WO2014024726A1 - 電子機器及び電子機器の製造方法 - Google Patents

電子機器及び電子機器の製造方法 Download PDF

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Publication number
WO2014024726A1
WO2014024726A1 PCT/JP2013/070548 JP2013070548W WO2014024726A1 WO 2014024726 A1 WO2014024726 A1 WO 2014024726A1 JP 2013070548 W JP2013070548 W JP 2013070548W WO 2014024726 A1 WO2014024726 A1 WO 2014024726A1
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Prior art keywords
wiring
resin
electronic device
electronic component
outer edge
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PCT/JP2013/070548
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English (en)
French (fr)
Inventor
泰史 道祖尾
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シャープ株式会社
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Publication date
Application filed by シャープ株式会社 filed Critical シャープ株式会社
Priority to CN201380029092.XA priority Critical patent/CN104335363B/zh
Publication of WO2014024726A1 publication Critical patent/WO2014024726A1/ja

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    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0516—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module specially adapted for interconnection of back-contact solar cells
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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
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    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to an electronic device including an electronic component having an electrode on the back surface and a wiring board in which wiring is formed on an insulating flexible base material, and a method for manufacturing the electronic device.
  • Patent Document 1 discloses a solar battery in which a solar battery cell (an example of an electronic component) having an electrode on the back surface and a wiring board are fixed with an adhesive.
  • the wiring of the wiring board is connected to the electrode of the photovoltaic cell, and the wiring is connected to the outside of the photovoltaic cell (upper and lower sides of FIG. 4 of FIG. 4).
  • the photovoltaic cell is adhered and fixed to the wiring substrate by disposing an adhesive between the electrode forming surface of the solar cell and the wiring forming surface of the wiring substrate. Therefore, the wiring is divided into a portion that is in contact with the adhesive and a portion that is not in contact with the adhesive, and the boundary of the presence or absence of the adhesive is formed on the wiring.
  • the wiring is firmly bonded and fixed to the solar cell together with the insulating base material of the wiring board by this adhesive, so the wiring in the part in contact with the adhesive corresponds to the wiring in the part in contact with the adhesive
  • the expansion / contraction and deformation due to temperature change, stress, and the like are suppressed together with the insulating base of the portion to be performed.
  • the part of the wiring not in contact with the adhesive is not fixed to the solar cell by the adhesive together with the part of the insulating substrate corresponding to the part of the wiring not in contact with the adhesive. It expands and contracts relatively freely due to stress and the like.
  • an object of the present invention is to provide a highly durable electronic device and a method for manufacturing the electronic device.
  • an electronic device is an electronic device including an electronic component having an electrode on the back surface and a wiring board in which wiring is formed on the surface of an insulating flexible base material.
  • the electronic component is fixed to the wiring board with an insulating resin, and the outer edge shape of the resin has a corner portion having an angle of 90 degrees or less in a portion located on the wiring (first Composition).
  • the outer edge line of the resin and the outer edge line of the wiring intersect obliquely (second configuration).
  • the wiring has a band shape
  • the outer edge shape of the resin has the corner portion at a portion located on a central portion in the width direction of the wiring (first 3 configuration).
  • the corner portion is formed in an arc shape (fourth configuration).
  • all of the resin is configured in a region on the back surface of the electronic component (fifth configuration).
  • the electronic device having the fifth configuration a plurality of the electronic components are provided, and the portion of the wiring board is formed between the adjacent electronic components as viewed from the surface side of the electronic component. It is preferable to use an existing configuration (sixth configuration).
  • a method of manufacturing an electronic device is a method of manufacturing an electronic device having any one of the first to sixth configurations, wherein a resin is disposed on the back surface of an electronic component by printing. Bonding the resin placement surface of the electronic component printed with the resin and the wiring surface of the wiring substrate on which the wiring is formed on the surface of the insulating flexible base material, and fixing the electronic component to the wiring substrate It is set as the structure containing these.
  • another method of manufacturing an electronic device is a method of manufacturing an electronic device having any one of the first to sixth configurations, wherein the wiring is formed on the surface of the insulating flexible substrate.
  • the step of placing resin on the wiring surface of the wiring board formed with the printed circuit board and the back surface of the electronic component and the resin placement surface of the wiring board on which the resin is printed are bonded together to fix the electronic component to the wiring board. It is set as the structure including the process to do.
  • the portion of the wiring where the outer edge line of the resin is located is hardly broken, a highly durable electronic device and a method for manufacturing the electronic device can be realized.
  • FIG. 11 is a plan view showing an electronic apparatus according to still another example of the present invention in a state before an electronic component is fixed to the wiring board after the resin is provided on the wiring board side and the electronic apparatus is fixed to the wiring board.
