WO2014068614A1 - 樹脂基板を用い、電気鋳造によりコイル素子を製造する方法 - Google Patents
樹脂基板を用い、電気鋳造によりコイル素子を製造する方法 Download PDFInfo
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- WO2014068614A1 WO2014068614A1 PCT/JP2012/006962 JP2012006962W WO2014068614A1 WO 2014068614 A1 WO2014068614 A1 WO 2014068614A1 JP 2012006962 W JP2012006962 W JP 2012006962W WO 2014068614 A1 WO2014068614 A1 WO 2014068614A1
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- Prior art keywords
- coil element
- coil
- pattern
- resin substrate
- substrate
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- 239000000758 substrate Substances 0.000 title claims abstract description 52
- 239000011347 resin Substances 0.000 title claims abstract description 25
- 229920005989 resin Polymers 0.000 title claims abstract description 25
- 238000005323 electroforming Methods 0.000 title claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 17
- 239000002184 metal Substances 0.000 claims abstract description 11
- 229910052751 metal Inorganic materials 0.000 claims abstract description 11
- 238000005530 etching Methods 0.000 claims abstract description 9
- 239000011248 coating agent Substances 0.000 claims abstract description 4
- 238000000576 coating method Methods 0.000 claims abstract description 4
- 239000004020 conductor Substances 0.000 claims description 45
- 230000005684 electric field Effects 0.000 claims description 6
- 239000010408 film Substances 0.000 description 30
- 238000007747 plating Methods 0.000 description 17
- 230000000712 assembly Effects 0.000 description 8
- 238000000429 assembly Methods 0.000 description 8
- 239000010949 copper Substances 0.000 description 7
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 229910052802 copper Inorganic materials 0.000 description 5
- 239000012212 insulator Substances 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009713 electroplating Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000007788 roughening Methods 0.000 description 2
- 229910000679 solder Inorganic materials 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000007772 electroless plating Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 238000002054 transplantation Methods 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
- H01F17/0013—Printed inductances with stacked layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/041—Printed circuit coils
Definitions
- the present invention relates to a method of manufacturing a coil element by electroforming (also referred to as electroplating) using a resin substrate.
- Patent Document 1 describes a method of forming a thin film conductor having a predetermined pattern.
- a patterned plating mask layer is provided on a plating base conductive film covering an insulator, and a plating film is formed by a first plating step so as to fill a non-mask portion of the plating mask layer.
- the plating mask layer from which the plating mask layer is exposed is removed, and the surface of the plating film is covered and thickened by the second plating step, thereby narrowing the conductor pattern interval. It is.
- Patent Document 2 a plating resist pattern is formed on a substrate, a coiled coiled conductor is formed by electroforming, the plating resist pattern is removed, and then transferred onto a sheet-like magnetic layer.
- a plurality of coiled coiled conductors are connected through through holes provided in a sheet-like magnetic layer.
- Patent Document 1 relates to a method of forming a coil component integrally with an insulator without being peeled off from the insulator, and the coil component is peeled off from the insulator and transferred by transfer. Is not intended to produce. Accordingly, no consideration is given to measures for preventing the conductor pattern from falling or falling off due to peeling transfer.
- Patent Document 2 The method described in Patent Document 2 is to peel a conductor pattern from a substrate and form a coiled plated conductor by transfer. By appropriately roughening the substrate surface, the adhesion of the plating resist pattern is improved. It is only described that the effect of preventing the release of the conductor pattern in the peeling process of the plating resist pattern is secondaryly improved, and it is possible to positively prevent the conductor pattern from falling or falling off due to peeling / transfer. There is no description about. Thus, in the conventional method for manufacturing a coil component, the problem of preventing the conductor pattern from falling or dropping due to the peeling / transfer of the conductor pattern has not been solved.
- the present invention has been made in order to solve the above-mentioned problems, and manufactured a coil component having a high aspect conductor pattern while preventing the conductor pattern from falling or falling off due to peeling / transfer of the conductor pattern from the substrate.
- the purpose is to do.
- Means in the present invention is a method of manufacturing a coil element by electroforming using a resin substrate, and in order to prevent the coil element from overturning or falling off, forming a groove on the substrate surface of the resin substrate; Forming a metal film to be a seed layer so as to cover the resin substrate on which the groove is formed, and a resist pattern that is a reversal pattern of the coil element pattern for forming a desired aspect ratio of the coil element.
- the means of the present invention is characterized by further comprising the step of transplanting the coil element peeled from the resin substrate onto a component substrate.
- a groove is formed on the substrate surface of the resin substrate, and the central conductor film of the coil element is formed on the substrate surface including the groove. Therefore, a high aspect coil element can be manufactured without causing the conductor pattern to be broken.
