JP5173214B2 - 導電性樹脂組成物とこれを用いた電極間の接続方法及び電子部品と回路基板の電気接続方法 - Google Patents
導電性樹脂組成物とこれを用いた電極間の接続方法及び電子部品と回路基板の電気接続方法 Download PDFInfo
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Description
前記流動媒体は、前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、
かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、
前記第1の流動媒体は熱硬化性樹脂で構成されており、
前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲であることを特徴とする。
前記流動媒体は、前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、
かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、前記第1の流動媒体は熱硬化性樹脂で構成されており、前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲の導電性樹脂組成物を準備し、
互いに対向して配置された複数の電極間に前記導電性樹脂組成物を供給し、前記電極と第1の流動媒体との濡れ性を利用して前記複数の電極間に金属粒子を分散した第1の流動媒体を配置させ、それ以外の領域には第2の流動媒体を配置させ、前記金属粒子を前記電極間に自己集合させ、選択的に電気接続させることを特徴とする。
前記回路基板の接続端子又は前記半導体チップの電極端子の所望の位置に、
前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、前記第1の流動媒体は熱硬化性樹脂で構成されており、前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲の導電性樹脂組成物を供給し、前記導電性樹脂組成物を供給した前記回路基板に前記半導体チップを所望のギャップで対向させて配置する第1の工程と、
前記半導体チップと前記回路基板を対向させた静止状態で、前記対向して配置された複数の電極端子と接続端子間には、前記金属粒子を分散した前記第1の流動媒体が界面張力により自己集合するように形成され、前記対向して配置された複数の電極端子と接続端子間以外の領域には前記第2の流動媒体が存在するように保持する第2の工程と、
前記回路基板と半導体チップ間に供給した前記導電性樹脂組成物を硬化させる第3の工程とを含み、
前記自己集合した第1の流動媒体中に含有する金属粒子の集合体により、前記回路基板の接続端子と前記半導体チップの電極端子とを電気的に接続させることを特徴とする。
以下に、図2A〜Eに示した実施例を具体的に説明する。図2Aの回路基板14は、4層配線のガラスエポキシ樹脂基板(パナソニックエレクトロデバイス(株)製 ALIVH登録商標)を用い、銅箔よりなる表層の配線パターンの一部に接続端子15となる配線層(直径50μm、ピッチ100μm、周辺に352端子)に半導体チップ(シリコンメモリー半導体、厚み:0.3mm、縦:10mm、横:10mm、回路基板14と同等の電極端子15を有する)を実装した。なお回路基板14の接続端子15及び配線パターン(図示せず)には、ニッケルと、その上に金メッキを施した。
a)金属粒子13:はんだ粉(Sn−3Ag−0.5Cu) 15質量%
b)第1の流動媒体12:エポキシ樹脂 15質量%
c)第2の流動媒体11:シリコーン樹脂 70質量%
上記材料を混練機で攪拌しながら混合した。混合して作製された導電性樹脂組成物を前記ディスペンサ20に投入し、前記回路基板14の半導体チップ16の実装部分に塗布した。この際、ディスペンサ20には各材料が分離しないように攪拌機能をもったものを用いた。導電性樹脂組成物は厚み約40μmの一定量となるよう制御して供給した。
以下に、図3A〜Fに示した実施例を具体的に説明する。使用した回路基板14及び半導体チップ16は、実施例1と同様のものを使用した。
a)金属粒子:三井金属鉱業株式会社(Sn粉 平均粒径2μm) 10質量%
b)第1の流動媒体:純水 15質量%
c)第2の流動媒体:(エポキシ樹脂70質量%+トルエン30質量%) 75質量%
上述の材料を混合した導電性樹脂組成物10を図3Cに示すようにディスペンサ20で塗布し、実施例1と同様に半導体チップ16を配置し、時間経過とともに第1の金属粒子13を含む第1の流動媒体12を接続端子15と電極端子17間に自己集合させた。第1の流動媒体(純水)が自己集合するメカニズムは、まず第1の流動媒体が水であり、第2の流動媒体がトルエンを溶解させた液状エポキシ樹脂であり、第1及び第2の流動媒体は溶解しないため時間経過とともに夫々分離された。このとき金属粒子(Sn)は水と濡れ性が良好となるように表面に水酸基を持つように表面処理されているので、Sn粉末は容易に純水に取り込まれた。また、前述のように回路基板14上には、有機膜としての撥水性有機膜19が形成されているため、分離された第1の流動媒体である純水は、撥水性有機膜19には濡れず、撥水性有機膜19のない部分である接続端子15部分に自己集合した(図3E)。
11 第2の有機媒体
11’ 固化した第2の有機媒体
12 第1の有機媒体
13 金属粒子
14 回路基板
15 接続端子
16 半導体チップ
17 電極端子
18 溶融した金属
19 撥水膜(有機層)
20 ディスペンサ
21 有機層