  • It is sectional drawing which shows the electronic device which concerns on the further another example of this invention in the state before fixing an electronic component to a wiring board in the case of fixing an electronic device to a wiring board after providing resin at the wiring board side.
  • FIG. 1 is a plan view showing the electronic apparatus according to the first embodiment of the present invention in a state before the electronic component is fixed to the wiring board.
  • FIG. 2 shows the electronic device according to the first embodiment of the present invention in a state before the electronic component is fixed to the wiring board, with the back surface of the electronic component facing the front surface of the wiring board.
  • FIG. 2 is a cross-sectional view taken along the line AA of FIG.
  • FIG. 3 is a plan view showing the electronic apparatus according to the first embodiment of the present invention in a state after the electronic component is fixed to the wiring board.
  • FIG. 4 is a cross-sectional view taken along the line AA of FIG. 3 showing the electronic apparatus according to the first embodiment of the present invention after the electronic component is fixed to the wiring board.
  • the outer edge lines of the wiring 4 and the resin 6 that are hidden by the main body of the electronic component 2 are indicated by dotted lines.
  • the electronic apparatus includes an electronic component 2 having an electrode 1 on the back surface and a wiring substrate 5 having a wiring 4 formed on the surface of an insulating flexible base 3.
  • an insulating resin 6 is disposed on the back surface of the electronic component 2 by printing, and the electrode 1 is disposed on the back surface of the electronic component 2.
  • a conductive material 7 such as solder is disposed so as to cover the surface. Note that the resin 6 surrounds the conductive material 7 in order to prevent the adjacent electrodes 1 from being electrically connected by the conductive material 7.
  • the electronic component 2 is wired by bonding the resin arrangement surface (back surface) of the electronic component 2 printed with the resin 6 and the wiring surface (front surface) of the wiring substrate 5 under temperature conditions equal to or higher than the melting temperature of the conductive material 7.
  • the conductive material 7 is deformed from the state of FIGS. 1 and 2 to the state of FIGS. 3 and 4.
  • the outer edge shape of the resin 6 has a corner at a portion located on the wiring 4.
  • the outer edge shape of the resin 6 since the outer edge shape of the resin 6 has a corner at the portion located on the wiring 4, stress from at least two directions with respect to the corner (for example, ⁇ 1 and ⁇ 2 shown in FIG. 3).
  • the outer edge line of the resin 6 is located on the part of the wiring 4 where the outer edge line is located, the wiring 4 is not completely disconnected, so that the wiring 4 is less likely to be disconnected.
  • the outer edge shape of the resin 6 has a corner at the portion located on the wiring 4, the length of the outer edge line of the resin 6 located on the wiring 4 is increased, and the stress per unit length is increased. Can be reduced, and disconnection of the wiring 4 is less likely to occur.
  • the wiring 4 has a belt-like shape, and the outer edge shape of the resin 6 has a corner at a portion located on the central portion in the width direction of the wiring 4 so that the corner is bordered.
  • the lengths of the outer edge lines of the two resins 6 can be made substantially equal, and the direction of stress that weakens against disconnection becomes difficult.
  • the durability of the electronic apparatus according to the first embodiment of the present invention is improved because the outer edge shape of the resin 6 has a corner at the portion located on the wiring 4.
  • the wiring 4 may be completely disconnected, so that the wiring 4 is easily disconnected.
  • the angle of the corner portion of the resin outer edge shape at the portion located on the wiring is 90 degrees or less. In this embodiment, the angle is 60 degrees as shown in FIG.
  • the angle of the corner is 90 degrees, for example, the direction in which the wiring 4 is expanded and contracted with respect to one side forming the outer edge line of the resin 6 on the wiring 4 and the other side forming the outer edge line of the resin 6 on the wiring 4 Therefore, the stress in the direction of expanding / contracting the wiring 4 with respect to one side forming the outer edge line of the resin 6 on the wiring 4 is applied to the other side forming the outer edge line of the resin 6 on the wiring 4. It is not a stress in the direction in which the wiring is expanded and contracted, and it is possible to effectively suppress the disconnection of the portion where the two sides forming the outer edge line of the resin 6 on the wiring 4 are located.
  • the angle of the corner is smaller than 90 degrees, the stress in the direction of expanding and contracting the wiring 4 with respect to one side forming the outer edge line of the resin 6 on the wiring 4 causes the outer edge of the resin 6 on the wiring 4 to be extended. A part of the stress in the direction of expanding and contracting the wiring 4 with respect to the other side forming the line is canceled, and the outer edge line of the resin 6 on the wiring 4 is applied to the stress that can be applied to the wiring 4 from various directions. It is possible to effectively suppress disconnection of the portion where the two sides formed are located. Furthermore, by setting the angle of the corner portion to an angle smaller than 90 degrees, the length of the outer edge line of the resin 6 positioned on the wiring 4 can be made longer, so it takes per unit length of the wiring 4.
