Component built-in device

Abstract

An RFID module includes a laminated body including thermoplastic resin layers, a passive element defined by a conductor pattern on the thermoplastic resin layers, and an RFID IC chip embedded in the laminated body. The RFID IC chip and the conductor pattern are connected to each other by joining an input and output terminal of the RFID IC chip and a pad electrode, and an insulator pattern overlapping the pad electrode is provided around the RFID IC chip in the laminated body in planar view.

Claims

1. A component built-in device comprising: a laminated body including a plurality of thermoplastic resin layers; a plurality of conductor patterns provided on the thermoplastic resin layers; and a chip electronic component embedded in the laminated body; wherein the chip electronic component includes an input and output terminal; the laminated body includes a pad electrode connected to the plurality of conductor patterns; the chip electronic component and the plurality of conductor patterns are connected to each other via a direct or indirect connection between the input and output terminal and the pad electrode; a belt-shaped, annular-shaped, or partially annular-shaped insulator pattern overlapping the pad electrode is provided around the chip electronic component in the laminated body in a planar view from a laminating direction of the thermoplastic resin layers; and the insulator pattern does not overlap the chip electronic component in the planar view from the laminating direction.

2. The component built-in device according to claim 1, wherein the plurality of conductor patterns include a coil-shaped conductor pattern; the coil-shaped conductor pattern is provided in a region that does not overlap the chip electronic component in the planar view from the laminating direction; and the insulator pattern is provided at a position that does not overlap the coil-shaped conductor pattern in the planar view from the laminating direction.

3. The component built-in device according to claim 1, wherein the insulator pattern overlaps an outer edge of the pad electrode in the planar view from the laminating direction.

4. The component built-in device according to claim 1, wherein the insulator pattern primarily includes a thermoplastic resin that is identical to a resin of the plurality of thermoplastic resin layers.

5. The component built-in device according to claim 1, wherein the insulator pattern is provided on at least two of the plurality of thermoplastic resin layers in the laminated body.

6. The component built-in device according to claim 1, wherein the insulator pattern surrounds an entire or substantially entire periphery of the chip electronic component in the planar view from the laminating direction.

7. The component built-in device according to claim 1, wherein the input and output terminal of the chip electronic component is in contact with the pad electrode, and at least a portion of the insulator pattern is in contact with the pad electrode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of an RFID module 101 according to a first preferred embodiment of the present invention.

(2) FIG. 2 is a plan view illustrating an example of thermoplastic resin sheets and various conductor patterns provided on the thermoplastic resin sheets defining the RFID module 101.

(3) FIG. 3 is a cross-sectional view illustrating the RFID module 101 taken along a line A-A in FIG. 2.

(4) FIG. 4 is a circuit diagram illustrating the RFID module 101.

(5) FIG. 5 is a plan view illustrating an example of resin sheets and various conductor patterns provided on the resin sheets defining an RFID module according to a second preferred embodiment of the present invention.

(6) FIG. 6 is a plan view illustrating one resin sheet included in another RFID module according to the second preferred embodiment of the present invention.

(7) FIG. 7 is a plan view illustrating one resin sheet included in still another RFID module according to the second preferred embodiment of the present invention.

(8) FIG. 8 is a plan view illustrating an example of thermoplastic resin sheets and various conductor patterns provided on the thermoplastic resin sheets defining an RFID module according to a third preferred embodiment of the present invention.

(9) FIG. 9 is a cross-sectional view illustrating the RFID module 103 taken along a line A-A in FIG. 8.

(10) FIG. 10 is a cross-sectional view illustrating an RFID module 104A according to a fourth preferred embodiment of the present invention.

(11) FIG. 11 is a cross-sectional view illustrating an RFID module 104B according to the fourth preferred embodiment of the present invention.

(12) FIG. 12 is a cross-sectional view illustrating an RFID module 104C according to the fourth preferred embodiment of the present invention.

(13) FIG. 13 is a cross-sectional view illustrating an RFID module 104D according to the fourth preferred embodiment of the present invention.

