Abstract:
A manufacturing method for integrating a passive component within a substrate is disclosed. The manufacturing method comprises the steps of: providing a circuit layer, wherein a positioning blind hole is formed in the circuit layer; forming a conductive material in the positioning blind hole; positioning the passive component in the positioning blind hole of the circuit layer and electrically connecting the passive component to the circuit layer via the conductive material in the positioning blind hole; and laminating a core layer, the passive component, and the circuit layer as the substrate.

Description:
RELATED APPLICATIONS 
     This application claims priority to Taiwan Application Serial Number 96100979, filed Jan. 10, 2007, which is herein incorporated by reference. 
     FIELD OF THE INVENTION 
     This invention relates to a manufacturing method for integrating at least one passive component within a substrate, and more particularly, to a method for positioning the passive component in the substrate in advance. 
     BACKGROUND OF THE INVENTION 
     For electronic devices today, the need of functionality and small size has gradually increased, and thus designers and suppliers thereof have to integrate more electronic devices into a package system. As to chip package, multi-chip module (MCM) or system-in-package (SIP) may provide the resolution of the foregoing problem. If MCM or SIP cooperated with embedding technique is used for integrating the Surface Mount Technology (SMT) passive components into a package substrate, more space on the surface of the substrate can be enhanced. Further, for the integrity of signal, in high frequency circuit design, the parasitic effect of electronic devices is a great issue. Compared with SMT passive components, an ideal embedded passive component has shorter connection therein, and thus has less parasitic effects. Therefore, the embedded passive component is suitable for the high frequency circuit design, and is important for the passive component design in the further. 
     Currently, when integrating the passive component into a substrate, the passive component is laminated within the substrate, and then the substrate is drilled for electrical connection. However, the position of drilling is predetermined, and if the position of the passive component is not accurate and precise, the position of drilling can not position to the electrical contact of the passive component. Therefore, the electrical connection of the passive component can not be achieved, thus affecting the product&#39;s yield significantly. 
     SUMMARY OF THE INVENTION 
     Therefore, an aspect of the present invention is to provide a manufacturing method for integrating at least one passive component within a substrate to prevent positioning error of the passive component therein, thereby enhancing the process yield thereof. 
     Another aspect of aspect of the present invention is to provide a manufacturing method for integrating at least one passive component within a substrate, whereby the passive component is positioned and electrically connected to a circuit layer on the substrate via an adhesive conductive material. 
     According to an embodiment of the present invention, the manufacturing method for integrating at least one passive component within a substrate comprises: providing at least one circuit layer, wherein at least one positioning blind hole is formed in the circuit layer; forming a conductive material in the positioning blind hole; positioning the passive component to the positioning blind hole of the circuit layer and electrically connecting the passive component to the circuit layer via the conductive material in the positioning blind hole; and laminating a core layer, the passive component and the circuit layer as the substrate, wherein the passive component is embedded in the core layer 
     According to another embodiment of the present invention, the foregoing conductive material is adhesive. 
     Therefore, with the application of the method disclosed in the embodiments of the present invention, the passive component can be positioned on the circuit layer and electrically connected thereto via a conductive material in the positioning blind hole before a laminating step, wherein the conductive material may be adhesive to position the passive component in advance, thereby preventing positioning error and the passive component can not electrically connect with the circuit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1A  through  FIG. 1H  are schematic flow diagrams showing the process for integrating at least one passive component within a substrate according to a first embodiment of the present invention; 
         FIG. 2A  and  FIG. 2B  are schematic flow diagrams showing the process for integrating at least one passive component within a substrate according to a second embodiment of the present invention; and 
         FIG. 3  is a cross-section view showing a substrate integrated with at least one passive component according to a third embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In order to make the illustration of the present invention more explicit and complete, the following description is stated with reference to  FIG. 1A  through  FIG. 3 . 
     Refer to  FIG. 1A  through  FIG. 1H .  FIG. 1A  through  FIG. 1H  are schematic flow diagrams showing the process for integrating at least one passive component within a substrate according to a first embodiment of the present invention. Refer to  FIG. 1A  again. First, a circuit layer  110  is provided. The circuit layer  110  includes an intermediate layer  111  and an electrically conductive layer  112 . The intermediate layer  111  is made of dielectric material. The electrically conductive layer  112  is formed at both sides of the intermediate layer  111  and made of metal material, such as Cu, Ni or Au. 
     Refer to  FIG. 1B  again. Next, at least one positioning blind hole  113  is formed in the circuit layer  110 . The positioning blind hole  113  may be formed by a method such as laser drilling or mechanical drilling. The positioning blind hole  113  is drilled from one side of the circuit layer  110  of the electrically conductive layer  112 , and another side of the electrically conductive layer  112  is not drilled, thereby forming the blind hole. 
     Refer to  FIG. 1C  again. Next, the electrically conductive layer  112  of the circuit layer  110  is patterned to form a circuit  114 . The electrically conductive layer  112  is patterned by a method such as photolithography etching or laser etching. The circuit  114  includes at least one contact  114   a  connected to the positioning blind hole  113 , thereby forming an electrical connection to at least one passive component  120 . 
     Refer to  FIG. 1D  again. Next, a conductive material  115  is formed in (such as filled in) the positioning blind hole  113 . The conductive material  115  is preferably adhesive, such as a conductive glue or a melted metal. 
