WO2018235715A1 - モジュールおよびその製造方法 - Google Patents

モジュールおよびその製造方法 Download PDF

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Publication number
WO2018235715A1
WO2018235715A1 PCT/JP2018/022700 JP2018022700W WO2018235715A1 WO 2018235715 A1 WO2018235715 A1 WO 2018235715A1 JP 2018022700 W JP2018022700 W JP 2018022700W WO 2018235715 A1 WO2018235715 A1 WO 2018235715A1
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WO
WIPO (PCT)
Prior art keywords
substrate
resin layer
sealing resin
solder ball
main surface
Prior art date
Application number
PCT/JP2018/022700
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English (en)
French (fr)
Inventor
喜孝 松川
彰夫 勝部
Original Assignee
株式会社村田製作所
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Filing date
Publication date
Application filed by 株式会社村田製作所 filed Critical 株式会社村田製作所
Priority to CN201880040581.8A priority Critical patent/CN110832636B/zh
Priority to JP2019525513A priority patent/JP6784330B2/ja
Priority to KR1020217039027A priority patent/KR102374316B1/ko
Priority to KR1020197033134A priority patent/KR102463386B1/ko
Publication of WO2018235715A1 publication Critical patent/WO2018235715A1/ja
Priority to US16/716,647 priority patent/US11276631B2/en

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    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
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Definitions

  • the present invention relates to a module and a method of manufacturing the same.
  • the module 100 described in Patent Document 1 includes an electrode pad 102 and an electrode pad 102 on a semiconductor chip 103 having an electrode pad 102 formed on the main surface of a semiconductor substrate 101.
  • a substantially spherical conductive ball 105 electrically connected is formed.
  • a resin layer 106 is formed on the semiconductor chip 103 so that the top of the conductive ball 105 is exposed, and an external connection terminal 107 made of a solder ball is provided on the top of the conductive ball 105 exposed from the resin layer 106. ing.
  • the conductive ball 105 is placed at a predetermined position of the wire 104 to form a support for connecting the wire 104 and the external connection terminal 107 in the resin layer 106.
  • a support of the desired height in a very short time as compared with the formation of the support by the plating method.
  • Patent No. 4626008 see paragraphs 0023 to 0025, FIG. 6, etc.
  • the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a module in which an external connection terminal without a constriction shape is formed of solder balls to improve reliability and mechanical strength.
  • a module according to the present invention comprises a substrate, a connection electrode provided on one main surface of the substrate, a first component mounted on the one main surface of the substrate, and the substrate Provided on the one main surface of the substrate and an external connection terminal consisting of solder balls disposed on the one main surface of the substrate via the connection electrode, and sealing the one main surface of the substrate and the first component A portion of the external connection terminal is exposed from the surface of the sealing resin layer opposite to the opposite surface to the one main surface of the substrate, and the external connection terminal is The height of the substrate from the one main surface is higher than the height of the sealing resin layer from the one main surface of the substrate, and there is a gap between the external connection terminal and the sealing resin layer.
  • An external connection terminal of the sealing resin layer surrounding the external connection terminal; Facing surface is characterized in that a curved curvilinear in the one main surface perpendicular cross-section of the substrate.
  • the external connection terminal is formed of the solder ball and has a shape without a constriction, so that the mechanical strength and reliability of the external connection terminal can be improved.
  • the external connection terminal is formed of solder, it is possible to realize high precision of the position of the external connection terminal by the self alignment effect at the time of reflow.
  • the solder balls are exposed and protruded from the sealing resin layer, it is not necessary to plate the terminal portions, and the manufacturing cost can be suppressed.
  • the opposing surface of the sealing resin layer surrounding the external connection terminal facing the external connection terminal is a curved surface forming a curve in a cross section perpendicular to one main surface of the substrate, whereby the opposing surface is a straight line in the cross section. Since the load for the stress in the horizontal direction with respect to the substrate is dispersed as compared with the case of the curved surface, the occurrence of peeling can be suppressed.
  • the external connection terminal may be formed by one solder ball.
  • the solder balls since the solder balls have a shape projecting in a circle from the sealing resin layer, they can be used as bumps when connecting to the mother substrate as they are.
  • the external connection terminal may not be in contact with the sealing resin layer at all.
  • the stress due to the difference between the thermal expansion coefficient of the solder and the resin can be reduced, and the generation of the crack in the solder ball can be suppressed. .
  • a part of the first component may be exposed from the opposite surface of the sealing resin layer. In this case, a reduction in the height of the module can be realized.
