Patent Application
20130069180
The present invention relates to an electro-acoustic conversion device mount substrate that is mounted with an electro-acoustic conversion device that converts a sound signal into an electric signal and to a microphone unit that includes the electro acoustic conversion device mount substrate. Besides, the present invention relates to a manufacturing method for the electro-acoustic conversion device mount substrate and microphone unit.
Conventionally, a microphone, which has a function to convert an input sound into an electric signal and output it, is applied to various types of voice input apparatuses (e.g., voice communication apparatuses such as a mobile phone, a transceiver and the like, information process apparatuses such as a voice identification system and the like that use a technology for analyzing an input voice, recording apparatuses and the like).
A microphone unit includes an electro-acoustic conversion device that converts a sound signal into an electric signal. The electro-acoustic conversion device is mounted on a substrate (electro-acoustic conversion device mount substrate) on which a wiring pattern is formed as shown in patent documents 1 and 2, for example. There is a case where an electro-acoustic conversion device, as shown in the patent document 1, is mounted on a substrate to cover an opening that connects to an intra-substrate space (which functions as a rear chamber in some cases and functions as a sound hole (sound path) in other cases) which is formed in the substrate.
Here, an “intra-substrate space” in the present specification is a space that is formed at a more inner portion with respect to a substrate outer circumferential surface (assuming that an opening surface forms the outer circumferential surface at a portion where the opening is formed) as a reference surface.
In the meantime, there is a case where as an electro-acoustic conversion device included in a microphone unit, a MEMS (Micro Electro Mechanical System) chip formed by using a semiconductor manufacturing technology is used because of reasons that size reduction is possible and the like. The MEMS chip includes a diaphragm and a fixed electrode that is disposed to oppose the diaphragm with a gap therebetween and forms a capacitor together with the diaphragm.
In the MEMS chip, the gap formed between the diaphragm and the fixed electrode is, for example, 1 μm, which is narrow. Because of this, if dust invades the gap, defective operation of the MEMS chip is caused.
As for a substrate such as an FR-4 substrate (glass epoxy substrate) and the like that includes a resin fiber, a fiber garbage (an example of dust) easily occurs from a surface that is scraped to form a through-hole, a groove and the like, for example. Because of this, in a microphone unit (e.g., shown in the patent document 1) having a structure which is mounted with a MEMS chip to cover an opening that connects to an intra-substrate space (which has a surface to which machining such as scraping and the like is applied), there is a problem that if a substrate such as an FR-4 substrate that easily emits dust is employed as the substrate, defective operation of the MEMS chip easily occurs.
In light of the above points, it is an object of the present invention to provide an electro-acoustic conversion device mount substrate that is able to reduce the likelihood that an electro-acoustic conversion device malfunctions because of dust. Besides, it is another object of the present invention to provide a small and high-quality microphone unit for which anti-dust measures are taken by including the electro-acoustic conversion device mount substrate. Further, it is another object of the present invention to provide a preferred method for manufacturing the electro-acoustic conversion device mount substrate and the microphone unit.
To achieve the above objects, an electro-acoustic conversion device mount substrate according to the present invention is an electro-acoustic conversion device mount substrate that is mounted with an electro-acoustic conversion device which converts a sound signal into an electric signal, the electro-acoustic conversion device mount substrate includes: a mount surface on which the electro-acoustic conversion device is mounted and which is provided with an opening that is covered by the electro-acoustic conversion device; an intra-substrate space that connects to the opening; and a coating layer that covers at least a portion of a wall surface of the intra-substrate space.
According to this structure, it is possible to obtain a state in which dust is unlikely to occur by covering a surface, to which machining such as severing, scraping and the like is applied, by means of the coating layer. Because of this, it is easy to prevent malfunction of the electro-acoustic conversion device by using the electro-acoustic conversion device mount substrate that has the present structure.
In the electro-acoustic conversion device mount substrate having the above structure, the coating layer may be a plated layer. According to this structure, it is easy to form the coating layer as well for anti-dust measures concurrently when forming, for example, a through-wiring through the electro-acoustic conversion device mount substrate, which is convenient.
Besides, in the electro-acoustic conversion device mount substrate having the above structure, a glass epoxy material may be used as a substrate material. As described above, the glass epoxy substrate easily emits dust from the surface to which machining such as severing, scraping and the like is applied. Because of this, in the case of this structure, the effect of the anti-dust measures due to the coating process becomes great.
Besides, in the electro-acoustic conversion device mount substrate having the above structure, the intra-substrate space may or may not connect to an opening other than the opening that is covered by the electro-acoustic conversion device. Further, in a case where the intra-substrate space connects to an opening other than the opening that is covered by the electro-acoustic conversion device, the other opening may be disposed through a rear surface which is opposite to the mount surface, or may be disposed through the mount surface. A microphone unit is produced into various forms depending on the purpose, and the electro-acoustic conversion device mount substrate according to the present invention is widely applicable to the various forms.
