TWI695517B - 小型光電模組 - Google Patents

小型光電模組 Download PDF

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TWI695517B
TWI695517B TW103140515A TW103140515A TWI695517B TW I695517 B TWI695517 B TW I695517B TW 103140515 A TW103140515 A TW 103140515A TW 103140515 A TW103140515 A TW 103140515A TW I695517 B TWI695517 B TW I695517B
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珍斯 吉傑
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新加坡商海特根微光學公司
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Abstract

本發明揭示一種小型光電模組,在一些實施方案中,該等小型光電模組可具有減小之高度,同時具有非常少之光學串擾或雜散光之偵測。具有光學通道之一光電模組可包含一支撐件,在該支撐件上安裝經配置以發射或偵測在一特定一或多個波長之光之一光電裝置。該模組具有一蓋,該蓋包含在該光電裝置上方之一光學透射部分。該光學透射部分係由該蓋之截面側向圍繞,該等截面對該一或多個波長係實質上不透明。一被動式光學元件呈現於該光學透射部分之一表面上。一間隔件將該支撐件與該蓋分離。該蓋可係相對薄的,使得該模組之總高度係相對小的。

Description

小型光電模組
本發明係關於光電模組,尤其諸如光學接近感測器模組、環境光感測器及閃光模組。
智慧型電話及其他裝置有時包含小型化光電模組,諸如光模組、感測器或攝影機。更一般言之,各種光電模組可經整合至寬廣範圍之小電子裝置中,尤其諸如生物裝置、行動式機器人、監視攝影機、攝錄影機、膝上型電腦及平板電腦。舉例而言,一光學接近感測器可經提供於一行動電話或其他手持式裝置中以偵測一物件之位置或場所。同樣地,環境光感測器可經提供以偵測圍繞行動裝置之光條件(例如)以調整顯示器亮度。亦可提供發光模組(諸如閃光模組)。然而,在此等裝置中,空間常係非常珍貴的。因此,吾人期望使光電模組盡可能小且緊湊。在設計小光電模組(諸如光學接近感測器及環境光感測器)中可產生之其他問題係關於通道之間的光學串擾及藉由模組之雜散光之偵測。亦期望不透光封裝來避免發光模組中之光洩漏。
小型光電模組經闡述為:在一些實施方案中,該等小型光電模組可具有減小之高度,同時具有非常少之光學串擾或雜散光之偵測。
舉例而言,在一個態樣中,具有光學通道之一光電模組包含一支撐件,在該支撐件上安裝經配置以發射或偵測在一特定一或多個波 長之光之一光電裝置。該模組具有一蓋,該蓋包含在該光電裝置上方之一光學透射部分。該光學透射部分係由該蓋之截面側向圍繞,該等截面對該一或多個波長實質上不透明。一被動式光學元件呈現於該光學透射部分之一表面上。一間隔件將該支撐件與該蓋分離。
該蓋可係相對薄的,使得該模組之總高度係相對小的。舉例而言,在一些實施方案中,該蓋之厚度係不超過150μm,且可導致一模組之高度不超過750μm。不同尺寸可應用於其他實施方案中。
在一些實施方案中,該蓋之該等不透明截面係由(例如)可在至少一側上具有一不透明材料之一塗層之一PCB、聚合物或陶瓷層組成。在一些情況中,該塗層係由一金屬或聚合物組成。該塗層之該厚度在一些例項中可係小至20μm,且在一些情況中可係不超過1μm。舉例而言,在一些情況中(其中該蓋之該等不透明截面係由一碳纖維強化聚合物組成),可省略該塗層;在一些實施方案中,仍期望包含該塗層。
