Method for producing a circuit board element
10426040 ยท 2019-09-24
Assignee
Inventors
Cpc classification
H05K3/007
ELECTRICITY
H05K1/185
ELECTRICITY
H01L2224/82138
ELECTRICITY
H05K3/4644
ELECTRICITY
H01L24/82
ELECTRICITY
H01L23/5389
ELECTRICITY
H01L21/568
ELECTRICITY
H01L2224/83192
ELECTRICITY
H01L2224/24137
ELECTRICITY
H01L24/19
ELECTRICITY
H01L2224/73104
ELECTRICITY
H01L2224/04105
ELECTRICITY
H01L2924/00
ELECTRICITY
H05K3/30
ELECTRICITY
H01L2224/83191
ELECTRICITY
H05K1/186
ELECTRICITY
H01L2224/2929
ELECTRICITY
H05K3/12
ELECTRICITY
H01L2224/92244
ELECTRICITY
H01L24/73
ELECTRICITY
H01L2224/82007
ELECTRICITY
H01L2924/00
ELECTRICITY
International classification
H05K3/30
ELECTRICITY
H01L23/538
ELECTRICITY
H05K3/12
ELECTRICITY
H05K1/18
ELECTRICITY
H05K3/00
ELECTRICITY
Abstract
The invention relates to a method for producing a circuit board element having at least one electronic component, which component has a connection side defined by electrical contacts or a conductive layer and is connected to a temporary carrier for positioning and embedded in an insulating material; the component is attached in a specified position directly to a plastic film as a temporary carrier, whereupon a composite layer having at least a carrier and an electrical conductor, preferably also having an insulating material, is attached on the side of the component opposite the plastic film, with the carrier facing away from the component, and thereafter the plastic film is removed; then the component is embedded in insulating material. After the embedding of the component in the insulating material, an additional composite layer is preferably attached to the component and the embedding of the component on the side opposite the first composite layer.
Claims
1. A method for producing a printed circuit board element comprising the steps of: (a) providing a plurality of electronic components with each having a connection side comprising a plurality of electrical contacts or a conductive layer; (b) affixing the plurality of electronic components directly on a plastic film as a temporary carrier with each of the plurality of electronic components being spaced apart from each other; (c) affixing a first composite layer comprising at least a carrier and an electrically conductive layer on a side of the plurality of electronic components that is opposite to the plastic film with the electrically conductive layer disposed between the carrier and the plurality of electronic components and with the electrically conductive layer extending over a space between the plurality of spaced apart electronic components; (d) detaching the plastic film from the plurality of electronic components; and (e) introducing insulating material into spaces between the plurality of electronic components.
2. The method according to claim 1, further comprising applying a second composite layer comprising at least an electrically conductive layer and a support on a side of the plurality of electronic components opposite the first composite layer.
3. The method according to claim 2, wherein the carrier of the first composite layer or the support of the second composite layer is formed from a dimensionally stable material or a dimensionally stable polymer.
4. The method according to claim 1, wherein the plastic film is an adhesive film.
5. The method according to claim 1, wherein the insulating material comprises preconditioned prepreg material having a plurality of recesses which can accommodate the plurality of electronic components.
6. The method according to claim 1, wherein the first composite layer has a thickness at least equal to a thickness of the plurality of electronic components and the insulating layer is introduced into the spaces between the plurality of electronic components before step (d).
7. The method according to claim 1, wherein each of the plurality of electronic components provided in step (a) comprises a dielectric layer and the plastic film is affixed in step (b) to a side of the plurality of electronic components that is opposite to the dielectric layer.
8. The method according to claim 1, wherein each of the plurality of electronic components provided in step (a) comprises an electrically conductive layer and the plastic film is applied to a side of the plurality of electronic components that is opposite to the electrically conductive layer.
9. The method according to claim 1, wherein the method comprises forming the composite layer by printing the electrically conductive layer on the carrier before affixing the composite layer on the plurality of electronic components in step (b).
10. The method according to claim 1, comprising affixing a pasty electrically conductive material on a side opposite the connection side of the plurality of electronic components after detaching the plastic film in step (d).
11. The method according to claim 1, wherein the first composite layer is affixed to the plurality of electronic components in a vacuum.
12. The method according to claim 1 comprising affixing at least one registration element on the plastic film to serve as a marker at the same time as the plurality of electronic components are affixed to the plastic film in step (b).
13. The method according to claim 1, wherein the plastic film comprises a compressible material.
14. The method according to claim 13, wherein a dimensionally stable layer is connected to the plastic film, wherein the dimensionally stable layer is releasably affixed to the compressible material on a side of the compressible material facing away from the plurality of electronic components.
