WO2020066490A1 - 積層体および積層体の製造方法 - Google Patents

積層体および積層体の製造方法 Download PDF

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Publication number
WO2020066490A1
WO2020066490A1 PCT/JP2019/034548 JP2019034548W WO2020066490A1 WO 2020066490 A1 WO2020066490 A1 WO 2020066490A1 JP 2019034548 W JP2019034548 W JP 2019034548W WO 2020066490 A1 WO2020066490 A1 WO 2020066490A1
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Prior art keywords
electronic component
main surface
region
connection pad
laminate
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PCT/JP2019/034548
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English (en)
French (fr)
Inventor
岩本 敬
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株式会社村田製作所
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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 CN201980062405.9A priority Critical patent/CN112740382B/zh
Publication of WO2020066490A1 publication Critical patent/WO2020066490A1/ja
Priority to US17/203,850 priority patent/US12002779B2/en

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    • H01L2225/00Details relating to assemblies covered by the group H01L25/00 but not provided for in its subgroups
    • H01L2225/03All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00
    • H01L2225/04All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers
    • H01L2225/065All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers the devices being of a type provided for in group H01L27/00
    • H01L2225/06503Stacked arrangements of devices
    • H01L2225/06548Conductive via connections through the substrate, container, or encapsulation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2225/00Details relating to assemblies covered by the group H01L25/00 but not provided for in its subgroups
    • H01L2225/03All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00
    • H01L2225/04All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers
    • H01L2225/065All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers the devices being of a type provided for in group H01L27/00
    • H01L2225/06503Stacked arrangements of devices
    • H01L2225/06555Geometry of the stack, e.g. form of the devices, geometry to facilitate stacking
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2225/00Details relating to assemblies covered by the group H01L25/00 but not provided for in its subgroups
    • H01L2225/03All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00
    • H01L2225/04All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers
    • H01L2225/065All the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/648 and H10K99/00 the devices not having separate containers the devices being of a type provided for in group H01L27/00
    • H01L2225/06503Stacked arrangements of devices
    • H01L2225/06555Geometry of the stack, e.g. form of the devices, geometry to facilitate stacking
    • H01L2225/06568Geometry of the stack, e.g. form of the devices, geometry to facilitate stacking the devices decreasing in size, e.g. pyramidical stack
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/01Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L24/02Bonding areas ; Manufacturing methods related thereto
    • H01L24/03Manufacturing methods
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/01Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L24/10Bump connectors ; Manufacturing methods related thereto
    • H01L24/12Structure, shape, material or disposition of the bump connectors prior to the connecting process
    • H01L24/13Structure, shape, material or disposition of the bump connectors prior to the connecting process of an individual bump connector
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03HIMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H3/00Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators
    • H03H3/007Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks
    • H03H3/08Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of resonators or networks using surface acoustic waves
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03HIMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02Details
    • H03H9/05Holders; Supports
    • H03H9/0538Constructional combinations of supports or holders with electromechanical or other electronic elements
    • H03H9/0547Constructional combinations of supports or holders with electromechanical or other electronic elements consisting of a vertical arrangement
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03HIMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02Details
    • H03H9/05Holders; Supports
    • H03H9/0538Constructional combinations of supports or holders with electromechanical or other electronic elements
    • H03H9/0547Constructional combinations of supports or holders with electromechanical or other electronic elements consisting of a vertical arrangement
    • H03H9/0557Constructional combinations of supports or holders with electromechanical or other electronic elements consisting of a vertical arrangement the other elements being buried in the substrate
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03HIMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
    • H03H9/00Networks comprising electromechanical or electro-acoustic devices; Electromechanical resonators
    • H03H9/02Details
    • H03H9/05Holders; Supports
    • H03H9/058Holders; Supports for surface acoustic wave devices
    • H03H9/059Holders; Supports for surface acoustic wave devices consisting of mounting pads or bumps

Definitions

  • the present invention relates to a laminate in which a plurality of electronic components are connected using solder bumps.
  • the laminated body described in Patent Literature 1 is formed by mounting another electronic component with a solder bump on a terminal of a structure including an electronic component therein.
  • an object of the present invention is to reduce the size of a laminate while enhancing the connection strength of the laminate.
  • a laminate of the present invention includes a first electronic component, a first region and a second region in plan view, a structure in which the first electronic component is arranged in the second region, and a connection pad connected to the structure. And the second electronic component bump-mounted.
  • the surface of the first region and the surface of the second region have a step.
  • the connection pad is formed on a surface of the first region, a surface of the second region, and a step surface formed by the step.
  • connection pad is larger than when the first region and the second region are flush with each other. For this reason, the area of the connecting portion between the first electronic component and the second electronic component is increased, and the connection strength of the laminate of the first electronic component and the second electronic component can be improved.
  • the increase in the area of the connection portion is formed by the step between the first region and the second region, the increase in the area of the structure in plan view can be suppressed, and the size of the stacked body can be reduced.
  • the method for manufacturing a laminate according to the present invention includes the following steps.
  • This manufacturing method includes a step of arranging the first electronic component on the surface of the support via the temporary fixing material, and a step of covering the temporary fixing material and the first electronic component, and supporting the first electronic component in an area other than the area where the first electronic component is arranged.
  • the above-described desired laminate is easily and accurately manufactured.
  • the method for manufacturing a laminate according to the present invention includes the following steps.
  • This manufacturing method includes a step of burying a part of the first electronic component in a temporary fixing material formed on the surface of the support, and a step of sealing with a resin so as to cover the temporary fixing material and the first electronic component. Removing the support and the temporary fixing material, and forming a connection pad so as to straddle a surface of the resin on which the support is disposed and a surface of the first electronic component on which the temporary fixing material is disposed. And bump mounting the second electronic component via the connection pad.
  • FIG. 1A is a side cross-sectional view showing a configuration of a laminate 10 according to a first embodiment of the present invention
  • FIG. 1B is a side cross-sectional view in which a part of FIG.
  • FIG. 2 is a plan view of the laminated body 10 according to the first embodiment of the present invention as viewed from the front side.
  • FIG. 3 is a flowchart showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • FIGS. 4A to 4D are side sectional views showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • 5A to 5C are side sectional views showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • FIG. 6A is a side cross-sectional view illustrating a configuration of a laminate 10A according to a second embodiment of the present invention
  • FIG. 6B is a side cross-sectional view in which a part of FIG. 6A is enlarged.
  • FIG. FIG. 7 is a flowchart showing a method for manufacturing the laminated body 10A according to the second embodiment of the present invention.
  • 8A to 8D are side cross-sectional views illustrating a method for manufacturing a laminated body 10A according to the second embodiment of the present invention.
  • FIGS. 9A to 9E are side cross-sectional views illustrating a method of manufacturing the laminated body 10A according to the second embodiment of the present invention.
  • FIGS. 14A to 14C are plan views of the laminate according to the seventh embodiment of the present invention as viewed from the front side.
  • FIG. 14A to 14C are plan views of the laminate according to the seventh embodiment of the present invention as viewed from the front side.
  • FIG. 15A is a side cross-sectional view illustrating a configuration of a stacked body 10J according to the eighth embodiment of the present invention
  • FIG. 15B is a stacked body 10J according to the eighth embodiment of the present invention.
  • FIG. 3 is a plan view when viewed from the front side.
  • FIG. 1A is a side cross-sectional view showing a configuration of a laminate 10 according to a first embodiment of the present invention
  • FIG. 1B is a side cross-sectional view in which a part of FIG.
  • FIG. 2 is a plan view of the laminated body 10 according to the first embodiment of the present invention as viewed from the front side.
  • FIG. 3 is a flowchart showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • FIGS. 4A to 4D are side sectional views showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • 5A to 5C are side sectional views showing a method for manufacturing the laminated body 10 according to the first embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are appropriately emphasized and described, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10 includes a first electronic component 100, a structure 150, a wiring electrode 161, a terminal electrode 162, a through electrode 165, solder resist layers 170 and 175, a connection pad 180, and a second pad.
  • the electronic component 200 includes a solder bump 300.
  • the first electronic component 100 is arranged on the structure 150.
  • the second electronic component 200 is mounted on the structure 150 on which the connection pads 180 are formed using the solder bumps 300.
  • the connection pad 180 is formed of, for example, Ni, Au, Pt, Pd, or the like.
  • the first electronic component 100 includes a main surface 101 and a main surface 102 that are substantially orthogonal to the height direction indicated by the thick arrow in FIG.
  • the main surface 101 is the “surface of the first electronic component” of the present invention.
  • the first electronic component 100 and the second electronic component 200 have, for example, a rectangular parallelepiped shape, and are an IC using a semiconductor substrate, a SAW filter using a piezoelectric substrate, or the like.
  • the structure 150 is formed of resin.
  • the structure 150 has a first region R1 and a second region R2 in plan view.
  • the second region R2 has a shape sandwiched between the first regions R1.
  • the first region R1 has a main surface 151 and a main surface 152 that are substantially perpendicular to the height direction and face each other.
  • the main surface 151 is the “surface of the first region” of the present invention.
  • the second region R2 has a main surface 153 and a main surface 154 that are substantially orthogonal to the height direction and face each other.
  • the structure 150 includes a first side surface S1 and a second side surface S2 that are substantially parallel to the height direction and face each other.
  • the main surface 152 of the first region R1 and the main surface 154 of the second region R2 are flush.
  • the main surface 151 of the first region R1 is formed at a position higher than the main surface 153 of the second region R2 in the height direction. At this time, the height difference between the main surface 151 and the main surface 153 is larger than the height of the first electronic component 100.
  • a through electrode 165 is formed inside the structure 150 in the first region R1.
  • a wiring electrode 161 is formed on the main surface 151.
  • the terminal electrode 162 is formed on the main surface 152.
  • the wiring electrode 161 is connected to the terminal electrode 162 via the through electrode 165.
  • Part of the terminal electrode 162 is covered with a solder resist layer 175.
  • the structure of the second region R2 of the structure 150 will be described.
  • the first electronic component 100 is arranged in the second region R2.
  • the first electronic component 100 is configured such that the main surface 102 of the first electronic component 100 and the main surface 153 of the structure 150 are in contact with each other, or the main surface 102 of the first electronic component 100 and the main surface 153 of the structure 150 are in contact with each other. It is arranged via an insulating layer and a metal conductor.
  • the position of the main surface 151 in the first region R1 is higher than the position of the main surface 101 of the first electronic component 100 in the height direction. Specifically, in the height direction, main surface 101 and main surface 151 have a step H1.
  • the step in the present invention is a height difference between the main surface 101 and the main surface 151 in the height direction, and the shape is not limited.
  • a height difference formed between a plurality of planes and a height difference formed between a high position and a low position are all described as steps.
  • the wiring electrode 161 is formed continuously from the main surface 151 described above to the main surface 101 of the first electronic component 100. That is, it is formed so as to straddle the step surface B1 connected to the main surface 151 of the structure 150 and the main surface 101 of the first electronic component 100.
