Status of Hybrid Qualification and Tender

1JD.Berst, U. Goerlach, CMS TRK APR 2003

Status of Hybrid Qualification and Tender

• Final Technical Specifications– Hybrid types

– Quality control, intermediate tests and inspections

– Some results on FE-Hybrids w.r.t. these criteria

• Visual inspections

• Bonding

• …

• Delivery Profile of Pre-Production

• Delivery Profile of Tender


FE-Hybrids Types

• Latest modifications in April 2003• Lamination onto ceramic stiffener

is a very critical operation• 12 different types of combinations

(the opposite of what was originally intended!!)– TIB, TOB, TEC

– 4 or 6 APV

– Connector up and down

– r and stereo ceramic (5)1 TEC, 2 TOB, 2 TIB

• APV25, positioning and bonding• Thermal cycle (simple, no bias)• Final acceptance test FHIT

I . 1 . 1 T O B _ 4 _ r _ u p

T y p e n a m e T O B _ 4 _ r _ u p _ 3 0 2 _ 1 6 7 1 C i r c u i t m u l t i c o u c h e s : I P C - A - 6 0 0 F

Q u a t r e c o u c h e s c o n d u c t r i c e s r é a l i s é e s s u r d e u x p l a n s C u i v r e 1 8 m i c r o n s d o u b l e f a c e , r e c h a r g é s s u r u n c ô t é j u s q u ’ à 3 0 m m a x i m u m p a r c u i v r a g e é l e c t r o l y t i q u e

F e u i l l e s P o l y i m i d e ( E s p a n e x ) 2 5 µ m , c o l l é e s p a r u n a d h é s i f v u l c a n i s é à c h a u d D u p o n t L F 2 0 0

L e s f e u i l l e s m u l t i c o u c h e s s e t e r m i n e n t p a r u n e e x t e n s i o n s o u p l e a v e c u n c o n n e c t e u r

M o n t a g e d e c o m p o s a n t s S M D I P C - A - 6 1 0 - C : C o m p o n e n t Q u . T y p e R 5 % 1 6 0 4 0 2 R 1 % 4 0 6 0 3 C 1 0 % 1 7 0 4 0 2 C 1 0 % 2 1 2 0 6 P L C C 2 2 4 b r o c h e s , p a s 0 . 5 m m P L C C 1 3 2 b r o c h e s , p a s 0 . 5 m m C o n n e c t e u r N A I S 1 4 0 b r o c h e s , p a s 0 . 8 m m

p o s i t i o n u p J 1 4 A S I C s , p u c e s n u e s ( A P V 2 5 ) à m o n t e r a v e c

u n e p r é c i s i o n é l e v é e e t à c o n n e c t e r s e l o n I P C -S M - 7 8 4

P o s i t i o n s : I C 1 I C 2 . . . . I C 5 I C 6

C M S H y b r i d S t r u c t u r e

C o p p e r 1 8 + 1 2 μ P o l y i m i d e 2 5 μ

S o l d e r M a s k 2 0 μ

g l u e 5 0 μ D u p o n t L F 2 0 0

C e r a m i c A l 2 O 3 3 8 0 μ

V i a s

F l e x i b l e C a b l eC o v e r l a y 2 5 μ + G l u e 2 5 μ g l u e

C o p p e r 1 8 + 1 2 μ

C o p p e r 1 8 μ

C o p p e r 1 8 μ

P o l y i m i d e 2 5 μ

A l i g n e m e n t h o l e s

T O B _ u pU G / J D B 3 - f e b - 0 3

g l u e 5 0 μ( 3 M I s o t a c 9 4 6 0 )

( E s p a n e x )

4 0 p i n N A I S

F i c h i e r s : f t p : / / l e p s i . i n 2 p 3 . f r / p u b / b e r s t / C M S _ H Y B R I D S _ A O / T O B S c h é m a s c m s _ t o b _ u p _ d o w n _ v 1 2 _ s c h e m a t i c A 3 . p s T o p o l o g i e ( G e r b e r ) c m s _ t o b _ u p _ d o w n _ v 1 2 . z i p T o p o l o g i e ( p d f ) c m s _ t o b _ u p _ d o w n _ v 1 2 . p d f L i s t e d e s c o m p o s a n t s c m s _ t o b _ u p d o w n _ v 1 2 . b o m D i a g r a m m e d e b o n d i n g

c m s _ t o b _ u p _ d o w n _ v 1 2 _ b o n d i n g _ a p v _ 1 2 . g i f c m s _ t o b _ u p _ d o w n _ v 1 2 _ b o n d i n g _ a p v _ 1 2 _ d e t a i l . g i f c m s _ t o b _ u p _ d o w n _ v 1 2 _ b o n d i n g _ a p v _ 5 6 . g i f c m s _ t o b _ u p _ d o w n _ v 1 2 _ b o n d i n g _ a p v _ f r o n t . g i f

C e r a m i c r i g i d i f i e r F i c h i e r : T O B M 2 1 5 4 P L _ 0 . p d f c m s t k o b m 0 0 2 7 _ c o p y . d x f

C a r t e d ’ i n t e r f a c e ( f o u r n i e p a r l ' a d m i n i s t r a t i o n ) T O B / T E C t y p e T e s t s d e r é c e p t i o n : a p r è s c y c l e t h e r m i q u e V o l . d e l a P r o d u c t i o n T O B _ 4 _ r _ u p _ 3 0 2 _ 1 6 7 1 1 0 5 0 p c s P r o f i l d e l i v r a i s o n : A 1 B 1 B 2 B 3 B 4 B 5 B 6

I C 1 I C 2 I C 3 I C 4 I C 5 I C 6


Quality Control• IPC-A-600F and IPC-A-610C, class 3

• Lamination:

– detailed procedure, although recent failure is not understood.

