Patent Publication Number: US-2022216164-A1

Title: Module and method for manufacturing same

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This is a continuation of International Application No. PCT/JP2020/035347 filed on Sep. 17, 2020 which claims priority from Japanese Patent Application No. 2019-176918 filed on Sep. 27, 2019. The contents of these applications are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     Field of the Disclosure 
     The present disclosure relates to a module and a method for manufacturing the same. 
     Description of the Related Art 
     An example of a module including a shield layer having an opening is described in Japanese Patent Laying-Open No. 2014-146624 (PTL 1).
     PTL 1: Japanese Patent Laying-Open No. 2014-146624   

     BRIEF SUMMARY OF THE DISCLOSURE 
     In PTL 1, a protruding portion is previously formed in a sealing resin in order to provide the opening not covered with the shield layer in the shield layer. However, in the method for forming the protruding portion, it is difficult to form the opening having a fine configuration. 
     An object of the present disclosure is to provide a module and a method for manufacturing the module for being able to easily prepare the region where the sealing resin is not covered with the shield film. 
     In order to achieve the above object, a module according to the present disclosure includes: a substrate that includes a first surface; a first component mounted on the first surface; and a first sealing resin that seals the first surface and the first component, wherein the first sealing resin contains a filler and a resin component filling a gap between the fillers, an upper surface of the first sealing resin includes a first region and a second region, a ratio of an area where the filler is exposed from the first sealing resin in the second region is smaller than a ratio of an area where the filler is exposed from the first sealing resin in the first region, and at least the first region and a side surface of the first sealing resin are covered with a shield film, and the second region is not covered with the shield film. 
     According to the present disclosure, the region where the sealing resin is not covered with the shield film can be easily produced in the module that has the component built therein and is covered with the sealing resin. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a first perspective view illustrating a module according to a first embodiment of the present disclosure. 
         FIG. 2  is a second perspective view illustrating the module of the first embodiment of the present disclosure. 
         FIG. 3  is a sectional view illustrating the module of the first embodiment of the present disclosure. 
         FIG. 4  is an enlarged view of a Z 1  portion in  FIG. 3 . 
         FIG. 5  is a partially enlarged view illustrating a first modification of the module in the first embodiment of the present disclosure. 
         FIG. 6  is a partially enlarged view illustrating a second modification of the module in the first embodiment of the present disclosure. 
         FIG. 7  is a sectional view illustrating a module according to a second embodiment of the present disclosure. 
         FIG. 8  is an enlarged view of a Z 2  portion in  FIG. 7 . 
         FIG. 9  is a sectional view illustrating a module according to a third embodiment of the present disclosure. 
         FIG. 10  is a perspective view illustrating a module according to a fourth embodiment of the present disclosure. 
         FIG. 11  is a flowchart illustrating a module manufacturing method according to a fifth embodiment of the present disclosure. 
         FIG. 12  is an explanatory view illustrating a first process of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 13  is an explanatory view illustrating a second process of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 14  is an explanatory view illustrating a third process of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 15  is an enlarged view of an A portion in  FIG. 14 . 
         FIG. 16  is an explanatory view illustrating a fourth process of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 17  is an explanatory view illustrating a fifth process of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 18  is an explanatory view illustrating a sixth step of the module manufacturing method in the fifth embodiment of the present disclosure. 
         FIG. 19  is a flowchart illustrating a module manufacturing method according to a sixth embodiment of the present disclosure. 
         FIG. 20  is an explanatory view illustrating a first step of the module manufacturing method in the sixth embodiment of the present disclosure. 
         FIG. 21  is an explanatory view illustrating a second step of the module manufacturing method in the sixth embodiment of the present disclosure. 
         FIG. 22  is an explanatory view illustrating a third step of the module manufacturing method in the sixth embodiment of the present disclosure. 
         FIG. 23  is an explanatory view illustrating a fourth step of the module manufacturing method in the sixth embodiment of the present disclosure. 
