KR20110051018A - A carrier member for manufacturing a substrate and a method of manufacturing a substrate using the same - Google Patents

Abstract

PURPOSE: A carrier member for manufacturing a substrate and a method for manufacturing the substrate using the same are provided to prevent the generation of wrinkles on insulating material which is laminated on a metal layer. CONSTITUTION: A carrier member(100) for manufacturing a substrate comprises a base substrate(110), an insulating material(120), a release film(130), and a metal layer(140). The insulating material fixes the metal layer. The release film is mounted in the insulating material in order to separate a build up layer from the carrier member. The release film is formed using a polymer film. The metal layer is formed with a metallic material which is easily etched.

Description

Carrier member for substrate manufacturing and substrate manufacturing method using same {A CARRIER MEMBER FOR MANUFACTURING A SUBSTRATE AND A METHOD OF MANUFACTURING A SUBSTRATE USING THE SAME}

The present invention relates to a carrier member for manufacturing a substrate and a method of manufacturing a substrate using the same.

In general, a printed circuit board is formed of copper foil on one or both sides of a board made of various thermosetting synthetic resins to arrange and fix integrated circuits (ICs) or electronic components on the board, and to implement electrical wiring therebetween and then coated with an insulator. .

Recently, due to the development of the electronics industry, the demand for high functionalization and light weight reduction of electronic components is rapidly increasing. Accordingly, printed circuit boards on which such electronic components are mounted also require high density wiring and thinning.

In particular, in order to cope with the thinning of printed circuit boards, a coreless substrate that can reduce the overall thickness and shorten the signal processing time by removing the core substrate has been attracting attention. However, in the case of the coreless substrate, since the core substrate is not used, a carrier member capable of performing a support function during the manufacturing process is required.

1A to 1D are diagrams illustrating a method of manufacturing a substrate using a conventional carrier member in a process sequence, and FIG. 2 is an enlarged view of main parts of the first metal layer and the second metal layer shown in FIG. Look at the problems of the prior art.

First, as shown in FIG. 1A, the carrier member 10 is prepared. The carrier member 10 is formed by stacking the adhesive film 12, the first metal layer 13, and the second metal layer 14 on both surfaces with the copper clad laminate 11 as the center. At this time, the edge of the adhesive film 12 bonds the copper-clad laminate 11 to the second metal layer 14 by applying heating and pressurization with a press. In addition, the first metal layer 13 and the second metal layer 14 are vacuum-adsorbed to each other.

Next, as shown in FIG. 1B, the build-up layer 15 is formed on both surfaces of the carrier member 10. In this case, the buildup layer 15 is formed in a general manner, and a separate third metal layer 16 is laminated on the outermost layer to prevent bending of the buildup layer 15.

Next, as shown in FIG. 1C, the buildup layer 15 is separated from the carrier member 10. At this time, the edge of the adhesive film 12 bonded to the copper-clad laminate 11 and the second metal layer 14 is removed through a routing process to separate the buildup layer 15 from the carrier member 10.

Next, as shown in FIG. 1D, the third metal layer 16 formed on the outermost layer of the buildup layer 15 is removed. In addition, a printed circuit board may be completed by forming a circuit layer including vias and a solder resist layer that insulates the circuit layer from the outside in the outermost insulating layer.

In the conventional method for manufacturing a substrate, copper foil is usually used as the first metal layer 13 and the second metal layer 14. However, the copper foil has a high M surface (matte surface) and a low surface roughness S surface (shiny surface). Therefore, as shown in FIG. 2, a fine space S is formed between the first metal layer 13 and the second metal layer 14 by the M surface, and thus it is difficult to maintain a perfect vacuum. As a result, when the insulating material of the buildup layer 15 is laminated on the second metal layer 14, wrinkles may occur.

In addition, when the edge of the adhesive film 12 is removed through a routing process to separate the build-up layer 15 from the carrier member 10, due to the difference in physical properties between the second metal layer 14 and the insulating material of the carrier member 10. There is a problem that warpage may occur severely.

