WO2009147936A1 - 多層プリント配線板の製造方法 - Google Patents

多層プリント配線板の製造方法 Download PDF

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Publication number
WO2009147936A1
WO2009147936A1 PCT/JP2009/058921 JP2009058921W WO2009147936A1 WO 2009147936 A1 WO2009147936 A1 WO 2009147936A1 JP 2009058921 W JP2009058921 W JP 2009058921W WO 2009147936 A1 WO2009147936 A1 WO 2009147936A1
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Prior art keywords
forming
resin
metal foil
wiring board
printed wiring
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PCT/JP2009/058921
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English (en)
French (fr)
Inventor
宏徳 田中
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イビデン株式会社
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Priority to JP2009529449A priority Critical patent/JPWO2009147936A1/ja
Publication of WO2009147936A1 publication Critical patent/WO2009147936A1/ja

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    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09209—Shape and layout details of conductors
    • H05K2201/095—Conductive through-holes or vias
    • H05K2201/09536—Buried plated through-holes, i.e. plated through-holes formed in a core before lamination
    • 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
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09209—Shape and layout details of conductors
    • H05K2201/09654—Shape and layout details of conductors covering at least two types of conductors provided for in H05K2201/09218 - H05K2201/095
    • H05K2201/0969—Apertured conductors
    • 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
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
    • H05K2201/09918—Optically detected marks used for aligning tool relative to the PCB, e.g. for mounting of components
    • 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
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
    • H05K2201/10621—Components characterised by their electrical contacts
    • H05K2201/10674—Flip chip
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/01—Tools for processing; Objects used during processing
    • H05K2203/0147—Carriers and holders
    • H05K2203/0152—Temporary metallic carrier, e.g. for transferring material
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/04—Soldering or other types of metallurgic bonding
    • H05K2203/043—Reflowing of solder coated conductors, not during connection of components, e.g. reflowing solder paste
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/06—Lamination
    • H05K2203/063—Lamination of preperforated insulating layer
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/14—Related to the order of processing steps
    • H05K2203/1461—Applying or finishing the circuit pattern after another process, e.g. after filling of vias with conductive paste, after making printed resistors
    • H05K2203/1469—Circuit made after mounting or encapsulation of the components
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/16—Inspection; Monitoring; Aligning
    • H05K2203/166—Alignment or registration; Control of registration
    • 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
    • H05K3/02—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding
    • H05K3/022—Processes for manufacturing precursors of printed circuits, i.e. copper-clad substrates
    • H05K3/025—Processes for manufacturing precursors of printed circuits, i.e. copper-clad substrates by transfer of thin metal foil formed on a temporary carrier, e.g. peel-apart copper
    • 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
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
    • H05K3/341—Surface mounted components
    • H05K3/3431—Leadless components
    • H05K3/3436—Leadless components having an array of bottom contacts, e.g. pad grid array or ball grid array components
    • 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
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
    • H05K3/3457—Solder materials or compositions; Methods of application thereof
    • H05K3/3485—Applying solder paste, slurry or powder
    • 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
    • H05K3/46—Manufacturing multilayer circuits
    • H05K3/4602—Manufacturing multilayer circuits characterized by a special circuit board as base or central core whereon additional circuit layers are built or additional circuit boards are laminated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
    • Y10T29/49146—Assembling to base an electrical component, e.g., capacitor, etc. with encapsulating, e.g., potting, etc.

Definitions

  • the present invention relates to a method for manufacturing a multilayer printed wiring board incorporating electronic components, and more particularly, to a method for manufacturing a multilayer printed wiring board incorporating electronic components such as IC chips.
  • Patent Document 1 a conductive adhesive is formed on a metal foil, and an electronic component is mounted on the metal foil via the conductive adhesive. After that, the electronic component mounted on the metal foil is built in an insulating substrate made of an inorganic filler and a thermosetting resin.
  • An object of the present invention is to provide a method for manufacturing a multilayer printed wiring board having a built-in electronic component and high connection reliability.
  • the production method of the present invention comprises: Preparing a metal foil having a first surface and a second surface opposite to the first surface; Forming a positioning mark on the metal foil; Forming bumps on the first surface of the metal foil based on the positioning mark; A step of aligning the bump and the electronic component with reference to the positioning mark; Mounting the electronic component on the bump; Storing the electronic component in a resin; Forming a pad connected to the bump with reference to the positioning mark.
  • FIG. 9A is a process diagram illustrating a method for manufacturing a multilayer printed wiring board according to a modification of the first embodiment
  • FIG. 9B is an explanatory diagram of conductor circuits and pads. It is process drawing which shows the manufacturing method of the multilayer printed wiring board of 2nd Example. It is sectional drawing which shows the multilayer printed wiring board of 2nd Example.
  • FIG. 12A is a process diagram illustrating a method for manufacturing a multilayer printed wiring board according to the third embodiment
  • FIG. 12B is a process diagram illustrating a method for manufacturing the multilayer printed wiring board according to the fourth embodiment.
  • FIG. 12C is a process diagram showing the method of manufacturing the multilayer printed wiring board according to the fifth embodiment. It is process drawing which shows the manufacturing method of the multilayer printed wiring board of 7th Example. It is process drawing which shows the manufacturing method of the multilayer printed wiring board of 7th Example.
  • a method of manufacturing the multilayer printed wiring board 10 according to the first embodiment of the present invention will be described with reference to FIGS. First, a method for manufacturing a core substrate incorporating an IC chip will be described.
  • a metal foil 100 with a carrier is prepared as a starting material (FIG. 1 (A)).
  • the metal foil with a carrier comprises a support 101 and a metal foil 12.
  • the metal foil has a thickness of 1.5 to 36 ⁇ m and is made of a conductive metal such as copper, aluminum or nickel.
  • a conductive material such as aluminum, steel, or copper, or an insulating film such as epoxy or polyimide can be used.
  • the thickness of the support is about 18 to 100 ⁇ m.
  • Metal foil can be laminated
  • the metal foil has a first surface and a second surface opposite to the first surface.
  • a second surface of the metal foil is formed on the support.
  • the starting material may be a metal foil 12 as shown in FIG.
  • a positioning mark 14 is formed on a metal foil by a laser (FIG. 1B).
  • solder resist layer (second solder resist layer) 16 is formed on the first surface of the metal foil (FIG. 1C). Next, using the positioning marks 14 as a reference, bump forming openings 16a are formed in the solder resist layer 16 (FIG. 1D).
  • solder paste 18 ⁇ is printed on the metal foil 160 exposed through the opening 16a of the solder resist layer 16 (FIG. 2A).
  • solder a metal containing Sn / Pb, Sn / Ag, Sn / Sb, Sn / Ag / Cu, or the like as a main component can be used.
  • reflow is performed at 200 to 280 ° C. to form solder bumps 18 in the openings 16a (FIG. 2B).
  • solder balls can be mounted on the metal foil 160.
  • Metal bumps such as solder and gold can be formed on the metal foil exposed through the openings 16a of the solder lace layer by electrolytic plating.
  • the solder paste or solder ball can be formed on the metal foil 160 with the positioning mark 14 as a reference.
  • the opening 16a is provided based on the positioning mark 14 provided on the metal foil 12 to form the solder bump
  • the positional accuracy of the solder bump 18 is increased.
  • the connection reliability between the solder bump and the metal foil is increased.
  • the solder bumps 18 are provided in the openings 16a of the solder resist layer 16, the solder resist layer functions as a dam so that the solder does not flow during reflow, and a fine pitch solder bump is formed with high connection reliability. be able to.
  • the solder resist layer can prevent a short circuit between the solder bumps.
  • the mounting position of the IC chip 20 is determined based on the positioning mark 14 so that the terminals 22 of the IC chip 20 are connected to the solder bumps 18. Thereafter, electronic components such as the IC chip 20 are mounted on the metal foil. Subsequently, the solder bumps 18 and the terminals 22 are connected by reflow (FIG. 2C). Since the mounting position of the IC chip 20 is positioned using the positioning mark 14, high position accuracy can be realized. The connection reliability between the solder bump 18 and the terminal 22 of the IC chip 20 can be improved. Further, an IC chip having a full grid terminal 22 can be mounted.
  • the underfill 24 is filled between the solder resist layer 16 and the IC chip 20 (FIG. 2D). Thereby, the reliability of the solder bump 18 can be improved.
  • the substrate (electronic component mounting substrate) 200 in which the electronic component is mounted on the metal foil 12 is completed by the steps from FIG. 1 (A) to FIG. 2 (D).
  • the resin film 26 ⁇ is preferably made of a thermosetting resin and an inorganic filler.
  • the inorganic filler for example, Al2O3, MgO, BN, AlN or SiO2 can be used, and the amount of the inorganic filler in that case is preferably 30 to 60 wt%.
  • the thermosetting resin for example, an epoxy resin, a phenol resin, a polyimide resin or a cyanate resin having high heat resistance is preferable, and among them, an epoxy resin having excellent heat resistance is particularly preferable.
  • the electronic component mounting substrate 200, the resin film 26 ⁇ , and the metal foil 28 are heated and pressed to incorporate the IC chip 20 in the resin insulating layer 26.
  • the support body 101 is peeled from the copper foil 12, and the intermediate
  • the resin film is cured and becomes the resin insulating layer 26.
