JP7166090B2 - Sealing sheet and method for producing electronic element device - Google Patents

Description

TECHNICAL FIELD The present invention relates to a sealing sheet and a method for manufacturing an electronic element device, and more particularly to a method for manufacturing an electronic element device and a sealing sheet used therein.

Conventionally, there is known a method of manufacturing an electronic device package by sealing an electronic device mounted on one side of a substrate with an electronic device sealing sheet (see, for example, Patent Document 1 below).

In this method, the sheet for encapsulating the electronic device embeds the electronic device so as to be in contact with one surface and side surface of the electronic device and one surface surrounding the electronic device on the substrate to seal the electronic device. .

JP 2015-179829 A

However, there is a demand for manufacturing a highly reliable electronic device package by suppressing the separation of the electronic device from the substrate.

Further, in the electronic device package, the sealing resin sheet, which is a cured product of the electronic device sealing sheet, is required to have shape stability.

Furthermore, it is required to form a thin encapsulating resin sheet to make the manufactured electronic device package thinner.

The present invention provides a sealing sheet capable of forming a sealing layer having excellent shape stability while suppressing the separation of an electronic element from a substrate, and a thin electronic element device. A manufacturing method is provided.

In the present invention (1), an electronic element mounted so as to face one surface in the thickness direction of a substrate is sealed so as to be in contact with one surface in the thickness direction of the substrate that does not face the electronic element. A sealing sheet used to form a layer, the ratio (t1/t2 ) is 0.7 or more and 2.3 or less.

[1] Since the thickness t1 of the sealing layer disposed on one side in the thickness direction of the electronic element is excessively large, the ratio (t1/t2) of the thickness t1 of the sealing layer to the thickness t2 of the electronic element , exceeds 2.3, as shown in FIG. 5A, it is impossible to reduce the thickness of the electronic element device having the thick sealing layer.

[2] When the thickness t2 of the electronic element is too thin and the ratio (t1/t2) of the thickness t1 of the sealing layer to the thickness t2 of the electronic element exceeds 2.3, The contact area of the thin sealing layer that embeds the electronic element with respect to the peripheral side surface of the electronic element becomes excessively small, and as shown in FIG. ) (see FIG. 2), the other surface in the thickness direction has a shape that approximates a flat shape. As a result, the binding force (anchoring effect) of the sealing layer to the electronic element is reduced, and as a result, the separation of the electronic element from the substrate cannot be suppressed.

However, in the sealing sheet of the present invention, the ratio (t1/t2) of the thickness t1 of the sealing layer to the thickness t2 of the electronic element is 2.3 or less. can be achieved. In addition, [2] the sealing layer can ensure a sufficient contact area with the peripheral side surface of the electronic element, and as shown in FIG. ). Therefore, the sealing layer exerts a restraining force (anchoring effect) on the electronic element, and as a result, it is possible to suppress the separation of the electronic element from the substrate.

On the other hand, [3] Since the thickness t1 of the sealing layer disposed on one side in the thickness direction of the electronic element is excessively thin, the ratio of the thickness t1 of the sealing layer to the thickness t2 of the electronic element (t1/t2 ) is less than 0.7, as shown in FIG. 4A, the thin sealing layer disposed on one side in the thickness direction of the electronic element is likely to be damaged or chipped, resulting in reduced sealing performance. As a result, it is not possible to prevent the electronic element from being detached from the substrate.

[4] When the thickness t2 of the electronic element is excessively thick and the ratio (t1/t2) of the thickness t1 of the sealing layer to the thickness t2 of the electronic element is less than 0.7 When the encapsulating sheet is pressed against the electronic element, the thick encapsulating sheet tends to flow toward the outside of the electronic element, as shown in FIG. 4B. Therefore, the peripheral edge portion of the sealing layer formed from the sealing sheet does not have a desired shape. As a result, the shape stability of the encapsulation layer is reduced.

However, in the sealing sheet of the present invention, the ratio (t1/t2) to the thickness t2 of the electronic element is 0.7 or more. damage or chipping of the electronic element can be suppressed, and therefore deterioration of the sealing performance can be suppressed, and as a result, peeling of the electronic element from the substrate can be suppressed. In addition, [4] when the sealing sheet is pressed against the electronic element, it is suppressed that the sealing sheet tends to flow toward the outside of the electronic element. The peripheral end portion of the formed sealing layer can be formed into a desired shape. As a result, deterioration of the shape stability of the sealing layer can be suppressed.

Therefore, according to this sealing sheet, it is possible to suppress the separation of the electronic element from the substrate, form a sealing layer excellent in shape stability, and manufacture a thin electronic element device. can do.

In the present invention (2), the total (t1+t2) of the thickness t1 of the sealing layer and the thickness t2 of the electronic element is 0.25 [mm] or more and 0.50 [mm] or less, (1 ) includes the sealing sheet described in .

When the thickness t1 of the sealing layer is thick and the total (t1+t2) is 0.25 [mm] or more, the thick sealing layer can reliably seal the electronic element. Further, when the thickness t2 of the electronic element is thick and the total (t1+t2) is 0.25 [mm] or more, a sufficient contact area of the sealing layer with respect to the peripheral side surface of the electronic element can be secured. The electronic element can be reliably sealed by the sealing layer.

On the other hand, when the thickness t1 of the sealing layer is thin and the total (t1 + t2) is 0.50 [mm] or less, or when the thickness t2 of the electronic element is thin and the total (t1 + t2) is 0.50 [mm] mm] or less, it is possible to manufacture a thin electronic device.

The present invention (3) includes a method for producing an electronic element device, in which an electronic element is sealed using the sealing sheet according to (1) or (2).

In this method for manufacturing an electronic element device, the sealing sheet is used to bring the electronic element mounted so as to face one surface in the thickness direction of the substrate into contact with the one surface in the thickness direction of the substrate that does not face the electronic element. A sealing layer for sealing is formed as follows. Therefore, the electronic element mounted on the substrate can be reliably sealed with the sealing layer. As a result, it is possible to manufacture a highly reliable electronic element device comprising a substrate, an electronic element and a sealing layer.

According to the sealing sheet of the present invention, it is possible to suppress the peeling of the electronic element from the substrate, and to form a sealing layer having excellent shape stability to manufacture a thin electronic element device. can do.

According to the method for manufacturing an electronic element device of the present invention, an electronic element device having excellent reliability can be manufactured.

FIG. 1 shows a cross-sectional view of an electronic element encapsulating sheet that is one embodiment of the encapsulating sheet of the present invention. FIG. 2 shows a process of sealing an electronic element using the sheet for electronic element sealing shown in FIG. 1, dicing the substrate and the sealing layer around the electronic element, and manufacturing an electronic element device. 3A and 3B are diagrams for explaining the process of manufacturing an electronic element device from an electronic element mounting board having one electronic element, and FIG. 3A is a process of preparing an electronic element mounting board having one electronic element. 3B show the step of dicing the substrate and sealing layer around the electronic element in the electronic element device. 4A and 4B are cross-sectional views of comparative examples in which the thickness ratio (t1/t2) of the sealing layer to the electronic element is too small, FIG. 4A being a comparative example in which the sealing layer is too thin, and FIG. shows a comparative example in which the electronic element is excessively thick. 5A and 5B are cross-sectional views of comparative examples in which the thickness ratio (t1/t2) of the sealing layer to the electronic element is excessive, FIG. 5A being a comparative example in which the sealing layer is excessively thick, and FIG. shows a comparative example in which the electronic element is excessively thin. FIG. 6 is a graph showing the relationship between the thickness t1 of the sealing layer and the thickness t2 of the electronic element.

An electronic element encapsulating sheet, which is one embodiment of the encapsulating sheet of the present invention, will be described with reference to FIGS. 1 and 2. FIG.

As shown in FIGS. 1 and 2, this electronic element encapsulating sheet 1 is used for manufacturing an electronic element device (electronic element package) 3 . As shown in FIG. 2, the electronic element device 3 includes a substrate 2, an electronic element 4 and a sealing layer 5, which will be described later.

Further, the electronic element sealing sheet 1 shown in FIG. 1 is not the sealing layer 5 after sealing the electronic element 4 (see FIG. 2), that is, before sealing the electronic element 4, It is a precursor sheet (preferably a curable sheet) for forming the stopping layer 5 .

As shown in FIG. 1, the sheet 1 for electronic element encapsulation has a substantially plate shape (film shape) extending in a direction (plane direction) perpendicular to the thickness direction. The electronic element encapsulating sheet 1 has a first sheet surface 6 that is one surface in the thickness direction and a second sheet surface 7 that is the other surface in the thickness direction. The first sheet surface 6 and the second sheet surface 7 are planes (flat surfaces) parallel to each other.

When the electronic element encapsulating sheet 1 seals the electronic element 4 (see FIG. 2), the first sheet surface 6 maintains its flat (flat) shape, for example, and is in contact with the second sheet surface 7. A predetermined thickness is provided by securing an interval in the thickness direction.

Although the second sheet surface 7 will be described later, when the electronic element sealing sheet 1 seals the electronic element 4, at least the first element surface 8 (described later) in the electronic element 4 and the electronic element 4 in the substrate 2 It is a contact surface that contacts both surfaces of the first substrate surface 11 (described later) that does not face the .

The material of the electronic element encapsulating sheet 1 is not particularly limited as long as it is a material that allows the encapsulating layer 5 to have the size described below. Examples of the material of the sheet 1 for encapsulating electronic elements include encapsulating compositions.

A sealing composition is, for example, a curable composition containing a thermosetting component.

The thermosetting component is a component that is once softened by heating when the electronic element 4 is sealed, melts and flows, and is cured by further heating.

Moreover, the thermosetting component is in the B stage (semi-cured state) in the sheet 1 for encapsulating an electronic element, and is not in the C stage (that is, the state before complete curing). In the B stage, the thermosetting component is in a state between the A stage in which it is liquid and the C stage in which it is completely cured. It is in a state smaller than the compression modulus.

Thermosetting components include, for example, a main agent, a curing agent and a curing accelerator.

Examples of base resins include epoxy resins, phenol resins, melamine resins, vinyl ester resins, cyano ester resins, maleimide resins, and silicone resins. From the viewpoint of heat resistance and the like, the main agent is preferably an epoxy resin. If the main agent is an epoxy resin, the thermosetting component constitutes an epoxy thermosetting component together with a curing agent (epoxy curing agent) and a curing accelerator (epoxy curing accelerator), which will be described later.

Examples of epoxy resins include bifunctional epoxy resins such as bisphenol A type epoxy resin, bisphenol F type epoxy resin, modified bisphenol A type epoxy resin, modified bisphenol F type epoxy resin, biphenyl type epoxy resin, and phenol novolac type epoxy resin. trifunctional or higher polyfunctional epoxy resins such as resins, cresol novolak-type epoxy resins, trishydroxyphenylmethane-type epoxy resins, tetraphenylolethane-type epoxy resins, and dicyclopentadiene-type epoxy resins. These epoxy resins can be used alone or in combination of two or more.

Preferably, a bifunctional epoxy resin is used alone, and specifically, a bisphenol F type epoxy resin is used alone.

The epoxy equivalent of the epoxy resin is, for example, 10 g/eq. above, preferably 100 g/eq. or more, and, for example, 300 g/eq. Below, preferably 250 g/eq. It is below.

The softening point of the main agent (preferably epoxy resin) is, for example, 50° C. or higher, preferably 70° C. or higher, and is, for example, 110° C. or lower, preferably 90° C. or lower.

The proportion of the main agent (preferably epoxy resin) in the sealing composition is, for example, 1% by mass or more, preferably 2% by mass or more, and is, for example, 30% by mass or less, preferably 10% by mass. It is below. The proportion of the main agent (preferably epoxy resin) in the thermosetting component is, for example, 50% by mass or more, preferably 60% by mass or more, and is, for example, 90% by mass or less, preferably 10% by mass. % by mass or less.

The curing agent is a component (preferably epoxy resin curing agent) that cures the main agent by heating. Examples of curing agents include phenolic resins such as phenolic novolac resins.

If the main agent is an epoxy resin and the curing agent is a phenolic resin, the ratio of the curing agent is such that the total amount of hydroxyl groups in the phenolic resin is, for example, 0.7 equivalents or more per equivalent of the epoxy groups in the epoxy resin. , preferably 0.9 equivalents or more, for example, 1.5 equivalents or less, preferably 1.2 equivalents or less. Specifically, the number of parts of the curing agent is, for example, 30 parts by mass or more, preferably 50 parts by mass or more, and for example, 75 parts by mass or less, preferably 60 parts by mass, with respect to 100 parts by mass of the main agent. Part by mass or less.

