Disclosure of Invention
One aspect of the present disclosure is a circuit board including a first conductive layer, at least one adhesive layer, at least one conductive bump, an insulating layer, and a second conductive layer. At least one adhesive layer is disposed on a surface of the first conductive layer, and the at least one adhesive layer has conductivity. At least one conductive bump comprising a top surface and a bottom surface opposite the top surface, wherein the bottom surface contacts the at least one adhesive layer and is adhered to the first conductive layer via the at least one adhesive layer. And the insulating layer covers the surface of the first conductive layer and at least one conductive block. The second conductive layer is arranged on the insulating layer.
In some embodiments, the thickness of the first conductive layer is at least one HTP200513CN page 2/8 relative to the first conductive layer
The ratio of the thicknesses of the adhesive layer and the at least one conductive bump is greater than 1:15.
In some embodiments, the sum of the thicknesses of the first conductive layer, the at least one adhesive layer, and the at least one conductive bump is 20 micrometers to 3 millimeters.
In some embodiments, the first conductive layer has a thickness greater than 3 microns.
In some embodiments, the thickness of the at least one adhesion layer is less than 5 microns.
In some embodiments, the at least one adhesion layer contacts a surface area of the bottom surface of the at least one conductive bump, not exceeding the surface area of the bottom surface of the at least one conductive bump.
In some embodiments, the plurality of conductive bumps are different in size, shape, or both.
In some embodiments, the conductive bump further comprises at least one conductive post penetrating the second conductive layer and the insulating layer and extending to the top surface of the at least one conductive bump.
In some embodiments, the top of the at least one conductive pillar is coplanar with the second conductive layer.
In some embodiments, the at least one conductive post is a conductive post and the at least one conductive bump is a conductive bump, the conductive post being located on the conductive bump.
In some embodiments, the at least one conductive post is a plurality of conductive posts and the at least one conductive bump is a conductive bump, the plurality of conductive posts being located on the conductive bump.
In some embodiments, the first conductive layer is a patterned first conductive layer, the second conductive layer is a patterned second conductive layer, or a combination thereof.
In some embodiments, the material of the at least one adhesion layer comprises metal particles.
One aspect of the present disclosure is a method of manufacturing a circuit board including providing a first conductive layer, providing an adhesive material and at least one conductive bump, wherein the adhesive material has conductivity, adhering the at least one conductive bump to a surface of the first conductive layer using the adhesive material, providing an insulating layer, disposing the insulating layer on the surface of the first conductive layer and on the at least one conductive bump, and disposing a second conductive layer on the insulating layer.
In some embodiments, the step of adhering the at least one conductive bump to the surface of the first conductive layer using an adhesive material includes heating the adhesive material to cause the adhesive material to be in a fluid state and adhering the at least one conductive bump to the surface of the first conductive layer using the adhesive material.
In some embodiments, an insulating layer is disposed on the surface of the first conductive layer and at least one HTP200513CN page 3/8
The step of forming the conductive block includes removing a portion of the insulating layer, forming at least one recess recessed upward, covering and accommodating the at least one conductive block in the at least one recess, and laminating the insulating layer, the at least one conductive block, and the first conductive layer.
In some embodiments, the method further comprises forming at least one conductive post penetrating the second conductive layer and the insulating layer and extending to the top surface of the at least one conductive bump.
In some embodiments, the step of forming at least one conductive post includes removing a portion of the insulating layer and a portion of the second conductive layer to expose a top surface of the at least one conductive bump to form at least one blind via, and filling the at least one blind via with a conductive material to contact the second conductive layer to form the at least one conductive post.
In some embodiments, the step of disposing the second conductive layer on the insulating layer includes patterning the first conductive layer and the second conductive layer.
It is to be understood that both the foregoing general description and the following detailed description are examples and are intended to provide further explanation of the disclosure as claimed.
Detailed Description
It is to be understood that the various implementations or embodiments provided below may implement different features of the subject matter of this disclosure. Embodiments of specific components and arrangements are presented to simplify the present disclosure and are not limiting. These are, of course, merely examples and are not intended to be limiting. For example, the recitation of a first feature being formed on a second feature described below includes the two being in direct contact, or the two being spaced apart by other additional features than being in direct contact. Furthermore, the present disclosure may repeat reference numerals and/or symbols in various embodiments. Such repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
The terms used in this specification generally have a general meaning in the art and in the context of the use. Examples of embodiments used in this specification, including any terms discussed herein, are illustrative only and do not limit the scope and meaning of the present disclosure or any exemplary terms. As such, the present disclosure is not limited to some embodiments provided in the present specification.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another element. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present embodiments.
In this document, the term "and/or" includes any and all combinations of one or more of the associated listed items.
Herein, the terms "comprising," "including," "having," and the like are to be construed as open-ended, i.e., to mean including, but not limited to.
Fig. 1A-1G exemplarily depict a flow of manufacturing a circuit board in some embodiments according to the present disclosure.