前述特徵可經併入至單通道模組及多通道模組兩者中。另外,闡述晶圓級製造技術來促進多個模組之製作。
下文在隨附圖式及說明中陳述一或多個實施方案之細節。自說明及圖示且自申請專利範圍將瞭解其他態樣、特徵及優點。
20‧‧‧模組
22A‧‧‧第一光電裝置/發光裝置/裝置/光電裝置
22B‧‧‧第二光電裝置/光偵測裝置/裝置/光電裝置
24‧‧‧支撐基板/基板/印刷電路板基板/支撐件
26‧‧‧蓋
26A‧‧‧蓋
28‧‧‧透射部分
29‧‧‧截面/不透明截面/不透明部分
29A‧‧‧截面/不透明截面/不透明部分
30‧‧‧層/陶瓷層
30A‧‧‧層/陶瓷層
30B‧‧‧層/陶瓷層
32‧‧‧塗層/薄不透明材料層/薄塗層
32A‧‧‧第一塗層/塗層
32B‧‧‧第二塗層/塗層
34‧‧‧光學元件/透鏡
36‧‧‧間隔件
36A‧‧‧部分
38A‧‧‧光學發射通道/通道/發射通道
38B‧‧‧光學偵測通道/通道/偵測通道
102‧‧‧支撐晶圓/印刷電路板支撐晶圓/
104‧‧‧間隔件晶圓
106‧‧‧薄塗層
106A‧‧‧塗層/薄塗層
106B‧‧‧塗層/薄塗層
108‧‧‧晶圓/較厚層
108A‧‧‧晶圓
108B‧‧‧晶圓
110‧‧‧複合基板
110A‧‧‧複合基板
110B‧‧‧複合基板
112‧‧‧透射窗/透射區域
114‧‧‧被動式光學元件/透鏡
116‧‧‧光學晶圓
116A‧‧‧光學晶圓
116B‧‧‧光學晶圓
120‧‧‧線
H‧‧‧總高度
h‧‧‧高度
T‧‧‧厚度
t‧‧‧總厚度/厚度
圖1繪示根據本發明之一光電模組之一實例。
圖2A至圖2B、圖3A至圖3C及圖4繪示用於製作如在圖1中展示之模組之一晶圓級製造程序中之步驟。
圖5繪示根據本發明之一光電模組之另一實例。
圖6A至圖6D繪示用於製作如在圖5中展示之模組之一晶圓級製造程序中之步驟。
圖7繪示根據本發明之一光電模組之又一實例。
圖8A至圖8D繪示用於製作如在圖7中展示之模組之一晶圓級製造程序中之步驟。
如在圖1中繪示,一模組20包含:第一光電裝置22A及第二光電裝置22B,其等經安裝於一印刷電路板(PCB)或其他支撐基板24上。在繪示之實例中,第一光電裝置22A包含一發光元件(諸如一LED、一IR LED、一OLED、一IR雷射或一VCSEL)。第二光電裝置22B包含一光偵測元件,諸如一光電二極體、CCD或經配置以偵測由發光裝置發射之在一或多個波長之光(例如,紅外光)之其他光感測器。儘管所繪示之模組20具有兩個通道(一個用於發光且一個用於偵測光),但此處闡述之不透光封裝技術亦可用於單通道模組,諸如環境光感測器或發光模組。
藉由充當模組之頂部之一蓋26來保護裝置22A、22B。分別與模組之光學發射通道38A及光學偵測通道38B對準之蓋26的透射部分28係由一材料(例如,玻璃、藍寶石或一聚合物)組成,該材料對由發光裝置22A發射且可由光偵測裝置22B偵測之光的波長係透明的。蓋26之透射部分28經嵌入於蓋26的截面29、29A內,截面29、29A宜對由發光裝置22A發射且可由光偵測裝置22B偵測之光(例如,紅外光或近紅外光)的(若干)特定波長係實質上不透明的。此外,透射部分28係藉由不透明截面29A中之一者而彼此分離。
在一些實施方案中,蓋26之不透明截面29、29A係由(例如)在至少一側上具有一薄不透明材料層(例如,塗層)32之一層30組成。塗層32可係由(例如)一金屬或聚合物材料組成,該材料對由發光裝置22A發射且可由光偵測裝置22B偵測之光的(若干)特定波長係實質上不透明的。用於塗層32之適當金屬包含(例如)銅或鉻。在一些實施方案中,金屬表面經氧化以獲得一暗色或黑色表面。用於塗層32之適當聚 合物的實例包含不透明光阻劑,諸如PMMA(聚(甲基丙烯酸甲酯))、酚甲醛樹脂或環氧基光阻劑。在圖1之實例中,塗層32經安置於層30之裝置側上。在其他實施方案中,塗層32可經安置於層30之相對側上。在又其他實施方案中,不透明金屬或聚合物塗層可經提供於層30之兩個側上(如下文所討論,請參閱圖4)。模組之蓋的不透明截面29、29A可幫助減少由光偵測裝置22B偵測之雜散光的量及在通道38A、38B之間之光學串擾的量。
