Diamond-Like Die Coating for Moisture-Resistant Device Reliability

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Solution Overview

Problem

Current die-coat materials provide limited performance benefits, particularly in withstanding high-humidity and high-temperature conditions, leading to issues like metal corrosion, ion migration, and interfacial delamination in electronic devices during accelerated reliability tests.

Innovation Solution

A diamond-like carbon (DLC) or diamond-like nanocomposite (DLN) material coating is applied to device parts, offering superior moisture and humidity barrier properties, enhanced thermal stability, and reduced friction, which can be tuned for specific properties like coefficient of thermal expansion to improve device reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional die-coat materials are used, then manufacturing cost is controlled, but device reliability under high-humidity and high-temperature conditions deteriorates

Engineering Contradiction:

Improvedevice reliabilityVSAvoidmoisture diffusion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs diamond-like carbon (DLC) and diamond-like nanocomposite (DLN) materials as die-coat layers. These composite materials provide superior moisture barrier properties and thermal stability compared to conventional die-coat materials, directly addressing the moisture diffusion issue while maintaining device reliability under harsh conditions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the die-coat material parameters by using DLC and DLN materials with specific properties including low water vapor transmission rates, adjustable coefficients of thermal expansion, and high thermal stability. These parameter changes enable the die-coat to effectively block moisture diffusion while adapting to thermal cycling conditions.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional die-coat materials are used, then material cost is reduced, but protection against metal corrosion and ion migration deteriorates

Engineering Contradiction:

Improvedevice reliabilityVSAvoidmetal corrosion

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The DLC and DLN die-coat materials form a protective barrier that prevents metal corrosion and ion migration. The dense structure and chemical stability of these composite materials provide superior protection compared to conventional die-coat materials, eliminating the harmful effects of corrosion and ion migration.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The diamond-like carbon and nanocomposite materials create an inert protective environment around the device components. This inert barrier prevents reactive interactions between moisture and metal components, thereby preventing corrosion and ion migration while maintaining device reliability.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Reliability

If conventional die-coat materials are used, then manufacturing simplicity is maintained, but resistance to interfacial delamination deteriorates

Engineering Contradiction:

Improvedevice reliabilityVSAvoidinterfacial strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The DLC and DLN materials provide enhanced interfacial strength through their adherent coating structure. These composite materials form strong bonds at interfaces while maintaining flexibility to accommodate thermal expansion differences, preventing delamination under thermal cycling conditions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent addresses thermal expansion mismatches by using DLC/DLN materials with adjustable coefficients of thermal expansion. This allows the die-coat to accommodate thermal cycling stresses without generating excessive interfacial stress, thereby preventing delamination while maintaining manufacturing simplicity.

Inventive Principle:

Principle #37Thermal expansion

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

The DLC or DLN coatings significantly reduce moisture diffusion, mitigate degradation mechanisms, and enhance mechanical and interfacial performance, improving device reliability under harsh conditions such as THB and H3TRB tests, while also addressing thermal cycling and ionic impurity migration.

Implementation Method 1

The DLC or DLN coatings significantly reduce moisture diffusion

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Implementation Method 2

enhanced thermal stability

Methodology Applied

Scientific EffectThermal stability:

Implementation Method 3

addressing thermal cycling

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS20240321659A1Die-coat material configured to enhance device reliability and devices and processes implementing the same

Publication Date: 2024.09.26 WOLFSPEED INC

AI summary

A device includes device parts, a diamond-like based material coating arranged on one or more of the device parts. Additionally, the diamond-like based material coating may include at least one of a diamond-like carbon (DLC) material and/or a diamond-like nanocomposite (DLN) material.