JPWO2017073350A1 - 薄膜素子およびその製造方法 - Google Patents

薄膜素子およびその製造方法 Download PDF

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JPWO2017073350A1
JPWO2017073350A1 JP2017547728A JP2017547728A JPWO2017073350A1 JP WO2017073350 A1 JPWO2017073350 A1 JP WO2017073350A1 JP 2017547728 A JP2017547728 A JP 2017547728A JP 2017547728 A JP2017547728 A JP 2017547728A JP WO2017073350 A1 JPWO2017073350 A1 JP WO2017073350A1
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film
external electrode
resist film
wiring conductor
resist
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JP6341336B2 (ja
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俊幸 中磯
俊幸 中磯
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Murata Manufacturing Co Ltd
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Murata Manufacturing Co Ltd
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Abstract

薄膜素子(101)は、基材(1)、基材(1)の表面に形成される配線導体膜(2)、少なくとも配線導体膜(2)の表面に被覆される保護膜(3)、外部電極(4)、保護膜(3)の表面に被覆される第1レジスト膜(11)および第2レジスト膜(12)を備える。保護膜(3)は(Z)方向から視て配線導体膜(2)と重なる位置にコンタクトホール(CH1)を有し、外部電極(4)はコンタクトホール(CH1)内、且つ、配線導体膜(2)の表面に形成される。外部電極(4)は保護膜(3)より厚く、側面(S1)を有する。第1レジスト膜(11)は、外部電極(4)の側面(S1)の全周に沿って接し、第2レジスト膜(12)は、外部電極(4)の側面(S1)および第1レジスト膜(11)から離間して配置される。

Description

本発明は、薄膜素子に関し、特に例えば、基材と基材上に形成される配線導体膜と、配線導体膜上に形成される外部電極とを有する薄膜素子に関する。また、その薄膜素子の製造方法に関する。
従来、基材と、基材上に形成される配線導体膜と、配線導体膜の表面に形成される外部電極と、基材の表面および配線導体膜の表面に被覆されるレジスト膜と、外部電極の表面に形成されるはんだバンプと、を備える端子構造が知られている(特許文献1)。
また、特許文献1に開示されているように、はんだ等の導電性接合材を外部電極に接合する際に、基材上に形成された配線導体膜や外部電極が、基材から剥離することを防止するため、配線導体膜や外部電極の外縁にレジスト膜を被せる方法(オーバーレジスト処理)が一般的である。
しかし、外部電極を構成するAuははんだに濡れやすく、はんだを外部電極に接合する際に、外部電極の表面とレジスト層との界面にはんだが浸入し、外部電極の表面がオーバーレジスト処理したレジスト層の剥離の起点となる虞がある。
一方、このようなレジスト層の剥離を抑制するため、レジスト層と外部電極との間に所定間隔(クリアランス)が設けられたクリアランスレジスト型の端子構造もある(特許文献2)。
特開2012−74487号公報 特開2013−98507号公報
しかし、レジスト層と外部電極との間に所定クリアランスを設けた場合、上記クリアランスからはんだが浸入し、上記クリアランス内で露出する配線導体膜とはんだとが反応すること(はんだ食われ等)によって、抵抗値の増大や、配線導体膜が断線する虞がある。また、上記クリアランスから水分やフラックス等が浸入し、上記クリアランス内に露出する配線導体膜が腐食する虞もある。