22 金属箔
Claims (15)
- 流動媒体中に金属粒子が分散し、電極間を電気的に接続するための導電性樹脂組成物であって、
前記流動媒体は、前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、
かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、
前記第1の流動媒体は熱硬化性樹脂で構成されており、
前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲であることを特徴とする導電性樹脂組成物。 - 前記金属粒子は混合時には前記第1及び第2の流動媒体に分散しており、静止状態では前記金属粒子が前記第1の流動媒体中に分散し、かつ前記第1及び第2の流動媒体は分散状態である請求項1に記載の導電性樹脂組成物。
- 前記第1の流動媒体の表面張力が、前記第2の流動媒体の表面張力より大きい請求項1に記載の導電性樹脂組成物。
- 前記第1の流動媒体が熱硬化性樹脂で構成されており、かつ前記第2の流動媒体が光硬化樹脂で構成されている請求項1に記載の導電性樹脂組成物。
- 前記第1の流動媒体又は前記第2の流動媒体が液状であり、前記第1の流動媒体又は前記第2の流動媒体に可溶な溶剤を添加した請求項1に記載の導電性樹脂組成物。
- 前記金属粒子の平均体積粒子径の範囲は、1〜30μmの範囲である請求項1に記載の導電性樹脂組成物。
- 流動媒体中に金属粒子が分散した導電性樹脂組成物を使用した電極間の電気的接続方法であって、
前記流動媒体は、前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、
かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、前記第1の流動媒体は熱硬化性樹脂で構成されており、前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲の導電性樹脂組成物を準備し、
互いに対向して配置された複数の電極間に前記導電性樹脂組成物を供給し、前記電極と第1の流動媒体との濡れ性を利用して前記複数の電極間に金属粒子を分散した第1の流動媒体を配置させ、それ以外の領域には第2の流動媒体を配置させ、前記金属粒子を前記電極間に自己集合させ、選択的に電気接続させることを特徴とする電極間の接続方法。 - 前記自己集合させた後、前記金属粒子を溶融する請求項7に記載の電極間の接続方法。
- 前記電極間以外の部分は濡れ性を低くするための有機物層を形成しておく請求項7に記載の電極間の接続方法。
- 前記濡れ性を低くするための有機物層が、シリコーン・アクリル共重合体もしくはフッ素・アクリル共重合体からなる撥水性又は撥油性の有機物層である請求項9に記載の電極間の接続方法。
- 複数の接続端子を有する回路基板に対向させて、複数の電極端子を有する半導体チップを配置し、前記回路基板の接続端子と前記半導体チップの電極端子とを、導電性樹脂組成物を介して電気的に接続する電気接続方法であって、
前記回路基板の接続端子又は前記半導体チップの電極端子の所望の位置に、
前記金属粒子との濡れ性が相対的に高い第1の流動媒体と、前記金属粒子との濡れ性が相対的に低い第2の流動媒体を含み、かつ前記第1の流動媒体と前記第2の流動媒体は互いに非相溶状態で分散しており、前記第1の流動媒体は熱硬化性樹脂で構成されており、前記金属粒子ははんだ金属からなり、かつ前記熱硬化性樹脂の硬化温度と等しいか、又は低い融点を有し、
前記金属粒子と、前記第1の流動媒体と、前記第2の流動媒体の配合割合は、
金属粒子:4〜40質量%
第1の流動媒体:10〜20質量%
第2の流動媒体:40〜76質量%
の範囲の導電性樹脂組成物を供給し、前記導電性樹脂組成物を供給した前記回路基板に前記半導体チップを所望のギャップで対向させて配置する第1の工程と、
前記半導体チップと前記回路基板を対向させた静止状態で、前記対向して配置された複数の電極端子と接続端子間には、前記金属粒子を分散した前記第1の流動媒体が界面張力により自己集合するように形成され、前記対向して配置された複数の電極端子と接続端子間以外の領域には前記第2の流動媒体が存在するように保持する第2の工程と、
前記回路基板と半導体チップ間に供給した前記導電性樹脂組成物を硬化させる第3の工程とを含み、
前記自己集合した第1の流動媒体中に含有する金属粒子の集合体により、前記回路基板の接続端子と前記半導体チップの電極端子とを電気的に接続させることを特徴とする電子部品と回路基板の電気接続方法。 - 前記金属粒子の集合体は、当該金属粒子が互いに接触して前記導電性樹脂組成物を構成する請求項11に記載の電子部品と回路基板の電気接続方法。
- 前記第2の工程と前記第3の工程の間に、前記回路基板の接続端子と前記半導体チップの電極端子間に自己集合させた前記金属粒子の集合体を含む前記導電性樹脂組成物を加熱し、前記第1の流動媒体中に含有する金属粒子を溶融させる工程をさらに含む請求項11に記載の電子部品と回路基板の電気接続方法。
- 前記第1の工程が、前記回路基板の接続端子と前記半導体チップの電極端子とを所望のギャップで対向させて配置し、前記半導体チップと前記回路基板の隙間に、流動媒体中に金属粒子を含有した導電性樹脂組成物を供給する工程である請求項11に記載の電子部品と回路基板の電気接続方法。
- 前記第1の工程において、前記接続端子以外の前記回路基板表面が、予め撥水化、又は撥油化処理が施されている請求項11に記載の電子部品と回路基板の電気接続方法。
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