To achieve the above objects, a microphone unit according to the present invention includes: the electro-acoustic conversion device mount substrate having the above structure; the electro-acoustic conversion device that is mounted on the mount surface to cover the opening; and a cover portion that collaborates with the electro-acoustic conversion device mount substrate to form a housing space for housing the electro-acoustic conversion device.
The microphone unit having the above structure is unlikely to emit dust in the intra-substrate space, accordingly, malfunction of the electro-acoustic conversion device is unlikely to occur. In other words, according to this structure, it is possible to provide the microphone unit that has a high quality.
In the microphone unit having the above structure, the electro-acoustic conversion device may be a MEMS chip that includes: a diaphragm and a fixed electrode that is disposed to oppose the diaphragm with a gap therebetween and forms a capacitor together with the diaphragm. It is possible to form the MEMS chip to be small, because of this, according to this structure, it is possible to provide the microphone unit that is small and has a high quality.
To achieve the above objects, a method for manufacturing the electro-acoustic conversion device mount substrate according to the present invention includes: a first step for preparing a substrate that is provided with an opening covered by the electro-acoustic conversion device, an intra-substrate space that connects to the opening, and a through-hole for a through-wiring; a second step for applying a plating process to the intra-substrate space and the through-hole for the through-wiring; and a third step for forming a wiring pattern on a substrate outer surface by performing an etching process after the plating process.
According to this structure, concurrently with the forming of the through-wiring, it is possible to cover, by means of the plated layer (a form of the coating layer), a wall surface of the intra-substrate space that connects to the opening covered by the electro-acoustic conversion device, whereby it is easy to perform the forming of the electro-acoustic conversion device mount substrate to which the anti-dust measures are applied.
The method for manufacturing the electro-acoustic conversion device mount substrate having the above structure may further include: a fourth step for attaching another substrate to a rear surface opposite to a surface of the substrate, on which the wiring pattern is formed in the third process, through which the opening is formed; a fifth step for mounting a protection cover to cover an entire surface of the substrate, on which the wiring pattern is formed in the third process, through which the opening is formed; a sixth step for forming a through-hole for a through-wiring through the other substrate; a seventh step for applying a plating process to the through-hole for the through-wiring that is formed in the sixth step after completion of the fourth step, the fifth step and the sixth step that are performed in random order; an eighth step for forming a wiring pattern on the other substrate by means of an etching process after the seventh step is completed; and a ninth step for separating the protection cover after the wiring pattern is formed on the other substrate.
For example, in a case where it is impossible to form the intra-substrate space by only digging in a substrate thickness direction, there is a case where it is convenient to form the electro-acoustic conversion device mount substrate by using a plurality of substrates. This structure envisions the case where the electro-acoustic conversion device mount substrate having the intra-substrate space is formed by using a plurality of substrates. And, in the case where the electro-acoustic conversion device mount substrate is formed by using a plurality of substrates, there is a worry over that a plating process liquid, an etching process liquid and the like invade the intra-substrate space, residues of them remain to the end and a contaminated electro-acoustic conversion device mount substrate is produced. In this point, according to this structure, in expectation of the likelihood that the plating liquid and the like remain in the intra-substrate space in the later steps, the protection cover is mounted beforehand to cover the intra-substrate space, thereafter, the plating process and the etching process are performed. Because of this, it is possible to reduce the likelihood of providing the above contaminated electro-acoustic conversion device mount substrate.
To achieve the above objects, a method for manufacturing a microphone unit according to the present invention includes: a step for manufacturing an electro-acoustic conversion device mount substrate by means of the manufacturing method having the above structure; a step for mounting the electro-acoustic conversion device onto the electro-acoustic conversion device mount substrate to cover the opening; and a step for placing a cover portion onto the electro-acoustic conversion device mount substrate to cover the electro-acoustic conversion device.
According to this structure, the electro-acoustic conversion device mount substrate to which the anti-dust measures are applied and which has a low contamination likelihood is manufactured and the microphone unit is assembled by using the electro-acoustic conversion device mount substrate, accordingly, it is possible to provide the microphone unit that has a high quality.
According to the present invention, it is possible to provide an electro-acoustic conversion device mount substrate that is able to reduce the likelihood that an electro-acoustic conversion device malfunctions thanks to dust. Besides, according to the present invention, by including the electro-acoustic conversion device mount substrate, it is possible to provide a small and high-quality microphone to which anti-dust measures are applied. Further, according to the present invention, it is possible to provide a preferred manufacturing method for the electro-acoustic conversion device mount substrate and the microphone unit.
Hereinafter, an electro-acoustic conversion device mount substrate, a microphone unit, and manufacturing methods of them are described in detail with reference to the drawings.
The MEMS chip 11 including a silicon chip is an embodiment of the electro-acoustic conversion device according to the present invention, and a small capacitor type microphone unit that is manufactured by using a semiconductor manufacturing technology.
