1. Field of the Invention
The present invention relates to a wiring board for mounting multiple IC chips and its manufacturing method.
2. Discussion of the Background
In Japanese Laid-Open Patent Publication 2000-353765, a multi-chip module is described. In such a module, a complex substrate is formed by laminating a flexible substrate on a rigid substrate, and a CPU and a memory are mounted on the complex substrate. The mounted CPU and memory are connected by wiring in inner layers of the complex substrate. The contents of this publication are incorporated herein by reference in their entirety.
According to one aspect of the present invention, a wiring board includes a first substrate having a penetrating hole penetrating through the first substrate, a built-up layer formed on one surface of the first substrate and including multiple interlayer resin insulation layers and multiple wiring layers, the built-up layer having an opening portion communicated with the penetrating hole of the first substrate and opened to the outermost surface of the built-up layer, an interposer accommodated in the opening portion of the built-up layer and including a second substrate and a wiring layer formed on the second substrate, the wiring layer of the interposer including multiple conductive circuits for being connected to multiple semiconductor elements, and a filler filling the opening portion of the built-up layer such that the interposer is held in the opening portion of the built-up layer. The opening portion of the built-up layer has a tapered portion tapering toward the outermost surface of the built-up layer.
According to another aspect of the present invention, a method for manufacturing a wiring board includes preparing a first substrate which has a penetrating hole penetrating through the first substrate, forming on one surface of the first substrate a built-up layer including multiple interlayer resin insulation layers and multiple conductive circuits, forming in the built-up layer an opening portion which is communicated with the penetrating hole of the first substrate and opened to the outermost surface of the built-up layer, accommodating in the opening portion of the built-up layer an interposer including a second substrate and a wiring layer formed on the second substrate, the wiring layer of the interposer including multiple second conductive circuits for being connected to multiple semiconductor elements, and filling a filler in the opening portion of the built-up layer such that the interposer is held in the opening portion of the built-up layer. The forming of the opening portion in the built-up layer includes forming a tapered portion in the opening portion such that the tapered portion of the opening portion is tapering toward the outermost surface of the built-up 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.
With reference to
As shown in
Interposer 80 has heat-resistant substrate 81 and a wiring layer formed on heat-resistant substrate 81. The wiring layer has signal lines 83 as second conductive circuits, insulative film 85 which is formed on signal lines 83 and has openings to partially expose signal lines 83, and bumps (82A, 82B) formed in the openings. Bumps (82A) are used to mount CPU chip 901, and bumps (82B) are used to mount memory chip 902. CPU chip 901 and memory chip 902 are electrically connected by signal lines 83. As shown in a plan view of
As shown in
As shown in
In the printed wiring board according to the first embodiment, by accommodating interposer 80 with fine-pitch wiring in built-up multilayer wiring board 11, semiconductor elements with various pitches may be mounted on built-up multilayer wiring board 11. Thus, the size of the built-up multilayer wiring board is reduced.
In the first embodiment, signal pads (901b) of CPU 901 and signal pads (902b) of memory 902 are respectively arranged along a single side, and those elements are mounted on built-up multilayer wiring board 11 in such a way that those sides with arranged signal pads face each other. Then, signal pads (901b) of CPU 901 and signal pads (902b) of memory 902 are connected by signal lines 83 of interposer 80. By connecting the CPU and the memory with short signal lines 83 of interposer 80, high-speed, high-capacitance transmission is achieved between the CPU and the memory.
