Title:
Circuit module with thermal casing systems
Document Type and Number:
United States Patent 7446410

Abstract:
Flexible circuitry is populated with integrated circuitry (ICs) disposed along one or both of major sides. Contacts are distributed along the flexible circuitry to provide connection between the module and an application environment. The populated flexible circuitry is disposed about an edge of a rigid substrate thus placing the integrated circuitry on one or both sides of the substrate with one or more layers of integrated circuitry on one or both sides of the substrate. The substrate form is preferably devised from thermally-conductive materials and one or more thermal spreaders are disposed in thermal contact with at least some of the constituent integrated circuitry of the module. Optionally, as an additional thermal management feature, the module may include a high thermal conductivity thermal sink or area that is disposed proximal to higher thermal energy IC devices. In preferred embodiments, extensions from the substrate body or substrate core encourage reduced thermal variations amongst the ICs of the module while providing an enlarged surface for shedding thermal energy from the module.

Inventors:
Wehrly Jr., James Douglas (Austin, TX, US)
Wilder, James (Austin, TX, US)
Wolfe, Mark (Round Rock, TX, US)
Goodwin, Paul (Austin, TX, US)
      Plaque It!

Application Number:
11/283355
Publication Date:
11/04/2008
Filing Date:
11/18/2005
View Patent Images:
Images are available in PDF form when logged in. To view PDFs, Login  or  Create Account (Free!)
Assignee:
Entorian Technologies, LP (Austin, TX, US)
Primary Class:
Other Classes:
257/717, 257/720, 257/713, 361/749, 361/709, 361/704, 438/122, 361/718, 257/707
International Classes:
H01L23/34; H01L21/00; H05K7/20
US Patent References:
3372310Universal modular packages for integrated circuitsMarch, 1968Kantor
3436604COMPLEX INTEGRATED CIRCUIT ARRAY AND METHOD FOR FABRICATING SAMEApril, 1969Hyltin
3582865MICROCIRCUIT MODULE AND CONNECTORJune, 1971Franck et al.
3654394FIELD EFFECT TRANSISTOR SWITCH, PARTICULARLY FOR MULTIPLEXINGApril, 1972Gordon
37044553D-COAXIAL MEMORY CONSTRUCTION AND METHOD OF MAKINGNovember, 1972Scarbrough
3718842February, 1973Abbott, III et al.
3727064OPTO-ISOLATOR DEVICES AND METHOD FOR THE FABRICATION THEREOFApril, 1973Bottini
3746934STACK ARRANGEMENT OF SEMICONDUCTOR CHIPSJuly, 1973Stein
3766439ELECTRONIC MODULE USING FLEXIBLE PRINTED CIRCUIT BOARD WITH HEAT SINK MEANSOctober, 1973Issacson
3772776METHOD OF INTERCONNECTING MEMORY PLANE BOARDSNovember, 1973Weisenburger
4169642Integrated circuit connectorOctober, 1979Mouissie
4288841Double cavity semiconductor chip carrierSeptember, 1981Gogal
4342069Integrated circuit packageJuly, 1982Link
4429349Coil connectorJanuary, 1984Zachry
4437235Integrated circuit packageMarch, 1984McIver
4513368Digital data processing system having object-based logical memory addressing and self-structuring modular memoryApril, 1985Houseman
4547834Structure for assembling complex electronic circuitsOctober, 1985Dumont et al.
4567543Double-sided flexible electronic circuit moduleJanuary, 1986Miniet
4587596High density mother/daughter circuit board connectorMay, 1986Bunnell
4645944MOS register for selecting among various data inputsFebruary, 1987Uya
4656605Single in-line memory moduleApril, 1987Clayton
4672421Semiconductor packaging and methodJune, 1987Lin
4682207Semiconductor device including leadless packages and a base plate for mounting the leadless packagesJuly, 1987Akasaki et al.
4696525Socket for stacking integrated circuit packagesSeptember, 1987Coller et al.
4709300Jumper for a semiconductor assemblyNovember, 1987Landis
4724611Method for producing semiconductor moduleFebruary, 1988Hagihara
4727513Signal in-line memory moduleFebruary, 1988Clayton
4733461Method of stacking printed circuit boardsMarch, 1988Nakano
4739589Process and apparatus for abrasive machining of a wafer-like workpieceApril, 1988Brehm et al.
4763188Packaging system for multiple semiconductor devicesAugust, 1988Johnson
4771366Ceramic card assembly having enhanced power distribution and coolingSeptember, 1988Blake et al.
4821007Strip line circuit component and method of manufactureApril, 1989Fields et al.
4823234Semiconductor device and its manufactureApril, 1989Konishi et al.
4833568Three-dimensional circuit component assembly and method corresponding theretoMay, 1989Berhold
4850892Connecting apparatus for electrically connecting memory modules to a printed circuit boardJuly, 1989Clayton et al.
4862249Packaging system for stacking integrated circuitsAugust, 1989Carlson
4911643High density and high signal integrity connectorMarch, 1990Perry et al.
4953060Stackable integrated circuit chip package with improved heat removalAugust, 1990Lauffer et al.
4956694Integrated circuit chip stackingSeptember, 1990Eide
4972580Method for connecting electronic components with dummy patternsNovember, 1990Nakamura
4982266Integrated circuit with metal interconnecting layers above and below active circuitryJanuary, 1991Watanabe et al.
4983533High-density electronic modules - process and productJanuary, 1991Go
4985703Analog multiplexerJanuary, 1991Kaneyama
4992849Directly bonded board multiple integrated circuit moduleFebruary, 1991Corbett et al.
4992850Directly bonded simm moduleFebruary, 1991Corbett et al.
5014115Coplanar waveguide semiconductor packageMay, 1991Moser
5014161System for detachably mounting semiconductors on conductor substrateMay, 1991Lee et al.
5016138Three dimensional integrated circuit packageMay, 1991Woodman
5025306Assembly of semiconductor chipsJune, 1991Johnson et al.
5034350Semiconductor device package with dies mounted on both sides of the central pad of a metal frameJuly, 1991Marchisi
5041015Electrical jumper assemblyAugust, 1991Travis
5053853Modular electronic packaging systemOctober, 1991Haj-Ali-Ahmadi et al.
5065277Three dimensional packaging arrangement for computer systems and the likeNovember, 1991Davidson
5099393Electronic package for high density applicationsMarch, 1992Bentlage et al.
5104820Method of fabricating electronic circuitry unit containing stacked IC layers having lead reroutingApril, 1992Go et al.
5109318Pluggable electronic circuit package assembly with snap together heat sink housingApril, 1992Funari et al.
5117282Stacked configuration for integrated circuit devicesMay, 1992Salatino
5119269Semiconductor with a battery unitJune, 1992Nakayama
5138430High performance versatile thermally enhanced IC chip mountingAugust, 1992Gow, III et al.
5138434Packaging for semiconductor logic devicesAugust, 1992Wood et al.
5140405Semiconductor assembly utilizing elastomeric single axis conductive interconnectAugust, 1992King et al.
5159535Method and apparatus for mounting a flexible film semiconductor chip carrier on a circuitized substrateOctober, 1992Desai et al.
5173840Molded IC cardDecember, 1992Kodai et al.
5191404High density memory array packagingMarch, 1993Wu et al.
5208729Multi-chip moduleMay, 1993Cipolla et al.
5214845Method for producing high speed integrated circuitsJune, 1993King et al.
5219377High temperature co-fired ceramic integrated phased array packageJune, 1993Poradish
5222014Three-dimensional multi-chip pad array carrierJune, 1993Lin
5224023Foldable electronic assembly moduleJune, 1993Smith et al.
5229916Chip edge interconnect overlay elementJuly, 1993Frankeny et al.
5229917VLSI integration into a 3-D WSI dual composite moduleJuly, 1993Harris et al.
5239198Overmolded semiconductor device having solder ball and edge lead connective structureAugust, 1993Lin et al.
5241454Mutlilayered flexible circuit packageAugust, 1993Ameen et al.
5241456Compact high density interconnect structureAugust, 1993Marcinkiewiez et al.
5247423Stacking three dimensional leadless multi-chip module and method for making the sameSeptember, 1993Lin et al.
5252857Stacked DCA memory chipsOctober, 1993Kane et al.
5259770Impedance controlled elastomeric connectorNovember, 1993Bates et al.
5261068Dual path memory retrieval system for an interleaved dynamic RAM memory unitNovember, 1993Gaskins et al.
5268815High density, high performance memory circuit packageDecember, 1993Cipolla et al.
5276418Flexible substrate electronic assemblyJanuary, 1994Klosowiak et al.
5281852Semiconductor device including stacked dieJanuary, 1994Normington
5289062Fast transmission gate switchFebruary, 1994Wyland
5309986Heat pipeMay, 1994Itoh
5313097High density memory moduleMay, 1994Haj-Ali-Ahmadi et al.
5347428Module comprising IC memory stack dedicated to and structurally combined with an IC microprocessor chipSeptember, 1994Carson et al.
5375041Ra-tab array bump tab tape based I.C. packageDecember, 1994McMahon
5386341Flexible substrate folded in a U-shape with a rigidizer plate located in the notch of the U-shapeJanuary, 1995Olson et al.
5394300Thin multilayered IC memory cardFebruary, 1995Yoshimura
5397916Semiconductor device including stacked dieMarch, 1995Normington
5400003Inherently impedance matched integrated circuit moduleMarch, 1995Kledzik
5428190Rigid-flex board with anisotropic interconnect and method of manufactureJune, 1995Stopperan
5438224Integrated circuit package having a face-to-face IC chip arrangementAugust, 1995Papageorge et al.
5448511Memory stack with an integrated interconnect and mounting structureSeptember, 1995Paurus et al.
5477082Bi-planar multi-chip moduleDecember, 1995Buckley, III et al.
5491612Three-dimensional modular assembly of integrated circuitsFebruary, 1996Nicewarner, Jr. et al.
5502333Semiconductor stack structures and fabrication/sparing methods utilizing programmable spare circuitMarch, 1996Bertin et al.
5523619High density memory structureJune, 1996McAlister et al.
5523695Universal test socket for exposing the active surface of an integrated circuit in a die-down packageJune, 1996Lin
5541812Bus communication system for stacked high density integrated circuit packages having an intermediate lead frameJuly, 1996Burns
5572065Hermetically sealed ceramic integrated circuit heat dissipating packageNovember, 1996Burns
5600178Semiconductor package having interdigitated leadsFebruary, 1997Russell
5612570Chip stack and method of making sameMarch, 1997Eide et al.
5631193High density lead-on-package fabrication methodMay, 1997Burns
5642055Electrical interconnect using particle enhanced joining of metal surfacesJune, 1997Difrancesco
5644161Ultra-high density warp-resistant memory moduleJuly, 1997Burns
5646446Three-dimensional flexible assembly of integrated circuitsJuly, 1997Nicewarner et al.
5654877Lead-on-chip integrated circuit apparatusAugust, 1997Burns
5661339Thin multichip moduleAugust, 1997Clayton
5686730Dimm pair with data memory and state memoryNovember, 1997Laudon et al.
5708297Thin multichip moduleJanuary, 1998Clayton
5714802High-density electronic moduleFebruary, 1998Cloud et al.
5717556Printed-wiring board having plural parallel-connected interconnectionsFebruary, 1998Yanagida
5729894Method of assembling ball bump grid array semiconductor packagesMarch, 1998Rostoker et al.
5731633Thin multichip moduleMarch, 1998Clayton257/723
5744862Reduced thickness semiconductor device with IC packages mounted in openings on substrateApril, 1998Ishii
5751553Thin multichip module including a connector frame socket having first and second aperturesMay, 1998Clayton
5754409Foldable electronic assembly moduleMay, 1998Smith
5764497Circuit board connection method and connection structureJune, 1998Mizumo
5776797Three-dimensional flexible assembly of integrated circuitsJuly, 1998Nicewarner, Jr. et al.
5789815Three dimensional semiconductor package having flexible appendagesAugust, 1998Tessier et al.
5790447High-memory capacity DIMM with data and state memoryAugust, 1998Laudon et al.
5802395High density memory modules with improved data bus performanceSeptember, 1998Connolly et al.
5805422Semiconductor package with flexible board and method of fabricating the sameSeptember, 1998Otake et al.
5828125Ultra-high density warp-resistant memory moduleOctober, 1998Burns
