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Each of the many PCB thermal optimization techniques described in this chapter will have some amount of impact on the thermal performance of the system Determining the relative impact of a single optimization is difficult to perform analyticallyWhen an entire ensemble of optimization techniques is employed across multiple devices operating at a variety of powers, analytical solutions of the thermal problem become impossibleThe simplicity of system-level temperature calculations implied by Eq 171 is misleading unless the effective qja of each component in the specific system is known a priori Since the impact of the PCB design on the thermal performance of the system must be determined before design completion and tooling, the question becomes how to quantify the impact of the PCB thermal features.

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Relayout and redesign of the PCB to fix thermal issues once tooling is generated is prohibitively expensive and leads to noncompetitive design cycle times The only predictive method currently available that addresses this need is computer simulation, which can incorporate all relevant PCB design features, perform a thermal analysis, and report back the component temperatures to identify problem locations Many commercial computer simulation tools exist, ranging in complexity, accuracy, and cost Computational fluid dynamics (CFD) programs incorporate equations that solve the problems of air flow around the PCB, thermal conduction from the PCB into the air, and thermal conduction within the PCB Solutions using CFD don t require special knowledge of convection coefficient equations, thereby making the modeling process easier and less prone to convection coefficient calculation errors Accuracy of CFD analysis can be as high as +/ 5 percent.

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CFD codes tend to be slow, however, taking substantial computer resources to run a reasonably complex model A step down from CFD are codes that employ user supplied convection coefficients that are applied to the PCB and component surfaces These solutions can be quite accurate, though no more than +/ 10 percent precision can be projected without substantial correlation to experimental data Whichever analysis code is selected, it should be capable of reading in data from the user s PCB layout tool and should be capable of incorporating the specific thermal conduction paths that were optimized for component performance It should be able to handle relatively complex system-level structures and should be capable of inputting a variety of thermal characteristics of the components Postprocessing identification of PCB regions and components above limit temperatures is a plus.

The code should run fast enough to enable multiple design iterations to optimize the PCB layout without slowing down the design cycle..

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System-Level Thermal Modeling Phases System-level thermal analysis normally includes three phases due to the complexity of the task and the difficulty of inputting a fully detailed system design into a tool. The first phase concentrates on airflow optimization through the system to minimize any dead zones in the cabinet. The PCBs, cables, fans, and other air blockages are included in the analysis during this phase. The second phase includes dissipation of power on the PCB by applying power areas to the PCB. During this phase, it is fairly easy to change locations of power sources to optimize the air cooling paths. The final phase is the fully detailed phase, which includes the PCB layout geometries and details of the electrical components. By the time phase three is reached, there should be few remaining major iterations for thermal optimization.

FIGURE 63.31 Small coverlay opening drilled by excimer laser. Hole diameter is 100 micrometer. (Source: Shinozaki.)

properties (Fig. 63.31). It keeps the good mechanical, electrical, and chemical properties of the film coverlay, and the circuits are available for dynamic flexing. The largest issue with this technology is the low productivity and high processing cost. The processing time and cost are proportional to the total size of the opening areas; therefore it could be expensive when there are high-density SMTs. Several new laser systems such as the YAG laser and carbon dioxide laser have been developed to achieve a higher processing speed and higher productivity. A carbon dioxide laser with a Galvano mirror has a speed one order higher than that of an excimer laser, even though engraving quality is worse than that of the excimer laser (Fig. 63.32). It cannot remove organic residue perfectly from copper surfaces, and it requires a supplemental cleaning process such as plasma etching or chemical etching.

FIGURE 63.32 Small coverlay opening drilled by carbon dioxide laser. Hole diameter is 200 micrometer. (Source: Shinozaki.)

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