用於層30自身之材料宜對由發光裝置22A發射且可由光偵測裝置22B偵測之光的(若干)波長係實質上不透明的。舉例而言,層30可係由一PCB、聚合物或陶瓷層30組成。適當PCB材料之實例包含G10及FR4,G10及FR4係指派給玻璃強化環氧樹脂積層材料之等級名稱。此等材料在達約300微米至400微米(μm)之一厚度時,可對(例如)紅外光(IR)輻射實質上不透明。另一方面,此等材料在較小厚度(例如,約150μm或更小之數量級上)時,可容許一些IR光穿過。在層30之至少一側上添加一薄不透明塗層32容許蓋之總厚度(t)係相對小的,且仍保持對由發光裝置22A發射且可由光偵測裝置22B偵測之光實質上不透明。在一些實施方案中,塗層32之厚度係小於20μm。舉例而言,可使用0.5μm至20μm之一塗層。在一些實施方案中,金屬塗層之厚度係在5μm至15μm之範圍中。在其他實施方案中,可提供具有在0.5μm至1.0μm之範圍中之一厚度之一非常薄的膜(例如,光阻劑膜)。使用此一相對薄塗層32可導致蓋26具有在100μm至150μm之範圍中之一總厚度(t)。相對薄蓋26可導致一模組20具有一小之總高度。
在一些實施方案中,蓋26可具有150μm或更小(例如,在100μm至150μm之範圍中)之一厚度,且蓋26之不透明部分29、29A仍係由一材料組成,該材料對在(若干)特定波長之光不足夠透明,使得不需要一塗層32。舉例而言,不透明部分29、29A可由一碳纖維強化聚合物 組成。儘管在一些情況中,仍期望在碳纖維強化聚合物層之一個或兩個側上提供一塗層32,但在其他情況中,可省略塗層。
一般言之,蓋26之透射部分28之厚度應具有與不透明截面29、29A大約相同之厚度。在一些實施方案中,光學元件34(諸如透鏡或散光器)經安置於蓋26之各透射部分28之頂部側及底部側中之一者或兩者上。如在圖1中展示,一第一對透鏡34係與光學發射通道38A對準,且一第二對透鏡34係與光學偵測通道38B對準。光學元件34可藉由(例如)一複製技術(例如,蝕刻、壓印或模製)形成。
蓋26係藉由一間隔件36與基板24分離。間隔件36較佳地係由一不透明材料組成,間隔件36側向圍繞光電裝置22A、22B且充當模組20之側壁。此外,間隔件36之一部分36A充當將發射通道38A及偵測通道38B與彼此分離之一內部壁。充當內部壁之間隔件之部分36A可經直接安置於模組之蓋26之不透明截面29A下方。如上文提及,此等特徵可幫助減少通道38A、38B之間的光學串擾,且可幫助減少進入模組之雜散光之量。在一些實施方案中,在蓋26上方提供一擋板以減少雜散光及/或甚至進一步減少光學串擾。在一些實施方案中,擋板之厚度係約100μm或更少。
光電裝置22A、22B可(例如)使用覆晶技術或線接合技術來安裝至基板24。在一些實施方案中,裝置22A、22B之下側可包含導電觸點,導電觸點將光電裝置22A、22B電耦合至PCB基板24之表面上之導電墊。接著,PCB基板24可包含電鍍導電通孔,導電通孔自導電墊延伸垂直穿過基板24,且耦合至在基板24之外部側上之一或多個焊球或其他導電觸點。在基板外部上之導電觸點容許模組20安裝於(例如)一手持式裝置(諸如一行動電話、平板電腦或其他消費者電子裝置)中之一印刷電路板上。
