JP2005322823A - Wiring board, method of forming the same, and film mask used for the method of forming the wiring board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a wiring board which has superior moisture resistance and water resistance and is capable of preventing shorts between wiring patterns, a method of forming the same, and to provide a film mask used for the method for forming the wiring board. <P>SOLUTION: The method of forming the wiring board 100 is to cover the wiring patterns 130 which are composed of an electrically conductive resin and are formed on a terminal part 110 of a board 120, with covering conductors 150, composed of an electrically conductive resin containing carbon grains by using a film mask for forming the wiring board. With this method, the surfaces 170 of the covering conductors 150 are planarized, and their side faces 160 are made to be of a sharp shape for realizing contact resistance reduction and miniaturization of the wiring patterns 130. Furthermore, migration of the wiring patterns 130 is prevented by the covering conductors 150, and shorts between neighboring covering conductors 150 are prevented, thus realizing a high reliability wiring board. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a wiring board in which a plurality of wiring patterns made of a conductive material are formed on a substrate, a method for manufacturing the wiring board, and a film mask for forming a wiring board used when forming the wiring board.

  2. Description of the Related Art Conventionally, a wiring board in which a wiring pattern made of a conductive paste containing silver, copper, tin or the like is formed on a board using a printing means such as screen printing is well known. However, migration of silver, copper, tin, etc. in the wiring pattern occurs when the wiring pattern formed of a conductive paste containing silver, copper, tin, etc. has moisture adhering to it due to moisture absorption or water drops or when an electric field is present. There was a problem that the wiring resistance changed. Among them, silver is an excellent conductive metal with low electrical resistance, and is generally used as a conductive paste because it can be fired at low temperatures and is inexpensive. However, it causes migration compared to other conductive metals. It is known to be easy. Therefore, various proposals for preventing migration of silver or the like have been made. In particular, the terminal portion of the wiring board for connecting to an external device is likely to migrate because the electrodes need to be exposed, and prevention of migration at this terminal portion is strongly demanded.

  As a wiring board configuration for preventing migration, there is a configuration as shown in FIG. FIG. 7 is a perspective view showing a terminal configuration of a connection portion with an external device in a conventional wiring board. The terminal unit 700 has a configuration in which a silver paste layer 720 made of silver paste is printed on the surface of a plastic film 710 and then a carbon paste layer 730 made of carbon paste is printed on the silver paste layer 720. The plastic film 710 between the terminal portions 700 is removed for easy connection. A protective film 740 is formed in a region other than the terminal portion 700. As described above, the two-layer structure in which the carbon paste layer 730 that hardly causes migration is stacked on the silver paste layer 720 prevents silver migration due to moisture absorption or water droplet adhesion (for example, Patent Document 1). ).

  Further, as a method for manufacturing a wiring board for preventing migration, as shown in FIG. 8, generally, a carbon paste layer 850 is formed by screen printing, stencil printing or the like to prevent silver migration. There is a way.

  In this method, first, a wiring pattern 830 is formed on a plastic film 820. Next, a protective layer 840 is formed so as to cover the wiring pattern 830 other than the terminal portion 810. Next, a screen or stencil plate 800 is disposed so as to straddle the protective layer 840, and the carbon paste layer 850 is formed by printing the carbon paste.

The wiring board manufactured by this method can prevent silver migration by covering the wiring pattern 830 made of silver with the carbon paste layer 850.
JP 2000-340607 A

  However, as shown in FIG. 7, in the case of a two-layer structure in which the carbon paste layer 730 is formed on the silver paste layer 720, the side portions of the silver paste layer 720 are not covered with the carbon paste layer 730. Silver may migrate from the exposed portion of the side surface of the layer 720, and migration could not be reliably prevented.

  Further, as shown in FIG. 8A, when the carbon paste layer 850 is formed by using a general screen printing method or stencil printing method, the screen or stencil plate 800 used as a mask requires flatness. Therefore, a certain amount of tension and rigidity are usually required. Therefore, a step 860 is generated between the screen or stencil plate 800 and the protective layer 840 at the end of the protective layer 840 of the terminal portion 810 as shown in FIG. The reason is that the screen and the stencil plate 800 cannot be freely deformed according to the shape of the step 860, and as a result, a gap 870 is generated at the position of the step 860. 8C, the carbon paste layer 850 to be printed flows through the gap 870, and the carbon paste layers 850 between the adjacent wiring patterns 830 are connected to each other, so that a short circuit portion 880 is generated. There was a problem that it would end up.

  Further, as shown in FIG. 8D, particularly in the case of the screen printing method, the printed carbon paste layer 850 has a semicircular shape due to, for example, a case where the surface tension is large or dripping at the time of heat curing. The flat surface cannot be formed easily. As a result, when connecting to an external device, the contact area with the counterpart connector is reduced, and the contact resistance is increased. In addition, when the surface tension and viscosity of the carbon paste layer 850 are small, the carbon paste layer 850 spreads and the side surfaces cannot be sharply formed, so the interval between the carbon paste layers 850 is narrowed. As a result, since it is necessary to consider the spread of the carbon paste layer 850, there is a problem in that the interval between the adjacent carbon paste layers 850 cannot be reduced.

  Further, in order to eliminate the step 860 caused by the protective layer 840 as shown in FIG. 8B, the wiring pattern 830 of the terminal portion 810 is formed on the carbon paste layer using a screen or a stencil plate 800 before the protective layer 840 is formed. As shown in FIG. 9 (b), a method of concealing a short circuit by reducing the step 910 is conceivable. However, when the screen 800 or the like is used as a mask, as shown in FIG. 9C, since the interval between the wiring patterns 830 is narrow, the mask cannot be deformed between the wiring patterns 830, and the gap 900 depends on the thickness of the wiring pattern 830. Is formed. Therefore, the problem that a short circuit part is formed between adjacent carbon paste layers is not solved.

  Therefore, the present invention solves the above-mentioned problems, prevents occurrence of migration and short circuit due to carbon paste between adjacent wiring patterns, reduces contact resistance at the time of connection with an external device, and eliminates a gap between wiring patterns. It is an object to provide a wiring board that can be miniaturized, a manufacturing method thereof, and a film mask for forming a wiring board used therefor.

  In order to achieve the above object, a wiring board of the present invention includes a plurality of wiring patterns made of a conductive resin on a substrate, terminal portions formed on the plurality of wiring patterns, and a plurality of wiring patterns at the terminal portions. In addition, it has a coated conductor made of a conductive resin containing carbon particles that covers a plurality of wiring patterns so as not to be exposed, and an insulating protective film that covers at least a plurality of wiring patterns other than the terminal portion, and is connected to an external device. The covered conductor has a flat surface and a sharp side surface.

  Further, the end surface on the terminal portion side of the insulating protective film may be tapered.

  With these configurations, the surface of the coated conductor that comes into contact with the mating connector is flattened, so that the contact resistance can be reduced and the contact resistance variation between the terminals can be suppressed. Further, since the side surface of the coated conductor is formed with a sharp shape, the wiring pattern can be easily miniaturized. Then, by printing a coated conductor made of a conductive resin containing carbon particles, the wiring pattern is completely covered, so that the migration of the wiring pattern can be prevented.

  The wiring board manufacturing method of the present invention includes a wiring pattern forming step for forming a plurality of wiring patterns made of a conductive resin on a substrate, a terminal portion forming step for forming terminal portions on the plurality of wiring patterns, and a terminal. A step of bonding the openings of the film mask for forming a wiring board so that each of the plurality of wiring patterns and its peripheral part are individually exposed, and a conductive resin containing carbon particles in the openings of the film mask for forming a wiring board The method comprises a coated conductor forming step for filling a coated conductor made of the above and a peeling step for peeling the wiring substrate forming film mask.

  By this method, the terminal portion of the wiring pattern can be covered with a coated conductor made of a conductive resin containing carbon particles by a simple process of bonding and peeling of the wiring substrate forming film mask. Further, since the coated conductor is formed in substantially the same shape as the opening of the film mask for forming a wiring board at the time of curing, the side conductor does not spread to the periphery and does not sag, and can have a flat shape on the surface. Therefore, it is possible to reduce the contact resistance of the connecting portion by preventing migration and preventing a short circuit due to the spread of the coated conductor made of a conductive resin containing carbon particles and increasing the contact area. And since the film mask for wiring board formation has the flexibility which can deform | transform along the level | step-difference part by an insulating protective film, it can coat | cover a level | step-difference part reliably. Furthermore, since the film mask for forming a wiring board is adhered to the substrate and the insulating protective film with an adhesive layer that can be easily attached and detached by heat, ultraviolet rays, or the like, no gap is formed. Therefore, a short circuit between the coated conductors made of conductive resin containing carbon particles through the gap does not occur.

  In addition, the method for manufacturing a wiring board according to the present invention includes a wiring pattern forming step of forming a plurality of wiring patterns made of a conductive resin on the substrate, and a plurality of wiring patterns at and around the wiring pattern forming positions. A step of bonding the openings of the film mask for forming the wiring board so that the portions are individually exposed, and formation of a coated conductor that fills the opening of the film mask for forming the wiring board with a conductive conductor containing carbon particles The method includes a step, a peeling step of peeling the wiring substrate forming film mask, and a terminal portion forming step of forming terminal portions on a plurality of wiring patterns.

  By this method, the film mask for forming a wiring board only needs to cover the thickness of the wiring pattern, not the insulating protective film, and has a flexibility that allows deformation along the cross-sectional shape of the wiring pattern. The film mask can reliably fill the gap formed at the stepped portion between the wiring patterns. Therefore, it is possible to form a fine wiring pattern up to the interval between the deformable wiring patterns of the wiring substrate forming film mask.

  In the method for manufacturing a wiring board according to the present invention, in the terminal portion forming step, a plurality of wiring patterns other than the terminal portions are covered with an insulating protective film, and the end surface on the terminal portion side of the insulating protective film is formed in a tapered shape. It consists of a method.

  By this method, even when the shape of the sharp step portion due to the thickness variation between the wiring pattern and the insulating protective film cannot be followed, the step portion of the insulating protective film is gently formed by the taper shape. And a level | step-difference part can be bonded together without a gap with the film mask for wiring board formation. Therefore, there is no flow or the like through the gap between the coated conductors made of conductive resin containing carbon particles, and a short circuit between adjacent coated conductors can be reliably prevented.

  Further, the film mask for forming a wiring board according to the present invention includes a plurality of wiring patterns made of a conductive resin formed on the substrate, a terminal portion formed in the plurality of wiring patterns, and a plurality of wiring patterns in the terminal portion. In a wiring board coated with a coated conductor using a forming film mask, the wiring board forming film mask has a water repellency or oil repellency on at least one side, and a resin having an adhesive layer on the other side The resin film is made of a film, and has a configuration in which at least each of the plurality of wiring patterns in the terminal portion and the peripheral portion thereof have openings that are individually exposed and are thicker than the thickness of the plurality of wiring patterns.

  The coated conductor may be made of a conductive resin containing carbon particles.

  In addition, the resin film may include a fluororesin or silicone resin material.

  The adhesive layer may be made of a material whose adhesiveness is lowered by heat or ultraviolet rays.

  With these configurations, it is possible to prevent the coated conductor and the like from adhering to the film substrate forming film mask other than the opening. Further, since the wiring substrate forming film mask can be peeled off by heat or ultraviolet rays at the time of drying or heat curing of the coated conductor or after curing, the coated conductor can be formed in substantially the same shape as the opening of the wiring substrate forming film mask. Since the resin film is more flexible than a screen or a stencil plate, the resin film is excellent in coverage of a stepped portion such as a wiring pattern and can be adhered to the substrate or the like with an adhesive layer other than the opening portion, so that no gap is generated.

  According to the present invention, it is possible to remarkably improve the moisture resistance and water resistance of a wiring pattern and suppress the occurrence of migration of the wiring pattern. Moreover, since the film mask for wiring board formation is peeled off after the coated conductor is cured, the side surface of the coated conductor can be formed sharp and the surface thereof can be formed in a flat shape. As a result, the contact resistance can be reduced by increasing the contact area and the wiring pattern can be miniaturized. Furthermore, since the film mask for forming a wiring board is brought into close contact with the substrate via an adhesive layer, no gap is generated. Therefore, there is a great effect that a highly reliable wiring board can be realized, for example, a short circuit due to the coated conductor does not occur.

(First embodiment)
Hereinafter, a wiring board according to a first embodiment of the present invention, a method for manufacturing the wiring board, and a film mask for forming a wiring board used therefor will be described with reference to FIGS.

  FIG. 1 is a diagram showing a wiring board according to a first embodiment of the present invention. 1A is a plan view, FIG. 1B is a cross-sectional view taken along line A-A ′, and FIG. 1C is a cross-sectional view taken along line B-B ′.

  FIG. 2 is a diagram for explaining a state in the middle of forming the terminal portion 110 of the wiring board 100 of FIG. 2A is a plan view, FIG. 2B is a sectional view taken along the line A-A ′, and FIG. 2C is a sectional view taken along the line B-B ′.

  As shown in FIG. 2A, a plurality of wiring patterns 130 made of conductive resin such as silver paste are formed on the surface of the insulating substrate 120, for example. An insulating protective film 140 is formed thereon except for the terminal portion 110. A wiring substrate forming film mask (hereinafter referred to as a film mask) 300 is bonded to the insulating protective film 140 from the terminal portion 110. The film mask 300 is formed with openings 330 that individually expose the individual wiring patterns 130 and their peripheral portions. With the film mask 300 attached through the adhesive layer as described above, a coated conductor (hereinafter referred to as a coated conductor) 150 made of a conductive resin containing carbon particles is filled in the opening 330. In the final state, the wiring substrate 100 shown in FIG. 1 is completed except for the film mask 300 after forming the covered conductor 150.

  With this configuration, even when the wiring pattern 130 is likely to undergo migration, for example, formed of a paste such as silver, copper, tin, or solder, the wiring pattern 130 is completely covered with the covered conductor 150, so Thus, the wiring substrate 100 that can prevent the migration of the wiring pattern 130 due to the above is manufactured.

  Further, as shown in FIGS. 1B and 1C, the surface 170 of the coated conductor 150 is formed in a flat shape, so that the contact area connected to the external device is increased. As a result, the contact resistance is reduced.

  Furthermore, since the side surface 160 of the coated conductor 150 is also formed in a sharp shape, the spread of the coated conductor 150 is eliminated, and the space between the coated conductors 150 can be easily miniaturized.

  Below, the film mask 300 used for preparation of the wiring board 100 is demonstrated using FIG.

  3A is a plan view schematically showing the film mask 300 according to the first embodiment of the present invention, and FIG. 3B is a cross-sectional view taken along line A-A ′ thereof.

  In the film mask 300 according to the first embodiment of the present invention, the adhesive strength is lowered by the resin film 310 having water repellency or oil repellency on at least one side and heat or ultraviolet rays provided on the other side. An adhesive layer 320 and an opening 330 for forming a coated conductor are included. The opening 330 has such a size that the individual wiring patterns 130 of the terminal portion 110 shown in FIG. The film mask 300 has a thickness that is at least thicker than the wiring pattern 130. For example, when the thickness of the wiring pattern is 30 μm, the thickness of the film mask 300 is about 50 μm. The thickness of the film mask 300 is equal to or greater than the thickness of the wiring pattern 130, and at least unevenness on the surface of the wiring pattern 130 is covered, and the environment (for example, humidity) conditions in which the wiring substrate 100 is used and the required wiring This is determined by adding the thickness of the coated conductor 150 in consideration of the resistance. That is, the resistivity of the coated conductor 150 made of a conductive resin containing carbon particles is generally larger than the resistivity of the wiring pattern 130 made of a conductive resin such as silver, copper, or tin, and the value is connected. It affects the characteristics of the device. Therefore, it is necessary to adjust a desired resistance value according to the thickness of the coated conductor 150 according to the power loss at the time of connection, the signal transmission speed, and the like, and the design of the thickness of the film mask 300 is important. For example, in an application where low resistance is required, the coated conductor 150 is formed thin.

  The resin film 310 has a water repellency or oil repellency, or at least a surface opposite to the adhesive layer 320, for example, a fluorine resin or the like, a polyester resin such as polyethylene terephthalate (PET), acrylonitrile butadiene styrene ( (ABS) resin, fluorine resin, silicone resin or the like. In particular, a fluororesin or a silicone resin is preferable as the resin film 310 because it has a small adhesive force with the coated conductor 150. The adhesive layer 320 is made of, for example, a material made of a thermoplastic resin whose adhesive strength is reduced at a glass transition temperature of about 50 ° C. to 90 ° C., or a material made of a UV self-isolating pressure-sensitive adhesive whose adhesive strength is reduced by ultraviolet rays. Is done. The resin film 310, the adhesive layer 320, and the like are preferably combined with optimum materials in consideration of the curing temperature of the conductive resin material of the wiring pattern 130 and the coated conductor 150. This is because the film mask 300 can be peeled off at the same time as the coated conductor 150 is cured, thereby simplifying the process.

  Further, as shown in FIG. 2B, the film mask 300 is formed of a resin film 310 having such flexibility that it can be deformed along a step portion 260 of about 300 μm, for example. Therefore, the film mask 300 is covered without forming a stepped portion 260 on the end surface portion of the insulating protective film 140 and a gap between the adjacent wiring patterns 130, and is further adhered and fixed by the adhesive layer 320. As a result, since the covered conductor 150 does not spread through the gap, a short circuit between the covered conductors 150 is prevented.

  Further, as shown in FIG. 2C, the coated conductor 150 is filled in the opening 330 of the film mask 300, and after the coated conductor 150 is dried or heated in this state, the film mask 300 is peeled off to cover the film mask 300. A conductor 150 is formed. As a result, as shown in FIG. 1C, the side surface 160 of the coated conductor 150 can be formed in a sharp shape without any slack, and the surface 170 can be formed in a flat shape. Therefore, it is possible to form the terminal portion 110 having the wiring pattern 130 that is miniaturized to the limit of formation between the openings 330 of the film mask 300.

  Further, when the coated conductor 150 is made of a conductive resin containing carbon particles having a finer particle size than the silver particles of the wiring pattern 130, for example, the unevenness on the surface of the wiring pattern 130 due to the silver particles is covered with the carbon particles. The surface portion is smoothed and flattened as described above. Therefore, when connecting with an external device, the contact area between the mating connector and the terminal portion 110 is expanded, and the contact resistance is reduced.

  Hereinafter, an example of a specific configuration of the wiring board 100 will be described.

  As the substrate 120 in the first embodiment of the present invention, an epoxy resin containing glass fiber, a relatively hard substrate such as a ceramic plate or a glass plate, a polyester resin such as polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS). ) Any material can be used as long as it is used for an ordinary wiring board, such as a film sheet substrate made of a polymer resin such as resin, polycarbonate or polyimide. Especially, the film sheet substrate is inexpensive because it is widely used as a general-purpose plastic, and the thickness of the substrate can be reduced to 100 μm to 400 μm, so that it is effective for thinning an electronic circuit device using this wiring substrate. This is preferable. Note that a conductive substrate may be used as long as the surface on which the wiring pattern is formed has an insulating property.

  As the plurality of wiring patterns 130 made of a conductive resin in the first embodiment of the present invention, a silver paste in which silver particles are dispersed and mixed in a binder is mainly used. Among them, silver paste using a thermosetting resin such as polyester resin, epoxy resin, acrylic resin, polyimide resin, or polyurethane resin as a binder has high adhesive strength with the film sheet substrate, and the wiring pattern 130 itself This is preferable in that the mechanical strength is increased.

  As the coated conductor 150 in the first embodiment of the present invention, conductive carbon fine particles are dispersed and mixed in a binder, and carbon particles having a particle size smaller than the particle size of silver particles used in the silver paste are used. It is preferable to use it because the irregularities on the surface of the silver paste can be smoothed. For example, in the case of spherical silver particles or scaly silver particles having a particle size of 0.5 μm to 10 μm used in the silver paste, the particle size of the carbon particles is preferably about 0.1 μm to 1 μm, and further 0.3 μm or less. Is more desirable. In addition, the coated conductor 150 using a thermosetting resin such as polyester resin, epoxy resin, acrylic resin, polyimide resin, or polyurethane resin as a binder has high adhesive strength with silver paste, and is excellent in moisture resistance and water resistance. Moreover, it is preferable in that it has excellent friction resistance.

  In the first embodiment of the present invention, the structure is shown in which the opening 330 of the film mask 300 is bonded to the position covered with the coated conductor 150 up to the stepped portion 260 by the insulating protective film 140. The coated conductor 150 may be formed by aligning and attaching the opening 330 of the film mask 300 so that a part of the film 140 is covered with the coated conductor 150. In this case, for example, it is possible to prevent the occurrence of migration due to the exposure of the wiring pattern 130 that occurs when the opening 330 of the film mask 300 and the stepped portion 260 of the insulating protective film 140 are bonded to each other. it can. Furthermore, since precise alignment between the film mask 300 and the stepped portion 260 of the insulating protective film 140 is not required, productivity is improved.

  Below, the manufacturing method of the wiring board based on the 1st Embodiment of this invention is demonstrated. FIG. 4 is a plan view showing an example of a method for manufacturing a wiring board according to the first embodiment of the present invention.

  First, as shown in FIG. 4A, for example, silver paste is printed on the substrate 120 by using printing means such as screen printing or gravure printing, which is generally used for forming a wiring pattern of the wiring substrate. Then, when dried or heated and cured, a plurality of wiring patterns 130 having low resistance and good adhesive strength can be obtained (this process is called a wiring pattern forming process). Among these, the screen printing method is preferable in that the wiring pattern 130 can be freely formed into a relatively fine pattern, is excellent in mass productivity, and is low in manufacturing cost. The surface portion of the wiring pattern 130 has relatively large unevenness. This is because, in the case of forming by screen printing, unevenness of the printing thickness due to the screen mesh finally remains and the influence of the shape variation of the silver particles of the silver paste.

  Next, as shown in FIG. 4B, an insulating protective film 140 is formed on the portion where the wiring pattern 130 other than the terminal portion 110 is formed. The insulating protective film 140 may be formed of a generally used insulating resin material such as polyimide, an inorganic material such as silicon dioxide or silicon nitride, or a structure in which an inorganic material and a resin material are laminated. Good. In addition, when the resin material is formed by screen printing, it is preferable because the insulating protective film 140 can be formed flat without reflecting the convex shape of the wiring pattern 130.

  Next, as shown in FIG. 4C, the opening 330 of the film mask 300 is aligned with the wiring pattern 130 of the terminal 110, and is bonded to the substrate 120 with an adhesive layer. At this time, the thickness of the film mask 300 is thicker than the thickness of the wiring pattern 130, and the opening 330 encloses the wiring pattern 130 other than the insulating protective film 140 side.

  Next, as shown in FIG. 4D, the coated conductor 150 is filled into the opening 330 of the film mask 300 using a method similar to screen printing or the like (this process is referred to as a coated conductor forming process).

  Next, as shown in FIG. 4E, for example, when the film mask 300 is a fluororesin and the adhesive layer is a thermoplastic resin, the film is heated to about 90 ° C. to reduce the adhesiveness of the film mask 300. The mask 300 is peeled off (this step is called a peeling step). At this time, the coated conductor 150 is formed by being cured in the shape of the opening 330 of the film mask 300 by heating when the film mask 300 is peeled off. If necessary, after the film mask 300 is peeled off, the coated conductor 150 may be further dried or heated to be cured. In this case, since the shape of the coated conductor 150 is determined in advance by heating at the time of peeling the film mask 300, no dripping occurs due to reheating.

  Through the above steps, the wiring substrate 100 in which the wiring pattern 130 of the terminal portion 110 is completely covered with the covered conductor 150 is obtained.

  In the peeling process, the adhesiveness of the film mask 300 is lowered by ultraviolet rays. For example, when a UV self-isolating pressure-sensitive adhesive is used, the film mask 300 is easily peeled off by irradiating with ultraviolet rays. be able to. Further, for example, if the substrate 120 made of PET or the insulating protective film 140 is transparent to ultraviolet rays, the ultraviolet rays can be irradiated from the substrate 120 side. In this case, before peeling off the film mask 300, it is necessary to cure the coated conductor 150 by drying or heating.

  As a result, the wiring pattern 130 of the terminal portion 110 is covered with the coated conductor 150, and even if the wiring substrate 100 is used in an atmosphere with high humidity or water droplets, the wiring pattern 130 made of silver paste is migrated. Can be prevented. Furthermore, since the film mask 300 is adhered to the substrate 120, no gap is formed between the adjacent wiring patterns 130, and therefore, a short circuit due to bleeding or flow of the coated conductor 150 can be prevented. Accordingly, the space between the wiring patterns 130 is not narrowed due to bleeding or the like of the covered conductor 150, and the covered conductor 150 is formed in the shape of the opening 330 of the film mask 300, so that the wiring pattern 130 can be easily miniaturized.

(Second Embodiment)
FIG. 5 is a plan view showing an example of a method of manufacturing a wiring board according to the second embodiment of the present invention. In FIG. 5, the same components as those in FIG.

  In the second embodiment of the present invention, after the covered conductor 150 is formed on the wiring pattern 130, the terminal portion 110 is formed by the insulating protective film 140.

  Hereinafter, the steps different from those of the first embodiment will be mainly described in the second embodiment with reference to FIG.

  First, as shown in FIG. 5A, a wiring pattern 130 made of, for example, silver paste is printed on a substrate 120, and the wiring pattern 130 having low resistance and good adhesive strength is formed by heat curing. (This process is called a wiring pattern forming process).

  Next, as shown in FIG. 5B, the film mask 300 is aligned with the wiring pattern 130 at the position where the terminal portion 110 is formed, and is bonded to the substrate 120 by the adhesive layer. The At this time, since the thickness of the film mask 300 is thicker than that of the wiring pattern 130, the opening 330 can contain the wiring pattern 130.

  Next, as shown in FIG. 5C, the coated conductor 150 is filled in the opening 330 of the film mask 300 using a method similar to screen printing or the like (this process is referred to as a coated conductor forming process). In this case, it is necessary to form the coated conductor 150 so as not to be applied on the wiring pattern 130 other than the opening 330 of the film mask 300.

  Next, as shown in FIG. 5D, for example, when the film mask 300 is a silicone resin and the adhesive layer is a thermoplastic resin, the film is heated to about 90 ° C. to reduce the adhesiveness of the film mask 300. The mask 300 is peeled off (this step is called a peeling step). In this case, the coated conductor 150 is dried or cured in the shape of the opening 330 of the film mask 300 by heating when the film mask 300 is peeled off. Further, if necessary, after the film mask 300 is peeled off, the carbon paste may be dried or heated to be cured. In this case, since the shape of the coated conductor 150 is determined in advance by heating at the time of peeling the film mask 300, no dripping occurs due to reheating.

  Next, as shown in FIG. 5E, an insulating protective film 140 is formed so as to cover at least a part of the covered conductor 150.

  Through the above steps, the wiring substrate 100 in which the wiring pattern 130 of the terminal portion 110 is covered with the covered conductor 150 and at least a part of the covered conductor 150 is covered with the insulating protective film 140 is obtained.

  Thereby, it is not necessary to cover the stepped portion 260 by the insulating protective film 140 in the first embodiment with the film mask 300, and it is only necessary to cover the stepped portion 500 (corresponding to the thickness) of the wiring pattern 130. The gap with the substrate 120 is almost eliminated by the adhesion of the film mask 300. Therefore, it is possible to further improve the effect of preventing a short circuit between the coated conductors 150 due to bleeding or flow of the coated conductors 150, and to realize the wiring board 100 with improved reliability. Further, since a part of the coated conductor 150 is covered with the insulating protective film 140, for example, the coated conductor 150 is less likely to be peeled off due to the deformation of the wiring board 100 that occurs when inserted into the mating connector. Therefore, the wiring board 100 with excellent reliability can be realized.

(Third embodiment)
6A is a plan view showing a wiring board according to the third embodiment of the present invention, FIG. 6B is a sectional view taken along the line AA ′ in FIG. 6, and FIG. FIG. 6B is an enlarged view of a portion B in FIG. 6B, and FIG. 6D is a cross-sectional view of a metal mask for forming an insulating protective film according to the third embodiment. In FIG. 6, the same components as those in FIG.

  In the third embodiment of the present invention, the end face shape of the insulating protective film 140 on the terminal portion 110 side is a tapered shape 600.

  The third embodiment will be described below with reference to FIG.

  In FIG. 6B, the method for forming the end face of the insulating protective film 140 of the terminal 110 is, for example, as shown in FIG. The insulating protective film 140 is formed by applying an insulating resin or the like using the metal mask or the like. Alternatively, after forming the insulating protective film 140 with an insulating resin or the like, a tapered cross section is formed by heating or the like, so that the insulating property of the tapered shape 600 as shown in the enlarged view of part B of FIG. A protective film 140 is formed. Further, in the screen printing or the like, by using the insulating protective film 140 material having a low viscosity, the end surface portion can be naturally bent after the screen is removed to form the tapered shape 600. Furthermore, the taper shape 600 may be formed by gradually moving the screen in the direction opposite to the terminal portion 110 during screen printing. By bonding the film mask 300 along the taper shape 600 formed in this way, a gap between the stepped portion and the wiring pattern 130 in the end surface portion of the insulating protective film 140 is not formed.

  Next, after the coated conductor 150 is filled in the opening 330 of the film mask 300, the film mask 300 is peeled off by heating, and at the same time, the coated conductor 150 is cured to completely cover the wiring pattern 130 with the coated conductor 150. A substrate is formed.

  With this configuration, since the end surface portion of the insulating protective film 140 is formed in a tapered shape 600, the film mask 300 is not easily deformed excessively as in the stepped portion 260 of FIG. In addition, it can be bonded without gaps.

  Further, the coated conductor 150 is formed so as to cover the insulating protective film 140 as compared with the case where the coated conductor 150 is attached and cured at the step portion 260 of the insulating protective film 140 as shown in FIG. Therefore, it is difficult for the coated conductor 150 to peel off. Further, as in the first embodiment, since the film mask 300 and the substrate 120 are bonded to each other between the adjacent wiring patterns 130 via an adhesive layer, it is formed by a commonly used mask such as a screen or a stencil plate. The gap that occurs when Therefore, it is possible to prevent a short circuit between the covered conductors 150 due to the flow or bleeding of the covered conductors 150 between the adjacent wiring patterns 130.

  Hereinafter, the production of the wiring board according to the first embodiment of the present invention will be specifically described based on examples. The same applies to other embodiments, and a description thereof will be omitted.

  In this example, a wiring pattern 130 made of, for example, a silver paste was printed on the substrate 120 under the following conditions. The substrate 120 is a film sheet made of polyimide resin, and its thickness is 100 μm. The silver paste is 75 parts by weight of a mixture of spherical silver particles and scale-like silver particles having a particle size of 0.5 μm to 10 μm and 15% by weight of a binder made of a thermosetting epoxy resin having a curing temperature of 120 ° C. The mixture was used in a part. This was printed by a screen printing method. At that time, the screen mesh wire diameter was 25 μm, the photosensitive emulsion layer thickness was 10 μm, and the designed line width of the wiring was 150 μm. After the silver paste was printed, the wiring pattern 130 was formed by thermosetting. The film thickness of the wiring pattern 130 at this time was 20 μm to 30 μm, the line width thereof was 160 μm to 170 μm, and the unevenness of the surface portion was about 10 μm.

  Next, an insulating protective film 140 was formed so as to cover the wiring pattern 130 other than the portion where the terminal portion 110 of the wiring substrate 100 was formed, thereby ensuring moisture resistance and water resistance. As the insulating protective film 140 at this time, a resin generally used as a resist film such as a plating is formed by screen printing.

  Next, the coated conductor 150 made of a conductive resin containing carbon particles is bonded to the opening portion 330 of the film mask 300 and the wiring pattern 130 at the position of the wiring pattern 130 of the terminal portion 110 without gaps. The openings 330 were filled by screen printing. Thereafter, the substrate 120 was heated at 130 ° C. for 10 minutes to heat and cure the coated conductor 150, and the adhesiveness of the adhesive layer 320 of the film mask 300 was lowered and peeled from the substrate 120. At this time, as the coated conductor 150, a binder composed of 85 parts by weight of conductive carbon made of acetylene black having a particle size of 0.1 μm to 0.3 μm and a thermosetting epoxy resin having a curing temperature of 120 ° C. A mixture of 15 parts by weight was used. The film mask 300 has a thickness of 50 μm, and the opening 330 has a shape that can reliably cover the wiring pattern 130 of the terminal portion 110.

  As a result, the wiring pattern 130 of the terminal portion 110 was covered with the hardened coated conductor 150, and the wiring substrate 100 without a short circuit due to bleeding or the like between the adjacent coated conductors 150 was obtained. The total thickness of the cured wiring pattern 130 and the coated conductor 150 was 45 μm to 50 μm, and the surface unevenness was 2 μm or less. The unevenness of the wiring pattern 130 was smoothed by the coated conductor 150. Further, the formed covered conductor 150 reflects the shape of the opening 330 of the film mask 300, and no one has its side 160 sharp and its surface 170 flat.

  A reliability evaluation test was performed in order to evaluate the reliability of the wiring board 100 thus manufactured. Test conditions and evaluation were performed by the following methods. That is, the surface of the wiring of the terminal portion 110 was observed after 1000 hours with the voltage applied in an atmosphere of 65 ° C. and 95% RH. As a result, no silver migration was observed. In addition, the contact resistance was measured by mechanically contacting the terminal portion 110 of the wiring pattern 130 for connection with the external device and the terminal of the external device. It has been found that the contact resistance can be made sufficiently small by an order of magnitude. Furthermore, as a result of measuring between the covered conductors 150 of the terminal portion 110 with an insulation resistance meter, it was the same value as the resistance value of the substrate 120, and there was no occurrence of a short circuit or a decrease in insulation resistance.

  In the embodiment of the present invention, an insulating protective film made of resist is formed on the wiring pattern not covered with the coated conductor, but the present invention is not limited to this. That is, a film sheet made of polyimide may be bonded, or a protective film made of an inorganic film may be formed by sputtering, chemical vapor deposition (CVD), or the like.

  In the embodiment of the present invention, only the terminal portion of the exposed portion of the wiring pattern is covered with the covered conductor, but the entire wiring pattern may be individually covered with the covered conductor.

  In the embodiments of the present invention, the wiring board having a single layer structure has been described. However, the present invention is not limited to this. A multilayer wiring structure may be used. In that case, a coated conductor made of a conductive resin containing carbon may be formed on the uppermost wiring pattern by the method described in the embodiment of the present invention.

  The wiring board according to the present invention can be applied to an electronic device that is required to be connected to an external device with a low contact resistance or to have a finer wiring pattern, or to various electronic devices that are used in a severe environment that requires suppression of migration. it can.

  Moreover, the film mask for forming a wiring board of the present invention is useful for forming a wiring pattern that requires a flat surface and a sharp side shape.

(A) Plan view of the wiring board according to the first embodiment of the present invention (b) A-A 'sectional view of the same figure (a) (c) B-B' sectional view of the same figure (a) (A) The top view explaining the state in the middle of forming the terminal part of the wiring board based on the 1st Embodiment of this invention (b) AA 'sectional drawing of the figure (a) (c) The figure BB 'sectional view of (a) (A) Plan view of the film mask according to the first embodiment of the present invention (b) A-A ′ sectional view of FIG. The top view which shows an example of the manufacturing method of the wiring board which concerns on the 1st Embodiment of this invention The top view which shows an example of the manufacturing method of the wiring board which concerns on the 2nd Embodiment of this invention (A) Plan view showing a wiring board according to a third embodiment of the present invention (b) AA ′ cross-sectional view of FIG. (A) (c) Enlarged view of portion B of FIG. d) A cross-sectional view of a metal mask for forming an insulating protective film according to the third embodiment of the present invention. The perspective view which showed the terminal structure of the connection part with the external apparatus in the conventional wiring board (A) Plan view for explaining the configuration of a conventional wiring board (b) AA ′ sectional view of FIG. (A) (c) State of the coated conductor after removing the screen mask of FIG. Plan view to explain (d) BB 'sectional view of the same figure (c) (A) Plan view for explaining the configuration of a conventional wiring board (b) A-A 'cross-sectional view of (a) (c) B-B' cross-sectional view of (a)

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 Wiring board 110 Terminal part 120 Board | substrate 130 Wiring pattern 140 Insulating protective film 150 Covered conductor 160 Side surface (of covering conductor) 170 (Surface of covering conductor) 260,500 Step part 300 (For wiring board formation) Film mask 310 Resin film 320 Adhesive layer 330 Opening 600 Taper shape

Claims (9)

A plurality of wiring patterns made of conductive resin on the substrate;
A plurality of terminal portions formed in the wiring pattern;
A coated conductor made of a conductive resin containing carbon particles that covers the plurality of wiring patterns in the terminal portion so that the plurality of wiring patterns are not exposed; and
An insulating protective film covering at least the plurality of wiring patterns other than the terminal portions;
A wiring board characterized in that a surface of the coated conductor connected to an external device is flat and has a sharp side surface. The wiring board according to claim 1, wherein an end surface of the insulating protective film on the terminal portion side is tapered. A wiring pattern forming step of forming a plurality of wiring patterns made of a conductive resin on a substrate;
A terminal part forming step of forming a terminal part in the plurality of wiring patterns;
Bonding the openings of the wiring board forming film mask so that each of the plurality of wiring patterns of the terminal part and its peripheral part are individually exposed;
A covered conductor forming step of filling the opening of the wiring board forming film mask with a covered conductor made of a conductive resin containing carbon particles;
A peeling step for peeling the wiring substrate forming film mask;
A method of manufacturing a wiring board, comprising: A wiring pattern forming step of forming a plurality of wiring patterns made of a conductive resin on a substrate;
At the position where the terminal portion is formed, a step of bonding the opening portion of the wiring board forming film mask so that each of the plurality of wiring patterns and its peripheral portion are individually exposed,
A covered conductor forming step of filling the opening of the wiring board forming film mask with a covered conductor made of a conductive resin containing carbon particles;
A peeling step for peeling the wiring substrate forming film mask;
A terminal part forming step of forming the terminal part in a plurality of the wiring patterns;
A method of manufacturing a wiring board, comprising: In the terminal portion forming step, the plurality of wiring patterns other than the terminal portions are covered with an insulating protective film, and the end surface on the terminal portion side of the insulating protective film is formed in a tapered shape. The method for manufacturing a wiring board according to claim 4. A plurality of wiring patterns made of a conductive resin formed on a substrate, terminal portions formed on the plurality of wiring patterns, and the plurality of wiring patterns on the terminal portions are coated conductors using a wiring substrate forming film mask. In the wiring board to be coated,
The film mask for forming a wiring board is formed of a resin film having water repellency or oil repellency on at least one side and having an adhesive layer on the other side, and the resin film includes at least a plurality of terminal portions. A film mask for forming a wiring board, wherein each wiring pattern and its peripheral part have openings that are individually exposed and are thicker than a plurality of wiring patterns. The film mask for forming a wiring board according to claim 6, wherein the coated conductor is made of a conductive resin containing carbon particles. The said resin film contains the material of a fluororesin or a silicone resin, The film mask for wiring board formation of Claim 6 or Claim 7 characterized by the above-mentioned. The film mask for forming a wiring board according to any one of claims 6 to 8, wherein the adhesive layer is made of a material whose adhesiveness is lowered by heat or ultraviolet rays.

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