Metal Core Substrate Structure for Flexible Insulation Reliability
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Solution Overview
Problem
Conventional metal core printed wiring boards with glass cloth-based insulating layers have low flexibility, constraining the metal core and limiting design freedom.
Innovation Solution
A metal core substrate design featuring a polyimide insulating layer on one side and a different insulating member in through holes, made of materials like epoxy or silicone resin, with higher dielectric breakdown voltage layers covering the ends to enhance flexibility and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass cloth-based insulating layers are used in metal core printed wiring boards, then insulation reliability is improved, but flexibility deteriorates
Solution Approach 1:
The patent applies different materials with different properties to different locations: polyimide for the first insulating layer (prioritizing flexibility) and glass cloth for the second insulating layer (prioritizing insulation reliability). This local differentiation resolves the contradiction by allowing each layer to optimize for its primary function.
Solution Approach 2:
The patent uses a composite structure combining polyimide and glass cloth in different layers. The first insulating layer uses polyimide for flexibility, while the second insulating layer uses glass cloth for insulation reliability, creating a composite system that achieves both flexibility and insulation performance simultaneously.
2Reliability
If glass cloth-based insulating layers are used, then insulation performance is improved, but design freedom deteriorates
Solution Approach 1:
The patent implements local quality by assigning different materials to different insulating layers based on their specific functional requirements. The first layer uses polyimide where flexibility is needed, while the second layer uses glass cloth where insulation performance is critical, thereby achieving both insulation performance and design freedom.
Solution Approach 2:
The patent changes the material parameters of the insulating layers - using polyimide with different physical and chemical properties compared to glass cloth. This parameter variation allows optimization of both insulation performance and design freedom by selecting materials with appropriate characteristics for each layer's specific requirements.
3Ease of operation
If polyimide is used for the first insulating layer to improve flexibility, then insulation reliability may deteriorate, so a different material is used for the insulating member in through holes
Solution Approach 1:
The patent applies local quality by using polyimide specifically for the first insulating layer where flexibility is required, while using glass cloth for the second insulating layer and insulating members where insulation reliability is critical. This localized material selection resolves the contradiction by matching material properties to functional requirements in each specific location.
Solution Approach 2:
The patent employs composite materials by combining polyimide and glass cloth in different structural positions. The polyimide provides flexibility in the first layer, while glass cloth provides superior insulation in the second layer and through-hole insulating members, creating a composite system that achieves both flexibility and insulation reliability.
Data Source
AI summary
A metal core substrate includes a metal core layer, a first insulating layer, a first conductive pattern, a via, and an insulating member. The metal core layer has a through hole. The via is disposed in the through hole and connected to the first conductive pattern. The insulating member is disposed between an inner surface of the through hole and the via. The first insulating layer is made of polyimide. The insulating member is made of a material that differs from the first insulating layer.