上述模組可經製成相對緊湊而具有一相對小之覆蓋區。此外 總高度可經製成相對小。舉例而言,在一些實施方案中,模組之總高度(H)(亦即,支撐件24、間隔件36之高度、蓋26之高度及擋板之高度(若存在)之組合高度;但不包含蓋26之外部側上之任何透鏡34)可係在約750μm之數量級上(或更小)。作為一特定實例,基板24之厚度(T)可係約150μm,間隔件36之高度(h)可係約400μm,蓋26之厚度(t)可係約100μm,且擋板之厚度可係約100μm。不同尺寸可適用於其他實施方案中。此等小且緊湊模組可尤其有利於行動電話及其中空間非常珍貴之其他裝置。
模組(諸如在圖1中繪示且在上文中闡述的模組)可在(例如)一晶圓級程序中製造。晶圓級程序容許可同時製造多個模組20。一般言之,一晶圓係指一實質上類碟狀或板狀形狀物項,其在一個方向(y方向或垂直方向)上的延伸相對於其在其他兩個方向(x方向及z方向或側向方向)上的延伸係小的。在一些實施方案中,晶圓之直徑係在5cm與40cm之間,且可係在(例如)10cm與31cm之間。晶圓可係圓柱狀而具有(例如)2英寸、4英寸、6英寸、8英寸或12英寸之一直徑,一英寸係約2.54cm。在一晶圓級程序之一些實施方案中,於各側向方向上可提供有至少十個模組,且在一些情況中,於各側向方向上提供至少三十個或甚至五十個或更多模組。
作為製造程序之部分,多個光電裝置22A、22B可(例如,藉由取放型設備)經安裝於一PCB或其他支撐晶圓102上(見圖2A)。在一些實施方案中,裝置22之一陣列經安裝於PCB支撐晶圓102上,其中各發光裝置22A經安裝鄰近於一光偵測裝置22B。接著,一間隔件晶圓104可(例如)經附接至PCB支撐晶圓102之裝置側(圖2B)。替代地,間隔件晶圓104可經附接至下文闡述之光學晶圓116。在一些實施方案中,間隔件晶圓104係由含有碳黑或其他暗顏料之一UV或熱固化環氧樹脂(或其他聚合物)製成。各種聚合物材料(例如,環氧樹脂、丙烯酸酯、 聚胺基甲酸酯或聚矽氧材料)可用作間隔件晶圓104之基底材料,其中添加一或多種顏料或其他粘合劑以減小間隔件晶圓在所關注(若干)波長(亦即,由裝置22A發射之光之(若干)波長)處的光學透射特性。間隔件晶圓104包含對應於光學發射通道及光學偵測通道之位置的開口。因此,間隔件晶圓104側向圍繞裝置22A、22B中之各者,其中間隔件晶圓之一部分將相鄰裝置22A、22B彼此分離。在一些實施方案中,取代一單獨間隔件晶圓104,間隔件可(例如)藉由一複製或真空射出模製技術而形成於PCB支撐晶圓102之裝置側上或光學晶圓116上。
除上述製造步驟外,亦製備包含光學晶圓之透明部分上之被動式光學元件(例如,透鏡)之一光學晶圓。圖3A至圖3C繪示用於製造此一光學晶圓之一技術。如在圖3A中展示,一不透明材料(例如,金屬或聚合物)之一薄塗層106經提供於一晶圓108之一表面上方,該晶圓由(例如)一PCB、聚合物或陶瓷材料組成以形成一複合基板110。如圖3B指示,開口經形成於複合基板110中,且用一光學透射材料(例如,對由裝置22A發射且可由裝置22B偵測之光之(若干)波長透明之一塑膠)充填以形成透射窗112。接著,被動式光學元件(例如,透鏡)114經形成於各透射區域112之一個(或兩個)表面上(圖3C)。透鏡114可(例如)藉由一複製技術形成於透射區域112上。產生包含在一光學晶圓之透射區域112上之被動式光學元件114之光學晶圓116,其中透射區域112係由不透明截面側向圍繞,不透明截面係由在PCB、聚合物或陶瓷材料之一較厚層108上之一不透明材料(例如,一金屬或聚合物)之一薄塗層106組成。在一些實施方案中,被動式光學元件可直接複製為複合基板110中之開口。