(14) FIG. 14 is a perspective view illustrating an RFID tag 205 according to a fifth preferred embodiment of the present invention.

(15) FIG. 15 is a cross-sectional view illustrating a structure of a connection portion of the RFID module 101 and an antenna base 91.

(16) FIG. 16 is a circuit diagram illustrating operation of the RFID module 101 in an RFID tag 205.

(17) FIG. 17A is a perspective view illustrating an RFID tag 206A according to a sixth preferred embodiment of the present invention; FIG. 17B is a perspective view illustrating shapes of radiating elements 81a, 81b while the RFID module 101 is separated.

(18) FIG. 18 is a perspective view illustrating another RFID tag 206B according to the sixth preferred embodiment of the present invention.

(19) FIG. 19 is a perspective view illustrating still another RFID tag 206C according to the sixth preferred embodiment of the present invention.

(20) FIG. 20A is a cross-sectional view illustrating a main portion of the RFID module when an IC chip is simply embedded in a laminated body of a thermoplastic resin layer, and FIG. 20B is a partially enlarged view of the RFID module.

(21) FIG. 21 is a partially enlarged cross-sectional view illustrating a main portion of another RFID module when the IC chip is embedded in the laminated body of the thermoplastic resin layer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(22) Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings by describing several specific examples. In each drawing, the same portion is denoted by the same reference numeral. The preferred embodiments are separately illustrated for the sake of ease of explanation or understanding of the gist, but configurations illustrated in different preferred embodiments may partially be substituted or combined. In the second and subsequent preferred embodiments, descriptions of matters common to those of the first preferred embodiment are omitted, and only different points will be described. In particular, the similar advantageous effects by the similar configurations will not sequentially be referred to in each preferred embodiment.

First Preferred Embodiment

(23) FIG. 1 is a perspective view illustrating an RFID module 101 according to a first preferred embodiment of the present invention. The RFID module 101 according to the first preferred embodiment is preferably, for example, an RFID module corresponding to a communication frequency of a 900 MHz band, namely, a UHF band, and includes a rectangular or substantially rectangular parallelepiped laminated body 11. The laminated body includes thermoplastic resin layers, such as liquid crystal polymer and polyimide, for example, that are laminated, and the laminated body 11 has flexibility. A dielectric constant of each insulating layer made of these materials is preferably smaller than that of a ceramic base material layer represented by LTCC.

(24) External terminals 24a, 24b are provided on a mounting surface (an upper surface from a viewpoint in FIG. 1) of the laminated body 11. The RFID module 101 is mounted on an antenna base material (to be described later). The external terminals 24a, 24b are connected to radiating elements on the antenna base material by the mounting.

(25) FIG. 2 is a plan view illustrating an example of thermoplastic resin sheets and various conductor patterns provided on the thermoplastic resin sheets defining the RFID module 101.

(26) Spiral conductor patterns 20a, 20b having a rectangular or substantially rectangular shape are provided on a thermoplastic resin sheet (hereinafter, simply referred to as a resin sheet) 11c. A pad electrode 21a is provided at a first end of the conductor pattern 20a, and an end electrode 22a is provided at a second end of the conductor pattern 20a. Similarly, a pad electrode 21b is provided at a first end of the conductor pattern 20b, and an end electrode 22b is provided at a second end of the conductor pattern 20b. A conductor pattern 20c including two rectangular or substantially rectangular spiral portions is provided on a resin sheet 11b. End electrodes 23a, 23b are provided at both ends of the conductor pattern 20c. External terminals 24a, 24b are provided on a resin sheet 11a. A passive element is defined by the conductor patterns 20a, 20b, 20c.

(27) The end electrode 22a of the conductor pattern 20a and the end electrode 23a of the conductor pattern 20c are connected to each other through a via conductor 31a. The end electrode 22b of the conductor pattern 20b and the end electrode 23b of the conductor pattern 20c are connected to each other through a via conductor 31b. The end electrodes 23a, 23b of the conductor pattern 20c and the external terminals 24a, 24b are connected to each other through via conductors 32a, 32b.

