Patent Description:
Conventionally, various technologies related to three-dimensional lay-out forming have been proposed.

For example, a technology disclosed in Patent Literature <NUM> is a high-speed prototype forming method, including: a. a process of electrolyzing an object into relatively thick multiple layers; b. a process of electrically slicing the multiple layers into multiple cross-sections corresponding to the thickness of an assembly material sheet; and c. a process of drawing, on a sheet, a physical section of the assembly material corresponding the cross-sections. The high-speed prototype forming method further includes: d. a process of slicing the physical sections from the assembly material sheet; e. a process of laying out the physical sections to assemble the layers; and f. a process of reforming a physical model of the object by laying out the layers.

Further relevant background art is disclosed in <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

The technology disclosed in Patent Literature <NUM> can avoid sequentially forming layers, for example, one by one at one time. However, since the technology relates to a prototype modeling technology, it is difficult to apply the technology to manufacturing of a three-dimensional multi-layer electronic device. Further, when a component is built in a cavity by a full additive method, it is complicated to consider a dimensional variation of the built-in component. This is because it is necessary to adjust the dimension of a cavity one by one according to a component variation, and further to adjust the amount of a resin embedded in the cavity.

The present disclosure has been made in view of the above-described points, and an object of the present disclosure is to provide a method of manufacturing a three-dimensional multi-layer electronic device and a three-dimensional multi-layer electronic device that can reduce a tact time and a cycle time. Further, another object of the present disclosure is to provide a method of manufacturing a three-dimensional multi-layer electronic device and a three-dimensional multi-layer electronic device that can have a high tolerance for a dimensional variation of embedded electronic components.

The present specification discloses a method of manufacturing a three-dimensional multi-layer electronic device as defined in claim <NUM>, the method including: a unit forming process of forming a multi-layer unit including an electronic component and a circuit wiring by three-dimensional lay-out forming; and a unit lay-out process of manufacturing a three-dimensional multi-layer electronic device by laying out the multi-layer units integrally in a vertical direction.

According to the present disclosure, a method of manufacturing a three-dimensional multi-layer electronic device can shorten a tact time and a cycle time. Further, according to the present disclosure, it is possible to have a high tolerance for dimensional variations of built-in electronic components.

Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the drawings.

<FIG> illustrates multi-layer unit forming device <NUM>. Multi-layer unit forming device <NUM> includes conveying device <NUM>, first forming unit <NUM>, second forming unit <NUM>, mounting unit <NUM>, and control device (see <FIG> and <FIG>) <NUM>. Multi-layer unit forming device <NUM> further includes transfer unit <NUM> and heating section <NUM>. Conveying device <NUM>, first forming unit <NUM>, second forming unit <NUM>, mounting unit <NUM>, transfer unit <NUM>, and heating section <NUM> are arranged on base <NUM> of multi-layer unit forming device <NUM>. Base <NUM> has a rectangular shape in general, and in the following description, the longitudinal direction of base <NUM> is referred to as an X-axis direction, the short-side direction of base <NUM> is referred to as a Y-axis direction, and a direction orthogonal to both the X-axis direction and the Y-axis direction is referred to as a Z-axis direction.

Conveying device <NUM> includes X-axis slide mechanism <NUM> and Y-axis slide mechanism <NUM>. X-axis slide mechanism <NUM> includes X-axis slide rail <NUM> and X-axis slider <NUM>. X-axis slide rail <NUM> is disposed on base <NUM> to extend in the X-axis direction. X-axis slider <NUM> is slidably held in the X-axis direction by X-axis slide rail <NUM>. Further, X-axis slide mechanism <NUM> has electromagnetic motor (see <FIG>) <NUM>, and X-axis slider <NUM> is moved to a predetermined position in the X-axis direction by driving electromagnetic motor <NUM>. Further, Y-axis slide mechanism <NUM> has Y-axis slide rail <NUM> and stage <NUM>. Y-axis slide rail <NUM> is disposed on base <NUM> to extend in the Y-axis direction. One end of Y-axis slide rail <NUM> is connected to X-axis slider <NUM>. Therefore, Y-axis slide rail <NUM> is movable in the X-axis direction. Stage <NUM> is held on Y-axis slide rail <NUM> to be slidable in the Y-axis direction. Further, Y-axis slide mechanism <NUM> has electromagnetic motor (see <FIG>) <NUM>, and stage <NUM> is moved to a predetermined position in the Y-axis direction by driving electromagnetic motor <NUM>. Accordingly, stage <NUM> is moved to a predetermined position on base <NUM> by driving X-axis slide mechanism <NUM> and Y-axis slide mechanism <NUM>.