  • the step surface B1 is a side surface of the first region R1 on the second region R2 side in the structure 150.
  • the main surface 101 of the second region R2 It is a surface exposed to the side.
  • the step surface B1 is a surface formed by the step H1.
  • connection pad 180 is opposite to the surface of the wiring electrode 161 opposite to the surface on the structure 150 side, that is, the surface of the wiring electrode 161 that is in contact with the main surface 151, the main surface 101 of the first electronic component 100, and the step surface B1. Formed on the side surface.
  • the second electronic component 200 is mounted on the connection pad 180 via the solder bump 300. At this time, the solder bumps 300 are connected so as to include the area of the step surface B1.
  • connection pad 180 is larger than the case where the main surface 101 and the main surface 151 are flush with each other by an area substantially equal to the area of the step surface B1. Therefore, the area of the connection portion with the solder bump 300 (hereinafter, connection area) can be increased.
  • the main surface 101 is lower than the main surface 151, and a portion of the connection pad 180 abutting on the step surface B ⁇ b> 1 is formed on the center side of the laminate 10 (the second region R ⁇ b> 2 side of the structure 150).
  • the laminated body 10 has a structure in which the region on the center side is more concave than the region on the outer edge side (the first region R1 side in the structure 150).
  • the thermal stress generated between the structure 150 and the second electronic component 200 is a force of the second electronic component 200 extending in a direction orthogonal to the height direction with respect to the main surface 151 of the structure 150.
  • the solder bump 300 is formed between the step surface B1 (step H1 portion) and the connection pad 180. It is pressed against the portion that contacts the step surface B1. Therefore, the connection strength between the connection pad 180 and the solder bump 300 is improved, and breakage can be suppressed.
  • FIG. 2 is a plan view of the laminated body 10 as viewed from the side on which the second electronic component 200 is mounted, in other words, from the main surface 101 side (the main surface 151 side).
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • FIG. 2 only the connection pads 180 and the solder bumps 300 are shown to indicate the direction of the step H1, and other configurations are omitted.
  • the solder bump 300 is formed so as to straddle the first region R1 and the second region R2. Further, two solder bumps 300 are formed at positions symmetrical with respect to the center position of the laminate 10.
  • the direction of the step H1 from the high surface (the main surface 151) to the low surface (the main surface 101) is from the first side surface S1.
  • the direction extends to the second side surface S2.
  • the direction from the high surface (main surface 151) to the low surface (main surface 101) of the step H1 of the right connection pad 180 (the connection pad 180 on the second side surface S2 side) is from the second side surface S2 to the first side surface. This is the direction extending to S1.
  • the solder bump 300 and the connection pad 180 is pressed against the step surface B1. Therefore, the connection strength between the solder bump 300 and the connection pad 180 is improved.
  • the contact area between the connection pad 180 and the solder bump 300 is increased by the step H1 (step surface B1) extending in the height direction, so that the side on which the second electronic component 200 is mounted, in other words, for example, it is possible to suppress an increase in the area of the connection pad 180 or the solder bump 300 when viewed from the main surface 101 side (main surface 151 side) in a plan view. Therefore, miniaturization of the laminate 10 can be realized.
  • FIG. 3 is a flowchart showing a method for manufacturing the laminate 10.
  • 4 (A), 4 (B), 4 (C), 4 (D), 5 (A), 5 (B), and 5 (C) show a method of manufacturing the laminated body 10. It is sectional drawing which shows the shape in the main process in the 1st example.
  • the support 440, the adhesive layer 430, and the power supply layer 420 are laminated in this order.
  • a through electrode 165 is formed on the surface of the power supply layer 420 opposite to the surface on which the support 440 is arranged by an electrolytic plating method or the like (S101).
  • the temporary fixing material 410 is partially disposed (between the through electrodes 165) on the surface of the power supply layer 420 opposite to the surface on which the support 440 is disposed, and the first temporary fixing material 410 is provided on the temporary fixing material 410.
  • the electronic component 100 is arranged (S102).
  • the temporary fixing member 410 is formed of, for example, a resin-based material such as a resin made of a polymer material or a resin containing a solvent.
  • the side of the power supply layer 420 opposite to the surface on which the support 440 is arranged is sealed with a resin and cured.
  • the penetrating electrode 165, the temporary fixing material 410, and the first electronic component 100 are sealed with resin so as to cover the through electrode 165, the temporary fixing material 410, and the first electronic component 100.
  • the structure 150 is formed in a region where the temporary fixing material 410 does not exist (S103).
  • the temporary fixing material 410, the power supply layer 420, the adhesive layer 430, and the support 440 are removed (S104).
  • the step H1 is formed by removing the temporary fixing material 410. That is, the step H1 is determined by the thickness of the temporary fixing material 410.
  • the wiring electrode 161 is formed on the side of the through electrode 165 where the structure 150 is not formed, in other words, on the portion where the temporary fixing material 410 is removed.
  • the wiring electrode 161 is formed so as to straddle a portion having the step H1 (portion of the step surface B1).
  • the connection pad 180 is formed so as to be in contact with the wiring electrode 161, that is, so as to straddle the portion having the step H1 (portion of the step surface B1) (S105).
  • the solder resist layer 170 is formed on the main surface of the structure 150 and the first electronic component 100 on the side where the wiring electrode 161 is formed, and on the wiring electrode 161. It may be formed.
  • the solder resist layer 170 is formed on a part of the solder resist layer 170 formed on the wiring electrode 161, specifically, on a part having a step H1.
  • the connection pad 180 that straddles the step surface B1 can be obtained.
  • the solder resist layer 170 is formed after the connection pad 180 is formed, the solder resist layer 170 is formed so as not to cover at least a part of the connection pad 180, so that the solder resist layer 170 extends over the step surface B1.
  • the connection pad 180 is obtained.
  • the main surface of the structure 150 on the side where the first electronic component 100 is not arranged is ground to expose the through electrode 165 (S106).
  • the terminal electrode 162 is formed so as to be connected to the through electrode 165.
  • a solder resist layer 175 is formed so as to cover a part of the terminal electrode 162 (S107).
  • the second electronic component 200 is mounted on the connection pad 180 via the solder bump 300 (S108).
  • FIG. 6A is a side cross-sectional view illustrating a configuration of a laminate 10A according to a second embodiment of the present invention
  • FIG. 6B is a side cross-sectional view in which a part of FIG. 6A is enlarged.
  • FIG. FIG. 7 is a flowchart illustrating a method for manufacturing the laminated body 10A.
  • 8A to 8D are side cross-sectional views illustrating a method for manufacturing a laminated body 10A according to the second embodiment of the present invention.
  • FIGS. 9A to 9D are side cross-sectional views illustrating a method of manufacturing the laminated body 10A according to the second embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are appropriately emphasized and described, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10A according to the second embodiment is different from the laminate 10 according to the first embodiment in that the first electronic component 100 shown in FIG. (A) differs in the arrangement position in the height direction indicated by the thick arrow, and in the shape of the step H2, the wiring electrode 161A, and the connection pad 180A.
  • the other basic configuration of the stacked body 10A is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • the first region R1 has a main surface 151 and a main surface 152 facing each other.
  • the second region R2 has a main surface 153A and a main surface 154 facing each other.
  • the main surface 152 of the first region R1 and the main surface 154 of the second region R2 are flush.
  • the main surface 151 is formed at a position higher than the main surface 153A in the height direction. However, the height difference between the main surface 151 and the main surface 153A is smaller than the height of the first electronic component 100.
  • the first electronic component 100 is disposed in the second region R2 of the structure 150A.
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • the first electronic component 100 is configured such that the main surface 102 of the first electronic component 100 abuts against the main surface 153A of the structure 150A, or the main surface 102 of the first electronic component 100 and the main surface 153A of the structure 150 contact each other. It is arranged via an insulating layer and a metal conductor.
  • the position of the main surface 151 in the first region R1 is lower than the position of the main surface 101 of the first electronic component 100 in the height direction.
  • the main surface 101 and the main surface 151 have a step H2.
  • the wiring electrode 161A is formed continuously over the main surface 101 of the first electronic component 100 and the main surface 151 of the structure 150A. That is, it is formed so as to straddle the step surface B2 of the main surface 151 of the structure 150A.
  • the step surface B2 is a side surface of the first region R1 on the second region R2 side in the structure 150A.
  • the main surface 101 of the second region R2 is removed. It is a surface exposed to the side.
  • the step surface B2 is a surface formed by the step H2.
  • connection pad 180A has a surface opposite to the surface of the wiring electrode 161A on the structure 150A side, that is, a surface that contacts the main surface 101, the main surface 151 of the first electronic component 100, and the step surface B2 in the wiring electrode 161A. It is formed on the opposite surface.
  • the second electronic component 200 is mounted on the connection pad 180A via the solder bump 300. At this time, the solder bumps 300 are connected so as to include the area of the step surface B2.
  • the main surface 101 and the main surface 151 have the step H2. That is, the connection pad 180A is larger than the case where the main surface 101 and the main surface 151 are flush with each other by an area substantially equal to the area of the step surface B2. Therefore, the connection area between the solder bump 300 and the connection pad 180A can be increased.
  • the stacked body 10A has a structure in which the main surface 101 is higher than the main surface 151, and a portion of the connection pad 180 that contacts the stepped surface B2 is exposed on the outer edge side of the stacked body 10A (on the first region R1 side in the structure 150A). It is. In other words, the region on the center side (the second region R2 side in the structure 150A) of the stacked body 10A protrudes from the region on the outer edge side.
  • the second electronic component 200 contracts in a direction perpendicular to the height direction with respect to the main surface 151 of the structure 150A.
  • the solder bumps 300 are connected to the step surface B2 (step H2 portion) and the connection pad 180A. Is pressed against a portion that contacts the step surface B2. Therefore, the connection strength between the connection pad 180A and the solder bump 300 is improved, and breakage can be suppressed.
  • step H2 step surface B2 extending in the height direction increases the contact area between the connection pad 180A and the solder bump 300, so that the side on which the second electronic component 200 is mounted, in other words, the main surface 101 side (the main surface 101 side) When viewed from above (from the surface 151 side), an increase in the area of the connection pads 180A and the solder bumps 300 can be suppressed. Therefore, miniaturization of the laminated body 10A can be realized.
  • FIG. 7 is a flowchart illustrating a method for manufacturing the laminated body 10A.
  • 8 (A), 8 (B), 8 (C), 8 (D), 8 (E), 9 (A), 9 (B), 9 (C), 9 (D) and FIG. 9 (E) are cross-sectional views showing shapes in main steps in a second example of the method of manufacturing the laminated body 10A.
  • the support 440, the temporary fixing material 410, and the power supply layer 420 are laminated in this order.
  • the through electrode 165 is formed on the surface of the power supply layer 420 opposite to the surface on which the support 440 is arranged by an electrolytic plating method, a conductive paste filling method, or the like (S201).
