WO2018194062A1 - 電子モジュールとその製造方法 - Google Patents

電子モジュールとその製造方法 Download PDF

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Publication number
WO2018194062A1
WO2018194062A1 PCT/JP2018/015881 JP2018015881W WO2018194062A1 WO 2018194062 A1 WO2018194062 A1 WO 2018194062A1 JP 2018015881 W JP2018015881 W JP 2018015881W WO 2018194062 A1 WO2018194062 A1 WO 2018194062A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
base material
electronic module
electrically insulating
wiring pattern
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2018/015881
Other languages
English (en)
French (fr)
Japanese (ja)
Inventor
摂 綿貫
憲市 本田
おりえ 篠原
石川　章
勤 石川
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tateyama Kagaku Kogyo Co Ltd
Original Assignee
Tateyama Kagaku Kogyo Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tateyama Kagaku Kogyo Co Ltd filed Critical Tateyama Kagaku Kogyo Co Ltd
Priority to US16/606,738 priority Critical patent/US11049780B2/en
Priority to CN201880024003.5A priority patent/CN110494974B/zh
Priority to EP18788521.5A priority patent/EP3564991B1/en
Publication of WO2018194062A1 publication Critical patent/WO2018194062A1/ja
Priority to TW108109037A priority patent/TWI686121B/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W74/00—Encapsulations, e.g. protective coatings
    • H10W74/01—Manufacture or treatment
    • H10W74/016—Manufacture or treatment using moulds
    • 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
    • H05K1/18—Printed circuits structurally associated with non-printed electric components
    • H05K1/181—Printed circuits structurally associated with non-printed electric components associated with surface mounted components
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/18—Printed circuits structurally associated with non-printed electric components
    • H05K1/182—Printed circuits structurally associated with non-printed electric components associated with components mounted in printed circuit boards [PCB], e.g. insert-mounted components [IMC]
    • H05K1/185—Printed circuits structurally associated with non-printed electric components associated with components mounted in printed circuit boards [PCB], e.g. insert-mounted components [IMC] associated with components encapsulated in the insulating substrate of the PCBs; associated with components incorporated in internal layers of multilayer circuit boards
    • H05K1/186—Printed circuits structurally associated with non-printed electric components associated with components mounted in printed circuit boards [PCB], e.g. insert-mounted components [IMC] associated with components encapsulated in the insulating substrate of the PCBs; associated with components incorporated in internal layers of multilayer circuit boards manufactured by mounting on or connecting to patterned circuits before or during embedding
    • 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
    • H05K1/18—Printed circuits structurally associated with non-printed electric components
    • H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of flexible or folded printed circuits
    • 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
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/28—Applying non-metallic protective coatings
    • H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
    • H10W70/60—Insulating or insulated package substrates; Interposers; Redistribution layers
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W70/00—Package substrates; Interposers; Redistribution layers [RDL]
    • H10W70/60—Insulating or insulated package substrates; Interposers; Redistribution layers
    • H10W70/67—Insulating or insulated package substrates; Interposers; Redistribution layers characterised by their insulating layers or insulating parts
    • H10W70/69—Insulating materials thereof
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W74/00—Encapsulations, e.g. protective coatings
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W74/00—Encapsulations, e.g. protective coatings
    • H10W74/10—Encapsulations, e.g. protective coatings characterised by their shape or disposition
    • H10W74/111—Encapsulations, e.g. protective coatings characterised by their shape or disposition the semiconductor body being completely enclosed
    • H10W74/114—Encapsulations, e.g. protective coatings characterised by their shape or disposition the semiconductor body being completely enclosed by a substrate and the encapsulations
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10106—Light emitting diode [LED]
    • 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
    • H05K2203/13—Moulding and encapsulation; Deposition techniques; Protective layers
    • H05K2203/1305—Moulding and encapsulation
    • H05K2203/1316—Moulded encapsulation of mounted components
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/13—Moulding and encapsulation; Deposition techniques; Protective layers
    • H05K2203/1305—Moulding and encapsulation
    • H05K2203/1327—Moulding over PCB locally or completely
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistors
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistors electrically connecting electric components or wires to printed circuits
    • H05K3/34—Assembling printed circuits with electric components, e.g. with resistors electrically connecting electric components or wires to printed circuits by soldering
    • H05K3/341—Surface mounted components
    • H05K3/3431—Leadless components
    • H05K3/3442—Leadless components having edge contacts, e.g. leadless chip capacitors, chip carriers
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/01—Manufacture or treatment
    • H10H20/036—Manufacture or treatment of packages
    • H10H20/0362—Manufacture or treatment of packages of encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/01—Manufacture or treatment
    • H10H20/036—Manufacture or treatment of packages
    • H10H20/0364—Manufacture or treatment of packages of interconnections
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/852—Encapsulations
    • H10H20/854—Encapsulations characterised by their material, e.g. epoxy or silicone resins
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/857—Interconnections, e.g. lead-frames, bond wires or solder balls
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W90/00—Package configurations

Definitions

  • the present invention relates to an electronic module in which a circuit part on which an electronic device such as a light emitting element or an IC chip is mounted is sealed with an electrically insulating resin, and a method for manufacturing the electronic module.