15. The method according to claim 1, wherein the first composite layer comprises an insulating material layer between the electrically conductive layer and the plurality of electronic components, wherein the insulating material layer is formed of a material that is capable of changing its viscosity when the first composite layer is heated and pressed into connection with the plurality of electronic components.
16. The method according to claim 1, wherein the first composite layer comprises an insulating material layer between the electrically conductive layer and the plurality of electronic components, wherein the insulating material layer is formed from a non-deformable dielectric material and the first composite layer comprises a further layer made from non-conductive material that is capable of changing its viscosity when the first composite layer is heated and pressed into connection with the plurality of electronic components.
17. The method according to claim 16, wherein the non-deformable dielectric material has a melting point which is higher than 220 C.
18. The method according to claim 17, wherein the non-deformable material is a hardened duroplastic.
19. The method according to claim 1 further comprising structuring the plurality of electronic conductors after step (c).
20. The method according to claim 1, further comprising forming contact connections to the plurality of electronic components after step (c).
21. A method for producing a printed circuit board element comprising the steps of: (a) providing a plurality of electronic components with each having a connection side comprising a plurality of electrical contacts or a conductive layer; (b) affixing the plurality of electronic components directly on a plastic film as a temporary carrier with each of the plurality of electronic components being spaced apart from each other; (c) affixing a first composite layer comprising at least a carrier and an electrically conductive layer on a side of the plurality of electronic components that is opposite to the plastic film with the electrically conductive layer disposed between the carrier and the plurality of electronic components; and (d) detaching the plastic film from the plurality of electronic components; and (e) introducing insulating material into spaces between the plurality of electronic components.
Description
(1) The invention is explained in more detail hereinafter on the basis of exemplary embodiments that are illustrated schematically in the attached drawing. In the figures:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10) It can be seen in
(11) In the following, a composite layer 4 is arranged on the electronic components 1 on the side of the contacts 3 according to the method step illustrated in
(12) The composite layer 4 can simultaneously cover the component(s) 1 to be embedded or to be integrated with an insulating material 5.
(13) In the following, a connection between the composite layer 4 and the electronic components 1 takes place according to the method step illustrated in
(14) After the connection of the electronic components 1 to the composite 4, particularly with the embedment of the contacts 3 in the insulating material 5, the plastic film 2 is removed and the unit contained is turned through 180, as indicated in
(15) Accordingly, it can be seen in the method step illustrated in
(16) However, it would also be conceivable here to cast the components 1 in a still-liquid resin, which is subsequently cured.
(17) Furthermore, the encapsulation of the components 1 could also take place as soon as during the step according to
(18) For the further construction of the printed circuit board to be produced, it can be seen in
(19) This further composite layer 11 is preferably constructed as identically as possible (mirror identically) to the composite layer 4, in order to thus achieve a symmetry in the structure shown in
(20) The individual layers or plies are illustrated in
(21) For a further processing or working of the printed circuit board to be produced, it is indicated in
(22) Approaches of this type are of course also to additionally be considered in the method examples explained in the following.
(23) Using the method described above (and in the following), an embedment of electronic components 1 in printed circuit boards is possible independently of the size of the components 1, and it is furthermore particularly advantageous that no adhesive, which constitutes a foreign substance and can lead to air bubbles, is introduced into the printed circuit board. The fixing of the components 1 with the composite layer 4 or 11 can take place in a vacuum, wherein no solvent is required and air bubbles are prevented. Furthermore, a small spacing can be obtained between the contacts 3 of the components 1 and the conductive layer 6 to be connected to the same (after the structuring), which is advantageous for the contacting during the placing of lasered holes. Moreover, the connection of the components 1 to the composite layer 4 (and also 11) takes place in a single step. Overall, comparatively particularly thin printed circuit board structures can be obtained with the described method.
(24) These measures and advantages also apply for the exemplary embodiments according to
(25) In the part figures
(26) In the method illustrated in
(27) In the method according to
(28) According to
(29) The local dielectric layers 5 on the components 1 can be particularly thin, so that a particularly small spacing between the components 1 and the conductor layer 6 of the composite layer 4 can be achieved, which is advantageous, as mentioned, during later contacting of the connections 3 when drilling lasered holes or vias.
(30) Laminating the composite layer 4 onto the components 1, more specifically onto the thin dielectric layers 5 thereof, can also inherently take place using a downward-facing connection side of the components 1, that is to say face down, i.e. when affixing the components 1 on the plastic film 2 with the dielectric layers 5.
