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Embedded Passive Components in Circuit Boards Sponsored By UNISYS Corp. Mentor: Jesse Ibaibarriaga Ken Reilich Team Members Victor Kohr Emmanuel Okonta Wing Ho Lam Roland Pang Agenda Overview Gantt Chart Equivalent CKTs for Embedded Passives Simulation Cost Preview Conclusion

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embedded passive components in circuit boards

Embedded Passive Components in Circuit Boards

Sponsored

By

UNISYS Corp.

Mentor: Jesse Ibaibarriaga

Ken Reilich

team members

Team Members

Victor Kohr

Emmanuel Okonta

Wing Ho Lam

Roland Pang

agenda
Agenda
  • Overview
  • Gantt Chart
  • Equivalent CKTs for Embedded Passives
  • Simulation
  • Cost Preview
  • Conclusion
overview
Overview
  • Analysis of Embedded Passives in comparison to Surface mount Technology in terms of:
    • Electrical Performance
    • Manufacturing Costs
    • PCB Real Estate Savings
slide6

Equivalent circuit model for Embedded Resistor

Full equivalent circuits for the embedded resistors

Reduced equivalent circuits for the embedded resistors

simulation
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
slide19

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 14.15*7.8 =110.37 inches2

So 110.37/0.23634 ~ 466 of Integrated Resistor can be placed using Surface Mount Technology (SMT)

embedded resistor
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)
slide21

SMT Capacitor

Length Approx.~0.1 inches

Width Approx.~0.1574 inches

Length* Width = 0.1* 0.1574 = .01574 inches2

Total surface area is 14.15*7.8 =110.37 inches2

So 110.37/0.1574 ~ 701 of capacitor can be placed on the surface.  Total Capacitance = 701*100pF = 70.1nF

embedded capacitor
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 < SMT(70.1nF)

cost analysis

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

cost dependent application specifics

Cost Dependent Application-specifics

Decreased board area(reduced discrete passives)

Decreased wiring density requirement,due to integration of R&C 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.

key aspects of modeling embedded passive cost 1board size routine calculations

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

breaking point for embedded passive components

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 .

conclusion
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
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