(28) FIG. 3 is a cross-sectional view illustrating the RFID module 101 taken along a line A-A in FIG. 2. The rectangular or substantially rectangular spiral portion on the left side of the conductor pattern 20c overlaps the conductor pattern 20a in a substantially coaxial relationship. Similarly, the rectangular or substantially rectangular spiral portion on the right side of the conductor pattern 20c overlaps the conductor pattern 20b in the substantially coaxial relationship. An input and output terminal 50E of an RFID IC chip 50 is connected to the pad electrodes 21a, 21b. With this structure, the rectangular or substantially rectangular spiral portion on the left side of the conductor pattern 20c and the conductor pattern 20a define a first coil-shaped conductor pattern, and the rectangular or substantially rectangular spiral portion on the right side of the conductor pattern 20c and the conductor pattern 20b define a second coil-shaped conductor pattern.

(29) The laminated body 11 has a longitudinal direction, the first coil-shaped conductor pattern is disposed closer to the first end in the longitudinal direction, the second coil-shaped conductor pattern is disposed closer to the second end in the longitudinal direction, and the RFID IC chip 50 is disposed between the first coil-shaped conductor pattern and the second coil-shaped conductor pattern in planar view from the laminating direction of the thermoplastic resin layer. This enables miniaturization of the RFID module 101, and unnecessary coupling between a coil defined by the first coil-shaped conductor pattern and a coil defined by the second coil-shaped conductor pattern is reduced or prevented.

(30) FIG. 4 is a circuit diagram of the RFID module 101. In FIG. 4, inductors L1, L2 correspond to the conductor patterns 20a, 20b, and inductors L3, L4 correspond to the conductor pattern 20c.

(31) As illustrated in FIGS. 2 and 3, in a planar view from the laminating direction of the resin sheet, an insulator pattern 41 having a belt shape, an annular shape or a partial annular shape is provided at a position overlapping the pad electrodes 21a, 21b around the RFID IC chip 50 in the laminated body 11.

(32) According to the first preferred embodiment, the insulator pattern 41 around the RFID IC chip 50 defines and functions as a reinforcing material to reduce or prevent deformation of the conductor pattern around the RFID IC chip 50, particularly the pad electrodes 21a, 21b. Since the insulator pattern 41 also reduces or prevents a flow of resin during pressurization and heating of the resin sheet, the deformation of the pad electrodes 21a, 21b is reduced or prevented. Contact between the pad electrodes 21a, 21b and the RFID IC chip 50 due to the deformation of the pad electrodes 21a, 21b is avoided by these functions and actions.

(33) Although outer edges of the pad electrodes 21a, 21b protrude beyond an outer shape of the RFID IC chip 50 in planar view, the problem caused by the deformation of the pad electrodes 21a, 21b is avoided, so that the RFID IC chips 50 having various sizes are able to be embedded. That is, the same laminated body 11 is able to be used for RFID IC chips having different sizes.

(34) A method for manufacturing the RFID module 101 according to the first preferred embodiment is as follows.

(35) A thermoplastic resin sheet to which a Cu foil is attached on one side is prepared, and the Cu foil is patterned by photolithography, for example, to form a predetermined conductor pattern on each of the thermoplastic resin sheets 11a, 11b, 11c. That is, the conductor patterns 20a, 20b and the pad electrodes 21a, 21b are formed on the thermoplastic resin sheet 11c. The conductor pattern 20c is formed on the thermoplastic resin sheet 11b. The external terminals 24a, 24b are formed on the thermoplastic resin sheet 11a.

(36) Subsequently, a via hole is formed at a predetermined position of the thermoplastic resin sheet by a laser processing method, and filled with a conductive paste by a screen printing method or other suitable method, for example. The conductive paste becomes a via conductor in a later process. That is, the via conductors 31a, 31b are formed in the thermoplastic resin sheet 11c, and the via conductors 32a, 32b are formed in the thermoplastic resin sheet 11b.

