Printed circuit boards (PCBs) are widely used for incorporating various circuits including radio frequency (RF) circuits, microwave circuits, and the like. Generally, PCBs are manufactured by forming a conductor pattern or circuitry on the surface of a dielectric material using various pattern forming techniques, such as etching, printing, and the like.
Various aspects of at least one embodiment are discussed below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to provide illustration and a further understanding of the various aspects and embodiments, and are incorporated in and constitute a part of this specification, but are not intended as a definition of the limits of the invention. Where technical features in the figures, detailed description or any claim are followed by references signs, the reference signs have been included for the sole purpose of increasing the intelligibility of the figures, detailed description, and/or claims. Accordingly, neither the reference signs nor their absence are intended to have any limiting effect on the scope of any claim elements. In the figures, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every figure. In the figures:
In the following detailed description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of illustrative embodiments according to the present teachings. However, it will be apparent to one having ordinary skill in the art having had the benefit of the present disclosure that other embodiments according to the present teachings that depart from the specific details disclosed herein remain within the scope of the appended claims. Moreover, descriptions of well-known apparatuses and methods may be omitted so as to not obscure the description of the illustrative embodiments. Such methods and apparatuses are clearly within the scope of the present teachings.
Representative embodiments are generally directed to methods of fabricating a cavity in a printed circuit board (PCB) that exposes the PCB circuitry for a package, such as flip-chip or die-attach assembly of semi-conductors, for example. The cavity has metal plated (e.g., copper plated) side and bottom surfaces, which may provide electromagnetic interference (EMI) from adjacent circuitry and a more robust electrical design solution. In addition, the construction of the cavity enables reduced thermal resistance to the bottom interface. Also, placement of components (e.g., dies) within the cavity reduces overmold thickness, and thus overall package thickness. The reduced overmold thickness also reduces overmold-induced stresses that may otherwise reduce die interconnect reliability and/or cause package warpage, particularly with thin PCB substrates, for example.
It is to be appreciated that embodiments of the methods and apparatuses discussed herein are not limited in application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying figures. The methods and apparatuses are capable of implementation in other embodiments and of being practiced or of being carried out in various ways. Examples of specific implementations are provided herein for illustrative purposes only and are not intended to be limiting. In particular, acts, elements and features discussed in connection with any one or more embodiments are not intended to be excluded from a similar role in any other embodiments. Like reference numerals in the figures refer to like elements.
Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Any references to embodiments or elements or acts of the systems and methods herein referred to in the singular may also embrace embodiments including a plurality of these elements, and any references in plural to any embodiment or element or act herein may also embrace embodiments including only a single element. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements. The use herein of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. Any references to front and back, left and right, top and bottom, and upper and lower are intended for convenience of description, not to limit the present systems and methods or their components to any one positional or spatial orientation. The terms “a” or “an”, as used herein are defined as one or more than one. The term “plurality” as used herein is defined as two or more than two.
As used in the specification and appended claims, and in addition to their ordinary meanings, the terms “substantial” or “substantially” mean to with acceptable limits or degree. Also, as used in the specification and the appended claims and in addition to its ordinary meaning, the terms “about” and “approximately” mean to within an acceptable limit or amount to one having ordinary skill in the art. For example, “approximately the same” means that one of ordinary skill in the art would consider the items being compared to be the same.
Various embodiments provide a reference PCB with desired electrical characteristics and a method for determining an optimal process for manufacturing PCBs, selected from among multiple possible manufacturing processes, based on the electrical characteristics of the reference PCB. The optimal manufacturing process is the manufacturing process that is best or most desirable from the perspective of producing PCBs having electrical characteristics that most nearly match the electrical characteristics of the reference PCB. The optimal manufacturing process may provide minimum processing error. For example, the optimal manufacturing process may produce PCBs such that misalignments in transmission lines and/or a vias (and corresponding effects on electrical characteristics) are minimized.
In accordance with an embodiment, there is provided a method for selecting an optimal manufacturing process for producing printed circuit boards. The method includes measuring electrical characteristics of a reference printed circuit board having circuitry; producing two or more printed circuit boards using two or more candidate manufacturing processes, respectively, each produced printed circuit board having circuitry that is the same as the circuitry of the reference printed circuit board; measuring electrical characteristics of each of the produced printed circuit boards; and selecting a candidate manufacturing process of the two or more candidate manufacturing processes based on the measured electrical characteristics of the reference printed circuit board.
In accordance with another aspect of the invention, there is provided a method for selecting an optimal process for manufacturing printed circuit boards. The method includes producing multiple printed circuit boards using multiple candidate manufacturing processes, respectively, each produced printed circuit board having circuitry that is the same as circuitry of a reference printed circuit board; measuring electrical characteristics of each of the produced printed circuit boards; determining which produced printed circuit board has measured electrical characteristics closest to corresponding electrical characteristics of the reference printed circuit board; and selecting the candidate manufacturing process corresponding to the determined printed circuit board to be the optimal manufacturing process. The selected candidate manufacturing process is then used for production of printed circuit board product.
For high frequency signals, such as RF signals and microwave signals, the upper and lower transmission lines 10, 12 act as impedance (i.e., series resistance and inductance). Due to the electromagnetic coupling between the upper and lower transmission lines 10, 12, capacitance may also be induced.
