US20070127224A1 - Electronic circuit device and method of manufacturing the same - Google Patents
Electronic circuit device and method of manufacturing the same Download PDFInfo
- Publication number
- US20070127224A1 US20070127224A1 US11/699,433 US69943307A US2007127224A1 US 20070127224 A1 US20070127224 A1 US 20070127224A1 US 69943307 A US69943307 A US 69943307A US 2007127224 A1 US2007127224 A1 US 2007127224A1
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- US
- United States
- Prior art keywords
- circuit board
- electronic component
- adhesive sheet
- circuit device
- electronic
- Prior art date
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- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/30—Technical effects
- H01L2924/301—Electrical effects
- H01L2924/3011—Impedance
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10378—Interposers
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
- H05K2201/10621—Components characterised by their electrical contacts
- H05K2201/10636—Leadless chip, e.g. chip capacitor or resistor
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
- H05K2201/10621—Components characterised by their electrical contacts
- H05K2201/10674—Flip chip
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
- H05K3/305—Affixing by adhesive
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
- Y10T29/49144—Assembling to base an electrical component, e.g., capacitor, etc. by metal fusion
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49155—Manufacturing circuit on or in base
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
- Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
Definitions
- the present invention relates to an electronic circuit device using a polymeric resin sheet as substrate material of a circuit board on which electronic components are mounted, and a method of manufacturing the electronic circuit device.
- FIGS. 5A-5C are sectional views showing major steps of manufacturing a conventional electronic circuit device.
- the conventional electronic circuit device is structured so that electrodes (not shown) on circuit board 41 are connected to corresponding connection terminals (not shown) on LSI 42 via solder bumps 43 .
- FIGS. 5A-5C A method of manufacturing the conventional electronic circuit device is described with reference to FIGS. 5A-5C .
- a plurality of solder bumps 43 are formed on the electrodes on circuit board 41 .
- adhesive sheet 45 including thermoplastic polyimide resin and having cylindrical holes 44 , is bonded to LSI 42 .
- the adhesive sheet is bonded to the LSI so that cylindrical holes 44 through adhesive sheet 45 correspond to the connection terminals provided on LSI 42 .
- solder bumps 43 formed on circuit board 41 are fitted into corresponding cylindrical holes 44 through adhesive sheet 45 . Further, circuit board 41 and LSI 42 are pressed and heated to at least a melting temperature of solder bumps 43 . Then melting of solder bumps 43 connects the connection terminals on LSI 42 and corresponding electrodes on circuit board 41 . At the same time, bonding circuit board 41 and LSI 42 via adhesive sheet 45 , softened by heating, forms an electronic circuit device.
- solder having a melting point of at least 200° C. is used as an electrically connecting material; thus, an inexpensive general-purpose polymeric resin sheet having a low heat-resistant temperature cannot be used as substrate material of a circuit board. Therefore, because expensive substrate material having a high heat-resistant temperature, e.g. epoxy resin including glass fiber or a ceramic plate, is used, there is a problem of an expensive electronic circuit device.
- An electronic circuit device of the present invention is structured so that an electronic component, having connection terminals provided on one side thereof, and a circuit board are bonded via an adhesive sheet having through-holes formed therethrough, and the connection terminals on the electronic component and electrode pads on the circuit board are connected by conductive adhesive provided in the through-holes.
- a method of manufacturing the electronic circuit device of the present invention includes the following steps of:
- connection terminals provided on the one side of the electronic component to the electrode pads provided on the circuit board with the conductive adhesive in the through-holes, and bonding the electronic component to the adhesive sheet.
- FIG. 1 is a sectional view schematically illustrating a structure of an electronic circuit device in accordance with an exemplary embodiment of the present invention.
- FIG. 2A is a sectional view schematically illustrating a structure in which a bump is formed on a surface of a connection terminal on an electronic component in an electronic circuit device in accordance with the exemplary embodiment of the present invention.
- FIG. 2B is a sectional view schematically illustrating a structure in which a bump is provided on a side of an electrode pad on a circuit board in an electronic circuit device in accordance with the exemplary embodiment of the present invention.
- FIGS. 3A, 3B , and 3 C are sectional views showing steps of a method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention.
- FIGS. 4A and 4B are sectional views showing steps of the method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention.
- FIGS. 5A, 5B , and 5 C are sectional views showing major steps of a method of manufacturing a conventional electronic circuit device.
- FIGS. 1 through 4 B An exemplary embodiment of the present invention is described hereinafter with reference to FIGS. 1 through 4 B. Same elements are denoted with the same reference marks and a detailed description of these elements is omitted.
- FIG. 1 is a sectional view schematically illustrating a structure of an electronic circuit device in accordance with an exemplary embodiment of the present invention.
