Patent Publication Number: US-2018053602-A1

Title: Thin film capacitor for increasing dielectric constant and method of manufacturing the same

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The instant disclosure relates to a thin film capacitor and a method of manufacturing the same, and more particularly to a thin film capacitor for increasing dielectric constant and a method of manufacturing the same. 
     2. Description of Related Art 
     Various applications of capacitors include home appliances, computer motherboards and peripherals, power supplies, communication products and automobiles. The capacitors such as solid electrolytic capacitors or thin film capacitors are mainly used to provide filtering, bypassing, rectifying, coupling, blocking or transforming function. Because the thin film capacitor has the advantages of small size, large electrical capacity and good frequency characteristic, it can be used as a decoupling element in the power circuit. However, the method of manufacturing the thin film capacitor is too complex, and dielectric constant provided by conventional thin film capacitors is relatively low. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention relates to a thin film capacitor for increasing dielectric constant and a method of manufacturing the same. 
     One of the embodiments of the instant disclosure provides a method of manufacturing a thin film capacitor for increasing dielectric constant, comprising: placing a carrier substrate on a processing machine, wherein the processing machine includes a plurality of processing units sequentially arranged along a planar production line, and each processing unit has a metal-layer forming module and an insulation-layer forming module; coating a first metal layer on the carrier substrate by the metal-layer forming module of a first processing unit of the processing units; coating a first insulation layer on the carrier substrate to cover the first metal layer by the insulation-layer forming module of the first processing unit; sequentially performing N repeat processing steps to finish a multilayer stacked structure, wherein each repeat processing step is respectively defined as 1 st , 2 nd , 3 rd , . . . , (N) th  repeat processing step; and then forming two terminal electrode structures to respectively enclose two opposite side end portions of the multilayer stacked structure. Each repeat processing step includes coating a (N+1) th  metal layer on a (N) th  insulation layer to cover a (N) th  metal layer by the metal-layer forming module of a (N+1) th  processing unit of processing units, and then coating a (N+1) th  insulation layer on the (N) th  insulation layer to cover the (N+1) th  metal layer by the insulation-layer forming module of the (N+ 1 ) th  processing unit. Each insulation layer includes an insulation material layer and a plurality of nanometer materials mixed with the insulation material layer so as to increase the dielectric constant of the multi-layer stacked structure. 
     Another one of the embodiments of the instant disclosure provides a method of manufacturing a thin film capacitor for increasing dielectric constant, comprising: placing a carrier substrate on a processing machine, wherein the processing machine includes at least one processing unit, and the at least one processing unit has a metal-layer forming module and an insulation-layer forming module that are arranged along a planar production line; forming a plurality of metal layers by the metal-layer forming module of the at least one processing unit, and forming a plurality of insulation layers by the insulation-layer forming module of the at least one processing unit, wherein the metal layers and the insulation layers are alternately stacked on the carrier substrate to form a multilayer stacked structure; and then forming two terminal electrode structures to respectively enclose two opposite side end portions of the multilayer stacked structure. Each insulation layer includes an insulation material layer and a plurality of nanometer materials mixed with the insulation material layer so as to increase the dielectric constant of the multi-layer stacked structure. 
     Yet another one of the embodiments of the instant disclosure provides a thin film capacitor for increasing dielectric constant, comprising: a multilayer stacked structure and two terminal electrode structures. The multilayer stacked structure is formed by a processing machine. The two terminal electrode structures are used to respectively enclose two opposite side end portions of the multilayer stacked structure. The multilayer stacked structure includes a carrier substrate, a plurality of metal layers and a plurality of insulation layers, and the metal layers and the insulation layers are alternately stacked on the carrier substrate. The processing machine includes a plurality of processing units sequentially arranged along a planar production line, and each processing unit has a metal-layer forming module for forming the corresponding metal layer and an insulation-layer forming module for forming the corresponding insulation layer. Each insulation layer includes an insulation material layer and a plurality of nanometer materials mixed with the insulation material layer so as to increase the dielectric constant of the multi-layer stacked structure. 