     Refer to  FIG. 1E  again. Next, the passive component  120  is disposed and positioned to the positioning blind hole  113  of the circuit layer  110 . Since the positioning blind hole  113  has the conductive material  115  therein, and the contact  114   a  of the circuit  114  is connected to the positioning blind hole  113 , the passive component  120  can be electrically connected to the circuit layer  110  via the conductive material  115  in the positioning blind hole  113 . Further, since the conductive material  115  is preferably adhesive, the passive component  120  can be bonded and positioned to the circuit layer  110 . For example, when the conductive material  115  is the conductive glue, the conductive material  115  is filled into the positioning blind hole  113  to bond and position the passive component  120  to the circuit layer  110 . When the conductive material  115  is metal material, the conductive material  115  is heated previously to a melted state, and then filled into the positioning blind hole  113 . The passive component  120  is bonded and positioned to the circuit layer  110  before the melted metal is solidified. 
     Refer to  FIG. 1F  again. Next, a core layer  130 , the passive component  120  and two circuit layers  110  are laminated as one substrate  100 , wherein a dielectric layer  140  is formed between the core layer  130  and the circuit layer  110 . After the laminating step, the circuit layers  110  are formed on both sides of the core layer  130 , and the passive component  120  is embedded in the core layer  130 . The core layer  130  is made of dielectric material, such as Bismaleimide Triazine (BT), epoxy resin, ceramics or organic glass fiber. The core layer  130  includes at least one through hole  131  to embed the passive component  120 . The through hole  131  may be formed by a method such as laser drilling or mechanical drilling. Therefore, the passive component  120  of the present embodiment can be positioned and bonded on the circuit layer  110  previously by the positioning blind hole  113 , and be electrically connected to the circuit  114  on the circuit layer  110  via the conductive material  115  within the positioning blind hole  113 , thereby preventing the passive component  120  from positioning error, wherein the conductive material  115  is preferably adhesive to previously bond the passive component  120  on the circuit layer  110 . 
     It is worth mentioning that the circuit  114  on the circuit layer  110  may be formed after the laminating step. Namely, the electrically conductive layer  112  is patterned to form the circuit  114  of the circuit layer  110  after the laminating step. 
     Refer to  FIG. 1G  again. Next, after the laminating step, at least one conductive through hole  150  is formed in the substrate  100  by a method such as laser drilling or mechanical drilling. A metal layer  151  (such as Cu layer) is formed on the surface of the conductive through hole  150  to electrically connect with the circuit layers  110  on both sides of the core layer  130 , wherein the metal layer  151  is formed by a method such as electroplating. 
     Refer to  FIG. 1H  again. Then, an isolation layer  160  (such as solder mask) is used to encapsulate the surface of the substrate  100  for packaging, wherein the circuit  114  is exposed on the circuit layers  110  after encapsulating the isolation layer  160 . Further, a conductive antioxidant  170  may be formed on the circuit  114  to prevent oxidation. Therefore, the passive component  120  can be integrated into the substrate  100  of the present embodiment. 
     Therefore, the passive component  120  of the present embodiment can be positioned on the circuit layer  110  before the laminating step, thereby preventing positioning error and the passive component  120  can not electrically connect with the circuit  114 . Consequently, the process yield of the substrate  100  integrated with the passive component  120  can be enhanced. 
     Refer to  FIG. 2A  and  FIG. 2B .  FIG. 2A  and  FIG. 2B  are schematic flow diagrams showing the process for integrating at least one passive component within a substrate according to a second embodiment of the present invention. Some reference numerals shown in the first embodiment are used in the second embodiment of the present invention. The construction shown in the second embodiment is similar to that in the first embodiment with respect to configuration and function, and thus is not stated in detail herein. 
     Refer again to  FIG. 2A  and  FIG. 2B , in comparison with the first embodiment, the circuit  214  is formed on the circuit layer  210 , and then the positioning blind hole  213  is formed in the circuit layer  210 . At this time, the circuit  214  may be formed by a method such as deposition (electroplating, thermal deposition, chemical vapor deposition, physical vapor deposition or sputtering) or printing (screen printing) on the two sides of the middle layer  211 , and the electrically conductive layer  112  is not necessary to exist. Then, after forming the circuit  214 , the circuit layer  210  is drilled to form the positioning blind hole  213 . 
     Refer to  FIG. 3 .  FIG. 3  is a cross-section view showing a substrate integrated with at least one passive component according to a third embodiment of the present invention. Some reference numerals shown in the first embodiment are used in the third embodiment of the present invention. The construction shown in the third embodiment is similar to that in the first embodiment with respect to configuration and function, and thus is not stated in detail herein. 
     Refer again to  FIG. 3 , in comparison with the first embodiment, the core layer  330  includes at least one blind hole  331  to embed the passive component  120 . The blind hole  331  may be formed by a method of such as laser drilling or mechanical drilling. At this time, the passive component  120  is positioned to the circuit layer  110  at one side of the core layer  330 . 
     Therefore, the manufacturing method for integrating the passive component within the substrate shown in the respective embodiments of the present invention can prevent positioning error of the passive component, thereby ensuring that the passive component electrically connects with the circuit of the substrate and enhancing the process yield thereof. 
     As is understood by a person skilled in the art, the foregoing embodiments of the present invention are strengths of the present invention rather than limiting of the present invention. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure.