JP5124693B1 - 電子機器 - Google Patents

電子機器 Download PDF

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JP5124693B1
JP5124693B1 JP2012098837A JP2012098837A JP5124693B1 JP 5124693 B1 JP5124693 B1 JP 5124693B1 JP 2012098837 A JP2012098837 A JP 2012098837A JP 2012098837 A JP2012098837 A JP 2012098837A JP 5124693 B1 JP5124693 B1 JP 5124693B1
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melting point
point metal
metallized
metal component
synthetic resin
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JP2012098837A
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JP2013229376A (ja
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重信 関根
由莉奈 関根
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有限会社 ナプラ
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Priority to JP2012098837A priority Critical patent/JP5124693B1/ja
Application filed by 有限会社 ナプラ filed Critical 有限会社 ナプラ
Publication of JP5124693B1 publication Critical patent/JP5124693B1/ja
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Priority to US13/859,175 priority patent/US20130277850A1/en
Priority to SG2013026984A priority patent/SG194295A1/en
Priority to EP13275090.2A priority patent/EP2657962A1/en
Priority to KR1020130043756A priority patent/KR101355748B1/ko
Priority to TW102113877A priority patent/TWI529853B/zh
Priority to CN2013101444077A priority patent/CN103378051A/zh
Publication of JP2013229376A publication Critical patent/JP2013229376A/ja
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Abstract

【課題】メタライズ配線に外部導体や電子部品を接続する際、耐酸化性を確保するとともに、両者間の電気的導通を確実に確保し得る電気機器を提供すること。
【解決手段】基板11は、メタライズ配線12を有している。メタライズ配線12は、メタライズ層121と、合成樹脂膜122とを含んでいる。メタライズ層121は、高融点金属成分と低融点金属成分とを含み、高融点金属成分及び低融点金属成分が互いに拡散接合している。合成樹脂膜122は、メタライズ層121の表面を覆い、膜厚が5nm〜1000nmの範囲にある。
【選択図】図2

Description

本発明は、電子機器、即ち、電子工学の技術を応用した電気製品に関する。
電子機器は、周知のように、基板の一面上に、所定のパターンを有する配線パターンを形成し、この配線パターン上に能動部品や受動部品等の電子部品をはんだ付けする。配線パターンは、基板上に予め形成されているCu箔に、エッチング・レジストを塗布した後、Cu箔をフォト・リソグラフィ工程によってパターン化することによって得られる。配線パターンのうち、電子部品をはんだ付けするのに必要な部分だけ、Cu箔が露出し、はんだ付けの不要な部分にはんだが付かないように、基板上に熱硬化性エポキシ樹脂などでなるソルダ・レジスト皮膜を形成する。そして、露出したCu箔に電子部品をはんだ付けする。
このように、従来の電子機器では、銅貼基板の準備、エッチング・レジスト塗布工程、フォト・リソグラフィ工程、ソルダ・レジスト塗布工程及び部品実装工程という多数の工程を経て製造しなければならなかった。このため、コスト低減や、量産性向上に限界があった。
上述した手法とは異なって、基板上に、導電ペーストを直接にスクリーン印刷する手法がとられることもある。このときに用いられる導電性ペーストは、導電成分となる金属粉末又は合金粉末を、有機ビヒクル中に分散させたものである。有機ビヒクルは、熱硬化性樹脂、又は、熱可塑性樹脂などの樹脂及び溶剤を含んでいる。場合によっては、金属粉末の分散性向上、或いは、難燃性確保のために、第3成分が添加されることもある。
こうして得られた配線パターンは、樹脂中に金属粉末が分散した構成になる。このため、金属導体そのものによる場合と比較して、導電性が悪くなる。
