The present application is based upon and claims the benefit of priority to Japanese Patent Application No. 2014-204504, filed Oct. 3, 2014, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a printed wiring board with a metal post and a method for manufacturing the same.
2. Description of Background Art
Japanese Patent Laid-Open Publication No. 2006-074002 describes a package substrate in which terminals as connecting parts between a package substrate and a semiconductor component are formed by mounting solder balls on conductor pads in openings of a solder resist. The entire contents of this publication are incorporated herein by reference.
According to one aspect of the present invention, a printed wiring board includes a resin insulating layer, a conductor layer formed on the resin insulating layer and including conductor pads, a solder resist layer formed on the resin insulating layer such that the solder resist layer is covering the conductor layer and has opening portions exposing the conductor pads, respectively, and metal posts formed on the conductor pads such that each of the metal posts is protruding from the solder resist layer and has a side surface forming an angle with respect to a surface of the solder resist layer.
According to another aspect of the present invention, a method for manufacturing a printed wiring board includes preparing a printed wiring board including a resin insulating layer, and a conductor layer formed on the resin insulating layer and including conductor pads, forming a solder resist layer on the resin insulating layer such that the solder resist layer covers the conductor layer, affixing a resin film having a bonding layer on the solder resist layer, forming opening portions penetrating through the solder resist layer and the resin film such that the opening portions reach the conductor pads, respectively, forming metal posts in the opening portions respectively such that the metal posts connect to the conductor pads, respectively, and peeling off the resin film from the solder resist layer such that each of the metal posts is protruding from the solder resist layer and has a side surface forming an angle with respect to a surface of the solder resist layer.
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:
The embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
A pitch (center-to-center distance) of the metal posts 4 is 30 μm or more and 80 μm or less. As a result, a package substrate can be formed on which, for example, mounted semiconductor components are connected by an ultrahigh density wiring. The electroless metal plating that forms the metal posts 4 is reliably filled in the openings (3a) of the solder resist layer 3 and in openings (7a) of a PET film (to be described later), the openings being finely formed along with a demand for fineness of the terminal pitch. Therefore, the metal posts 4 have uniform heights. Further, the solder bumps 6 are formed on the metal posts 4 that protrude from the solder resist layer 3. Therefore, the terminals are increased in height, and an underfill material for insulation between the terminals and for bonding of a semiconductor component can be easily filled in a gap between a surface of the solder resist layer 3 and the semiconductor component that is connected to the solder bumps 6 on the metal posts 4.
The conductor pads (2a) may be SMD (Solder Mask Defined) type conductor pads or NSMD (Non Solder Mask Defined) type conductor pads. In the case of SMD type conductor pads, as illustrated in the drawings, the conductor pads (2a) are partially exposed from the openings (3a) of the solder resist layer 3. On the other hand, in the case of NSMD type conductor pads, although not illustrated in the drawings, the conductor pads (2a) are entirely exposed from the openings (3a) of the solder resist layer 3.
A side surface (4a) of each of the metal posts 4 has a portion (4b) that is inside the solder resist layer 3 and a portion (4c) that protrudes from the solder resist layer 3. The portions (4b, 4c) mutually smoothly connected and are mutually continuous in an illustration of a cross section perpendicular to a surface of the conductor pad (2a). As a result, there is no projection on the side surface (4a). Therefore, an insulation distance is ensured between the metal posts 4 in an ultrahigh-density wiring.
The portion (4c) of the side surface (4a) of each of the metal posts 4 that protrudes from the solder resist layer 3 forms an angle (α) with respect to the surface of the solder resist layer 3. It is preferable that the angle (α) between the portion (4c) of the side surface (4a) of each of the metal posts 4 that protrudes from the solder resist layer 3 and the surface of the solder resist layer 3 be 45 degrees or more and 90 degrees or less. When the angle (α) is less than 45 degrees, an outer diameter of an upper end part of each of the metal posts 4 becomes too large and an insulation distance between adjacent metal posts 4 is insufficient. When the angle (α) is more than 90 degrees, the outer diameter of the upper end part of each of the metal posts 4 becomes too small and it is possible that a sufficient height of each of the solder bumps 6 cannot be ensured. It is preferable that the angle (α) with respect to the surface of the solder resist layer 3 be less than 90 degrees. An insulation distance against migration can be further increased by increasing a distance between the openings (3a) on the surface of the solder resist layer 3.
The electroless metal plating that forms the metal posts 4 may be electroless copper plating. However, it is preferable that the electroless metal plating be electroless nickel plating. The electroless nickel plating can be formed thicker than the electroless copper plating in a short period of time and thus can be reliably filled in the openings (3a) of the solder resist layer 3 and in the openings (7a) of the PET film. Further, nickel is more migration resistant than copper and thus electrical reliability is increased.
It is preferable that phosphorus content in the electroless nickel plating that forms the metal posts 4 be 5% or more and 12% or less. When the phosphorus content is less than 5%, it is likely to cause reduction in insulation due to migration. When the phosphorus content is more than 12%, adhesion strength of the solder bumps 6 (to be described later) decreases.
Among an upper surface (4d) and the side surface (4a) of each of the metal posts 4, the intermediate metal layer 5 is provided only on the upper surface (4d). As a result, the intermediate metal layer 5 does not protrude from the side surface (4a) and thus an insulation distance between the metal posts 4 is ensured. The solder bumps 6 are respectively formed on the intermediate metal layers 5. It is preferable that the intermediate metal layer 5 be formed by sequentially laminating a palladium layer (5a) and a gold layer (5b). Palladium and gold facilitate formation of a nickel alloy between nickel of the metal posts 4 and solder of the solder bumps 6, and increases the adhesion strength of the solder bumps 6 to the metal posts 4.