Stage <NUM> includes base <NUM>, holding devices <NUM>, and lifting and lowering device <NUM>. Base <NUM> is formed in a flat plate shape, and base material (see <FIG>) <NUM> is placed on the upper surface of base <NUM>. Holding devices <NUM> are provided on both sides of base <NUM> in the X-axis direction. Both edge portions of base material <NUM> placed on base <NUM> in the X-axis direction are sandwiched by holding devices <NUM>, so that base material <NUM> is fixedly held. Lifting and lowering device <NUM> is disposed below base <NUM>, and lifts and lowers base <NUM> in the Z-axis direction.

A material made of a wax-based material (for example, a brazing material) soluble by heat or a solvent is used as base material <NUM>. However, base material <NUM> is not limited thereto, and may be made of, for example, a strippable base material (for example, a double-sided tape, a film material or the like having a low adhesive force). However, when such a double-sided tape is used as base material <NUM>, base material <NUM> is fixedly held on base <NUM> by the adhesive force, and thus, holding devices <NUM> become unnecessary.

First forming unit <NUM> is a unit for forming a circuit wiring on base material <NUM> mounted on base <NUM> of stage <NUM>, and includes first printing section <NUM> and sintering section <NUM>. First printing section <NUM> has inkjet head (see <FIG>) <NUM>, and linearly ejects metal ink onto base material <NUM> placed on base <NUM>. The metal ink is obtained by dispersing fine particles of metal in a solvent. Inkjet head <NUM> ejects metal ink from multiple nozzles by, for example, a piezo method using a piezoelectric element.

Sintering section <NUM> has laser irradiation device (see <FIG>) <NUM>. Laser irradiation device <NUM> is a device for irradiating the metal ink ejected onto base material <NUM> with a laser beam, and the metal ink irradiated with the laser is sintered to form the circuit wiring. Sintering of the metal ink is a phenomenon in which evaporation of a solvent, decomposition of protective films of metal microparticles, or the like is performed by applying energy, and the metal microparticles contact or are fused with each other, so that conductivity is increased. Then, the metal ink is sintered to form a circuit wiring made of metal.

Further, second forming unit <NUM> is a unit for forming a resin layer on base material <NUM> placed on base <NUM> of stage <NUM>, and includes second printing section <NUM> and curing section <NUM>. Second printing section <NUM> includes inkjet head (see <FIG>) <NUM>, and ejects an ultraviolet curable resin onto base material <NUM> placed on base <NUM>. The ultraviolet curable resin is a resin that is cured by irradiation with ultraviolet rays. Inkjet head <NUM> may be, for example, a piezo type using a piezoelectric element, or may be a thermal type in which a resin is heated to generate air bubbles, which are ejected from multiple nozzles.

Curing section <NUM> includes flattening device (see <FIG>) <NUM> and irradiation device (see <FIG>) <NUM>. Flattening device <NUM> flattens the upper surface of the ultraviolet curable resin ejected onto base material <NUM> by inkjet head <NUM>, and for example, scrapes off excess resin by a roller or a blade while smoothening the surface of the ultraviolet curable resin, to make the thickness of the ultraviolet curable resin uniform. Further, irradiation device <NUM> includes a mercury lamp or an LED as a light source, and irradiates the ultraviolet curable resin ejected onto base material <NUM> with ultraviolet rays. Accordingly, the ultraviolet curable resin ejected onto base material <NUM> is cured to form a resin layer.

