EML 4561 Introduction to Electronic Packaging W. Kinzy Jones, Professor MME MWF 11:00-11:50 Jones@fiu.edu 305-393-0506(mobile) 305-348-4663 (office)

Notes on the field I am Past President and Fellow, IMAPS, The Microelectronics and Packaging Society Research in advanced packaging, 1st Level Assembly, Thermal Management, Components and Electronic Materials- Funded over $7MM in past 15 years Electronic packaging is a application field that crosses over many disciplines. There are 80,000 ME working in the field. Conferences/journals by ASME, IEEE, ASM, IMAPS, etc. All former graduate student hired prior to graduation!

Outline Technological Drivers Design Process Interconnect Technology Electrical Consideration Mechanical Constraints Thermal Management Material Science Fundamentals Interconnect Technology Laminate technology Ceramic Processes ( thick film, cofire ceramic) Thin Film Deposited

Outline (Cont.) Components Active components technologies Passive Components technologies IC Packaging ( from DIP to System-on-package (SOP)) Assembly First Level Assembly ( wire bonding, flip chip) Soldering Manufacturing Processes Reliability MIL Standards Reliability Projections

Introduction to Microsystems Packaging

Definition of Packaging Packaging is a Bridge from IC to System Board IC It Controls: >90% size Performance Cost Reliability

Packaging Hierarchy

Microsystems Technologies

System Packaging Involves Electrical, Mechanical and Materials Technologies

Analogy Between Human and Electronics

Trend to Convergent Microsystems Packaging Photonics Microelectronics Discrete Systems RF Convergent Microsystems MEMS Bioelectronics Past Future

Building Block of Microsystems Packaging

Trend to Convergent Systems Transistors / chip WW S/C Revenue ($B) 10000 All businesses, people, objects Network computing Wide area / bandwidth Graphical, voice, multimedia, etc. Many vendors / platforms 100B 10B 1000 1B PCs / Servers Wireless Wired Internet 100M 100 10M Mainframes Businesses & some people Client-server computing Local area connection Text/graphical interface Many vendors / few architectures 1M 10 PCs 100K Businesses Host-based computing Mainframe Dumb terminal Few vendors / architecture 10K 1 1K 1975 1995 2015 Today Source: Russ Lange, IBM Microelectronics Year

What are Convergent Microminiaturized Microsystems (CMM)? Convergent: Two or more functions Microminiaturized: >1000x volume reductions Microsystems: systems with micro-scale technologies

Trend to Convergent Microminiaturized Systems (CMM) Functional Data and Voice Video Cell Phone CONSUMER ELECTRONICS Medical Implant/ Diagnostic Monitor/ Communicator MEDICAL Technology Digital, RF, Analog and Optical Product Computer, consumer and telecom

The Invention of the First IC

Moore ’s Law: Doubles Every 18 Months

Moore’s Law Cu - low K SOC Advances SiGe SOI

SOC Challenges Integration RF Limits Fundamental Digital Limits Major Delay Problems Summary Fundamental Design & Verification Complexity Test Complexity Process Complexity Mixed Function Costs Wafer Fab Costs Legal Problems Time-to-market

SOC: Integration of Two or More Mixed Functions in a Single IC (b)

What is Wrong with Current Packaging for Tomorrow’s Needs? Higher Cost Bulky Size Cellular Phone Weight Trend Active ICs 10% Passives: 90% Lower Performance Poorer Reliability IC: PPB Systems Pkg: PPM Barrier to all future systems

What is SOP, SIP, or Board? A.) Today’s Board: Interconnect Components RF IC Digital IC Optical IC Substrate A.) Today’s Board: Interconnect Components Flash RAM mP IC Package Super IC Stack (ASET) Package (Fujitsu) Stacked IC (Amkor) B.) SIP: Stacked Chip/Package for Reduced Form Factors 3-D ICs IC RF IC Opto IC Digital IC RF Opto Electrical Package with Opto, RF, Digital Functions C.) SOP: Optimizes Functions Between ICs and Package

What are SOC, SIP, and SOP? SOC: System on Chip SIP: System in Package Highly integrated and mixed signal IC with partial system functions in one component SIP: System in Package 3-D IC or Package Assembly Requires Systems Board SOP: System on Package Microminiaturized system-level board with two or more embedded RF, digital, analog and optical functions Best of on-chip and package integration for cost, performance, size and reliability Similar to SOC but total system function in a microminiaturized board

SOP: SIP + SOC+Systems Board 3 -D Stacking of ICS or Package Structures, Similar to PWB Macro dimensions Vertical stack up Testable 3 -D Build up, similar to IC Fabrication Micro to Nano dimensions Sequential build up and test similar to MCM-D and IC Wafer to IC concept for high yield MEMS Ga-As SIP SOC SOC MEMS Ga-As SIP

Why SOP? SOC is complex to design and test, expensive to Fabricate, long time-to-market and presents fundamental limits. IC company’s dream for decades. No complete system has been shipped to date. SOP optimizes the best of IC and package integration for cost, performance, size and reliability. Faster turn-around and faster time-to-market. Provides full system solution today that SOC provides tomorrow. SIP is a 3-D IC or package, not a complete system