  • the resin insulating layer 26 has a first surface and a second surface opposite to the first surface. As shown in FIG. 3B, the first surface is a surface facing the starting metal foil.
  • the metal foil 12 and the metal foil 28 are preferably metal foils having the same thickness. On the way, warpage of the substrate 201 is reduced.
  • the positioning mark 14 may be filled with resin, making it difficult to recognize the position of the positioning mark.
  • the second positioning mark (through hole) 140 may be formed with reference to the positioning mark 14 (see FIG. 9A).
  • the positioning mark 14 can be recognized by X-rays or the like.
  • the second positioning mark 140 may be formed at the same position as the positioning mark 14 or may be formed at a position different from the positioning mark 14.
  • a through-hole 36a for a through-hole conductor is formed in the midway substrate 201 (FIG. 3C).
  • the through hole 36 a is formed with reference to the positioning mark 14 or the second positioning mark 140.
  • an electroless plating process and an electrolytic plating process are performed to form a through-hole conductor 36 on the inner wall of the through hole (FIG. 3D).
  • an electroless plating film and an electrolytic plating film are also formed on the metal foil 12 and the metal foil 28.
  • An electroless copper plating film is formed on the surface of the substrate 201 on the way. Further, an electrolytic copper plating film is formed. At this time, the filler 37 filled in the through-hole conductor 36 is simultaneously covered with the electroless plating film 330 and the electrolytic plating film 33 (FIG. 4B).
  • An etching resist is formed on the electrolytic plating film 33. Thereafter, the etching resist is exposed and developed to pattern the etching resist. Then, the plating film (electroless plating film and electrolytic plating film) and the metal foils 12 and 28 where the etching resist is not formed are dissolved and removed with an etching solution. Further, the etching resist is removed to form a conductor circuit 34 on the resin insulating layer 26 and a conductor circuit 34 that covers the filler 37 (see FIG. 4C). At the same time, an alignment mark (not shown) 1400 is formed on the core substrate. Thereby, the core substrate 30 is completed. The conductor circuit 34 has a pad 34P connected to the bump 18 (see FIG. 9B). The patterning of the etching resist is formed with reference to the positioning mark 14 or the second positioning mark.
  • An interlayer resin insulation layer 50 is formed by affixing a resin film for an interlayer resin insulation layer on both surfaces of the core substrate 30 (FIG. 4D).
  • a via hole opening 50a is formed in the interlayer resin insulation layer 50 with a laser (FIG. 5A).
  • a laser here, an opening is provided by a laser, but the opening can also be formed by photolithography.
  • the via hole opening 50 a is formed with reference to the alignment mark 1400.
  • an electroless copper plating film 52 is formed on the surface of the interlayer resin insulation layer 50 including the inner wall of the via hole opening 50a (FIG. 5B).
  • a plating resist 54 is provided on the electroless copper plating film 52 (FIG. 5C).
  • electrolytic plating is performed to form an electrolytic copper plating film 56 having a thickness of 15 ⁇ m in a portion where the plating resist 54 is not formed (FIG. 5D).
  • the plating resist 54 is peeled off. Thereafter, the electroless plating film under the plating resist is etched and removed to form independent conductor circuits 58 and via holes 60 (FIG. 6A).
  • an interlayer insulating layer 150 having an upper conductor circuit 158 and a via hole 160 can be formed to produce a multilayer wiring board (FIG. 6B).
  • solder resist layer (first solder resist layer) 70 having openings 71 and 72 is formed on both surfaces of the multilayer wiring board (FIG. 6C).
  • solder paste is printed on the opening 71 and reflowed to form solder bumps 78U on the upper surface and solder bumps 78D on the lower surface, thereby completing the multilayer printed wiring board 10 (FIG. 7).
  • the starting material is a copper foil with a carrier consisting of a carrier (copper foil of 25 to 100 ⁇ m) 101, a release layer (not shown), and a copper foil 12 of 3 to 15 ⁇ m (FIG. 8A).
  • a positioning mark 14 is formed on a metal foil (copper foil) with a laser (FIG. 8B).
  • a solder paste is formed on the copper foil 12 by potting or printing based on the positioning mark 14. Thereafter, reflow is performed to form solder bumps 18 on the copper foil 12 (FIG. 8C).
  • solder bumps are formed based on the positioning marks provided on the metal foil 12. Thereafter, an IC chip is mounted on the metal foil via the solder bump. The mounting of the IC chip and the formation of the solder bump are performed with reference to the same positioning mark 14. The positional accuracy between the solder bump 18 and the IC chip 20 is increased. As a result, the connection reliability between an electronic component such as an IC chip and a printed wiring board incorporating the electronic component is increased.
  • the modified example of the first embodiment is easier to manufacture than the first embodiment because the second solder resist layer is not provided.
  • a solder resist layer (second solder resist layer) 16 is provided on the metal foil 12 as in the first embodiment described above with reference to FIGS. Thereafter, the IC chip 20 is mounted through the solder bumps 18 (FIG. 10A).
  • An insulating film 27 ⁇ having an opening 27a for accommodating an electronic component such as an IC chip, a B-stage second insulating film 260 ⁇ , and a copper foil 28 are prepared.
  • the insulating film 27 ⁇ is made of a core material such as glass cloth or aramid fiber and a B-stage resin, and the core material is impregnated with a thermosetting resin such as epoxy or a composite resin made of a thermosetting resin and a thermoplastic resin. Film.
  • the insulating film 27 ⁇ has a positioning mark 2800.
  • An opening 27a for accommodating an electronic component such as an IC chip is formed with reference to the positioning mark 2800.
  • the second insulating film 260 ⁇ is a prepreg having no opening (insulating film made of one core material of glass cloth, glass fiber, and aramid fiber and a resin), a resin film 26 ⁇ , or a thermosetting resin.
  • a film made of 70-90 wt% inorganic filler is preferred.
  • the thickness of the copper foil 28 is preferably substantially the same as that of the copper foil 12.
  • An opening 27a larger than the IC chip is formed in the insulating film 27 ⁇ in advance.
  • the metal foil on which the IC chip 20 is mounted and the insulating film 27 ⁇ are aligned. The alignment is performed with reference to the positioning mark 14 and the positioning mark 2800 of the insulating film 27 ⁇ .
  • an insulating film (thickness 150 ⁇ m) 27 ⁇ having an opening 27a corresponding to the IC chip is laminated on the metal foil 12 on which the IC chip 20 is mounted. Further, a second insulating film 260 ⁇ having a thickness of 50 ⁇ m and a metal foil 28 having a thickness of 1.5 to 36 ⁇ m are laminated on the insulating film 27 ⁇ (FIG. 10B). Then, it heat-presses. At this time, the resin begins to ooze from the second insulating film 260 ⁇ and the insulating film 27 ⁇ into the opening 27a of the insulating film, and fills the opening 27a (FIG. 10C).
  • the insulating film, the second insulating film, and the resin filling the opening 27a are cured.
  • the insulating substrate 270 is formed.
  • the insulating substrate 270 has a first surface and a second surface opposite to the first surface.
  • the first surface is a surface facing the starting metal foil.
  • the resin (filling resin) 280 filling the opening is made of an inorganic filler and a thermosetting resin, and the amount of the inorganic filler is 30 to 90 wt%.
  • the intermediate substrate illustrated in FIG. 10C corresponds to FIG. 3B of the first embodiment. Thereafter, the intermediate substrate in FIG.
  • the core substrate of the second embodiment includes a resin substrate 27 having an opening, a resin insulating layer 260, an IC chip 12 accommodated in the opening, a filling resin 280, a conductor circuit 34, and a through-hole conductor 36.
  • the resin substrate 27 is a substrate on which the insulating film 27 ⁇ is cured.
  • the resin insulating layer 260 is a resin layer obtained by curing the second insulating film 260 ⁇ .
  • the same material as the second insulating film prepreg, resin film, film made of an inorganic filler and a thermosetting resin
  • the core substrate 30 of the second embodiment includes a resin substrate 27 having a core material such as glass cloth or aramid fiber. Therefore, the strength of the core substrate 30 is high, and high reliability can be provided even if a heat cycle test is performed.
  • the configuration of the multilayer printed wiring board 10 according to the first embodiment of the present invention will be described with reference to FIG.
  • the IC chip 20 is built in the core substrate 30.
  • Conductor circuits 34 are formed on the first surface and the second surface (surface opposite to the first surface) of the core substrate 30.
  • the conductor circuits on the first surface and the second surface of the core substrate 30 are connected via a through-hole conductor 36.
  • the conductor circuit on the first surface has a pad 34P for mounting an IC chip.
  • an interlayer resin insulation layer 50 in which a via hole 60 is formed and an interlayer resin insulation layer 150 in which a via hole 160 is formed are formed on the core substrate 30.
  • a solder resist layer 70 is formed on the interlayer resin insulation layer 150.
  • Conductor circuit 58 is formed between interlayer resin insulation layer 50 and interlayer resin insulation layer 150. The conductor circuit 58 and the conductor circuit 34 are connected by a via hole 60.
  • a conductor circuit 158 is formed between the interlayer resin insulation layer 150 and the solder resist layer 70. Conductor circuit 158 and conductor circuit 58 are connected by via hole 160.