Accordingly, the present invention has been made to solve the above problems, the object of the present invention is to employ a release film to maintain a complete vacuum with the metal layer, the side edges or edges of the release film generated during the routing process An object of the present invention is to provide a carrier member for manufacturing a substrate capable of preventing warpage and a method of manufacturing a substrate using the same.

Carrier member for substrate manufacturing according to a preferred embodiment of the present invention is formed on an insulating material laminated on one or both sides of the base substrate, a smaller area than the insulating material buried in one surface of the insulating material and laminated on one surface of the release film The edge comprises a metal layer bonded with the insulating material.

The side edges of the release film may be removed in a predetermined pattern, and the insulating material and the metal layer may be adhered through the removed predetermined pattern.

In addition, an opening of a predetermined pattern is formed along the edge of the release film or a cross opening is formed in the release film, and the insulating material and the metal layer are bonded through the opening.

In addition, the predetermined pattern is characterized in that the circular or oval.

In addition, the release film is characterized in that the polymer film.

In addition, the metal layer is characterized in that formed of copper, nickel or aluminum.

In addition, the insulating material is characterized in that the prepreg.

Method of manufacturing a substrate using a carrier member for manufacturing a substrate according to a preferred embodiment of the present invention (A) laminating an insulating material on one or both sides of the base substrate, (B) a release film formed of a smaller area than the insulating material of the insulating material (C) laminating a metal layer on one surface of the release film, embedding the release film on one surface of the insulating material through pressure and heat fixing, and bonding the edge of the metal layer with the insulating material to a carrier for manufacturing a substrate. Providing a member and (D) forming a buildup layer on one surface of the metal layer, and then removing the edge of the metal layer bonded with the insulating material to separate the buildup layer from the carrier member for manufacturing the substrate. .

Here, in step (B), the side edges of the release film is removed in a predetermined pattern, and in step (C), the insulating material and the metal layer are bonded through the removed predetermined pattern.

 In addition, in the step (B), the opening of the predetermined pattern is formed along the edge of the release film, and in the step (C), characterized in that the insulating material and the metal layer through the opening.

In addition, the step (D), (D1) removing only a part of the predetermined pattern when removing the edge of the metal layer and (D2) separating the insulating material and the metal layer bonded through the remaining predetermined pattern by physical force. By separating the build-up layer from the carrier member for manufacturing the substrate characterized in that it comprises.

In addition, the step (D), (D1) removing only a part of the opening when removing the edge of the metal layer and (D2) separating the insulating material and the metal layer bonded through the remaining opening by physical force to the And separating the build-up layer from the carrier member for substrate production.

In addition, in the step (D), the edge of the metal layer is characterized in that removed through a routing process.

In the step (B), the cross-shaped opening is formed in the release film, and in the step (C), the insulating material and the metal layer are bonded through the opening.

In addition, the predetermined pattern is characterized in that the circular or oval.

The features and advantages of the present invention will become more apparent from the following detailed description based on the accompanying drawings.

Prior to this, the terms or words used in this specification and claims are not to be interpreted in a conventional and dictionary sense, and the inventors may appropriately define the concept of terms in order to best describe their own invention. It should be interpreted as meaning and concept corresponding to the technical idea of the present invention based on the principle that the present invention.

According to the present invention, by employing a release film in the carrier member by the perfect vacuum suction of the metal layer and the release film there is an effect that can prevent the wrinkles of the insulating material laminated on the metal layer.

In addition, according to the present invention, by removing a side edge of the release film in a predetermined pattern, or by forming an opening of a predetermined pattern on the edge of the release film to prevent the warpage caused by the difference in physical properties between the release film and the insulation of the carrier member during the routing process. There is an advantage that can be reduced.

The objects, specific advantages and novel features of the present invention will become more apparent from the following detailed description and the preferred embodiments associated with the accompanying drawings. In adding reference numerals to the components of each drawing, it should be noted that the same components as much as possible, even if displayed on the other drawings. In addition, terms such as “one side” and “side” are used as a reference for distinguishing one component from another component, and the component is not limited by the terms. In describing the present invention, when it is determined that the detailed description of the related known technology may unnecessarily obscure the gist of the present invention, the detailed description thereof will be omitted.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

3A is a cross-sectional view of a carrier member for manufacturing a substrate according to a preferred embodiment of the present invention, FIG. 3B is an enlarged view of main parts of the insulating material and the metal layer shown in FIG. 3A, and FIGS. 4A to 4F are carriers for manufacturing the substrate shown in FIG. 3A. It is a top view of the release film of a member.