The base substrate 111 is provided with a through-hole 111a having a substantially circular shape when viewed from top through its central portion. The plate-shaped fixed electrode 112 is disposed on the base substrate 111 and provided with a plurality of small-diameter (about 10 μm in diameter) through-holes 112a. The intermediate substrate 113 is disposed on the fixed electrode 112 and, like the base substrate 111, is provided with a through-hole 113a having a substantially circular shape when viewed from top through its central portion. The diaphragm 114 disposed on the intermediate substrate 113 is a thin film which receives a sound pressure to vibrate (i.e., vibrate vertically in
In the MEMS chip 11, when a sound wave reaches and the diaphragm 114 vibrates, an inter-electrode distance between the diaphragm 114 and the fixed electrode 112 changes, accordingly, electrostatic capacity changes. As a result of this, it is possible to fetch the sound wave (sound signal) entering the MEMS chip 11 as an electric signal. Here, in the MEMS chip 11, thanks to the presence of the through-hole 111a formed through the base substrate 111, the plurality of through-holes 112a formed through the fixed electrode 112 and the through-hole 113a formed through the intermediate substrate 113, a lower surface of the diaphragm 114 also is able to communicate with an outside space (outside the MEMS chip 11).
The mike substrate 12, which is formed to have a substantially rectangular shape when viewed from top, is an embodiment of the electro-acoustic conversion device mount substrate according to the present invention, and on an upper surface 12a of which the MEMS chip 11 is mounted. Although skipped in
Besides, the mike substrate 12 is provided with an opening 121 through the mount surface (the upper surface) 12a on which the MEMS chip 11 is mounted, and the MEMS chip 11 is disposed to cover the opening 121. The opening 121 connects to an intra-substrate space 122 that has a substantially cylindrical shape. The intra-substrate space 122 connects to only the opening 121 but does not connect to another opening. In other words, the mike substrate 12 is provided with a recess by means of the opening 121 and the intra-substrate space 122. The intra-substrate space 122 is disposed with intention of increasing a volume of a rear chamber (a tightly closed space that faces a lower surface of the diaphragm 114). If the rear chamber volume increases, the diaphragm 114 is easily displaced, and the mike sensitivity of the MEMS chip 11 improves.
Here, the mike substrate 12 may be, for example, an FR-4 (glass epoxy substrate) substrate, however, may be another kind of substrate.
The cover 13, which is formed to have a substantially rectangular-parallelepiped shape in outer shape, is placed over the mike substrate 12, thereby collaborating with the mike substrate 12 to form a housing space 14 that houses the MEMS chip 11. The cover 13 is provided with a sound hole 131 that guides a sound occurring outside the microphone unit 1 to the diaphragm 114 of the MEMS chip 11. Here, the cover 13 is an embodiment of a cover portion of the present invention.
When a sound wave input into the housing space 14 via the sound hole 131 reaches the diaphragm 114, the diaphragm 114 vibrates, whereby as described above, a change in the electrostatic capacity occurs. The microphone unit 1 is structured to fetch the change in the electrostatic capacity as an electric signal and to output the electric signal. Here, it is preferable that an electric circuit portion for fetching the change in the electrostatic capacity as an electric signal is disposed in the housing space 14; however, the electric circuit portion may be disposed outside the housing space 14. Besides, the electric circuit portion may be monolithically formed on a silicon substrate that forms the MEMS chip 11.
In the meantime, in the microphone unit 1 according to the first embodiment, a wall surface 122a (in the present embodiment, the entire wall surface of the intra-substrate space 122) of the intra-substrate 122 formed in the mike substrate 12 is covered by a coating layer CL. The covering by the coating layer CL is obtainable by, for example, a plating process, and the coating layer CL may be, for example, a metal plated layer such as a Cu plated layer and the like. Thanks to the covering by the coating layer CL, it is possible to reduce a likelihood that dust occurs in the intra-substrate space 122 of the mike substrate 12.
In a case where the mike substrate 12 is composed of, for example, a glass epoxy substrate (FR-4 substrate), a fiber-like dust easily occurs from a machined surface (a surface to which machining such as severing, scraping or the like is applied) of the mike substrate 12. In a case where the wall surface 122a of the intra-substrate space 122 is not covered by means of the coating layer CL (in a case different from the present embodiment), dust easily enters the MEMS chip 11 that is disposed to cover the opening 121 which connects to the intra-substrate space 122. The invasion of dust into the MEMS chip 11 causes malfunction of the MEMS chip 11. As an example, there is a situation in which dust enters from the through-hole 112a disposed through the fixed electrode 112 and clogs the gap Gp (see
Next, methods for manufacturing the mike substrate 12 and the microphone unit 1 described above are described with chief reference to
When manufacturing the mike substrate 12, first, a substrate 12′ (flat-plated shape), whose upper surface and lower surface are covered by a metal material (electro-conductive material) 101 such as Cu or the like, is prepared (step a; see
At a substantially central position of the prepared substrate 12′, the substrate 12′ is dug from the upper surface to a position in a thickness direction (the vertical direction of
In the meantime, here, the substrate (a substrate provided with a recess) which is provided with the opening 121 and the intra-substrate space 122 is obtained by using the NC apparatus; however, this is not limiting. In other words, a first substrate (flat-plated shape) provided with a through-hole (formed by a drill or a laser, for example) and a second substrate with no through-hole are attached to each other, whereby one substrate provided with the opening 121 and the intra-substrate space 122 may be obtained.
