Altera Lidless Flip Chip Ball-Grid Array Application Note

Thermal Management and Mechanical
Handling for Lidless Flip Chip Ball-Grid
Array
AN-659-1.1
Application Note
This application note provides guidance on thermal management and mechanical
handling of lidless flip chip ball-grid array (FCBGA) for Altera® devices.
This application note includes the following sections:
■
“Lidless FCBGA Overview”
■
“General Properties of Thermal Interface Materials”
■
“Attaching Heat-Sinks” on page 4
■
“Device Reworkability” on page 12
■
“Handling and Transfer for Lidless FCBGA” on page 13
■
“Vendors List” on page 14
Lidless FCBGA Overview
Lidless FCBGA packages maximize PCB real estate by allowing closer spacing
between passive components and the flip chip die. Lidless FCBGA packages enable
the die to contact with an external heat sink, ensuring the thinnest band line and best
thermal impedance between the flip chip die and the attached heat sink.
Altera produces the lidless FCBGA package in an exposed die configuration. This
configuration maintains the excellent thermal performance of bare die for the lidless
FCBGA and provides a support surface around the bare die for a direct heat-sink
attachment.
Figure 1 shows the cross section of the lidless FCBGA.
Figure 1. Cross Section of the Lidless FCBGA
Underfill
Die
Laminate Substrate
Solder Ball
101 Innovation Drive
San Jose, CA 95134
www.altera.com
August 2014
© 2014 Altera Corporation. All rights reserved. ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS,
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respective holders as described at www.altera.com/common/legal.html. Altera warrants performance of its semiconductor
products to current specifications in accordance with Altera's standard warranty, but reserves the right to make changes to any
products and services at any time without notice. Altera assumes no responsibility or liability arising out of the application or use
of any information, product, or service described herein except as expressly agreed to in writing by Altera. Altera customers are
advised to obtain the latest version of device specifications before relying on any published information and before placing orders
for products or services.
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Page 2
General Properties of Thermal Interface Materials
The coplanarity specification limits for lidless FCBGA less than or equal to
35 mm x 35 mm: 8 mils (0.20 mm). Table 1 lists an example of the coplanarity data
measured from production of an Arria II GX EP2AGX260 device in F1152 package.
Table 1. Coplanarity Data
Yield
Min (mil)
Max
(mil)
Average
(mil)
Std Dev
Std Dev + 3 
Cpk
100%
4.74
6.71
5.73
0.40
6.93
1.89
General Properties of Thermal Interface Materials
Altera recommends considering the suitable thermal interface material (TIM) type
early in your design. TIMs can be the limiting factors in the expense of thermal
management designs. You can use TIM effectively to help reduce the size of the heat
sinks and the need for larger cooling fans. The extended benefit of an effective TIM is
a solution that is faster, easier to apply, and less costly than changing heat sinks or
redesigning a chassis.
Table 2 lists the types of TIM and their advantages and disadvantages.
Table 2. TIM Type Advantage and Disadvantage (Part 1 of 2)
TIM Type
Thermally
Conductive
Adhesive or
Epoxy
Description
■
■
Thermally conductive adhesive
is silicone-based formulation
that contain filler. Thermally
conductive adhesive offers a
superior mechanical bond.
Advantage
Disadvantage
■
Provides structural support,
eliminating the need for
mechanical clamping.
■
May not provide sufficient
bond strength because of the
small contact area.
■
Cured to allow for cross-linking
of the polymer, which provides
the adhesive property.
■
The relative high impedance
might affect the thermal
performance significantly.
■
Device rework is very difficult
and may result in damaging the
device.
■
Plastic ICs are usually concave
in the center, and heat-sink
surfaces may vary. This
unevenness can result in air
gaps in the interface.
■
May not provide sufficient
bond strength without the help
of mechanical attachment,
causing the heat sink to fall off.
■
Device rework is very difficult
and may result in damaging the
device.
■
Heat sinks may come off over
time because of the heat and
weight of the heat sinks for
vertically-mounted PCBs.
Epoxy is particle-laden, one-or
two-component materials that
you can apply through
dispensing or stencil printing.
■
Convenient for heat-sink
attachment with mid-range
thermal performance.
■
Does not require mechanical
clamping.
■
Works best on flat surfaces.
Filled pressure sensitive adhesives
(PSAs) coated on a support matrix
Thermal Tape
such as polyimide film, fiberglass
mat, or aluminum foil.
