JP2000077822A - Concave printed wiring board and manufacture thereof and electronic component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To correspond to high density, high brightness and wide field of view of a light emitting diode display device with less production processes and to facilitate mass production. SOLUTION: Recess shapes 5 (5a-5c) are formed in a circuit forming surface. The recess shape is formed by molding and pressing the laminated body of a copper foil and a prepreg 2 through a protruding-shape member. The above described circuit forming surface is formed by removing the copper foil by etching and by the addititive method on the surface. The substrate is formed of conductor layer 3 having the bonding strength of 1.5 kg/cm or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a recessed printed wiring board and a method of manufacturing the same, and more particularly, to a recessed printed wiring board suitable for mounting a light emitting diode, a photodiode, and an electronic component, a method of manufacturing the same, and an electronic component.

[0002]

2. Description of the Related Art Light-emitting diode display devices are used for large-sized outdoor displays, railway crossing train approach information display, destination guidance and news display in vehicles, vending machine menu displays, PR displays of shops and coffee shops, image sensors, and fax machines. It is often used for line light sources. At the same time, a display device having a reflection function and an optical system mechanism having light directivity has been demanded. Such a display device is manufactured by mounting a light emitting diode element on a recessed printed wiring board and coating a sealing material on the surface thereof.

[0003] One conventional method of manufacturing a recessed printed wiring board is to perform a drilling process that does not penetrate a double-sided copper-clad laminate,
There is a method of forming a conductor circuit through the steps of pretreatment, electroless copper plating, electrolytic copper plating, liquid resist coating, parallel exposure via a film, development, etching, etching resist removal, and nickel gold plating. A light emitting diode display device or the like is obtained by mounting a bare chip of a light emitting diode or the like in a perforated portion of the recessed printed wiring board.

As another method of manufacturing the recessed printed wiring board, for example, there is a method shown in FIG. FIG. 14 is a schematic view showing a manufacturing process of a conventional recessed printed wiring board.
Using the engineering plastic 15, the concave shape and the through hole are injection molded. Drilling is particularly performed when the through-hole hole 5d or the like has a small diameter (FIG. 14).
(A)) After that, each process such as surface roughening, pretreatment, electroless copper plating, electrolytic copper plating, liquid resist coating, parallel exposure through a film, development, etching, etching resist removal, nickel gold plating, etc. As a result, the conductor circuit 16 is formed, and a recessed printed wiring board is obtained (FIG. 14B). In the light emitting diode display device, a bare chip of the light emitting diode is mounted in the concave portion of the concave printed wiring board, the electrode of the light emitting diode and the previously formed conductor circuit are connected by wire bonding, and the surface thereof is connected. The encapsulant is coated and manufactured.

[0005]

However, in recent years,
Light-emitting diode displays are used for multiple purposes such as large outdoor displays, railway crossing train approach information display, destination information and news display in vehicles, menu display of vending machines, PR displays of shops and coffee shops, etc. The demand for the equipment is higher density, higher brightness,
There is an urgent need for a wider field of view, higher productivity, and lower prices, but conventional recessed printed wiring boards cannot meet these demands.

For example, a recessed printed wiring board having a perforated portion that does not penetrate a double-sided copper-clad laminate requires high precision in the depth direction (Z-axis direction) of the recessed shape and a specially shaped drill bit. Therefore, stable processing in the depth direction is difficult, such as wear of a drill bit, and mass production or manufacture of a large-area light-emitting diode display device has a problem of low yield and high cost.

In the case of a recessed printed wiring board obtained by injection-molding engineering plastic into a recessed shape, a high-performance engineering plastic, for example, a liquid crystal polyester resin is injection-molded to produce a three-dimensionally uneven resin plate. However, this injection mold is very expensive, and unless a large quantity of resin plates of the same shape are manufactured, the depreciation cost of the mold is high, and the total production number is generally 50,000 to 200,000. There is a problem that the use is limited because it cannot be adopted.

The present invention has been made to address such a problem, and can cope with high-density, high-brightness, and wide-view fields of a light-emitting diode display device and the like, and the number of production steps is small. It is an object of the present invention to provide a recessed printed wiring board which can be easily mass-produced, a method for manufacturing the same, and an electronic component.

[0009]

According to a first aspect of the present invention, there is provided a recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating a copper foil and a prepreg via a convex member. The circuit forming surface is formed by a laminate forming press, the above-mentioned circuit forming surface is etched away from the copper foil, formed on the etched-removed surface by an additive method, and formed by a conductor layer having an adhesive force of 1.5 kg / cm or more. It is characterized by becoming.
By removing the copper foil by etching and using the etched surface as a base, the surface roughening step can be omitted and the adhesive strength can be improved. The additive method refers to a method in which a circuit is formed by adding a conductor layer on an electrically insulating substrate, a full additive method in which a conductor layer is formed only by electroless copper plating, and a method in which electroless copper plating and electrolytic copper are used. It includes any of the semi-additive methods of forming a conductor layer in combination with plating.

