The present application is based upon and claims the benefit of priority to Japanese Patent Application No. 2022-082263, filed May 19, 2022, the entire contents of which are incorporated herein by reference.
The present invention relates to a wiring substrate.
Japanese Patent Application Laid-Open Publication No. 2004-22713 describes a multilayer wiring substrate having a pad part that is formed on an insulating layer and is bonded to a semiconductor element. The entire contents of this publication are incorporated herein by reference.
According to one aspect of the present invention, a wiring substrate includes a core substrate, a build-up part formed on a surface of the core substrate and including insulating layers and conductor layers, and a covering insulating layer formed on the build-up part such that the covering insulating layer is covering the outermost surface of the build-up part. The build-up part is formed such that the insulating layers include a first insulating layer forming the outermost one of the insulating layers, that the conductor layers include a first conductor layer formed on the first insulating layer and including a first conductor pad, and that an elongation rate of the first insulating layer is greater than an elongation rate of each of the insulating layers other than the first insulating layer in the build-up part, and the covering insulating layer is formed such that the covering insulating layer has an opening entirely exposing an upper surface and a side surface of the first conductor pad.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
A wiring substrate according to an embodiment of the present invention is described with reference to the drawings.
As illustrated in
In the description of the wiring substrate of the present embodiment, a side farther from the core insulating layer 101 is referred to as “upper,” “upper side,” “outer side,” or “outer,” and a side closer to the core insulating layer 101 is referred to as “lower,” “lower side,” “inner side,” or “inner.” Further, for each of the structural components, a surface facing the opposite side with respect to the core substrate 100 is also referred to as an “upper surface,” and a surface facing the core substrate 100 side is also referred to as a “lower surface.” Therefore, in the description of each of the elements of the wiring substrate 1, a side farther from the core substrate 100 is also referred to as an “upper side,” “upper-layer side,” or “outer side,” or simply “upper” or “outer,” and a side closer to the core substrate 100 is also referred to as a “lower side,” “lower-layer side,” or “inner side,” or simply “lower” or “inner.”
Among the insulating layers of the first build-up part 10, the outermost insulating layer 111 is also referred to as the first insulating layer 111. Further, among the conductor layers of the first build-up part 10, the outermost conductor layer 112 is also referred to as the first conductor layer 112. A covering insulating layer 110 that covers the first insulating layer 111 exposed from conductor patterns of the first conductor layer 112 is formed on the first build-up part 10. A covering insulating layer 210 is formed on the second build-up part 20. The covering insulating layers (110, 210) are, for example, solder resist layers that form the outermost insulating layers of the wiring substrate 1.
The wiring substrate 1 has a surface (1F) on one side and a surface (1S) on the opposite side with respect to the surface (1F), as two surfaces of the wiring substrate 1 that extend in a direction orthogonal to a thickness direction of the wiring substrate 1. The thickness direction of the wiring substrate 1 is also simply referred to as a “Z direction.” In the illustrated example, the surface (1F) on one side is formed by exposed surfaces of the first insulating layer 111, the first conductor layer 112, and the covering insulating layer 110 in the first build-up part 10 of the wiring substrate 1. Further, the surface (1S) on the other side is formed by exposed surfaces of the outermost conductor layer 22 and the covering insulating layer 210 in the second build-up part 20.
Each of the insulating layers (101, 11, 111, 21) of the wiring substrate 1 may be formed, for example, using an insulating resin such as an epoxy resin, a bismaleimide triazine resin (BT resin) or a phenol resin. The insulating layer 101 or any one of the insulating layers (11, 111, 21) may contain a core material such as a glass fiber and/or an inorganic filler such as silica. Each of the covering insulating layers (110, 210), which are solder resist layers, may be formed using, for example, a photosensitive epoxy resin or polyimide resin, or the like.
In the insulating layer 101 of the core substrate 100, through-hole conductors 103 are formed connecting the conductor layer 102 that forms the first surface (100F) of the core substrate 100 and the conductor layer 102 that forms the second surface (100S) of the core substrate 100. The through-hole conductors 103 are integrally formed with the two conductor layers 102. The through-hole conductors 103 are formed along inner walls of through holes (103o) penetrating the insulating layer 101 and each have a tubular shape. Inner sides of the tubular through-hole conductors 103 are each filled with, for example, a resin body (103a) containing any resin such as an epoxy resin. In the insulating layers (11, 111, 21), via conductors (13, 23) connecting the conductor layers sandwiching the insulating layers (11, 111, 21) are formed.