Further, mounting unit <NUM> is a unit for mounting first electronic component (see <FIG>) <NUM>, second electronic component (see <FIG>) <NUM>, and probe pin (see <FIG>) <NUM> on base material <NUM> placed on base <NUM> of stage <NUM>, and has supply section <NUM> and mounting section <NUM>. Supply section <NUM> has multiple first tape feeders (see <FIG>) <NUM> for feeding taped first electronic component <NUM> one by one and multiple second tape feeders (see <FIG>) <NUM> for feeding taped second electronic component <NUM> one by one, and supplies first electronic component <NUM> and second electronic component <NUM> at each supply position. Further, supply section <NUM> has tray (see <FIG>) <NUM> arranged in a state in which probe pin <NUM> stands up, and supplies probe pin <NUM> in a state in which probe pin <NUM> can be picked up from tray <NUM>. The supply of first electronic component <NUM> and second electronic component <NUM> is not limited to supply by first tape feeders <NUM> and second tape feeders <NUM>, but may be supplied by a tray. On the other hand, the supply of probe pin <NUM> is not limited to supply by tray <NUM>, but may be supply by a tape feeder. Further, first electronic component <NUM>, second electronic component <NUM>, and probe pin <NUM> may be supplied by both the tape feeder and the tray, or may be supplied by another method.

Mounting section <NUM> has mounting head (see <FIG>) <NUM> and moving device (see <FIG>) <NUM>. Mounting head <NUM> has suction nozzle <NUM> (see <FIG>) for picking up and holding first electronic component <NUM>, second electronic component <NUM>, or probe pin <NUM> (hereinafter, referred to as the first electronic component <NUM> or the like). Suction nozzle <NUM> picks up and holds first electronic component <NUM> and the like by picking up air as a negative pressure is supplied from a positive/negative pressure supply device (not illustrated). As a slight positive pressure is supplied from the positive/negative pressure supply device, first electronic component <NUM> and the like are separated. Further, moving device <NUM> moves mounting head <NUM> between each supply position or tray <NUM> of first tape feeder <NUM> and second tape feeder <NUM> and base material <NUM> placed on base <NUM>. Accordingly, in mounting section <NUM>, first electronic component <NUM> or the like is held by suction nozzle <NUM>, and first electronic component <NUM> or the like held by suction nozzle <NUM> is mounted on base material <NUM>. For example, a sensor element such as a gyro sensor is used as first electronic component <NUM> or second electronic component <NUM>. Further, probe pin <NUM> may be a probe pin of which a tip end can be stroked, but such a stroke may not be possible.

Transfer unit <NUM> is a unit for transferring first conductive adhesive <NUM> (see <FIG>) and second conductive adhesive <NUM> (see <FIG>) onto base material <NUM> placed on base <NUM> of stage <NUM>. First conductive adhesive <NUM> and second conductive adhesive <NUM> are conductive pastes that are cured by heating. However, first conductive adhesive <NUM> is cured by ultraviolet ray before the heating. Irradiation of the ultraviolet rays is performed by irradiation device <NUM>.

Further, transfer unit <NUM> includes supply section <NUM> and transfer section <NUM>. Supply section <NUM> includes first adhesive supply device <NUM> (see <FIG>) and second adhesive supply device <NUM> (see <FIG>). First adhesive supply device <NUM> has a dip plate (not illustrated) onto which first conductive adhesive <NUM> is ejected, and supplies first conductive adhesive <NUM> in a state in which first conductive adhesive <NUM> has a uniform thickness by being pushed and spread by a squeegee (not illustrated) in the dip plate. Similarly, second adhesive supply device <NUM> has a dip plate (not illustrated) onto which second conductive adhesive <NUM> is ejected, and supplies second conductive adhesive <NUM> in a state in which second conductive adhesive <NUM> has a uniform thickness by being extruded and spread by a squeegee (not illustrated) in the dip plate.