本発明の目的は、レジスト層を外部電極から離間して配置する構造において、配線導体膜のはんだ食われや腐食等を抑制した、信頼性の高い外部電極を有する薄膜素子を提供することにある。また、その薄膜素子の製造方法を提供することにある。
(1)本発明の薄膜素子は、
基材と、
前記基材の表面に形成される配線導体膜と、
少なくとも前記配線導体膜の表面に被覆され、平面視で前記配線導体膜と重なる位置にコンタクトホールを有する保護膜と、
前記コンタクトホール内、且つ、前記配線導体膜の表面に形成され、前記保護膜より厚く、側面を有する外部電極と、
前記保護膜の表面に被覆される第1レジスト膜および第2レジスト膜と、
を備え、
前記第1レジスト膜は、前記外部電極の前記側面の全周に沿って接し、
前記第2レジスト膜は、前記外部電極の前記側面および前記第1レジスト膜から離間して配置されることを特徴とする。
この構成では、外部電極の側面および第1レジスト膜と第2レジスト膜との間に形成された離間部内に配線導体膜が露出しないため、この離間部から導電性接合材や水分、フラックス等が浸入したとしても、配線導体膜と導電性接合材5の反応等は抑制される。
また、この構成では、外部電極の側面の全周に沿って接する第1レジスト膜を備えるため、外部電極の側面と保護膜との界面からの導電性接合材や水分、フラックス等の浸入が抑制される。
(2)上記(1)において、前記第1レジスト膜は熱硬化性樹脂であることが好ましい。この構成により、第1レジスト膜はキュアした際に収縮するため、硬化したループ状の第1レジスト膜には内側に向かって締まるような応力が発生する。したがって、保護膜の表面に被覆される第1レジスト膜が、外部電極の側面を締め付けるため、外部電極の側面と保護膜との界面からの導電性接合材や水分、フラックス等の浸入が抑制される。
また、この構成により、硬化した第2レジスト膜には外部電極から外側に向かう応力が発生するが、第2レジスト膜は第1レジスト膜と離間して配置されているため、外部電極と第1レジスト膜との間の隙間の発生がさらに抑制される。
(3)上記(1)または(2)において、前記外部電極は、前記側面の全周に沿って形成される庇部を有し、前記第1レジスト膜は、平面視で前記庇部に重なることが好ましい。この構成により、硬化したループ状の第1レジスト膜が、外部電極の底面から表面に向かって脱落することを抑制できる。
(4)上記(3)において、前記外部電極は、底面から表面に向かって前記側面が逆テーパー状に形成されていてもよい。
(5)上記(1)から(4)のいずれかにおいて、前記配線導体膜は銅を主成分とする金属膜であり、前記保護膜はチタンを主成分とする金属膜であり、前記外部電極はニッケルを主成分とする金属であってもよい。
(6)本発明の薄膜素子の製造方法は、
基材の表面に配線導体膜を形成する第1工程と、
少なくとも前記配線導体膜の表面に、前記配線導体膜と重なる位置にコンタクトホールを有する保護膜を被覆する第2工程と、
前記コンタクトホール内、且つ、前記配線導体膜の表面に、側面の全周に沿って庇部を有する外部電極を形成する第3工程と、
前記保護膜の表面にレジスト膜を被覆する第4工程と、
前記レジスト膜のうち、平面視で前記庇部に重なる第1レジスト膜と、前記第1レジスト膜以外である第2レジスト膜とを離間する離間部を除去する第5工程と、
を備えることを特徴とする。
この製造方法により、配線導体膜のはんだ食われや腐食等を抑制した、信頼性の高い外部電極を有する薄膜素子を容易に製造できる。
(7)上記(6)において、前記第5工程は、前記レジスト膜はポジ型感光性レジスト膜であり、前記離間部をフォトリソグラフィにより除去し、前記外部電極の前記庇部をフォトマスクにして露光する工程を含むことが好ましい。この製造方法により、外部電極の側面の全周に沿って接する第1レジスト膜を容易に形成できる。
(8)上記(6)または(7)において、前記第5工程の後に、前記外部電極の表面にはんだをプリコートする工程をさらに有していてもよい。
本発明によれば、レジスト層と外部電極との間に所定のクリアランスを設ける構造において、配線導体膜のはんだ食われや腐食等を抑制した、信頼性の高い外部電極を有する薄膜素子を実現できる。