- the figure which shows the preparation processes of the coil element by this invention The top view of the coil element aggregate
- FIG. 1 is a diagram showing a manufacturing process of a coil element according to the present invention.
- a resin substrate is used, and a coil element is manufactured on this substrate.
- the coil element formed on the resin substrate is peeled off from the resin substrate by transfer, and the resin substrate after peeling the coil element is not used again. Therefore, such a resin substrate is called a consumable mold. Can do.
- a resin substrate 100 is prepared, and a groove 102 is formed on the substrate surface in order to prevent a coil element formed on the resin substrate 100 from falling or dropping in a later step.
- the shape of the groove 102 is not particularly limited, and a plurality of grooves having an arbitrary shape may be formed. However, merely roughening the surface of the substrate has a small effect of preventing overturning or falling off, and thus it is necessary to form a groove having a sufficient level difference.
- a metal film 104 serving as a seed layer is formed so as to cover the surface of the resin substrate on which the groove 102 is formed.
- the metal coating 104 can be formed by electroless plating with copper, nickel, or the like, or by vapor deposition.
- a resist pattern 106 which is a reversal pattern of the coil element pattern, for forming a desired aspect ratio of the coil element is formed on the substrate surface with the groove 102 interposed therebetween so as to have a desired thickness T.
- the pattern density can be further improved by making the side wall of the resist pattern 106 overlap with the substrate surface.
- this resist pattern 106 is used as a mask, for example, copper (Cu) is electrodeposited by electroforming, so that the central conductor film 108 of the coil element is formed on the surface of the substrate including the groove 102 so as to have a height t equal to or less than the thickness T. Form.
- the height t is controlled in this way to prevent the center conductor film 108 from overhanging the center conductor film 108 when the center conductor film 108 is electrodeposited beyond the thickness T of the resist pattern 106. It is.
- the resist pattern 106 is removed, and the exposed metal film 104 is also removed as shown in FIG. 1c.
- the coil element 112 is transferred to the component substrate 200 by transfer, or simply peeled off from the resin substrate and taken out as shown in FIG. 1f.
- it may be transplanted to the component substrate 200 via an adhesive, or may be transplanted to a green sheet (not shown) without using an adhesive.
- a portion 108a formed in the groove 102 in the central conductor film 108 protrudes into the shape of the groove. Therefore, reverse electric field etching is performed to remove this portion 108a.
- the reverse electric field etching is a process in which the electric field direction is reversed and the plated metal is removed by reverse etching.
- the etching rate is increased and etching is selectively performed.
- the coil element 112 having a uniform shape and no protrusion is formed. In this way, a coil component with an arbitrary aspect ratio and a narrow pattern interval can be manufactured.
- FIG. 2 is a plan view of a coil element assembly 1000 manufactured according to the present invention.
- the mold substrate for producing the coil element assembly 1000 has the same shape as this shape.
- a rib 502, a gate 504, and a runner 506 are provided.
- Holes 508 are provided at the four corners of the rib 502, and the positions of the conductor patterns of the coil elements 500m and n formed in each layer of the plurality of coil element assemblies 1000 using the pins 510 penetrating the holes 508. Align.
- a plurality of coil element assemblies 1000-1, 1000-2,... 1000-N are aligned via pins 510 so that corresponding coil elements in each coil element assembly are aligned with each other.
- the tin plating constituting the bonding film is melted and acts as solder to join the coil elements of the respective layers.
- FIG. 4 is a diagram for explaining that a plurality of coil element assemblies are stacked and the coil elements of each layer are connected to form a coil.
- FIG. 4 a case where six coil element assemblies are stacked and the coil elements in each layer are connected to each other to produce one coil is shown.
- Corresponding coil elements in the plurality of coil element assemblies can be configured to include different coil patterns.
- the first layer (Layer 1), the third layer (Layer 3), and the sixth layer (Layer 6) have different coil patterns, respectively, and the second layer (Layer 2) and The fourth layer (Layer 4) has the same coil pattern, and the third layer (Layer 3) and the fifth layer (Layer 5) have the same coil pattern.
- (B) and (C) six layers of coil element assemblies were laminated, joined so that corresponding coil elements in each layer were aligned, and the coil elements were connected to form one coil. It shows the state.
- the connecting portions of the respective layers have different heights.
- the height (H) is 100 ⁇ m in the normal coil element pattern, but the height (H) is 150 ⁇ m in the connection portion between the layers.
- Such coil patterns with different heights (H) are produced in the same layer by increasing the depth of the etching pattern formed in the transfer mold at the connection portion, and a special copper plating solution for field vias. By using this, it is possible to selectively fill the deepened portion, or to perform copper plating using the mask twice.
