WO2018097265A1 - 多層配線板の製造方法 - Google Patents
多層配線板の製造方法 Download PDFInfo
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- WO2018097265A1 WO2018097265A1 PCT/JP2017/042289 JP2017042289W WO2018097265A1 WO 2018097265 A1 WO2018097265 A1 WO 2018097265A1 JP 2017042289 W JP2017042289 W JP 2017042289W WO 2018097265 A1 WO2018097265 A1 WO 2018097265A1
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Definitions
- the present invention relates to a method for manufacturing a multilayer wiring board.
- multilayered printed wiring boards have been widely used.
- Such a multilayer printed wiring board is used for the purpose of weight reduction and size reduction in many portable electronic devices.
- the multilayer printed wiring board is required to further reduce the thickness of the interlayer insulating layer and further reduce the weight of the wiring board.
- a multilayer printed wiring board manufacturing method using a coreless build-up method has been adopted as a technology that satisfies such requirements.
- the coreless build-up method is a method called build-up method on a so-called core (core material), in which insulating layers and wiring layers are alternately stacked (build-up) to form a multilayer, and then the core (core material) is removed.
- core core material
- the wiring board is formed only with the build-up layer.
- Patent Document 1 Japanese Patent Application Laid-Open No.
- an insulating resin layer is attached to the carrier surface of a carrier-attached copper foil as a support, and a photoresist is processed on the ultrathin copper layer side of the carrier-attached copper foil.
- a process such as pattern electrolytic copper plating, resist removal, forming a build-up wiring layer, peeling a support substrate with a carrier, and removing an ultrathin copper layer.
- an RDL-First is formed by forming a wiring layer and, if necessary, a build-up wiring layer on the surface of the coreless support, and further peeling the support if necessary, and then mounting the chip. There is a method called (Redistribution Layer-First) method.
- Patent Document 2 Japanese Patent Application Laid-Open No. 2015-35551 discloses the formation of a metal peeling layer on the main surface of a support made of glass or silicon wafer, the formation of an insulating resin layer thereon, and the build on it. Formation of a redistribution layer including an up layer, mounting and sealing of a semiconductor integrated circuit thereon, exposure of the release layer by removing the support, exposure of the secondary mounting pad by removing the release layer, and A method of manufacturing a semiconductor device including formation of solder bumps on the surface of a secondary mounting pad and secondary mounting is disclosed.
- Patent Document 3 Japanese Patent Laid-Open No.
- Patent Document 4 Japanese Patent Laid-Open No. 2015-170767 discloses the formation of a release layer on a coreless support, the formation of a buried wiring layer and a buildup layer thereon, and the formation of a wiring board on the surface of the buildup layer.
- a circuit board manufacturing method including mounting, carrier peeling, and mounting of a semiconductor chip is disclosed.
- This release layer contains a composition that generates a gas due to the irradiation of ultraviolet rays, thereby making it possible to easily and easily remove the support substrate and remove the release layer without damaging the wiring layer. ing.
- Patent Document 5 Japanese Patent Laid-Open No. 2015-764757 discloses the formation of a first release layer on a support, the formation of a second release layer covering the first release layer, and the wiring on the second release layer.
- a method for manufacturing an electronic device which includes forming a resin layer, connecting a resin layer to a substrate, peeling a support by removing the first release layer and the second release layer, and connecting an electronic component on the resin layer.
- the first release layer is made of an alkali-soluble inorganic insulating material
- the second release layer is made of an alkali-insoluble inorganic material.
- the multilayer wiring layer can be reinforced so as not to be locally bent, thereby improving the connection reliability of the multilayer wiring layer and the flatness (coplanarity) of the surface of the multilayer wiring layer.
- the next issue is how to efficiently peel the reinforcing sheet adhered to the multilayer laminate by the adhesive release layer without applying excessive stress to the multilayer laminate.
- the manufacturing method of this invention it is a process flowchart which shows the process from preparation of a lamination sheet to lamination
- it is a process flowchart which shows the process from peeling of a base material to mounting of an electronic device.
- the antireflection layer is preferably composed of at least one metal selected from Cr, W, Ta, Ti, Ni and Mo. Since these metals have the property of not dissolving in the copper flash etching solution, they can exhibit excellent chemical resistance against the copper flash etching solution.
- Metal layer etching removal (optional process) If desired, the metal layer 16 is removed by etching before the reinforcing sheet 30 is peeled off, as shown in FIG. Etching of the metal layer 16 may be performed based on a known method such as flash etching.
- the multilayer laminate 26 is mounted on the surface opposite to the reinforcing sheet 30.
- the soluble pressure-sensitive adhesive layer 28 and the reinforcing sheet 30 excellent surface flatness (coplanarity) that is advantageous for mounting the electronic element 32 can be obtained. This can be realized on the surface of the build-up wiring layer including the wiring layer 18 as a buried electrode. That is, even when the electronic device 32 is mounted, the multilayer laminate 26 is not locally bent by the reinforcing sheet 30. As a result, the connection yield for mounting the electronic elements can be increased.
- the soluble adhesive layer 28 inherently has a higher peel strength than the release layer 14, the soluble adhesive layer 28 peels more than the release layer 14 unless special treatment is performed. It is difficult to do.
- the soluble adhesive layer 28 being dissolved or softened by contact or permeation with the dissolving solution, the adhesion between the multilayer laminate 26 and the reinforcing sheet 30 is weakened or neutralized. 30 can be easily peeled off.
- the resin include epoxy resin, aramid resin, polyimide resin, nylon resin, liquid crystal polymer, PEEK resin, polyimide resin, polyamideimide resin, polyethersulfone resin, polyphenylene sulfide resin, PTFE resin, ETFE resin and the like. It is done. More preferably, the coefficient of thermal expansion (CTE) is less than 25 ppm / K (preferably 1.0 to 23 ppm / K, more preferably 1 from the viewpoint of preventing warpage of the coreless support due to heating when mounting the electronic device. 0.0 to 15 ppm / K, more preferably 1.0 to 10 ppm / K).
- the substrate 12 is preferably made of a resin film, glass or ceramics, more preferably glass or ceramics, and particularly preferably glass.
- a glass sheet When glass is used as the substrate 12, it has advantages such as being light, having a low coefficient of thermal expansion, high insulation, being rigid and having a flat surface, so that the surface of the metal layer 16 can be made extremely smooth.
- the base material 12 when the base material 12 is glass, it has the surface flatness (coplanarity) advantageous at the time of electronic device mounting, and has chemical resistance in the desmear and various plating processes in the printed wiring board manufacturing process. There are advantages such as points.
- the thickness of the substrate 12 is preferably 100 to 2000 ⁇ m, more preferably 300 to 1800 ⁇ m, and still more preferably 400 to 1100 ⁇ m. When the thickness is within such a range, it is possible to reduce the thickness of the printed wiring board and reduce the warpage that occurs when mounting electronic components while ensuring an appropriate strength that does not hinder handling.
- the surface of the substrate 12 on the peeling layer 14 side (the adhesion metal layer side if present) has an arithmetic average roughness Ra of 0.1 to 70 nm, measured according to JIS B 0601-2001. It is preferably 0.5 to 60 nm, more preferably 1.0 to 50 nm, particularly preferably 1.5 to 40 nm, and most preferably 2.0 to 30 nm.
- the smaller the arithmetic average roughness the lower the average average roughness Ra on the surface of the metal layer 16 opposite to the release layer 14 (the outer surface of the metal layer 16).
- the laminated sheet 10 may have a close-contact metal layer and / or a release auxiliary layer on the surface of the base material 12 on the release layer 14 side, and preferably has the close-contact metal layer and the release auxiliary layer in this order.
- the adhesion metal layer provided as desired is preferably a layer composed of at least one metal selected from the group consisting of Ti, Cr and Ni, from the viewpoint of ensuring adhesion with the base material 12, It may be a pure metal or an alloy.
- the metal constituting the adhesion metal layer may contain inevitable impurities due to raw material components, film formation processes, and the like.