The curing accelerator is a catalyst (thermosetting catalyst) (preferably an epoxy resin curing accelerator) that accelerates the curing of the main agent by heating, and is, for example, an organic phosphorus compound such as 2-phenyl-4,5 -Imidazole compounds such as dihydroxymethylimidazole (2PHZ-PW). Imidazole compounds are preferred. The amount of the curing accelerator compounded is, for example, 0.05 parts by mass or more and, for example, 5 parts by mass or less with respect to 100 parts by mass of the main agent.

The encapsulating composition can contain additives such as inorganic fillers, thermoplastic components, pigments, and silane coupling agents in addition to the thermosetting components described above.

The inorganic filler is an inorganic particle that improves the strength of the sealing layer 5 (described later) and imparts excellent toughness to the sealing layer 5 . Examples of inorganic filler materials include inorganic compounds such as quartz glass, talc, silica, alumina, aluminum nitride, silicon nitride, and boron nitride. These can be used singly or in combination of two or more. Silica is preferred.

The shape of the inorganic filler is not particularly limited, and examples thereof include a substantially spherical shape, a substantially plate shape, a substantially needle shape, and an irregular shape. A substantially spherical shape is preferred.

The average maximum length of the inorganic filler (average particle diameter in the case of a substantially spherical shape) M is, for example, 50 μm or less, preferably 20 μm or less, more preferably 10 μm or less. It is 1 μm or more, preferably 0.5 μm or more. The average particle diameter M is obtained as a D50 value (cumulative 50% median diameter) based on a particle size distribution determined by a particle size distribution measurement method in laser scattering, for example.

In addition, the inorganic filler may include a first filler and a second filler having an average maximum length M2 smaller than the average maximum length M1 of the first filler.

The average maximum length of the first filler (average particle diameter in the case of a substantially spherical shape) M1 is, for example, 1 μm or more, preferably 3 μm or more, and is, for example, 50 μm or less, preferably 30 μm or less. is.

The average maximum length of the second filler (average particle size in the case of a substantially spherical shape) M2 is, for example, less than 1 μm, preferably 0.8 μm or less, and, for example, 0.01 μm or more, preferably is 0.1 μm or more.

The ratio (M1/M2) of the average maximum length of the first filler to the average maximum length of the second filler (M1/M2) is, for example, 2 or more, preferably 5 or more, and, for example, 50 or less. , preferably 20 or less.

The materials of the first filler and the second filler may be the same or different.

Furthermore, the surface of the inorganic filler may be partially or wholly treated with a silane coupling agent or the like.

When the inorganic filler contains the first filler and the second filler described above, the proportion of the first filler in the sealing composition is, for example, 40% by mass or more, preferably more than 50% by mass, and , for example, 80% by mass or less, preferably 70% by mass or less, more preferably 60% by mass or less. The amount of the second filler compounded is, for example, 40 parts by mass or more, preferably 50 parts by mass or more, and for example, 70 parts by mass or less, preferably 60 parts by mass, with respect to 100 parts by mass of the first filler. It is below.

The proportion of the inorganic filler in the sealing composition is, for example, 50% by mass or more, preferably 65% by mass or more, more preferably 70% by mass or more, and still more preferably 75% by mass or more. , 95% by mass or less, preferably 90% by mass or less.

The thermoplastic component is a component that improves the flexibility of the electronic element sealing sheet 1 when the electronic element 4 is sealed. A thermoplastic component is, for example, a thermoplastic resin.

Examples of thermoplastic resins include natural rubber, butyl rubber, isoprene rubber, chloroprene rubber, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, polybutadiene resin, polycarbonate resin, Thermoplastic polyimide resin, polyamide resin (6-nylon, 6,6-nylon, etc.), phenoxy resin, acrylic resin, saturated polyester resin (PET, etc.), polyamideimide resin, fluorine resin, styrene-isobutylene-styrene block copolymer etc. These thermoplastic resins can be used alone or in combination of two or more.

The thermoplastic resin is preferably an acrylic resin from the viewpoint of improving dispersibility with the main agent (preferably epoxy resin).

As the acrylic resin, for example, a carboxyl group-containing (meta ) acrylic acid ester copolymers (preferably carboxyl group-containing acrylic acid ester copolymers), and the like.

Examples of alkyl groups include alkyl groups having 1 to 6 carbon atoms such as methyl, ethyl, propyl, isopropyl, n-butyl, t-butyl, isobutyl, pentyl and hexyl.

Examples of other monomers include carboxyl group-containing monomers such as acrylic acid, methacrylic acid, carboxyethyl acrylate, carboxypentyl acrylate, itaconic acid, maleic acid, fumaric acid and crotonic acid.

The weight average molecular weight of the thermoplastic component is, for example, 100,000 or more, preferably 300,000 or more, and is, for example, 1,000,000 or less, preferably 900,000 or less. The weight average molecular weight is measured by gel permeation chromatography (GPC) based on standard polystyrene conversion values.

The ratio of the thermoplastic component (solid content ratio) is adjusted so as not to hinder the thermosetting of the sealing composition. is 2% by mass or more, and is, for example, 10% by mass or less, preferably 5% by mass or less. In addition, the thermoplastic component may be prepared by being diluted with an appropriate solvent.

Pigments include, for example, black pigments such as carbon black. The average particle size of the pigment is, for example, 0.001 μm or more and, for example, 1 μm or less. The proportion of the pigment is, for example, 0.1% by mass or more and, for example, 2% by mass or less, relative to the sealing composition.

Silane coupling agents include, for example, silane coupling agents containing epoxy groups. Silane coupling agents containing an epoxy group include, for example, 3-glycidoxydialkyldialkoxysilanes such as 3-glycidoxypropylmethyldimethoxysilane and 3-glycidoxypropylmethyldiethoxysilane; 3-glycidoxyalkyltrialkoxysilanes such as glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane. Preferred is 3-glycidoxyalkyltrialkoxysilane. The mixing ratio of the silane coupling agent is, for example, 0.1 parts by mass or more, preferably 1 part by mass or more, and for example, 10 parts by mass or less, preferably 5 parts by mass, with respect to 100 parts by mass of the inorganic filler. Part by mass or less.