Transfer section <NUM> includes transfer head <NUM> (see <FIG>) and moving device (see <FIG>) <NUM>. Transfer head <NUM> has multiple dip needles (see <FIG>) <NUM> for transferring first conductive adhesive <NUM> or second conductive adhesive <NUM>. Dip needle <NUM> is dipped into first conductive adhesive <NUM> or second conductive adhesive <NUM> in each dip plate of first adhesive supply device <NUM> or second adhesive supply device <NUM>. Accordingly, first conductive adhesive <NUM> or second conductive adhesive <NUM> adheres to a tip end of dip needle <NUM>. Transfer head <NUM> uses multiple dip needles <NUM> separately to which first conductive adhesive <NUM> is attached and to which second conductive adhesive <NUM> is attached. Further, transfer device <NUM> moves transfer head <NUM> between each dip plate of first adhesive supply device <NUM> or second adhesive supply device <NUM> and base material <NUM> mounted on base <NUM>. Accordingly, in transfer section <NUM>, first conductive adhesive <NUM> or second conductive adhesive <NUM> adhering to the tip end of dip needle <NUM> is transferred onto base material <NUM>.

Heating section <NUM> has irradiation device (see <FIG>) <NUM>. Irradiation device <NUM> includes an infrared lamp or an infrared heater, and irradiates base material <NUM> with infrared rays. Accordingly, first conductive adhesive <NUM> or second conductive adhesive <NUM> transferred onto base material <NUM> is cured by heating. Heating section <NUM> may include an electric furnace instead of irradiation device <NUM>.

Further, as illustrated in <FIG> and <FIG>, control device <NUM> includes controller <NUM> and multiple driving circuits <NUM>. As illustrated in <FIG>, multiple driving circuits <NUM> are connected to electromagnetic motors <NUM> and <NUM>, holding device <NUM>, lifting and lowering device <NUM>, inkjet head <NUM>, laser irradiation device <NUM>, inkjet head <NUM>, flattening device <NUM>, irradiation device <NUM>, first tape feeder <NUM>, second tape feeder <NUM>, mounting head <NUM>, and moving device <NUM>. Further, as illustrated in <FIG>, multiple driving circuits <NUM> are connected to first adhesive supply device <NUM>, second adhesive supply device <NUM>, transfer head <NUM>, moving device <NUM>, and irradiation device <NUM>. Controller <NUM> includes a CPU, a ROM, a RAM, and the like, mainly includes a computer, and is connected to multiple driving circuits <NUM>. Accordingly, controller <NUM> controls operations of conveying device <NUM>, first forming unit <NUM>, second forming unit <NUM>, mounting unit <NUM>, transfer unit <NUM>, and heating section <NUM>.

(B) Method of manufacturing three-dimensional multi-layer electronic device Next, a method of manufacturing a three-dimensional multi-layer electronic device will be described. As illustrated in <FIG>, method <NUM> of manufacturing a three-dimensional multi-layer electronic device includes unit forming process P10 and unit lay-out process P12. In unit forming process P10, multi-layer units 218A, 218B, and 218C (see <FIG>) are formed on base material <NUM> by multi-layer unit forming device <NUM>. On the other hand, in unit lay-out process P12, multi-layer units 218A, 218B, and 218C are laid out in a vertical direction, so that three-dimensional multi-layer electronic device <NUM> (see <FIG>) is manufactured. In the following description, when respective multi-layer units 218A to 218C are collectively referred without distinction, multi-layer units 218A to 218C are referred to as multi-layer unit <NUM>.

Unit forming process P10 is executed by controller <NUM>, and includes resin multi-layer forming process S10, conductive terminal forming process S20, circuit wiring forming process S30, and mounting process S40. An order of execution of steps S10, S20, S30, and S40 is determined by a multi-layer structure or the like of three-dimensional multi-layer electronic device <NUM> (that is, each of multi-layer units 218A to 218C). Therefore, steps S10, S20, S30, and S40 are not repeated in a notation order. In the following description, unit lay-out process P12 when each of multi-layer units 218A to 218C illustrated in <FIG> is formed will be described.