  • An opening 71 is formed in the solder resist layer 70 on the upper surface side. Solder bumps 78U for mounting electronic components such as IC chips are formed in the openings 71.
  • An opening 72 is formed in the solder resist layer 70 on the lower surface side. Solder bumps 78D for connecting to an external substrate such as a daughter board are formed in the opening 72.
  • the IC chip 20 is accommodated in the core substrate 30 by the resin insulating layer 26.
  • the terminals 24 and the pads 34P of the IC chip 20 are connected via the solder bumps 18.
  • Bumps (including plating bumps) are formed on the pads 34P.
  • the second solder resist layer 16 is formed between the interlayer resin insulation layer 50 and the resin insulation layer 26 on the first surface of the core substrate.
  • An underfill 24 is filled between the second solder resist layer 16 and the IC chip 20.
  • the resin insulating layer 26 is made of resin and silica filler, and the amount of silica filler is 50 wt%.
  • a method for manufacturing the multilayer printed wiring board 10 described above with reference to FIG. 7 will be described with reference to FIGS.
  • a method for manufacturing a core substrate incorporating an IC chip will be described.
  • a copper foil with a carrier (MTSD-H, carrier (copper foil): 35 ⁇ m, copper foil: 5 ⁇ m) manufactured by Mitsui Kinzoku Co., Ltd. was used as a starting material (FIG. 1A).
  • the positioning mark 14 was formed by laser or etching (FIG. 1B).
  • a commercially available solder resist composition was applied to a thickness of 20 ⁇ m and dried to form a second solder resist layer 16 (FIG. 1C).
  • a positioning mark 14 as a reference, an opening 16a for bump formation was formed in the second solder resist layer 16 (FIG. 1D).
  • the opening 16a is formed by a laser.
  • solder paste 18 ⁇ was formed on the metal foil exposed through the opening 16a of the solder resist layer 16 by printing (FIG. 2A). Then, reflow was performed at 200 ° C. to form solder bumps 18 on the metal foil exposed through the openings 16a (FIG. 2B).
  • the mounting position of the IC chip is determined based on the positioning mark 14 so that the terminals 22 of the IC chip 20 are connected to the solder bumps 18. Thereafter, the solder bumps 18 and the IC chip terminals 22 were connected by reflow to mount the IC chip on the metal foil via the solder bumps (FIG. 2C).
  • a 200 ⁇ m thick resin film (B stage resin film made of epoxy and 50 wt% silica filler) 26 ⁇ and a 5 ⁇ m thick copper foil 28 are provided on the copper foil 12 on which the IC chip 20 is mounted. It laminated
  • a through-hole 36a for a through-hole conductor was formed by a drill in the substrate 30 incorporating the IC chip (FIG. 3C). Thereafter, an electroless plating process and an electrolytic plating process were performed to form a through-hole conductor 36 (FIG. 3D). At the same time, an electroless copper plating film (first electroless plating film) and an electrolytic copper plating film (first electroplating film) were formed on the copper foils 12 and 28.
  • the substrate 30 on which the through-hole conductors 36 were formed was washed with water and dried. Then, NaOH (10g / l), NaClO 2 (40g / l), were blackened with an aqueous solution containing Na 3 PO 4 (6g / l ). Subsequently, reduction treatment was performed with an aqueous solution containing NaOH (10 g / l) and NaBH4 (6 g / l) to form roughened surfaces on the surface of the through-hole conductor 36 and the electrolytic copper plating film (not shown).
  • An electroless copper plating film 330 having a thickness of 0.6 ⁇ m was formed by applying a palladium catalyst (manufactured by Atotech) to the substrate surface and performing electroless copper plating. Furthermore, electrolytic copper plating was performed under the following conditions to form an electrolytic copper plating film having a thickness of 15 ⁇ m. At the same time, the filler 37 filled in the through-hole conductor 36 is covered with an electroless plating film (second electroless plating film) 330 and an electrolytic plating film (second electrolytic plating film) 33 (FIG. 4B )).
  • a commercially available photosensitive dry film was pasted on the electrolytic plating film 33, and exposure and development processing was performed to form an etching resist having a thickness of 15 ⁇ m.
  • the portions of the copper foils 12 and 28 where the etching resist is not formed and the plating film on the copper foil (the plating film is the first electroless plating film on the metal foil and the first electroless plating film on the first foil).
  • the plating film is the first electroless plating film on the metal foil and the first electroless plating film on the first foil.
  • the second electroless plating film on the first electroplating film, and the second electroplating film on the second electroless plating film It was dissolved and removed with an etching solution.
  • the etching resist was stripped and removed with 5% KOH to form a conductor circuit 34 on the resin insulating layer 26, a conductor circuit 34 covering the filler 37, and a pad 34P (see FIG. 4C).
  • the conductor circuit 34 and the pad 34P on the resin insulating layer 26 are the metal foil, the first electroless plating film on the metal foil, the first electroplating film and the first electroplating film on the first electroless plating film. It consists of the second electroless plating film and the second electroplating film on the second electroless plating film.
  • the conductor circuit 34 covering the filler 37 includes a second electroless plating film and a second electroplating film on the second electroless plating film.
  • the lamination of the interlayer resin insulation layer and the conductor circuit on the core substrate will be described.
  • the surface of the conductor circuit 34 was roughened using Cz8100 made by MEC (not shown).
  • a resin film for an interlayer resin insulation layer (manufactured by Ajinomoto Co., Inc .: trade name: ABF-45SH) was laminated on both surfaces of the core substrate 30 using a vacuum laminator apparatus. The conditions are a degree of vacuum of 67 Pa, a pressure of 0.47 MPa, a temperature of 85 ° C., and a pressure bonding time of 60 seconds. Thereafter, the resin film for an interlayer resin insulation layer was thermally cured at 170 ° C. for 40 minutes to form an interlayer resin insulation layer 50 on the core substrate (FIG. 4D).
  • the substrate on which the via hole opening (50a) was formed was immersed in an 80 ° C. solution containing 60 g / l permanganic acid for 10 minutes to remove particles present on the surface of the interlayer resin insulation layer (50).
  • a roughened surface was formed on the surface of the interlayer resin insulating layer 50 including the inner wall of the via hole opening 50a (not shown).
  • the substrate after the above treatment was immersed in a neutralization solution (manufactured by Shipley Co., Ltd.) and then washed with water. Further, catalyst nuclei were adhered to the surface of the interlayer resin insulation layer subjected to the roughening treatment (roughening depth 3 ⁇ m) and the inner wall surface of the via hole opening.
  • a neutralization solution manufactured by Shipley Co., Ltd.
  • Electroless copper plating film 52 was formed on the surface of interlayer resin insulation layer 50 including the inner wall of via hole opening 50a (FIG. 5B). [Electroless plating conditions] 45 minutes at a liquid temperature of 34 ° C
  • a commercially available photosensitive dry film was attached to the substrate on which the electroless copper plating film 52 was formed, and an exposure and development treatment was performed to provide a plating resist 54 having a thickness of 25 ⁇ m (FIG. 5C).
  • electrolytic plating was performed under the following conditions, and an electrolytic copper plating film 56 having a thickness of 15 ⁇ m was formed in a portion where the plating resist 54 was not formed (FIG. 5D).
  • solder resist composition was applied to both surfaces of the multilayer wiring board. Thereafter, exposure and development were performed to form openings 71 and 72 in the solder resist composition (FIG. 6C). Further, heat treatment was performed under the conditions of 80 ° C. for 1 hour, 100 ° C. for 1 hour, 120 ° C. for 1 hour, and 150 ° C. for 3 hours, respectively. Solder resist layer, thickness: 15-25 ⁇ m) 70 was formed.
  • solder paste was printed on the metal film in the openings 71 and 72. Thereafter, by reflowing at 230 ° C., solder bumps 78U were formed on the upper surface and solder bumps 78D were formed on the lower surface, thereby completing the multilayer printed wiring board 10 (FIG. 7).
  • FIG. 11 shows a cross section of the multilayer printed wiring board of the second embodiment.
  • the core substrate 30 of the multilayer printed wiring board 110 includes a resin substrate 27 made of a core material such as glass cloth, glass fiber, and araimide fiber and a cured resin.
  • the resin substrate is a substrate obtained by curing a prepreg in which a core material is impregnated with a thermosetting resin such as epoxy, or a composite resin composed of a thermosetting resin and a thermoplastic resin.
  • the resin substrate 27 has an opening 27a.
  • An IC chip is accommodated in the opening 27a.
  • a filling resin 280 is filled in the opening 27a.
  • the IC chip is built in the opening by the filling resin.
  • a second solder resist layer is formed between the first surface of the insulating substrate and the interlayer resin insulating layer on the first surface.
  • An underfill is formed between the second solder resist layer and the IC chip.
  • solder resist layer 16 is provided on the copper foil 12, and an IC chip is provided via solder bumps 18. 20 is mounted (FIG. 10A).
  • a prepreg 27 ⁇ (150 ⁇ m thick) was prepared as an insulating film having an opening 27a for accommodating the IC chip 20.
  • a prepreg 27 ⁇ was laminated on the copper foil 12 on which the IC chip 20 was mounted with reference to the positioning mark 14 and the positioning mark 2800. The opening and the IC chip were aligned accurately.