  • the surface exposed from the opposite surface of the sealing resin layer of the first component may be flush with the opposite surface of the sealing resin layer. In this case, a reduction in the height of the module can be realized.
  • the second component may be mounted on the other main surface of the substrate.
  • the mounting area can be increased by mounting the component also on the other main surface of the substrate, and the degree of freedom in design can be improved.
  • a step of laminating a sealing resin layer for sealing the component and the solder ball on the one main surface of the substrate, and the solder ball is opposed to the one main surface of the sealing resin layer Polishing the opposite surface of the sealing resin layer and a part of the solder ball so as to be exposed from the surface opposite to the surface; and the height of the solder ball from the one main surface of the substrate And reheating the substrate in a reflow furnace such that the height of the sealing resin layer is higher than the height of the sealing resin layer from the one main surface of the substrate.
  • solder balls are deformed into spherical shapes by surface tension and a shape protruding from the polished surface of the sealing resin layer. Therefore, it is not necessary to form a bump for connecting to the mother substrate again. Further, since the solder balls are mounted as the external connection terminals, there is no need to perform plating, so that abnormal plating does not occur, and a module with high reliability and mechanical strength can be manufactured.
  • a module with high reliability and mechanical strength can be provided, and a reduction in height of the module can be realized.
  • FIG. 1 It is a sectional view of a module concerning one embodiment of the present invention. It is an expanded sectional view which shows the example of the mounting method of the solder ball of the module of FIG. It is a figure which shows the manufacturing process of the module of FIG. It is a figure which shows the manufacturing process of the module of FIG. It is a figure which shows the process of mounting the module of FIG. 1 in a motherboard. It is a figure for demonstrating the shape of the sealing resin layer of solder ball periphery. It is a figure which shows the conventional module.
  • FIG. 1 is a cross-sectional view of the module 1 and FIG. 2 is an enlarged cross-sectional view showing an example of a method of mounting solder balls of the module 1.
  • the module 1 is mounted on a substrate 2, a plurality of components 3 mounted on the upper surface 2a of the substrate 2, a component 4 mounted on the lower surface 2b, and the lower surface 2b.
  • a plurality of solder balls 5 serving as external connection terminals, sealing resin layers 6 a and 6 b stacked on the upper surface 2 a and the lower surface 2 b of the substrate 2 and sealing the substrate 2, the components 3 and the components 4 And a shield film 7 covering the upper surface, and mounted on a mother substrate (not shown) via solder balls 5.
  • the substrate 2 is made of, for example, low-temperature co-fired ceramic, glass epoxy resin, etc., and via conductors (not shown) and various wiring electrodes (not shown) are formed inside. Further, on the upper surface 2 a and the lower surface 2 b of the substrate 2, connection electrodes 8 for connecting to the plurality of components 3, the components 4 and the solder balls 5 are formed.
  • the substrate 2 may have either a single layer structure or a multilayer structure.
  • the component 3 (corresponding to the “second component” of the present invention) is formed of, for example, a semiconductor element made of Si or the like, and an electronic component such as a chip capacitor, a chip inductor, a chip resistor, or a chip antenna.
  • the component 3 is sealed by the sealing resin layer 6a.
  • the component 4 (corresponding to the “first component” in the present invention) is a semiconductor component such as a semiconductor element formed of Si or the like, and is mounted on the lower surface 2 b of the substrate 2.
  • the component 4 is sealed by the sealing resin layer 6b, but a part thereof corresponds to the surface 60b of the sealing resin layer 6b (the "surface opposite to the surface facing the one main surface” of the present invention). It may be exposed from).
  • the solder balls 5 are mounted on the lower surface 2 b (corresponding to the “one main surface” of the present invention) of the substrate 2 and connected to the connection electrodes 8 on the lower surface 2 b.
  • the solder ball 5 is partly exposed and protruded from the surface 60b of the sealing resin layer 6b, and the module body 1 is connected to the mother substrate in the portion exposed from the surface 60b of the sealing resin layer 6b. It functions as an external connection terminal.
  • the height of the solder ball 5 and the sealing resin layer 6b from the lower surface 2b of the substrate 2 is higher than the latter, and a portion of the solder ball 5 protrudes from the surface 60b of the sealing resin layer 6b.
  • the module 1 can be connected to the mother substrate by connecting the protruding portions of the solder balls 5 to the electrodes of the mother substrate as bumps.
  • a gap 9 (corresponding to the "gap" in the present invention) between the solder ball 5 and the sealing resin layer 6b. That is, there is a portion where the solder ball 5 and the sealing resin layer 6b are not in contact with each other.
  • connection electrode 8 is electrically connected to the wiring layer 11.