(37) The insulator pattern 41 is formed by application on the thermoplastic resin sheet 11c around the RFID IC chip 50 and at a position overlapping the pad electrodes 21a, 21b in planar view.

(38) The thermoplastic resin sheets 11a, 11b and 11c are laminated together with the RFID IC chip 50, and pressed and heated to form the laminated body 11.

(39) An aggregate substrate including a large number of RFID modules 101 is processed in each of the above processes, and then divided into individual pieces to obtain a large number of RFID modules 101.

Second Preferred Embodiment

(40) Some examples having a shape of an insulator pattern or a shape of a pad electrode different from that of the first preferred embodiment are illustrated in a second preferred embodiment of the present invention.

(41) FIG. 5 is a plan view illustrating an example of resin sheets and various conductor patterns provided on the resin sheets defining an RFID module according to the second preferred embodiment. An annular insulator pattern 42 having a rectangular or substantially rectangular shape is provided in this example. Other configurations are the same or substantially the same as those of the RFID module 101 according to the first preferred embodiment.

(42) FIG. 6 is a plan view illustrating one resin sheet included in another RFID module according to the second preferred embodiment. In this example, pad electrodes 21c, 21d are provided in addition to pad electrodes 21a, 21b. The pad electrodes 21a, 21b are electrically connected to a circuit in an RFID IC chip, while the pad electrodes 21c, 21d are dummy electrodes. Additionally, an annular insulator pattern 42 having a rectangular or substantially rectangular shape, which overlaps the pad electrodes 21a, 21b, 21c, 21d in planar view, is provided in this example. Other configurations are the same or substantially the same as those of the RFID module of the first preferred embodiment.

(43) FIG. 7 is a plan view illustrating one resin sheet included in still another RFID module according to the second preferred embodiment. In this example, pad electrodes 21c, 21d are provided in addition to pad electrodes 21a, 21b. Additionally, partial annular shaped (L-shaped) insulator patterns 43a, 43b, 43c, 43d having rectangular or substantially rectangular shapes, which individually overlap the pad electrodes 21a, 21b, 21c, 21d in planar view, are provided. Other configurations are the same or substantially the same as those of the RFID module of the first preferred embodiment.

(44) As illustrated in FIGS. 5 and 6, the insulator pattern may have an annular shape. Consequently, a degree of reinforcement around the embedded position of the RFID IC chip 50 is easily equalized, and the deformation of the pad electrodes 21a, 21b is effectively reduced or prevented.

(45) As illustrated in FIGS. 6 and 7, when the pad electrodes are equally arranged around the RFID IC chip 50, an inclination of the RFID IC chip 50 is relaxed in the laminated body, and the deformation of the pad electrodes 21a, 21b is effectively reduced or prevented.

Third Preferred Embodiment

(46) An example in which the connection structure between the input and output terminal of the RFID IC chip and the pad electrode is different from that of the first preferred embodiment is illustrated in a third preferred embodiment of the present invention.

(47) FIG. 8 is a plan view illustrating an example of thermoplastic resin sheets and various conductor patterns provided on the thermoplastic resin sheets defining an RFID module of the third preferred embodiment.

(48) Spiral conductive patterns 20a, 20b having a rectangular or substantially rectangular shape are provided on a lower surface of a resin sheet 11c. A pad electrode 21a is provided at a first end of a conductor pattern 20a, and an end electrode 22a is provided at a second end of a conductor pattern 20a. Similarly, a pad electrode 21b is provided at a first end of a conductor pattern 20b, and an end electrode 22b is provided at a second end of a conductor pattern 20b. A conductor pattern 20c including two rectangular or substantially rectangular spiral portions is provided on a lower surface of a resin sheet 11b. End electrodes 23a, 23b are provided at both ends of the conductor pattern 20c. External terminals 24a, 24b are provided on an upper surface of a substrate 11a.