  • an electronic device is mounted on a substrate on which a wiring pattern is formed, and the substrate on which the electronic device is mounted is positioned and accommodated in a case. Yes.
  • the electronic device is positioned in the case, and the case is filled with resin, whereby the substrate on which the electronic device is mounted is sealed in the resin.
  • Patent Document 1 when the substrate on which the electronic device is mounted is sealed with resin, a large pressure is applied to the substrate and the electronic device due to the molten resin filled in the case. For this reason, there has been a problem that the electronic device mounted on the substrate is damaged or the wiring pattern on the substrate is disconnected.
  • the present invention has been made in view of such problems, and an object of the present invention is to provide an electronic module capable of avoiding damage to an electronic device and occurrence of disconnection of a wiring pattern, and a manufacturing method thereof. To do.
  • the present invention provides a base material having flexibility and electrical insulation, a circuit part in which an electronic device is mounted on a wiring pattern formed on at least one surface of the base material, and the circuit part made of an electrically insulating resin.
  • the base is a flexible electronic module that can be deformed by pressure during sealing with the electrically insulating resin.
  • the wiring pattern is made of a solderable metal foil, and the metal foil is made of a material having a recrystallization temperature equal to or lower than a molding temperature when the circuit portion is sealed with the electrically insulating resin. It is what. Or this metal foil may be comprised from the material which has melting
  • the metal foil is preferably composed of a solder foil. Furthermore, it is preferable that a base layer having conductivity is provided on the one surface of the base material, and the metal foil is formed on the base layer.
  • the underlayer is preferably wettable with respect to molten solder.
  • the base material is made of a material having air permeability.
  • the base material is composed of a glass cloth made of a large number of glass fibers, and the surface of the glass cloth opposite to the surface on which the electronic device is mounted is flexible at least as much as the glass cloth.
  • the holding layer is made of, for example, a urethane resin.
  • the present invention also provides a circuit part forming step in which a wiring pattern is formed on the surface of a substrate having flexibility and electrical insulation, and an electronic device is mounted on the wiring pattern to form a circuit part.
  • An electronic module manufacturing method including a sealing step of sealing with a resin body of an insulating resin, wherein the base material is made of a flexible material that can be deformed when sealed with the electrical insulating resin. In the sealing step, the electronic module is manufactured by sealing the base material and the circuit portion with the electrically insulating resin.
  • the wiring pattern is composed of a solderable metal foil, and the metal foil has a recrystallization temperature equal to or lower than a molding temperature of the electrically insulating resin.
  • the electronic device is attached to the wiring pattern. Is to be soldered.
  • the metal foil may have a melting point equal to or lower than the molding temperature of the electrically insulating resin, and in the circuit part forming step, the electronic device may be soldered to the wiring pattern.
  • the base material and the circuit portion are installed in a cavity of a mold, and the molten thermoplastic electrically insulating resin is injection-molded and cured in the cavity.
  • the circuit part is sealed with the electrically insulating resin.
  • the base material and the circuit part may be sandwiched between sheets of the thermoplastic electrically insulating resin, and the base material and the circuit part may be sealed by pressing the sheets together.
  • the base material and the circuit part are installed in a cavity of a mold, and a fluid thermosetting resin is injected into the cavity to be cured. It may be sealed with the electrically insulating resin.
  • the base material and the circuit part are installed in the housing part of the mold, and a fluid thermosetting resin is injected into the housing part, and the base material is injected into the thermosetting resin.