- the upper core of the magnetic body having the protruding portion 604 penetrating the central portion of the coil as shown in FIG. Using 600 and the lower core 602, the electrode lead-out portion 606 is exposed to the outside to seal the coil.
- the upper core 600 and the lower core 602 are attached so as to avoid the gate 504 for pattern reinforcement shown in FIG.
- the upper core 600 and the lower core 602 are cut along the dicing line 608 in a subsequent dicing process.
- an insulating material 612 is filled from a gap (not shown) between the upper core 600 and the lower core 602, and the coil is fixed.
- the laminated coil element assemblies are cut using a cutter 700 in units of coils.
- (A) shows a coil element assembly
- (B) shows one coil component
- the electrode lead-out portion 606 is formed as a part of the first layer (Layer 1).
- the external electrode 610 is attached to the electrode lead-out portion 606 by a method such as a solder dipping method, and soldering is performed as a pretreatment for subsequent soldering to complete the coil component 3000. .
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- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Electrochemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coils Or Transformers For Communication (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
- Parts Printed On Printed Circuit Boards (AREA)
Abstract
Description
また、コイルパターン幅が細く、かつ厚さの大きい、いわゆるハイアスペクトの導体パターンを持ったコイル部品の必要性も高い。
この方法は、絶縁体を被覆するメッキ用下地導電膜上にパターン化されためっき用マスク層を設け、このメッキ用マスク層の非マスク部分を埋めるように、第1のメッキ工程により、メッキ膜を設け、次いで、メッキ用マスク層を露出したメッキ用マスク層とを除去し、第2のメッキ工程により前記メッキ膜の表面を被覆して太らせることにより、導体パターン間隔を狭めるようにしたものである。
従って、剥離転写に伴う導体パターンの転倒又は脱落を防止することについての対策については何等考慮されていない。
このように従来のコイル部品の製造方法においては、導体パターンの剥離・転写に伴う導体パターンの転倒又は脱落を防止するという課題が解決されていなかった。
本発明における手段は、樹脂基板を用い、電気鋳造によりコイル素子を製造する方法であって、前記コイル素子の転倒又は脱落を防止するため、前記樹脂基板の基板表面に溝部を形成するステップと、前記溝部の形成された前記樹脂基板を覆うようにシード層となる金属被膜を形成するステップと、前記コイル素子の所望のアスペクト比を形成するための、コイル素子パターンの反転パターンであるレジストパターンを所望の厚さTとなるよう前記溝部を挟んで前記基板表面に形成するステップと、前記レジストパターンをマスクに、第1の電気鋳造により前記コイル素子の中心導体膜を前記所望の厚さT以下の高さtとなるよう前記溝部を含む前記基板表面に形成するステップと、前記レジストパターンと露出した前記金属被膜とを除去するステップと、前記中心導体膜を下地として第2の電気鋳造により表面導体膜を形成し、前記中心導体膜と前記表面導体膜とからなる前記コイル素子を形成するステップと、前記コイル素子を前記樹脂基板から剥離するステップと、剥離された前記コイル素子の前記中心導体膜の内、前記溝部内に形成された部分を逆電界エッチングにより除去するステップと、を有することを特徴とする。
図1は、本発明によるコイル素子の作製工程を示す図である。
本発明では、樹脂基板を用い、この基板上にコイル素子を製造する。
この樹脂基板上に形成されたコイル素子は、樹脂基板から転写によって剥離され、コイル素子剥離後の樹脂基板は再び使用されることはないので、このような樹脂基板は消耗型金型と呼ぶことができる。
しかし、基板表面を単に粗面加工するだけでは、転倒又は脱落防止効果が薄いため、十分な段差のある溝部を形成する必要がある。
ついで、図1bに示すように、レジストパターン106を除去し、露出した金属被膜104も図1cに示すように除去する。
この処理は、太らせめっきとも呼ばれ、これにより中心導体膜108と表面導体膜110とからなるコイル素子112のパターン間隔を狭めることができる。ついで、図1eに示すように、コイル素子112は部品基板200に転写により移植されるか、あるいは、図1fに示すように、単に樹脂基板から剥離されて取り出される。なお、転写による移植に際しては、接着剤を介して部品基板200に移植しても良いし、接着剤を介さずグリーンシート(図示しない)に移植しても良い。
そこで、この部分108aを除去するために逆電界エッチングを行う。
逆電界エッチングとは、電界方向を逆にし、めっきされた金属を逆エッチングして取り除く処理をいう。ここで部分108aには、他の部分に比較して電界が集中するため、エッチング速度が上がり、選択的にエッチングが行なわれる。