  • the stress can be reduced, and disconnection of the wiring 4 is less likely to occur.
  • the length of the outer edge line of the resin 6 positioned on the wiring 4 shown in FIG. 3 may be twice as long as the length of the outer edge line of the resin 6 positioned on the wiring 4 shown in FIG. it can.
  • the thermal temperature cycle test was performed on the electronic device according to the present invention and the comparative example shown in FIG. 5, the wiring 4 was completely disconnected in some samples in the comparative example shown in FIG. On the other hand, in the electronic device according to the present invention, there was no sample in which the wiring 4 was completely disconnected.
  • the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect at an angle.
  • the angle of the corner is 90 degrees or less, and the outer edge shape of the two resins 6 with the corner as the boundary is approximately equal to the outer edge shape of the resin 6 on the central portion in the width direction of the wiring 4 Since it is desirable to have a corner at the position where the corner is located and to make the corner symmetric with respect to the width direction of the wiring 4, the intersection angle between the outer edge line of the resin 6 and the outer edge line of the wiring 4 It is more desirable that the intersection angle of the portion where the resin 6 is not disposed on the wiring 4 is 45 degrees or less. In the present embodiment, the intersection angle between the outer edge line of the resin 6 and the outer edge line of the wiring 4, and the intersection angle of the portion where the resin 6 is not disposed on the wiring 4 is 30 degrees as shown in FIG. .
  • the outer edge line of the wiring 4 and the outer edge line of the wiring 4 may be cut or split by shearing stress applied to the portion where the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect. Crossing each other diagonally (non-perpendicularly), even if the shear stress is applied to a portion where the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect, Since the cross-sectional area of the wiring 6 is smaller, the wiring 6 at the intersecting portion is more easily deformed than the portion of the other wiring 6, and the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect due to the deformation.
  • the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect when the shear stress is applied to the wiring 4 as compared with the example shown in FIG. It is hard to generate cuts and tears.
  • the outer edge shape of the resin 6 located on the wiring 4 has a plurality of corners. By doing in this way, it can prevent that the wiring 4 completely disconnects with respect to the stress from at least more than one direction with a plurality of corners as a boundary.
  • the outer edge shape of the resin 6 positioned on the wiring 4 the number and shape of the corners and the angle at which the outer edge line of the resin 6 and the outer edge line of the wiring 4 intersect are the stresses applied to the wiring 4. What is necessary is just to determine suitably from a direction and intensity
  • the size of the wiring board becomes large, and it is difficult to place resin on the wiring board with high positional accuracy at a time. It is desirable to fix the electronic device to the wiring board after providing resin on the side.
  • the electronic device may be fixed to the wiring board after the resin is provided on the wiring board side.
  • FIG. 7 is a plan view showing an electronic apparatus according to still another example of the present invention in a state before the electronic component in this case is fixed to the wiring board.
  • FIG. 8 shows a state in which the back surface of the electronic component and the front surface of the wiring board are opposed to each other, showing an electronic device according to still another example of the present invention before the electronic component is fixed to the wiring board in this case.
  • FIG. 8 is a cross-sectional view taken along the line AA of FIG.
  • the electronic component can be arranged at a predetermined position on the wiring board while recognizing the resin shape pattern. That is, a resin shape pattern can be used for alignment.
  • FIG. 9 is a plan view showing an electronic apparatus according to the second embodiment of the present invention in a state before the electronic component is fixed to the wiring board.
  • the corner portion of the resin 6 is formed in an arc shape, and the connecting portion that connects the corner portion and the corner portion of the resin 6 is formed in an arc shape.
  • This is different from the electronic device according to the first embodiment of the invention.
  • the corner portion is sharp like the electronic device according to the first embodiment of the present invention, stress is likely to concentrate on the portion, and the wiring may be easily torn starting from the corner portion.
  • the corner portions are arced like the electronic apparatus according to the present embodiment, stress concentration on the corner portions can be prevented, and thus disconnection of the wiring 4 can be further suppressed.
  • the electronic component 2 may be an integrated circuit chip that is bump-connected to the substrate, but in this embodiment, the electronic component 2 is a back electrode type solar cell.
  • FIG. 10 is a schematic longitudinal sectional view of the back electrode type solar battery cell 20 included in the electronic apparatus of the present embodiment.
  • the back electrode type solar cell 20 is formed on a concavo-convex surface of a semiconductor substrate 21 such as a silicon substrate having n-type or p-type conductivity, and the semiconductor substrate 21 serving as a light receiving surface of the back electrode type solar cell 20.
  • an electrode 25 One of the first conductivity type and the second conductivity type may be p-type and the other n-type.