  • the said circuit part may be immersed, the said thermosetting resin may be hardened, and the said base material and the said circuit part may be sealed with the said electrically insulating resin.
  • the base material and the circuit part are installed in a housing part of a mold, the base material and the circuit part are sandwiched by a flexible thermosetting resin, and the electrically insulating resin is provided by the mold.
  • the base material and the circuit part may be sealed.
  • an electronic device is connected to a wiring pattern formed on the surface of a flexible and electrically insulating substrate to form a circuit portion.
  • the portion and the substrate are resin-sealed, it is possible to suppress a load applied to the electronic device and the wiring pattern due to the resin sealing, and to prevent damage to the electronic device and disconnection of the wiring pattern.
  • FIG. 9 is a cross-sectional view illustrating a state in which a circuit unit in which an electronic device is mounted on a base material is mounted in a mold in the longitudinal sectional view of a pair of upper and lower molds in FIG. 8. It is a longitudinal cross-sectional view of the part which shape
  • FIG. 10 is a vertical cross-sectional view of a pair of upper and lower molds in FIG. 10 showing a state in which a primary molded product in which one side of a circuit portion on which an electronic device is mounted on a substrate is resin-sealed is mounted in the mold.
  • FIG. It is the schematic which shows the manufacturing method of the electronic module of 2nd embodiment of this invention. It is the schematic which shows the manufacturing method of the electronic module of 3rd embodiment of this invention. It is the schematic which shows the manufacturing method of the electronic module of 4th embodiment of this invention.
  • FIG. 1 shows an electronic module 10 according to the first embodiment of the present invention.
  • the electronic module 10 includes a base material 12 having flexibility and flexibility, electrical insulation, and having a sheet shape or a plate shape and having a front surface and a back surface.
  • the substrate 12 has a wiring pattern 13 formed on one of the front surface and the back surface.
  • the circuit portion 15 in which an electronic device 14 such as a light emitting element is mounted on the wiring pattern 13 and the circuit portion 15 are electrically connected.
  • a resin body 16 sealed with an insulating resin The circuit portion 15 is formed such that the terminal portion 15a, which is one end portion, is not sealed with the resin body 16, and can be electrically connected to a device or the like (not shown).
  • the light emitting element which is the electronic device 14 is mounted on the base material 12 to constitute the optical electronic module 10.
  • the light emitting element a light emitting diode, a laser diode, or the like can be used.
  • the electronic device 14 may include a light receiving element, a chip-shaped electronic component, an IC, and other electronic components.
  • the base material 12 is deformed by the pressure from the molten resin, The force which the base material 12 and the circuit part 15 receive from molten resin can be reduced.
  • the term “flexibility” as used herein refers to a degree of flexibility that can be deformed by the pressure acting from the electrically insulating resin during sealing with the electrically insulating resin. Thereby, the electronic module 10 does not damage the electronic device 14 mounted on the base material 12 at the time of resin sealing, and the disconnection of the wiring pattern 13 does not occur.
  • the base material 12 is comprised from the material which has air permeability. Specifically, the base material 12 is good to be comprised with the glass cloth which consists of many glass fibers. In addition, any material may be used as long as it is flexible and electrically insulative, such as paper, non-woven fabric, and a sheet made of a synthetic resin cloth in which a large number of synthetic fibers are knitted. Since the base material 12 is made of a material having air permeability, the molten resin is also applied to the side surface opposite to the surface on which the electronic device 14 is mounted on the base material 12 (the lower surface of the base material 12 in FIG. 2). It becomes easy to turn.
  • the molten electrical insulating resin enters the gaps (glass cloth mesh) formed in the base material 12 having air permeability, so that the molten resin acting on the electronic device 14 mounted on the base material 12 Can be effectively relieved. Thereby, there is little generation
  • the underlayer 17 is made of a conductive resin. As described above, if the base layer 17 is made of a conductive resin, even if a crack is generated in the wiring pattern 13, the electrons mounted on the substrate 12 through the conductive base layer 17. Energization between the device 14 and the wiring pattern 13 can be maintained.
  • the underlayer 17 may be composed of a conductive resin or a metal layer different from solder, such as a nickel (Ni) plating layer, a gold (Au) plating layer, or a copper (Cu) plating layer. .
