Embedded Passive Components in Circuit Boards

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Embedded Passive Components in Circuit Boards

• Sponsored
• By
• UNISYS Corp.
• Mentor Jesse Ibaibarriaga
• Ken Reilich

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Team Members

• Victor Kohr
• Emmanuel Okonta
• Wing Ho Lam
• Roland Pang

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Agenda

• Overview
• Gantt Chart
• Equivalent CKTs for Embedded Passives
• Simulation
• Cost Preview
• Conclusion

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Overview

• Analysis of Embedded Passives in comparison to
  Surface mount Technology in terms of
• Electrical Performance
• Manufacturing Costs
• PCB Real Estate Savings

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Gantt Chart
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Equivalent circuit model for Embedded Resistor
Full equivalent circuits for the embedded
resistors
Reduced equivalent circuits for the embedded
resistors
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Equivalent circuit model for Embedded Capacitor
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Simulation

• Tools Sigrity Speed 2000
• Assumptions Made at this Point
• Both Discrete and Embedded Passives have same
  Equivalent Model
• One Simple Resistor or Capacitor to Replace
  the Full Equivalent CKT
• Only the Length of Interconnects Affects
  Performance

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Enable plane and transmission line skin effect
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Simulation of Capacitor (short wire version)
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Simulation of Capacitor (long wire version)
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Simulation of Resistor (short wire version)
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Via count1 Total Etch
length 5.6 in
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Simulation of Resistor (5 inch wire version)
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One Pack of Integrated Resister
Length Approx.0.1387 inches Width
Approx.0.1704 inches Length Width 0.1387
0.1704 .023634 inches2 Total surface area is
14.157.8 110.37 inches2 So 110.37/0.23634 466
of Integrated Resistor can be placed using
Surface Mount Technology (SMT)
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Embedded Resistor
Ohmega-Ply thin-film resistor

• Total board area 110.37 inches2
• Assumption
• Half of the layer can be used due to
• spacing needed among the embedded
• resistors
• Sheet Resistance 25 ohms/square
• 1 square 20 micro inch
• 1 pack 8 squares
• Total of Resistors that can be embedded
• 110.37 / (2(20(10-3)2)8) 17245 packs (466
  for SMT)

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SMT Capacitor
Length Approx.0.1 inches Width Approx.0.1574
inches Length Width 0.1 0.1574 .01574
inches2 Total surface area is 14.157.8 110.37
inches2 So 110.37/0.1574 701 of capacitor can
be placed on the surface. ? Total Capacitance
701100pF 70.1nF
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Embedded Capacitor

• Assumptions
• Sanmina-sci ZBC-2000 is used
• Capacitance 0.5nF/in2
• Whole layer can be used
• Total capacitance 110.34in2 0.5nF/in2
• 55.17nF lt SMT(70.1nF)

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COST ANALYSIS

• Estimates For Some Embedded Passives
• 73 savings,for embedding R in digital
  application.
• 27 savings, for embedding L and C in RF
  application

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Cost Dependent Application-specifics

• Decreased board area(reduced discrete passives)
• Decreased wiring density requirement,due to
  integration of RC into the Board.
• Increased wiring density due to decreased board
  size.
• Increased board cost/unit area.
• Decreased assembly cost.
• Increased overall assembly yield.
• Decreased assembly-level rework.

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Modeling Embedded Passive Economics
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Key Aspects of Modeling Embedded Passive
Cost1Board Size Routine Calculations

• Where S is minimum assembly spacing
• Li and Wi are length and width of the ith
  discrete passive
• N is all discrete passives that where converted
  to embedded passives
• Acon is the conventional board area and
• Anew is the new board that calculated after
  embedding the passive components

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Comparison of Profit Margin Between Conventional
Board and Integrated Passives Board
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Breaking Point For embedded Passive Components

• From the Above graph we can see that embedding
  100 will not be feasible as Law of Diminishing
  Return will take a toll on our design.
• We are still working to find a breaking point
  where embedding will stop being profit oriented .

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Conclusion

• Try to Obtain the Exact CKT Models from
  Manufacturers for Different Materials
• Familiarize Sigrity Speed 2000
• Attempt getting Full Version of Sigrity
• Begin Simulation