  • the insulating film 23 may have a function as a passivation film.
  • a first conductivity type impurity diffusion region 26 formed by diffusing first conductivity type impurities and a second conductivity type impurity diffusion region 27 formed by diffusing second conductivity type impurities. are alternately formed at predetermined intervals.
  • the first conductivity type electrode 24 and the first conductivity type impurity diffusion region 26 are connected via a contact hole provided in the insulating film 23.
  • the second conductivity type electrode 25 and the second conductivity type impurity diffusion region 27 are electrically connected through a contact hole provided in the insulating film 23.
  • the wiring board is a wiring sheet.
  • FIG. 11 is a schematic longitudinal sectional view of the wiring sheet 50 provided in the electronic apparatus of the present embodiment.
  • the wiring sheet 50 includes an insulating flexible base 51 and first and second wirings 52 and 53 disposed on the surface of the insulating flexible base 51.
  • the first wiring 53 corresponds to the first conductivity type electrode 24, and the second wiring 53 corresponds to the second conductivity type electrode 25.
  • the insulating flexible base material expands and contracts due to a temperature change. There is a high possibility that the wiring is located on the outer edge of the wire. Therefore, the disconnection of the wiring can be effectively prevented by applying the above embodiment to the wiring sheet.
  • outer edge shape of the resin 6, the conductive material 7, and the like may be the same as those in the first embodiment or the second embodiment, and thus the description thereof is omitted here.
  • one electronic component is fixed to one wiring board.
  • a plurality of electronic components may be fixed to one wiring board.
  • the wiring sheet is configured to include three cell arrangement portions 25 as in the example shown in FIG.
  • the wiring sheet when viewed from the front surface side of the back electrode type solar cell (an example of an electronic component), the wiring sheet is provided between the adjacent back electrode type solar cells, that is, between the adjacent cell placement portions 54. There is a portion where the wiring is formed. On both sides of the wiring of the portion, the outer edge line of the resin is present in the portion where the resin outer edge line is located on the wiring in the cell arrangement portion 54. Since the possibility of disconnection is higher than in the case where it exists in the portion, the application of the present invention that suppresses disconnection is more effective.

