US20010026017A1 - An electronic circuit element of conductor/insulator stacked type using high machinability substrate and benzocylobutene as insulator - Google Patents
An electronic circuit element of conductor/insulator stacked type using high machinability substrate and benzocylobutene as insulator Download PDFInfo
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- US20010026017A1 US20010026017A1 US08/826,094 US82609497A US2001026017A1 US 20010026017 A1 US20010026017 A1 US 20010026017A1 US 82609497 A US82609497 A US 82609497A US 2001026017 A1 US2001026017 A1 US 2001026017A1
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
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- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H7/00—Multiple-port networks comprising only passive electrical elements as network components
- H03H7/01—Frequency selective two-port networks
- H03H7/09—Filters comprising mutual inductance
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- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H1/00—Constructional details of impedance networks whose electrical mode of operation is not specified or applicable to more than one type of network
- H03H1/0007—Constructional details of impedance networks whose electrical mode of operation is not specified or applicable to more than one type of network of radio frequency interference filters
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
-
- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H1/00—Constructional details of impedance networks whose electrical mode of operation is not specified or applicable to more than one type of network
- H03H2001/0021—Constructional details
- H03H2001/0085—Multilayer, e.g. LTCC, HTCC, green sheets
Definitions
- This invention relates to an electronic component and, in particular, to an electronic component of a surface-mounted type or a leaded type such as an inductor (L), a capacitor (C), an electric resistance element (R), a thin film EMI filter, a common choke coil, a current sensor, a signal transformer, and a composite electronic component comprising an integral combination of the above-mentioned electronic components.
- a surface-mounted type or a leaded type such as an inductor (L), a capacitor (C), an electric resistance element (R), a thin film EMI filter, a common choke coil, a current sensor, a signal transformer, and a composite electronic component comprising an integral combination of the above-mentioned electronic components.
- a conventional multilayer interconnection board is disclosed in Japanese Unexamined Patent Publication (JP-A) No. 4-167596 (167596/1992) (Reference 1).
- the multilayer interconnection board comprises a ceramics substrate 51 mainly containing silicon, alumina, and the like, and a conductive interconnection layer 52 comprising Cu formed on a predetermined region of the ceramics substrate 51 .
- an entire surface of the ceramics substrate 51 and the conductive interconnection layer 52 is coated with an insulator resin layer 53 of benzocyclobutene (BCB).
- BCB benzocyclobutene
- a Cu film is overlaid an entire surface by sputtering and then etched.
- a Cr or Ti film is overlaid the entire surface by sputtering, a Cu sputtered film or a Cu or Au or Al plated film is formed to thereby provide a conductive interconnection layer 55 .
- JP-A Japanese Unexamined Patent Publication
- the electronic component comprises an insulator substrate 101 of, for example, alumina.
- an insulator resin layer 102 of polyimide resin and internal conductor patterns 103 and 104 of Ti, Ti—Ag, or Ag formed by sputtering are alternately stacked.
- an end portion of the insulator resin layer 102 is removed to expose an end portion of the uppermost conductor pattern 104 .
- a high frequency coil 100 is formed as the electronic component.
- a terminal underlayer portion is formed on the side surface of the electronic component so as to connect with the end portion of the conductor pattern 104 .
- the terminal underlayer portion is covered with a conductor layer which extends from an end of the upper surface through the side surface to an end of the lower surface of the component.
- an external electrode terminal portion is formed.
- Reference 1 describes the multilayer interconnection board which is neither an electronic component as a circuit element nor an electronic component having a plurality of circuit elements.
- the insulator layers and the conductor layers for a plurality of the electronic components are alternately stacked on different portions of the insulator substrate of a relatively large size.
- a plurality of the electronic components are formed on the single insulator substrate.
- the insulator substrate is cut to separate the individual electronic components.
- the insulator substrate comprises a very hard material such as alumina, cutting cost is high in the cutting process.
- occurrence of chipping of the insulator substrate results in high fraction defective and low yielding percentage.
- the irregularity of the underlying conductor pattern layer reflects or is reproduced on the surface of the insulator resin layer formed thereon. This results in the unevenness of the overlying conductor pattern layer stacked on the insulator resin layer. In this event, a desired characteristic can not be achieved.
- the moisture contained in the ambient air enters into the electronic component through a gap between the insulator resin layer and the electrode terminal portion. This brings about corrosion of the conductor pattern and fluctuation of the characteristic. As a result, the quality of the electronic component is considerably deteriorated.
- It is another object of the present invention to provide a circuit element comprising at least one of a low pass filter, a common choke coil, a transformer, an inductance, a capacitance, and an electric resistance each of which is formed as the above-mentioned electronic component.
- an electronic component comprising an insulator substrate, a layered member composed of a plurality of insulator resin layers and a plurality of conductor pattern layers alternately stacked on the insulator substrate to form a first conductor line and a second conductor line each of which comprises at least one conductor layer, first and second external electrode terminal portions connected to opposite ends of the first conductor line and covering first and second areas of side surfaces of the layered member and the insulator substrate, respectively, and a third external electrode terminal portion connected to one end of the second conductor line and covering a third area of the side surfaces of the layered member and the insulator substrate.