  • the opposing surface 61 b of the sealing resin layer facing the outer peripheral surface 50 a of the solder ball 5 is a curved surface that forms a curve in a cross section perpendicular to the lower surface 2 b of the substrate 2.
  • the opposing surface 61b has a shape in which a part of the sphere is hollowed out of the sealing resin layer 6b.
  • the sealing resin layer 6 a is provided on the upper surface 2 a of the substrate 2 so as to cover the upper surface 2 a of the substrate 2 and the respective components 3.
  • the sealing resin layer 6 b is provided on the lower surface 2 b of the substrate 2 so as to cover the component 4. Further, as shown in FIGS. 2A to 2C, the solder balls 5 are surrounded by the sealing resin layer 6b.
  • the sealing resin layers 6a and 6b can be formed of a resin generally employed as a sealing resin such as an epoxy resin containing a silica filler. Alumina fillers can also be used because of their high thermal conductivity.
  • the shield film 7 is for shielding various electrodes in the substrate 2 and electromagnetic waves from the outside with respect to the respective components 3 and 4, and the side surface and the upper surface (surface 60 a of the sealing resin layer 6 a) of the module 1 It is arranged to cover. Further, the shield film 7 can be formed in a multilayer structure having an adhesive film, a conductive film laminated on the adhesive film, and a protective film laminated on the conductive film.
  • a substrate 2 on which components can be mounted is prepared on the upper surface 2a and the lower surface 2b, solder paste is applied to the lower surface 2b of the substrate 2, and connection electrodes 8 are printed.
  • the amount of the applied solder paste may be increased, and the solder ball 5 may be formed utilizing the fact that the solder paste becomes ball-like when heated later in a reflow furnace. .
  • heat treatment is performed to fix the component 4 and the solder ball 5 on the lower surface 2 b of the substrate 2. Flux cleaning may be performed after the heat treatment in the reflow furnace.
  • the sealing resin layer 6b is laminated on the lower surface 2b of the substrate 2 so as to cover the component 4 and the solder ball 5.
  • the surface 60b of the sealing resin layer 6b is polished until the solder balls 5 are exposed.
  • the polishing amount of the sealing resin layer 6b is adjusted so that parts other than the solder balls 5 are not exposed.
  • the height of the sealing resin layer 6b may be adjusted so that a part of the component 4 is exposed from the surface 60b of the sealing resin layer 6b.
  • solder paste is applied to the upper surface 2 a of the substrate 2 to print the connection electrodes 8, and the components 3 are mounted. Thereafter, a flux is applied to the exposed surfaces 5a of the solder balls 5 on the surface 60b of the sealing resin layer 6b, and heat treatment is performed in a reflow furnace. Flux cleaning may be performed after the heat treatment in the reflow furnace.
  • each component 3 is fixed to the substrate 2 as shown in FIG. 3E, and the solder ball 5 protrudes from the surface 60b of the sealing resin layer 6b by surface tension of the solder. It becomes a shape that
  • the sealing resin layer 6a is laminated on the upper surface 2a of the substrate 2 so as to cover the respective components 3.
  • the module 1 is completed by depositing the shield film 7 using a sputtering apparatus or a vacuum evaporation apparatus.
  • FIG. 5A is a view showing a state after the surface 60b of the sealing resin layer 6b is polished to expose the solder balls 5 from the surface 60b of the sealing resin layer 6b.
  • the surface 60 b of the sealing resin layer 6 b and the exposed surface 5 a of the solder ball 5 form the same plane.
  • the solder ball 5 becomes substantially spherical due to the surface tension of the solder and the sealing resin It protrudes from the surface 60b of the layer 6b.
  • void 9 which is a portion where the solder ball 5 and the sealing resin layer 6b are not in contact with each other.
  • the portion protruding from the surface 60b of the solder ball 5 can be mounted on the mother substrate 12 as it is as a solder bump.
  • the external connection terminal of the module 1 is formed by one solder ball 5, it has a shape without a constriction, and the reliability and the mechanical strength can be improved. Further, by using the solder balls 5 for the external connection terminals, it is possible to realize high precision of the positions of the external connection terminals by the self alignment effect when the heat treatment is performed in the reflow furnace. Moreover, since a part of solder ball 5 is exposed from surface 60b of sealing resin layer 6b and a part of solder ball 5 protrudes from surface 60b of the sealing resin layer, the solder ball is not plated. 5 can be used as an external connection terminal.
  • the presence of the air gap 9 between the solder ball 5 and the sealing resin layer 6 b makes it possible to reduce the stress due to the difference in thermal expansion coefficient between the solder and the resin, and a crack occurs in the solder ball 5. Can be suppressed.