そこで、導電性を向上させるために、粒径の小さい金属粉末を用いて、充てん率を増加させることが考えられる。しかし、金属粉末は、粒径の小さいほど凝集しやすいため、導電性ペースト中に均一に分散させるのが難しい。また、隣り合う金属粒子間の接触部分が増加して、接続抵抗が増加する分、充てん率の増加に見合う導電性向上の効果が得られない。
上記金属粉末として、銀粉またはCu粉を用いると、導電性の良好な配線が得られることが知られている。しかし、銀粉を含有する導電性ペーストは、高温多湿の雰囲気下で電界が印加されると、電気回路や電極にマイグレーションと称する銀の電析を生じ、配線パターンによって形成される電極間または配線間に短絡現象が発生するという欠点が生じる。このマイグレーションを防止するための対策手段として、例えば、銀粉の表面に防湿塗料を塗布することや、導電性ペーストに窒素化合物などの腐食抑制剤を添加する等の手法が知られているが、十分な効果の得られるものではなかった(特許文献1参照)。また、導電性の高い導体を得るには銀粉の配合量を増加しなければならず、銀粉が高価であることから、電子機器が高価になるという欠点があった。
また、Cu粉を含有する導電性ペーストは、加熱硬化後のCuの酸化性が高いため、空気中及びバインダ中に含まれる酸素とCu粉が反応し、その表面に酸化膜を形成し、導電性を著しく低下させる。その対策として、特許文献2には、各種添加剤を加えて、Cu粉の酸化を防止し、導電性を安定させたCuペーストが開示されている。しかし、その導電
性が銀ペーストには及ばず、また保存・安定性にも欠点があった。
マイグレーションを改善し、安価な導電性ペーストを得るために、銀メッキCu粉を使用した導電性ペーストが提案されている(特許文献3、特許文献4参照)。しかし、銀を均一に、かつ、厚く被膜すると、マイグレーションの改善効果が十分に得られない場合がある。逆に、薄く被膜すると、良好な導電性確保のために導電粉の充てん量を増加させる必要があり、その結果、相対的なバインダ成分の減少に伴う接着力(接着強度)の低下が起こるという問題が生じる場合があった。
更に、屋外で使用される電子機器、例えば、太陽電池では、長期間にわたって、過酷な環境変動に耐え得る耐久性が要求される。特に、太陽電池が、日照時間の長い砂漠等に設置された場合には、設置場所の温度変動幅が100℃を超えることがある。ところが、上述した技術によって電極を形成した従来の太陽電池は、このような厳しい自然環境におかれた場合、数年程度で電極が酸化によって劣化してしまうという問題があった。
上述した問題点を解決する手段として、特許文献5は、高融点金属成分及び低融点金属成分を、互いに拡散接合させてメタライズ層を形成するとともに、このメタライズ層を合成樹脂膜の表面を、合成樹脂膜によって覆う技術を開示している。
この技術によれば、導電性、電気化学的安定性、耐酸化性、充填性、緻密性、機械的・物理的強度に優れ、しかも基板に対する接着力・密着力の高い高品質・高信頼度のメタライズ配線を有する電子機器を実現することができる。
ただ、メタライズ層を絶縁層によって覆う構造であるので、上述した優れた効果が得られる半面、メタライズ配線上に電子部品の端子電極を接続する場合、または、他の外部導体を接続する場合、接続作業の巧拙によっては、絶縁層が、メタライズ層と端子電極との間に残り、電気的接続の信頼性を低下させてしまうことがある。
特開2001−189107号公報 特開平5−212579号公報 特開平7−138549号公報 特開平10−134636号公報 特許第4778120号公報
本発明の課題は、耐酸化性に優れた高品質・高信頼度のメタライズ配線を有する電子機器を提供することである。
本発明のもう一つの課題は、耐酸化性を確保しつつ、メタライズ配線に外部導体や、電子部品を接続する際、両者間の電気的導通を、確実に確保することができる電気機器を提供することである。
上述した課題を解決するため、本発明に係る電子機器は、基板を含み、前記基板は、メタライズ配線を有している。前記メタライズ配線は、メタライズ層と、合成樹脂膜とを含んでいる。前記メタライズ層は、高融点金属成分と低融点金属成分とを含み、前記高融点金属成分及び前記低融点金属成分が互いに拡散接合している。前記合成樹脂膜は、前記メ
タライズ層の表面を覆い、膜厚が5nm〜1000nmの範囲にある。
上述のように、高融点金属成分及び低融点金属成分は互いに拡散接合しているので、電気化学的安定性、耐酸化性に優れ、マイグレーションや酸化膜等を生じにくいメタライズ層を有する電子機器を実現することができる。
また、高融点金属成分及び低融点金属成分の拡散接合により、ポアや、断線のほとんどない連続するメタライズ層となるので、メタライズ層の充填度、緻密性が上がり、導電性が高く、機械的・物理的強度の高いメタライズ層を有する電子機器を得ることができる。しかも、高融点金属成分と低融点金属成分とを含んでいるので、その材料選定により、導電性の高いメタライズ層を有する電子機器を得ることができる。
また、合成樹脂膜が、メタライズ層の表面を覆っているから、メタライズ層の外的損傷を回避することができるほか、耐酸化性、耐久性、耐候性が向上する。しかも、基板に対するメタライズ層自体の密着力・接着力の他に、合成樹脂膜による密着力・接着力も発生するので、メタライズ配線の全体としての密着力・接着力が向上する。
上述した作用効果の総合として、導電性、電気化学的安定性、耐酸化性、充填性、緻密性、機械的・物理的強度に優れ、しかも基板に対する接着力・密着力の高い高品質・高信頼度のメタライズ配線を有する電子機器が得られる。