  • the temporary fixing material 410 also functions as an adhesive layer 430 for adhering the support 440 and the power supply layer 420.
  • the power supply layer 420 is etched to form the power supply electrode 425, and the temporary fixing material 410 in the arrangement region of the first electronic component 100 is exposed (S202).
  • the first electronic component 100 is arranged in the exposed area of the temporary fixing material 410 (S203). At this time, the first electronic component 100 is arranged on the temporary fixing material 410 such that the first electronic component 100 fills the temporary fixing material 410 at a predetermined depth.
  • the side of the temporary fixing material 410 opposite to the surface on which the support 440 is arranged is sealed with a resin and cured (S204). At this time, sealing is performed with resin so as to cover the through electrode 165, the temporary fixing material 410, and the first electronic component 100. Thereby, the structure 150A is formed.
  • the portion of the structure 150A opposite to the temporary fixing member 410 is ground to expose the through electrode 165 (S205).
  • the temporary fixing material 410, the power supply layer 425, and the support 440 are removed (S206).
  • the first electronic component 100 is disposed so as to be buried in the temporary fixing member 410 at a predetermined depth.
  • a step H2 is formed. That is, the step H2 is determined by the amount of the first electronic component 100 embedded in the temporary fixing member 410.
  • the wiring electrode 161A is formed on the side of the through electrode 165 where the structure 150A is not formed, in other words, on the side where the temporary fixing material 410 is removed.
  • the wiring electrode 161A is formed so as to straddle the portion having the step H2 (the portion of the step surface B2).
  • the connection pad 180A is formed so as to be in contact with the wiring electrode 161A, that is, so as to straddle the portion having the step H2 (portion of the step surface B2) (S207).
  • the solder resist layer 170 is placed on the main surface of the structure 150A and the first electronic component 100 on the side where the wiring electrode 161A is formed, and on the wiring electrode 161A. It may be formed.
  • the solder resist layer 170 is formed before the connection pad 180A is formed, the solder resist layer 170 is formed on a part of the solder resist layer 170 formed on the wiring electrode 161A, specifically, on a part having a step H2.
  • a connection pad 180A that straddles the step surface B2 can be obtained.
  • the solder resist layer 170 is formed after the connection pad 180A is formed, the solder resist layer 170 is formed so as not to cover at least a part of the connection pad 180A, so that the solder resist layer 170 extends over the step surface B2.
  • the connection pad 180A is obtained.
  • the terminal electrode 162 is formed so as to be connected to the through electrode 165.
  • a solder resist layer 175 is formed so as to cover a part of the terminal electrode 162 (S208).
  • the second electronic component 200 is mounted on the connection pad 180A via the solder bump 300 (S209).
  • FIG. 10 is a side cross-sectional view illustrating a configuration of a laminate 10B according to the third embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are emphasized as appropriate, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10B according to the third embodiment is different from the laminate 10 according to the first embodiment in that a resin film 190 is provided and a connection electrode 195 is provided. , And the shapes of the wiring electrode 161B and the connection pad 180B.
  • the other basic configuration of the stacked body 10B is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • the laminated body 10B includes the first electronic component 100, the structure 150, the terminal electrode 162, the wiring electrode 161B, the through electrode 165, the solder resist layers 170 and 175, the connection pad 180B, the resin film 190, and the connection.
  • An electrode 195, a second electronic component 200, and a solder bump 300 are provided.
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • the resin film 190 is formed continuously over the main surface 151, the step surface B1, and the main surface 101.
  • the resin film 190 is formed so as to straddle the step H1. More specifically, the resin film 190 covers an angle (a sharp portion) generated between the step surface B1 of the step H1 and the main surface 151 and between the step surface B1 and the main surface 101, and 151 and the main surface 101 are formed so as to be connected in a gentle shape (slope shape).
  • the wiring electrode 161B is formed so as to cover the surface of the resin film 190 opposite to the surface on the main surface 151, 101 side. Note that a connection electrode 195 is formed on the resin film 190, and the wiring electrode 161B is connected to the through electrode 165 via the connection electrode 195.
  • connection pad 180B is formed on the surface of the wiring electrode 161B opposite to the main surface 101, the step surface B1, and the main surface 151 of the first electronic component 100. More specifically, the connection pad 180B is formed so as to cover a slope-shaped surface connecting the first electronic component 100 and the structure 150 via the wiring electrode 161B and the resin film 190.
  • the second electronic component 200 is connected to the connection pad 180B via the solder bump 300.
  • the main surface 101 and the main surface 151 have the step H1. That is, the area of the connection pad 180B is larger than when the main surface 101 and the main surface 151 are flush with each other, and the connection area between the solder bump 300 and the connection pad 180B can be increased.
  • the stacked body 10B has a structure in which the main surface 101 is lower than the main surface 151 and the central region of the stacked body 10B is recessed from the outer edge region.
  • the thermal stress generated between the structure 150 and the second electronic component 200 is a force of the second electronic component 200 extending in a direction orthogonal to the height direction with respect to the main surface 151 of the structure 150.
  • the solder bump 300 is pressed against the step surface B1 (the portion of the step H1). Therefore, the connection strength between the connection pad 180B and the solder bump 300 is improved, and breakage can be suppressed.
  • FIG. 11 is a side cross-sectional view illustrating a configuration of a stacked body 10C according to the fourth embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are appropriately emphasized and described, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10C according to the fourth embodiment is different from the laminate 10A according to the second embodiment in that a resin film 190 is provided and a connection electrode 195 is provided. , And the shapes of the wiring electrode 161C and the connection pad 180C.
  • the other basic configuration of the stacked body 10C is the same as that of the stacked body 10A, and the description of the same portions will be omitted.
  • the laminate 10C includes a first electronic component 100, a structure 150C, a terminal electrode 162, a wiring electrode 161C, a through electrode 165, solder resist layers 170 and 175, connection pads 180C, a resin film 190, and a connection.
  • An electrode 195, a second electronic component 200, and a solder bump 300 are provided.
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • the resin film 190 is formed continuously over the main surface 151, the step surface B2, and the main surface 101.
  • the resin film 190 is formed so as to straddle the portion having the step H2. More specifically, the resin film 190 covers an angle (a sharp portion) generated between the step surface B2 of the step H2 and the main surface 151 and between the step surface B2 and the main surface 101, and 151 and the main surface 101 are formed so as to be connected in a gentle shape (slope shape).
  • the wiring electrode 161C is formed so as to cover the surface of the resin film 190 opposite to the surface on the main surface 151, 101 side.
  • the connection electrode 195 is formed on the resin film 190, and the wiring electrode 161C is connected to the through electrode 165 via the connection electrode 195.
  • connection pad 180C is formed on the surface of the wiring electrode 161C opposite to the main surface 101, the step surface B2, and the main surface 151 of the first electronic component 100. More specifically, the connection pad 180C is formed so as to cover a slope-shaped surface connecting the first electronic component 100 and the structure 150C via the wiring electrode 161C and the resin film 190.
  • the second electronic component 200 is connected to the connection pad 180C via the solder bump 300.
  • the main surface 101 and the main surface 151 have a step H2. That is, the area of the connection pad 180C is larger than in the case where the main surface 101 and the main surface 151 are flush with each other, and the connection area between the solder bump 300 and the connection pad 180 can be increased.
  • the thermal stress generated between the structure 150C and the second electronic component 200 is a force that causes the second electronic component 200 to shrink in a direction perpendicular to the height direction with respect to the main surface 151 of the structure 150C.
  • the solder bump 300 is pressed against the step H2. Therefore, the connection strength between the connection pad 180C and the solder bump 300 is improved, and breakage can be suppressed.
  • FIG. 12 is a side cross-sectional view illustrating a configuration of a stacked body 10D according to the fifth embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are emphasized as appropriate, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10D according to the fifth embodiment differs from the laminate 10 according to the first embodiment in that resin layers 191 and 192 are provided and connection electrodes 195 and 196 are provided.
  • the difference is in the provision thereof and the shapes of the wiring electrodes 161D and 163D and the connection pad 180D.
  • the other basic configuration of the stacked body 10D is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • the laminate 10D includes the first electronic component 100, the structure 150, the terminal electrodes 162, the wiring electrodes 161D and 163D, the through electrodes 165, the solder resist layers 170 and 175, the connection pads 180D, and the resin film 191. , 192, connection electrodes 195, 196, second electronic component 200, and solder bump 300.
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • the resin film 191 is formed continuously over the main surface 151, the step surface B1, and the main surface 101.
  • the resin film 191 is formed so as to straddle the portion having the step H1. More specifically, the resin film 191 covers an angle (an acute angle portion) generated between the step surface B1 of the step H1 and the main surface 151 and between the step surface B1 and the main surface 101, and 151 and the main surface 101 are formed so as to have a gentle shape (slope shape).
  • the wiring electrode 161D is formed so as to cover the surface of the resin film 191 on the side opposite to the surface on the main surface 151, 101 side.
  • the connection electrode 195 is formed on the resin film 191, and the wiring electrode 161D is connected to the through electrode 165 via the connection electrode 195.
  • the resin film 192 is formed so as to cover the surface of the resin film 191 and the wiring electrode 161D on the side opposite to the surface on the resin film 191 side. Similarly to the resin film 191, the resin film 192 is formed continuously over the main surface 151, the step surface B1, and the main surface 101.
  • the resin film 192 is formed so as to straddle the portion having the step H1. More specifically, the resin film 192 covers an angle (an acute angle portion) generated between the step surface B1 of the step H1 and the main surface 151 and between the step surface B1 and the main surface 101. 151 and the main surface 101 are formed so as to be connected in a gentle shape (slope shape).
  • the wiring electrode 163D is formed so as to cover the surface of the resin film 192 on the side opposite to the surface on the side of the wiring electrode 161D. Note that a connection electrode 196 is formed on the resin film 192. The wiring electrode 163D is connected to the wiring electrode 161D via the connection electrode 196.
  • connection pad 180D is formed on the surface of the wiring electrode 163D opposite to the main surface 101, the step surface B1, and the main surface 151 of the first electronic component 100. More specifically, the connection pad 180D is formed so as to cover a slope-shaped surface connecting the first electronic component 100 and the structure 150 via the wiring electrodes 161D and 163D and the resin films 191 and 192. .
  • the second electronic component 200 is connected to the connection pad 180D via the solder bump 300.
  • the main surface 101 and the main surface 151 have the step H1. That is, the area of the connection pad 180D is larger than when the main surface 101 and the main surface 151 are flush with each other, and the connection area between the solder bump 300 and the connection pad 180 can be increased.
  • the corners (sharp portions) formed between the step surface B1 of the step H1 and each of the main surfaces 151 and 101 are covered with a plurality of resin films 191 and 192, so that the sharp portions are covered with one resin film.
  • the stress of the solder bump 300 is less likely to concentrate at a specific location. Therefore, breakage in the solder bump 300 can be further suppressed.