The thickness T of the electronic element sealing sheet 1 is, for example, 0.25 mm or more, preferably 0.27 mm or more. Specifically, the thickness T of the electronic element encapsulating sheet 1 is the distance (average length) between the first sheet surface 6 and the second sheet surface 7 .

On the other hand, the thickness T of the electronic element sealing sheet 1 is, for example, less than 0.50 mm, preferably 0.45 mm or less, more preferably 0.40 mm or less.

The shape of the electronic element encapsulating sheet 1 in the orthogonal direction (plane direction) is not particularly limited, and the size of the electronic element encapsulating sheet 1 is such that the plurality of electronic elements 4 are embedded (sealed) and exposed from the plurality of electronic elements 4. It is set so as to be in contact with the first substrate surface 11 of the substrate 2 (the first substrate surface 11 around the electronic element 4). Specifically, the length in the surface direction of the sheet 1 for encapsulating an electronic element (the length of one side that is the maximum length when the sheet 1 for encapsulating an electronic element is rectangular in plan view) is, for example, 1 mm. or more, and for example, 500 mm or less.

In order to manufacture the sheet 1 for electronic element encapsulation, first, a sealing composition is prepared. Specifically, the components described above are blended and mixed to prepare a sealing composition. Preferably, each component described above (and if necessary, a solvent (ketone, alcohol, etc.) are blended and mixed to prepare a varnish. After that, the varnish is applied to a release sheet (not shown) and dried to seal the electronic element. A sealing sheet 1 is obtained.The electronic element encapsulating sheet 1 can also be formed from the encapsulating composition by kneading and extruding without preparing the varnish.

By this, the sheet|seat 1 for electronic element sealing is formed as 1 layer from a sealing composition.

The sheet 1 for electronic element sealing is B stage, for example, when it contains a thermosetting component.

(Manufacturing method of electronic element device)
Next, a method for manufacturing the electronic element device 3 using the electronic element encapsulating sheet 1 will be described.

This manufacturing method includes a preparatory step (see FIG. 1) of preparing the electronic element sealing sheet 1 and the electronic element 4, and sealing the electronic element 4 using the electronic element sealing sheet 1 to seal the electronic element 4. A sealing step (see FIG. 2) for forming the stopping layer 5 is provided.

(Preparation process)
As shown in FIG. 1, in the preparation step, the electronic element encapsulating sheet 1 (preferably B-stage electronic element encapsulating sheet 1) is prepared. Separately, as indicated by the phantom lines in FIG. 1, in the preparation step, the electronic element 4 mounted on the substrate 2 is prepared.

A plurality of electronic elements 4 are arranged at intervals on a first substrate surface 11 (described later) of the substrate 2 . Each of the plurality of electronic elements 4 has a substantially flat plate shape extending in the plane direction. Specifically, each of the plurality of electronic elements 4 has a first element surface 8, a second element surface 9, and an element peripheral side surface 10 in succession.

The first element surface 8 and the second element surface 9 are planes that are spaced apart from each other in the thickness direction and parallel to each other.

The element peripheral side surface 10 connects the peripheral edges of the first element surface 8 and the second element surface 9 in the thickness direction. The element peripheral side surface 10 extends in the thickness direction, and more specifically, the element peripheral side surface 10 is perpendicular to the surface direction.

The electronic element 4 is not particularly limited, and includes various electronic elements such as hollow electronic elements and semiconductor elements. A plurality of electronic elements 4 are mounted so as to face the first substrate surface 11 of the substrate 2 . Specifically, the plurality of electronic elements 4 are flip-chip mounted on the substrate 2 . In this case, electrodes (not shown) provided on the second element surface 9 of the plurality of electronic elements 4 are electrically connected to terminals (not shown) provided on the first substrate surface 11 of the substrate 2. be. Alternatively, the electronic element 4 may be die-bonded to the substrate 2 via an adhesive layer (die-bonding film or the like) not shown.

The material of the electronic element 4 is not particularly limited, and examples thereof include hard materials such as silicon.

The thickness t2 of the electronic element 4 is, for example, 0.05 mm or more, preferably 0.10 mm or more, and is, for example, 0.5 mm or less, preferably 0.4 mm or less, more preferably 0.3 mm or less. is. A thickness t<b>2 of the electronic element 4 is the distance between the first element surface 8 and the second element surface 9 .

If the thickness t2 of the electronic element 4 is equal to or less than the above-described upper limit, it is possible to prevent the electronic element device 3 from being restricted in thickness.

On the other hand, if the thickness t2 of the electronic element 4 is equal to or greater than the above-described lower limit, the area where the element peripheral side surface 10 of the electronic element 4 contacts the sealing layer 5 is sufficiently ensured, and the sealing layer by the sealing layer 5 is formed. can be improved.

The surface direction length of the electronic element 4 (if the electronic element 4 has a rectangular shape in plan view, the maximum length of the four sides) is the length at which the electronic element 4 is fixed to the first substrate surface 11 of the substrate 2 (and thus , area) is not particularly limited, and is, for example, 0.01 mm or more, preferably 0.1 mm or more, and for example, 10 mm or less, preferably 1 mm or less.

In addition, the interval between the adjacent electronic elements 4 is not particularly limited as long as the electronic element encapsulating sheet 1 is filled in such an interval and can be in contact with the first substrate surface 11 of the substrate 2. For example, 0.01 mm or more, It is preferably 0.1 mm or more and, for example, 10 mm or less, preferably 1 mm or less.

The substrate 2 is provided on the electronic device mounting substrate 13 together with the electronic device 4 . That is, the electronic element mounting board 13 includes a plurality of electronic elements 4 and a substrate 2 on which the plurality of electronic elements 4 are mounted. Preferably, the electronic device mounting board 13 consists of the plurality of electronic devices 4 and the substrate 2 only.

The substrate 2 has a substantially flat plate shape extending in the plane direction. The substrate 2 has a size surrounding the plurality of electronic elements 4 in plan view. The substrate 2 has a first substrate surface 11 that is one surface in the thickness direction and a second substrate surface 12 that is the other surface in the thickness direction.