Information Technology is a Trillion $ Industry Microsystems & Packaging is 25% of IT Industrial & Medical 11% $105B Automotive 5% $ 48B Military 9% $ 8.7B Consumer 26% $112B Business Equip 38% $ 383B Communications 26% $ 259B Source: Prismark

MSP Market ($320 B) Opto & MEMS ($30B) Microelectronics ($165B) Systems Packaging ($125B)

Information Technology and Microsystem Markets Billion $/Year

Hardware and Software Markets

Functions of Packaging

Package Interconnections

System Level Packaging Core Technologies Substrates, circuit boards Interconnect Passive components Active components Packaging Traditionally these were treated as discrete elements Advanced applications require integrated approach of System Level Packaging

Substrates and Circuit Boards Printed Circuit Board (PCB), Printed Wiring Board (PWB) Epoxy-glass composite, copper FR-4, FR = fire retardant Advanced Resins Polyimide BT = bismaleimide traizine CE = cyanate ester Ceramic substrates Aluminum oxide, aluminum nitride, beryllium oxide, glass-ceramic Interconnect metals - W, Mo, Au, Cu, Ag Multichip Modules MCM-D,C,L Platform Support interconnect and components Thermal path away from ICs Withstand mechanical stresses and vibrations

Packaging Evolution ?

Microelectronic Density Trends microprocessors logic

Rent’s Rule

Packaging Evolution

I/O Density Trends Chip

Package Evolution

Packaging Trends (Cont.)

Assembly Processes Board Fabrication Populating the board Soldering Single layer Multilayer PCB Flex Ceramic Populating the board Pick and place Insertion Die attach Soldering Solder paste reflow Wave solder Solder bump reflow Encapsulation

SIA Roadmap for Chip Interconnections, 1995

CMOS Device Trends Buda et al, 42 CPMT, pp36-41, 1992

NEMI Roadmap, 1996 Packaging trends in Consumer Electronics Packaging trends in Automotive Electronics

iNEMI Roadmap, 2009

NEMI Roadmap for Packaging Trends in High-Performance Systems

High Performance Systems, iNEMI 2009

Interconnect Density, Std. PWB .1mm = 4 mils

Thermal Cooling Requirements

Types of First Level Packages

Chip-Scale Packages

Types of Ball Grid Arrays

Flip Chip Assembly Chip Substrate Example- Controlled Collapse Chip Connection-C4 (IBM) assembly on ceramic substrate

Solder Primary functions Electrical connection between component and interconnect Mechanical attachment of component to board Thermal path from component to board Alloys of various compositions and melting points Lead-Tin solder most common Eutectic composition: 63% Tin, 47% Lead 60/40 or 2% silver added Solder paste for screen printing, pressure dispensing Alloy particles Flux and activator chemicals Vehicle to control viscosity Wave soldering Foam or spray flux Preheat board Turbulent wave to spread solder Laminar wave to smooth

Effect of Underfill on Temp Cycling Performance With filler, 27ppm

Functions of a Multichip Package

Illustrations of MCM Types

Low Temperature Cofired Ceramics with Buried Components

Packaging Efficiency

Packaging Considerations that Effect the Electrical Performance

Interconnects Worsen: Signal Integrity Performance: switching, speed Reliability Form, fit, and function- weight, volume, power

Interconnects Can Have Very Important Electrical Properties Property Self-inductance Capacitance to ground transmission line Mutual Inductance, capacitance Resistance, loss Possible Impact Ground bounce Delay, power sag Propagation delay, reflection Cross-talk, noise Damping, ringing, power sag

Drivers for Reduction of Interconnect Length Directly reduces inductance, capacitance, resistance and delay Indirectly reduces switching time, power, size, ringing, ground bounce, and power sag

Electrical Fundamentals Resistance ( ohms). Relates Ohms law relationship between current and voltage, V=IR. Resistivity, , is a materials property, in ohm-meters. Resistance, R = Length x  / cross-sectional area of conductor Capacitance (farads) relates to the ability to store charge. Capacitance for a parallel plate capacitor is proportional to the dielectric constant,K, times the area of the plate/ thickness of dielectric. Inductance ( henry)- relates to the voltage generated to oppose a change in current

Basic Resistance Equation Resistance R = L / A = L  /wt = L/w Rs where Rs is defined as the sheet resistivity,  is resistivity, L is the length and A is the cross sectional area of the conductor/resistor A square ( L=W ) for a fixed thickness of material has a fixed resistance per square, independent of size. A square anything

Capacitance is In the insulation between more than one conductor Orders of Magnitude higher outside the chip than inside The dominate determinant of digital speed

Dielectric Constants of Some Insulators

Capacitance of Electrically Short Interconnections Capacitance is the sum of all output capacitance of all drivers to that interconnect, the input capacitance of all receivers, and the distributed capacitance to ground of the interconnection

Switching Time, Power If a step voltage is applied to an RC network, the time delay is proportional to RC. If the capacitor is charged from zero to full charge, the energy dissipated, W, is independent of R and equals CV2/2. But energy is also power X time delay. If we operate twice as fast, the circuit will dissipate twice the power.