- Circuit board 11 having wiring patterns (not shown) formed thereon has electrode pads 12 in positions corresponding to connection terminals 16 on electronic component 15 .
- connection terminals 16 Formed on a surface of one side of electronic component 15 , e.g. an LSI, are connection terminals 16 each having a shape protruding at least from the surface of the electronic component.
- Through adhesive sheet 13 through-holes 14 , each having a shape to receive a respective connection terminal 16 , are provided in positions corresponding to connection terminals 16 .
- Connection terminals 16 on electronic component 15 , and electrode pads 12 on circuit board 11 are bonded and electrically connected by conductive adhesive 17 provided in through-holes 14 . Further, circuit board 11 and electronic component 15 are bonded via adhesive sheet 13 . This enables a highly reliable connection.
- Possible substrates for circuit board 11 include a heat-resistant substrate made of epoxy resin including glass fiber, or a ceramic plate, and a polymeric resin sheet including a film sheet made of polyethylene terephthalate (PET) resin, acrylnitrile-butadiene-styrene (ABS) resin, polycarbonate resin, or polyimide resin. Any material used for a general circuit board is applicable. Especially preferable is a polymeric resin sheet made of PET resin, ABS resin, polycarbonate resin, polyimide resin, or the like. Because such polymeric resin sheets find a wide variety of applications as general-purpose plastic, they are inexpensive. Additionally, because circuit board 11 can be formed to have a thickness ranging from approximately 50 to 400 ⁇ m, such polymeric resin sheets are effective in reducing a thickness of electronic circuit devices.
- Applicable adhesive sheet 13 includes an adhesive sheet including thermosetting resin, e.g. epoxy resin or acrylic resin, and a generally well-known hot-melt sheet including thermoplastic resin. In this case, it is preferable that a thickness of adhesive sheet 13 ranges from 100 to 800 ⁇ m, in consideration of a thinner electronic circuit device and adhesive strength and connection resistance between circuit board 11 and electronic component 15 .
- Preferable conductive adhesive 17 is conductive paste in which conductive particles made of pulverized conductive material, e.g. gold (Au), silver (Ag), cupper (Cu), nickel (Ni), palladium (Pd), and Ag—Pd alloys, are dispersed in a binder.
- a binder including thermosetting resin e.g. polyester resin, epoxy resin, acrylic resin, polyimide resin, or polyurethane resin, is preferable because it securely bonds electrode pads 12 on circuit board 11 to connection terminals 16 on electronic component 15 .
- thermosetting resin and conductive adhesive 17 can be selected.
- Combinations of adhesive sheet 13 made of thermosetting resin and conductive adhesive 17 including thermosetting resin binder are preferable. Because these combinations are applicable even to circuit boards poor in heat resistance that are made of PET resin, ABS resin, or the like, circuit boards can be selected from a broader range. Most preferable among these is combinations in which thermosetting resin in adhesive sheet 13 starts curing at a lower temperature than does thermosetting resin binder in a conductive paste used as conductive adhesive 17 . The combinations can prevent warp of adhesive sheet 13 when the thermosetting resin and the thermosetting resin binder are heated and cured.
- electronic component 15 general electronic components, such as chip components including LSIs, resistors, capacitors, and coils, can be used.
- an electronic circuit device can be structured so that bump 20 protruding into through-hole 14 is formed on at least one of connection terminal 16 on electronic component 15 , and electrode pad 12 on circuit board 11 .
- this structure increases an area in which conductive adhesive 17 is in contact with connection terminal 16 or electrode pad 12 .
- This structure also allows connection terminal 16 and electrode pad 12 to be bonded more securely and decreases connection resistance between connection terminal 16 and electrode pad 12 .
- the electronic circuit device can also be structured so that connection terminal 16 is in direct contact with electrode pad 12 . In this case, connection resistance between connection terminal 16 and electrode pad 12 is further reduced.
- FIG. 2A is a sectional view schematically illustrating a structure in which bump 20 is formed on a surface of connection terminal 16 on electronic component 15 .
- bump 20 made of Au is formed by a stud-bump bonding process, for example, and has a thickness ranging from approximately 10 to 100 ⁇ m.
- This structure increases an area in which the bump is in contact with conductive adhesive 17 and reduces a distance from the bump to electrode pad 12 , thus drastically reducing connection resistance.
- As the shape of bump 20 it is necessary that an outer dimension thereof is smaller than at least a dimension of through-hole 14 , provided through adhesive sheet 13 , and a thickness thereof is smaller than at least that of adhesive sheet 13 .
- Materials of bump 20 include Cu, Ni, and solder, other than the above-mentioned Au.