  • the glass cloth of the base material 12 is formed by weaving a large number of glass fibers, the glass fibers are easy to be broken. Therefore, in order to prevent the loosening, the side of the base material 2 on which the electronic device 14 is mounted. It is preferable to provide a urethane resin holding layer 18 having flexibility on the surface opposite to the surface (the lower surface in FIG. 2).
  • the holding layer 18 is formed by applying a molten urethane resin to the lower surface of the substrate 12. Since the urethane resin holding layer 18 having flexibility is integrated with the glass cloth meshing into the mesh, the flexibility of the glass cloth is not hindered.
  • a highly flexible urethane resin is used as the holding layer 18, but various resin layers having flexibility may be used as the holding layer 18.
  • the resin body 16 made of a flexible electrically insulating resin seals the electronic device 14 that is an optical device, and thus is made of a transparent resin.
  • the material of the resin body 16 of the electrically insulating resin include polyethylene terephthalate (PET), polyimide (PI), polyethylene naphthalate (PEN), polyethersulfone (PES), polyetheretherketone (PEEK), polycarbonate ( PC), polypropylene (PP), polyamide (PA), polystyrene (PS), acrylic, cycloolefin polymer, polyacetal, amorphous polyolefin resin, cyclic polyolefin resin, aliphatic cyclic polyolefin, norbornene thermoplastic transparent resin Are preferably used.
  • thermosetting transparent resin may be used as the resin body 16 made of an electrically insulating resin.
  • the resin body 16 is sealed with a transparent resin. Therefore, the resin body 16 made of an electrically insulating resin may not be a transparent resin as long as it is a resin material that can transmit light. Moreover, what coated the coating material of the grade which can permeate
  • the wiring pattern 13 is composed of a metal foil that can be soldered.
  • the metal foil is made of a solder foil, and the connection of the electronic device 14 to the wiring pattern 13 by soldering is easy and reliable. Yes.
  • the solder foil of the wiring pattern 13 is formed by injecting molten electrically insulating resin into cavities 19S and 19S1 of a mold 19 to be described later, and molding temperature of the electrically insulating tree when the circuit portion 15 is sealed. It is comprised from the material which has the following melting
  • the metal foil (in this case, the solder foil) constituting the wiring pattern 13 is made of a material having a melting point equal to or lower than the molding temperature of the resin body 16, so that the molten electrically insulating resin is cavityd. At least a part of the metal material constituting the metal foil is softened or melted by the molding temperature at the time of being injected into 19S and 19S1 and sealing the circuit portion 15. Thus, even when the molten resin flows into the cavities 19S and 19S1 vigorously when the circuit portion 15 is sealed, the metal foil of the wiring pattern 13 resists deformation of the base material 12 and does not break.
  • the stress which the base material 12 receives by each thermal expansion and contraction of the resin body 16 of the electrically insulating resin and the wiring pattern 13 of the metal foil at the time of molding for sealing the circuit portion 15 can be reduced. . Since the oxide film is already formed on the surface of the metal foil, the metal foil is less likely to lose its shape due to melting of the metal material.
  • the metal material is heated if the temperature in the cavity 9S is equal to or higher than the recrystallization temperature of the metal material.
  • the metal foil such as solder foil is easily deformed and is not easily damaged.
  • the stress that the substrate 12 receives due to the thermal expansion and contraction of the resin body 16 of the electrically insulating resin and the wiring pattern 13 of the metal foil at the time of molding for sealing the circuit portion 15. Can be reduced.
  • the electronic module 10 manufacturing method includes forming a wiring pattern 13 on the surface of a base material having electrical insulation, and mounting the electronic device 14 on the wiring pattern 13 to form a circuit portion 15;
  • the sealing step of sealing the circuit portion 15 with the resin body 16 of an electrically insulating resin is a main step.
  • the circuit part forming process includes a holding layer forming process, a screen printing process, a wiring pattern forming process, and an electronic device 14 mounting process.
  • the holding layer forming step the melted urethane resin is applied to the back surface (the lower surface in FIG. 2) of the substrate 12.
  • the base material 12 By forming the holding layer 18 on the base material 12, the base material 12 can be sucked and fixed at the time of printing, and the separation of the screen plate can be improved. Furthermore, it is possible to prevent the base ink from penetrating the back surface side of the substrate 12.