The conductor layers (102, 12, 112, 22), the via conductors (13, 23), and the through-hole conductors 103 are formed using any metal such as copper or nickel, and, for example, may be formed of a metal foil such as a copper foil and/or a metal film formed by plating or sputtering or the like. Each of the conductor layers (102, 12, 112, 22), the via conductors (13, 23), and the through-hole conductors 103 is illustrated in
The conductor layers (102, 12, 112, 22) of the wiring substrate 1 are each patterned to have predetermined conductor patterns. In particular, the first conductor layer 112 in the first build-up part 10 is formed to have patterns including first conductor pads (P1). The first conductor pads (P1) can be electrically connected with connection pads (E1p) of an external element (E1) that can be connected to the wiring substrate 1 in use of the wiring substrate 1. Further, in the illustrated example, the outermost conductor layer 22 in the second build-up part 20 is patterned to have conductor pads (P2). The conductor pads (P2) can be connected to connection pads (E2p) of an external element (E2).
As illustrated in
The openings (110a) expose surfaces of the first conductor pads (P1) on the opposite side with respect to the first insulating layer 111 and side surfaces of the first conductor pads (P1). That is, the entire side surfaces and upper surfaces of the first conductor pads (P1) are exposed in the openings (110a). The wiring substrate 1 and the external element (E1) can be firmly connected to each other with a large area. In the illustrated example, the covering insulating layer 210 covering the surface (1S) on the other side in the second build-up part 20 has openings (210a) exposing the conductor pads (P2). The covering insulating layer 210 covers peripheral edges of the conductor pads (P2), and portions (upper surfaces) other than the peripheral edges of the conductor pads (P2) are exposed in the openings (210a).
The first conductor pads (P1) can be electrically and mechanically connected to the connection pads (E1p) of the external element (E1) by a bonding material such as solder. The external element (E1) may be a motherboard of any electrical device, or may be any electronic component having a package size larger than the wiring substrate 1. Without being limited to these, the first conductor pads (P1) can be connected to any substrate, electrical component, mechanical component, or the like. In the illustrated example, each of the first conductor pads (P1) is larger than each of the conductor pads (P2) included in the conductor layer 22 provided on the surface (1S) side. It may be possible that the external element (E1), which is larger than the external element (E2), and the wiring substrate 1 are firmly connected to each other with a large area.
In the wiring substrate of the present embodiment, in particular, the first insulating layer 111 in contact with the first conductor pads (P1), of which the upper surfaces and the side surfaces are exposed, has physical properties different from the insulating layers 11 on an inner side of the first insulating layer 111 in the first build-up part 10. Specifically, the first insulating layer 111 is formed of an insulating layer material having an elongation rate greater than that of any of the insulating layers 11 on an inner side of the first insulating layer 111.
In the first insulating layer 111 on which the first conductor pads (P1) are formed, a stress may occur due to a difference in thermal expansion coefficient between the first insulating layer 111 and the first conductor pads (P1) or due to deformation of the first insulating layer 111 and the first conductor pads (P1) that can occur as a result of the difference in thermal expansion coefficient, and a stress may occur due to an external force or the like applied to the first conductor pads (P1) when an external electronic component is connected to the first conductor pads (P1). Such stresses can concentrate near peripheral edges of the first conductor pads (P1) on the surface of the first insulating layer 111, the peripheral edges serving as boundaries between areas where the first conductor pads (P1) are present and areas where the first conductor pads (P1) are not present.
In the wiring substrate 1 of the embodiment, the entire side surfaces and upper surfaces of the first conductor pads (P1) are exposed. In such a structure, expansion and contraction of the first conductor pads (P1) are not restricted by the covering insulating layer 110. Therefore, a particularly large stress is likely to occur in the first insulating layer 111 near outer peripheries of the first conductor pads (P1). A crack may occur in the first insulating layer 111 when it cannot withstand the stress.
In the present embodiment, as described above, the first insulating layer 111 in contact with the first conductor pads (P1) is formed of an insulating layer material with a relatively large elongation rate. It is thought that a stress that can occur in the first insulating layer 111 near the first conductor pads (P1) is relaxed by elongation of the first insulating layer 111. As a result, it is thought that occurrence of a crack in the first insulating layer 111 near the first conductor pads (P1) is suppressed.
