The present application is based upon and claims the benefit of priority to Japanese Patent Application No. 2016-145926, filed Jul. 26, 2016, the entire contents of which are incorporated herein by reference.
The present invention relates to a coil substrate having multiple conductive layers laminated via insulating layers, and relates to a method for manufacturing the coil substrate.
A coil substrate may have a coil part provided in multiple conductive layers in a center portion in a plate thickness direction.
According to one aspect of the present invention, a coil substrate includes insulating layers, and conductive layers laminated on the insulating layers in a plate thickness direction of the insulating layers, respectively. The conductive layers include three or more conductive layers and a set of conductive layers such that the set of conductive layers includes a first outermost conductive layer on one end side in the plate thickness direction and does not include a second outermost conductive layer on the opposite end side in the plate thickness direction and that the set of conductive layers includes coil portions each having a spiral form respectively and aligned in the plate thickness direction.
According to another aspect of the present invention, a method for manufacturing a coil substrate includes laminating insulating layers and conductive layers in a plate thickness direction of the insulating layers respectively such that the laminating of the conductive layers includes laminating three or more conductive layers and forming a set of conductive layers such that the set of conductive layers includes a first outermost conductive layer on one end side in the plate thickness direction and does not include a second outermost conductive layer on the opposite end side in the plate thickness direction and that the set of conductive layers includes coil portions each having a spiral form respectively and aligned in the plate thickness direction.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
In the following, embodiments according to the present invention are described with reference to
In the following, a surface at one end in a plate thickness direction of the coil substrate 10 is referred to as a first surface (10F) and a surface at the other end is referred to as a second surface (10S). Further, a surface of the core substrate 11 on the first surface (10F) side is referred to as an F surface (11F), and a surface of the core substrate 11 on an opposite side of the F surface (11F) is referred to as an S surface (11S). Further, when the multiple conductive layers 22 are distinguished from each other, the multiple conductive layers 22 are respectively referred to as a first conductive layer (22A), a second conductive layer (22B), a third conductive layer (22C), . . . , and an eighth conductive layer (22H), in an order from the outermost conductive layer 22 on the first surface (10F) side to the outermost conductive layer 22 on the second surface (10S) side.
The core substrate 11 is a prepreg obtained by impregnating a woven fabric of reinforcing fibers (for example, a glass cloth) with a resin. The core substrate 11 has a thickness of, for example, about 50-70 μm. The interlayer insulating layers 21 and the solder resist layers 26 are each a resin layer that does not contain reinforcing fibers. Further, the interlayer insulating layers 21 each have a thickness of, for example, about 16-20 μm. A thickness of each of the solder resist layers 26 is larger than the thickness of each of the interlayer insulating layers 21, and is, for example, about 18-22 μm. Further, as will be described in detail later, the conductive layers 22 are each mainly formed of copper plating. A thickness of each of the conductive layers 22 is smaller than the thickness of each of the interlayer insulating layers 21 and is, for example, about 14-18 μm.
The first-sixth conductive layers (22A-22F) each have a coil part 23 (see
Specifically,
Further, the inner end of the coil part 23 forms a quadrangular inner land part 24 having a side larger than a width of a middle linear portion of the coil part 23. The inner land part 24 is positioned at substantially a centroid of the quadrangular shape of the entire coil part 23, and is slightly shifted toward a side of a short side (10A) on one side from a centroid of the coil substrate 10. On the other hand, the outer end of the coil part 23 forms an outer land part 25 having substantially the same shape as that of the inner land part 24, and is positioned closer to a short side (10B) on the other side of the coil substrate 10 and is near a long side (10C) on one side. Further, the first land part (28A) has, for example, substantially the same quadrangular shape as that of the inner land part 24 and the outer land part 25, and is positioned near a corner between the short side (10B) on the other side and a long side (10D) on the other side of the coil substrate 10.
The inner land parts 24 of the first-sixth conductive layers (22A-22F) are formed to overlap when viewed from the plate thickness direction of the coil substrate 10. The outer land parts 25 of the second-sixth conductive layers (22B-22F) and the second land parts (28B) of the seventh and eighth conductive layers (22G, 22H) are also formed to overlap when viewed from the plate thickness direction of the coil substrate 10. Further, the first land parts (28A) of the first-eighth conductive layers (22B-22H) are also formed to overlap when viewed from the plate thickness direction of the coil substrate 10.