図1は第1の実施形態に係る薄膜素子101の外部電極4の構成を示す平面詳細図である。 図2は、図1におけるA−A断面図である。 図3は薄膜素子101の外部電極4の実際の様子を示す断面図である。 図4(A)は、比較例として、保護膜および第1レジスト膜を備えていない薄膜素子100Aの外部電極4の構成を示す断面詳細図であり、図4(B)は、第1レジスト膜を備えていない薄膜素子100Bの外部電極4の構成を示す断面詳細図である。 図5は、薄膜素子101の製造工程を順に示す断面図である。 図6は、第2の実施形態に係る薄膜素子102の外部電極4の構成を示す断面詳細図である。
以降、図を参照して幾つかの具体的な例を挙げて、本発明を実施するための複数の形態を示す。各図中には同一箇所に同一符号を付している。要点の説明または理解の容易性を考慮して、便宜上実施形態を分けて示すが、異なる実施形態で示した構成の部分的な置換または組み合わせが可能である。第2の実施形態以降では第1の実施形態と共通の事柄についての記述を省略し、異なる点についてのみ説明する。特に、同様の構成による同様の作用効果については実施形態毎には逐次言及しない。
《第1の実施形態》
図1は第1の実施形態に係る薄膜素子101の外部電極4の構成を示す平面詳細図である。図2は、図1におけるA−A断面図である。図3は薄膜素子101の外部電極4の実際の様子を示す断面図である。図2において、各部の厚みは誇張して図示している。以降の各実施形態における断面図についても同様である。薄膜素子101は、例えばキャパシタ等の受動素子やLC複合電子部品、半導体集積回路素子、ESD保護素子等の薄膜デバイス(Thin−Film Device)である。
薄膜素子101は、基材1、配線導体膜2、保護膜3、外部電極4、導電性接合材5、第1レジスト膜11、第2レジスト膜12を備える。
基材1は表面が平面状の絶縁性平板である。基材1の表面には配線導体膜2が形成されている。基材1は例えば受動素子やLC複合電子部品、集積回路素子、ESD保護素子等を構成するためのベース材であり、例えばSi基板やガラス基板である。なお、基材1と配線導体膜2との間には、他の絶縁層や配線導体層が設けられていてもよい。
配線導体膜2の表面には保護膜3が被覆されている。保護膜3は、図2に示すように、Z方向から視て(平面視で)配線導体膜2と重なる位置にコンタクトホールCH1を有する。すなわち、保護膜3には、Z方向から視て、配線導体膜2が形成されている位置にコンタクトホールCH1が形成されている。コンタクトホールCH1は保護膜3に形成される開口であり、配線導体膜2の表面に保護膜3が被覆されることにより、コンタクトホールCH1から配線導体膜2が露出する。配線導体膜2は例えばCu膜である。保護膜3は例えばTiを主成分とする金属膜である。
外部電極4は平面形状が円形の金属めっき膜であり、第1電極層41および第2電極層42を有する。第1電極層41は配線導体膜2の表面に形成され、第2電極層42は第1電極層41の表面に形成されている。外部電極4は例えばNiを主成分とする金属めっき膜である。第1電極層41は例えばNiめっき膜であり、第2電極層42は例えばAuめっき膜である。
外部電極4は、コンタクトホールCH1から露出する配線導体膜2の表面に形成される。すなわち、外部電極4はコンタクトホールCH1内、且つ、配線導体膜2の表面に形成される。図1に示すように、外部電極4は保護膜3より厚く、側面S1を有する。図1に示すように、外部電極4は底面から表面に向かって側面S1が逆テーパー状に形成される。そのため、外部電極4は側面S1に庇部6を有する。庇部6は外部電極4の側面S1の全周に沿って形成される。なお、本発明における「庇部」とは、Z方向から視て(平面視で)、外部電極4の底面(基部)よりもはみ出した部分全体をいう。
外部電極4の表面には導電性接合材5が形成されている。導電性接合材5は、例えば外部電極4の表面にプリコートされたはんだである。なお、導電性接合材5は、フラックス等で外部電極4の表面に仮固定されたはんだボールであってもよい。
第1レジスト膜11は保護膜3の表面に被覆される熱硬化性樹脂であり、外部電極4の側面S1の全周に沿って接している。そのため、本実施形態に係る第1レジスト膜11は、外部電極4と保護膜3との界面を覆うようなループ状(環状、リング状。但し、部分的に切れた形状であってもよい。)である。第1レジスト膜11は、Z方向から視て、全体が外部電極4の庇部6内に収まる。したがって、第1レジスト膜11は、Z方向から視て、外部電極4で覆われている(外部電極4に重なっている)。第1レジスト膜11は例えばポジ型感光性のソルダーレジスト膜である。
