WO2010073745A1 - キャリア付金属箔 - Google Patents
キャリア付金属箔 Download PDFInfo
- Publication number
- WO2010073745A1 WO2010073745A1 PCT/JP2009/054482 JP2009054482W WO2010073745A1 WO 2010073745 A1 WO2010073745 A1 WO 2010073745A1 JP 2009054482 W JP2009054482 W JP 2009054482W WO 2010073745 A1 WO2010073745 A1 WO 2010073745A1
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- WIPO (PCT)
- Prior art keywords
- carrier
- foil
- metal foil
- copper
- copper foil
- Prior art date
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Classifications
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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
- 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
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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
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/09—Use of materials for the conductive, e.g. metallic pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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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
- 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
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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
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/02—Details related to mechanical or acoustic processing, e.g. drilling, punching, cutting, using ultrasound
- H05K2203/0285—Using ultrasound, e.g. for cleaning, soldering or wet treatment
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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
- H05K3/46—Manufacturing multilayer circuits
- H05K3/4644—Manufacturing multilayer circuits by building the multilayer layer by layer, i.e. build-up multilayer circuits
- H05K3/4652—Adding a circuit layer by laminating a metal foil or a preformed metal foil pattern
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- 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
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
Definitions
- the present invention relates to a copper foil with a carrier used in the production of a single-sided or multilayer laminate having two or more layers used for a printed wiring board.
- a typical example of a multilayer laminate is a printed circuit board.
- a printed circuit board has a basic configuration of a dielectric material called “prepreg” obtained by impregnating a synthetic resin into a base material such as a synthetic resin plate, a glass plate, a glass nonwoven fabric, and paper. Sheets such as copper or copper alloy foil having electrical conductivity are joined to the prepreg surface (front and back surfaces).
- the laminated body thus assembled is generally called a CCL (Copper Clad Laminate) material.
- CCL Copper Clad Laminate
- the laminated body thus assembled is generally called a CCL (Copper Clad Laminate) material.
- substrate instead of the copper or copper alloy foil, a foil of aluminum, nickel, zinc or the like may be used. Their thickness is about 5 to 200 ⁇ m.
- the copper foil with a carrier is used for the purpose of preventing foreign matters from adhering to the surface of the copper foil and for improving the handling property.
- a stainless steel plate having a smooth press surface with a thickness of 0.2 to 2 mm is used.
- a press plate commonly called “mirror plate”
- an ultrathin copper foil that is peelably bonded to a carrier is placed with the M surface (rough surface) facing upward, and then a predetermined number of sheets.
- the worker needs to repeat the work of arranging the copper foil with the M surface facing up or arranging the M surface with the lowering at the time of layup (stacking and stacking work). Therefore, there is a problem that work efficiency is lowered. Further, since the copper foil and the carrier have the same dimensions, it is difficult to separate each copper foil at the time of layup, and there is a problem that workability is lowered in this respect as well.
- the linear expansion coefficients (room temperature) of various materials used for the printed wiring board are as follows. It can be seen that the linear expansion coefficient of the aluminum plate is prominently large. Copper foil: 16.5 ( ⁇ 10 ⁇ 6 / ° C) SUS304: 17.3 ⁇ 10 ⁇ 6 / ° C SUS301: 15.2 ⁇ 10 ⁇ 6 / ° C ⁇ SUS630: 11.6 ⁇ 10 -6 / ° C ⁇ Prepreg (C stage): 12-18 ⁇ 10 -6 / ° C Aluminum plate (JIS # 5182): 23.8 ⁇ 10 ⁇ 6 / ° C Although not directly related to the present invention, examples of the ultrathin copper foil with a carrier include the following documents (Patent Document 2, Patent Document 3, and Patent Document 4). Japanese Patent No. 3100833 JP 2005-161840 A JP 2007-186797 A Japanese Patent Laid-Open No. 2001-140090
- the present invention has been made in view of these events, and relates to a carrier-attached copper foil used in the production of a single-sided or two-layer multilayer board or an ultra-thin coreless board used for printed wiring boards. .
- the present invention relates to a copper foil with a carrier used in the production of a laminated board, and its purpose is to realize improved handling in a printed circuit board production process and cost reduction by increasing yield.