As shown in FIGS. 3 to 4, the carrier member 100 for manufacturing a substrate according to the present embodiment is formed with an area smaller than the insulating material 120 and the insulating material 120 laminated on one or both surfaces of the base substrate 110. And a metal film 140 laminated on one surface of the insulating material 120 and laminated on one surface of the release film 130 and bonded to the edge by the insulating material 120.

The insulating material 120 serves to adhere and fix the metal layer 140 and is laminated on the base substrate 110. Although the insulating material 120 is formed on both sides of the base substrate 110 in the drawings, it is not necessarily limited thereto, and may be selectively stacked only on one surface of the base substrate 110. Since the insulating material 120 must adhere to the metal layer 140, it is preferable to employ a prepreg having excellent adhesive strength. Meanwhile, the base substrate 110 is not particularly limited, but as shown in FIG. 3A, a copper clad laminate (CCL) having copper foil laminated on both surfaces of an insulating material may be used.

The release film 130 serves as a release layer to separate the build-up layer 150 (see FIGS. 8 to 9) from the carrier member 100 together with the metal layer 140, and is embedded in the insulating material 120. The release film 130 should not be embedded with respect to the entire surface of the insulating material 120, it should be formed in a smaller area than the insulating material 120 so that the insulating material 120 can be bonded to the edge of the metal layer 140. In addition, as shown in Figure 3b, the release film 130 is vacuum-absorbed with the metal layer 140, the release film 130 for the M surface (matte surface) of the copper foil commonly used as the metal layer 140. By absorbing surface roughness, a perfect vacuum can be maintained. Here, the release film 130 is not particularly limited, but it is preferable to employ a polymer film.

Meanwhile, the side edges of the release film 130 may be removed by the predetermined pattern 133 (see FIG. 4B), and the insulating material 120 and the metal layer 140 adhere through the removed predetermined pattern 133. In consideration of the structural stability of the carrier member 100, it is preferable to remove the four side edges of the release film 130 in the same pattern 133. In addition, an opening 135 having a predetermined pattern may be formed along the edge of the release film 130 (see FIGS. 4C to 4E), or the opening 135 may be formed crosswise (see FIGS. 4D to 4F). The insulating material 120 and the metal layer 140 adhere to each other through the opening 135. In consideration of the structural stability of the carrier member 100, the opening 135 formed along the edge is preferably formed along an imaginary line spaced apart from the side surface of the release film 130. In addition, the predetermined pattern is not particularly limited, but in order to prevent cracking of the release film 130 in advance, it may be circular (see FIGS. 4C to 4E) or elliptical (see FIGS. 4D to 4F). desirable.

Stable printed circuit using the carrier member 100 by reinforcing adhesion between the insulating material 120 and the metal layer 140 by employing the predetermined pattern 133 having the side edges removed or the opening 135 formed at the edge or crosswise. Not only can the substrate manufacturing process be performed, but there is an advantage that the warpage caused by the difference in physical properties between the insulating material of the metal layer 140 and the build-up layer 150 can be reduced during the routing process. A detailed description of the effects of reducing the warpage during the routing process will be given later.

The metal layer 140 serves as a release layer that separates the buildup layer 150 from the carrier member 100 together with the release film 130, and is stacked on one surface of the release film 130. As described above, since the release film 130 is formed with a smaller area than the insulating material 120 to expose the edge of the insulating material 120, the metal layer 140 is laminated on one surface of the release film 130, and then heated and pressed. The edge of the metal layer 140 is bonded to the edge of the lower surface insulating material 120. In this case, the metal layer 140 and the release film 130 are vacuum-adsorbed, and the release film 130 may maintain a perfect vacuum by absorbing the surface roughness of the metal layer 140.