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
General Properties of Thermal Interface Materials
Page 3
Table 2. TIM Type Advantage and Disadvantage (Part 2 of 2)
TIM Type
Description
Thermal
Grease
Advantage
Contains silicone oil loaded with
thermally conductive filler.
Thermal Gel
Low thermal resistance.
■
Requires mechanical clamping.
■
Does not require curing.
■
■
Flows and conforms to
surfaces.
Messy and difficult to apply
because of its high viscosity.
■
Can degrade, pump-out, or dry
out during extended operation
and over time, causing the
thermal performance of the
TIM to suffer significantly.
■
Offers a reworkable thermal
interface layer.
■
Low thermal resistance.
■
Conforms to surfaces, while
displaying reduced material
pump-out.
Fabricated by molding
non-reinforced silicone with
conductive fillers.
■
Pre-cut.
■
Requires mechanical clamping.
■
Offers gap-filling functionality.
■
Limited thermal performance.
■
Sensitive to pressure.
■
Reinforcements for thermal
pads include woven glass,
metal foils, and polymer films.
Undergoes a transition from a
solid to a semi-solid phase with
the application of heat and
pressure. The material is in a
liquid phase at die-operating
conditions.
Phase
Change
Material
(PCM)
■
Low modulus, paste-like material
that is lightly cross-linked.
■
Thermal Pad
Disadvantage
Requires mechanical clamping.
■
Low thermal resistance.
■
Requires mechanical clamping.
■
Able to conform to mating
surfaces.
■
Rework is difficult.
■
Does not require curing
Recommended TIMs
Table 3 lists the TIMs recommended by Altera TIM vendors. Factors such as
gap-filling capability, conductivity of materials, compatibility with molding
compound, and ease of use determine the typical application recommendations.
Table 3. TIMs Recommended for the Lidless FCBGA Package (Part 1 of 2)
Vendor
Product
Type
Conductivity
Format
Typical Application
Laird Technologies
Tpcm 780
Phase change
5.5 W/m°K
Pad
Desktop and laptop PCs
Laird Technologies
Tpcm 780SP
Phase change
5.5 W/m°K
Liquid
Desktop and laptop PCs
Laird Technologies
Tpcm 580
Phase change
3.8 W/m°K
Pad
CPUs, custom ASIC, and GPUs
Laird Technologies
Tgrease 980
Thermal grease
3.8 W/m°K
Grease
CPUs, custom ASIC, and GPUs
Laird Technologies
Tgrease 880
Thermal grease
3.1 W/m°K
Grease
CPUs, custom ASIC, and GPUs
Laird Technologies
Tgrease
2500
Thermal grease
3.8 W/m°K
Paste
High-performance CPUs and
GPUs
Bergquist
3500S35
Gap filler (2 parts) 3.6 W/m°K
Pad
PCBA to housing
Chomerics
T777
Phase change
3.5 W/m°K
Pad
CPUs, GPUs, and chipsets
Chomerics
976
Gap filler
3.0 W/m°K
Pad
CPUs, GPUs, and chipsets
Chomerics
579
Gap filler
1.5 W/m°K
Pad
CPUs, GPUs, and chipsets
August 2014
Altera Corporation
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Page 4
Attaching Heat-Sinks
Table 3. TIMs Recommended for the Lidless FCBGA Package (Part 2 of 2)
Vendor
Product
Chomerics
T411
Laird Technologies
Laird Technologies
Type
Thermal
conductive tape
Conductivity
Format
Typical Application
0.5 W/m°K
Tape
CPUs, GPUs, and chipsets
T Flex HR600 Gap filler
3.0 W/m°K
Pad
Cooling to chassis, frames
T Flex HR400 Gap filler
1.8 W/m°K
Pad
Cooling to chassis, frames
1
To prevent the die from chipping or cracking, ensure that the TIM is enough
to cover the edges of the die when applying TIM to the heat sink and
package.
Attaching Heat-Sinks
You can attach a heat sink to a heat source in several ways. For efficient heat
dissipation, you must consider the advantages and disadvantages of each heat sink
attachment method.
When attaching a heat sink to a heat source with a small contact area such as the
lidless FCBGA package, you must consider the following factors:
■
Possibility of the heat sink tipping or tilting
■
Possibility of damaging the exposed die during the heat sink installation
■
Contact area can be too small to form a strong bond with an adhesive or a tape
attachment
Heat-Sink Attachment Methods
You can use two types of heat-sinks attachment; mechanical and non-mechanical.
