Circuit Board Having an Asymmetric Layer Structure
20170339784 · 2017-11-23
Inventors
- Andreas Zluc (Leoben, AT)
- Gerald Weidinger (Leoben, AT)
- Mario Schober (Trofaiach, AT)
- Hannes Stahr (St. Lorenzen im Mürztal, AT)
- Timo Schwarz (St. Michael i.O., AT)
- Benjamin Gruber (Niklasdorf, AT)
Cpc classification
H05K1/0353
ELECTRICITY
H01L2924/19105
ELECTRICITY
H01L2224/92144
ELECTRICITY
H05K2201/0191
ELECTRICITY
H05K1/0271
ELECTRICITY
H05K1/185
ELECTRICITY
H05K3/0097
ELECTRICITY
H05K1/115
ELECTRICITY
H01L24/20
ELECTRICITY
H05K1/189
ELECTRICITY
H01L23/5389
ELECTRICITY
H05K3/4602
ELECTRICITY
H01L21/568
ELECTRICITY
H05K2201/068
ELECTRICITY
H05K2201/0187
ELECTRICITY
H05K3/0017
ELECTRICITY
H01L24/19
ELECTRICITY
H01L2924/0002
ELECTRICITY
H01L2224/2518
ELECTRICITY
H01L21/481
ELECTRICITY
H01L2224/04105
ELECTRICITY
International classification
H01L21/48
ELECTRICITY
H05K1/11
ELECTRICITY
H05K1/18
ELECTRICITY
H01L23/538
ELECTRICITY
H05K3/00
ELECTRICITY
Abstract
A circuit board is described which includes a layer composite with at least one dielectric layer which includes a planar extension in parallel with respect to an xy-plane which is spanned by an x-axis and a y-axis perpendicular thereto, and which includes a layer thickness along a z-axis which is perpendicular with respect to the x-axis and to the y-axis; and at least one metallic layer which is attached to the dielectric layer in a planar manner. The layer composite along the z-axis is free from a symmetry plane which is oriented in parallel with respect to the xy-plane, and the dielectric layer includes a dielectric material which has an elastic modulus E in a range between 1 and 20 GPa and along the x-axis and along the y-axis a coefficient of thermal expansion in a range between 0 and 17 ppm/K. A method of manufacturing such a circuit board is also described. Further, a method of manufacturing a circuit board structure comprising two asymmetric circuit boards and a method of manufacturing two processed asymmetric circuit boards from a larger circuit board structure is described.
Claims
1. A circuit board, comprising: a layer composite with at least one dielectric layer which comprises a planar extension in parallel with respect to an xy-plane which is spanned by an x-axis and a y-axis which is perpendicular thereto, and comprises a layer thickness along a z-axis which is perpendicular with respect to the x-axis and to the y-axis; and at least one metallic layer which is attached to the dielectric layer in a planar manner; wherein the layer composite along the z-axis is free from a symmetry plane which is oriented in parallel with respect to the xy-plane, and the dielectric layer comprises a dielectric material which has an elastic modulus E in a range between 1 and 20 GPa and along the x-axis and along the y-axis a coefficient of thermal expansion in a range between 0 and 17 ppm/K.
2. The circuit board of claim 1, wherein the dielectric material comprises a creeping property which is determined by at least one of the following properties: (a) a plastic deformability in a range between 0.01% and 10%, (b) a viscoelastic deformability in a range between 0% and 10%.
3. The circuit claim 1, wherein the dielectric material is a blend or a copolymer, consisting of at least one first material with a first elastic modulus E and a first coefficient of thermal expansion and a second material with a second elastic modulus E and a second coefficient of thermal expansion, wherein the first elastic modulus is larger than the second elastic modulus and the first coefficient of thermal expansion is smaller than the second coefficient of thermal expansion.
4. The circuit board of claim 3, wherein the first material comprises a first glass transition temperature and the second material comprises a second glass transition temperature.
5. The circuit board of claim 1, wherein the first material comprises a resin and a hard filler which is located therein.
6. The circuit board of claim 3, wherein the second material is a thermally curable resin which is connected to a softening substance.
7. The circuit board of claim 1, comprising at least one of the following features: wherein the value for the elastic modulus E is in a range between 2 and 7 GPa and in particular in a range between 3 and 5 GPa wherein the coefficient of thermal expansion is in a range between 3 and 10; and/or wherein the layer composite comprises an asymmetry with respect to the number of the layers along the z-axis; and/or wherein the layer composite comprises an asymmetry with respect to the thicknesses of the single layers along the z-axis; and/or wherein the layer composite comprises an asymmetry with respect to the materials of the single layers along the z-axis.
8.-11. (canceled)
12. The circuit board of claim 1, further comprising: a component which is embedded in the dielectric and/or in a dielectric core-layer of the circuit board.