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Abstract

　電子機器は、裏面に電極を備えた電子部品と、絶縁性可撓基材の表面に配線を形成した配線基板とを含む。前記電子部品は前記配線基板に絶縁性の樹脂によって固定されている。前記樹脂の外縁形状は、前記配線上に位置する部分において角度が９０度以下である角部を有している。

Description

電子機器及び電子機器の製造方法
　本発明は、裏面に電極を備えた電子部品と、絶縁性可撓基材に配線を形成した配線基板とを含む電子機器及び当該電子機器の製造方法に関する。
　絶縁性基材の少なくとも一方の主面に配線を形成した配線基板の配線形成面上に電子部品を配置し、電子部品の電極を配線基板の配線に接続するとともに、電子部品と配線基板とを樹脂などの接着剤で固定する技術は広く知られている。例えば、特許文献１には、裏面に電極を備えた太陽電池セル（電子部品の一例）と配線基板とが接着剤で固定されている太陽電池が開示されている。
特開２００９－８８１４５号公報
　特許文献１では、太陽電池セルの出力を外部に取り出すために、太陽電池セルの電極に配線基板の配線を接続し、その配線を太陽電池セルの外側（特許文献１の第４図の紙面上下方向）に引き出している。また、太陽電池セルの電極形成面と配線基板の配線形成面との間に接着剤が配置されることで太陽電池セルが配線基板に接着されて固定されている。したがって、配線は接着剤に接触している部分と接着剤に接していない部分とに分かれており、接着剤の有無の境界が配線上にできている。
　この接着剤によって配線は配線基板の絶縁性基材とともに太陽電池セルに強固に接着されて固定されるため、接着剤に接している部分の配線は、接着剤に接している部分の配線に対応する部分の絶縁性基材とともに、温度変化や応力などによる伸縮や変形が抑制される。一方で、接着剤に接していない部分の配線は、接着剤に接していない部分の配線に対応する部分の絶縁性基材とともに、接着剤によって太陽電池セルに固定されていないので、温度変化や応力などによって比較的自由に伸縮や変形してしまう。
　このため、温度変化や応力などによって配線に伸縮や変形が生じた場合に、配線が一様に変形せずに、特に接着剤の有無の境界部分に歪みが集中してしまい、この境界部分で配線が断線するおそれがあった。
　本発明は、上記の状況に鑑み、耐久性の高い電子機器及び当該電子機器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に本発明に係る電子機器は、裏面に電極を備えた電子部品と、絶縁性可撓基材の表面に配線を形成した配線基板とを含む電子機器であって、前記電子部品は前記配線基板に絶縁性の樹脂によって固定されており、前記樹脂の外縁形状は、前記配線上に位置する部分において角度が９０度以下である角部を有している構成（第１構成）とする。
　また、上記第１構成の電子機器において、前記樹脂の外縁線と前記配線の外縁線とが斜めに交差する構成（第２構成）にすることが好ましい。
　また、上記第２構成の電子機器において、前記配線は帯状であり、前記樹脂の外縁形状は、前記配線の幅方向の中央部上に位置する部分において前記角部を有している構成（第３構成）にすることが好ましい。
　また、上記第１～３のいずれかの構成の電子機器において、前記角部が弧状に形成されている構成（第４構成）にすることが好ましい。
　また、上記第１～４のいずれかの構成の電子機器において、前記樹脂の全てが前記電子部品の裏面の領域内に配置されている構成（第５構成）にすることが好ましい
　また、上記第５構成の電子機器において、前記電子部品を複数備え、前記電子部品の表面側から見て、隣接する前記電子部品同士の間に前記配線基板の前記配線が形成されている部分が存在する構成（第６構成）にすることが好ましい。
　上記目的を達成するために本発明に係る電子機器の製造方法は、上記第１～６のいずれかの構成の電子機器の製造方法であって、電子部品の裏面に樹脂を印刷によって配置する工程と、前記樹脂が印刷された前記電子部品の樹脂配置面と絶縁性可撓基材の表面に配線を形成した配線基板の配線面とを貼り合わせて前記電子部品を前記配線基板に固定する工程とを含む構成とする。
　上記目的を達成するために本発明に係る電子機器の他の製造方法は、上記第１～６のいずれかの構成の電子機器の製造方法であって、絶縁性可撓基材の表面に配線を形成した配線基板の配線面に樹脂を印刷によって配置する工程と、電子部品の裏面と前記樹脂が印刷された前記配線基板の樹脂配置面とを貼り合わせて前記電子部品を前記配線基板に固定する工程を含む構成とする。
