Modeling, design, fabrication and characterization of glass package-to-PCB interconnections
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Emerging I/O density and bandwidth requirements are driving packages to low-CTE silicon, glass and organic substrates for higher wiring density and reliability of interconnections and Cu-low k dielectrics. These are needed for high performance applications as 2.5D packages in large-size, and also as ultra-thin packages for consumer applications that are directly assembled on the board without the need for an intermediate package. The trend to low-CTE packages (CTE of 3-8ppm/°C), however, creates large CTE mismatch with the board on which they are assembled. Interconnection reliability is, therefore, a major concern when low CTE interposers are surface mounted onto organic system boards via solder joints. This reliability concern is further aggravated with large package sizes and finer pitch. For wide acceptance of low CTE packages in high volume production, it is also critical to assemble them on board using standard Surface Mount Technologies (SMT) without the need for under-fill. This research aims to demonstrate reliable 400 micron pitch solder interconnections from low CTE glass interposers directly assembled onto organic boards by overcoming the above challenges using two approaches; 1) Stress-relief dielectric build up layers on the back of the interposer, 2) Polymer collar around the solder bumps for shear stress re-distribution. A comprehensive methodology based on modeling, design, test vehicle fabrication and characterization is employed to study and demonstrate the efficacy of these approaches in meeting the interposer-to-board interconnection requirements. The effect of varying geometrical and material properties of both build-up layers and polymer collar is studied through Finite Element Modeling. Interposers were designed and fabricated with the proposed approaches to demonstrate process feasibility.