According to a second aspect of the present invention, there is provided a recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating and pressing a laminate of a copper foil and a prepreg via a convex member. The circuit forming surface is formed by a subtractive method and is formed of a conductor layer having an adhesive force of 1.5 kg / cm or more. By forming the circuit forming surface by the subtractive method, the number of steps can be reduced and a concave shape can be obtained. Note that the subtractive method refers to a method of forming a circuit by subtracting unnecessary portions of a conductor layer formed over an electrically insulating substrate. In this case, the formation of through holes and the like may be performed by using an additive method.

According to a third aspect of the present invention, there is provided a recessed printed wiring board having a recessed shape on a circuit forming surface. The recessed shape is formed by pressing a laminate of a copper foil and a prepreg through a convex-shaped member and then pressing the circuit. The laminated body of the formed single-sided printed wiring board and the prepreg is formed by laminating press. By selecting a single-sided printed wiring board on which a circuit is formed as a starting material, a subsequent circuit forming step can be omitted.

According to a fourth aspect of the present invention, there is provided a recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by a molded resin body having a recessed shape, and the circuit forming surface is laminated and bonded to the resin body. Characterized by being formed by a double-sided printed wiring board. By forming the concave shape in advance from the resin body, it is possible to form a concave shape corresponding to the shape of the light emitting diode element or the like, and it is possible to respond to diversification of light emitting diode display devices and the like.

According to a fifth aspect of the present invention, there is provided a recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating and pressing a thermoplastic resin body via a convex-shaped member. The formation surface is formed by a double-sided printed wiring board laminated and bonded to a thermoplastic resin body. By forming the concave shape by laminating and pressing the thermoplastic resin body, the concave shape can be obtained with a small number of steps.

According to a sixth aspect of the present invention, there is provided the recessed printed wiring board according to the first, second, or third aspect, wherein a hole is formed at a position where the recessed shape of the recessed printed wiring board is formed. The finished prepreg is arranged on the copper foil side with the hole positions thereof aligned and pressed by lamination molding to have a concave shape with a substantially vertical inclined portion. Here, the substantially vertical inclined portion refers to an angle from the surface peripheral edge to the bottom of the concave portion, that is, an inclination rising angle from the concave portion bottom surface, which is close to vertical when the concave portion is viewed in a sectional view, for example, 45 degrees. It means that it is at 70 degrees. By forming a recessed printed wiring board having such a recessed portion, the density of the recessed portion can be increased, which can contribute to a higher density of a light emitting diode display device or the like. Further, the thickness of the recessed printed wiring board can be reduced.

According to a seventh aspect of the present invention, in the concave printed wiring board according to the first, second, third, or sixth aspect, the copper foil has a concave shape of the concave printed wiring board. It is characterized in that a portion to be formed is previously drilled. By using a copper foil that has been drilled in advance, when a concave shape is formed, it is possible to prevent cracking of the copper foil and penetration of the copper foil into the concave portion.

In the recessed printed wiring board according to the present invention, the prepreg or the resin body is formed by laminating a mica sheet on at least a part of a main surface forming a recessed shape. By laminating the mica sheets, light from the light emitting diodes can be prevented from diffusing to the bottom of the base material or the inclined portion having the concave shape, and a light emitting diode display device having directivity and excellent light emission efficiency can be obtained.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a concave printed wiring board, comprising the steps of: laminating and pressing a laminate of a copper foil and a plurality of prepregs via a convex member; and etching and removing the copper foil. A method of manufacturing a recessed printed wiring board including a step of forming a conductor layer by electroless copper plating on the surface to be etched, and a step of forming a circuit by exposure, at least to a bottom portion and an inclined portion of the recessed shape. Is performed through an exposure light path control film laminated on the etching resist surface.

According to a tenth aspect of the present invention, there is provided a method for manufacturing a recessed printed wiring board, comprising the steps of: laminating and pressing a laminate of a copper foil and a plurality of prepregs via a convex member; Forming a recessed printed wiring board, wherein at least the exposure of the bottom and the inclined portion of the recess is performed through an exposure light path control film laminated on the etching resist surface. And In the method for manufacturing a recessed printed wiring board of the present invention, by exposing through an exposure light path control film, a precise parallel light beam for exposure is not required, and a general single light source exposure machine is used. be able to.

[0019] According to an eleventh aspect of the present invention, in the method for manufacturing a concave printed wiring board according to the ninth or tenth aspect, the copper foil and the plurality of prepregs are interposed via the convex member. The step of laminating and pressing the laminate is performed on the copper foil side, where the prepreg having been drilled with the hole position aligned with the position where the concave shape of the concave printed wiring board is formed is subjected to the laminating press. Process. By using a prepreg that has been drilled, the inclination angle of the concave portion can be made steep, so that the density of the concave portion can be easily increased.

According to a twelfth aspect of the present invention, there is provided a method of manufacturing a concave printed wiring board according to the eleventh aspect, wherein the laminate of copper foil and a plurality of prepregs is interposed via the convex member. The copper foil used in the laminating and pressing step is characterized in that a portion for forming the recessed shape of the recessed printed wiring board is pre-drilled. Cracking of the copper foil in the concave portion can be prevented. In addition, etching in a later step becomes easy.