第2レジスト膜12は保護膜3の表面に被覆される熱硬化性樹脂であり、第1レジスト膜11と同じ樹脂で構成され、外部電極4の側面S1および第1レジスト膜11から離間して配置される。したがって、外部電極4の側面S1および第1レジスト膜11と第2レジスト膜12との間には、図2等に示すように、離間部31(クリアランス)が形成されている。第2レジスト膜12は例えばポジ型感光性のソルダーレジスト膜である。第1レジスト膜11および第2レジスト膜は同一のレジスト膜をパターニングしたものであるが、第1レジスト膜11の高さ寸法は第2レジスト膜の高さ寸法よりも小さい。
次に、保護膜3および第1レジスト膜11を備えることの利点について、図を参照して説明する。図4(A)は、比較例として、保護膜および第1レジスト膜を備えていない薄膜素子100Aの外部電極4の構成を示す断面詳細図であり、図4(B)は、第1レジスト膜を備えていない薄膜素子100Bの外部電極4の構成を示す断面詳細図である。
図4(A)に示すように、外部電極4と第2レジスト層との間には離間部31が形成されている。そのため、この離間部31から外部電極4に沿って導電性接合材5が浸入することがあり、離間部31内に露出する配線導体膜2と導電性接合材5とが接触して反応(はんだ食われ等)し、抵抗値の増大や、配線導体膜2が断線する虞がある。また、上記離間部31から水分やフラックス等が浸入し、上記離間部31内に露出する配線導体膜2が腐食する虞もある。
また、図4(B)に示すように、配線導体膜2の表面に保護膜3が被覆されている場合には、この離間部31から導電性接合材5が浸入しても、離間部31内に配線導体膜2が露出していないため、配線導体膜2と導電性接合材5との反応は抑制される。しかし、外部電極4の側面と保護膜3との界面50は物理的に隣接・接触しているだけであり、化学的に結合してはいない。そのため、導電性接合材5や水分、フラックス等がこの界面50から浸入し、配線導体膜2と導電性接合材5とが反応したり、配線導体膜2が腐食する虞がある。
一方、本実施形態では、保護膜3が配線導体膜2の表面に被覆される。また、本実施形態では、第1レジスト膜11が、保護膜3の表面に被覆されるループ状の熱硬化性樹脂であり、外部電極4の側面S1の全周に沿って接している。この構成では、離間部31内で配線導体膜2が露出しないため、この離間部31から導電性接合材5や水分、フラックス等が浸入したとしても、配線導体膜2と導電性接合材5との反応等は抑制される。また、薄膜素子101は、外部電極4の側面S1の全周に沿って接する第1レジスト膜11を備えるため、外部電極4の側面と保護膜3との界面50からの導電性接合材や水分、フラックス等の浸入が抑制される。
さらに、第1レジスト膜11はキュアした際に収縮するため、硬化したループ状の第1レジスト膜11には内側に向かって締まるような応力が発生する(図1中の中抜き矢印を参照)。したがって、保護膜3の表面に被覆される第1レジスト膜11が、外部電極4の側面S1を締め付けるため、外部電極4の側面と保護膜3との界面50からの導電性接合材や水分、フラックス等の浸入がさらに抑制される。
また、本実施形態では、第2レジスト膜12が第1レジスト膜11と離間して配置され、第1レジスト膜11と第2レジスト層との間に離間部31が形成されている。もし離間部31が設けられていない場合、レジスト膜には外部電極4との界面から外側に向かう応力が発生するため、外部電極4の側面とレジスト膜との間に隙間が生じ、この隙間から導電性接合材や水分、フラックス等が浸入する虞がある。一方、本実施形態では、硬化した第2レジスト膜12には外部電極4から外側に向かう応力が発生するが(図1中の矢印を参照)、第2レジスト膜12は第1レジスト膜11と離間して配置されているため、外部電極4とレジスト膜との間の隙間の発生がさらに抑制される。
また、本実施形態の外部電極4は、側面S1の全周に沿って形成される庇部6を有し、第1レジスト膜11が、Z方向から視て庇部6に重なっている。この構成により、硬化したループ状の第1レジスト膜11が、外部電極4の底面から表面に向かって脱落することを抑制できる。
上記薄膜素子101は例えば次の工程で製造される。図5は、薄膜素子101の製造工程を順に示す断面図である。