- the present invention 1) It is a laminate in which the carrier A and the metal foil B are alternately overlapped, and the carrier A and the metal foil B each have a glossy surface (S surface) and are laminated so that the glossy surfaces face each other.
- a metal foil with a carrier is provided. 2) The carrier-attached metal foil according to 1) above, wherein the carrier A and the metal foil B are rectangular. 3) The metal foil B is a copper foil or a copper alloy foil. 2) Metal foil with a carrier according to 2) 4) A copper foil with a carrier, wherein the carrier A and the metal foil B are alternately laminated, and the carrier A and the metal foil B are ultrasonically bonded, I will provide a.
- the present invention 5) The laminate according to any one of 1) to 3) above, wherein the carrier A and the metal foil B are alternately laminated, and the carrier A and the metal foil B are ultrasonically bonded.
- Carrier A is copper foil or copper alloy foil
- metal foil B is copper foil or copper alloy foil
- the rough surface of the copper foil of carrier A and the glossy surface of the copper foil of metal foil B are
- the copper foil with a carrier characterized by being ultrasonically bonded
- the carrier A is aluminum, copper or a copper alloy foil
- the metal foil B is a copper foil or a copper alloy foil 1) above To 6)
- To 7) A metal foil with a carrier according to any one of the above items. To.
- the present invention also provides: 9) The metal foil with a carrier according to any one of 1) to 8) above, wherein the metal foil is an electrolytic foil having a thickness of 5 to 120 ⁇ m. 10) The metal foil has a thickness of 5 to 120 ⁇ m.
- the metal foil with a carrier of the present invention is a laminate in which the carrier A and the metal foil B are alternately overlapped, and the carrier A and the metal foil B are alternately laminated in which the carrier A and the metal foil B are glossy surfaces (
- the first feature is that it has a structure in which each of the glossy surfaces is laminated so as to face each other. Since any rough surface (M surface) of the carrier A and the metal foil B can be used, this eliminates the need for the reversing operation of placing the M surface of the copper foil on the top or the top so that the work efficiency is improved. Will improve dramatically.
- the carrier it is optional to make the carrier a copper foil, but when the carrier is a copper foil, the linear expansion coefficient is at the same level as the copper foil that is a constituent material of the substrate and the prepreg after polymerization, Since the circuit is not displaced, the generation of defective products is reduced and the yield can be improved.
- the present invention is characterized in that the copper foil with a carrier having a structure in which the metal foil B is ultrasonically bonded so as to be in contact with the carrier A made of aluminum, copper, or a copper alloy.
- the carrier A is a rolled copper foil or an electrolytic copper foil, and ultrasonic bonding is performed so that the glossy surface of the copper foil B is in contact with the roughened surface of the rolled copper foil or the roughened or roughened surface of the electrolytic copper foil. It is effective to do.
- the material of the carrier A and the metal foil B particularly by selecting the material and the surface state, it is possible to improve the releasability when the bond is peeled off. Therefore, there is an effect that these can be used in any combination.
- a printed circuit board uses a dielectric material called “prepreg” obtained by impregnating a synthetic resin into a base material such as a synthetic resin plate, a glass plate, a glass nonwoven fabric, and paper, and sandwiches the prepreg therebetween.
- a sheet of copper or copper alloy foil having electrical conductivity is joined.
- the laminated body thus assembled is generally called a CCL (CopperoppClad Laminate) material.
- CCL CopperoppClad Laminate
- a foil of aluminum, nickel, zinc or the like may be used. Their thickness is about 5 to 200 ⁇ m.
- FIG. 1 shows a metal foil with a carrier according to the present invention.
- the carrier is indicated by A and the metal foil is indicated by B in the metal foil with carrier.
- the carrier-attached metal foil of the present invention has a structure in which the carrier A and the metal foil B are finally separated and can be easily peeled mechanically. Have. In this respect, since the CCL material is not peeled off, the structure and function are completely different.
- the metal foil with a carrier of the present invention is laminated so that the carrier A and the metal foil B each have a glossy surface (S surface) and the glossy surfaces face each other.
- the rough surface or roughening surface of the carrier A mentioned later can be used as needed. That is, in the case of a rolled copper foil, the rolled surface is a glossy surface, which can be used after being roughened. In the case of an electrolytic copper foil, the glossy surface or rough surface can be further roughened and used as the carrier A.
- any surface joining it is very effective to join by using the sonic welding method.
- a copper foil is used for the upper metal foil B, the upper surface is the M surface (rough surface), the lower surface is the S surface (glossy surface), and the upper surface of the lower carrier A is the S surface (glossy). Surface), the lower surface is an M surface (rough surface), and these S surfaces (glossy surfaces) are bonded to each other.
- the carrier A and the metal foil B are made of the same material, the rough surfaces on the front and back surfaces of the carrier A and the metal foil B can be used without turning them over when laying up. This can significantly improve workability.
- the carrier A and the metal foil B are rectangular (rectangular or square). This shape may be a shape convenient for handling in manufacturing, and is arbitrary, but generally a square or a rectangle is used. Further, the carrier A may have a larger area than the metal foil B so that the carrier A protrudes. In this case, it becomes easy to distinguish between another set of carrier A and metal foil B of the same type as the paired carrier A and metal foil B, and the dimensions are different when the carrier is peeled from the copper foil. Since there is a portion (edge or side), peeling is also facilitated. When these are combined, there is an effect that the handling property of the worker is remarkably improved as compared with the conventional process, and the saliency of the present invention is obvious.
- FIG. 3 shows an example in which the glossy surface of the carrier (for example, copper foil) A is facing up and the glossy surface of the metal (copper) foil B is facing down, and is welded by ultrasonic waves. That is, FIG. 3 shows a state in which both the carrier and the glossy surface of the metal foil are bonded face to face.
- the carrier A since the carrier A has a structure in which the area of the carrier A is larger than that of the metal foil B and the carrier A protrudes, the glossy surface of the carrier (for example, copper foil) A is partially exposed on the right side. Moreover, it turns out that the rough surface (M surface) of metal (copper) foil B is visible in the back. As described above, since the carrier A and the metal foil B are fixed to the operator, the lay-up (lamination) operation is efficiently improved. Further, since the entire surface is not fixed, the peeling (disassembling) work after the lamination is also facilitated.
- the metal foil B copper or copper alloy foil is representative, and most preferably, foil of aluminum, nickel, zinc or the like can be used.
- the carrier A can be made of the same material as the metal foil B.
- electrolytic foil or rolled foil having a thickness of 5 to 120 ⁇ m can be used.
- the thermal expansion coefficient of the metal foil B is within + 10% and ⁇ 30% of the thermal expansion coefficient of the metal foil B.
- the carrier A and the metal foil B are mechanically peeled off before a process such as plating or etching, so that the peel strength of both is preferably 1 g / cm or more and 1 kg / cm or less.
- the peeling surface is a boundary between the carrier A and the metal B, and it is necessary to avoid that the residue of the counterpart material remains between them because a removal process is required and the process becomes complicated. Don't be.
- Example 1 A prepreg produced from an epoxy resin was used as the resin material. On the metal foil with carrier, a desired number of prepregs, then a two-layer printed circuit board called the inner core, then prepreg, and then a metal foil with carrier are stacked in order to complete a set of four-layer board material assembly units. I let you. Next, this unit (commonly called “page”) was repeated about 10 times to form a press assembly (commonly called “book”).
- FIG. 5 shows this structure.
- a unit (commonly called “page”) of a four-layer board in which a metal foil with a carrier, a desired number of prepregs, a two-layer printed circuit board as an inner core, a prepreg, and a metal foil with a carrier are sequentially stacked.
- a state in which the mirror plate (intermediate plate) is further sandwiched is shown (two steps in FIG. 5). Usually, this is repeated about 10 times to produce an assembly for press (commonly called “book”).
- this book was set in a hot press machine, and a four-layer substrate could be manufactured by press molding at a predetermined temperature and pressure.
- a substrate having four or more layers can be produced in the same process by increasing the number of inner core layers.