For example, the elongation rate of the first insulating layer 111 is preferably 1.5% or more. It is thought that, by having such an elongation rate, in the first insulating layer 111, a thermal stress of the first conductor pads (P1) due to a temperature change or a localized external stress is efficiently relaxed in the first insulating layer 111. A desired high elongation rate of the first insulating layer 111 can be obtained by appropriately selecting a type, a skeleton, a structure, or the like of a resin component contained in the material used for the first insulating layer 111. Further, the first insulating layer 111 may be formed such that the elongation rate of the first insulating layer 111 is increased by adjusting an amount of a filler contained in the first insulating layer 111 or blending a filler with a high elongation rate.
In the wiring substrate 1 of the illustrated example, the first conductor pads (P1) are not directly connected to conductor pads and/or wiring patterns, which can be included in the first conductor layer 112, other than the first conductor pads (P1). That is, the first conductor pads (P1) in the illustrated example are so-called independent pads.
Further, in the illustrated example, the first conductor pads (P1) are connected to the via conductors 13 that connect the conductor layers (the first conductor layer 112 and the conductor layer (second conductor layer) 12) sandwiching the first insulating layer 111. Therefore, the first conductor pads (P1) in the illustrated example are so-called via pads. It is thought that, since the first conductor pads (P1) are via pads, an external force that can be applied to the first conductor pads (P1) is dispersed to the via conductors 13, and thus, occurrence of a crack in the first insulating layer 111 may be further suppressed.
From a point of view of suppressing transmission loss in signals transmitted via the conductor layers (12, 112, 22) in the first and second build-up parts (10, 20) and realizing a good signal transmission quality, the insulating layers (11, 111, 21) preferably have a relatively small dielectric loss tangent. In particular, the dielectric loss tangent of the first insulating layer 111 is preferably 0.17 or less at a frequency of 5.8 GHz. Since the insulating layers (11, 111, 21) included in the first and second build-up parts (10, 20) are superior in high-frequency characteristics, the wiring substrate 1 can have a better signal transmission quality.
In the wiring substrate 1 of the illustrated example, the second build-up part 20, which is provided on the opposite side of the first build-up part 10 with respect to the core substrate 100, has the same layer structure as the first build-up part 10. Specifically, the number of the insulating layers 21 and the number of the conductor layers 22 included in the second build-up part 20 are respectively equal to the number of the insulating layers (11, 111) and the number of the conductor layers (12, 112) included in the first build-up part 10.
In the wiring substrate 1 of the illustrated example, the insulating layers 21 of the second build-up part 20 and the insulating layers (11, 111) of the first build-up part 10 are formed of the same materials. Specifically, in the second build-up part 20 and the first build-up part 10, the insulating layers of the same rank relative to the core substrate 100 are formed using the same material. The term “rank” is a number assigned to each of the conductor layers (12, 112, 22) when the number that increases by 1 for each layer starting from the core substrate 100 side is sequentially assigned starting from 1 to each of the multiple conductor layers (12, 112, 22) laminated in each of the first build-up part 10 and the second build-up part 20. In other words, in the wiring substrate 1 of the illustrated example, the first and second build-up parts (10, 20) are symmetrical in layer structure with respect to the core substrate 100.
Although omitted in
With reference to
The inner sides of the through-hole conductors 103 formed on the inner walls of the through holes (103o) are filled with the resin bodies (103a) by injecting, for example, an epoxy resin into the inner sides of the through-hole conductors 103. After the filling resin bodies (103a) are solidified, an electroless plating film and an electrolytic plating film are further formed on the resin bodies (103a) and the upper surface of the electrolytic plating film. As a result, the conductor layers 102 each having a five-layer structure including the metal foil, the electroless plating film, the electrolytic plating film, the electroless plating film, and the electrolytic plating film are respectively formed on both sides of the insulating layer 101. Then, the core substrate 100 having predetermined conductor patterns is obtained by patterning the conductor layers 102 using a subtractive method.
Next, as illustrated in
The conductor layers (12, 22) are formed using any method for forming conductor patterns, such as a semi-additive method, at the same time as the via conductors (13, 23) filling openings that may be formed in the insulating layers (11, 21), for example, using laser. The formation of the insulating layers (11, 21) and the conductor layers (12, 22) is repeated, and as illustrated, the outermost insulating layer (first insulating layer) 111 on the first surface (100F) side and the outermost insulating layer 21 on the second surface (100S) side are laminated. The multiple insulating layers (11, 111) and conductor layers 12 laminated on the first surface (100F) and the multiple insulating layers 21 and conductor layers 22 laminated on the second surface (100S) are the same in number of layers.
