Edge-Protected RDL Interposer Assembly Against Warpage and Delamination

The patent applies different material properties to different regions of the RDL interposer structure. Specifically, the interposer uses a core substrate material with certain thermal expansion properties, while the edge protection layer uses a different material composition that provides enhanced mechanical support and different thermal characteristics. This local differentiation of material properties allows the structure to maintain low height while resisting warpage and delamination through the edge-protected regions.

The patent implements edge protection layers that extend beyond the functional boundaries of the RDL interposer before final assembly completion. These protection layers are applied in advance to cover and shield vulnerable edge regions during manufacturing and handling processes. The protection layers act as a first line of defense against environmental impurities and mechanical damage, allowing the compact RDL interposer structure to maintain its height-reducing benefits while gaining enhanced protection.

The patent employs a composite material structure for the RDL interposer, combining multiple materials with complementary properties. The core substrate provides mechanical support, while the added functional layers contribute to operational capacity. The edge protection layers use materials specifically selected to provide thermal expansion compensation and mechanical reinforcement. This composite construction allows the interposer to accommodate multiple functional layers for increased operational capacity while the edge-protected composite structure resists warpage and delamination.