The No-Flow Fluxing Underfill adhesive for low cost, high reliability flip chip assembly

Author(s):  
T. DeBarros ◽  
P. Neathway ◽  
Q. Chu
Author(s):  
D. Scott Copeland ◽  
M. Kaysar Rahim ◽  
Jeffrey C. Suhling ◽  
Guoyun Tian ◽  
Pradeep Lall ◽  
...  

In this work, we report on our efforts to develop high reliability flip chip on laminate assemblies for deployment in harsh thermal cycling environments characteristic of ground and aerospace vehicles (e.g. −55 to 150 °C). Reliability enhancement has been achieved through the use of a novel low expansion, high stiffness, and relatively low cost laminate substrate material that virtually eliminates CTE mismatches between the silicon die and top layer PCB interconnect. The utilized laminate features a sandwich construction that contains standard FR-406 outer layers surrounding a low expansion high thermal conductivity carbon fiber-reinforced composite core (STABLCOR®). Through both experimental testing and modeling, we have demonstrated that robust flip chip assemblies can be produced that illustrate ultra-high solder joint reliability during thermal cycling and extremely low die stresses. Liquid to liquid thermal shock testing has been performed on test assemblies incorporating daisy chain test die, and piezoresistive test chips have been used to characterize temperature dependent die stresses. In both sets of experiments, results obtained using the hybrid PCB laminate with FR-406 outer layers and carbon fiber core have been compared to those obtained with more traditional glass-epoxy laminate substrates including FR-406 and NELCO 4000-13. Nonlinear finite element modeling results for the low expansion flip chip on laminate assemblies have been correlated with the experimental data. Unconstrained thermal expansion measurements have also been performed on the hybrid laminate materials using strain gages to demonstrate their low CTE characteristics. Other experimental testing has demonstrated that the new laminate successfully passes toxicity, flammability, and vacuum stability testing as required for pressurized and un-pressurized space applications.


2007 ◽  
Vol 30 (4) ◽  
pp. 781-786 ◽  
Author(s):  
Jianhua Zhang ◽  
Changhai Wang ◽  
Jun Zeng ◽  
Ah Ju Pang

2007 ◽  
Vol 30 (2) ◽  
pp. 359-359
Author(s):  
Robert W. Kay ◽  
Stoyan Stoyanov ◽  
Greg P. Glinski ◽  
Chris Bailey ◽  
Marc P. Y. Desmulliez

2002 ◽  
Vol 124 (3) ◽  
pp. 240-245 ◽  
Author(s):  
Johan Liu ◽  
Zonghe Lai

A reliability study on anisotropically conductive adhesive joints on a Flip-Chip/FR-4 assembly has been carried out. In the study, nine types of anisotropic conductive adhesive (ACA) and one nonconductive film (NCF) were used. In total, nearly one-thousand single joints were subjected to reliability tests in terms of temperature cycling between −40°C and 125°C with a dwell time of 15 minutes and a ramp rate of 110°C/min. The test chip used for this extensive reliability test had a pitch of 100 μm. Therefore, this work was particularly focused on evaluation on the reliability of ultra fine pitch flip-chip interconnections using anisotropically conductive adhesives on a low-cost substrate. The reliability was characterized by single contact resistance measurement using the four-probe method during temperature cycling testing up to 3000 cycles. The Mean Time To Failure (MTTF) (defined as 50% failure of all tested joints) are 650, 2500, and 3500 cycles when the failure definition is defined as 20% increase, larger than 50 mΩ and larger than 100 mΩ, respectively, using the in-situ electrical resistance measurement technique. Using the discontinuous (manual) measurement at room temperature by taking out the sample from the cycling chamber, the MTTF for the same joint system is around 2500 cycles in the case that the failure criteria is defined as 20% of the resistance increase, far better than the results from the in-situ measurement. The results show clearly that in optimized conditions, high reliability flip-chip anisotropically conductive adhesive joints on low-cost substrate can be achieved.


1998 ◽  
Vol 08 (01) ◽  
pp. 39-50 ◽  
Author(s):  
DANIEL F. BALDWIN ◽  
NATHAN W. PASCARELLA

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