First, please refer to fig. 1A. A first conductive layer 111 is provided. In some embodiments, the first conductive layer 111 is a metal, such as copper (copper foil), but not limited thereto. In some embodiments, the first conductive layer has a thickness greater than 3 microns, such as, but not limited to, 3 microns to 10 microns (3 microns, 4 microns, 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, or 10 microns).
Next, please refer to fig. 1B and fig. 1C. An adhesive material having conductivity is coated on the surface 1111 of the first conductive layer 111 as the adhesive layer 120, and the conductive block 130 is adhered to the surface 1111 of the first conductive layer 111. In some embodiments, an adhesive material may be applied to the bottom surface of the conductive block 130, and the conductive block 130 may be adhered to the surface 1111 of the first conductive layer 111.
In some embodiments, the surface area of the adhesive layer 120 contacting the bottom surface of the conductive block 130 does not exceed the surface area of the bottom surface of the conductive block 130, i.e., the adhesive layer 120 does not exceed the bottom surface of the conductive block 130. In some embodiments, the adhesive material comprises a conductive paste with a conductive substance, such as a transient liquid phase sintering (TRANS I ENT Liqu ID PHASE SI NTER I NG; TLPS) adhesive material. The transient liquid phase sintering adhesive material comprises a combination of metal particles (such as copper and tin) and a solvent, and is characterized in that after the combination of metal particles capable of generating a liquid phase at an adhesive interface by heating, the liquid phase flow is formed, and then the liquid phase gradually rises along with the progress of reaction diffusion, so that the melting point of the adhesive layer 120 exceeds the adhesive temperature, the adhesive layer 120 is solidified, and the effect of adhering the first conductive layer 111 is achieved. The adhesive layer 120 formed by the transient liquid phase sintering adhesive material has high reliability, low resistance (excellent electrical conductivity, resistivity may be less than 1x10 -6 Ω·m) and high heat conduction (thermal conductivity greater than 20W/mk) effects, and can conduct the conductive block 130 and the first conductive layer 111 and assist heat dissipation of the conductive block 130. In an embodiment, the transient liquid phase sintering adhesive material is heated to a temperature higher than 150 ℃ and lower than the melting point (e.g., 160 ℃, 170 ℃, 180 ℃, 190 ℃, or 200 ℃) of the first conductive layer 111 and the conductive bump 130, but not limited thereto, such that the transient liquid phase sintering adhesive material is in a liquid phase flowing state. In one embodiment, the adhesion layer 120 has a thickness of less than 5 microns, such as 0.01 microns to 5 microns, such as1 micron, 2 microns, 3 microns, 4 microns, or HTP200513CN page 6/8 of any of the foregoing
Numerical values, but are not limited thereto.
In some embodiments, the conductive block 130 is not limited in size and shape. In one embodiment, the conductive bumps 130 may be the same size or shape, and in another embodiment, the conductive bumps 130 may be different sizes or shapes (e.g., the first conductive bumps 131, the second conductive bumps 132, and the third conductive bumps 133 of fig. 1C). In one embodiment, the conductive block 130 may be an elongated extension structure, such as a conductive pad or line.
In some embodiments, the sum of the thicknesses of the first conductive layer 111, the adhesive layer 120, and the conductive block 130 may be 20 micrometers to 3 millimeters, such as 20 micrometers, 40 micrometers, 60 micrometers, 80 micrometers, 100 micrometers, 200 micrometers, 400 micrometers, 600 micrometers, 800 micrometers, 1 millimeter, 2 millimeters, 3 millimeters, or any of the foregoing ranges, but is not limited thereto. It should be noted that, by using the adhesive layer 120 and bonding the conductive block 130 to the first conductive layer 111 and then bonding other components, the conductive block 130 is not limited by the thickness of the conventional circuit board, and a more flexible application is provided for the structure of the circuit board embedded with the conductive block 130. For example, in some embodiments, thicker conductive blocks 130 may be used such that the ratio of the thickness of the first conductive layer 111 to the thickness of the first conductive layer 111, the adhesive layer 120, and the conductive blocks 130 is less than 1:15, such as 1:15 to 1:30 (e.g., 1:16, 1:17, 1:18, 1:19, 1:20, 1:21, 1:22, 1:23, 1:24, 1:25, 1:26, 1:27, 1:28, 1:29, 1:30, or ratios in any of the foregoing), but is not limited thereto.
Next, please refer to fig. 1D to fig. 1G. In fig. 1D, an insulating layer 140 is provided. In fig. 1E, a portion of the insulating layer 140 is removed, and a recess a is formed on the surface of the insulating layer 140, which is recessed upward and can accommodate the conductive bump 130. In fig. 1F and 1G, the insulating layer 140 is disposed on the surface 1111 of the first conductive layer 111 and the conductive bump 130, such that the conductive bump 130 is accommodated in the groove a, and at the same time, the second conductive layer 112 is provided and the second conductive layer 112 is disposed on the insulating layer 140, thereby obtaining the circuit board 100.
In some embodiments, the material and thickness of the second conductive layer 112 may be the same as or similar to the first conductive layer 111.