Next, a method for manufacturing printed wiring board 10 outlined above with reference to
(1) The starting material was copper-clad laminate (30A) formed by laminating 5˜250 μm-thick copper foil 32 on both surfaces of insulative substrate 30 made of 0.2˜0.8 mm-thick glass-epoxy resin or BT (bismaleimide triazine) resin (
(2) Next, filler 37 containing copper particles with an average particle diameter of 10 μm (such as nonconductive filling copper paste, brand name DD Paste, made by Tatsuta Electric Wire & Cable Co., Ltd.) is filled in through holes 36 by screen printing, dried and cured (
(3) A palladium catalyst (made by Atotech) is attached to the surfaces of substrate 30, and electroless copper plating is performed to form 0.6 μm-thick electroless copper-plated films 23. Then, electrolytic copper plating is performed to form 15 μm-thick electrolytic copper-plated films 24. Accordingly, portions to become conductive circuits 34 are thickened, and portions to become plated-cover layers (through-hole lands), which cover filler 37 filled in through holes 36, are formed (
(4) On both surfaces of substrate 30 where portions are formed to become conductive circuits and plated-cover layers, commercially available photosensitive dry film is laminated to form etching resists 25 (
(5) Then, plated films (23, 24) and copper foil 32 in portions where etching resists 25 are not formed are dissolved and removed using an etching solution, and etching resists 25 are further removed. In doing so, independent conductive circuits 34 and plated-cover layers (36a) covering filler 37 are formed (
(6) On both surfaces of substrate 30, resin film for interlayer resin insulation layers (brand name: ABF-45SH, made by Ajinomoto) with a little larger size than substrate 30 is laminated, preliminarily pressed and cut to size. Then, the film is laminated using vacuum laminator equipment, and interlayer resin insulation layers 50 are formed (
(7) Next, via-hole openings 51 were formed in interlayer resin insulation layers 50 using a CO2 gas laser (
(8) Next, after the above treatment, the substrate was immersed in a neutralizer solution (made by Shipley Company) and then washed with water. Moreover, a palladium catalyst was applied to the substrate surfaces after the roughening treatment (roughened depth 3 μm) to attach catalyst nuclei on the surfaces of interlayer resin insulation layers and the inner-wall surfaces of via-hole openings.
(9) Next, the substrate with the catalyst was immersed in an electroless copper plating solution (Thru-Cup PEA) made by C. Uyemura & Co., Ltd. to form electroless copper-plated film with a thickness of 0.3˜3.0 μm on the entire roughened surface. Accordingly, a substrate was obtained where electroless copper-plated film 52 was formed on the surfaces of interlayer resin insulation layers 50 including the inner walls of via-hole openings 51 (
(10) Commercially available photosensitive film was laminated on the substrate with electroless copper-plated films 52, a mask was placed, and the dry film was exposed to light and developed. Accordingly, 25 μm-thick plating resists 54 were formed. Then, the substrate was degreased, washed with water, and further cleansed with sulfuric acid. After that, electrolytic plating was performed to form 15 μm-thick electrolytic copper-plated films 56 in portions where plating resists 54 were not formed (
(11) Furthermore, after dissolving and removing plating resists 54, the electroless plated film under the plating resists were dissolved and removed by etching. Accordingly, independent conductive circuits 58 and via holes 60 were formed (
(12) By repeating the above steps (6)˜(11), further upper-layer interlayer insulation layers 150 containing conductive circuit 158 and via holes 160 were formed and a multilayer wiring board was obtained (
(13) Next, on both surfaces of the multilayer wiring board, a commercially available solder-resist composition was applied to be 20 μm thick and dried. Then, to cure the solder resist, a laser was irradiated on the solder-resist composition except for opening portions. After that, the uncured portions of the solder resist were removed using a chemical solution to form 15-25 μm-thick solder-resist pattern layers 70 having openings (71, 71) (
(14) Next, the substrate with solder-resist layers 70 was immersed in an electroless nickel plating solution and 5 μm-thick nickel-plated layers 72 were formed in opening portions (71, 71). Furthermore, the substrate was immersed in an electroless gold plating solution to form 0.03 μm-thick gold-plated layers 74 on nickel-plated layers 72, and solder pads were formed (
(15) First opening section (31a) is formed to penetrate through core substrate 30 by drilling from a surface opposite the chip-mounting surface of built-up multilayer wiring board 11 (
(16) A laser is irradiated from the side of first opening section (31a) in built-up multilayer wiring board 11 toward the chip-mounting surface, and second opening section (31b) is formed in interlayer resin insulation layers (50, 150) and solder-resist layer 70 on the chip-mounting side. Second opening section (31b) tapers toward the chip-mounting surface. Accordingly, penetrating hole 31 is formed with first opening section (31a) and second opening section (31b) (
(17) Built-up multilayer wiring board 11 is placed on support board 110, interposer 80 is accommodated in penetrating hole 31, and penetrating hole 31 is encapsulated with under-fill resin 84 (
(18) Built-up multilayer wiring board 11 is removed from support board 110. By printing solder paste in openings 71 in built-up multilayer wiring board 11 and reflowing, solder bumps (78S, 78D) are formed. Printed wiring board 10 is completed (
CPU 901 is mounted by aligning pads (901b) with bumps (82A) of interposer 80 and pads (901a) with solder bumps (78S) of built-up multilayer wiring board 11. Furthermore, memory chip 902 is mounted by aligning pads (902b) with bumps (82B) of interposer 80 and pads (902a) with solder bumps (78S) of built-up multilayer wiring board 11. Then, through a reflow process, CPU chip 901 and memory chip 902 are mounted on wiring board 10 (
In the first embodiment, penetrating hole 31 to accommodate interposer 80 is made up of first opening section (31a) formed to penetrate through core substrate 30 by drilling from the side opposite the chip-mounting surface of built-up multilayer wiring board 11, and of second opening section (31b) formed by a laser in interlayer resin insulation layers (50, 150) on the side of the chip-mounting surface. Since a hole is formed by a laser on the chip-mounting side in interlayer resin insulation layers (50, 150) where conductive circuits (58, 158) are formed, fine-pitched conductive circuits (58, 158) are seldom damaged.