- the first and the second conductor lines have magnetic and electrocapacitive coupling with each other.
- a common choke coil comprising the above mentioned electronic component.
- the common choke coil further comprises a fourth external electrode terminal connected to the other end of the second conductor line and formed on the side surfaces of the layered member and the insulator substrate at a fourth area different from the first through the third external electrode terminal portions.
- Each of the first and the second conductor lines have a pattern circulated on different conductor layers, the number of turns in both lines being equal to each other.
- a pair of the first and the third external electrode terminals and another pair of the second and the fourth external electrode terminals serves as an input terminal pair and an output terminal pair, respectively.
- a transformer comprising the above mentioned electronic component.
- the transformer further comprises a fourth external electrode terminal connected to the other end of the second conductor line and formed on the side surfaces of the layered member and the insulator substrate at a fourth area different from the first through the third external electrode terminal portions.
- Each of the first and the second conductor lines have a pattern circulated on different conductor layers.
- a pair of the first and the second external electrode terminal and another pair of the third and the fourth external connection terminals serves as an input terminal pair and an output terminal pair, respectively.
- FIG. 1 is a sectional view of a conventional multilayer interconnection board
- FIG. 2 is a sectional view of a conventional electronic component
- FIG. 3 is a perspective view of a low pass filter as an electronic component according to a first embodiment of this invention.
- FIG. 4 is an exploded perspective view of the electronic component illustrated in FIG. 3;
- FIGS. 5A through 5D show a first part of a process of forming a layered structure for the electronic component illustrated in FIG. 3;
- FIGS. 6A through 6D show a second part of the process following the first part illustrated in FIGS. 5A through 5D;
- FIGS. 7A through 7D show a third part of the process following the second part illustrated in FIGS. 6A through 6D;
- FIG. 8 is a perspective view of showing a plurality of the layered structures formed on an insulator substrate of a large size before separation into the individual electronic components;
- FIG. 9 is a sectional view of a terminal structure formed on one of the electronic components cut from the insulator substrate illustrated in FIG. 8;
- FIG. 10 shows another terminal structure for an electronic component having a three terminal structure
- FIG. 11 is an exploded perspective view of conductor patterns of a common choke coil as another electronic component according to a second embodiment of this invention.
- FIG. 12 is a partial sectional view of a terminal structure of the common choke coil illustrated in FIG. 11;
- FIG. 13 is an exploded perspective view of conductor patterns of a transformer as still another electronic component according to a third embodiment of this invention.
- an electronic component according to a first embodiment of this invention is an EMI filter.
- the electronic component 10 comprises a main body 1 and first through third external electrode terminal portions 2 a , 2 b , and 2 c formed on different side surfaces of the main body 1 , respectively, to extend from an end of the upper surface through the side surfaces to an end of the lower surface.
- the first and the second external electrode terminal portions 2 a and 2 b cover the side surfaces of the main body 1 opposite to each other in a longitudinal direction.
- the third external electrode terminal portion 2 c covers the center area of one of the side surfaces parallel to the longitudinal direction.
- the main body 1 comprises a ceramics substrate 11 as an insulator substrate, a plurality of insulator resin layers 12 a through 12 d , and a plurality of conductor pattern layers 13 a through 13 d .
- the insulator resin layers 12 a , 12 b , 12 c , and 12 d and the conductor pattern layers 13 a , 13 b , 13 c , and 13 d are alternately stacked on the ceramics substrate 11 .
- an additional conductor pattern layer 13 c ′ may be interposed together with an additional insulator layer.
- the ceramics substrate 11 comprises a machinable ceramics material manufactured and sold by Mitsui Mining Material, Co., Ltd. under the trade name “Macerite”.
- the characteristics of the ceramics material are shown in Table 1 in comparison with alumina.
- Each of the insulator resin layers 12 a through 12 d comprises benzocyclobutene (BCB) as ultraviolet photosensitive resin.
- BCB benzocyclobutene
- the use of BCB as the insulator resin layers achieves an excellent flatness of the insulator resin layers. As a consequence, it is possible to obtain a layered structure having a flat surface without an unevenness. Therefore, the electronic component 10 has excellent electric characteristics.
- FIGS. 5 A through SD, 6 A through 6 D, and 7 A through 7 D a process of forming the layered structure of the insulator resin layers and the conductor pattern layers will be described.
- the insulator resin layer 12 a is formed on the ceramics substrate 11 (not shown) after the ceramics substrate 11 is cleaned by the use of acetone, methylalcohol, or the like. If necessary, the insulator resin layer 12 a is cleaned by reverse sputtering, as shown in FIG. 5A.
- an underlayer 3 comprising a Ti film and a Cu film is deposited by sputtering, as illustrated in FIG. 5B.
- the Ti film and the Cu film have a thickness of 0.05 ⁇ m and a thickness of 0.25-0.3 ⁇ m, respectively, although not separately shown in the figure.
- a resist 4 is applied on the underlayer 3 . Then, by the use of photolithography, the resist 4 is exposed through a mask 5 and developed, as illustrated in FIG. 5D.