- the laminated plate thus produced was peeled and separated between the carrier and the copper foil, and then a circuit was formed through a plating step and / or an etching step to obtain a finished product.
- a circuit was formed through a plating step and / or an etching step to obtain a finished product.
- no generation of wrinkles was observed on the metal foil.
- the copper foil is used for the carrier A and the copper foil and the metal foil B, the linear expansion coefficient is almost the same level as that of the copper foil which is the constituent material of the substrate, the prepreg after polymerization and the mirror plate. Therefore, the circuit was not misaligned. Therefore, compared with the case where a conventional CAC is used, the generation of defective products is reduced, and the yield can be improved.
- the laminated plate thus produced was peeled and separated between the carrier and the copper foil, and then a circuit was formed through a plating step and / or an etching step to obtain a finished product. Since the metal foil B was supported over the entire surface by the carrier A, no generation of wrinkles was observed in the metal foil during the lamination. Furthermore, since copper is used for the carrier A and the copper alloy foil and the metal foil B, the linear expansion coefficient is almost the same as that of the copper foil as a constituent material of the substrate and the prepreg after polymerization. There was no misalignment. Therefore, compared with the case where a conventional CAC is used, the generation of defective products is reduced, and the yield can be improved.
- Example 3 A hot press machine is used as a book in the same manner as in Example 1 except that the roughened surface of the rolled copper foil of the carrier A and the S surface of the electrolytic copper foil of the metal foil B are joined using an ultrasonic welding method.
- a four-layer substrate was manufactured by press molding at a predetermined temperature and pressure. And a circuit was formed through the plating process and / or the etching process, and it was made to peel and separate between a carrier and copper foil, and it was set as the finished product.
- this exfoliation separation in Example 2, there were some cases where the copper foil after exfoliation separation was broken or the copper carrier remained on the copper foil. There was no residue of copper carrier on the copper foil. From the above, it has been found that it is very effective to join the roughened surface of the rolled copper foil of the carrier A and the S surface of the electrolytic copper foil of the metal foil B using an ultrasonic welding method.
- Example 4 Electrolytic copper foil was used for carrier A.
- the electrolytic copper foil has a rough surface and a glossy surface.
- the rough surface of the electrolytic copper foil and the S surface of the electrolytic copper foil of the metal foil B were joined using an ultrasonic welding method.
- the others were made into a book by the same method as in Example 1, set in a hot press machine, and pressure molded at a predetermined temperature and pressure to produce a four-layer substrate. And a circuit was formed through the plating process and / or the etching process, and it was made to peel and separate between a carrier and copper foil, and it was set as the finished product.
- there was no breakage of the copper foil or any remaining copper carrier on the copper foil there was no breakage of the copper foil or any remaining copper carrier on the copper foil. From the above, it has been found that it is very effective to join the rough surface of the electrolytic copper foil of the carrier A and the S surface of the electrolytic copper foil of the metal foil B using an ultrasonic welding method.
- Example 5 A rolled aluminum foil was used as the carrier A, and the aluminum rolled foil and the S surface of the electrolytic copper foil of the metal foil B were joined using an ultrasonic welding method to make a book in the same manner as in Example 1, A four-layer substrate was manufactured by setting in a press and press molding at a predetermined temperature and pressure. And a circuit was formed through the plating process and / or the etching process, and it was made to peel and separate between a carrier and copper foil, and it was set as the finished product. In this separation and separation, as in Example 3, in the configuration of this example, there was no breakage of the copper foil or any residual aluminum carrier on the copper foil.
- the metal foil B a copper foil or a copper alloy foil is usually used, but it goes without saying that another metal foil can be used as the metal foil B.
- carrier A copper foil, copper alloy foil or aluminum foil is used.
- a rolled aluminum foil is usually used for aluminum.
- the copper foil includes a rolled copper foil and an electrolytic copper foil, both of which can be applied to the carrier A of the present invention. That is, the glossy surface of rolled copper foil and electrolytic copper foil can be used, and a rough surface can also be used.
- the rolled surface is a glossy surface, which can be used after being roughened.
- the glossy surface or rough surface can be further roughened and used as the carrier A. Further, by selecting the material of the carrier A and the metal foil B, particularly by selecting the material and the surface state, it is possible to improve the releasability when the bond is peeled off. Therefore, these can be used in any combination.
