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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 l.jpg

Embedded Passive Components in Circuit Boards

Sponsored

By

UNISYS Corp.

Mentor: Jesse Ibaibarriaga

Ken Reilich


Team members l.jpg

Team Members

Victor Kohr

Emmanuel Okonta

Wing Ho Lam

Roland Pang


Agenda l.jpg
Agenda

  • Overview

  • Gantt Chart

  • Equivalent CKTs for Embedded Passives

  • Simulation

  • Cost Preview

  • Conclusion


Overview l.jpg
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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Equivalent circuit model for Embedded Resistor

Full equivalent circuits for the embedded resistors

Reduced equivalent circuits for the embedded resistors



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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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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 l.jpg
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 14.15*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 l.jpg
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)


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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 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 l.jpg

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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Breaking Point For embedded Passive Components Integrated Passives Board

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 Integrated Passives Board

  • 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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