First, in resin multi-layer forming step S10, as illustrated in <FIG>, first resin layer <NUM> of multi-layer unit <NUM> is formed on base material <NUM>. Therefore, base material <NUM> is set with respect to base <NUM>. Stage <NUM> is moved below second forming unit <NUM>. Thereafter, in second printing section <NUM>, inkjet head <NUM> ejects the ultraviolet curable resin in a thin film shape onto the upper surface of base material <NUM>. Subsequently, in curing section <NUM>, flattening device <NUM> flattens the ejected ultraviolet curable resin such that the film thickness thereof becomes uniform. Further, irradiation device <NUM> irradiates the flattened ultraviolet curable resin with ultraviolet rays. Accordingly, the ultraviolet curable resin is cured. Thereafter, the ejection, the flattening, and the curing of the ultraviolet curable resin are repeated, so that first resin layer <NUM> is formed on base material <NUM> in multi-layer unit <NUM>.

Resin multi-layer forming step S10 includes space forming step S12 (see <FIG>). In space forming step S12, when the ejection, the flattening, and the curing of the ultraviolet curable resin are repeated, the inkjet head <NUM> ejects the ultraviolet curable resin such that a predetermined portion is exposed to the upper surface of base material <NUM> in a generally circular shape. Accordingly, multiple through-holes <NUM> are formed in resin layer <NUM> of each of multi-layer units 218B and 218C.

In conductive terminal forming step S20, stage <NUM> is moved below transfer unit <NUM>. In transfer unit <NUM>, first conductive adhesive <NUM> supplied in first adhesive supply device <NUM> is attached to a tip end of dip needle <NUM> of transfer head <NUM>. Attached first conductive adhesive <NUM> is filled in each through hole <NUM> of resin layer <NUM> as transfer head <NUM> is moved by moving device <NUM>. Accordingly, in resin layer <NUM> of each of multi-layer units 218B and 218C, first conductive adhesive <NUM> is transferred to each through hole <NUM>. Thereafter, stage <NUM> is moved to curing section <NUM> of second forming unit <NUM>. In curing section <NUM>, irradiation device <NUM> irradiates transferred first conductive adhesive <NUM> with ultraviolet rays. Accordingly, in resin layer <NUM> of each of multi-layer units 218B and 218C, first conductive adhesive <NUM> in each through-hole <NUM> is cured to form each conductive terminal <NUM>.

In circuit wiring forming step S30, stage <NUM> is moved below first forming unit <NUM>. Thereafter, in first printing section <NUM>, inkjet head <NUM> linearly ejects the metal ink onto the upper surface of resin layer <NUM> of multi-layer unit <NUM> according to a wiring circuit pattern. At this time, inkjet head <NUM> also ejects the metal ink onto the upper surface of conductive terminal <NUM> of each of multi-layer units 218B and 218C according to the wiring circuit pattern. Subsequently, in sintering section <NUM>, laser irradiation device <NUM> irradiates the ejected metal ink with a laser beam. Accordingly, first circuit wiring <NUM> is formed on the upper surface of resin layer <NUM> of multi-layer unit <NUM> by sintering the metal ink. Circuit wiring <NUM> is also formed on the upper surface of conductive terminal <NUM> of each of multi-layer units 218B and 218C.

Thereafter, in the present embodiment, resin multi-layer forming step S10 and circuit wiring forming step S30 are repeated. Accordingly, second resin layer <NUM> and second circuit wiring <NUM> are formed in each of multi-layer units 218A and 218B. On the other hand, in multi-layer unit 218C, second resin layer <NUM> is formed.