  • a second insulating film (prepreg made by Hitachi Chemical Co., Ltd.) 260 ⁇ having a thickness of 50 ⁇ m and a copper foil 28 having a thickness of 5 ⁇ m were laminated on the prepreg 27 ⁇ (FIG. 10B).
  • the carrier-attached copper foil on which the IC chip was mounted, the prepreg, the insulating film, and the copper foil were heated and pressed by a vacuum press machine.
  • the prepreg was cured to form a resin substrate 27.
  • the second insulating film was cured to form an insulating resin layer 260.
  • the resin squeezed into the opening was cured to become a filling resin 280. (FIG. 10C).
  • the carrier was peeled off.
  • the steps after FIG. 3C of Example 1 were performed, and a buildup layer was formed on the core substrate incorporating the IC chip.
  • a substrate in which a resin substrate and an insulating resin layer are integrated is an insulating substrate.
  • FIG. 12A shows a copper foil (18 ⁇ m thick) which is a starting material of the third embodiment. Thereafter, a printed wiring board incorporating an IC chip was manufactured in the same process as that in FIG.
  • FIG. 12B shows a copper foil (18 ⁇ m thick) which is a starting material of the fourth embodiment. Thereafter, a printed wiring board incorporating an IC chip was manufactured in the same steps as those in FIG. 8B and subsequent drawings of the modified example of the first embodiment.
  • FIG. 12C shows a copper foil (18 ⁇ m thick) which is a starting material of the fifth embodiment.
  • a metal foil with a carrier (copper foil) is used as a starting material, but in the fifth embodiment, a metal foil (copper foil) is used as a starting material.
  • the printed wiring board was manufactured similarly to 2nd Example.
  • the manufacturing method of the sixth embodiment is the same process from FIG. 1A to FIG. 1D of the first embodiment.
  • gold bumps gold plated bumps
  • the gold-plated bumps were formed using Microfab Au manufactured by Tanaka Kikinzoku Co., Ltd. with the metal foil 12 as a lead.
  • the IC chip having the gold stud bump and the gold bump (gold plating bump) were aligned with reference to the positioning mark 14.
  • an IC chip was mounted on the metal foil by metal bonding of a gold bump (gold plated bump) and a gold stud bump.
  • the steps from FIG. 2D to FIG. 7 of the first embodiment were performed to manufacture a printed wiring board with an IC chip built-in.
  • a method for manufacturing a multilayer printed wiring board according to a modification of the seventh embodiment will be described with reference to FIG.
  • a copper foil with a carrier (MTSD-H, carrier (copper foil): 35 ⁇ m, copper foil: 5 ⁇ m) 100 manufactured by Mitsui Kinzoku Kogyo Co., Ltd. was used as a starting material (FIG. 13A).
  • a positioning mark 14 was formed on the copper foil (metal foil) 12 and the support plate 101 with a laser (FIG. 13B).
  • a plating resist 60 having an opening 60a was formed on the first surface of the metal foil (FIG. 13C). The opening 60 a was formed with reference to the positioning mark 14.
  • solder resist layer 12 Copper foil 14 Positioning mark 16 (Second) solder resist layer 18 Solder bump 20 IC chip 30 Substrate 36 Through hole conductor 50 Interlayer resin insulating layer 58 Conductor circuit 60 Via hole 70 (First) solder resist layer

Abstract

　　【課題】　電子部品を内蔵し、接続信頼性の高い多層プリント配線板の製造方法を提供する。 　　【解決手段】　金属箔１２に設けた位置決めマーク１４に基づき開口１６ａを設け半田バンプを形成するため、半田バンプ１８の位置精度が高く、高い接続信頼性を備えることができる。また、ソルダーレジスト層１６の開口１６ａに半田バンプ１８を設けるため、ソルダーレジスト層がダムの働きをして半田がリフローの際に流れ出さず、ファインピンチな半田バンプ１８を高い接続信頼性で形成することができる。

Description

多層プリント配線板の製造方法
この発明は、電子部品を内蔵する多層プリント配線板の製造方法に係り、特に、ＩＣチップ等の電子部品を内蔵する多層プリント配線板の製造方法に関する。
電子部品の高性能化、小型化の要求に伴い、回路部品の高密度化が一層求められている。
このために、電子部品をプリント配線板の表面に実装するのでは無く、電子部品をプリント配線板に内蔵する構成が開発されている。特許文献１では、金属箔上に導電性接着剤を形成し、その導電性接着剤を介して金属箔上に電子部品を搭載している。その後、金属箔上に搭載された電子部品を無機フィラーと熱硬化性樹脂からなる絶縁基板内に内蔵している。
特開平１１－２２０２６２号
しかしながら、プリント配線板内に電子部品を内蔵すると、樹脂層に内蔵された電子部品の端子とその端子に接続するプリント配線板の導体回路とを精度よく合わせることが困難であった。
本発明の目的は、電子部品を内蔵し、接続信頼性の高い多層プリント配線板の製造方法を提供することを目的とする。
上記目的を達成するため、本願発明の製造方法は、
