TWI581697B - Method for manufacturing heat dissipation structure of ceramic substrate - Google Patents
Method for manufacturing heat dissipation structure of ceramic substrate Download PDFInfo
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本發明是有關一種陶瓷基板散熱結構的製造方法,尤指一種具有良好散熱度的陶瓷基板散熱結構的製造方法。 The invention relates to a method for manufacturing a heat dissipation structure of a ceramic substrate, in particular to a method for manufacturing a heat dissipation structure of a ceramic substrate having good heat dissipation.
不論是LED散熱基板或是被動元件基板,基本上都是以陶瓷為基座,並成型導體導線於其上,一般而言由於陶瓷基板具有高度機械強度,除搭載元件外,亦可作為支持構件使用;又由於其表面光滑而具有良好加工性,精密尺寸,以及可多層化、絕緣破壞電壓高、於溫度高、濕度大的條件下性能穩定,具有可靠性、熱導率高、耐熱性優良、化學穩定性好、並且容易金屬化、線路圖形與陶瓷基板間附著力強等等特點,更具備材料取得容易、製造容易的重要特質,使得陶瓷散熱基板具有廣泛商業利用價值。 Regardless of whether the LED heat sink substrate or the passive component substrate is basically made of ceramic as a base and the conductor wire is formed thereon, generally, since the ceramic substrate has high mechanical strength, in addition to the component, it can also serve as a supporting member. Use; and because of its smooth surface, good processability, precision size, and multi-layer, high insulation breakdown voltage, stable performance under high temperature and high humidity conditions, reliability, high thermal conductivity and excellent heat resistance It has good chemical stability, easy metallization, strong adhesion between circuit patterns and ceramic substrates, and has important characteristics such as easy material acquisition and easy manufacturing, making the ceramic heat dissipation substrate widely used.
LED散熱基板最主要的作用就是在於利用其散熱基板材料本身具有較佳的熱傳導性,而有效的將熱能從LED晶粒傳導到系統散熱,可降低LED晶粒的溫度,增加發光效率進而避免熱累積而致使產品損害,延長LED壽命。而LED散熱基板主要分為系統電路板與LED晶粒基板兩大類別。 The main function of the LED heat dissipating substrate is to use the heat dissipating substrate material to have better thermal conductivity, and effectively transfer heat energy from the LED die to the system to reduce the temperature of the LED die, increase the luminous efficiency and avoid heat. Accumulation causes damage to the product and extends LED life. The LED heat sink substrate is mainly divided into two major categories: system board and LED die board.
系統電路板主要是作為LED散熱系統中,將熱能導至散熱片、外殼或大氣中的最終端。近年來印刷電路板(PCB)的生產技術已非常純熟,早期LED產品的系統電路板多以PCB為主,但隨著高功率LED的需求增加,PCB之材料散熱能力有限,使其無法應用於其高功率產品,為了改善高功率LED散熱問題,近期已發展出高熱導係數鋁基板(MCPCB),利用其金屬材料具有較優的散 熱特性,可達到高功率產品散熱的目的。然而隨著LED亮度與效能要求的持續發展,儘管系統電路板可將LED晶片所產生的熱有效的散熱到大氣環境,但是LED晶粒所產生的熱能卻無法有效的從晶粒基板傳導至系統電路板。 The system board is mainly used as the LED terminal cooling system to conduct thermal energy to the heat sink, the outer casing or the most terminal in the atmosphere. In recent years, the production technology of printed circuit boards (PCBs) has been very mature. The system boards of early LED products are mostly PCB-based. However, with the increasing demand for high-power LEDs, the heat dissipation capability of PCB materials is limited, making it unusable. In order to improve the heat dissipation of high-power LEDs, high-power products have recently developed a high thermal conductivity aluminum substrate (MCPCB), which has a superior dispersion of metal materials. The thermal characteristics can achieve the purpose of heat dissipation of high-power products. However, with the continuous development of LED brightness and performance requirements, although the system board can effectively dissipate the heat generated by the LED chip to the atmosphere, the thermal energy generated by the LED die cannot be effectively transmitted from the die substrate to the system. Circuit board.
LED晶粒基板主要是作為LED晶粒與系統電路板之間熱能導出的媒介,藉由打線、共晶或覆晶的其中一種方式與LED晶粒結合。基於散熱方面考量,目前市面上LED晶粒基板主要以陶瓷基板為主,常見的陶瓷基板結構為低溫共燒多層陶瓷基板(LTCC)、高溫共燒多層陶瓷基板(HTCC)、直接覆銅基板(DBC)、以及直接濺鍍銅基板(DPC)四種。 The LED die substrate is mainly used as a medium for deriving thermal energy between the LED die and the system board, and is combined with the LED die by one of wire bonding, eutectic or flip chip. Based on heat dissipation considerations, LED die substrates on the market are mainly ceramic substrates. Common ceramic substrate structures are low temperature co-fired multilayer ceramic substrates (LTCC), high temperature co-fired multilayer ceramic substrates (HTCC), and direct copper-clad substrates ( DBC), as well as direct sputter copper substrates (DPC).
第一種低溫共燒陶瓷基板製程為利用氧化鋁粉末混合玻璃材料以及黏著劑使成為一漿料,乾燥後進行鑽孔作業,並利用網印方式進行填孔及成形線路圖案,最終將多層線路燒結成型,因此,網印方式製作的線路因為網版張網問題,容易產生線路粗糙、對位不精準的現象,且藉由此製程形成陶瓷基板結構其導電性不足,導熱係數約為3-6,故已不適用於今日產品微型化、精確的需求。 The first low-temperature co-fired ceramic substrate process is to use a alumina powder mixed glass material and an adhesive to make a slurry, dry and then drill, and use a screen printing method to fill holes and form a line pattern, and finally the multilayer line Sintering molding, therefore, the screen made by the screen printing method is prone to rough circuit and inaccurate alignment due to the problem of screen-laid net, and the ceramic substrate structure formed by the process has insufficient conductivity, and the thermal conductivity is about 3- 6, it is not applicable to today's product miniaturization, precise needs.
