Glass Core Hybrid Panels With Interlocking Frames for Package Substrates
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Solution Overview
Problem
The transition from copper clad laminate (CCL) cores to glass cores in package substrates is hindered by the fragility of glass, which leads to cracking, shifting, and adhesion issues during manufacturing, resulting in yield loss and material waste.
Innovation Solution
Reconstituting glass cores into hybrid panels with frames that enhance adhesion through interlocking features and surface modifications, using laser etching and mechanical grinding to form complementary shapes on glass and frame surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If glass cores are used in package substrates to enable larger sizes and smaller feature dimensions, then substrate size and feature scaling are improved, but handling and adhesion reliability deteriorate due to glass fragility causing cracking and shifting
Solution Approach 1:
The patent uses a hybrid panel structure combining glass core with CCL (copper clad laminate) border sections. This composite construction allows the substrate to leverage the advantages of both materials: glass provides the necessary thermal stability and electrical properties for the core area, while CCL provides mechanical robustness and ease of handling for the border sections. The interlocking features between glass and CCL sections create a unified structure that maintains reliability during manufacturing while enabling large substrate sizes.
2Area of stationary object
If glass cores are used to enable larger package substrate sizes, then substrate area is improved, but manufacturing precision deteriorates due to glass fragility causing cracking and damage during processing
Solution Approach 1:
The substrate is segmented into distinct glass core sections and CCL border sections, each optimized for their specific function. The glass sections can be precisely fabricated with small feature dimensions while the CCL sections provide a robust framework that maintains dimensional stability during manufacturing processes. The interlocking features ensure precise alignment between segments, preserving manufacturing precision across the entire large-area substrate.
3Length of moving object
If glass cores are used to enable smaller feature dimensions, then feature size is improved, but ease of manufacture deteriorates due to handling difficulties and adhesion issues
Solution Approach 1:
The CCL border sections act as intermediary elements that facilitate the manufacturing process. These sections provide mechanical support and ease of handling during fabrication, allowing precise features to be created on the glass core without directly manipulating the fragile glass. The interlocking features between CCL and glass create a unified structure that maintains ease of manufacture while enabling small feature dimensions on the glass portion.
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
Enhances handling and adhesion of glass cores during manufacturing, reducing damage and waste while enabling smaller feature sizes and larger substrate sizes, thus improving yield and process efficiency.
Implementation Method 1
using laser etching and mechanical grinding to form complementary shapes on glass and frame surfaces
Implementation Method 2
using laser etching and mechanical grinding to form complementary shapes on glass and frame surfaces
Data Source
Figure 1
Figure 2A~2B
Figure 3A
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.