Inductance Opposes a change in current by generating a back voltage. If the current change is positive, the back voltage subtracts from the voltage applied, causing a power sag. The voltage is equal to the inductance times the rate of change of the current , VL= L di/dt Self inductance exists in every wire, trace, wire bond, solder joint, etc..It is minimized by large, short conductors, or a sheet conductor as a ground or power plane. Example: If we switch 1 amp in 5 nsec on a 1” trace with 7.8 nH, we generate a back voltage of 1.6 volts.

Crosstalk There is a mutual capacitance between two adjacent insulated conductors that couples a fraction of one voltage to the other There is also mutual inductance, functioning as a transformer by generating a voltage in each when the current changes in the other. This is crosstalk. Can be minimized by design (keep talkers and listeners apart) and use of ground/power traces between talkers/listeners

Ground Bounce, Power Sag Cause: Common-mode impedance, usually inductive Digital devices require most of their power supply current during switching. Clocked signals switch together, so there could be a large total surge The inductance in the power and ground leads causes ground bounce and power sag.

Bypass ( decoupling) Capacitors To reduce power sag and ground bounce, add decoupling capacitors. Value should be 20-100 nF/sq.cm of silicon. Decoupling capacitors should have low parasitic inductance. Capacitors serve as local energy reserves and need to be close to the power/ground leads

RLC Circuit Switching The voltage step sent down an interconnect can be distorted badly by the R, C, and L on the interconnect This distortion can be removed by the right balance of the values of R,L and C. When R = 2* sqrt(L/C), critical damping occurs If R is above critical damping, switching slows down; if below, ringing of the signal occurs

Critical Damping

Transmission Lines Any interconnect whose length is over a small fraction of the wavelength of the signal it carries acts like both a transmission line and an antenna radiating or receiving noise As speed increase, the lumped analysis of L,R,and C components must be replaced by the distributed network of L,R, and C. Property shielded interconnects minimize the effect of antenna properties, but the transmission properties remain

Transmission Line Properties A transmission line appears as a string of small inductors and capacitors, with seven principal properties: length L, inductance per unit length, capacitance per unit length, impedance (Z), attenuation, propagation velocity, and time delay

Transmission Line Equations

Transmission line traces Matched impedance systems require containment of the electrical fields. This has lead to designs including the stripline, the microstrip, the buried microstrip. Additionally, for multilayer routing, vias must be considered Stripline microstrip

Microstrip Design for 50 Impedance

Traveling Waves on an Infinite Line Switching on a DC source voltage, V, : draws the same current as a resistor of value Zo connected to V. current flows down the line at the propagation velocity, while the current progressively charges up the line capacitance to voltage V. Hence a voltage step V also travels down the line. Draws current indefinitely due to an infinitely long line The source only sees a resistive load Zo continuously drawing current

Traveling Waves on an Unterminated Line When the line is unterminated ( R is infinite): Kirchoff’s current law still applies at the far end: the sum of current entering the end must equal the current leaving the end. But there is no load to draw current from the end node. Therefore, an equal reflected current wave is generated that travels back toward the source. This reflected current wave requires an extra voltage source, V, to propel it, so the voltage at the far end steps up to 2V. This increased voltage travels back towards the source along with the reflected current. What happens at the source depends on the source’s internal impedance The waves can on occasion reflected back and forth several times

Lines Traveling Waves Capacitively Terminated The problem of reflection is compounded by capacitance at the ends. When a transmission line drives a capacitor, the extra capacitance causes: reflections, since the line is now mismatched ringing for some drivers, since there is no longer critical damping CMOS inputs are essentially capacitive.

AC Termination To minimize power dissipation, a series capacitor,C, can be added to the terminating resistor This terminated the line only when a voltage transition occurs and allows no DC power dissipation in R The value of C must be selected carefully, either by simulation or experimentation to minimize the effect of capacitively terminated lines.

When Interconnections are Electrically Significant When interconnects degrade switching time When the signals are not correctly damped When large amounts of current switch In the time domain, when the line propagation delay approaches the driver switching time. Propagation delay is proportional to length In the frequency domain, when the wavelength of the signal ( including harmonics) are not long compared to the length of the interconnect ( for 100 Mhz- over a few centimeters)

Packaging What packaging provides: Interconnection Power Distribution Thermal Management Environmental Protection What the package is made from--materials, parts What is used to design and fabricate packages: Facilities and Equipment Manufacturing and Design Tools Process by which the package is produced over time

Technology Drives Increases in semiconductor complexity from decreased feature size Corresponding increases in systems speed Increase in input/output (I/O) density Increase in power density (W/cm2)

Levels of Packaging 1st Level Connection 2nd Level Connection IC to Common Circuit Base Wirebonds or solder bumps to package base 2nd Level Connection Common Circuit Base to Circuit Board Package leads soldered to PCB 3rd Level Connection Assembly of multiple boards into larger assembly Video card, modem, game port on a PC motherboard 4th and 5th Level Connections System level assembly with several 3rd Level subassemblies Motion control, visual alignment, user interface, etc. in manufacturing equipment