Abstract:
Disclosed herein is a method of manufacturing a block module including: mounting an electronic part on a base substrate on which a ground terminal is formed; forming a lead frame to extend to the outside of the base substrate from the ground terminal; connecting a flexible printed circuit to a circuit layer on the base substrate; forming a mold to surround the base substrate; cutting the lead frame and exposing the cut surface of the lead frame to the outside of the mold; and forming a metal coating layer connected to the lead frame on the mold, whereby the metal coating layer is formed to surround the mold to interrupt the electromagnetic waves and the metal coating layer is connected to the ground terminal by the lead frame to make the process simple.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of Korean Patent Application No. 10-2010-0099368, filed on Oct. 12, 2010, entitled “Method of Manufacturing Block Module”, which is hereby incorporated by reference in its entirety into this application. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    The present invention relates to a method of manufacturing a block module. 
         [0004]    2. Description of the Related Art 
         [0005]    Recently, a demand for multi-functional and high-speed electronic products has suddenly increased. In order to meet the demands, a semiconductor device and a block module connecting the semiconductor device with a main board has been developed at very rapid speed. 
         [0006]    Requirements for the development of the block module are closely associated with how rapidly the block module is developed and how highly the block module is integrated. In order to satisfy these requirements, there is a need to more improve and develop the block module in view of slimness and lightness, fine circuit, excellent electrical characteristics, high reliability, high-speed signal transfer structure, or the like, of the block module. 
         [0007]    Meanwhile, most electronic devices undergo electromagnetic interference (EMI)/electromagnetic compatibility (EMC) even though there is a slight difference therebetween. Electronic energy generated from the electronic devices may be emitted through a path of any medium to cause the interference with other devices or the electronic devices may experience the interference due to electromagnetic noises or conductive noises from the outside. The electromagnetic interference is considered as a factor that functionally disorders electronic devices and degrades circuit functions and causes the malfunction of the electronic devices. 
         [0008]    Therefore, research into the block module capable of interrupting the electromagnetic waves has been conducted recently. 
         [0009]      FIG. 1A  is a cross-sectional view of a block module  10  according to the prior art and  FIG. 1B  is a plan view of the block module  10  shown in  FIG. 1A . Hereinafter, the block module  10  according to the prior art will be described with reference to  FIGS. 1A and 1B . 
         [0010]    The block module  10  according to the prior art includes a circuit layer  11 , a substrate  13  on which a ground terminal  12  is formed, an electronic element  14 , and a flexible printed circuit (FPC)  15 , and a mold  16 . 
         [0011]    The electronic element  14  is mounted on the substrate  13  and the electronic element  14  is connected to the circuit layer  11  of the substrate  13 . In addition, the flexible printed circuit  15  is connected to the circuit layer  11  of the substrate  13  to electrically connect the block module  10  to the outside and the mold  16  is formed to surround the substrate  13  to protect other components. 
         [0012]    However, the block module  10  according to the prior art does not have a device for interrupting the electromagnetic waves, which degrades the performance of the block module  10 . 
         [0013]    In addition, since a metal coating layer is connected to a ground terminal  12  by punching vias on the mold  16  for implementing a ground, even when the surface of the mold  16  is coated with metal so as to interrupt the electromagnetic waves, a process may be complicated. 
       SUMMARY OF THE INVENTION 
       [0014]    The present invention has been made in an effort to provide a method of manufacturing a block module capable of effectively interrupting electromagnetic waves. 
         [0015]    In addition, the present invention has been made in an effort to provide a method of manufacturing a block module by a simple ground process of a metal coating layer when the metal coating layer is formed so as to interrupt electromagnetic waves. 
         [0016]    According to a preferred embodiment of the present invention, there is a method of manufacturing a block module, including: mounting an electronic part on a base substrate on which a ground terminal is formed; forming a lead frame to extend to the outside of the base substrate from the ground terminal; connecting a flexible printed circuit to a circuit layer on the base substrate; forming a mold to surround the base substrate; cutting the lead frame and exposing the cut surface of the lead frame to the outside of the mold; and disposing a metal coating layer connected to the lead frame on the mold. 
         [0017]    At the forming of the metal coating layer, the metal coating layer may be disposed to surround the mold. 
         [0018]    At the forming of the lead frame, the lead frames each may extend from the ground terminals formed at four corner directions of the base substrate. 
         [0019]    At the exposing to the outside, the cut surface of the lead frame may be co-plane with the surface exposed to the outside of the mold. 
