Embedded Passive Components in Circuit Boards

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## 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**Team Members**Victor Kohr Emmanuel Okonta Wing Ho Lam Roland Pang**Agenda**• Overview • Gantt Chart • Equivalent CKTs for Embedded Passives • Simulation • Cost Preview • Conclusion**Overview**• Analysis of Embedded Passives in comparison to Surface mount Technology in terms of: • Electrical Performance • Manufacturing Costs • PCB Real Estate Savings**Equivalent circuit model for Embedded Resistor**Full equivalent circuits for the embedded resistors Reduced equivalent circuits for the embedded resistors**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**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**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)**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**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**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**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 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**Comparison of Profit Margin Between Conventional Board and**Integrated Passives Board**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**• Try to Obtain the Exact CKT Models from Manufacturers for Different Materials • Familiarize Sigrity Speed 2000 • Attempt getting Full Version of Sigrity • Begin Simulation