Between the first and second conductive layers (22A, 22B), between the third and fourth conductive layers (22C, 22D), and between the fifth and sixth conductive layers (22E, 22F), the inner land parts (24, 24) are connected to each other by a via conductor 17 that penetrates the interlayer insulating layer 21. Further, between the second and third conductive layers (22B, 22C), and between the fourth and fifth conductive layers (22D, 22E), the outer land parts (25, 25) are connected to each other by a via conductor 17 or connection conductors 15 that each penetrate the interlayer insulating layer 21 or the core substrate 11. That is, the multiple coil parts 23 are connected by connecting, in the order of, from the first surface (10F) side, the inner ends, the outer ends, the inner ends, the outer ends, and the inner ends, and a series circuit of the multiple coil parts 23 is formed. As a result, when a current flows through the series circuit of the multiple coil parts 23, magnetic fluxes generated in the coil parts 23 are oriented in the same direction.
Further, the first land parts (28A) of the first-eighth conductive layers (22A-22H) are connected by the via conductors 17 or the connection conductors 15, and form an “extended connection part” according to an embodiment of the present invention. Further, the outer land part 25 of the sixth conductive layer (22F) and the second land parts (28B) of the seventh and eighth conductive layers (22G, 22H) are connected by the via conductors 17, and form an “extended connection part” according to an embodiment of the present invention. The first land part (28A) and the second land part (28B) of the eighth conductive layer (22H) are respectively exposed on deep sides of openings (26A, 26A) provided in the solder resist layer 26 on the second surface (10S) side of the coil substrate 10, and respectively form the pads (29, 29).
The coil substrate 10 of the present embodiment is manufactured as follows.
(1) As illustrated in
(2) As illustrated in
(3) An electroless plating treatment is performed. An electroless plating film (not illustrated in the drawings) is formed on the copper foil (11C) and on inner surfaces of the through holes (11H). Next, as illustrated in
(4) As illustrated in
(5) The plating resist 33 is peeled off, and the electroless plating film (not illustrated in the drawings) and the copper foil (11C), which are below the plating resist 33, are removed. As illustrated in
(6) As illustrated in
(7) As illustrated in
(8) An electroless plating treatment is performed. An electroless plating film (not illustrated in the drawings) is formed on the interlayer insulating layers (21, 21) and on inner surfaces of the via holes (21H). Next, as illustrated in
(9) An electrolytic plating treatment is performed. As illustrated in
(10) Next, the plating resist 40 is peeled off, and the electroless plating film (not illustrated in the drawings) below the plating resist 40 is removed. By the remaining electrolytic plating film 39 and electroless plating film, the third conductive layer (22C) is formed on the F surface (11F), and the sixth conductive layer (22F) is formed on the S surface (11S) side. Then, the third and fourth conductive layers (22C, 22D) are connected by the via conductors 17, and the fifth and sixth conductive layers (22E, 22F) are connected by the via conductors 17.
(11) Next, in the same way, as illustrated in
(12) Next, as illustrated in
(17) Then, the tapered openings (26A) are formed at predetermined places of the solder resist layer 26 on the S surface (11S), and a portion of the first land part (28A) and a portion of the second land part (28B) of the eighth conductive layer (22H) are exposed from the solder resist layer 26, and the pair of the pads (29, 29) are formed. As a result, the coil substrate 10 illustrated in
The description about the structure and the manufacturing method of the coil substrate 10 of the present embodiment is as given above. Next, an operation effect of the coil substrate 10 is described. The coil substrate 10 of the present embodiment is applied, for example, as a coil element. Specifically, for example, the pair of the pads (29, 29) of the coil substrate 10 are formed opposing a pair of pads of a circuit board (not illustrated in the drawings) and are connected by solder balls provided on any ones of the pads. In this way, the coil substrate 10 can be applied as a coil element of a circuit on a circuit board.