  • the cushioning property of the laminate 10D can be improved, and damage to the laminate 10 at the time of mounting the second electronic component 200 or the like can be suppressed.
  • the stacked body 10D has a structure in which the main surface 101 is lower than the main surface 151, and the central region of the stacked body 10D is recessed from the outer edge region.
  • the thermal stress generated between the structure 150 and the second electronic component 200 is a force of the second electronic component 200 extending in a direction orthogonal to the height direction with respect to the main surface 151 of the structure 150.
  • the solder bump 300 is pressed against the step surface B1 (the portion of the step H1). Therefore, the connection strength between the connection pad 180D and the solder bump 300 is improved, and breakage can be suppressed.
  • the laminate 10C according to the above-described fourth embodiment may have a configuration including a plurality of resin films that straddle the step surface B1. In this case, the same effect as that of the present embodiment can be obtained.
  • FIG. 13 is a side cross-sectional view illustrating a configuration of a stacked body 10E according to the sixth embodiment of the present invention.
  • the vertical and horizontal dimensional relationships are emphasized as appropriate, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • the laminate 10E according to the sixth embodiment differs from the laminate 10 according to the first embodiment in that a plurality of auxiliary members 400 are provided.
  • the other basic configuration of the laminated body 10E is the same as that of the laminated body 10, and the description of the same parts will be omitted.
  • the plurality of auxiliary members 400 are formed on the surface of the connection pad 180 on the side where the second electronic component 200 is mounted.
  • the auxiliary member 400 is preferably a conductor.
  • the auxiliary member 400 is made of the same material as the connection pad 180, there is no difference in linear expansion coefficient between the auxiliary member 400 and the connection pad 180, so that it is more preferable in that high reliability can be obtained.
  • connection area between the solder bump 300 and the connection pad 180 can be further increased.
  • the position at which the plurality of auxiliary members 400 are arranged may be any position on the surface of the connection pad 180 where the connection pad 180 and the solder bump 300 are in contact.
  • the position where the auxiliary member 400 is arranged is such that a step is formed on the surface of the connection pad 180 (the surface opposite to the surface of the connection pad 180 on the wiring electrode 161 side) with the solder bump 300 by the auxiliary member 400.
  • the configuration in which two auxiliary members 400 are formed has been described. However, one or three or more configurations may be used, and a number that does not hinder the connection between the connection pad 180 and the solder bump 300 may be used. May be provided.
  • connection area is increased by forming the plurality of auxiliary members 400
  • the same effect can be obtained by making the surface of the connection pad 180 rough.
  • the solder bumps 300 enter the rough portion on the surface of the connection pad 180, the connection area increases, and the connection strength between the connection pad 180 and the solder bump 300 further improves.
  • the thickness of the step H1 in the height direction is preferably larger than the thickness of the roughest portion on the surface of the connection pad 180 described above. Thereby, the connection strength between the connection pad 180 and the solder bump 300 is more remarkably improved.
  • FIGS. 14A to 14C are plan views of the laminate according to the seventh embodiment of the present invention as viewed from the front side.
  • the vertical and horizontal dimensional relationships are appropriately emphasized, and do not always match the vertical and horizontal dimensional relationships in the actual size.
  • 14 (A), 14 (B), and 14 (C) show only the solder bumps 300, and other components are omitted.
  • the first electronic component 100 is arranged so as to overlap the second electronic component 200 in a plan view.
  • the stacked body 10F according to the seventh embodiment is different from the stacked body 10 according to the first embodiment in that two solder bumps 300F are provided on the first side surface S1 side, The difference is that two portions are formed on the two side surfaces S2. That is, the connection pads 180 connected to each of the solder bumps 300F are also formed at two places on the first side face S1 side and two places on the second side face S2 side.
  • the other basic configuration of the laminated body 10F is the same as that of the laminated body 10, and the description of the same portions will be omitted.
  • connection area of the connection pad 180 and the solder bump 300F can be further increased. Further, since the step H1 is formed in the height direction of the stacked body 10F, the area when the stacked body 10F is viewed in plan does not increase. Therefore, miniaturization of the laminate 10F can be realized.
  • the stacked body 10G according to the seventh embodiment is different from the stacked body 10 according to the first embodiment in that three solder bumps 300G are provided on the first side surface S1 side, and The difference is that three portions are formed on the two side surfaces S2. That is, the connection pads 180 connected to each of the solder bumps 300G are also formed at three places on the first side face S1 side and three places on the second side face S2 side.
  • the other basic configuration of the stacked body 10G is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • connection area of the connection pad 180 and the solder bump 300G can be further increased. Further, since the step H1 is formed in the height direction of the stacked body 10G, the area when the stacked body 10G is viewed in plan does not increase. Therefore, miniaturization of the stacked body 10G can be realized.
  • the stacked body 10H according to the seventh embodiment is different from the stacked body 10 according to the first embodiment in that the solder bumps 300H are different from the first side surface S1 and the second side surface S2.
  • the third side S1 and the second side S2 extend in a direction connecting the second side S2, and are different from each other in that one is formed on each of the third side S3 and the fourth side S4 facing each other.
  • the solder bump 300H is formed so as to straddle a step surface B1 (not shown) on the first side surface S1 side among a plurality of step surfaces B1 formed between the first electronic component 100 and the structure 150.
  • the step surface B1 formed on the first side surface S1 side and the second side surface S2 side is the "first step surface" of the present invention.
  • solder bump 300H is connected to a connection pad 180 formed so as to straddle a step surface B1 (not shown) on the third side surface S3 side among step surfaces formed between the first electronic component 100 and the structure 150. And two solder bumps 300H connected to the respective connection pads 180 formed so as to straddle the step surface B1 (not shown) on the fourth side surface S4 side.
  • the step surface B1 formed on the third side surface S3 side and the fourth side surface S4 side is the “second step surface” of the present invention.
  • the other basic configuration of the stacked body 10H is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • connection pad 180 can have a larger connection area with the solder bump 300H. Furthermore, since the step H1 is formed in the height direction of the stacked body 10H, the area when the stacked body 10H is viewed in plan does not increase. Therefore, miniaturization of the laminate 10H can be realized.
  • the first side surface S1 and the second side surface S2 are connected by the two solder bumps 300H on the first side surface S1 side and the second side surface S2 side and the connection pads 180 connected thereto.
  • the connection strength against the stress in the direction can be improved.
  • the two solder bumps 300H on the third side S3 side and the fourth side S4 side and the connection pads 180 connected thereto are parallel to the first side S1 and the second side S2.
  • the connection strength against stress in various directions can also be improved. As described above, even when the directions in which the plurality of stresses are generated are different from each other, the connection strength between the first electronic component 100 and the structure 150 and the second electronic component 200 can be improved. It can be further improved.
  • each of the laminates 10F to 10H according to the seventh embodiment includes a plurality of connection pads 180.
  • the second electronic component 200 is easily fixed to the first electronic component 100 and the structure 150, and the connection strength of the stacked bodies 10F to 10H is further improved.
  • the configuration in which the main surface 101 of the first electronic component 100 is exposed has been described.
  • the main surface 101 of the first electronic component 100 may be covered with the solder resist layer 170.
  • the configuration for exposing the main surface 101 can be omitted, and the above-described laminates 10 to 10H can be formed at low cost.
  • FIG. 15A is a side cross-sectional view illustrating a configuration of a multilayer body 10J according to the eighth embodiment of the present invention
  • FIG. 15B is a cross-sectional view illustrating the multilayer body 10J according to the eighth embodiment of the present invention. It is the top view seen from the surface side. 15A and 15B, vertical and horizontal dimensional relationships are appropriately emphasized and described, and do not always match the vertical and horizontal dimensional relationships in actual dimensions.
  • the laminate 10J according to the eighth embodiment is different from the laminate 10 according to the first embodiment in that only one step H1 is formed. Is different.
  • the other basic configuration of the stacked body 10J is the same as that of the stacked body 10, and the description of the same portions will be omitted.
  • the stacked body 10J has only one step H1 (left side in FIG. 15A).
  • the penetrating electrode 165 in the portion where the step H1 is not formed (the right side in FIG. 15A) is connected to the second electron via the wiring electrode 161, the connection pad 180, and the solder bump 300 substantially parallel to the main surface 151. It is connected to the component 200.
  • the main surface 101 and the main surface 151 have the step H1.
  • the connection pad 180 is larger than the case where the main surface 101 and the main surface 151 are flush with each other by an area substantially equal to the area of the step surface B1. Therefore, the connection area between the solder bump 300 and the connection pad 180 can be increased.
  • the thermal stress generated between the structure 150 and the second electronic component 200 is a force that extends the second electronic component 200 in a direction orthogonal to the height direction with respect to the main surface 151 of the structure 150.
  • the solder bump 300 is formed on the step surface B1 (the portion of the step H1) and the step of the connection pad 180. It is pressed against the portion that comes into contact with the surface B1. Therefore, the connection strength between the connection pad 180 and the solder bump 300 is improved, and breakage can be suppressed.