その結果、図1gに示すように、突出部がなく均一な形状のコイル素子112が形成される。
このようにして任意のアスペクト比を有するパターン間隔の細いコイル部品を作製することができる。
次に、このように作製されたコイル素子集合体を用いてコイル部品を作製する方法について説明する。後述するように、コイル部品はコイル素子集合体を複数枚積層して作製される。
そこで、各層のコイル素子同士を接合して接続するために、予めコイル素子の周囲に接合膜を形成しておく必要がある。
このような高さ(H)の異なるコイルパターンの同一層中での作製は、転写金型に形成される食刻パターンの深さを接続部分において深くし、フィールドビア用の特殊な銅めっき液を用いることで、深くなった部分を、選択的に充填めっきを行ったり、マスクを2回用いて銅めっきを行ったりすることで実現できる。
最後に、図8に示すように、電極引出し部606にはんだディップ法などの方法により、外部電極610を取付け、その後のはんだ付けのための前処理としてはんだ上げを行い、コイル部品3000を完成する。
102:溝部
104:金属被膜
106:レジストパターン
108:中心導体膜
108a:中心導体膜の内、溝部に形成された部分
110:表面導体膜
112:コイル素子
200:部品基板
Claims (2)
- 樹脂基板を用い、電気鋳造によりコイル素子を製造する方法であって、
前記コイル素子の転倒又は脱落を防止するため、前記樹脂基板の基板表面に溝部を形成するステップと、
前記溝部の形成された前記樹脂基板を覆うようにシード層となる金属被膜を形成するステップと、
前記コイル素子の所望のアスペクト比を形成するための、コイル素子パターンの反転パターンであるレジストパターンを所望の厚さTとなるよう前記溝部を挟んで前記基板表面に形成するステップと、
前記レジストパターンをマスクに、第1の電気鋳造により前記コイル素子の中心導体膜を前記所望の厚さT以下の高さtとなるよう前記溝部を含む前記基板表面に形成するステップと、
前記レジストパターンと露出した前記金属被膜とを除去するステップと、
前記中心導体膜を下地として第2の電気鋳造により表面導体膜を形成し、前記中心導体膜と前記表面導体膜とからなる前記コイル素子を形成するステップと、
前記コイル素子を前記樹脂基板から剥離するステップと、
剥離された前記コイル素子の前記中心導体膜の内、前記溝部内に形成された部分を逆電界エッチングにより除去するステップと、を有することを特徴とする方法。 - 請求項1に記載の方法において、
前記樹脂基板から剥離した前記コイル素子を部品基板に移植するステップを更に有することを特徴とする方法。
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
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CN201280076724.3A CN104756211A (zh) | 2012-10-30 | 2012-10-30 | 使用树脂基板,通过电铸来制造线圈元件的方法 |
KR1020157014410A KR20150079935A (ko) | 2012-10-30 | 2012-10-30 | 수지 기판을 이용해 전기 주조에 의해 코일 소자를 제조하는 방법 |
JP2013513446A JP5294288B1 (ja) | 2012-10-30 | 2012-10-30 | 樹脂基板を用い、電気鋳造によりコイル素子を製造する方法 |
US14/438,960 US20150294789A1 (en) | 2012-10-30 | 2012-10-30 | Method for producing coil element using resin substrate and using electroforming |
PCT/JP2012/006962 WO2014068614A1 (ja) | 2012-10-30 | 2012-10-30 | 樹脂基板を用い、電気鋳造によりコイル素子を製造する方法 |
EP12887740.4A EP2916336A1 (en) | 2012-10-30 | 2012-10-30 | Method for producing coil element using resin substrate and using electroforming |
TW102132139A TW201435936A (zh) | 2012-10-30 | 2013-09-06 | 用樹脂基板並藉由電鑄造而製造線圈元件的方法 |
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Cited By (2)
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WO2020178944A1 (ja) * | 2019-03-04 | 2020-09-10 | 株式会社プリケン | コイル装置及び製造方法 |
JP2021002677A (ja) * | 2019-03-04 | 2021-01-07 | 株式会社プリケン | コイル装置 |
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KR20180133153A (ko) * | 2017-06-05 | 2018-12-13 | 삼성전기주식회사 | 코일 부품 및 그 제조방법 |
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KR101973448B1 (ko) | 2017-12-11 | 2019-04-29 | 삼성전기주식회사 | 코일 부품 |
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Also Published As
Publication number | Publication date |
---|---|
CN104756211A (zh) | 2015-07-01 |
EP2916336A1 (en) | 2015-09-09 |
TW201435936A (zh) | 2014-09-16 |
US20150294789A1 (en) | 2015-10-15 |
JP5294288B1 (ja) | 2013-09-18 |
KR20150079935A (ko) | 2015-07-08 |
JPWO2014068614A1 (ja) | 2016-09-08 |
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