An electronic component according to a thirteenth aspect is an electronic component in which an element is mounted on a concave portion or a convex portion of a concave printed wiring board, wherein the concave printed wiring board is any one of the first to eighth aspects. Characterized in that it is a recessed printed wiring board described in the item. By using the recessed printed wiring board of the present invention, higher density of electronic components, higher brightness,
It can respond to demands for a wider field of view, higher productivity and lower prices.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An example of a recessed printed wiring board according to the present invention will be described with reference to FIG. FIG. 1 is a sectional view of a recessed printed wiring board on which a light emitting element is mounted. In the recessed printed wiring board 1, the prepreg 2 is a laminate, the conductor layer 3 is formed on the circuit forming surface of the laminate, and the circuit forming surface on the upper surface has a concave shape. The dent shape is the bottom 5a, the slope 5
b and the surface portion 5c. 5d is a through-hole. The light emitting element 5e is mounted on the concave bottom 5a. The shape of the recess may be any size as long as the light emitting element 5e can be mounted, and the angle and the like of the inclined portion 5b can be arbitrarily changed according to the required characteristics of the light emitting diode display device or the like.
For example, in the case of a recessed printed wiring board with a thickness of about 0.6 mm to 1.0 mm, the top diameter of the recess is about 1.5 to 6 mm, the bottom diameter is about 0.5 to 5 mm, and the depth is about 0.3 to 0.5 mm. be able to. Also, by changing the convex member,
The top diameter and / or bottom diameter can also be square. The adhesive strength between the prepreg laminate 2 and the conductor layer 3 is 1.5
It is preferably at least kg / cm. When it is 1.5 kg / cm or more, the allowable heat capacity at the time of wire bonding between the bare chip of the light emitting diode and the bottom portion 5a can be allowed, and the yield can be improved without peeling of the conductor layer or occurrence of floating failure.

FIG. 15 is a sectional view of the recessed printed wiring board in which the light emitting element 5e is mounted on the surface portion 5c of the recessed printed wiring board 1. By mounting the light emitting element 5e on the surface portion 5c, it is possible to widen the field of view, and the display content can be accurately recognized even when viewed from an oblique direction.

A method of manufacturing the recessed printed wiring board 1 according to the present invention will be described with reference to FIG. FIG. 2 is a flowchart of a manufacturing process of a recessed printed wiring board on which a light emitting diode is mounted. First, a prepreg 2, a copper foil 3a to be a conductor layer 3, a stainless plate 4a, and a convex stainless plate 4 as a convex member are prepared. Next, the prepreg 2 and the copper foil 3a are overlapped and set up between the stainless plate 4a and the convex stainless plate 4. Further, a cushion plate or the like for lamination is overlaid and inserted into a hot plate of a hot press to perform a lamination molding press. At this time, a plurality of sets are overlapped as necessary, and a lamination molding press is performed simultaneously under predetermined conditions.

The prepreg according to the present invention can be used as long as the base material is impregnated with a thermosetting resin. Paper, glass cloth, glass nonwoven fabric, polyester nonwoven fabric, aromatic polyamide paper, or a combination thereof, and the like.Examples of the thermosetting resin include an epoxy resin, a phenol resin, a polyimide resin, and an imide-modified epoxy resin. Can be mentioned. Among them, in order to connect the conductor of the recessed printed wiring board of the present invention and the electrode such as the mounted light emitting diode by wire bonding, and in a short time, with heat resistance of 300 ° C. or more and processing step. In order to reduce the dimensional change of
In particular, it is preferable to use a glass cloth as a base material and an epoxy resin as a thermosetting resin.

In the case where the inclination angle of the concave shape is required to be close to vertical, it is preferable to use a prepreg which has been drilled in advance at a position where the concave shape of the concave printed wiring board is to be formed.

As the copper foil according to the present invention, it is preferable to use an electrolytic copper foil having a thickness of about 35 μm. The reason for this is the thickness
The roughness of the back side of the 35 μm electrolytic copper foil is treated to 12 to 15 μm, and the electroless plating described below is performed, and the adhesion of the copper foil formed in the subsequent electroplating process to the base material is reduced to 1.5 μm.
kg / cm or more can be secured.

The copper foil may be pre-drilled at the portion forming the recessed shape of the recessed printed wiring board. Difficulty of etching can be suppressed due to cracking of the copper foil in the concave portion and biting during etching.

The convex member according to the present invention has a hardness and a depth of not less than 60 at room temperature Barcol hardness at which a concave portion required for a concave printed wiring board can be formed on a prepreg or a copper foil surface in a laminating press step. Accuracy of ± 0.05mm or less in direction and ± 0.1mm or less in XY direction, 2 × 10 ^-4 cal
Any material that is a good conductor of heat of about / cm · s · ° C can be used. Specifically, a convex metal plate is preferable, and a convex stainless steel plate is particularly preferable. As a method for forming a convex shape on the stainless steel plate, mechanical cutting, etching, or the like can be used.