　第１面と前記第１面とは反対側の第２面を有する金属箔を準備する工程と、
　前記金属箔に位置決めマークを形成する工程と、
　前記位置決めマークを基準にして、前記金属箔の第１面上にバンプを形成する工程と、
　前記位置決めマークを基準にして、前記バンプと電子部品を位置合わせする工程と、
　前記バンプに前記電子部品を実装する工程と、
　前記電子部品を樹脂内に収容する工程と、
　前記位置決めマークを基準にして、前記バンプと接続するパッドを形成する工程と、を有している。
本発明の第１実施例に係る多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板の製造方法を示す工程図である。 第１実施例の多層プリント配線板を示す断面図である。 第１実施例の改変例に係る多層プリント配線板の製造方法を示す工程図である。 図９（Ａ）は、第１実施例の改変例に係る多層プリント配線板の製造方法を示す工程図であり、図９（Ｂ）は、導体回路とパッドとの説明図である。 第２実施例の多層プリント配線板の製造方法を示す工程図である。 第２実施例の多層プリント配線板を示す断面図である。 図１２（Ａ）は第３実施例の多層プリント配線板の製造方法を示す工程図であり、図１２（Ｂ）は第４実施例の多層プリント配線板の製造方法を示す工程図であり、図１２（Ｃ）は第５実施例の多層プリント配線板の製造方法を示す工程図である。 第７実施例の多層プリント配線板の製造方法を示す工程図である。 第７実施例の多層プリント配線板の製造方法を示す工程図である。
[実施形態]
[第１実施形態]
本発明の第１実施形態に係る多層プリント配線板１０の製造方法について図１～図６を参照して説明する。ここでは先ず、ＩＣチップを内蔵するコア基板の製造方法について説明する。
（１）出発材料として、キャリア付き金属箔１００を準備する（図１（Ａ））。キャリア付き金属箔は支持体１０１と金属箔１２とからなる。金属箔は、厚さが１．５～３６μｍであって、銅、アルミニューム、ニッケル等の導電性金属から成る。支持体としてはアルミニューム、鋼、銅などの導電性材料やエポキシ、ポリイミドなどの絶縁性フィルムなどを用いることができる。支持体の厚みは１８～１００μｍ程度である。金属箔は剥離層を介して支持体上に積層することができる。金属箔は第１面と第１面とは反対側の第２面を有している。金属箔の第２面が支持体上に形成されている。出発材料は図１２（Ａ）に示すように金属箔１２でもよい。まず、金属箔にレーザにより位置決めマーク１４を形成する（図１（Ｂ））。
（２）金属箔の第1面上にソルダーレジスト層（第２のソルダーレジスト層）１６を形成する（図１（Ｃ））。次いで、位置決めマーク１４を基準にして、ソルダーレジスト層１６にバンプ形成用の開口１６ａを形成する（図１（Ｄ））。
（３）ソルダーレジスト層１６の開口１６ａにより露出した金属箔１６０上に半田ペースト１８αを印刷する（図２（Ａ））。半田としては、Ｓｎ／Ｐｂ、Ｓｎ／Ａｇ、Ｓｎ／Ｓｂ、Ｓｎ／Ａｇ／Ｃｕなどが主成分となる金属を用いることができる。そして、２００～２８０℃でリフローを行い、開口１６ａに半田バンプ１８を形成する（図２（Ｂ））。半田ペーストの代わりに、半田ボールを金属箔１６０上に搭載することもできる。ソルダーレースト層の開口１６ａにより露出している金属箔上に電解めっきで半田や金などの金属バンプを形成することができる。半田ペーストや半田ボールは、位置決めマーク１４を基準にして金属箔１６０上に形成することができる。第１実施形態においては、金属箔１２に設けた位置決めマーク１４に基づき開口１６ａを設け半田バンプを形成するため、半田バンプ１８の位置精度が高くなる。半田バンプと金属箔との接続信頼性が高くなる。また、ソルダーレジスト層１６の開口１６ａに半田バンプ１８を設けるため、ソルダーレジスト層がダムの働きをして半田がリフローの際に流れ出さず、ファインピッチな半田バンプを高い接続信頼性で形成することができる。また、ソルダーレジスト層により、半田バンプ間での短絡を防止することができる。
（４）半田バンプ１８にＩＣチップ２０の端子２２が接続するよう、位置決めマーク１４に基づき、ＩＣチップ２０の搭載位置を決定する。その後、ＩＣチップ２０などの電子部品を金属箔上に搭載する。続いて、リフローにより半田バンプ１８と端子２２とを接続する（図２（Ｃ））。位置決めマーク１４を用いＩＣチップ２０の搭載位置を位置決めするため、高い位置精度を実現できる。半田バンプ１８とＩＣチップ２０の端子２２との接続信頼性を高めることができる。また、フルグリッドの端子２２を有するＩＣチップを搭載することができる。
（５）ソルダーレジスト層１６とＩＣチップ２０との間にアンダーフィル２４を充填する（図２（Ｄ））。これにより、半田バンプ１８の信頼性を高めることができる。図１（Ａ）から図２（Ｄ）の工程により、金属箔１２に電子部品が搭載された基板（電子部品搭載基板）２００が完成する。
（６）ＩＣチップ２０を搭載した金属箔１２上に、Ｂステージの樹脂フィルム２６α、及び、厚さ１．５～３６μｍの金属箔２８を積層する（図３（Ａ））。樹脂フィルム２６αは、熱硬化性樹脂と無機フィラーとからなることが好ましい。無機フィラーには、たとえば、Ａｌ2Ｏ3、ＭｇＯ、ＢＮ、ＡｌＮまたはＳｉＯ2などを用いることができ、その場合の無機フィラー量は、３０～６０ｗｔ％であることが好ましい。熱硬化性樹脂には、たとえば、耐熱性が高いエポキシ樹脂、フェノール樹脂、ポリイミド樹脂またはシアネート樹脂が好ましく、この中でも、耐熱性が優れるエポキシ樹脂が特に好ましい。次いで、電子部品搭載基板２００と樹脂フィルム２６αと金属箔２８とを加熱プレスし、ＩＣチップ２０を樹脂絶縁層２６内に内蔵する。その後、支持体１０１を銅箔１２から剥離し、図３（Ｂ）に示す途中基板２０１を得る。このとき、樹脂フィルムは硬化し、樹脂絶縁層２６となる。樹脂絶縁層２６は第１面と第１面とは反対側の第２面を有する。図３（Ｂ）に示すように、第１面は出発材料の金属箔と対向する面である。
金属箔１２と金属箔２８は同じ厚みの金属箔が好ましい。途中基板２０１の反りが減少する。
位置決めマーク１４に樹脂が埋まり、位置決めマークの位置の認識が困難になることがある。その場合、位置決めマーク１４を基準にして、第２の位置決めマーク（貫通孔）１４０を形成してもよい（図９（Ａ）参照）。位置決めマーク１４の認識はＸ線などで行うことができる。第２の位置決めマーク１４０は、位置決めマーク１４と同じ位置に形成してもよいし、位置決めマーク１４と異なる位置に形成してもよい。
（７）途中基板２０１にスルーホール導体用の貫通孔３６ａを形成する（図３（Ｃ））。貫通孔３６ａは位置決めマーク１４、あるいは、第２の位置決めマーク１４０を基準に形成される。次に、無電解めっき処理および電解めっき処理を施し、貫通孔の内壁にスルーホール導体３６を形成する（図３（Ｄ））。このとき、金属箔１２と金属箔２８上にも、無電解めっき膜と電解めっき膜が形成される。
（９）次に、樹脂と粒子とからなる充填剤３７をスルーホール導体３６内へ充填し、乾燥、硬化させる（図４（Ａ））。
（１０）途中基板２０１の表面に無電解銅めっき膜を形成する。更に、電解銅めっき膜を形成する。この時、同時にスルーホール導体３６内に充填した充填剤３７を無電解めっき膜３３０と電解めっき膜３３で覆う（図４（Ｂ））。
（１１）電解めっき膜３３上にエッチングレジストを形成する。その後、エッチングレジストを露光・現像してエッチングレジストをパターンニングする。そして、エッチングレジストが形成されていない部分のめっき膜（無電解めっき膜と電解めっき膜）と金属箔１２、２８を、エッチング液にて溶解除去する。さらに、エッチングレジストを剥離して、樹脂絶縁層２６上の導体回路３４、および、充填剤３７を覆う導体回路３４を形成する（図４（Ｃ）参照）。同時に、コア基板にアライメントマーク（図示せず）１４００を形成する。これにより、コア基板３０を完成する。導体回路３４はバンプ１８と接続しているパッド３４Ｐを有している（図９（Ｂ）参照）。
エッチングレジストのパターニングは位置決めマーク１４、あるいは、第２の位置決めマークを基準に形成されている。
引き続き、コア基板上への層間樹脂絶縁層及び導体回路の積層について説明する。
（１２）コア基板３０の両面に、層間樹脂絶縁層用樹脂フィルムを貼り付けることにより層間樹脂絶縁層５０を形成する（図４（Ｄ））。
（１３）次に、レーザにて層間樹脂絶縁層５０にバイアホール用開口５０ａを形成する（図５（Ａ））。ここでは、レーザで開口を設けたが、フォトリソにより開口を形成することもできる。バイアホール用開口５０ａはアライメントマーク１４００を基準に形成されている。
（１４）次に、バイアホール用開口５０ａの内壁を含む層間樹脂絶縁層５０の表面に無電解銅めっき膜５２を形成する（図５（Ｂ））。
（１５）無電解銅めっき膜５２にめっきレジスト５４を設ける（図５（Ｃ））。ついで、電解めっきを施し、めっきレジスト５４非形成部に、厚さ１５μｍの電解銅めっき膜５６を形成する（図５（Ｄ））。
（１６）さらに、めっきレジスト５４を剥離する。その後、そのめっきレジスト下の無電解めっき膜をエッチング処理することにより、溶解除去し、独立の導体回路５８及びバイアホール６０を形成する（図６（Ａ））。