更に、合成樹脂膜は、メタライズ層の表面を、5nm〜1000nmの範囲の膜厚で覆っている。5nm〜1000nmの範囲にある膜厚の合成樹脂膜であれば、メタライズ配線に外部導体や、電子部品を接続する際の熱処理により、合成樹脂膜が軟化もしくは流動化して接続領域の外側に流れ出し、または、融解して焼失する。このため、メタライズ層と、外部導体や、電子部品との間には、合成樹脂膜がなくなり、メタライズ層に対して、外部導体や、電子部品が直接に接続されることになる。仮に、合成樹脂膜がメタライズ層と、外部導体又は電子部品の端子電極との間に残存したとしても、5nm〜1000nmの範囲にある膜厚の合成樹脂膜であれば、トンネル効果等を期待することもできるから、両者間の電気的導通を確保することができる。接続部分の外側は、合成樹脂膜によって覆われているから、合成樹脂膜による酸化防止機能が損なわれることがない。即ち、本発明によれば、メタライズ層に対する外部導体及び電子部品の電気的接続の信頼性が高く、しかも、メタライズ層に対する酸化防止機能を有するメタライズ配線を実現することができる。
合成樹脂膜が5nmよりも薄くなると、酸化防止機能が低くなり、1000nmを超過すると、絶縁膜としての性質が強く現れるようになる。こうした酸化防止機能及び導電性確保の観点からみて、合成樹脂膜の好ましい膜厚の範囲は、5nm〜500nmの範囲である。
合成樹脂膜は、メタライズ層の表面の全体に拡がっていて、その表面の全体を連続して完全に覆うのが理想であるが、合成樹脂膜の膜面内に、メタライズ層の露出する露出部分を含んでいてもよい。もっとも、露出部分の面積は、酸化防止機能を損なわない範囲に設定する。
好ましくは、合成樹脂膜は、メタライズ層と同時に形成する。この場合には、メタライズ層と樹脂層とを異時に形成したものと異なって、メタライズ層が空気に触れることがない。よって、酸化を受けない高品質のメタライズ層を有する電子機器を得ることができる。
メタライズ配線は、Cu膜(Cu箔)等の金属または合金膜の上に形成されていてもよい。高融点金属成分及び低融点金属成分でなるメタライズ配線を、Cu膜の上に形成すれば、Cu箔の厚みは変えないままで、メタライズ配線全体としての断面積を増大させ、電気抵抗を低減することができる。また、Cu箔を薄くしたままで、メタライズ配線全体としての断面積を増大させ、電気抵抗を低減することができる。
本発明において、電子機器には、電子工学の技術を応用した電気製品の全てを含むことができる。本発明では、それらのうち、コンピュータ、携帯電話機、積層電子装置、電子機器、電子部品、太陽電池、発光ダイオード、発光装置、照明装置、信号灯及び液晶ディスプレイについて開示する。これらは、具体的な名称によって特定されているが、電子工学の技術を応用した電気製品であるという点で、本発明にいう電子機器のカテゴリに含まれる。
上述したように、本発明によれば、次のような効果を得ることができる。
(a)耐酸化性、導電性、電気化学的安定性、充填性、緻密性、機械的・物理的強度に優れ、しかも基板に対する接着力・密着力の高い高品質・高信頼度のメタライズ配線を有する電子機器を提供することができる。
(b)メタライズ配線に外部導体や電子部品を接続する際、耐酸化性を確保しつつ、両者間の電気的導通を確実に確保し得る電気機器を提供することができる。
本発明の他の目的、構成及び利点については、添付図面を参照し、更に詳しく説明する。添付図面は、単なる例示に過ぎない。
本発明に係る電子機器の一例を示す図である。 図1に示した電子機器に用いられているメタライズ配線の一部を示す断面図である。 図1に示した電子機器に用いられているメタライズ配線の別の位置における断面図である。 メタライズ配線形成用導電ペーストを示す図である。 図4に示した導電ペーストの塗布状態を示す図である。 本発明に係る電子機器に用いられるメタライズ配線の別の例を示す断面図である。 本発明に係る電子機器の一例たる積層電子装置を示す図である。 本発明に係る電子機器の他の例である太陽電池の平面図である。 図8に示した太陽電池の底面図(光入射側とは反対側)である。 本発明に係る電子機器の他の例である発光ダイオードの断面図である。 図10に示した発光ダイオードを用いた発光装置、照明装置又は信号灯を示す図である。 図11に示した発光ダイオードをバックライトして用いた液晶ディスプレイの部分断面図である。
図1を参照すると、本発明に係る電子機器は、基板11と、電子部品141〜146とを含む。これらは、一般に、外装体2の内部に配置される。基板11は、所定のパターンを有するメタライズ配線12を有している。基板11は、有機基板であってもよいし、無機基板であってもよい。また、半導体回路を構成し得る基板、例えばSi基板であってもよいし、単なる絶縁基板であってもよい。
電子部品141〜146は、基板11上でメタライズ配線12に電気的に接続されている。図1には、電子部品141〜146を、群として表示する参照符号14が付されている。電子部品141〜146のそれぞれは、能動部品、受動部品又はそれらの複合部品であり、その個数、種類、形状等は電子機器の機能、設計に応じて変化する。電子部品141〜146は、電子システム内で電子の振る舞いやそれに関わる力場に決まった形で影響を与え、システムが意図した機能を果たすようにするものである。電子部品141〜146は、メタライズ配線12で相互に接続され、特定の機能を持った電子回路を構成する。電子部品141〜146は個別にパッケージングされる場合と、集積回路の形で複合的にパッケージングされ、モジュール化される場合がある。
更に、本発明の電子機器に含まれるものとしては、基板11と電子部品141〜146との明確な区分をもたず、基板11が電子部品141〜146としての機能を担う電子機器、例えば太陽電池等もある。
メタライズ配線12は、図2及び図3に図示されているように、メタライズ層121と、合成樹脂膜122とを含んでいる。メタライズ層121は、低融点金属成分123と、高融点金属成分124とを含み、高融点金属成分124及び低融点金属成分123は互いに拡散接合し、充填密度の高い一連の連続する金属層を構成している。高融点金属成分124は、Ag、Cu、Au、Pt、Ti、Zn、Al、Fe、Si、または、Niの群から選択された少なくても1種を含むことができ、低融点金属成分123は、Sn、In、BiまたはGaの群から選択された少なくても1種を含むことができる。