- Bump 20 can be formed by plating, evaporation and sputtering, other than the stud-bump bonding process.
- FIG. 2B is a sectional view schematically illustrating a structure in which bump 24 is provided on a side of electrode pad 12 on circuit board 11 , for connection. Bump 24 is provided on electrode pad 12 on circuit board 11 for connection to connection terminal 16 on electronic component 15 via conductive adhesive 17 .
- a method of forming bump 24 , and material thereof, are the same as those of FIG. 2A .
- forming bump 20 or 24 on at least one of electrode pad 12 on circuit board 11 , and connection terminal 16 on electronic component 15 can reduce an amount of applied conductive adhesive 17 . Further, if the amount of conductive adhesive 17 applied to through-hole 14 varies, a large contact area prevents variation in connection resistance.
- connection terminals 16 on electronic component 15 do not necessarily protrude from the surface thereof.
- connection terminals 16 are formed on electronic component 15 with the connection terminals recessed from a surface of the electronic component, the connection terminals can be connected to corresponding electrode pads 12 on circuit board 11 by forming bumps 20 on connection terminals 16 .
- FIGS. 3A-4B are sectional views showing steps in a method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention.
- circuit board 11 On this circuit board 11 , resistors, capacitors, semiconductor devices, or the like can be mounted by soldering or other methods. Alternatively, only wiring patterns can be formed. Then, electrode pads 12 are formed on circuit board 11 at predetermined positions on which electronic component 15 is to be mounted. Further, through adhesive sheet 13 , including thermosetting resin, e.g. epoxy resin or acrylic resin, through-holes 14 are provided at positions corresponding to electrode pads 12 on circuit board 11 .
- thermosetting resin e.g. epoxy resin or acrylic resin
- adhesive sheet 13 is bonded to circuit board 11 so that through-holes 14 , through adhesive sheet 13 , are aligned with corresponding electrode pads 12 on circuit board 11 (sheet bonding step).
- Conductive adhesive 17 is provided into through-holes 14 by screen printing, an ink-jet process, plotting, transfer printing, or other various methods. At this time, it is desirable that conductive adhesive 17 is provided so that a height thereof is smaller than a height of through-holes 14 , provided through adhesive sheet 13 , in consideration of sizes of connection terminals 16 and bumps 20 or 24 to be received by through-holes 14 .
- connection terminals 16 are electrically and mechanically connected to corresponding electrode pads 12 via conductive adhesive 17 in through-holes 14 (electronic component bonding step).
- adhesive sheet 13 including thermosetting resin can be heated while, or after, being pressed to electronic component 15 . Either method can securely bond wiring board 11 and electronic component 15 .
- This manufacturing method can provide an electronic circuit device in which electronic component 15 is mounted on circuit board 11 as shown in FIG. 4B .
- connection terminals 16 on electronic component 15 are connected to electrode pads 12 on circuit board 11 via conductive adhesive 17 , and electronic component 15 is connected to circuit board 11 via adhesive sheet 13 , a highly reliable connection is possible even with use of sheet-shaped circuit board 11 .
- An electronic circuit device can also be manufactured by providing conductive adhesive 17 in through-holes 14 through adhesive sheet 13 , aligning the through-holes with corresponding electrode pads 12 on circuit board 11 , and then bonding adhesive sheet 13 to circuit board 11 .
- circuit board 11 Materials used as circuit board 11 , electronic component 15 , and conductive adhesive 17 are described below.
- Used as circuit board 11 is a 100- ⁇ m-thick polyethylene terephthalate (PET) film sheet having wiring patterns formed on both sides thereof.
- Used as electronic component 15 is an LSI that has semi-spherical bumps 20 , each approximately 0.2 mm in diameter, formed on a surface of corresponding connection terminals 16 . In this case, a pitch of arranged bumps 20 is approximately 0.4 mm.
- Used as adhesive sheet 13 is a 0.6- mm-thick thermosetting hot-melt sheet having a curing temperature of 80° C. (Macromelt 6301 made by the Henkel Japan Ltd.)
- Used as conductive adhesive 17 is Ag paste. As a binder of the Ag paste, thermosetting epoxy resin having a curing temperature of 110° C. is used.
- wiring patterns (not shown) and electrode pads 12 are printed onto the PET film sheet by a general screen-printing method, to provide circuit board 11 as shown in FIG. 3A .
- adhesive sheet 13 that has through-holes 14 , each 0.3 mm in diameter and formed to be aligned with corresponding electrode pads 12 on circuit board 11 , is bonded to circuit board 11 .
- a temperature is 80° C. and a heating time is 15 seconds.