（１７）上記（１２）～（１６）の工程を繰り返すことにより、さらに上層の導体回路１５８、バイアホール１６０を有する層間絶縁層１５０を形成し、多層配線板を作製できる（図６（Ｂ））。
（１８）次に、多層配線基板の両面に開口７１、７２を備えるソルダーレジスト層（第１のソルダーレジスト層）７０を形成する（図６（Ｃ））。
（２０）この後、開口７１に半田ペーストを印刷し、リフローすることにより上面に半田バンプ７８Ｕを、下面に半田バンプ７８Ｄを形成し、多層プリント配線板１０を完成する（図７）。
[第１実施形態の改変例]
図８を参照して第１実施形態の改変例に係る多層プリント配線板の製造方法について説明する。
（１）出発材料はキャリア（２５～１００μｍの銅箔）１０１と剥離層（図示せず）と３～１５μｍの銅箔１２とからなるキャリア付き銅箔である（図８（Ａ））。まず、レーザにより金属箔（銅箔）に位置決めマーク１４を形成する（図８（Ｂ））。
（２）位置決めマーク１４に基づき、ポッティング又は印刷により、銅箔１２上に半田ペーストを形成する。その後、リフローして銅箔１２上に半田バンプ１８を形成する（図８（Ｃ））。
（３）位置決めマーク１４に基づき、ＩＣチップと半田バンプを、位置合わせし、ＩＣチップ２０を半田バンプ上に載置する。その後、リフローを行い、半田バンプ１８とＩＣチップ２０の端子２２とを接続する（図８（Ｄ））。以降の工程は、第１実施形態と同様であるため、説明を省略する。第１実施形態の改変例においても、金属箔１２に設けた位置決めマークに基づき半田バンプを形成する。その後、半田バンプを介して、金属箔上にＩＣチップを搭載している。ＩＣチップの搭載と半田バンプの形成が同じ位置決めマーク１４を基準にして行われている。半田バンプ１８とＩＣチップ２０との間の位置精度が高くなる。その結果、ＩＣチップなどの電子部品とその電子部品を内蔵するプリント配線板との接続信頼性が高くなる。第１実施形態の改変例では、第２のソルダーレジスト層を設けない分、第１実施形態よりも製造が容易である。
[第２実施形態]
引き続き第２実施形態の多層プリント配線板の製造方法について、図１０を参照して説明する。
（１）図１、図２を参照して上述した第１実施形態と同様に、金属箔１２上にソルダーレジスト層（第２のソルダーレジスト層）１６を設ける。その後、半田バンプ１８を介してＩＣチップ２０を実装する（図１０（Ａ））。
（２）ＩＣチップなどの電子部品を収容するための開口２７ａを有する絶縁フィルム２７αとＢステージの第２の絶縁フィルム２６０αと銅箔２８を準備する。絶縁フィルム２７αはガラスクロス、アラミド繊維等の芯材とＢステージの樹脂とからなり、芯材にエポキシ等の熱硬化性樹脂、もしくは、熱硬化性樹脂及び熱可塑性樹脂とからなる複合樹脂を含浸させたフィルムである。絶縁フィルム２７αは位置決めマーク２８００を有している。ＩＣチップなどの電子部品を収容するための開口２７ａは位置決めマーク２８００を基準にして形成されている。第２の絶縁フィルム２６０αは、開口を有しないプリプレグ（ガラスクロス、ガラス繊維、アラミド繊維の内の１つの心材と樹脂とからなる絶縁フィルム）、あるいは、樹脂フィルム２６α、あるいは、熱硬化性樹脂と７０～９０ｗｔ％の無機フィラーからなるフィルムであることが好ましい。銅箔２８の厚みは銅箔１２と実質的に同じ厚みであることが好ましい。絶縁フィルム２７αには、ＩＣチップよりも大きな開口２７ａが予め形成されている。ＩＣチップ２０を実装した金属箔と絶縁フィルム２７αを位置あわせする。位置合わせは位置決めマーク１４と絶縁フィルム２７αの位置決めマーク２８００を基準にして行う。位置決め後、ＩＣチップ２０を実装した金属箔１２上に、ＩＣチップに対応する開口２７ａを有する絶縁フィルム（厚さ１５０μｍ）２７αを積層する。更に、該絶縁フィルム２７αの上に、厚さ５０μｍの第２の絶縁フィルム２６０α、及び、厚さ１．５～３６μｍの金属箔２８を積層する（図１０（Ｂ））。その後、加熱プレスする。この時、絶縁フィルムの開口２７ａ内に第２の絶縁フィルム２６０αや絶縁フィルム２７αから樹脂が滲みだし、開口２７ａ内を充填する（図１０（Ｃ））。また、同時に、絶縁フィルムや第２の絶縁フィルム、開口２７ａ内を充填する樹脂は硬化する。絶縁フィルムと第２の絶縁フィルムが接着すると共に硬化することで、絶縁基板２７０となる。
絶縁基板２７０は第１面と第１面とは反対側の第２面を有する。図１０（Ｃ）に示すように、第１面は出発材料の金属箔と対向する面である。ここで、開口内を充填する樹脂（充填樹脂）２８０は無機フィラーと熱硬化性樹脂とからなり、無機フィラー量は、３０～９０ｗｔ％である。図１０（Ｃ）に示す中間基板は、実施形態１の図３（Ｂ）に対応している。図１０（Ｃ）の中間基板は、その後、実施形態１の図３（Ｃ）以降と同様な工程を施される。図４（Ｃ）までの工程を行うことで、第２実施形態のコア基板が形成される。第２実施形態のコア基板は、開口を有する樹脂基板２７と樹脂絶縁層２６０と開口内に収容されるＩＣチップ１２と充填樹脂２８０と導体回路３４とスルーホール導体３６とを有している。樹脂基板２７は絶縁フィルム２７αが硬化した基板である。樹脂絶縁層２６０は第２の絶縁フィルム２６０αが硬化した樹脂層である。絶縁フィルムは、第２の絶縁フィルムと同様な材料（プリプレグ、樹脂フィルムや無機フィラーと熱硬化性樹脂からなるフィルム）を使用できる。
第２実施形態のコア基板３０は、ガラスクロス、アラミド繊維等の芯材を有する樹脂基板２７を備える。そのため、コア基板３０の強度が高く、ヒートサイクル試験を行っても高い信頼性を備えることができる。
[実施例]
[第１実施例]
次に、本発明の第１実施例に係る多層プリント配線板１０の構成について図７を参照して説明する。多層プリント配線板１０では、コア基板３０にＩＣチップ２０が内蔵されている。コア基板３０の第１面と第２面（第１面と反対側の面）には、導体回路３４が形成されている。コア基板３０の第１面と第２面の導体回路はスルーホール導体３６を介して接続されている。第１面の導体回路はＩＣチップを搭載するためのパッド３４Ｐを有している。コア基板３０上に、バイアホール６０が形成された層間樹脂絶縁層５０と、バイアホール１６０が形成された層間樹脂絶縁層１５０とが形成されている。層間樹脂絶縁層１５０上にソルダーレジスト層７０が形成されている。層間樹脂絶縁層５０と層間樹脂絶縁層１５０の間には導体回路５８が形成されている。導体回路５８と導体回路３４はバイアホール６０で接続されている。また、層間樹脂絶縁層１５０とソルダーレジスト層７０の間には導体回路１５８が形成されている。導体回路１５８と導体回路５８はバイアホール１６０で接続されている。上面側のソルダーレジスト層７０には開口７１が形成されている。開口７１には、ＩＣチップ等の電子部品を実装するための半田バンプ７８Ｕが形成されている。下面側のソルダーレジスト層７０には開口７２が形成されている。開口７２には、ドータボード等の外部基板へ接続するための半田バンプ７８Ｄが形成されている。
ＩＣチップ２０は、樹脂絶縁層２６によりコア基板３０内に収容されている。ＩＣチップ２０の端子２４とパッド３４Ｐとは、半田バンプ１８を介して接続されている。パッド３４Ｐ上にはバンプ（めっきバンプを含む）が形成されている。コア基板の第１面上の層間樹脂絶縁層５０と樹脂絶縁層２６の間には第２のソルダーレジスト層１６が形成されている。第２のソルダーレジスト層１６とＩＣチップ２０との間にはアンダーフィル２４が充填されている。樹脂絶縁層２６は、樹脂とシリカフィラーとからなり、シリカフィラー量は５０ｗｔ％である。
引き続き、図７を参照して上述した多層プリント配線板１０の製造方法について図１～図６を参照して説明する。ここでは先ず、ＩＣチップを内蔵するコア基板の製造方法について説明する。
（１）三井金属工業株式会社製のキャリア付き銅箔（ＭＴＳＤ－Ｈ、キャリア（銅箔）：３５μｍ、銅箔：５μｍ）を出発材料とした（図１（Ａ））。まず、レーザ、又はエッチングにより位置決めマーク１４を形成した（図１（Ｂ））。
（２）次に、市販のソルダーレジスト組成物を２０μｍの厚さで塗布し、乾燥処理を行い第２のソルダーレジスト層１６を形成した（図１（Ｃ））。位置決めマーク１４を基準として、第２のソルダーレジスト層１６にバンプ形成用の開口１６ａを形成した（図１（Ｄ））。ここでは、レーザにより開口１６ａを形成したが、この代わりに、位置決めマークでマスクを位置決めし、フォトリソにより開口を有するソルダーレジスト層を形成することも可能である。
（３）ソルダーレジスト層１６の開口１６ａにより露出する金属箔上に印刷により半田ペースト１８αを形成した（図２（Ａ））。そして、２００℃でリフローを行い、開口１６ａにより露出した金属箔上に半田バンプ１８を形成した（図２（Ｂ））。
（４）半田バンプ１８にＩＣチップ２０の端子２２が接続するよう、位置決めマーク１４に基づきＩＣチップの搭載位置を決定した。その後、リフローにより半田バンプ１８とＩＣチップの端子２２とを接続することで、金属箔に半田バンプを介してＩＣチップを実装した（図２（Ｃ））。
（５）次いで、第２のソルダーレジスト層１６とＩＣチップ２０との間にアンダーフィル２４を充填した（図２（Ｄ））。
