewall, compensated by a recess or gradient change, ensures precise and homogeneous application of the electrically insulating coating material, maintaining consistent thickness and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrically insulating coating material is applied to a component carrier with a cavity, then electrical insulation is improved, but manufacturing precision of the cavity dimensions deteriorates due to non-constant coating thickness on sidewalls
Solution Approach 1:
The cavity sidewalls are designed with different properties at different locations: the intermediate portion has a larger radius of curvature compared to the end portions. This local geometric variation ensures that the coating material forms a uniform thickness layer across the entire sidewall, compensating for the naturally non-constant coating distribution. The local quality change in sidewall geometry directly addresses the coating thickness variation problem while maintaining electrical insulation reliability.
2Manufacturing precision
If the cavity width is reduced to improve precision, then manufacturing precision is improved, but the complexity of manufacturing increases due to difficulty in achieving uniform coating
Solution Approach 1:
The cavity geometry is pre-designed with an intermediate portion having a larger radius of curvature before the coating application process. This preliminary geometric preparation ensures that when the coating material is applied, it naturally forms a uniform thickness layer without requiring complex coating process control. The pre-adjusted geometry simplifies the subsequent coating operation while achieving the desired precision.
3Reliability
If the cavity dimensions are manufactured with high precision and little variation, then component integration reliability is improved, but the difficulty of detecting and measuring increases due to tight tolerances
Solution Approach 1:
The cavity sidewalls incorporate an intermediate portion with a distinct geometric feature (larger radius of curvature) that creates a more favorable surface for coating uniformity. This local geometric modification results in a final cavity with consistent dimensions and reduced variation, making the cavity easier to manufacture within tight tolerances while improving component integration reliability. The geometric feature acts as a built-in reference that simplifies quality verification.
Data Source
AI summary
A component carrier includes a stack with at least one electrically conductive layer structure and at least one electrically insulating layer structure; a through cavity extending vertically through the stack delimited by sidewalls; and an electrically insulating coating material covering part of both opposing main surfaces of the stack and at least part of the sidewalls of the through cavity of the stack. Along at least one main planar direction of the cavity a change of the cavity width is provided at an intermediate portion of at least one sidewall with respect to the, preferably straight, remaining extension of the respective sidewall. There is also described a method of manufacturing a component carrier.