The first substrate surface 11 is exposed on one side in the thickness direction. The first substrate surface 11 is provided with terminals (not shown) for flip-chip mounting with the electronic element 4 .

The second substrate surface 12 is a plane parallel to the first substrate surface 11 .

Materials for the substrate 2 are not particularly limited, and examples thereof include resins, ceramics (alumina, etc.), and metals. Ceramic is preferable from the viewpoint of ensuring a low coefficient of linear expansion.

The thickness t3 of the substrate 2 is not particularly limited, and is, for example, 10 μm or more, 1,000 μm or less, preferably 500 μm or less.

(sealing process)
In the sealing step, the electronic element 4 is then sealed using the electronic element sealing sheet 1 as shown by the arrow in FIG. 1 and FIG. 2 .

For example, the electronic element encapsulating sheet 1 is hot-pressed onto the electronic element mounting board 13 . The temperature, time and pressure of hot pressing are not particularly limited. By this hot pressing, the electronic element encapsulating sheet 1 (in particular, the second sheet surface 7) is deformed.

Then, the second sheet surface 7 of the electronic element sealing sheet 1 comes into contact with the first element surface 8 and the element peripheral side surface 10 of the electronic element 4 and the first substrate surface 11 around the electronic element 4 on the substrate 2. Then, the electronic element encapsulating sheet 1 embeds the electronic element 4 .

After the hot pressing described above, if the material of the electronic element encapsulating sheet 1 contains a thermosetting component and the electronic element encapsulating sheet 1 is in the B stage, the electronic element encapsulating sheet 1 is heated. , completely hardened (to C stage). Thereby, the sealing layer 5 is formed from the electronic element sealing sheet 1 .

As indicated by thick virtual lines in FIG. 2, in the electronic device device 3, the substrate 2 and the sealing layer 5 around the electronic device 4 are then diced. For example, a dicing tape 14 shown in phantom lines is placed on the second substrate surface 12 of the substrate 2, and then the substrate 2 and the sealing layer 5 between the adjacent electronic elements 4 are cut by a dicing saw (not shown). Cut along the direction. At the same time, the substrate 2 and the sealing layer 5 on the outside of the electronic element 4 are cut along the surface direction (that is, the outer shape is processed).

Thus, the electronic element device 3 including the substrate 2, one electronic element 4, and the sealing layer 5 is obtained. The electronic device device 3 preferably consists of only the substrate 2 , the electronic device 4 and the sealing layer 5 .

In the electronic element device 3 , the electronic element 4 is blocked from communication with the outside by the substrate 2 and the sealing layer 5 . That is, the electronic element 4 is shielded from the outside. In other words, a plurality of electronic elements 4 are encapsulated by the encapsulation layer 5 .

As shown in FIG. 2 (phantom lines), the sealing layer 5 includes a first sealing surface 15 , a second sealing surface 16 , and a sealing peripheral side surface 21 .

The first sealing surface 15 is formed from the first sheet surface 6 of the electronic element sealing sheet 1 . The first sealing surface 15 is a plane along the surface direction.

The second sealing surface 16 is formed from the second sheet surface 7 of the electronic element encapsulating sheet 1, and has a substantially U-shaped (substantially hat) shape that opens to the other side in the thickness direction in a cross-sectional view. Specifically, the second sealing surface 16 includes an element contact surface 17 that contacts the electronic element 4 and a substrate contact surface 18 that contacts the substrate 2 in succession.

The element contact surface 17 is in contact with (adheres to) both the element first surface 8 and the element peripheral side surface 10 of the electronic element 4 . That is, the element contact surface 17 has a shape corresponding to the electronic element 4 . Specifically, the element contact surface 17 continuously includes a third sealing surface 19 that contacts the first element surface 8 and a fourth sealing surface 20 that contacts the element peripheral side surface 10 .

The third sealing surface 19 has the same shape as the first element surface 8 of the electronic element 4 in plan view.

The fourth sealing surface 20 is an inner surface extending from the peripheral edge of the third sealing surface 20 to the other side in the thickness direction. The fourth sealing surface 20 has the same shape as the element peripheral side surface 10 of the electronic element 4 in a side view.

The substrate contact surface 18 is continuous with the other edge in the thickness direction of the fourth sealing surface 20 and has a shape extending outward in the surface direction from the other edge in the thickness direction of the fourth sealing surface 20 . The substrate contact surface 18 is in contact (close contact) with the first substrate surface 11 surrounding the electronic element 4 on the substrate 2 . Therefore, the substrate contact surface 18 has the same planar shape as the first substrate surface 11 surrounding the electronic element 4 on the substrate 2 .

The sealing peripheral side surface 21 is a peripheral surface that connects peripheral edges of the first sealing surface 15 and the second sealing surface 16 (substrate contact surface 18). The sealing peripheral side surface 21 has a shape extending in the thickness direction. The angle formed by the sealing peripheral side surface 21 and the first sealing side surface 15 is, for example, 60 degrees or more, preferably 80 degrees or more, and is, for example, 120 degrees or less, preferably 100 degrees or less. and most preferably 90 degrees (perpendicular).

The thickness t1 of the sealing layer 5 is the thickness of the portion in contact with the one side 8 in the thickness direction of the electronic element 4, that is, the minimum thickness of the sealing layer 5, and is, for example, 0.15 mm or more, preferably 0.17 mm. Above, more preferably 0.19 mm or more, still more preferably 0.20 mm or more, and for example, 0.50 mm or less, preferably 0.40 mm or less, more preferably 0.35 mm or less. The thickness t1 of the sealing layer 5 described above is the distance in the thickness direction between the first sealing surface 15 and the third sealing surface 19 .

When the thickness t1 of the sealing layer 5 is equal to or greater than the above-described lower limit, the electronic element 4 can be reliably sealed by the sealing layer 5 . Specifically, it is possible to suppress damage or loss of the sealing layer 5 in contact with the one surface 8 in the thickness direction of the electronic element 4 (see the symbol 22 of the phantom line in FIG. 4A). can be improved.

If the thickness t1 of the sealing layer 5 is equal to or less than the above-described upper limit, the electronic element device 3 is prevented from becoming excessively thick, and the electronic element device 3 is previously suppressed (prevented) from being subject to thickness restrictions. can be done. Moreover, the peripheral end portion of the first sealing surface 15 of the sealing layer 5 can be formed into a desired shape.