まず、図5中の(1)に示すように、集合基板状態の基材1を用意し、基材1の表面に、イオンスパッタリング等によって約1μmの配線導体膜2を形成する。基材1は例えば受動素子やLC複合電子部品、集積回路素子、ESD保護素子等のSi基板等であり、配線導体膜2は例えばCu等の金属膜である。基材1の表面に配線導体膜2を形成するこの工程が、本発明における「第1工程」に相当する。
次に、配線導体膜2の表面に、イオンスパッタリング等によって約0.1μmの保護膜3を連続形成する。保護膜3は例えばTi等を主成分とする金属膜である。その後、スピンコートによって保護膜3の全面に約5μmのポジ型感光性のレジスト膜を形成し、露光してパターニングする。この工程により、底面から表面に向かってテーパー状のレジスト膜51が形成される。さらに、レジスト膜51をマスクとしてエッチングを行い、保護膜3の配線導体膜2と重なる位置にコンタクトホールCH1を形成する。この工程により、コンタクトホールCH1から配線導体膜2が露出する。配線導体膜2の表面に保護膜3を形成し、保護膜3の配線導体膜2と重なる位置にコンタクトホールCH1を形成するこの工程が、本発明における「第2工程」に相当する。
次に図5中の(2)に示すように、コンタクトホールCH1に露出する配線導体膜2の表面に、外部電極4を形成する。具体的には、コンタクトホールCH1内、且つ、配線導体膜2の表面に、電解めっき法によって、約3μmの第1電極層41および約0.1μmの第2電極層42を連続形成する。第1電極層41は例えばNiを主成分とする金属めっき膜であり、第2電極層42はAuを主成分とする金属めっき膜である。
外部電極4の金属めっき膜は、底面から表面に向かってテーパー状のレジスト膜51に沿って成長する。そのため、外部電極4は、底面から表面に向かって側面が逆テーパー状に形成され、その側面の全周に沿って庇部6が形成される。コンタクトホールCH1内、且つ、配線導体膜2の表面に、側面の全周に沿って庇部6を有する外部電極4を形成するこの工程が、本発明における「第3工程」に相当する。
次に図5中の(4)に示すように、レジスト膜51をアッシングにより取り除いた後、スピンコートによって保護膜3および外部電極4の表面に約5μmのレジスト膜10を形成する。レジスト膜10は例えばポジ型感光性のソルダーレジスト膜である。なお、レジスト膜51はウェット処理で剥離装置にかけて取り除いてもよい。保護膜3の表面にレジスト膜10を形成するこの工程が、本発明における「第4工程」に相当する。
次に図5中の(5)(6)に示すように、レジスト膜10のうち、平面視で庇部6に重なる部分(第1レジスト膜11)と、それ以外の部分(第2レジスト膜12)とを離間する離間部31をフォトリソグラフィにより除去する。具体的には、レジスト膜10のうち、除去したくない部分にフォトマスク61を被せて、光線L1で露光する。このとき、外部電極4の庇部6がフォトマスクとなり、平面視で庇部6に重なる部分は露光されないため、現像して洗浄(リンス)した後、第1レジスト膜11と第2レジスト膜12とを離間する離間部31が除去される。光線L1は例えば紫外線(UV光)である。
レジスト膜10のうち、平面視で庇部6に重なる第1レジスト膜11と、第2レジスト膜12とを離間する離間部31を除去するこの工程が、本発明における「第5工程」に相当する。そして、この第5工程は外部電極4の庇部6をフォトマスクにして露光する工程を含む。
上記第5工程の後に、外部電極4の表面に導電性接合材5をプリコートする。導電性接合材5は例えばはんだである。なお、導電性接合材5ははんだペーストをスクリーン印刷した後、リフロープロセスによって形成してもよい。また、外部電極4の表面にフラックス等を塗付して、はんだボールをマウントして仮固定した後、リフロープロセスによって形成してもよい。さらに、導電性接合材5は、外部電極4の表面にフラックス等を塗付して、はんだボールを仮固定した状態であってもよい。
上記製造方法により、配線導体膜2のはんだ食われや腐食等を抑制した、信頼性の高い外部電極4を有する薄膜素子101を容易に製造できる。
また、上記製造方法では、レジスト膜10がポジ型感光性レジスト膜であり、外部電極4の庇部6がフォトマスクとなるため、外部電極4の側面の全周に沿って接する第1レジスト膜11を容易に形成できる。
《第2の実施形態》
第2の実施形態では、外部電極4および第1レジスト膜11の形状が第1の実施形態とは異なる例を示す。
図6は、第2の実施形態に係る薄膜素子102の外部電極4の構成を示す断面詳細図である。
本実施形態に係る外部電極4は、図6に示すように、ネジ頭のように側面上部が突出した形状である。このような構造であっても、外部電極4は側面の全周に沿って形成される庇部6を有する。また、第1レジスト膜11は外部電極4の側面の全周に沿って接しており、Z方向から視て、全体が外部電極4の庇部6内に収まる。
《その他の実施形態》
なお、上述の実施形態では、外部電極4の平面形状が円形である例を示したが、これ限定されるものではない。外部電極4の平面形状は、正方形、矩形、多角形、楕円形等、適宜変更可能である。
また、庇部6は、外部電極4の側面上部に形成されるものに限定されるものではない。庇部6は、Z方向から視て、外部電極4の底面(基部)からはみ出した部分であればよく、外部電極4の底面以外に形成されていればよい。すなわち、庇部6は、外部電極4の側面中央部等に形成されていてもよい。
また、配線導体膜2は基材1の表面全体に形成されるものに限定されるものではなく、基材1の表面の一部にのみ形成されていてもよい。また、保護膜3は少なくとも配線導体膜2の表面に形成されていればよく、基材1の表面に形成されていてもよい。
なお、上述の実施形態では、基材1の表面が平面状である例を示したが、これに限定されるものではない。基材1の表面は、曲面であってもよく、基材1の表面に段差があってもよい。
CH1…コンタクトホール
L1…光線
S1…外部電極の側面
1…基材
2…配線導体膜
3…保護膜
4…外部電極
5…導電性接合材
6…庇部
10…レジスト膜
11…第1レジスト膜
12…第2レジスト膜
31…離間部
41…第1電極層
42…第2電極層
50…界面
51…レジスト膜
61…フォトマスク
100A,100B,101,102…薄膜素子

Claims (8)

  1. 基材と、
    前記基材の表面に形成される配線導体膜と、
    少なくとも前記配線導体膜の表面に被覆され、平面視で前記配線導体膜と重なる位置にコンタクトホールを有する保護膜と、
    前記コンタクトホール内、且つ、前記配線導体膜の表面に形成され、前記保護膜より厚く、側面を有する外部電極と、
    前記保護膜の表面に被覆される第1レジスト膜および第2レジスト膜と、
    を備え、
    前記第1レジスト膜は、前記外部電極の前記側面の全周に沿って接し、
    前記第2レジスト膜は、前記外部電極の前記側面および前記第1レジスト膜から離間して配置される、薄膜素子。
  2. 前記第1レジスト膜は熱硬化性樹脂である、請求項1に記載の薄膜素子。
  3. 前記外部電極は、前記側面の全周に沿って形成される庇部を有し、
    前記第1レジスト膜は、平面視で前記庇部に重なる、請求項1または2に記載の薄膜素子。
  4. 前記外部電極は、底面から表面に向かって前記側面が逆テーパー状に形成される、請求項3に記載の薄膜素子。
  5. 前記配線導体膜は銅を主成分とする金属膜であり、
    前記保護膜はチタンを主成分とする金属膜であり、
    前記外部電極はニッケルを主成分とする金属である、請求項1から4のいずれかに記載の薄膜素子。
  6. 基材の表面に配線導体膜を形成する第1工程と、
    少なくとも前記配線導体膜の表面に、前記配線導体膜と重なる位置にコンタクトホールを有する保護膜を被覆する第2工程と、
    前記コンタクトホール内、且つ、前記配線導体膜の表面に、側面の全周に沿って庇部を有する外部電極を形成する第3工程と、
    前記保護膜の表面にレジスト膜を被覆する第4工程と、
    前記レジスト膜のうち、平面視で前記庇部に重なる第1レジスト膜と、前記第1レジスト膜以外である第2レジスト膜とを離間する離間部を除去する第5工程と、
    を備える、薄膜素子の製造方法。
  7. 前記第5工程は、
    前記レジスト膜はポジ型感光性レジスト膜であり、前記離間部をフォトリソグラフィにより除去し、
    前記外部電極の前記庇部をフォトマスクにして露光する工程を含む、請求項6に記載の薄膜素子の製造方法。
  8. 前記第5工程の後に、前記外部電極の表面にはんだをプリコートする工程をさらに有する、請求項6または7に記載の薄膜素子の製造方法。
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