  • the holding layer forming step may be performed before or after the screen printing step or the mounting step, and the urethane resin holding layer 18 may be formed on the substrate 12 in advance. Note that the holding layer forming step may be omitted if the fixing of the base material 12 and the unraveling of the fibers of the base material 12 do not matter.
  • the screen printing process uses a screen 20 having a large number of holes 20 ⁇ / b> A formed at predetermined positions and a squeegee 21, and one surface on the mounting side of the substrate 12 (upper surface in FIG. 3). And a step of applying a base ink 17a for forming the base layer 17.
  • the wiring pattern forming process after the screen printing process is completed, as shown in FIG. 4, after the base ink 17a is cured, wiring solder 13a for forming the wiring pattern 13 is applied on the base ink 17a. It is. As shown in FIG. 5, the wiring solder 13 a is applied over the cured base layer 17. After completion of the wiring pattern forming process, a mounting process is executed.
  • the mounting process is not shown, the electronic device 14 such as a light emitting element is placed on the wiring pattern 13, and the electrodes of the electronic device 14 are connected to the wiring pattern 13 with solder 22 as shown in FIG.
  • the mounting process of the electronic device 14 is completed.
  • the circuit part formation process is completed by the above processes.
  • the process proceeds to the sealing process.
  • the sealing step the base material 12 including the circuit unit 15 is sealed on each side, and both surfaces of the circuit unit 15 are sealed.
  • die 19 used for a sealing process is demonstrated.
  • the mold 19 includes a fixed-side mold part 19A located on the upper side and a movable-side mold part 19B located on the lower side and movable in the vertical direction.
  • a rectangular mark 23 for determining the attachment position of the circuit part 15 on which the electronic device 14 is mounted is formed on the surface of the movable mold part 19 ⁇ / b> B by a broken line.
  • the mark 23 is drawn in the same size as the outer shape of the circuit unit 15, and the outer shape of the circuit unit 15 is pasted in accordance with the broken line of the mark 23.
  • the mark 23 may be a solid line or a color, and may be a mark that can be distinguished from the surroundings.
  • the mold part 19B has a secondary-side first recess 24 for secondary molding of the primary molded product D1 by the first molding.
  • the first recess 24 is located adjacent to the mark 23 in parallel, and accommodates a primary molded product D1 in which the mounting side surface of the circuit unit 15 on which the electronic device 14 is mounted is sealed with resin by primary molding. It is space.
  • the first concave portion 24 includes a main body portion side concave portion 24 ⁇ / b> A that accommodates a main body portion D ⁇ b> 1 a that is a resin-sealed portion of the primary molded product Dl of the circuit portion 15, and the circuit portion 15.
  • the terminal part side recessed part 24B which accommodates the terminal part 15a which is the one end part which is not resin-sealed of the primary molded product D1 is provided.
  • the terminal portion side end portion 24B is slightly narrower than the main body portion side concave portion 24A, and has a shallow depth enough for the base material 12 to enter.
  • the fixed-side mold portion 19A accommodates the upper surface side of the circuit portion 15 on which the electronic device 14 is mounted in the primary molding, and is mounted on the surface of the circuit portion 15 on the mounting side.
  • a second recess 25 for forming a cavity 19S for resin sealing is provided.
  • the second concave portion 25 of the mold portion 19A includes a resin filling concave portion 25A that forms a cavity 19S filled with resin, and a terminal portion 15a that is one end portion of the circuit portion 15 on which the electronic device 14 is mounted that is not resin-sealed.
  • the terminal part side recessed part 25B to accommodate is provided.
  • the terminal-side concave portion 25B is slightly narrower than the resin-filling concave portion 25A and has a shallow depth that allows the base material 12 to enter.
  • the mold part 19A is adjacent to the second recess 25 and covers the surface of the primary molded product Dl opposite to the side on which the circuit part 15 is resin-sealed, and is subjected to secondary molding.
  • the third recess 26 is formed. By filling the secondary side third recess 26 with molten resin, the surface opposite to the mounting side of the primary molded product Dl is resin-sealed. As shown in FIGS. 10 and 11, the secondary third recess 26 is formed adjacent to the primary second recess 25, and a cavity 19S1 filled with resin is formed. This 3rd recessed part 26 is comprised by the same magnitude
  • the pair of upper and lower mold parts 19A and 19B are opened by lowering the movable mold part 19B.