As an example of the setup in the laminating press step using the convex stainless steel plate 4 and the laminating jig, the method shown in FIGS. 3 and 4 can be mentioned. FIG. 3 is a diagram showing a set-up in the laminating press step. FIG. 4 shows an example in which a plurality of units are stacked. As shown in FIG. 3, the copper foil 3a, the prepreg 2, and the copper foil 3b are stacked in order from the top, and the release aluminum plate 6 is placed on the lower surface side of the copper foil 3b. The convex stainless steel plate 4 is arranged on the side of the plate 4a and the copper foil 3a with the cushion film 7 interposed therebetween, and the sandwiching set is completed between the hot plates 8 of the hot press via the cushion plates 7a and 7b. Further, as shown in FIG.
a, the prepreg 2, and the copper foil 3b are laminated in order from the top, and the release aluminum plate 6 is placed on the lower surface side of the copper foil 3b, and the flat aluminum plate 6 side has a flat stainless steel plate 4a, and the copper foil 3a has A unit in which the convex stainless steel plate 4 is arranged via the cushion film 7 is formed as one block, and a large number of units can be laminated and pressed simultaneously.

When a large number of units are simultaneously laminated and pressed after the laminating press step, the units are disassembled into individual units, and the subsequent conductor layer forming step, circuit forming step, and the like are performed. As the conductor layer, the laminated copper foil 3a can be used as it is (path b in FIG. 2). In this case, the adhesive force is 1.5kg / c
m or more. Further, in order to further improve the adhesiveness with the prepreg 2, the conductor layer can be formed by the following method (path a in FIG. 2). The copper foil 3a is adhered to the prepreg 2 and the copper foil on the surface of the laminate in which the concave shape is formed is removed by etching. The etched surface of the prepreg 2 is roughened, and becomes a base sufficient for forming a conductor by the additive method. For example, a conventional roughening step can be omitted. When electroless copper plating is applied to the base surface, the adhesion to the surface of the laminated prepreg 2 is further improved,
Adhesion between the conductor layer and the prepreg 2 can be secured to 1.5 kg / cm or more. In the formation of the conductor layer, a known electroless copper plating method can be used, and a conductor layer can be formed by a known plating pretreatment step or electroless copper plating after electroless copper plating. After the formation of the conductor layer, a circuit is formed by a known method such as resist coating, exposure, development, and etching.

FIG. 5 shows another method of manufacturing the recessed printed wiring board.
7 to FIG. 5 to 7 are flowcharts of the respective manufacturing steps. In FIG. 5, after a laminate of copper foil 3a and prepreg 2 is laminated and pressed in advance, a circuit is formed on the copper foil surface to obtain single-sided printed wiring board 10a, and lamination of single-sided printed wiring board 10a and prepreg 2 is performed. The body is pressed by lamination through the convex stainless steel plate 4 to form a recessed shape. In FIG. 6, a recessed shape is formed by laminating a molded resin body 11a having a recessed shape in advance on a double-sided printed wiring board 10b and performing a laminate forming press. The molded resin body 11a having a concave shape can be produced by, for example, injection molding a thermoplastic resin. In FIG. 7, the resin body is laminated on the double-sided printed wiring board 10b without forming the resin body into a concave shape using a thermoplastic resin 11b, and the resin body is pressed by laminating and molding via the convex-shaped member 4. A shape is formed.

In the method shown in FIGS. 5 to 7, the materials such as prepreg and copper foil and the conditions of the laminating press are the same as in the method shown in FIG. 6 and 7 in which the double-sided printed wiring board is used as a circuit forming surface, the resin body 11a and the thermoplastic resin 11b have a concave shape and a hole for connecting a light emitting element or the like. Is preferred. In addition, even in the recessed printed wiring board obtained by the method shown in FIGS.
It is preferable that the conductive layer has the above-mentioned adhesive strength.

In the method of manufacturing a recessed printed wiring board described above, it is preferable to perform a heat treatment after drilling a through hole. In particular, when drilling a through hole near the concave shape, the stress concentration near the concave shape is reduced.
Cracking and cracking of copper foil and the like can be prevented by the heat treatment. The specific heat treatment conditions are as follows: room temperature (20 ° C)
A heat treatment step in which the temperature is raised to 200 ° C. over 2 hours, maintained in that state for 2 hours, and allowed to cool to room temperature (20 ° C.) over about 10 hours can be mentioned.

It is preferable that a mica sheet is laminated on at least a part of the main surface of the recessed printed wiring board, particularly the recessed printed wiring board used in the light emitting diode device, which forms the recessed shape. By laminating mica sheets, a light emitting diode display device having directivity and excellent luminous efficiency can be obtained. As the mica sheet, either peeled mica or laminated mica may be used, but a laminated mica sheet that easily forms a concave shape is preferable. Specifically, a polyethylene terephthalate sheet mixed with mica powder is preferred.

The exposure light path control film according to the present invention can be used as long as it has a slit or the like that can always expose the bottom and the inclined portion of the concave shape to predetermined parallel rays.

The electronic component of the present invention can be obtained by mounting an element, for example, a light emitting element, on the above-mentioned recessed printed wiring board. In particular, it can be suitably used as an electronic component used in a display device having an optical system mechanism having a light directivity and having a reflective function, and a display device having a reflective function and a light emitting function in a wide field of view. Specifically, there may be mentioned electronic components used in light emitting diode display devices. For example, an electronic component in which a light emitting diode is mounted on a recessed printed wiring board has a light emission luminance that is improved by 30 to 50% as compared with a case in which the light emitting diode is mounted on a flat printed wiring board. Further, by mounting the element in the recessed portion, a chip-in-board can be realized, and the use of the electronic component of the present invention can reduce the thickness of a portable electronic device. Further, an embedded module or the like in which the recessed printed wiring board and other components are integrated can be provided.