  • the height of the module 1 can be reduced by polishing the surface 60b of the sealing resin layer 6b until the component 4 is exposed.
  • a flux is applied to the exposed surfaces 5a of the solder balls 5 and heat treatment is performed in a reflow furnace. It becomes spherical and has a shape protruding from the surface 60b, and can be used as a bump for mounting on a mother substrate as it is.
  • the opposing surface of the sealing resin layer facing the outer peripheral surface of the external connection terminal is a curved surface forming a curve in a cross section perpendicular to one main surface of the substrate, whereby the opposing surface is a curved surface forming a straight line in the cross section.
  • the opposing surface 61b1 is a straight line in the cross section, the cross-sectional area of the sealing resin layer 6b1 linearly decreases between A1-B1, and the sealing resin layer 6b1 between B1-C. The cross section does not decrease.
  • the cross-sectional area reduction rate of the sealing resin layer 6b1 changes rapidly with B1 as a boundary, so when stress is applied in the horizontal direction of the module 1, the load is concentrated on B1 and sealing is performed from the substrate 2 Peeling of the resin layer 6b1 is likely to occur.
  • the opposing surface 61b2 has a curved line in the cross section as in the embodiment described above, the decrease in the cross sectional area of the sealing resin layer 6b2 is not linear between A2 and B2, and the cross sectional area decreases from A2 to B2. Since the rate gradually decreases, there is no abrupt change in the cross-sectional area reduction rate at B2. For this reason, concentration of the load in B2 can be avoided and generation

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Abstract

モジュール１は、基板２と、基板２の上面２ａに実装された複数の部品３と、下面２ｂに実装された部品４と、下面２ｂに実装され、外部接続端子として機能する半田ボール５と、基板２の上面２ａおよび上面２ｂに積層された封止樹脂層６ａ、６ｂと、モジュール１の側面と上面を覆うシールド膜７とを備える。半田ボール５は、封止樹脂層６ｂの表面６０ｂから一部が露出しており、露出した部分が封止樹脂層６ｂから突出した形状となっている。半田ボール５の突出部分を外部接続端子としてマザー基板の電極と接続することにより、モジュール１をマザー基板に接続することができる。半田ボール５と封止樹脂層６ｂとの間には空隙部９があり、半田と樹脂との熱膨張係数の差によるストレスを軽減して、半田ボール５にクラックが発生することを抑制することができる。

