Patent Grant
9591767
Field of the Invention
This invention relates to a component built-in board having an electronic component built in thereto, and a method of manufacturing the same, and to a component built-in board mounting body.
Description of the Prior Art
Known to achieve high density mounting of an electronic component is a component built-in board disclosed in Japanese Unexamined Patent Application Publication No. 2008-305937 A which has an electronic component built in to the board. Such a component built-in board has the electronic component buried in an insulating layer formed in a wiring board, hence it becomes a problem how efficiently heat generated by the electronic component is released to outside. A conventional component built-in board is configured to transmit heat generated by the electronic component to a heat sink (heat radiator) disposed in a layer above the wiring board via an insulating layer excelling in heat conductivity and a thermal via contacting a back surface (surface on an opposite side to a mounting surface) of the electronic component, and thereby radiate the heat generated by the electronic component.
In the above-described component built-in board of the conventional technology disclosed in Japanese Unexamined Patent Application Publication No. 2008-305937 A, connection between the back surface of the electronic component and the heat radiator is made via a thermal via formed by a heat-conducting resin composition. However, generally, heat conductivity of a conductive paste is lower than heat conductivity of copper, hence there is a problem that heat radiation characteristics are worse than when copper is connected.
On the other hand, in order to make heat more easily transmitted, the back surface of the electronic component is brought into direct contact with a heat-conducting member such as the heat radiator. On doing so, moisture that has infiltrated from outside infiltrates between the back surface of the electronic component and the heat radiator that have a weak force of attachment. Moreover, there is also a problem that a gap is generated therebetween, and reliability of the component built-in board gets lowered.
This invention has an object of overcoming the above-mentioned problems due to the conventional technology to provide a component built-in board in which close attachment between the electronic component and a heat-conducting layer can be secured and heat radiation characteristics can be improved, and a method of manufacturing the component built-in board, and to provide a component built-in board mounting body.
A component built-in board according to the present invention comprises stacked therein a plurality of printed wiring bases having a wiring pattern and a via formed on/in a resin base thereof, and comprises an electronic component built in thereto, wherein at least a portion of the plurality of printed wiring bases include a thermal wiring in the wiring pattern and include a thermal via in the via, at least one of the plurality of printed wiring bases has formed therein an opening where the electronic component is built, and has formed therein a heat-conducting layer configured from a metallic member and closely attached to a surface on an opposite side to an electrode formation surface of the electronic component built in to the opening, and the electronic component is fixed in the opening by an adhesive layer stacked on the heat-conducting layer, via a hole formed in a region facing onto the opening of the heat-conducting layer.
Due to the component built-in board according to the present invention, the surface on the opposite side to the electrode formation surface of the electronic component built in to the component built-in board is closely attached to the heat-conducting layer configured from the metallic member having a heat conductivity higher than that of a conductive paste in the opening, and is fixed in the opening by the adhesive layer stacked on the heat-conducting layer, via the hole formed in the region facing onto the opening of the heat-conducting layer, hence close attachment between the electronic component and the heat-conducting layer can be secured and heat radiation characteristics can be improved.
In an embodiment of the present invention, the hole is formed discretely in the region.
Moreover, in another embodiment of the present invention, the heat-conducting layer is connected via the thermal via and the thermal wiring to a bump formed in a surface layer of the component built-in board.
A method of manufacturing a component built-in board according to the present invention, the component built-in board comprising stacked therein a plurality of printed wiring bases that have a wiring pattern and a via formed on/in a resin base thereof, and the component built-in board comprising an electronic component built in thereto, comprises the steps of: forming the wiring pattern including a thermal wiring and the via including a thermal via in a plurality of the resin bases, forming in at least one of the plurality of resin bases an opening where the electronic component is built in, and forming a heat-conducting layer that is configured from a metallic member, includes a hole in a region facing onto the opening, and is closely attached to a surface on an opposite side to an electrode formation surface of the electronic component built in to the opening, thereby forming the plurality of printed wiring bases; and collectively stacking the plurality of printed wiring bases by thermal compression bonding such that the surface on the opposite side to the electrode formation surface of the electronic component is fixed in the opening by an adhesive layer stacked on the heat-conducting layer, via the hole and is thereby closely attached to the heat-conducting layer.