[0038]

Embodiment 1 A recessed printed wiring board and a method of manufacturing the same according to the present invention will be described with reference to a flowchart shown in FIG. As prepreg 2, glass fiber prepreg EW- manufactured by Risho Kogyo Co., Ltd.
Prepare 3105. This prepreg has a thickness of 0.21mm
The resin content is 40% by weight. As a copper foil 3a on the upper surface of this glass fiber prepreg, JAPAN ENE
A 35 μm copper foil of RGY STCS is overlaid and set up by the setup method of the lamination press shown in FIG.

FIG. 16 shows an example of a set-up method in a laminating press in which a prepreg having been drilled is arranged on the copper foil side and a laminate with a plurality of prepregs is formed as one block. A hole 2a is previously formed in the prepreg 2 disposed on the copper foil 3a side, and this hole is formed in accordance with a position where a concave shape is formed. FIG. 17 shows an example of a set-up method using a copper foil 3a in which a hole 3c is preliminarily formed in accordance with a position where a concave shape is to be formed. In addition, a perforated copper foil may be used for a prepreg that has not been perforated.

STCS 35 μm copper foil has a high elongation at room temperature of 16% and an elongation at 180 ° C. as high as 25%, and is optimal without cracking during dent forming. Cushion plate 7a
KN-42P2 for multilayer boards manufactured by Yamauchi Corporation is used. A 1.0 mm thick TPP16 made by Takasago Iron Works Co., Ltd. is used for the stainless plate 4a. The release aluminum plate 6 has a DU made by Osada Corporation with a thickness of 0.38 mm.
Use OFOIR. The material of the convex stainless steel plate 4 is TPP16 manufactured by Takasago Iron Works Co., Ltd. having a thickness of 1.0 mm. In order to form a convex shape on this stainless plate, a liquid resist is applied to the surface, exposed through a film, developed,
A convex shape is formed on the surface through an etching process. The cushion film 7 has a T made by Mitsui Petrochemical Industries, Ltd.
Use a PX (polymethylpentene) film having a thickness of 50 μm. This film has been formed into a film by a casting method, and has a low surface tension after a fluororesin, and is excellent in releasability and heat resistance.

Next, as shown in FIG. 4, six units are superimposed to form one block,
The heating press is operated at a temperature of 110 ° C. for about 1 hour, and the laminate is formed under heating and pressure.

When manufacturing a recessed printed wiring board along the route b shown in FIG. 2, the following steps are performed. Since the adhesive of the prepreg is completely cured, the dent laminated board formed by lamination is drilled for a through-hole hole diameter of 0.5 mm φ under almost the same conditions as FR-4 of the conventional double-sided printed wiring board. Processing was performed by setting the rotation speed to 65,000 to 70,000 rpm and the feed rate to 2 m / min.

In the case of manufacturing a recessed printed wiring board along the path a shown in FIG. 2, the conductor layer on the entire surface of the panel was removed by etching using a ferric chloride solution at 45 ° C. with an etching machine. Then, a 0.5 mm φ through-hole was provided by the above method. Also, the through-hole holes were roughened as necessary.

The laminate obtained through the route a and the route b is subjected to a catalyst activation treatment with a palladium solution as a plating pretreatment for the through-hole hole walls, and then subjected to electroless copper plating. Electrolytic copper plating 25 μ thick
m. After the catalyst activation treatment with a palladium solution, instead of the method of performing electroless copper plating, it is also possible to conduct electricity by a direct plating method and perform electrolytic copper plating.

Subsequently, a conductive pattern is formed. The liquid resist was evenly dip-coated on the recess. This liquid resist is a non-contact exposure photo-developed etching resist FINE manufactured by Tamura Corporation.
DEL LER-420 (alkali development type) was used.
Overlay the film with the prescribed pattern and
Exposure was performed by irradiating 100 mj / cm ² . Next, the resist at an unnecessary portion of the conductor pattern is removed by a developing machine. Next, unnecessary portions of the conductor pattern were removed by etching using a ferric chloride solution at 45 ° C. with an etching machine. Thereafter, the resist on the conductor pattern was removed with a 2 to 3% aqueous sodium hydroxide solution at 50 ° C.

Subsequently, noble metal plating for wire bonding to the conductor pattern, for example, electric nickel plating is performed with a thickness of 5 to 15 μm, and electrolytic gold plating is performed on the surface with a thickness of 1 to 3 μm. The noble metal plating is not limited to electroplating, but may be other types of electroless plating.
Subsequently, the sheet is punched into a predetermined shape by a punching press, or is processed into a predetermined shape by an NC outer shape processing machine to complete a dent printed wiring board. When the adhesive force between the conductor layer and the prepreg layer in the obtained recessed printed wiring board was measured, it was 1.6 kg / cm for the route a and 1.9 kg / cm for the route b.
Met.