Description

モジュールおよびその製造方法
　本発明は、モジュールとその製造方法に関する。
　従来、基板に略球状の導電性支柱を配置することにより外部接続端子を形成する技術が知られている。例えば、図７に示すように、特許文献１に記載のモジュール１００は、半導体基板１０１の主面に形成されている電極パッド１０２を有する半導体チップ１０３上に、配線１０４を介して電極パッド１０２と電気的に接続されている略球状の導電性ボール１０５が形成されている。半導体チップ１０３上には、導電性ボール１０５の頂部が露出するように樹脂層１０６が形成され、樹脂層１０６から露出した導電性ボール１０５の頂部には半田ボールからなる外部接続端子１０７が設けられている。このような構成のモジュール１００では、導電性ボール１０５を配線１０４の所定の位置に載置することにより、樹脂層１０６内に配線１０４と外部接続端子１０７とを接続するための支柱を形成することができ、めっき法による支柱の形成に比べて極めて短時間に目的の高さの支柱を形成することができる。
特許第４６２６００８号公報（段落００２３～００２５、図６など参照）
　しかしながら、特許文献１のように、導電性ボール１０５の頂部に外部接続端子１０７を設ける場合、マザー基板に実装する際に、導電性ボール１０５と外部接続端子１０７との接続部分がくびれた形状となるため、信頼性や機械的強度が低下するという問題がある。また、導電性ボール１０５の頂部は樹脂層１０６と同一平面上にあり、マザー基板と接続する際のバンプとして、半田ボールからなる外部接続端子１０７を設ける必要があり、製造工程の数が増加するという課題や、樹脂層１０６に半田ボールからなる外部接続端子１０７を載せるため低背化が難しいという課題がある。
　本発明は、上記した課題に鑑みてなされたものであり、くびれ形状のない外部接続端子を半田ボールにより形成し、信頼性や機械的強度を向上させたモジュールを提供することを目的とする。
　上記した目的を達成するために、本発明のモジュールは、基板と、前記基板の一方主面に設けられた接続電極と、前記基板の前記一方主面に実装された第１部品と、前記基板の前記一方主面に前記接続電極を介して配設された半田ボールからなる外部接続端子と、前記基板の前記一方主面に設けられ、前記基板の一方主面および前記第１部品を封止する封止樹脂層とを備え、前記外部接続端子の一部は、前記封止樹脂層の前記基板の前記一方主面との対向面と反対側の面から露出し、前記外部接続端子の前記基板の前記一方主面からの高さは、前記封止樹脂層の前記基板の前記一方主面からの高さよりも高く、前記外部接続端子と前記封止樹脂層との間には隙間があり、前記外部接続端子を囲っている前記封止樹脂層の前記外部接続端子との対向面は、前記基板の前記一方主面と垂直な断面において曲線をなす曲面であることを特徴としている。
　この構成によると、外部接続端子が半田ボールにより形成されており、くびれのない形状となるため、外部接続端子の機械的強度や信頼性を向上させることができる。また、半田により外部接続端子を形成するため、リフロー時のセルフアライメント効果により外部接続端子の位置の高精度化を実現することができる。また、半田ボールが封止樹脂層より露出して突出した形状となっているため、端子部にめっきを施す必要がなく、製造コストを抑制することができる。
　また、外部接続端子を囲っている封止樹脂層の前記外部接続端子との対向面が、基板の一方主面と垂直な断面において曲線をなす曲面であることにより、対向面が断面において直線をなす曲面である場合と比較して、基板に対する水平方向への応力に対する負荷が分散されるため、剥離の発生を抑制することができる。
　また、前記外部接続端子は、１つの半田ボールにより形成されていてもよい。この場合、半田ボールが封止樹脂層から丸く突出した形状となるため、このままマザー基板へ接続する際のバンプとして利用することができる。
　また、前記外部接続端子と前記封止樹脂層とが全く接していなくてもよい。この場合、半田ボールと封止樹脂層とが接していないことにより、半田と樹脂との熱膨張係数の差によるストレスを軽減することができ、半田ボールへのクラックの発生を抑制することができる。
　また、前記第１部品の一部は、前記封止樹脂層の前記反対側の面から露出していてもよい。この場合、モジュールの低背化を実現することができる。
　前記第１部品の前記封止樹脂層の前記反対側の面から露出している面は、前記封止樹脂層の前記反対側の面と同一平面上にあってもよい。この場合、モジュールの低背化を実現することができる。
　また、前記基板の他方主面に第２部品が実装されていてもよい。この場合、基板の他方主面にも部品を実装することで実装面積を広くすることができ、設計自由度を向上させることができる。