合成樹脂膜122は、メタライズ層121の表面を、5nm〜1000nmの範囲の膜厚で覆っている。合成樹脂膜122が、5nmよりも薄くなると、酸化防止機能が低くなり、1000nmを超過すると、絶縁膜としての性質が強く現れるようになる。酸化防止機能及び導電性確保の観点から、合成樹脂膜122の好ましい膜厚の範囲は、5nm〜500nmの範囲である。
合成樹脂膜122は、メタライズ層121の表面のみならず、線幅方向の両側面及び長さ方向の端面を連続して覆っていてもよい。電子部品141〜146は、図3に図示するように、その端子電極13が、合成樹脂膜122を突き抜け、その下側のメタライズ層121に食い込むようにして、接続されている。
合成樹脂膜122を構成する樹脂は、熱硬化性樹脂、または、熱可塑製樹脂を含むもので構成することができる。熱硬化性樹脂を使用する場合、その硬化点は、低融点金属成分123の融点より高く、高融点金属成分124の融点より低いものが好ましい。
好ましくは、樹脂は、エポキシ樹脂、アクリレート樹脂又はフェノール樹脂から選択された少なくとも1種を含む。ペースト化のための溶剤としては、ブチルカルビトール、ブチルカルビトールアセテート、ブチルセロソルブ、メチルイソブチルケトン、トルエン、または、キシレンのような公知の有機溶媒を使用することができる。
合成樹脂膜122は、メタライズ層121の表面の全体に拡がっていて、その表面の全体を連続して完全に覆っているのが理想であるが、その一部に、メタライズ層121の露出する露出部分B1、B2を含んでいてもよい。メタライズ層121は、高融点金属成分124と低融点金属成分123とを含んでいるから、例えば、低融点金属微粒子123を溶解させて、高融点金属微粒子124と拡散接合させた場合、高融点金属微粒子124は溶けずに、微粒子状態を保っていることがある。このような場合には、メタライズ層121の表面は、高融点金属微粒子124の突出する凸部と、低融点金属微粒子123の溶解した凹部とが入り組んだ複雑な凹凸面となる可能性がある。この結果、合成樹脂膜122は、メタライズ層121の表面を、完璧に覆う構造をとらず、特に、高融点金属微粒子124の突出する凸部分に、メタライズ層121の露出する露出部分B1,B2が発生しがちである。露出部分B1,B2の面積は、酸化防止機能を損なわない範囲に設定する。そのような設定は、合成樹脂と、低融点金属成分123及び高融点金属成分124との組成比率を調整する等によって可能である。
上述したように、メタライズ層121は、高融点金属成分124と低融点金属成分123とを含んでいて、高融点金属成分124及び低融点金属成分123が互いに拡散接合しているので、以下に述べるような作用効果が得られる。
まず、高融点金属成分124及び低融点金属成分123が互いに拡散接合しているので、電気化学的安定性、耐酸化性に優れたメタライズ層121を有する電子機器を実現することができる。
例えば、融点金属成分としてAgを使用した場合、メタライズ層121では、Agと低融点金属成分123との間で拡散接合が生じることにより、その電気化学的安定性が増し、Agのマイグレーションが確実に防止される。高融点金属成分124としてCuを使用した場合にも、Cuと低融点金属成分123との間に拡散接合が生じ、Cuの酸化が防止される。
次に、高融点金属成分124及び低融点金属成分123の拡散接合により、ポアや、断線のない連続するメタライズ層121となるので、メタライズ層121の充填度、緻密性が上がり、導電性が高くなるとともに、機械的・物理的強度が増す。しかも、高融点金属成分124と低融点金属成分123とを含んでいるので、その材料選定により、導電性の高いメタライズ層121を有する電子機器を得ることができる。
本発明においては、更に、合成樹脂膜122が、メタライズ層121の表面を覆っているから、メタライズ層121の外的損傷を回避することができるほか、耐酸化性が向上する。更に、耐久性、耐候性も向上する。しかも、基板に対するメタライズ層121自体の密着力・接着力の他に、合成樹脂膜122による密着力・接着力も発生するので、メタライズ配線12の全体としての密着力・接着力が向上する。
合成樹脂膜122は、メタライズ層121の表面を、5nm〜1000nmの範囲の膜厚で覆っている。5nm〜1000nmの範囲にある膜厚の合成樹脂膜122であれば、メタライズ配線12に、電子部品141〜146の端子電極13を接続する際の熱処理により、合成樹脂膜122が、軟化もしくは流動化して接続領域の外側に流れ出し、または、融解して焼失する。このため、メタライズ層121と、電子部品141〜146の端子電極13との間には、合成樹脂膜がなくなり、メタライズ層121に対して、電子部品141〜146の端子電極13が直接に接続されることになる。仮に、合成樹脂膜122が、メタライズ層121と、電子部品141〜146の端子電極13との間に残存したとしても、5nm〜1000nmの範囲にある膜厚の合成樹脂膜122であれば、トンネル効果等を期待することもできるから、両者間の電気的導通を確保することができる。接続部分の外側は、合成樹脂膜122によって覆われているから、合成樹脂膜122による酸化防止機能が損なわれることがない。即ち、本発明によれば、メタライズ層121に対する電子部品141〜146の端子電極13の電気的接続の信頼性が高く、しかも、メタライズ層121に対する酸化防止機能を有するメタライズ配線12を実現することができる。
また、上記膜厚であれば、合成樹脂膜122を、化学的、または、機械的に部分的に除去し、メタライズ層121に対し、外部導体又は電子部品141〜146の端子電極13を直接に接合することも容易である。
好ましくは、合成樹脂膜122は、メタライズ層121と同時に形成する。この場合には、メタライズ層121と樹脂層とを異時に形成したものと異なって、メタライズ層121が空気に触れることがない。よって、酸化を受けない高品質のメタライズ層121を有する電子機器を得ることができる。