（６）ＩＣチップ２０を実装した銅箔１２上に、厚さ２００μｍの樹脂フィルム（エポキシと５０ｗｔ％のシリカフィラーとからなるＢステージの樹脂フィルム）２６α、及び、厚さ５μｍの銅箔２８を積層した（図３（Ａ））。その後、ＩＣチップが実装されているキャリア付き銅箔と樹脂フィルムと銅箔２８を加熱プレスして、一体化した。加熱プレスにより、ＩＣチップは樹脂フィルム２６α内に内蔵された（図３（Ｂ））。加熱プレス条件は圧力０．４５ＭＰａ、温度８０℃、圧着時間６０秒である。続いて、１７０度で樹脂フィルムを硬化し、樹脂フィルムを樹脂絶縁層２６とした。
（７）ＩＣチップを内蔵した基板３０にドリルでスルーホール導体用の貫通孔３６ａを形成した（図３（Ｃ））。その後、無電解めっき処理および電解めっき処理を施し、スルーホール導体３６を形成した（図３（Ｄ））。同時に、銅箔１２、２８上に無電解銅めっき膜（第１の無電解めっき膜）と電解銅めっき膜（第１の電解めっき膜）を形成した。
（８）スルーホール導体３６を形成した基板３０を水洗いし、乾燥した。その後、ＮａＯＨ（１０ｇ／ｌ）、ＮａＣｌＯ2 （４０ｇ／ｌ）、Ｎａ3 ＰＯ4 （６ｇ／ｌ）を含む水溶液で黒化処理した。続いて、ＮａＯＨ（１０ｇ／ｌ）、ＮａＢＨ4 （６ｇ／ｌ）を含む水溶液で還元処理を行い、スルーホール導体３６及び電解銅めっき膜の表面に粗化面を形成した（図示せず）。
（９）次に、平均粒径１０μｍのシリカ粒子とエポキシ樹脂と硬化剤とからなる充填剤３７を、スルーホール導体３６内へスクリーン印刷によって充填した。その後、充填材３７を乾燥、硬化させた（図４（Ａ））。
引き続き、スルーホール導体３６からはみ出した充填剤３７を研磨により除去した。
（１０）基板表面に、パラジウム触媒（アトテック製）を付与し、無電解銅めっきを施すことにより、厚さ０．６μｍの無電解銅めっき膜３３０を形成した。更に、以下の条件で電解銅めっきを施し、厚さ１５μｍの電解銅めっき膜を形成した。同時に、スルーホール導体３６内に充填された充填剤３７を無電解めっき膜（第２の無電解めっき膜）３３０と電解めっき膜（第２の電解めっき膜）３３で覆った（図４（Ｂ））。
　〔電解めっき水溶液〕
　　　硫酸　　　　　　　　１８０　ｇ／ｌ
　　　硫酸銅　　　　　　　　８０　ｇ／ｌ
　　　添加剤（アトテックジャパン製、商品名：カパラシドＧＬ）
　　　　　　　　　　　　　　　１　ｍｌ／ｌ
　〔電解めっき条件〕
　　　電流密度　　　　　　　１Ａ／ｄｍ２　
　　　時間　　　　　　　　　　　７０分
　　　温度　　　　　　　　　　　室温
（１１）電解めっき膜３３上に、市販の感光性ドライフィルムを張り付け、露光現像処理することにより、厚さ１５μｍのエッチングレジストを形成した。そして、エッチングレジストを形成してない部分の銅箔１２、２８と銅箔上のめっき膜（めっき膜は金属箔上の第１の無電解めっき膜と第１の無電解めっき膜上の第１の電解めっき膜と第１の電解めっき膜上の第２の無電解めっき膜と第２の無電解めっき膜上の第２の電解めっき膜とからなる）を、塩化第２銅を主成分とするエッチング液にて溶解除去した。さらに、エッチングレジストを５％ＫＯＨで剥離除去して、樹脂絶縁層２６上の導体回路３４、および、充填剤３７を覆う導体回路３４、パッド３４Ｐを形成した（図４（Ｃ）参照）。これにより、コア基板３０が完成した。樹脂絶縁層２６上の導体回路３４とパッド３４Ｐは金属箔と金属箔上の第１の無電解めっき膜と第１の無電解めっき膜上の第１の電解めっき膜と第１の電解めっき膜上の第２の無電解めっき膜と第２の無電解めっき膜上の第２の電解めっき膜とからなる。充填剤３７を覆う導体回路３４は第２の無電解めっき膜と第２の無電解めっき膜上の第２の電解めっき膜とからなる。
引き続き、コア基板上への層間樹脂絶縁層及び導体回路の積層について説明する。
先ず、導体回路３４の表面をメック株式会社製のＣｚ８１００を用いて粗化した（図示せず）。
（１２）コア基板３０の両面に、層間樹脂絶縁層用樹脂フィルム（味の素社製：商品名；ＡＢＦ－４５ＳＨ）を真空ラミネーター装置を用いて積層した。その条件は真空度６７Ｐａ、圧力０．４７ＭＰａ、温度８５℃、圧着時間６０秒である。その後、層間樹脂絶縁層用樹脂フィルムを１７０℃で４０分間熱硬化し、コア基板上に層間樹脂絶縁層５０を形成した（図４（Ｄ）。
（１３）次に、ＣＯ2 ガスレーザにて、層間樹脂絶縁層５０にバイアホール用開口５０ａを形成した（図５（Ａ））。
バイアホール用開口５０ａを形成した基板を、６０ｇ／ｌの過マンガン酸を含む８０℃の溶液に１０分間浸漬し、層間樹脂絶縁層５０の表面に存在する粒子を除去した。バイアホール用開口５０ａの内壁を含む層間樹脂絶縁層５０の表面に粗化面が形成された（図示せず）。
上記処理を終えた基板を、中和溶液（シプレイ社製）に浸漬してから水洗いした。
さらに、粗面化処理（粗化深さ３μｍ）した層間樹脂絶縁層の表面およびバイアホール用開口の内壁面に触媒核を付着させた。
（１４）次に、上村工業社製の無電解銅めっき水溶液（スルカップＰＥＡ）中に、触媒を付与した基板を浸漬して、粗面全体に厚さ０．３～３．０μｍの無電解銅めっき膜を形成した。バイアホール用開口５０ａの内壁を含む層間樹脂絶縁層５０の表面に無電解銅めっき膜５２が形成された（図５（Ｂ））。
〔無電解めっき条件〕
３４℃の液温度で４５分
（１５）無電解銅めっき膜５２が形成された基板に市販の感光性ドライフィルムを張り付け、露光現像処理することにより、厚さ２５μｍのめっきレジスト５４を設けた（図５（Ｃ））。ついで、以下の条件で電解めっきを施し、めっきレジスト５４非形成部に、厚さ１５μｍの電解銅めっき膜５６を形成した（図５（Ｄ））。
〔電解めっき液〕
硫酸　　　　　　　　　　　２．２４　ｍｏｌ／ｌ
硫酸銅　　　　　　　　　　０．２６　ｍｏｌ／ｌ
添加剤　　　　　　　　　　１９．５　　ｍｌ／ｌ
（アトテックジャパン社製、カパラシドＧＬ）
〔電解めっき条件〕
電流密度　　　　　　　　　　１　Ａ／ｄｍ2
時間　　　　　　　　　　　　７０　分
温度　　　　　　　　　　　　２２±２　℃
（１６）さらに、めっきレジスト５４を剥離した後、そのめっきレジスト下の無電解めっき膜を硫酸と過酸化水素との混合液でエッチング処理して溶解除去した。独立の導体回路５８及びバイアホール６０が形成された（図６（Ａ））。ついで、上記と同様の処理を行い、導体回路５８及びバイアホール６０の表面に粗化面を形成した（図示せず）。
（１７）上記（１２）～（１６）の工程を繰り返すことにより、さらに上層の導体回路１５８、バイアホール１６０を有する層間絶縁層１５０を形成し、多層配線板を得た（図６（Ｂ））。
（１８）次に、多層配線基板の両面に、市販のソルダーレジスト組成物を塗布した。その後、露光現像処理し、ソルダーレジスト組成物に開口７１、７２を形成した（図６（Ｃ））。そして、さらに、８０℃で１時間、１００℃で１時間、１２０℃で１時間、１５０℃で３時間の条件でそれぞれ加熱処理を行って、開口７１、７２を有するソルダーレジスト層（第１のソルダーレジスト層、厚さ：１５～２５μｍ）７０を形成した。
（１９）次に、ソルダーレジスト層７０の開口７１、７２により露出した導体回路１５８やバイアホール１６０の表面にニッケル膜、金めっき膜の順で金属膜を形成した（図示せず）。
（２０）この後、開口７１、７２内の金属膜上に半田ペーストを印刷した。その後、２３０℃でリフローすることにより上面に半田バンプ７８Ｕを、下面に半田バンプ７８Ｄを形成し、多層プリント配線板１０を完成した（図７）。
[第１実施例の改変例]
図８を参照して第１実施例の改変例に係る多層プリント配線板の製造方法について説明する。
（１）三井金属工業株式会社製のキャリア付き銅箔（ＭＴＳＤ－Ｈ、キャリア（銅箔）：３５μｍ、銅箔：５μｍ）１２を出発材料とした（図８（Ａ））。まず、レーザにより銅箔に位置決めマーク１４を形成した（図８（Ｂ））。
（２）位置決めマーク１４に基づき、ポッティングにより半田ペースト１８αを銅箔１２上に形成した。その後、リフローすることで、銅箔１２上に半田バンプ１８を形成した（図８（Ｃ））。
（３）位置決めマーク１４に基づきＩＣチップの搭載位置を決定し、半田バンプ１８上にＩＣチップ２０を載置した。その後、リフローを行い、半田バンプ１８とＩＣチップ２０の端子２２とを接続した（図８（Ｃ））。以降の工程は、第１実施例と同様であるため、説明を省略する。
[第２実施例]
引き続き第２実施例の多層プリント配線板の製造方法について説明する。
図１１は、第２実施例の多層プリント配線板の断面を示している。
多層プリント配線板１１０のコア基板３０は、ガラスクロス、ガラス繊維、アライミド繊維等の芯材と硬化済みの樹脂からなる樹脂基板２７を有している。樹脂基板は、エポキシ等の熱硬化性樹脂、もしくは、熱硬化性樹脂及び熱可塑性樹脂からなる複合樹脂を芯材に含浸したプリプレグを硬化させた基板である。樹脂基板２７は開口２７ａを有している。その開口２７ａ内にＩＣチップが収容されている。充填樹脂２８０が開口２７ａ内に充填されている。充填樹脂により、ＩＣチップが開口内に内蔵されている。絶縁基板の第１面と第１面上の層間樹脂絶縁層との間には、第２のソルダーレジスト層が形成されている。第２のソルダーレジスト層とＩＣチップとの間には、アンダーフィルが形成されている。
第２実施例の多層プリント配線板の製造方法について、図１０を参照して説明する。
（１）図１、図２を参照して上述した第１実施例と同様に、銅箔１２上にソルダーレジスト層（第２のソルダーレジスト層）１６を設け、半田バンプ１８を介してＩＣチップ２０を実装する（図１０（Ａ））。