Next, in the substrate 12′ where the opening 121 and the intra-substrate space 122 are formed, a through-hole 103 (e.g., 0.3 mm in diameter) is formed through a portion where it is necessary to electrically connect the upper surface and the lower surface to each other as shown in
When the through-hole 103 is formed through the substrate 12′, next, a plating process (e.g., electroless copper plating process) is applied to the through-hole 103 to form a through-wiring 104 as shown in
Here, the forming of the through-wiring 104 and the process of covering the wall surface of the intra-substrate space 122 by means of the coating layer CL may be performed with a method other than the plating process, for example, may be performed with a method (burying, applying and the like) that uses electro-conductive paste and the like.
Next, a portion of the upper surface and the lower surface of the substrate 12′ where the wiring pattern is necessary is masked by means of an etching resist 105 as shown in
When the masking by means of the etching resist 105 is completed, the substrate 12′ is dipped into an etching liquid (step f). In this way, of the electro-conductive material (e.g., Cu) disposed on the upper surface and the lower surface of the substrate 12′, a portion which is not covered by the etching resist 105 is removed as shown in
In the meantime, here, the unnecessary electro-conductive material is removed by the etching; however, this is not limiting, and the unnecessary electro-conductive material may be removed by, for example, laser machining and scrape machining.
When the etching is completed, the washing of the substrate 12′ and the removal of the etching resist 105 are performed (step g). In this way, as shown in
By disposing the MEMS chip 11 onto the upper surface 12a of the mike substrate 12 to cover the opening 121 and further by placing the cover 13 to cover the MEMS chip 11, the microphone unit 1 shown in
Besides, the cover 13 also is connected to the upper surface of the mike substrate 12 by using, for example, an adhesive or an adhesive sheet for air-tight sealing. In a case where the electric circuit portion is mounted onto the mike substrate 12, the MEMS chip 11 and the electric circuit portion are connected to the mike substrate 12, thereafter, the cover 13 is connected to the upper surface (a mount surface of the MEMS chip 11 and the like) of the mike substrate 12. The wiring pattern formed on the lower surface of the mike substrate 12 is used as an external electrode.
In the above description, the structure is described, in which the wiring pattern disposed on the mike substrate 12 is formed by means of a subtraction method that uses the etching method; however this is not limiting. In other words, the wiring pattern disposed on the mike substrate 12 may be formed by means of an addition method that uses printing, burying and the like.
The structure of the MEMS chip 21 (an embodiment of the electro-acoustic conversion device according to the present invention), which has a fixed electrode 212 (which has a plurality of through-holes 212a) and a diaphragm 214, is the same as the structure of the MEMS chip 11 in the first embodiment, accordingly, a detailed description is skipped.
The structure of the mike substrate 22 (an embodiment of the electro-acoustic conversion device mount substrate according to the present invention) is substantially the same as the structure of the mike substrate 12 in the first embodiment, but is different from the structure of the first embodiment in that an intra-substrate space 222 connecting to a first opening 221 formed through a mount surface (upper surface) of the mike substrate 22 connects to a second opening 223 that is formed through a rear surface (lower surface) 22b opposite to the mount surface of the mike substrate 22. In other words, the mike substrate 22 is not provided with a recess, unlike the first embodiment, but provided with a through-hole, by means of the first opening 121, the intra-substrate space 122 and the second opening 223, that penetrates the mike substrate 22 in a thickness direction. Besides, the cover 23 (an embodiment of the cover portion according to the present invention) also has substantially the same structure as the cover 13 in the first embodiment, but is different from the structure of the first embodiment in that a sound hole is not disposed.
Here, the mike substrate 22 may be, for example, an FR-4 (glass epoxy substrate) substrate, however, may be another kind of substrate.
In the microphone unit 2 according to the second embodiment, the MEMS chip 21 is disposed to cover the first opening 221 that is formed through the mount surface 22a of the mike substrate 22. The through-hole formed of the first opening 221, the intra-substrate space 222 and the second opening 223 functions as a sound hole. In other words, a sound wave occurring outside the microphone unit 2 reaches a lower surface of the diaphragm 214 via the second opening 223, the intra-substrate space 222 and the first opening 221.
In this way, the diaphragm 214 vibrates, whereby a change in the electrostatic capacity occurs. The microphone unit 2 is structured to fetch the change in the electrostatic capacity as an electric signal and to output the electric signal. Here, a caution item regarding the disposition of the electric circuit portion for fetching the change in the electrostatic capacity of the MEMS chip 21 as an electric signal is the same as the case of the first embodiment.