- a resist pattern 4 ′ is formed as illustrated in FIG. 6A. Then, surface treatment is carried out by the use of H 2 SO 4 . Subsequently, an electrolytic Cu plated layer 6 is formed by electrolytic Cu plating, as illustrated in FIG. 6B.
- the resist pattern 4 ′ is removed to form an intermediate conductor pattern 7 .
- the intermediate conductor pattern 7 illustrated in FIG. 6C is subjected to wet-etching (or dry-etching) to remove those portions of the underlayer 3 exposed without the electrolytic Cu plated layer 6 . Then, cleaning is carried out by the use of HCl. As a consequence, an isolated conductor pattern layer 13 a is formed on the insulator resin layer 12 a , as illustrated in FIG. 6D. Although the upper surface of the Cu plated layer 6 is slightly etched during etching, the intermediate conductor pattern 7 will not be removed because it is thicker than the underlayer 3 .
- the conductor pattern layer 13 a thus obtained comprises the patterns of underlayer 3 and the electrolytic Cu plated layer 6 and has a thickness of about 3-5 ⁇ m and a width of about 30 ⁇ m. No trouble or inconvenience has been encountered during cleaning, photolithography, and etching in the manufacturing process.
- FIGS. 7A through 7D formation of another insulator resin layer 12 b is described.
- the conductor pattern layer 13 a formed on the insulator resin layer 12 a (FIG. 6D) is coated with the ultraviolet photosensitive resin of BCB by spin coating to form an intermediate insulator resin layer 8 .
- the intermediate insulator resign layer 8 is exposed through a mask 9 , as illustrated in FIG. 7B.
- through holes 14 are formed in the intermediate insulator resin layer 8 , as illustrated in FIG. 7C.
- the through holes 14 serve to establish electrical contact between the conductor pattern layer 13 a and another conductor pattern layer formed above. It is therefore unnecessary to form the through holes 14 over the entire surface of the conductor pattern layer 13 a.
- the other conductor layers 13 b , 13 c , and 13 d illustrated in FIG. 4 are formed in the manner similar to that described in conjunction with FIGS. 5A through 5D and 6 A through 6 D.
- the other insulator layers 12 c and 12 D are formed in the manner similar to that described in conjunction with FIGS. 7A through 7D.
- a plurality of main bodies 1 of the electronic components 10 are formed on the insulator substrate, as shown in FIG. 8.
- a protection layer 12 f of, for example, polyimide is formed on a surface region of the insulator resin layer 12 e which is not covered with the electrode extracting pattern 17 .
- the protection layer 12 f may be made of any appropriate material selected from various materials such as those specified in Table 2 in dependence upon the applications.
- the ceramics substrate (FIG. 8) with a plurality of the main bodies 1 formed thereon is cut by a dicing saw along a dash-and-dot line. Thus, the individual main bodies 1 are separated. In FIG. 8, one of the main bodies 1 is depicted by the solid line.
- the main body 1 is cleaned by the use of 5% HCl solution.
- Ni conductive paste comprising, for example, epoxy resin containing Ni powder is applied to an area from an end portion of the electrode extracting pattern 17 through the side surface to the lower surface of the main body 1 and is subjected to thermosetting or thermal curing.
- ultrasonic cleaning is carried out by the use of both a KOH solution and a H 2 SO 4 solution as a pretreatment prior to plating.
- a Ni plated film 18 is formed as an underlayer by electrolytic barrel plating of a nickel sulfanate bath.
- Ni is excellent in electrolysis migration and serves to protect the internal diffusion of solder or the like.
- solder plated film 19 is formed on the Ni plated film 18 by electrolysis barrel plating of a tin-lead alkanolsulfonate bath.
- the tin-lead alkanolsulfonate bath prevents the deterioration of the insulator resin layer because no chelating agent is contained.
- the solder plated film 19 can be formed by a phenolsulfonate plating bath.
- a tin plated film may be formed instead of the solder plated film.
- the electrode extracting pattern 17 is formed above the insulator resin layer 12 at the interface between the electrode extracting pattern 17 and the insulator resin layer. Therefore, the separation therebetween hardly occurs so that external moisture is effectively prevented from entering.
- FIG. 10 another terminal structure of an electronic component according to a second embodiment of this invention will be described.
- FIG. 8 a three terminal structure used in the EMI filter, LCR parts, and the like, is illustrated.
- the electrode extracting pattern 17 is connected to the second conductor pattern layer 13 counted from the topmost conductor pattern layer 13 .
- the protection film is not shown in the figure.
- a common choke coil according to a third embodiment of this invention has first through fourth conductor pattern layers 13 a through 13 d .
- the first through the fourth conductor pattern layers 13 a through 13 d are successively stacked with the insulator resin layers interposed therebetween although the insulator resin layers are not shown in FIG. 11 for convenience of illustration.
- each of the first through the fourth conductor pattern layers 13 a through 13 d has end patterns 15 a through 15 d .
- the end patterns 15 a of the first through the fourth conductor pattern layers 13 a through 13 d are overlapped on one another through notches formed in the insulator resin layers to be electrically connected.
- the end patterns 15 b , 15 c , and 15 d are respectively overlapped and electrically connected.