  • the circuit portion 15 is arranged in a state where the outer shape of the base material 12 is matched with the mark 23 of the lower movable mold portion 19B.
  • the circuit unit 15 is arranged so that the surface on which the electronic device 14 is mounted faces upward.
  • the circuit unit 15 is fixed to the flat surface (upper surface) 19c of the lower movable mold part 19B with a double-sided tape, and the circuit part 15 moves greatly in the mold when molten resin is injected. Make sure there is nothing.
  • the lower movable mold part 19B is raised to close the pair of mold parts 19A, 19B.
  • the second recessed portion 25 of the upper fixed-side mold part 19A is formed from the injection port H1 formed near the center part in the longitudinal direction of the upper fixed-side mold part 19A and near one end in the short-side direction.
  • a thermoplastic molten resin is injected into the resin filling recess 25A. The injected molten resin covers the electronic device 14 and the molten resin reaches the surface on the mounting side of the substrate 12 and the surface of the substrate 12 opposite to the mounting side through the mesh of the substrate 12. Make sure that the mounting side is completely covered.
  • the mold parts 19A and 19B are cooled, the lower movable mold part 19B is lowered to open the mold parts 19A and 19B, and the one side of the substrate 12 is resin-sealed. 15 is taken out.
  • the mold 19 includes the mold parts 19A and 19B that open and close in the vertical direction.
  • the mold 19 may include a mold part that opens and closes in the horizontal direction.
  • the secondary molding of the circuit part 15 to which the electronic device 14 is attached in which the surface on the side opposite to the mounting side of the primary molded product D1 whose surface on the mounting side is resin-sealed is resin-sealed.
  • the primary molded product D1 is arranged in the first concave portion 24 of the lower movable mold part 19B so that the surface of the molded primary molded product D1 opposite to the mounting side faces upward.
  • the lower movable mold part 19B is raised to close the pair of mold parts 19A, 19B.
  • thermoplastic molten resin is injected into the recess 26.
  • the surface opposite to the mounting side surface of the substrate 12 is covered with the molten resin by the injected molten resin.
  • both surfaces of the circuit portion 15 of the base 12 are completely covered with the resin, and the portion covered with the resin is waterproof.
  • the inner surface of the wiring pattern 13 and the inner surface of the base layer 17 are also covered with the resin that has entered through the mesh of the substrate 12.
  • the mold parts 19A and 19B are cooled and the lower movable mold part 19B is lowered to open the pair of mold parts 19A and 19B.
  • the resin-sealed electronic module 10 is taken out, and the sealing process of the circuit unit 15 is completed.
  • the resin temperature filled in the cavities 19S and 19S1 of the mold parts 19A and 19B is, for example, about 250 ° C.
  • the melting point or recrystallization temperature of the solder of the solder foil constituting the wiring pattern 13, and the electronic device is about 220 ° C., which is lower than the resin temperature filled in the cavities 19S and 19S1.
  • the solder that configures the wiring pattern 13 and the solder that mounts the electronic device 14 are composed of melting points of the same temperature, that is, of the same component, but may be solders having melting points of different temperatures.
  • the stress applied to the base material 12 due to the thermal expansion and contraction of the solder foil at the time of molding for sealing the circuit portion 15 is applied. Can be reduced. Moreover, since the softening temperature of a general glass cloth is about 750 ° C. or higher, it is not deformed or melted out by the molten resin at the time of injection.
  • the base material 12 is pressed by the pressure from the resin to be sealed.
  • transforming the force which the base material 12 receives from resin can be reduced. Therefore, the device 4 connected to the base material 12 is not damaged. Furthermore, it is possible to avoid the occurrence of disconnection in the wiring pattern 13 of the circuit unit 15 of the base 12.
  • the wiring pattern 13 is made of a solderable metal foil, and the metal foil has a melting point equal to or lower than a molding temperature when the circuit portion 15 is sealed with an electrically insulating resin. Or it is comprised from the material which has recrystallization temperature. Therefore, the resin body 16 and the metal foil wiring pattern 13 are thermally expanded by the molding temperature when the circuit portion 15 is sealed with the electrically insulating resin, and at least one of the metal materials constituting the metal foil is expanded. By melting or softening the part, the metal foil can withstand deformation even if the molten resin flows in vigorously.
  • the stress received by the substrate 12 due to the thermal expansion and contraction of the metal foil at the time of molding for sealing the circuit portion 15 is achieved. Can be reduced.
