JP2006100400A - Wiring board manufacturing method and electronic apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of forming a fine wiring pattern accurately and stably on various types of substrates. <P>SOLUTION: The wiring board manufacturing method comprises a frame-like insulation film formation process wherein a first liquid material is arranged in the shape of a frame in a top view on a substrate to form a frame-like insulation film; a liquid material arrangement process wherein, in an area on the substrate surrounded by the frame-like insulation film, a second liquid material for forming an insulation film is arranged with a space left between; a lyophilic treatment process wherein lyophilic treatment is performed to a surface area on the substrate, causing the second liquid material to flow on the substrate and fill an area on the substrate surrounded by the frame-like insulation film; a curing process wherein the second liquid material is cured to form a foundation insulation film; and a wiring formation process wherein a wiring formation material is arranged on the foundation insulation film to form a wiring pattern. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a wiring board and an electronic device.

  For example, a photolithography method is used to form a wiring pattern constituting an electronic device. However, the photolithography method not only requires large-scale equipment such as a vacuum apparatus and a complicated process, but also has a material use efficiency of about several percent, so that most of the material must be discarded, and the manufacturing cost is high. Furthermore, there is a limit to the miniaturization of the wiring pattern.

In view of this, a method (droplet discharge method) in which a wiring pattern is directly drawn and formed by discharging a liquid containing a functional material onto a substrate as a process replacing the photolithography method has been studied. In this method, first, a liquid in which conductive fine particles are dispersed is discharged from a droplet discharge head onto a substrate to form a liquid line. Next, the liquid line is baked by heat treatment or laser irradiation to form a wiring pattern (see, for example, Patent Document 1). According to this droplet discharge method, the manufacturing process is simplified and the material use efficiency is high, so that the manufacturing cost can be reduced. In addition, the wiring pattern can be miniaturized.
US Pat. No. 5,132,248

By the way, in recent years, the density of circuits constituting electronic devices has been further increased, and further miniaturization and thinning of wiring patterns constituting the circuits are required. However, when such a fine wiring pattern is formed by the above-described method by the droplet discharge method, the discharged droplet spreads after being landed on the substrate, so that the fine wiring pattern is formed accurately and stably. Requires appropriate surface control. And since such surface control must be appropriately performed according to the kind of board | substrate, the material change of a board | substrate will lead to a big process change and may raise a manufacturing cost.
An object of the present invention is to solve the above-described problems and provide a method for forming a fine wiring pattern on various substrates accurately and stably.

In order to solve the above-described problems, the present invention provides a frame-shaped insulating film process in which a first liquid material is arranged in a frame shape in plan view on a substrate to form a frame-shaped insulating film, and the frame-shaped insulating film A liquid material disposing step of disposing a second liquid material for forming an insulating film in the surrounded region on the substrate with a gap from the frame-shaped insulating film; and a surface region on the substrate. A lyophilic treatment step of causing the second liquid material to flow on the substrate by lyophilic treatment and filling a region surrounded by the frame-like insulating film with the second liquid material; and the second liquid material And a wiring forming step of forming a wiring pattern by disposing a wiring forming material on the base insulating film.
According to this manufacturing method, first, since the wiring pattern is formed on the base insulating film formed on the base by the above steps, the base insulating film can eliminate the influence of the surface state of the base. Regardless of the type of substrate, a fine wiring pattern can be formed accurately and stably. Next, when the base insulating film is formed, a frame-like insulating film that divides the base insulating film forming region is provided on the base, so that the second liquid material for forming the base insulating film is formed on the base. It is possible to prevent variations in the planar shape and film thickness of the base insulating film caused by flowing in the substrate. Furthermore, since the second liquid material is disposed at a distance from the frame-shaped insulating film, the substrate does not get over the frame-shaped insulating film when disposed on the substrate, and has a uniform thickness. Formed on top. Next, since the frame-like insulating film is formed by arranging the first liquid material on the substrate, it can be formed in an arbitrary planar shape, and a complex-shaped base insulating film is very easily and stably formed. Can be formed.

  In the method for manufacturing a wiring board according to the present invention, it is preferable that the lyophilic processing step is a step of irradiating the second liquid material disposed on the substrate with ultraviolet rays. The lyophilic treatment by light irradiation is preferable as a processing means because the surface to be treated can be made uniformly lyophilic and contamination of the surface to be treated can be prevented.

In the method for manufacturing a wiring board according to the present invention, the frame-like insulating film can be formed to have a film thickness equal to or greater than that of the base insulating film. According to this manufacturing method, since the frame-like insulating film is formed with ridges at the periphery of the base insulating film, the base insulating film is formed when a wiring pattern or the like is formed by a liquid phase method in a subsequent step. The liquid material disposed above can be prevented from overflowing to the outside, and this is a manufacturing method advantageous for improving the electrical reliability of the wiring pattern and insulating film constituting the wiring board.
The film thickness of the frame-like insulating film can also be made thin as long as the liquid material for forming the base insulating film can be prevented from overflowing to the outside of the frame-like insulating film. Advantages such as speeding up the insulating film forming process and saving of materials can be obtained.

  In the method for manufacturing a wiring board according to the present invention, in the frame-shaped insulating film forming step, another frame-shaped insulating film that is planarly separated from the frame-shaped insulating film is provided in a region surrounded by the frame-shaped insulating film. In the liquid material arranging step, the second liquid material can be arranged in a region between the plurality of frame-like insulating films. Since the frame-like insulating film is formed by using a liquid phase method, even a complicated shape can be formed very easily and quickly. And like this manufacturing method, another frame-shaped insulating film can also be formed inside one frame-shaped insulating film. With such a manufacturing method, a base insulating film having an opening in the planar region can be formed. For example, the opening can be used as a mounting region for an IC chip or the like, and the circuit board can be freely designed. The degree can be improved.

  In the method for manufacturing a wiring board according to the present invention, a multilayer wiring structure is formed on the substrate by repeatedly performing the wiring forming step and an interlayer insulating film forming step for forming an interlayer insulating film covering the wiring pattern. You can also. That is, the method for manufacturing a wiring board according to the present invention can be suitably used for a wiring board having a multilayer wiring structure. In that case, the frame-like insulating film is preferably used only for forming the base insulating film in the lowermost layer (the layer closest to the substrate side). This is for ensuring the flatness in the formation region of the wiring pattern and the interlayer insulating film and improving the electrical reliability of the wiring pattern and the interlayer insulating film.

  In the method for manufacturing a wiring board according to the present invention, the wiring forming step may include a conductor post forming step of forming a conductive post by discharging and arranging a liquid material on the surface of the wiring pattern. That is, the manufacturing method of the present invention can also be applied to a configuration in which wiring patterns stacked via an interlayer insulating film or the like are electrically connected by the conductor posts. With such a manufacturing method, the conductive connection structure between the layers can be formed using the liquid phase method, and a highly integrated wiring board can be manufactured at low cost.

  An electronic apparatus according to the present invention is characterized by including a wiring board obtained by the manufacturing method according to the present invention described above. According to this configuration, an electrical connection is made by the wiring board having excellent electrical reliability, and an electronic device having excellent reliability is provided.

  Embodiments of the present invention will be described below with reference to the drawings. In each drawing used for the following description, the scale of each member is appropriately changed to make each member a recognizable size.

(Droplet discharge device)
First, a droplet discharge device used in an embodiment of a method for manufacturing a wiring board will be described. FIG. 1 is a perspective configuration diagram illustrating an example of a droplet discharge device. A droplet discharge device 20 shown in FIG. 1 discharges and disposes a liquid material containing a functional material on a substrate (base body) 11 in the form of droplets, and includes a carriage having one or more discharge heads. 1, an X-direction guide shaft 2 that supports the carriage 1 movably in the X-direction, and an X-direction drive motor 3 that rotationally drives the X-direction guide shaft 2. A mounting table 4 for mounting the substrate 11, a Y-direction guide shaft 5 that supports the mounting table 4 movably in the Y direction, and a Y-direction drive motor 6 that rotationally drives the Y-direction guide shaft 5 are provided. Yes. The X-direction guide shaft 2 and the Y-direction guide shaft 5 are respectively fixed at predetermined positions on the base 7, and a control device 8 is disposed below the base 7. Further, a cleaning mechanism 14 and a heater 15 are provided.

The carriage 1 includes a plurality of ejection heads (ejection heads) capable of ejecting a liquid material such as a dispersion containing conductive fine particles from a nozzle (ejection port) and applying the liquid material to the substrate at predetermined intervals. Each of the plurality of ejection heads can individually eject the liquid material in accordance with the ejection voltage supplied from the control device 8.
The carriage 1 is fixed to an X direction guide shaft 2, and an X direction drive motor 3 is connected to the X direction guide shaft 2. The X-direction drive motor 3 is a stepping motor or the like, and rotationally drives the X-direction guide shaft 2 when a drive pulse signal in the X-axis direction is supplied from the control device 8. The carriage 1 moves in the X-axis direction with respect to the base 7 as the X-direction guide shaft 2 rotates.

Here, details of the ejection head mounted on the carriage 1 will be described. 2A and 2B are diagrams illustrating the ejection head 30, in which FIG. 2A is a perspective configuration diagram illustrating an essential part of the ejection head 30 in an exploded manner, and FIG. 2B is a partial cross-sectional configuration diagram of the ejection head 30.
As shown in FIG. 2A, the discharge head 30 includes, for example, a stainless nozzle plate 32 and a vibration plate 33, which are joined via a partition member (reservoir plate) 34. A plurality of cavities 35 and reservoirs 36 are formed by a partition member 34 between the nozzle plate 32 and the diaphragm 33. The interior of each cavity 35 and reservoir 36 is filled with a liquid material, and each cavity 35 communicates with the reservoir 36 via a supply port 37. In addition, nozzle holes 38 for injecting a liquid material from the cavity 35 to the outside are arranged in the nozzle plate 32 vertically and horizontally. On the other hand, the diaphragm 33 is formed with an introduction port 39 for supplying a liquid material to the reservoir 36.

  Also, a piezoelectric element (piezo element) 40 is bonded to the surface of the diaphragm 33 opposite to the surface facing the cavity 35 as shown in FIG. The piezoelectric element 40 is disposed in a state sandwiched between a pair of electrodes 41, and when the electrodes 41 and 41 are energized, the piezoelectric elements 40 are elastically deformed so as to protrude outward (the upper side in the drawing). Yes. With such a configuration, the diaphragm 33 to which the piezoelectric element 40 is bonded is bent outwardly integrally with the piezoelectric element 40 due to the deformation of the piezoelectric element 40, and the cavity 35 is accompanied by this deformation. Increase in volume. Accordingly, the liquid material corresponding to the increase in volume in the cavity 35 flows into the cavity 35 from the reservoir 36 through the supply port 37. When the energization of the piezoelectric element 40 is released, the liquid material inside the cavity 35 is pressed toward the nozzle hole 38 by the pressure when the piezoelectric element 40 and the diaphragm 33 return to the original shape, and the nozzle hole 38 is applied to the substrate. A liquid material droplet 42 is discharged.

The discharge head 30 having the above-described configuration has a substantially rectangular bottom surface, and is arranged in a rectangular shape with the nozzles N (nozzle holes 38) aligned vertically at equal intervals as shown in FIG. It has been done. In this example, each of these nozzles N (N1, N2,...) Is provided with an independent piezoelectric element 40 corresponding to the nozzle N (N1, N2,...), And a discharge signal related to each nozzle is controlled by a control signal to each piezoelectric element 40. Each can be controlled independently. That is, by controlling the discharge waveform as an electrical signal sent to the piezoelectric element 40, the discharge amount of the droplets from each nozzle N can be adjusted and changed. Here, the control of the discharge waveform can be performed by the control device 8, and the control device 8 also functions as a discharge amount adjusting means for changing the droplet discharge amount from each nozzle N.
The method of the ejection head 30 is not limited to the piezo jet method using the piezoelectric element 40, and a thermal method, for example, can be adopted. In that case, the length of the heating time is changed. The discharge amount of the liquid material can be changed by such means.

  Returning to FIG. 1, the mounting table 4 mounts and fixes a substrate 11 to be used for a droplet discharge method using the droplet discharge device 20, and a mechanism for fixing the mounted substrate 11 at a predetermined position. It has. The mounting table 4 is supported by a Y-direction guide shaft 5, and Y-direction drive motors 6 and 16 are connected to the Y-direction guide shaft 5. The Y direction drive motors 6 and 16 are stepping motors or the like, and when the drive pulse signal in the Y axis direction is supplied from the control device 8, the Y direction guide shaft 5 is rotationally driven. As the Y-direction guide shaft 5 rotates, the mounting table 4 moves in the Y-axis direction with respect to the base 7.

  The cleaning mechanism unit 14 includes a mechanism for cleaning the ejection head 30 of the carriage 1. The cleaning mechanism unit 14 is moved along the Y-direction guide shaft 5 by the Y-direction drive motor 16. The movement of the cleaning mechanism unit 14 is also controlled by the control device 8.

  Here, the heater 15 is a means for heat-treating the substrate 11 by lamp annealing, and performs heat treatment for evaporating and drying the liquid discharged on the substrate and converting it into a conductive film. The heater 15 is also turned on and off by the control device 8.

  In the droplet discharge device 20 of the present embodiment, in order to discharge the dispersion liquid to a predetermined wiring formation region, a predetermined drive pulse signal is sent from the control device 8 to the X direction drive motor 3 and / or the Y direction drive motor 6. The carriage 1 and / or the mounting table 4 are moved to move the carriage 1 and the substrate 11 (mounting table 4) relative to each other. During this relative movement, a discharge voltage is supplied from the control device 8 to a predetermined discharge head 30 in the carriage 1, and the dispersion liquid is discharged from the discharge head 30.

  In the droplet discharge device 20 of this embodiment, the discharge amount of droplets from each discharge head 30 of the carriage 1 can be adjusted by the magnitude of the discharge voltage supplied from the control device 8. The pitch of the droplets discharged onto the substrate 11 is determined by the relative moving speed between the carriage 1 and the substrate 11 (mounting table 4) and the discharge frequency (discharge voltage supply frequency) in the discharge head 30.

(Method for manufacturing a wiring board)
Next, a method for manufacturing a wiring board according to the present invention will be described in detail with reference to FIGS. 4 to 6 and Table 1. FIG. 4 and 5 are cross-sectional process diagrams for explaining the method of manufacturing the wiring board according to the embodiment. FIG. 5 shows a manufacturing process subsequent to FIG. FIG. 6 is a plan process diagram showing a foundation forming process among the processes shown in FIG. Table 1 is a process chart of the manufacturing method of the wiring board. Below, each process is demonstrated in order of the step number of the left end column of Table 1.

  In the present embodiment, as shown in FIG. 5E, a method of manufacturing a wiring board having a multilayer wiring structure in which a plurality of wiring patterns 116 and 118 are laminated on a film substrate 11 with a base insulating film 110 interposed therebetween. It is. In addition, as will be described later, the method for manufacturing the wiring board of the present embodiment includes a base formation step (frame-like insulating film formation step, liquid material placement step, lyophilic treatment step, curing step), first surface treatment step, wiring This includes a forming step, a conductor post forming step, a second surface treatment step, an insulating film forming step, and an interlayer insulating film forming step.

<Base formation process>
First, the surface (film formation surface) of the film substrate 11 shown in FIG. 4A is cleaned (step 1). Specifically, excimer UV having a wavelength of 172 nm is irradiated on the surface of the film substrate 11 for about 300 seconds. In addition, you may wash | clean the film board | substrate 11 using washing | cleaning liquids, such as water, In that case, an ultrasonic wave can also be used together.

[Frame-shaped insulating film forming step]
Next, as a premise for forming the base insulating film 110 on the surface of the film substrate 11, a frame-like insulating film 110a for controlling the position of the base insulating film 110 is drawn and formed (step 2). This drawing is performed by a droplet discharge method (inkjet method). That is, as shown in FIG. 6A, a resin material before curing (first liquid material), which is the same liquid material as the formation material of the base insulating film 110, is used by using the previous droplet discharge device 20. Then, it is applied and formed in a frame shape along the peripheral edge of the film formation region 11 a of the base insulating film 110. Note that the forming material of the frame insulating film 110 a may be different from the forming material of the base insulating film 110.
Next, the resin material for forming the frame-like insulating film 110a applied on the film substrate 11 is cured (step 3). Specifically, UV with a wavelength of 365 nm is irradiated for about 4 seconds to cure the UV curable resin that is the material for forming the frame-shaped insulating film 110a. Thereby, a frame-like insulating film (weir) 110a surrounding the film forming region 11a on the film substrate 11 on which the base insulating film 110 is formed is formed.

[Liquid material placement process]
Next, as shown in FIG. 6B, the base insulating film 110 is drawn and formed inside the frame-shaped insulating film 110a formed on the film substrate 11 (step 4). This drawing is also performed by a droplet discharge method. Specifically, while the ejection head 30 of the droplet ejection apparatus 20 is scanned almost entirely inside the film formation region 11a surrounded by the frame-shaped insulating film 110a, the nozzle N of the ejection head 30 forms the base insulating film 110. A resin material (second liquid material) 110s before curing, which is a forming material, is discharged and arranged. Here, in the manufacturing method of this embodiment, as shown in FIG. 6B, a gap is provided between the frame-shaped insulating film 110a and the resin material 110s is discharged and arranged on the film substrate 11.
In the state shown in FIG. 5B, there is no particular problem even if the resin material 110s discharged on the film substrate 11 flows and partially contacts the frame-like insulating film 110a provided on the peripheral edge. Further, even if the resin material 110s flows in this manner, it is blocked by the frame-like insulating film 110a, so that it does not spread over the formation region of the base insulating film 110.

[Liquid treatment process]
Next, a lyophilic process is performed on the film formation region 11a including the application region of the resin material 110s (step 5). Specifically, excimer UV with a wavelength of 172 nm is irradiated for about 10 seconds to make the substrate surface in the region (gap) between the resin material 110s and the frame-like insulating film 110a lyophilic. By this lyophilic treatment, as shown in FIG. 6C, the resin material 110s in the region surrounded by the frame-like insulating film 110a flows to the outer peripheral side and fills the film forming region 11a. . Thus, when the resin material 110s is discharged and arranged, the resin material 110s is disposed with a gap from the frame-shaped insulating film 110a, so that the resin material gets over the frame-shaped insulating film 110a and leaks to the outside when the resin material 110s is discharged. Can be prevented. As a result, the base insulating film 110 having a uniform film thickness can be obtained, and a predetermined amount of the resin material 110s can be arranged with respect to the predetermined region (film formation region 11a). The advantage that it can be obtained.

[Curing process]
Next, the discharged resin material is cured (step 6). Specifically, UV with a wavelength of 365 nm is irradiated for about 60 seconds to cure the UV curable resin that is a material for forming the base insulating film 110. As a result, a base insulating film 110 is formed on the surface of the film substrate 11 as shown in FIG.

<First surface treatment step>
Next, as a premise for forming a wiring pattern on the surface of the base insulating film 110, the contact angle of the surface of the base insulating film 110 is adjusted (step 7). That is, the surface treatment is performed so that the surface of the base insulating film 110, which is the wiring pattern formation region, is in a state suitable for the formation of the wiring pattern.
When droplets containing the wiring pattern forming material are ejected, if the contact angle of the surface of the base insulating film 110 is too large, the ejected droplets are repelled in a ball shape, and have a predetermined shape of electricity at a predetermined position. It becomes difficult to form wiring. On the other hand, if the contact angle of the surface of the base insulating film 110 is too small, the discharged droplets spread and the wiring pattern becomes difficult to miniaturize.
As a specific surface treatment method, since the surface of the cured base insulating film 110 exhibits liquid repellency, the surface of the base insulating film 110 is exposed to excimer UV having a wavelength of 172 nm for about 15 seconds. And the degree of affinity with the liquid material for forming a wiring pattern discharged onto the base insulating film 110 in a subsequent process is adjusted. This surface treatment can be adjusted by the irradiation time of ultraviolet light, but can also be adjusted by a combination with the intensity of ultraviolet light, wavelength, heat treatment (heating) and the like. Note that other methods of surface treatment include plasma treatment using oxygen as a reactive gas and treatment of exposing a substrate to an ozone atmosphere.

<Wiring formation process>
Next, as shown in FIG. 4C, a liquid pattern 111 for forming a wiring pattern is drawn and formed on the surface of the base insulating film 110 (step 8). In FIG. 4C and subsequent sectional views, the frame-like insulating film 110a surrounding the base insulating film 110 is not shown.
The liquid pattern 111 is drawn by a droplet discharge method using the droplet discharge device 20. What is discharged here is a dispersion liquid in which conductive fine particles, which are wiring forming materials, are dispersed in a dispersion medium. Silver is preferably used as the conductive fine particles. In addition, fine particles of conductive polymer or superconductor can be used in addition to metal fine particles containing any of gold, copper, palladium, and nickel.

  The conductive fine particles can be used by coating the surface with an organic substance or the like in order to improve dispersibility. Examples of the coating material that coats the surface of the conductive fine particles include polymers that induce steric hindrance and electrostatic repulsion. The particle diameter of the conductive fine particles is preferably 5 nm or more and 0.1 μm or less. If it is larger than 0.1 μm, nozzle clogging is likely to occur and ejection by the ejection head 30 becomes difficult. On the other hand, if the thickness is smaller than 5 nm, the volume ratio of the coating agent to the conductive fine particles becomes large, and the ratio of organic substances in the obtained film becomes excessive.

  The dispersion medium to be used is not particularly limited as long as it can disperse the above-mentioned conductive fine particles and does not cause aggregation. In addition to water, alcohols such as methanol, ethanol, propanol and butanol, n- Hydrocarbon compounds such as heptane, n-octane, decane, toluene, xylene, cymene, durene, indene, dipentene, tetrahydronaphthalene, decahydronaphthalene, cyclohexylbenzene, or ethylene glycol dimethyl ether, ethylene glycol diethyl ether, ethylene glycol methyl ethyl Ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, diethylene glycol methyl ethyl ether, 1,2-dimethoxyethane, bis (2-methoxyethyl) ether Le, p- ether compounds such as dioxane, propylene carbonate, .gamma.-butyrolactone, N- methyl-2-pyrrolidone, dimethylformamide, dimethyl sulfoxide, may be mentioned polar compounds such as cyclohexanone. Among these, water, alcohols, hydrocarbon compounds, and ether compounds are preferable and particularly preferable from the viewpoints of fine particle dispersibility, dispersion stability, and ease of application to the droplet discharge method. Examples of the dispersion medium include water and hydrocarbon compounds. These dispersion media can be used alone or as a mixture of two or more.

The liquid dispersion medium containing conductive fine particles preferably has a vapor pressure at room temperature of 0.001 mmHg or more and 200 mmHg or less (about 0.133 Pa or more and 26600 Pa or less). This is because when the vapor pressure is higher than 200 mmHg, the dispersion medium rapidly evaporates after discharge, making it difficult to form a good film.
The vapor pressure of the dispersion medium is more preferably 0.001 mmHg or more and 50 mmHg or less (about 0.133 Pa or more and 6650 Pa or less). This is because when the vapor pressure is higher than 50 mmHg, nozzle clogging due to drying tends to occur when droplets are ejected by the droplet ejection method, and stable ejection becomes difficult. On the other hand, in the case of a dispersion medium whose vapor pressure at room temperature is lower than 0.001 mmHg, drying is slow and the dispersion medium tends to remain in the film, and a high-quality conductive film can be obtained after heat and / or light treatment in the subsequent process. Hateful.

  The dispersoid density | concentration in the case of disperse | distributing the said electroconductive fine particles to a dispersion medium is 1 mass% or more and 80 mass% or less, and can be adjusted according to the desired film thickness of an electrically conductive film. If it exceeds 80% by mass, aggregation tends to occur and it is difficult to obtain a uniform film.

  The surface tension of the conductive fine particle dispersion is preferably in the range of 0.02 N / m to 0.07 N / m. When the liquid is discharged by the droplet discharge method, if the surface tension is less than 0.02 N / m, the wettability of the liquid material used for discharge to the nozzle surface increases, and thus flight bending easily occurs. If it exceeds 0.07 N / m, the shape of the meniscus at the tip of the nozzle is not stable, and it becomes difficult to control the discharge amount and the discharge timing.

  In order to adjust the surface tension, a small amount of a fluorine, silicon or nonionic surface tension regulator can be added to the dispersion within a range where the contact angle with the base insulating film 110 is not excessively lowered. . The nonionic surface tension modifier improves the wettability to the underlying insulating film 110, improves the leveling property of the film, and helps to prevent the occurrence of protrusions on the surface of the coating film and the generation of distorted skin. . The dispersion liquid may contain an organic compound such as alcohol, ether, ester, or ketone as necessary.

The viscosity of the dispersion is preferably 1 mPa · s or more and 50 mPa · s or less.
When discharging with the droplet discharge method, if the viscosity is less than 1 mPa · s, the nozzle periphery is easily contaminated by the outflow of the ink, and if the viscosity is more than 50 mPa · s, the nozzle hole has an eye. This is because clogging frequency increases and it becomes difficult to smoothly discharge droplets.

In the present embodiment, the dispersion liquid droplets are ejected from the ejection head 30 and dropped onto the position where the wiring pattern is to be formed. At this time, it is desirable to adjust the overlapping degree of the liquid droplets to be continuously discharged so that the liquid pool (bulge) does not occur.
As a result, the liquid pattern 111 is formed on the surface of the base insulating film 110.

  Next, the liquid material pattern 111 is temporarily dried to obtain a liquid material pattern temporarily dried material 112 as shown in FIG. 4C (step 9). This temporary drying is performed to such an extent that at least the surface of the liquid pattern 111 is dried. Specifically, dry air such as low-humidity air or inert gas is blown toward the liquid pattern 111. The temperature of the dry air may be normal temperature (about 25 ° C.) or high temperature. Further, instead of blowing dry air, the liquid material pattern 111 may be irradiated with infrared rays by using a heater 15 made of an infrared lamp or the like provided in the previous droplet discharge device 20. In this way, by adopting dry air spraying or infrared irradiation as a specific method of temporary drying, temporary drying can be performed with simple manufacturing equipment and manufacturing processes, which increases equipment costs and manufacturing costs. Can be suppressed. Moreover, even if the temperature rises temporarily due to temporary drying, it can be immediately returned to room temperature, so that the manufacturing time can be shortened.

<Conductor post formation process>
Next, as shown in FIG. 4D, a liquid sub-post 113s serving as a conductor post is drawn and formed on a part of the temporary dry body 112 (step 10). This drawing is also performed by a droplet discharge method using the droplet discharge device 20, similarly to the drawing of the liquid material pattern 111 in step 8. What is discharged here is a dispersion liquid in which conductive fine particles, which are the material for forming the conductor posts, are dispersed in a dispersion medium, and specifically, the same liquid material used for drawing the liquid pattern 111. That is, after the liquid pattern 111 is drawn, the liquid material may be discharged to the position where the conductor post is formed using the same droplet discharge head.

  Since the conductor post is used for electrical connection between the wiring layers via the interlayer insulating film, it needs to be formed at an appropriate height. For this purpose, it is necessary to form a liquid post having a considerably high height by ejecting and arranging a large number of droplets at the same position by the droplet ejection method. However, even if a large number of droplets are ejected and arranged at a time, it is difficult to ensure the height of the liquid post, and conversely, the liquid post wets and spreads on the film substrate 11 and shorts with the adjacent wiring or conductor post. There is a risk. Therefore, the liquid droplets are discharged in a plurality of times. In one droplet discharge, a liquid sub-post lower than the required liquid post height is formed. For example, about 10 droplets are ejected at a time, and first the liquid sub-post 113s of the first layer is drawn and formed.

  Next, the liquid sub-post 113s is temporarily dried (step 11). This temporary drying is performed so that at least the surface of the liquid subpost 113s is dried. As a specific method thereof, it is desirable to employ dry air spraying or infrared irradiation similarly to the method used to temporarily dry the liquid pattern 111 in Step 8.

  Thereafter, Step 10 and Step 11 are repeated (Step 12). As described above, since the liquid sub-post 113s of the first layer is temporarily dried, even if a new droplet is ejected onto the surface, it does not spread on the surface of the base insulating film 110. Therefore, when about 10 droplets are newly ejected, the second liquid sub-post 113s can be stacked on the first liquid sub-post 113s as shown in FIG. 4 (f). As described above, by repeating Step 10 and Step 11, a plurality of layers (two layers in the drawing) of liquid sub-posts 113 s are stacked on the film substrate 11, and a liquid post 113 having a considerable height can be obtained.

  Next, main baking is performed on the temporarily dried body 112 of the liquid pattern and the liquid post 113 (step 13). Through the above-described steps, since the temporary dried body 112 and the liquid post 113 are both formed in a temporarily dried state, these are entirely fired collectively. Specifically, the film substrate 11 on which the temporarily dried body 112 and the liquid post 113 are formed is heated with a hot plate at 150 ° C. for about 30 minutes.

  Although the main calcination is usually performed in the air, it can also be performed in an inert gas atmosphere such as nitrogen, argon, or helium as necessary. In addition, although the processing temperature of this baking was 150 degreeC, the boiling point (vapor pressure) of the dispersion medium contained in the provisional dry body 112 and the liquid post 113, the kind and pressure of atmospheric gas, dispersibility, oxidation nature, etc. of fine particles It is desirable to set appropriately considering the thermal behavior, the presence / absence and amount of the coating material, the heat-resistant temperature of the substrate, and the like.

  Such a baking process can be performed by lamp annealing in addition to a process using a normal hot plate, an electric furnace, or the like. The light source used for lamp annealing is not particularly limited, but excimer laser such as infrared lamp, xenon lamp, YAG laser, argon laser, carbon dioxide laser, XeF, XeCl, XeBr, KrF, KrCl, ArF, ArCl, etc. Can be used as a light source. These light sources generally have a power output in the range of 10 W or more and 5000 W or less, but in this embodiment, a range of 100 W or more and 1000 W or less is sufficient.

  By such main firing, the dispersion medium contained in the temporarily dried body 112 and the liquid post 113 is volatilized, and electrical contact between the metal fine particles is ensured. As a result, as shown in FIG. 5A, the wiring pattern 116 and the conductor post 117 are formed on the base insulating film 110.

<Second surface treatment step>
Next, as a premise for forming the in-layer insulating film 114 (see FIG. 5B) in the formation layer of the wiring pattern 116, the contact angle of the surface of the base insulating film 110 is adjusted (step 13). As described above, the surface of the hardened base insulating film 110 exhibits liquid repellency and is suitable for forming a wiring pattern although it has been made lyophilic to some extent in the first surface treatment step. The surface characteristics suitable for forming the in-layer insulating film are different from each other. Specifically, the liquid material for forming the in-layer insulating film 114 flows well over the base insulating film 110. Therefore, in order to increase the affinity between the liquid material and the surface of the base insulating film 110, excimer UV with a wavelength of 172 nm is irradiated for about 60 seconds for the purpose of imparting more lyophilicity to the base insulating film 110. To do.

<Insulating film formation process>
Subsequently, as shown in FIG. 5B, an in-layer insulating film 114 is drawn and formed around the wiring pattern 116 (step 15). The formation of the in-layer insulating film 114, which is an insulating film forming step according to the present invention, is also performed by a droplet discharge method, similarly to the drawing of the base insulating film 110. Here, when the liquid resin material, which is the material for forming the in-layer insulating film, is discharged so as to come into contact with the conductor post 117, the resin material wets the upper end of the conductor post 117, and at the connection portion with the upper wiring pattern. There is a risk of poor conduction. Therefore, a gap is formed around the conductor post 117 and the wiring pattern 116, and the resin material is discharged to the outside.

Next, an excimer UV having a wavelength of 172 nm is applied to the gap between the conductor post 116 and the wiring pattern 117 to perform lyophilic treatment (step 16). As a result, lyophilicity is imparted to the gap around the conductor post 117 and the wiring pattern 116, and as a result, the resin material flows into the gap and comes into contact with the wiring pattern 116. In this case, the resin material may partially wet on the surface of the wiring pattern 116, but does not reach the upper end of the conductor post 117 protruding on the wiring pattern 116. Therefore, it is possible to ensure electrical continuity between the conductor post 117 and the upper wiring pattern formed in the subsequent process.
Then, the discharged resin material is cured (step 17). Specifically, UV with a wavelength of 365 nm is irradiated for about 4 seconds to cure the UV curable resin that is the material for forming the in-layer insulating film. Thereby, an in-layer insulating film is formed.

<Interlayer insulating film formation process>
Next, as shown in FIG. 5C, an interlayer insulating film 115 is drawn mainly on the surface of the wiring pattern 116 (step 17). This drawing is also performed using a droplet discharge device, similarly to the drawing of the base insulating film 110. Also in this case, it is desirable to discharge the resin material with a gap around the conductor post 117.
Next, the discharged resin material is cured (step 18). Specifically, UV with a wavelength of 365 nm is irradiated for about 60 seconds to cure the UV curable resin that is the material for forming the interlayer insulating film. Thereby, the interlayer insulating film 115 is formed.

Next, as shown in FIG. 5D, an upper wiring pattern 118 is formed on the surface of the interlayer insulating film 115. The specific method is the same as the series of steps 7 to 9 for forming the lower wiring pattern 116.
Next, as shown in FIG. 5E, an in-layer insulating film 119 is formed on the formation layer of the upper wiring pattern 118. The specific method is the same as the series of steps 15 to 17 for forming the in-layer insulating film in the formation layer of the wiring pattern 116. Furthermore, by performing Step 18 and Step 19, an interlayer insulating film 120 can be formed on the surface of the upper wiring pattern 118 as shown in FIG.

Thus, the wiring pattern can be laminated on the film substrate 11 by repeating the series of steps 7 to 19. A protective film may be formed on the surface of the uppermost electrical wiring by the same method as in Step 17 and Step 18.
Through the above steps, a wiring board having a multilayer wiring structure can be manufactured.

  As described above, the method for manufacturing a wiring board according to the present embodiment includes a base formation process (steps 1 to 6) prior to the process of drawing and forming the liquid material pattern 111 by the droplet discharge method (step 7). is doing. That is, it has a step of forming the base insulating film 110 on the surface of the film substrate 11 in the region where the wiring pattern 116 and the in-layer insulating film 114 are formed, and prior to forming the base insulating film 110, A frame-like insulating film 110a that partitions the formation region is formed. Thus, by forming the base insulating film 110 in a predetermined region on the surface of the film substrate 11, the influence of the surface state of the film substrate 11 on the wiring pattern 116 and the in-layer insulating film 114 can be eliminated, and the film A fine wiring pattern can be stably formed regardless of the material of the substrate 11 or the like. Further, when the base insulating film 110 is formed by the droplet discharge method, the frame-like insulating film 110a formed on the film substrate 11 is used, so that a predetermined amount of resin material is discharged and arranged on the film substrate 11 in a predetermined region. As a result, the base insulating film 110 having a uniform film thickness, excellent electrical reliability, and excellent reproducibility of the film thickness can be formed.

  Furthermore, when the resin material for forming the base insulating film 110 is discharged and disposed on the film substrate 11, the resin material is disposed at a distance from the frame-shaped insulating film 110a, and the substrate surface is formed by a subsequent lyophilic process (step 5). Is made lyophilic to allow the resin material 110s to flow and fill the film formation region 11a surrounded by the frame-like insulating film 110a with the resin material 110s. The base insulating film 110 having a uniform thickness can be formed in the film formation region 11a.

  In the present embodiment, as shown in FIG. 4B, the film thickness of the base insulating film 110 and the film thickness of the frame-shaped insulating film 110a have been described as being substantially the same. The thickness of the film 110a can be made thin as long as the resin material 110s can be prevented from overflowing to the outside of the frame-like insulating film 110a, or may be formed thicker than the base insulating film 110. In particular, if the frame-shaped insulating film 110a is formed sufficiently thicker than the base insulating film 110, the in-layer insulating film 114 disposed on the base insulating film 110 is formed in a later step. It is possible to effectively prevent the resin material from overflowing to the outside.

Furthermore, in the above-described embodiment, the case where only one frame-like insulating film 110a having a rectangular frame shape in plan view is provided on the film substrate 11 has been described. However, the frame-like insulating film has a form as shown in FIG. Can be applied. FIG. 7 is a plan view showing a modification of the frame-like insulating film according to the present invention.
As shown in FIG. 7, in the configuration according to the modification, a frame-shaped insulating film 110a having a rectangular frame shape in plan view is formed on the film substrate 11, and two frames are further formed inside the frame-shaped insulating film 110a. Insulating films 110b and 110c are formed. Since the frame-like insulating film is formed using the droplet discharge method as described above (step 2), it can be formed in any shape and number. Then, when formed in the arrangement as shown in FIG. 7, a region inside the frame-like insulating film 110 a and outside the frame-like insulating films 110 b and 110 c is used as a film-forming region 11 a of the base insulating film 110. A wiring board can be manufactured on the assumption that a base insulating film is not provided in a region inside the frame-shaped insulating films 110b and 110c. The region inside the frame-shaped insulating films 110b and 110c can be used as a mounting region for an IC chip, a capacitor or the like, for example.

  In addition, after temporarily drying the liquid pattern 111 formed on the film substrate 11, a step of drawing and forming a liquid post on a part of the temporary dry body 112 by a droplet discharge method (steps 10 to 12); A step (step 13) of firing the liquid pattern temporary dried body 112 and the liquid post 113 is performed. That is, since the liquid post 113 is drawn and formed on the surface of the liquid pattern 111 in the temporarily dried state, both can be fused at the interface. Then, the wiring pattern 116 and the conductor post 117 can be integrally formed by collectively firing the temporarily dried body 112 and the liquid post of the liquid pattern. As a result, the occurrence of cracks at the interface between the wiring pattern 116 and the conductor post 117 can be prevented, and a wiring substrate having the wiring pattern 116 having excellent conductive connection reliability can be obtained.

  Further, in the method for manufacturing a wiring board according to the present embodiment, since the droplet discharge method is adopted for forming the wiring pattern, the conductor post, and various insulating films, it is possible to improve the material use efficiency and the manufacturing cost. Can be reduced. Further, the wiring pattern can be multilayered and miniaturized. For example, the line × space width of a plurality of wiring patterns can be reduced from the conventional 50 μm × 50 μm to about 30 μm × 30 μm. As a result, the wiring board can be miniaturized and highly integrated, which contributes to the miniaturization of electronic equipment that employs the wiring board.

  In the present embodiment, the method for manufacturing a wiring board having a multilayer wiring structure has been described as an example. However, the present invention can also be applied as a method for forming a wiring pattern (circuit wiring) on a hard board. In the present embodiment, the case where the conductor post is formed on the wiring pattern has been described. However, the case where the conductor post is formed on the electrode land of the wiring pattern is also included in the technical scope of the present invention.

  In the above embodiment, the wiring pattern 116 and the in-layer insulating film 114 are formed in the same layer on the base insulating film 110. However, depending on the thickness of the wiring pattern 116, the wiring pattern 116 may be covered. An in-layer insulating film 114 can also be formed. In this case, since the in-layer insulating film 114 also serves as the interlayer insulating film 115, the step of forming the interlayer insulating film 115 can be omitted, and the cost can be reduced by reducing the number of steps.

  In the above embodiment, the wiring board to be manufactured has a two-layer structure having the lower layer side wiring pattern 116, the upper layer side wiring pattern 118, and the conductor posts 117 that conduct between these wirings on the substrate 11. However, the present invention is not limited to this, and can be applied to the production of a wiring board having a three-layer structure or a multilayer wiring structure having a structure of four layers or more. In addition, the wiring board obtained by such a method of manufacturing a wiring board is used in various electronic devices configured to include, for example, a semiconductor element. Various electronic devices including such a multilayer wiring substrate are used. Are all electronic devices of the present invention.

(Electro-optical device)
In the said embodiment, the wiring board provided with the laminated wiring pattern was illustrated and demonstrated. Therefore, with reference to FIG. 8, a liquid crystal module which is an example of an electro-optical device in which the wiring board of the above embodiment is employed will be described.

  FIG. 8 is an exploded perspective view of a liquid crystal module including a circuit board having a COF (Chip On Film) structure. The liquid crystal module 901 is roughly configured to include a liquid crystal panel 902 for color display, a circuit board 903 connected to the liquid crystal panel 902, and a liquid crystal driving IC 900 mounted on the circuit board 903. Note that a lighting device such as a backlight and other auxiliary devices are attached to the liquid crystal panel 902 as necessary.

  The liquid crystal panel 902 includes a pair of substrates 905a and 905b bonded by a sealant 904, and liquid crystal is sealed in a so-called cell gap formed between the substrates 905b and 905b. That is, the liquid crystal is sandwiched between the substrate 905a and the substrate 905b. These substrates 905a and 905b are generally formed of a light-transmitting material such as glass or synthetic resin. A polarizing plate 906a is attached to the outer surfaces of the substrate 905a and the substrate 905b.

  An electrode 907a is formed on the inner surface of the substrate 905a, and an electrode 907b is formed on the inner surface of the substrate 905b. These electrodes 907a and 907b are made of a light-transmitting conductive material such as ITO (Indium Tin Oxide). The substrate 905a is disposed so as to partially protrude in the surface direction with respect to the substrate 905b, and has a plurality of terminals 908 formed in the protruding portion. These terminals 908 are formed together with the electrodes 907a when the electrodes 907a are formed on the substrate 905a. Therefore, these terminals 908 are made of, for example, ITO. These terminals 908 include those formed by extending the electrode 907a to the end of the substrate and those connected to the electrode 907b via another conductive material (not shown).

  On the other hand, the circuit board 903 uses the wiring board obtained by the manufacturing method of the previous embodiment, and the liquid crystal driving IC 900 is mounted at a predetermined position on the wiring board 909. Although illustration is omitted, a resistor, a capacitor, and other chip components can be mounted in a portion other than the region where the liquid crystal driving IC 900 is mounted. The wiring substrate 909 is obtained by forming a wiring pattern 912 formed using silver or the like on a flexible film substrate 911 such as polyimide.

  In addition, in the mounting area of the liquid crystal driving IC 900 in which the tips of the wiring patterns 912 and 912 extending from the ends of both short sides of the substrate are arranged, electrode pads (not shown) are formed at the ends of the wiring patterns 912. ing. A plurality of bump electrodes formed on the active surface of the liquid crystal driving IC 900 are electrically connected to the plurality of electrode pads via an unillustrated ACF (Anisotropic Conductive Film). ing. The ACF is obtained by dispersing a large number of conductive particles in a thermoplastic or thermosetting adhesive resin. The mounted bump electrodes of the liquid crystal driving IC 900 and the electrode pads of the wiring pattern 912 Both are electrically connected by the conductive particles interposed between them.

  The circuit board 903 on which the liquid crystal driving IC 900 is mounted is connected to the board 905a of the liquid crystal panel 902. Specifically, the wiring pattern 912 of the circuit board 903 is electrically connected to the terminal 908 of the board 905a via an ACF (not shown). Note that since the circuit board 903 has flexibility, it can be folded freely to realize space saving.

  In the liquid crystal module 901 configured as described above, a signal is input to the liquid crystal driving IC 900 via the wiring pattern 912 extending to the outside of the circuit board 903, and the driving signal output from the liquid crystal driving IC 900 is the liquid crystal panel. It is input to the liquid crystal panel 902 via the wiring pattern 912 extending to the side, and display driving of the liquid crystal panel 902 is performed.

  Note that the electro-optical device of the present invention includes a device having an electro-optic effect that changes the light transmittance by changing the refractive index of a substance by an electric field, and a device that converts electric energy into optical energy. ing. That is, the present invention is not limited to the liquid crystal display device described above, but also an organic EL (Electro-Luminescence) device, an inorganic EL device, a plasma display device, an electrophoretic display device, a display device using an electron-emitting device (Field Emission Display and It can be widely applied to light emitting devices such as Surface-Conduction Electron-Emitter Display. For example, an organic EL module can be configured by connecting a circuit board using the wiring board of the above embodiment to an organic EL panel.

(Electronics)
Next, an electronic apparatus manufactured using the film forming method of this embodiment will be described with reference to FIG. FIG. 9 is a perspective view of the mobile phone. In FIG. 9, reference numeral 1000 denotes a mobile phone, and reference numeral 1001 denotes a display unit. The display unit 1001 of the cellular phone 1000 employs an electro-optical device provided with the wiring board of the previous embodiment. Therefore, it is possible to provide a small mobile phone 1000 with excellent electrical connection reliability.
The present invention is not limited to the above mobile phone, but is an electronic book, personal computer, digital still camera, liquid crystal television, viewfinder type or monitor direct-view type video tape recorder, car navigation device, pager, electronic notebook, calculator, word processor, work It can be suitably used as an image display means for electronic devices such as stations, videophones, POS terminals, touch panels, etc. In any case, a small electronic device with excellent electrical connection reliability can be provided.

  The technical scope of the present invention is not limited to the above-described embodiments, and includes various modifications made to the above-described embodiments without departing from the spirit of the present invention. That is, the specific materials and configurations described in the embodiments are merely examples, and can be changed as appropriate.

The perspective view of a droplet discharge device. (A) is a disassembled perspective view of a discharge head, (b) is a side cross-sectional block diagram. FIG. 3 is a plan configuration diagram of an ejection head. Sectional process drawing of the manufacturing method of the wiring board which concerns on embodiment. Sectional process drawing of the manufacturing method of the wiring board which concerns on embodiment. FIG. 6 is a plan process diagram showing a foundation forming process according to the embodiment. The plane block diagram which shows the modification of a frame-shaped insulating film. 1 is a diagram illustrating an example of an electro-optical device that includes a wiring board according to an embodiment. FIG. FIG. 11 is a perspective configuration diagram illustrating an example of an electronic device.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Board | substrate (film substrate, base | substrate), 11a ... Film-forming area | region, 110 ... Base insulating film, 110a-110c ... Frame-shaped insulating film, 110s ... Resin material (1st liquid material), 111 ... Liquid body pattern, 112 ... Temporarily dried body, 113, 119... Insulating film within layer, 115, 120... Interlayer insulating film, 116, 119.

Claims (6)

A frame-shaped insulating film step of forming a frame-shaped insulating film by arranging the first liquid material on the substrate in a frame shape in plan view;
A liquid material disposing step of disposing a second liquid material for forming an insulating film in a region on the substrate surrounded by the frame-shaped insulating film with a gap from the frame-shaped insulating film;
A lyophilic treatment step of causing the second liquid material to flow on the substrate by lyophilic treatment of a surface region on the substrate and filling a region surrounded by the frame-like insulating film with the second liquid material; ,
A curing step of curing the second liquid material to form a base insulating film;
And a wiring forming step of forming a wiring pattern by arranging a wiring forming material on the base insulating film.   The method for manufacturing a wiring board according to claim 1, wherein the lyophilic treatment step is a step of irradiating the second liquid material disposed on the substrate with ultraviolet rays.   The method for manufacturing a wiring board according to claim 1, wherein the frame-shaped insulating film is formed to have a film thickness equal to or greater than a film thickness of the base insulating film. In the frame-shaped insulating film forming step, in the region surrounded by the frame-shaped insulating film, another frame-shaped insulating film that is planarly separated from the frame-shaped insulating film is formed,
4. The wiring board manufacturing method according to claim 1, wherein, in the liquid material arranging step, the second liquid material is arranged in a region between the plurality of frame-like insulating films. 5. Method.   5. The multilayer wiring structure is formed on the substrate by repeatedly performing the wiring forming step and an interlayer insulating film forming step of forming an interlayer insulating film covering the wiring pattern. The manufacturing method of the wiring board of any one of Claims 1.   An electronic apparatus comprising the wiring board obtained by the manufacturing method according to claim 1.

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