- the metal foil with a carrier of the present invention is a laminate in which the carrier A and the metal foil B are alternately overlapped, and the copper surface of the copper foil of the carrier A and the metal foil B is overlapped with each other, so that the operator can change the M surface of the copper foil.
- the work efficiency is drastically improved because there is no need for the reversing work of placing it on the bottom or on the top.
- it is optional to make the carrier a copper foil but when the carrier is a copper foil, the linear expansion coefficient is at the same level as the copper foil that is a constituent material of the substrate and the prepreg after polymerization, Since the circuit is not displaced, the generation of defective products is reduced and the yield can be improved.
- the merit of the metal foil with carrier obtained by the present invention is great, and is particularly useful for the production of printed circuit boards.
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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
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- Parts Printed On Printed Circuit Boards (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
Description
プリプレグ表面(表裏面)には電気伝導性を持った銅又は銅合金箔等のシートが接合されている。このように組み立てられた積層物を、一般にCCL(Copper Clad Laminate)材と呼んでいる。そしてCCL材料に、さらに銅箔をプリプレグを介して多層化したものを多層基板と呼んでいる。
前記銅又は銅合金箔の替りに、アルミニウム、ニッケル、亜鉛などの箔を使用する場合もある。これらの厚さは5~200μm程度である。
例えば、従来知られているキャリア付銅箔(特許文献2,3,4参照)を使用した4層基板の製造工程においては、厚さが0.2~2mmのプレス面が平滑なステンレス製のプレス板(通称、「鏡面板」と言う。)の上に、キャリアに剥離可能に接着された極薄銅箔をM面(粗面)が上になるように載置し、次に所定枚数のプリプレグ、次に内層コアと称するCCL材料に回路を形成したプリント回路基板、次にプリプレグ、次にキャリアに剥離可能に接着された極薄銅箔をM面(粗面)が下になるように載置し、これらを鏡面板の順に重ねることにより、1組の4層基板材料からなる組み立てユニットが完成する。
この際、使用されるキャリア付銅箔は、極薄銅箔とキャリアとが全面で接着しているため、積層後に作業者がこのキャリアを剥離するのに、かなりの力を必要とし手間がかかるという問題がある。
また、前記の通り、作業者はレイアップ(積層積み作業)の際に、銅箔のM面を上にして配置する、又はM面を下にして配置する作業を、交互に繰り返す必要があるため、作業効率が低下するという問題がある。さらに、銅箔及びキャリアが同寸法であるため、レイアップ時に銅箔1枚1枚を取り分けることが難しく、この点においても作業性が低下するという問題がある。
・銅箔:16.5(×10-6/°C)
・SUS304:17.3×10-6/°C
・SUS301:15.2×10-6/°C
・SUS630:11.6×10-6/°C
・プリプレグ(Cステージ):12~18×10-6/°C
・ アルミニウム板(JIS#5182):23.8×10-6/°C