Table 4 lists the types of heat-sink attachments, typical attachment methods,
advantage and disadvantage of the attachment methods and their suitability for
lidless packages.
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
Attachment Method
Attachment Type
Advantage
Altera Corporation
Epoxy or Thermally Conductive Adhesive
Epoxy or
Thermally
Conductive
Adhesive
Non-Mechanical
Requires no additional spaces
on the PCB.
Non-Mechanical
Requires no additional spaces
on the PCB.
■
Harder to control the
application process.
■
Rework is very difficult.
■
May damage the die.
■
For more information about
the risks, refer to
“Non-Mechanical Heat-Sink
Attachment Risks and
Disadvantages” on page 8.
■
■
Suitability for Lidless Package
■
Does not provide sufficient bond
strength because of the small contact
area.
■
May cause the heat sink to tip or tilt.
For more information, refer to
“Overcoming Heat Sink Tipping or
Tilting for Small Heat Source and
Lidless Packages” on page 9.
Relatively high impedance of
tape significantly affects the
thermal performance.
■
Does not provide sufficient bond
strength because of the small contact
area.
For more information about
the risks, refer to
“Non-Mechanical Heat-Sink
Attachment Risks and
Disadvantages” on page 8.
■
Not suitable for applications in which
the PCB or heat sink is perpendicular
to the ground, especially for lidless
package.
■
May cause the heat sink to tip or tilt.
For more information, refer to
“Overcoming Heat Sink Tipping or
Tilting for Small Heat Source and
Lidless Packages” on page 9
Page 5
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Thermal Tape
Disadvantage or Risk
Attaching Heat-Sinks
August 2014
Table 4. Advantage and Disadvantage for Each Attachment Method (Part 1 of 3)
Attachment Method
Attachment Type
Advantage
Disadvantage or Risk
Suitability for Lidless Package
Provides stable attachment to
heat source and transfers load
to mounting anchors or the
PCB.
Requires additional space on
the PCB for anchor locations;
however, Z-clip requires lesser
space than other mechanical
attachment types, such as push
pins and shoulder screws.
May cause the heat sink to tip or tilt. For
more information, refer to “Overcoming
Heat Sink Tipping or Tilting for Small
Heat Source and Lidless Packages” on
page 9
Provides stable attachment to
heat source and transfers load
to mounting anchors or the
PCB.
Requires additional space on
the PCB for anchor locations;
however, Talon-clip requires
lesser space than other
mechanical attachment types,
such as push pins and shoulder
screws.
May cause the heat sink to tip or tilt. For
more information, refer to “Overcoming
Heat Sink Tipping or Tilting for Small
Heat Source and Lidless Packages” on
page 9
Page 6
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Table 4. Advantage and Disadvantage for Each Attachment Method (Part 2 of 3)
Z-Clip
Mechanical
Attachment
Talon Clip
Mechanical
Attachment
Attaching Heat-Sinks
August 2014 Altera Corporation
Attachment Method
Attachment Type
Push Pin
Advantage
Altera Corporation
■
Provides a stable
attachment to a heat sink
and transfers load to the
PCB.
■
Allows for tight control
over mounting force and
load placed on chip and
solder balls.
Mechanical
Attachment
Shoulder Screw
Provides stable
attachment to heat sink and
transfers load to the PCB,
backing plate, or chassis.
■
Suitable for high mass heat
sinks.
■
Allows for tight control
over mounting force and
load placed on chip and
solder balls.
Suitability for Lidless Package
Requires additional space on
the PCB for push pin locations.
May cause the heat sink to tip or tilt. For
more information, refer to “Overcoming
Heat Sink Tipping or Tilting for Small
Heat Source and Lidless Packages” on
page 9
Requires additional space on
the PCB for shoulder screws
locations.
May cause the heat sink to tip or tilt. For
more information, refer to “Overcoming
Heat Sink Tipping or Tilting for Small
Heat Source and Lidless Packages” on
page 9
Page 7
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Mechanical
Attachment
■
Disadvantage or Risk
Attaching Heat-Sinks
August 2014
Table 4. Advantage and Disadvantage for Each Attachment Method (Part 3 of 3)
Page 8
Attaching Heat-Sinks
Non-Mechanical Heat-Sink Attachment Risks and Disadvantages
Figure 2 and Figure 3 show the risk of die damage and poor thermal performance due
to uneven heat sink placement for non-mechanical heat-sink attachment.