13. The circuit board of claim 1, wherein the component is embedded in the dielectric layer.
14. The circuit board of claim, 1, further comprising: the dielectric core-layer which is attached to the metallic layer and/or to the dielectric layer in a planar manner; wherein the component is embedded in the dielectric core-layer and the dielectric layer is arranged above or below the dielectric core-layer and the embedded electronic component.
15. The circuit board of claim 14, comprising at least one of the following features: wherein the component is adhered within the dielectric core-layer; and/or wherein the dielectric core-layer comprises a dielectric core material which has a coefficient of thermal expansion from 0 to 11 ppm/k.
16. (canceled)
17. The circuit board of claim 12, wherein the entire thickness of the layer composite is smaller than approximately 200 μm.
18. The circuit board of claim 1, wherein the dielectric layer is a dielectric prepreg-layer and/or the dielectric material is a dielectric prepreg-material.
19. A method of manufacturing a circuit board, the method comprising: building up a superordinated layer composite with at least one dielectric layer which comprises a planar extension in parallel with respect to an xy-plane which is spanned by an x-axis and a y-axis which is perpendicular thereto, and comprises a layer thickness along a z-axis which is perpendicular with respect to the x-axis and to the y-axis; and at least one metallic layer which is attached to the dielectric layer in a planar manner; wherein the layer composite along the z-axis is free from a symmetry plane which is oriented in parallel with respect to the xy-plane, and the dielectric layer comprises a dielectric material which has an elastic modulus E in a range between 1 and 20 GPa and along the x-axis and along the y-axis a coefficient of thermal expansion in a range between 0 and 17 ppm/K.
20. The method of claim 19, further comprising: forming a recess in the dielectric layer and/or in a dielectric core-layer; and inserting an electronic component into the recess.
21. The method of claim 20, wherein the recess is larger than the electronic component, such that after an inserting of the electronic component into the recess, a hollow remains.
22. The method of claim 20, further comprising if the electronic component is inserted in the dielectric layer, applying a further dielectric layer on the dielectric layer and the electronic component, wherein the further dielectric layer has the same properties as the dielectric layer; and if the electronic component is embedded in the dielectric core-layer, applying the dielectric layer on the dielectric core-layer and the electronic component.
23. The method of claim 19, further comprising at least one of the following features: forming a metallic layer at the dielectric layer, and/or pressing all layers of the circuit board (200).
24.-26. (canceled)
27. A method of manufacturing two processed circuit boards, the method, comprising: building up a layer composite comprising a first circuit board according to claim 1, a second circuit board according to claim 1, and a release layer which is arranged between the first circuit board and the second circuit board; processing the entire layer composite; and separating the layer composite at the release layer such that a first processed circuit board and a second processed circuit board with respectively one asymmetric layer build-up are generated.
28. The method of claim 27, comprising at least one of the following features: wherein the built up layer composite comprises a symmetry plane along the z-axis, which is oriented in parallel with respect to the xy-plane, and/or wherein the release layer comprises a printable adhesion reducing material and wherein the method further comprises printing the adhesion reducing material on at least a subregion of the first circuit board or on at least a subregion of the second circuit board.
29. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0104]
[0105]
[0106]
[0107]
[0108]
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0109] It should be noted that in the following detailed description, features and components, respectively, of different embodiments which are equal or at least functionally equal to the respective features and components, respectively, of another embodiment, are provided with the same reference signs or with a reference sign which only differs in the first digit from the reference sign of the equal or at least functionally equal features and components, respectively. In order to avoid unnecessary repetitions, features and components, respectively, which have been already described by means of a previously described embodiment, shall not be described in detail later.
[0110] Further, it should be noted that the subsequently described embodiments merely constitute a restricted selection of possible variants of the embodiments of the invention. In particular, it is possible to combine the features of the single embodiments in a suitable manner, such that with the variants of the embodiments which are explicitly shown here, a multiplicity of different embodiments are to be considered as obviously disclosed for those skilled in the art.
[0111] Moreover, it should be noted that spatially related terms, such as “front” and “back”, “above” and “below”, “left” and “right”, etc. are used to describe the relationship of an element to another element or to other elements, as illustrated in the figures. Accordingly, the spatially related terms may apply for orientations which differ from the orientations which are shown in the figures. However, it is self-evident that all such spatially related terms, for the sake of simplicity of the description, relate to the orientations which are shown in the figures and are not necessarily limiting, since the respectively shown device, component etc., when in use, can assume orientations which differ from the orientations which are shown in the drawing.
