Novel encapsulation materials for High Pressure-High Temperature (HPHT) applications

Abstract

A modified thermoset polymer resin (PR) is evaluated as a form of alternative packaging material to traditional epoxy. It is understood that the thermoset cross-links to a higher degree at high temperature. Hence, its mechanical properties can be improved by changing treatment duration and temperature, rendering the material mechanically stronger for application temperatures beyond 300°C. Material strength was evaluated through a modified compressive testing setup which shows neat PR is comparable to epoxy. Concurrently, adhesion to silicon die and ceramic substrate were evaluated by means of bond shear using the DAGE-4000 shear tester both at room temperature and elevated temperature. Bond shear strength of PR is observed to be higher at room temperature as compared to elevated temperatures when bonded to Silicon (Si) and Alumina (Al2O3), a phenomenon which can be attributed to mismatches in coefficient of thermal expansions (CTE). For high pressure only applications, PR is a good alternative. Pre- and post-pressure loading analysis was carried out by forming an encapsulation analogous to that of a glob top on DIP packages. Observation shows no crack formation, indicating that the material is suitable for high pressure loading up to 207 MPa. For high pressure and high temperature applications (HPHT), pure PR is good up to 250°C at 25 kPsi (172 MPa).