The microphone unit 2 according to the second embodiment is structured to use a tightly closed space 24 (a housing space for housing the MEMS chip 21), which is formed by the mike substrate 22 and the cover 23, as the rear chamber; accordingly, it is easy to enlarge the rear chamber volume. Because of this, it is easy to improve the mike sensitivity.
Here, also in the microphone unit 2 according to the second embodiment, a wall surface 222a (in the present embodiment, the entire wall surface of the intra-substrate space 222) of the intra-substrate space 222 formed in the mike substrate 22 is covered by the coating layer CL. The covering by the coating layer CL is obtainable by, for example, a plating process, and the coating layer CL may be, for example, a metal plated layer such as a Cu plated layer and the like. The effect of the covering by the coating layer CL is the same as the case of the first embodiment, and also in the microphone unit 2 according to the second embodiment, it is possible to prevent the occurrence of dust in the intra-substrate space 222 and reduce malfunction of the MEMS chip 21.
Next, methods for manufacturing the mike substrate 22 and the microphone unit 2 described above are described with chief reference to
When manufacturing the mike substrate 22, first, a substrate 22′ (flat-plated shape), whose upper surface and lower surface are covered by a metal material (electro-conductive material) 201 such as Cu or the like, is prepared (step a; see
At a substantially central position of the prepared substrate 22′, along a thickness direction (the vertical direction of
Thereafter, the same processes as the first embodiment are successively performed.
First, a through-hole 203 is formed through a portion where it is necessary to electrically connect the upper surface and the lower surface to each other as shown in
Next, portions of the upper surface and the lower surface of the substrate 22′ where a wiring pattern is necessary are masked by means of an etching resist 205 (step e). At this time, the coating layer CL (e.g., a Cu plated layer) applied to the wall surface of the intra-substrate space 222 is also masked by means of the etching resist 105.
When the masking by means of the etching resist 205 is completed, the substrate 22′ is dipped into an etching liquid to remove an unnecessary electro-conductive material (e.g., Cu) as shown in
By disposing the MEMS chip 21 onto the upper surface 22a of the mike substrate 22 to cover the opening 221 and further by placing the cover 23 to cover the MEMS chip 21, the microphone unit 2 shown in
The structure of the MEMS chip 31 (an embodiment of the electro-acoustic conversion device according to the present invention), which has a fixed electrode 312 (which has a plurality of through-holes 312a) and a diaphragm 314, is the same as the structure of the MEMS chip 11 in the first embodiment, accordingly, a detailed description is skipped. Besides, the structure of the cover 33 (an embodiment of the cover portion of the present invention) provided with a sound hole 331 is also the same as the structure of the cover 13 in the first embodiment, accordingly, a detailed description is skipped.
The structure of the mike substrate 32 (an embodiment of the electro-acoustic conversion device according to the present invention) is different from the structure of the first embodiment. Because of this, in the microphone unit 3 according to the third embodiment, the rear chamber has a structure different from the microphone unit 1 according to the first embodiment.
The mike substrate 32 formed to have a substantially rectangular shape when viewed from top is composed by attaching three substrates 32a, 32b and 32c to one another as shown in
Besides, the mike substrate 32 is provided with an opening 321 through the mount surface (upper surface) 32d on which the MEMS chip 31 is mounted, and the MEMS chip 31 is disposed to cover the opening 321. The opening 321 connects to an intra-substrate space 322 that has a substantially L shape in section. The intra-substrate space 322 connects to only the opening 321 but does not connect to another opening. As described above, the mike substrate 32 has the structure obtained by attaching the plurality of substrates, accordingly, it is easy to obtain the intra-substrate space 322 that has the substantially L shape in section. Here, the mike substrate 32 may be, for example, an FR-4 (glass epoxy substrate) substrate, however, may be another kind of substrate.
The intra-substrate space 322 is disposed with intention of increasing a volume of the rear chamber (a tightly closed space that faces a lower surface of the diaphragm 314). Because of the shape (substantially L shape in section), it is possible to enlarge the volume of the intra-substrate space 322 in the present embodiment compared with the intra-substrate space 122 in the first embodiment. Because of this, the microphone unit 3 according to the third embodiment is expected to be improved in mike sensitivity compared with the microphone unit 1 according to the first embodiment. Here, to make it possible to enlarge the rear chamber volume, the intra-substrate space 322 may be structured to have a hollow space that connects to the digging in the substrate thickness direction, or is not limited to the structure of the present embodiment: for example, a substantially inverse T shape in section and the like may be used.
In the microphone unit 3 according to the third embodiment, when a sound wave input into a housing space 34 (formed by the mike substrate 32 and the cover 33) via the sound hole 331 of the MEMS chip 31 reaches the diaphragm 314, the diaphragm 314 vibrates, whereby a change in the electrostatic capacity occurs. The microphone unit 3 is structured to fetch the change in the electrostatic capacity as an electric signal and to output the electric signal. Here, the caution item regarding the disposition of the electric circuit portion for fetching the change in the electrostatic capacity of the MEMS chip 31 as an electric signal is the same as the case of the first embodiment.