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Abstract

積層体(10)は、第1電子部品(100)と、平面視において第1領域(R1)と第2領域(R2)とを備え、第1電子部品(100)が第2領域(R2)に配置された構造体(150)と、構造体(150)に接続パッド(180)を介してバンプ実装された第2電子部品(200)とを備える。構造体(150)の高さ方向において、第1領域(R1)の表面と第2領域(R2)の表面とは、段差(H1)を有する。接続パッド(180)は、第1領域(R1)の表面、第2領域(R2)の表面、および段差(H1)によって形成された段差面(B1)に形成されている。

Description

積層体および積層体の製造方法
 本発明は、半田バンプを用いて複数の電子部品を接続した、積層体に関する。
 従来、各種の積層体が実用化されている。例えば、特許文献1に記載の積層体は、電子部品を内部に備える構造体の端子に、他の電子部品を半田バンプで実装することによって形成されている。
特開2016-201565号公報
 特許文献1に示す構成では、構造体の端子と、積層される電子部品の半田バンプとの接続部分の面積が小さい場合に接続強度が確保できず、熱応力が繰り返しかかること等によって当該接続部分で破断する虞がある。また、構造体の端子と、電子部品との接続部分の面積を大きくした場合には、それに伴い積層体が大型化してしまう。
 したがって、本発明の目的は、積層体の接続強度を強化しつつ、積層体の小型化を図ることである。
 この発明の積層体は、第1電子部品と、平面視において第1領域と第2領域とを備え、第1電子部品が第2領域に配置された構造体と、構造体に接続パッドを介してバンプ実装された第2電子部品とを備える。構造体の高さ方向において、第1領域の表面と第2領域の表面とは、段差を有する。接続パッドは、第1領域の表面、第2領域の表面、および段差によって形成された段差面に形成されている。
 この構成では、第1領域と第2領域とが面一の場合よりも接続パッドの表面積は大きくなる。このため、第1電子部品と第2電子部品との接続部分の面積が大きくなり、第1電子部品と第2電子部品との積層体の接続強度を向上できる。また、当該接続部分における面積の増加は、第1領域と第2領域の段差で形成されるため、平面視における構造体の面積の増大を抑制でき、積層体を小型化できる。
 この発明の積層体の製造方法は、次の各工程を有する。この製造方法は、支持体の表面に仮固定材を介して第1電子部品を配置する工程と、仮固定材と第1電子部品とを覆い、第1電子部品の配置領域を除く領域では支持体に当接するように、樹脂で封止する工程と、支持体と仮固定材とを取り除く工程と、樹脂における支持体が配置された側の面と第1電子部品における仮固定材が配置された面とを跨ぐように、接続パッドを形成する工程と、第2電子部品を、接続パッドを介してバンプ実装する工程とを有する。
 この製造方法では、上述の所望の積層体が、容易、且つ、精度良く製造される。
 この発明の積層体の製造方法は、次の各工程を有する。この製造方法は、支持体の表面に形成された仮固定材に、第1電子部品の一部を埋める工程と、仮固定材と第1電子部品とを覆うように樹脂で封止する工程と、支持体と仮固定材とを取り除く工程と、樹脂における支持体が配置された側の面と第1電子部品における仮固定材が配置された面とを跨ぐように、接続パッドを形成する工程と、第2電子部品を、接続パッドを介してバンプ実装する工程とを有する。
 この製造方法では、上述の所望の構造体が、容易、且つ、精度良く製造される。
 この発明によれば、積層体の接続強度を強化しつつ、積層体の小型化を図ることができる。
図1(A)は、本発明の第1の実施形態に係る積層体10の構成を示す側面断面図であり、図1(B)は、図1(A)の一部を拡大した側面断面図である。 図2は本発明の第1の実施形態に係る積層体10を表面側から視た平面図である。 図3は本発明の第1の実施形態に係る積層体10の製造方法を示すフローチャートである。 図4(A)-図4(D)は、本発明の第1の実施形態に係る積層体10の製造方法を示す側面断面図である。 図5(A)-図5(C)は、本発明の第1の実施形態に係る積層体10の製造方法を示す側面断面図である。 図6(A)は、本発明の第2の実施形態に係る積層体10Aの構成を示す側面断面図であり、図6(B)は、図6(A)の一部を拡大した側面断面図である。 図7は本発明の第2の実施形態に係る積層体10Aの製造方法を示すフローチャートである。 図8(A)-図8(D)は、本発明の第2の実施形態に係る積層体10Aの製造方法を示す側面断面図である。 図9(A)-図9(E)は、本発明の第2の実施形態に係る積層体10Aの製造方法を示す側面断面図である。 図10は本発明の第3の実施形態に係る積層体10Bの構成を示す側面断面図である。 図11は本発明の第4の実施形態に係る積層体10Cの構成を示す側面断面図である。 図12は本発明の第5の実施形態に係る積層体10Dの構成を示す側面断面図である。 図13は本発明の第6の実施形態に係る積層体10Eの構成を示す側面断面図である。 図14(A)-図14(C)は、本発明の第7の実施形態に係る積層体を表面側から視た平面図である。 図15(A)は、本発明の第8の実施形態に係る積層体10Jの構成を示す側面断面図であり、図15(B)は、本発明の第8の実施形態に係る積層体10Jを表面側から視た平面図である。
 (第1の実施形態)
 本発明の第1の実施形態に係る積層体について、図を参照して説明する。図1(A)は、本発明の第1の実施形態に係る積層体10の構成を示す側面断面図であり、図1(B)は、図1(A)の一部を拡大した側面断面図である。図2は、本発明の第1の実施形態に係る積層体10を表面側から視た平面図である。図3は、本発明の第1の実施形態に係る積層体10の製造方法を示すフローチャートである。図4(A)-図4(D)は、本発明の第1の実施形態に係る積層体10の製造方法を示す側面断面図である。図5(A)-図5(C)は、本発明の第1の実施形態に係る積層体10の製造方法を示す側面断面図である。各図において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 <積層体の構造>
 図1(A)に示すように、積層体10は、第1電子部品100、構造体150、配線電極161、端子電極162、貫通電極165、ソルダーレジスト層170,175、接続パッド180、第2電子部品200、半田バンプ300を備える。
 第1電子部品100は、構造体150に配置されている。第2電子部品200は、半田バンプ300を用いて、接続パッド180が形成された構造体150に実装されている。詳細な配置構造、実装構造については後述する。接続パッド180は、例えば、Ni、Au、Pt、Pd等で形成されている。
 第1電子部品100は、図1(A)の太矢印で示す高さ方向に略直交し、互いに対向する主面101、主面102を備えている。主面101が本発明の「第1電子部品の表面」である。
 第1電子部品100、第2電子部品200は、例えば直方体形状であり、半導体基板を用いたICまたは圧電体基板を用いたSAWフィルタ等である。
 構造体150は、樹脂で形成されている。構造体150は、平面視において、第1領域R1、第2領域R2を有する。第2領域R2は、第1領域R1の間に挟まれる形状である。第1領域R1は、高さ方向に略直交し、互いに対向する主面151、主面152を有する。主面151が本発明の「第1領域の表面」である。第2領域R2は、高さ方向に略直交し、互いに対向する主面153、主面154を有する。構造体150は、高さ方向に略平行で、互いに対向する第1側面S1、第2側面S2を備える。
 第1領域R1の主面152と第2領域R2の主面154は面一である。第1領域R1の主面151は、高さ方向において、第2領域R2の主面153よりも高い位置に形成されている。この際、主面151と主面153との高低差は、第1電子部品100の高さよりも大きい。
 構造体150の第1領域R1の構造について説明する。第1領域R1における構造体150の内部には、貫通電極165が形成されている。主面151には、配線電極161が形成されている。主面152には、端子電極162が形成されている。配線電極161は、貫通電極165を介して、端子電極162に接続されている。端子電極162の一部は、ソルダーレジスト層175で覆われている。
 構造体150の第2領域R2の構造について説明する。第2領域R2には、第1電子部品100が配置されている。第1電子部品100は、第1電子部品100の主面102と、構造体150の主面153が当接するように、あるいは第1電子部品100の主面102と構造体150の主面153との間に絶縁層と金属導体を介して、配置されている。
 図1(B)に示すように、高さ方向において、第1領域R1における主面151の位置は、第1電子部品100の主面101の位置よりも高い。具体的には、高さ方向において、主面101と主面151は、段差H1を有する。
 本願発明における段差とは、高さ方向において、主面101と主面151との間における高低差であり、形状については限定しない。なお、以下に示す構造について、複数の平面で形成される高低差、また高い位置と低い位置で形成される高低差は、全て段差として説明する。
 配線電極161は、上述の主面151から第1電子部品100の主面101に亘って連続して形成されている。すなわち、構造体150の主面151と、第1電子部品100の主面101とにつながる段差面B1を跨ぐように形成されている。なお、段差面B1とは、構造体150における第1領域R1の第2領域R2側の側面であり、配線電極161および接続パッド180を取り除いた構造体150において、第2領域R2の主面101側に露出する面である。言い換えれば、段差面B1は、段差H1で形成される面である。
 接続パッド180は、配線電極161における構造体150側の面と反対側の面、すなわち、配線電極161において主面151、第1電子部品100の主面101および段差面B1に当接する面と反対側の面に形成されている。
 第2電子部品200は、半田バンプ300を介して、接続パッド180に実装されている。この際、半田バンプ300は、段差面B1の領域を含むように接続している。
 上述のとおり、主面101と主面151は、段差H1を有する。すなわち、接続パッド180は、主面101と主面151が面一である場合よりも、段差面B1の面積と略同じ面積分だけ大きくなる。したがって、半田バンプ300との接続部分の面積(以下、接続面積)を大きくできる。
 積層体10は、主面101が主面151よりも低く、接続パッド180のうち段差面B1に当接する部分が積層体10の中心側(構造体150における第2領域R2側)に形成される構造である。言い換えれば、積層体10の中心側の領域が外縁側(構造体150における第1領域R1側)の領域よりも凹んだ構造である。ここで、構造体150と第2電子部品200との間に生じる熱応力が、第2電子部品200が構造体150の主面151に対して、高さ方向に直交する方向に延びる力である場合、すなわち、積層体10の中心側の領域から外縁側の領域に向かう方向に掛かる力である場合には、半田バンプ300が段差面B1(段差H1の部分)、および、接続パッド180のうち段差面B1に当接する部分に押しつけられる。したがって、接続パッド180と半田バンプ300との間の接続強度が向上して、破断を抑制できる。
 具体的には、次に示す通りである。図2は、積層体10の第2電子部品200が実装された側、言い換えれば主面101側(主面151側)から視た平面図である。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。なお、図2では、段差H1の向きを示すため、接続パッド180、半田バンプ300のみを示しており、その他の構成は省略している。
 半田バンプ300は、第1領域R1と第2領域R2を跨ぐように形成されている。また、積層体10の中心位置に対して対称な位置に、半田バンプ300は2箇所形成されている。
 図2において、左側の接続パッド180(第1側面S1側の接続パッド180)では、段差H1における高い面(主面151)から低い面(主面101)に並ぶ向きは、第1側面S1から第2側面S2へ延びる方向である。逆に右側の接続パッド180(第2側面S2側の接続パッド180)の段差H1における高い面(主面151)から低い面(主面101)に並ぶ向きは、第2側面S2から第1側面S1へ延びる方向である。したがって、第2電子部品200が延びた時、すなわち、第2電子部品200において積層体10の中心側の領域から外縁側の領域に向かう方向に力が掛かった時は、半田バンプ300と接続パッド180とが段差面B1に押しつけられる。よって、半田バンプ300と接続パッド180との間の接続強度は、向上する。