(49) The end electrode 22a of the conductor pattern 20a and the end electrode 23a of the conductor pattern 20c are connected to each other through a via conductor 31a. The end electrode 22b of the conductor pattern 20b and the end electrode 23b of the conductor pattern 20c are connected to each other through a via conductor 31b. The end electrodes 23a, 23b of the conductor pattern 20c and the external terminals 24a, 24b are connected through via conductors 32a, 33a, 32b, 33b.

(50) FIG. 9 is a cross-sectional view illustrating the RFID module 103 taken along a line A-A in FIG. 8. An input and output terminal 50E of an RFID IC chip 50 is connected to the pad electrodes 21a, 21b through via conductors 34a, 34b. In planar view from the laminating direction of the resin sheet, an annular insulator pattern 42 having a rectangular or substantially rectangular shape is provided at a position overlapping the pad electrodes 21a, 21b around the RFID IC chip 50 in a laminated body 11.

(51) The conductor patterns 20a, 20b may be covered with a resin layer by laminating the resin sheet on which the conductor pattern is not provided on a bottom of the resin sheet 11c.

(52) Even in the structure in which the input and output terminal 50E of the RFID IC chip 50 is indirectly connected to the pad electrodes 21a, 21b through the via conductors 34a, 34b as in the third preferred embodiment, the insulator pattern 42 around the RFID IC chip 50 defines and functions as a reinforcing material, the deformation of the conductor patterns around the RFID IC chip 50, particularly the pad electrodes 21a, 21b is reduced or prevented, and contact between the pad electrodes 21a, 21b and the RFID IC chip 50 due to the deformation of the pad electrodes 21a, 21b is avoided.

(53) Even in the third preferred embodiment, the insulator pattern 42 and the pad electrodes 21a, 21b are able to have various shapes as in the second preferred embodiment.

Fourth Preferred Embodiment

(54) Some examples in which insulator patterns are provided in a plurality of layers are illustrated in a fourth preferred embodiment of the present invention.

(55) FIG. 10 is a cross-sectional view illustrating an RFID module 104A according to the fourth preferred embodiment. In this example, an annular insulator pattern 42a having a rectangular or substantially rectangular shape is provided at a position directly overlapping pad electrodes 21a, 21b. An annular insulator pattern 42b having a rectangular or substantially rectangular shape, which overlaps the pad electrodes 21a, 21b in planar view, is provided. Other configurations are the same or substantially the same as those of the RFID module 101 of the first preferred embodiment.

(56) FIG. 11 is a cross-sectional view illustrating an RFID module 104B of the fourth preferred embodiment. In this example, three annular insulator patterns 42a, 42b, 42c having rectangular or substantially rectangular shapes are provided.

(57) FIG. 12 is a cross-sectional view illustrating an RFID module 104C of the fourth preferred embodiment. In this example, an insulator pattern 42 is provided only in a layer different from the layer in which an RFID IC chip 50 is embedded.

(58) FIG. 13 is a cross-sectional view illustrating an RFID module 104D of the fourth preferred embodiment. In the structure of this example, input and output terminals of the RFID IC chip 50 are indirectly connected to the pad electrodes, and the insulator patterns 42a, 42b are provided in a plurality of layers.

(59) As illustrated in the fourth preferred embodiment, the insulator pattern may be provided in the plurality of layers. The insulator pattern may be provided in a layer different from the embedded layer of the RFID IC chip.

Fifth Preferred Embodiment

(60) An example of an RFID tag is illustrated in a fifth preferred embodiment of the present invention. For example, the RFID tag according to the fifth preferred embodiment is preferably applied to a linen management tag, a clothes label tag used for uniform management, and various name tags.

(61) FIG. 14 is a perspective view illustrating an RFID tag 205 according to the fifth preferred embodiment. The RFID tag 205 includes an antenna base material 91 on which radiating elements 81a, 81b defined by conductor patterns are provided and an RFID module 101. The configuration of the RFID module 101 is preferably the same or substantially the same as that of the first preferred embodiment.