Another factor that results in deviation in electrical characteristics may occur in the via 14, as illustrated in
As described above, misalignment of transmission lines and/or a via may influence the circuit capacitance, and in turn, may cause non-optimal deviations or changes in the electrical characteristics of the circuit from those intended. Particularly, when the frequency of a signal is high, a small change in the capacitance may result in a relatively large deviation in electrical characteristics. Accordingly, it is desirable to suppress and/or control misalignments of the transmission lines and/or vias during the course of manufacturing PCBs. This may be accomplished by selecting an optimal manufacturing process from among multiple possible manufacturing processes.
Referring to
One end of the first transmission line 110 is connected to a signal pad 132 and the other end is connected to termination impedance 142. Similarly, one end of the second transmission line 120 is connected to a signal pad 134 and the other end is connected to termination impedance 144. The signal pads 132, 134 may be used for measuring electrical characteristics, such as the S-parameters (e.g., S21 parameter) of the first and second transmission lines 110, 120. The termination impedances 142, 144 are provided for impedance matching for the first and second transmission lines 110, 120, respectively.
According to a representative embodiment, the dimensions of the reference PCB may be about 15.00 nm (W) by about 5.00 mm (L), for example, although other dimensions may be incorporated without departing from the scope of the present teachings.
The reference PCB shown in
The conductor 150 and the vias 162 to 178 may be placed in an area where the first and second transmission lines 110, 120 are not formed, such as a center portion of the PCB, for example, and separated from the lines 110 and 120. Accordingly, the addition of the conductor 150 and the vias 162 to 178 do not alter the electrical characteristics of the first and second transmission lines 110, 120.
For the reference PCB, the distance between an outer perimeter of each of the vias 162 to 178 and the conductor 150, also referred to a via-GND distance, is a preset distance.
In various embodiments, the reference PCB may include one or more rectangular-shaped vias 162, 164, 166 and 168 and/or one or more circular-shaped vias 172, 174, 176 and 178. Because a rectangular-shaped via and a circular-shaped via may be treated differently during the manufacturing process and may be subject to different processing errors, they are both formed in the reference PCB to be considered in determining the optimal manufacturing process.
In method 700, initially electrical characteristics of a reference PCB are measured in step 710. The reference PCB has circuitry that is produced to have substantially no misalignment between transmission lines (e.g., first and second transmission lines 110, 120) and/or between vias and a conductor (e.g., vias 162 to 178 and conductor 150), such as the illustrative reference PCBs discussed above with reference to
The electrical characteristics may include S21 parameters and/or via-GND distances, for example, as discussed above. In various embodiments, measuring the electrical characteristics includes measuring the S21 parameters using signal pads (e.g., the signal pads 132, 134 in
In step 720, two or more PCBs are produced using two or more candidate manufacturing processes, respectively, which have respective processing errors. Each produced PCB has circuitry that is the same as the circuitry of the reference PCB. Although the produced PCBs have circuitry that is substantially the same as that of the reference PCB as shown in
Next, in step 730, electrical characteristics of each of the produced PCBs are measured. In an embodiment, multiple PCBs may be produced using each of the candidate manufacturing processes. In this case, one PCB may be selected as representative of the multiple PCBs produced using each of the candidate manufacturing processes for measuring electrical characteristics in step 730. However, more than one PCB (or all of the PCBs) produced from each candidate manufacturing process may be used for measuring the electrical characteristics of PCBs produced using each of the candidate manufacturing processes. Measuring the electrical characteristics in step 730 may be performed in substantially the same manner as described above with reference to step 710. For example, the electrical characteristics may include S21 parameters and/or via-GND distances. In one embodiment, measuring the electrical characteristics includes measuring S21 parameters using the signal pads (like signal pads 132, 134 in
In step 740, a candidate manufacturing process of the two or more candidate manufacturing processes is selected as the optimal manufacturing process based on the measured electrical characteristics of the reference PCB. For example, the optimal manufacturing process may be determined by comparing the measured electrical characteristics of the PCBs produced by each corresponding candidate manufacturing process (step 730) with the corresponding measured electrical characteristics of the reference PCB (step 710). The candidate manufacturing process that produces the PCB(s) having measured electrical characteristics closest to the measured characteristics of the reference PCB is determined to be the optimal manufacturing process, and thus selected. The selected candidate manufacturing process is then used for manufacturing product PCBs.
In various embodiments, determining which candidate manufacturing process is to be selected as the optimal manufacturing process may include producing a lot or a batch of products using each of the candidate manufacturing processes. When a lot or a batch of products has been produced by each of the candidate manufacturing processes, selecting which candidate manufacturing process is the optimal manufacturing process may result in using the corresponding lot or batch of PCBs produced by that manufacturing process. However, producing actual products by multiple candidate manufacturing processes, only one of which may ultimately be selected, results in waste of the unselected lots or batches of PCBs. Therefore, it may be desirable to determine the optimal manufacturing process before manufacturing a significant amount of products in order to reduce costs.
According to an embodiment, it is possible to determine an optimal manufacturing process by producing PCBs having relatively simple structure (e.g., corresponding to the reference PCB) at relatively low cost. This allows for cost savings that would not have been incurred by choosing a non-optimal manufacturing process and making products that are subsequently discovered to be faulty. Notably, the cost of producing reference PCBs, e.g., as shown in
To verify that the candidate manufacturing process C is actually the optimal manufacturing process, the relationship between the S21 parameters and yield rates for PCBs produced by the candidate manufacturing processes are measured, as shown in
Having thus described several aspects of at least a representative embodiment, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only, and the scope of the invention should be determined from proper construction of the appended claims, and their equivalents.