Manufacturing method for component incorporated substrate and component incorporated substrate manufactured using the method
09596765 ยท 2017-03-14
Assignee
Inventors
Cpc classification
H05K3/0008
ELECTRICITY
H01L2221/68359
ELECTRICITY
H05K3/4682
ELECTRICITY
H01L2224/92144
ELECTRICITY
H05K3/4655
ELECTRICITY
H05K1/185
ELECTRICITY
H01L24/82
ELECTRICITY
H05K3/4038
ELECTRICITY
H05K3/4602
ELECTRICITY
H01L21/568
ELECTRICITY
H01L2224/83192
ELECTRICITY
H01L2224/29387
ELECTRICITY
H01L24/19
ELECTRICITY
H01L2224/83132
ELECTRICITY
H05K3/4661
ELECTRICITY
H05K3/4658
ELECTRICITY
H05K2201/09063
ELECTRICITY
H05K1/188
ELECTRICITY
H01L2224/2919
ELECTRICITY
H05K2203/0361
ELECTRICITY
H05K3/403
ELECTRICITY
H01L2224/04105
ELECTRICITY
H01L2924/00
ELECTRICITY
H05K2201/09918
ELECTRICITY
H01L2224/82132
ELECTRICITY
H01L2224/2929
ELECTRICITY
H01L2223/54486
ELECTRICITY
H01L2924/00
ELECTRICITY
H05K2201/09472
ELECTRICITY
H01L23/544
ELECTRICITY
H05K1/09
ELECTRICITY
International classification
H05K3/30
ELECTRICITY
H01L23/544
ELECTRICITY
H05K3/40
ELECTRICITY
H05K3/00
ELECTRICITY
H05K1/09
ELECTRICITY
Abstract
A manufacturing method for a component incorporated substrate according to the present invention includes positioning an electronic component with reference to a mark formed on a copper layer, the mark consisting of a material less easily etched than copper by a copper etching agent used for etching of copper, after mounting the electronic component on the copper layer with an adhesive layer interposed therebetween, embedding the electronic component and the mark in an insulating substrate, thereafter, etching and removing a part of the copper layer to form a window for exposing the mark, forming an LVH reaching a terminal of the electronic component with reference to the exposed mark, electrically connecting the terminal and the copper layer via a conduction via formed by applying copper plating to the LVH, and, thereafter, forming the copper layer into a wiring pattern.
Claims
1. A manufacturing method for a component incorporated substrate in which, in an insulating substrate including a wiring pattern on a surface, an electric or electronic component including a terminal electrically connected to the wiring pattern is incorporated, the manufacturing method comprising: a mark forming step for forming a copper layer, which should be the wiring pattern, on a supporting plate and forming a mark on a second surface on an opposite side of a first surface in contact with the supporting plate of the copper layer; a component mounting step for positioning the component with reference to the mark and mounting the component on the second surface of the copper layer with an insulative adhesive layer interposed therebetween; an embedding layer forming step for forming, on the second surface of the copper layer on which the component is mounted, an embedding layer functioning as the insulating substrate in which the component and the mark are embedded; a window forming step for, after peeling the supporting plate off the copper layer, etching and removing, with a copper etching agent used for etching of copper, a part of the copper layer from the first surface of the copper layer exposed by the peeling and forming a window for partially exposing the embedding layer together with an entire proximal end face of the mark which was in contact with the second surface of the copper layer before removing the part of the copper layer; a conduction via forming step for specifying a position of a terminal of the component with reference to the mark exposed from the window and, after forming a via hole reaching the terminal, filling a conductive material in the via hole and forming a conduction via for electrically connecting the terminal and the copper layer; and a pattern forming step for forming the copper layer electrically connected to the terminal via the conduction via into the wiring pattern, wherein in the mark forming step, the mark is formed using an etching resistant material having greater etching resistance against etching by the copper etching agent than copper.
2. The manufacturing method for the component incorporated substrate according to claim 1, wherein the manufacturing method further includes, before the component mounting step, a surface roughening step for applying surface roughening treatment to the second surface of the copper layer using the copper etching agent.