（２）ＩＣチップ２０を収容するための開口２７ａを有する絶縁フィルムとして、プリプレグ２７α（１５０μｍ厚さ）を準備した。ＩＣチップ２０を実装した銅箔１２上に、位置決めマーク１４と位置決めマーク２８００を基準にしてプリプレグ２７αを積層した。開口とＩＣチップが精度よく位置合わせされた。更に、該プリプレグ２７αの上に、厚さ５０μｍの第２の絶縁フィルム（日立化成工業社製のプリプレグ）２６０α、及び、厚さ５μｍの銅箔２８を積層した（図１０（Ｂ））。その後、ＩＣチップを実装したキャリア付き銅箔とプリプレグと絶縁フィルムと銅箔とを真空プレス機で加熱プレスした。加熱プレス時、プリプレグの開口２７ａ内に第２の絶縁フィルム２６α及びプリプレグから樹脂が沁みだした。同時に、プリプレグが硬化し樹脂基板２７となった。第２の絶縁フィルムが硬化し絶縁樹脂層２６０となった。開口内に沁みだした樹脂が硬化し充填樹脂２８０となった。（図１０（Ｃ））。その後、キャリアを剥離した。以降は、実施例１の図３（Ｃ）以降の工程を行い、ＩＣチップを内蔵したコア基板にビルドアップ層を形成した。樹脂基板と絶縁樹脂層が一体化した基板が絶縁基板である。
[第３実施例]
図１２（Ａ）に第３実施例の出発材料である銅箔（１８μｍ厚）を示す。以降は、第１実施例の図１（Ｂ）以降と同様な工程でＩＣチップを内蔵したプリント配線板を製造した。
[第４実施例]
図１２（Ｂ）に第４実施例の出発材料である銅箔（１８μｍ厚）を示す。以降は、第１実施例の改変例の図８（Ｂ）以降と同様な工程でＩＣチップを内蔵したプリント配線板を製造した。
[第５実施例]
図１２（Ｃ）に第５実施例の出発材料である銅箔（１８μｍ厚）を示す。第２実施例では、出発材料にキャリア付金属箔（銅箔）を用いたが、第５実施例では、出発材料に金属箔（銅箔）を用いている。それ以外は、第２実施例と同様にプリント配線板を製造した。
[第６実施例]
第６実施例の製造方法は、第１実施例の図１（Ａ）から図１（Ｄ）までは同様な工程である。その後、ソルダーレジストの開口により露出する金属箔１２上に金バンプ（金めっきバンプ）を形成した。金めっきバンプは金属箔１２をリードにして、田中貴金属社製のミクロファブＡｕを用いて形成された。続いて、金スタッドバンプを有するＩＣチップと金バンプ（金めっきバンプ）を位置決めマーク１４を基準にして位置あわせした。その後、金バンプ（金めっきバンプ）と金スタッドバンプを金属接合することで、金属箔上にＩＣチップを実装した。それ以降は、第１実施例の図２（Ｄ）から図７までの工程を行い、ＩＣチップを内蔵したプリント配線板を製造した。
[第７実施例]
図１３を参照して第７実施例の改変例に係る多層プリント配線板の製造方法について説明する。
（１）三井金属工業株式会社製のキャリア付き銅箔（ＭＴＳＤ－Ｈ、キャリア（銅箔）：３５μｍ、銅箔：５μｍ）１００を出発材料とした（図１３（Ａ））。まず、レーザにより銅箔（金属箔）１２と支持板１０１に位置決めマーク１４を形成した（図１３（Ｂ））。
（２）金属箔の第１面上に開口６０ａを有するめっきレジスト６０を形成した（図１３（Ｃ））。開口６０ａは位置決めマーク１４を基準にして形成された。
（３）銅箔（金属箔）１２をシードとして、開口６０ａにより露出する銅箔（金属箔）上に金めっきバンプ６０ｂを形成した（図１３（Ｄ））。
（４）めっきレジスト６０を剥離した（図１４（Ａ））。
（５）位置決めマーク１４を基準にして、金スタッドバンプ２２を有するＩＣチップ２０と金めっきバンプ６０ｂを位置合わせした。その後、その後、金バンプ（金めっきバンプ）と金スタッドバンプを金属接合することで、金属箔上にＩＣチップを実装した（図１４（Ｂ））。以降は第２実施例の図１０（Ａ）以降の工程を行い、ＩＣチップを内蔵したプリント配線板を作成した。
１２　銅箔
１４　位置決めマーク
１６　（第２の）ソルダーレジスト層
１８　半田バンプ
２０　ＩＣチップ
３０　基板
３６　スルーホール導体
５０　層間樹脂絶縁層
５８　導体回路
６０　バイアホール
７０　（第１の）ソルダーレジスト層

Claims (13)

  1. 　第１面と前記第１面とは反対側の第２面を有する金属箔を準備する工程と、
    　前記金属箔に位置決めマークを形成する工程と、
    　前記位置決めマークを基準にして、前記金属箔の第１面上にバンプを形成する工程と、
    　前記位置決めマークを基準にして、前記バンプと電子部品を位置合わせする工程と、
    　前記バンプに前記電子部品を実装する工程と、
    　前記電子部品を樹脂内に収容する工程と、
    　前記位置決めマークを基準にして、前記バンプと接続するパッドを形成する工程と、からなるプリント配線板の製造方法。
  2. 　請求項１に記載のプリント配線板の製造方法は、さらに、前記金属箔の第１面上にソルダーレジスト層を形成する工程と、
    　前記位置決めマークを基準にして、前記ソルダーレジスト層にバンプ形成用の開口を形成する工程と、
    　前記位置決めマークを基準にして、前記バンプ形成用の開口により露出する金属箔上に半田ペーストを形成する工程と、
    　前記半田ペーストをリフローする工程と、を有する。
  3. 　請求項１に記載のプリント配線板の製造方法は、さらに、前記金属箔の第１面上にめっきレジスト層を形成する工程と、
    　前記位置決めマークを基準にして、前記めっきレジスト層にめっきバンプ形成用の開口を形成する工程と、
    　前記バンプ形成用の開口により露出する金属箔上にめっきバンプを形成する工程と、を有する。
  4. 　請求項３に記載のプリント配線板の製造方法は、さらに、前記めっきレジストを剥離する工程を有する。
  5. 　請求項１に記載のプリント配線板の製造方法は、さらに、前記金属箔の第１面と前記電子部品との間にアンダーフィル樹脂を充填する工程を有する。
  6. 　請求項１に記載のプリント配線板の製造方法において、
    　前記電子部品を樹脂内に収容する工程は、
    　前記金属箔の第１面と前記電子部品上に樹脂フィルムを積層する工程と、
    　電子部品を実装した金属箔と前記樹脂フィルムとを加熱プレスする工程と、とからなる。
  7. 　請求項６に記載のプリント配線板の製造方法は、さらに、前記樹脂フィルムを硬化することで、第１面と前記第１面とは反対側の第２面とを有する樹脂絶縁層を形成する工程と、
    　前記樹脂絶縁層に貫通孔を形成する工程と、
    　前記樹脂絶縁層の第１面と第２面に導体回路を形成する工程と、
    　前記貫通孔にスルーホール導体を形成することで、樹脂絶縁層の第１面と第２面に形成されている導体回路を接続する工程と、を有し、
    　前記樹脂絶縁層の第１面は電子部品を実装した金属箔の第１面に対向している面である。
  8. 　請求項１に記載のプリント配線板の製造方法において、
    　前記電子部品を樹脂内に収容する工程は、
    　電子部品を収容するための開口部を有し、第１面と第１面とは反対側の第２面を有する絶縁フィルムを準備する工程と、
    　前記絶縁フィルムと電子部品を位置合わせする工程と、
    　前記金属箔の第１面上に前記絶縁フィルムの第１面を積層する工程と、
    　前記絶縁フィルムと前記金属箔を接着する工程と、
    　前記開口部に充填樹脂を充填する工程と、からなる。
  9. 　請求項８に記載のプリント配線板は、さらに、前記絶縁フィルムの第２面上に第２の絶縁フィルムを積層する工程と、
    　電子部品を実装した金属箔と絶縁フィルムと第２の絶縁フィルムとを加熱プレスする工程と、
    　前記絶縁フィルムと前記第２の絶縁フィルムから第１面と前記第１面とは反対側の第２面を有する絶縁基板を形成する工程と、を有する。
  10. 　請求項９に記載のプリント配線板の製造方法は、さらに、前記絶縁基板に貫通孔を形成する工程と、
    　前記絶縁基板の第１面と第２面に導体回路を形成する工程と、
    　前記貫通孔にスルーホール導体を形成することで、絶縁基板の第１面と第２面に形成されている導体回路を接続する工程と、を有し、
    　絶縁基板の第１面は電子部品を実装した金属箔の第１面に対向している面である。
  11. 　請求項７に記載のプリント配線板の製造方法は、さらに、前記樹脂絶縁層の第１面と第２面上に層間樹脂絶縁層を形成する工程と、
    　前記層間樹脂絶縁層上に導体回路を形成する工程と、
    　層間樹脂絶縁層の導体回路と樹脂絶縁層の導体回路とを接続するビア導体を形成する工程と、を有する。
  12. 　請求項１０に記載のプリント配線板の製造方法は、さらに、前記絶縁基板の第１面と第２面上に層間樹脂絶縁層を形成する工程と
    　前記層間樹脂絶縁層上に導体回路を形成する工程と、
    　層間樹脂絶縁層の導体回路と絶縁基板の導体回路とを接続するビア導体を形成する工程と、を有する。
  13. 請求項８に記載のプリント配線板の製造方法において、前記絶縁フィルムはプリプレグである。
PCT/JP2009/058921 2008-06-02 2009-05-13 多層プリント配線板の製造方法 WO2009147936A1 (ja)

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