- the adhesion metal layer is preferably a layer formed by a vapor phase method such as sputtering.
- the adhesion metal layer is particularly preferably a layer formed by a magnetron sputtering method using a metal target because the uniformity of the film thickness distribution can be improved.
- the thickness of the adhesion metal layer is preferably 5 to 500 nm, more preferably 10 to 300 nm, still more preferably 18 to 200 nm, and particularly preferably 20 to 150 nm. This thickness is a value measured by analyzing the cross section of the layer with an energy dispersive X-ray spectrometer (TEM-EDX) of a transmission electron microscope.
- TEM-EDX energy dispersive X-ray spectrometer
- the peeling auxiliary layer is particularly preferably a layer formed by a magnetron sputtering method using a copper target from the viewpoint of improving the uniformity of the film thickness distribution.
- the thickness of the peeling assist layer is preferably 5 to 500 nm, more preferably 10 to 400 nm, still more preferably 15 to 300 nm, and particularly preferably 20 to 200 nm. This thickness is a value measured by analyzing the cross section of the layer with an energy dispersive X-ray spectrometer (TEM-EDX) of a transmission electron microscope.
- TEM-EDX energy dispersive X-ray spectrometer
- Carbon has low mutual diffusivity and reactivity with the base material 12 and is heated at a high temperature between the metal layer 16 (for example, a copper foil layer) and the bonding interface even when subjected to press working at a temperature exceeding 300 ° C. It is possible to prevent the metal bond from being formed and to maintain a state in which the substrate 12 is easily peeled and removed.
- This release layer 14 is also a layer formed by a vapor phase method such as sputtering, which suppresses excessive impurities in amorphous carbon, and continuous production with the formation of the adhesion metal layer and / or the release auxiliary layer described above. From the point of property etc., it is preferable.
- the thickness of the release layer 14 is preferably 1 to 20 nm, more preferably 1 to 10 nm. This thickness is a value measured by analyzing the cross section of the layer with an energy dispersive X-ray spectrometer (TEM-EDX) of a transmission electron microscope.
- TEM-EDX energy dispersive X-ray spectrometer
- the peel strength of the release layer 14 can be controlled by controlling the thickness of the release layer 14, selecting the composition of the release layer 14, and the like.
- a particularly preferable power feeding layer is a copper layer formed by a vapor phase method such as sputtering or vacuum deposition from the viewpoint of easily supporting fine pitch by ultrathinning, and most preferably a copper layer manufactured by sputtering. It is.
- the ultra-thin copper layer is preferably a non-roughened copper layer, but pre-roughening, soft etching treatment, cleaning treatment, oxidation treatment, as long as it does not hinder the formation of wiring patterns during printed wiring board production.
- the secondary roughening may be caused by the reduction treatment.
- the glossiness Gs (60 °) of the surface on the power feeding layer side of the antireflection layer is preferably 500 or less, more preferably 450 or less, still more preferably 400 or less, Particularly preferred is 350 or less, and most preferred is 300 or less.
- the lower limit of the glossiness Gs (60 °) is preferably as low as possible, and is not particularly limited. However, the glossiness Gs (60 °) on the surface of the antireflection layer on the power feeding layer side is actually 100 or more. More realistically, it is 150 or more.
- the specular gloss Gs (60 °) by image analysis of the roughened particles can be measured using a commercially available gloss meter in accordance with JIS Z 8741-1997 (mirror gloss-measurement method).
- the surface of the antireflection layer on the power feeding layer side is a metal whose projected area equivalent circle diameter determined by SEM image analysis is 10 to 100 nm. It is preferably composed of an aggregate of particles, more preferably 25 to 100 nm, still more preferably 65 to 95 nm.
- a projected area equivalent circle diameter can be measured by photographing the surface of the antireflection layer with a scanning electron microscope at a predetermined magnification (eg, 50000 times) and analyzing the obtained SEM image. Specifically, an arithmetic average value of the projected area equivalent circle diameter measured using commercially available image analysis type particle size distribution software (for example, Mactech-VIEW, manufactured by Mounttech Co., Ltd.) is adopted.