         FIG. 24  is an explanatory view illustrating a fifth step of the module manufacturing method in the sixth embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     A dimensional ratio in the drawings does not necessarily represent the actual dimensional ratio, and the dimensional ratio may be exaggerated for convenience of description. In the following description, when referring to an upper or lower concept, it does not necessarily mean absolute upper or lower, but may mean relative upper or lower in an illustrated posture. 
     First Embodiment 
     With reference to  FIGS. 1 to 4 , a module according to a first embodiment of the present disclosure will be described.  FIG. 1  is a perspective view illustrating a module  101  of the first embodiment. An upper surface and a side surface of module  101  are covered with a shield film  8 . Shield film  8  has an opening  9 . Opening  9  includes a stripe-shaped opening  9   a  and a dot-shaped opening  9   b . A position, a shape, a number, and a size of opening  9  illustrated here are merely examples, but are not limited to those illustrated here.  FIG. 2  is a perspective view illustrating module  101  when viewed obliquely from below. External terminals  4  are arrayed on a lower surface of module  101 . Although  FIG. 2  illustrates an example in which eight external terminals  4  are arrayed as an example, the shape, the size, the number, and layout of external terminals  4  are not limited thereto. 
       FIG. 3  is a sectional view of module  101 . As illustrated in  FIG. 3 , module  101  includes a substrate  1 . Substrate  1  includes a first surface  1   a  and a second surface  1   b . First surface  1   a  and second surface  1   b  form front and back surfaces. Substrate  1  is a wiring substrate. For example, substrate  1  is a ceramic multilayer substrate. Substrate  1  may be a resin multilayer substrate. Substrate  1  may be a single-layer substrate or a multilayer substrate. Wiring may be provided on a surface or an inside of substrate  1 . In the example illustrated here, as illustrated in  FIG. 3 , a ground electrode  7  is built in substrate  1 . Ground electrode  7  is exposed on the side surface of substrate  1 . Shield film  8  is electrically connected to ground electrode  7  at the side surface of substrate  1 .  FIG. 4  illustrates an enlarged portion Z 1  in  FIG. 3 . 
     Module  101  includes substrate  1  including first surface  1   a , a first component  3   a  mounted on first surface  1   a , and a first sealing resin  6   a  sealing first surface  1   a  and first component  3   a . Not only first component  3   a  but also another component  3   b  is mounted on first surface  1   a . First sealing resin  6   a  contains a filler  23 . First sealing resin  6   a  further contains a resin component  21  filling a gap between fillers  23 . The upper surface of first sealing resin  6   a  includes a first region  61  and a second region  62 . A ratio of an area where filler  23  in second region  62  is exposed from first sealing resin  6   a  is smaller than a ratio of an area where filler  23  in first region  61  is exposed from first sealing resin  6   a . At least first region  61  and the side surface of first sealing resin  6   a  are covered with shield film  8 . Second region  62  is not covered with shield film  8 . Opening  9  in  FIGS. 1 and 3  corresponds to second region  62 . 
     In  FIG. 4 , filler  23  in second region  62  is drawn not to be exposed at all from first sealing resin  6   a , but may be actually exposed to some extent. When the ratio of the areas in which filler  23  is exposed from first sealing resin  6   a  is compared between first region  61  and second region  62 , it is sufficient that first region  61  and second region  62  have the above-described magnitude relationship. A region having the large ratio is referred to as a “filler-rich region”, and a region having the small ratio is referred to as a “filler-poor region”. 
     As illustrated in  FIG. 4 , even when filler  23  is exposed from first sealing resin  6   a  in first region  61 , filler  23  is not exposed to be directly exposed to the outside air because first region  61  is further covered with shield film  8 . Filler  23  may be completely covered with shield film  8 . What is noted here is the ratio of the area where filler  23  is exposed from first sealing resin  6   a . Filler  23  may be covered with some other layer while exposed from first sealing resin  6   a.    
     In the example illustrated here, the upper surface of first sealing resin  6   a  includes a groove  13  such that groove  13  separates first region  61  and second region  62 . 