メタライズ層121及び合成樹脂膜122は、樹脂と、金属成分と、溶剤とを含む導電ペーストを用いて、同時に形成することができる。
メタライズ層121及び合成樹脂膜122は、図4に示すように、金属微粒子たる高融点金属成分124及び金属微粒子たる低融点金属成分123よりなる金属成分と、樹脂122とを含む導電ペーストを、スクリーン印刷、グラビア印刷技術等を用いて、図5に図示するように、所定のパターンとなるように、基板11に塗布し、熱処理し、拡散接合を生じさせることによって得られる。したがって、従来必須であった銅貼基板の準備、エッチング・レジスト塗布工程及びフォト・リソグラフィ工程が不要になり、著しいコスト低減及び量産性向上の効果が得られる。金属微粒子は、球状であってもよいし、扁平状であってもよい。ナノコンポジット構造のものが特に好ましい。ナノコンポジット構造とは、母材に結晶または非結晶のナノ粒子を混合または生成させた構造をいう。
拡散接合を生じさせる手法には、2つの手法が含まれる。一つは、低融点金属材料の持つ低融点を利用する方法であり、もう一つは、ナノサイズ効果、特に、量子サイズ効果を利用する方法である。前者の場合は、低融点金属成分123を、材料の持つ低い融点で溶解させ、高融点金属成分124と拡散接合させる。後者の場合は、高融点金属材料として、粒径又は厚みが、例えば、100nm以下に微小化された高融点金属微粒子124を用い、ナノサイズ効果を利用して、高融点金属材料自体が持つ融点(初期融点)よりも、低い温度で溶解させ、拡散接合を生じさせる。
上記2つの手法のうち、低融点金属材料の持つ低融点を利用する場合は、熱処理にあたって、低融点金属成分123の融点より高く、高融点金属成分124の融点より低い温度、例えば100〜300℃で加熱することが望ましい。この熱処理により、低融点金属成分123が溶解し、高融点金属成分124及び低融点金属成分123が凝集し、高融点金属成分124の相互間が、溶解した低融点金属成分123によって埋めた充てん構造が得られるとともに、低融点金属成分123と高融点金属成分124との間に拡散接合(金属間結合)が生じる。この拡散接合により、樹脂を含有しないメタライズ層121が形成される。メタライズ層121は、その比重差によって樹脂層122よりも下側に沈降する。これによって、基板11に付着したメタライズ層121の表面(表面及び側面)を、合成樹脂膜122で覆ったメタライズ配線12が形成される。合成樹脂膜122は、メタライズ層121の表面(表面、側面)を覆う合成樹脂膜122を構成するから、合成樹脂膜122を塗布するための別工程が不要である。
また、高融点金属成分124としてAgを使用した場合も、メタライズ層121では、Agと低融点金属成分123との間で、拡散接合が生じ、更に、導電性組成物全体では、メタライズ層121を合成樹脂膜122が被覆する。この構成により、Agのマイグレーションを確実に防止することができる。同様に、高融点金属成分124として、Cuを使用した場合にも、Cuと低融点金属成分123との間に拡散接合が生じ、更にメタライズ層121が合成樹脂膜122によって被覆されるから、Cuの酸化が防止される。
低融点金属微粒子123及び高融点金属微粒子124は、球状であってもよいし、扁平状であってもよい。扁平状である場合には、一例であるが、最大厚みが50nm以下で、最大差し渡し径が厚みの2倍以上であるようなものが適している。
導電ペーストの別の例としては、高融点金属微粒子124の表面を、低融点金属膜123で覆った金属微粒子を用いたものであってもよいし、あるいはこれとは逆に、低融点金属微粒子123の表面を高融点金属膜で覆った金属微粒子を用いたものであってもよい。
高融点金属成分124及び低融点金属成分123でなるメタライズ配線12は、図6に例示するように、Cu膜等の金属膜125の上に形成されていてもよい。高融点金属成分124及び低融点金属成分123でなるメタライズ層121を、Cu膜125(Cu箔)の上に形成すれば、Cu膜125の厚みは変えないままで、メタライズ配線12全体としての断面積を増大させ、電気抵抗を低減することができる。或いは、Cu膜125の厚みを薄くしながら、その上に付着される高融点金属成分124及び低融点金属成分123でなるメタライズ層121を、厚く形成することによって、メタライズ配線12の全体としての断面積を増大させ、電気抵抗を低減することができる。
本発明における電子機器には、電子工学の技術を応用した電気製品の全てを含むことができる。代表的に例示すると、例えば、コンピュータ、モバイル情報機器、コンピュータ周辺端末装置、OA機器、通信機器、業務用情報端末・自動認識装置、カーエレクトロニクス機器、産業用機械、エンターテインメント機器、音響機器、映像機器又は家庭用電気機器等である。限定するものではないが、その具体例として、液晶ディスプレイ、パーソナルコンピュータ、カーナビゲーション、携帯電話機、積層電子装置、太陽電池、太陽光発電装置、発光ダイオード、発光装置、照明装置、信号灯、ゲーム機、デジタルカメラ、テレビジョン受像機、DVDプレイヤー、電子手帳、電子辞書、ハードディスクレコーダ、携帯情報端末(PDA)、ビデオカメラ、プリンタ、プラズマディスプレイ、ラジオ等を例示することができる。紙面に限りがあることから、上述した電子機器の一例として、積層電子装置、太陽電池、発光ダイオード、発光装置、照明装置、信号灯、及び、液晶ディスプレイを例にとって説明する。
<積層電子装置>
