Finite volume based CFD simulation of pressurized flip-chip underfill encapsulation process

This paper presents the simulation of pressurized underfill encapsulation process for high I/O flip chip package. 3D model of flip chip packages is built using GAMBIT and simulated using FLUENT software. Injection methods such as central point, one line, L-type and U-type are studied. Cross-viscosity model and volume of fluid (VOF) technique are applied for melt front tracking of the encapsulant. The melt front profiles and pressure field for all injection types are analyzed and presented. The pressure distribution within the flip-chip, fill volume versus filling time and viscosity versus shear rate are also plotted. The U-type injection is found to be faster in filling. The numerical results are compared with the previous experimental results and found in good conformity. The strength of CFD software in handling underfill encapsulation problems is proved to be excellent.