(62) The radiating elements 81a, 81b define a dipole antenna. The antenna base 91 is a resin sheet, such as PET, for example, which has flexibility. The radiating elements 81a, 81b are flexible conductors, such as aluminum foil and copper foil, for example.

(63) FIG. 15 is a cross-sectional view illustrating a structure of a connection portion of the RFID module 101 and the antenna base 91. External terminals 24a, 24b of the RFID module 101 are connected to the radiating elements 81a, 81b through solder 36a, 36b. In the RFID module 101, a region in which the external terminals 24a, 24b are provided and a region in which an RFID IC chip 50 is embedded are rigid regions, and other regions are flexible regions. Consequently, even when the RFID tag 205 is curved, the antenna base 91 and the RFID module 101 are flexible as illustrated in FIG. 15, and large bending stress is not applied to the RFID IC chip 50.

(64) FIG. 16 is a circuit diagram illustrating operation of the RFID module 101 in the RFID tag 205. Capacitance Cp of the RFID IC chip 50 exists between the external terminals 24a, 24b, and two resonances are generated in the RFID tag 205. A first resonance is generated in a current path, which is indicated by current i1 and defined by the radiating elements 81a, 81b and inductors L3 and L4, and a second resonance is generated in a current path (current loop), which is indicated by current i2 and defined by inductors L1 to L4 and the capacitance Cp. The two resonances are coupled by the inductors L3, L4 shared by the current paths.

(65) Both a resonance frequency due to the first resonance and a resonance frequency due to the second resonance are affected by the inductors L3, L4. A difference of several tens of megahertz (specifically, about 5 MHz to about 50 MHz, for example) is generated between the resonance frequency due to the first resonance and the resonance frequency due to the second resonance. In this manner, a broadband resonance frequency characteristic is obtained by combining the two resonances.

Sixth Preferred Embodiment

(66) Several RFID tags in which shapes of the antenna base material and the radiating element are different from those of the fifth preferred embodiment are illustrated in a sixth preferred embodiment of the present invention.

(67) FIG. 17A is a perspective view illustrating an RFID tag 206A according to the sixth preferred embodiment. FIG. 17B is a perspective view illustrating shapes of radiating elements 82a, 82b while an RFID module 101 is separated. In the center in a lengthwise direction of radiating elements 82a, 82b, a rectangular or substantially rectangular through-hole HL2 is provided, and furthermore, a notch CT1 extending from an outer edge to the through-hole HL2 is provided. In this manner, a matching conductor pattern may preferably be provided at a mounting position of the RFID module.

(68) FIG. 18 is a perspective view illustrating another RFID tag 206B according to the sixth preferred embodiment. A rectangular or substantially rectangular loop-shaped radiating element 83 in which a portion thereof is opened is provided on the antenna base material 92, and an external terminal of the RFID module 101 is connected to the opened portion.

(69) FIG. 19 is a perspective view illustrating still another RFID tag 206C according to the sixth preferred embodiment. A rectangular or substantially rectangular loop-shaped radiating element 84 including the through-hole HL2 and the notch CT1 similar to the radiating element in FIG. 17B is provided on the antenna base material 92, and an external terminal of the module 101 is connected to both ends of the notch CT1.

(70) As illustrated in FIGS. 17A, 17B, and 19, a matching conductor pattern may preferably be provided in the radiating element. As illustrated in FIGS. 18 and 19, the radiating element may preferably have a loop shape, for example.

(71) In the above examples, the via conductor is described as an example of an interlayer connection conductor connecting the conductors provided in different layers. A hole (via hole conductor hole) made in the sheet is filled with a conductive material such as conductive paste, for example, and the conductive material is metallized to define the via conductor. In addition to the via conductor, a through-hole conductor in which a metal film is provided on an inner surface of a hole by plating or other suitable method and a metal body, such as a metal pin and a stud-shaped solder are described as the interlayer connecting conductor.

(72) While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.