  • the metal foil is particularly preferably composed of a solder foil. Thereby, it is possible to easily and reliably connect the solder foil of the electronic device 14 and the wiring pattern 13 with solder.
  • the base layer 12 is provided on the surface of the base material 12, and the metal foil is formed on the base layer 17.
  • the electronic device mounted on the base material 12 through the conductive underlying layer 17 even if a crack is generated in the wiring pattern 13 because the underlying layer 17 is made of a conductive resin. 14 and the wiring pattern 13 can be kept energized.
  • the base material 12 is made of a material having air permeability
  • the molten resin easily turns to the side surface opposite to the connection side surface of the base material 12.
  • the pressure from the molten resin can be relieved in the electronic device 14 connected to the base material. Thereby, there is little generation
  • the base 12 includes a glass cloth made of a large number of glass fibers, and the glass cloth surface on the side opposite to the surface on the electronic device connection side has the same or higher flexibility as the glass cloth. Since the resin holding layer 18 is provided, the glass layer of the substrate 12 can be reliably prevented from being broken by the holding layer 18. In addition, since the holding layer 18 having flexibility is integrated in a state where the holding layer 18 bites into the mesh of the glass cloth, the flexibility of the glass cloth is not hindered.
  • the holding layer 18 may be made of a urethane resin. If the holding layer 18 is made of a highly flexible urethane resin, it is preferable that the flexibility of the glass cloth is not further hindered.
  • the two surfaces of the circuit unit 15 are covered with resin by performing two steps of covering each side of the circuit unit 15 with resin.
  • both surfaces of the circuit unit 15 are coated with resin. You may make it cover with.
  • FIG. 12 shows a method for manufacturing the electronic module 10 according to the second embodiment of the present invention.
  • the electronic device 14 is mounted on the circuit unit 15 by a pair of resin sheets 30 and 31 made of a thermoplastic resin and a flexible electrically insulating resin.
  • the substrate 12 is sandwiched in a vacuum.
  • the electrically insulating resin of the resin sheets 30 and 31 the thermoplastic resin described in the above embodiment can be used.
  • the method of sandwiching and sealing the base material 12 and the circuit portion 15 with the resin sheets 30 and 31 includes the base material 12 and the circuit portion 15 sandwiched between the resin sheets 30 and 31 in a vacuum bag. Then, the air in the vacuum bag is evacuated, put in an oven in that state, heated, and the resin sheets 30 and 31 are brought into close contact, and then cured to form the electronic module 10.
  • the electronic module 10 in which the electronic device 14 is sealed with the resin body 16 of the electrically insulating resin can be manufactured more easily.
  • the base material 12 and the circuit unit 15 sandwiched between the resin sheets 30 and 31 are placed in a vacuum laminator device, the air in the vacuum laminator device is evacuated, and the resin sheet 30 and 31 is pressurized and heated in that state. May be adhered and cured to form the electronic module 10.
  • FIG. 13 shows a method for manufacturing the electronic module 10 of the third embodiment of the present invention.
  • a silicone resin is used as an electrically insulating resin that is a thermosetting resin and has flexibility.
  • the base material 12 on which the circuit portion 15 is formed is installed in the housing portion 32a of the mold 32, and the liquid silicone resin 33, which is a fluid thermosetting resin, and a curing agent are mixed and the housing portion 32a.
  • the liquid silicone resin 33 which is a fluid thermosetting resin, and a curing agent are mixed and the housing portion 32a. Inject.
  • the silicone resin 33 is cured, and one surface of the substrate 12 and the circuit unit 15 is electrically insulated resin. Seal with.
  • the other surface of the base material 12 and the circuit portion 15, here, the surface where the electronic device 14 is not mounted is turned up, and the housing portion 32 a of the mold 32 is placed.
  • the base material 12 is installed, the silicone resin 34 is injected into the housing portion 32a, and the silicone resin 34 is cured with a curing agent.
  • the electronic module 10 in which the electronic device 14 is sealed with the resin body 16 by the silicone resins 33 and 34 is formed.
  • a liquid silicone resin is used to install a base material 12 on which a circuit portion 15 is formed in a cavity of a mold (not shown), and liquid silicone is contained in the cavity.
  • the electronic module 10 may be molded by injecting resin.