In the meantime, in the microphone unit 3 according to the third embodiment, a portion of a wall surface 322a (a portion except for a bottom wall of the intra-substrate space 322) of the intra-substrate space 322 formed in the mike substrate 32 is covered by the coating layer CL. The covering by the coating layer CL is obtainable by, for example, a plating process, and the coating layer CL may be, for example, a metal plated layer such as a Cu plated layer and the like. The effect of the covering by the coating layer CL is the same as the case of the first embodiment, and also in the microphone unit 3 according to the third embodiment, it is possible to prevent occurrence of dust in the intra-substrate space 322 and reduce malfunction of the MEMS chip 31.
Here, of course, a structure may be employed, in which also the bottom wall of the intra-substrate space 322 is covered by the coating layer CL. In the present embodiment, the structure is employed, in which the mike substrate 32 is formed by attaching the plurality of substrates 32a to 32c to one another, and the bottom wall of the intra-substrate space 32 is formed of an upper surface of the substrate 32c. The upper surface of the substrate 32c is not a surface to which machining such as severing, scraping and the like is applied, accordingly, dust is unlikely to occur. Because of this, in the present embodiment, the structure is employed, in which the bottom wall of the intra-substrate space 322 is not covered by means of the coating layer CL.
Next, methods for manufacturing the mike substrate 32 and the microphone unit 3 described above are described with chief reference to
When manufacturing the mike substrate 32, first, a first substrate 32a (flat-plated shape), whose upper surface is covered by, for example, a metal material (electro-conductive material) 301 such as Cu or the like, is prepared. And, along a thickness direction (the vertical direction of
Besides, a second substrate 32b (flat-plated shape), whose lower surface is covered by the metal material (electro-conductive material) 301 such as Cu or the like, is prepared. The thicknesses of the second substrate 32b and the electro-conductive material 301 are the same as the case of the first substrate 32a. And, along a thickness direction (the vertical direction of
Next, an adhesive is applied onto at least one of the lower surface of the first substrate 32a and the upper surface of the second substrate 32b, and the first substrate 32a and the second substrate 32b are attached to each other by pressing (step c; see
Besides, the substrate formed by attaching the first substrate 32a and the second substrate 32b as shown in
Next, a third through-hole 304 (e.g., 0.3 mm in diameter) is formed through a portion where electric connection is necessary between the upper surface of the first substrate 32a and the lower surface of the second substrate 32b (step d; see
Next, a plating process (e.g., electroless copper plating process) is applied to the third through-hole 304 to form a first through-wiring 305 as shown in
Next, portions of the upper surface of the first substrate 32a and the lower surface of the second substrate 32b where a wiring pattern is necessary are masked by means of an etching resist 306 (step f; see
Next, the first substrate 32a and the second substrate 32b which are in a relationship of being attached to each other, are dipped into an etching liquid. In this way, of the electro-conductive material (e.g., Cu) disposed on the substrate, a portion which is not covered by the etching resist 306 is removed (step g;
Next, the substrate dipped in the etching liquid is washed, thereafter, the removal of the etching resist 306 is performed (step h; see
Next, a protection cover 307 is mounted to cover and close tightly the entire upper surface of the first substrate 32a (step j; see
The step of mounting the protection cover 307 is disposed for the purpose of preventing a substrate treatment liquid from invading the intra-substrate space 322 during later substrate manufacturing processes and the finally obtained electro-acoustic conversion device mount substrate 32 from being contaminated. In detail, in a case where the protection cover 307 is not present, there is a likelihood that the plating liquid and the etching liquid invade the intra-substrate space 322 during the plating, etching and washing steps and residues remain to contaminate the substrate. In this point, as in the present embodiment, by mounting the protection cover 307, it is possible to prevent the contamination of the substrate.
Next, a fourth through-hole 308 having a substantially circular shape when viewed from top is opened, which extends from the lower surface of the third substrate 32c to the lower surface of the second substrate 32b (step k; see
Next, a plating process (e.g., electroless copper plating process) is applied to the fourth through-hole 308 to form a second through-wiring 309 as shown in
Next, a portion of the lower surface of the third substrate 32c where a wiring pattern is necessary is masked by means of the etching resist 306 (step m; see
In the meantime, here, the unnecessary electro-conductive material is removed by the etching; however, this is not limiting, and the unnecessary electro-conductive material may be removed by, for example, laser machining and scrape machining.
When the etching is completed, the substrate washing is performed, and further, the removal of the etching resist 306 is performed (step o; see
By disposing the MEMS chip 31 onto the upper surface 32d of the mike substrate 32 to cover the opening 321 and further by placing the cover 33 to cover the MEMS chip 31, the microphone unit 3 shown in
The structure of the MEMS chip 41 (an embodiment of the electro-acoustic conversion device according to the present invention), which has a fixed electrode 412 (which has a plurality of through-holes 412a) and a diaphragm 414, is the same as the structure of the MEMS chip 11 according to the first embodiment, accordingly, detailed description is skipped.