The maximum thickness of the sealing layer 5 is the sum of the minimum thickness t1 and the thickness t2 of the electronic element 4 (=t1+t2). is the distance in the thickness direction between The maximum thickness of the sealing layer 5 is also the length in the thickness direction of the sealing peripheral side surface 21 . The maximum thickness (t1+t2) of the sealing layer 5 is, for example, 0.25 mm or more, preferably 0.30 mm or more, more preferably 0.35 mm or more, and for example, 0.50 mm or less, preferably 0.45 mm or less.

If the maximum thickness of the sealing layer 5 is equal to or more than the above-described lower limit, the sealing performance with respect to the electronic element 3 can be improved. On the other hand, if the maximum thickness of the sealing layer 5 is equal to or less than the above-described upper limit, it is possible to manufacture a thin electronic element device 3 .

Further, the ratio ([t1+t2]/t1) of the maximum thickness (t1+t2) of the sealing layer 5 to the minimum thickness t1 of the sealing layer 5 is, for example, 1.4 or more, preferably 1.7 or more, Also, for example, it is 2.2 or less, preferably 2.0 or less.

Further, the ratio ([t1+t2]/T) of the maximum thickness (t1+t2) of the sealing layer 5 to the thickness T of the sealing sheet 1 for electronic elements is, for example, 0.8 or more, preferably 1.0 or more. , or, for example, 1.6 or less, preferably 1.4 or less.

In this electronic element device 3, the ratio (t1/t2) of the thickness t1 of the sealing layer 5 to the thickness t2 of the electronic element 4 is 0.7 or more and 2.3 or less.

If the above ratio (t1/t2) is less than the above 0.7, the separation of the electronic element 4 from the substrate 2 cannot be suppressed, and the first sealing of the sealing layer 5 will be described in detail later. The peripheral edge of the stop surface 15 cannot be formed into a desired shape.

On the other hand, if the ratio (t1/t2) exceeds 2.3, the thickness of the electronic element device 3 cannot be reduced, and the electronic element 4 is peeled off from the substrate 2, as will be described in detail later. cannot be suppressed.

Also, the above ratio is preferably 0.80 or more, more preferably 0.90 or more, and still more preferably 1.00 or more. Also, the above ratio is preferably 2.00 or less, more preferably 1.80 or less, even more preferably 1.70 or less, and most preferably 1.50 or less. If the above ratio (t1/t2) exceeds the above lower limit, it is possible to suppress the peeling of the electronic element 4 from the substrate 2, and at the same time, the peripheral edge of the first sealing surface 15 of the sealing layer 5 can be of any desired shape. On the other hand, if the ratio (t1/t2) is below the upper limit, the thickness of the electronic element device 3 can be reduced, and at the same time, the separation of the electronic element 4 from the substrate 2 can be suppressed.

The length L in the surface direction of the substrate contact surface 18 of the sealing layer 5 is, for example, 0.01 mm or more, preferably 0.02 mm or more, and preferably 1.0 mm or less, as the shortest distance. is 0.5 mm or less. The length L on the substrate contact surface 18 is the distance L from the peripheral edge of the second element surface 9 of the electronic element 4 to the other edge in the thickness direction of the sealing peripheral side surface 21. It is the contact length L that the substrate contact surface 18 is in contact with the first substrate surface 11 of the substrate 2 when proceeding from the other edge in the thickness direction of the stop surface 20 toward the outside in the surface direction. In addition, each of the sealing layer 5 and the electronic element 4 has a substantially rectangular shape in plan view, and in plan view, each of the four sealing peripheral side surfaces 21 of the sealing layer 5 corresponds to the four element peripheral side surfaces of the electronic element 4. 10 , the length L at the substrate contact surface 18 is the shortest distance between adjacent sealing peripheral side surfaces 21 and device peripheral side surfaces 10 .

The tensile storage modulus E′ of the sealing layer 5 at 25° C. is, for example, 5,000 [N/mm ² ] or more, preferably 9,000 [N/mm ² ] or more, more preferably 10,000. [N/mm ² ] or more, more preferably 13,000 [N/mm ² ] or more, and for example, 20,000 [N/mm ² ] or less, preferably 15,000 [N/mm ² ] or less, more preferably 14,000 [N/mm ² ] or less. The tensile storage modulus E′ of the sealing layer 5 at 25° C. is determined by a dynamic viscoelasticity test with a heating rate of 10° C./min and a frequency of 1 Hz.

The thickness T0 of the electronic element device 3 is, for example, 0.80 mm or less from the viewpoint of limiting the use of the electronic element device 3, and preferably 0.70 mm or less or more from the viewpoint of manufacturing a thinner electronic device device 3. Preferably, it is 0.60 mm or less and, for example, 0.40 mm or more. The thickness T0 of the electronic element device 3 is the sum of the thickness t1 of the sealing layer 5, the thickness t2 of the electronic element 4, and the thickness t3 of the substrate 2 (=t1+t2+t3). and the thickness direction length (distance) between the sealing layer 5 and the first sealing surface 15 .

[1] Since the thickness t1 of the sealing layer 5 disposed on the first element surface 8 of the electronic element 4 is excessively thick, the thickness t1 of the sealing layer 5 described above with respect to the thickness t2 of the electronic element 4 If the ratio (t1/t2) exceeds 2.3, as shown in FIG. 5A, it is not possible to reduce the thickness of the electronic element device 3 having the thick sealing layer 5 described above.

[2] When the thickness t2 of the electronic element 4 is excessively thin and the ratio (t1/t2) of the thickness t1 of the sealing layer 5 to the thickness t2 of the electronic element 4 exceeds 2.3 5B, the contact area of the thin sealing layer 5 embedding the electronic element 4 with the peripheral side surface of the electronic element 4 becomes excessively small, and as shown in FIG. It does not have a U-shape (U-shape) (see FIG. 2), but has a shape in which the other side in the thickness direction approximates a flat shape. Therefore, the binding force (anchoring effect) of the sealing layer 5 to the electronic element 4 is reduced, and as a result, the peeling of the electronic element 4 from the substrate 2 cannot be suppressed.