[0112] The
[0113] The circuit board 100a comprises a layer sequence which comprises respectively alternating along a vertical z-axis a metallic layer 130, a dielectric layer 110, a metallic layer 132, a dielectric layer 112, a metallic layer 134, a dielectric layer 114 and a metallic layer 136. According to the here described embodiment, the metallic layers 130, 132, 134 and 136 are, at least previously to pressing the layer sequence, metal foils which comprise the material copper or consist of copper in a known manner.
[0114] According to the here described embodiment, all dielectric partial layers 110, 112 and 114 have the properties with respect to the elasticity (the elastic modulus E is in a range between 1 and 20 GPa) and the thermal expansion (the coefficient of thermal expansion CTE is in a range between 0 and 17 ppm/K) which have been described above in this document.
[0115] As can be seen in
[0116] It should be noted that the circuit board 100a after manufacturing thereof, in particular by means of pressing, can also be separated and singularized, respectively, into multiple single circuit boards, such that in each single circuit board only one single electronic component 120 is embedded, for example.
[0117] It should further be noted that the electronic components 120 may be so-called bare dies and unhoused chips, respectively. Alternatively, the electronic components 120 may also be housed electronic components which comprise metallic contact structures and contact pads, respectively, which are not shown in
[0118] For electrically contacting the electronic components 120, according to the here described embodiment, vias 160 are used in a known manner. These may be formed by means of laser drilling, for example. According to the here described embodiment, these vias 160 extend both from above and also from below up to the both electronic components 120. By a metallization of these vias 160, the electronic components 120 may be electrically contacted later in a suitable manner by the both metallic layers 134 and 136 and, where applicable, by further metallic layers (by further vias which are not shown).
[0119] It should be noted that vias can also be implemented in other plies of the circuit board 100a. For example, (further) vias may be implemented from the dielectric layer 110 up to the metallic layer 134 and/or between the both metallic layers 132 and 134.
[0120] The circuit board 100b which is shown in
[0121] A further difference between the circuit board 100b and the circuit board 100a consists in that not only the electronic components 120, but also the metallic layers 130 and 132 are contacted by means of vias 160. It should be noted that the vias 160 which are formed in the dielectric layers 110 and 112 may also be present in the circuit board 100a, but cannot be taken from the sectional view of
[0122] A further difference between the circuit board 100b and the circuit board 100a consists in that the circuit board 100b is not a layer build-up which uses the same dielectric material which is above described in detail for all dielectric layers. Rather, for the circuit board 100b, a mixture of this dielectric material and (for the core) a material with an especially small CTE was used.
[0123] The circuit board 100c which is shown in
[0124] The dielectric core-layer 150 comprises a dielectric core-material which, according to the embodiment which is shown here, has a coefficient of thermal expansion in a range from 6 to 9 ppm/K along the x-axis and along the y-axis. In this context, it should be noted that the x-axis and the y-axis span an xy-plane which is oriented perpendicular with respect to the vertical z-axis. This means that the planar surfaces of the single layers of the circuit boards 100a, 100b and 100c are oriented in parallel with respect to this xy-plane.
[0125] It should be noted that at least one of the above described dielectric layers may also be a dielectric prepreg-layer which has the special mechanical and thermal properties which are described in this document and which constitutes a material composite made of glass fibers and resin. The same also applies for the subsequently described embodiments.
[0126] The
[0127] In
[0128] As can be seen in
[0129] As can further be seen in
[0130] As can be seen in
[0131] After the procedure of pressing, in a known manner, for example by means of laser drilling, the vias 160 are formed. According to the embodiment which is shown here, these vias 160 extend both from above and also from below up to the both electronic components 120. By means of a metallization of these vias 160, the electronic components 120 can be electrically contacted later in a suitable manner.
[0132] The
[0133] As can be seen in
[0134] Further, on the temporary carrier 370 (beside the electronic components 120) a layer sequence is applied which, according to the embodiment which is shown here, is consisting of the following layers: (a) a metallic layer 337, (b) a dielectric layer 312, (c) a metallic layer 338, (d) a dielectric core-layer 350 and (e) a metallic layer 336.
[0135] According to the embodiment which is shown here, during forming the above-mentioned layer sequence, between a sidewall of the electronic component 120 and that sidewall of the layer sequence which is facing the electronic component 120, respectively a gap and a spacing 321, respectively, is let free. This gap and spacing 321, respectively, may already be let free during a successive applying of the concerned layers of the layer sequence. Alternatively, this gap and spacing 321, respectively, may be formed by a suitable removing, for example by means of an etching process, after a completed forming of a layer sequence which extends up to the sidewall of the electronic component 120.
[0136] As can be seen in
[0137] After putting on the carrier structure, the resulting layer composite is pressed. This pressing may in particular be performed together with the temporary carrier 370. If the pressing is performed together with the temporary carrier 370, the temporary carrier is removed from the circuit board 300 after the procedure of pressing (cf.