まず、図7を参照すると、第1のチップ部品14Aと、第2のチップ部品14Bと、第3のチップ部品14Cとを積層した積層電子装置が図示されている。第1のチップ部品14A及び第3のチップ部品14Cは、例えばたコンピュータにおいて、メイン・メモリのチップ及びそれに接続されるロジックICチップ等である。第2のチップ部品14Bは、例えばインターポーザであり、メイン・メモリ・チップを構成する第1のチップ部品14Aと、ロジックICチップを構成する第3のチップ部品14Cとの間にあって、両者間に所定の配線を形成するものである。第2のチップ部品14Bと第3のチップ部品14Cとの間、及び、第2のチップ部品14Bと第1のチップ部品14Aとの間には、所定のパターンを有するメタライズ配線12が形成されている。メタライズ配線12には、第1のチップ部品14Aの端子電極13及び第2のチップ部品14Bの端子電極13が接続されている。第1のチップ部品14Aと第2のチップ部品14Bとの間、及び、第2のチップ部品14Bと第3のチップ部品14Cとの間には、絶縁層132が設けられている。
メタライズ配線12は、本発明に係るものであって、メタライズ層121と、合成樹脂膜122とを含んでいる(図2、図3等参照)。メタライズ層121は、高融点金属成分124と低融点金属成分123とを含み、高融点金属成分124及び低融点金属成分123が互いに拡散接合し、一連の連続するメタライズ層121を形成している。合成樹脂膜122は、メタライズ層121と同時に形成され、メタライズ層121の表面を、5nm〜1000nmの範囲の厚みで覆っている。
これにより、導電性、電気化学的安定性、耐酸化性、充填性、緻密性、機械的・物理的強度に優れ、しかも基板相互間の接着力の高い高品質・高信頼度のメタライズ配線12を
有する積層電子装置が得られる。
合成樹脂膜122は、メタライズ層121の表面を、5nm〜1000nmの範囲の膜厚で覆っているから、メタライズ層121に対する酸化防止膜としての機能を確保しつつ、実質的に導電性を有する膜として機能させることもできる。5nm〜1000nmの範囲にある膜厚の合成樹脂膜122であれば、メタライズ配線12に、第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cを接続する際の熱処理により、合成樹脂膜122が、軟化もしくは流動化して接続領域の外側に流れ出し、または、融解して焼失する。このため、メタライズ層121と、第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cの端子電極との間には、合成樹脂膜がなくなり、メタライズ層121に対して、第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cの端子電極が直接に接続されることになる。仮に、合成樹脂膜122が、メタライズ層121と、第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cの端子電極との間に残存したとしても、5nm〜1000nmの範囲にある膜厚の合成樹脂膜122であれば、トンネル効果等を期待することもできるから、両者間の電気的導通を確保することができる。接続部分の外側は、合成樹脂膜122によって覆われるから、合成樹脂膜122による酸化防止機能が損なわれることがない。即ち、本発明によれば、メタライズ層121に対する第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cの端子電極の電気的接続の信頼性が高く、しかも、メタライズ層121に対する酸化防止機能を有するメタライズ配線12を実現することができる。
また、上記膜厚であれば、合成樹脂膜122を、化学的、または、機械的に部分的に除去し、メタライズ層121に対し、第1のチップ部品14A、第2のチップ部品14B及び第3のチップ部品14Cの端子電極を直接に接合することも容易である。
第2のチップ部品14Bが、インターポーザである場合、いわゆるTSV(Through Silicon Via)技術を適用し、厚み方向に貫通電極を形成したものであることが望ましい。これにより、三次元回路配置構造を実現し、線幅の微細化とは異なる手法で、大容量化、転送速度の高速化、高周波特性の改善などに資することができる。
TSV構造の実現において、中心的な役割を担う縦導体は、流動性導電材充填法によって形成した導体であることが好ましい。流動性導電材充填法によって縦導体(貫通電極)を形成するには、例えば、予め、基板に開けられた微細孔内に流動性導電材を充填し、充填された流動性導電材に、押圧板を用いたプレス、インジェクション射出圧又は転圧を印加したままで、冷却し、硬化させる。この流動性導電材充填法によれば、めっきなどに比較して、極めて短時間に、空洞等のない高品質の縦導体(貫通電極)を形成することができる。したがって、線幅の微細化とは異なる手法で、大容量化、転送速度の高速化、高周波特性の改善などを図った高品質の三次元構造の電子機器が実現される。
別の形態として、メモリや論理IC等の電子部品141〜146そのものに、TSV 技術を適用して、三次元構造を実現してもよい。
<太陽電池>
図8及び図9を参照すると、シリコン基板11の裏面(光入射面とは反対側)のp+半導体層14pおよびn+半導体層14nとの電気的接続を行なうために、シリコン基板11の裏面に形成されたパッシベーション膜126が所望のパターン形状に除去され、パッシベーション膜126が除去された部分に合わせて、p+半導体層14p上にp電極コンタクト15pが形成されるとともに、n+半導体層14n上にn電極コンタクト15pが形成される。また、パッシベーション膜126及びn電極コンタクト15nの上に、メタ
ライズ配線12nが形成されるとともに、パッシベーション膜126及びp電極コンタクト15pの上にメタライズ配線12pが形成される。メタライズ配線12pおよびメタライズ配線12nは、主に太陽電池セルに発生した電流を収集する電極であり、これらは、インター・デジタル電極として形成されている。一枚のシリコン基板11上に、多数の太陽電池セルを配列してゆく場合には、メタライズ配線12pおよびメタライズ配線12nの何れか一方に、太陽電池セル間を接続するバス電極としての役割を担わせることができる。