However, in this electronic element encapsulating sheet 1, the ratio (t1/t2) of the thickness t1 of the encapsulating layer 5 to the thickness t2 of the electronic element 4 is 2.3 or less. 3 can be made thinner. In addition, [2] the sealing layer 5 can ensure a sufficient contact area with the peripheral side surface of the electronic element 4, and as shown in FIG. U-shaped). Therefore, the sealing layer 5 exerts a restraining force (anchoring effect) on the electronic element 4 , and as a result, it is possible to suppress the separation of the electronic element 4 from the substrate 2 .

On the other hand, [3] Since the thickness t1 of the sealing layer 5 disposed on the first element surface 8 of the electronic element 4 is excessively thin, the thickness t1 of the sealing layer 5 described above with respect to the thickness t2 of the electronic element 4 When the ratio (t1/t2) is less than 0.7, as shown in FIG. 4A, the thin sealing layer 5 disposed on the first element surface 8 of the electronic element 4 is likely to be damaged or chipped. Therefore, the sealing property is deteriorated, and as a result, the separation of the electronic element 4 from the substrate 2 cannot be suppressed.

[4] Since the thickness t2 of the electronic element 4 is excessively large, the ratio (t1/t2) of the thickness t1 of the sealing layer 5 to the thickness t2 of the electronic element 4 is less than 0.7. In this case, when the electronic element encapsulating sheet 1 is pressed against the electronic element 4, the thick electronic element encapsulating sheet 1 flows toward the outside of the electronic element 4 as shown in FIG. 4B. becomes easier. Therefore, the peripheral edge portion of the sealing layer 5 formed from the electronic element sealing sheet 1 does not have a desired shape. As a result, the shape stability of the sealing layer 5 is lowered.

However, in this electronic element encapsulating sheet 1, the ratio (t1/t2) to the thickness t2 of the electronic element 4 is 0.7 or more. Damage or loss of the encapsulating layer 5 can be suppressed, and therefore deterioration of the sealing performance can be suppressed, and as a result, peeling of the electronic element 4 from the substrate 2 can be suppressed. In addition, [4] when the electronic element encapsulating sheet 1 is pressed against the electronic element 4, the electronic element encapsulating sheet 1 is prevented from easily flowing toward the outside of the electronic element 4. Therefore, the peripheral end portion of the sealing layer 5 formed from the electronic element sealing sheet 1 can be formed into a desired shape. As a result, deterioration in the shape stability of the sealing layer 5 can be suppressed.

Therefore, according to the electronic element encapsulating sheet 1, it is possible to suppress the separation of the electronic element 4 from the substrate 2, and to form the encapsulating layer 5 excellent in shape stability, thereby reducing the thickness. The electronic element device 3 can be manufactured.

Further, when the thickness t1 of the sealing layer 5 is thick and the total (t1+t2) is 0.25 [mm] or more, the electronic element 4 can be reliably sealed with the thick sealing layer 5 . Further, when the thickness t2 of the electronic element 4 is thick and the above-mentioned total (t1+t2) is 0.25 [mm] or more, the contact area of the sealing layer 5 with the element peripheral side surface 10 of the electronic element 4 is sufficiently large. Since it can be secured, the electronic element 4 can be reliably sealed by the sealing layer 5 .

On the other hand, when the thickness t1 of the sealing layer 5 is thin and the total (t1+t2) is 0.50 [mm] or less, or when the thickness t2 of the electronic element 4 is thin and the total (t1+t2) is 0.50 [mm]. When it is 50 [mm] or less, it is possible to manufacture a thin electronic element device 3 .

In this manufacturing method, the electronic element mounted on the substrate 2 can be reliably sealed with the sealing layer 5 using the electronic element sealing sheet 1 described above. As a result, it is possible to manufacture the electronic element device 3 having the substrate 2, the electronic element 4 and the sealing layer 5 and having excellent reliability.

Modifications In each modification below, the same reference numerals are given to the same members and steps as in the above-described embodiment, and detailed description thereof will be omitted. Moreover, each modification can have the same effects as the one embodiment, unless otherwise specified. Furthermore, one embodiment and its modifications can be combined as appropriate.

In one embodiment, as shown in FIG. 1, the electronic element mounting board 13 includes a plurality of electronic elements 4, but the number is not particularly limited, and may be one, for example, as shown in FIG. 3A. may Even in this case, as shown by the thick virtual line in FIG. The size (surface direction length) of 3 in plan view is adjusted (outer shape processing).

EXAMPLES Examples and comparative examples are shown below to describe the present invention more specifically. In addition, the present invention is not limited to Examples and Comparative Examples. In addition, specific numerical values such as the mixing ratio (content ratio), physical property values, and parameters used in the following description are the corresponding mixing ratios ( content ratio), physical properties, parameters, etc. can.

Components used in Examples and Comparative Examples are shown below.

Epoxy resin: YSLV-80XY manufactured by Nippon Steel Chemical Co., Ltd. (bisphenol F type epoxy resin, high molecular weight epoxy resin, epoxy equivalent 200 g / eq. softening point 80 ° C.)
Curing agent: LVR-8210DL manufactured by Gun Ei Kagaku Co., Ltd. (novolac type phenolic resin, epoxy resin curing agent, hydroxyl equivalent: 104 g/eq., softening point: 60 ° C.)
Acrylic resin: HME-2006M manufactured by Negami Kogyo Co., Ltd., carboxyl group-containing acrylic acid ester copolymer (acrylic polymer), weight average molecular weight: 600,000, glass transition temperature (Tg): -35 ° C., solid content concentration 20% by mass Methyl ethyl ketone solution Curing accelerator: Shikoku Kasei Co., Ltd. 2PHZ-PW (2-phenyl-4,5-dihydroxymethylimidazole), epoxy resin curing accelerator Silane coupling agent: Shin-Etsu Chemical Co., Ltd. KBM-403 (3 -glycidoxypropyltrimethoxysilane)
Carbon black: #20 manufactured by Mitsubishi Chemical Corporation
First filler: FB-8SM (spherical fused silica powder (inorganic filler), average particle size 7.0 μm)
Second filler: an inorganic filler obtained by surface-treating SC220G-SMJ (average particle size 0.5 μm) manufactured by Admatechs with 3-methacryloxypropyltrimethoxysilane (product name: KBM-503 manufactured by Shin-Etsu Chemical Co., Ltd.). A surface treated with 1 part by mass of a silane coupling agent with respect to 100 parts by mass of the inorganic filler.

