Fractures of low-k materials in a RF package with integrated passive device based on TGV

The radio frequency (RF) chips and passive devices integrated on the through-glass-via (TGV) substrate meets the demands of miniaturization, high performance and low losses in the application. The RF chip and integrated passive devices (IPDs) are interconnected electrically by a redistribution layer (RDL) on the TGV substrate with the isolation low-k materials. The low-k materials, however, are susceptible to fracture during the thermal process in packaging due to their weak mechanical properties. In this study, the fractures of the low-k material were studied by experiments and the finite element analysis (FEA) for a RF package with integrated passive device based on TGV. The mechanical properties of the low-k material used in the FEA were tested by fabricating freestanding low-k films using microfabrication techniques. Then the fracture behaviors of the low-k material in the package and its impact factors under thermal loadings were examined. The impact factors, such as the initial defect location, direction and length, were investigated by evaluating the stress intensity factors (SIFs) at the defect tips. The results revealed that the most hazardous location in the low-k material is the region below the micro-joint of RF chip. The vertical defects along thickness in low-k film are more likely to propagate than horizontal ones. The SIF value increases linearly with the defect length both in heating and cooling conditions.