Further, the coil substrate 10 can also be applied as a component of a sensor. As an example, a resistor is connected to the pair of the pads (29, 29) of the coil substrate 10, and the entire coil substrate 10 is fixed to a movable part of a home electric appliance or the like. A sensor main body having an electromagnetic coil (not illustrated in the drawings) is fixed to a supporting component that supports the movable part. Further, one end of the electromagnetic coil is formed opposing the first surface (10F) of the coil substrate 10. Then, a position or vibration of the movable part is detected based on a change in mutual inductance between the electromagnetic coil and the coil part 23, the mutual inductance varying according to the position of the movable part. That is, the coil substrate 10 can be applied as a component of a sensor.
Here, in the coil substrate 10 of the present embodiment, the conductive layers 22 containing the coil parts 23 are not sandwiched between conductive layers 22 that do not contain coil parts 23, and are formed closer to the first surface (10F) side of the coil substrate 10. As a result, it is unnecessary to provide an insulating layer having a high magnetic permeability that is required for a conventional coil substrate. That is, the coil substrate 10 of the present embodiment can have a simpler structure than a conventional coil substrate. Further, the core substrate 11 is provided in the center portion in the plate thickness direction of the coil substrate 10. Therefore, the coil substrate 10 has a higher strength than a conventional coil substrate, and is well balanced between the first surface (10F) side and the second surface (10S) side, and warpage is prevented. Further, since the conductive layers (22, 22) are laminated also in the core substrate 11 having a reinforcing effect, effective application of the core substrate 11 is achieved. Further, in the coil substrate 10, of a conductive layer 22 that does not have a coil part 23, a portion overlapping with the coil parts 23 in the plate thickness direction is a blank part (23K) where a conductor does not exist. Therefore, a decrease in a magnetic flux intensity of the coil parts 23 due to a conductive layer 22 that does not have a coil part 23 is suppressed.
The present invention is not limited to the above-described embodiment. For example, embodiments described below are also included in the technical scope of the present invention.
(1) In the coil substrate 10 of the above embodiment, the coil part 23 is provided at only place in the planar shape. However, it is also possible that the coil part 23 is provided at multiple places in the planar shape.
(2) In the coil substrate 10 of the above embodiment, the conductive layers 22 containing the coil parts 23 are not sandwiched between conductive layers 22 that do not contain coil parts 23 and are formed closer to the first surface (10F) side. However, it is also possible that the coil substrate 10 has a structure in which the conductive layers 22 containing the coil parts 23 are sandwiched between conductive layers 22 that do not contain coil parts 23.
(3) It is also possible that a dummy circuit that is not connected to the outer land part 25 is formed in the blank part (23K) of the conductive layer 22 that does not contain a coil part 23.
(4) In the coil substrate 10 of the above embodiment, winding directions of the spiral shapes of adjacent coil parts 23 are different from each other. However, it is also possible that the winding directions of the spiral shapes of adjacent coil parts 23 are the same.
(5) In the coil substrate 10 of the above embodiment, the shape of each of the lands is quadrangular. However, it is also possible that the shape of each of the lands is circular.
(6) In the coil substrate 10 of the above embodiment, the coil parts 23 each have a square spiral shape. However, it is also possible that the coil parts 23 each have a circular spiral shape.
In a coil substrate, in order to suppress a decrease in a magnetic force of a coil part, an insulating layer having a high magnetic permeability may be applied between the coil part and a surface of the coil substrate, and problems such as having a complicated structure are likely to occur.
A coil substrate according to an embodiment of the present invention has a simpler structure than a conventional coil substrate, and another embodiment of the present invention provides a method for manufacturing the coil substrate.
A coil substrate according to an embodiment of the present invention includes three or more conductive layers laminated via insulating layers. Spiral-shaped coil parts are respectively formed in some of the multiple conductive layers including an outermost conductive layer on one end side in a plate thickness direction of the coil substrate but not including an outermost conductive layer on the other end side in the plate thickness direction of the coil substrate. The coil parts are aligned in the plate thickness direction.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
Number | Date | Country | Kind |
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2016-145926 | Jul 2016 | JP | national |