Sacrificial Structure Dummy Core Low-Flow Material Delamination Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods of manufacturing coreless component carriers face issues with delamination and wrinkling of electrically conductive layers, leading to reliability concerns and the need for trimming after lamination, which complicates further processing.
Innovation Solution
A sacrificial structure with a dummy core covered by spatially separated sections of low-flow material is used, providing additional support and stability to prevent delamination and wrinkling of copper foils, allowing for the manufacture of coreless component carriers without trimming and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to manufacture coreless component carriers, then production can proceed with standard processes, but delamination and wrinkling of electrically conductive layers occur leading to reliability issues
Solution Approach 1:
A sacrificial structure with a dummy core and low-flow material is introduced as an intermediary carrier during the manufacturing process. This sacrificial structure provides mechanical support to prevent delamination and wrinkling of copper foils during lamination, and is subsequently removed to achieve the final coreless component carrier without compromising reliability
Solution Approach 2:
The dummy core and low-flow material are installed in advance on the sacrificial structure before lamination occurs. This preliminary action provides preemptive mechanical support and stability to prevent delamination and wrinkling during the subsequent lamination process, eliminating the need for trimming and ensuring reliability
2Manufacturing precision
If trimming is performed after lamination to remove excess material, then the component carrier dimensions are precise, but further processing is complicated and productivity decreases
Solution Approach 1:
The sacrificial structure with dummy core and low-flow material is designed to self-limit the lamination process to the required dimensions. The low-flow material prevents excess resin flow and the dummy core defines the boundary, allowing the component carrier to be formed with precise dimensions directly during lamination without requiring subsequent trimming operations
3Device complexity
If coreless component carriers are manufactured without a dummy core, then the structure is simpler and thinner, but delamination and decontamination of layers occur
Solution Approach 1:
The dummy core on the sacrificial structure serves as a temporary intermediary that provides mechanical support during manufacturing. It prevents delamination and decontamination of layers by maintaining structural integrity during lamination, and is subsequently removed to achieve the final coreless structure with improved reliability
4Ease of manufacture
If standard lamination processes are used without low-flow material, then the manufacturing process is simpler, but excessive resin flow causes delamination and requires trimming
Solution Approach 1:
Low-flow material is applied locally at specific positions on the sacrificial structure where resin flow control is critical. This local application provides targeted control over resin flow during lamination, preventing delamination and excess material flow without complicating the overall manufacturing process
Data Source
AI summary
A semifinished product with a sacrificial structure and two component carriers releasably formed on opposing main surfaces of the sacrificial structure. The sacrificial structure includes a central structure and releasing layers on or over both opposing main surfaces of the central structure The central structure includes a dummy core being covered, in particular fully, on or over both main surfaces thereof with a respective one of two spatially separated sections of separate material, in particular separate dielectric material.