　また、本発明のモジュールの製造方法は、基板の一方主面の実装電極に部品と半田ボールを搭載する工程と、前記基板をリフロー炉で加熱し、前記部品と前記半田ボールを前記基板に固定する工程と、前記部品と前記半田ボールとを封止する封止樹脂層を前記基板の前記一方主面に積層する工程と、前記半田ボールが前記封止樹脂層の前記一方主面との対向面と反対側の面から露出するように、前記封止樹脂層の前記反対側の面および前記半田ボールの一部を研磨する工程と、前記半田ボールの前記基板の前記一方主面からの高さが前記封止樹脂層の前記基板の前記一方主面からの高さよりも高くなるように、前記基板をリフロー炉で再加熱する工程とを備えることを特徴としている。
　この場合、封止樹脂層を研磨して半田ボールを露出させた後、リフロー炉で加熱処理を行うと、半田ボールが表面張力により球状に変形して封止樹脂層の研磨面より突出した形状となり、半田ボールをバンプとして利用することができる。このため、改めてマザー基板へ接続するためのバンプを形成する必要がない。また、半田ボールを外部接続端子として搭載するので、めっきを施す必要がないため、めっき異常析出が発生せず、信頼性や機械的強度の高いモジュールを製造することができる。
　本発明によれば、信頼性や機械的強度の高いモジュールを提供することができ、また、モジュールの低背化を実現することができる。
本発明の一実施形態に係るモジュールの断面図である。 図１のモジュールの半田ボールの実装方法の例を示す拡大断面図である。 図１のモジュールの製造工程を示す図である。 図１のモジュールの製造工程を示す図である。 図１のモジュールをマザー基板に実装する工程を示す図である。 半田ボール周辺の封止樹脂層の形状を説明するための図である。 従来のモジュールを示す図である。
　本発明の一実施形態に係るモジュール１について、図１および図２を参照して説明する。なお、図１はモジュール１の断面図、図２はモジュール１の半田ボールの実装方法の例を示す拡大断面図である。
　この実施形態に係るモジュール１は、図１に示すように、基板２と該基板２の上面２ａに実装された複数の部品３と、下面２ｂに実装された部品４と、下面２ｂに搭載され外部接続端子となる複数の半田ボール５と、基板２の上面２ａおよび下面２ｂに積層され、基板２、各部品３および部品４を封止する封止樹脂層６ａ、６ｂと、モジュール１の側面および上面を被覆するシールド膜７とを備え、半田ボール５を介してマザー基板（図示省略）に搭載される。
　基板２は、例えば、低温同時焼成セラミックスやガラスエポキシ樹脂などで形成され、内部にビア導体（図示省略）や各種の配線電極（図示省略）が形成される。また、基板２の上面２ａおよび下面２ｂには、複数の部品３、部品４および半田ボール５と接続するための接続電極８が形成される。なお、基板２は単層構造および多層構造のいずれであってもよい。
　部品３（本発明の「第２部品」に相当する）は、例えば、Ｓｉ等で形成された半導体素子や、チップコンデンサ、チップインダクタ、チップ抵抗、チップアンテナなどの電子部品で構成される。部品３は封止樹脂層６ａにより封止されている。
　部品４（本発明の「第１部品」に相当する）は、Ｓｉ等で形成された半導体素子などの半導体部品であり、基板２の下面２ｂに実装されている。なお、部品４は封止樹脂層６ｂにより封止されているが、一部が封止樹脂層６ｂの表面６０ｂ（本発明の「一方主面との対向面と反対側の面」に相当する）から露出していてもよい。
　半田ボール５は、基板２の下面２ｂ（本発明の「一方主面」に相当する）に実装され、下面２ｂの接続電極８に接続される。また、半田ボール５は、封止樹脂層６ｂの表面６０ｂから一部が露出して突出しており、封止樹脂層６ｂの表面６０ｂから露出している部分は、モジュール１をマザー基板に接続する際の外部接続端子として機能する。換言すると、半田ボール５および封止樹脂層６ｂそれぞれの基板２の下面２ｂからの高さは、前者が後者より高く、半田ボール５の一部が封止樹脂層６ｂの表面６０ｂから突出した形状となっており、半田ボール５の突出部分をバンプとしてマザー基板の電極と接続することにより、モジュール１をマザー基板に接続することができる。また、半田ボール５と封止樹脂層６ｂとの間には空隙部９（本発明の「隙間」に相当する）がある。すなわち、半田ボール５と封止樹脂層６ｂとが接していない部分がある。
　また、半田ボール５の実装方法には、図２（ａ）に示すような、接続電極８の周縁部がソルダーレジスト１０により覆われているオーバーレジスト構造や、図２（ｂ）に示すような、接続電極８とソルダーレジスト１０との間にクリアランスがある、すなわち、接続電極８とソルダーレジスト１０とが接触していないクリアランスレジスト構造、図２（ｃ）に示すような構造などがある。また、図２（ａ）～（ｃ）に示すように、接続電極８は配線層１１と電気的に接続されている。また、半田ボール５の外周面５０ａと対向する封止樹脂層の対向面６１ｂは、基板２の下面２ｂと垂直な断面において曲線をなす曲面である。換言すれば、対向面６１ｂは封止樹脂層６ｂから球体の一部をくり抜いたような形状をしている。