         [0020]    The electronic part may be an active device, a passive device, or a package substrate. 
         [0021]    At the exposing to the outside, the cutting of the lead frame may be made by a dicing process. 
         [0022]    At the exposing to the outside, the block module may be divided into a unit block module by the dicing process. 
         [0023]    At the forming of the lead frame, the lead frame may be bonded to the ground terminal, having a solder layer interposed between the lead frame and the ground terminal. 
         [0024]    At the mounting of the electronic part, the ground terminal may be an align mark. 
         [0025]    At the exposing to the outside, the lead frame and the outside of the mold may be cut together. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIGS. 1A and 1B  are a cross-sectional view and a plan view of a block module according to the prior art. 
           [0027]      FIGS. 2A to 7B  are diagrams for explaining a method of manufacturing a block module according to a preferred embodiment of the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    Various features and advantages of the present invention will be more obvious from the following description with reference to the accompanying drawings. 
         [0029]    The terms and words used in the present specification and claims should not be interpreted as being limited to typical meanings or dictionary definitions, but should be interpreted as having meanings and concepts relevant to the technical scope of the present invention based on the rule according to which an inventor can appropriately define the concept of the term to describe most appropriately the best method he or she knows for carrying out the invention. 
         [0030]    The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings. In the specification, in adding reference numerals to components throughout the drawings, it is to be noted that like reference numerals designate like components even though components are shown in different drawings. Further, in describing the present invention, a detailed description of related known functions or configurations will be omitted so as not to obscure the subject of the present invention. 
         [0031]    Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. 
         [0032]      FIGS. 2A to 7B  are diagrams for explaining a method of manufacturing a block module  100  according to a preferred embodiment of the present invention. In the drawings,  FIG. 2A  are a process cross-sectional view and  FIG. 2B  shows a process plan view. Hereinafter, a method of manufacturing a block module  100  according to the preferred embodiment of the present invention will be described with reference to  FIGS. 2A to 7B . 
         [0033]    First, as shown in  FIGS. 2A and 2B , an electronic part  120  is mounted on the base substrate  110 . 
         [0034]    In this case, the base substrate  110 , which is a basic member of the block module  100 , may be a build-up layer that is configured to include multi-layer or single-layer insulating layer, circuit layer, and via. In addition, a metal layer, which is used as a heat radiation layer, may be disposed under the base substrate  110 . Alternatively, the base substrate  110  may be a ceramic substrate such as a high temperature co-fired ceramic (HTCC), a low temperature co-fired ceramic (LTCC), or the like. Hereinafter, a circuit layer  111  connected to a flexible printed circuit  140  and ground terminals  112  connected to lead frames  130  may be disposed on an uppermost layer, a lowermost layer, or an intermediate layer of the base substrate  110 . In this configuration, the circuit layer  111  serves to transfer and process various electrical signals within the block module  100  and the ground terminal  112  may be connected to a ground area within the block module  100 . In addition, the ground terminal  112  may be disposed, for example, at four corners of the base substrate  110 , respectively, so as to be used as an align mark. In addition, the circuit layer  111  and the ground terminal  112  may be made of a conductive metal such as, for example, gold, silver, copper, nickel, or the like. 
         [0035]    In addition, the electronic part  120 , which is a part mounted on the base substrate  110 , may be electrically connected to the circuit layer  111  disposed on the base substrate  110  by, for example, a solder ball  121 , a wire, or the like. In this case, the electronic part  120  may be, for example, an active device such as a semiconductor device, or the like, a passive device such as a capacitor, an inductor, or the like, or a package substrate in a type in which a semiconductor device, or the like, is mounted on a substrate, wherein at least one of the electronic parts may be mounted on the base substrate  110 . Further, the electronic part  120  may be mounted by, for example, a surface mount technology (SMT). In this case, the ground terminal  112  may serve as an align mark. 
         [0036]    Meanwhile,  FIG. 2B  shows a case in which two unit block modules  100  are manufactured together, but a case in which one or at least three unit block modules  100  may be manufactured together. 
         [0037]    Next, as shown in  FIGS. 3A and 3B , the lead frames  130  are disposed to extend to the outside of the base substrate  110  from the ground terminals  112 . 
         [0038]    In this configuration, the lead frame  130  may be bonded to the ground terminal  112 , having a solder layer  131  interposed therebetween. In addition, the lead frame  130  may extend to the outside of the base substrate  110  from the ground terminal  112 . Therefore, an end of the lead frame  130  may be protruded from the base substrate  110 . In addition, the lead frame  130 , which is made of a conductive metal, may electrically connect the metal coating layer  160  to the ground terminal  112 , which are described below. 