3. The manufacturing method for the component incorporated substrate according to claim 1, wherein, in the mark forming step, the mark consisting of a plated layer of nickel serving as the etching resistant material is formed by at least one of an electroless plating method and an electroplating method.
4. The manufacturing method for the component incorporated substrate according to claim 3, wherein a plated layer of gold serving as the etching resistant material is further provided on the plated layer of nickel by at least one of the electroless plating method and the electroplating method, and the mark is formed by a nickel-gold plated layer.
5. The manufacturing method for the component incorporated substrate according to claim 1, wherein, in the mark forming step, the mark consisting of a plated layer of silver serving as the etching resistant material is formed by at least one of an electroless plating method and an electroplating method.
6. The manufacturing method for the component incorporated substrate according to claim 1, wherein, in the mark forming step, the mark is formed by supplying a silver paste serving as the etching resistant material onto the copper layer.
7. A component incorporated substrate manufactured using the manufacturing method according to claim 1.
8. The component incorporated substrate according to claim 7, comprising: the mark embedded in the insulating substrate such that the proximal end face is flush with a surface of the insulating substrate; and a land for component mounting consisting of a copper plated layer formed on the proximal end face of the mark and having a flat surface.
9. The component incorporated substrate according to claim 8, wherein the land for component mounting further includes a nickel plated layer formed on the copper plated layer and a gold plated layer formed on the nickel plated layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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MODE FOR CARRYING OUT THE INVENTION
(18) (First Embodiment)
(19) In the present invention, first, a mark for positioning consisting of a columnar body made of copper is formed on a starting material (a mark forming step). The starting material is prepared, for example, as explained below.
(20) First, as shown in
(21) Note that, as the supporting plate 2, a thin plate made of aluminum can be used. In this case, the first copper layer 4 consists of, for example, a copper foil and is stuck to the surface of a thin plate made of aluminum.
(22) Subsequently, as shown in
(23) The setting position of the mark 12 can be arbitrarily selected. However, it is preferable to provide the mark 12 in a position where an optical system sensor of an optical system positioning device (not shown in the figure), which performs positioning of an electronic component (hereinafter referred to as intra-substrate component) 14 that should be incorporated in the insulating substrate, can easily recognize the mark 12. In this embodiment, as shown in
(24) It is preferable to apply surface roughening treatment to the second surface 5 of the first copper layer 4 using a sulfuric acid-hydrogen peroxide-based copper etching agent among copper etching agents used for etching of copper. In this case, the marks consisting of nickel are not eroded because the marks have resistance against the sulfuric acid-hydrogen peroxide-based copper etching agent. It is possible to maintain a glossy surface. As a result, a contrast between the marks having glossiness and the roughened first copper layer 4 around the marks is made clear. The marks contribute to a reduction in a detection error of the optical sensor. Since the first copper layer 4 is roughened, in an embedding layer forming step, which is a later step, an anchor effect is exhibited between the insulating substrate and the first copper layer 4 and improvement of adhesion can be attained.
(25) Subsequently, the intra-substrate component 14 is mounted on the copper-plated steel plate 6 via an adhesive 16 (a component mounting step).
(26) First, as shown in
(27) The adhesive 16 hardens and changes to an adhesive layer 18 having predetermined thickness. The adhesive layer 18 to be obtained fixes the intra-substrate component 14 in a predetermined position and has a predetermined insulation property. The adhesive 16 is not particularly limited as long as the adhesive 16 exhibits predetermined bonding strength and a predetermined insulation property after the hardening. However, an adhesive obtained by adding a filler to thermosetting epoxy resin or polyimide resin is used. As the filler, for example, fine powder of silica (silicon dioxide), glass fiber, or the like is used.
(28) In the present invention, a form of the adhesive 16 supplied to the mounting planned region S is not particularly limited. A form may be adopted in which the adhesive 16 in a liquid state is applied at predetermined thickness. A form may be adopted in which the adhesive 16 of a sheet shape having predetermined thickness is placed. In this embodiment, an adhesive in a liquid state obtained by adding fine powder of silica to thermosetting epoxy resin is used.
(29) Subsequently, as shown in
(30) Specifically, as it is evident from
(31) Subsequently, an insulating base material is stacked to embed the intra-substrate component 14 and the mark 12 (an embedding layer forming step).