　封止樹脂層６ａは、基板２の上面２ａおよび各部品３を被覆するように基板２の上面２ａに設けられる。また、封止樹脂層６ｂは、基板２の下面２ｂ、部品４を被覆するように基板２の下面２ｂに設けられる。また、図２（ａ）～（ｃ）に示すように、半田ボール５は封止樹脂層６ｂに囲まれている。封止樹脂層６ａ、６ｂは、シリカフィラ入りのエポキシ樹脂等の封止樹脂として一般的に採用される樹脂で形成することができる。また、高熱伝導のため、アルミナフィラを使用することもできる。
　シールド膜７は、基板２内の各種電極や、各部品３、４に対する外部からの電磁波を遮蔽するためのものであり、モジュール１の側面と上面（封止樹脂層６ａの表面６０ａ）とを被覆するように配置される。また、シールド膜７は、密着膜と、密着膜に積層された導電膜と、導電膜に積層された保護膜とを有する多層構造で形成することができる。
　（モジュールの製造方法）
　次に、本発明のモジュール１の製造方法の一例について、図３および図４を参照して説明する。
　まず、図３（ａ）に示すように、その上面２ａおよび下面２ｂに部品を実装可能な基板２を用意し、基板２の下面２ｂに半田ペーストを塗布して接続電極８を印刷して、部品４および半田ボール５を実装する。なお、半田ボール５を実装する代わりに、半田ペーストの塗布量を多くして、後にリフロー炉で加熱する際に半田ペーストがボール状になることを利用して半田ボール５を形成してもよい。その後、リフロー炉に投入して加熱処理を行い、基板２の下面２ｂに部品４と半田ボール５を固定する。リフロー炉での加熱処理の後にフラックス洗浄を行ってもよい。
　次に、図３（ｂ）に示すように、部品４と半田ボール５を被覆するように基板２の下面２ｂに封止樹脂層６ｂを積層する。
　次に、図３（ｃ）に示すように、封止樹脂層６ｂの表面６０ｂを、半田ボール５が露出するまで研磨する。この時、半田ボール５以外の部品が露出しないように封止樹脂層６ｂの研磨量を調節する。なお、封止樹脂層６ｂの表面６０ｂから部品４の一部が露出するように封止樹脂層６ｂの高さを調整してもよい。
　次に、図３（ｄ）に示すように、基板２の上面２ａに半田ペーストを塗布して接続電極８を印刷し、各部品３を実装する。その後、封止樹脂層６ｂの表面６０ｂの半田ボール５の露出面５ａにフラックスを塗布して、リフロー炉にて加熱処理を行う。リフロー炉での加熱処理の後にフラックス洗浄を行ってもよい。
　リフロー炉で加熱処理を行うと、図３（ｅ）に示すように、各部品３が基板２に固定され、また、半田の表面張力により半田ボール５が封止樹脂層６ｂの表面６０ｂから突出した形状となる。
　次に、図４（ａ）に示すように、各部品３を被覆するように基板２の上面２ａに封止樹脂層６ａを積層する。
　次に、図４（ｂ）に示すように、スパッタ装置や真空蒸着装置を用いてシールド膜７を成膜することにより、モジュール１が完成する。
　なお、基板２の上面２ａに各部品３を実装した後にリフロー炉で加熱処理を行って各部品３を基板２に固定した後、封止樹脂層６ｂの表面６０ｂを研磨して、露出面５ａにフラックスを塗布し、再度リフロー炉で加熱処理を行ってもよい。
　ここで、モジュール１の表面６０ｂの研磨からマザー基板への実装までの一連の工程を、図５を参照して説明する。なお、図５では、シールド膜７が図示省略されている。
　図５（ａ）は、封止樹脂層６ｂの表面６０ｂを研磨して半田ボール５を封止樹脂層６ｂの表面６０ｂから露出させた後を示す図である。このとき、封止樹脂層６ｂの表面６０ｂと半田ボール５の露出面５ａとは同一平面を形成している。半田ボール５の露出面５ａにフラックスを塗布し、リフロー炉で加熱処理を行うと、図５（ｂ）に示すように、半田の表面張力により、半田ボール５は、略球状になり封止樹脂層６ｂの表面６０ｂから突出した形状となる。このとき、半田ボール５と封止樹脂層６ｂとが接触していない部分である空隙部９ができる。図５（ｃ）に示すように、半田ボール５の表面６０ｂから突出した部分をそのまま半田バンプとして利用して、マザー基板１２へ実装することができる。
　したがって、上記した実施形態によれば、モジュール１の外部接続端子は１つの半田ボール５により形成されているためくびれのない形状となり、信頼性や機械的強度を向上させることができる。また、外部接続端子に半田ボール５を使用することで、リフロー炉で加熱処理を行う際のセルフアライメント効果により、外部接続端子の位置の高精度化を実現することができる。また、封止樹脂層６ｂの表面６０ｂから半田ボール５の一部が露出し、また、半田ボール５の一部が封止樹脂層の表面６０ｂから突出しているため、めっきを施すことなく半田ボール５を外部接続端子として使用することができる。さらに、外部接続端子に金属ピンを使用した場合と比べて、めっき処理が不要であるため封止樹脂層６ｂの表面６０ｂを研磨する際の研磨残渣によるめっき異常析出が発生しない。また、半田ボール５と封止樹脂層６ｂとの間に空隙部９があることにより、半田と樹脂との熱膨張係数の差によるストレスを軽減することができ、半田ボール５にクラックが発生するのを抑制することができる。