Also, since second opening section (31b) is formed by a laser in interlayer resin insulation layers (50, 150), a tapered portion is formed in second opening section (31b) tapering toward the chip-mounting surface. Therefore, when resin filler 84 is filled from the side opposite the chip-mounting surface, the flow of the filler is slowed by the tapered portion, and the resin filler does not overflow outside the penetrating hole, making filling easier. In addition, by forming a tapered portion, the contact area increases between the resin filler and the built-up layers (interlayer resin insulation layers), and stress generated due to differences in thermal expansion coefficients with semiconductor elements is mitigated. As a result, cracks in the built-up layers are suppressed from occurring.
A printed wiring board of the second embodiment is described with reference to
The structure of a printed wiring board according to the second embodiment is the same as that in the first embodiment described above with reference to
In addition, passive element 86 such as a resistor is arranged on a surface of interposer 80 in the second embodiment. Such passive element 86 may also be arranged inside built-up multilayer wiring board 11.
A printed wiring board according to an embodiment of the present invention has the following: a first substrate for mounting multiple chips, which is formed by building up layers on a core substrate with through holes by alternately laminating interlayer resin insulation layers and conductive circuits, and which has a penetrating hole; a second substrate accommodated in the penetrating hole; and filler filled in the penetrating hole. The technical features of such a printed wiring board are as follows: The second substrate contains pads to secure the multiple chips to be mounted on the first substrate and signal lines to link the pads and to electrically connect the multiple chip terminals.
For example, if conductive circuits connecting semiconductor elements mounted on a wiring board are formed on a second substrate, the wiring line/space of conductive circuits in built-up layers on a first substrate is eased. As a result, yield rates of wiring boards are improved. At that time, for example, signal pads of a CPU and a memory are arranged respectively along a single side, and the CPU and memory are mounted on the first substrate in such a way that those sides with arranged signal pads face each other. Then, the CPU's signal pads and the memory's signal pads are connected by signal lines in the second substrate. By connecting the CPU and the memory with short signal lines in the second substrate, high-speed, high-capacitance transmission is achieved between the CPU and the memory.
The second substrate is accommodated in an opening section formed in built-up layers on the first substrate. The opening section has a tapered portion which tapers toward the outermost surface of the built-up layers. Therefore, when filler is filled in the opening section after the second substrate is accommodated in the opening section, the flow of the filler is slowed by the tapered portion, and the filler does not overflow outside the opening section, making filling easier. In addition, by forming a tapered portion, the contact area increases between the filler and the built-up layers. Stress generated due to differences in thermal expansion coefficients between semiconductor elements is mitigated, and cracks in the built-up layers are suppressed from occurring.
In the above-described embodiments, examples are shown in which a CPU chip and a memory chip are mounted as semiconductor chips. However, a printed wiring board of the present invention may mount various types of chips. Furthermore, in the above-described embodiments, examples are shown in which a pair of chips are mounted. However, the number of semiconductor chips such as CPU chips, memory chips and the like is not limited specifically.
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.
The present application claims the benefits of priority to U.S. Application No. 61/319,024, filed Mar. 30, 2010. The contents of that application are incorporated herein by reference in their entirety.
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Number | Date | Country |
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2000-353765 | Dec 2000 | JP |
2003-298234 | Oct 2003 | JP |
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Number | Date | Country | |
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20110240357 A1 | Oct 2011 | US |
Number | Date | Country | |
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61319024 | Mar 2010 | US |