On the other hand, the material of the metal layer 140 is not particularly limited, but after being separated from the carrier member 100 together with the build-up layer 150, can be removed by etching from the build-up layer 150, copper, which is easy to etch, It is preferable to form with nickel or aluminum, for example, a copper foil can be used.

Unlike the conventional carrier member, the carrier member 100 according to the present exemplary embodiment employs a release film 130 to completely vacuum-absorb the metal layer 140 to form an insulating material of the build-up layer 150 to be stacked on the metal layer 140. Wrinkles can be prevented. In addition, by processing side edges or edges of the release film 130 to ensure structural stability during the manufacturing process of the substrate using the carrier member 100, a thinner metal layer 140 can be used, which may occur during the routing process. The warpage can be reduced. Hereinafter, a method of manufacturing a substrate using the carrier member 100 according to the present embodiment will be described.

5 to 11 are diagrams showing a method of manufacturing a substrate using a carrier member for manufacturing a substrate according to a preferred embodiment of the present invention in the order of process.

5 to 11, in the method of manufacturing a substrate using the carrier member 100 for manufacturing a substrate according to the present embodiment, (A) the insulating material 120 is laminated on one or both surfaces of the base substrate 110. Step, (B) laminating the release film 130 formed of a smaller area than the insulating material 120 on one surface of the insulating material 120, (C) laminating and pressing the metal layer 140 on one surface of the release film 130 And embedding the release film 130 on one surface of the insulating material 120 through a heating process, and bonding the edge of the metal layer 140 with the insulating material 120 to provide a carrier member 100 for manufacturing a substrate, (D) After the build-up layer 150 is formed on one surface of the metal layer 140, the edge of the metal layer 140 adhered to the insulating material 120 is removed to separate the build-up layer 150 from the carrier member 100 for manufacturing a substrate. It is a configuration to include.

First, as shown in FIG. 5, the insulating material 120 is laminated on the base substrate 110. Here, since the insulating material 120 serves to adhere and fix the metal layer 140, it is preferable to use a prepreg having excellent adhesive strength. In addition, although the insulating material 120 is laminated on both surfaces of the base substrate 110 in the drawing, the material limited thereto may be selectively stacked only on one surface of the base substrate 110.

Next, as shown in FIG. 6, the release film 130 is stacked on one surface of the insulating material 120. Here, the release film 130 serves as a release layer to separate the build-up layer 150 from the carrier member 100 in a step to be described later so that the edge of the insulating material 120 can be bonded to the edge of the metal layer 140. It is preferable to form an area smaller than the insulating material 120. The release film 130 is not particularly limited, but a polymer film may be employed. In addition, the side edges of the release film 130 may be removed with a predetermined pattern 133 (see FIG. 4B), or an opening 135 having a predetermined pattern may be formed along the edge of the release film 130 (FIGS. 4C to 4D). The cross-shaped opening 135 may be formed in the release film 130. At this time, the opening 135 or the cross-shaped opening 135 of the predetermined pattern formed along the edge is circular (see FIGS. 4C to 4E) or elliptical (FIGS. 4D to 4F) in order to prevent cracking of the release film 130. Reference), but is not limited thereto. The insulating material 120 and the metal layer 140 are bonded to each other through the predetermined pattern 133 having the side edges removed, the opening 135 formed along the edge, or the cross opening 135.

Next, as shown in FIG. 7, the metal layer 140 is laminated and the metal layer 140 is bonded to the insulating material 120 to provide a carrier member 100 for manufacturing a substrate. Here, the metal layer 140 is laminated on one surface of the release film 130, and the release film 130 is embedded in one surface of the insulating material 120 through a pressing and heating process, and at the same time the edge of the metal layer 140 is the insulating material. A carrier member 100 is provided in adherence with 120.

On the other hand, when the side edge of the release film 130 is removed in a predetermined pattern 133 in the above-described step, the insulating material 120 and the metal layer 140 is bonded through the predetermined pattern 133, the release film ( When the opening 135 of a predetermined pattern is formed along the edge of the 130 or the cross opening 135 is formed, the insulating material 120 and the metal layer 140 are bonded through the opening 135. Therefore, the adhesion area is wider than that of the release film 130 having a basic structure (see FIG. 4A), thereby achieving a more stable structure.