[0138] Also in this embodiment, during pressing the spacings 321 are filled with the dielectric material which, as described above, comprises a certain creeping capability. As a result, the concerned electronic component 120 is at least to a large extent completely surrounded by the dielectric material with its advantageous properties with respect to elasticity and thermal expansion.
[0139] As can further be seen in
[0140] It should further be noted that a circuit board which corresponds to the circuit board 300 can be also realized without the dielectric core-layer 350 and instead with a further dielectric layer. Further, also layer sequences are possible in which the dielectric core layer is formed at another position.
[0141] It should further be noted that the circuit board 300 can be also used as semi-finished product for manufacturing a larger circuit board structure.
[0142] The
[0143] In the upper illustrations of the
[0144] As can be seen in
[0145] According to the embodiment which is shown here, a cavity is formed within this layer structure, in which an electronic component 120 is located. This cavity was formed during building up the layer structure subsequently to forming the lower dielectric partial layer 410a. Only after inserting the electronic component 120, the remaining layers were formed, that is the upper dielectric partial layer 410a and the metallic layer 435.
[0146] As can be seen in
[0147] It should be noted that the height of the cavity shown in
[0148] For sake of completeness, it should be mentioned that suitable vias 160 can be formed in the circuit board 400a, which subsequently to a metallization which is performed in a known manner, generate electrical connections which extend in a vertical direction. As can be seen in the lower illustration of
[0149] In
[0150] In
[0151] The reduction of the build-up dimension is illustrated in the
[0152]
[0153] a metallic layer 530
[0154] a dielectric layer 510
[0155] a metallic layer 532
[0156] a dielectric core-layer 550
[0157] a metallic layer 534
[0158] a dielectric layer 512 and a release layer 590 which respectively form a common layer in different planar subregions within an xy-plane which is perpendicular with respect to the z-axis, in the shown layer composite
[0159] a metallic layer 536
[0160] a dielectric core-layer 552
[0161] a metallic layer 538
[0162] a dielectric layer 514
[0163] a metallic layer 539
[0164] At this point it should be noted that for the here described symmetric manufacturing method, all asymmetric build-ups which are described above by means of the
[0165] As can be seen in
[0166] In a respective manner, below the release layer 590 two electronic components 520c and 520d are embedded. These are entirely surrounded by the dielectric layer 514 at their bottom side and at their lateral surfaces. At the top side of the both electronic components 520c and 520d, the release layer 590 is abutting.
[0167] Furthermore, as can be seen in
[0168] The
[0169] The advantage of the here described manufacturing of two asymmetric circuit boards 500a and 500b is consisting in that many processing steps which are not shown in
[0170] Finally, it should be noted that in all embodiments described above, the respective circuit board may be built up without an embedded component 120.
[0171] This means that the respective circuit board is used as component carrier at which only at the planar surface and/or at the planar bottom side electronic components may be attached and assembled, respectively.
REFERENCE SIGNS
[0172] 100 circuit board with embedded electronic components [0173] 110 dielectric layer [0174] 110a,b,c dielectric partial layer [0175] 120 electronic component [0176] 121 gap/spacing [0177] 130 metallic layer/metal foil [0178] 132 metallic layer/metal foil [0179] 160 vias [0180] 200 circuit board with embedded electronic components [0181] 210 dielectric layer [0182] 210b dielectric partial layer [0183] 250 dielectric core-layer [0184] 234 metallic layer/metal foil [0185] 300 circuit board with embedded electronic components [0186] 310 dielectric layer [0187] 312 dielectric layer [0188] 321 gap/spacing [0189] 335 metallic layer [0190] 336 metallic layer [0191] 337 metallic layer [0192] 350 dielectric core-layer [0193] 362 vias [0194] 370 temporary carrier/tape [0195] 400a,b,c circuit board with embedded electronic component [0196] 410a dielectric partial layers [0197] 410a′ united dielectric layer [0198] 410b dielectric layer [0199] 412a dielectric partial layers [0200] 412a′ united dielectric layer [0201] 412b dielectric layer [0202] 421 hollow [0203] 435 metallic layer [0204] 436 metallic layer [0205] 437 metallic layer [0206] 438 metallic layer [0207] 450 dielectric core-layer [0208] 480 dash-dot-line [0209] 500a circuit board (asymmetric) [0210] 500b circuit board (asymmetric) [0211] 505 circuit board structure (symmetric layer build-up) [0212] 510 dielectric layer [0213] 512 dielectric layer [0214] 514 dielectric layer [0215] 530 metallic layer [0216] 532 metallic layer [0217] 534 metallic layer [0218] 536 metallic layer [0219] 538 metallic layer [0220] 539 metallic layer [0221] 550 dielectric core-layer [0222] 552 dielectric core-layer [0223] 560 vias [0224] 590 release layer [0225] 590a/b portion of release layer