 また、図2に示すように、高さ方向に延びる段差H1(段差面B1)によって、接続パッド180と半田バンプ300との接触面積が大きくなるため、第2電子部品200を実装する側、言い換えれば主面101側(主面151側)から平面視した場合の、接続パッド180や半田バンプ300の面積の増加を抑制できる。したがって、積層体10の小型化を実現できる。
 <積層体の製造方法>
 図3は、積層体10の製造方法を示すフローチャートである。図4(A)、図4(B)、図4(C)、図4(D)、図5(A)、図5(B)、図5(C)は、積層体10の製造方法の第1例における主要工程での形状を示す断面図である。
 図3、図4(A)に示すように、支持体440、接着層430、給電層420をこの順に積層する。給電層420の支持体440が配置されている面とは逆側の面に貫通電極165を電解めっき法等で形成する(S101)。同様に、給電層420の支持体440が配置されている面とは逆側の面に仮固定材410を部分的に(貫通電極165同士の間に)配置し、仮固定材410に第1電子部品100を配置する(S102)。なお、仮固定材410は、例えば、高分子材からなる樹脂や溶剤を含有した樹脂などの樹脂主体材料で形成されている。
 図3、図4(B)に示すように、給電層420の支持体440が配置されている面とは逆側を樹脂で封止し硬化させる。この際、貫通電極165、仮固定材410、および、第1電子部品100を覆うように、貫通電極165、仮固定材410、および、第1電子部品100を樹脂で封止する。このことによって、仮固定材410が存在しない領域に構造体150が形成される(S103)。
 図3、図4(C)に示すように、仮固定材410、給電層420、接着層430、支持体440を除去する(S104)。この際、仮固定材410が除去されることによって、段差H1が形成される。すなわち、段差H1は、仮固定材410の厚みによって決定される。
 図3、図4(D)に示すように、貫通電極165の構造体150が形成されていない側、言い換えれば、仮固定材410を除去した部分に配線電極161を形成する。配線電極161は、段差H1を有する部分(段差面B1の部分)を跨ぐように形成される。次に、配線電極161に当接するように、すなわち段差H1有する部分(段差面B1の部分)を跨ぐように、接続パッド180を形成する(S105)。
 なお、接続パッド180が形成される前後に、ソルダーレジスト層170が、構造体150、および、第1電子部品100における配線電極161が形成された側の主面上と、配線電極161上とに形成されてもよい。
 例えば、接続パッド180が形成される前にソルダーレジスト層170を形成する場合には、配線電極161上に形成されたソルダーレジスト層170の一部、具体的には、段差H1を有する部分に形成されたソルダーレジスト層170を除去した部分に接続パッド180を形成することで、段差面B1を跨ぐような接続パッド180を得られる。また、ソルダーレジスト層170を接続パッド180が形成された後に形成する場合には、ソルダーレジスト層170を接続パッド180の少なくとも一部を覆わないように形成することで、段差面B1を跨ぐような接続パッド180を得られる。
 図3、図5(A)に示すように、構造体150における第1電子部品100が配置されていない側の主面を研削し、貫通電極165を露出させる(S106)。
 図3、図5(B)に示すとおり、貫通電極165と接続するように端子電極162を形成する。端子電極162の一部を覆うようにソルダーレジスト層175を形成する(S107)。
 図3、図5(C)に示すように、第2電子部品200を、半田バンプ300を介して接続パッド180に実装する(S108)。
 このような製造方法を用いることによって、上述の積層体10の構成を確実且つ高精度に実現できる。
 (第2の実施形態)
 次に、第2の実施形態に係る積層体について、図を参照して説明する。図6(A)は、本発明の第2の実施形態に係る積層体10Aの構成を示す側面断面図であり、図6(B)は、図6(A)の一部を拡大した側面断面図である。図7は、積層体10Aの製造方法を示すフローチャートである。図8(A)-図8(D)は、本発明の第2の実施形態に係る積層体10Aの製造方法を示す側面断面図である。図9(A)-図9(D)は、本発明の第2の実施形態に係る積層体10Aの製造方法を示す側面断面図である。各図において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 <積層体の構造>
 図6(A)、図6(B)に示すように、第2の実施形態に係る積層体10Aは、第1の実施形態に係る積層体10に対して、第1電子部品100の図6(A)に太矢印で示す高さ方向における配置位置、および段差H2、配線電極161A、接続パッド180Aの形状において異なる。積層体10Aにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 第1領域R1は、互いに対向する主面151、主面152を有する。第2領域R2は、互いに対向する主面153A、主面154を有する。
 第1領域R1の主面152と第2領域R2の主面154は面一である。主面151は、高さ方向において、主面153Aよりも高い位置に形成されている。しかしながら、主面151と主面153Aとの高低差は、第1電子部品100の高さよりも小さい。
 構造体150Aの第2領域R2には、第1電子部品100が配置されている。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。第1電子部品100は、第1電子部品100の主面102と、構造体150Aの主面153Aが当接するように、あるいは第1電子部品100の主面102と構造体150の主面153Aとの間に絶縁層と金属導体を介して、配置されている。このように第1電子部品100を主面102に配置することによって、高さ方向における主面151の位置は、第1電子部品100の主面101の位置よりも低くなる。言い換えれば、主面101は、主面151よりも高くなる。
 より具体的には、図6(B)に示すように、高さ方向において、第1領域R1における主面151の位置は、第1電子部品100の主面101の位置よりも低い。具体的には、高さ方向において、主面101と主面151は、段差H2を有する。
 配線電極161Aは、第1電子部品100の主面101と構造体150Aの主面151とに亘って連続して形成されている。すなわち、構造体150Aの主面151の段差面B2を跨ぐように形成されている。なお、段差面B2とは、構造体150Aにおける第1領域R1の第2領域R2側の側面であり、配線電極161Aおよび接続パッド180Aを取り除いた構造体150において、第2領域R2の主面101側に露出する面である。言い換えれば、段差面B2は、段差H2で形成される面である。
 接続パッド180Aは、配線電極161Aにおける構造体150A側の面と反対側の面、すなわち、配線電極161Aにおいて主面101、第1電子部品100の主面151および、段差面B2に当接する面と反対側の面に形成されている。
 第2電子部品200は、半田バンプ300を介して、接続パッド180Aに実装されている。この際、半田バンプ300は、段差面B2の領域を含むように接続している。
 上述のとおり、主面101と主面151は、段差H2を有する。すなわち、接続パッド180Aは、主面101と主面151が面一である場合よりも、段差面B2の面積と略同じ面積分だけ大きくなる。したがって、半田バンプ300と接続パッド180Aとの接続面積を大きくできる。
 積層体10Aは、主面101が主面151よりも高く、接続パッド180のうち段差面B2に当接する部分が積層体10Aの外縁側(構造体150Aにおける第1領域R1側)に露出する構造である。言い換えれば、積層体10Aの中心側(構造体150Aにおける第2領域R2側)の領域が外縁側の領域よりも出っ張った構造である。ここで、構造体150Aと第2電子部品200との間に生じる熱応力が生じる場合、第2電子部品200が構造体150Aの主面151に対して、高さ方向に直交する方向に縮む力である場合、すなわち、積層体10の外縁側の領域から中心側の領域に向かう方向に掛かる力である場合には、半田バンプ300が段差面B2(段差H2の部分)、および、接続パッド180Aのうち段差面B2に当接する部分に押しつけられる。したがって、接続パッド180Aと半田バンプ300との間の接続強度が向上して、破断を抑制できる。
 また、高さ方向に延びる段差H2(段差面B2)によって、接続パッド180Aと半田バンプ300との接触面積が大きくなるため、第2電子部品200を実装する側、言い換えれば主面101側(主面151側)から平面視した場合の、接続パッド180Aや半田バンプ300の面積の増加を抑制できる。したがって、積層体10Aの小型化を実現できる。
 <積層体の製造方法>
 図7は、積層体10Aの製造方法を示すフローチャートである。図8(A)、図8(B)、図8(C)、図8(D)、図8(E)、図9(A)、図9(B)、図9(C)、図9(D)、図9(E)は、積層体10Aの製造方法の第2例における主要工程での形状を示す断面図である。
 図7、図8(A)に示すように、支持体440、仮固定材410、給電層420をこの順に積層する。給電層420の支持体440が配置されている面とは逆側の面に貫通電極165を電解めっき法や導電ペースト充填法などで形成する(S201)。このとき、仮固定材410は、支持体440と給電層420とを接着する接着層430としても機能する。
 図7、図8(B)に示すように、給電層420をエッチングし、給電電極425を形成するとともに、第1電子部品100の配置領域の仮固定材410を露出させる(S202)。
 図7、図8(C)に示すように、仮固定材410の露出された領域に、第1電子部品100を配置する(S203)。この際、第1電子部品100が仮固定材410を所定の深さで埋まるように、第1電子部品100を仮固定材410に配置する。
 図7、図8(D)に示すように、仮固定材410の支持体440が配置されている面とは逆側を樹脂で封止し硬化させる(S204)。この際、貫通電極165、仮固定材410、および、第1電子部品100を覆うように樹脂で封止する。このことによって、構造体150Aが形成される。
 図7、図9(A)に示すように、構造体150Aにおける仮固定材410と反対側の部分を研削し、貫通電極165を露出させる(S205)。
 図7、図9(B)に示すように、仮固定材410、給電層425、支持体440を除去する(S206)。上述のとおり、第1電子部品100が仮固定材410に所定の深さで埋まるように配置されている。この仮固定材410を除去することによって、段差H2が形成される。すなわち、段差H2は、仮固定材410に対する第1電子部品100の埋め込み量によって決定される。
 図7、図9(C)に示すように、貫通電極165の構造体150Aが形成されていない側、言い換えれば、仮固定材410を除去した側に配線電極161Aを形成する。配線電極161Aは、段差H2を有する部分(段差面B2の部分)を跨ぐように形成される。次に、配線電極161Aに当接するように、すなわち段差H2を有する部分(段差面B2の部分)を跨ぐように、接続パッド180Aを形成する(S207)。
 なお、接続パッド180が形成される前後に、ソルダーレジスト層170が、構造体150A、および、第1電子部品100における配線電極161Aが形成された側の主面上と、配線電極161A上とに形成されてもよい。
 例えば、接続パッド180Aが形成される前にソルダーレジスト層170を形成する場合には、配線電極161A上に形成されたソルダーレジスト層170の一部、具体的には、段差H2を有する部分に形成されたソルダーレジスト層170を除去した部分に接続パッド180Aを形成することで、段差面B2を跨ぐような接続パッド180Aを得られる。また、ソルダーレジスト層170を接続パッド180Aが形成された後に形成する場合には、ソルダーレジスト層170を接続パッド180Aの少なくとも一部を覆わないように形成することで、段差面B2を跨ぐような接続パッド180Aを得られる。
 図7、図9(D)に示すとおり、貫通電極165と接続するように端子電極162を形成する。端子電極162の一部を覆うようにソルダーレジスト層175を形成する(S208)。
 図7、図9(E)に示すように、第2電子部品200を、半田バンプ300を介して接続パッド180Aに実装する(S209)。
 このような製造方法を用いることによって、上述の積層体10Aの構成を確実且つ高精度に実現できる。
 (第3の実施形態)