第二種高溫共燒陶瓷基板於大多製程與低溫共燒陶瓷基板相同,然而高溫共燒陶瓷基板並無加入玻璃材質,故需要高溫1300~1600℃進行燒結溫度,且由於需要較高的燒結溫度,因而造成選擇線路金屬材質受到限制,一般而言,熔點高的金屬材料如鎢、鉬、錳…等金屬,,不僅具有網印成形線路的對位缺失,另一方面亦具有導電性較差的問題。 The second high-temperature co-fired ceramic substrate is the same as the low-temperature co-fired ceramic substrate in most processes. However, the high-temperature co-fired ceramic substrate is not added with a glass material, so a high temperature of 1300 to 1600 ° C is required for the sintering temperature, and a higher sintering temperature is required. Therefore, the metal material of the selected circuit is limited. Generally, metal materials such as tungsten, molybdenum, manganese, etc., which have a high melting point, not only have a misalignment of the screen printing line, but also have poor conductivity. problem.
第三種直接接合銅基板(DBC)為利用陶瓷基板覆上銅金屬進行貼合,利用高溫1065~1085℃使所述陶瓷基板和銅共晶熔體,最後再以蝕刻的方式進行成型線路,其製造成本較高,且陶瓷基板與銅金屬間具有微氣泡問題。 The third direct-bonding copper substrate (DBC) is formed by coating a ceramic substrate with copper metal, and the ceramic substrate and the copper eutectic melt are used at a high temperature of 1065 to 1085 ° C, and finally, a molding line is formed by etching. The manufacturing cost is high, and there is a problem of microbubbles between the ceramic substrate and the copper metal.
第四種直接鍍銅基板(DPC)為先進行一前處理程序後,再以一濺鍍手段沉積銅金屬層,而後披覆光阻,進行曝光顯影製程以成型線路,最後再藉由一電鍍或化鍍方式以增厚線路層,雖然其具有導熱係數約為20-170的較高導熱率可應用於高功率產品,惟其高成本的特點卻限縮其應用性。 The fourth direct copper plating substrate (DPC) is first subjected to a pre-treatment process, and then a copper metal layer is deposited by a sputtering method, and then the photoresist is coated, and an exposure and development process is performed to form a circuit, and finally, a plating process is performed. Or the plating method to thicken the circuit layer, although its high thermal conductivity with a thermal conductivity of about 20-170 can be applied to high-power products, but its high cost characteristics limit its applicability.
鑒於上述陶瓷基板散熱結構皆具有其缺失,為因應電子產業的快速發展,近年來相關產業致力於尋求開發高功率LED的更佳散熱方法以符合電子元件的散熱需求,如第1圖所示,一改良的陶瓷基板散熱結構的製造方法包含步驟(1)為在一帶層中形成一個或多個通孔,步驟(2)在該帶層之一第一表面上提供一中間層,步驟(3)在該中間層上提供一真空襯紙,以及步驟(4)使用一印刷機真空台填充該等通孔。 In view of the rapid development of the above-mentioned ceramic substrate heat dissipation structure, in response to the rapid development of the electronics industry, in recent years, the related industries have been seeking to develop a better heat dissipation method for high-power LEDs to meet the heat dissipation requirements of electronic components, as shown in FIG. A modified ceramic substrate heat dissipation structure manufacturing method comprising the steps of: (1) forming one or more through holes in a strip layer, and step (2) providing an intermediate layer on a first surface of the strip layer, step (3) A vacuum liner is provided on the intermediate layer, and step (4) fills the through holes using a printer vacuum table.
如第2圖所示,又另一改良的陶瓷基板散熱結構製造方法包含步驟(1)上色步驟101,步驟(2)鑽孔步驟102:使用聚焦的高溫雷射,從陶瓷基板背面以氣化方式鑽孔加工,使線路正面形成較小孔徑;步驟(3)清潔步驟103:利用有機溶劑將基板表面可能殘留的金屬與有機物去除,然後清潔基板,確保基板上沒有其他會影響後續製程的物質存在;步驟(4)導電銅層沉積步驟104:以垂直連續式濺鍍法,在基板上沉積導電層銅(Cu),並且加上一層中介層(TiCu合金、Ti、TiW合金或NiCr合金)於銅層與基板之間,以增加線路附著性;步驟(5)黃光微影成像步驟105:使用負型乾膜光阻覆蓋於第一層金屬上,再依照各第二層金屬厚度要求,選擇適合乾膜光阻的厚度,配合適當的加熱溫度、壓力、貼合速度及乾膜張力,填入第二層金屬線路;步驟(6)電鑄填孔步驟106:利用電鍍方式在未被光阻覆蓋的種子層上方進行沉積,以鍍厚銅線路,並且將通孔填滿導通;步驟(7)剝膜步驟107:使用強鹼型溶液藥劑藉水平式去膜線或浸泡式去膜槽進行去 膜;步驟(8)蝕刻步驟108:以濕蝕刻藉由強酸型藥劑移除鈦銅合金層,或噴灑強酸藥劑與鈦銅合金表面產生化學反應以移除該導電層,然後進行清潔;步驟(9)磨刷步驟109:使基板表面平整,然後進行清潔;步驟(10)絕緣層防護印刷步驟110:使用熱固型防焊塗料作為表面絕緣層;以及步驟(11)表面改質步驟111:在銅線路上鍍上銀、鎳金或鎳鈀金之金屬層,以提高表面焊錫強度及打線強度,進而增加產品的穩定性。 As shown in FIG. 2, another modified ceramic substrate heat dissipation structure manufacturing method comprises the steps of (1) coloring step 101, step (2) drilling step 102: using a focused high temperature laser, and gas from the back surface of the ceramic substrate. The drilling method is used to form a small aperture on the front side of the line; Step (3) Cleaning step 103: removing the metal and organic substances remaining on the surface of the substrate by using an organic solvent, and then cleaning the substrate to ensure that there are no other substrates on the substrate that may affect subsequent processes. Substance existence; step (4) conductive copper layer deposition step 104: depositing a conductive layer of copper (Cu) on the substrate by vertical continuous sputtering, and adding an interposer (TiCu alloy, Ti, TiW alloy or NiCr alloy) Between the copper layer and the substrate to increase the line adhesion; step (5) yellow lithography imaging step 105: using a negative dry film photoresist to cover the first layer of metal, and then according to the thickness requirements of the second layer of metal, Select the thickness suitable for the dry film photoresist, fill in the second metal line with appropriate heating temperature, pressure, bonding speed and dry film tension; Step (6) Electroforming filling step 106: Using electroplating Depositing over the seed layer covered by the barrier to plate a thick copper line and filling the via hole; step (7) stripping step 107: using a strong alkali type solution agent by a horizontal stripping line or a immersion stripping tank Go on Film; step (8) etching step 108: removing the titanium-copper alloy layer by a strong acid type agent by wet etching, or spraying a strong acid agent to chemically react with the surface of the titanium-copper alloy to remove the conductive layer, and then performing cleaning; 9) a rubbing step 109: flattening the surface of the substrate, followed by cleaning; step (10) insulating layer protective printing step 110: using a thermosetting solder resist as the surface insulating layer; and step (11) surface modifying step 111: The copper line is plated with a metal layer of silver, nickel gold or nickel palladium to increase the surface solder strength and wire strength, thereby increasing the stability of the product.
惟上述第一習知技術藉由網板印刷填充通孔其具有張網對位問題,第二習知技術為利用電鍍沉積一金屬層再貼一乾膜,並再以電鑄手段形成一增厚金屬層,需經過繁複的製程手段使能完成陶瓷基板的散熱結構,故其具有較高的製程成本。 However, the first conventional technique has the problem of web alignment by filling the through hole by screen printing. The second conventional technique is to deposit a metal layer by electroplating and then attach a dry film, and then form a thickening by electroforming. The metal layer requires a complicated process to complete the heat dissipation structure of the ceramic substrate, so that it has a high process cost.
有鑑於此,實有必要提供一種藉由簡易、低成本製程卻可達到良好散熱度的陶瓷基板散熱結構的製造方法。 In view of the above, it is necessary to provide a method for manufacturing a heat dissipation structure of a ceramic substrate which can achieve good heat dissipation by a simple and low-cost process.
本發明的主要目的在於提供一種適用於各種陶瓷基板散熱結構的製造方法,利用電鑄電通散熱的方式提昇陶瓷基板至導熱係數約370~400,大幅提高熱傳導的散熱,並提升LED的發光效率,使各種不同類型的陶瓷基板皆達到良好散熱能力,大幅降低熱量累積於產品內部造成熱損害。 The main object of the present invention is to provide a manufacturing method suitable for various heat dissipation structures of ceramic substrates, which utilizes electroforming heat dissipation to increase the thermal conductivity of the ceramic substrate to about 370-400, greatly improve heat dissipation of heat conduction, and improve luminous efficiency of the LED. A variety of different types of ceramic substrates are achieved to achieve good heat dissipation, greatly reducing heat accumulation inside the product and causing thermal damage.
本發明的次要目的在於提供一種陶瓷基板散熱結構的製造方法除了具有高散熱度之外,其製造方法亦具有製程簡單的特點,可達到降低成本的目的,進而大幅提升產業應用性。 A secondary object of the present invention is to provide a method for manufacturing a heat dissipation structure for a ceramic substrate, in addition to having a high heat dissipation degree, the manufacturing method thereof has the characteristics of simple process, and can achieve the purpose of reducing cost, thereby greatly improving industrial applicability.
為實現前述目的,本發明一種陶瓷基板散熱結構的製造方法,包含: (A)提供一已進行穿孔處理的陶瓷基板,上述陶瓷基板具有至少一由頂面貫通至底面的貫通孔;(B)將一金屬材料鄰接於上述陶瓷基板的一表面,並使上述金屬材料覆蓋於上述貫通孔一端;(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱;(D)去除上述金屬材料,讓上述金屬柱和陶瓷基板共同形成一陶瓷散熱基板。 To achieve the foregoing object, a method for manufacturing a heat dissipation structure for a ceramic substrate according to the present invention comprises: (A) providing a ceramic substrate subjected to perforation treatment, wherein the ceramic substrate has at least one through hole penetrating from the top surface to the bottom surface; (B) a metal material is adjacent to a surface of the ceramic substrate, and the metal material is Covering one end of the through hole; (C) depositing metal to the through hole by electroforming, forming a metal post connected to the metal material inside the through hole; (D) removing the metal material, allowing the metal column and The ceramic substrates collectively form a ceramic heat sink substrate.
所述已進行穿孔處理的陶瓷基板可藉由低溫共燒製程而形成,上述穿孔處理可透過具有穿孔的模具成孔。 The perforated ceramic substrate can be formed by a low temperature co-firing process, and the perforation treatment can be performed through a hole having a perforated mold.
所述穿孔處理亦可設為超音波加工、電子束加工、雷射加工、蝕刻成孔、噴砂成孔的其中一種加工方法。 The perforation treatment may also be one of processing methods of ultrasonic processing, electron beam processing, laser processing, etching into holes, and sandblasting into holes.
上述金屬材料採用研磨機、研磨紙、研磨帶、研磨片、研磨液的其中一種研磨方式去除。 The above metal material is removed by one of a grinding machine, an abrasive paper, a polishing tape, an abrasive sheet, and a polishing liquid.
本發明一種陶瓷基板散熱結構的製造方法更包含一步驟:以電鍍或化學鍍沉積方式於上述金屬柱表面增加一金屬防護層。 The method for fabricating a heat dissipation structure for a ceramic substrate further comprises the step of: adding a metal protective layer to the surface of the metal pillar by electroplating or electroless deposition.
上述金屬防護層是由化學銀層、錫及錫合金層的其中一種來構成單一金屬層或為電鍍鎳層、電鍍金層、電鍍銀層的其中一種來構成單一金屬層,亦可為由一化學鎳層上方沉積一化學金層或化學銀層的其中一種來構成複合金屬層,或為一電鍍鎳層上方電鍍一金層或銀層的其中一種來構成複合金屬層。 The metal protective layer is composed of one of a chemical silver layer, a tin and a tin alloy layer, or a single layer of a nickel plating layer, an electroplated gold layer or an electroplated silver layer, or a single metal layer. A composite metal layer is formed by depositing one of a chemical gold layer or a chemical silver layer over the electroless nickel layer, or plating a gold layer or a silver layer over an electroplated nickel layer to form a composite metal layer.
於第一實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度小於上述貫通孔高度,上述金屬柱與陶瓷基板之間可形成至少一凹部。 In the first embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal post connected to the metal material inside the through hole. When the height of the deposited metal is smaller than the height of the through hole, At least one recess may be formed between the metal post and the ceramic substrate.
於第二實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度等於上述貫通孔高度,上述金屬柱與陶瓷基板將共同形成一平面。 In the second embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal post connected to the metal material inside the through hole. When the height of the deposited metal is equal to the height of the through hole, The metal post and the ceramic substrate will together form a plane.
於第三實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度大於上述貫通孔高度,上述金屬柱將於上述陶瓷基板上形成至少一凸部,再將上述凸部研磨去除,使上述金屬柱與陶瓷基板的表面互相切齊形成共平面。 In the third embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal post connected to the metal material inside the through hole. When the height of the deposited metal is greater than the height of the through hole, The metal post forms at least one convex portion on the ceramic substrate, and then the convex portion is polished and removed, so that the surface of the metal post and the ceramic substrate are mutually aligned to form a coplanar surface.
於第四實施例中,一種陶瓷基板散熱結構的製造方法,包含:(A)提供一已進行穿孔處理的陶瓷基板,上述陶瓷基板具有至少一由頂面貫通至底面的貫通孔;(B)將一金屬材料鄰接於上述陶瓷基板的一表面,並使上述金屬材料覆蓋於上述貫通孔一端;(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱;(D)去除上述金屬材料,讓上述金屬柱和陶瓷基板共同形成一陶瓷散熱基板;(E)以蒸鍍或濺鍍沉積方式於上述金屬柱與陶瓷基板表面增加一金屬導電層;(F)利用壓膜(抗蝕刻膜)、曝光顯影及蝕刻製程於上述金屬導電層形成線路圖案;(G)將上述抗蝕刻膜剝除。 In a fourth embodiment, a method for manufacturing a heat dissipation structure for a ceramic substrate, comprising: (A) providing a ceramic substrate subjected to a perforation process, wherein the ceramic substrate has at least one through hole penetrating from a top surface to a bottom surface; (B) a metal material is adjacent to a surface of the ceramic substrate, and the metal material is covered on one end of the through hole; (C) a metal is deposited by electroforming to the through hole, and a metal material is formed inside the through hole a metal pillar connected; (D) removing the metal material, and the metal pillar and the ceramic substrate together form a ceramic heat dissipation substrate; (E) adding a metal conductive layer to the surface of the metal pillar and the ceramic substrate by evaporation or sputtering deposition (F) forming a wiring pattern on the metal conductive layer by a film (etching resistant film), an exposure developing process, and an etching process; (G) stripping the etching resistant film.
所述已進行穿孔處理的陶瓷基板可藉由低溫共燒製程而形成,上 述穿孔處理可透過具有穿孔的模具成孔。 The ceramic substrate subjected to the perforation treatment can be formed by a low temperature co-firing process, The perforation process can be made into a hole through a mold having perforations.
所述穿孔處理亦可設為超音波加工、電子束加工、雷射加工、蝕刻成孔、噴砂成孔的其中一種加工方法。 The perforation treatment may also be one of processing methods of ultrasonic processing, electron beam processing, laser processing, etching into holes, and sandblasting into holes.
上述金屬材料採用研磨機、研磨紙、研磨帶、研磨片、研磨液的其中一種研磨方式去除。 The above metal material is removed by one of a grinding machine, an abrasive paper, a polishing tape, an abrasive sheet, and a polishing liquid.
本發明一種陶瓷基板散熱結構的製造方法更包含一步驟:以電鍍或化學鍍沉積方式於上述金屬柱表面增加一金屬防護層。 The method for fabricating a heat dissipation structure for a ceramic substrate further comprises the step of: adding a metal protective layer to the surface of the metal pillar by electroplating or electroless deposition.
上述金屬防護層是由化學銀層、錫及錫合金層的其中一種來構成單一金屬層或為電鍍鎳層、電鍍金層、電鍍銀層的其中一種來構成單一金屬層,亦可為由一化學鎳層上方沉積一化學金層或化學銀層的其中一種來構成複合金屬層,或為一電鍍鎳層上方電鍍一金層或銀層的其中一種來構成複合金屬層。 The metal protective layer is composed of one of a chemical silver layer, a tin and a tin alloy layer, or a single layer of a nickel plating layer, an electroplated gold layer or an electroplated silver layer, or a single metal layer. A composite metal layer is formed by depositing one of a chemical gold layer or a chemical silver layer over the electroless nickel layer, or plating a gold layer or a silver layer over an electroplated nickel layer to form a composite metal layer.
於一實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度小於上述貫通孔高度,上述金屬柱與陶瓷基板之間可形成至少一凹部。 In an embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal pillar connected to the metal material inside the through hole. When the height of the deposited metal is less than the height of the through hole, the metal At least one recess may be formed between the post and the ceramic substrate.
於另一實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度等於上述貫通孔高度,上述金屬柱與陶瓷基板將共同形成一平面。 In another embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal pillar connected to the metal material inside the through hole. When the height of the deposited metal is equal to the height of the through hole, the above The metal post and the ceramic substrate will together form a plane.
於又一實施例中,其步驟(C)以電鑄方式沉積金屬至上述貫通孔,使上述貫通孔內部形成一與上述金屬材料連接的金屬柱,當沉積金屬高度大於上述貫通孔高度,上述金屬柱將於上述陶瓷基板上形成至少一凸部,再將上述凸部研磨去除,使上述金屬柱與陶瓷基板的表面互相切齊形成共平面。 In still another embodiment, the step (C) deposits metal into the through hole by electroforming, and forms a metal pillar connected to the metal material inside the through hole. When the height of the deposited metal is greater than the height of the through hole, The metal post forms at least one convex portion on the ceramic substrate, and then the convex portion is polished and removed, so that the surface of the metal post and the ceramic substrate are mutually aligned to form a coplanar surface.
本發明的特點在於將所述陶瓷基板成型多數個貫通孔,藉由電鑄 填充沉積所述貫通孔內部以形成密實的實心金屬柱,改善習知技術的陶瓷基板散熱結構藉由濺鍍和電鍍手段成型金屬薄膜層於貫通孔內部的方法,不僅僅具有簡化製程的特點,亦可降低製作成本,進而提升產業應用性。此外,透過上揭實心金屬柱結構,使各種陶瓷基板具有良好散熱度。 The invention is characterized in that the ceramic substrate is formed into a plurality of through holes by electroforming Filling and depositing the inside of the through hole to form a solid solid metal column, and improving the heat dissipation structure of the ceramic substrate of the prior art by forming a metal thin film layer inside the through hole by sputtering and electroplating means not only simplifying the process, but also simplifying the process. It can also reduce production costs and improve industrial applicability. In addition, various ceramic substrates have good heat dissipation by uncovering the solid metal pillar structure.
(習知) (known)
101‧‧‧上色步驟 101‧‧‧Coloring steps
102‧‧‧鑽孔步驟 102‧‧‧ drilling steps
103‧‧‧清潔步驟 103‧‧‧ cleaning steps
104‧‧‧導電銅層沉積步驟 104‧‧‧ Conductive copper layer deposition step
105‧‧‧黃光微影成像步驟 105‧‧‧Yellow lithography imaging steps
106‧‧‧電鑄填孔步驟 106‧‧‧Electrical casting and filling steps
107‧‧‧剝膜步驟 107‧‧‧Striping step
108‧‧‧蝕刻步驟 108‧‧‧ etching step
109‧‧‧磨刷步驟 109‧‧‧Brushing steps
110‧‧‧絕緣層防護印刷步驟 110‧‧‧Insulation protection printing steps
111‧‧‧表面改質步驟 111‧‧‧ Surface modification steps
(本發明) (this invention)
20‧‧‧陶瓷基板 20‧‧‧Ceramic substrate
201‧‧‧混合粉末 201‧‧‧ mixed powder
30‧‧‧貫通孔 30‧‧‧through holes
40‧‧‧金屬材料 40‧‧‧Metal materials
50‧‧‧金屬柱 50‧‧‧Metal column
60‧‧‧金屬防護層 60‧‧‧ metal protective layer
71‧‧‧下模具 71‧‧‧Next mold
72‧‧‧上模具 72‧‧‧Upper mold
80‧‧‧金屬導電層 80‧‧‧Metal conductive layer
90‧‧‧膜 90‧‧‧ film
第1圖為習知陶瓷基板散熱結構製造方法流程圖;第2圖為另一習知陶瓷基板散熱結構製造方法流程圖;第3圖為本發明陶瓷基板散熱結構製造方法流程圖;第4圖為本發明陶瓷基板散熱結構製造方法第一實施例結構示意圖;第5圖為本發明陶瓷基板散熱結構製造方法第二實施例結構示意圖;第6圖為本發明陶瓷基板散熱結構製造方法第三實施例結構示意圖;第7-8圖為本發明陶瓷基板散熱結構製造方法第四實施例結構示意圖;第9-10圖為本發明陶瓷基板散熱結構製造方法第五實施例結構示意圖;第11-12圖為本發明陶瓷基板散熱結構製造方法第六實施例結構示意圖;第13圖為本發明陶瓷基板散熱結構製造方法應用示意圖。 1 is a flow chart of a conventional ceramic substrate heat dissipation structure manufacturing method; FIG. 2 is a flow chart of another conventional ceramic substrate heat dissipation structure manufacturing method; and FIG. 3 is a flow chart of a ceramic substrate heat dissipation structure manufacturing method according to the present invention; FIG. 5 is a schematic structural view of a second embodiment of a method for manufacturing a heat dissipation structure of a ceramic substrate according to the present invention; FIG. 6 is a schematic view showing a second embodiment of a method for manufacturing a heat dissipation structure of a ceramic substrate according to the present invention; FIG. 7-8 is a schematic structural view of a fourth embodiment of a method for manufacturing a heat dissipation structure of a ceramic substrate according to the present invention; and FIG. 9-10 is a schematic structural view of a fifth embodiment of a method for manufacturing a heat dissipation structure of a ceramic substrate according to the present invention; The figure is a schematic structural view of a sixth embodiment of a method for manufacturing a heat dissipation structure of a ceramic substrate of the present invention; and FIG. 13 is a schematic view showing the application of a method for manufacturing a heat dissipation structure of a ceramic substrate of the present invention.
茲為便於更進一步對本發明之構造、使用及其特徵有更深一層明確、詳實的認識與瞭解,爰舉出較佳實施例,配合圖式詳細說明如下:首先,請參閱第3圖與第4圖,本發明第一實施例一種陶瓷基板散熱結構的製造方法,包含: For a better understanding and understanding of the structure, the use and the features of the present invention, the preferred embodiments are described in detail with reference to the drawings as follows: First, please refer to FIG. 3 and FIG. A method for manufacturing a heat dissipation structure for a ceramic substrate according to a first embodiment of the present invention includes:
(A)提供一已進行穿孔處理的陶瓷基板20,上述陶瓷基板20具有至少一由頂面貫通至底面的貫通孔30;上述陶瓷基板20可為氧化鋁、氮化鋁、碳化矽、氧化鈹、氧化鋅或氧化矽、藍寶石基板10的其中一種陶瓷材料,上述陶瓷基板20藉由穿孔處理而形成具有複數個貫通孔30的陶瓷基板20,所述穿孔處理可設為超音波加工、電子束加工、水刀加工、雷射加工、蝕刻成孔、噴砂成孔的其中一種加工方法,以使貫通孔30成為圓孔、方孔或其他幾何形狀樣態的貫通孔30的其中一種。 (A) providing a ceramic substrate 20 subjected to a perforation process, wherein the ceramic substrate 20 has at least one through hole 30 penetrating from the top surface to the bottom surface; the ceramic substrate 20 may be aluminum oxide, aluminum nitride, tantalum carbide or hafnium oxide. a ceramic material of the zinc oxide substrate or the sapphire substrate 10, wherein the ceramic substrate 20 is formed by a perforation process to form a ceramic substrate 20 having a plurality of through holes 30, and the perforation processing can be performed as ultrasonic processing or electron beam One of the processing methods of processing, water jet processing, laser processing, etching into holes, and sandblasting into holes, so that the through holes 30 become one of the through holes 30 of a circular hole, a square hole or other geometric shape.
(B)將一金屬材料40鄰接於上述陶瓷基板20的一表面,上述金屬材料40可為金屬基板10或金屬箔的其中一種,並使上述金屬材料40覆蓋於上述貫通孔30一端;所述使金屬材料40鄰接於陶瓷基板20可藉由夾合、膠合、貼合的其中一種方式使陶瓷基板20設置於金屬材料40上方。 (B) a metal material 40 is adjacent to a surface of the ceramic substrate 20, the metal material 40 may be one of the metal substrate 10 or the metal foil, and the metal material 40 is covered at one end of the through hole 30; The ceramic substrate 20 can be disposed above the metal material 40 by one of sandwiching, gluing, and laminating the metal material 40 adjacent to the ceramic substrate 20.
(C)以電鑄方式沉積金屬至上述貫通孔30,使上述貫通孔30內部形成一與上述金屬材料40連接的金屬柱50;電鑄製程為一高效率且精密的成型技術,透過電鍍沉積的原理,並藉由外界所提供的電能,使得含有金屬離子及其他添加物的混合溶液,在陰極或陽極表面進行電化學的氧化還原反應,將想要沉積的金屬形成於物件表面,本發明藉由電鑄技術手段沉積金屬於貫通孔30中,於第一實施例中,當沉積金屬高度小於上述貫通孔30高度,上述金屬柱50與陶瓷基板20之間形成至少一凹陷樣態的凹部,又,上述電鑄沉積金屬其可為銅(Cu)或為銅合金。 (C) depositing metal into the through hole 30 by electroforming, forming a metal pillar 50 connected to the metal material 40 inside the through hole 30; the electroforming process is a highly efficient and precise molding technique, and is deposited by electroplating. The principle, and by the externally supplied electric energy, the mixed solution containing metal ions and other additives is subjected to an electrochemical redox reaction on the surface of the cathode or the anode to form a metal to be deposited on the surface of the object, the present invention The metal is deposited in the through hole 30 by electroforming. In the first embodiment, when the height of the deposited metal is less than the height of the through hole 30, at least one concave portion is formed between the metal post 50 and the ceramic substrate 20. Further, the above electroformed deposition metal may be copper (Cu) or a copper alloy.
(D)去除上述金屬材料40,讓上述金屬柱50和陶瓷基板20共同形成一陶瓷散熱基板,所述去除上述金屬材料40可藉由研磨方式,研磨金屬材料40 至完全去除,使得陶瓷基板20和金屬柱50顯露出來,上述研磨可為研磨機、研磨紙、研磨帶、研磨片、研磨液的其中一種方式。 (D) removing the metal material 40, and the metal pillar 50 and the ceramic substrate 20 together form a ceramic heat dissipation substrate, and the removing the metal material 40 can polish the metal material 40 by grinding. The ceramic substrate 20 and the metal post 50 are exposed to complete removal, and the polishing may be one of a grinder, an abrasive paper, a polishing tape, an abrasive sheet, and a polishing liquid.
最後,於上述金屬柱50表面形成一金屬防護層60,其中所述金屬防護層60藉由化鍍或電鍍的技術手段成型於金屬柱50兩側表面,上述金屬防護層60可由單一金屬層化學銀層、錫及錫合金層的其中一種構成或為電鍍鎳層、電鍍金層、電鍍銀層的其中一種來構成單一金屬層,亦可為一化學鎳層上方沉積一化學金層或化學銀層的其中一種來構成複合金屬層,或為一電鍍鎳層上方電鍍一金層或銀層的其中一種來構成複合金屬層的其中一種。 Finally, a metal protection layer 60 is formed on the surface of the metal pillar 50, wherein the metal barrier layer 60 is formed on both sides of the metal pillar 50 by chemical plating or electroplating. The metal shield layer 60 can be chemistry by a single metal layer. One of the silver layer, the tin and the tin alloy layer or one of the electroplated nickel layer, the electroplated gold layer, and the electroplated silver layer constitutes a single metal layer, or a chemical gold layer or chemical silver may be deposited over the chemical nickel layer. One of the layers constitutes a composite metal layer, or one of a gold layer or a silver layer is plated over an electroplated nickel layer to form one of the composite metal layers.
上述化鍍製程部份為於無通電的情況下,利用氧化還原的原理使材料於具有催化表面的鍍件上成型一材料層;而上述電鍍製程是利用電解的原理將導電體表面上形成一金屬層的方法。 The electroplating process partially forms a material layer on the plated part having the catalytic surface by using the principle of redox in the absence of electrification; and the electroplating process uses the principle of electrolysis to form a surface on the electric conductor. Method of metal layer.
上述電鍍製程為利用電解的原理將導電體披覆上一層金屬的方法。 The above electroplating process is a method of coating a conductor with a layer of metal by the principle of electrolysis.