(31) Furthermore, in the method according to
(32) In the method illustrated in
(33) A further variant of the present method for producing printed circuit boards or printed circuit board elements is illustrated in the Part
(34) In the method according to
(35) The electrically conductive material 20 on the components 1 can be obtained from a strip material, which contains a binding agent in the form of a resin which is partially cured (thus is in a B stage) and metal powder, e.g. silver. This material is bubble-free and is affixed on the rear side of the components 1. The material of these layers 20 is non-adhesive at room temperature, and an elevated temperature is required if it is connected to the metal layer, i.e. the conductors 6. The conductive material 20 can be used in the finished printed circuit board for heat dissipation and/or as a contact, e.g. for the drain electrode of an IGBT transistor.
(36) The method variant according to
(37) The electrically conductive material of the layers or part layers 20 or 20 can for example also consist of a paste, which contains a metal powder, such as silver, and a binding agent. This paste can be thermally sintered. It can be applied on the conductor layer 6 (or on the components 1) in advance by means of printing on, for example by screen printing, stencil printing and similar application technologies. The paste is dried at an elevated temperature, in order to remove binding agent and solvent. After the drying of this material, a porous structure is obtained. Connecting in a vacuum in turn prevents the inclusion of air bubbles at the connection areas between the components 1 and the electrically conductive layers 20 or 20. During the lamination process, the porous structure is condensed by applying pressure and temperature, so that in each case solid metal layers are formed in this low-temperature sintering process.
(38) In the method variant according to
(39) After the step according to
(40) A lamination of an additional two-layer composite layer 11 with a conductor 13 and a support 14 then takes place, cf.
(41) The advantage of this approach is a reduced outlay during the registration of process steps. In the method according to
(42) The pastes or layers 20 or 20 sometimes shrink during heating and lamination of the composite layer 11 by 50% in terms of thickness.
(43) For positioning or registering the components 1 to be embedded, registration elements or markings can generally be provided on the temporary support 2. It is particularly advantageous furthermore, if for the following process steps, registration elements 17 are provided, as are shown schematically in
(44) Aside from these registration elements 17, components 1 already present on the plastic film 2 can also be used as registration elements.
(45) For temporarily fixing the components 1, the support plastic film 2 is, as mentioned, preferably constructed as an adhesive tape or film, particularly with a pressure-sensitive adhesive, which enables a reliable positioning and provisional fixing of the components 1 and also a subsequent simple removal of the temporary support 2 after the method step illustrated e.g. in
(46) To compensate different heights of the components 1 to be accommodated and if appropriate production tolerances in the dimensions of the components 1 to be accommodated, it may also be expedient to equip the temporary support 2 with a compressible material, which allows the thicker components 1 to be pressed in. With a compensation of this type between differently sized components 1, an exact connection of the components 1 to the common composite layer 4 is enabled in the subsequent production steps e.g. according to
(47) Such a construction of a temporary support or carrier 2, as indicated previously, can be drawn from the illustration in
(48) With regards to the previously mentioned good dimensional stability, it is therefore furthermore possible in the case of such a temporary composite support 2, as shown in
(49) With regards to a corresponding mechanical strength during further processing or working steps, the support 7 of the composite layer 4 can also preferably consist of a correspondingly dimensionally stable material, for example of a metal, such as for example copper, aluminium, etc., or of a dimensionally stable polymer. Furthermore, it is conceivable to incorporate a dimensionally stable layer in the region of the insulating-material layer 5 of the composite layer 4 (and correspondingly in the composite layer 11). This is shown in
(50) To achieve a smaller thickness of the printed circuit board to be produced, a comparatively small thickness is chosen for the conductor layer 6 or the additional conductor layer 13, which thickness is chosen to be less than 20 m, in particular between 10 nm and 10 m. The application can take place e.g. by means of sputtering.
(51) For maintaining a corresponding contacting of the components 1 or a connection between the components 1, particularly the surfaces having the contacts 3, and the insulating layer 5 or 12 of the composite layer 4 or 11, this insulating layer 5 or 12 can also be formed of a correspondingly temperature-resistant material, for example a hardened duroplastic, such as epoxy. If using such materials for the layer 5 or 12, a desired and correspondingly smaller spacing between the contacts 3 and the conductor layer 6 or 13 can also be reliably maintained, so that in turn the height of the printed circuit board can be correspondingly minimised.
(52) It is additionally noted that the dimensional ratios or relative dimensions of the individual elements illustrated in the drawing are not true to scale.
(53) A multi-layer printed circuit board is also enabled with the present method. By multiple repetition of the method steps illustrated and described in the drawing, a multi-layer printed circuit board can be obtained, wherein electronic components 1 can be integrated at different levels or planes in a simple and reliable manner.