Embodiment 2 FIG. 8 shows a flowchart of Embodiment 2. This embodiment will be described with reference to a path d in FIG. As the mica sheet 9, an M grade unilate manufactured by Unitika Ltd. is prepared. This mica sheet 9 is prepared by adding mica powder to a thermoplastic polyethylene terephthalate resin having a thickness of 0.30 mm.
A composite sheet resin plate reinforced with 30% by weight of filling. A plurality of mica sheets 9 are stacked and set up by the setup method of the lamination press shown in FIG. KN-42P2 for multilayer boards manufactured by Yamauchi Co., Ltd. is used for the cushion boards 7a and 7b. A 1.0 mm thick TPP16 made by Takasago Iron Works Co., Ltd. is used for the stainless plate 4a.
In substantially the same manner as in FIG. 4, six units are superimposed and inserted as a block between hot plates of a heating press, the heating press is operated based on a predetermined program, and a laminating press is performed under heating and pressing.

Next, an adhesive is applied to one side of the laminated mica sheet. Carbodilite (CAF-F4) manufactured by Nisshinbo Co., Ltd. is used for this adhesive. Carbodilite is an isocyanate-based solventless one-part adhesive having a carbodiimide group. Next, touch drying is performed at 100 ° C. for 10 min in a hot air drying oven. Thereafter, in order to protect the surface of the adhesive that has been touch-dried, a protective film, for example, a polyethylene film with an adhesive manufactured by Sekisui Chemical Co., Ltd. is attached. Subsequently, a pilot hole is punched by a press machine. Next, the polyethylene film with the adhesive is peeled off and removed.

Subsequently, the setup for the laminating press is performed. The setup method is shown in FIG.
A prepared laminated mica sheet 9a from which a polyethylene film with an adhesive has been removed is prepared. As the double-sided printed wiring board 10b with noble metal plating, a double-sided printed wiring board with noble metal plating for wire bonding to a conductor pattern, for example, an electric nickel plating on the surface of a normal double-sided printed wiring board with a thickness of 5 to 15 μm
This is a double-sided printed wiring board whose surface is electroplated with gold to a thickness of 1 to 3 μm. The noble metal plating is not limited to electroplating, but may be other types of electroless plating. KN-42P2 for multilayer boards manufactured by Yamauchi Co., Ltd. is used for the cushion boards 7a and 7b. Stainless plate 4a
Used is TPP16 manufactured by Takasago Iron Works Co., Ltd. having a thickness of 1.0 mm. The convex stainless steel plate 4 is formed in a convex shape in the same manner as in Example 1 using TPP16 manufactured by Takasago Iron Works Co., Ltd. having a thickness of 1.0 mm. TPX (polymethylpentene) manufactured by Mitsui Petrochemical Industry Co., Ltd.
Use a film thickness of 50 μm.

In a manner similar to the method shown in FIG. 4, six units are superimposed as one block, inserted between hot plates of a heating press, and the heating press is operated based on a predetermined program. Lamination molding is performed. Subsequently, it is disassembled and punched into a predetermined shape by a punching press, or processed into a predetermined shape by an NC outer shaper to complete a dent printed wiring board. FIG. 11 shows a cross-sectional view of the obtained recessed printed wiring board. The recessed printed wiring board 1 has a hole for mounting the light emitting element 5e on the surface of the double-sided printed wiring board 10b, and a protrusion is formed by the laminated mica sheet 9a having the adhesive 9b. It becomes a concave shape, and the light emitting element 5e is mounted.

Third Embodiment FIG. 5 shows a flowchart of the third embodiment. As in the first embodiment, a stainless steel plate 4a, a prepreg 2, and a copper foil 3a are prepared, and laminated and formed under heat and pressure. After disassembly, a conductor pattern is formed. The liquid resist was evenly dip-coated on the recess. This liquid resist is a non-contact exposure photo-developing type etching resist FINEDEL LER-420 manufactured by Tamura Corporation.
(Alkali development type) was used.

An exposure light path control film having a predetermined pattern shown in FIG. 13, for example, a convex film 12 was superposed thereon and exposed to ultraviolet light at 100 mj / cm ² . The convex film 12 is formed by exposing and developing a photosensitive film on a polyester film 13 having a thickness of 200 μm to form a pattern. In the subsequent step, the photosensitive film of the printing pattern film comes into contact with the surface of the copper foil at the time of contact exposure, so that scratches and contact scratches reduce the yield. In order to prevent the yield from lowering, a protective film is laminated on the surface of the photosensitive film of the film. This protective film is 4 μm thick on an 8 μm thick polyester film manufactured by Sekisui Chemical Co., Ltd.
A film coated with m.

Next, a method of processing the printing pattern film 12 into a convex shape will be described. In FIG.
The process of laminating and molding the prepreg in a concave shape having a x portion of φ2.0 mm was performed in the same manner as in Example 1. In order to process the pattern film for printing into a convex shape, a convex stainless steel plate of this size was manufactured in order to process the dimension of the y part to φ1.45 mm. The production method was the same as that for the convex stainless steel plate for laminating and molding the prepreg.

FIG. 12 shows a setup method for forming the pattern film for printing into a convex shape. The stainless steel plate 4a of Example 1 was disposed on the film surface of the pattern film 12 for printing via a foamed silicon sheet 14 having a thickness of 2 mm. Further, the cushion film 7 of Example 1 was used on the surface opposite to the film surface of the pattern film for printing, and the convex stainless plate 4 was disposed on the upper surface thereof. Subsequently, the prepreg of Example 1 was subjected to molding by heating / pressing / vacuum under the method of laminating and molding. The molding was performed at a keep temperature of 170 ° C., a pressure of 20 kg / cm ² , and a degree of vacuum of 20 Torr in order to form a polyester film having a thickness of 200 μm. Subsequent drilling was performed in the same manner as in Example 1. When the adhesive strength between the conductor layer and the prepreg layer in the obtained recessed printed wiring board was measured.
It was 2.05 kg / cm.