- conductive adhesive 17 in an amount of approximately 0.035 to 0.040 mm 3 is provided in each through-hole 14 , through adhesive sheet 13 , by performing a screen-printing method. Then, electronic component 15 is bonded to adhesive sheet 13 so that connection terminals 16 on electronic component 15 are aligned with corresponding electrode pads 12 on circuit board 11 . Further, conductive adhesive 17 is cured under heating conditions where a temperature is 110° C. and a time is 30 minutes. Thus, electronic component 15 is securely bonded to circuit board 11 via adhesive sheet 13 . At the same time, connection terminals 16 and corresponding electrode pads 12 are mechanically and electrically connected via conductive adhesive 17 . A resistance between electrode pads 12 and connection terminals 16 is approximately 20 m ⁇ .
- an LSI i.e. electronic component 15
- the PET film sheet i.e. circuit board 11
- an optimum combination of adhesive sheet 13 and conductive adhesive 17 can realize an electronic circuit device that has a warp of the PET film sheet at a negligible level.
- the above-described method can realize an electronic circuit device by using an inexpensive and flexible polymeric resin sheet, that enables production at low temperatures, as a circuit board. Further, an adhesive sheet having conductive adhesive in through-holes thereof advantageously realizes a highly reliable electronic circuit device that provides high adhesive strength and low connection resistance between the circuit board and electronic component.
Abstract
An electronic component having connection terminals on one side thereof is bonded to a circuit board via an adhesive sheet having through-holes. The connection terminals on the electronic component are connected to electrode pads provided on the circuit board via a conductive adhesive in the through-holes. Thus, an electronic circuit device is formed. Using a polymeric resin film sheet for the circuit board and mounting an electronic component, e.g. an LSI, onto the circuit board can provide a small, light, thin, and inexpensive electronic circuit device.
Description
- The present invention relates to an electronic circuit device using a polymeric resin sheet as substrate material of a circuit board on which electronic components are mounted, and a method of manufacturing the electronic circuit device.
- 1. Field of the Invention
- In recent years, there have been an increasing number of demands for reduction in size, weight, and thickness of electronic circuit devices incorporated into electronic equipment, such as a portable phone. For this purpose, a technique of mounting high-density thin electronic components, such as large scale integrated circuits (hereinafter referred to as LSIs), has been proposed.
- 2. Background art
- For example, Japanese Patent Unexamined Publication No. 2000-340607 is disclosed.
FIGS. 5A-5C are sectional views showing major steps of manufacturing a conventional electronic circuit device. The conventional electronic circuit device is structured so that electrodes (not shown) oncircuit board 41 are connected to corresponding connection terminals (not shown) onLSI 42 viasolder bumps 43. - A method of manufacturing the conventional electronic circuit device is described with reference to
FIGS. 5A-5C . - First, as shown in
FIG. 5A , a plurality ofsolder bumps 43 are formed on the electrodes oncircuit board 41. - Next, as shown in
FIG. 5B ,adhesive sheet 45, including thermoplastic polyimide resin and havingcylindrical holes 44, is bonded toLSI 42. At this time, the adhesive sheet is bonded to the LSI so thatcylindrical holes 44 throughadhesive sheet 45 correspond to the connection terminals provided onLSI 42. - Next, as shown
FIG. 5C ,solder bumps 43 formed oncircuit board 41 are fitted into correspondingcylindrical holes 44 throughadhesive sheet 45. Further,circuit board 41 andLSI 42 are pressed and heated to at least a melting temperature ofsolder bumps 43. Then melting ofsolder bumps 43 connects the connection terminals onLSI 42 and corresponding electrodes oncircuit board 41. At the same time,bonding circuit board 41 and LSI 42 viaadhesive sheet 45, softened by heating, forms an electronic circuit device. - However, in the conventional electronic circuit device, solder having a melting point of at least 200° C. is used as an electrically connecting material; thus, an inexpensive general-purpose polymeric resin sheet having a low heat-resistant temperature cannot be used as substrate material of a circuit board. Therefore, because expensive substrate material having a high heat-resistant temperature, e.g. epoxy resin including glass fiber or a ceramic plate, is used, there is a problem of an expensive electronic circuit device.
- Further, there is another problem. When the adhesive sheet is heated to bond the LSI and circuit board, air may be mixed into the adhesive sheet, or melted solder may diffuse into adjacent bumps, thus decreasing insulation resistance. For this reason, it is difficult to manufacture highly reliable electronic circuit devices with high yields.
- An electronic circuit device of the present invention is structured so that an electronic component, having connection terminals provided on one side thereof, and a circuit board are bonded via an adhesive sheet having through-holes formed therethrough, and the connection terminals on the electronic component and electrode pads on the circuit board are connected by conductive adhesive provided in the through-holes.
- A method of manufacturing the electronic circuit device of the present invention includes the following steps of:
- A) bonding the adhesive sheet to the circuit board so that the through-holes formed through the adhesive sheet are aligned with corresponding electrode pads provided on a surface of the circuit board;
- B) providing conductive adhesive in the through-holes; and
- C) bonding the connection terminals provided on the one side of the electronic component to the electrode pads provided on the circuit board with the conductive adhesive in the through-holes, and bonding the electronic component to the adhesive sheet.
-
FIG. 1 is a sectional view schematically illustrating a structure of an electronic circuit device in accordance with an exemplary embodiment of the present invention. -
FIG. 2A is a sectional view schematically illustrating a structure in which a bump is formed on a surface of a connection terminal on an electronic component in an electronic circuit device in accordance with the exemplary embodiment of the present invention. -
FIG. 2B is a sectional view schematically illustrating a structure in which a bump is provided on a side of an electrode pad on a circuit board in an electronic circuit device in accordance with the exemplary embodiment of the present invention. -
FIGS. 3A, 3B , and 3C are sectional views showing steps of a method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention. -
FIGS. 4A and 4B are sectional views showing steps of the method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention. -
FIGS. 5A, 5B , and 5C are sectional views showing major steps of a method of manufacturing a conventional electronic circuit device. - An exemplary embodiment of the present invention is described hereinafter with reference to
FIGS. 1 through 4 B. Same elements are denoted with the same reference marks and a detailed description of these elements is omitted. -
FIG. 1 is a sectional view schematically illustrating a structure of an electronic circuit device in accordance with an exemplary embodiment of the present invention.Circuit board 11 having wiring patterns (not shown) formed thereon haselectrode pads 12 in positions corresponding toconnection terminals 16 onelectronic component 15. Formed on a surface of one side ofelectronic component 15, e.g. an LSI, areconnection terminals 16 each having a shape protruding at least from the surface of the electronic component. Throughadhesive sheet 13, through-holes 14, each having a shape to receive arespective connection terminal 16, are provided in positions corresponding toconnection terminals 16.Connection terminals 16 onelectronic component 15, andelectrode pads 12 oncircuit board 11 are bonded and electrically connected byconductive adhesive 17 provided in through-holes 14. Further,circuit board 11 andelectronic component 15 are bonded viaadhesive sheet 13. This enables a highly reliable connection. - Possible substrates for
circuit board 11 include a heat-resistant substrate made of epoxy resin including glass fiber, or a ceramic plate, and a polymeric resin sheet including a film sheet made of polyethylene terephthalate (PET) resin, acrylnitrile-butadiene-styrene (ABS) resin, polycarbonate resin, or polyimide resin. Any material used for a general circuit board is applicable. Especially preferable is a polymeric resin sheet made of PET resin, ABS resin, polycarbonate resin, polyimide resin, or the like. Because such polymeric resin sheets find a wide variety of applications as general-purpose plastic, they are inexpensive. Additionally, becausecircuit board 11 can be formed to have a thickness ranging from approximately 50 to 400 μm, such polymeric resin sheets are effective in reducing a thickness of electronic circuit devices. - Applicable
adhesive sheet 13 includes an adhesive sheet including thermosetting resin, e.g. epoxy resin or acrylic resin, and a generally well-known hot-melt sheet including thermoplastic resin. In this case, it is preferable that a thickness ofadhesive sheet 13 ranges from 100 to 800 μm, in consideration of a thinner electronic circuit device and adhesive strength and connection resistance betweencircuit board 11 andelectronic component 15. - Preferable
conductive adhesive 17 is conductive paste in which conductive particles made of pulverized conductive material, e.g. gold (Au), silver (Ag), cupper (Cu), nickel (Ni), palladium (Pd), and Ag—Pd alloys, are dispersed in a binder. Especially, a binder including thermosetting resin, e.g. polyester resin, epoxy resin, acrylic resin, polyimide resin, or polyurethane resin, is preferable because it securely bondselectrode pads 12 oncircuit board 11 toconnection terminals 16 onelectronic component 15. - Depending on material of
circuit board 11 and a shape and material ofelectronic component 15, optimum combinations ofadhesive sheet 13 and conductive adhesive 17 can be selected. Combinations ofadhesive sheet 13 made of thermosetting resin and conductive adhesive 17 including thermosetting resin binder are preferable. Because these combinations are applicable even to circuit boards poor in heat resistance that are made of PET resin, ABS resin, or the like, circuit boards can be selected from a broader range. Most preferable among these is combinations in which thermosetting resin inadhesive sheet 13 starts curing at a lower temperature than does thermosetting resin binder in a conductive paste used asconductive adhesive 17. The combinations can prevent warp ofadhesive sheet 13 when the thermosetting resin and the thermosetting resin binder are heated and cured. - As
electronic component 15, general electronic components, such as chip components including LSIs, resistors, capacitors, and coils, can be used. - As shown in
FIG. 2A or 2B, an electronic circuit device can be structured so thatbump 20 protruding into through-hole 14 is formed on at least one ofconnection terminal 16 onelectronic component 15, andelectrode pad 12 oncircuit board 11. In other words, this structure increases an area in which conductive adhesive 17 is in contact withconnection terminal 16 orelectrode pad 12. This structure also allowsconnection terminal 16 andelectrode pad 12 to be bonded more securely and decreases connection resistance betweenconnection terminal 16 andelectrode pad 12. The electronic circuit device can also be structured so thatconnection terminal 16 is in direct contact withelectrode pad 12. In this case, connection resistance betweenconnection terminal 16 andelectrode pad 12 is further reduced. -
FIG. 2A is a sectional view schematically illustrating a structure in which bump 20 is formed on a surface ofconnection terminal 16 onelectronic component 15. On the surface ofconnection terminal 16, bump 20 made of Au is formed by a stud-bump bonding process, for example, and has a thickness ranging from approximately 10 to 100 μm. This structure increases an area in which the bump is in contact with conductive adhesive 17 and reduces a distance from the bump toelectrode pad 12, thus drastically reducing connection resistance. As the shape ofbump 20, it is necessary that an outer dimension thereof is smaller than at least a dimension of through-hole 14, provided throughadhesive sheet 13, and a thickness thereof is smaller than at least that ofadhesive sheet 13. There are no other restrictions. Materials ofbump 20 include Cu, Ni, and solder, other than the above-mentioned Au.Bump 20 can be formed by plating, evaporation and sputtering, other than the stud-bump bonding process. -
FIG. 2B is a sectional view schematically illustrating a structure in which bump 24 is provided on a side ofelectrode pad 12 oncircuit board 11, for connection.Bump 24 is provided onelectrode pad 12 oncircuit board 11 for connection toconnection terminal 16 onelectronic component 15 viaconductive adhesive 17. A method of formingbump 24, and material thereof, are the same as those ofFIG. 2A . - As described above, forming
bump electrode pad 12 oncircuit board 11, andconnection terminal 16 onelectronic component 15, can reduce an amount of appliedconductive adhesive 17. Further, if the amount of conductive adhesive 17 applied to through-hole 14 varies, a large contact area prevents variation in connection resistance. - In the embodiment of the present invention,
connection terminals 16 onelectronic component 15 do not necessarily protrude from the surface thereof. Whenconnection terminals 16 are formed onelectronic component 15 with the connection terminals recessed from a surface of the electronic component, the connection terminals can be connected tocorresponding electrode pads 12 oncircuit board 11 by formingbumps 20 onconnection terminals 16. - Hereinafter, a description is provided of a method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention.
-
FIGS. 3A-4B are sectional views showing steps in a method of manufacturing an electronic circuit device in accordance with the exemplary embodiment of the present invention. - First, as shown in
FIG. 3A , necessary wiring patterns (not shown) are formed oncircuit board 11. On thiscircuit board 11, resistors, capacitors, semiconductor devices, or the like can be mounted by soldering or other methods. Alternatively, only wiring patterns can be formed. Then,electrode pads 12 are formed oncircuit board 11 at predetermined positions on whichelectronic component 15 is to be mounted. Further, throughadhesive sheet 13, including thermosetting resin, e.g. epoxy resin or acrylic resin, through-holes 14 are provided at positions corresponding toelectrode pads 12 oncircuit board 11. - Next, as shown in
FIG. 3B ,adhesive sheet 13 is bonded tocircuit board 11 so that through-holes 14, throughadhesive sheet 13, are aligned withcorresponding electrode pads 12 on circuit board 11 (sheet bonding step). - Next, as shown in
FIG. 3C , through-holes 14, throughadhesive sheet 13, are filled with conductive adhesive 17 (conductive adhesive filling step).Conductive adhesive 17 is provided into through-holes 14 by screen printing, an ink-jet process, plotting, transfer printing, or other various methods. At this time, it is desirable that conductive adhesive 17 is provided so that a height thereof is smaller than a height of through-holes 14, provided throughadhesive sheet 13, in consideration of sizes ofconnection terminals 16 and bumps 20 or 24 to be received by through-holes 14. - Next, as shown in
FIG. 4A , afterelectrode pads 12 oncircuit board 11, havingadhesive sheet 13 bonded thereto, are aligned withcorresponding connection terminals 16 onelectronic component 15,electronic component 15 is pressed ontoadhesive sheet 13. This bondscircuit board 11 andelectronic component 15 to each other viaadhesive sheet 13. Further,connection terminals 16 are electrically and mechanically connected tocorresponding electrode pads 12 viaconductive adhesive 17 in through-holes 14 (electronic component bonding step). For example,adhesive sheet 13 including thermosetting resin can be heated while, or after, being pressed toelectronic component 15. Either method can securely bondwiring board 11 andelectronic component 15. - This manufacturing method can provide an electronic circuit device in which
electronic component 15 is mounted oncircuit board 11 as shown inFIG. 4B . - As shown in this embodiment, because
connection terminals 16 onelectronic component 15 are connected to electrodepads 12 oncircuit board 11 viaconductive adhesive 17, andelectronic component 15 is connected tocircuit board 11 viaadhesive sheet 13, a highly reliable connection is possible even with use of sheet-shapedcircuit board 11. - The present invention is not limited to the above-described manufacturing method. An electronic circuit device can also be manufactured by providing conductive adhesive 17 in through-
holes 14 throughadhesive sheet 13, aligning the through-holes withcorresponding electrode pads 12 oncircuit board 11, and then bondingadhesive sheet 13 tocircuit board 11. - Hereinafter, a detailed description is provided of an electronic circuit device using an LSI as
electronic component 15, and a polymeric resin sheet ascircuit board 11. - Materials used as
circuit board 11,electronic component 15, and conductive adhesive 17 are described below. - Used as
circuit board 11 is a 100-μm-thick polyethylene terephthalate (PET) film sheet having wiring patterns formed on both sides thereof. Used aselectronic component 15 is an LSI that hassemi-spherical bumps 20, each approximately 0.2 mm in diameter, formed on a surface ofcorresponding connection terminals 16. In this case, a pitch of arrangedbumps 20 is approximately 0.4 mm. Used asadhesive sheet 13 is a 0.6-mm-thick thermosetting hot-melt sheet having a curing temperature of 80° C. (Macromelt 6301 made by the Henkel Japan Ltd.) Used asconductive adhesive 17 is Ag paste. As a binder of the Ag paste, thermosetting epoxy resin having a curing temperature of 110° C. is used. - The method of manufacturing the electronic circuit device is specifically described with reference to
FIGS. 3A-4B . First, wiring patterns (not shown) andelectrode pads 12 are printed onto the PET film sheet by a general screen-printing method, to providecircuit board 11 as shown inFIG. 3A . - Next, according to the method described as shown in
FIG. 3B ,adhesive sheet 13 that has through-holes 14, each 0.3 mm in diameter and formed to be aligned withcorresponding electrode pads 12 oncircuit board 11, is bonded tocircuit board 11. As for bonding conditions, a temperature is 80° C. and a heating time is 15 seconds. - Next, as shown in
FIG. 3C ,conductive adhesive 17, in an amount of approximately 0.035 to 0.040 mm3 is provided in each through-hole 14, throughadhesive sheet 13, by performing a screen-printing method. Then,electronic component 15 is bonded toadhesive sheet 13 so thatconnection terminals 16 onelectronic component 15 are aligned withcorresponding electrode pads 12 oncircuit board 11. Further,conductive adhesive 17 is cured under heating conditions where a temperature is 110° C. and a time is 30 minutes. Thus,electronic component 15 is securely bonded tocircuit board 11 viaadhesive sheet 13. At the same time,connection terminals 16 andcorresponding electrode pads 12 are mechanically and electrically connected viaconductive adhesive 17. A resistance betweenelectrode pads 12 andconnection terminals 16 is approximately 20 mΩ. Additionally, an LSI, i.e.electronic component 15, and the PET film sheet, i.e.circuit board 11, have sufficient adhesive strength. Further, an optimum combination ofadhesive sheet 13 and conductive adhesive 17 can realize an electronic circuit device that has a warp of the PET film sheet at a negligible level. - The above-described method can realize an electronic circuit device by using an inexpensive and flexible polymeric resin sheet, that enables production at low temperatures, as a circuit board. Further, an adhesive sheet having conductive adhesive in through-holes thereof advantageously realizes a highly reliable electronic circuit device that provides high adhesive strength and low connection resistance between the circuit board and electronic component.
Claims (4)
1-7. (canceled)
8. A method of manufacturing an electronic circuit device, comprising:
bonding an adhesive sheet to a circuit board so that a through-hole, through said adhesive sheet, is aligned with an electrode pad provided on a surface of said circuit board;
providing a conductive adhesive in said through-hole; and
bonding a connection terminal, provided on one side of an electronic component, to said electrode pad on said circuit board via said conductive adhesive in said through-hole, and bonding said electronic component to said adhesive sheet.
9. The method according to claim 8 , wherein said adhesive sheet is one of a thermosetting resin sheet and a thermoplastic resin sheet.
10. The method according to claim 8 , wherein said conductive adhesive consists essentially of conductive particles and a thermosetting resin binder, and said adhesive sheet includes a thermosetting resin, with said thermosetting resin being such that it begins to cure at a lower temperature than does said thermosetting resin binder.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/699,433 US20070127224A1 (en) | 2003-03-24 | 2007-01-30 | Electronic circuit device and method of manufacturing the same |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2003080299A JP4123998B2 (en) | 2003-03-24 | 2003-03-24 | Electronic circuit device and manufacturing method thereof |
JP2003-080299 | 2003-03-24 | ||
US10/798,398 US7186925B2 (en) | 2003-03-24 | 2004-03-12 | Electronic circuit device and method of manufacturing the same |
US11/699,433 US20070127224A1 (en) | 2003-03-24 | 2007-01-30 | Electronic circuit device and method of manufacturing the same |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/798,398 Division US7186925B2 (en) | 2003-03-24 | 2004-03-12 | Electronic circuit device and method of manufacturing the same |
Publications (1)
Publication Number | Publication Date |
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US20070127224A1 true US20070127224A1 (en) | 2007-06-07 |
Family
ID=33127227
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/798,398 Expired - Fee Related US7186925B2 (en) | 2003-03-24 | 2004-03-12 | Electronic circuit device and method of manufacturing the same |
US11/699,433 Abandoned US20070127224A1 (en) | 2003-03-24 | 2007-01-30 | Electronic circuit device and method of manufacturing the same |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US10/798,398 Expired - Fee Related US7186925B2 (en) | 2003-03-24 | 2004-03-12 | Electronic circuit device and method of manufacturing the same |
Country Status (3)
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US (2) | US7186925B2 (en) |
JP (1) | JP4123998B2 (en) |
CN (1) | CN1532919B (en) |
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US7964800B2 (en) * | 2006-05-25 | 2011-06-21 | Fujikura Ltd. | Printed wiring board, method for forming the printed wiring board, and board interconnection structure |
US20080226813A1 (en) * | 2007-03-16 | 2008-09-18 | Xerox Corporation | Method and System for A Composite Polymer for Printed MEMS |
JP5342034B2 (en) * | 2012-04-17 | 2013-11-13 | 株式会社東芝 | Electronic components and equipment |
TW201344268A (en) * | 2012-04-27 | 2013-11-01 | Hon Hai Prec Ind Co Ltd | Chip assembly, chip assembling method and optical fiber coupling module |
US9265147B2 (en) * | 2012-11-14 | 2016-02-16 | Fujikura Ltd. | Multi-layer wiring board |
JP2015135878A (en) * | 2014-01-16 | 2015-07-27 | デクセリアルズ株式会社 | Connection body, method for manufacturing connection body, connection method and anisotropic conductive adhesive |
US10064287B2 (en) | 2014-11-05 | 2018-08-28 | Infineon Technologies Austria Ag | System and method of providing a semiconductor carrier and redistribution structure |
US10192846B2 (en) * | 2014-11-05 | 2019-01-29 | Infineon Technologies Austria Ag | Method of inserting an electronic component into a slot in a circuit board |
US10553557B2 (en) | 2014-11-05 | 2020-02-04 | Infineon Technologies Austria Ag | Electronic component, system and method |
US20170245367A1 (en) * | 2016-02-22 | 2017-08-24 | Raytheon Company | Circuit card assembly (cca) with reduced susceptibility to deform under loading |
JP2019021752A (en) * | 2017-07-14 | 2019-02-07 | 富士通株式会社 | Wiring board, electronic equipment, method of manufacturing wiring board and method of manufacturing electronic equipment |
JP7111457B2 (en) * | 2017-10-27 | 2022-08-02 | 新光電気工業株式会社 | Semiconductor device and its manufacturing method |
JP7185252B2 (en) | 2018-01-31 | 2022-12-07 | 三国電子有限会社 | Method for producing connection structure |
JP7160302B2 (en) * | 2018-01-31 | 2022-10-25 | 三国電子有限会社 | CONNECTED STRUCTURE AND METHOD OF MAKING CONNECTED STRUCTURE |
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Also Published As
Publication number | Publication date |
---|---|
US7186925B2 (en) | 2007-03-06 |
US20040200065A1 (en) | 2004-10-14 |
CN1532919A (en) | 2004-09-29 |
JP2004288959A (en) | 2004-10-14 |
CN1532919B (en) | 2010-05-05 |
JP4123998B2 (en) | 2008-07-23 |
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