- the antireflection layer is composed of at least one metal selected from Cr, W, Ta, Ti, Ni and Mo, preferably at least one metal selected from Ta, Ti, Ni and Mo, and more Preferably it is at least one metal selected from Ti, Ni and Mo, most preferably composed of Ti. These metals may be pure metals or alloys. In any case, it is preferred that these metals are essentially unoxidized (essentially not metal oxides) because they exhibit a desirable dark color that improves visual contrast with Cu, specifically reflective
- the oxygen content of the prevention layer is preferably 0 to 15 atomic%, more preferably 0 to 13 atomic%, and still more preferably 1 to 10 atomic%.
- the metal has a property that it does not dissolve in the copper flash etching solution, and as a result, can exhibit excellent chemical resistance with respect to the copper flash etching solution.
- the thickness of the antireflection layer is preferably 1 to 500 nm, more preferably 10 to 300 nm, still more preferably 20 to 200 nm, and particularly preferably 30 to 150 nm.
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Abstract
Description
前記多層積層体の一方の面に可溶性粘着層を介して補強シートを積層する工程であって、前記補強シートと前記多層積層体とが対向する対向領域内に可溶性粘着層が形成されない非占有領域が存在する工程と、
前記可溶性粘着層を溶解可能な液体を前記非占有領域に浸入させて、前記可溶性粘着層を溶解又は軟化させる工程と、
前記補強シートを前記多層積層体から前記可溶性粘着層の位置で剥離して多層配線板を得る工程と、
を含む、多層配線板の製造方法が提供される。
本発明による多層配線板の製造方法は、(1)所望により用いられる積層シートの用意、(2)多層積層体の作製、(3)補強シートの積層、(4)所望により行われる基材の剥離、(5)所望により行われる金属層のエッチング除去、(6)所望により行われる第1配線層の表面処理、(7)所望により行われる電子素子の搭載、(8)可溶性粘着層の溶解又は軟化、及び(9)補強シートの剥離の各工程を含む。
所望により、図1(a)に示されるように、多層配線板を形成するためのベースとなる積層シート10を用意する。積層シート10は、基材12、剥離層14及び金属層16を順に備える。積層シート10は、いわゆるキャリア付銅箔の形態であってもよい。積層シート10の本発明の好ましい態様については後述するものとする。
図1(b)及び(c)に示されるように、配線層18及び絶縁層20を交互に形成して多層積層体26を作製する。図1(b)及び(c)に示される配線層18及び絶縁層20で構成される逐次積層構造は、ビルドアップ層ないしビルドアップ配線層と一般的に称されるものであるが、本発明の製造方法においては、一般的にプリント配線板において採用される公知のビルドアップ配線層の構成のみからなる多層積層体の形成方法のみならず、予め形成されたバンプ付の多層積層体の一部となる積層体を、絶縁性接着剤を介して積層する方法等も採用することができ、特に限定されない。