Fourth Embodiment FIG. 6 shows a flowchart of the fourth embodiment. The recess of the present invention
A printed wiring board and a method of manufacturing the same will be described with reference to FIG.
You. As a mold, injection molding of general thermoplastic resin (A
Prepare a mold for injection). Injection molding machine
The thickness of the board is 0.6-1.0mm, the size is about 500mm x about 350mm
Injection molding of dents requires a thrust of 10 tons.
An injection molding machine having an injection pressure equal to or higher than the injection pressure was used. Injection
The resin to be shaped includes thermoplastic modified polysulfone (PS
F) was used. This resin is an amorphous thermoplastic policer.
A resin with an improved heat resistance by introducing an aromatic ring into
And commercial products such as Mindel manufactured by Amoco Japan Co., Ltd.
There is S1000. Mold temperature 140 ° C, back pressure
3.5kgf / cm ^TwoMolded resin molded article 11a
Was manufactured.

Next, an adhesive is applied under the same conditions as in Example 2 and touch drying is performed. Subsequently, the setup for the laminating press was performed in the same manner as that shown in FIG. 10 except that the convex stainless steel plate 4 was changed to a flat stainless steel plate. The laminate is formed under heat and pressure. By performing the same outer shape processing and the like as in the second embodiment, a recessed printed wiring board is completed.

[0057]

The concave printed wiring board of the present invention has a concave shape formed by laminating and pressing a laminate of a copper foil and a prepreg via a convex member, and the circuit forming surface is formed of a copper foil. It is formed by the additive method on the etched and removed surface, and is formed of a conductor layer having an adhesive force of 1.5 kg / cm or more.Therefore, injection molding dies are not required, and the surface is roughened. The steps can be omitted, and the production cost can be reduced. Further, since the adhesive strength is improved, an arbitrary pattern can be formed, which contributes to a higher density of the light emitting diode display device and the like.

Further, since the circuit forming surface after the formation of the dent is formed by a subtractive method and is formed of a conductor layer having an adhesive force of 1.5 kg / cm or more, the dent can be obtained with less man-hour. Production cost can be further reduced.

Further, since the laminate of the copper foil and the prepreg is laminated and pressed using a single-sided printed wiring board on which a circuit is formed after the laminate is pressed, the prepreg and the prepreg are laminated and pressed. it can.

Further, the prepreg having been drilled at the position where the recessed shape of the recessed printed wiring board is to be formed is arranged on the copper foil side while aligning the hole position, and is subjected to laminating press to obtain a substantially vertical inclination. Since the recessed printed wiring board having the recessed shape provided with the portion is used, it is possible to contribute to the high density of the light emitting diode display device and the like. Further, since the copper foil which has been drilled in advance is used for the portion of the printed wiring board in which the concave shape is to be formed, the copper foil does not remain in the concave portion. As a result, a recessed printed wiring board having a more accurate recessed shape can be obtained.

The recessed printed wiring board of the present invention is formed by using a double-sided printed wiring board as a circuit-forming surface, by using a molded resin body having a recessed shape, or by laminating and pressing a thermoplastic resin body. Therefore, it can be formed in a concave shape corresponding to the shape of the light emitting diode element and the like, and can cope with diversification of the light emitting diode display device and the like.

The concave printed wiring board of the present invention is formed by laminating a mica sheet on at least a part of a main surface of a prepreg or a resin body forming a concave shape, so that a light emitting diode display having directivity and excellent luminous efficiency is provided. An apparatus or the like is obtained.

In the method of manufacturing a recessed printed wiring board according to the present invention, since the exposure to the bottom and the inclined portion of the recess is performed through the exposure light path control film laminated on the etching resist surface, a precise parallelism for exposure is achieved. No light beam is required, and a general single light source exposure machine can be used, and the production cost of the recessed printed wiring board can be reduced.

Further, in the step of performing the laminating press,
Drilled prepreg is placed on the copper foil side,
A recessed printed wiring board having a recessed shape having a substantially vertical inclined portion can be easily obtained. As a result, it is possible to contribute to an increase in the density of a light emitting diode display device or the like. Furthermore, since a laminate forming press is performed using a copper foil that has been drilled in advance, a highly accurate concave shape can be obtained more easily.

In the electronic component of the present invention, since the elements are mounted on the above-described recessed printed wiring board, the emission luminance can be improved, and the integration, size, and thickness of the electronic device can be achieved.

[Brief description of the drawings]

FIG. 1 is a sectional view of a recessed printed wiring board on which a light emitting element is mounted.

FIG. 2 is a flowchart showing a manufacturing process of a recessed printed wiring board.

FIG. 3 is a diagram showing an example of a setup in a laminating press step.

FIG. 4 is an example of a case where six units are stacked in a laminating press step.

FIG. 5 is a flowchart showing another manufacturing process of the recessed printed wiring board.