Due to the method of manufacturing a component built-in board according to the present embodiment, the surface on the opposite side to the electrode formation surface of the electronic component built in to the component built-in board is closely attached to the heat-conducting layer configured from the metallic member having a heat conductivity higher than that of a conductive paste in the opening, and is fixed in the opening by the adhesive layer stacked on the heat-conducting layer, via the hole formed in the region facing onto the opening of the heat-conducting layer, hence working effects similar to those described above can be displayed.
In an embodiment of the present invention, the hole is formed discretely in the region.
Another embodiment of the present invention further comprises the step of forming in a surface layer of the component built-in board a bump connected to the heat-conducting layer via the thermal via and the thermal wiring.
A component built-in board mounting body according to the present invention comprising a component built-in board mounted on a mounting board, the component built-in board comprising stacked therein a plurality of printed wiring bases that have a wiring pattern and a via formed on/in a resin base thereof, and the component built-in board comprising an electronic component built in thereto, wherein at least a portion of the plurality of printed wiring bases include a thermal wiring in the wiring pattern and include a thermal via in the via, at least one of the plurality of printed wiring bases has formed therein an opening where the electronic component is built, and has formed therein a heat-conducting layer configured from a metallic member and closely attached to a surface on an opposite side to an electrode formation surface of the electronic component built in to the opening, the electronic component is fixed in the opening by an adhesive layer stacked on the heat-conducting layer, via a hole formed in a region facing onto the opening of the heat-conducting layer, and the component built-in board is configured to be mounted on the mounting board via a bump formed in a surface layer of the component built-in board and connected to the heat-conducting layer via the thermal via and the thermal wiring.
Due to the component built-in board mounting body according to the present invention, the surface on the opposite side to the electrode formation surface of the electronic component built in to the component built-in board is connected to the mounting board via the heat-conducting layer, the thermal via, the thermal wiring, and the bump formed in the surface layer of the component built-in board. Therefore, heat of the electronic component is transmitted along the heat-conducting layer, the thermal via, the thermal wiring, and the bump that act as a heat radiation path, to be radiated efficiently and reliably to the mounting board. The mounting board has a sufficiently broad area compared to the electronic component or the component built-in board, hence is better as a heat radiation medium than a conventional kind of heat radiator, and does not need to be provided with a heat radiator. As a result, miniaturization is possible and flexibility of layout of the electronic component can be increased, and furthermore, improvement of heat radiation characteristics of the built in electronic component can be achieved.
In an embodiment of the present invention, the hole is formed discretely in the region.
Due to the present invention, close attachment between the electronic component and the heat-conducting layer can be secured and heat radiation characteristics can be improved.
A component built-in board and method of manufacturing the same and a component built-in board mounting body according to embodiments of this invention will be described in detail below with reference to the accompanying drawings.
The component built-in board 1 comprises a structure in which a second printed wiring base 20, a third printed wiring base 30, a fourth printed wiring base 40, and a cover lay film 3 substituting for a first printed wiring base are stacked collectively by thermal compression bonding. Moreover, the component built-in board 1 comprises an electronic component 90 which is built in to an opening 29 formed in a second resin base 21 of the second printed wiring base 20, in a state of being sandwiched by the third printed wiring base 30 and the cover lay film 3. Furthermore, the component built-in board 1 comprises a bump 49 formed on a mounting surface 2a side of the fourth printed wiring base 40.
The third and fourth printed wiring bases 30 and 40 respectively comprise: third and fourth resin bases 31 and 41; and signal-dedicated wiring lines 32 and 42, and thermal wiring lines 33 and 43 formed on at least one surface of these third and fourth resin bases 31 and 41. In addition, the third and fourth printed wiring bases 30 and 40 respectively comprise thermal vias 34 and 44, and signal-dedicated vias 35 and 45 that are formed by filling inside via holes formed in the third and fourth resin bases 31 and 41.
On the other hand, the second printed wiring base 20 comprises: a thermal wiring line 23 formed on one surface of the second resin base 21; a conductor layer 8 having a hole formed on another surface of the second resin base 21; and a thermal via 24 that is formed inside a via hole formed in the second resin base 21 such that both surfaces of the second resin base 21 are electrically continuous. Employable as these second through fourth printed wiring bases 20 to 40 are, for example, a single-sided copper clad laminated board (single-sided CCL) or a double-sided copper clad laminated board (double-sided CCL), and so on.
In the present example, the second printed wiring base 20 is formed based on a double-sided CCL, and the third and fourth printed wiring bases 30 and 40 are formed based on a single-sided CCL. Therefore, the conductor layer 8 and the thermal wiring line 23 of the second printed wiring base 20 are formed on both surfaces of the second resin base 21, and the thermal via 24 provides interlayer connection between the conductor layer 8 and the thermal wiring line 23 of both these surfaces.
In this case, the thermal via 24 is configured from a structure in which, for example, a plating is applied inside a through-hole formed from a thermal wiring line 23 side without penetrating the conductor layer 8, and is formed by, for example, a copper plating. At this time, it is also possible to adopt a structure where the inside of the through-hole is filled with a conductive paste instead of being plated. Note that the conductor layer 8, along with a plated layer 23a formed thereon, configure a heat-conducting layer 23A that conducts heat from the electronic component 90.
The second through fourth resin bases 21 to 41 and the cover lay film 3 are each configured by, for example, a resin film having a thickness of about 25 μm. Now, employable as the resin film are, for example, a resin film configured from the likes of a polyimide, polyolefin, or liquid crystal polymer, or a resin film configured from a thermosetting epoxy resin, and so on.
The electronic component 90 is the likes of a semiconductor component such as an IC chip, for example, or a passive component, and the electronic component 90 shown in
Note that the signal-dedicated wiring lines 32 and 42, and the thermal wiring lines 23, 33, and 43 are configured by, for example, pattern-forming a conductive material such as copper foil having a thickness of about 12 μm. The signal-dedicated vias 35 and 45, and the thermal vias 34 and 44 are configured from a conductive paste respectively filled into the via holes, and the thermal via 24 is formed by plating as described above. The thermal wiring lines and thermal vias, excluding a portion thereof, are formed to be disposed on an outer peripheral side of the electronic component 90.
The conductive paste includes, for example, at least one kind of metallic particle of low electrical resistance selected from the likes of nickel, gold, silver, copper, aluminum, andiron, and at least one kind of metallic particle of low melting point selected from the likes of tin, bismuth, indium, and lead, and is configured from a paste that has mixed therein a binder component whose main component is an epoxy, an acrylic, a urethane, and so on.
The conductive paste configured in this way has low heat conductivity of, for example, 5 to 13.5 W/(m·K), and enables the metal of low melting point contained therein to melt and form an alloy at a temperature of 200° C. or less, specifically the likes of copper or silver comprise characteristics allowing an intermetallic compound to be formed. Note that the conductive paste may also be configured by a nanopaste in which, for example, a filler of the likes of gold, silver, copper, or nickel with a nanolevel particle diameter is mixed into a binder component of the above-described kind.
In addition, the conductive paste may also be configured by a paste having metallic particles of the above-described nickel, and so on, mixed into a binder component of the above-described kind. In this case, the conductive paste is characterized in that electrical connection is performed by contact between fellow metallic particles. Employable as a method of filling the conductive paste into the via holes is, for example, a printing method, a spin coating method, a spray coating method, a dispensing method, a laminating method, a method combining use of these methods, and so on.
The bump 49 is configured from the likes of solder, and is formed at a portion above the signal-dedicated wiring line 42 and the thermal wiring line 43 formed on the mounting surface 2a side of the fourth resin base 41 of the fourth printed wiring base 40 not covered by a solder resist 48. The component built-in board 1 is mounted on the mounting surface 2a of the mounting board 2 via these bumps 49. Note that the second through fourth printed wiring bases 20 to 40 and the cover lay film 3 are stacked via an adhesive layer 9. The adhesive layer 9 is configured from, for example, the likes of an epoxy system or acrylic system adhesive material, or the likes of an organic system adhesive material including a volatile component.
The electronic component 90 disposed in the opening 29 of the second printed wiring base 20 has a back surface 91a thereof on an opposite side to the electrode formation surface 91b thereof closely attached to the conductor layer 8 of the heat-conducting layer 23A. In addition, the back surface 91a is adhered by the adhesive layer 9 of the cover lay film 3, via a hole 23B formed in a region facing onto the opening 29 of the heat-conducting layer 23A. As a result, the electronic component 90 is fixed in the opening 29 in a state where the back surface 91a and the conductor layer 8 have been closely attached.
In the case that the conductor layer 8 is configured from a copper foil of pure copper, the pure copper has an extremely high heat conductivity of 403 W/(m·K) at 0° C. and 395 W/(m·K) at 100° C., hence closely attaching the conductor layer 8 to the back surface 91a is extremely effective in improving heat radiation characteristics. Note that if the electronic component 90 is fixed in the opening 29 without providing the hole 23B, then the conductor layer 8 and the back surface 91a of the electronic component 90 cannot be directly adhered, hence some kind of adhesive medium becomes required between these conductor layer 8 and back surface 91a of the electronic component 90 and heat conducting characteristics are inferior compared to when the electronic component 90 is closely attached to the conductor layer 8 having a hole.
The component built-in board mounting body 100 configured in this way leads to a structure in which the electronic component 90 is disposed between the heat-conducting layer 23A and the mounting board 2. Moreover, heat of the electronic component 90 built in to the component built-in board 1 follows the following heat radiation path to be transmitted to the mounting board 2. That is, heat of the electronic component 90 is transmitted from the back surface 91a of the electronic component 90 to the heat-conducting layer 23A of the second printed wiring base 20.
Heat transmitted to the heat-conducting layer 23A passes through the thermal via 24 formed on the outer peripheral side of the electronic component 90 to be transmitted to the thermal via 34 and the thermal wiring line 33 of the third printed wiring base 30, and is further transmitted to the thermal via 44 and the thermal wiring line 43 of the fourth printed wiring base 40 to be transmitted to the bump 49. Heat transmitted to the bump 49 in this way is transmitted via this bump 49 to the mounting board 2 which has an area larger than that of the component built-in board 1, to be radiated from the mounting board 2.
Due to such a structure, almost all of the heat generated by the electronic component 90 built in to the component built-in board 1 is radiated by being transmitted to the mounting board 2 from the component built-in board 1 that has a structure not requiring a conventional kind of heat radiator.
Next, a method of manufacturing the component built-in board according to the first embodiment will be described.
First, the manufacturing steps of the third and fourth printed wiring bases 30 and 40 will be described. Note that these can be manufactured by similar steps, hence although here, the manufacturing steps of the fourth printed wiring base 40 will be described representatively with reference to
As shown in
The single-sided CCL used in step S100 is, for example, configured from a structure in which the fourth resin base 41 having a thickness of about 25 μm is affixed to the conductor layer 8 configured from a copper foil having a thickness of about 12 μm. Note that usable as this single-sided CCL is, for example, a single-sided CCL produced by applying a varnish of polyimide to the copper foil and hardening the varnish, by a casting method.
The casting method is a publicly known method of forming a flat film or sheet by extruding resin melted by an extruder from a linear slit provided in a flat die, and rapidly cooling the melted film by a cooled roller, and winding the film while rolling the film. This method is highly reliable and frequently used.
Otherwise usable as the single-sided CCL are the likes of a single-sided CCL in which a seed layer is formed on a polyimide film by sputtering and the conductor layer 8 is formed by growing copper by plating, or a single-sided CCL produced by attaching a rolled or electrolytic copper foil and a polyimide film by an adhesive material. Note that the fourth resin base 41 is not necessarily required to be configured from a polyimide, and may be configured from a plastic film of a liquid crystal polymer, or the like. Moreover, the etching in step S102 may employ the likes of an etchant whose main component is ferric chloride or an etchant whose main component is cupric chloride.
When the wiring pattern has been formed, then as shown in
Note that an inter-layer adhesive material employed in the adhesive layer 9 or the adhesive material 9a may be not only an epoxy system thermosetting resin, but also the likes of an acrylic system adhesive material or a thermoplastic adhesive material typified by a thermoplastic polyimide, or the like. Moreover, the inter-layer adhesive material is not necessarily required to be in a film state, and may have resin coated in a varnish state. Employable as the mask material are various kinds of films attachable or detachable by UV irradiation, in addition to the above-mentioned resin film or a plastic film of the likes of PET and PEN.