図1(d)に示されるように、多層積層体26の一方の面(例えば多層積層体26の積層シート10と反対側の表面)に可溶性粘着層28を介して補強シート30を積層する。これにより、多層積層体26は補強シート30によって局部的に大きく湾曲されないように補強されることができる。すなわち、剥離時や湾曲が効果的に防止ないし抑制される。こうして、湾曲により引き起こされることがあるビルドアップ配線層内部の配線層の断線や剥離を回避して、多層配線層の接続信頼性を向上することができる。また、湾曲が効果的に防止ないし抑制されることで、多層配線層表面の平坦性(コプラナリティ)を向上することができる。
積層シート10を用いる場合、図2(e)に示されるように、補強シート30の積層後で、かつ、補強シート30の剥離前に、基材12を金属層16から剥離層14で剥離するのが好ましい。すなわち、基材12、密着金属層(存在する場合)、剥離補助層(存在する場合)、及び剥離層14が剥離除去される。この剥離除去は、物理的な剥離により行われるのが好ましい。物理的分離法は、手や治工具、機械等で基材12等をビルドアップ配線層から引き剥がすことにより分離する手法である。このとき、可溶性粘着層28を介して密着した補強シート30が多層積層体26を補強していることで、多層積層体26が局部的に大きく湾曲するのを防止することができる。すなわち、補強シート30は、基材12が剥離される間、引き剥がし力に抗すべく多層積層体26を補強し、湾曲をより一層効果的に防止ないし抑制することができる。こうして、湾曲により引き起こされることがあるビルドアップ配線層内部の配線層の断線や剥離を回避して、多層配線層の接続信頼性を向上することができる。また、湾曲が効果的に防止ないし抑制されることで、多層配線層表面の平坦性(コプラナリティ)を向上することができる。
所望により、図2(f)に示されるように、補強シート30の剥離前に、金属層16をエッチングにより除去する。金属層16のエッチングは、フラッシュエッチング等の公知の手法に基づき行えばよい。
上記工程の後、必要に応じて、第1配線層18の表面には、ソルダ―レジスト層、表面金属処理層(例えば、OSP(Organic Solderbility Preservative)処理層、Auめっき層、Ni-Auめっき層等)、電子素子搭載用の金属ピラー、及び/又ははんだバンプ等が形成されていてもよい。
所望により、図2(g)に示されるように、補強シート30の積層後(或いは金属層16の除去又はその後の電気検査後)で、かつ、補強シート30の剥離前に、多層積層体26の補強シート30と反対側の表面に電子素子32を搭載させる。本発明の製造方法においては、可溶性粘着層28及び補強シート30を採用することで、電子素子32の搭載に有利となる優れた表面平坦性(コプラナリティ)を多層積層体26の表面(例えば第1配線層18を埋込み電極として含むビルドアップ配線層の表面)において実現することができる。すなわち、電子素子32の搭載時においても、多層積層体26は補強シート30によって局部的に大きく湾曲されずに済む。その結果、電子素子搭載の接続歩留まりを高くすることができる。
可溶性粘着層28を溶解可能な液体を非占有領域Uに浸入させて、可溶性粘着層28を溶解又は軟化させる。軟化は、典型的には、可溶性粘着層28の膨潤によって実現されうる。前述のとおり、溶解液は可溶性粘着層28を溶解可能な液体を用いているため、可溶性粘着層28は溶解液と接触することで少なくとも部分的に溶解し、それによって可溶性粘着層28に溶解液が浸透しうる。そして、かかる溶解液との接触又は浸透は、可溶性粘着層28の溶解又は軟化をもたらし、多層積層体26と補強シート30との密着力を弱める又は無力化する。こうして、次の工程における補強シート30の剥離を、溶解剥離又はそれに準じた手法を用いて、極めて容易に行うことができる。すなわち、役目を果たした補強シート30の剥離を多層積層体26に与える応力を最小化しながら極めて短時間で行うことができる。
図3(h)及び(i)に示されるように、補強シート30を多層積層体26から可溶性粘着層28の位置で剥離して多層配線板40を得る。補強シート30は可溶性粘着層28の溶解又は軟化に起因して極めて剥離しやすい状態となっている(又は場合によっては部分的に自然剥離している)ため、手や治工具、機械等で補強シート30を多層積層体26から軽く引き剥がすことにより極めて容易に分離することができる。したがって、多層積層体26に与える応力を最小化しながら極めて短時間で補強シート30の剥離を行うことができる。こうして多層積層体26に加わる応力が最小化されることで、多層配線板40における配線の断線や実装部の断線を効果的に回避することができる。また、上記応力の低減のために可溶性粘着層28を用いることを考えたとしても、それだけでは溶剤剥離に多大な時間を要するところ、本発明の方法によれば開口部30aを活用して溶解液との接触又は浸透を促進することで、補強シート30の剥離に要する時間の飛躍的な短縮化を実現することができる。