 次に、第3の実施形態に係る積層体について、図を参照して説明する。図10は、本発明の第3の実施形態に係る積層体10Bの構成を示す側面断面図である。図10において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 図10に示すように、第3の実施形態に係る積層体10Bは、第1の実施形態に係る積層体10に対して、樹脂膜190を備えている点、接続電極195を備えている点、および配線電極161B、接続パッド180Bの形状において異なる。積層体10Bにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 図10に示すように、積層体10Bは、第1電子部品100、構造体150、端子電極162、配線電極161B、貫通電極165、ソルダーレジスト層170,175、接続パッド180B、樹脂膜190、接続電極195、第2電子部品200、半田バンプ300を備える。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。
 樹脂膜190は、主面151、段差面B1、主面101に亘って、連続して形成されている。
 すなわち、樹脂膜190は、段差H1を跨ぐように形成されている。より具体的には、樹脂膜190は、段差H1の段差面B1と主面151との間、および、段差面B1と主面101との間に生じる角(鋭角な部分)を覆い、主面151と、主面101とをなだらかな形状(スロープ状)で接続するように形成されている。
 配線電極161Bは、樹脂膜190における主面151,101側の面とは反対側の面を覆うように形成されている。なお、樹脂膜190には、接続電極195が形成されており、配線電極161Bは、接続電極195を介して、貫通電極165に接続されている。
 接続パッド180Bは、配線電極161Bにおける、主面101、段差面B1、第1電子部品100の主面151とは反対側の面に形成されている。より具体的には、接続パッド180Bは、配線電極161B、樹脂膜190を介して、第1電子部品100と構造体150とを繋ぐスロープ状の面を覆うように形成されている。
 第2電子部品200は、半田バンプ300を介して、接続パッド180Bに接続されている。
 このような構成であっても、主面101と主面151は、段差H1を有する。すなわち、主面101と主面151が面一である場合よりも、接続パッド180Bの面積は大きくなり、半田バンプ300と接続パッド180Bとの接続面積を大きくできる。
 さらに、段差H1の段差面B1と主面151,101のそれぞれとの間に生じる角(鋭角な部分)を樹脂膜190で覆うことにより、半田バンプ300において応力が特定の箇所に集中し難くなる。したがって、半田バンプ300内の破断を抑制できる。
 積層体10Bは、主面101が主面151よりも低く、積層体10Bの中央領域が外縁領域よりも凹んだ構造である。ここで、構造体150と第2電子部品200の間に生じる熱応力が、第2電子部品200が構造体150の主面151に対して、高さ方向に直交する方向に延びる力であった場合、半田バンプ300は、段差面B1(段差H1の部分)に押しつけられる。したがって、接続パッド180Bと半田バンプ300との接続強度が向上して、破断を抑制できる。
 また、第2電子部品200を実装する側、言い換えれば主面101側(主面151側)から平面視した場合の面積の増加を抑制できる。したがって、積層体10Bの小型化を実現できる。
 (第4の実施形態)
 次に、第4の実施形態に係る積層体について、図を参照して説明する。図11は、本発明の第4の実施形態に係る積層体10Cの構成を示す側面断面図である。図11において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 図11に示すように、第4の実施形態に係る積層体10Cは、第2の実施形態に係る積層体10Aに対して、樹脂膜190を備えている点、接続電極195を備えている点、および配線電極161C、接続パッド180Cの形状において異なる。積層体10Cにおける他の基本構成は、積層体10Aと同様であり、同様の箇所の説明は省略する。
 図11に示すように、積層体10Cは、第1電子部品100、構造体150C、端子電極162、配線電極161C、貫通電極165、ソルダーレジスト層170,175、接続パッド180C、樹脂膜190、接続電極195、第2電子部品200、半田バンプ300を備える。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。
 樹脂膜190は、主面151、段差面B2、主面101に亘って、連続して形成されている。
 すなわち、樹脂膜190は、段差H2を有する部分を跨ぐように形成されている。より具体的には、樹脂膜190は、段差H2の段差面B2と主面151との間、および、段差面B2と主面101との間に生じる角(鋭角な部分)を覆い、主面151と、主面101とをなだらかな形状(スロープ状)で接続するように形成されている。
 配線電極161Cは、樹脂膜190における主面151,101側の面とは反対側の面を覆うように形成されている。なお、樹脂膜190には、接続電極195が形成されており、配線電極161Cは、接続電極195を介して、貫通電極165に接続されている。
 接続パッド180Cは、配線電極161Cにおける、主面101、段差面B2、第1電子部品100の主面151と反対側の面に形成されている。より具体的には、接続パッド180Cは、配線電極161C、樹脂膜190を介して、第1電子部品100と構造体150Cとを繋ぐスロープ状の面を覆うように形成されている。
 第2電子部品200は、半田バンプ300を介して、接続パッド180Cに接続されている。
 このような構成であっても、主面101と主面151は、段差H2を有する。すなわち、主面101と主面151が面一である場合よりも、接続パッド180Cの面積は大きくなり、半田バンプ300と接続パッド180との接続面積を大きくできる。
 さらに、段差H2の段差面B2と主面151,101のそれぞれとの間に生じる角(鋭角な部分)を樹脂膜190で覆うことにより、半田バンプ300において応力が特定の箇所に集中し難くなる。したがって、半田バンプ300内の破断を抑制できる。
 また、構造体150Cと第2電子部品200の間に生じる熱応力が、第2電子部品200が構造体150Cの主面151に対して、高さ方向に直交する方向に縮む力であった場合、半田バンプ300は、段差H2の部分に押しつけられる。したがって、接続パッド180Cと半田バンプ300との接続強度が向上し、破断を抑制できる。
 また、第2電子部品200を実装する側、言い換えれば主面101側(主面151側)から平面視した場合の面積の増加を抑制できる。したがって、積層体10Cの小型化を実現できる。
 (第5の実施形態)
 次に、第5の実施形態に係る積層体について、図を参照して説明する。図12は、本発明の第5の実施形態に係る積層体10Dの構成を示す側面断面図である。図12において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 図12に示すように、第5の実施形態に係る積層体10Dは、第1の実施形態に係る積層体10に対して、樹脂膜191,192を備えている点、接続電極195,196を備えている点、および配線電極161D,163D、接続パッド180Dの形状において異なる。積層体10Dにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 図12に示すように、積層体10Dは、第1電子部品100、構造体150、端子電極162、配線電極161D,163D、貫通電極165、ソルダーレジスト層170,175、接続パッド180D、樹脂膜191,192、接続電極195,196、第2電子部品200、半田バンプ300を備える。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。
 樹脂膜191は、主面151、段差面B1、主面101に亘って、連続して形成されている。
 樹脂膜191は、段差H1を有する部分を跨ぐように形成されている。より具体的には、樹脂膜191は、段差H1の段差面B1と主面151との間、および、段差面B1と主面101との間に生じる角(鋭角な部分)を覆い、主面151と、主面101とをなだらかな形状(スロープ状)とするように形成されている。
 配線電極161Dは、樹脂膜191における主面151,101側の面とは反対側の面を覆うように形成されている。なお、樹脂膜191には、接続電極195が形成されており、配線電極161Dは、接続電極195を介して貫通電極165に接続されている。
 樹脂膜192は、樹脂膜191、配線電極161Dにおける樹脂膜191側の面とは反対側の面を覆うように形成されている。樹脂膜192は、樹脂膜191と同様に、主面151、段差面B1、主面101に亘って連続して形成されている。
 すなわち、樹脂膜192は、段差H1を有する部分を跨ぐように形成されている。より具体的には、樹脂膜192は、段差H1の段差面B1と主面151との間、および、段差面B1と主面101との間に生じる角(鋭角な部分)を覆い、主面151と、主面101とをなだらかな形状(スロープ状)で接続するように形成されている。
 配線電極163Dは、樹脂膜192における配線電極161D側の面とは反対側の面を覆うように形成されている。なお、樹脂膜192には、接続電極196が形成されている。配線電極163Dは、接続電極196を介して、配線電極161Dに接続されている。
 接続パッド180Dは、配線電極163Dにおける、主面101、段差面B1、第1電子部品100の主面151と反対側の面に形成されている。より具体的には、接続パッド180Dは、配線電極161D,163D、樹脂膜191,192を介して、第1電子部品100と構造体150とを繋ぐスロープ状の面を覆うように形成されている。
 第2電子部品200は、半田バンプ300を介して、接続パッド180Dに接続されている。
 このような構成であっても、主面101と主面151は、段差H1を有する。すなわち、主面101と主面151が面一である場合よりも、接続パッド180Dの面積は大きくなり、半田バンプ300と接続パッド180との接続面積を大きくできる。
 さらに、段差H1の段差面B1と主面151,101のそれぞれとの間に生じる角(鋭角な部分)を複数の樹脂膜191,192で覆うことにより、当該鋭角な部分を1つの樹脂膜で覆う場合と比べて、半田バンプ300の応力が特定の箇所により集中し難くなる。したがって、半田バンプ300内の破断をさらに抑制できる。
 また、樹脂膜191,192を形成することによって、積層体10Dにおけるクッション性を向上させることができ、第2電子部品200の実装時等の積層体10の破損を抑制できる。
 積層体10Dは、主面101が主面151よりも低く、積層体10Dの中央領域が外縁領域よりも凹んだ構造である。ここで、構造体150と第2電子部品200の間に生じる熱応力が、第2電子部品200が構造体150の主面151に対して、高さ方向に直交する方向に延びる力であった場合に、半田バンプ300は、段差面B1(段差H1の部分)に押しつけられる。したがって、接続パッド180Dと半田バンプ300との間の接続強度が向上し、破断を抑制できる。
 また、第2電子部品200を実装する側、言い換えれば主面101側(主面151側)から平面視した場合の面積の増加を抑制できる。したがって、積層体10Dの小型化を実現できる。
 なお、上述の第4の実施形態に係る積層体10Cは、段差面B1を跨ぐ複数の樹脂膜を有する構成であってもよい。この場合にも、本実施形態と同様の効果が得られる。
 (第6の実施形態)
 次に、第6の実施形態に係る積層体について、図を参照して説明する。図13は、本発明の第6の実施形態に係る積層体10Eの構成を示す側面断面図である。図13において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 図13に示すように、第6の実施形態に係る積層体10Eは、第1の実施形態に係る積層体10に対して、補助部材400を複数備えている点において異なる。積層体10Eにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 図13に示すように、複数の補助部材400は、接続パッド180の第2電子部品200が実装されている側の面に形成されている。補助部材400は、導体であることが好ましい。また、補助部材400が接続パッド180と同じ材質である場合には、補助部材400と接続パッド180との線膨張率の差が生じないため、高い信頼性を得られる点でより好ましい。
 この構成では、補助部材400が形成されていることにより、半田バンプ300と接続パッド180との接続面積をさらに大きくできる。