     Therefore, the dielectric constant of the thin film capacitor is increased by using the insulation layer including the insulation material layer and the nanometer materials so as to increase electrical performances such as thermal stabilization, capacitance (Cap), equivalent series resistance (ESR), dissipation factor (DF), and leakage current (LC) etc. 
     To further understand the techniques, means and effects of the instant disclosure, the following detailed descriptions and appended drawings are hereby referred to, such that, and through which, the purposes, features and aspects of the instant disclosure can be thoroughly and concretely appreciated. However, the appended drawings are provided solely for reference and illustration, without any intention to limit the instant disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the instant disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the instant disclosure and, together with the description, serve to explain the principles of the instant disclosure. 
         FIG. 1  shows a partial flowchart of the method of manufacturing the thin film capacitor for increasing dielectric constant according to the instant disclosure; 
         FIG. 2  shows the other flowchart of the method of manufacturing the thin film capacitor for increasing dielectric constant according to the instant disclosure; 
         FIG. 3  shows a function block of the processing machine according to the instant disclosure; 
         FIG. 4  shows a schematic view of the processing machine according to the instant disclosure; 
         FIG. 5  shows a schematic view of the metal-layer processing module and the insulation-layer processing module of the first processing unit according to the instant disclosure; 
         FIG. 6  shows a cross-sectional, schematic view of coating the first insulation layer on the first metal layer by the first processing unit according to the instant disclosure; 
         FIG. 7  shows a schematic view of the metal-layer processing module and the insulation-layer processing module of the second processing unit according to the instant disclosure; 
         FIG. 8  shows a cross-sectional, schematic view of coating the second insulation layer on the second metal layer by the second processing unit according to the instant disclosure; 
         FIG. 9  shows a schematic view of the metal-layer processing module and the insulation-layer processing module of the third processing unit according to the instant disclosure; 
         FIG. 10  shows a cross-sectional, schematic view of coating the third insulation layer on the third metal layer by the third processing unit according to the instant disclosure; 
         FIG. 11  shows a cross-sectional, schematic view of the thin film capacitor for increasing dielectric constant according to the instant disclosure; 
         FIG. 12  shows a partial, cross-sectional, schematic view of the multilayer stacked structure of the thin film capacitor for increasing dielectric constant according to the instant disclosure; 
         FIG. 13  shows a cross-sectional, schematic view of the thin film capacitor for increasing dielectric constant applied to a first type of thin film capacitor package structure according to the instant disclosure; and 
         FIG. 14  shows a cross-sectional, schematic view of the thin film capacitor for increasing dielectric constant applied to a second type of thin film capacitor package structure according to the instant disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Embodiments of a thin film capacitor for increasing dielectric constant and a method of manufacturing the same according to the instant disclosure are described herein. Other advantages and objectives of the instant disclosure can be easily understood by one skilled in the art from the disclosure. The instant disclosure can be applied in different embodiments. Various modifications and variations can be made to various details in the description for different applications without departing from the scope of the instant disclosure. The drawings of the instant disclosure are provided only for simple illustrations, but are not drawn to scale and do not reflect the actual relative dimensions. The following embodiments are provided to describe in detail the concept of the instant disclosure, and are not intended to limit the scope thereof in any way. 
     Referring to  FIG. 1  to  FIG. 12 , the instant disclosure provides a method of manufacturing a thin film capacitor Z for increasing dielectric constant, comprising the following steps: first, referring to  FIG. 1  to  FIG. 5 , placing a carrier substrate  10  on a processing machine M, the processing machine M including a plurality of processing units R sequentially arranged along a planar (plane type) production line, and each processing unit R having a metal-layer forming module X and an insulation-layer forming module Y (S 100 ); next, referring to  FIG. 1 ,  FIG. 2 ,  FIG. 3  and  FIG. 5 , coating a first metal layer  11  on the carrier substrate  10  by the metal-layer forming module X of a first processing unit R(R 1 ) of the processing units (S 102 ); afterward, referring to  FIG. 1 ,  FIG. 2 ,  FIG. 3  and  FIG. 5 , coating a first insulation layer  12  on the carrier substrate  10  to cover the first metal layer  11  by the insulation-layer forming module Y of the first processing unit R(R 1 ) (S 104 ); and then, referring to  FIG. 1 ,  FIG. 4 ,  FIG. 7  and  FIG. 11 , sequentially performing N repeat processing steps to finish a multilayer stacked structure  1 , and each repeat processing step is respectively defined as 1 st , 2 nd , 3 rd , . . . , (N) th  repeat processing step. 