- the end portion of a conductor pattern 21 of the first or the lowest conductor pattern layer 13 a is connected through a central conductor pattern 23 of the second conductor pattern layer 13 b to the end portion of an extracting conductor pattern 25 of the third conductor pattern layer 13 c .
- the end portions 15 b and 15 d of the conductor patterns serve as opposite ends of a single circulated conductor line.
- a circulating conductor pattern 24 of the second conductor pattern layer 13 b is connected to the end portion of an extracting conductor pattern 26 of the third conductor pattern layer 13 c .
- the end portions 15 a and 15 c of the conductor patterns serve as opposite ends of another circulated conductor line. These conductor lines have the same number of turns.
- FIG. 12 shows the structure of the terminal portion of the electronic component illustrated in FIG. 11.
- the terminal portion has a four terminal structure.
- the electrode extracting pattern 17 is connected to the uppermost conductor pattern layer 13 .
- the protection film is not shown in the figure.
- a transformer according to a fourth embodiment of the present invention has first through fourth conductor pattern layers 13 a through 13 d .
- the first through the fourth conductor pattern layers 13 a through 13 d are successively stacked with the insulator resin layers interposed therebetween.
- each of the conductor pattern layers 13 a through 13 d has end patterns 15 a through 15 d .
- the end patterns 15 a are overlapped on one another through notches formed in the insulator resin layers to be electrically connected.
- the end patterns 15 b , 15 c , and 15 d are respectively overlapped and electrically connected.
- the end portion of a circulated conductor pattern 27 of the first conductor pattern layer 13 a is connected to the end portion of an extracting conductor pattern 28 of the second conductor pattern layer 13 b .
- the end portions 15 a and 15 b of the conductor patterns serve as opposite ends of a single circulated conductor line.
- the end portion of a circulating conductor pattern 30 of the third conductor pattern layer 13 c is connected to another extracting conductor pattern 29 of the second conductor pattern layer 13 b .
- the end portions 15 c and 15 d of the conductor patterns serve as opposite ends of another circulated conductor line.
- the turn ratio of these conductor lines is 1:n.
- each of the conductor pattern layers is formed in the manner described in conjunction with FIGS. 5A through 5D and 6 A through 6 D.
- the insulator resin layers which are not shown in FIGS. 11 and 13 are formed in the manner described in conjunction with FIGS. 7A through 7D. In either case, the terminal structure illustrated in FIG. 12 is used.
- a plurality of the above-mentioned electronic components are simultaneously formed on the insulator substrate 11 of a large size in the manner similar to that described in conjunction with FIG. 8. After separation into each individual component, the terminal structure is formed.
- the cutting operation is easily carried out if the insulator substrate comprises a machinable material, for example, having a Vickers hardness within the range between 100 and 1000. Thus, the cost can be reduced.
- this invention is also applicable to an element such as an inductor, a capacitor, or an electric resistance element.
- the electronic component of this invention can be easily manufactured and reduced in size, has desired characteristics, and is highly reliable.
- a circuit element comprising at least one of the low pass filter, the common choke coil, the transformer, the inductance, the capacitance, and the electric resistance each of which is formed as the electronic component is obtained according to the present invention.
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Abstract
Description
- This invention relates to an electronic component and, in particular, to an electronic component of a surface-mounted type or a leaded type such as an inductor (L), a capacitor (C), an electric resistance element (R), a thin film EMI filter, a common choke coil, a current sensor, a signal transformer, and a composite electronic component comprising an integral combination of the above-mentioned electronic components.
- A conventional multilayer interconnection board is disclosed in Japanese Unexamined Patent Publication (JP-A) No. 4-167596 (167596/1992) (Reference 1). As shown in FIG. 1, the multilayer interconnection board comprises a ceramics substrate51 mainly containing silicon, alumina, and the like, and a
conductive interconnection layer 52 comprising Cu formed on a predetermined region of the ceramics substrate 51. Then, an entire surface of the ceramics substrate 51 and theconductive interconnection layer 52 is coated with aninsulator resin layer 53 of benzocyclobutene (BCB). After a photo resist pattern is formed on theinsulator resin layer 53, theinsulator resin layer 53 of BCB is etched to form viaholes 54. After thevia holes 54 are formed, a Cu film is overlaid an entire surface by sputtering and then etched. Alternatively, after a Cr or Ti film is overlaid the entire surface by sputtering, a Cu sputtered film or a Cu or Au or Al plated film is formed to thereby provide aconductive interconnection layer 55. - On the other hand, Japanese Unexamined Patent Publication (JP-A) No. 3-201417 (201417/1991) (Reference 2) discloses an electronic component of the type illustrated in FIG. 2. The electronic component comprises an
insulator substrate 101 of, for example, alumina. On theinsulator substrate 101, aninsulator resin layer 102 of polyimide resin andinternal conductor patterns insulator resin layer 102 is removed to expose an end portion of theuppermost conductor pattern 104. Thus, ahigh frequency coil 100 is formed as the electronic component. - Practically, a terminal underlayer portion is formed on the side surface of the electronic component so as to connect with the end portion of the
conductor pattern 104. The terminal underlayer portion is covered with a conductor layer which extends from an end of the upper surface through the side surface to an end of the lower surface of the component. Thus, an external electrode terminal portion is formed. -
Reference 1 describes the multilayer interconnection board which is neither an electronic component as a circuit element nor an electronic component having a plurality of circuit elements. - On the other hand, when the electronic component of the type disclosed in
Reference 2 is manufactured, the insulator layers and the conductor layers for a plurality of the electronic components are alternately stacked on different portions of the insulator substrate of a relatively large size. Thus, a plurality of the electronic components are formed on the single insulator substrate. Thereafter, the insulator substrate is cut to separate the individual electronic components. However, since the insulator substrate comprises a very hard material such as alumina, cutting cost is high in the cutting process. In addition, occurrence of chipping of the insulator substrate results in high fraction defective and low yielding percentage. - In the above-mentioned structure, the irregularity of the underlying conductor pattern layer reflects or is reproduced on the surface of the insulator resin layer formed thereon. This results in the unevenness of the overlying conductor pattern layer stacked on the insulator resin layer. In this event, a desired characteristic can not be achieved.
- Furthermore, the moisture contained in the ambient air enters into the electronic component through a gap between the insulator resin layer and the electrode terminal portion. This brings about corrosion of the conductor pattern and fluctuation of the characteristic. As a result, the quality of the electronic component is considerably deteriorated.
- It is therefore an object of the present invention to provide a highly reliable electronic component which can be easily manufactured and reduced in size and which has characteristics desired.
- It is another object of the present invention to provide a circuit element comprising at least one of a low pass filter, a common choke coil, a transformer, an inductance, a capacitance, and an electric resistance each of which is formed as the above-mentioned electronic component.
- According to this invention, there is provided an electronic component comprising an insulator substrate, a layered member composed of a plurality of insulator resin layers and a plurality of conductor pattern layers alternately stacked on the insulator substrate to form a first conductor line and a second conductor line each of which comprises at least one conductor layer, first and second external electrode terminal portions connected to opposite ends of the first conductor line and covering first and second areas of side surfaces of the layered member and the insulator substrate, respectively, and a third external electrode terminal portion connected to one end of the second conductor line and covering a third area of the side surfaces of the layered member and the insulator substrate. The first and the second conductor lines have magnetic and electrocapacitive coupling with each other.
- According to this invention, there is also provided a common choke coil comprising the above mentioned electronic component. The common choke coil further comprises a fourth external electrode terminal connected to the other end of the second conductor line and formed on the side surfaces of the layered member and the insulator substrate at a fourth area different from the first through the third external electrode terminal portions. Each of the first and the second conductor lines have a pattern circulated on different conductor layers, the number of turns in both lines being equal to each other. A pair of the first and the third external electrode terminals and another pair of the second and the fourth external electrode terminals serves as an input terminal pair and an output terminal pair, respectively.
- According to this invention, there is also provided a transformer comprising the above mentioned electronic component. The transformer further comprises a fourth external electrode terminal connected to the other end of the second conductor line and formed on the side surfaces of the layered member and the insulator substrate at a fourth area different from the first through the third external electrode terminal portions. Each of the first and the second conductor lines have a pattern circulated on different conductor layers. A pair of the first and the second external electrode terminal and another pair of the third and the fourth external connection terminals serves as an input terminal pair and an output terminal pair, respectively.
- FIG. 1 is a sectional view of a conventional multilayer interconnection board;
- FIG. 2 is a sectional view of a conventional electronic component;
- FIG. 3 is a perspective view of a low pass filter as an electronic component according to a first embodiment of this invention;
- FIG. 4 is an exploded perspective view of the electronic component illustrated in FIG. 3;
- FIGS. 5A through 5D show a first part of a process of forming a layered structure for the electronic component illustrated in FIG. 3;
- FIGS. 6A through 6D show a second part of the process following the first part illustrated in FIGS. 5A through 5D;
- FIGS. 7A through 7D show a third part of the process following the second part illustrated in FIGS. 6A through 6D;
- FIG. 8 is a perspective view of showing a plurality of the layered structures formed on an insulator substrate of a large size before separation into the individual electronic components;
- FIG. 9 is a sectional view of a terminal structure formed on one of the electronic components cut from the insulator substrate illustrated in FIG. 8;
- FIG. 10 shows another terminal structure for an electronic component having a three terminal structure;
- FIG. 11 is an exploded perspective view of conductor patterns of a common choke coil as another electronic component according to a second embodiment of this invention;
- FIG. 12 is a partial sectional view of a terminal structure of the common choke coil illustrated in FIG. 11; and
- FIG. 13 is an exploded perspective view of conductor patterns of a transformer as still another electronic component according to a third embodiment of this invention.
- Now, description will be made about preferred embodiments of this invention with reference to the drawing.
- At first referring to FIG. 3, an electronic component according to a first embodiment of this invention is an EMI filter. As shown in FIG. 3, the
electronic component 10 comprises amain body 1 and first through third externalelectrode terminal portions main body 1, respectively, to extend from an end of the upper surface through the side surfaces to an end of the lower surface. Specifically, the first and the second externalelectrode terminal portions main body 1 opposite to each other in a longitudinal direction. The third externalelectrode terminal portion 2 c covers the center area of one of the side surfaces parallel to the longitudinal direction. - Referring to FIG. 4, the
main body 1 comprises aceramics substrate 11 as an insulator substrate, a plurality of insulator resin layers 12 a through 12 d, and a plurality of conductor pattern layers 13 a through 13 d. As shown in FIG. 4, the insulator resin layers 12 a, 12 b, 12 c, and 12 d and the conductor pattern layers 13 a, 13 b, 13 c, and 13 d are alternately stacked on theceramics substrate 11. - In order to increase the number of turns of a coil of the EMI filter, an additional
conductor pattern layer 13 c′ may be interposed together with an additional insulator layer. - In this embodiment, the
ceramics substrate 11 comprises a machinable ceramics material manufactured and sold by Mitsui Mining Material, Co., Ltd. under the trade name “Macerite”. The characteristics of the ceramics material are shown in Table 1 in comparison with alumina.TABLE 1 Machinable Ceramics (Macerite) Alumina Vickers Hardness 220 about 2000 (kg/mm2) Dielectric 6.5 10 Constant ε Relative 1 1 Permiability μ Resistivity 5 × 1015 1014 (Ω · cm) Breakdown 150 150 Voltage (kv/cm) Water 0 0 Absorption (%) Upper Limit 700 (1500) Temperature (° C.) - Each of the insulator resin layers12 a through 12 d comprises benzocyclobutene (BCB) as ultraviolet photosensitive resin. The use of BCB as the insulator resin layers achieves an excellent flatness of the insulator resin layers. As a consequence, it is possible to obtain a layered structure having a flat surface without an unevenness. Therefore, the
electronic component 10 has excellent electric characteristics. - Referring to FIGS.5A through SD, 6A through 6D, and 7A through 7D, a process of forming the layered structure of the insulator resin layers and the conductor pattern layers will be described.
- Referring to FIGS. 5A through 5D, the
insulator resin layer 12 a is formed on the ceramics substrate 11 (not shown) after theceramics substrate 11 is cleaned by the use of acetone, methylalcohol, or the like. If necessary, theinsulator resin layer 12 a is cleaned by reverse sputtering, as shown in FIG. 5A. On theinsulator resin layer 12 a, anunderlayer 3 comprising a Ti film and a Cu film is deposited by sputtering, as illustrated in FIG. 5B. In FIG. 5B, the Ti film and the Cu film have a thickness of 0.05 μm and a thickness of 0.25-0.3 μm, respectively, although not separately shown in the figure. - Next, as shown in FIG. 5C, a resist4 is applied on the
underlayer 3. Then, by the use of photolithography, the resist 4 is exposed through amask 5 and developed, as illustrated in FIG. 5D. - In the above-mentioned manner, a resist
pattern 4′ is formed as illustrated in FIG. 6A. Then, surface treatment is carried out by the use of H2SO4. Subsequently, an electrolytic Cu platedlayer 6 is formed by electrolytic Cu plating, as illustrated in FIG. 6B. - Referring to FIG. 6C, the resist
pattern 4′ is removed to form anintermediate conductor pattern 7. - Then, the
intermediate conductor pattern 7 illustrated in FIG. 6C is subjected to wet-etching (or dry-etching) to remove those portions of theunderlayer 3 exposed without the electrolytic Cu platedlayer 6. Then, cleaning is carried out by the use of HCl. As a consequence, an isolatedconductor pattern layer 13 a is formed on theinsulator resin layer 12 a, as illustrated in FIG. 6D. Although the upper surface of the Cu platedlayer 6 is slightly etched during etching, theintermediate conductor pattern 7 will not be removed because it is thicker than theunderlayer 3. - The
conductor pattern layer 13 a thus obtained comprises the patterns ofunderlayer 3 and the electrolytic Cu platedlayer 6 and has a thickness of about 3-5 μm and a width of about 30 μm. No trouble or inconvenience has been encountered during cleaning, photolithography, and etching in the manufacturing process. - Referring to FIGS. 7A through 7D, formation of another
insulator resin layer 12 b is described. As shown in FIG. 7A, theconductor pattern layer 13 a formed on theinsulator resin layer 12 a (FIG. 6D) is coated with the ultraviolet photosensitive resin of BCB by spin coating to form an intermediateinsulator resin layer 8. Then, by the use of photolithography, the intermediate insulator resignlayer 8 is exposed through amask 9, as illustrated in FIG. 7B. As a result, throughholes 14 are formed in the intermediateinsulator resin layer 8, as illustrated in FIG. 7C. The through holes 14 serve to establish electrical contact between theconductor pattern layer 13 a and another conductor pattern layer formed above. It is therefore unnecessary to form the throughholes 14 over the entire surface of theconductor pattern layer 13 a. - Then, half-curing is carried out in the nitrogen atmosphere at 210° C. for 30 minutes to obtain the
insulator resin layer 12 b illustrated in FIG. 7D. - The other conductor layers13 b, 13 c, and 13 d illustrated in FIG. 4 are formed in the manner similar to that described in conjunction with FIGS. 5A through 5D and 6A through 6D. The other insulator layers 12 c and 12D are formed in the manner similar to that described in conjunction with FIGS. 7A through 7D.