Examples 1 to 6 and Comparative Examples 1 to 8
A sealing composition was prepared according to the formulation shown in Table 1, and an electronic element encapsulating sheet 1 having a thickness T shown in Table 1 was produced from this sealing composition as shown in FIG.

After that, as shown in FIG. 2 , a sealing layer 5 was formed by sealing a plurality of electronic elements 4 with the electronic element encapsulating sheet 1 .

Specifically, a plurality of electronic elements 4 made of silicon, 3 mm square, and having a thickness t2 shown in Table 1 are prepared, and this is made of alumina through a die bonding film (adhesive layer) having a thickness of 20 μm, It was die-bonded to the first substrate surface 11 of the substrate 2 having a size of 50 mm square and a thickness t3 of 0.22 mm. The interval between adjacent electronic elements 4 was 0.3 mm. Thus, as shown in FIG. 1, an electronic element mounting substrate 13 including a plurality of electronic elements 4 and the substrate 2 was prepared.

Next, the electronic element encapsulating sheet 1 is placed on one side in the thickness direction of the electronic element mounting board 13, and then the electronic element encapsulating sheet 1 is placed against the electronic element mounting board 1 at 75°C for 60 seconds. A plurality of electronic elements 4 were embedded with the electronic element encapsulating sheet 1 by vacuum pressing at a pressure of 100 kPa. After that, the electronic element mounting substrate 13 and the electronic element encapsulating sheet 1 were heated at 150° C. for 1 hour to bring the electronic element encapsulating sheet 1 into a C-stage. Thereby, as shown in FIG. 2, a sealing layer 5 for sealing a plurality of electronic elements 4 was formed.

After that, as indicated by thick virtual lines in FIG. 2, the sealing layer 5 and the substrate 2 around each of the plurality of electronic elements 4 were diced. Thus, an electronic element device (electronic element package) 3 including the substrate 2, the electronic element 4, and the sealing layer 5 was manufactured. The length (average length) L at the substrate contact surface 18 was 0.15 mm.

(evaluation)
The following items were evaluated. The results are listed in Table 1.

(Thickness of sealing layer)
The thickness t1 of the sealing layer 5 was measured with a linear gauge (manufactured by PEACOCK). FIG. 6 shows the relationship between the thickness t1 of the sealing layer 5 and the thickness t2 of the electronic element 4. As shown in FIG. The thickness t2 of the electronic element 4 is known and shown in Table 1. In addition, in FIG. 6, the range defined by the present invention is hatched.

In FIG. 6, a line (solid line) where the ratio (t1/t2) of the thickness t1 of the sealing layer 5 to the thickness t2 of the electronic element 4 is 0.7 and a line (solid line) where the ratio is 2.3. , and the region sandwiched between these two lines indicates the range of the ratio (t1/t2) of 0.7 or more and 2.3 or less.

Furthermore, in FIG. 6, a line (chain line) where the total (t1+t2) of the thickness t1 of the sealing layer 5 and the thickness t2 of the electronic element 4 is 0.25 [mm] and A certain line (one-dot chain line) is shown, and the area sandwiched between these two one-dot chain lines indicates a range in which the total (t1+t2) is 0.25 [mm] or more and 0.50 [mm] or less.

(Evaluation of bonding strength) (Observation of peeling)
The electronic device device 3 was subjected to the following temperature cycle test.

Temperature: -40°C to 85°C
Total transfer time : 1 minute or less
Total Dwell Time: 10 minutes or more
Specified temp reached in: 15 minutes or less Cycle: 1000 cycles Then, using an ultrasonic imaging device [SAT] (manufactured by Hitachi Kenki Fine Tech, "FineSAT II"), the interface between the substrate 2 and the electronic element 4, and The interface between the substrate 2 and the sealing layer 5 was observed and evaluated according to the following criteria.
○: No peeling was observed at the interface between the substrate 2 and the electronic element 4 , nor was peeling observed at the interface between the substrate 2 and the sealing layer 5 .
Δ: Peeling was observed at the interface between the substrate 2 and the electronic element 4 . On the other hand, peeling was not observed at the interface between the substrate 2 and the sealing layer 5 . See FIGS. 4A and 5. FIG. 4A and 5 show a gap between the substrate 2 and the electronic element 4, in fact, in this comparative example, there is no gap, and the electronic element 4 is simply fixed to the substrate 2. This is an example in which (adhesion) (bonding) is detached (separated), and a gap is drawn to show the above-described "separation" for easy understanding.
x: Peeling was observed at the interface between the substrate 2 and the electronic element 4 . Delamination was also observed at the interface between substrate 2 and sealing layer 5 . In FIG. 4B, a gap is drawn between the substrate 2 and the electronic element 4 and the sealing layer 5, but actually, in this comparative example, there is no gap, and the electronic element 4 and the sealing layer 5 are simply This is an example in which the fixing (adhesion) of the stopping layer 5 to the substrate 2 has come off (peeled off), and the gap is drawn to show the above-described "peeling" for easy understanding.

Thickness of Electronic Element Device The thickness T0 of the electronic element device was measured and evaluated according to the following criteria.
○: The thickness T0 of the electronic element device was 0.70 mm or less.
x: The thickness T0 of the electronic element device was over 0.70 mm.

1 electronic element sealing sheet 2 substrate 3 electronic element device 4 electronic element 5 sealing layer 11 first substrate surface t1 thickness (sealing layer)
t2 thickness (electronic element)

Claims (3)

formed from a sealing composition comprising a thermosetting component and a thermoplastic component;
Used to form a sealing layer that seals an electronic element mounted on one surface in the thickness direction of a substrate so as to be in contact with the one surface in the thickness direction of the substrate that does not face the electronic element. is a sheet for sealing,
the thermoplastic component comprises an acrylic resin;
The ratio (t1/t2) of the thickness t1 of the sealing layer disposed on one side in the thickness direction of the electronic element to the thickness t2 of the electronic element is 0.7 or more and 2.3 or less. A sheet for sealing, characterized by: The sum total (t1 + t2) of the thickness t1 of the sealing layer and the thickness t2 of the electronic element is 0.25 [mm] or more and 0.50 [mm] or less, Sealing sheet described. A method for manufacturing an electronic element device, comprising sealing an electronic element using the sealing sheet according to claim 1 or 2.

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