本願発明には直接関係しないが、キャリア付極薄銅箔に関する例として次の文献がある(特許文献2、特許文献3、特許文献4)。
この知見に基づき、本発明は、
1)キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアA及び金属箔Bがそれぞれ光沢面(S面)を有し、それぞれ光沢面が互いに向き合うように積層されていることを特徴とするキャリア付金属箔、を提供する。
2)キャリアA及び金属箔Bが矩形であることを特徴とする上記1)記載のキャリア付金属箔
3)金属箔Bが、銅箔又は銅合金箔であることを特徴とする上記1)又は2)記載のキャリア付金属箔
4)キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアAと金属箔Bとが超音波接合されていることを特徴とするキャリア付銅箔、を提供する。
5)キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアAと金属箔Bとが超音波接合されていることを特徴とする上記1)~3)のいずれか一項に記載のキャリア付銅箔
6)キャリアAが銅箔又は銅合金箔で、金属箔Bが銅箔又は銅合金箔であり、キャリアAの銅箔の粗面と金属箔Bの銅箔の光沢面が超音波接合されていることを特徴とするキャリア付銅箔
7)キャリアAがアルミニウム又は銅若しくは銅合金箔であり、金属箔Bが銅箔又は銅合金箔であることを特徴とする上記1)~6)のいずれか一項に記載のキャリア付銅箔
8)キャリアA及び金属箔Bがずれないように、接着剤、かしめ若しくは重ね折又は溶着により接合されていることを特徴とする上記1)~7)のいずか一項に記載のキャリア付金属箔、を提供する。
9)金属箔が、5~120μmの厚みを有する電解箔であることを特徴とする上記1)~8)のいずかに記載のキャリア付金属箔
10)金属箔が、5~120μmの厚みを有する圧延箔であることを特徴とする請求項1)~8)のいずかに記載のキャリア付金属箔
11)キャリアの熱膨張率が金属箔の熱膨張率の+10%、-30%以内であることを特徴とする上記1)~10)のいずかに記載のキャリア付金属箔、を提供する。
また、キャリアを銅箔にすることは任意であるが、キャリアを銅箔にした場合には線膨張係数が基板の構成材料である銅箔及び重合後のプリプレグと同等のレベルにあることから、回路の位置ずれを招くことがないので、不良品発生が少なくなり、歩留りを向上させることができるという優れた効果を有する。
特に、キャリアAが圧延銅箔又は電解銅箔であり、銅箔Bの光沢面が、圧延銅箔の粗化処理面又は電解銅箔の粗面若しくは粗化処理面に接するように超音波接合することが有効である。
また、キャリアAと金属箔Bの材料の選択によって、特に材質と表面状態を選ぶことによって、接合を剥離する際の剥離性を改善することができる。したがって、これらを任意に組み合わせて使用することができるという効果を有する。
超音波溶着法を使用して接合すると、銅キャリアAと金属箔Bの剥離分離工程において、剥離分離後の金属箔が破断したり、銅キャリアが金属箔上に残留したりすることなくなるという効果がある。
図1において、上方の金属箔Bに、例えば銅箔を使用し上面をM面(粗面)とし、下面をS面(光沢面)とすると共に、下のキャリアAの上面をS面(光沢面)とし、下面をM面(粗面)とし、これらのS面(光沢面)相互を接着したものである。
従来、作業者はレイアップ(積層組み作業)の際に、銅箔のM面を上にして配置すること、さらにM面を下にして配置する作業を、交互に繰り返す必要があるため、作業効率が低下するという問題があったが、これが一挙に解決させることができる効果を有する。
また、キャリアAを金属箔Bよりも面積を大きくしてキャリアAがはみ出した構造とすることもできる。この場合、積層された一組のキャリアAと金属箔Bと同種の別の組のキャリアAと金属箔Bとの区別が容易となり、またキャリアを銅箔から剥離する際にも、寸法が異なっている箇所(縁部又は辺部)があるので、剥離も容易となる。
これらを綜合すると、従来の工程に比べて、作業者のハンドリング性が著しく向上する効果があり、本願発明の顕著性が明らかである。
図3に、キャリア(例えば銅箔)Aの光沢面を上にして、金属(銅)箔Bの光沢面を下にして、超音波により溶着させた例を示す。すなわち図3では、キャリアと金属箔の光沢面の双方が向かい合って接合されている様子を示す。
以上により、作業者はキャリアAと金属箔Bが固定されているので、レイアップ(積層)作業が効率的に改善される。また、全面が固定されているわけではないので、積層後の剥離(解体)作業も容易となる。
銅又は銅合金箔の場合、5~120μmの厚みを有する電解箔又は圧延箔を使用することができる。