- By repeating the above-mentioned steps, a plurality of
main bodies 1 of theelectronic components 10 are formed on the insulator substrate, as shown in FIG. 8. - Next referring to FIG. 9, description proceeds to a step of forming the external electrode terminal portion (simply depicted at2) on the
main body 1 of each of the electronic components shown in FIG. 8. In the state illustrated in FIG. 8, the conductor pattern is exposed in the upper surface of themain body 1. Before separating the individualmain bodies 1 by cutting, an external surface of eachmain body 1 is covered with aninsulator resin layer 12 e. In addition, anelectrode extracting portion 16 in the form of a through hole is formed in the manner similar to that described above. Then, theelectrode extracting portion 16 is filled with a conductive metal material, for example, Cu, to form anelectrode extracting pattern 17. In addition, aprotection layer 12 f of, for example, polyimide, is formed on a surface region of theinsulator resin layer 12 e which is not covered with theelectrode extracting pattern 17. Theprotection layer 12 f may be made of any appropriate material selected from various materials such as those specified in Table 2 in dependence upon the applications.TABLE 2 Material of Insulator Layer in Multilayer Protection Structure Layer Effect BCB (Benzo- Polyimide 1. Improvement of Mechanical cyclobutene) Strength → Reduction of (Water Defects upon Mounting Absorption between Steps 0.25%) 2. Assurance of Fire Proofness (Shielding BCB from Atmosphere (oxygen)) Epoxy 3. Easy Application (Spin Coater) Formation at Low Tempera- ture → Low Cost SiO 2 1. Improvement of Mechanical (CVD Strength Deposition) 2. Assurance of Fire Proofness Si3N4 (3. Further Improvement of (CVD Anti-Humidity) Deposition) Polyimide BCB 1. Improvement of (Water (Benzo- Anti-Humidity Absorption cyclobutene) 2. Low Cost (Spin Coater, 0.25%) Formation at Low Tempera- ture) SiO 21. Improvement of (CVD Film) Anti-Humidity Si3N4 (3. Further Improvement of (CVD Film) Mechanical Strength) - The ceramics substrate (FIG. 8) with a plurality of the
main bodies 1 formed thereon is cut by a dicing saw along a dash-and-dot line. Thus, the individualmain bodies 1 are separated. In FIG. 8, one of themain bodies 1 is depicted by the solid line. - Then, the
main body 1 is cleaned by the use of 5% HCl solution. Thereafter, Ni conductive paste comprising, for example, epoxy resin containing Ni powder is applied to an area from an end portion of theelectrode extracting pattern 17 through the side surface to the lower surface of themain body 1 and is subjected to thermosetting or thermal curing. Next, ultrasonic cleaning is carried out by the use of both a KOH solution and a H2SO4 solution as a pretreatment prior to plating. Thereafter, a Ni platedfilm 18 is formed as an underlayer by electrolytic barrel plating of a nickel sulfanate bath. Herein, Ni is excellent in electrolysis migration and serves to protect the internal diffusion of solder or the like. Thereafter, a solder platedfilm 19 is formed on the Ni platedfilm 18 by electrolysis barrel plating of a tin-lead alkanolsulfonate bath. The tin-lead alkanolsulfonate bath prevents the deterioration of the insulator resin layer because no chelating agent is contained. It is noted here that the solder platedfilm 19 can be formed by a phenolsulfonate plating bath. A tin plated film may be formed instead of the solder plated film. - In the above-mentioned terminal structure, the
electrode extracting pattern 17 is formed above theinsulator resin layer 12 at the interface between theelectrode extracting pattern 17 and the insulator resin layer. Therefore, the separation therebetween hardly occurs so that external moisture is effectively prevented from entering. - Referring to FIG. 10, another terminal structure of an electronic component according to a second embodiment of this invention will be described. In FIG. 8, a three terminal structure used in the EMI filter, LCR parts, and the like, is illustrated. The
electrode extracting pattern 17 is connected to the secondconductor pattern layer 13 counted from the topmostconductor pattern layer 13. The protection film is not shown in the figure. - Referring to FIG. 11, a common choke coil according to a third embodiment of this invention has first through fourth conductor pattern layers13 a through 13 d. Practically, in the manner similar to that illustrated in FIG. 3, the first through the fourth conductor pattern layers 13 a through 13 d are successively stacked with the insulator resin layers interposed therebetween although the insulator resin layers are not shown in FIG. 11 for convenience of illustration. In FIG. 11, each of the first through the fourth conductor pattern layers 13 a through 13 d has
end patterns 15 a through 15 d. Theend patterns 15 a of the first through the fourth conductor pattern layers 13 a through 13 d are overlapped on one another through notches formed in the insulator resin layers to be electrically connected. Likewise, theend patterns conductor pattern 21 of the first or the lowestconductor pattern layer 13 a is connected through acentral conductor pattern 23 of the secondconductor pattern layer 13 b to the end portion of an extractingconductor pattern 25 of the thirdconductor pattern layer 13 c. In this structure, theend portions conductor pattern 24 of the secondconductor pattern layer 13 b is connected to the end portion of an extractingconductor pattern 26 of the thirdconductor pattern layer 13 c. In this structure, theend portions - FIG. 12 shows the structure of the terminal portion of the electronic component illustrated in FIG. 11. In FIG. 12, the terminal portion has a four terminal structure. The