接著,如在圖4中繪示,光學晶圓116(其可稱為一蓋晶圓)經附接至間隔件晶圓104之頂部,使得間隔件晶圓104夾置於光學晶圓116與PCB支撐晶圓102之間。在一些實施方案中,可經提供為一單獨晶圓 之一擋板晶圓亦經附接至光學晶圓116之頂部。替代地,擋板特徵可(例如)藉由一真空射出技術形成於光學晶圓116之頂部表面上。晶圓可藉由(例如)一黏合劑固持在一起。產生一晶圓堆疊118,其可沿線120(例如,藉由切割)分為如圖1之模組20之個別模組。
在圖1之繪示之模組20中,蓋26包含在層30之裝置側上之一薄塗層32。在其他實施方案中,塗層32可經安置於層30之相對(亦即,外)側上。如亦在上文中提及,在一些實施方案中,一不透明材料之一薄塗層經提供於層30之兩個側上。圖5繪示此一模組20A之一實例。
除蓋26A包含在層30之裝置側上之一不透明材料(例如,一金屬或聚合物)之一第一塗層32A及在層30之外側上之一第二塗層32B外,模組20A係類似於圖1之模組20。圖6A至圖6D繪示作為一晶圓級程序之部分之用於製作多個模組20A之製造步驟。圖6A至圖6C展示用於製作一光學晶圓116A之步驟,且除一不透明材料(例如,金屬或聚合物)之薄塗層106A、106B經提供於一晶圓108(例如,由一PCB、聚合物或陶瓷材料組成以形成一複合基板110A)之兩個表面上方外,圖6A至圖6C係分別類似於圖3A至圖3C。塗層106A、106B可由相同或不同不透明材料組成。透射窗112及透鏡114經提供以形成光學晶圓116A(圖6C)。接著,如在圖6D中繪示,光學晶圓116A經附接至間隔件晶圓104之頂部,使得間隔件晶圓104夾置於光學晶圓116A與PCB支撐晶圓102之間。接著,所得晶圓堆疊可經分離(例如,藉由切割)以形成如圖5之模組20A之個別模組。
在上述實例中,塗層32、32A、32B中之各者經提供於層30之一外表面上。在其他實施方案中,不透明材料(例如,金屬或聚合物)之一薄塗層32可夾置於兩個PCB、聚合物或陶瓷層30A、30B之間(見圖7之模組20B)。在一些情況中,兩個層30A、30B係由相同材料組成,而在其他實施方案中,其等可由不同材料組成。
圖8A至圖8D繪示作為一晶圓級程序之部分之用於製作多個模組20B之製造步驟。圖8A至圖8C展示用於製作一光學晶圓116B之步驟,且除一不透明材料(例如,金屬或聚合物)之一薄塗層106夾置於兩個晶圓108A、108B(其等中之各者(例如)由一PCB、聚合物或陶瓷材料組成以形成一複合基板110B)之間外,圖8A至圖8C分別類似於圖3A至圖3C。晶圓108A、108B可由相同或不同材料組成。透射窗112及透鏡114經提供以形成光學晶圓116B(圖8C)。接著,如在圖8D中繪示,光學晶圓116B經附接至間隔件晶圓104之頂部,使得間隔件晶圓104夾置於光學晶圓116B與PCB支撐晶圓102之間。接著,所得晶圓堆疊可經分離(例如,藉由切割)以形成如圖7之模組20B之個別模組。
如在本發明中使用,術語「透明」及「不透明」參考由光電裝置中之發光元件發射或可由光偵測元件偵測之光譜之可見及/或不可見部分(例如,紅外光)中之光之(若干)波長。因此,舉例而言,若模組之一特定特徵係不透明的,則該特徵對由光電裝置中之發光元件發射或可由光偵測元件偵測之光之特定(若干)波長實質上不透明。然而,特定特徵相對於其他波長可係透明或部分透明的。
此處闡述各種模組及用於製作模組之製造技術。在一些實施方案中,模組可係實質上不透光的(亦即,容許非常少量雜散光(若存在)進入模組且減少發射通道38A與偵測通道38B之間的光學串擾之量)。此外,模組可具有非常小之尺寸(例如,約2.0mm(長度)x 2.3mm(寬度)x 0.75mm(高度)),包含一相對小之總高度。
上述實施方案意在作為實例,且一般技術者將容易瞭解各種修改。因此,其他實施方案係在申請專利範圍之範疇內。
20:模組
22A:第一光電裝置/發光裝置/裝置/光電裝置
22B:第二光電裝置/光偵測裝置/裝置/光電裝置
24:支撐基板/基板/印刷電路板基板/支撐件