     In the first embodiment, because the filler-rich region and the filler-poor region are formed on the surface of first sealing resin  6   a , the adhesion of shield film  8  increases in the filler-rich region while the adhesion of shield film  8  decreases in the filler-poor region. Using this, the module can be produced by the method for removing shield film  8  of the filler poor region. Accordingly, in the first embodiment, a region where the sealing resin is not covered with the shield film can be easily produced in the module that has the component built therein and is covered with the sealing resin. The shape of the region where the sealing resin is not covered with the shield film is not limited, but can be freely designed. The region where the sealing resin is not covered with the shield film can also be miniaturized. The manufacturing method will be described later in detail. 
     As described in the first embodiment, first sealing resin  6   a  preferably has groove  13  at the boundary between first region  61  and second region  62 . Because groove  13  is provided, when shield film  8  of the filler-poor region is removed, shield film  8  covering the filler-rich region can be prevented from being dragged and peeled off together. 
     As described in the first embodiment, opening  9 , namely, second region  62  is alternately arranged with first region  61 , thereby preferably including a stripe-shaped portion. In the example of  FIG. 1 , opening  9   a  that is a part of opening  9  is disposed in the stripe shape. When the shield film disposed so as to overlap the region where the inductor is disposed is not in the stripe shape but in a solid shape, an eddy current flows through the shield film due to the magnetic field generated by the inductor, and as a result, the characteristic of the inductor is degraded. However, when the portion disposed in the stripe shape exists as described above, the generation of eddy current in the relevant region of shield film  8  can be prevented. 
     (First Modification) 
     With reference to  FIG. 5 , a first modification of the first embodiment will be described.  FIG. 4  illustrates an example in which groove  13  is provided along a boundary line between first region  61  and second region  62 . However, as illustrated in  FIG. 5 , groove  13  may not be provided. 
     (Second Modification) 
     With reference to  FIG. 6 , a second modification of the first embodiment will be described. In the example of  FIG. 6 , an adhesion layer  11  is interposed between shield film  8  and first sealing resin  6   a . Bonding strength between shield film  8  and first sealing resin  6   a  can be increased by adopting this configuration. Adhesion layer  11  is preferably a passive state. That is, a material of adhesion layer  11  is preferably a passive metal. For example, the passive metal herein may be Ti, Cr, Ni, or an alloy of at least two metals selected from these metals. An inorganic oxide such as SiO 2  is preferably used as filler  23 . Oxygen in the inorganic oxide is stably and firmly bonded to the passive metal, so that the bonding strength between adhesion layer  11  and first sealing resin  6   a  can be increased. 
     Second Embodiment 
     With reference to  FIGS. 7 to 8 , a module according to a second embodiment of the present disclosure will be described.  FIG. 7  is a sectional view illustrating a module  102  of the second embodiment.  FIG. 8  is an enlarged view of a Z 2  portion in  FIG. 7 . 
     In module  102 , filler-less resin layer  12  is disposed so as to cover second region  62 . Filler-less resin layer  12  is a resin containing substantially no glass filler. At this point, the name “filler-less resin layer” is used, but this does not necessarily mean that the content of the filler is completely zero. The filler-less resin layer may contain a small amount of filler as long as the shield film can be peeled off. The formation of filler-less resin layer  12  may be performed by an inkjet printer or screen printing. Filler-less resin layer  12  may be formed by removing an unnecessary portion after the formation of the entire surface, or formed only in a partial region from the beginning. 
     In the second exemplary embodiment, filler-less resin layer  12  is disposed so as to cover second region  62 , so that shield film  8  is easily peeled off in second region  62 . 
     Third Embodiment 
     With reference to  FIG. 9 , a module according to a third embodiment of the present disclosure will be described.  FIG. 9  is a sectional view illustrating a module  103  of the third embodiment. The basic configuration of module  103  is similar to that of module  101  of the first embodiment, but module  103  includes the following configuration. 