electrode extracting pattern 17 is connected to the uppermostconductor pattern layer 13. The protection film is not shown in the figure. - Referring to FIG. 13, a transformer according to a fourth embodiment of the present invention has first through fourth conductor pattern layers13 a through 13 d. Practically, in the manner similar to that illustrated in FIG. 4, the first through the fourth conductor pattern layers 13 a through 13 d are successively stacked with the insulator resin layers interposed therebetween. In FIG. 13, each of the conductor pattern layers 13 a through 13 d has
end patterns 15 a through 15 d. Theend patterns 15 a are overlapped on one another through notches formed in the insulator resin layers to be electrically connected. Likewise, theend patterns conductor pattern 27 of the firstconductor pattern layer 13 a is connected to the end portion of an extractingconductor pattern 28 of the secondconductor pattern layer 13 b. In this structure, theend portions conductor pattern 30 of the thirdconductor pattern layer 13 c is connected to another extractingconductor pattern 29 of the secondconductor pattern layer 13 b. In this structure, theend portions - In the common choke coil (FIG. 11) and the transformer (FIG. 13), each of the conductor pattern layers is formed in the manner described in conjunction with FIGS. 5A through 5D and6A through 6D. The insulator resin layers which are not shown in FIGS. 11 and 13 are formed in the manner described in conjunction with FIGS. 7A through 7D. In either case, the terminal structure illustrated in FIG. 12 is used.
- In either case, a plurality of the above-mentioned electronic components are simultaneously formed on the
insulator substrate 11 of a large size in the manner similar to that described in conjunction with FIG. 8. After separation into each individual component, the terminal structure is formed. The cutting operation is easily carried out if the insulator substrate comprises a machinable material, for example, having a Vickers hardness within the range between 100 and 1000. Thus, the cost can be reduced. - Although the foregoing embodiments have been directed to the low pass filter, the common choke coil, and the transformer, this invention is also applicable to an element such as an inductor, a capacitor, or an electric resistance element.
- As thus far been described, the electronic component of this invention can be easily manufactured and reduced in size, has desired characteristics, and is highly reliable.
- Furthermore, a circuit element comprising at least one of the low pass filter, the common choke coil, the transformer, the inductance, the capacitance, and the electric resistance each of which is formed as the electronic component is obtained according to the present invention.
Claims (16)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/298,437 US6376912B1 (en) | 1996-03-29 | 1999-04-23 | Common mode choke coil of the conductor/insulator stacked type that uses a high machinability substrate and benzocyclobutene as the insulator |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP8-103700 | 1996-03-29 | ||
JP103700 | 1996-03-29 | ||
JP8103700A JPH09270325A (en) | 1996-03-29 | 1996-03-29 | Electronic part |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/298,437 Division US6376912B1 (en) | 1996-03-29 | 1999-04-23 | Common mode choke coil of the conductor/insulator stacked type that uses a high machinability substrate and benzocyclobutene as the insulator |
Publications (2)
Publication Number | Publication Date |
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US20010026017A1 true US20010026017A1 (en) | 2001-10-04 |
US6392297B2 US6392297B2 (en) | 2002-05-21 |
Family
ID=14361044
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/826,094 Expired - Fee Related US6392297B2 (en) | 1996-03-29 | 1997-03-28 | Electronic circuit element of conductor/insulator stacked type using high machinability substrate and benzocyclobutene as insulator |
US09/298,437 Expired - Fee Related US6376912B1 (en) | 1996-03-29 | 1999-04-23 | Common mode choke coil of the conductor/insulator stacked type that uses a high machinability substrate and benzocyclobutene as the insulator |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/298,437 Expired - Fee Related US6376912B1 (en) | 1996-03-29 | 1999-04-23 | Common mode choke coil of the conductor/insulator stacked type that uses a high machinability substrate and benzocyclobutene as the insulator |
Country Status (5)
Country | Link |
---|---|
US (2) | US6392297B2 (en) |
EP (1) | EP0798851A1 (en) |
JP (1) | JPH09270325A (en) |
KR (1) | KR100282010B1 (en) |
CN (1) | CN1172413A (en) |
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- 1997-03-28 KR KR1019970011021A patent/KR100282010B1/en not_active IP Right Cessation
- 1997-03-28 US US08/826,094 patent/US6392297B2/en not_active Expired - Fee Related
- 1997-03-29 CN CN97109663A patent/CN1172413A/en active Pending
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Also Published As
Publication number | Publication date |
---|---|
US6392297B2 (en) | 2002-05-21 |
EP0798851A1 (en) | 1997-10-01 |
CN1172413A (en) | 1998-02-04 |
US6376912B1 (en) | 2002-04-23 |
JPH09270325A (en) | 1997-10-14 |
KR100282010B1 (en) | 2001-11-14 |
KR970068758A (en) | 1997-10-13 |
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