　また、封止樹脂層６ｂの表面６０ｂを部品４が露出するまで研磨することにより、モジュール１の低背化が可能である。
　また、封止樹脂層６ｂの表面６０ｂを半田ボール５が露出するまで研磨した後、半田ボール５の露出面５ａにフラックスを塗布してリフロー炉で加熱処理を行うことにより、半田ボール５が略球状となって表面６０ｂから突出した形状となり、このままマザー基板に実装する際のバンプとして利用することができる。
　また、外部接続端子の外周面と対向する封止樹脂層の対向面が、基板の一方主面と垂直な断面において曲線をなす曲面であることにより、対向面が断面において直線をなす曲面である場合と比較して、基板に対する水平方向への応力に対する負荷が分散されるため、剥離の発生を抑制することができる。図６に示すように、断面において対向面６１ｂ１が直線をなす場合、Ａ１－Ｂ１間において封止樹脂層６ｂ１の断面積が線型的に減少し、Ｂ１－Ｃ間においては封止樹脂層６ｂ１の断面積は減少しない。このとき、Ｂ１を境界として封止樹脂層６ｂ１の断面積減少率が急激に変化するため、モジュール１の水平方向への応力がかかった場合に、Ｂ１に負荷が集中して基板２から封止樹脂層６ｂ１の剥離が発生しやすい。一方、上記した実施形態のように、断面において対向面６１ｂ２が曲線をなす場合、Ａ２－Ｂ２間において封止樹脂層６ｂ２の断面積の減少は線形ではなく、Ａ２からＢ２に向かうに従い断面積減少率が徐々に小さくなるため、Ｂ２における急激な断面積減少率の変化がない。このため、Ｂ２における負荷の集中を回避することができ、基板２からの封止樹脂層６ｂ２の剥離の発生を抑制することができる。
　なお、本発明は上記した実施形態に限定されるものではなく、その趣旨を逸脱しない限りにおいて、上記したもの以外に種々の変更を行なうことが可能である。
　また、本発明は、種々のモジュールに適用することができる。
　１　　　　モジュール
　２　　　　基板
　３　　　　部品（第１部品）
　４　　　　部品（第２部品）
　５　　　　半田ボール（外部接続端子）
　６ａ、６ｂ　　　　封止樹脂層
　６１ｂ　　　　対向面
　８　　　　接続電極
 

Claims (7)

  1. 　基板と、
    　前記基板の一方主面に設けられた接続電極と、
    　前記基板の前記一方主面に実装された第１部品と、
    　前記基板の前記一方主面に前記接続電極を介して配設された半田ボールからなる外部接続端子と、
    　前記基板の前記一方主面に設けられ、前記基板の前記一方主面および前記第１部品を封止する封止樹脂層とを備え、
    　前記外部接続端子の一部は、前記封止樹脂層の前記基板の前記一方主面との対向面と反対側の面から露出し、
    　前記外部接続端子の前記基板の前記一方主面からの高さは、前記封止樹脂層の前記基板の前記一方主面からの高さよりも高く、
    　前記外部接続端子と前記封止樹脂層との間には隙間があり、
    　　前記外部接続端子を囲っている前記封止樹脂層の前記外部接続端子との対向面は、前記基板の前記一方主面と垂直な断面において曲線をなす曲面である
    　ことを特徴とするモジュール。
  2. 　前記外部接続端子は、１つの半田ボールにより形成されていることを特徴とする請求項１に記載のモジュール。
  3. 　前記外部接続端子と前記封止樹脂層とが全く接していないことを特徴とする請求項１または２のいずれかに記載のモジュール。
  4. 　前記第１部品の一部は、前記封止樹脂層の前記反対側の面から露出していることを特徴とする請求項１ないし３のいずれかに記載のモジュール。
  5. 　前記第１部品の前記封止樹脂層の前記反対側の面から露出している面は、前記封止樹脂層の前記反対側の面と同一平面上にあることを特徴とする請求項４に記載のモジュール。
  6. 　前記基板の他方主面に第２部品が実装されていることを特徴とする請求項１ないし５のいずれかに記載のモジュール。
  7. 　基板の一方主面の実装電極に部品と半田ボールを搭載する工程と、
    　前記基板をリフロー炉で加熱し、前記部品と前記半田ボールを前記基板に固定する工程と、
    　前記基板、前記部品および前記半田ボールを封止する封止樹脂層を前記基板の前記一方主面に設ける工程と、
    　前記半田ボールが前記封止樹脂層の前記一方主面との対向面と反対側の面から露出するように、少なくとも前記封止樹脂層の前記反対側の面および前記半田ボールの一部を研磨する工程と、
    　前記半田ボールの前記基板の前記一方主面からの高さが前記封止樹脂層の前記基板の前記一方主面からの高さよりも高くなるように、前記基板をリフロー炉で再加熱する工程とを備える
    　ことを特徴とするモジュールの製造方法。
     
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US11276631B2 (en) 2022-03-15
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