In other embodiments, the step of disposing the insulating layer 140 on the surface 1111 of the first conductive layer 111 and the conductive block 130 may be performed by forming the groove a capable of accommodating the conductive block 130 on the first insulating layer, and then covering the first insulating layer containing the groove a on the conductive block 130 and the first conductive HTP200513CN 7/8 th page of the conductive layer 111, so that the groove a accommodates the conductive block 130. One or more second insulating layers, which have not been subjected to a recess forming process, are then disposed on the first insulating layer including the recess a according to the desired thickness of the insulating layer 140. Finally, the second conductive layer 112 is disposed on the second insulating layer or the uppermost second insulating layer, thereby obtaining the circuit board 100. In some embodiments, the steps of disposing the insulating layer 140 on the surface 1111 of the first conductive layer 111 and the conductive bump 130 and disposing the second conductive layer 112 on the insulating layer 140 include using a thermal compression method to simultaneously compress the first conductive layer 111, the insulating layer 140, the conductive bump 130 and the second conductive layer 112 to obtain the circuit board 100, wherein the first conductive layer 111, the conductive bump 130, the adhesive layer 120 and the second conductive layer 112 have conductivity and are electrically connected to each other to form a conductive structure.
Turning to fig. 2A-2B, a process for fabricating a circuit board including conductive pillars 150 in accordance with some embodiments of the present disclosure is illustratively described.
First, referring to fig. 2A, a portion of the insulating layer 140 and a portion of the second conductive layer 112 are removed, exposing the top surface 134 of the conductive block 130 to form a blind hole B. Next, referring to fig. 2B again, a conductive material is filled into the blind holes B to form conductive pillars 150. That is, the conductive pillars 150 penetrate through the second conductive layer 112 and the insulating layer 140, and extend onto the top surface 134 of the conductive block 130. In some embodiments, the conductive pillars 150 may not be disposed on the top surface 135 of a portion of the conductive bumps 130 (e.g., the third conductive bumps 133).
In some embodiments, the conductive material may be the same as the material of conductive layer 110, such as copper. In some embodiments, the blind holes B may be formed by laser or selective etching, and the second conductive layer 112 is used as a plating seed layer to fill the blind holes B with a conductive material, thereby forming the conductive pillars 150. In some embodiments, the tops of the conductive pillars 150 are coplanar with the second conductive layer 112.
The conductive pillars 150 are used to assist in heat dissipation of the conductive block 130, and one skilled in the art can selectively form one or more conductive pillars 150 on the conductive block 130 according to heat dissipation requirements, cost, and subsequent processing.
In some embodiments, please refer to fig. 3A-3B, which schematically illustrate a process of manufacturing a circuit board 100 including conductive pillars 150 according to other embodiments of the present disclosure, wherein in addition to one conductive pillar 150 being formed on one conductive block 130, a plurality of conductive pillars 150 are formed on one conductive block 130, which is currently characterized by enlarging the HTP200513CN page 8/8 for the conductive block 130 that is prone to heat during use
Heat dissipation area. Fig. 3A illustrates that one blind hole B is formed on the first conductive block 131, and two blind holes B are formed on the second conductive block 132, respectively. Fig. 3B illustrates filling the blind via B with a conductive material to form a conductive pillar 150. In some embodiments, fig. 3A and 3B may be similar to the methods described in fig. 2A and 2B, forming blind holes B and conductive pillars 150.
That is, the circuit board 100 in the present disclosure may include the conductive pillars 150 on the conductive block 130, a plurality of conductive pillars 150 on the conductive block 130, no conductive pillars 150 on the conductive block 130, or the above arrangement.
In some embodiments, please refer to fig. 4, the first conductive layer 111, the second conductive layer 112, or both may be patterned by photolithography and etching to form a patterned first conductive layer 113, a patterned second conductive layer 114, or both the patterned first conductive layer 113 and the patterned second conductive layer 114 for wiring.
For example, the first conductive layer 111 and the second conductive layer 112 may be further patterned in the circuit board 100 including the conductive block 130, forming the patterned first conductive layer 113 and the patterned second conductive layer 114. Referring to fig. 5, the first conductive layer 111 and the second conductive layer 112 may be further patterned in the circuit board 100 including the conductive bumps 130 and the conductive pillars 150. It is emphasized that, due to some embodiments of the present disclosure, the conductive bump 130 does not penetrate the insulating layer 140 and the second conductive layer 112, and a portion of the conductive bump 130 does not have the conductive post 150 (e.g., the third conductive bump 133) thereon. Therefore, the second conductive layer 112 is not limited to the position of the conductive bump 130 when patterning.
The circuit board and the method for manufacturing the circuit board according to some embodiments of the present disclosure utilize conductive adhesive materials to adhere the conductive layer and the conductive bump, and compared with the conventional electroplating method for forming the conductive bump on the conductive layer or filling the conductive material into the through hole of the insulating layer in the substrate, the thickness of the conductive bump of the present disclosure is not limited by the substrate or the electroplating method, and has better flexibility, and the patterning position of the conductive layer is not limited by the position of the conductive bump, so as to provide more various design changes for the circuit pattern.
While the present disclosure has been described in detail with respect to certain embodiments, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the embodiments described herein.