 複数の補助部材400を配置する位置は、接続パッド180において、接続パッド180と半田バンプ300とが接する側の面上のいずれかの位置であればよい。すなわち、補助部材400を配置する位置は、補助部材400により接続パッド180の表面(接続パッド180における配線電極161側の面とは反対側の面)に半田バンプ300と接続される段差ができるような位置であれば、限定する必要はない。また、本実施形態では補助部材400を2つ形成する構成について示したが、1つ、または、3つ以上の構成であってもよく、接続パッド180と半田バンプ300との接続を妨げない数の補助部材400を設けてもよい。
 なお、上述の構成では、複数の補助部材400を形成することによって、接続面積を大きくする構成について示した。しかしながら、接続パッド180の表面を粗くすることでも同様の効果を得ることができる。このことによって、接続パッド180の表面における粗い部分に半田バンプ300が入り込み、接続面積が増加し、接続パッド180と半田バンプ300の接続強度がより向上する。
 なお、高さ方向における段差H1の厚みは、上述の接続パッド180表面の最も粗い部分の厚みよりも大きいことが好ましい。このことによって、接続パッド180と半田バンプ300の接続強度がより顕著に向上する。
 (第7の実施形態)
 次に、第7の実施形態に係る積層体について、図を参照して説明する。図14(A)-図14(C)は、本発明の第7の実施形態に係る積層体を表面側から視た平面図である。図14(A)、図14(B)、図14(C)において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。また、図14(A)、図14(B)、図14(C)においては、半田バンプ300のみを示しており、その他の構成は省略している。第1電子部品100は、平面視において第2電子部品200と重なるように配置されている。
 図14(A)に示すように、第7の実施形態に係る積層体10Fは、第1の実施形態に係る積層体10に対して、半田バンプ300Fが第1側面S1側に2箇所、第2側面S2側に2箇所形成されている点で異なる。すなわち、半田バンプ300Fのそれぞれと接続される接続パッド180も第1側面S1側に2箇所、第2側面S2側に2箇所形成されている。積層体10Fにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 この構成であっても、接続パッド180は、半田バンプ300Fと接続面積をより大きくできる。さらに、段差H1は、積層体10Fの高さ方向に形成されているため、積層体10Fを平面視した場合の面積は増加しない。したがって、積層体10Fの小型化を実現できる。
 図14(B)に示すように、第7の実施形態に係る積層体10Gは、第1の実施形態に係る積層体10に対して、半田バンプ300Gが第1側面S1側に3箇所、第2側面S2側に3箇所形成されている点で異なる。すなわち、半田バンプ300Gのそれぞれと接続される接続パッド180も第1側面S1側に3箇所、第2側面S2側に3箇所形成されている。積層体10Gにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 この構成であっても、接続パッド180は、半田バンプ300Gと接続面積をさらに大きくできる。さらに、段差H1は、積層体10Gの高さ方向に形成されているため、積層体10Gを平面視した場合の面積は増加しない。したがって、積層体10Gの小型化を実現できる。
 図14(C)に示すように、第7の実施形態に係る積層体10Hは、第1の実施形態に係る積層体10に対して、半田バンプ300Hが第1側面S1側、第2側面S2側に加えて、第1側面S1と第2側面S2とを結ぶ方向に延び、かつ、互いに対向する第3側面S3側、第4側面S4側にそれぞれ1箇所ずつ形成されている点で異なる。
 具体的には、半田バンプ300Hは、第1電子部品100と構造体150との間にできる複数の段差面B1のうち、第1側面S1側の段差面B1(不図示)を跨ぐように形成された接続パッド180と、第2側面S2側の段差面B1(不図示)を跨ぐように形成された接続パッド180のそれぞれと接続される2つの半田バンプ300Hを含む。なお、第1側面S1側と第2側面S2側に形成されている段差面B1が、本発明の「第1段差面」である。
 また、半田バンプ300Hは、第1電子部品100と構造体150との間にできる段差面のうち、第3側面S3側の段差面B1(不図示)を跨ぐように形成された接続パッド180と、第4側面S4側の段差面B1(不図示)を跨ぐように形成された接続パッド180のそれぞれと接続される2つの半田バンプ300Hを含む。なお、第3側面S3側と第4側面S4側に形成されている段差面B1が、本発明の「第2段差面」である。積層体10Hにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 この構成であっても、接続パッド180は、半田バンプ300Hとの接続面積をより大きくできる。さらに、段差H1は、積層体10Hの高さ方向に形成されているため、積層体10Hを平面視した場合の面積は増加しない。したがって、積層体10Hの小型化を実現できる。
 さらに、複数の半田バンプ300Hのうち、第1側面S1側、および、第2側面S2側の2つの半田バンプ300Hとそれらに接続される接続パッド180により第1側面S1、第2側面S2を結ぶ方向の応力に対する接続強度を向上できる。また、複数の半田バンプ300Hのうち、第3側面S3側、および、第4側面S4側の2つの半田バンプ300Hとそれらに接続される接続パッド180によって第1側面S1、第2側面S2に平行な方向の応力に対する接続強度も向上できる。このように、複数の応力が生じる方向がそれぞれ異なる場合であっても、第1電子部品100および構造体150と第2電子部品200との接続強度を向上できるため、積層体10Hの接続強度をさらに向上できる。
 なお、第7の実施形態に係る積層体10F~積層体10Hはいずれも、接続パッド180を複数個備えている。これにより、第2電子部品200が第1電子部品100および構造体150に固定されやすくなるため、積層体10F~10Hの接続強度は、さらに向上する。
 上述の構成では、第1電子部品100の主面101が露出している構成について説明した。しかしながら、第1電子部品100の主面101は、ソルダーレジスト層170で覆われていてもよい。この構成であれば、主面101を露出させる構成を省略することができ、上述の積層体10~積層体10Hを安価に形成できる。
 (第8の実施形態)
 次に、第8の実施形態に係る積層体について、図を参照して説明する。15(A)は、本発明の第8の実施形態に係る積層体10Jの構成を示す側面断面図であり、図15(B)は、本発明の第8の実施形態に係る積層体10Jを表面側から視た平面図である。図15(A)、図15(B)において縦横の寸法関係は適宜強調して記載しており、実寸での縦横の寸法関係と一致しているとは限らない。
 図15(A)、図15(B)に示すように、第8の実施形態に係る積層体10Jは、第1の実施形態に係る積層体10に対して、段差H1が1箇所のみ形成されている点で異なる。積層体10Jにおける他の基本構成は、積層体10と同様であり、同様の箇所の説明は省略する。
 図15(A)に示すように、積層体10Jは、段差H1が1箇所のみ(図15(A)における左側)形成されている。段差H1が形成されていない部分(図15(A)における右側)における貫通電極165は、主面151に略平行な形状の配線電極161、接続パッド180、半田バンプ300を介して、第2電子部品200に接続されている。
 この構成であっても、主面101と主面151は、段差H1を有する。すなわち、少なくとも1箇所でも段差H1が形成されていれば、接続パッド180は、主面101と主面151が面一である場合よりも、段差面B1の面積と略同じ面積分だけ大きくなる。したがって、半田バンプ300と接続パッド180との接続面積を大きくできる。
 また、構造体150と第2電子部品200との間に生じる熱応力が、第2電子部品200が構造体150の主面151に対して、高さ方向に直交する方向に延びる力である場合、すなわち、積層体10Jの中心側の領域から外縁側の領域に向かう方向に掛かる力である場合には、半田バンプ300が段差面B1(段差H1の部分)、および、接続パッド180のうち段差面B1に当接する部分に押しつけられる。したがって、接続パッド180と半田バンプ300との間の接続強度が向上して、破断を抑制できる。
 なお、上述の各実施形態の構成に限られるものではなく、これらの実施形態の組み合わせを変更したものであっても良い。
B1、B2…段差面
H1、H2…段差
R1…第1領域
R2…第2領域
S1…第1側面
S2…第2側面
S3…第3側面
S4…第4側面
10、10A、10B、10C、10D、10E、10F、10G、10H、10J…積層体
100…第1電子部品
101、102、151、152、153、153A、154…主面
150、150A、150C…構造体
161、161A、161B、161C、161D、163D…配線電極
162…端子電極
165…貫通電極
170、175…ソルダーレジスト層
180、180A、180B、180C、180D…接続パッド
190、191、192…樹脂膜
195、196…接続電極
200…第2電子部品
300、300F、300G、300H…半田バンプ
400…補助部材
410…仮固定材
420…給電層
425…給電電極
430…接着層
440…支持体

Claims (10)

  1.  第1電子部品と、
     平面視において、第1領域と第2領域とを備え、前記第1電子部品が前記第2領域に配置された構造体と、
     前記構造体に、接続パッドを介してバンプ実装された第2電子部品と、
     を備え、
     前記構造体の高さ方向において、前記第1領域の表面と、前記第2領域の表面とは段差を有し、
     前記接続パッドは、前記第1領域の表面、前記第2領域の表面、および前記段差によって形成された段差面に、形成されている、
     積層体。
  2.  前記構造体の高さ方向において、
     前記第1領域の表面の位置は、前記第2領域の表面の位置よりも高い、請求項1に記載の積層体。
  3.  前記構造体の高さ方向において、
     前記第1領域の表面の位置は、前記第2領域の表面の位置よりも低い、請求項1に記載の積層体。
  4.  前記段差を有する部分と、前記接続パッドとの間に樹脂膜が形成されている、
     請求項1乃至請求項3のいずれかに記載の積層体。
  5.  前記樹脂膜は、
     複数の樹脂膜を積層して形成されている、請求項4に記載の積層体。
  6.  前記接続パッドは、前記接続パッド上に形成された複数の補助部材を有する、
     請求項1乃至請求項5のいずれかに記載の積層体。
  7.  前記第1領域の表面、前記第2領域の表面、および、前記段差面に形成された、複数の前記接続パッドを有し、
     前記第1電子部品は、複数の前記接続パッドを介して、実装されている、
     請求項1乃至請求項6のいずれかに記載の積層体。
  8.  複数の前記段差面を備え、
     前記構造体は互いに対向する第1側面および第2側面と、前記第1側面および前記第2側面を結ぶ方向に延び、かつ、互いに対向する第3側面および第4側面を有し、
     複数の前記段差面は、前記第1側面および前記第2側面のうち少なくとも一方の側面側に形成された第1段差面と、前記第3側面および前記第4側面のうち少なくとも一方の側面側に形成された第2段差面と、を含み、
     複数の前記接続パッドは、
     前記第1段差面または、前記第2段差面に形成されている、
     請求項7に記載の積層体。
  9.  支持体の表面に仮固定材を介して、第1電子部品を配置する工程と、
     前記仮固定材と、前記第1電子部品とを覆うように樹脂で封止する工程と、
     前記支持体と、前記仮固定材と、を取り除く工程と、
     前記樹脂における前記支持体が配置された側の面と、前記第1電子部品における前記仮固定材が配置された面とを跨ぐように、接続パッドを形成する工程と、
     第2電子部品を、前記接続パッドを介してバンプ実装する工程と、
     を備える、積層体の製造方法。
  10.  支持体の表面に形成された仮固定材に、第1電子部品の一部を埋める工程と、
     前記仮固定材と、前記第1電子部品とを覆うように樹脂で封止する工程と、
     前記支持体と、前記仮固定材と、を取り除く工程と、
     前記樹脂における前記支持体が配置された側の面と、前記第1電子部品における前記仮固定材が配置された面とを跨ぐように、接続パッドを形成する工程と、
     第2電子部品を、前記接続パッドを介してバンプ実装する工程と、
     を備える、積層体の製造方法。
PCT/JP2019/034548 2018-09-28 2019-09-03 積層体および積層体の製造方法 WO2020066490A1 (ja)

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