This disclosure relates generally to electronic devices, and more particularly, to electronic devices having circuit substrates with enhanced structural supports.
Electronic components are mounted on a substrate, such as a printed circuit board (PCB), for an electronic device. During manufacturing, the components and the PCB may be heated and cooled, and the resulting temperature cycle can cause warpage in the overall mounted structure. For example, in surface mounting devices onto the PCB, solder joint connections are formed through melting, wetting, and solidification process. During this process, differences in the component and PCB thermal expansions can lead to warpage in the final assembly. Additionally, these differences in thermal expansion can introduce warpage and stress into the assembled PCB, solder joints, and components under component power cycling and environmental temperature cycling.
An electronic device can include a substrate, such as a printed circuit board (PCB), that provides a structural support and electrical connections for electrical components (e.g., analog components, digital components, integrated circuits, or the like) mounted thereon. PCB warpage can occur during the component surface mount process, where solder joint connections are formed through melting, wetting, and solidification process. During this process, differences in the component and PCB thermal expansion can lead to warpage in the final assembly. Additionally, these differences in thermal expansion can introduce warpage and stress into the assembled PCB, solder joints, and components under component power cycling and environmental temperature cycling. When the PCBs have one lateral dimension greater than another lateral dimension, the mismatch can have greater impact along the longer lateral dimension and lead to corresponding structural deformations or warpages.
To reduce the warpage of the PCB, embodiments of the present technology can include low CTE strips (e.g., material with a CTE value of less than a threshold level, such as 5 parts per millimeter per degree Celsius (ppm/° C.)) added into the core layer of the PCB. The added low CTE strips can have one lateral dimension (e.g., a length along the longitudinal direction) that is greater (by, e.g., a factor of 1.5 or greater) than an orthogonal lateral dimension. Adding the low CTE strips can lower the overall CTE mismatch between the PCB and the components, thereby reducing the thermal induced warpage introduced during the reflow assembly process. Reducing the CTE mismatch between a PCB and the components improves reliability by reducing warpage and stress in the final assembly.
In some embodiments, the low CTE strips are added into the core layer of the PCB in the longitudinal and/or the traverse directions of the PCB. The position number, length, and width of the low CTE strips can vary based on the location of the components mounted on the PCB. As described in detail below, embodiments of the present technology can provide technical advantages over conventional technology and provide at least: 1) PCB warpage reduction; 2) no change in component design; 3) flexible treatment of PCB warpage; 4) solder joint reliability on the PCB; and 5) an improvement to the warpage due to the reflow assembly process and improved reliability due to the reduced thermal expansion mismatch between the components and the PCB after solder joints are formed.
The mounted components 104, 106, 108, 110, and 112 can generate heat during operation that causes warpage at various locations on the PCB 102. A factor causing warpage/deformations can be a mismatch in the CTE between the PCB 102 and the components 104, 106, 108, 110, and 112. Additionally, the different components can generate different amounts of heat and further provide different structural influences given their varied locations, sizes, and/or shapes. The combination of such factors can have greater impact along a longer lateral dimension in the longitudinal direction of PCB 102 than in a shorter lateral dimension in the traverse direction of the PCB 102. For example, a PCB with a dimension ratio greater than 3.6 of the longitudinal dimensions to the traverse dimensions has warpage during operation of the components. To reduce the warpage of the PCB 102, low CTE strips are added into the core layer of the PCB 102 to bring down the CTE of the PCB 102. The CTE strips lower the CTE mismatch effect between the PCB 102 and the components, thus reducing thermal induced warpage.
In some embodiments, the core layer 210 can include the core material 208 and the low CTE strips 206 arranged side-by-side or as a single layer along a lateral plane as illustrated in
The low CTE strips 206 can be placed in the core layers 210a and 210b between core material 208. Accordingly, one or more of the low CTE strips 206 in the layer 210a can overlap another CTE strip or instances of the core material 208 in the layer 210b. The multiple layers can be used to provide better control and/or gradients in an overall CTE at various locations in the PCB. Examples of materials for the low CTE strips 206 can include silicon with a CTE of 2.6 ppm/° C., ceramic with a CTE of 3-5 ppm/° C., material with a CTE in a range of 2.6-3.3 ppm/° C., or any material with a CTE value below 5 ppm/° C. In some embodiments, the low CTE strips 206 are added to the prepreg layers 202 in addition to or alternatively from the core layer 210.
At block 602, method 600 can include determining locations where components will be mounted on a PCB. The locations of the components can be determined based on the function of a component, heat displacement, footprint, wiring requirement, or any component placement design preferences or standards. The locations can be determined from coordinates assigned to each component that identify where on the PCB each component will be mounted. In other embodiments, the locations can be determined according to a circuit diagram or a requirement regarding the same provided by another party or entity, such as a circuit designer or a customer.
At block 604, method 600 can include determining the parameters (e.g., position, number, length, direction, and/or width) of the low CTE strips based on the location of components on the PCB. The low CTE strips can be placed under and/or around a footprint of the components to reduce the thermal warpage to the PCB caused by the operating components. Due to the hard properties of the low CTE strips, the components are generally attached over or closer to the core material (e.g., core material 208 of
Method 600 can include determining the parameters (e.g., locations and/or shapes) of the low CTE strips based on vias, sockets, receptacles, solder locations, holes, connectors, or any feature of the PCB in which a core material is preferred for mounting a component on the PCB. For example, the manufacturing system can generate a layout for the low CTE strips that avoids placing the low CTE strips at, under, overlapping, and/or within a threshold distance from vias on the PCB. The low CTE strips can be continuous or intermittent in the longitudinal direction and/or the traverse direction. The position, number, length, direction, and/or width of the low CTE strips can vary based on the location and/or function of the components to be mounted on the PCB and the connectors on the PCB. As illustrated in
A machine learning or artificial intelligence (ML/AI) module may be configured to analyze component locations on a PCB and determine the parameters of low CTE strips to add to the core layer of the PCB to reduce thermal induced warpage. The ML/AI learning module may be configured to analyze the component locations and determine the parameters of the low CTE strips based on at least one ML/AI model trained on at least one dataset reflecting previous user determined parameters of low CTE strips based on component locations. The at least one ML/AI algorithm (and model) may be stored locally at databases and/or externally at databases (e.g., cloud databases and/or cloud servers). Client devices (e.g., personal computers, smart phones, tablets, etc.) may be equipped to access these ML/AI algorithms and intelligently determine parameters of low CTE strips in the core layer of a PCB based on at least one ML/AI model that is trained on historical low CTE strip parameters. For example, low CTE strip parameter history may be collected to train a ML/AI model to automatically determine the number, length, direction, and/or width of low CTE strips based on the locations of where components are mounted to a PCB.
As described herein, a ML/AI model may refer to a predictive or statistical utility or program that may be used to determine a probability distribution over one or more character sequences, classes, objects, result sets or events, and/or to predict a response value from one or more predictors. A model may be based on, or incorporate, one or more rule sets, machine learning, a neural network, or the like. In examples, the ML/AI models may be located on the client device, service device, a network appliance (e.g., a firewall, a router, etc.), or some combination thereof. The ML/AI models may process historical parameters of low CTE strip in PCBs and other data stores (e.g., PCB standards, etc.) to analyze the location of components to be mounted on a PCB and design the core layer of the PCB with inserted low CTE strips. Based on an aggregation of data from a PCB design database, external/internal portals, and other user data stores, at least one ML/AI model may be trained and subsequently deployed to automatically design PCBs with low CTE strips inserted in the core layer. The trained ML model may be deployed to one or more devices. As a specific example, an instance of a trained ML model may be deployed to a server device and to a client device. The ML model deployed to a server device may be configured to be used by the client device when, for example, the client device is connected to the internet. Conversely, the ML model deployed to a client device may be configured to be used by the client device when, for example, the client device is not connected to the internet. In some instances, a client device may not be connected to the internet but still configured to receive satellite signals with release assessment information. In such examples, the ML model may be locally cached by the client device.
At block 606, method 600 can include calculating (using, e.g., a computing system) the thermal induced warpage or CTE mismatch value for the PCB. The calculation can be based on simulation testing on the PCB design with the added low CTE strips to determine the thermal induced warpage or CTE mismatch value for the PCB. For example, by adding the low CTE strips in the longitudinal direction of the PCB, the CTE mismatch between the PCB and the mounted components can be reduced. The simulation results can show the predicted warpage improvement or the changes in the CTE mismatch by adding the low CTE strips in the core layer of the PCB.
At decision block 608, method 600 can include determining whether the thermal induced warpage or CTE mismatch value for the PCB is below a threshold (e.g., 230 μm of warpage or a corresponding estimate of the CTE mismatch). If the estimated warpage for the PCB is not below a predetermined acceptance threshold, method 600 can include adjusting the parameters of the CTE strips inserted in the core layer of the PCB as illustrated by the feedback loop to block 604. If the thermal induced warpage or CTE mismatch value for the PCB is below the threshold, at block 610, method 600 can include approving the PCB design for manufacture.
Based on the approval, the PCB design can be utilized to manufacture the PCB with low CTE strips in the core layer. For example, the PCB design can be provided to the PCB manufacturer. When manufacturing the PCB according to the approved design, the low CTE strips or material can be arranged with the core material according to the design. The arranged materials and strips can be pressed between or attached to holding structures (e.g., the metal layers 204 of
The memory device 700 can include features generally similar to those of the apparatus described above with reference to
From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. In addition, certain aspects of the new technology described in the context of particular embodiments may also be combined or eliminated in other embodiments. Moreover, although advantages associated with certain embodiments of the new technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the present technology and associated technology can encompass other embodiments not expressly shown or described herein.
In the illustrated embodiments above, the apparatuses have been described in the context of DRAM devices. Apparatuses configured in accordance with other embodiments of the present technology, however, can include other types of suitable storage media in addition to or in lieu of DRAM devices, such as, devices incorporating NAND-based or NOR-based non-volatile storage media (e.g., NAND flash), magnetic storage media, phase-change storage media, ferroelectric storage media, etc.
The term “processing” as used herein includes manipulating signals and data, such as writing or programming, reading, erasing, refreshing, adjusting or changing values, calculating results, executing instructions, assembling, transferring, and/or manipulating data structures. The term data structures includes information arranged as bits, words or code-words, blocks, files, input data, system generated data, such as calculated or generated data, and program data. Further, the term “dynamic” as used herein describes processes, functions, actions or implementation occurring during operation, usage or deployment of a corresponding device, system or embodiment, and after or while running manufacturer's or third-party firmware. The dynamically occurring processes, functions, actions or implementations can occur after or subsequent to design, manufacture, and initial testing, setup or configuration.
The above embodiments are described in sufficient detail to enable those skilled in the art to make and use the embodiments. A person skilled in the relevant art, however, will understand that the technology may have additional embodiments and that the technology may be practiced without several of the details of the embodiments described above with reference to
The present application claims priority to U.S. Provisional Patent Application No. 63/471,125, filed Jun. 5, 2023, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63471125 | Jun 2023 | US |