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In this paper a three-dimensional model of a novel electronic package has been developed using Finite element analysis to evaluate the shear load, tensile, bending and thermal stresses. Simulations of a complete flexible flip chip electronic packaging method are performed to minimize stresses on the packaged electronic device to improve robustness and reliability. Three component under-fill adhesives (Loctite 4860, Loctite 480 and Loctite 4902) and three circuit substrate materials (Kapton, Mylar and PEEK) are compared and the optimal thickness of each is found by shear load, tensile load, bending test and thermal expansion simulations. A fixed die size of 3.5 mm × 8 mm × 0.53 mm has been simulated and evaluated experimentally under shear and bending load. The shear and bending experimental results show good agreement with the simulation results and verify the simulated optimal thickness of the adhesive layer. The Kapton substrate together with the Loctite 4902 adhesive were identified as the optimum in the simulation. The simulation of under-fill adhesive and substrate thickness identified an optimum configuration of a 0.045–0.052 mm thick substrate layer and a 0.042–0.045 mm thickness of the Loctite 4902 adhesive. The bending simulation has also been used to determine the neutral axis of the encapsulated electronic package in this paper, thus identifying the optimal material and thickness for the encapsulation layer of the package.

Finite element analysis (FEA) modelling and experimental verification to optimise flexible electronic packaging for e-textiles