請參考第5圖,於一較佳第二實施例中,步驟(A)、步驟(B)、步驟(D)以及成型一金屬防護層60步驟皆與第一實施例相同,僅於步驟(C)於電鑄沉積一實心金屬柱50時,其金屬柱50沉積高度與上述貫通孔30高度為一致,使得上述實心金屬柱50與陶瓷基板20將共同形成一平面。 Referring to FIG. 5, in a preferred second embodiment, the steps (A), (B), (D), and forming a metal shield 60 are the same as in the first embodiment, only in the step ( C) When a solid metal pillar 50 is deposited by electroforming, the height of the metal pillar 50 is consistent with the height of the through hole 30, so that the solid metal pillar 50 and the ceramic substrate 20 together form a plane.
請參考第6圖,另一第三實施例中,步驟(A)、步驟(B)、步驟(D)以及成形一金屬防護層60步驟皆與第一實施例相同,僅於步驟(C)當電鑄沉積一實心金屬柱50時,其金屬柱50的沉積高度大於上述貫通孔30的高度,使得上述金屬柱50將凸出於上述陶瓷基板20上方而形成至少一凸部,所述上述凸部可藉 由研磨方式去除,將上述金屬柱50研磨至與陶瓷基板20的表面具有相同水平高度並互相切齊成為一共平面。 Referring to FIG. 6, in another third embodiment, steps (A), (B), (D), and forming a metal shield 60 are the same as in the first embodiment, only in step (C). When the solid metal pillar 50 is deposited by electroforming, the height of the metal pillar 50 is greater than the height of the through hole 30, so that the metal pillar 50 protrudes above the ceramic substrate 20 to form at least one convex portion. The convex part can be borrowed The metal pillars 50 are polished to have the same level as the surface of the ceramic substrate 20 and are aligned with each other to form a common plane.
又一第四實施例中請參考第7-8圖所示,所述陶瓷基板20可藉由習知低溫共燒製程而形成,先將一混合粉末201置放於具有孔穴的下模具71中,上述混合粉末201為利用氧化鋁粉末與玻璃材料以及黏著劑相互混合而構成,再覆蓋一上模具72以施加壓力於上述混合粉末201,使得上述混合粉末201被壓實形成緻密結構,而後將上述壓實的混合粉末201取出後進行燒結作業則可直接形成一具有貫通孔30的陶瓷基板20,另一可行實施方式為將上述混合粉末201乾燥後進行沖壓成孔作業並燒結以形成一具有貫通孔30的陶瓷基板20,透過上揭方式無需雷射鑽孔的穿孔處理,可大幅降低製程成本。 In still another fourth embodiment, as shown in FIGS. 7-8, the ceramic substrate 20 can be formed by a conventional low-temperature co-firing process, in which a mixed powder 201 is first placed in a lower mold 71 having a cavity. The mixed powder 201 is formed by mixing aluminum oxide powder with a glass material and an adhesive, and is covered with an upper mold 72 to apply pressure to the mixed powder 201, so that the mixed powder 201 is compacted to form a dense structure, and then After the compacted mixed powder 201 is taken out and then sintered, a ceramic substrate 20 having through holes 30 can be directly formed. In another possible embodiment, the mixed powder 201 is dried, punched into a hole and sintered to form a The ceramic substrate 20 of the through-hole 30 can be subjected to the perforation process without the laser drilling by the above-described method, and the process cost can be greatly reduced.
第四實施例惟步驟(A)藉由低溫共燒製程以及穿孔處理形成一具有貫通孔30的陶瓷基板20,其餘後續步驟(B)、(C)、(D)皆與上述實施例相同,在此不加贅述。 In the fourth embodiment, the step (A) is to form a ceramic substrate 20 having through-holes 30 by a low-temperature co-firing process and a perforation process, and the remaining subsequent steps (B), (C), and (D) are the same as the above embodiment. I will not repeat them here.
於另一較佳第五實施例中,請參考第9-10圖,其步驟(A)-(D)皆與前述實施例相同,在此不加贅述,然於步驟(D)後,可進一步利用物理氣相沉積方式於金屬柱50和陶瓷基板20上方形成一金屬導電層80,讓金屬導電層80與陶瓷基板20散熱結構構成電性導通;其中,物理氣相沉積可為蒸鍍或濺渡的其中任何一種方式,並由高導電性的金屬材料40形成上述金屬導電層80,其中上述金屬導電層80可為10-1000nm鎳層或鈦層再鍍上10-2000nm的銅層。 In another preferred fifth embodiment, please refer to FIG. 9-10. Steps (A)-(D) are the same as the previous embodiment, and are not described here. However, after step (D), Further, a metal conductive layer 80 is formed on the metal pillar 50 and the ceramic substrate 20 by physical vapor deposition, and the metal conductive layer 80 and the heat dissipation structure of the ceramic substrate 20 are electrically connected; wherein the physical vapor deposition may be evaporation or Any one of the methods of sputtering, and the metal conductive layer 80 is formed of a highly conductive metal material 40, wherein the metal conductive layer 80 may be a 10-1000 nm nickel layer or a titanium layer and then plated with a 10-2000 nm copper layer.
利用壓膜90(抗蝕刻膜90)、曝光顯影及蝕刻製程形成線路圖案;其中,壓膜90製程是在基板上欲形成線路圖案的金屬導電層80表面黏貼一對紫 外線反應的膜90,所述膜90可為聚合性樹脂的乾膜90(Dry Film)亦可為濕膜90(Wet Film),其主要用在聚合後保護線路圖案不會被蝕刻掉。 The circuit pattern is formed by using the lamination film 90 (anti-etching film 90), the exposure developing process, and the etching process; wherein, the lamination film 90 process is to adhere a pair of purple on the surface of the metal conductive layer 80 on the substrate on which the circuit pattern is to be formed. The film 90 of the external reaction, the film 90 may be a dry film 90 of a polymerizable resin or a wet film 90, which is mainly used for protecting the wiring pattern from being etched away after polymerization.
曝光顯影製程中的曝光部分,是將線路圖案製成正版的光罩後,先行定位及平貼於貼好膜90的金屬導電層80上,再經曝光機進行抽真空、壓板及紫外線照射而完成。受到紫外線的照射的膜90將產生聚合作用,而膜90上受到光罩阻擋無法由紫外線透射的線路圖案,將無法產生聚合作用。 The exposed part of the exposure and development process is that after the circuit pattern is made into a genuine mask, it is first positioned and flattened on the metal conductive layer 80 of the film 90, and then vacuumed, pressed, and irradiated by the exposure machine. carry out. The film 90 irradiated with ultraviolet rays will be polymerized, and the film 90 is blocked by the mask to be blocked by ultraviolet rays, and polymerization will not occur.
曝光顯影製程中的顯影部分,則是利用顯影液將未產生聚合的膜90部分去除,而以物理及化學剝除方式將需要保留的線路顯現出來,以此一製程步驟所構成之線路,具有細直平整之特性。 In the developing part of the exposure developing process, the film 90 which is not polymerized is partially removed by the developer, and the line to be retained is visually and physically peeled off, and the circuit formed by the process step has The characteristics of straightness and flatness.
而蝕刻製程是以一蝕刻藥液來進行蝕刻(Etching),將金屬導電層80表面未具有膜90阻擋的部分溶蝕去除。 The etching process is performed by etching with an etching solution to remove the portion of the surface of the metal conductive layer 80 that is not blocked by the film 90.
最後,將抗蝕刻膜90剝除,並另行電鍍或化鍍一由抗氧化金屬構成的金屬防護層60於上述金屬導電層80的線路圖案上方。 Finally, the anti-etching film 90 is stripped, and a metal protective layer 60 made of an anti-oxidation metal is additionally plated or plated over the wiring pattern of the metal conductive layer 80.
於另一可行的第六實施例請參考第11圖、第12圖,本發明步驟(A)提供一已進行穿孔處理的陶瓷基板20,上述陶瓷基板20具有至少一由頂面貫通至底面的貫通孔30,所述穿孔處理可設為蝕刻成孔,於所述陶瓷基板20表面上先設有一壓膜90(抗蝕刻膜90),藉由上述曝光顯影及蝕刻製程後使陶瓷基板20上形成貫通孔30,再將抗蝕刻膜90剝除,而後其餘步驟(B)、步驟(C)、以及步驟(D)皆與其餘實施例相同,在此不多加贅述。 In another feasible sixth embodiment, referring to FIG. 11 and FIG. 12, the step (A) of the present invention provides a ceramic substrate 20 which has been subjected to a perforation process, and the ceramic substrate 20 has at least one surface penetrating from the top surface to the bottom surface. The through hole 30 may be etched into a hole, and a pressing film 90 (etching resistant film 90) is first disposed on the surface of the ceramic substrate 20, and the ceramic substrate 20 is formed by the exposure developing and etching processes. The through hole 30 is formed, and the anti-etching film 90 is stripped, and the remaining steps (B), (C), and (D) are the same as the other embodiments, and will not be further described herein.
請參考第13圖,為一產業上實際應用實例,將左側貫通孔30設為一陽極,右側貫通孔30設為一陰極,中間貫通孔30上方設有一晶粒,進行後續的打線技術(wire bonding)以將晶粒與陶瓷基板上之連結點連接的封裝製程。 Please refer to FIG. 13 for an industrial application example, the left through hole 30 is set as an anode, the right through hole 30 is set as a cathode, and a die is arranged above the intermediate through hole 30 for subsequent wire bonding technology (wire Bonding) A packaging process that connects the die to the junction on the ceramic substrate.
綜上所述,本發明的特點為藉由鄰接金屬材料40和陶瓷基板20並進行穿孔作業,形成一由陶瓷基板20上方導通至下方的貫通孔30,而後利用電鑄製程於貫通孔30內部成型一實心金屬柱50,此實心金屬柱50與習知技術的鍍金屬薄膜於通孔內部相互比較而言,其為一較厚實的結構,故具有一較優傳導性,與習知的氮化鋁散熱基板相互比較而言,習知的氮化鋁散熱結構導熱率為150-170W/mK且具有高成本、又習知氧化鋁基板散熱結構導熱率為16-24W/mK,而本發明案陶瓷基板散熱結構導熱率約為370-400W/mK,爰是,本發明藉由上揭簡易且低成本的製程能大幅提升陶瓷基板20的垂直方向的熱傳導能力,將元件產生的熱能有效地傳導出去,實具有一優良的散熱度並符合市場需求。 In summary, the present invention is characterized in that a through hole 30 that is electrically connected to the lower side of the ceramic substrate 20 is formed by abutting the metal material 40 and the ceramic substrate 20, and then is electrically formed into the through hole 30 by an electroforming process. A solid metal pillar 50 is formed. The solid metal pillar 50 has a relatively thick structure compared with the metallized film of the prior art in the through hole. Therefore, it has a superior conductivity and a conventional nitrogen. Compared with the aluminum heat dissipation substrate, the conventional aluminum nitride heat dissipation structure has a thermal conductivity of 150-170 W/mK and has high cost, and the thermal conductivity of the aluminum substrate heat dissipation structure is 16-24 W/mK, and the present invention The thermal conductivity of the heat dissipation structure of the ceramic substrate is about 370-400 W/mK. Therefore, the present invention can greatly improve the thermal conductivity of the ceramic substrate 20 in the vertical direction by the simple and low-cost process, and the heat energy generated by the component is effectively Conducted out, it has an excellent heat dissipation and meets market demand.
以上所舉實施例,僅用為方便說明本發明並非加以限制,在不離本發明精神範疇,熟悉此一行業技藝人士依本發明申請專利範圍及發明說明所作之各種簡易變形與修飾,均仍應含括於以下申請專利範圍中。 The above embodiments are intended to be illustrative only, and are not intended to limit the scope of the present invention. It is included in the scope of the following patent application.
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