Figure 2. Die Damage
Damage
Heat sink
Die
Laminate Substrate
Molding
PCB
Figure 3. Uneven Bond Line Thickness of TIM
Uneven TIM
Heat sink
Molding
Die
Molding
Laminate Substrate
PCB
With mechanical heat-sink attachments, the force on all sides of the heat sink is even,
resulting in an even bond line thickness of the TIM and even dissipation of heat from
the heat sink. Figure 4 shows the even compressive force on the heat-sink mount with
mechanical attachment.
Figure 4. Mechanical Heat-Sink Attachment
Even force
Even force
Heat sink
TIM
Die
Laminate Substrate
PCB
Push pins
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
Attaching Heat-Sinks
Page 9
Designing Heat-Sink Attachment for Lidless FCBGA Package
When designing heat sink attachments for a lidless package, you must consider the
height of the die above the substrate and also the height of decoupling capacitors (in
some devices).
Figure 5 shows a cross-sectional view of a lidless FCBGA package (with optional
capacitors).
Figure 5. Cross-Sectional View of a Lidless FCBGA Package
Underfill
Die
Capacitator
Capacitator
Laminate Substrate
Solder Ball
f For more information about package information, refer to the Altera Device Package
Information Data Sheet.
Overcoming Heat Sink Tipping or Tilting for Small Heat Source and Lidless
Packages
When you attach a heat sink to a small heat source or a lidless package, the heat sink
can tip or tilt; thus damaging the die. You can apply sponge pads (small compressible
foam pads) to the heat sink to prevent the heat sink from tipping or tilting. The
sponge pad helps to stabilize the heat sink during attachment. For heat sinks
attachment on a lidless package, you must consider using compressible foam pads to
prevent die chipping.
Figure 6 shows a type of sponge pad.
Figure 6. Sponge Pad
August 2014
Altera Corporation
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Page 10
Attaching Heat-Sinks
The thermally conductive epoxies method requires an adhesive dispense on the center
of the chip, followed by separate dots or beads along opposing corners or edges in
one of the following patterns shown in Figure 7:
Figure 7. Dispense Patterns for Thermally Conductive Epoxies
Dot Posts
Bead Posts
Die Surface
Substrate Surface
These methods help to stabilize the heat sinks attachment to the lidless package. A
commonly-used thermally conductive epoxy is Loctite 3873-EN with Loctite 7387-EN
as a surface activator.
Figure 8. Heat Sink Attachment with PCM and Sponge Pads at Four Corners for Stability
Sponge Pad
TIM
Heat sink
Sponge Pad
Die
Laminate Substrate
PCB
Selecting Heat Sink for Small Heat Source
It is difficult to cool a smaller sized heat source because the base material of the heat
sink resists the spreading of the heat, through the base, to the outer fins.
1
Current Altera devices with small heat source are the lidless FCBGA and also flip chip
molded ball-grid array (FCMBGA).
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
Attaching Heat-Sinks
Page 11
Figure 9 shows an aluminum heat sink and a small heat source.
Figure 9. Aluminum Heat Sink
Aluminum Heat Sink
Small Heat Source
To spread the heat from a small heat source to the entire base, some vendors offer
efficient and reliable copper embedded heat sinks.
Figure 10 shows a copper embedded heat sink.
Figure 10. Copper Embedded Heat Sink
Aluminum Heat Sink
Copper Heat Spreader
Small Heat Source
Compression During Heat Sink Attachments
■
■
August 2014
Altera’s recommendation for constant compressive load on the packages with
eutectic SnPb balls:
■
8g per solder ball for 1mm pitch FBGA package
■
12g per solder ball for 1.27mm pitch BGA package
For SAC solder balls, customers can use the following constant compressive loads
in use:
■
16g per solder ball for 1mm pitch FBGA package
■
24g per solder ball for 1.27mm pitch BGA package
Altera Corporation
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Page 12
Device Reworkability
For heat-sink application, Altera’s recommendation is to not exceed 20g load per
solder ball.
■
■
This load is equivalent of 125psi load on a F1020 package
■
Typical TIM2 vendor recommendation is to apply a 50 psi load during TIM2
curing
Device Reworkability
Table 5 lists the reworkability of different combinations of heat sinks and TIMs.
Although non-mechanical heat sink attachment requires less PCB space, you must
consider the possibility of damaging the device or PCB during rework. However,
reworking the heat sink with mechanical heat sink attachment is very straight
forward and easy.