一般に、キャリアAと金属箔Bとは、めっき又はエッチング等の工程前に機械的に剥がすことになるので、両者の剥離強度は、1g/cm以上、1kg/cm以下であることが望ましい。さらに、剥離面はキャリアAと金属Bとの境界であることが望ましく、両者の間で、相手材料の残渣が残ることは、除去工程が必要となり、工程の複雑化になるので、避けなければならない。
樹脂材料として、エポキシ樹脂から作製したプリプレグを用いた。キャリア付金属箔上に、所望枚数のプリプレグ、次に内層コアと称する2層プリント回路基板、次にプリプレグ、さらにキャリア付金属箔を順に重ねることで1組の4層基板の材料組み立てユニットを完成させた。
次に、このユニット(通称「ページ」と言う)を10回程度繰り返し、プレス組み立て物(通称「ブック」と言う)を構成した。
鏡面板(中間板)を挟んで、さらに積み重ねた様子を示す(図5では2段)。通常、これを10回程度繰り返してプレス用の組立物(通称、「ブック」)を作製する。なお、図5に示す「×n」は、多層(n=1、2、3・・n)を意味する。
上記の通り、このプレス用の組立物を作製する前段階で、さらに作業効率の大きな改善が図ることができた。すなわち、キャリアA及び金属箔Bのいずれの粗面(M面)も使用できるので、これによって、作業者が銅箔のM面を下に置くとか上に置くという、反転作業が必要としなくなるので作業効率は飛躍的に向上した。
さらに、キャリアAに銅箔と金属箔Bにも銅箔を使用しているので、線膨張係数が基板の構成材料である銅箔及び重合後のプリプレグ及び鏡面板と、殆ど同じレベルにあることから、回路の位置ずれを起こすことがなかった。したがって、従来のCACを使用する場合に比べて、不良品発生が少なくなり、歩留りを向上させることができた。
本発明においては、実施例1と同様であるが、キャリアAに圧延銅合金箔を金属箔Bに電解銅箔を使用し、それぞれの光沢面(S面)相互を接合した。構造的には図5と同一なので、説明は省略する。
図5にキャリア付金属箔、所望枚数のプリプレグ、内層コアである2層プリント回路基板、プリプレグ、さらにキャリア付金属箔を順に重ね合わせた4層基板のユニット(通称、「ページ」)を形成する。鏡面板(中間板)を挟んで、さらに積み重ねた様子を示す(図4では2段)。通常、これを10回程度繰り返してプレス用の組立物(通称、「ブック」)を作製する。なお、図5に示す「×n」は、多層(n=1、2、3・・n)を意味する。
さらに、キャリアAに銅合金箔と金属箔Bに銅を使用しているので、線膨張係数が基板の構成材料である銅箔及び重合後のプリプレグと、殆ど同じレベルにあることから、回路の位置ずれを起こすことがなかった。したがって、従来のCACを使用する場合に比べて、不良品発生が少なくなり、歩留りを向上させることができた。
キャリアAの圧延銅箔の粗化処理面と金属箔Bの電解銅箔のS面とを超音波溶着法を使用して接合させた以外は実施例1と同じ方法でブックとし、ホットプレス機にセットし、所定の温度及び圧力で加圧成型することにより4層基板を製造した。そして、めっき工程及び又はエッチング工程経て回路を形成し、さらにキャリアと銅箔の間で、剥離分離させて完成品とした。
この剥離分離において、実施例2の場合、剥離分離後の銅箔が破断したり、銅キャリアが銅箔上に残留したりすることが若干あったが、本例の構成では銅箔の破断ないし銅キャリアの銅箔上への残留は全くなかった。
以上から、キャリアAの圧延銅箔の粗化処理面と金属箔Bの電解銅箔のS面とを超音波溶着法を使用して接合することが非常に有効であることが分かった。
キャリアAに電解銅箔を使用した。電解銅箔には粗面と光沢面があるが、この電解銅箔の粗面と金属箔Bの電解銅箔のS面とを超音波溶着法を使用して接合した。そして、他は実施例1と同じ方法でブックとし、ホットプレス機にセットし、所定の温度及び圧力で加圧成型することにより4層基板を製造した。そして、めっき工程及び又はエッチング工程経て回路を形成し、さらにキャリアと銅箔の間で、剥離分離させて完成品とした。
本例の構成では、実施例3と同様に、銅箔の破断ないし銅キャリアの銅箔上への残留は全くなかった。
以上から、キャリアAの電解銅箔の粗面と金属箔Bの電解銅箔のS面とを超音波溶着法を使用して接合することが非常に有効であることが分かった。
キャリアAとしてアルミニウム圧延箔を用い、このアルミニウム圧延箔と金属箔Bの電解銅箔のS面とを超音波溶着法を使用して接合させた以外は実施例1と同じ方法でブックとし、ホットプレス機にセットし、所定の温度及び圧力で加圧成型することにより4層基板を製造した。そして、めっき工程及び又はエッチング工程経て回路を形成し、さらにキャリアと銅箔の間で、剥離分離させて完成品とした。
この剥離分離において、実施例3と同様に、本例の構成では銅箔の破断ないしアルミニウムキャリアの銅箔上への残留は全くなかった。
銅箔には、圧延銅箔と電解銅箔があるが、いずれも本願発明のキャリアAに適用できる。すなわち、圧延銅箔と電解銅箔の光沢面を使用することもできるし、粗面を使用することもできる。
