Layered Glass Core Substrate Structure for Crack Propagation Resistance
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Solution Overview
Problem
Current glass core substrates, composed of glass fiber and epoxy resin, fail to meet increasing reliability requirements due to insufficient crack propagation inhibition.
Innovation Solution
A glass core substrate design featuring a first and second glass layer bonded by a conductive connector, with the bonding layer acting as a crack-stopping structure to inhibit crack propagation, providing a vertical conductive path and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fiber and epoxy resin materials are used for glass core substrate, then the substrate can be manufactured with basic structural integrity, but the reliability of the substrate is insufficient
Solution Approach 1:
The glass core substrate is divided into multiple glass layers (first glass layer, second glass layer, third glass layer) bonded together with bonding layers in between. This segmentation allows each layer to independently resist crack propagation, and the bonding layers act as crack-stopping structures that prevent cracks from propagating across the entire substrate, thereby improving reliability without requiring a complete redesign of the substrate structure
Solution Approach 2:
The substrate combines multiple materials including glass layers, bonding layers (comprising organic resin and inorganic filler), and conductive connectors. This composite structure leverages the strengths of each material: glass provides structural integrity and crack resistance, bonding layers provide adhesion and crack-stopping functionality, and conductive connectors provide electrical connectivity while maintaining structural continuity
2Reliability
If a single-layer glass structure is used, then the manufacturing process is simple, but cracks can rapidly propagate from the edge to the center of the substrate
Solution Approach 1:
The substrate is segmented into multiple glass layers separated by bonding layers. This segmentation creates multiple interfaces that act as barriers to crack propagation. When a crack encounters a bonding layer, its propagation is stopped or deflected, preventing rapid crack spread from the edge to the center of the substrate. The segmentation is achieved through a manufacturable process involving layer-by-layer assembly and bonding
Solution Approach 2:
The bonding layers serve as intermediary structures between the glass layers. These bonding layers comprise organic resin and inorganic filler, creating an intermediate material that bonds the glass layers together while simultaneously acting as a crack-stopping structure. The intermediary bonding layer absorbs and dissipates crack energy, preventing cracks from propagating through the entire substrate
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 design effectively reduces the rapid propagation of brittle cracks from the edge to the center of the substrate, enhancing the reliability of subsequent products by using the bonding layer as a crack-stopping structure.
Implementation Method 1
The first bonding layer bonds the first glass layer and the second glass layer
Implementation Method 2
The conductive connector is configured to provide a vertical conductive path to the glass core substrate
Data Source
AI summary
A glass core substrate includes a first glass layer, a second glass layer, a first bonding layer, and a conductive connector. The second glass layer is disposed on the first glass layer. The first bonding layer bonds the first glass layer and the second glass layer. The conductive connector passes through the first glass layer, the first bonding layer, and the second glass layer. The conductive connector is configured to provide a vertical conductive path to the glass core substrate. A manufacturing method of the glass core substrate is also provided.