         [0039]    Next, as shown in  FIGS. 4A and 4B , a flexible printed circuit  140  is connected to the circuit layer  111  on the base substrate  110 . 
         [0040]    In this configuration, the flexible printed circuit  140 , which is a member electrically connecting the base substrate  110  to an external electronic part, or the like, may be directly connected to the circuit layer  111  on the base substrate  110  or may be connected thereto via a separate solder layer. In addition, the lead frame  130  is connected to the ground terminal  112 , but the flexible printed circuit  140  is not connected to the ground terminal  112  but may be connected to only the circuit layer  111  on the base substrate  110 . 
         [0041]    Next, as shown in  FIGS. 5A and 5B , a mold  150  is formed to surround the base substrate  110 . 
         [0042]    In this case, the mold  150  may be formed to surround the entire surface of the base substrate  110  and may be formed to surround a part of the lead frame  130  Therefore, the mold  150  may protect the circuit layer  111  or the electronic part  120  formed on the base substrate  110  from external impact. The mold  150  may be made of, for example, epoxy mold compound (EMC) or silicon gel. 
         [0043]    Next, as shown in  FIGS. 6A and 6B , the lead frame  130  is cut and then, the cut surface of the lead frame  130  is exposed to the outside of the mold  150 . 
         [0044]    In this case, the cut surface of the lead frame  130  is exposed to the outside of the mold  150  and the cut surface of the lead frame  130  and the surface exposed to the outside of the mold  150  may be a co-plane. In addition, although  FIGS. 6A and 6B  show a case in which only the lead frame  130  is cut, the cut surface of the lead frame  130  may be exposed to the outside of the mold  150  by cutting a part of the mold  150 . 
         [0045]    Meanwhile, the dicing process of the lead frame  130  or the lead frame  130  and the mold  150  may be performed by a dicing process and each unit block module may be separately divided from the lead frame body  132  by the dicing process. In this case, the plurality of block modules  100  may be manufactured by one-time manufacturing process, thereby improving the productivity. 
         [0046]    Next, as shown in  FIGS. 7A and 7B , the metal coating layer  160  is disposed. 
         [0047]    In this case, the metal coating layer  160  may be connected to the cut surface of the lead frame  130  and formed to surround the mold  150 . Further, the metal coating layer  160  may be formed by coating the conductive coating and may be disposed to surround the entire surface of the mold  150 . In addition, the metal coating layer  160  may be formed by a sputtering method, a deposition method, a plating method, or the like. Further, the metal coating layer  160  is formed to surround the mold  150 , thereby improving the mechanical strength of the block module  100 . 
         [0048]    Meanwhile, the metal coating layer  160  is electrically connected to the ground terminal  112  through the lead frame  130 , wherein the metal coating layer  160  may also be a ground state. Therefore, the metal coating layer  160  may interrupt harmful electromagnetic waves generated from the electronic part  120 , or the like, or harmful electromagnetic waves generated from the outside. That is, the electromagnetic interference (EMI)/electromagnetic compatibility (EMC) phenomenon may be interrupted. Meanwhile, the metal coating layer  160  may be relatively simply ground by the lead frame  130 . 
         [0049]    The block module  100  according to the preferred embodiment of the present invention as shown in  FIGS. 7A and 7B  is manufactured by the above-mentioned manufacturing process. 
         [0050]    As set forth above, the preferred embodiment of the present invention forms the metal coating layer connected to the ground so as to surround the mold, thereby effectively interrupting the electromagnetic waves from the inside and the outside. 
         [0051]    In addition, the preferred embodiment of the present invention connects the ground terminal in the block module with the metal coating layer using the lead frame, thereby simplifying the ground process of the metal coating layer. 
         [0052]    Further, the preferred embodiment of the present invention forms the metal coating layer on the surface of the mold, thereby improving the mechanical strength of the block module. 
         [0053]    Further, the preferred embodiment of the present invention manufactures the block module in a plural unit by one-time manufacturing process, thereby improving the productivity. 
         [0054]    Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, they are for specifically explaining the present invention and thus a method of manufacturing a block module according to the present invention is not limited thereto, but those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. 
         [0055]    Accordingly, such modifications, additions and substitutions should also be understood to fall within the scope of the present invention.