     First, for example, as shown in  FIG. 4 , the processing units R are sequentially arranged along a planar production line, and the drop height of the planar production line can be very small. In addition, the planar production line may be a linear (straight) production line or a non-linear production line, or may be a surrounding production line. Moreover, the processing machine M includes a transmission mechanism T (such as using a transmission band mated with rollers) for linearly or straightly driving the carrier substrate  10  to sequentially pass through the processing units R, and each processing unit R is placed in a room temperature environment. For example, the processing unit R can be placed in a temperature environment at approximately 25° C. without vacuum. 
     Moreover, for example, referring to  FIG. 3  and  FIG. 5 , each metal-layer forming module X includes a metal coating module A for forming the metal layer  11  and a first curing (or baking) module B for curing (or baking) the formed metal layer  11 , and each insulation-layer forming module Y includes an insulation coating module C for forming the insulation layer  12  and a second curing (or baking) module D for curing (or baking) the insulation layer  12 . Please note that the aforementioned coating module (A or C) may be replaced by a spraying module or a printing module according to different requirements. 
     More particularly, referring to  FIG. 1  to  FIG. 5 , the step S 102  of coating the first metal layer  11  on the carrier substrate  10  by the metal-layer forming module X of the first processing unit R(R 1 ) further comprises the following steps: first, coating the first metal layer  11  on the carrier substrate  10  by the metal coating module A of the first processing unit R(R 1 ) (S 102   a ), and then curing the first metal layer  11  by the first curing module B of the first processing unit R(R 1 ) (S 102   b ) so as to harden the first metal layer  11 . 
     According to the above description, referring to  FIG. 1  to  FIG. 5 , the step S 104  of coating the first insulation layer  12  on the carrier substrate  10  to cover the first metal layer  11  by the insulation-layer forming module Y of the first processing unit R(R 1 ) further comprises the following steps: first, coating the first insulation layer  12  on the carrier substrate  10  to cover the first metal layer  11  by the insulation coating module C of the first processing unit R(R 1 ) (S 104   a ), and then curing the first insulation layer  12  by the second curing module D of the first processing unit R(R 1 ) (S 104   b ) so as to harden the first insulation layer  12 . 
     More particularly, referring to  FIG. 5  and  FIG. 6 , each insulation layer  12  may be a composite material layer, and each insulation layer  12  includes an insulation material layer  120  and a plurality of nanometer materials  121  mixed with the insulation material layer  120  so as to increase the dielectric constant of the multi-layer stacked structure  1 . For example, each nanometer material  121  can be selected from one of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material, or each nanometer material  121  can be selected from at least two of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material. 
     More particularly, referring to  FIG. 1  to  FIG. 9 , in the step of sequentially performing the N repeat processing steps, each repeat processing step includes the following steps: first, coating a (N+1) th  metal layer  11  on a (N) th  insulation layer  12  to cover a (N) th  metal layer  11  by the metal-layer forming module X of a (N+1) th  processing unit R of processing units (S 106 ), and then coating a (N+1) th  insulation layer  12  on the (N) th  insulation layer  12  to cover the (N+1) th  metal layer  11  by the insulation-layer forming module Y of the (N+1) th  processing unit R (S 108 ). 
     More particularly, referring to  FIG. 1  to  FIG. 9 , the step S 106  of coating the (N+1) th  metal layer  11  on the (N) th  insulation layer  12  to cover the (N) th  metal layer  11  by the metal-layer forming module X of the (N+1) th  processing unit R further comprises the following steps: first, coating the (N+1) th  metal layer  11  on the (N) th  insulation layer  12  to cover the (N) th  metal layer  11  by the metal coating module A of the (N+1) th  processing unit R (S 106   a ), and then curing the (N+1) th  metal layer  11  by the first curing module B of the (N+1) th  processing unit R (S 106   b ) so as to harden the (N+1) th  metal layer  11 . Moreover, the step S 108  of coating the (N+1) th  insulation layer  12  on the (N) th  insulation layer  12  to cover the (N+1) th  metal layer  11  by the insulation-layer forming module Y of the (N+1) th  processing unit R further comprises the following steps: first, coating the (N+1) th  insulation layer  12  on the (N) th  insulation layer  12  to cover the (N+1) th  metal layer  11  by the insulation coating module C of the (N+1) th  processing unit R (S 108   a ), and then curing the (N+1) th  insulation layer  12  by the second curing module D of the (N+1) th  processing unit R (S 108   b ) so as to harden the (N+1) th  insulation layer  12 . 
     For example, referring to  FIG. 2 ,  FIG. 4  and  FIG. 7 , when performing the 1 st  repeat processing step (N=1), coating the second metal layer  11  on the first insulation layer  12  to cover the first metal layer  11  by the metal coating module A of the second processing unit R(R 2 ), curing the second metal layer  11  by the first curing module B of the second processing unit R(R 2 ) so as to harden the second metal layer  11 , coating the second insulation layer  12  on the first insulation layer  12  to cover the second metal layer  11  by the insulation coating module C of the second processing unit R(R 2 ), and then curing the second insulation layer  12  by the second curing module D of the second processing unit R(R 2 ) so as to harden the second insulation layer  12 . 
     More particularly, referring to  FIG. 7  and  FIG. 8 , each insulation layer  12  may be a composite material layer, and each insulation layer  12  includes an insulation material layer  120  and a plurality of nanometer materials  121  mixed with the insulation material layer  120  so as to increase the dielectric constant of the multi-layer stacked structure  1 . For example, each nanometer material  121  can be selected from one of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material, or each nanometer material  121  can be selected from at least two of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material. 
     For example, referring to  FIG. 2 ,  FIG. 4  and  FIG. 9 , when performing the 2 nd  repeat processing step (N=2), coating the third metal layer  11  on the second insulation layer  12  to cover the second metal layer  11  by the metal coating module A of the third processing unit R(R 3 ), curing the third metal layer  11  by the first curing module B of the third processing unit R(R 3 ) so as to harden the third metal layer  11 , coating the third insulation layer  12  on the second insulation layer  12  to cover the third metal layer  11  by the insulation coating module C of the third processing unit R(R 3 ), and then curing the third insulation layer  12  by the second curing module D of the third processing unit R(R 3 ) so as to harden the third insulation layer  12 . 
     More particularly, referring to  FIG. 9  and  FIG. 10 , each insulation layer  12  may be a composite material layer, and each insulation layer  12  includes an insulation material layer  120  and a plurality of nanometer materials  121  mixed with the insulation material layer  120  so as to increase the dielectric constant of the multi-layer stacked structure  1 . For example, each nanometer material  121  can be selected from one of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material, or each nanometer material  121  can be selected from at least two of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material. 
     Furthermore, referring to  FIG. 1 ,  FIG. 2  and  FIG. 11 , after the step of sequentially performing the N repeat processing steps, the method of the instant disclosure further comprises: forming two terminal electrode structures  2  to respectively enclose two opposite side end portions  20 P of the multilayer stacked structure  1  (S 110 ) so as to finish the manufacture of the multilayer stacked structure  1 . For example, each terminal electrode structure  2  includes a first enclosing layer  21  contacting the side end portion  20 P of the multilayer stacked structure  1  so as to enclose the side end portion  20 P of the multilayer stacked structure  1 , a second enclosing layer  22  contacting the first enclosing layer  21  so as to enclose the first enclosing layer  21 , and a third enclosing layer  23  contacting the second enclosing layer  22  so as to enclose the second enclosing layer  22 . In addition, the first enclosing layer  21 , the second enclosing layer  22  and the third enclosing layer  23  may be a sliver layer (Ag), a nickel layer (Ni) and a stannum layer (Sn), but that is merely an example and is not meant to limit the instant disclosure. 
     In conclusion, referring to  FIG. 1  to  FIG. 12 , the instant disclosure provides a method of manufacturing a thin film capacitor Z for increasing dielectric constant, comprising the following steps: first, placing a carrier substrate  10  on a processing machine M, the processing machine M including a plurality of processing units R sequentially arranged along a planar production line, and each processing unit R having a metal-layer forming module X and an insulation-layer forming module Y; next, forming a plurality of metal layers  11  by the metal-layer forming module X of the at least one processing unit R, and forming a plurality of insulation layers  12  by the insulation-layer forming module Y of the at least one processing unit R, in which the metal layers  11  and the insulation layers  12  are alternately stacked on the carrier substrate  10  to form a multilayer stacked structure  1 ; and then forming two terminal electrode structures  2  to respectively enclose two opposite side end portions  20 P of the multilayer stacked structure  1 . Therefore, referring to  FIG. 11  and  FIG. 12 , the instant disclosure provides a thin film capacitor Z for increasing dielectric constant, comprising a multilayer stacked structure  1  and two terminal electrode structures  2 . The multilayer stacked structure  1  is formed or manufactured by a processing machine M, and the multilayer stacked structure  1  includes a carrier substrate  10 , a plurality of metal layers  11  and a plurality of insulation layers  12 , and the metal layers  11  and the insulation layers  12  are alternately stacked on the carrier substrate  10 . In addition, the two terminal electrode structures  2  are used to respectively enclose two opposite side end portions  20 P of the multilayer stacked structure  1 . More particularly, each insulation layer  12  may be a composite material layer, and each insulation layer  12  includes an insulation material layer  120  and a plurality of nanometer materials  121  mixed with the insulation material layer  120  so as to increase the dielectric constant of the multi-layer stacked structure  1 . For example, each nanometer material  121  can be selected from one of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material, or each nanometer material  121  can be selected from at least two of a graphene nanosheet material, a carbon nanotube material, a metal nanowire material, a metal nanoparticle material, a ceramic material (such as oxide, nitride or carbide) and a polymer material. 
     Please note that the processing machine M includes at least one processing unit R in another embodiment of the instant disclosure. The at least one processing unit R has a metal-layer forming module X and an insulation-layer forming module Y that are arranged along a planar production line, and the planar production line may be a planar annular production line. 
     For one example, referring to  FIG. 11  and  FIG. 13 , the thin film capacitor Z can be enclosed by a package body P (such as an insulation package body) in advance, and then two conductive pins L electrically contacting the thin film capacitor Z are extended from the thin film capacitor Z constant to the exterior of the package body P so as to finish a thin film capacitor package structure. In addition, for another example, referring to  FIG. 11  and  FIG. 14 , the thin film capacitor Z can be enclosed by a package body P (such as an insulation package body) in advance and the thin film capacitor Z with the package body P is received inside a metal casing H (such as an aluminum casing), and then two conductive pins L electrically contacting the thin film capacitor Z are extended from the thin film capacitor Z to the exterior of the metal casing H so as to finish another thin film capacitor package structure. That is to say, the multilayer stacked structure  1  and the two terminal electrode structures  2  are enclosed by a package body P, and two conductive pins L respectively electrically contact the two terminal electrode structures  2  and are exposed from the package body P. However, the aforementioned description for the thin film capacitor package structure is merely an example and is not meant to limit the instant disclosure. 
     In conclusion, the dielectric constant of the thin film capacitor Z is increased by using the insulation layer  12  including the insulation material layer  120  and the nanometer materials  121  so as to increase electrical performances such as thermal stabilization, capacitance (Cap), equivalent series resistance (ESR), dissipation factor (DF), and leakage current (LC) etc. 
     More particularly, the metal layers  11  and the insulation layers  12  are alternately stacked on the carrier substrate  10  to form the multilayer stacked structure  1  of the thin film capacitor Z for increasing dielectric constant due to the features of “the processing machine M including a plurality of processing units R arranged along a planar production line” and “each processing unit R having a metal-layer forming module X for forming the metal layer  11  and an insulation-layer forming module Y for forming the insulation layer  12 ”. 
     The aforementioned descriptions merely represent the preferred embodiments of the instant disclosure, without any intention to limit the scope of the instant disclosure which is fully described only within the following claims. Various equivalent changes, alterations or modifications based on the claims of the instant disclosure are all, consequently, viewed as being embraced by the scope of the instant disclosure.