ここで、図2〜図3に示したように、メタライズ配線12pは、メタライズ層121pと、合成樹脂膜122pとを含んでいる。メタライズ層121pは、高融点金属成分124と低融点金属成分123とを含んでいる。高融点金属成分124及び低融点金属成分123は互いに拡散接合している。合成樹脂膜122pは、メタライズ層121pと同時に形成され、メタライズ層121pの表面を、5nm〜1000nmの範囲の厚みで覆っている。
メタライズ配線12nも同様であって、メタライズ層121nと、合成樹脂膜122nとを含んでいる。メタライズ層121nは、高融点金属成分124と低融点金属成分123とを含んでいる。高融点金属成分124及び低融点金属成分123は互いに拡散接合し、メタライズ層121nを構成している。合成樹脂膜122nは、メタライズ層121nと同時に形成され、メタライズ層121nの表面を、5nm〜1000nmの範囲の膜厚で覆っている。その形成方法については、既に述べたとおりである。
合成樹脂膜122p、122nは、メタライズ配線12p、12nの表面を、5nm〜1000nmの範囲の膜厚で覆っているから、メタライズ層121p、121nに対する酸化防止膜としての機能を確保しつつ、実質的に導電性を有する膜として機能させることもできる。5nm〜1000nmの範囲にある膜厚の合成樹脂膜122p、122nであれば、メタライズ配線12p、12nに、外部導体(図示しない)を接続する際の熱処理により、合成樹脂膜122p、122nが、軟化もしくは流動化して接続領域の外側に流れ出し、または、融解して焼失する。このため、メタライズ層121p、121nと、外部導体との間には、合成樹脂膜がなくなり、メタライズ層121p、121nに対して、外部導体が直接に接続されることになる。仮に、合成樹脂膜122p、122nが、メタライズ層121p、121nと、外部導体との間に残存したとしても、5nm〜1000nmの範囲にある膜厚の合成樹脂膜122p、122nであれば、トンネル効果等を期待することもできるから、両者間の電気的導通を確保することができる。接続部分の外側は、合成樹脂膜122p、122nによって覆われるから、合成樹脂膜122p、122nによる酸化防止機能が損なわれることがない。即ち、本発明によれば、メタライズ層121p、121nに対する外部導体の電気的接続の信頼性が高く、しかも、メタライズ層121p、121nに対する酸化防止機能を有するメタライズ配線12p、12nを実現することができる。
また、上記膜厚であれば、合成樹脂膜122p、122nを、化学的、または、機械的に部分的に除去し、メタライズ層121p、121nに対し、外部導体を直接に接触させることも容易である。
本発明に係るメタライズ配線12は、図示の太陽電池のみならず、他のタイプの太陽電池にも適用することができる。例えば、太陽光入射側にITO等の透明電極を有する太陽電池において、透明電極を形成する場合や、色素増感型太陽電池において、電極を形成する場合等である。
<発光ダイオード>
次に、図10を参照すると、本発明に係る発光ダイオードが図示されている。図10に例示された発光ダイオードは、発光素子140と、nメタライズ配線(第1メタライズ配線)12nと、pメタライズ配線(第2メタライズ配線)12pとを含んでいる。発光素子140は、透明結晶基板161に積層されている。透明結晶基板161は、サファイヤ等で構成されたもので、表面が光出射面であり、発光素子140は透明結晶基板161の光出射面とは反対側の他面に積層されている。
発光素子140は、透明結晶基板161に積層したバッファ層162の上に、n型半導体層14nを形成し、n型半導体層14nの上に、活性層14aを介して、p型半導体層14pを積層した構造になっている。透明結晶基板161の側に位置するn型半導体層14nは、P型半導体層14pと重ならない部分164を有しており、この部分164の段差が金属導電層165によって埋められている。
メタライズ配線12nは、n型半導体層14nに接続され、メタライズ配線12pは、p型半導体層14pに接続されている。メタライズ配線12nは、メタライズ層121nと合成樹脂膜122nとを含み、メタライズ層121nが金属導電層165の表面に接合されている。メタライズ配線12pのメタライズ層121pは、メタライズ配線12nと同じ側の面に設けられ、反射膜163を介して、p型半導体層14pに接続されている。
メタライズ層121n及びメタライズ層121pには、支持基板11及び合成樹脂膜122n、122pを貫通する第1及び第2貫通電極17NT、17PTが接続されている。
メタライズ配線12nは、樹脂と金属成分とを含む同一導電ペーストを用いて同時に形成されたものである。金属成分は、高融点金属成分124と低融点金属成分123とを含み、高融点金属成分124及び低融点金属成分123は互いに拡散接合して、メタライズ層121nを構成している。合成樹脂膜122nは、樹脂からなり、メタライズ層121nの表面を、5nm〜1000nmの範囲の膜厚で覆っている。メタライズ層121nは、n電極コンタクト15nに接続される。
メタライズ配線12pも、樹脂と金属成分とを含む同一導電ペーストを用いて同時に形成されたものである。金属成分は、高融点金属成分124と低融点金属成分123とを含み、高融点金属成分124及び低融点金属成分123は互いに拡散接合して、メタライズ層121pを構成している。合成樹脂膜122pは、メタライズ層121pの表面を、5nm〜1000nmの範囲の膜厚で覆っている。参照符号16は、絶縁層である。
上記構成によれば、導電性、電気化学的安定性、耐酸化性、充填性、緻密性、機械的・物理的強度に優れ、しかも基板に対する接着力・密着力の高い高品質・高信頼度のメタライズ層121p、121nを有する発光ダイオードが得られる。
