Edge-Protected Glass Core Structure for Crack-Resistant Packaging
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Solution Overview
Problem
The fabrication of glass core substrates for integrated circuit packages is challenging due to the fragile nature of glass, which can lead to damage and defects such as cracking and delamination during manufacturing processes, especially when stresses are introduced during patterning and singulation.
Innovation Solution
The use of a multi-layer glass core with protective layers and dielectric materials between glass layers, along with a multi-layer fill method for forming through-glass vias, reduces stress and damage by providing mechanical support and edge protection, allowing for higher aspect ratio vias and improved signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass core substrates are used for integrated circuit packages, then signal integrity is improved, but the fragile nature of glass leads to damage and defects during manufacturing processes
Solution Approach 1:
A protective layer is formed over the glass core substrate before subsequent manufacturing steps. This protective layer acts as a cushion that prevents stress-induced cracking and damage during patterning, singulation, and other fabrication processes, while still allowing the glass core to provide its signal integrity benefits
Solution Approach 2:
The substrate structure combines glass core material with a protective layer material to create a composite structure. The glass core provides signal integrity and mechanical support, while the protective layer provides damage resistance and stress relief, creating a composite material system that exhibits both properties simultaneously
2Ease of manufacture
If stress is introduced during patterning and singulation processes, then manufacturing is enabled, but glass cracking and delamination occur
Solution Approach 1:
The protective layer is formed beforehand to cushion the glass core during stress-intensive operations like patterning and singulation. This layer absorbs and distributes mechanical stresses, preventing stress concentration that would cause cracking or delamination, thereby enabling standard manufacturing processes without compromising glass integrity
Solution Approach 2:
The protective layer serves as an intermediary between the glass core and the external mechanical stresses applied during manufacturing. It mediates the stress transmission, protecting the glass core from direct exposure to damaging forces while still allowing the manufacturing processes to proceed
Data Source
AI summary
Methods and apparatus for edge protected glass cores are disclosed herein. An example package substrate includes a first glass layer including a first surface, a second surface opposite the first surface, and first lateral surfaces extending between the first and second surfaces, the first glass layer having a first via extending between the first surface and the second surface; and a dielectric material in contact with the first surface of the first glass layer and in contact with the first lateral surfaces of the first glass layer.