Recent high-end server design trends have continued to challenge electronic packaging engineers to design and integrate larger form factor land grid array (LGA) attached modules within their assemblies. These trends have included the application of larger, denser, organic packaged modules whose electrical performance and postencapsulation physical characteristics have been enabled by both the continued development of hybrid LGA connectors as well as new module actuation hardware designs. In this paper, we'll discuss these recent trends, including the specific technical attributes and challenges that need to be addressed to ensure a repeatable and reliable assembly design is developed. Initially, overviews of the latest connector and module design trends, including styles and physical sizes and their implications to the module's bottom surface metallurgy (BSM) flatness requirements, etc. are provided. Pursuant to this, recent system integration trending is reviewed; including both the module quantity per system assembly as well as module to module physical placements and how each of these impact printed wiring board (PWB) design (i.e., layer count, LGA site flatness, etc.) as well as the PWB assembly's solder processing characteristics (i.e., LGA pre- and post-solder attach contact co-planarity, etc.). Completing the application portion, is a description of some recent LGA actuation hardware and module external cooling apparatus designs (e.g., air-cooled heats sinks and water-cooling cold-plates and thermal interface materials (TIMs), etc.). The remaining portion of the paper is dedicated to the description of the mechanical analysis efforts completed to provide a fundamental understanding of the design's “as-assembled” attributes and a review of the associated evaluation completed to verify the integrated assembly's reliability characteristics. From the analysis methodology perspective, both the means of including each of the integrated assembly's key attributes (e.g., module mechanical construction and as encapsulated flatness, LGA contact compliance and stiffness as well as soldered contact coplanarity, TIM stiffness, actuation hardware, heat sink and cold-plate mechanical construction, etc.) and the resulting estimation of the predicted module internal TIM and hybrid-LGA's Pb-free soldered interface strains, actuation hardware stresses and LGA contact load variation are provided. Completing the discussion is a review of the variety of testing executed to validate the design's intended reliability. Included in this is a description of the test vehicle's design, the environmental stress testing conducted (i.e., mechanical pre-conditioning, accelerated thermal cycling (ATC), mixed flowing gas (MFG) and heat aging (HA), etc.) and the resulting data.