In particular, among the three insulating layers (11, 111) laminated on the first surface (100F) side, the outermost insulating layer (first insulating layer) 111 is formed as an insulating layer that, in the cured state, has physical properties different from those of the insulating layers 11 on the inner side of the insulating layer 111. Specifically, the first insulating layer 111 is formed to have a larger elongation rate than the insulating layers 11 on the inner side of the first insulating layer 111. For example, the first insulating layer 111 having a greater elongation rate than the insulating layers 11 may be formed by pressing and curing a resin film that contains a resin component with a different structure or the like and/or has a different filler content from the resin component forming the insulating layers 11 onto the conductor layer 12.
The multiple (three in the illustrated example) insulating layers 21 laminated on the second surface (100S) side are formed to have a layer structure symmetric to the multiple (three in the illustrated example) insulating layers (11, 111) laminated on the first surface (100F) side with respect to the core substrate 100. In this case, insulating layers of the same rank relative to the core substrate 100 are formed using the same material. Therefore, the outermost insulating layer 21 of the wiring substrate 1 to be manufactured is formed by pressing a resin film of the same material as the first insulating layer 111 onto the conductor layer 22. Similar to the first insulating layer 111, the insulating layer 21 laminated outermost on the second surface (100S) side of the core substrate 100 is formed to have a higher elongation rate than the inner-side insulating layers 21 (the two insulating layers 21 near the core substrate 100 in the illustrated example).
Subsequently, as illustrated in
The outermost first conductor layer 112 is formed to have patterns including the first conductor pads (P1). The outermost conductor layer 21 is formed to have patterns including the conductor pads (P2). The surface treatment layer is formed on the surfaces of the first conductor pads (P1) and the conductor pads (P2). For example, by applying a heat-resistant organic substance by spraying, an organic coating film containing an organic substance such as an imidazole compound is formed. Or, for example, by depositing a metal such as nickel, palladium, or gold by electroless plating or the like, a metal coating film is formed. As a result, the formation of the first build-up part 10 and the second build-up part 20 on both sides of the core substrate 100 is completed.
Subsequently, as illustrated in
The wiring substrate of the embodiment is not limited to those having the structures illustrated in the drawings and those having the structures, shapes, and materials exemplified in the present specification. The wiring substrate of the embodiment includes the core substrate and the first build-up part. The entire surfaces (side surfaces and upper surfaces) of the first conductor pads in the first build-up part are exposed from the covering insulating layer. The elongation rate of the first insulating layer may be larger than the elongation rate of the insulating layers on the inner side of the first insulating layer. For example, the wiring substrate of the embodiment may include any number of conductor layers and any number of insulating layers.
Japanese Patent Application Laid-Open Publication No. 2004-22713 describes a multilayer wiring substrate having a pad part that is formed on an insulating layer and is bonded to a semiconductor element. A solder resist is provided on the insulating layer, and the pad part is formed in an opening of the solder resist in a state of being separated from the solder resist.
In the pad part described in Japanese Patent Application Laid-Open Publication No. 2004-22713, a stress may occur due to a difference in thermal expansion between the pad part and the insulating layer or due to an external force applied to a conductor pad. It is thought that there is a risk that a defect such as a crack due to the stress may occur near the insulating layer on which the pad is formed.
A wiring substrate according to an embodiment of the present invention includes: a core substrate having a first surface and a second surface on the opposite side with respect to the first surface; a first build-up part that is formed on the first surface of the core substrate and includes multiple insulating layers and a conductor layer; and a covering insulating layer covering an outermost surface of the first build-up part. The first build-up part includes: an outermost first insulating layer among the multiple insulating layers; and a first conductor layer that is formed on the first insulating layer and includes a first conductor pad. The covering insulating layer has an opening that exposes entire upper surface and side surface of the first conductor pad. An elongation rate of the first insulating layer is greater than an elongation rate of an insulating layer other than the first insulating layer in the first build-up part.
According to an embodiment of the present invention, a wiring substrate is provided in which an elongation rate of a first insulating layer in contact with a first conductor pad provided in the wiring substrate is increased and it is thought that occurrence of a defect such as a crack in the insulating layer around the first conductor pad is suppressed.
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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2022-082263 | May 2022 | JP | national |