(32) First, as shown in
(33) Subsequently, the first insulating base material 22 is stacked on the first copper layer 4. The second insulating base material 24 is superimposed on the upper side of the first insulating base material 22. A copper foil, which should be a second copper layer 28, is further superimposed on the upper side of the second insulating base material 24 to form a stacked body. The first insulating base material 22 is disposed such that the intra-substrate component 14 is located in the through-hole 30. Thereafter, so-called hot press for pressing and heating is applied to the entire stacked body.
(34) Consequently, after being pressurized and filled in a gap such as the through-hole 30, the thermosetting resin in the unhardened state of the prepregs is hardened by heat of the hot press. As a result, as shown in
(35) Subsequently, as shown in
(36) Subsequently, a predetermined part of the first copper layer 4 is removed to form a window in the obtained intermediate product 40 (a window forming step).
(37) First, as shown in
(38) Subsequently, the first copper layer 4 in the exposed portions is removed from the intermediate product 40 by a normal etching method using a copper etching agent consisting of a cupric chloride aqueous solution. Thereafter, the mask layers 39 and 41 are removed. Consequently, as shown in
(39) Subsequently, via holes are formed in the adhesive layer 18 of the terminal present sections T (a via hole forming step).
(40) First, the exposed marks 12, 12 are recognized by the optical system sensor of the optical system positioning device (not shown in the figure). The positions of the terminals 20 of the intra-substrate component 14 hidden by the adhesive layer 18 are specified with reference to the positions of the marks 12, 12. Thereafter, a laser, for example, a carbon dioxide laser is irradiated on the adhesive layer 18 in the specified terminal positions to remove the adhesive layer 18. As shown in
(41) As it is evident from the forms explained above, the present invention is characterized in that the marks 12, 12 used for the positioning of the intra-substrate component 14 are used for the formation of the LVHs 46 again. That is, in the present invention, since the marks common to the positioning of the intra-substrate component 14 and the positioning of the LVHs 46 are used, it is possible to exhibit extremely high positioning accuracy. It is possible to form the LVHs 46 in accurate positions with respect to the terminals 20 hidden by the adhesive layer 18.
(42) Subsequently, after a resin residue is removed from the intermediate product 40, in which the LVHs 46 are formed, by desmear treatment, plating treatment is applied to the intermediate product 40 to deposit copper on the surface of the intermediate product 40. The copper is filled in the LVHs 46. Consequently, conduction vias that electrically connect the terminals 20 of the intra-substrate component 14 and the first copper layer 4 are formed (a conduction via forming step).
(43) First, electroless plating treatment of copper is applied to the insides of the LVHs 46 to cover the inner wall surfaces of the LVHs 46 and the surfaces of the terminals 20 of the intra-substrate component 14. Thereafter, electroplating treatment of copper is applied to grow, as shown in
(44) Subsequently, a part of the first copper layer 4 and the second copper layer 28 on the surface of the insulating substrate 34 is removed to form predetermined wiring patterns 50 (a pattern forming step).
(45) For the removal of a part of both the copper layers 4 and 28, the normal etching method is used. Consequently, as shown in
(46) After the wiring patterns 50 are formed, a solder resist is applied to a portion where adhesion of solder is desired to be avoided on the surface of the insulating substrate 34. Consequently, a solder resist layer 60 is formed on the surface of the insulating substrate 34. In this embodiment, as shown in
(47) As explained above, a component incorporated substrate 1 is obtained in which, in the insulating substrate 34 including the predetermined wiring patterns 50 on the surface, the intra-substrate component 14 including the terminals 20 electrically connected to the wiring patterns 50 is incorporated.
(48) The component incorporated substrate 1 obtained in this way can be formed as a module substrate by surface-mounting other electronic components on the surface. The component incorporated substrate 1 can also be used as a core substrate to form a multilayer circuit substrate using a normally-performed build-up method.
(49) Note that, in the first embodiment, the second windows are formed together with the first windows in the window forming step. However, the present invention is not limited to such a form. A form for forming only the first windows may be adopted. In this case, the positions of the terminals 20 of the component 14 are specified with reference to the marks 12 exposed from the first windows. The adhesive layer 18 including the copper layer 4 is removed to form via holes using, for example, a copper direct method.