  • the liquid silicone resin to be injected and its curing agent are separately separately injected into the mold cavity to cure the liquid silicone resin.
  • the base material 12 and the circuit part 15 can be sealed in a silicone resin which is a flexible thermosetting resin.
  • FIG. 14 shows a method for manufacturing the electronic module 10 according to the fourth embodiment of the present invention.
  • a silicone resin which is an electrically insulating resin
  • the silicone resin 37 used here is a thermosetting resin having flexibility and plasticity, and is a raw rubber-like silicone resin that can be press-molded, and is also referred to as silicone rubber.
  • the upper die 36A and the lower die 36B of the press die 36 are opened, and a lump 37a of the silicone resin 37 in a plastically deformable state is placed in the accommodating portion 36c of the lower die 36B.
  • the amount of the lump 37a is an amount that covers the surface of the substrate 12 on which the electronic device 14 is not mounted.
  • the base material 12 on which the circuit portion 15 is formed is placed on the lump 37a of the silicone resin 37, and as shown in FIG.
  • the mass 37b of the resin 37 is placed, the upper die 36A and the lower die 36B of the press die 36 are closed, and pressure molding is performed. At this time, heat is also applied to cure and mold the silicone resin 37.
  • FIG. 14C the electronic module 10 in which the electronic device 14 is sealed with the resin body 16 made of the silicone resin 37 is formed.
  • the electronic module 10 in which the electronic device 14 is sealed with the resin body 16 of the thermosetting electric insulating resin can be manufactured more easily.
  • the electronic module and the manufacturing method thereof according to the present invention are not limited to the above embodiment, and the electronic device includes a chip-shaped electronic component such as a resistor, a coil, a capacitor, a diode, a transistor, various power elements, and an IC. Integrated circuit elements.
  • the resin body does not necessarily have to be made of a transparent resin material.
  • the holding layer of the flexible urethane resin is provided on the surface of the glass cloth opposite to the surface on the mounting side of the electronic device is shown, but the holding layer may be omitted.
  • the underlayer may be formed by screen printing, offset printing, gravure printing, ink jet printing, or the like.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Non-Metallic Protective Coatings For Printed Circuits (AREA)
  • Structures Or Materials For Encapsulating Or Coating Semiconductor Devices Or Solid State Devices (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
  • Structures For Mounting Electric Components On Printed Circuit Boards (AREA)
PCT/JP2018/015881 2017-04-19 2018-04-17 電子モジュールとその製造方法 Ceased WO2018194062A1 (ja)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US16/606,738 US11049780B2 (en) 2017-04-19 2018-04-17 Electronic module and method for manufacturing same
CN201880024003.5A CN110494974B (zh) 2017-04-19 2018-04-17 电子模块及其制造方法
EP18788521.5A EP3564991B1 (en) 2017-04-19 2018-04-17 Method for manufacturing an electronic module
TW108109037A TWI686121B (zh) 2017-04-19 2019-03-18 電子模組及其製造方法

Applications Claiming Priority (2)

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JP2017-082569 2017-04-19
JP2017082569A JP6495368B2 (ja) 2017-04-19 2017-04-19 電子モジュール

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US12156356B2 (en) * 2020-04-13 2024-11-26 Flex Ltd. Electronic encapsulation through stencil printing
CN114126207B (zh) * 2020-08-27 2024-03-26 致伸科技股份有限公司 薄膜线路板及其制作方法
CN116529734A (zh) * 2021-01-14 2023-08-01 凸版印刷株式会社 卡型介质以及卡型介质的制造方法
US12154860B2 (en) * 2021-06-16 2024-11-26 SanDisk Technologies, Inc. Method of forming a semiconductor device including vertical contact fingers
CN115457880B (zh) * 2022-09-14 2024-10-15 深圳市美亚迪光电有限公司 Led软模组的成型方法

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US20200135598A1 (en) 2020-04-30
EP3564991A1 (en) 2019-11-06
JP2018182180A (ja) 2018-11-15
JP6495368B2 (ja) 2019-04-03
TW201944873A (zh) 2019-11-16
EP3564991A4 (en) 2020-08-05
US11049780B2 (en) 2021-06-29
TWI686121B (zh) 2020-02-21
CN110494974B (zh) 2023-02-28
EP3564991B1 (en) 2023-02-15
CN110494974A (zh) 2019-11-22

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