　本発明によると、樹脂の外縁線が位置している配線の部分が断線しにくくなるため、耐久性の高い電子機器及び当該電子機器の製造方法を実現することができる。
電子部品を配線基板に固定する前の状態における本発明の第１実施形態に係る電子機器を示す平面図である。 電子部品を配線基板に固定する前の状態における本発明の第１実施形態に係る電子機器を示す断面図である。 電子部品を配線基板に固定した後の状態における本発明の第１実施形態に係る電子機器を示す平面図である。 電子部品を配線基板に固定した後の状態における本発明の第１実施形態に係る電子機器を示す断面図である。 電子部品を配線基板に固定した後の状態における比較例の電子機器を示す平面図である。 電子部品を配線基板に固定した後の状態における本発明の他の例に係る電子機器を示す平面図である。 配線基板側に樹脂を設けてから電子機器を配線基板に固定する場合の電子部品を配線基板に固定する前の状態における本発明のさらに他の例に係る電子機器を示す平面図である。 配線基板側に樹脂を設けてから電子機器を配線基板に固定する場合の電子部品を配線基板に固定する前の状態における本発明のさらに他の例に係る電子機器を示す断面図である。 電子部品を配線基板に固定する前の状態における本発明の第２実施形態に係る電子機器を示す平面図である。 本発明の第３実施形態に係る電子機器が備える裏面電極型太陽電池セルの模式的な縦断面図である。 本発明の第３実施形態に係る電子機器が備える配線基板の模式的な縦断面図である。 ３つのセル配置部を備える配線基板の一例を示す模式的な平面図である。
　本発明の実施形態について図面を参照して以下に説明する。
＜第１実施形態＞
　図１は、電子部品を配線基板に固定する前の状態における本発明の第１実施形態に係る電子機器を示す平面図である。また、図２は、電子部品を配線基板に固定する前の状態における本発明の第１実施形態に係る電子機器を示す電子部品の裏面と配線基板の表面とを対向させた状態での図１のＡ－Ａ断面での断面図である。
　図３は、電子部品を配線基板に固定した後の状態における本発明の第１実施形態に係る電子機器を示す平面図である。また、図４は、電子部品を配線基板に固定した後の状態における本発明の第１実施形態に係る電子機器を示す図３のＡ－Ａ断面での断面図である。なお、図３においては、電子部品２の本体などで隠れている配線４及び樹脂６の外縁線を点線で示している。
　本発明の第１実施形態に係る電子機器は、裏面に電極１を備えた電子部品２と、絶縁性可撓基材３の表面に配線４を形成した配線基板５とを含んでいる。
　本発明の第１実施形態に係る電子機器は、例えば、図１及び図２に示すように、電子部品２の裏面に絶縁性の樹脂６を印刷によって配置し、電子部品２の裏面に電極１を覆うように半田などの導電性材料７を配置する。なお、隣接する電極１同士が導電性材料７によって導通することを防止するために、樹脂６が導電性材料７を囲むようにしている。
　導電性材料７の融点温度以上の温度条件下で、樹脂６が印刷された電子部品２の樹脂配置面（裏面）と配線基板５の配線面（表面）とを貼り合わせて電子部品２を配線基板５に固定すると、図１及び図２の状態から導電性材料７が変形して図３及び図４の状態になる。
　図３から分かるように、樹脂６の外縁形状は、配線４上に位置する部分において角部を有している。このように、樹脂６の外縁形状が配線４上に位置する部分において角部を有していることで、角部を境に少なくとも２方向以上からの応力（例えば図３に示すσ１及びσ２）が樹脂６の外縁線が位置している配線４の部分にかからない限り、配線４が完全に断線することはないので、配線４の断線が起きにくくなる。
　また、樹脂６の外縁形状が配線４上に位置する部分において角部を有していることで、配線４上に位置する樹脂６の外縁線の長さが長くなり、単位長当たりにかかる応力を減少させることができ、配線４の断線が起きにくくなる。さらに、本実施形態のように、配線４は帯状であり、樹脂６の外縁形状が配線４の幅方向の中央部上に位置する部分において角部を有するようにすることで、角部を境とした２つの樹脂６の外縁線の長さを概ね等しくすることができ、断線に対して弱くなる応力の方向ができにくくなる。
　上記の通り、樹脂６の外縁形状が配線４上に位置する部分において角部を有していることで、本発明の第１実施形態に係る電子機器の耐久性が向上する。
　これに対して、図５に示す比較例のように、樹脂６の外縁形状が配線４上に位置する部分において角部を有していなければ、１方向からの応力（例えば図５に示すσ３）が樹脂６の外縁線が位置している配線４の部分にかかっても、配線４が完全に断線するおそれがあるので、配線４の断線が起きやすくなる。
　なお、本発明に係る電子機器では、前記樹脂の外縁形状が配線上に位置する部分において有する角部の角度を９０度以下とする。本実施形態では、図３に示すように６０度としている。