     Module  103  has a double-sided mounting structure. That is, in module  103 , substrate  1  includes second surface  1   b  as the surface opposite to first surface  1   a , and at least one component is mounted on second surface  1   b . Specifically, in module  103 , components  3   c ,  3   d  are mounted on second surface  1   b  of substrate  1 . Components  3   c ,  3   d  are sealed with a second sealing resin  6   b . An external terminal  4  is provided on a lower surface of module  103 . External terminal  4  includes a columnar conductor  17  and a solder bump  18 . Columnar conductor  17  is disposed on second surface  1   b . Columnar conductor  17  penetrates second sealing resin  6   b . Solder bump  18  is connected to a lower end of columnar conductor  17 . The configuration of external terminal  4  illustrated here is merely an example, and is not limited to this. Columnar conductor  17  may be formed by a protruded electrode, a metal pin, plating, or the like. In addition, a solder bump may be used instead of the columnar conductor. 
     An enlarged portion Z 3  in  FIG. 9  is the same as that in  FIG. 4 . 
     Also in the third embodiment, the effect similar to that of the first embodiment can be obtained. In the third embodiment, the double-sided mounting structure is adopted, so that more components can be mounted on substrate  1 . 
     Fourth Embodiment 
     With reference to  FIG. 10 , a module according to a fourth embodiment of the present disclosure will be described.  FIG. 10  is a perspective view illustrating a module  104  of the fourth embodiment. Module  104  includes shield film  8 , and shield film  8  includes an opening  9   i . Opening  9   i  is a marking portion. Opening  9   i  is formed in second region  62 . That is, in module  104 , second region  62  includes the portion serving as the marking portion. Although  FIG. 10  illustrates an example in which opening  9   i  has a “+” shape, this is merely an example of the marking portion, and the position, the shape, the number, and the size of opening  9   i  are not limited to those illustrated here. 
     As described in the fourth embodiment, second region  62  includes the portion disposed as the marking portion, so that the marking portion can be easily formed. 
     For example, the marking portion may be a character, a symbol, or some sort of graphic. The marking portion may be a simple line, a point, or the like. The marking portions may be simultaneously provided at a plurality of locations in one module. All of second regions  62  are not the marking portions. Only a part of second region  62  may form the marking portion. 
     Fifth Embodiment 
     With reference to  FIGS. 11 to 18 , a method for manufacturing a module according to a fifth embodiment of the present disclosure will be described. This module manufacturing method is for obtaining module  101  of the first embodiment.  FIG. 11  illustrates a flowchart of the method for manufacturing the module. 
     A module manufacturing method of the fifth embodiment includes: a process S 1  of mounting a first component on a first surface of an aggregate substrate; a process S 2  of disposing a first sealing resin containing a filler and a resin component filling a gap between the fillers so as to seal the first surface and the first component; a process S 3  of irradiating a first region that is a part of a surface of the first sealing resin with a laser beam to expose the filler; a process S 4  of dividing the aggregate substrate into a plurality of pieces after process S 3  of exposing the filler; a process S 5  of forming a shield film on each of the plurality of pieces so as to cover an upper surface and a side surface of the first sealing resin; and a process S 6  of removing the shield film in a second region selected from a region different from the first region in the surface of the first sealing resin while the shield film in the first region is left. Each process will be described below in detail. 
     First, as illustrated in  FIG. 12 , first component  3   a  is mounted on first surface  1   a  of aggregate substrate  10  as process S 1 . In the example of  FIG. 12 , not only first component  3   a  but also component  3   b  is mounted. As described above, some sort of component other than first component  3   a  may be mounted on first surface  1   a  in addition to first component  3   a.    
     In process S 2 , as illustrated in  FIG. 13 , first sealing resin  6   a  is disposed so as to seal first surface  1   a  and first component  3   a . First sealing resin  6   a  contains the filler and the resin component that fills the gap between the fillers. When some sort of component other than first component  3   a  is also mounted on first surface  1   a , the component is also sealed by first sealing resin  6   a.    
     As illustrated in  FIG. 14 , a laser beam  15  is emitted as process S 3 .  FIG. 15  is an enlarged view of an A portion. The right half of the A portion is a region irradiated with laser beam  15 . In process S 3 , first region  61  that is a part of the surface of first sealing resin  6   a  is irradiated with laser beam  15  to expose filler  23 . A wavelength of laser beam  15  is preferably less than or equal to 532 nm. Fine processing with little variation can be performed by adopting the wavelength. 