FIG. 6 is a flowchart showing another manufacturing process of the recessed printed wiring board.

FIG. 7 is a flowchart showing another manufacturing process of the recessed printed wiring board.

FIG. 8 is a flowchart showing another manufacturing process of the recessed printed wiring board.

FIG. 9 is a diagram illustrating an example of a setup in a lamination pressing process.

FIG. 10 is a diagram showing an example of a setup in a laminating press step.

FIG. 11 is a sectional view of a recessed printed wiring board.

FIG. 12 is a diagram showing a setup method.

FIG. 13 is a sectional view of an exposure light path control film.

FIG. 14 is a schematic view showing a manufacturing process of a conventional recessed printed wiring board.

FIG. 15 is a cross-sectional view of a recessed printed wiring board having a light emitting element mounted on a surface portion.

FIG. 16 is a view showing another example of the setup in the laminating press step.

FIG. 17 is a view showing another example of the setup in the laminating press step.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 recess printed wiring board 2 prepreg 3 conductor layer 3 a, 3 b copper foil 4 convex stainless plate 4 a stainless plate 5 a recess bottom 5 b recess slope 5 c recess surface 5 d through-hole hole 5 e light emitting element 6 mold release Aluminum plate 7 Cushion film 7a, 7b Cushion plate 8 Hot plate 9 Mica sheet 9a Laminated mica sheet 9b Adhesive 10a Single-sided printed wiring board 10b Double-sided printed wiring board 11a Molded resin body having concave shape 11b Thermoplastic resin 12 Convex shape Film 12a Pattern film for printing 13 Polyester film 14 Foamed silicon sheet

Claims (13)

[Claims] 1. A recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating and pressing a laminate of a copper foil and a prepreg via a convex-shaped member. The circuit forming surface is formed by etching the copper foil, and the etched surface is formed by an additive method.
A recessed printed wiring board formed of a conductor layer having an adhesive force of not less than / cm. 2. A recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating and pressing a laminate of a copper foil and a prepreg via a convex-shaped member. A concave printed wiring board, wherein the circuit forming surface is formed by a subtractive method and is formed of a conductor layer having an adhesive force of 1.5 kg / cm or more. 3. A recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed after a laminate formed of a copper foil and a prepreg is laminated and pressed through a convex-shaped member. A concave printed wiring board formed by laminating and pressing a laminated body of a single-sided printed wiring board and a prepreg. 4. A recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by a molded resin body having a recessed shape, and the circuit formation surface is laminated and bonded to the resin body. A recessed printed wiring board formed of a double-sided printed wiring board. 5. A recessed printed wiring board having a recessed shape on a circuit forming surface, wherein the recessed shape is formed by laminating and pressing a thermoplastic resin body via a convex member. A concave printed wiring board, wherein the surface is formed by a double-sided printed wiring board laminated and bonded to the resin body. 6. The recessed printed wiring board according to claim 1, wherein the recessed printed wiring board is formed at a position where a recessed shape is formed.
A hole-printed prepreg is arranged on the copper foil side with its hole position aligned, and is subjected to lamination molding press, thereby having the above-mentioned concave shape having a substantially vertical inclined portion. . 7. The recessed printed wiring board according to claim 1, 2, 3, or 6, wherein a portion of the copper foil that forms the recessed shape of the recessed printed wiring board is pre-drilled. A recessed printed wiring board, comprising: 8. The prepreg or the resin body according to claim 1, wherein a mica sheet is laminated on at least a part of a main surface forming the concave shape. The dent printed wiring board as described. 9. A step of laminating and pressing a laminate of a copper foil and a plurality of prepregs via a convex-shaped member, etching the copper foil, and electroless copper plating the etched-removed surface of the conductor. A method of manufacturing a recessed printed wiring board including a step of forming a layer and a step of forming a circuit by exposure, wherein at least exposure to the bottom and the inclined portion of the recessed shape is performed by exposing an exposure resist layer to an etching resist surface. A method for producing a recessed printed wiring board, wherein the method is performed via an optical path control film. 10. A concave printed wiring board comprising: a step of laminating and pressing a laminate of a copper foil and a plurality of prepregs via a convex member; and a step of forming a circuit on the copper foil layer by exposure. A method of manufacturing a recessed printed wiring board, wherein at least exposure to the bottom and the inclined portion of the recess is performed through an exposure light path control film laminated on an etching resist surface. 11. The method for manufacturing a recessed printed wiring board according to claim 9, wherein the step of laminating and pressing a laminate of a copper foil and a plurality of prepregs via the convex-shaped member is performed. A step of forming a recessed shape of the recessed printed wiring board, arranging a hole-prepared prepreg on the copper foil side by aligning the hole position, and pressing and laminating and forming the prepreg. Manufacturing method. 12. The method of manufacturing a recessed printed wiring board according to claim 11, wherein the copper foil used in the step of laminating and pressing a laminate of the copper foil and a plurality of prepregs via the convex member is:
A method for manufacturing a recessed printed wiring board, wherein a portion forming the recessed shape of the recessed printed wiring board is pre-drilled. 13. An electronic component in which an element is mounted on a concave portion or a convex portion of a concave printed wiring board, wherein the concave printed wiring board is any one of claims 1 to 8. An electronic component, characterized in that: