JP4592762B2 - 半田ボール搭載方法及び半田ボール搭載装置 - Google Patents
半田ボール搭載方法及び半田ボール搭載装置 Download PDFInfo
- Publication number
- JP4592762B2 JP4592762B2 JP2007556015A JP2007556015A JP4592762B2 JP 4592762 B2 JP4592762 B2 JP 4592762B2 JP 2007556015 A JP2007556015 A JP 2007556015A JP 2007556015 A JP2007556015 A JP 2007556015A JP 4592762 B2 JP4592762 B2 JP 4592762B2
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- ball
- solder
- wiring board
- printed wiring
- alignment mask
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- 229910000679 solder Inorganic materials 0.000 title claims description 185
- 238000000034 method Methods 0.000 title claims description 26
- 239000004020 conductor Substances 0.000 description 17
- 239000010410 layer Substances 0.000 description 12
- 239000000758 substrate Substances 0.000 description 9
- 238000010586 diagram Methods 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 230000004907 flux Effects 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 238000001514 detection method Methods 0.000 description 4
- 239000011229 interlayer Substances 0.000 description 4
- 238000009413 insulation Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000010949 copper Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000001179 sorption measurement Methods 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 1
- 230000004931 aggregating effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000011889 copper foil Substances 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
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- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/3457—Solder materials or compositions; Methods of application thereof
- H05K3/3478—Applying solder preforms; Transferring prefabricated solder patterns
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/06—Solder feeding devices; Solder melting pans
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- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
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Description
(1)パッケージ基板に形成された電極にフラックスを印刷する工程。
(2)フラックスの印刷された電極に、半田ボールを搭載する工程。
(3)リフローを行い半田ボールから半田バンプを形成する工程。
このため、上述した吸着ヘッドを用いた際には、電極の上方で吸着ヘッドから落下させるように空気を圧送しても、吸着ヘッドに半田ボールが付着し落下せず、半田バンプの未形成という課題が生じていた。
ボール整列用マスクの上方に、該ボール整列用マスクに対向する開口部を備える筒部材を位置させ、該筒部材で空気を吸引することで、当該筒部材直下のボール整列用マスク上に半田ボールを集合させ、
前記ボール整列用マスク及びプリント配線板を水平方向に移動させることで、前記筒部材直下に集合させた半田ボールを、ボール整列用マスクの開口を介してプリント配線板のパッドへ落下させることを技術的特徴とする。
プリント配線板のパッドに対応する複数の開口を備えるボール整列用マスクと、
ボール整列用マスクの上方に位置し、開口部から空気を吸引することで開口部直下に半田ボールを集合させる筒部材と、
前記ボール整列用マスク及びプリント配線板を水平方向に移動させる移動機構であって、該ボール整列用マスク及びプリント配線板を水平方向に移動させることで、前記筒部材直下に集合させた半田ボールを、ボール整列用マスクの開口を介してプリント配線板のパッドへ落下させる移動機構と、を備えることを技術的特徴とする。
図5(A)に示すように表面のソルダーレジスト層70の開口71にパッド75を形成した多層プリント配線板10の表面にフラックス80を印刷する。図5(B)に示すように多層プリント配線板10の上側のパッド75上に後述する半田ボール搭載装置を用いて微少な半田ボール78s(例えば日立金属社製、タムラ社製、直径40以上、200μm未満)を搭載する。ファイン化対応のため直径200μm未満の半田ボールが望ましい。直径40μm未満では半田ボールが軽すぎるためパッド上に落下し難くなる。一方、200μm以上になると逆に重すぎるため筒部材内に半田ボールを集合させることができず、半田ボールが載っていないパッドが存在し易くなる。
図1(A)は、本発明の一実施形態に係る半田ボール搭載装置の構成を示す構成図であり、図1(B)は、図1(A)の半田ボール搭載装置を矢印B側から見た矢視図である。
(1)多層プリント配線板の位置認識、補正
図2(A)に示すように多層プリント配線板10のアライメントマーク34Mをアライメントカメラ46により認識し、ボール整列用マスク16に対して多層プリント配線板10の位置をXYθ吸引テーブル14によって補正する。即ち、ボール整列用マスク16の開口16aがそれぞれ多層プリント配線板10のパッド75に対応するように位置調整する。なお、ここでは、図示の便宜上、1枚分の多層プリント配線板10のみを示しているが、実際には、複数枚の多層プリント配線板を構成するワークシートサイズの多層プリント配線板に対して半田ボールが搭載され、半田バンプの形成後に個片の多層プリント配線板に切り分けられる。
図2(B)に示すように半田ボール供給装置22から半田ボール78sを搭載筒24側へ定量供給する。
図3(A)に示すように、ボール整列用マスク16の上方に、該ボール整列用マスクとの所定のクリアランス(例えば、ボール径の100%〜300%)を保ち搭載筒24を位置させ、吸引部24Bから空気を吸引することで、搭載筒とプリント配線板間の隙間の流速を5m/sec〜50m/secにして、当該搭載筒24の開口部24A直下のボール整列用マスク16上に半田ボール78sを集合させた後、図3(B)及び図4(A)、並びに図1(B)及び図1(A)に示すようにプリント配線板10及びボール整列用マスク16を、XYθ吸引テーブル14によりX軸に沿って水平方向へ送る。これにより、搭載筒24直下に集合させた半田ボール78sを、ボール整列用マスク16及びプリント配線板10の移送に伴い移動させ、ボール整列用マスク16の開口16aを介して多層プリント配線板10のパッド75へ落下、搭載させて行く。これにより、半田ボール78sが多層プリント配線板10側の全パッド上に順次整列される。
図4(B)に示すように、プリント配線板10及びボール整列用マスク16を移送することにより、余剰の半田ボール78sをボール整列用マスク16上に開口16aの無い位置まで誘導した後、ボール除去筒61により吸引除去する。
XYθ吸引テーブル14から多層プリント配線板10を取り外す。
[実施例]
(1)プリント配線板の作製
出発材料として両面銅張積層板(例えば、日立化成工業株式会社製 MCL−E−67)を用い、この基板に周知の方法でスルーホール導体及び導体回路を形成した。その後、周知の方法(例えば、2000年6月20日 日刊工業新聞社発行の「ビルドアップ多層プリント配線板」(高木清著)で層間絶縁層と導体回路層とを交互に積層し、最外層の導体回路層において、ICと電気的に接続するための直径150μm、150μmピッチ、50×50個(格子状配置)からなるパッド群を形成した。その上に市販のソルダーレジストを形成し、パッド上に、写真法で直径100μmの開口を形成した。ここで、バイアホールからなる接続パッド(バイアホールの直上に半田バンプを形成)は、フィルドビアとし、表面の凹み量、凸量は、導体回路158の導体厚さに対し、図8(A)に示すように凹み量(上端面からの窪み量)P1が−5μm以下、及び、図8(B)に示すように凸量(上部平坦面からの突出量)P2が+5μm以下の範囲が望ましい。フィルドビアの凹み量が5μmを越える(−5μm)と、半田ボールとフィルドビアからなる接続パッドの接点が少なくなるので、半田バンプとするとき濡れ性が悪くなり、半田内にボイドを巻き込んだり、未搭載(ミッシングバンプ)になりやすい。一方、5μmを越えると導体回路158の厚みが厚くなるので、ファイン化に向かない。
(1)で作製したプリント配線板の表面(IC実装面)に市販のロジン系フラックスを塗布した。その後上述した本願発明の半田ボール搭載装置の吸着テーブルに搭載し、プリント配線板およびボール搭載用マスクのアライメントマークをCCDカメラを用いて認識し、プリント配線板とボール搭載用マスクを位置合わせした。ここで、ボール搭載用マスクは、プリント配線板のパッドに対応した位置に直径110μmの開口を有する25μm〜50μm厚みのNi製のメタルマスクを用いた。その他SUS製やポリイミド製のボール搭載用マスクを用いることも可能である。尚、ボール搭載用マスクに形成する開口径は、使用するボールの径に対して1.1〜1.5倍が好ましい。次に、パッド領域に対応した大きさ(パッド領域に対して1.2〜3倍)で、高さ200mmの搭載筒を半田ボール径の2倍のクリアランスを保ってプリント配線板上に位置させ、その周囲近辺のボール搭載用マスク上にボール直径80μmのSn63Pb37半田ボール(日立金属社製)を載せた。
実施例において、半田ボールをパッドに供給する方法を変更させた以外は実施例と同様である。
つまり、従来技術の方法を用い、スキージを用いて半田ボールを移動させ、ボール搭載用の開口部から半田ボールを落下させてパッドに半田ボールを搭載した。
リフロー後において、ソルダーレジスト上からのバンプ高さをランダムに50個、KEYENCE社製 レーザー顕微鏡VX−8500により測定した。
バンプの平均高さ バンプ高さバラツキ
実施例 35.22μm 1.26
比較例 32.64μm 2.00
この結果から、同じ半田ボールを用いても、本願発明の実施例ではバンプ高さが高く、バンプ高さのバラツキが小さいことが分る。これは、本願発明の実施例では、半田ボールがスキージ等で削られることがないので、初期の半田ボールそのままのボリュームを維持してパッドに搭載されるからである。
不良の個数
実施例 0
比較例 3
この結果より、本願発明では、バンプ高さのバラツキが小さいため、バンプにおける接続信頼性が高いことがわかる。
12 上下移動軸
14 XYθ吸引テーブル
16 ボール整列用マスク
16a 開口
18 残量検出センサ
20 半田ボール搭載装置
22 半田ボール供給装置
24 搭載筒(筒部材)
26 吸引ボックス
44 マスククランプ
46 アライメントカメラ
61 ボール除去筒
66 吸引ボックス
68 吸着ボール除去吸引装置
75 パッド
80 フラックス
Claims (5)
- プリント配線板のパッドに対応する複数の開口を備えるボール整列用マスクを用い、半田バンプとなる半田ボールをプリント配線板のパッドに搭載するための半田ボール搭載方法であって、
ボール整列用マスクの上方に、該ボール整列用マスクに対向する開口部を備える筒部材を位置させ、該筒部材で空気を吸引することで、当該筒部材直下のボール整列用マスク上に半田ボールを集合させ、
前記ボール整列用マスク及びプリント配線板を水平方向に移動させることで、前記筒部材直下に集合させた半田ボールを、ボール整列用マスクの開口を介してプリント配線板のパッドへ落下させることを特徴とする半田ボール搭載方法。 - 半田バンプとなる半田ボールをプリント配線板のパッドに搭載する半田ボール搭載装置であって、
プリント配線板のパッドに対応する複数の開口を備えるボール整列用マスクと、
ボール整列用マスクの上方に位置し、開口部から空気を吸引することで開口部直下に半田ボールを集合させる筒部材と、
前記ボール整列用マスク及びプリント配線板を水平方向に移動させる移動機構であって、該ボール整列用マスク及びプリント配線板を水平方向に移動させることで、前記筒部材直下に集合させた半田ボールを、ボール整列用マスクの開口を介してプリント配線板のパッドへ落下させる移動機構と、を備えることを特徴とする半田ボール搭載装置。 - 前記筒部材をプリント配線板の幅に対応させて複数並べたことを特徴とする請求項2の半田ボール搭載装置。
- 前記ボール整列用マスク上に残った半田ボールを回収するための吸引筒を備えることを特徴とする請求項2又は請求項3の半田ボール搭載装置。
- 前記筒部材の少なくとも半田ボール接触部位を導電性部材により構成したことを特徴とする請求項2〜請求項4のいずれか1の半田ボール搭載装置。
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