– Crucial visual inspection of lamination after all processing steps

• Cleaning: has improved after some iterations

• APV positioning and bonding is crucial (cost driving?) element

– Certainly at limit of industrial standards

– Detailed specs for precision placement and bonding

• Dicing of APV-wafer is included as an option (1), ask for separated costing

• Trace-ability of APVs at Wafer level

• Trace-ability of individual APVs: Option (2)

• Short temperature cycle is an option (3)

• FHIT final functionality test (100%) and record for DB


Positioning of APVs

Montage APV IPC-SM-784 Position relative entre APV

Précision en x (95% des circuits)

22 µm Min-max

Précision in x (<5% des circuits)

40 µm Min-max

Précision en y 50 µm Min-max pour 4 coins des APV

Variation de hauteur < 200 µm total Position absolue des APV

Précision en x

50 µm Min-max


Positioning of APVs• TOB, Hybrid SA, 1st series, 55 measured• Kapton on ceramic• Overall shrink: 27 µm

0-50-40-1

95% should be in this area


Positioning of APVs• TOB, Hybrid SA, 2nd series, 45 measured• Kapton on ceramic• Overall shrink: 31 µm

0-50-40-1



Positioning of APVs

• TIB, Hopp, series of 40 measured• Overall shrink FR4: 15 µm

APV0-5APV0-4APV0-1



Bonding StrengthBonding IPC-SM-784 25 µm AlSi Force

d'arrachement Val. moyenne 5 g RMS < 1g

Minimum 3 g

Hauteur de boucles 50 - 400 µm Distance libre au

bord des puces > 50 µm

Diagrammes A respecter sans déviation Taux de réparations

par livraison Autorisées sur 5% des hybrides Maximum de 5 réparations par hybride Maximum de 1 réparation par plage de connexion

GS-Hopp, TIBHybrid_SA, TOB


Pre-Production I« M900 »• 300 TOB ordered (ceramic)

– 16+80 delivered December 2002• 78 -> CERN

– 31 FNAL– 5 UCSB– 2 KA– 40 CERN

• 29 with PA (25 bonded), 5 active thermal cycle

– 100 delivered end Jan 2003, – bad laminationbad lamination– Can only be used for system tests

– 20 TOB made in Feb/March, OK given end March– 80 to be done, in production

– Lamination complete– 50 finished, 45 ok with FHIT, now in Strasbourg– 26 will be ready today– FHIT remained at factory

• 200 TIB and 200 TEC ordered in Jan 2003

Problem not understood!


Pre-Production II« Large volume order by CERN »– 4370 TEC/TIB/TOB ordered, – 200+200+4370 considered as single production– With new designs never prototyped!– Qualification batch: 3 lots of ca. 100 in production

• Lamination of TEC about to start after electrical test• Also bad circuits will be laminated for tests• Evaluation sample, delivery ca. May 6:

– 10 TOB: 5x 4-APV_rphi_down, 5x 6-APV_rphi_up– 10 TIB: 5x 4-APV_rphi_down, 5x 6-APV_stereo_up– 10 TEC: 5x 6-APV_down, 5x 4-APV_up

• 3x 90 TOB, TIB, TEC delivery (2 weeks) not before May 20

– Production batches• Start May 6(?), circuits tested mid June• Lamination starts June 20, 600-800 pcs/ week, finnish end July• Assembly and test: could start June 23, 600/week• Delivery to CERN starts July 7, finish beginning of Sept


Tendering Status• Technical specifications are « frozen »• Documents for French administration:

– Translation of Technical Specification into French • CCPT, Cahier des Clauses Techniques Particulières• CCAP, Cahier des Clauses Administratives Particulières • RDC, Règlement de la Consultation• Journal officiel des communautés européennes

– All submitted on Monday, 07/04 to in2p3

• Official Start of Tendering 15th of April 2003– All documents are/will be available on the ftp site:

ftp://lepsi.in2p3.fr/pub/berst/CMS_HYBRIDS_AO /TIB; /TOB; /TEC;

– “Appel d’offre ouvert”– Open for 52 days (end 17 June 17:00)

• Opening of letters in week 25 (16/06)• Place Contract before 14th of July


Production Delivery Profile Livraison par mois et type

total TOB TIB TEC

Ens

embl

e m

ois

4_ r _

dow

n 16

72

4_ r _

up

1671

6_r

_ up

16

73

4_

ster

eo_

up

167

5

4_st

ereo

_dow

n 16

76

Sou

s-to

tal

4_r

_dow

n 16

68

6_r

_dow

n 16

70

6_st

ereo

_dow

n

1678

6_st

ereo

_up

1677

sou

s-to

tal

4_up

16

63

6_up

16

65

6_ d

own

1666

sou

s-to

tal

A1 + 4 2700 200 350 350 150 150 1200 200 150 100 200 650 550 150 150 850 B1 + 2 1590 150 250 150 550 200 100 100 400 400 140 100 640 B2 + 3 1750 300 220 150 670 200 200 400 400 140 140 680 B3 + 4 1620 300 150 450 130 200 170 500 400 140 130 670 B4 + 5 1450 130 220 150 500 130 100 230 450 140 130 720 B5 + 6 1320 100 100 130 130 460 130 150 280 450 130 580 B6 + 7 1070 750 170 150 1070 B1 - B6 8800 380 700 690 430 430 2630 590 400 200 620 1810 2850 730 780 4360

Total 11500 580 1050 1040 580 580 3830 790 550 300 820 2460 3400 880 930 5210

Status of Hybrid Qualification and Tender

Documents

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