Then, as shown in
The via hole 6 formed in step S106 has a diameter φ of about 100 μm, and is formed in a certain place using a UV laser. The via hole 6 may otherwise be formed by the likes of a carbon dioxide laser or an excimer laser, or may be formed by the likes of drill processing or chemical etching. Moreover, the plasma desmear processing can be performed by a mixed gas of CF4 and O2 (tetrafluoromethane+oxygen), but may also employ another inert gas such as Ar (argon), and may be configured as wet desmear processing employing a chemical, rather than so-called dry processing.
Then, as shown in
Next, the manufacturing steps of the second printed wiring base 20 will be described with reference to
Next, as shown in
Then, as shown in
Note that as shown in, for example,
Finally, as shown in
Note that the electronic component 90 built in to the opening 29 of the second printed wiring base 20 formed in this way is manufactured, for example, as follows. The manufacturing steps of the electronic component 90 will be described with reference to
Next, as shown in
Then, as shown in
Note that employable as resin of the insulating layer 91d formed in step S124 are, for example, benzo-cyclo-butene (BCB) or poly-benzo-oxazole (PBO), and so on. Moreover, the photosensitive resin does not necessarily need to be coated by spin coating, and may be coated by curtain coating or screen printing, or by spray coating, and so on. The electronic component 90 produced in this way may also be provided with various functions of an inductor, a capacitor, a resistance, and so on, as well as an ordinary conductive circuit.
When the second through fourth printed wiring bases 20 to 40 and the electronic component 90 have been produced in this way, then as shown in
Then, as shown in
Then, the fourth resin base 41 on the signal-dedicated wiring line 42 and thermal wiring line 43 side of the fourth printed wiring base 40 in the component built-in board 1 has the solder resist 48 pattern-formed thereon (step S134). When the solder resist 48 has been formed, the bump 49 is formed on each of the wiring lines 42 and 43 by solder or the like (step S136), and the component built-in board 1 is mounted on the mounting surface 2a of the mounting board 2 (step S138), thereby manufacturing the component built-in board mounting body 100 according to the first embodiment of the kind shown in
Specifically, the first printed wiring base 10 basically can be manufactured by steps similar to those for the fourth printed wiring base 40 described using
The first printed wiring base 10 configured in this way has formed therein a plurality of thermal vias 14 connected to the conductor layer 8, and is stacked in a state where each of the thermal vias 14 is connected to the heat-conducting layer 23A of the second printed wiring base 20. In addition, a heat radiation-dedicated fin 80 which is separately formed and is configured from a member of high heat conductivity is connected in close attachment along an entire surface on the conductor layer 8.
Therefore, heat generated by the electronic component 90 passes through the heat-conducting layer 23A to be radiated from the mounting board 2, and passes through the thermal via 14 and the conductor layer 8 to be radiated also from the heat radiation-dedicated fin 80. As a result, heat radiation characteristics can be further improved.
While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-262217 | Nov 2011 | JP | national |
This application is a continuation application of PCT Application No. PCT/JP2012/079463, filed on Nov. 14, 2012, which is based on and claims the benefit of priority from prior Japanese Patent Application No. 2011-262217, filed on Nov. 30, 2011, the entire contents of which are incorporated herein by reference.
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| 6400573 | Mowatt | Jun 2002 | B1 |
| 7514636 | Sasaki | Apr 2009 | B2 |
| 8379400 | Sunohara | Feb 2013 | B2 |
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| Number | Date | Country |
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| 2000-058735 | Feb 2000 | JP |
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| Entry |
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| Extended European Search Report dated Jun. 26, 2015, issued in counterpart European application No. 12854222.2 (6 pages). |
| International Search Report, dated Dec. 11, 2012, issued in corresponding application No. PCT/JP2012/079463. |
| Number | Date | Country | |
|---|---|---|---|
| 20140268574 A1 | Sep 2014 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2012/079463 | Nov 2012 | US |
| Child | 14290173 | US |