基材12及び/又は補強シート30の少なくとも一辺がビルドアップ配線層の端部から延出しているのが好ましい。こうすることで、基材ないし補強シートを剥離する際、端部を把持することが可能となり、剥離を容易にすることができるとの利点がある。
前述したとおり、本発明の方法において所望により用いられる積層シート10は、基材12、剥離層14及び金属層16を順に備える。積層シート10は、いわゆるキャリア付銅箔の形態であってもよい。
Claims (13)
- 配線層及び絶縁層を交互に形成して多層積層体を作製する工程と、
前記多層積層体の一方の面に可溶性粘着層を介して補強シートを積層する工程であって、前記補強シートと前記多層積層体とが対向する対向領域内に可溶性粘着層が形成されない非占有領域が存在する工程と、
前記可溶性粘着層を溶解可能な液体を前記非占有領域に浸入させて、前記可溶性粘着層を溶解又は軟化させる工程と、
前記補強シートを前記多層積層体から前記可溶性粘着層の位置で剥離して多層配線板を得る工程と、
を含む、多層配線板の製造方法。 - 前記対向領域の面積に対する前記非占有領域の割合が、20~90面積%である、請求項1に記載の方法。
- 前記可溶性粘着層で覆われる個々の占有領域の外接円の直径が0.1~10mmであり、前記非占有領域が前記個々の占有領域の周りを取り囲んでいる、請求項1又は2に記載の方法。
- 前記可溶性粘着層の厚さが0.5~50μmである、請求項1~3のいずれか一項に記載の方法。
- 前記可溶性粘着層が溶液可溶型樹脂を含む、請求項1~4のいずれか一項に記載の方法。
- 前記可溶性粘着層が酸可溶型樹脂又はアルカリ可溶型樹脂を含む、請求項1~5のいずれか一項に記載の方法。
- 前記補強シートの積層後で、かつ、前記補強シートの剥離前に、前記多層積層体の補強シートと反対側の表面に電子素子を搭載する工程をさらに含む、請求項1~6のいずれか一項に記載の方法。
- 前記補強シートが開口部を有する、請求項1~7のいずれか一項に記載の方法。
- 前記可溶性粘着層を介して補強シートを積層する工程が、
第1保護フィルム上に前記可溶性粘着層を備えた複合フィルムを準備する工程と、
前記複合フィルムを前記補強シート及び/又は前記多層積層体に、前記可溶性粘着層が前記補強シート及び/又は前記多層積層体に接するように積層する工程と、
前記第1保護フィルムを前記可溶性粘着層から引き剥がす工程と、
を含む、請求項1~8のいずれか一項に記載の方法。 - 前記複合フィルムを準備する工程が、前記複合フィルムの前記可溶性粘着層側の面に第2保護フィルムを設ける工程をさらに含み、
前記方法が、前記複合フィルムの前記補強シート及び/又は前記多層積層体への積層前に、前記第2保護フィルムを引き剥がす工程をさらに含む、請求項9に記載の方法。 - 前記多層積層体が、基材、剥離層及び金属層をこの順に備えた積層シートの前記金属層の表面に作製される、請求項1~10のいずれか一項に記載の方法。
- 前記補強シートの積層後で、かつ、前記補強シートの剥離前に、前記基材を前記金属層から前記剥離層で剥離する工程をさらに含む、請求項11に記載の方法。
- 前記補強シートの剥離前に、前記金属層をエッチングにより除去する工程をさらに含む、請求項11又は12に記載の方法。
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CN109997418A (zh) | 2019-07-09 |
KR20190088470A (ko) | 2019-07-26 |
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WO2018097266A1 (ja) | 2018-05-31 |
JP6496882B2 (ja) | 2019-04-10 |
KR102493697B1 (ko) | 2023-02-01 |
KR20190087422A (ko) | 2019-07-24 |
US20190292415A1 (en) | 2019-09-26 |
JPWO2018097266A1 (ja) | 2018-11-22 |
CN110023435B (zh) | 2021-09-10 |
JP7208011B2 (ja) | 2023-01-18 |
KR102444584B1 (ko) | 2022-09-20 |
TWI829627B (zh) | 2024-01-21 |
TWI745494B (zh) | 2021-11-11 |
JP2019077884A (ja) | 2019-05-23 |
CN110023435A (zh) | 2019-07-16 |
US11525073B2 (en) | 2022-12-13 |
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