(50) Next, second to fifth embodiments are explained. In explaining the embodiments, concerning steps same as the steps already explained, detailed explanation of the steps is omitted. Constituent members and parts that exhibit functions same as the functions of the constituent members and the parts explained above are denoted by the same reference numerals and signs and explanation of the constituent members and the parts is omitted.
(51) (Second Embodiment)
(52) A second embodiment is different from the first embodiment only in that a mark 12 is formed by a nickel-gold plated layer in the mark forming step in the first embodiment.
(53) In the mark forming step in the second embodiment, first, electroless plating of nickel is applied to the copper-plated steel plate 6 including the mask layer 8 to form nickel plated layers in the openings 10. Thereafter, electroless plating of gold is applied onto such a nickel plated layer to form the marks 12 consisting of a nickel-gold plated layer. Note that a method of forming the marks 12 consisting of the nickel-gold plated layer is not limited to an electroless plating method. An electroplating method can also be adopted. The electroless plating method and the electroplating method can also be used together.
(54) (Third Embodiment)
(55) A third embodiment is different from the first embodiment only in that the marks 12 are formed by a silver plated layer in the mark forming step in the first embodiment.
(56) In a mark forming step in the third embodiment, electroless plating of silver is applied to the copper-plated steel plate 6 including the mask layer 8 to form the marks 12 consisting of a silver plated layer. Note that a method of forming the marks 12 consisting of the silver plated layer is not limited to an electroless plating method. An electroplating method can also be adopted. The electroless plating method and the electroplating method can also be used together.
(57) (Fourth Embodiment)
(58) A fourth embodiment is different from the first embodiment only in that the marks 12 are formed using silver paste in the mark forming step in the first embodiment.
(59) In a mark forming step in the fourth embodiment, silver paste obtained by dispersing silver powder serving as a conductive filler in an organic binder is prepared. The silver paste is screen-printed on the first copper layer 4. Consequently, posts consisting of the silver paste are formed in predetermined positions on the first copper layer 4. Thereafter, the copper-plated steel plate 6, on which the posts of the silver paste are placed, is retained under a temperature atmosphere of 100 to 180 C. for 10 to 60 minutes, whereby the silver paste is hardened and formed into the marks 12.
(60) (Fifth Embodiment)
(61) A fifth embodiment is different from the first embodiment only in that, when the land for component mounting is formed in the first embodiment, a nickel plated layer 64 is formed on the copper plated layer 48 and a gold plated layer 66 is further formed on the nickel plated layer 64.
(62) In the fifth embodiment, as shown in
(63) As explained above, the marks 12 in the first to fifth embodiments consist of nickel, nickel-gold, silver, or silver paste. All of the marks 12 have greater etching resistance against erosion by the copper etching agents such as the sulfuric acid-hydrogen peroxide-based etching agent, the cupric chloride aqueous solution, and the ferric chloride aqueous solution, than copper. Therefore, in the surface roughening of copper and the etching of copper, the marks 12 are not eroded together with copper. That is, the marks 12 can maintain the initial shape. The marks 12 contribute to improvement of the positioning accuracy of the component and the accuracy of specifying of the terminal position.
(64) Note that, in the present invention, the component incorporated in the insulating substrate is not limited to the package component. Other various electronic components such as a chip component can be components incorporated in the insulating substrate.
EXPLANATION OF REFERENCE SIGNS
(65) 1 Component incorporated substrate
(66) 2 Supporting plate
(67) 3 First surface
(68) 4 First copper layer
(69) 5 Second surface
(70) 6 Copper-plated steel plate
(71) 8 Mask layer
(72) 12 Marks
(73) 14 Electronic component (intra-substrate component)
(74) 16 Adhesive
(75) 18 Adhesive layer
(76) 20 Terminals
(77) 34 Insulating substrate
(78) 40 Intermediate product
(79) 46 Laser via holes (LVHs)
(80) 47 Conduction vias
(81) 50 Wiring patterns
(82) S Mounting planned region
(83) T Terminal present sections