In the following, an embodiment of a method for manufacturing the printed wiring board with a metal post of the present invention is described based on the drawings. FIG. 2A-2D are cross-sectional views illustrating an embodiment of a method for manufacturing the printed wiring board with a metal post of the present invention.
In the method for manufacturing the printed wiring board of the present embodiment, as illustrated in
The solder resist layer 3 is formed on the resin insulating layer 1 and the conductor layer 2. As a resin film with a bonding layer, for example, a PET film 7 with a bonding layer is affixed on the solder resist layer 3. The PET film 7 has a thickness of 7-30 μm, preferably 10-15 μm, which allows the PET film 7 to be easily melted by laser. As illustrated in
As illustrated in
The side surface (4a) of a metal posts 4 includes the portion (4b) and the portion (4c), the portion (4b) being formed by an opening (3a) of the solder resist layer 3 and being inside the solder resist layer 3, and the portion (4c) being formed by an opening (7a) of the PET film 7 and protruding from the solder resist layer 3. Inner wall surfaces of the opening (3a) and the opening (7a) are mutually smoothly connected and thus the portions (4b, 4c) are also mutually smoothly connected and mutually continuous.
As illustrated in
The intermediate metal layer 5 is formed, for example, by first laminating the palladium layer (5a) on the upper surface (4d) of the metal post 4 and then laminating the gold layer (5b) on the palladium layer (5a). It is also possible that the palladium layer (5a) is omitted and the intermediate metal layer 5 is formed by only the gold layer (5b). As illustrated in
It is also possible that the solder bumps 6 are formed on the intermediate metal layers 5 before the PET film 7 is peeled off from the solder resist layer 3.
As a result, the printed wiring board of the embodiment illustrated in
In the embodiment illustrated in
In the embodiment illustrated in
In the printed wiring board with metal post of the present invention, for example, for a case where a semiconductor component having solder bumps is mounted, it is also possible that the solder bumps 6 are not provided on some or all of the metal posts 4.
When the lower side package substrate (P1) is manufactured, it is possible that, after a solder resist layer 3 for the large-diameter metal posts (4B) and a solder resist layer 3 for the small-diameter metal posts (4A) are together covered by a PET film 7, openings (3a, 7a) of the solder resist layer 3 and the PET film 7 on the solder resist layer 3 for the large-diameter metal posts (4B), together with openings (3a, 7a) of the solder resist layer 3 and the PET film 7 on the solder resist layer 3 for the small-diameter metal posts (4A), are formed, for example, using the same UV laser, or are formed sequentially using different laser such as CO2 laser, and the metal posts (4A, 4B) are formed together or separately in the openings (3a, 7a) by electroless plating, and thereafter, the PET film 7 is peeled off. Or, it is also possible that, in a first process, the solder resist layer 3 for the small-diameter metal posts (4A) is covered by a PET film 7, the openings (3a, 7a) of the solder resist layer 3 and the PET film 7 on the solder resist layer 3 for the small-diameter metal posts (4A) are formed, for example, using UV laser, and the small-diameter metal posts (4A) are formed in the openings (3a, 7a) by electroless plating, and thereafter, in a second process, the openings (7a) of the PET film 7 on the solder resist layer 3 for the small-diameter metal posts (4A) and the solder resist layer 3 for the large-diameter metal posts (4B) are covered by another PET film 7, the openings (3a, 7a) of the solder resist layer 3 and the PET film 7 on the solder resist layer 3 for the large-diameter metal posts (4B) are formed, for example, using UV laser or different laser such as CO2 laser, or by etching or the like, and the large-diameter metal posts (4B) are formed in the openings (3a, 7a) by electroless plating, and thereafter the PET films 7 are peeled off.
Terminals as connecting parts between a package substrate and a semiconductor component may be formed by mounting solder balls on conductor pads in openings of a solder resist or by printing of solder paste. However, along with demand for a fine terminal pitch, it has become difficult to reliably fill solders in openings of a solder resist.
Further, the terminals may be formed by forming solder bumps on the conductor pads in the openings of the solder resist and thus the terminals are not so high. Therefore, it is not easy for an underfill material for insulation between the terminals and for bonding of the semiconductor component to be filled in a gap between a surface of the solder resist and the semiconductor component.
A printed wiring board according to an embodiment of the present invention reliably forms conductors in openings of a solder resist and reduces variation in heights of terminals as connecting parts between a package substrate and a semiconductor component. A printed wiring board according to another embodiment of the present invention increases insulation reliability between adjacent terminals by suppressing extension of a plating conductor in a later direction. A printed wiring board according to yet another embodiment of the present invention allows an underfill material to be easily filled in a gap by increasing the height of the terminals.
A printed wiring board with a metal post according to an embodiment of the present invention includes: a resin insulating layer; a conductor layer that is formed on the resin insulating layer and includes a conductor pad; a solder resist layer that is formed on the resin insulating layer and the conductor layer and allows at least a portion of the conductor pad to exposed; and a metal post that is formed on the conductor pad. The metal post protrudes from the solder resist layer. A side surface of the metal post forms an angle with respect to a surface of the solder resist layer.
A method for manufacturing a printed wiring board with a metal post according to an embodiment of the present invention includes: preparing a printed wiring board that has a resin insulating layer and a conductor layer that is formed on the resin insulating layer and includes a conductor pad; forming a solder resist layer on the resin insulating layer and the conductor layer; affixing a resin film with a bonding layer on the solder resist layer; forming an opening that penetrates through the solder resist layer and the resin film with the bonding layer and reaches the conductor pad; forming a metal post in the opening, the metal post electrically connecting to the conductor pads; and peeling off the resin film with the bonding layer from the solder resist layer.
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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2014-204504 | Oct 2014 | JP | national |