Mounting step S40 includes transfer step S42 (see <FIG>), mounting step S44 (see <FIG>), and heating step S46 (see <FIG>). In transfer step S42, stage <NUM> is moved below transfer unit <NUM>. In transfer unit <NUM>, second conductive adhesive <NUM> supplied in second adhesive supply device <NUM> is attached to a tip end of dip needle <NUM> of transfer head <NUM>. Attached second conductive adhesive <NUM> is transferred to multiple predetermined positions in each of multi-layer units 218A and 218B as transfer head <NUM> moves by moving device <NUM>. Any of transferred second conductive adhesive <NUM> is filled up to the through-hole of second resin layer <NUM> in a gap of second circuit wiring <NUM>, so that second circuit wiring <NUM> and first circuit wiring <NUM> are electrically connected to each other.

Thereafter, above-described resin multi-layer forming step S10 is repeated. Accordingly, third resin layer <NUM> is formed in multi-layer unit <NUM> as illustrated in <FIG>. In detail, in each of multi-layer units 218A and 218B, third resin layer <NUM> is formed on the upper surface of second resin layer <NUM> or the upper surface of second circuit wiring <NUM>. At this time, space <NUM> is formed at planned mounting position <NUM> of each of multi-layer units 218A and 218B by space forming step S12. To the contrary, in multi-layer unit 218C, third resin layer <NUM> is formed on the upper surface of second resin layer <NUM>. However, the upper surface of third resin layer <NUM> is not flattened, but is formed in a dome shape.

In mounting step S44, stage <NUM> is moved below mounting unit <NUM>. In mounting unit <NUM>, first electronic component <NUM> supplied by first tape feeder <NUM> is held by suction nozzle <NUM> of mounting head <NUM>. As mounting head <NUM> moves by moving device <NUM>, held first electronic component <NUM> is mounted in space <NUM> of multi-layer unit 218B, as illustrated in <FIG>. At this time, each electrode <NUM> of first electronic component <NUM> is arranged to face the lower side with straddling a gap of first circuit wiring <NUM>, and is connected to the upper surface of each circuit wiring <NUM> forming the gap via second conductive adhesive <NUM>. In this way, second conductive adhesive <NUM> has a structure in which circuit wirings <NUM> forming the gap are electrically connected to each other via first electronic component <NUM>. First electronic component <NUM> is separated from third resin layer <NUM> forming the wall surface of space <NUM>. Further, the upper surface of first electronic component <NUM> is located below the upper surface of third resin layer <NUM>.

In mounting unit <NUM>, second electronic component <NUM> supplied by second tape feeder <NUM> is held by suction nozzle <NUM> of mounting head <NUM>. Held second electronic component <NUM> is mounted in space <NUM> of multi-layer unit 218A as mounting head <NUM> moves by moving device <NUM>. At this time, each electrode (not illustrated) of second electronic component <NUM> faces the lower side and is connected to the upper surface of first circuit wiring <NUM> via second conductive adhesive <NUM>. Multiple second electronic components <NUM> are mounted in space <NUM> of multi-layer unit 218A. Each of second electronic components <NUM> is in a state of being separated from third resin layer <NUM> forming the wall surface of space <NUM>. Further, the upper surface of each second electronic component <NUM> is located below the upper surface of third resin layer <NUM>.

In mounting unit <NUM>, probe pin <NUM> supplied from tray <NUM> is held by suction nozzle <NUM> of mounting head <NUM>. Held probe pin <NUM> is mounted in space <NUM> of each of multi-layer units 218A and 218B as mounting head <NUM> moves by moving device <NUM>. Accordingly, multiple probe pins <NUM> are mounted on respective multi-layer units 218A and 218B. A lower end of probe pin <NUM> is connected to the upper surface of second circuit wiring <NUM> via second conductive adhesive <NUM>. An upper end of probe pin <NUM> is located above the upper surface of third resin layer <NUM>.

Thereafter, in mounting step S44, stage <NUM> is moved below heating section <NUM>. In heating section <NUM>, irradiation device <NUM> irradiates infrared rays onto base material <NUM>. Accordingly, in each of multi-layer units 218A, 218B, and 218C, first conductive adhesive <NUM> and second conductive adhesive <NUM> are cured, and first electronic component <NUM>, second electronic component <NUM>, and probe pins <NUM> are fixed.

Unit lay-out process P12 includes unit peeling step S50 and unit lay-out step S60. In unit peeling step S50, base material <NUM> is melted by heat or a solvent. Accordingly, multi-layer units 218A, 218B, and 218C are separated from base material <NUM>.

In unit lay-out step S60, as illustrated in <FIG>, multi-layer units 218A, 218B, and 218C are laid out in the vertical direction. Accordingly, as illustrated in <FIG>, each of multi-layer units 218A, 218B, and 218C is integrated into three-dimensional multi-layer electronic device <NUM>.

In detail, intermediate multi-layer unit 218B is laid out on lower multi-layer unit 218A. At this time, the upper end portion of each probe pin <NUM> of lower multi-layer unit 218A is brought into contact with each conductive terminal <NUM> of intermediate multi-layer unit 218B, and is further inserted into each conductive terminal <NUM>. Accordingly, lower multi-layer unit 218A is electrically connected to intermediate multi-layer unit 218B. Further, central space <NUM> of lower multi-layer unit 218A is closed by bottom surface <NUM> of intermediate multi-layer unit 218B. Accordingly, cavity portion <NUM> in which multiple second electronic components <NUM> are incorporated is formed in lower multi-layer unit 218A.

Upper multi-layer unit 218C is laid out on intermediate multi-layer unit 218B. At this time, the upper end portion of each probe pin <NUM> of intermediate multi-layer unit 218B is brought into contact with each conductive terminal <NUM> of upper multi-layer unit 218C, and is further inserted into conductive terminal <NUM>. Accordingly, intermediate multi-layer unit 218B is electrically connected to upper multi-layer unit 218C. Further, central space <NUM> of intermediate multi-layer unit 218B is closed by bottom surface <NUM> of upper multi-layer unit 218C. Accordingly, cavity portion <NUM> in which first electronic component <NUM> is incorporated is formed in intermediate multi-layer unit 218B.

multi-layer units 218A, 218B, and 218C are integrated by a general method such as bonding, pressure bonding, or screw tightening (using an adhesive or a photocurable resin).

As described in detail above, in method <NUM> of manufacturing a three-dimensional multi-layer electronic device, three-dimensional multi-layer electronic device <NUM> is manufactured, so that a tact time and a cycle time of the manufacturing can be shortened.

In the present embodiment, first electronic component <NUM>, second electronic component <NUM>, and probe pin <NUM> are examples of electronic components. Probe pin <NUM> is an example of a connection pin. Unit lay-out step S60 is an example of a cavity forming step. When multi-layer unit 218B is laid out on multi-layer unit 218A, multi-layer unit 218B is an example of an upper layer multi-layer unit, and multi-layer unit 218A is an example of a lower layer multi-layer unit. When multi-layer unit 218C is laid out on multi-layer unit 218B, multi-layer unit 218C is an example of an upper layer multi-layer unit, and multi-layer unit 218B is an example of a lower layer multi-layer unit.

The present disclosure is not limited to the above-described embodiments, and various modification examples can be made.

For example, in unit forming process P10, multi-layer units 218A, 218B, and 218C are collectively formed on base material <NUM>. However, multi-layer units 218A, 218B, and 218C may be formed on (base material <NUM> of) a separate multi-layer unit forming device <NUM>.

Further, three-dimensional multi-layer electronic device <NUM> is configured by three multi-layer units <NUM>, but may be configured by two or four or more multi-layer units. The number of multi-layer units constituting three-dimensional multi-layer electronic device <NUM> is determined from the viewpoint of the number of layers of circuit wiring, the number of connection layers of electronic components, the tact time, or the like.

Further, in intermediate multi-layer unit 218B, the upper surface of first electronic component <NUM> is located below the upper surface of third resin layer <NUM>, but may be located above the upper surface of third resin layer <NUM>. However, in such a case, when upper multi-layer unit 218C is laid out on intermediate multi-layer unit 218B on bottom surface <NUM> of upper multi-layer unit 218C, a space facing space <NUM> in which first electronic component <NUM> is mounted is formed, and an upper portion of first electronic component <NUM> is accommodated in the space.

Further, in formation of circuit wirings <NUM> and <NUM>, sintering of the metal ink is performed by laser irradiation. However, the sintering of the metal ink may be performed collectively by a heating method using an electric furnace, an infrared heater, a hot plate or the like, depending on the type of the metal ink and a work size.

Further, first conductive adhesive <NUM> is cured by ultraviolet rays and heating and second conductive adhesive <NUM> is cured by heating. However, first conductive adhesive <NUM> and second conductive adhesive <NUM> may be cured by a laser, a flash lamp, or the like.

Further, in the above embodiment, it is possible to replace multi-layer unit 218B with a multi-layer unit in which an electronic component different from first electronic component <NUM> is incorporated, or replace multi-layer unit 218B with a multi-layer unit in which a circuit wiring of a wiring circuit pattern different from circuit wirings <NUM> and <NUM> is formed.

In detail, for example, in unit lay-out step S60, instead of multi-layer unit 218B, multi-layer unit 218D illustrated in <FIG> may be integrated with multi-layer units 218A and 218C. Multi-layer unit 218D differs from multi-layer unit 218B at least in terms of third electronic component <NUM> accommodated in central space <NUM> and a wiring circuit pattern of first layer circuit wiring <NUM> on which third electronic component <NUM> is mounted. Accordingly, in method <NUM> of manufacturing a three-dimensional multi-layer electronic device, three-dimensional multi-layer electronic device <NUM> illustrated in <FIG>, which is different from three-dimensional multi-layer electronic device <NUM> described above, is produced. Detailed description of multi-layer unit 218D will be omitted by attaching the same reference numerals to portions substantially common to those of multi-layer unit 218B in <FIG>. Third electronic component <NUM> is an example of an electronic component.

This point is also applied to multi-layer unit 218A. Further, in the embodiment, multi-layer unit 218C can be replaced with a multi-layer unit in which a circuit wiring having a wiring circuit pattern different from that of circuit wiring <NUM> is formed.

Claim 1:
A method (<NUM>) of manufacturing a three-dimensional multi-layer electronic device (<NUM>), comprising:
a unit forming process (P10) of forming multi-layer units (218A, 218B, 218C) including an electronic component (<NUM>, <NUM>, <NUM>) and a circuit wiring (<NUM>, <NUM>) by three-dimensional lay-out forming; and
a unit lay-out process (P12) of manufacturing a three-dimensional multi-layer electronic device (<NUM>) by laying out the multi-layer units (218A, 218B, 218C) integrally in a vertical direction, wherein the unit forming process (P10) includes:
a resin multi-layer forming step (S10) of forming multiple resin layers (<NUM>, <NUM>, <NUM>) for each multi-layer unit (218A, 218B, 218C) by ejection of ultraviolet curable resin and subsequent flattening and curing of the ultraviolet curable resin,
a conductive terminal forming step (S20) of forming a conductive terminal (<NUM>) in a multi-layer unit (218B, 218C), which is to be an upper multi-layer unit (218B, 218C), for electrical connection to a lower multi-layer unit (218A, 218B) when the multi-layer units are laid out in the vertical direction, and
a circuit wiring forming step (S30) of forming a circuit wiring (<NUM>, <NUM>) for each multi-layer unit (218A, 218B, 218C) by ejection of metal ink according to a wiring circuit pattern and subsequent sintering of the metal ink,
wherein the electronic component (<NUM>, <NUM>, <NUM>) of a multi-layer unit (218A, 218B), which is to be a lower multi-layer unit (218A, 218B), includes:
a connection pin (<NUM>) for electrical connection to a conductive terminal (<NUM>) of an upper multi-layer unit (218B, 218C) when the multi-layer units are laid out in the vertical direction.