Table 5. Heat Sink and TIM Reworkability
Heat Sink Types
TIM Type
Application
Thermally
Conductive
Adhesive
Difficult to control the bond line thickness. May not have
optimal thermal performance.
High risk of damaging the
device or PCB.
Thermal tape
Must be larger than die size. Need sponge pads for
stability. May not have optimal thermal performance.
High risk of damaging the
device or PCB.
PCM
Pre-cut to size. Need sponge pads for stability. Good
thermal performance
Easy to remove.
Gap filler
Pre-cut to size. Conform to contour of the device. May
not have optimal thermal performance
Easy to remove.
Thermal grease
High performance. Conform to contour of the device.
Pump-out concerns.
Easy to remove.
■
Non Mechanical
Attachment
Mechanical
Attachment
■
Rework
Epoxy
Reworking or Removing Heat Sinks
To remove a heat sink attached with a thermal conductive tape or epoxy, follow these
steps:
1. Soak the device in isopropyl alcohol for 45 minutes to soften the TIM.
2. Carefully insert the edge of a razor blade into the TIM bond line between the heat
sink and the device.
3. Slowly twist the blade to exert upward pressure on the package while moving the
blade inward as the heat sink begins to separate.
4. Check for die edge damage.
To remove a heat sink attached with PCM or thermal gap filler, follow these steps:
1. Remove the push pins or clips that hold the mechanical attached heat sink.
2. Insert a single-edge razor blade into the TIM bond line between the heat sink and
the component.
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
Handling and Transfer for Lidless FCBGA
Page 13
3. Slowly twist the blade forward with an upward tilt force to separate the heat sink
and the component.
4. Check for die edge damage.
c Do not use a heat gun to remove heat sinks with mechanical or non-mechanical
attachments. High temperature from the heat gun may cause delamination to the
underfill of the lidless FCBGA device, destroying the device in the process.
Figure 11. Removal of heat sink with exactor knife or razor blade
Heat sink
Apply exactor knife
between the heat sink
and TIM
TIM
Die
Substrate
PCB
Handling and Transfer for Lidless FCBGA
You must always handle lidless FCBGA devices with great care. Lidless FCBGA
devices must remain secure in the tray carriers except during transfer operations from
tray to tray. You must also use the correct lidless FCBGA trays.
Table 6 lists the lidless FCBGA tray specifications for different packages.
Table 6. Tray Specifications
Package Size (Pin Count)
Tray Part Number
17 mm x 17 mm (U358, M1019)
Daewon 1F1-1717-A19
23 mm x 23 mm (F484)
Daewon T0812012
25 mm x 25 mm (F572)
Daewon 14Y-2525-119
29 mm x 29 mm (F780)
Kostat KS-880466
35 mm x 35 mm (F1152)
Daewon 125-3535-919
Do not use tweezers of any form to pick up the lidless FCBGA device. Tweezers can
cause mechanical damage to the die, whether as scratches to the top of the die or to
the bulk silicon in the form of chipped-outs, micro-cracks, or cracks. Altera
recommends that you handle the devices manually with suitable design tools such as
vacuum pencils with rubberized tips for pick-ups.
You must use a soft silicon or rubber tip for an automated pick-and-place machine. To
prevent damage to the die area of the device, minimize the pressure of the
pick-and-place machine.
If you must replace the existing solder balls of the device, use the correct fixture to
prevent the die from chipping on the device.
August 2014
Altera Corporation
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
Page 14
Vendors List
Vendors List
The following list contains recommended TIM vendors:
■
Laird Technologies(www.lairdtech.com)
■
Chomerics (www.chomerics.com)
■
The Bergquist Company (www.bergquistcompany.com)
■
3M (www.3m.com)
■
ShinEtsu MicroSi (www.microsi.com)
The following list contains recommended heat sink vendors:
■
Alpha Company (www.alphanovatech.com)
■
Malico (www.malico.com.tw)
■
Aavid Thermalloy (www.aavidthermalloy.com)
■
Radian Heatsinks (www.radianheatsinks.com)
The following list contains recommended FCMBGA tray vendors:
■
Daewon (www.daewonspic.com)
■
Kostat (www.kostat.com)
Document Revision History
Table 7 lists the revision history for this document.
Table 7. Document Revision History
Date
Version
Changes
August 2014
1.1
Updated Compression During Heat Sink Attachments.
March 2012
1.0
Initial release.
Thermal Management and Mechanical Handling for Lidless Flip Chip Ball-Grid Array
August 2014
Altera Corporation
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