The structure of the mike substrate 42 (an embodiment of the electro-acoustic conversion device according to the present invention) is different from the structures of the first, second and third embodiments. The mike substrate 42 formed to have a substantially rectangular shape when viewed from top is composed by attaching three substrates 42a, 42b and 42c to one another as shown in
Besides, the mike substrate 42 is provided with a first opening 421 near a center of the mount surface (upper surface) 42d on which the MEMS chip 11 is mounted, and the MEMS chip 41 is disposed to cover the first opening 421. The first opening 421 connects to an intra-substrate space 422 that has a substantially U shape in section. The intra-substrate space 422 connects to not only the first opening 421 but also to a second opening 423 that is formed through the mount surface 42d of the mike substrate 42. As described above, the mike substrate 42 has the structure obtained by attaching the plurality of substrates, accordingly, it is easy to obtain the intra-substrate space 422 that has the first opening 421, the intra-substrate space 422 and the second opening 423. Here, the mike substrate 42 may be, for example, an FR-4 (glass epoxy substrate) substrate, however, may be another kind of substrate.
The cover 43, which is formed to have a substantially rectangular-parallelepiped shape, is placed over the mike substrate 42, thereby collaborating with the mike substrate 42 to form a housing space 44 that houses the MEMS chip 41. The cover 43 is provided with a first sound hole 431 that communicates with the housing space 44. Besides, the cover 33 is provided with a second sound hole 432 that communicates with the intra-substrate space 422 via the second opening 423. Here, the cover 43 is an embodiment of the cover portion of the present invention.
In the microphone unit 4 according to the fourth embodiment, a sound wave input into the housing space 44 via the first sound hole 431 reaches an upper surface of the diaphragm 414. Besides, a sound wave input into the intra-substrate space 422 via the second sound hole 432 reaches a lower surface of the diaphragm 414. Because of this, when a sound occurs outside the microphone unit 4, the diaphragm 414 vibrates thanks to a difference between a sound pressure acting on the upper surface and a sound pressure acting on the lower surface.
A sound pressure (amplitude of a sound wave) of a sound wave is inversely proportional to the distance from a sound source. And, the sound pressure attenuates sharply at a position near the sound source, and attenuate more slowly at a position that is more distant from the sound source. Because of this, in a case where a distance from the sound source to the upper surface of the diaphragm 414 and a distance from the sound source to the lower surface of the diaphragm 414 are different from each other, a user voice, which occurs near the microphone unit 4 and enters from the upper surface and the lower surface of the diaphragm 414, generates a large sound pressure difference between the upper surface and the lower surface of the diaphragm 414 to vibrate the diaphragm. On the other hand, noises from distant places, which enter from the upper surface and the lower surface of the diaphragm 414 have substantially the same sound pressures, accordingly, they cancel out each other and hardly vibrate the diaphragm.
Accordingly, the electric signal fetched by means of the vibration of the diaphragm 414 is regardable as an electric signal from which the noise is removed and which indicates the user voice. In other words, the microphone unit 4 according to the present embodiment is suitable for a close-talking mike that is required to alleviate a distant noise and collect a near sound.
Here, the electric circuit portion for fetching the change in the electrostatic capacity of the MEMS chip 41 as an electric signal may be disposed, for example, in the housing space 44, or outside the microphone unit. Besides, the electric circuit portion may be monolithically formed on the silicon substrate that forms the MEMS chip 41.
In the meantime, in the microphone unit 4 according to the fourth embodiment, a portion of a wall surface 422a of the intra-substrate space 422 formed in the mike substrate 42 is covered by the coating layer CL. The covering by the coating layer CL is obtainable by, for example, a plating process, and the coating layer CL may be, for example, a metal plated layer such as a Cu plated layer and the like. The effect of the covering by the coating layer CL is the same as the case of the first embodiment, and also in the microphone unit 4 according to the fourth embodiment, it is possible to prevent the occurrence of dust in the intra-substrate space 422 and reduce malfunction of the MEMS chip 41.
Here, of course, a structure may be employed, in which the entire wall surface that forms the intra-substrate space 422 is covered by the coating layer CL. In the present embodiment, the structure is employed, in which the mike substrate 42 is formed by attaching the plurality of substrates 42a to 42c to one another. A portion (wall surface) where the coating layer CL of the intra-substrate space 422 is not disposed is formed of an upper surface of the third substrate 42c. This portion is not a surface to which machining such as severing, scraping and the like is applied, accordingly, dust is unlikely to occur. Because of this, in the present embodiment, the structure is employed, in which a portion of the wall surface of the intra-substrate space 422 is not covered by means of the coating layer CL.
Next, methods for manufacturing the mike substrate 42 and the microphone unit 4 described above are described with chief reference to
When manufacturing the mike substrate 42, first, a first substrate 42a (flat-plated shape), whose upper surface is covered by, for example, a metal material (electro-conductive material) 401 such as Cu or the like, is prepared. And, along a thickness direction (the vertical direction of
Besides, a second substrate 42b (flat-plated shape), whose lower surface is covered by the metal material (electro-conductive material) 401 such as Cu or the like, is prepared. The thicknesses of the second substrate 42b and the electro-conductive material 401 are the same as the case of the first substrate 42a. And, along a thickness direction (the vertical direction of
Here, in the present embodiment, a right end of the third through-hole 404 is formed to be situated at the same position of a right end of the first through-hole 402, while a left end of the third through-hole 404 is formed to be situated at the same position of a left end of the second through-hole 403; however, this structure is not limiting. For example, a structure may be employed, in which the left and right ends of the third through-hole 404 are more widened to the left and right than the present embodiment. Besides, also the shape of the third through-hole 404 is not limited to the shape (substantially rectangular shape when viewed from top) of the present embodiment, and is suitably modifiable. Here, of course, the order of the step a and the step b may be reversed.
Next, the lower surface of the first substrate 42a and the upper surface of the second substrate 42b are attached to each other (step c; see
Hereinafter, although there is a difference in the substrate shape, the manufacturing of the mike substrate 42 is performed in a procedure similar to the case of the third embodiment. Points overlapping the third embodiment are skipped or described briefly.
A fourth through-hole 405 (e.g., 0.3 mm in diameter) is formed through a portion where electric connection is necessary between the upper surface of the first substrate 42a and the lower surface of the second substrate 42b by using, for example, a drill, a laser, an NC apparatus or the like (step d; see
Here, the forming of the through-wiring 406 and the process of covering the wall surface of the intra-substrate space 422 by means of the coating layer CL may be performed with a method other than the plating process, which is the same as the case of the third embodiment.
Next, portions of the upper surface of the first substrate 42a and the lower surface of the second substrate 42b where a wiring pattern is necessary to be formed are masked by means of an etching resist 407 (step f; see
In the meantime, here, the unnecessary electro-conductive material is removed by the etching; however, this is not limiting, and the unnecessary electro-conductive material may be removed by, for example, laser machining and scrape machining.
Next, the third substrate 42c (an embodiment of another substrate according to the present invention) whose lower surface is covered by the electro-conductive material 401 is attached onto the lower surface of the second substrate 42b (step i; see
Next, a plating process (e.g., electroless copper plating process) is applied to the fourth through-hole 409 to form a second through-wiring 410 as shown in
Next, a portion of the lower surface of the third substrate 42c where a wiring pattern is necessary is masked by means of an etching resist 407 (step m; see
In the meantime, here, the unnecessary electro-conductive material is removed by the etching; however, this is not limiting, and the unnecessary electro-conductive material may be removed by, for example, laser machining and scrape machining.
When the etching is completed, the substrate washing is performed, and further, the removal of the etching resist 407 is performed (step o; see
By disposing the MEMS chip 41 onto the upper surface 42d of the mike substrate 42 to cover the first opening 421 and further by placing the cover 43 such that the second sound hole 432 overlies the second opening 423, the microphone unit 4 shown in
(Others)
The microphone units 1 to 4, the electro-acoustic conversion device mount substrates (e.g., the mike substrates) 12, 22, 32, 42, and the manufacturing methods of them according to the embodiments described above are mere examples of the present invention, and the application scope of the present invention is not limited to the embodiments described above. In other words, it is possible to add various modifications to the embodiments described above without departing the object of the present invention.
For example, in the embodiments described above, the structure is employed, in which the electro-acoustic conversion device is the MEMS chip that is formed by using a semiconductor manufacturing technology; however, the structure is not limiting. The electro-acoustic conversion device formed of the MEMS chip is especially weak for dust, accordingly, the present invention is preferably applied; however, the present invention is applicable to a case where an electro-acoustic conversion device other than the MEMS chip is used.
Besides, in the above embodiments, the case is described, in which the electro-acoustic conversion device is a so-called capacitor type microphone; however, the present invention is applicable to a case where the electro-acoustic conversion device is a microphone (e.g., a moving conductor (dynamic) microphone, an electromagnetic (magnetic) microphone, a piezo-electric microphone and the like) which has a structure other than the capacitor type microphone.
Besides, in the above embodiments, the case is described, in which the coating layer disposed in the intra-substrate space of the electro-acoustic conversion device mount substrate is a metal layer such as a plated layer and the like; however, this is not limiting. In short, the coating layer disposed in the intra-substrate space may be a layer other than the metal layer if the layer has the function to alleviate dust that has a likelihood of occurring in the intra-substrate space.
In addition, the shapes of the electro-acoustic conversion device and the microphone unit (inclusive of the opening, the intra-substrate space and the like that are disposed in them) are not limited to the shapes according to the embodiments, and of course, modifiable into various shapes.
The present invention is suitable for a microphone unit that is included in voice input apparatuses such as, for example, a mobile phone and the like.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-125532 | Jun 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/061392 | 5/18/2011 | WO | 00 | 11/29/2012 |