     The fifth embodiment is described based on the example in which filler-less resin layer  12  is not provided. However, when filler-less resin layer  12  is formed as described in the second embodiment, filler-less resin layer  12  is scraped off by the irradiation of laser beam  15  in process S 3 . Accordingly, the surface of first sealing resin  6   a  hidden under filler-less resin layer  12  is scraped, thereby exposing filler  23 . 
     As illustrated in  FIG. 16 , aggregate substrate  10  is divided into a plurality of pieces as process S 4 . Process S 4  is performed after process S 3  of exposing filler  23 . 
     As process S 5 , as illustrated in  FIG. 17 , shield film  8  is formed on each of the plurality of pieces so as to cover the upper surface and the side surface of first sealing resin  6   a . In this case, because the depth of the recess scraped by the irradiation of laser beam  15  in process S 3  is exaggerated and displayed, a thick portion and a thin portion of shield film  8  are generated in  FIG. 17 . However, in practice, shield film  8  may have a substantially constant thickness. 
     A process of forming groove  13  at the boundary between first region  61  and second region  62  is performed before or after process S 5 . Groove  13  may be formed by laser processing. The laser processing for forming groove  13  is different from the laser processing in process S 3  in a processing condition. 
     As process S 6 , as illustrated in  FIG. 18 , shield film  8  of second region  62  is removed while shield film  8  of first region  61  is left. Second region  62  becomes opening  9 . This process can be performed using an adhesive tape. In first region  61 , a large amount of filler  23  is exposed on the surface of first sealing resin  6   a , so that unevenness exists, and thus shield film  8  is sufficiently firmly fixed to first sealing resin  6   a . On the other hand, in second region  62 , filler  23  is not so much exposed on the surface of first sealing resin  6   a , and the unevenness is small, so that shield film  8  is easily peeled off from first sealing resin  6   a . As a result, module  101  in  FIG. 18  is obtained. That is, shield film  8  does not exist in second region  62 , and second region  62  becomes opening  9 . When groove  13  is previously formed at the boundary between first region  61  and second region  62 , burrs of shield film  8  are hardly generated at the boundary, which is preferable. 
     Furthermore, external terminal  4  is attached to second surface  1   b  as necessary. Thus, module  101  in  FIG. 3  is obtained. 
     In this case, it has been described that the installation of external terminal  4  is performed last. However, the installation of external terminal  4  may be performed at different timing. For example, external terminals  4  may be installed in the state of the aggregate substrate. External terminal  4  may be already installed before process S 1  in the state of the aggregate substrate. 
     In the fifth embodiment, first region  61  and second region  62  are distinguished from each other with respect to the surface of first sealing resin  6   a , and first region  61  is irradiated with laser beam  15 , and first region  61  is set as the region where shield film  8  is left later. Accordingly, first region  61  and second region  62  can be distinguished by controlling the irradiation position of laser beam  15 . 
     According to the manufacturing method of the fifth embodiment, the region where the sealing resin is not covered with the shield film can be easily prepared in the module that has the component built therein and is covered with the sealing resin. 
     Sixth Embodiment 
     With reference to  FIGS. 12 and 13  and  FIGS. 19 to 24 , a method for manufacturing a module according to a sixth embodiment of the present disclosure will be described.  FIG. 19  illustrates a flowchart of the method for manufacturing the module. Among the processes of the module manufacturing method of the sixth embodiment, the same process as that in the fifth embodiment is assigned by the same process number. A new process number is assigned to a new process as compared with the fifth embodiment. 
     A module manufacturing method of the sixth embodiment includes: process S 1  of mounting a first component on a first surface of an aggregate substrate; process S 2  of disposing a first sealing resin containing a filler and a resin component filling a gap between the fillers such that the first surface is covered to seal the first component; a process S 11  of dividing the first sealing resin along a boundary line dividing the aggregate substrate into a plurality of pieces to form an outer peripheral groove having a depth reaching the aggregate substrate; process S 3  of irradiating a first region that is a part of a surface of the first sealing resin with a laser beam to expose a filler; a process S 12  of forming a shield film so as to cover an upper surface and a side surface of the first sealing resin surrounded by the outer peripheral groove of the first sealing resin after process S 11  of forming the outer peripheral groove and process S 3  of exposing the filler; process S 6  of removing the shield film in a second region selected from a region different from the first region in the surface of the first sealing resin while the shield film in the first region is left; and a process S 13  of dividing the aggregate substrate into the plurality of individual sizes along the outer peripheral groove. Each process will be described below in detail. 