Next, as shown in FIG. 8, the build-up layer 150 is formed on one surface of the metal layer 140. The build-up layer 150 is formed by stacking a separate insulating material and forming a via hole using a YAG laser or a CO ₂ laser, and then performing a via (Semi-Additive Process) or a modified semi-additive process (MSAP). This can be completed by forming the circuit layer 153 including the 151.

Next, as shown in FIG. 9, the edge of the metal layer 140 adhered to the insulating material 120 is removed to separate the build-up layer 150 from the carrier member 100. When the edge of the metal layer 140 is bonded by the insulating material 120, the metal layer 140 and the release film 130 does not have an adhesive force to each other, so if the edge of the metal layer 140 bonded by the insulating material 120 is removed The buildup layer 150 is separated from the carrier member 100. In this case, the removal of the edge of the metal layer 140 may be generally performed through a routing process.

However, when the side edges or edges of the release film 130 are processed in the above-described steps, there are points to be considered when removing the edges of the metal layer 140, which will be described below with reference to the drawings.

FIG. 12 is a view illustrating a reference line for removing an edge of the metal layer for manufacturing a substrate illustrated in FIG. 8, and FIGS. 13A to 13D are plan views illustrating the reference line illustrated in FIG. 12 on a release film.

When the side edge of the release film 130 is removed in a predetermined pattern 133 in the above-described step to bond the insulating material 120 and the metal layer 140 through the predetermined pattern 133 (see FIG. 4B), in this step First, when the edge of the metal layer 140 is removed, only a portion of the predetermined pattern 133 is removed to maintain adhesion between the insulating material 120 and the metal layer 140 through the remaining portion 137 (see FIG. 13B). Thereafter, the buildup layer 150 can be separated from the carrier member 100 by separating the insulating material 120 and the metal layer 140 which are relatively weakly bonded by applying a physical force.

In addition, in the above-described step, when the opening 135 of the predetermined pattern is formed along the edge of the release film 130 to bond the insulating material 120 and the metal layer 140 through the opening 135 (FIGS. 4C to 4D). In this step, when the edge of the metal layer 140 is first removed, only a part of the opening 135 is removed to maintain adhesion between the insulating material 120 and the metal layer 140 through the remaining portion 139 (FIG. 12C). To FIG. 12D). Thereafter, the buildup layer 150 can be separated from the carrier member 100 by separating the insulating material 120 and the metal layer 140 which are relatively weakly bonded by applying a physical force.

As described above, in the method of manufacturing a substrate using the carrier member 100 for manufacturing a substrate according to the present embodiment, unlike the prior art, the build-up layer 150 is not separated from the carrier member 100 at a time through a routing process. Since the separation through the step can be reduced compared to the prior art due to the difference in physical properties between the insulating material of the metal layer 140 and the carrier member 100 in the separation process can be reduced.

Next, as shown in FIGS. 10 to 11, after the metal layer 140 is removed from the buildup layer 150, a hole 157 is formed in the solder resist layer 155. Here, the metal layer 140 may be removed by etching, and the hole 157 may be formed in the solder resist layer 155 for electrical connection with an external circuit. However, this step is not necessarily performed as an additional process.

Although the present invention has been described in detail through specific examples, this is for describing the present invention in detail, and the carrier member for manufacturing the substrate and the method for manufacturing the substrate using the same according to the present invention are not limited thereto. It will be apparent that modifications and improvements are possible by those skilled in the art.

All simple modifications and variations of the present invention fall within the scope of the present invention, and the specific scope of protection of the present invention will be apparent from the appended claims.

1A to 1D are diagrams showing a method of manufacturing a substrate using a conventional carrier member in a process order;

FIG. 2 is an enlarged view of main parts of the first metal layer and the second metal layer shown in FIG. 1; FIG.

3A is a cross-sectional view of a carrier member for manufacturing a substrate according to a preferred embodiment of the present invention;

3B is an enlarged view illustrating main parts of the insulating material and the metal layer shown in FIG. 3A;

4A to 4F are plan views of a release film of a carrier member for manufacturing a substrate shown in FIG. 3A;

5 to 11 are diagrams showing a method of manufacturing a substrate using a carrier member for manufacturing a substrate according to a preferred embodiment of the present invention in the order of a process;

FIG. 12 is a view illustrating a reference line for removing an edge of the metal layer for manufacturing a substrate shown in FIG. 8; FIG. And

13A to 13D are plan views illustrating the reference line illustrated in FIG. 12 on the release film.

<Description of the symbols for the main parts of the drawings>

100: carrier member 110: base substrate

120: insulation material 130: release film

133: pattern 135: opening

137 and 139: remaining portion 140: metal layer

150: buildup layer 151: via

153: circuit layer 155: solder resist layer

157: hall

Claims (15)

An insulating material laminated on one or both surfaces of the base substrate; A release film formed with a smaller area than the insulating material and embedded in one surface of the insulating material; And A metal layer laminated on one surface of the release film and having an edge bonded to the insulating material; Carrier member for substrate production comprising a. The method according to claim 1, Side edges of the release film is removed in a predetermined pattern, the carrier member for substrate manufacturing, characterized in that the insulating material and the metal layer is bonded through the removed predetermined pattern. The method according to claim 1, An opening having a predetermined pattern is formed along the edge of the release film or a cross opening is formed in the release film, and the insulating member and the metal layer are adhered through the opening. The method of claim 3, The predetermined pattern is a carrier member for manufacturing a substrate, characterized in that the circular or oval. The method according to claim 1, The release film is a carrier member for manufacturing a substrate, characterized in that the polymer film. The method according to claim 1, The metal layer is a carrier member for manufacturing a substrate, characterized in that formed of copper, nickel or aluminum. The method according to claim 1, The insulation member is a carrier member for manufacturing a substrate, characterized in that the prepreg. (A) stacking an insulating material on one or both sides of the base substrate; (B) stacking a release film formed on a smaller surface than the insulating material on one surface of the insulating material; (C) laminating a metal layer on one surface of the release film, embedding the release film on one surface of the insulating material through pressure and heat fixing, and bonding the edge of the metal layer with the insulating material to provide a carrier member for manufacturing a substrate; And (D) forming a buildup layer on one surface of the metal layer, and then removing the edge of the metal layer bonded with the insulating material to separate the buildup layer from the carrier member for manufacturing the substrate; Method of manufacturing a substrate using a carrier member for substrate production comprising a. The method according to claim 8, In the step (B), Side edges of the release film is removed in a predetermined pattern, In the step (C), A method of manufacturing a substrate using a carrier member for manufacturing a substrate, characterized in that the insulating material and the metal layer are bonded through the removed predetermined pattern. The method according to claim 8, In the step (B), An opening of a predetermined pattern is formed along an edge of the release film, In the step (C), A method of manufacturing a substrate using a carrier member for manufacturing a substrate, characterized in that the insulating material and the metal layer are bonded through the opening. The method according to claim 9, Step (D), (D1) removing only a part of the predetermined pattern when removing the edge of the metal layer; And (D2) separating the build-up layer from the carrier member for manufacturing a substrate by separating the insulating material and the metal layer bonded through the predetermined pattern remaining with the physical force. Manufacturing method. The method according to claim 10, Step (D), (D1) removing only a part of the opening when removing the edge of the metal layer; And (D2) separating the build-up layer from the carrier member for manufacturing the substrate by separating the insulating material and the metal layer bonded through the remaining openings with a physical force, and manufacturing the substrate using the carrier member for manufacturing the substrate. Way. The method according to claim 8, In the step (D), The edge of the metal layer is removed by a routing process, the method of manufacturing a substrate using a carrier member for manufacturing a substrate. The method according to claim 8, In the step (B), A cross-shaped opening is formed in the release film, In the step (C), A method of manufacturing a carrier member for manufacturing a substrate, characterized in that the insulating material and the metal layer are bonded through the opening. The method according to claim 10, The predetermined pattern is a manufacturing method of the carrier member for producing a substrate, characterized in that the circular or oval.

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