5835988Packed semiconductor device with wrap around external leadsNovember, 1998Ishii
5869353Modular panel stacking processFebruary, 1999Levy et al.
5899705Stacked leads-over chip multi-chip moduleMay, 1999Akram
5917709Multiple circuit board assembly having an interconnect mechanism that includes a flex connectorJune, 1999Johnson et al.
5925934Low cost and highly reliable chip-sized packageJuly, 1999Lim
5926369Vertically integrated multi-chip circuit package with heat-sink supportJuly, 1999Ingraham et al.
5949657Bottom or top jumpered foldable electronic assemblySeptember, 1999Karabatsos
5953214Dual substrate package assembly coupled to a conducting memberSeptember, 1999Dranchak et al.
5953215Apparatus and method for improving computer memory speed and capacitySeptember, 1999Karabatsos
5959839Apparatus for heat removal using a flexible backplaneSeptember, 1999Gates
5963427Multi-chip module with flexible circuit boardOctober, 1999Bollesen
5966287Clip on heat exchanger for a memory module and assembly methodOctober, 1999Lofland et al.361/704
5973395IC package having a single wiring sheet with a lead pattern disposed thereonOctober, 1999Suzuki et al.
5995370Heat-sinking arrangement for circuit elementsNovember, 1999Nakamori
6002167Semiconductor device having lead on chip structureDecember, 1999Hatano et al.
6002589Integrated circuit package for coupling to a printed circuit boardDecember, 1999Perino et al.
6008538Method and apparatus providing redundancy for fabricating highly reliable memory modulesDecember, 1999Akram et al.
6014316IC stack utilizing BGA contactsJanuary, 2000Eide
6021048High speed memory moduleFebruary, 2000Smith
6025992Integrated heat exchanger for memory moduleFebruary, 2000Dodge et al.361/704
6028352IC stack utilizing secondary leadframesFebruary, 2000Eide
6028365Integrated circuit package and method of fabricationFebruary, 2000Akram et al.
6034878Source-clock-synchronized memory system and memory unitMarch, 2000Osaka et al.
6038132Memory moduleMarch, 2000Tokunaga et al.
6040624Semiconductor device package and methodMarch, 2000Chambers et al.
6049975Method of forming a thin multichip moduleApril, 2000Clayton
6060339Method and apparatus providing redundancy for fabricating highly reliable memory modulesMay, 2000Akram et al.
6072233Stackable ball grid array packageJune, 2000Corisis et al.
6078515Memory system with multiple addressing and control bussesJune, 2000Nielsen et al.
6084294Semiconductor device comprising stacked semiconductor elementsJuly, 2000Tomita
6091145Thin multichip module including a connector frame socketJuly, 2000Clayton
6097087Semiconductor package including flex circuit, interconnects and dense array external contactsAugust, 2000Farnworth et al.
6111757SIMM/DIMM memory moduleAugust, 2000Dell et al.
6121676Stacked microelectronic assembly and method thereforSeptember, 2000Solberg
RE36916Apparatus for stacking semiconductor chipsOctober, 2000Moshayedi
6157541Stack arrangement for two semiconductor memory chips and printed board for accepting a plurality of such stack arrangementsDecember, 2000Hacke
6172874System for stacking of integrated circuit packagesJanuary, 2001Bartilson
6178093Information handling system with circuit assembly having holes filled with filler materialJanuary, 2001Bhatt et al.
6180881Chip stack and method of making sameJanuary, 2001Isaak
6187652Method of fabrication of multiple-layer high density substrateFebruary, 2001Chou et al.
6205654Method of manufacturing a surface mount packageMarch, 2001Burns
6208521Film carrier and laminate type mounting structure using sameMarch, 2001Nakatsuka
6208546Memory moduleMarch, 2001Ikeda
6214641Method of fabricating a multi-chip moduleApril, 2001Akram
6215181Method and apparatus providing redundancy for fabricating highly reliable memory modulesApril, 2001Akram et al.
6215687Semiconductor device and process for manufacturing the sameApril, 2001Sugano et al.
6222737Universal package and method of forming the sameApril, 2001Ross
6222739High-density computer module with stacked parallel-plane packagingApril, 2001Bhakta et al.
6225688Stacked microelectronic assembly and method thereforMay, 2001Kim et al.
6232659Thin multichip moduleMay, 2001Clayton
6233650Using FET switches for large memory arraysMay, 2001Johnson et al.
6234820Method and apparatus for joining printed circuit boardsMay, 2001Perino et al.
6262476Composite member composed of at least two integrated circuits and method for the manufacture of a composite member composed of at least two integrated circuitsJuly, 2001Vidal
6262895Stackable chip package with flex carrierJuly, 2001Forthun
6265660Package stack via bottom leaded plastic (BLP) packagingJuly, 2001Tandy
6266252Apparatus and method for terminating a computer memory busJuly, 2001Karabatsos
6281577Chips arranged in plurality of planes and electrically connected to one anotherAugust, 2001Oppermann et al.
6288907High density integrated circuit module with complex electrical interconnect rails having electrical interconnect strain reliefSeptember, 2001Burns
6288924Semiconductor device and process for manufacturing the sameSeptember, 2001Sugano et al.
6300679Flexible substrate for packaging a semiconductor componentOctober, 2001Mukerji et al.
6316825Chip stack package utilizing a connecting hole to improve electrical connection between leadframesNovember, 2001Park et al.
6323060Stackable flex circuit IC package and method of making sameNovember, 2001Isaak
6336262Process of forming a capacitor with multi-level interconnection technologyJanuary, 2002Dalal et al.
6343020Memory moduleJanuary, 2002Lin et al.
6347394Buffering circuit embedded in an integrated circuit device module used for buffering clocks and other input signalsFebruary, 2002Ochoa et al.
6349050Methods and systems for reducing heat flux in memory systemsFebruary, 2002Woo et al.
6351029Stackable flex circuit chip package and method of making sameFebruary, 2002Isaak
6357023Connector assembly for testing memory modules from the solder-side of a PC motherboard with forced hot airMarch, 2002Co et al.
6358772Semiconductor package having semiconductor element mounting structure of semiconductor package mounted on circuit board and method of assembling semiconductor packageMarch, 2002Miyoshi
6360433Universal package and method of forming the sameMarch, 2002Ross
6368896Method of wafer level chip scale packagingApril, 2002Farnworth et al.
6370668High speed memory system capable of selectively operating in non-chip-kill and chip-kill modesApril, 2002Garrett, Jr. et al.
6376769High-density electronic package, and method for making sameApril, 2002Chung
6392162Double-sided flexible jumper assembly and method of manufactureMay, 2002Karabatsos
6404043Panel stacking of BGA devices to form three-dimensional modulesJune, 2002Isaak
6410857Signal cross-over interconnect for a double-sided circuit card assemblyJune, 2002Gonya
6424532Heat sink and memory module with heat sinkJuly, 2002Kawamura361/708
6426240Stackable flex circuit chip package and method of making sameJuly, 2002Isaak
6426549Stackable flex circuit IC package and method of making sameJuly, 2002Isaak
6426560Semiconductor device and memory moduleJuly, 2002Kawamura et al.
6428360Memory module with offset notches for improved insertion and stability and memory module connectorAugust, 2002Hassanzadeh et al.
6433418Apparatus for a vertically accumulable semiconductor device with external leads secured by a positioning mechanismAugust, 2002Fujisawa et al.
6444921Reduced stress and zero stress interposers for integrated-circuit chips, multichip substrates, and the likeSeptember, 2002Wang et al.
6446158Memory system using FET switches to select memory banksSeptember, 2002Karabatsos
6449159Semiconductor module with imbedded heat spreaderSeptember, 2002Haba
6452826Memory module systemSeptember, 2002Kim et al.
6459152Semiconductor device having a chip, reinforcing plate, and sealing material sharing a common rear surfaceOctober, 2002Tomita et al.
6462412Foldable, flexible laminate type semiconductor apparatus with reinforcing and heat-radiating platesOctober, 2002Kamei et al.
6465877Semiconductor package including flex circuit, interconnects and dense array external contactsOctober, 2002Farnworth et al.
6465893Stacked chip assemblyOctober, 2002Khandros et al.
6472735Three-dimensional memory stacking using anisotropic epoxy interconnectionsOctober, 2002Isaak
6473308Stackable chip package with flex carrierOctober, 2002Forthun
6486544Semiconductor device and method manufacturing the same, circuit board, and electronic instrumentNovember, 2002Hashimoto
6489687Semiconductor device and method of manufacturing the same, manufacturing device, circuit board, and electronic equipmentDecember, 2002Hashimoto
6502161Memory system including a point-to-point linked memory subsystemDecember, 2002Perego et al.
6514793Stackable flex circuit IC package and method of making sameFebruary, 2003Isaak
6521984Semiconductor module with semiconductor devices attached to upper and lower surface of a semiconductor substrateFebruary, 2003Matsuura
6528870Semiconductor device having a plurality of stacked wiring boardsMarch, 2003Fukatsu et al.
6531772Electronic system including memory module with redundant memory capabilityMarch, 2003Akram et al.
6544815Panel stacking of BGA devices to form three-dimensional modulesApril, 2003Isaak
6552910Stacked-die assemblies with a plurality of microelectronic devices and methods of manufactureApril, 2003Moon et al.
6552948Methods and systems for reducing heat flux in memory systemsApril, 2003Woo et al.
6560117Packaged microelectronic die assemblies and methods of manufactureMay, 2003Moon
6566746Panel stacking of BGA devices to form three-dimensional modulesMay, 2003Isaak et al.
6572387Flexible circuit connector for stacked chip moduleJune, 2003Burns et al.
6573593Integrated circuit with a housing accommodating the integrated circuitJune, 2003Syri et al.
6576992Chip scale stacking system and methodJune, 2003Cady et al.
6588095Method of processing a device by electrophoresis coatingJuly, 2003Pan
6590282Stacked semiconductor package formed on a substrate and method for fabricationJuly, 2003Wang et al.
6600222Stacked microelectronic packagesJuly, 2003Levardo
6614664Memory module having series-connected printed circuit boardsSeptember, 2003Lee
6627984Chip stack with differing chip package typesSeptember, 2003Bruce et al.
6629855Memory system including guides that receive memory modulesOctober, 2003North et al.
6646936Semiconductor memory device shiftable to test mode in module as well as semiconductor memory module using the sameNovember, 2003Hamamatsu et al.
6660561Method of assembling a stackable integrated circuit chipDecember, 2003Forthun
6661092Memory moduleDecember, 2003Shibata et al.
6677670Semiconductor deviceJanuary, 2004Kondo
6683377Multi-stacked memory packageJanuary, 2004Shim et al.
6690584Information-processing device having a crossbar-board connected to back panels on different sidesFebruary, 2004Uzuka et al.
6699730Stacked microelectronic assembly and method thereforMarch, 2004Kim et al.
6720652Apparatus providing redundancy for fabricating highly reliable memory modulesApril, 2004Akram et al.
6721181Elongated heat sink for use in converter assembliesApril, 2004Pfeifer et al.
6721185Memory module having balanced data I/O contacts padsApril, 2004Dong et al.
6721226Methods and systems for reducing heat flux in memory systemsApril, 2004Woo et al.
6744656Semiconductor device and process for manufacturing the sameJune, 2004Sugano et al.
6751113Arrangement of integrated circuits in a memory moduleJune, 2004Bhakta et al.
6756661Semiconductor device, a semiconductor module loaded with said semiconductor device and a method of manufacturing said semiconductor deviceJune, 2004Tsuneda et al.
6760220Rugged modular PC 104 chassis with blind mate connector and forced convection cooling capabilitiesJuly, 2004Canter et al.
6762942Break away, high speed, folded, jumperless electronic assemblyJuly, 2004Smith
6768660Multi-chip memory devices and modules including independent control of memory chipsJuly, 2004Kong et al.
6833981Spin valve magnetic head with three underlayersDecember, 2004Suwabe et al.
6833984Semiconductor module with serial bus connection to multiple diesDecember, 2004Belgacem
6839266Memory module with offset data lines and bit line swizzle configurationJanuary, 2005Garrett, Jr. et al.
6841868Memory modules including capacity for additional memoryJanuary, 2005Akram et al.
6850414Electronic printed circuit board having a plurality of identically designed, housing-encapsulated semiconductor memoriesFebruary, 2005Benisek et al.
6873534Arrangement of integrated circuits in a memory moduleMarch, 2005Bhakta et al.
6878571Panel stacking of BGA devices to form three-dimensional modulesApril, 2005Isaak et al.
6884653Folded interposerApril, 2005Larson
6914324Memory expansion and chip scale stacking system and methodJuly, 2005Rapport et al.
6919626High density integrated circuit moduleJuly, 2005Burns
6956284Integrated circuit stacking system and methodOctober, 2005Cady et al.
7053478Pitch change and chip scale stacking systemMay, 2006Roper et al.
7079396Memory module coolingJuly, 2006Gates et al.361/719
7094632Low profile chip scale stacking system and methodAugust, 2006Cady et al.
7180167Low profile stacking system and methodFebruary, 2007Patridge et al.
7289327Active cooling methods and apparatus for modulesOctober, 2007Goodwin et al.361/701
7324352High capacity thin module system and methodJanuary, 2008Goodwin361/803
20010001085Memory module with offset notches for improved insertion and memory module connectorMay, 2001Hassanzadeh et al.
20010006252Stacked microelectronic assembly and method thereforJuly, 2001Kim et al.
20010013423FLIP CHIP ATTACH ON FLEXIBLE CIRCUIT CARRIER USING CHIP WITH METALLIC CAP ON SOLDERAugust, 2001Dalal et al.
20010015487Stackable chip package with flex carrierAugust, 2001Forthun
20010026009Semiconductor devicse, a semicinductor module loaded with said semiconductor device and a method of manufacturing said semicoductor deviceOctober, 2001Tsuneda et al.
20010028588Semiconductor memoryOctober, 2001Yamada et al.
20010035572Stackable flex circuit chip package and method of making sameNovember, 2001Isaak
20010040793Electronic device and method of producing the sameNovember, 2001Inaba361/749
20010052637Memory modules including capacity for additional memoryDecember, 2001Akram et al.
20020001216SEMICONDUCTOR DEVICE AND PROCESS FOR MANUFACTURING THE SAMEJanuary, 2002Sugano et al.
20020006032Low-profile registered DIMMJanuary, 2002Karabatsos
20020030995HeadlightMarch, 2002Shoji
20020076919Composite interposer and method for producing a composite interposerJune, 2002Peters et al.
20020094603Three-dimensional memory stacking using anisotropic epoxy interconnectionsJuly, 2002Isaak
20020101261Tri-directional, high-speed bus switchAugust, 2002Karabatsos
20020139577In-street integrated circuit wafer viaOctober, 2002Miller
20020164838Flexible ball grid array chip scale packages and methods of fabricationNovember, 2002Moon et al.
20020180022Semiconductor deviceDecember, 2002Emoto
20020185731Method and apparatus providing redundancy for fabricating highly reliable memory modulesDecember, 2002Akram et al.
20020196612Arrangement of memory chip housings on a DIMM circuit boardDecember, 2002Gall et al.
20030002262Electronic printed circuit board having a plurality of identically designed, housing-encapsulated semiconductor memoriesJanuary, 2003Benisek et al.
20030026155Semiconductor memory module and register buffer device for use in the sameFebruary, 2003Yamagata
20030035328Semiconductor memory device shiftable to test mode in module as well as semiconductor memory module using the sameFebruary, 2003Hamamatsu et al.
20030045025Method of fabricating a molded package for micromechanical devicesMarch, 2003Coyle et al.
20030049886Electronic system modules and method of fabricationMarch, 2003Salmon
20030064548Panel stacking of BGA devices to form three-dimensional modulesApril, 2003Isaak
20030081387Module and connector having multiple contact rowsMay, 2003Schulz
20030081392Integrated circuit stacking system and methodMay, 2003Cady et al.
20030089978Memory-module and a method of manufacturing the sameMay, 2003Miyamoto et al.
20030090879Dual inline memory moduleMay, 2003Doblar et al.
20030096497Electrode structure for use in an integrated circuitMay, 2003Moore et al.
20030109078Semiconductor device, method for manufacturing the same, and method for mounting the sameJune, 2003Takahashi et al.
20030116835Memory-module and a method of manufacturing the sameJune, 2003Miyamoto et al.
20030159278Methods and apparatus for fabricating Chip-on-Board modulesAugust, 2003Peddle
20030168725Methods of making microelectronic assemblies including folded substratesSeptember, 2003Warner et al.
20040000708Memory expansion and chip scale stacking system and methodJanuary, 2004Rapport et al.
20040012991Semiconductor memory moduleJanuary, 2004Kozaru
20040021211Microelectronic adaptors, assemblies and methodsFebruary, 2004Damberg
20040099938Assemblies having stacked semiconductor chips and methods of making sameMay, 2004Kang et al.
20040150107Stack package and fabricating method thereofAugust, 2004Cha et al.
20040229402Low profile chip scale stacking system and methodNovember, 2004Cady et al.
20040236877Switch/network adapter port incorporating shared memory resources selectively accessible by a direct execution logic element and one or more dense logic devices in a fully buffered dual in-line memory module format (FB-DIMM)November, 2004Burton
20050082663Semiconductor device and semiconductor moduleApril, 2005Wakiyama et al.
20050108468MEMORY DEVICE WITH PROGRAMMABLE RECEIVERS TO IMPROVE PERFORMANCEMay, 2005Hazelzet et al.
20050133897Stack package with improved heat radiation and module having the stack package mounted thereonJune, 2005Baek et al.
20050242423Stacked module systems and methodsNovember, 2005Patridge et al.
20050263911Circuit device and manufacturing method thereofDecember, 2005Igarashi et al.
20060020740Multi-node architecture with daisy chain communication link configurable to operate in unidirectional and bidirectional modesJanuary, 2006Bartley et al.
20060049502Module thermal management system and methodMarch, 2006Goodwin et al.257/686
20060050492Thin module system and methodMarch, 2006Goodwin et al.361/767
20060050496Thin module system and methodMarch, 2006Goodwin
20060050497Buffered thin module system and methodMarch, 2006Goodwin
20060053345Thin module system and methodMarch, 2006Goodwin
20060091529High capacity thin module system and methodMay, 2006Wehrly et al.
20060095592Multi-channel memory architecture for daisy chained arrangements of nodes with bridging between memory channelsMay, 2006Borkenhagen
20060111866Method, apparatus, and system for memory read transaction biasing in mirrored mode to provide thermal managementMay, 2006LeClerg et al.
20060125067Flex circuit constructions for high capacity circuit module systems and methodsJune, 2006Wehrly et al.
Foreign References:
EP0000122October, 1984Cell for ultracentrifuge in interferometric optical analyses.
EP0298211January, 1989Ceramic card assembly having enhanced power distribution and cooling
EP1119049July, 2001Laminate type semiconductor apparatus
GB2130025May, 1984
JP5385159July, 1978
JP5896756June, 1983
JP3102862April, 1991
JP0529534February, 1993
JP5335695December, 1993
JP2821315November, 1998
JP2001077294March, 2001SEMICONDUCTOR DEVICE
JP2001085592March, 2001SEMICONDUCTOR DEVICE, MANUFACTURE THEREOF, CIRCUIT BOARD AND ELECTRONIC APPARATUS
JP2001332683November, 2001LAMINATED SEMICONDUCTOR DEVICE AND MANUFACTURING METHOD THEREOF
JP2002009231January, 2002SEMICONDUCTOR DEVICE
JP200337246February, 2003
JP2003086760March, 2003SEMICONDUCTOR DEVICE AND MANUFACTURING METHOD THEREFOR
JP2003086761March, 2003SEMICONDUCTOR DEVICE AND MANUFACTURING METHOD THEREFOR
JP2003309246October, 2003SEMICONDUCTOR MODULE
JP2003347503December, 2003SEMICONDUCTOR DEVICE AND METHOD OF MANUFACTURING THE SAME, AND SEMICONDUCTOR MOUNTING STRUCTURE
WO/2003/037053May, 2003CHIP SCALE STACKING SYSTEM AND METHOD
WO/2004/109802December, 2004MEMORY EXPANSION AND INTEGRATED CIRCUIT STACKING SYSTEM AND METHOD
Other References:
PCT/US05/28547 International Search Report and Written Opinion, PCT, Aug. 18, 2006.
PCT/US05/28547 Notification Concerning Transmittal of International Preliminary Report on Patentability, Mar. 15, 2007.
GB 0516622.8 Search Report, May 25, 2006.
PCT/US06/04690 International Search Report, PCT, Feb. 16, 2007.
PCT/US06/38720 International Search Report and Written Opinion, PCT, Apr. 5, 2007.
U.S. Appl. No. 11/306,803, filed Jan. 11, 2006, Chris Karabatsos.
Complaint filed Mar. 8, 2007, in the United States District Court for the District of Massachusetts, Boston Division, Civil Action No. 07 CA 10468 DPW.
Letter dated Sep. 11, 2006, from Chris Karabatsos of Kentron Technologies to John Kelly, President of JEDEC Solid State Technology Association, concerning potential interferences involving U.S. Appl. No. 11/306,803.
Pages 19-22 of Presentation by Netlist, Aug. 2004.
Flexible Printed Circuit Technology—A Versatile Interconnection Option. (Website 2 pages) Fjelstad, Joseph. Dec. 3, 2002.
Die Products: Ideal IC Packaging for Demanding Applications—Advanced packaging that's no bigger than the die itself brings together high performance and high reliability with small size and low cost. (Website 3 pages with 2 figures) Larry Gilg and Chris Windsor. Dec. 23, 2002. Published on Internet.
Tessera uZ Ball Stack Package. 4 figures that purport to be directed to the uZ—Ball Stacked Memory, Published on the Internet, date unavailable.
Chip Scale Review Online—An Independent Journal Dedicated to the Advancement of Chip-Scale Electronics. (Website 9 pages) Fjelstad, Joseph, Pacific Consultants L.LC., Published Jan. 2001 on Internet.
Flexible Thinking: Examining the Flexible Circuit Tapes. (Website 2 pages) Fjelstad, Joseph., Published Apr. 20, 2000 on Internet.
Ron Bauer, Intel. “Stacked-CSP Delivers Flexibility, Reliability, and Space-Saving Capabilities”, vol. 3, Spring 2002. Published on the Internet.
Tessera Technologies, Inc.—Semiconductor Intellectual Property, Chip Scale Packaging—Website pp. (3), Internet, date unavailable.
Tessera Introduces uZ ä—Ball Stacked Memory Package for Computing and Portable Electronic Products Joyce Smaragdis, Tessera Public Relations, Sandy Skees, MCA PR (www.tessera.com/news—events/press—coverage.cfm); 2 figures that purport to be directed to the uZ ä—Ball Stacked Memory Package. Published Jul. 17, 2002 in San Jose, CA.
William R. Newberry, Design Techniques for Ball Grid Arrays, Xynetix Design Systems, Inc., Portland, Maine, Published on the Internet, date unavailable.
Chip Scale Packaging and Redistribution, Paul A. Magill, Glenn A. Rinne, J. Daniel Mis, Wayne C. Machon, Joseph W. Baggs, Unitive Electronics Inc., date unavailable.
Dense-Pac Microsystems, 16 Magabit High Speed CMOS SRAM DPS1MX16MKn3, date unavailable.
Dense-Pac Microsystems, 256 Megabyte CMOS DRAM DP3ED32MS72RW5, date unavailable.
Dense-Pac Microsystems, Breaking Space Barriers, 3-D Technology 1993.
Dense-Pac Microsystems, DPS512X16A3, Ceramic 512K+6 CMOS SRAM Module, date unavailable.
IBM Preliminary 168 Pin SDRAM Registered DIMM Functional Description & Timing Diagrams, date unavailable.
3D Interconnection for Ultra-Dense Multichip Modules, Christian VAL, Thomson-CSF DCS Computer Division, Thierry Lemoine, Thomson-CSF RCM Radar Countermeasures Division, date unavailable.
High Density Memory Packaging Technology High Speed Imaging Applications, Dean Frew, Texas Instruments Incorporated, date unavailable.
Vertically-Intergrated Package, Alvin Weinberg, Pacesetter, Inc. and W. Kinzy Jones, Florida International University, date unavailable.
Primary Examiner:
Chambliss, Alonzo
Attorney, Agent or Firm:
Fish & Richardson P.C.
Parent Case Data:

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 11/231,418, filed Sep. 21, 2005, pending, which application is, in turn, a continuation-in-part of Pat. App. No. PCT/US05/28547 filed Aug. 10, 2005, pending, as well as a continuation-in-part of U.S. patent application Ser. No. 11/068,688 filed Mar. 1, 2005, now U.S. Pat. No. 7,324,352, which application is a continuation-in-part of U.S. patent application Ser. No. 11/007,551 filed Dec. 8, 2004, pending, which application is a continuation-in-part of U.S. patent application Ser. No. 10/934,027 filed Sep. 3, 2004, pending. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/005,992 filed Dec. 7, 2004, pending, which application is a continuation-in-part of U.S. patent application Ser. No. 10/934,027 filed Sep. 3, 2004. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/193,954 filed Jul. 29, 2005, pending, which application is a continuation-in-part of U.S. patent application Ser. No. 11/007,551 filed Dec. 8, 2004, pending. This application is also a continuation-in-part of U.S. patent application Ser. No. 10/934,027 filed Sep. 3, 2004, pending. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/123,721 filed May 6, 2005, pending, which application is a continuation-in-part of both U.S. patent application Ser. No. 11/068,688 filed Mar. 1, 2005, now U.S. Pat. No. 7,324,352 and U.S. patent application Ser. No. 11/005,992 filed Dec. 7, 2004, both of which are pending.

Claims:
The invention claimed is:

1. A circuit module comprising: a rigid substrate having two opposing lateral sides, an edge and a substrate extension; flex circuit having a first side which has plural contacts adapted for connection to a circuit board socket and first-flex-side first and second ranks of plural memory ICs between which are disposed the plural contacts, and the flex circuit having a second side which has second-flex-side first and second ranks of plural memory ICs, the flex circuit being disposed about the edge of the rigid substrate to dispose the second-flex-side first and second ranks of plural memory lCs adjacent to the rigid substrate; a first thermal spreader adjacent to and thermally connected to the first-flex-side first rank of plural memory ICs and a second thermal spreader adjacent to and thermally connected to the first-flex-side second rank of plural memory lCs, wherein the first and second thermal spreaders each exhibiting a thermal path extension which cooperates with a substrate extension to provide a thermal conduction path from the second-flex-side first and second ranks of plural ICs to the first and second thermal spreaders, respectively.

2. The circuit module of claim 1 in which the rigid substrate is comprised of thermally conductive material.

3. The circuit module of claims 1 or 2 in which an IC having a function other than memory is populated on the second side of the flex circuit.

4. The circuit module of claim 3 in which the IC having a function other than Memory is an AMB.

5. The circuit module of claims 2 or 4 in which the first and second thermal spreaders each have at least one added extension in addition to the thermal path extension.

6. The circuit module of claim 1 in which the rigid substrate and the thermal spreaders are comprised of metallic thermally conductive material.

7. The circuit module of claim 1 in which the rigid substrate is comprised of aluminum.

8. The circuit module of claim 1 in which the rigid substrate and the thermal spreaders are comprised of aluminum.

9. A circuit module comprising: (a) a rigid substrate having two opposing lateral sides and an edge and a thermal sink accessible on at least one of the two opposing lateral sides of the substrate; and (b) a flex circuit having first and second sides, the first side of the flex circuit having plural contacts adapted for connection to a circuit board socket and at least the first of the first and second sides of the flex circuit being populated with plural memory CSPs with the second major side of the flex circuit being populated with at least an AMB, the flex circuit being disposed about the edge of the rigid substrate to dispose the AMB in thermal contact with the thermal sink; (c) first and second thermal spreaders each exhibiting a thermal path extension which cooperates with a substrate extension to provide a thermal conduction path front the first side plural memory CSPs to the first and second thermal spreaders, respectively.

10. The circuit module of claim 9 in which the rigid substrate is comprised of thermally conductive material.

11. The circuit module of claim 9 or 10 in which the substrate exhibits at least one extension.

12. The circuit module of claim 9 or 10 in which the rigid substrate is comprised of aluminum.

13. The circuit module of claim 9 in which at least a portion of the thermal sink provides an indentation into which, at least in part, a portion of the AMB is introduced.

14. The circuit module of claim 9 in which the thermal contact is realized through thermally conductive adhesive.

15. The circuit module of claim 9 in which both the first and second sides of the flex circuit are populated with plural memory CSPs.

16. The circuit module of claim 9 in which the thermal sink is comprised of copper.

17. The circuit module of claim 9 in which the thermal sink is comprised of non-metallic material that is thermally-conductive.

18. The circuit module of claim 9 in which the rigid substrate exhibits a window through which the thermal sink is accessible.

19. The circuit module of claim 9 in which the thermal sink is across a window of the rigid substrate.

20. The circuit module of claim 9 in which the thermal sink covers a window of the rigid substrate.

21. A circuit module comprising: a rigid substrate comprised of thermally conductive material and having first and second opposing lateral sides and an edge the rigid substrate having a window through the substrate; (a) to first and second thermal spreaders; (b) first and second thermal spreaders; (c) a thermal sink, at least a part of which is accessible in the window through the substrate; (d) a flex circuit having first and second sides, the firm side of the flex circuit having plural contacts adapted for connection to a circuit board socket and the first and second sides of the flex circuit being populated with plural CSPs of a first type with the second major side of the flex circuit being populated with at least one CSP of a second type, the flex circuit being disposed about the edge of the rigid substrate to dispose the at least one CSP of the second type in thermal contact with the thermal sink and the first thermal spreader being disposed adjacent to and in thermal connection with at least a selected first one of the plural CSPs of the first type and the second thermal spreader being disposed adjacent to and in thermal connection with at least a selected second one of the plural CSPs of the first type, wherein the first and second thermal spreaders each exhibiting a thermal path extension which cooperates with a substrate extension to provide a thermal conduction path from the plural memory CSPs to tire first and second thermal spreaders, respectively.

22. The circuit module of claim 21 in which the rigid substrate is comprised of thermally conductive material.

23. The circuit module of claim 21 in which the thermal sink is configured with an indentation into which, at least in part, a portion of the at least one CSP of the second type is introduced.

24. The circuit module of claim 21 in which the substrate is comprised of aluminum and the first and second thermal spreaders are comprised of aluminum and the substrate exhibits an extension.

25. The circuit module of claim 21 in which the rigid substrate is comprised of metallic thermally-conductive material.

26. The circuit module of claim 21 in which the thermal sink is comprised of copper.

27. The circuit module of claim 21 further comprising at least one alignment hole in the flex circuit for use in aligning the flex circuit with the substrate during assembly.

28. The circuit module of claim 21 in which the flex circuit is comprised of more than one conductive layer.

29. The circuit module of claim 21 in which the flex circuit is comprised for four conductive layers.

30. A circuit module comprising: a rigid substrate have first and second lateral sides, an edge, and a substrate extension; a flex circuit populated with plural ICs and having a set of contacts for insertion in a circuit board edge connector, the flex circuit being disposed about the edge of the substrate to place the flex circuit on each side of the rigid substrate; and first and second thermal spreaders disposed in thermal connection with and adjacent to selected ones of the plural ICs, each of the first and second thermal spreaders exhibiting a thermal path extension which cooperates with a substrate extension to provide a thermal conduction path from the plural ICs to the first and second thermal spreaders.

31. The circuit module of claim 30 in which the rigid substrate is comprised of thermally conductive material.

32. The circuit module of claim 31 in which the rigid substrate exhibits a substrate extension which forms a part of a thermal path between the rigid substrate and the selected ones of the plural ICs which are adjacent to the first or second thermal spreaders.

33. The circuit module of claim 30 in which the flex circuit is comprised of more than one conductive layer.

34. A circuit module comprising: (a) a rigid substrate having two opposing lateral sides and an edge and an extension; (b) a flex circuit having plural contacts adapted for connection to a circuit board socket, the flex circuit being populated with plural CSPs of a first type and at least one CSP of a second type, the flex circuit being disposed about the edge of the rigid substrate to dispose the at least one CSP of the second type in thermal contact with the rigid substrate: and (c) first and second thermal spreaders each of which is adjacent to selected ones of the plural CSPs of the first type, each of the first and second thermal spreaders exhibiting a thermal path extension which cooperates with a substrate extension thermal conduction path from the plural CSPs to the first and second thermal spreaders.

Description:

FIELD

The present invention relates to systems and methods for creating high density circuit modules and, in particular, to systems and methods for creating such modules with features directed to reducing thermal loading.

BACKGROUND

Memory expansion is one of the many fields where high density circuit module solutions provide space-saving advantages. For example, the well-known DIMM (Dual In-line Memory Module) has been used for years, in various forms, to provide memory expansion. A typical DIMM includes a conventional PCB (printed circuit board) with memory devices and supporting digital logic devices mounted on both sides. The DIMM is typically mounted in the host computer system by inserting a contact-bearing edge of the DIMM into a card edge connector. Typically, systems that employ DIMMs provide limited profile space for such devices and conventional DIMM-based solutions have typically provided only a moderate amount of memory expansion.

As bus speeds have increased, fewer devices per channel can be reliably addressed with a DIMM-based solution. For example, 288 ICs or devices per channel may be addressed using the SDRAM-100 bus protocol with an unbuffered DIMM. Using the DDR-200 bus protocol, approximately 144 devices may be addressed per channel. With the DDR2-400 bus protocol, only 72 devices per channel may be addressed. This constraint has led to the development of the fully-buffered DIMM (FB-DIMM) with buffered C/A and data in which 288 devices per channel may be addressed. That buffering function is provided by what is typically identified as the Advanced Memory Buffer or AMB. With the FB-DIMM, not only has capacity increased, pin count has declined to approximately 69 signal pins from the approximately 240 pins previously required.

The FB-DIMM circuit solution is expected to offer practical motherboard memory capacities of up to about 192 gigabytes with six channels and eight DIMMs per channel and two ranks per DIMM using one gigabyte DRAMs. This solution should also be adaptable to next generation technologies and should exhibit significant downward compatibility.

There are several known methods to improve the limited capacity of a DIMM or other circuit board. In one strategy, for example, small circuit boards (daughter cards) are connected to the DIMM to provide extra mounting space. The additional connection may, however, cause flawed signal integrity for the data signals passing from the DIMM to the daughter card while the additional thickness of the daughter card(s) increases the profile of the module.

Multiple die packages (MDP) can also be used to increase DIMM capacity. This scheme increases the capacity of the memory devices on the DIMM by including multiple semiconductor die in a single device package. The additional heat generated by the multiple die typically requires, however, additional cooling capabilities to operate at maximum operating speed. Further, the MDP scheme may exhibit increased costs because of increased yield loss from packaging together multiple die that are not fully pre-tested.

Stacked packages are yet another way to increase module capacity. Capacity is increased by stacking packaged integrated circuits to create a high-density circuit module for mounting on the larger circuit board. In some techniques, flexible conductors are used to selectively interconnect packaged integrated circuits. Staktek Group L.P. has developed numerous systems for aggregating CSP (chipscale packaged) devices in space saving topologies. The increased component height of some stacking techniques may, however, alter system requirements such as, for example, required cooling airflow or the minimum spacing around a circuit board on its host system.

Typically, the known methods for improved memory module performance or enlarged capacity raise thermal management issues. For example, when a conventional packaged DRAM is mounted on a DIMM, the primary thermal path is through the balls of the package into the core of a multilayer DIMM that has less than desirable thermal characteristics. In particular, when an advanced memory buffer (AMB) is employed in an FB-DIMM, a significant amount of heat is generated. Consequently, the already marginal thermal shedding attributes of DIMM circuit modules is exacerbated in a typical FB-DIMM by the localized generation of heat by the AMB.

What is needed, therefore, are methods and structures for providing high capacity circuit boards in thermally-efficient, reliable designs that perform well at higher frequencies but are not too large, yet can be made at reasonable cost with commonly available and readily managed materials.

SUMMARY

Flexible circuitry is populated with integrated circuitry (ICs) disposed along one or both major sides of the flexible circuitry. Contacts are distributed along the flexible circuitry to provide connection between the module and an application environment. The populated flexible circuitry is supported by a rigid substrate, about which it is disposed in preferred embodiments, thus placing the integrated circuitry on one or both sides of the substrate with one or more layers of integrated circuitry on one or both sides of the substrate. The substrate is preferably devised from thermally-conductive materials and one or more thermal spreaders are disposed in thermal contact or connection with at least some of the constituent integrated circuitry of the module. Optionally, as an additional thermal management feature, the module may include a high thermal conductivity thermal sink or area that is disposed proximal to higher thermal energy IC devices. In preferred embodiments, extensions from the substrate body encourage reduced thermal variations amongst the ICs of the module while providing an enlarged surface for shedding thermal energy from the module.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of a module devised in accordance with a preferred embodiment of the present invention.

FIG. 2 is an enlarged view of the area marked “A” in FIG. 1.

FIG. 3 is a cross-sectional depiction of a preferred embodiment taken along a perspective line that corresponds to line B-B of FIG. 1.

FIG. 4 is a cross-sectional view of a preferred embodiment taken along a perspective line that corresponds to line C-C of FIG. 1.

FIG. 5 is a depiction of a substrate employed in a preferred embodiment of the present invention.

FIG. 6 illustrates a substrate employed with an alternative embodiment of the present invention in which an area of the substrate is deformed to provide an indentation.

FIG. 7 depicts one side of a flex circuit employed in a preferred embodiment of the present invention.

FIG. 8 depicts another side of the flex circuit depicted in FIG. 7.

FIG. 9 is a view of a preferred embodiment before thermal spreaders devised in accordance with a preferred embodiment of the present invention are included in the module. A cutaway area D is provided to enhance illustration of certain features.

FIG. 10 is an enlarged depiction of the area identified with “D” in FIG. 9.

FIG. 11 is a cross-sectional depiction of the area near an end of a substrate as employed in a preferred embodiment of the present invention.

FIG. 12 is an exploded cross-sectional view of a flex circuit employed in a preferred embodiment of the present invention.

FIG. 13 is a cross-sectional view of another preferred embodiment devised in accordance with the invention.

FIG. 14 is an enlarged perspective view of the preferred embodiment of FIG. 13 devised in accordance with the present invention.

FIG. 15 is another cross-sectional view of another preferred embodiment devised in accordance with the invention.

FIG. 16 is an enlarged perspective view of the preferred embodiment of FIG. 15 devised in accordance with the present invention.

FIG. 17 is another cross-sectional view of another preferred embodiment devised in accordance with the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 and 2 depict a module 10 devised in accordance with a preferred embodiment of the present invention. The depictions illustrate module 10 having substrate 14 about which is disposed flex circuit 12 populated with ICs 18 which are, in a preferred embodiment, integrated circuitry in CSP packages. Some alternative embodiments will have separate flex circuit on each side of substrate 14 . Substrate 14 is shown with an optional extension 16 T which, in this embodiment, is integral with the body 14 B of substrate 14 .

Optional extension 16 T may be devised in a variety of configurations and need not extend laterally from the main axis of substrate 14 in both directions. For example, extension 16 T may extend from substrate 14 in only one direction and need not project perpendicular from the body 14 B of substrate 14 .

Preferably, substrate 14 is comprised of thermally conductive material. Metallic materials are preferred choices. For example, aluminum like many other metallic materials, is thermally conductive and may be readily manipulated for configuration as substrate 14 . Materials such as FR4 may be employed, but if non-metallic materials are employed, other non-metallic materials that are thermally conductive are preferred over FR4. Carbon-based materials and certain plastics, for example, are known to readily conduct thermal energy and, as alternatives to metallic materials, such materials may be employed to advantage in preferred embodiments in accordance with the present invention where metallic materials are not available or wanted.

In the depicted embodiment, thermal spreaders 13 1 and 13 2 are thermally connected to ICs 18 and substrate 14 . Thermal spreaders 13 1 and 13 2 are comprised of thermally conductive material with higher conductivity metallic materials being preferred. Aluminum is a preferred choice for thermal spreaders in this embodiment due to its amenability to fabrication and relatively high thermal conductivity. Those of skill will recognize, however, that use of copper and copper alloys for thermal spreaders 13 1 and 13 2 will typically provide even greater thermal benefits although at typically a higher cost. Thermal spreaders 13 1 and 13 2 are preferably thermally connected to ICs 18 (or other ICs where accessible) with thermal adhesive.

ICs 18 are partially shown in FIG. 2 with portions of profiles that represent just some of the many profiles that may be exhibited by ICs 18 . ICs 18 on flexible circuit 12 are, in this preferred embodiment, CSP packaged memory devices of small scale. For purposes of this disclosure, the term chip-scale or “CSP” shall refer to integrated circuitry of any function with an array package providing connection to one or more die through contacts (often embodied as “bumps” or “balls” for example) distributed across a major surface of the package or die. CSP does not refer to leaded devices that provide connection to an integrated circuit within the package through leads emergent from at least one side of the periphery of the package such as, for example, a TSOP.

Embodiments of the present invention may be employed with leaded or CSP devices or other devices in both packaged and unpackaged forms but where the term CSP is used, the above definition for CSP should be adopted. Consequently, although CSP excludes leaded devices, references to CSP are to be broadly construed to include the large variety of array devices (and not to be limited to memory only) and whether die-sized or other size such as BGA and micro BGA as well as flip-chip. As those of skill will understand after appreciating this disclosure, some embodiments of the present invention may be devised to employ stacks of ICs each disposed where an IC 18 is indicated in the exemplar Figs.

Multiple integrated circuit die may be included in a package depicted as a single IC 18 . While in this embodiment memory ICs are used to provide a memory expansion board or module, various embodiments may include a variety of integrated circuits and other components and may be directed principally to functions other than or in addition to memory. Such variety may include processors—whether general purpose or function specific such as graphics, FPGA's, RF transceiver circuitry, and digital logic as a list of non-limiting examples, while primary module functions may include, as a non limiting list of examples, memory, graphics, communications, and computing to name just a few examples. Some modules in accordance with a preferred embodiment will exhibit plural CSPs of a first type, such as memory CSPs, for example, and will have at least one CSP of a second type, such as a microprocessor, graphics processor or buffer or, more particularly, an AMB, for example. Other modules will exhibit ICs of only a first type such as memory CSPs, for example, while other modules may exhibit many types of ICs such as, for example, memory ICs, logic ICs, and one or more buffer ICs.

FIG. 3 is a cross-sectional depiction of an exemplar module 10 taken along a line corresponding to B-B of FIG. 1. ICs 18 are shown as being thermally connected to thermal spreaders 13 1 and 13 2 . The thermal connection between thermal spreaders 13 1 and 13 2 and ICs 18 can be effectuated by direct contact or through an intermediate substance, particularly one that encourages thermal conduction. An example of such a substance is indicated in FIG. 3 with reference 30 representative of a thermal adhesive. Thermal adhesive is also preferred between ICs 18 and substrate 14 as shown. Optional flex support 14 FS supports flex circuit 12 in its transition from end 16 A of substrate 14 toward the ICs.

Those of skill will also note that FIG. 3 may be also representative of a cross-sectional view through an exemplar module 10 along a line corresponding to C-C of FIG. 1 as well as line B-B in those instances where module 10 consists primarily of ICs 18 along its entire length. For example, if no larger IC such as an AMB is employed, a typical memory module 10 comprising constituent CSP ICs 18 along its length may have a cross-sectional aspect that may be represented by the depiction of FIG. 3 when flex circuit 12 is populated on both sides while thermal spreaders 13 1 and 13 2 are disposed adjacent and thermally connected to ICs 18 B which are populated on side 8 of flex circuit 12 as further shown in FIG. 7. Reference to FIG. 7 illustrates that the ICs 18 B represented as being thermally connected to thermal spreaders 13 1 and 13 2 are disposed in two ranks separated by contacts 20 .

It should be recognized that optional substrate extension 16 T enables a thermal conduction path for thermal energy to flow from inner ICs 18 A (shown proximal to substrate 14 in FIG. 3) into thermal spreaders 13 1 and 13 2 through the thermal connection shown extant between substrate 14 and thermal spreaders 13 1 and 13 2 effectuated by substrate extension 16 T in thermal connection with thermal spreader extensions 13 1 A and 13 2 A, respectively.

FIG. 4 is a cross-sectional view of an exemplar module 10 that employs a larger IC 19 such as an AMB 19 with the view of FIG. 4 being taken along a line that corresponds to C-C of FIG. 1. FIG. 4 shows a substrate 14 with a window 250 through which an optional thermal sink 14 TS is accessible. Thermal sink 14 TS is comprised, in this preferred embodiment, from metallic material of high thermal conductivity such as, for example, copper or copper alloy and has, in this preferred embodiment, a central portion 14 TC that is a copper field substantially larger than and preferably in thermal contact with IC 19 which, in this preferred embodiment, is an AMB. AMB die 19 D is in contact with area 14 TC of thermal sink 14 TS either directly, or through thermally conductive adhesive or a thermally conductive gasket material, for example. Thermal contact with a part of circuit 19 should be considered thermal contact with circuit 19 .

In this preferred embodiment, central portion 14 TC of thermal sink 14 TS is raised above the periphery of thermal sink 14 TS and additionally provides an indentation into which may be introduced at least a portion of AMB circuit 19 such as, for example, AMB die 19 D, to assist in realization of a low profile for module 10 . Neither thermal sink 14 TS nor an indentation are required, however, to practice the invention. In the preferred depicted embodiment, thermal sink 14 TS is disposed over a window 250 through substrate 14 . AMB circuit 19 , which is mounted on the “inside” of flex circuit 12 , is disposed, at least in part, into window 250 from the “back” side of substrate 14 to realize thermal contact with thermal sink 14 TS to provide a conduit to reduce thermal energy loading of AMB circuit 19 .

Thermal sink 14 TS need not cover the entirety of window 250 . In other embodiments, for example, thermal sink 14 TS may merely be across the window 250 or thermal sink 14 TS may be set into window 250 instead of over or across the opening of window 250 . Thermal sink 14 TS is typically a separate piece of metal from substrate 14 but, after appreciating this specification, those of skill will recognize that, in alternative instances, thermal sink 14 TS may be integral with substrate 14 or a particular portion of substrate 14 may be constructed to be a thermal sink 14 TS in accordance with the teachings herein. For example, substrate 14 may be comprised of aluminum, while a thermal sink area 14 TS of substrate 14 may be comprised of copper yet substrate 14 and thermal sink 14 TS are of a single piece. In a variation of the integral thermal sink-substrate embodiment, the thermal sink could be attached to the substrate without a window and thus be preferentially accessible only on one side of substrate 14 . Construction expense will be more likely to militate against such construction but the principles of the invention encompass such constructions. Consequently, a window in substrate 14 is not required to practice some embodiments of the invention. Therefore, a thermal sink 14 TS should be considered to be an area or element integral with or attached to a substrate 14 and the material from which that thermal sink is composed exhibits greater thermal conductivity than the material of the substrate. To continue the example, substrate 14 may be aluminum while thermal sink 14 TS is comprised of copper.

Substrate 14 has first and second lateral sides identified as S 1 and S 2 . Flex 12 is wrapped about perimeter edge 16 A of substrate 14 . Some alternative embodiments may employ individual flex circuits on each side of substrate 14 . As will be further shown, AMB circuit 19 is mounted on inner side 9 of flex circuit 12 . When flex circuit 12 is disposed about substrate 14 , AMB circuit 19 is introduced, at least in part, into window 250 with AMB die 19 D being disposed, preferably, in thermal contact with thermal sink 14 TS of substrate 14 . That thermal contact is preferably through thermally conductive adhesive 30 but, in an alternative embodiment, another preferred construction may place AMB die 19 D in direct physical contact with thermal sink 14 TS to realize the thermal contact or connection between AMB circuit 19 and thermal sink 14 TS. Other thermal conduction enhancing materials may also be used in place of, or addition to thermal adhesive 30 such as for example, thermal grease or a thermal gasket.

In FIGS. 3 and 4, thermal spreaders 13 1 and 13 2 exhibit optional thermal spreader extensions 13 1 A and 13 2 A which, as previously described, provide a thermal conduction path for thermal energy from the inner ICs 18 A. They also, as shown, in cooperation with extension 16 T, form a thermally conductive enclosure 11 over module 10 . Thermal spreader extensions are not required as a part of thermal spreaders 13 1 and 13 2 , but where employed as those of skill will recognize, they may provide thermal or structural advantages.

In FIG. 5 a depicted substrate 14 is shown as having an integral thermal sink 14 TS. The different materials used for the thermal sink 14 TS as opposed to the substrate in general which result in the different thermal conductivity characteristics between substrate 14 and thermal sink 14 TS are represented by the different hatching of the FIG. 5. For example, thermal sink 14 TS in this depiction may be copper, for example, while the main body of substrate 14 may be comprised of aluminum, to name just one example. Another example could be a plastic bodied substrate 14 and a copper based thermal sink 14 TS. Flex support 14 FS is also shown in FIG. 5 and is typically comprised of the same material as substrate 14 .

Despite the advantages of using a thermal sink with module 10 , for cost reasons, amongst other rationales, some may wish to construct modules with low profiles lacking the conductivity differential of that feature. In that case, FIG. 6 illustrates a substrate employed with another alternative embodiment of the present invention in which an area of the substrate is deformed to provide an indentation but no thermal sink 14 TS is employed. Thus, embodiments that employ substrates such as that depicted in FIG. 6 will not have a thermal sink, but may rely on thermal connection or contact between substrate 14 and IC 19 to dissipate heat generated by IC 19 where IC 19 has been mounted on inner side 9 of flex circuit 12 as shown later. As those of skill will note, indentation 14 IN is not required but provides low profile advantages.

Consequently, an exemplar embodiment that employed a substrate such as that shown in FIG. 6 and does not exhibit a thermal sink 14 TS would look very much like the embodiment shown in FIG. 4 except that the structure labeled 14 TS would not be separate from substrate 14 and would be a part of substrate 14 and composed from the same material. Further, no window 250 would be present since no opening in substrate 14 would be needed. IC 19 would preferably be in thermal contact with substrate 14 .

Where a window 250 in substrate 250 is employed, at least a part of thermal sink 14 TS should be accessible through window 250 from the “other” side of substrate 14 . AMB circuit 19 or other high heat IC 19 and, in particular, AMB die 19 D, may be disposed in or across or over window 250 and preferably, will be introduced into an indentation of thermal sink 14 TS and disposed in thermal contact with thermal sink 14 TS and, more preferably, with the central core 14 TC of thermal sink 14 TS (where a central core has been optionally included in thermal sink 14 TS) either with direct contact or through thermal adhesives or glues. Other embodiments may include additional windows where other high heat circuits are employed on module 10 . Still other embodiments may insert some or all of ICs 18 into cutout areas in substrate 14 as described in detail in U.S. patent application Ser. No. 11/005,992 which has been incorporated by reference herein.

In a preferred embodiment, thermal sink 14 TS covers window 250 on one side of substrate 14 while AMB circuit 19 is disposed, at least in part, into window 250 to realize contact between thermal sink 14 TS and AMB circuit 19 and particularly AMB die 19 D either directly or as mediated through a thermally-conductive adhesive or glue.

FIG. 7 depicts a first side 8 of flex circuit 12 (“flex”, “flex circuitry”, “flexible circuit”) used in constructing a module according to an embodiment of the present invention. Flex circuit 12 is preferably made from one or more conductive layers supported by one or more flexible substrate layers as further described with reference to later FIG. 12. The construction of flex circuitry is known in the art. The entirety of the flex circuit 12 may be flexible or, as those of skill in the art will recognize, the flexible circuit structure 12 may be made flexible in certain areas to allow conformability to required shapes or bends, and rigid in other areas to provide rigid and planar mounting surfaces. Preferred flex circuit 12 has openings 17 for use in aligning flex circuit 12 to substrate 14 during assembly.

The depiction of FIG. 7 shows flex circuit 12 as having first and second fields or ranks of ICs 18 with contacts 20 being disposed between said ranks or fields of ICs 18 . After flex circuit is assembled with substrate 14 , those of skill will recognize that contacts 20 may appear on one or both sides of module 10 depending on the mechanical contact interface particulars of the application. Other embodiments may employ flex circuitry that exhibits contacts closer to an edge of the flex circuit.

Flex circuit 12 may also referenced by its perimeter edges, two of which are typically long (PE long1 and PE long 2 ) and two of which are typically shorter (PE short1 and PE short2 ) although flex circuit 12 may come in a variety of shapes including square. Contact arrays such as array 11 A are disposed beneath ICs 18 and IC 19 , where employed, and are comprised of array contacts 11 C. An exemplar contact array 11 A is shown as is exemplar IC 18 to be mounted at contact array 11 A as depicted.

A first rank, group or plurality of ICs 18 is shown on side 8 of flex circuit 12 and is identified as IC R1 and a second rank, group or plurality of CSPs on side 8 is identified as IC R2 . Those of skill will recognize that the identified pluralities of CSPs are, when disposed in the configurations depicted, typically described as “ranks”. Between the ranks IC R2 and IC R2 , flex circuit 12 bears a plurality of module contacts allocated in this embodiment into two rows (C R1 and C R2 ) of module contacts 20 . When flex circuit 12 is folded about substrate 14 as earlier depicted, side 9 which is depicted in later FIG. 8, is closer to the substrate 14 about which flex circuit 12 is disposed than is side 8 and thus, ICs 18 A which are identified in the cross-sectional view of FIG. 3, for example, are populated along the inner side 9 of flex circuit 12 while those ICs 18 B identified in FIG. 3 are populated along the outer side 8 of flex circuit 12 . Other embodiments may have other numbers of ranks and combinations of plural CSPs connected to create the module of the present invention.

FIG. 7 depicts an exemplar conductive trace 21 connecting row C R2 of module contacts 20 to ICs 18 . Those of skill will understand that there are many such traces in a typical embodiment. Traces 21 may also connect to vias that may transit to other conductive layers of flex 12 in certain embodiments having more than one conductive layer. In a preferred embodiment, vias connect ICs 18 on side 9 of flex 12 to module contacts 20 . An example via is shown as reference 23 . Traces 21 may make other connections between the ICs on either side of flex 12 and may traverse the rows of module contacts 20 to interconnect ICs. Together the various traces and vias make interconnections needed to convey data and control signals amongst the various ICs and buffer circuits. Those of skill will understand that the present invention may be implemented with only a single row of module contacts 20 and may, in other embodiments, be implemented as a module bearing ICs on only one side of flex circuit 12 .

FIG. 8 shows side 9 of flex circuit 12 depicting the other side of the flex circuit shown in FIG. 7 as may be employed in a preferred embodiment. Side 9 of flex circuit 12 is shown as being populated with multiple CSPs 18 and AMB circuit 19 . Side 9 includes fields F 1 and F 2 that each include at least one mounting contact array site for CSPs and, in the depicted case, include multiple contact arrays. Each of fields F 1 and F 2 include, in the depicted preferred embodiment, two pluralities of ICs in this embodiment. Other embodiments may have other arrangements and constituent ICs and, in some cases, may have ICs on only one side of flex circuit 12 . Other embodiments may also have fewer or greater numbers of ranks or pluralities of ICs in each field or on a side of a flex circuit.

FIG. 9 is a view of a preferred embodiment before thermal spreaders devised in accordance with a preferred embodiment of the present invention are appended about the module. A cutaway area D is provided to enhance illustration of certain features.

Flex circuit 12 is cutaway in area “D” to illustrate internal preferred features of module 10 . Area “D” is shown in greater enlargement in later FIG. 10. Within area D are seen thermal sink 14 TS and beyond the cutaway section of thermal sink 14 TS, there is shown a part of a circuit 19 which, in the depicted preferred embodiment, is an AMB employed in FB-DIMM circuitry. AMB circuit 19 includes AMB die 19 D and contacts 19 C.

FIG. 10 is an enlarged depiction of the area D identified in FIG. 9 of an exemplar module 10 depicting in partial cutaway, details concerning the relationship between a high heat IC 19 such as an AMB 19 and substrate 14 in a preferred embodiment. This view provides insight that would otherwise be blocked from view if thermal spreaders 13 1 and 13 2 were included in the depiction. AMB circuit 19 is shown through window 250 through substrate 14 . Preferably, AMB circuit 19 is mounted on what will become the internal side 9 of flex circuit 12 relative to module 10 and is, therefore, inserted into window 250 from the “rear” relative to the perspective shown in FIG. 10. Those of skill will recognize, particularly with reference to FIG. 10, that a portion of flex circuit 12 has been removed to expose thermal sink 14 TS and a part of 14 TS has also been cutaway.

FIG. 11 depicts an enlarged view of the area near end or edge 16 A of an exemplar module 10 . While a rounded configuration is shown, edge 16 A may take on other shapes devised to mate with various connectors or sockets. The form and function of various edge card connectors are well know in the art. In many preferred embodiments, flex 12 is wrapped around edge 16 A of substrate 14 and may be laminated or adhesively connected to substrate 14 with adhesive 30 . The depicted adhesive 30 and flex 12 may vary in thickness and are not drawn to scale to simplify the drawing. The depicted substrate 14 has a thickness such that when assembled with the flex 12 and adhesive 30 , the thickness measured between module contacts 20 falls in the range specified for the mating connector. In some other embodiments, flex circuit 12 may be implemented with two flex circuits 12 A and 12 B instead of one wrapped about end 16 A. For example, a flex circuit 12 A may be disposed on one side of module 10 while another flex circuit 12 B may be disposed on another side of module 10 . Adhesive 30 is employed to attached flex circuit 12 to substrate 14 and contacts 20 are disposed on each side of module 10 . In other embodiments, contacts 20 need not be on both sides of module 10 and may be exhibited on only one side in configurations.

FIG. 12 is an exploded depiction of a flex circuit 12 cross-section according to one preferred embodiment of the present invention. The depicted flex circuit 12 has four conductive layers 1201 - 1204 and seven insulative layers 1205 - 1211 . The numbers of layers described are merely those used in one preferred embodiment and other numbers of layers and arrangements of layers may be employed. Even a single conductive layer flex circuit 12 may be employed in some embodiments, but flex circuits with more than one conductive layer prove to be more adaptable to more complex embodiments of the invention.

Top conductive layer 1201 and the other conductive layers are preferably made of a conductive metal such as, for example, copper or alloy 110 . In this arrangement, conductive layers 1201 , 1202 , and 1204 express signal traces 1212 that make various connections by use of flex circuit 12 . These layers may also express conductive planes for ground, power or reference voltages.

In this embodiment, inner conductive layer 1202 expresses traces connecting to and among various ICs. The function of any one of the depicted conductive layers may be interchanged in function with others of the conductive layers. Inner conductive layer 1203 expresses a ground plane, which may be split to provide VDD return for pre-register address signals. Inner conductive layer 1203 may further express other planes and traces. In this embodiment, floods or planes at bottom conductive layer 1204 provides VREF and ground in addition to the depicted traces.

Insulative layers 1205 and 1211 are, in this embodiment, dielectric solder mask layers which may be deposited on the adjacent conductive layers for example. Other embodiments may not have such adhesive dielectric layers. Insulating layers 1206 , 1208 , and 1210 are preferably flexible dielectric substrate layers made of polyimide. However, any suitable flexible circuitry may be employed in the present invention and the depiction of FIG. 12 should be understood to be merely exemplary of one of the more complex flexible circuit structures that may be employed as flex circuit 12 .

FIG. 13 depicts another preferred embodiment in accordance with the present invention. The depicted module 10 includes thermal spreaders 13 1 and 13 2 configured with plural extensions 13 E which reside above substrate extension 16 T and project inwardly. As those of skill will recognize, plural spreader extensions will encourage thermal shedding from the module. FIG. 14 provides a perspective view of a module 10 shown in cross-section in prior FIG. 13.

FIG. 15 depicts another preferred embodiment in accordance with the present invention. The module 10 depicted in FIG. 15 exhibits plural spreader extensions above substrate extension 16 T but unlike the plural spreader extensions depicted in FIG. 13, the spreader extensions 13 E exhibited by the module 10 depicted in FIG. 15 project outwardly. FIG. 16 depicts a perspective view of a module 10 with plural thermal spreader extensions that project outwardly above substrate extension 16 T.

FIG. 17 depicts an exemplar module 10 that exhibits multiple radiative projects from thermal spreaders 13 1 and 13 2 to provide even more surface area for thermal shedding from module 10 .

One advantageous methodology for efficiently assembling an embodiment of a module 10 depicted herein is as follows. In a preferred method of assembling a preferred module assembly 10 , flex circuit 12 is placed flat and both sides populated according to circuit board assemb