　角部の角度が例えば９０度である場合には、配線４上の樹脂６の外縁線を成す一辺に対して配線４を伸縮させる方向と配線４上の樹脂６の外縁線を成す他の辺とが平行になるため、配線４上の樹脂６の外縁線を成す一辺に対して配線４を伸縮させる方向の応力は、配線４上の樹脂６の外縁線を成す他の辺に対しては配線を伸縮させる方向の応力にはならず、配線４上の樹脂６の外縁線を成す２つの辺が位置する部分が断線することを効果的に抑制できる。さらに、角部の角度を９０度よりも小さい角度とすれば、配線４上の樹脂６の外縁線を成す一辺に対して配線４を伸縮させる方向の応力が、配線４上の樹脂６の外縁線を成す他方の辺に対して配線４を伸縮させる方向の応力の一部を打ち消すことになり、様々な方向から配線４にかかり得る応力に対して、配線４上の樹脂６の外縁線を成す２つの辺が位置する部分が断線することを効果的に抑制できる。さらに、角部の角度を９０度よりもより小さい角度とすることで、配線４上に位置する樹脂６の外縁線の長さをより長くすることができるので、配線４の単位長当たりにかかる応力を減少させることができ、配線４の断線が起きにくくなる。たとえば、図３に示す配線４上に位置する樹脂６の外縁線の長さは、図５に示す配線４上に位置する樹脂６の外縁線の長さに比べて、２倍とすることができる。実際に、本発明に係る電子機器と図５に示す比較例とに対して冷熱温度サイクル試験を実施したところ、図５に示す比較例では一部のサンプルで配線４が完全に断線したのに対し、本発明に係る電子機器では配線４が完全に断線したサンプルはなかった。
　また、本発明に係る電子機器では、樹脂６の外縁線と配線４の外縁線とが斜めに交差することが望ましい。角部の角度が９０度以下であり、角部を境とした２つの樹脂６の外縁線の長さを概ね等しくするために、樹脂６の外縁形状が配線４の幅方向の中央部上に位置する部分において角部を有するようにして、さらに角部を配線４の幅方向に対して左右対称にすることが望ましいことから、樹脂６の外縁線と配線４の外縁線との交差角度であって、配線４上に樹脂６が配置されていない部分の交差角度が４５度以下であることがより望ましい。本実施形態では、樹脂６の外縁線と配線４の外縁線との交差角度であって、配線４上に樹脂６が配置されていない部分の交差角度が図３に示すように３０度である。
　樹脂６の外縁線と配線４の外縁線とが交差する部分にかかるせん断応力によって配線４の外縁線に切れ目や裂け目が発生する可能性があるが、樹脂６の外縁線と配線４の外縁線とが斜めに（非直角で）交差することで、せん断応力が樹脂６の外縁線と配線４の外縁線とが交差する部分にかかっても、交差する部分の配線６の断面積が他の配線６の断面積よりも小さくなることから、交差する部分の配線６が他の配線６の部分よりも変形しやすくなり、その変形によって樹脂６の外縁線と配線４の外縁線とが交差する部分にかかるせん断応力を吸収しやすくなるため、切れ目や裂け目を発生しにくくすることができる。このため、本発明の第１実施形態に係る電子機器は、図６に示す例に比べて、せん断応力が配線４にかかる場合に樹脂６の外縁線と配線４の外縁線とが交差する部分に切れ目や裂け目を発生しにくい。一方で、図６に示す例では、配線４上に位置する樹脂６の外縁形状が複数の角部を有している。このようにすることで、複数の角部を境に少なくともさらに多方向からの応力に対して、配線４が完全に断線することを防ぐことが出来る。したがって、配線４上に位置する樹脂６の外縁形状において、角部を配置する数や形状、そして、樹脂６の外縁線と配線４の外縁線とが交差する角度は、配線４にかかる応力の方向と強度や、配線４の弾性率や加工硬化のしやすさ等から、適宜決めればよい。また、配線４上に位置する樹脂６の外縁形状が複数の角部を有しながら、樹脂６の外縁線と配線４の外縁線とが斜めに交差するようにするために、図６に示す例のさらなる変形例として、配線４上に位置する樹脂６の外縁形状が、Ｗ字状などとすることもできる。
　１つの配線基板に複数の電子機器を配置するような場合には、配線基板のサイズが大きくなり配線基板に一度に樹脂を位置精度良く配置することが難しいので、本実施形態のように電子機器側に樹脂を設けてから電子機器を配線基板に固定することが望ましい。
　一方、配線基板に樹脂を配置する位置精度に問題がなければ、本実施形態とは異なり、配線基板側に樹脂を設けてから電子機器を配線基板に固定してもよい。
　図７は、この場合の電子部品を配線基板に固定する前の状態における本発明のさらに他の例に係る電子機器を示す平面図である。また、図８は、この場合の電子部品を配線基板に固定する前の状態における本発明のさらに他の例に係る電子機器を示す電子部品の裏面と配線基板の表面とを対向させた状態での図７のＡ－Ａ断面での断面図である。
　また、この場合、例えば、樹脂の形状パターンを画像認識しながら電子部品を配線基板上の所定の位置に配置することができる。すなわち、樹脂の形状パターンを位置合わせに用いることができる。
＜第２実施形態＞
　図９は、電子部品を配線基板に固定する前の状態における本発明の第２実施形態に係る電子機器を示す平面図である。
　本発明の第２実施形態に係る電子機器は、樹脂６の角部が弧状に形成されており、樹脂６の角部と角部とを繋ぐ連結部分が弧状に形成されている点で、本発明の第１実施形態に係る電子機器と異なっている。本発明の第１実施形態に係る電子機器のように角部が尖っていると、その箇所に応力が集中しやすくなり、角部を起点として配線が裂けやすくなる可能性がある。これに対して、本実施形態に係る電子機器のように角部を弧状にすることで、角部への応力集中を防止できるので、配線４の断線をより抑制できる。
＜第３実施形態＞
　電子部品２は、基板にバンプ接続される集積回路チップなどであっても構わないが、本実施形態では、電子部品２を裏面電極型太陽電池セルにする。図１０は、本実施形態の電子機器が備える裏面電極型太陽電池セル２０の模式的な縦断面図である。