合成樹脂膜122n、122pは、メタライズ層121n、121pの表面を、5nm〜1000nmの範囲の膜厚で覆っているから、メタライズ層121p、121nに対する酸化防止膜としての機能を確保しつつ、実質的に導電性を有する膜として機能させることもできる。5nm〜1000nmの範囲にある膜厚の合成樹脂膜122p、122nであれば、メタライズ配線12p、12nに、第1及び第2貫通電極17NT、17PTを接続する際の熱処理により、合成樹脂膜122p、122nが、軟化もしくは流動化して接続領域の外側に流れ出し、または、融解して焼失する。このため、メタライズ層121p、121nと、第1及び第2貫通電極17NT、17PTとの間には、合成樹脂膜がなくなり、メタライズ層121p、121nに対して、第1及び第2貫通電極17NT、17PTが直接に接続されることになる。仮に、合成樹脂膜122p、122nが、メタラ
イズ層121p、121nと、第1及び第2貫通電極17NT、17PTとの間に残存したとしても、5nm〜1000nmの範囲にある膜厚の合成樹脂膜122p、122nであれば、トンネル効果等を期待することもできるから、両者間の電気的導通を確保することができる。接続部分の外側は、合成樹脂膜122p、122nによって覆われるから、合成樹脂膜122p、122nによる酸化防止機能が損なわれることがない。即ち、本発明によれば、メタライズ層121p、121nに対する第1及び第2貫通電極17NT、17PTの電気的接続の信頼性が高く、しかも、メタライズ層121p、121nに対する酸化防止機能を有するメタライズ配線12p、12nを実現することができる。
また、上記膜厚であれば、合成樹脂膜122p、122nを、化学的、または、機械的に部分的に除去し、メタライズ層121p、121nに対し、第1及び第2貫通電極17NT、17PTを直接に接触させることも容易である。
なお、本発明に係るメタライズ配線12は、図示の発光ダイオードのみならず、他のタイプの発光ダイオードにも適用することができる。例えば、光出射側にITO等の透明電極を有する発光ダイオード池において、透明電極を形成する場合等である。
<発光装置、照明装置又は信号灯>
図11を参照すると、m個の発光ダイオードLED1〜LEDmを有する発光装置が図示されている。発光ダイオードLED1〜LEDmは、図10に示したものであって、発光素子140と、nメタライズ配線(第1メタライズ配線)12nと、pメタライズ配線(第2メタライズ配線)12pとを含んでいる。発光ダイオードLED1〜LEDmの具体的な構造は、図10を参照して詳説したとおりである。発光ダイオードLED1〜LEDmは、単列、又は、複数列配置してもよい。また、基板は、発光ダイオードLED1〜LEDmにおいて、共通のものであってもよい。更に、R、G、Bの発光ダイオードの配列であってもよいし、単色光の発光ダイオードを配列したものであってもよい。
図11に示した発光装置は、照明装置としても用いることができるし、交通信号の信号灯として用いることもできる。これらの発光装置、照明装置又は信号灯が、高品質で、信頼性が高くなることは、これまでの説明から自明である。
<液晶ディスプレイ>
図12は、液晶ディスプレイを示す図で、液晶パネル8とバックライト9とを組み合わせた構造となっている。バックライト9は、図11に示したm個の発光ダイオードLED1〜LEDmを、行列状に整列したものである。この液晶ディスプレイが、高品質で、信頼度が高いものであることは、これまでの説明から明らかである。
以上、好ましい試料を参照して本発明の内容を具体的に説明したが、本発明の基本的技術思想及び教示に基づいて、当業者であれば、種々の変形態様を採り得ることは自明である。
11 基板
12 メタライズ配線
121 メタライズ層
122 合成樹脂膜
14 電子部品

Claims (4)

  1. 基板と、電子部品とを含む電子機器であって、
    前記基板は、メタライズ配線を有しており、
    前記メタライズ配線は、メタライズ層と、合成樹脂膜とを含んでおり、
    前記メタライズ層は、高融点金属成分と低融点金属成分とを含み、前記高融点金属成分及び前記低融点金属成分が互いに拡散接合し、前記基板の表面に付着しており、
    前記合成樹脂膜は、前記メタライズ層と同時に形成され、前記メタライズ層の表面を覆い、膜厚が5nm〜1000nmの範囲にあり、
    前記電子部品は、前記メタライズ層に電気的に接続されている。
  2. 請求項1に記載された電子機器であって、前記合成樹脂膜は、膜厚が5nm〜500nmの範囲にある。
  3. 請求項1又は2に記載された電子機器であって、前記高融点金属成分及び前記低融点金属成分は、ナノコンポジット構造を有する。
  4. 請求項1乃至3の何れかに記載された電子機器であって、コンピュータ、モバイル情報機器、コンピュータ周辺端末装置、OA機器、通信機器、業務用情報端末・自動認識装置、カーエレクトロニクス機器、産業用機械、エンターテインメント機器、音響機器、映像機器又は家庭用電気機器の群から選択された少なくとも一種である。
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EP2657962A1 (en) 2013-10-30
US20130277850A1 (en) 2013-10-24
SG194295A1 (en) 2013-11-29
KR20130119872A (ko) 2013-11-01
TW201401437A (zh) 2014-01-01
KR101355748B1 (ko) 2014-01-27
JP2013229376A (ja) 2013-11-07
CN103378051A (zh) 2013-10-30

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