Glass Core Hybrid Panel Structure for Crack-Resistant Packaging

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Solution Overview

Problem

The transition from fiberglass resin cores to glass cores in package substrates is hindered by the fragility of glass, which leads to cracking, chipping, and breaking during handling, and insufficient adhesion between glass and organic materials results in cracking, debonding, and material waste during the reconstitution process.

Innovation Solution

A hybrid panel is formed by reconstituting a glass core with a frame, enhancing adhesion through increased surface area contact and interlocking features, using laser etching and mechanical grinding to pattern protrusions and cavities, and incorporating dielectric and metal materials to improve handling and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If glass core panels are used to enable larger package substrate sizes and smaller feature sizes, then substrate size scalability and feature size reduction are improved, but handling difficulty increases due to glass fragility causing cracking, chipping, and breaking

Engineering Contradiction:

Improvesubstrate size scalabilityVSAvoidhandling ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The glass core panel is divided into multiple smaller glass core subpanels, each manageable in size. These subpanels are then assembled into a larger hybrid panel configuration, enabling scalable substrate sizes while maintaining handling ease for individual components during manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a hybrid panel by bonding glass core subpanels to a carrier panel using adhesive materials. This composite structure combines the advantages of glass (small feature size capability, substrate scalability) with the handling advantages of the carrier panel, reducing fragility issues during manufacturing.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If glass core panels are used for manufacturing, then feature size scaling below 5 μm is improved, but manufacturing precision deteriorates due to cracking and chipping during handling

Engineering Contradiction:

Improvefeature size precisionVSAvoidpanel integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

By segmenting the large glass core into smaller manageable subpanels, each subpanel can be processed with high precision for small feature sizes while maintaining structural integrity. The segmentation reduces the risk of cracking across large panels during precision manufacturing operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The carrier panel and adhesive bonding provide beforehand cushioning and support to the glass core subpanels during manufacturing processes. This protective structure prevents cracking and chipping before they can occur, ensuring panel integrity is maintained throughout precision manufacturing operations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If glass core panels are reconstituted with organic materials, then adhesion is improved through increased surface area contact, but reliability worsens due to insufficient adhesion causing cracking and debonding

Engineering Contradiction:

Improvereconstitution processabilityVSAvoidadhesion strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Segmenting the glass core into subpanels increases the total surface area available for adhesive bonding to the carrier panel. This enhanced surface area contact improves adhesion strength and reduces the risk of debonding during the reconstitution process and subsequent manufacturing operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a composite material system consisting of glass core subpanels, adhesive materials, and carrier panel. This multi-material composite structure is specifically designed to achieve strong adhesion between dissimilar materials, preventing cracking and debonding while enabling effective reconstitution and manufacturing processes.

Inventive Principle:

Principle #40Composite materials

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 solution provides improved handling characteristics, reduces material waste, and ensures robust adhesion, preventing cracking and debonding, thereby facilitating the use of specialized tooling designed for large CCL panels in glass cored substrate manufacturing.

Implementation Method 1

using laser etching and mechanical grinding to pattern protrusions and cavities

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

using laser etching and mechanical grinding to pattern protrusions and cavities

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS20260005078A1Fabricating integrated circuit packages with glass core hybrid panels

Publication Date: 2026.01.01 INTEL CORP

AI summary

An apparatus comprises a glass core comprising a top surface and a bottom surface opposite the top surface. A plurality of vias extending between the top and bottom surfaces. A metallization layer is over at least a portion of the top surface. An edge is between the top and bottom surfaces. The edge comprises one or more protrusions or one or more cavities. Each of the protrusions or cavities comprises a first surface parallel to the top surface, a second surface non-parallel to the top surface, and a polymer or a metal on the first or second surface.