　裏面電極型太陽電池セル２０は、例えばｎ型またはｐ型の導電型を有するシリコン基板などの半導体基板２１と、裏面電極型太陽電池セル２０の受光面となる半導体基板２１の凹凸形状の表面上に形成される反射防止膜２２と、裏面電極型太陽電池セル２０の裏面となる半導体基板２１の裏面上に形成される絶縁膜２３と、第１導電型用電極２４と、第２導電型用電極２５とを備えている。第１導電型及び第２導電型は、いずれか一方をｐ型とし、他方をｎ型にするとよい。また、絶縁膜２３はパッシベーション膜としての機能を有していても良い。
　半導体基板２１の裏面には、第１導電型不純物が拡散して形成された第１導電型不純物拡散領域２６と、第２導電型不純物が拡散して形成された第２導電型不純物拡散領域２７とが所定の間隔を空けて交互に形成されている。第１導電型用電極２４と第１導電型不純物拡散領域２６とは絶縁膜２３に設けられたコンタクトホールを介して接続されている。同様に、第２導電型用電極２５と第２導電型不純物拡散領域２７とは絶縁膜２３に設けられたコンタクトホールを介して電気的に接続されている。
　本実施形態では、配線基板を配線シートにする。図１１は、本実施形態の電子機器が備える配線シート５０の模式的な縦断面図である。
　配線シート５０は、絶縁性可撓基材５１と、絶縁性可撓基材５１の表面上に配置された第１配線５２及び第２配線５３とを備えている。第１配線５３は第１導電型用電極２４に対応しており、第２配線５３は第２導電型用電極２５に対応している。このように、絶縁性可撓基材の表面上に配線を備えた配線シートでは、温度変化によって絶縁性可撓基材が伸縮するため、絶縁性可撓基材が伸縮する際の応力が樹脂の外縁部に位置する配線にかかる可能性が高い。したがって、上記の実施形態を配線シートに適用することで、配線の断線を効果的に防止できる。
　なお、樹脂６の外縁形状、導電性材料７などについては、第１実施形態あるいは第２実施形態と同様にすればよいので、ここでは説明を省略する。
＜その他＞
　以上、本発明の実施形態につき説明したが、本発明の範囲はこれに限定されるものではなく、発明の主旨を逸脱しない範囲で種々の変更を加えて実施することができる。
　上述した実施形態では、１つの配線基板に対して１つの電子部品を固定する形態であったが、当然の事ながら、１つの配線基板に対して複数の電子部品を固定する形態であってもよい。例えば、１つの配線シートに３つの裏面電極型太陽電池セルを接続する場合には、配線シートを図１２に示す例のように３つのセル配置部２５を備える構成とする。この場合、裏面電極型太陽電池セル（電子部品の一例）の表面側から見て、隣接する前記裏面電極型太陽電池セル同士の間に、すなわち、隣接するセル配置部５４同士の間に配線シートの配線が形成されている部分が存在する。当該部分の配線の両側には、セル配置部５４において樹脂の外縁線が配線上に位置する部分に存在するため、上述した実施形態のように片側のみに樹脂の外縁線が配線上に位置する部分に存在する場合に比べて、断線の可能性が高くなるので、断線を抑制する本発明の適用がより一層効果的である。
　　　１　電極
　　　２　電子部品
　　　３　絶縁性可撓基材
　　　４　配線
　　　５　配線基板
　　　６　樹脂
　　　７　導電性材料
　　　２０　裏面電極型太陽電池セル
　　　２１　半導体基板
　　　２２　反射防止膜
　　　２３　絶縁膜
　　　２４　第１導電型用電極
　　　２５　第２導電型用電極
　　　２６　第１導電型不純物拡散領域
　　　２７　第２導電型不純物拡散領域
　　　５０　配線シート
　　　５１　絶縁性可撓基材
　　　５２　第１配線
　　　５３　第２配線
　　　５４　セル配置部

Claims (8)

  1. 　裏面に電極を備えた電子部品と、
    　絶縁性可撓基材の表面に配線を形成した配線基板とを含む電子機器であって、
    　前記電子部品は前記配線基板に絶縁性の樹脂によって固定されており、
    　前記樹脂の外縁形状は、前記配線上に位置する部分において角度が９０度以下である角部を有している、電子機器。
  2. 　前記樹脂の外縁線と前記配線の外縁線とが斜めに交差する、請求項２に記載の電子機器。
  3. 　前記配線は帯状であり、
    　前記樹脂の外縁形状は、前記配線の幅方向の中央部上に位置する部分において前記角部を有している、請求項１または請求項２に記載の電子機器。
  4. 　前記角部が弧状に形成されている、請求項１～３のいずれか１項に記載の電子機器。
  5. 　前記樹脂の全てが前記電子部品の裏面の領域内に配置されている、請求項１～４のいずれか１項に記載の電子機器。
  6. 　前記電子部品を複数備え、
    　前記電子部品の表面側から見て、隣接する前記電子部品同士の間に前記配線基板の前記配線が形成されている部分が存在する、請求項５に記載の電子機器。
  7. 　請求項１～６のいずれか１項に記載の電子機器の製造方法であって、
    　電子部品の裏面に樹脂を印刷によって配置する工程と、
    　前記樹脂が印刷された前記電子部品の樹脂配置面と絶縁性可撓基材の表面に配線を形成した配線基板の配線面とを貼り合わせて前記電子部品を前記配線基板に固定する工程とを含む、電子機器の製造方法。
  8. 　請求項１～６のいずれか１項に記載の電子機器の製造方法であって、
    　絶縁性可撓基材の表面に配線を形成した配線基板の配線面に樹脂を印刷によって配置する工程と、
    　電子部品の裏面と前記樹脂が印刷された前記配線基板の樹脂配置面とを貼り合わせて前記電子部品を前記配線基板に固定する工程を含む、電子機器の製造方法。
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