また、キャリアAと金属箔Bの材料の選択によって、特に材質と表面状態を選ぶことによって、接合を剥離する際の剥離性を改善することができる。したがって、これらを任意に組み合わせて使用することができる。
さらに、キャリアを銅箔にすることは任意であるが、キャリアを銅箔にした場合には線膨張係数が基板の構成材料である銅箔及び重合後のプリプレグと同等のレベルにあることから、回路の位置ずれを招くことがないので、不良品発生が少なくなり、歩留りを向上させることができるという優れた効果を有する。
本願発明により得られるキャリア付金属箔のメリットは大きく、特にプリント回路板の製造に有用である。
Claims (8)
- キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアA及び金属箔Bがそれぞれ光沢面(S面)を有し、それぞれ光沢面が互いに向き合うように積層されていることを特徴とするキャリア付金属箔。
- キャリアA及び金属箔Bが矩形であることを特徴とする請求項1記載のキャリア付金属箔。
- 金属箔Bが、銅箔又は銅合金箔であることを特徴とする請求項1又は2記載のキャリア付金属箔。
- キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアAと金属箔Bとが超音波接合されていることを特徴とするキャリア付銅箔。
- キャリアAと金属箔Bが交互に重なり合う積層体であって、キャリアAと金属箔Bとが超音波接合されていることを特徴とする請求項1~3のいずれか一項に記載のキャリア付銅箔。
- キャリアAが銅箔又は銅合金箔で、金属箔Bが銅箔又は銅合金箔であり、キャリアAの銅箔の粗面と金属箔Bの銅箔の光沢面が超音波接合されていることを特徴とするキャリア付銅箔。
- キャリアAがアルミニウム又は銅若しくは銅合金箔であり、金属箔Bが銅箔又は銅合金箔であることを特徴とする請求項1~6のいずれか一項に記載のキャリア付銅箔。
- キャリアA及び金属箔Bがずれないように、接着剤、かしめ若しくは重ね折又は溶着により接合されていることを特徴とする請求項1~7のいずか一項に記載のキャリア付金属箔。
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US13/132,766 US9992874B2 (en) | 2008-12-24 | 2009-03-10 | Metal foil with carrier |
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- 2009-03-10 KR KR1020137030828A patent/KR20130133099A/ko not_active Application Discontinuation
- 2009-03-10 EP EP09834551.5A patent/EP2383114B1/en active Active
- 2009-03-10 SG SG2011034899A patent/SG171728A1/en unknown
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Also Published As
Publication number | Publication date |
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EP2383114A1 (en) | 2011-11-02 |
US20110244255A1 (en) | 2011-10-06 |
EP2383114B1 (en) | 2015-07-08 |
JPWO2010073745A1 (ja) | 2012-06-14 |
CN102264541A (zh) | 2011-11-30 |
EP2383114A4 (en) | 2013-01-16 |
JP2013252704A (ja) | 2013-12-19 |
KR20110081340A (ko) | 2011-07-13 |
CN102264541B (zh) | 2014-08-13 |
KR20130133099A (ko) | 2013-12-05 |
US9992874B2 (en) | 2018-06-05 |
JP2009143234A (ja) | 2009-07-02 |
KR101377820B1 (ko) | 2014-03-25 |
SG171728A1 (en) | 2011-07-28 |
JP5723927B2 (ja) | 2015-05-27 |
JP5378415B2 (ja) | 2013-12-25 |
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