     First, as illustrated in  FIG. 12 , first component  3   a  is mounted on first surface  1   a  of aggregate substrate  10  as process S 1 . In the example of  FIG. 12 , not only first component  3   a  but also component  3   b  is mounted. Ground electrode  7  is previously disposed inside aggregate substrate  10 . 
     In process S 2 , as illustrated in  FIG. 13 , first sealing resin  6   a  is disposed so as to seal first surface  1   a  and first component  3   a . First sealing resin  6   a  contains the filler and the resin component that fills the gap between the fillers. When some sort of component other than first component  3   a  is also mounted on first surface  1   a , the component is also sealed by first sealing resin  6   a.    
     In process S 11 , as illustrated in  FIG. 20 , first sealing resin  6   a  is divided along the boundary line dividing aggregate substrate  10  into a plurality of pieces to form an outer peripheral groove  16  having a depth reaching aggregate substrate  10 . Outer peripheral groove  16  is formed to have the depth enough to divide ground electrode  7 . Thus, the side surface of ground electrode  7  is exposed to the inner surface of outer peripheral groove  16 . 
     In process S 3 , as illustrated in  FIG. 21 , the first region that is a part of the surface of first sealing resin  6   a  is irradiated with the laser beam to expose the filler.  FIG. 21  illustrates a state in which the irradiation of the laser beam is finished. In the first region of the surface of first sealing resin  6   a , the unevenness is formed on the surface. In the second region, a smooth surface is maintained. Either process S 11  or process S 3  may be performed first. 
     After process S 11  and process S 3 , as step S 12 , shield film  8  is formed so as to cover the upper surface and the side surface of first sealing resin  6   a  surrounded by outer peripheral groove  16  of first sealing resin  6   a  as illustrated in  FIG. 22 . The side surface of ground electrode  7  exposed to the inner surface of outer peripheral groove  16  is also covered with shield film  8 . Thus, ground electrode  7  is electrically connected to shield film  8 . 
     In process S 6 , as illustrated in  FIG. 23 , shield film  8  of the second region is removed while shield film  8  of the first region is left. The second region becomes opening  9 . 
     As process S 13 , aggregate substrate  10  is divided into the plurality of individual sizes along outer peripheral groove  16 . As a result, as illustrated in  FIG. 24 , pieces having individual sizes are obtained. In this state, a portion that is not covered with shield film  8  exists on the side surface of substrate  1 . 
     Also in the sixth embodiment, the effect similar to that of the fifth embodiment can be obtained. In the sixth embodiment, because process S 13  of dividing aggregate substrate  10  into individual pieces is performed at a later stage, the processing of each process can be performed with the aggregate substrate size until then, and handling becomes easy. 
     External terminal  4  may be installed on second surface  1   b  at any timing. This point is similar to that described in the fifth embodiment. 
     A plurality of the above embodiments may be appropriately combined. 
     It should be noted that the above embodiments disclosed herein are merely an example in all respects, and are not restrictive. The scope of the present disclosure is indicated by the claims, and all modifications within the meaning and scope of the claims are included in the present disclosure. 
       1 : substrate,  1   a : first surface,  1   b : second surface,  3   a : first component,  3   b ,  3   c ,  3   d : component,  4 : external terminal,  6   a : first sealing resin,  7 : ground electrode,  8 : shield film,  9 : opening,  9   a : (stripe-shaped) opening,  9   b : (dot-shaped) opening,  9   i : opening (as marking),  10 : aggregate substrate,  11 : adhesion layer,  12 : filler-less resin layer,  13 : groove,  15 : laser beam,  16 : outer peripheral surface,  17 : columnar conductor,  18 : solder bump,  21 : resin component,  23 : filler,  61 : first region,  62 : second region,  101 ,  102 ,  103 ,  104 : module