26:蓋
28:透射部分
29:截面/不透明截面/不透明部分
29A:截面/不透明截面/不透明部分
30:層/陶瓷層
32:塗層/薄不透明材料層/薄塗層
34:光學元件/透鏡
36:間隔件
36A:部分
38A:光學發射通道/通道/發射通道
38B:光學偵測通道/通道/偵測通道
H:總高度
h:高度
T:厚度
t:總厚度/厚度

Claims (13)

  1. 一種光電模組,其具有光學通道,該模組包括:一支撐件,在該支撐件上安裝經配置以發射或偵測在一特定一或多個波長之光之一光電裝置;一蓋,其包含在該光電裝置上方之一光學透射部分,其中該光學透射部分係由對該一或多個波長實質上不透明之該蓋的截面側向圍繞,其中該蓋之該等不透明截面係由在至少一側上具有一不透明材料之一塗層之一PCB、聚合物或陶瓷層組成,該蓋具有不超過150μm之一厚度;一被動式光學元件,其係在該光學透射部分之一表面上;及一間隔件,其將該支撐件與該蓋分離。
  2. 如請求項1之光電模組,其中該塗層之該不透明材料係一金屬或聚合物。
  3. 如請求項1之光電模組,其包含在該PCB、聚合物或陶瓷層之兩個側上之一不透明材料塗層。
  4. 如請求項1或2之光電模組,其中該光電裝置可操作以發射紅外光或可操作以偵測紅外光。
  5. 一種光電模組,其具有一光學發射或偵測通道,該模組包括:一支撐件,在該支撐件上安裝一發光或光偵測元件;一蓋,其包含在該發光或光偵測元件上方之一光學透射部分,其中該光學透射部分係由對由該發光元件發射或可由該光偵測元件偵測之光之一或多個波長實質上不透明之該蓋的截面側向圍繞,且其中該蓋之該等不透明截面係由具有一不透明材料之一塗層之一PCB、聚合物或陶瓷層組成;一透鏡,其係在該光學透射部分之一表面上;及 一間隔件,其將該支撐件與該蓋分離。
  6. 如請求項5之光電模組,其中該塗層之該不透明材料係一金屬或聚合物。
  7. 如請求項5之光電模組,其包含:一光學發射通道及一光學偵測通道,其等安裝於該支撐件上;其中該蓋包含在該發光裝置上方之一第一光學透射部分及在該光偵測裝置上方之一第二光學透射部分,其中該等光學透射部分係由對由該發光裝置發射且可由該光偵測裝置偵測之光之一或多個波長實質上不透明之該蓋的截面側向圍繞,且其中該蓋之該等不透明截面係由具有一不透明材料之一塗層之一PCB、聚合物或陶瓷層組成;該模組包含一透鏡,其在該第一光學透射部分之一表面上,及一透鏡,其在該第二光學透射部分之一表面上。
  8. 如請求項7之光電模組,其中該塗層包括一金屬或聚合物。
  9. 如請求項7之光電模組,其中該塗層係選自由銅、鉻、聚(甲基丙烯酸甲酯)、酚甲醛樹脂及一環氧基光阻劑組成之一群組之一材料所組成。
  10. 一種用於製作複數個光電模組之一晶圓級製造方法,該方法包括:提供一支撐晶圓,在該支撐晶圓上安裝複數個光電裝置,其等中之各者經配置以發射或偵測在一特定一或多個波長的光;提供一光學晶圓,其包含由對該一或多個波長實質上不透明之截面側向圍繞的光學透射部分,該等透射部分中之各者包含在其表面上之一各別被動式光學元件,其中該等不透明截面具有不超過150μm之一厚度,其中該光學晶圓之該等不透明截面 係由在至少一側上具有一不透明材料之一塗層之一PCB、聚合物或陶瓷層組成;及藉由一間隔件將該支撐件附接至該光學晶圓,以形成一晶圓堆疊。
  11. 如請求項10之方法,進一步包含將該晶圓堆疊分為多個光電模組,其等中之各者包含一發光通道及一光偵測通道。
  12. 如請求項10之方法,其中該塗層之該不透明材料係一金屬或聚合物。
  13. 如請求項10之方法,其中該PCB、聚合物或陶瓷層之兩個側包含一不透明材料塗層。
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