WO2016092693A1 - Moudled circuit module, and production method therefor - Google Patents

Moudled circuit module, and production method therefor Download PDF

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Publication number
WO2016092693A1
WO2016092693A1 PCT/JP2014/082956 JP2014082956W WO2016092693A1 WO 2016092693 A1 WO2016092693 A1 WO 2016092693A1 JP 2014082956 W JP2014082956 W JP 2014082956W WO 2016092693 A1 WO2016092693 A1 WO 2016092693A1
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WO
WIPO (PCT)
Prior art keywords
resin
substrate
shield layer
circuit module
molded circuit
Prior art date
Application number
PCT/JP2014/082956
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French (fr)
Japanese (ja)
Inventor
悟 三輪
Original Assignee
株式会社メイコー
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Publication date
Application filed by 株式会社メイコー filed Critical 株式会社メイコー
Priority to PCT/JP2014/082956 priority Critical patent/WO2016092693A1/en
Publication of WO2016092693A1 publication Critical patent/WO2016092693A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
    • H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
    • H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/93—Batch processes
    • H01L24/95—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
    • H01L24/97—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
    • H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
    • H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/15—Details of package parts other than the semiconductor or other solid state devices to be connected
    • H01L2924/181—Encapsulation
    • H01L2924/1815—Shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/30—Technical effects
    • H01L2924/301—Electrical effects
    • H01L2924/3025—Electromagnetic shielding

Definitions

  • the present invention relates to a molded circuit module.
  • the mold circuit module includes a substrate having wiring (for example, a printed circuit board), an electronic component mounted so as to be electrically connected to the wiring of the substrate, and a resin that covers the substrate together with the electronic component.
  • the molded circuit module can protect the electronic component by covering the electronic component with resin, and can protect a portion where the electronic component and the wiring on the substrate are electrically connected.
  • the molded circuit module includes electronic components. Some electronic components are vulnerable to electromagnetic waves. Some electronic components emit electromagnetic waves. In many situations where a molded circuit module is actually used, the molded circuit module is combined with other electronic components. Other electronic components may or may not be included in other molded circuit modules. In addition, other electronic components may be vulnerable to electromagnetic waves, and others may emit electromagnetic waves. When a molded circuit module is actually used, there is a case where it is desired to reduce the influence of an electronic component included in the molded circuit module from electromagnetic waves emitted from other electronic components outside the molded circuit module. In some cases, it is desired to reduce the influence of other electronic components outside the molded circuit module from electromagnetic waves emitted from the electronic components included in the molded circuit module.
  • the metal shield is a box that is open on one side made of a thin metal plate.
  • the metal shield is a box that is open on one side made of a thin metal plate.
  • the box is normal not to mold with resin, but it was positioned inside the box by attaching the box to the substrate with the edge surrounding the box opening in contact with the substrate. Shield the electronic components with a box.
  • the height from the substrate to the top surface of the box tends to increase, and the thickness of the circuit module tends to increase.
  • a metal shield layer is formed by applying a paste containing metal powder to the surface of the resin used in the mold, or by performing plating regardless of whether dry or wet. Proposal of the technique of doing is also made
  • the electronic component mounted on the substrate of the molded circuit module may include a communication device that performs wireless communication with other electronic components outside the molded circuit module.
  • a communication device is included in the molded circuit module, if there is a shield layer intended to shield electromagnetic waves, communication that the communication device should perform may be hindered by the shield layer.
  • An object of the present invention is to improve a molded circuit module including a communication device in an electronic component mounted on a substrate and having a shield layer so that communication by the communication device is not hindered.
  • the present invention relates to a first resin that is a resin that covers a substrate having a ground electrode, at least one electronic component mounted on one surface of the substrate, and one surface of the substrate together with the electronic component. Formed by covering the first resin layer, the surface (upper surface) of the first resin layer, the side surface of the first resin layer, and the side surface of the substrate so as to be electrically connected to the grounding electrode.
  • a molded circuit module including the shield layer formed.
  • at least one of the electronic components is a communication device that performs wireless communication, and the predetermined part covering the surface of the first resin layer of the shield layer An opening is provided so that the communication device can perform wireless communication.
  • the molded circuit module In the molded circuit module, one surface of the substrate is covered with the first resin by the first resin.
  • the first resin corresponds to the resin in the prior art.
  • the molded circuit module also includes a shield layer.
  • the shield layer is the same as the shield layer in the prior art, and shields electromagnetic waves.
  • the presence of the shield layer reduces the influence of the electronic components included in the molded circuit module from the electromagnetic waves emitted by other electronic components outside the molded circuit module, and the electromagnetic waves emitted by the electronic components included in the molded circuit module. Therefore, it is possible to reduce the influence of other electronic components outside the molded circuit module. And if it has such a function, the shield layer may be comprised with what kind of metal.
  • At least one of the electronic components is a communication device that performs wireless communication. Therefore, the communication performed by the communicator may be hindered by the shield layer in some cases. However, an opening is provided in a predetermined portion covering the surface of the first resin layer in the shield layer of the molded circuit module so that the communication device can perform wireless communication therethrough. Therefore, according to this mold circuit module, it is possible to suppress a situation in which the shield layer prevents the communication device from communicating with a device outside the mold circuit module.
  • an opening is provided in the shield layer of the molded circuit module.
  • a predetermined portion of the shield layer covering the surface of the first resin layer more specifically, a position suitable for enabling the communication device to perform wireless communication through the opening.
  • the opening is provided in a predetermined range including a position corresponding to a part of the communication device in a plan view of the substrate, of the portion of the shield layer covering the surface of the first resin layer. It may be done. This makes it possible to reduce the size of the opening necessary for the communication device to perform wireless communication. This means that the range in which the shielding function of the electromagnetic wave that the shield layer should perform is impaired is small.
  • all of the openings do not need to correspond to the communication device when the substrate is viewed in plan, and a part of the opening does not correspond to the communication device when the substrate is viewed in plan. May exist (that is, may protrude from the communication device).
  • the shield layer (or a first metal coating layer and a second metal coating layer described later included therein) is formed by applying a paste containing metal powder or plating.
  • the plating is not limited to a wet dry type.
  • wet plating include electrolytic plating and electroless plating.
  • dry plating include physical vapor deposition (PVD) and chemical vapor deposition (CVD).
  • PVD physical vapor deposition
  • CVD chemical vapor deposition
  • Examples of the former include sputtering and vacuum deposition. Examples of the latter include heat. Examples include CVD and photo-CVD.
  • wet plating is the most cost-effective, and the residual stress in the metal film layer (shield layer) formed by wet plating is the residual stress in the shield layer made by other methods.
  • wet plating is suitable for application to the present invention.
  • the thickness of the shield layer obtained by PVD or CVD, which are thin film formation techniques is from the order of nm to several ⁇ m, whereas by wet plating, a thicker film of several ⁇ m to several tens of ⁇ m is used. Formation is possible.
  • the shield layer has a thickness of at least several ⁇ m, so that wet plating is also compatible with the present invention in this respect.
  • Wet plating includes electroless plating and electrolytic plating. Considering the possibility of damage to electronic components included in the molded circuit module, it is necessary to apply a current to the surface of the molded circuit module to be processed.
  • the shield layer in the present invention is electrically connected to the grounding electrode of the substrate.
  • the shield layer may be in direct contact with the grounding electrode or indirectly in contact with the grounding electrode via another conductive metal.
  • the grounding electrode may be present in layers in a predetermined portion in the thickness direction of the substrate. In that case, in the half-cut process described later, if the first resin and the substrate having a predetermined width including the boundary lines of many partitions are removed up to the grounding electrode inside the substrate, each partition Thus, the end face of the grounding electrode is exposed in the periphery.
  • the shield layer is in direct contact with the exposed end face of the ground electrode.
  • the shield layer can be electrically connected to the grounding electrode by using an appropriate metal member such as a partition member.
  • the shield layer may be a single layer or a multilayer.
  • the metal constituting each of the multiple shield layers may be the same, but may be different.
  • the shield layer includes a first metal coating layer made of a first metal which is a metal having excellent characteristics for electric field shielding, and a second metal coating made of a second metal which is a metal having excellent characteristics for shielding a magnetic field. It can also be formed as including two layers. If the shield layer includes such two layers, the electronic component can be more efficiently protected from electromagnetic waves.
  • the first metal for example, copper or iron can be used.
  • nickel can be used as the second metal. Either the first metal coating layer or the second metal coating layer may be exposed to the outside.
  • the first metal coating layer composed of copper should not be exposed to the outside. good.
  • the inventor of the present application also provides the following method for solving the above-described problems.
  • the following method is an example of a manufacturing method for obtaining the above-described molded circuit module. Such a method is divided into a first production method and a second production method.
  • the first manufacturing method is a communicator that has a large number of virtual sections adjacent to each other on one surface, and at least one of the sections on the one surface performs wireless communication.
  • a first covering step in which at least one electronic component is mounted, and the one whole surface of the substrate having the grounding electrode is covered and cured with a first resin that is a resin together with the electronic component;
  • a plating resist layer forming process in which a plating resist is applied to the surface of the first resin to form at least one layered plating resist layer in each of the sections, and the first width of the predetermined width including the boundary lines of a number of the sections
  • a shield layer forming process for forming a shield layer which is a metal layer that is electrically connected to the grounding electrode, by applying a paste containing metal powder on the side surface of the substrate or by plating; And a full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting each of the sections by cutting a substrate.
  • the molded circuit is configured so that the shield layer is not formed on a portion of the surface of the first resin that is covered with the plating resist layer.
  • An opening for allowing the communication device to perform wireless communication is provided in a predetermined portion of the shield layer of each module that covers the surface of the first resin.
  • the plating resist layer forming process is performed, so that the plating resist layer is formed in a portion where an opening is to be provided after the shield layer. Thereafter, the shield layer forming process is executed to form openings in appropriate portions of the shield layer.
  • the execution of the plating resist layer forming process and the half-cut process is not limited. Whichever step is performed first, a similar molded circuit module can be obtained.
  • the second manufacturing method is a communicator that has a large number of virtual sections adjacent to each other on one surface, and at least one of the sections on the one surface performs wireless communication.
  • a first covering step in which at least one electronic component is mounted and the one whole surface of the substrate having the grounding electrode is covered with a first resin that is a resin and cured together with the electronic component;
  • the first resin having a predetermined width including the boundary line of the partition and the substrate are removed by a half-cut process for removing the first resin to a predetermined thickness, the surface of the first resin, and the half-cut process.
  • Shield layer type for forming a shield layer which is a metal layer electrically connected to the grounding electrode by applying or plating a paste containing metal powder on the side surface of the first resin and the side surface of the substrate And a full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting the substrate at the boundary of the sections to separate the sections. It is.
  • At least one convex portion is provided in each of the sections, and after the shield layer forming process and before executing the full cut process, By performing the process of removing the convex portion together with the shield layer covering the surface of the convex portion, a predetermined portion covering the surface of the first resin in each of the shield layers of the molded circuit module, An opening for allowing the communication device to perform wireless communication is provided through the opening.
  • a convex portion is provided in a portion where an opening is to be provided after the shield layer of each section.
  • an opening can be provided in the appropriate position of a shield layer by removing a convex part with the shield layer which covers the surface of a convex part. .
  • the first manufacturing method although not limited to this, a resin containing a filler may be used as the first resin.
  • the first manufacturing method is a resin containing no filler on the surface of the first resin coated with the substrate after the first coating process and before performing the plating resist layer forming process.
  • a second coating process of covering and curing with two resins, and in the shield layer forming process, a surface of the second resin, a side surface of the first resin exposed by the half-cut process, and a side surface of the substrate In addition, a shield layer, which is a metal layer electrically connected to the grounding electrode, can be formed by applying a paste containing metal powder or plating.
  • the first resin in the present invention corresponds to the resin contained in the molded circuit module described in the prior art.
  • a filler may be mixed in the first resin.
  • the filler is granular. Further, since the filler is composed of a material having a linear expansion coefficient different from that of the resin constituting the first resin, it suppresses the degree of thermal expansion and contraction of the molded circuit module. Often used in modules.
  • the shield layer is formed by applying a paste containing metal powder to the surface of the first resin mixed with the filler or by performing plating, the shield layer may fall off. The filler that is present on the surface of the first resin and is exposed from the first resin may be easily removed from the first resin.
  • Part of the shield layer falls off. It is the second resin that prevents the shield layer from falling off.
  • the second resin covers the surface of the first resin.
  • the shield layer is formed on the surface of the second resin, the side surface of the first resin exposed by the half-cut process performed prior to the full cut for later dicing, and the side surface of the substrate. As described above, the second resin does not contain a filler. Therefore, the shield layer formed in this way has no connection with the dropout due to the dropout of the filler. Even in this case, the portion of the shield layer that covers the side surface of the first resin covers the first resin without using the second resin.
  • the present invention is also meaningful in that wet plating can be selected in the process of forming a shield layer when manufacturing a molded circuit module.
  • the second manufacturing method although not limited to this, a resin containing a filler may be used as the first resin.
  • the second manufacturing method is a resin containing no filler on the surface of the first resin covering the substrate after the first covering process and before executing the shield layer forming process.
  • a second coating process in which the resin is coated and cured, and in the shield layer forming process, the surface of the second resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate The shield layer, which is a metal layer that is electrically connected to the grounding electrode, can be formed by applying a paste containing metal powder or by plating. Also by this, like the above-mentioned case, dropping of the shield layer can be suppressed by the presence of the second resin. Further, by using the second resin, wet plating can be selected in the process of forming the shield layer.
  • the shield layer is prevented from dropping from the first resin by using the second resin.
  • a shield layer is formed on the first resin via the second resin. Therefore, when the second resin is dropped from the first resin, the shield layer is eventually dropped. It will occur.
  • the high adhesion of the second resin to the first resin is important. This adhesion is realized by an anchor effect between the first resin and the second resin, an intermolecular force, and a slight covalent bond.
  • main resin means the resin if the resin contained in the first resin is one kind, and if the first resin contains a plurality of kinds of resins, the most weight among them. It means something that is more in ratio.
  • the second resin can be an epoxy resin. Thereby, the adhesiveness of 1st resin and 2nd resin becomes large to such an extent that it is practical.
  • covers the part coat
  • the thickness of the second resin is reduced within a range in which the filler exposed from the first resin can be prevented from falling off the first resin and the strength of the second resin can be maintained. Is good. Thinning the second resin layer is advantageous when the shield layer is formed by plating because it is easy to roughen in the next step.
  • the layer made of the second resin is preferably thin enough not to fill the uneven shape on the surface of the first resin.
  • the surface of the cured first resin is shaved so that the surface is parallel to the one surface of the substrate. It is possible to perform one resin molding process. When a plurality of electronic components are mounted on the molded circuit module, naturally the height of each electronic component may be different. In that case, the surface of the first resin may be uneven. By performing a first resin molding process in which the surface of the cured first resin is cut so that the surface is parallel to the one surface of the substrate, the first resin existing on the tallest electronic component is obtained. Although the thickness of one resin can be reduced while maintaining the necessary limit, the thickness of the molded circuit module can be reduced by this.
  • the thickness of the first resin existing on the tallest electronic component can be controlled to some extent, but such control has low accuracy.
  • the thickness of the first resin existing on the tallest electronic component is controlled by, for example, mechanical cutting. In that case, the accuracy is generally ⁇ 35 ⁇ m. Can be about.
  • the thickness of the first resin existing on the tallest electronic component could not be made thinner than about 500 ⁇ m, but by adding the first resin molding process, the thickness is reduced to 100 ⁇ m or less. In some cases, the thickness can be reduced to about 80 ⁇ m.
  • the filler present in the cured first resin may easily fall off. However, if the surface of the first resin is coated with the second resin by performing the second coating process after that, it is still possible to suppress the shield layer from falling off due to the filler falling off. .
  • the first coating process when the entire one surface of the substrate is coated with the first resin, which is a resin containing a filler, together with the electronic component, it may be performed by any method. In that case, for example, a vacuum printing method can be used. If the vacuum printing method is used, it is possible to prevent the formation of minute bubbles in the cured first resin, and it becomes possible to cover electronic parts having various shapes with the first resin without any gaps. Although there is an advantage, when using vacuum printing in the first coating process, if the thickness of the resin layer present on the component attached to the substrate is thin, the unevenness caused by the difference in height of the electronic component, It always appears on the surface of the first resin.
  • a vacuum printing method can be used. If the vacuum printing method is used, it is possible to prevent the formation of minute bubbles in the cured first resin, and it becomes possible to cover electronic parts having various shapes with the first resin without any gaps.
  • the first resin molding process is very compatible with vacuum printing, and can be used for manufacturing a molded circuit module. It can also be regarded as technology.
  • the first resin has a filling property for entering between electronic components (this is a property before curing), adhesion to the electronic component or substrate, and a property that does not cause warping (these are properties after curing). 3) is required.
  • a filling property for entering between electronic components this is a property before curing
  • adhesion to the electronic component or substrate adhesion to the electronic component or substrate
  • a property that does not cause warping (these are properties after curing). 3) is required.
  • the characteristics to be satisfied by the first resin are the ratio of the filler with respect to the total amount of the first resin including the filler in a weight ratio of 80% or more as a characteristic before curing, and the linear expansion coefficient ( ⁇ 1) as a characteristic after curing is 11 ppm / TMA or less, linear expansion coefficient ( ⁇ 2) is 25 ppm / TMA or less, and 25 ° C. elastic modulus is 15 GPa / DMA or more.
  • the high filling property contributes to reducing the thickness of the completed molded circuit module. There is usually a gap between the underside of the electronic component and the substrate. Such a gap must be designed to be large enough to fill the gap with the first resin.
  • the gap between the lower side of the electronic component and the substrate can be reduced.
  • the thickness of the molded circuit module can be reduced.
  • the gap between the lower side of the electronic component and the substrate can be reduced to 30 ⁇ m (generally 150 to 200 ⁇ m).
  • FIG. 2 is a side sectional view showing a state in which electronic components are mounted on the substrate shown in FIG.
  • the sectional side view which shows the state which attached the partition member to the board
  • the side sectional view showing the state where the substrate shown in Drawing 1 (c) was covered with the 1st resin together with the part, and the 1st resin was hardened.
  • the sectional side view for showing the range removed among the 1st resin shown in Drawing 1 (d).
  • FIG. 2 is a side sectional view showing a state after a half-cut process is performed on the substrate shown in FIG.
  • FIG. 2 is a side sectional view showing a state in which a shield layer is provided on the substrate shown in FIG. FIG.
  • FIG. 2 is a side sectional view showing a state where a full cut process and plating resist removal are performed on the substrate shown in FIG.
  • the perspective view which shows the structure of the partition member used with the manufacturing method of the mold circuit module of 1st Embodiment.
  • the top view which shows the structure of the other partition member used with the manufacturing method of the mold circuit module of 1st Embodiment, a left view, and a front view.
  • the top view which shows the structure of the other partition member used with the manufacturing method of the mold circuit module of 1st Embodiment, a left view, and a front view.
  • the side view which shows the principle of the vacuum printing method used with the manufacturing method of the mold circuit module of 1st Embodiment.
  • the sectional side view which shows an example of a structure of the shield layer obtained by the manufacturing method of the mold circuit module of 1st Embodiment.
  • the sectional side view of the mold circuit module obtained by the manufacturing method of the mold circuit module by 1st Embodiment.
  • the side sectional view showing the state where the upper surface of the 1st resin was covered with the 2nd resin, and the 2nd resin was hardened.
  • FIG. 8 is a side sectional view showing a state after a half-cut process is performed on the substrate shown in FIG.
  • FIG. 8 is a side sectional view showing a state in which a shield layer is provided on the substrate shown in FIG.
  • FIG. 8 is a side cross-sectional view showing a state in which the top of the substrate shown in FIG.
  • a molded circuit module is manufactured using the substrate 100 shown in FIG.
  • the substrate 100 may be extremely general, and the substrate 100 of this embodiment is also extremely general.
  • the substrate 100 includes wiring not shown.
  • the wiring is electrically connected to an electronic component, which will be described later, and supplies power to the electronic component, and is known or known.
  • the wiring is designed so that it is possible.
  • the wiring may be provided on the substrate 100 by any method, and may be provided anywhere on the substrate 100.
  • the wiring may be provided on the surface of the substrate 100 by printing.
  • the substrate 100 is generally called a printed wiring board.
  • the wiring may also exist inside the substrate 100.
  • the shape of the substrate 100 in plan view is, for example, a rectangle.
  • a ground electrode 110 is provided at an appropriate position on the substrate 100.
  • the grounding electrode 110 may be all or part of the ground electrode 110 inside the substrate 100, or may be all or part of the ground electrode 110 on any surface of the substrate 100. .
  • the ground electrode 110 is used for grounding a shield layer, which will be described later, via the ground electrode 110 when the completed molded circuit module is used.
  • the grounding electrode 110 is designed so that it is possible.
  • a large number of molded circuit modules are manufactured from one substrate 100. That is, in this embodiment, so-called many molded circuit modules are taken from one substrate 100.
  • the substrate 100 is divided into a large number of virtual adjacent sections 120, and one molded circuit module is manufactured from each section 120.
  • the molded circuit modules produced from each compartment 120 are not necessarily the same, but are usually the same.
  • each section 120 has the same size, and each section 120 is provided with wiring and a ground electrode 110 in the same pattern.
  • the mold circuit module manufactured from each division 120 shall be the same.
  • the electronic component 200 is attached. All of the electronic components 200 may be existing ones, for example, active elements such as IC (integrated circuit) amplifiers, oscillators, detectors, and transceivers or passive elements such as resistors, capacitors, and coils. Selected.
  • the electronic component 200 of this embodiment includes at least one communication device. The communication device performs wireless communication with a device outside the molded circuit module manufactured by this manufacturing method, and performs transmission, reception, or both.
  • the electronic component 200 is attached to each compartment 120 such that terminals (not shown) of the electronic component 200 are electrically connected to the wiring of each compartment 120.
  • the electronic components 200 mounted on each section 120 are the same. Since how to attach the electronic component 200 to each section 120 may be a known or well-known technique, detailed description thereof is omitted.
  • a gap between the lower side of the electronic component 200 and the substrate 100 is smaller than usual, and may be, for example, about 30 ⁇ m.
  • the partition member 300 is attached to the substrate 100 (FIG. 1C).
  • the partition member 300 is a member for creating a partition in the molded circuit module.
  • the purpose of partitioning is to reduce the influence of electromagnetic waves generated by the electronic component 200 in the molded circuit module on other electronic components 200 in the molded circuit module.
  • the partition member 300 may be used as necessary when the following circumstances exist, and is not essential.
  • the electronic component 200A shown in FIG. 1C is a high-frequency oscillator, a strong electromagnetic wave is emitted from the electronic component 200A.
  • the other electronic component 200 is replaced with an electronic component.
  • the electronic component 200A is particularly susceptible to electromagnetic waves produced by other electronic components 200. In such a case, the electronic component 200A is protected from electromagnetic waves produced by the other electronic components 200. There is a need. In any case, it is preferable to shield electromagnetic waves between the electronic component 200 ⁇ / b> A and the other electronic component 200. This is made possible by the partition made by the partition member 300.
  • the partition member 300 is made of a metal having conductivity so as to shield electromagnetic waves. In the manufactured molded circuit module, the partition member 300 is electrically connected to the ground electrode 110 directly or via a shield layer described later. It has become.
  • the partition member 300 is an electronic component 200 (not necessarily only one) when the substrate 100 is viewed in plan by a partition made by the partition member 300 alone or by a partition made by the partition member 300 and a shield layer described later. It is designed as a shape that can be enclosed. Although not limited to this, the partition member 300 in this embodiment has a shape as shown in FIG.
  • the partition member 300 is connected to a ceiling 310 that is a triangle when viewed in plan, more specifically a right triangle, and two sides other than the oblique sides of the ceiling 310, and adjacent ones thereof are connected to each other.
  • the rectangular side wall portion 320 is formed.
  • the partition made by the partition member 300 in this embodiment is electrically connected to the shield layer when the molded circuit module is completed.
  • the partition member 300 may be attached to the substrate 100 in any manner.
  • the partition member 300 can be attached to the substrate 100 by bonding.
  • the grounding electrode 110 and the partitioning member 300 are designed as such, and the grounding electrode 110 and the grounding electrode 110 can be connected with a known conductive adhesive or the like. What is necessary is just to adhere
  • the lower end of the side wall portion 320 of the partition member 300 is brought into contact with the grounding electrode 110 that has been exposed from the beginning of the substrate 100 or exposed from the substrate 100 by scraping the surface of the substrate 100. Can be made.
  • the partition member 300 only needs to be electrically connected to the ground electrode 110 as a result.
  • the partition member 300 may be in direct contact with the grounding electrode 110 or indirectly in contact with the grounding electrode 110 via another conductive metal (for example, a shield layer). Also good. And of course, if one of these is achieved, the other need not be achieved.
  • Other examples of the partition member 300 are shown in FIGS. 2B, 2C, and 2D.
  • Each partition member 300 shown in each figure includes a ceiling portion 310 and a side wall portion 320.
  • a plurality of ceiling holes 311 which are openings are formed in the ceiling portion 310 of the partition member 300 shown in FIGS. 2B, 2C, and 2D.
  • the ceiling hole 311 is a hole for allowing the first resin 400 to flow inside the partition member 300 when the first resin 400 is filled, and prevents the partition member 300 and the first resin 400 from being separated after curing. It plays a role.
  • a plurality of side wall holes 321 that are openings are formed in the side wall portion 320 of the partition member 300 shown in FIG.
  • the side wall holes 321 serve to prevent the partition member 300 and the first resin 400 from being separated after the first resin 400 is cured.
  • a resin sealing method such as molding or potting can be used.
  • a vacuum printing method is used. According to the vacuum printing method, it is possible to prevent fine bubbles from being mixed into the molded first resin 400, and it is possible to omit the defoaming process for removing the fine bubbles.
  • the vacuum printing method can be performed using a known vacuum printing machine.
  • VE500 (trademark) which is a vacuum printing sealing device manufactured and sold by Toray Engineering Co., Ltd.
  • the principle of the vacuum printing method will be briefly described with reference to FIG.
  • the substrate 100 is placed between, for example, a metal mask 450 which is a metal mask.
  • a squeegee 460 that is rod-shaped while supplying the first resin 400 in an uncured state and whose length direction is perpendicular to the paper surface in FIG. 3 is shown on the one side shown in FIG. It moves from the position located on the metal mask 450 toward the metal mask 450 on the other side as viewed in FIG.
  • the upper surface of the first resin 400 is leveled by the lower surface of the squeegee 460 and covers the surface of the substrate 100 without any gap while entering between the electronic components 200.
  • the vacuum printing method is performed in a state where the substrate 100, the metal mask 450, and the squeegee 460 are all placed in a vacuum chamber (not shown) in which a vacuum is drawn. Therefore, there is no room for bubbles to enter the first resin 400.
  • the squeegee 460 is moved as shown in FIG. 3, the distance or height of the squeegee 460 from the substrate 100 is usually constant.
  • the first resin 400 covering the substrate 100 is cured by setting an appropriate time.
  • a ceiling hole 311 is provided in the ceiling part 310 of the partition member 300, and a side wall hole 321 is provided in the side wall part 320 of the partition member 300.
  • the first resin 400 before curing enters the partition member 300 from them.
  • the side wall hole 321 provided in the side wall part 320 of the partition member 300 shown in FIG. 2D is hardened in a state where the first resin 400 wraps around the side wall hole 321, so that the partition member 300 The function of fixing the first resin 400 better is exhibited. Even when the below-described process of scraping the upper portion of the first resin 400 is performed, when the ceiling portion 310 of the partition member 300 remains in the first resin 400, the ceiling hole 311 of the ceiling portion 310 also has the same function. Will have.
  • the first resin 400 has a filling property for entering between the electronic components 200 (this is a property before curing), adhesion with the electronic component 200 or the substrate 100, and a property that does not cause warping (these Is a property after curing.
  • the first resin 400 may have the following characteristics. If it is the 1st resin 400 which has the following characteristic, the 1st resin before hardening and after hardening will satisfy the above-mentioned characteristic.
  • the characteristics of the first resin 400 that is preferably satisfied are, as far as the characteristics before curing, the ratio of the filler to the total amount of the first resin including the filler is 80% by weight or more, and the characteristics after curing are linear.
  • the expansion coefficient ( ⁇ 1) is 11 ppm / TMA or less
  • the linear expansion coefficient ( ⁇ 2) is 25 ppm / TMA or less
  • the 25 ° C. elastic modulus is 15 GPa / DMA or more.
  • the resin composition product number: CV5385 (trademark) which Panasonic Corporation manufactures and sells can be mentioned.
  • These resin compositions contain silica (as filler), epoxy resin, curing agent, modifier and the like.
  • the resin composition contains only one type of resin. Therefore, the main resin in the present application of the first resin 400 is an epoxy resin.
  • the first resin 400 includes a filler, but the above-described resin composition (product number: CV5385) includes a filler.
  • the amount of filler contained in these resin compositions is 83%, which is 80% or more by weight with respect to the entire first resin 400.
  • the filler is made of a material having a small linear expansion coefficient, and is usually made of silica. Further, in order to satisfy the filling property of the first resin 400, the filler preferably has a particle size of 30 ⁇ m or less. Both of the fillers contained in the above-described two resin compositions described above satisfy these conditions.
  • the linear expansion coefficient ( ⁇ 1) after curing of the above-described resin composition illustrated is 11 ppm / TMA
  • the linear expansion coefficient ( ⁇ 2) after curing is 25 ppm / TMA
  • the 25 ° C. elastic modulus after curing is 15 GPa / DMA. Yes, satisfying the above-mentioned preferable conditions.
  • the upper portion of the first resin 400 is removed.
  • the main purpose of this is to reduce the thickness of the finally obtained molded circuit module by reducing the thickness of the first resin 400 on the substrate 100.
  • the 1st resin 400 located above the position shown with the broken line L of FIG.1 (e) among the 1st resin 400 is removed.
  • the state which removed the 1st resin 400 located above the position shown with the broken line L is shown by FIG.1 (f).
  • the upper surface of the first resin 400 after removing the first resin 400 positioned above the broken line L is parallel to one surface of the substrate 100. ing.
  • the first resin 400 after removing the first resin 400 located above the broken line L from the uppermost portion when the tallest electronic component 200 is the electronic component 200B.
  • the distance to the top surface of 400 is between 30 ⁇ m and 80 ⁇ m.
  • the partition member 300 when removing the portion of the first resin 400 located above the broken line L, together with the first resin 400, the upper side of the ceiling portion 310 and the side wall portion 320 of the partition member 300. A certain range of is also removed.
  • the partition member 300 is in a state in which only the side wall portion 320 remains in the first resin 400.
  • the side wall portion 320 of the partition member 300 remaining in the first resin 400 serves as a partition that partitions the first resin 400.
  • the upper portion of the partition member 300 is not necessarily removed together with the first resin 400 when the portion of the first resin 400 positioned above the broken line L is removed.
  • the height of the partition member 300 is designed such that the ceiling portion 310 is lower than the broken line L.
  • a suitable known technique can be used for the method of removing the portion of the first resin 400 located above the broken line L.
  • the first resin 400 can be removed by a cutting device such as a milling machine or a polishing cutting device such as a dicer.
  • the upper surface of the first resin 400 (the surface facing the substrate 100) parallel to the substrate 100 is covered with the second resin 500, and the second resin 500 is cured ( FIG. 1 (g)).
  • the reason why the upper surface of the first resin 400 is covered with the second resin 500 is to prevent the filler contained in the first resin 400 from dropping off from the first resin 400.
  • At least a portion of the upper surface of the first resin 400 that is covered with a shield layer described later is covered with the second resin 500.
  • the second resin 500 contains no filler.
  • the material of the second resin 500 is selected from those having high adhesion to the first resin 400 of the second resin 500 after being cured.
  • an epoxy resin or an acrylic resin can be used as the material of the second resin 500.
  • the second resin 500 is an epoxy resin, although not limited to this.
  • the thickness of the second resin 500 is preferably as thin as possible within a range where the following two conditions are satisfied. First, since the 2nd resin 500 plays the role which hold
  • the second resin 500 covers the entire upper surface of the first resin 400.
  • a known technique can be used as the technique used to coat the upper surface of the first resin 400 with the second resin 500.
  • the upper surface of the first resin 400 can be covered with the second resin 500 by spray application using a spray device.
  • the second resin 500 coated with the first resin 400 is cured by putting an appropriate time.
  • the surface of the second resin 500 is roughened.
  • the surface of the second resin 500 is roughened so that a shield layer, which will be described later, is better adhered to the surface of the second resin 500, and the purpose is achieved. Since the technique for roughening the surface of the resin is known or well known, such as etching using a strong acid or strong alkali, the technique may be used for roughening the surface of the second resin 500.
  • a mask 700 is overlaid on the surface of the second resin 500 (FIG. 1H).
  • the mask 700 is a mold for forming a layer made of a plating resist described later.
  • the layer made of the plating resist is for forming an opening which will be described later in a shield layer which will be described later. Such an opening is to prevent the shield layer from interfering when the communication device included in the electronic component 200 performs wireless communication.
  • the electronic component 200C is assumed to be a communication device.
  • the opening will be described later.
  • the mask 700 may be a known one, the mask 700 has a sheet shape, and a mask opening 710 is provided at a position where a layer made of a plating resist is to be formed.
  • one mask opening 710 is provided for each section 120 and at a common position in the section 120.
  • the number of mask openings 710 for each section 120 is one or more and may be plural. The number may be appropriately determined according to the number of communication devices included in the electronic component 200.
  • a plating resist 800 is applied from above the mask 700 (FIG. 1 (i)).
  • the plating resist 800 is made of a material such that the shield layer 600 is not formed on the surface thereof.
  • the plating resist 800 in this embodiment is made of a material that does not adhere to the surface when plating, for example, electroless plating is performed. Since the plating resist is well known, its description is omitted.
  • the plating resist 800 adheres to the surface of the second resin 500 at a portion corresponding to the mask opening 710 of the mask 700 and does not adhere to the surface of the second resin 500 at a portion covered with the mask 700.
  • the layer made of the plating resist 800 is provided in a predetermined range including a position corresponding to a part of the electronic component 200C as a communication device when the substrate 100 is viewed in plan. In other words, when the substrate 100 is viewed in plan, at least a part of the layer made of the plating resist 800 overlaps the electronic component 200 ⁇ / b> C as a communication device.
  • the mask 700 is removed (FIG. 1 (j)). Then, the layer made of the plating resist 800 remains on an appropriate portion of the surface of the second resin 500.
  • Half-cut processing is performed on the substrate 100 (FIG. 1 (k)).
  • Half-cut is a process of making a groove-like cut 100X in the second resin 500, the first resin 400, and the substrate 100.
  • the range into which the incision 100X is made is a range having a predetermined width across the boundary line between adjacent sections 120.
  • the depth of the cut 100X is not limited to this, but in this embodiment, the depth reaches the grounding electrode 110 in the substrate 100. As a result, the end face of the ground electrode 110 is exposed at the periphery of each section 120 after the half-cut process.
  • the width of the cut 100X is not limited to this, but is, for example, 200 ⁇ m to 400 ⁇ m.
  • the width of the cut 100X is determined by the characteristics of the first resin 400, the blade width of a dicer used for half-cutting, and the like.
  • a known technique can be used for the half-cut process.
  • half cut processing can be performed using a DFD641 (trademark), which is a full-auto dicing saw manufactured and sold by Disco Corporation, with a blade having an appropriate width.
  • the half-cut process may be performed before the plating resist 800 layer is formed on the surface of the second resin 500.
  • the shield layer 600 is formed in a portion where the layer made of the plating resist 800 does not exist, but is not formed in a portion where the layer made of the plating resist 800 exists.
  • the shield layer 600 protects the electronic component 200 included in the molded circuit module from electromagnetic waves caused by the electronic components outside the molded circuit module. Alternatively, the electronic component outside the molded circuit module is protected from electromagnetic waves caused by the electronic component 200 in the molded circuit module.
  • the shield layer 600 is formed of a conductive metal suitable for shielding electromagnetic waves.
  • the shield layer 600 may be a single layer or a multilayer.
  • the shield layer 600 of this embodiment is, but not limited to, two layers, a first metal coating layer 610 made of a first metal, which is a metal having excellent characteristics for electric field shielding, and characteristics excellent for magnetic field shielding. It is formed so as to include two layers of a second metal covering layer 620 made of a second metal that is a metal having a (FIG. 4).
  • a first metal coating layer 610 made of a first metal
  • a second metal covering layer 620 made of a second metal that is a metal having a (FIG. 4).
  • copper or iron can be used as the first metal.
  • nickel can be used as the second metal.
  • copper is used as the first metal and nickel is used as the second metal. Either the first metal coating layer 610 or the second metal coating layer 620 may be exposed to the outside.
  • the second metal coating layer 620 is exposed to the outside. This is because when copper is used as the first metal, copper naturally oxidizes and changes color to black, thus preventing such deterioration of the appearance.
  • the shield layer 600 is provided on the surface of the second resin 500 and the side surface of the first resin 400 and the side surface of the substrate 100 that are exposed to the outside by performing half-cutting.
  • the shield layer 600 is electrically connected to the grounding electrode 110 included in the substrate 100 on the side surface of the substrate 100.
  • the shield layer 600 includes two sides facing the sides connecting the side wall portions 320 among the side wall portions 320 of the partition member 300 constituting the partition (these are due to the half-cut process being performed.
  • the first resin 400 is exposed from the side surface of the first resin 400, and the first resin 400 is electrically connected to the side surface.
  • the partition member 300 is electrically connected to the ground electrode 110 through the shield layer 600.
  • the partition member 300 may already be electrically connected to the grounding electrode 110 at the lower end without the shield layer 600 being interposed.
  • the shield layer 600 can be electrically connected to the grounding electrode 110 via the partition member 300 without being directly connected to the end face of the grounding electrode 110 at the lower end thereof.
  • the shield layer 600 can be formed by applying a paste containing metal powder or by plating. When the shield layer 600 is a multilayer, the formation method of each layer may or may not be the same.
  • the first metal coating layer 610 and the second metal coating layer 620 are formed by the same method.
  • the plating is not limited to a wet dry type.
  • An example of wet plating is electroless plating.
  • Examples of dry plating include physical vapor deposition (PVD) and chemical vapor deposition (CVD).
  • Examples of the former include sputtering and vacuum deposition. Examples of the latter include heat. Examples include CVD and photo-CVD.
  • wet plating should be selected in terms of cost and the aspect of reducing the residual stress in the shield layer 600.
  • the thickness of the shield layer 600 can be increased, more specifically, several ⁇ m to several tens ⁇ m, and a sufficient thickness can be easily obtained to shield electromagnetic waves.
  • wet plating includes electroless plating and electrolytic plating.
  • electroless plating considering the possibility of damage to electronic components included in the mold circuit module, it is necessary to pass a current through the surface of the mold circuit module to be processed. It is preferable to employ no electroless plating.
  • both the first metal coating layer 610 and the second metal coating layer 620 are formed by electroless plating.
  • a full cut process is performed to divide the substrate 100 into the respective sections 120 along the cuts 100X made by performing the half cut (FIG. 1 (m)).
  • a known technique can be used for the full cut processing.
  • full cutting can be performed by mounting and using a blade having an appropriate width on the above-described full-auto dicing saw DFD641 (trademark). Thereby, a mold circuit module is obtained one by one from each section of the substrate 100.
  • FIG. 5 is a sectional view of the molded circuit module M obtained by the above method
  • FIG. 6 is a perspective plan view of the molded circuit module M.
  • the substrate 100 included in the molded circuit module M is covered with the first resin 400 together with the electronic component 200.
  • the upper surface of the first resin 400 is covered with the second resin 500.
  • the upper surface of the second resin 500, the side surfaces of the first resin 400 and the second resin 500, and the side surface of the substrate 100 exposed by the half cut are covered with a shield layer 600.
  • the shield layer 600 includes the first metal coating layer 610 and the second metal coating layer 620, which are electrically connected to the side surface of the grounding electrode 110 inside the substrate 100 as shown in FIG. is doing.
  • the second resin 500 exists in the portion of the shield layer 600 that covers the first resin 400 via the second resin 500, the dropout caused by the filler dropping off from the first resin 400 is It is unrelated.
  • the portion of the shield layer 600 that covers the side surface of the first resin 400 covers the first resin 400 without the second resin 500 interposed therebetween.
  • the side surface of the first resin 400 is covered by the half-cut process. Since it is in a somewhat rough state, the adhesion of the shield layer 600 to the first resin 400 is high, and it is difficult for the first resin 400 to fall off from the side surface.
  • the shield layer 600 includes two sides of the side wall portion 320 of the partition member 300 that constitute the partition, the sides facing the side connecting the side wall portions 320, and the first resin 400. Conducted on the side.
  • the electronic component 200 ⁇ / b> A is surrounded by two side surfaces by the side wall portion 320, two side surfaces by the shield layer 600, and the upper surface by the shield layer 600.
  • an opening 630 is provided above the electronic component 200C that is a communication device.
  • the opening 630 is provided at a position where the shield layer 600 does not interfere with the electronic component 200 ⁇ / b> C, which is a communication device, so as not to obstruct the shield layer 600.
  • the opening 630 in this embodiment is not limited to this, but the position corresponding to a part of the electronic component 200 ⁇ / b> C when the substrate 100 is viewed in a plane in the shield layer 600 covering the upper surface of the second resin 500. It is provided within a predetermined range. In other words, when the substrate 100 is viewed in plan, the opening 630 overlaps the electronic component 200C. In the example shown in FIG. 6, the opening 630 is slightly smaller than the electronic component 200 ⁇ / b> C when viewed in plan, but is not limited to this, and the opening 630 is changed from the electronic component 200 ⁇ / b> C when viewed in plan to A part may come out.
  • the method for manufacturing the molded circuit module according to the second embodiment is similar to the method for manufacturing the molded circuit module according to the first embodiment, in which a part of the upper shield layer 600 is not present and is opened. It is a method to do.
  • the method of manufacturing the molded circuit module according to the second embodiment is generally the same as that described in the above embodiment. In particular, the process up to the process of covering the upper surface of the first resin 400 with the second resin 500 and curing the second resin 500 described with reference to FIG.
  • the partition member is different from the manufacturing method of the molded circuit module of the second embodiment.
  • the method of manufacturing the molded circuit module according to the second embodiment when the substrate 100 is covered with the electronic component 200 together with the point that the 300 is not used (the partition member 300 may be used in the second embodiment).
  • the thickened portion 410 having a large thickness from the substrate 100 is provided in an appropriate portion of the first resin 400, and the process of cutting the upper portion of the first resin 400 described with reference to FIG. (Fig. 7 (a)).
  • the opening of the shield layer mentioned later is formed in the part in which the raised part 410 exists. That is, the raised portion 410 is provided in a portion where the opening of the shield layer is desired to exist.
  • a shield layer 600 having the same two-layer structure as that described in the above embodiment is formed by the same method as that described in the first embodiment (FIG. 7C).
  • the raised portion 410 is removed together with the second resin 500 covering the raised portion 410 and the shield layer 600 covering the second resin 500 covering the raised portion 410.
  • the portion where the raised portion 410 was present is flush with the surface of the shield layer 600 that covers the portion other than the raised portion 410 via the second resin 500.
  • the above-mentioned part is removed.
  • a molded circuit module having an opening 630 at a desired position of the shield layer 600 is completed (FIG. 7D).
  • the molded circuit module obtained by the manufacturing method of the second embodiment is substantially the same as that of the first embodiment.
  • the position and size of the opening 630 in the shield layer 600 are the same as in the first embodiment.
  • the above-described raised portion 410 is formed so as to be so.

Abstract

The purpose of the present invention is to improve a moulded circuit module, which includes a communication unit among the electronic components mounted to a substrate thereof, and which is provided with a shield layer, such that communication using the communication unit is not hindered. This moulded circuit module is provided with a substrate (100) having, mounted thereto, electronic components (200) including an electronic component (200C), i.e. a communication unit. In the substrate (100), all of the electronic components (200) are covered by a first resin (400). The upper surface of the first resin (400) is covered by a second resin (500). The upper surface of the second resin (500) and the side surfaces of the first resin (400) are covered by a shield layer (600) made from plating which blocks electromagnetic waves. An opening (630) in the shield layer (600) is provided directly above the electronic component (200C), i.e. the communication unit.

Description

モールド回路モジュール及びその製造方法Molded circuit module and manufacturing method thereof
　本発明は、モールド回路モジュールに関する。 The present invention relates to a molded circuit module.
　モールド回路モジュールが知られている。
　モールド回路モジュールは、配線を有する基板（例えばプリント基板）と、基板の配線と導通するようにして実装された電子部品と、基板を電子部品ごと被覆する樹脂とからなる。モールド回路モジュールは、電子部品を樹脂にて覆うことにより、電子部品を保護することができ、また、電子部品と基板の配線とが導通する箇所を保護することができる。 Molded circuit modules are known.
The mold circuit module includes a substrate having wiring (for example, a printed circuit board), an electronic component mounted so as to be electrically connected to the wiring of the substrate, and a resin that covers the substrate together with the electronic component. The molded circuit module can protect the electronic component by covering the electronic component with resin, and can protect a portion where the electronic component and the wiring on the substrate are electrically connected.
　上述のようにモールド回路モジュールは、電子部品を含んでいる。そして、電子部品には、電磁波に弱いものがある。また、電子部品には、電磁波を放出するものもある。
　モールド回路モジュールが実際に使用される多くの場面では、モールド回路モジュールは他の電子部品と組合せられる。他の電子部品は、他のモールド回路モジュールに含まれている場合もあるし、そうでない場合もある。また、他の電子部品は、電磁波に弱い場合もあり、また電磁波を放出するものもある。
　モールド回路モジュールが実際に使用されるとき、当該モールド回路モジュール外の他の電子部品が放出する電磁波から、そのモールド回路モジュールに含まれる電子部品が受ける影響を低減したい場合がある。また、モールド回路モジュールに含まれる電子部品が放出する電磁波から、当該モールド回路モジュール外の他の電子部品が受ける影響を低減したい場合がある。 As described above, the molded circuit module includes electronic components. Some electronic components are vulnerable to electromagnetic waves. Some electronic components emit electromagnetic waves.
In many situations where a molded circuit module is actually used, the molded circuit module is combined with other electronic components. Other electronic components may or may not be included in other molded circuit modules. In addition, other electronic components may be vulnerable to electromagnetic waves, and others may emit electromagnetic waves.
When a molded circuit module is actually used, there is a case where it is desired to reduce the influence of an electronic component included in the molded circuit module from electromagnetic waves emitted from other electronic components outside the molded circuit module. In some cases, it is desired to reduce the influence of other electronic components outside the molded circuit module from electromagnetic waves emitted from the electronic components included in the molded circuit module.
　そのような観点から、樹脂によるモールドが行われていない回路モジュールについてではあるが、回路モジュール全体を電磁波を遮蔽する金属製のシールドで囲むという技術が実用されている。
　ある例においては、金属製のシールドは、薄い金属板にて形成のその一面が開口された箱である。箱を用いる場合には、樹脂によるモールドを施さないのが通常であるが、箱の開口を囲む縁を基板に当接させた状態で箱を基板に取付けることにより、箱の内部に位置させた電子部品を箱によって囲んでシールドする。
　しかしながら、箱を用いる場合には、基板から箱の上面までの高さが大きくなりがちであり、回路モジュールの厚さが大きくなりがちである。箱を用いる場合には箱を作る手間、コストが嵩む上、電子部品の高さに合わせて複数種類の箱を準備するとなると箱を作る手間、コストが益々上昇するから、箱の高さが電子部品の基板からの高さと比較すると無駄といえる程高くなることも起こり得る。
　回路モジュールの厚さは、それが組込まれる最終製品の寸法に大きな影響を与えるため、それを小さくすることは非常に大きな価値があるが、箱を使うと回路モジュールの厚さが大きくなりがちである。 From such a viewpoint, although it is about the circuit module which is not molded by resin, the technique of surrounding the whole circuit module with the metal shield which shields electromagnetic waves is put into practical use.
In one example, the metal shield is a box that is open on one side made of a thin metal plate. When using a box, it is normal not to mold with resin, but it was positioned inside the box by attaching the box to the substrate with the edge surrounding the box opening in contact with the substrate. Shield the electronic components with a box.
However, when a box is used, the height from the substrate to the top surface of the box tends to increase, and the thickness of the circuit module tends to increase. In the case of using a box, the labor and cost of making the box increase, and more than one type of box is prepared according to the height of the electronic component. It can happen that it becomes useless compared to the height of the component from the substrate.
Since the thickness of a circuit module has a large impact on the dimensions of the final product in which it is incorporated, it is very valuable to reduce it, but using a box tends to increase the thickness of the circuit module. is there.
　他方、モールド回路モジュールにおいて、モールドに用いられた樹脂の表面に、金属粉を含んだペーストを塗布したり、或いは乾式、湿式の別は問わずめっきを行うことによって、金属製のシールド層を形成するという技術の提案もなされており、特にペーストの塗布や、乾式のめっきの一種であるスパッタリングは、実用もされている。これらによれば、モールド回路モジュールの厚さが過大となることは防げる。 On the other hand, in a molded circuit module, a metal shield layer is formed by applying a paste containing metal powder to the surface of the resin used in the mold, or by performing plating regardless of whether dry or wet. Proposal of the technique of doing is also made | formed, and especially the application | coating of a paste and sputtering which is a kind of dry-type plating are also used practically. According to these, it is possible to prevent the thickness of the molded circuit module from becoming excessive.
　ところで、モールド回路モジュールの基板に実装される電子部品の中には、モールド回路モジュール外の他の電子部品との間で無線の通信を行う通信器が含まれることがある。モールド回路モジュールに通信器が含まれる場合、電磁波を遮蔽することを目的とするシールド層が存在すると、そのシールド層によって通信器が行うべき通信が阻害されることがあり得る。 By the way, the electronic component mounted on the substrate of the molded circuit module may include a communication device that performs wireless communication with other electronic components outside the molded circuit module. When a communication device is included in the molded circuit module, if there is a shield layer intended to shield electromagnetic waves, communication that the communication device should perform may be hindered by the shield layer.
　本願発明は、基板に実装される電子部品の中に通信器を含み、且つシールド層を有するモールド回路モジュールを、通信器による通信が阻害されないように改良することをその課題とする。 An object of the present invention is to improve a molded circuit module including a communication device in an electronic component mounted on a substrate and having a shield layer so that communication by the communication device is not hindered.
　上述の課題を解決するため、本願発明者は以下の発明を提案する。
　本願発明は、接地用電極を有する基板と、前記基板の一方の面上に実装された少なくとも１つの電子部品と、前記基板の一方の面を前記電子部品ごと被覆する、樹脂である第１樹脂による第１樹脂層と、前記第１樹脂層の表面（上面）と、前記第１樹脂層の側面と、前記基板の側面とを、前記接地用電極と導通するようにして被覆することによって形成されたシールド層と、を含むモールド回路モジュールである。
　そして、このモールド回路モジュールでは、前記電子部品のうちの少なくとも一つが、無線の通信を行う通信器であり、前記シールド層のうちの前記第１樹脂層の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられている。
　このモールド回路モジュールは、第１樹脂により基板の一方の面が電子部品ごと被覆されている。第１樹脂は、従来技術における樹脂に相当する。
　また、このモールド回路モジュールは、シールド層を備えている。シールド層は、従来技術におけるシールド層と同様のものであり、電磁波を遮蔽するものとなっている。シールド層の存在により、モールド回路モジュール外の他の電子部品が放出する電磁波から、モールド回路モジュールに含まれる電子部品が受ける影響を低減することと、モールド回路モジュールに含まれる電子部品が放出する電磁波から、モールド回路モジュール外の他の電子部品が受ける影響を低減することとが可能となる。そして、そのような機能を有するのであれば、シールド層はどのような金属により構成されていても良い。
　そして、このモールド回路モジュールでは、前記電子部品のうちの少なくとも一つが、無線の通信を行う通信器となっている。したがって、通信器が行う通信は、場合によってはシールド層によって妨げられる可能性がある。しかしこのモールド回路モジュールのシールド層のうちの第１樹脂層の表面を覆う所定の部分には、それを介して通信器が無線の通信を行えるようにするための開口が設けられている。したがって、このモールド回路モジュールによれば、通信器がモールド回路モジュール外の装置と通信することをシールド層によって妨げられるという事態を抑制できる。 In order to solve the above-mentioned problems, the present inventor proposes the following invention.
The present invention relates to a first resin that is a resin that covers a substrate having a ground electrode, at least one electronic component mounted on one surface of the substrate, and one surface of the substrate together with the electronic component. Formed by covering the first resin layer, the surface (upper surface) of the first resin layer, the side surface of the first resin layer, and the side surface of the substrate so as to be electrically connected to the grounding electrode. A molded circuit module including the shield layer formed.
In this molded circuit module, at least one of the electronic components is a communication device that performs wireless communication, and the predetermined part covering the surface of the first resin layer of the shield layer An opening is provided so that the communication device can perform wireless communication.
In the molded circuit module, one surface of the substrate is covered with the first resin by the first resin. The first resin corresponds to the resin in the prior art.
The molded circuit module also includes a shield layer. The shield layer is the same as the shield layer in the prior art, and shields electromagnetic waves. The presence of the shield layer reduces the influence of the electronic components included in the molded circuit module from the electromagnetic waves emitted by other electronic components outside the molded circuit module, and the electromagnetic waves emitted by the electronic components included in the molded circuit module. Therefore, it is possible to reduce the influence of other electronic components outside the molded circuit module. And if it has such a function, the shield layer may be comprised with what kind of metal.
In the molded circuit module, at least one of the electronic components is a communication device that performs wireless communication. Therefore, the communication performed by the communicator may be hindered by the shield layer in some cases. However, an opening is provided in a predetermined portion covering the surface of the first resin layer in the shield layer of the molded circuit module so that the communication device can perform wireless communication therethrough. Therefore, according to this mold circuit module, it is possible to suppress a situation in which the shield layer prevents the communication device from communicating with a device outside the mold circuit module.
　上述のように、このモールド回路モジュールのシールド層には、開口が設けられている。シールド層のうちの第１樹脂層の表面を覆う所定の部分に、より詳細には、開口を介して通信器が無線の通信を行えるようにするために相応しい位置に、その目的を達成するに相応しい大きさで設けられる。
　前記開口は、前記シールド層のうちの前記第１樹脂層の表面を覆う部分のうちの、前記基板を平面視した場合における、前記通信器の一部に対応する位置を含む所定の範囲に設けられていてもよい。これにより、通信器が無線の通信を行えるようにするために必要な開口の大きさを小さくすることが可能となる。これは、シールド層が本来果たすべき電磁波の遮蔽の機能が損なわれる範囲が小さくて済むということを意味する。
　この場合、開口は、そのすべての部分が、基板を平面視した場合の通信器に対応している必要がなく、その一部が、基板を平面視した場合の通信器に対応していない部分に存在していても（つまり、通信器から食み出していても）良い。 As described above, an opening is provided in the shield layer of the molded circuit module. In order to achieve the object, a predetermined portion of the shield layer covering the surface of the first resin layer, more specifically, a position suitable for enabling the communication device to perform wireless communication through the opening. Provided with appropriate size.
The opening is provided in a predetermined range including a position corresponding to a part of the communication device in a plan view of the substrate, of the portion of the shield layer covering the surface of the first resin layer. It may be done. This makes it possible to reduce the size of the opening necessary for the communication device to perform wireless communication. This means that the range in which the shielding function of the electromagnetic wave that the shield layer should perform is impaired is small.
In this case, all of the openings do not need to correspond to the communication device when the substrate is viewed in plan, and a part of the opening does not correspond to the communication device when the substrate is viewed in plan. May exist (that is, may protrude from the communication device).
　シールド層（或いはこれに含まれる、後述する第１金属被覆層と第２金属被覆層）は、金属粉を含んだペーストの塗布、又はめっきにより形成する。めっきは、湿式乾式を問わない。湿式のめっきの例としては電解めっき、無電解めっきを挙げることができる。乾式のめっきの例としては、物理気相成長（ＰＶＤ）、化学気相成長（ＣＶＤ）を挙げることができ、前者の例としては、スパッタリング、真空蒸着を挙げられ、後者の例としては、熱ＣＶＤ、光ＣＶＤを挙げられる。これらのうち、湿式めっきがもっともコスト面からは有利であり、また、湿式めっきにより形成された金属皮膜層（シールド層）内の残留応力は、他の方法で作られたシールド層内の残留応力よりも小さい点でも湿式めっきは本願発明への応用に向いている。更に、薄膜形成の技術であるＰＶＤやＣＶＤによって得られるシールド層の厚さはｎｍのオーダーから数μｍまでであるのに対し、湿式めっきによれば、数μｍ～数十μｍまでの厚めの膜形成が可能である。電磁波に対するシールド効果を考えると、シールド層には、少なくとも数μｍの厚さがある方が好ましいので、その点でも湿式めっきは本願発明との相性が良い。なお、湿式めっきには無電解めっきと電解めっきが含まれるが、モールド回路モジュールに含まれる電子部品の損傷の可能性を考えると、加工の対象となるモールド回路モジュールの表面に電流を流すことになる電解めっきよりも、電流を流さなくとも済む無電解めっきの方が好ましい。
　なお、本願発明におけるシールド層は、基板が持つ接地用電極に導通させられる。シールド層は、接地用電極と導通していれば、接地用電極に直接接触していても、導電性のある他の金属を介して接地用電極に間接的に接触していても良い。例えば、接地用電極は、基板の厚さ方向の所定の部分に層状に存在する場合がある。その場合には、後述するハーフカット過程で、多数の区画の境界線上を含む所定幅の第１樹脂と基板とを、基板の内部の接地用電極に至るまで除去することとすれば、各区画の周辺に接地用電極の端面が露出することになる。その状態で、金属粉を含んだペーストの塗布、又はめっきを行えば、シールド層は、露出した接地用電極の端面に、直接接することになる。或いは、発明の実施の形態で説明するように、パーテーション部材などの適当な金属部材を用いることで、シールド層を接地用電極と導通させることができる。 The shield layer (or a first metal coating layer and a second metal coating layer described later included therein) is formed by applying a paste containing metal powder or plating. The plating is not limited to a wet dry type. Examples of wet plating include electrolytic plating and electroless plating. Examples of dry plating include physical vapor deposition (PVD) and chemical vapor deposition (CVD). Examples of the former include sputtering and vacuum deposition. Examples of the latter include heat. Examples include CVD and photo-CVD. Of these, wet plating is the most cost-effective, and the residual stress in the metal film layer (shield layer) formed by wet plating is the residual stress in the shield layer made by other methods. In terms of smaller size, wet plating is suitable for application to the present invention. Furthermore, the thickness of the shield layer obtained by PVD or CVD, which are thin film formation techniques, is from the order of nm to several μm, whereas by wet plating, a thicker film of several μm to several tens of μm is used. Formation is possible. Considering the shielding effect against electromagnetic waves, it is preferable that the shield layer has a thickness of at least several μm, so that wet plating is also compatible with the present invention in this respect. Wet plating includes electroless plating and electrolytic plating. Considering the possibility of damage to electronic components included in the molded circuit module, it is necessary to apply a current to the surface of the molded circuit module to be processed. Electroless plating that does not require a current to flow is preferable to electrolytic plating.
The shield layer in the present invention is electrically connected to the grounding electrode of the substrate. As long as the shield layer is electrically connected to the grounding electrode, the shield layer may be in direct contact with the grounding electrode or indirectly in contact with the grounding electrode via another conductive metal. For example, the grounding electrode may be present in layers in a predetermined portion in the thickness direction of the substrate. In that case, in the half-cut process described later, if the first resin and the substrate having a predetermined width including the boundary lines of many partitions are removed up to the grounding electrode inside the substrate, each partition Thus, the end face of the grounding electrode is exposed in the periphery. In this state, if a paste containing metal powder is applied or plated, the shield layer is in direct contact with the exposed end face of the ground electrode. Alternatively, as described in the embodiment of the invention, the shield layer can be electrically connected to the grounding electrode by using an appropriate metal member such as a partition member.
　シールド層は１層でも良く、多層でも良い。多層のシールド層をそれぞれ構成する金属は、同一でも良いが、異なるものとすることができる。
　本願発明では、前記シールド層を、電場のシールドに優れる特性を持つ金属である第１金属による第１金属被覆層と、磁場のシールドに優れる特性を持つ金属である第２金属による第２金属被覆層との２層を含むものとして形成することもできる。
　シールド層をこのような２層を含むものとすれば、電磁波からより効率的に電子部品を保護できるようになる。
　前記第１金属として、例えば、銅又は鉄を用いることができる。
　前記第２金属として、例えば、ニッケルを用いることができる。
　第１金属被覆層と、第２金属被覆層は、そのいずれを外部に露出させても良い。いずれにしても、上述の機能に関しては特に影響はない。もっとも、第１金属として銅を用いる場合、銅は酸化して黒色に変色することがあるから、見栄えに配慮するのであれば、銅によって構成される第１金属被覆層は外部に露出させない方が良い。 The shield layer may be a single layer or a multilayer. The metal constituting each of the multiple shield layers may be the same, but may be different.
In the present invention, the shield layer includes a first metal coating layer made of a first metal which is a metal having excellent characteristics for electric field shielding, and a second metal coating made of a second metal which is a metal having excellent characteristics for shielding a magnetic field. It can also be formed as including two layers.
If the shield layer includes such two layers, the electronic component can be more efficiently protected from electromagnetic waves.
As the first metal, for example, copper or iron can be used.
For example, nickel can be used as the second metal.
Either the first metal coating layer or the second metal coating layer may be exposed to the outside. In any case, there is no particular effect on the above-described functions. However, when copper is used as the first metal, copper may be oxidized and discolored to black. Therefore, if the appearance is taken into consideration, the first metal coating layer composed of copper should not be exposed to the outside. good.
　本願発明者は、上述の課題を解決するものとして、以下の方法をも提供する。以下の方法は、上述のモールド回路モジュールを得るための製造方法の例となる。かかる方法は、第１製法と、第２製法に２分される。
　第１製法は、互いに隣接する多数の仮想の区画をその一方の面に有するとともに、前記一方の面の前記区画のそれぞれに、その中のうちの少なくとも１つが無線の通信を行う通信器である、少なくとも１つの電子部品が実装されたものであり、接地用電極を有する基板の前記一方の全面を、前記電子部品ごと、樹脂である第１樹脂で被覆し硬化させる第１被覆過程と、前記第１樹脂の表面に、めっきレジストを塗布して層状のめっきレジスト層を前記区画のそれぞれに少なくとも一つずつ設けるめっきレジスト層形成過程と、多数の前記区画の境界線上を含む所定幅の前記第１樹脂と前記基板とを、前記基板の所定の厚さまで除去するハーフカット過程と、前記第１樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成するシールド層形成過程と、前記区画の境界で前記基板を切断することにより、前記各区画を切り離すことにより、前記区画のそれぞれに基づく複数のモールド回路モジュールを得るフルカット過程と、を含むモールド回路モジュールの製造方法である。
　そしてこのモールド回路モジュールの製造方法における前記シールド層形成過程では、前記第１樹脂の表面のうち前記めっきレジスト層に覆われている部分に前記シールド層を形成しないようにすることで、前記モールド回路モジュールのそれぞれの前記シールド層のうちの前記第１樹脂の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられるようにする。
　この方法では、シールド層形成過程を実行する前に、めっきレジスト層形成過程を実行することにより、めっきレジスト層を、シールド層の後に開口が設けられるべき部分に形成する。その後でシールド層形成過程を実行することにより、シールド層の適宜の部分に開口が形成される。
　なお、めっきレジスト層形成過程と、ハーフカット過程とは、その実行につき先後を問わない。いずれを先に行っても、同様のモールド回路モジュールを得ることができる。 The inventor of the present application also provides the following method for solving the above-described problems. The following method is an example of a manufacturing method for obtaining the above-described molded circuit module. Such a method is divided into a first production method and a second production method.
The first manufacturing method is a communicator that has a large number of virtual sections adjacent to each other on one surface, and at least one of the sections on the one surface performs wireless communication. A first covering step in which at least one electronic component is mounted, and the one whole surface of the substrate having the grounding electrode is covered and cured with a first resin that is a resin together with the electronic component; A plating resist layer forming process in which a plating resist is applied to the surface of the first resin to form at least one layered plating resist layer in each of the sections, and the first width of the predetermined width including the boundary lines of a number of the sections A half-cut process of removing one resin and the substrate to a predetermined thickness of the substrate; a surface of the first resin; and a side surface of the first resin exposed by the half-cut process. A shield layer forming process for forming a shield layer, which is a metal layer that is electrically connected to the grounding electrode, by applying a paste containing metal powder on the side surface of the substrate or by plating; And a full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting each of the sections by cutting a substrate.
In the shield layer forming process in the method of manufacturing the molded circuit module, the molded circuit is configured so that the shield layer is not formed on a portion of the surface of the first resin that is covered with the plating resist layer. An opening for allowing the communication device to perform wireless communication is provided in a predetermined portion of the shield layer of each module that covers the surface of the first resin.
In this method, before the shield layer forming process is performed, the plating resist layer forming process is performed, so that the plating resist layer is formed in a portion where an opening is to be provided after the shield layer. Thereafter, the shield layer forming process is executed to form openings in appropriate portions of the shield layer.
The execution of the plating resist layer forming process and the half-cut process is not limited. Whichever step is performed first, a similar molded circuit module can be obtained.
　第２製法は、互いに隣接する多数の仮想の区画をその一方の面に有するとともに、前記一方の面の前記区画のそれぞれに、その中のうちの少なくとも１つが無線の通信を行う通信器である、少なくとも１つの電子部品が実装されたものであり、接地用電極を有する基板の前記一方の全面を、前記電子部品ごと、樹脂である第１樹脂で被覆し硬化させる第１被覆過程と、多数の前記区画の境界線上を含む所定幅の前記第１樹脂と前記基板とを、前記基板の所定の厚さまで除去するハーフカット過程と、前記第１樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成するシールド層形成過程と、前記区画の境界で前記基板を切断することにより、前記各区画を切り離すことにより、前記区画のそれぞれに基づく複数のモールド回路モジュールを得るフルカット過程と、を含むモールド回路モジュールの製造方法である。
　そして、このモールド回路モジュールの製造方法における前記第１被覆過程では、前記区画のそれぞれに少なくとも１つの凸部を設けるとともに、前記シールド層形成過程の後で、前記フルカット過程を実行する前に、前記凸部を前記凸部の表面を覆う前記シールド層ごと除去する過程を実行することにより、前記モールド回路モジュールのそれぞれの前記シールド層のうちの前記第１樹脂の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられるようにする。
　このモールド回路モジュール形成方法では、第１被覆過程で、各区画のシールド層の後に開口が設けられるべき部分に凸部を設けておく。そして、シールド層形成過程の後で、フルカット過程を実行する前に、凸部を、凸部の表面を覆うシールド層ごと除去することにより、シールド層の適宜の位置に開口を設けることができる。 The second manufacturing method is a communicator that has a large number of virtual sections adjacent to each other on one surface, and at least one of the sections on the one surface performs wireless communication. A first covering step in which at least one electronic component is mounted and the one whole surface of the substrate having the grounding electrode is covered with a first resin that is a resin and cured together with the electronic component; The first resin having a predetermined width including the boundary line of the partition and the substrate are removed by a half-cut process for removing the first resin to a predetermined thickness, the surface of the first resin, and the half-cut process. Shield layer type for forming a shield layer which is a metal layer electrically connected to the grounding electrode by applying or plating a paste containing metal powder on the side surface of the first resin and the side surface of the substrate And a full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting the substrate at the boundary of the sections to separate the sections. It is.
And in the first covering process in the method of manufacturing the molded circuit module, at least one convex portion is provided in each of the sections, and after the shield layer forming process and before executing the full cut process, By performing the process of removing the convex portion together with the shield layer covering the surface of the convex portion, a predetermined portion covering the surface of the first resin in each of the shield layers of the molded circuit module, An opening for allowing the communication device to perform wireless communication is provided through the opening.
In this mold circuit module forming method, in the first covering process, a convex portion is provided in a portion where an opening is to be provided after the shield layer of each section. And after performing a shield layer formation process and before performing a full cut process, an opening can be provided in the appropriate position of a shield layer by removing a convex part with the shield layer which covers the surface of a convex part. .
　第１製法では、これには限られないが、前記第１樹脂として、フィラーを含む樹脂を用いるようにしてもよい。その場合、第１製法は、前記第１被覆過程の後で、前記めっきレジスト層形成過程を実行する前に、前記基板を被覆した前記第１樹脂の表面を、フィラーを含まない樹脂である第２樹脂で被覆し硬化させる第２被覆過程を含み、前記シールド層形成過程では、前記第２樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成するようにすることができる。
　本願発明における第１樹脂は、従来技術で説明したモールド回路モジュールに含まれる樹脂に相当する。第１樹脂には、フィラーが混入されることがある。フィラーは、粒状である。また、フィラーは、第１樹脂を構成する樹脂とは異なる線膨張係数を持つ材料によりそれを構成することにより、モールド回路モジュールの熱膨張収縮の程度を抑制するものであるから、現時点におけるモールド回路モジュールにおいては使用される場合が多い。
　他方、フィラーが混入された第１樹脂の表面に、金属粉を含んだペーストを塗布したり、或いはめっきを行うことによりシールド層を形成した場合には、シールド層の脱落が生じうる。第１樹脂の表面に存在し、第１樹脂から露出しているフィラーは第１樹脂から脱落し易くなっている場合があり、フィラーが第１樹脂から脱落する事態が生じると、それに伴って当該部分のシールド層が脱落する。
　かかるシールド層の脱落を防止するのが第２樹脂である。第２樹脂は第１樹脂の表面を覆うものである。そして、シールド層は、第２樹脂の表面と、後のダイシングのためのフルカットに先立って行うハーフカット過程によって露出した前記第１樹脂の側面、及び前記基板の側面とに、形成される。上述のように第２樹脂はフィラーを含まない。したがって、このようにして形成されたシールド層は、フィラーの脱落に起因する脱落とは無縁である。なお、この場合であっても、シールド層のうち第１樹脂の側面を被覆する部分は、第２樹脂を介さずに第１樹脂を被覆することになる。しかしながら、通常の方法でハーフカットを行えば、第１樹脂の側面は適度に荒れるので、そこではシールド層が第１樹脂によく密着し、シールド層の脱落は生じにくいことが本願発明者によって確認されている。
　なお、湿式めっきをシールド層の形成に用いた場合には、仮に第２樹脂による層が存在しないとすると、フィラーの脱落によるシールド層の脱落が起こりやすい。本願発明は、モールド回路モジュールを製造する際におけるシールド層の形成の過程に、湿式めっきを選択できるようにするという点でも意味を持つ。 In the first manufacturing method, although not limited to this, a resin containing a filler may be used as the first resin. In that case, the first manufacturing method is a resin containing no filler on the surface of the first resin coated with the substrate after the first coating process and before performing the plating resist layer forming process. A second coating process of covering and curing with two resins, and in the shield layer forming process, a surface of the second resin, a side surface of the first resin exposed by the half-cut process, and a side surface of the substrate In addition, a shield layer, which is a metal layer electrically connected to the grounding electrode, can be formed by applying a paste containing metal powder or plating.
The first resin in the present invention corresponds to the resin contained in the molded circuit module described in the prior art. A filler may be mixed in the first resin. The filler is granular. Further, since the filler is composed of a material having a linear expansion coefficient different from that of the resin constituting the first resin, it suppresses the degree of thermal expansion and contraction of the molded circuit module. Often used in modules.
On the other hand, when the shield layer is formed by applying a paste containing metal powder to the surface of the first resin mixed with the filler or by performing plating, the shield layer may fall off. The filler that is present on the surface of the first resin and is exposed from the first resin may be easily removed from the first resin. When a situation in which the filler is detached from the first resin occurs, Part of the shield layer falls off.
It is the second resin that prevents the shield layer from falling off. The second resin covers the surface of the first resin. The shield layer is formed on the surface of the second resin, the side surface of the first resin exposed by the half-cut process performed prior to the full cut for later dicing, and the side surface of the substrate. As described above, the second resin does not contain a filler. Therefore, the shield layer formed in this way has no connection with the dropout due to the dropout of the filler. Even in this case, the portion of the shield layer that covers the side surface of the first resin covers the first resin without using the second resin. However, if half-cutting is performed by a normal method, the side surface of the first resin is moderately roughened. Therefore, the inventor has confirmed that the shield layer is in close contact with the first resin and the shield layer does not easily fall off. Has been.
In addition, when wet plating is used for the formation of the shield layer, if the layer made of the second resin does not exist, the shield layer is likely to drop due to the filler being dropped. The present invention is also meaningful in that wet plating can be selected in the process of forming a shield layer when manufacturing a molded circuit module.
　第２製法では、これには限られないが、前記第１樹脂として、フィラーを含む樹脂を用いるようにしてもよい。その場合、第２製法は、前記第１被覆過程の後で、前記シールド層形成過程を実行する前に、前記基板を被覆した前記第１樹脂の表面を、フィラーを含まない樹脂である第２樹脂で被覆し硬化させる第２被覆過程を含み、前記シールド層形成過程では、前記第２樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成する、ようにすることができる。
　これによっても、上述の場合と同様に、第２樹脂の存在により、シールド層の脱落を抑制できるようになる。また、第２樹脂を用いることにより、シールド層の形成の過程に、湿式めっきを選択できるようになる。 In the second manufacturing method, although not limited to this, a resin containing a filler may be used as the first resin. In that case, the second manufacturing method is a resin containing no filler on the surface of the first resin covering the substrate after the first covering process and before executing the shield layer forming process. A second coating process in which the resin is coated and cured, and in the shield layer forming process, the surface of the second resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate The shield layer, which is a metal layer that is electrically connected to the grounding electrode, can be formed by applying a paste containing metal powder or by plating.
Also by this, like the above-mentioned case, dropping of the shield layer can be suppressed by the presence of the second resin. Further, by using the second resin, wet plating can be selected in the process of forming the shield layer.
　上述のように、第１製法、第２製法とも、第２樹脂を用いることによりシールド層が第１樹脂から脱落することを抑制できるようになる。もっとも、第２樹脂を用いる場合には、第１樹脂に対して、第２樹脂を介してシールド層を形成するので、第２樹脂が第１樹脂から脱落すると、結果的にシールド層の脱落が生じてしまう。
　第２樹脂の第１樹脂からの脱落を防止するには、第２樹脂の第１樹脂に対する密着性の高さが重要である。この密着性は第１樹脂と第２樹脂の間のアンカー効果、分子間力、若干の共有結合で実現されている。
　第２樹脂の第１樹脂に対する密着性を上げるには、第２樹脂として、前記第１樹脂に主樹脂として含まれる樹脂と同種のものを用いるのが簡単である。なお、本願において「主樹脂」とは、第１樹脂に含まれる樹脂が一種類であればその樹脂を意味し、第１樹脂に複数種類の樹脂が含まれるのであれば、その中で最も重量比で多いものを意味するものとする。
　前記第１樹脂に主樹脂として含まれる樹脂がエポキシ樹脂である場合、前記第２樹脂は、エポキシ樹脂とすることができる。これにより、第１樹脂と第２樹脂の密着性は、実用性に足る程度に大きくなる。
　なお、第２樹脂は上述のように、第１樹脂の一方の面の少なくともシールド層で被覆される部分を被覆する。第２樹脂の厚さは、例えば、第１樹脂から露出するフィラーを被覆することでフィラーの第１樹脂からの脱落を防ぐことができ、且つ第２樹脂の強度を維持できる範囲で薄くするのが良い。第２樹脂の層を薄くすることは、次工程での粗化が容易であるという理由により、シールド層をめっきにより形成する場合に有利である。例えば、第２樹脂による層は、第１樹脂の表面の凹凸形状を埋めない程度に薄くするのが良い。 As described above, in both the first manufacturing method and the second manufacturing method, it is possible to prevent the shield layer from dropping from the first resin by using the second resin. However, when the second resin is used, a shield layer is formed on the first resin via the second resin. Therefore, when the second resin is dropped from the first resin, the shield layer is eventually dropped. It will occur.
In order to prevent the second resin from falling off from the first resin, the high adhesion of the second resin to the first resin is important. This adhesion is realized by an anchor effect between the first resin and the second resin, an intermolecular force, and a slight covalent bond.
In order to increase the adhesion of the second resin to the first resin, it is easy to use the same type of resin as the second resin that is contained in the first resin as the main resin. In addition, in this application, "main resin" means the resin if the resin contained in the first resin is one kind, and if the first resin contains a plurality of kinds of resins, the most weight among them. It means something that is more in ratio.
When the resin contained as the main resin in the first resin is an epoxy resin, the second resin can be an epoxy resin. Thereby, the adhesiveness of 1st resin and 2nd resin becomes large to such an extent that it is practical.
In addition, as above-mentioned, 2nd resin coat | covers the part coat | covered with at least a shield layer of one side of 1st resin. For example, the thickness of the second resin is reduced within a range in which the filler exposed from the first resin can be prevented from falling off the first resin and the strength of the second resin can be maintained. Is good. Thinning the second resin layer is advantageous when the shield layer is formed by plating because it is easy to roughen in the next step. For example, the layer made of the second resin is preferably thin enough not to fill the uneven shape on the surface of the first resin.
　第１製法、第２製法のいずれにおいても、前記第１被覆過程を実行した後に、硬化した前記第１樹脂の表面を、その表面が前記基板の前記一方の面と平行となるように削る第１樹脂成形過程を実行することが可能である。
　モールド回路モジュールに複数の電子部品が実装される場合、当然に各電子部品の背の高さが異なる場合がある。その場合第１樹脂の表面に凹凸ができることがあり得る。硬化した前記第１樹脂の表面を、その表面が前記基板の前記一方の面と平行となるように削る第１樹脂成形過程を実行することにより、最も背の高い電子部品の上に存在する第１樹脂の厚さを必要な限度を保ちつつではあるが、小さくすることができるから、これによりモールド回路モジュールの厚さを小さくすることができる。なお、第１樹脂の基板への塗布を行う際にも、最も背の高い電子部品の上に存在する第１樹脂の厚さをある程度制御することができるが、かかる制御はその精度が低い。第１樹脂成形過程では、例えば機械的な切削により、最も背の高い電子部品の上に存在する第１樹脂の厚さを制御することになるが、その場合にはその精度は一般に、±３５μｍ程度とすることができる。通常、最も背の高い電子部品の上に存在する第１樹脂の厚さは、５００μｍ程度より薄くすることができなかったが、第１樹脂成形過程を加えることにより、その厚さを、１００μｍ以下、場合によっては８０μｍ程度にまで薄くすることも可能となる。
　なお、第１樹脂成形過程を実行すると、硬化した第１樹脂の中に存在するフィラーが脱落し易い状態となる場合もある。しかしながら、その後に第２被覆過程を実行することにより、第１樹脂の表面を第２樹脂で被覆することにすれば、それでもなお、フィラーの脱落に起因するシールド層の脱落を抑制することができる。 In either of the first manufacturing method and the second manufacturing method, after performing the first coating process, the surface of the cured first resin is shaved so that the surface is parallel to the one surface of the substrate. It is possible to perform one resin molding process.
When a plurality of electronic components are mounted on the molded circuit module, naturally the height of each electronic component may be different. In that case, the surface of the first resin may be uneven. By performing a first resin molding process in which the surface of the cured first resin is cut so that the surface is parallel to the one surface of the substrate, the first resin existing on the tallest electronic component is obtained. Although the thickness of one resin can be reduced while maintaining the necessary limit, the thickness of the molded circuit module can be reduced by this. In addition, when applying the first resin to the substrate, the thickness of the first resin existing on the tallest electronic component can be controlled to some extent, but such control has low accuracy. In the first resin molding process, the thickness of the first resin existing on the tallest electronic component is controlled by, for example, mechanical cutting. In that case, the accuracy is generally ± 35 μm. Can be about. Normally, the thickness of the first resin existing on the tallest electronic component could not be made thinner than about 500 μm, but by adding the first resin molding process, the thickness is reduced to 100 μm or less. In some cases, the thickness can be reduced to about 80 μm.
In addition, when the first resin molding process is executed, the filler present in the cured first resin may easily fall off. However, if the surface of the first resin is coated with the second resin by performing the second coating process after that, it is still possible to suppress the shield layer from falling off due to the filler falling off. .
　第１被覆過程において、基板の前記一方の全面を、前記電子部品ごと、フィラーを含む樹脂である第１樹脂で被覆する際には、どのような方法でそれを実行しても良い。その際には、例えば、真空印刷法を用いることができる。
　真空印刷法を用いれば、硬化後の第１樹脂の中に微小な気泡が生じることを防ぐことができ、様々な形状を持つ電子部品を、隙間なく第１樹脂で被覆できるようになる。
　という利点はあるものの、第１被覆過程で真空印刷を用いる場合には、基板に取付けられる部品の上に存在する樹脂層の厚みが薄いと、電子部品の高さの違いに起因する凹凸が、第１樹脂の表面にどうしても現れてしまう。これを避けるために、真空印刷を用いる場合には、電子部品の上に位置する第１樹脂の厚さに余裕を持たせることが必要になるが、これは結果として完成したモールド回路モジュールの厚みが大きくなるという欠点につながる。第１樹脂成形過程を行えば、これを解決することができるため、第１樹脂成形過程は、真空印刷と非常に相性が良く、モールド回路モジュールの製造に真空印刷を使用できるようにするための技術であるととらえることもできる。 In the first coating process, when the entire one surface of the substrate is coated with the first resin, which is a resin containing a filler, together with the electronic component, it may be performed by any method. In that case, for example, a vacuum printing method can be used.
If the vacuum printing method is used, it is possible to prevent the formation of minute bubbles in the cured first resin, and it becomes possible to cover electronic parts having various shapes with the first resin without any gaps.
Although there is an advantage, when using vacuum printing in the first coating process, if the thickness of the resin layer present on the component attached to the substrate is thin, the unevenness caused by the difference in height of the electronic component, It always appears on the surface of the first resin. In order to avoid this, when using vacuum printing, it is necessary to provide a margin for the thickness of the first resin located on the electronic component, which results in the thickness of the completed molded circuit module. Leads to the disadvantage of becoming larger. Since the first resin molding process can solve this problem, the first resin molding process is very compatible with vacuum printing, and can be used for manufacturing a molded circuit module. It can also be regarded as technology.
　第１樹脂には、電子部品の間に入り込むための充填性（これは硬化前の特性である。）と、電子部品或いは基板との密着性と、反りを生じない特性（これらは硬化後の特性である。）の３つが求められる。
　第１樹脂が、上述の特性を満たすには、以下のような特性を有するのが良い。下記特性を有する第１樹脂であれば、硬化前、硬化後の第１樹脂がともに上述の特性を充足する。
　第１樹脂が満たすべき特性は、硬化前の特性として、フィラーを含む第１樹脂の全量に対するフィラーの比率が重量比で８０％以上、硬化後の特性として、線膨張係数（α１）が１１ｐｐｍ／ＴＭＡ以下、線膨張係数（α２）が２５ｐｐｍ／ＴＭＡ以下、２５℃弾性率が１５ＧＰａ／ＤＭＡ以上である。
　第１樹脂に求められる特性のうち、充填性の高さは、完成したモールド回路モジュールの厚さを小さくすることに寄与する。電子部品の下側と、基板との間には通常隙間が存在する。かかる隙間は、その隙間に第１樹脂が充填できる程度に大きくなるように設計せざるを得ない。ここで、第１樹脂の充填性が高ければ、電子部品の下側と基板との隙間を小さくできる。それにより、モールド回路モジュールの厚さを小さくすることができるのである。上述の特性を持つ樹脂を用いた場合には、電子部品の下側と基板との隙間を３０μｍまで小さく（一般には１５０～２００μｍである。）することができる。 The first resin has a filling property for entering between electronic components (this is a property before curing), adhesion to the electronic component or substrate, and a property that does not cause warping (these are properties after curing). 3) is required.
In order for the first resin to satisfy the above-described characteristics, it is preferable to have the following characteristics. If it is the 1st resin which has the following characteristic, the 1st resin before hardening after hardening will satisfy the above-mentioned characteristic.
The characteristics to be satisfied by the first resin are the ratio of the filler with respect to the total amount of the first resin including the filler in a weight ratio of 80% or more as a characteristic before curing, and the linear expansion coefficient (α1) as a characteristic after curing is 11 ppm / TMA or less, linear expansion coefficient (α2) is 25 ppm / TMA or less, and 25 ° C. elastic modulus is 15 GPa / DMA or more.
Among the characteristics required for the first resin, the high filling property contributes to reducing the thickness of the completed molded circuit module. There is usually a gap between the underside of the electronic component and the substrate. Such a gap must be designed to be large enough to fill the gap with the first resin. Here, if the filling property of the first resin is high, the gap between the lower side of the electronic component and the substrate can be reduced. Thereby, the thickness of the molded circuit module can be reduced. When a resin having the above-described characteristics is used, the gap between the lower side of the electronic component and the substrate can be reduced to 30 μm (generally 150 to 200 μm).
本願発明の一実施形態によるモールド回路モジュールの製造方法で使用される基板の構成を示す側断面図。The sectional side view which shows the structure of the board | substrate used with the manufacturing method of the mold circuit module by one Embodiment of this invention. 図１（ａ）に示した基板に電子部品を実装した状態を示す側断面図。FIG. 2 is a side sectional view showing a state in which electronic components are mounted on the substrate shown in FIG. 図１（ｂ）に示した基板にパーテーション部材を取付けた状態を示す側断面図。The sectional side view which shows the state which attached the partition member to the board | substrate shown in FIG.1 (b). 図１（ｃ）に示した基板を部品ごと第１樹脂で被覆して、第１樹脂を硬化させた状態を示す側断面図。The side sectional view showing the state where the substrate shown in Drawing 1 (c) was covered with the 1st resin together with the part, and the 1st resin was hardened. 図１（ｄ）に示した第１樹脂のうち除去される範囲を示すための側断面図。The sectional side view for showing the range removed among the 1st resin shown in Drawing 1 (d). 図１（ｅ）に示した第１樹脂のうち除去されるべき部分が除去された状態を示す側断面図。The sectional side view which shows the state from which the part which should be removed among the 1st resin shown in FIG.1 (e) was removed. 図１（ｆ）に示した第１樹脂の上面を第２樹脂で被覆し、第２樹脂を硬化させた状態を示す側断面図。The sectional side view which shows the state which coat | covered the upper surface of 1st resin shown in FIG.1 (f) with 2nd resin, and hardened 2nd resin. 第１実施形態のモールド回路モジュールの製造方法において、第２樹脂の上にマスクを重ねた状態を示す側断面図。The sectional side view which shows the state which accumulated the mask on 2nd resin in the manufacturing method of the mold circuit module of 1st Embodiment. 図１（ｈ）に示したマスクの上からめっきレジストを塗布した状態を示す側断面図。The sectional side view which shows the state which apply | coated the plating resist from the mask shown in FIG.1 (h). 図１（ｉ）に示したマスクを除去した状態を示す側断面図。The sectional side view which shows the state which removed the mask shown in FIG.1 (i). 図１（ｊ）に示した基板にハーフカットの処理を行った後の状態を示す側断面図。FIG. 2 is a side sectional view showing a state after a half-cut process is performed on the substrate shown in FIG. 図１（ｋ）に示した基板に対してシールド層を設けた状態を示す側断面図。FIG. 2 is a side sectional view showing a state in which a shield layer is provided on the substrate shown in FIG. 図１（ｌ）に示した基板に対してフルカットの処理・めっきレジスト除去を行った状態を示す側断面図。FIG. 2 is a side sectional view showing a state where a full cut process and plating resist removal are performed on the substrate shown in FIG. 第１実施形態のモールド回路モジュールの製造方法で用いられるパーテーション部材の構成を示す斜視図。The perspective view which shows the structure of the partition member used with the manufacturing method of the mold circuit module of 1st Embodiment. 第１実施形態のモールド回路モジュールの製造方法で用いられる他のパーテーション部材の構成を示す平面図、左側面図、及び正面図。The top view which shows the structure of the other partition member used with the manufacturing method of the mold circuit module of 1st Embodiment, a left view, and a front view. 第１実施形態のモールド回路モジュールの製造方法で用いられる他のパーテーション部材の構成を示す平面図、左側面図、及び正面図。The top view which shows the structure of the other partition member used with the manufacturing method of the mold circuit module of 1st Embodiment, a left view, and a front view. 第１実施形態のモールド回路モジュールの製造方法で用いられる他のパーテーション部材の構成を示す平面図、左側面図、及び正面図。The top view which shows the structure of the other partition member used with the manufacturing method of the mold circuit module of 1st Embodiment, a left view, and a front view. 第１実施形態のモールド回路モジュールの製造方法で用いられる真空印刷法の原理を示す側面図。The side view which shows the principle of the vacuum printing method used with the manufacturing method of the mold circuit module of 1st Embodiment. 第１実施形態のモールド回路モジュールの製造方法によって得られるシールド層の構成の一例を示す側断面図。The sectional side view which shows an example of a structure of the shield layer obtained by the manufacturing method of the mold circuit module of 1st Embodiment. 第１実施形態によるモールド回路モジュールの製造方法によって得られるモールド回路モジュールの側断面図。The sectional side view of the mold circuit module obtained by the manufacturing method of the mold circuit module by 1st Embodiment. 第１実施形態によるモールド回路モジュールの製造方法によって得られるモールド回路モジュールの透視平面図。The perspective top view of the mold circuit module obtained by the manufacturing method of the mold circuit module by 1st Embodiment. 第２実施形態のモールド回路モジュールの製造方法において、第１樹脂の上面を第２樹脂で被覆し、第２樹脂を硬化させた状態を示す側断面図。In the manufacturing method of the mold circuit module of a 2nd embodiment, the side sectional view showing the state where the upper surface of the 1st resin was covered with the 2nd resin, and the 2nd resin was hardened. 図７（ａ）に示した基板にハーフカットの処理を行った後の状態を示す側断面図。FIG. 8 is a side sectional view showing a state after a half-cut process is performed on the substrate shown in FIG. 図７（ｂ）に示した基板に対してシールド層を設けた状態を示す側断面図。FIG. 8 is a side sectional view showing a state in which a shield layer is provided on the substrate shown in FIG. 図７（ｃ）に示した基板における盛上部を除去し、基板に対してフルカットの処理を行った状態を示す側断面図。FIG. 8 is a side cross-sectional view showing a state in which the top of the substrate shown in FIG.
　以下、図面を参照しつつ、本発明のモールド回路モジュールの製造方法の好ましい第１及び第２実施形態を説明する。
　各実施形態の説明において、共通する対象には共通する符号を付すものとする。また、共通する説明は、場合により省略するものとする。 Hereinafter, preferred first and second embodiments of a method for producing a molded circuit module of the present invention will be described with reference to the drawings.
In the description of each embodiment, common objects are denoted by common reference numerals. In addition, common explanation is omitted depending on circumstances.
≪第１実施形態≫
　第１実施形態では、図１（ａ）に示した基板１００を用いて、モールド回路モジュールを製造する。
　基板１００は極一般的なもので良く、この実施形態の基板１００も極一般的なものである。基板１００は、図示を省略の配線を備えている。配線は、後述する電子部品に対して導通させられ、電子部品に給電を行うものであり、公知或いは周知のものである。それが可能なように配線は設計されている。配線はどのような方法で基板１００に設けられたものでも良く、基板１００のどこに設けられていても良い。配線は例えば、基板１００の表面に印刷で設けられていても良い。その場合の基板１００は、プリント配線基板と一般的に称されるものとなる。配線はまた、基板１００の内部に存在する場合もある。
　平面視した場合における基板１００の形状は例えば矩形である。もっとも基板１００の形状は、後述するようにしてモールド回路モジュールを多数個取りする場合に無駄が少なくなるような形状として、適宜設定されるのが通常である。
　基板１００の適当な位置には、接地用電極１１０が設けられている。接地用電極１１０は、そのすべての部分、或いはその一部が基板１００の内部に存在する場合もあり、そのすべての部分、或いはその一部が基板１００のいずれかの表面に存在する場合もある。この実施形態では、接地用電極１１０は、基板１００の内部の適当な深さに、層状に存在するものとする。接地用電極１１０は、完成したモールド回路モジュールが使用されるときに、後述するシールド層を、接地用電極１１０を介して接地するために用いられる。接地用電極１１０は、それが可能となるように設計されている。
　この実施形態で説明するモールド回路モジュールの製造方法では、１枚の基板１００から多数のモールド回路モジュールを製造する。つまり、この実施形態では、１枚の基板１００からモールド回路モジュールを、所謂多数個取りする。基板１００は、仮想の隣接する多数の区画１２０に区分されており、各区画１２０から１つのモールド回路モジュールが製造されることになる。各区画１２０から製造されるモールド回路モジュールは必ずしも同じものとする必要はないが、通常は同じものである。各区画１２０から製造されるモールド回路モジュールが同じものである場合、各区画１２０は同じ大きさであり、各区画１２０には同じパターンで、配線と、接地用電極１１０とが設けられている。これには限られないが、この実施形態では、各区画１２０から製造されるモールド回路モジュールは同じものであるものとする。 << First Embodiment >>
In the first embodiment, a molded circuit module is manufactured using the substrate 100 shown in FIG.
The substrate 100 may be extremely general, and the substrate 100 of this embodiment is also extremely general. The substrate 100 includes wiring not shown. The wiring is electrically connected to an electronic component, which will be described later, and supplies power to the electronic component, and is known or known. The wiring is designed so that it is possible. The wiring may be provided on the substrate 100 by any method, and may be provided anywhere on the substrate 100. For example, the wiring may be provided on the surface of the substrate 100 by printing. In this case, the substrate 100 is generally called a printed wiring board. The wiring may also exist inside the substrate 100.
The shape of the substrate 100 in plan view is, for example, a rectangle. However, the shape of the substrate 100 is normally set as appropriate so as to reduce waste when a large number of molded circuit modules are taken as described later.
A ground electrode 110 is provided at an appropriate position on the substrate 100. The grounding electrode 110 may be all or part of the ground electrode 110 inside the substrate 100, or may be all or part of the ground electrode 110 on any surface of the substrate 100. . In this embodiment, it is assumed that the grounding electrode 110 exists in layers at an appropriate depth inside the substrate 100. The ground electrode 110 is used for grounding a shield layer, which will be described later, via the ground electrode 110 when the completed molded circuit module is used. The grounding electrode 110 is designed so that it is possible.
In the method for manufacturing a molded circuit module described in this embodiment, a large number of molded circuit modules are manufactured from one substrate 100. That is, in this embodiment, so-called many molded circuit modules are taken from one substrate 100. The substrate 100 is divided into a large number of virtual adjacent sections 120, and one molded circuit module is manufactured from each section 120. The molded circuit modules produced from each compartment 120 are not necessarily the same, but are usually the same. When the molded circuit modules manufactured from each section 120 are the same, each section 120 has the same size, and each section 120 is provided with wiring and a ground electrode 110 in the same pattern. Although not restricted to this, in this embodiment, the mold circuit module manufactured from each division 120 shall be the same.
　モールド回路モジュールを製造するには、まず、図１（ｂ）に示したようにして、上述の基板１００の一方の面（この実施形態では、図１（ｂ）の上側の面）に対して、電子部品２００を取付ける。電子部品２００はすべて既存のものでよく、例えば、ＩＣ（ｉｎｔｅｇｒａｔｅｄ ｃｉｒｃｕｉｔ：集積回路）増幅器、発振器、検波器、送受信器等の能動素子或いは抵抗、コンデンサ、コイル等の受動素子であり、必要に応じて選択される。この実施形態の電子部品２００には、少なくとも一つの通信器が含まれる。通信器は、この製法で作られるモールド回路モジュール外の機器と無線の通信を行うものであり、送信、受信、或いはその双方を行うものである。
　電子部品２００は、それらが持つ図示せぬ端子を、各区画１２０の配線に導通させるようにして、各区画１２０に取付けられる。この実施形態では各区画１２０から同じモールド回路モジュールが得られるのであるから、各区画１２０に実装される電子部品２００は同じものとされる。電子部品２００の各区画１２０への取付け方は、公知或いは周知の技術を用いれば良いので、詳しい説明は省略する。
　電子部品２００の下側と基板１００との隙間は、通常より小さく、例えば３０μｍ程度であっても良い。 To manufacture a molded circuit module, first, as shown in FIG. 1B, with respect to one surface of the substrate 100 described above (in this embodiment, the upper surface of FIG. 1B). The electronic component 200 is attached. All of the electronic components 200 may be existing ones, for example, active elements such as IC (integrated circuit) amplifiers, oscillators, detectors, and transceivers or passive elements such as resistors, capacitors, and coils. Selected. The electronic component 200 of this embodiment includes at least one communication device. The communication device performs wireless communication with a device outside the molded circuit module manufactured by this manufacturing method, and performs transmission, reception, or both.
The electronic component 200 is attached to each compartment 120 such that terminals (not shown) of the electronic component 200 are electrically connected to the wiring of each compartment 120. In this embodiment, since the same molded circuit module is obtained from each section 120, the electronic components 200 mounted on each section 120 are the same. Since how to attach the electronic component 200 to each section 120 may be a known or well-known technique, detailed description thereof is omitted.
A gap between the lower side of the electronic component 200 and the substrate 100 is smaller than usual, and may be, for example, about 30 μm.
　次いで、この実施形態では、必ずしも必要ではないが、パーテーション部材３００を基板１００に取付ける（図１（ｃ））。パーテーション部材３００は、モールド回路モジュールの中にパーテーションを作るための部材である。パーテーションは、モールド回路モジュール内の電子部品２００が作る電磁波が、そのモールド回路モジュール内の他の電子部品２００に与える影響を低減することを目的とする。なお、パーテーション部材３００は、以下のような事情が存在するとき等に必要に応じて使用すれば良いものであり、必須のものではない。
　例えば、この実施形態では、図１（ｃ）に示した電子部品２００Ａが高周波発振器である場合、電子部品２００Ａからは強い電磁波が発せられる。そのような場合であり、且つ電子部品２００Ａの周囲の電子部品２００が、強い電磁波によって、その本来の機能に対してノイズを生じさせるようなものである場合には、他の電子部品２００を電子部品２００Ａが作る電磁波から守る必要がある。或いは、電子部品２００Ａが特に、他の電子部品２００が作る電磁波の影響を受けやすいものであることも考えられ、そのような場合には、電子部品２００Ａを他の電子部品２００が作る電磁波から守る必要がある。いずれの場合においても、電子部品２００Ａと他の電子部品２００との間で電磁波を遮蔽するのが良い。それを可能とするのがパーテーション部材３００によって作られるパーテーションである。
　パーテーション部材３００は、電磁波を遮蔽するべく導電性を持つ金属でできており、製造されたモールド回路モジュールにおいて、直接的に、或いは、後述するシールド層を介して、接地用電極１１０に導通するようになっている。パーテーション部材３００は、パーテーション部材３００によって作られるパーテーション単独で、或いはパーテーション部材３００によって作られるパーテーションと後述するシールド層によって、基板１００を平面視した場合におけるある電子部品２００（必ずしも、１つのみとは限らない。）を、囲むことができるような形状として設計される。
　これには限られないが、この実施形態におけるパーテーション部材３００は、図２（ａ）に示したような形状をしている。このパーテーション部材３００は、平面視したときに三角形、より詳細には直角三角形である天井部３１０と、天井部３１０の斜辺以外の２辺の下に接続され、且つそれらの隣接する一辺が互いに接続された矩形の側壁部３２０とからなる。この実施形態におけるパーテーション部材３００によって作られるパーテーションは、モールド回路モジュールの完成時においては、シールド層と導通するようになっている。例えば、パーテーション部材３００によって作られるパーテーションは、モールド回路モジュールが完成した際には、モールド回路モジュールの側面において、２つの側壁部３２０の互いに接続された辺と対向する辺がシールド層と当接することによって導通するようになっている。なお、この点については後述する。
　パーテーション部材３００の基板１００への取付け方はどのようにして行っても良い。例えば、接着によって、パーテーション部材３００を基板１００へ取付けることができる。パーテーション部材３００の例えば下端を、接地用電極１１０に導通させるのであれば、接地用電極１１０とパーテーション部材３００とをそのように設計するとともに、公知の導電性接着剤等で、接地用電極１１０とパーテーション部材３００とを接着すれば良い。例えば、当初から基板１００の表面から露出していた、或いは基板１００の表面を削り取ることにより基板１００から露出させられた接地用電極１１０に、パーテーション部材３００の側壁部３２０の下端を接触させ、導通させることができる。
　なお、パーテーション部材３００は、結果として、接地用電極１１０に導通していれば良い。換言すれば、パーテーション部材３００は、直接、接地用電極１１０に接触していても良いし、他の導電性の金属（例えばシールド層）を介して間接的に接地用電極１１０に接触していても良い。そして当然に、これらのうちの一方が達成されているのであれば、その他方は達成されている必要はない。
　パーテーション部材３００の他の例を、図２（ｂ）、（ｃ）、（ｄ）に示す。図２（ｂ）、（ｃ）、（ｄ）においては、パーテーション部材３００の平面図と、その左側に左側面図と、その下側に正面図とが描かれている。各図において示されたパーテーション部材３００は、それぞれ、天井部３１０と、側壁部３２０とを備えている。図２（ｂ）、（ｃ）、（ｄ）で示されたパーテーション部材３００の天井部３１０には、開口である複数の天井孔３１１が穿たれている。この天井孔３１１は、第１樹脂４００充填の際に第１樹脂４００をパーテーション部材３００の内側に流入させるための孔であり、硬化後にはパーテーション部材３００と第１樹脂４００との剥離を防止する役割を担うものである。また、図２（ｄ）で示されたパーテーション部材３００の側壁部３２０には、開口である複数の側壁孔３２１が穿たれている。この側壁孔３２１は、第１樹脂４００の硬化後にはパーテーション部材３００と第１樹脂４００との剥離を防止する役割を担う。 Next, in this embodiment, although not necessarily required, the partition member 300 is attached to the substrate 100 (FIG. 1C). The partition member 300 is a member for creating a partition in the molded circuit module. The purpose of partitioning is to reduce the influence of electromagnetic waves generated by the electronic component 200 in the molded circuit module on other electronic components 200 in the molded circuit module. The partition member 300 may be used as necessary when the following circumstances exist, and is not essential.
For example, in this embodiment, when the electronic component 200A shown in FIG. 1C is a high-frequency oscillator, a strong electromagnetic wave is emitted from the electronic component 200A. In such a case and when the electronic component 200 around the electronic component 200A is such that strong electromagnetic waves cause noise to its original function, the other electronic component 200 is replaced with an electronic component. It is necessary to protect from electromagnetic waves generated by the component 200A. Alternatively, it is conceivable that the electronic component 200A is particularly susceptible to electromagnetic waves produced by other electronic components 200. In such a case, the electronic component 200A is protected from electromagnetic waves produced by the other electronic components 200. There is a need. In any case, it is preferable to shield electromagnetic waves between the electronic component 200 </ b> A and the other electronic component 200. This is made possible by the partition made by the partition member 300.
The partition member 300 is made of a metal having conductivity so as to shield electromagnetic waves. In the manufactured molded circuit module, the partition member 300 is electrically connected to the ground electrode 110 directly or via a shield layer described later. It has become. The partition member 300 is an electronic component 200 (not necessarily only one) when the substrate 100 is viewed in plan by a partition made by the partition member 300 alone or by a partition made by the partition member 300 and a shield layer described later. It is designed as a shape that can be enclosed.
Although not limited to this, the partition member 300 in this embodiment has a shape as shown in FIG. The partition member 300 is connected to a ceiling 310 that is a triangle when viewed in plan, more specifically a right triangle, and two sides other than the oblique sides of the ceiling 310, and adjacent ones thereof are connected to each other. The rectangular side wall portion 320 is formed. The partition made by the partition member 300 in this embodiment is electrically connected to the shield layer when the molded circuit module is completed. For example, in the partition made by the partition member 300, when the molded circuit module is completed, the side of the side surface of the molded circuit module facing the side where the two side wall portions 320 are connected to each other comes into contact with the shield layer. It is supposed to be conducted by. This point will be described later.
The partition member 300 may be attached to the substrate 100 in any manner. For example, the partition member 300 can be attached to the substrate 100 by bonding. For example, if the lower end of the partition member 300 is electrically connected to the grounding electrode 110, the grounding electrode 110 and the partitioning member 300 are designed as such, and the grounding electrode 110 and the grounding electrode 110 can be connected with a known conductive adhesive or the like. What is necessary is just to adhere | attach the partition member 300. FIG. For example, the lower end of the side wall portion 320 of the partition member 300 is brought into contact with the grounding electrode 110 that has been exposed from the beginning of the substrate 100 or exposed from the substrate 100 by scraping the surface of the substrate 100. Can be made.
The partition member 300 only needs to be electrically connected to the ground electrode 110 as a result. In other words, the partition member 300 may be in direct contact with the grounding electrode 110 or indirectly in contact with the grounding electrode 110 via another conductive metal (for example, a shield layer). Also good. And of course, if one of these is achieved, the other need not be achieved.
Other examples of the partition member 300 are shown in FIGS. 2B, 2C, and 2D. 2B, 2C, and 2D, a plan view of the partition member 300, a left side view on the left side, and a front view on the lower side are illustrated. Each partition member 300 shown in each figure includes a ceiling portion 310 and a side wall portion 320. A plurality of ceiling holes 311 which are openings are formed in the ceiling portion 310 of the partition member 300 shown in FIGS. 2B, 2C, and 2D. The ceiling hole 311 is a hole for allowing the first resin 400 to flow inside the partition member 300 when the first resin 400 is filled, and prevents the partition member 300 and the first resin 400 from being separated after curing. It plays a role. Also, a plurality of side wall holes 321 that are openings are formed in the side wall portion 320 of the partition member 300 shown in FIG. The side wall holes 321 serve to prevent the partition member 300 and the first resin 400 from being separated after the first resin 400 is cured.
　次いで、電子部品２００と必要に応じてパーテーション部材３００とが取付けられた基板１００の上記一方の面の全面を、電子部品２００とパーテーション部材３００ごと、第１樹脂４００で被覆し、第１樹脂４００を硬化させる（図１（ｄ））。
　第１樹脂４００で基板１００の一方の面の全面を被覆するには、モールド、ポッティング等の樹脂封止法を用いることができるが、この実施形態では、真空印刷法を用いることとしている。真空印刷法によれば、モールドされた第１樹脂４００の内部に細かな気泡が混入することを防ぐことができ、また細かな気泡を除くための脱泡の過程を省略することができる。
　真空印刷法は、公知の真空印刷機を用いて実施することができる。公知の真空印刷機としては、東レエンジニアリング株式会社が製造・販売する真空印刷封止装置であるVE５００（商標）を例示することができる。
　真空印刷法の原理について、図３を用いて簡単に述べる。真空印刷法を実施する際には、基板１００を例えば金属製のマスクであるメタルマスク４５０の間に置く。そして、硬化していない状態の第１樹脂４００を供給しながら棒状の、図３においては紙面に垂直な方向がその長さ方向となるスキージ４６０を、図３（ａ）に示した一方側のメタルマスク４５０の上に位置する位置から、他方側のメタルマスク４５０に向けて、同図の（ｂ）で矢視したしたようにして、移動させる。第１樹脂４００は、スキージ４６０の下面でその上面を均され、電子部品２００の間に入り込みつつ、基板１００の表面を隙間なく覆っていく。真空印刷法は、基板１００、メタルマスク４５０、スキージ４６０のすべてを真空を引いた図示せぬ真空チャンバの中に入れた状態で実行される。それ故、第１樹脂４００の中に気泡が入り込む余地がない。なお、スキージ４６０を、図３に示したように移動させる場合、スキージ４６０の基板１００からの距離ないし高さは通常、一定である。
　基板１００を被覆した第１樹脂４００は、適当な時間を置くことで硬化させられる。
　なお、パーテーション部材３００の天井部３１０には天井孔３１１が設けられており、また、パーテーション部材３００の側壁部３２０には側壁孔３２１が設けられている場合がある。硬化前の第１樹脂４００は、それらから、パーテーション部材３００の内部に入り込む。
　図２（ｄ）で示されたパーテーション部材３００の側壁部３２０に設けられた側壁孔３２１は、第１樹脂４００が側壁孔３２１の中に回り込んだ状態で硬化することで、パーテーション部材３００と第１樹脂４００とがより良く固定されるようにする機能を発揮する。第１樹脂４００の上部を削りとる後述の処理を行った場合でも第１樹脂４００の中にパーテーション部材３００の天井部３１０が残る場合においては、天井部３１０の天井孔３１１も、同様の機能を持つことになる。 Next, the entire surface of the one surface of the substrate 100 on which the electronic component 200 and, if necessary, the partition member 300 are attached, is covered with the first resin 400 together with the electronic component 200 and the partition member 300, and the first resin 400. Is cured (FIG. 1 (d)).
In order to cover the entire surface of one surface of the substrate 100 with the first resin 400, a resin sealing method such as molding or potting can be used. In this embodiment, a vacuum printing method is used. According to the vacuum printing method, it is possible to prevent fine bubbles from being mixed into the molded first resin 400, and it is possible to omit the defoaming process for removing the fine bubbles.
The vacuum printing method can be performed using a known vacuum printing machine. As a known vacuum printer, VE500 (trademark) which is a vacuum printing sealing device manufactured and sold by Toray Engineering Co., Ltd. can be exemplified.
The principle of the vacuum printing method will be briefly described with reference to FIG. When performing the vacuum printing method, the substrate 100 is placed between, for example, a metal mask 450 which is a metal mask. Then, a squeegee 460 that is rod-shaped while supplying the first resin 400 in an uncured state and whose length direction is perpendicular to the paper surface in FIG. 3 is shown on the one side shown in FIG. It moves from the position located on the metal mask 450 toward the metal mask 450 on the other side as viewed in FIG. The upper surface of the first resin 400 is leveled by the lower surface of the squeegee 460 and covers the surface of the substrate 100 without any gap while entering between the electronic components 200. The vacuum printing method is performed in a state where the substrate 100, the metal mask 450, and the squeegee 460 are all placed in a vacuum chamber (not shown) in which a vacuum is drawn. Therefore, there is no room for bubbles to enter the first resin 400. When the squeegee 460 is moved as shown in FIG. 3, the distance or height of the squeegee 460 from the substrate 100 is usually constant.
The first resin 400 covering the substrate 100 is cured by setting an appropriate time.
In some cases, a ceiling hole 311 is provided in the ceiling part 310 of the partition member 300, and a side wall hole 321 is provided in the side wall part 320 of the partition member 300. The first resin 400 before curing enters the partition member 300 from them.
The side wall hole 321 provided in the side wall part 320 of the partition member 300 shown in FIG. 2D is hardened in a state where the first resin 400 wraps around the side wall hole 321, so that the partition member 300 The function of fixing the first resin 400 better is exhibited. Even when the below-described process of scraping the upper portion of the first resin 400 is performed, when the ceiling portion 310 of the partition member 300 remains in the first resin 400, the ceiling hole 311 of the ceiling portion 310 also has the same function. Will have.
　第１樹脂４００には、電子部品２００の間に入り込むための充填性（これは硬化前の特性である。）と、電子部品２００或いは基板１００との密着性と、反りを生じない特性（これらは硬化後の特性である。）の３つが求められる。
　これら特性を第１樹脂４００が有するためには、第１樹脂４００は、以下のような特性を有するのが良い。下記特性を有する第１樹脂４００であれば、硬化前、硬化後の第１樹脂がともに上述の特性を充足する。
　満たされるのが好ましい第１樹脂４００の特性は、硬化前の特性についていえば、フィラーを含む第１樹脂の全量に対するフィラーの比率が重量比で８０％以上、硬化後の特性についていえば、線膨張係数（α１）が１１ｐｐｍ／ＴＭＡ以下、線膨張係数（α２）が２５ｐｐｍ／ＴＭＡ以下、２５℃弾性率が１５ＧＰａ／ＤＭＡ以上である。
　なお、上記の特性を充足する第１樹脂４００の例としては、パナソニック株式会社が製造・販売を行う、樹脂組成物（品番：ＣＶ５３８５（商標））を挙げることができる。これら樹脂組成物には、シリカ（フィラーとして）、エポキシ樹脂、硬化剤、改質剤等が含まれている。樹脂組成物には１種類の樹脂しか含まれていない。したがって、第１樹脂４００の本願で言う主樹脂は、エポキシ樹脂である。
　上述の通り第１樹脂４００には、フィラーが含まれているが、上述の樹脂組成物（品番：ＣＶ５３８５）には、フィラーが含まれている。また、これら樹脂組成物に含まれるフィラーの量は、第１樹脂４００の全体に対して、重量比で８０％以上となる８３％である。フィラーは、線膨張係数が小さい素材でできており、通常はシリカによりできている。また、フィラーは、第１樹脂４００の充填性を満足するために、その粒径は３０μｍ以下とするのがよい。例示した上述の２つの樹脂組成物に含まれるフィラーは、いずれもこれらの条件を満足している。
　また、例示した上述の樹脂組成物の硬化後の線膨張係数（α１）は１１ｐｐｍ／ＴＭＡ、硬化後の線膨張係数（α２）は２５ｐｐｍ／ＴＭＡ、硬化後の２５℃弾性率は１５ＧＰａ／ＤＭＡであり、上述した好ましい条件を充足している。 The first resin 400 has a filling property for entering between the electronic components 200 (this is a property before curing), adhesion with the electronic component 200 or the substrate 100, and a property that does not cause warping (these Is a property after curing.
In order for the first resin 400 to have these characteristics, the first resin 400 may have the following characteristics. If it is the 1st resin 400 which has the following characteristic, the 1st resin before hardening and after hardening will satisfy the above-mentioned characteristic.
The characteristics of the first resin 400 that is preferably satisfied are, as far as the characteristics before curing, the ratio of the filler to the total amount of the first resin including the filler is 80% by weight or more, and the characteristics after curing are linear. The expansion coefficient (α1) is 11 ppm / TMA or less, the linear expansion coefficient (α2) is 25 ppm / TMA or less, and the 25 ° C. elastic modulus is 15 GPa / DMA or more.
In addition, as an example of the 1st resin 400 which satisfies said characteristic, the resin composition (product number: CV5385 (trademark)) which Panasonic Corporation manufactures and sells can be mentioned. These resin compositions contain silica (as filler), epoxy resin, curing agent, modifier and the like. The resin composition contains only one type of resin. Therefore, the main resin in the present application of the first resin 400 is an epoxy resin.
As described above, the first resin 400 includes a filler, but the above-described resin composition (product number: CV5385) includes a filler. The amount of filler contained in these resin compositions is 83%, which is 80% or more by weight with respect to the entire first resin 400. The filler is made of a material having a small linear expansion coefficient, and is usually made of silica. Further, in order to satisfy the filling property of the first resin 400, the filler preferably has a particle size of 30 μm or less. Both of the fillers contained in the above-described two resin compositions described above satisfy these conditions.
Moreover, the linear expansion coefficient (α1) after curing of the above-described resin composition illustrated is 11 ppm / TMA, the linear expansion coefficient (α2) after curing is 25 ppm / TMA, and the 25 ° C. elastic modulus after curing is 15 GPa / DMA. Yes, satisfying the above-mentioned preferable conditions.
　次いで、これは必ずしも必須ではないが、第１樹脂４００の上部を除去する。これは、基板１００上の第１樹脂４００の厚さを小さくすることによって、最終的に得られるモールド回路モジュールの厚さを小さくすることを主たる目的とするものである。この実施形態では、第１樹脂４００のうち、図１（ｅ）の破線Ｌで示した位置よりも上側に位置する第１樹脂４００を除去することしている。また、破線Ｌで示した位置よりも上側に位置する第１樹脂４００を除去した状態が、図１（ｆ）に示されている。
　必ずしもこの限りではないが、この実施形態では、破線Ｌよりも上側に位置する第１樹脂４００を除去した後の第１樹脂４００の上面は、基板１００の一方の面と平行となるようになっている。また、これもこの限りではないが、最も背の高い電子部品２００を電子部品２００Ｂとした場合におけるその最上部から、破線Ｌよりも上側に位置する第１樹脂４００を除去した後の第１樹脂４００の上面までの距離は、３０μｍ～８０μｍの間となるようになっている。
　必ずしもこの限りではないが、この実施形態では、第１樹脂４００の破線Ｌよりも上側に位置する部分を除去するとき、第１樹脂４００とともに、パーテーション部材３００の天井部３１０及び側壁部３２０の上側の一定の範囲も除去される。これにより、パーテーション部材３００は、その側壁部３２０のみが第１樹脂４００の中に残った状態となる。第１樹脂４００の中に残ったパーテーション部材３００の側壁部３２０が、第１樹脂４００を仕切るパーテーションとなる。
　なお、パーテーション部材３００の上方の部分は、第１樹脂４００の破線Ｌよりも上側に位置する部分を除去するときに、必ずしも第１樹脂４００ごと除去される必要はない。その場合、パーテーション部材３００の高さは、その天井部３１０が破線Ｌよりも低くなるように設計される。
　第１樹脂４００の破線Ｌよりも上側に位置する部分を除去する方法には、適当な公知技術を用いることができる。例えば、フライス盤等の切削装置或いはダイサー等の研磨切削装置によって、第１樹脂４００を除去することができる。 Next, although this is not always necessary, the upper portion of the first resin 400 is removed. The main purpose of this is to reduce the thickness of the finally obtained molded circuit module by reducing the thickness of the first resin 400 on the substrate 100. In this embodiment, the 1st resin 400 located above the position shown with the broken line L of FIG.1 (e) among the 1st resin 400 is removed. Moreover, the state which removed the 1st resin 400 located above the position shown with the broken line L is shown by FIG.1 (f).
Although not necessarily limited to this, in this embodiment, the upper surface of the first resin 400 after removing the first resin 400 positioned above the broken line L is parallel to one surface of the substrate 100. ing. Moreover, this is not limited to this, but the first resin 400 after removing the first resin 400 located above the broken line L from the uppermost portion when the tallest electronic component 200 is the electronic component 200B. The distance to the top surface of 400 is between 30 μm and 80 μm.
Although not necessarily limited to this, in this embodiment, when removing the portion of the first resin 400 located above the broken line L, together with the first resin 400, the upper side of the ceiling portion 310 and the side wall portion 320 of the partition member 300. A certain range of is also removed. Thereby, the partition member 300 is in a state in which only the side wall portion 320 remains in the first resin 400. The side wall portion 320 of the partition member 300 remaining in the first resin 400 serves as a partition that partitions the first resin 400.
Note that the upper portion of the partition member 300 is not necessarily removed together with the first resin 400 when the portion of the first resin 400 positioned above the broken line L is removed. In that case, the height of the partition member 300 is designed such that the ceiling portion 310 is lower than the broken line L.
A suitable known technique can be used for the method of removing the portion of the first resin 400 located above the broken line L. For example, the first resin 400 can be removed by a cutting device such as a milling machine or a polishing cutting device such as a dicer.
　次いで、これも必ずしも必須ではないが、基板１００と平行とされた第１樹脂４００の上面（基板１００と対向する面）を、第２樹脂５００にて被覆し、第２樹脂５００を硬化させる（図１（ｇ））。第２樹脂５００で第１樹脂４００の上面を被覆するのは、第１樹脂４００に含まれたフィラーが第１樹脂４００から脱落するのを防止するためである。第１樹脂４００の上面の少なくとも後述のシールド層で被覆される部分が、第２樹脂５００で被覆される。
　第２樹脂５００にはフィラーは含まれていない。第２樹脂５００の素材は、硬化した後の第２樹脂５００の第１樹脂４００に対する密着性が高いものから選択する。例えば、エポキシ樹脂やアクリル樹脂を、第２樹脂５００の素材とすることができる。第２樹脂５００の第１樹脂４００に対する密着性を上げるには、第２樹脂５００として、第１樹脂４００に主樹脂として含まれる樹脂と同種のものを用いるのが簡単である。第１樹脂４００の主樹脂は上述のようにエポキシ樹脂なのであるから、この実施形態では、エポキシ樹脂を第２樹脂５００の素材とすることができる。この実施形態では、これには限られないが、第２樹脂５００はエポキシ樹脂であるものとする。
　第２樹脂５００の厚さは、以下の２つの条件が充足される範囲でなるべく薄くするのが良い。まず、第２樹脂５００は、第１樹脂４００内のフィラーを保持する役割を担うため、それが可能な程度には厚くする必要がある。次に、第２樹脂５００の表面には、めっきの第２樹脂５００表面への密着性を良くするために表面粗化を行う場合があるが、第２樹脂５００の層が薄過ぎると表面粗化に支障が生じることがあるので、表面粗化を行う場合にはそれに支障がでない程度に厚くする必要がある。これら２つの条件が充足されるようにしつつも、第２樹脂５００の厚さを小さくするのが良い。
　また、これには限られないがこの実施形態では、第２樹脂５００は、第１樹脂４００の上面すべてを被覆することとしている。
　第２樹脂５００で第１樹脂４００の上面を被覆するために用いる技術には、公知の技術を用いることができる。例えば、スプレー装置による噴霧塗布によって、第２樹脂５００で第１樹脂４００の上面を被覆することができる。
　第１樹脂４００を被覆した第２樹脂５００は、適当な時間を置くことで硬化させられる。
　次いで、第２樹脂５００の表面を粗化する。第２樹脂５００の表面の粗化は、その上に後述するシールド層がより良く密着するようにすることを目的とするものであり、その目的が達成されるようにして行う。樹脂の表面の粗化の技術は、強酸或いは強アルカリを用いたエッチング等、公知或いは周知であるので、第２樹脂５００の表面の粗化には、その技術を用いれば良い。 Next, although this is not necessarily essential, the upper surface of the first resin 400 (the surface facing the substrate 100) parallel to the substrate 100 is covered with the second resin 500, and the second resin 500 is cured ( FIG. 1 (g)). The reason why the upper surface of the first resin 400 is covered with the second resin 500 is to prevent the filler contained in the first resin 400 from dropping off from the first resin 400. At least a portion of the upper surface of the first resin 400 that is covered with a shield layer described later is covered with the second resin 500.
The second resin 500 contains no filler. The material of the second resin 500 is selected from those having high adhesion to the first resin 400 of the second resin 500 after being cured. For example, an epoxy resin or an acrylic resin can be used as the material of the second resin 500. In order to improve the adhesion of the second resin 500 to the first resin 400, it is easy to use the same resin as the resin contained in the first resin 400 as the main resin. Since the main resin of the first resin 400 is an epoxy resin as described above, the epoxy resin can be used as the material of the second resin 500 in this embodiment. In this embodiment, the second resin 500 is an epoxy resin, although not limited to this.
The thickness of the second resin 500 is preferably as thin as possible within a range where the following two conditions are satisfied. First, since the 2nd resin 500 plays the role which hold | maintains the filler in the 1st resin 400, it is necessary to make it as thick as possible. Next, surface roughening may be performed on the surface of the second resin 500 in order to improve the adhesion of the plating to the surface of the second resin 500. If the layer of the second resin 500 is too thin, the surface roughening may be performed. Therefore, when roughening the surface, it is necessary to increase the thickness so as not to hinder it. It is preferable to reduce the thickness of the second resin 500 while satisfying these two conditions.
Although not limited to this, in this embodiment, the second resin 500 covers the entire upper surface of the first resin 400.
A known technique can be used as the technique used to coat the upper surface of the first resin 400 with the second resin 500. For example, the upper surface of the first resin 400 can be covered with the second resin 500 by spray application using a spray device.
The second resin 500 coated with the first resin 400 is cured by putting an appropriate time.
Next, the surface of the second resin 500 is roughened. The surface of the second resin 500 is roughened so that a shield layer, which will be described later, is better adhered to the surface of the second resin 500, and the purpose is achieved. Since the technique for roughening the surface of the resin is known or well known, such as etching using a strong acid or strong alkali, the technique may be used for roughening the surface of the second resin 500.
　次いで、この実施形態では、第２樹脂５００の表面に、マスク７００を重ねる（図１（ｈ））。マスク７００は、後述するめっきレジストによる層を形成するための型である。めっきレジストによる層は、後述するシールド層に、これも後述する開口を形成するためのものである。かかる開口は、電子部品２００に含まれる通信器が無線による通信を行う際に、シールド層がその妨げにならないようにするためのものである。以下、電子部品２００Ｃが通信器であるものとして話を進める。また、開口については、追って説明する。
　マスク７００は公知のもので良いが、マスク７００はシート状であり、また、めっきレジストによる層が形成されるべき位置に、マスク開口７１０が設けられている。この実施形態では、各区画１２０につき１つずつ、且つ当該区画１２０の中の共通する位置に、マスク開口７１０が設けられている。各区画１２０ごとのマスク開口７１０の数は１つ以上であり、複数であっても構わない。電子部品２００に含まれる通信器の数に応じてその数を適宜決定すれば良い。 Next, in this embodiment, a mask 700 is overlaid on the surface of the second resin 500 (FIG. 1H). The mask 700 is a mold for forming a layer made of a plating resist described later. The layer made of the plating resist is for forming an opening which will be described later in a shield layer which will be described later. Such an opening is to prevent the shield layer from interfering when the communication device included in the electronic component 200 performs wireless communication. Hereinafter, the electronic component 200C is assumed to be a communication device. The opening will be described later.
Although the mask 700 may be a known one, the mask 700 has a sheet shape, and a mask opening 710 is provided at a position where a layer made of a plating resist is to be formed. In this embodiment, one mask opening 710 is provided for each section 120 and at a common position in the section 120. The number of mask openings 710 for each section 120 is one or more and may be plural. The number may be appropriately determined according to the number of communication devices included in the electronic component 200.
　次いで、マスク７００の上からめっきレジスト８００を塗布する（図１（ｉ））。めっきレジスト８００は、その表面にシールド層６００が形成されないような素材でできている。この実施形態におけるめっきレジスト８００は、めっき、例えば、無電解めっきを行ったときに、めっきがその表面に付着しないような素材でできている。めっきレジストは周知のものであるため、その説明は省略する。
　めっきレジスト８００は、マスク７００のマスク開口７１０に対応する部分では第２樹脂５００の表面に付着し、マスク７００で覆われた部分では、第２樹脂５００の表面に付着しない。
　めっきレジスト８００による層は、基板１００を平面視した場合における、通信器としての電子部品２００Ｃの一部に対応する位置を含む所定の範囲に設けられる。換言すれば、めっきレジスト８００による層は、基板１００を平面視した場合、その少なくとも一部が通信器としての電子部品２００Ｃと重なりあうようにされる。 Next, a plating resist 800 is applied from above the mask 700 (FIG. 1 (i)). The plating resist 800 is made of a material such that the shield layer 600 is not formed on the surface thereof. The plating resist 800 in this embodiment is made of a material that does not adhere to the surface when plating, for example, electroless plating is performed. Since the plating resist is well known, its description is omitted.
The plating resist 800 adheres to the surface of the second resin 500 at a portion corresponding to the mask opening 710 of the mask 700 and does not adhere to the surface of the second resin 500 at a portion covered with the mask 700.
The layer made of the plating resist 800 is provided in a predetermined range including a position corresponding to a part of the electronic component 200C as a communication device when the substrate 100 is viewed in plan. In other words, when the substrate 100 is viewed in plan, at least a part of the layer made of the plating resist 800 overlaps the electronic component 200 </ b> C as a communication device.
　次いで、マスク７００を除去する（図１（ｊ））。そうすると、めっきレジスト８００による層が、第２樹脂５００の表面のうちの適宜の部分に残る。 Next, the mask 700 is removed (FIG. 1 (j)). Then, the layer made of the plating resist 800 remains on an appropriate portion of the surface of the second resin 500.
　次いで、基板１００に対してハーフカットの処理を行う（図１（ｋ））。ハーフカットは、第２樹脂５００、第１樹脂４００、及び基板１００に対して溝状の切込み１００Ｘを入れる処理である。
　切込み１００Ｘを入れる範囲は、隣り合う区画１２０の境界線を跨ぐ所定幅の範囲である。切込み１００Ｘの深さは、これには限られないが、この実施形態では基板１００内の接地用電極１１０に至るようなものにする。それにより、ハーフカットの処理後において、各区画１２０の周縁に、接地用電極１１０の端面が露出することになる。切込み１００Ｘの幅は、これには限られないが、例えば、２００μｍ～４００μｍである。切込み１００Ｘの幅は、第１樹脂４００の特性、ハーフカットを行うのに用いられるダイサーのブレード幅等によって決定される。
　ハーフカットの処理には、公知の技術を用いることができる。例えば、株式会社ディスコが製造・販売していたフルオートダイシングソーであるＤＦＤ６４１（商標）に、適切な幅のブレードを装着したものを使用して、ハーフカットの処理を行うことができる。
　なお、ハーフカットの処理は、めっきレジスト８００の層を第２樹脂５００の表面に作る前に行っても構わない。 Next, half-cut processing is performed on the substrate 100 (FIG. 1 (k)). Half-cut is a process of making a groove-like cut 100X in the second resin 500, the first resin 400, and the substrate 100.
The range into which the incision 100X is made is a range having a predetermined width across the boundary line between adjacent sections 120. The depth of the cut 100X is not limited to this, but in this embodiment, the depth reaches the grounding electrode 110 in the substrate 100. As a result, the end face of the ground electrode 110 is exposed at the periphery of each section 120 after the half-cut process. The width of the cut 100X is not limited to this, but is, for example, 200 μm to 400 μm. The width of the cut 100X is determined by the characteristics of the first resin 400, the blade width of a dicer used for half-cutting, and the like.
A known technique can be used for the half-cut process. For example, half cut processing can be performed using a DFD641 (trademark), which is a full-auto dicing saw manufactured and sold by Disco Corporation, with a blade having an appropriate width.
The half-cut process may be performed before the plating resist 800 layer is formed on the surface of the second resin 500.
　次いで、第１樹脂４００、第２樹脂５００、及び基板１００のうちの以下に説明する位置を、シールド層６００で被覆する（図１（ｌ））。
　シールド層６００は、めっきレジスト８００による層が存在しない部分には形成されるが、めっきレジスト８００による層が存在する部分には形成されない。
　シールド層６００は、製造されたモールド回路モジュールが使用される場合に、当該モールド回路モジュールの中に含まれる電子部品２００を、当該モールド回路モジュールの外にある電子部品に起因する電磁波から保護するか、或いは当該モールド回路モジュール外にある電子部品を当該モールド回路モジュール内にある電子部品２００に起因する電磁波から保護するためのものである。
　シールド層６００は、電磁波の遮蔽を行うに向いた、導電性を有する金属によって形成される。シールド層６００は、１層でも良いし、多層でも良い。シールド層６００が多層である場合、それぞれの層を構成する金属は、異なるものとすることができる。
　この実施形態のシールド層６００は、これには限られないが２層であり、電場のシールドに優れる特性を持つ金属である第１金属による第１金属被覆層６１０と、磁場のシールドに優れる特性を持つ金属である第２金属による第２金属被覆層６２０との２層を含むものとして形成する（図４）。第１金属として、例えば、銅又は鉄を用いることができる。第２金属として、例えば、ニッケルを用いることができる。この実施形態では、これには限られないが、第１金属として銅を、第２金属としてニッケルをそれぞれ用いることとする。第１金属被覆層６１０と、第２金属被覆層６２０は、そのいずれを外部に露出させても良い。これには限られないが、この実施形態では、第２金属被覆層６２０を外部に露出させることとしている。第１金属として銅を用いる場合には、銅は自然に酸化して黒色に変色するので、そのような外観の劣化を防止するためである。
　シールド層６００は、第２樹脂５００の表面と、ハーフカットを行うことによって外部に露出することになった、第１樹脂４００の側面及び基板１００の側面とに設ける。シールド層６００は、基板１００の側面で基板１００が備える接地用電極１１０に導通する。また、シールド層６００は、パーテーションを構成するパーテーション部材３００の側壁部３２０のうちの、側壁部３２０同士を接続する辺に対向する２つの辺（これらは、ハーフカット処理が行われたことにより、第１樹脂４００の側面から露出している）と、第１樹脂４００の側面で導通する。これにより、パーテーション部材３００は、シールド層６００を介して接地用電極１１０と導通することになる。もっとも、パーテーション部材３００は、シールド層６００を介さずとも、その下端で接地用電極１１０と既に導通している場合もあり得る。その場合には、シールド層６００は、その下端で直接接地用電極１１０の端面と導通せずとも、パーテーション部材３００を介して接地用電極１１０と導通させることも可能である。
　シールド層６００は、金属粉を含んだペーストの塗布、又はめっきにより形成することができる。シールド層６００が多層である場合、各層の形成方法は同じであっても同じでなくとも良い。この実施形態では、第１金属被覆層６１０と、第２金属被覆層６２０とを同じ方法で形成するものとする。
　めっきは、湿式乾式を問わない。湿式のめっきの例としては無電解めっきを挙げることができる。乾式のめっきの例としては、物理気相成長（ＰＶＤ）、化学気相成長（ＣＶＤ）を挙げることができ、前者の例としては、スパッタリング、真空蒸着を挙げられ、後者の例としては、熱ＣＶＤ、光ＣＶＤを挙げられる。
　これらのうち、コスト面、及びシールド層６００内の残留応力を小さくできるという面からすれば湿式めっきを選択するべきである。また、湿式めっきでは、シールド層６００の厚さを厚めに、より具体的には数μｍ～数十μｍとすることができ、電磁波を遮蔽するに十分な厚さを稼ぎやすい。また、湿式めっきには無電解めっきと電解めっきが含まれるが、モールド回路モジュールに含まれる電子部品の損傷の可能性を考えると、加工の対象となるモールド回路モジュールの表面に電流を流す必要のない無電解めっきを採用するのが好ましい。
　これには限られないが、この実施形態では、第１金属被覆層６１０と、第２金属被覆層６２０との双方を、無電解めっきにて形成するものとする。 Next, the following positions of the first resin 400, the second resin 500, and the substrate 100 are covered with the shield layer 600 (FIG. 1 (l)).
The shield layer 600 is formed in a portion where the layer made of the plating resist 800 does not exist, but is not formed in a portion where the layer made of the plating resist 800 exists.
When the manufactured molded circuit module is used, the shield layer 600 protects the electronic component 200 included in the molded circuit module from electromagnetic waves caused by the electronic components outside the molded circuit module. Alternatively, the electronic component outside the molded circuit module is protected from electromagnetic waves caused by the electronic component 200 in the molded circuit module.
The shield layer 600 is formed of a conductive metal suitable for shielding electromagnetic waves. The shield layer 600 may be a single layer or a multilayer. When the shield layer 600 is a multilayer, the metal constituting each layer can be different.
The shield layer 600 of this embodiment is, but not limited to, two layers, a first metal coating layer 610 made of a first metal, which is a metal having excellent characteristics for electric field shielding, and characteristics excellent for magnetic field shielding. It is formed so as to include two layers of a second metal covering layer 620 made of a second metal that is a metal having a (FIG. 4). For example, copper or iron can be used as the first metal. For example, nickel can be used as the second metal. In this embodiment, although not limited to this, copper is used as the first metal and nickel is used as the second metal. Either the first metal coating layer 610 or the second metal coating layer 620 may be exposed to the outside. Although not limited to this, in this embodiment, the second metal coating layer 620 is exposed to the outside. This is because when copper is used as the first metal, copper naturally oxidizes and changes color to black, thus preventing such deterioration of the appearance.
The shield layer 600 is provided on the surface of the second resin 500 and the side surface of the first resin 400 and the side surface of the substrate 100 that are exposed to the outside by performing half-cutting. The shield layer 600 is electrically connected to the grounding electrode 110 included in the substrate 100 on the side surface of the substrate 100. In addition, the shield layer 600 includes two sides facing the sides connecting the side wall portions 320 among the side wall portions 320 of the partition member 300 constituting the partition (these are due to the half-cut process being performed. The first resin 400 is exposed from the side surface of the first resin 400, and the first resin 400 is electrically connected to the side surface. As a result, the partition member 300 is electrically connected to the ground electrode 110 through the shield layer 600. However, the partition member 300 may already be electrically connected to the grounding electrode 110 at the lower end without the shield layer 600 being interposed. In that case, the shield layer 600 can be electrically connected to the grounding electrode 110 via the partition member 300 without being directly connected to the end face of the grounding electrode 110 at the lower end thereof.
The shield layer 600 can be formed by applying a paste containing metal powder or by plating. When the shield layer 600 is a multilayer, the formation method of each layer may or may not be the same. In this embodiment, the first metal coating layer 610 and the second metal coating layer 620 are formed by the same method.
The plating is not limited to a wet dry type. An example of wet plating is electroless plating. Examples of dry plating include physical vapor deposition (PVD) and chemical vapor deposition (CVD). Examples of the former include sputtering and vacuum deposition. Examples of the latter include heat. Examples include CVD and photo-CVD.
Of these, wet plating should be selected in terms of cost and the aspect of reducing the residual stress in the shield layer 600. Also, in wet plating, the thickness of the shield layer 600 can be increased, more specifically, several μm to several tens μm, and a sufficient thickness can be easily obtained to shield electromagnetic waves. In addition, wet plating includes electroless plating and electrolytic plating. However, considering the possibility of damage to electronic components included in the mold circuit module, it is necessary to pass a current through the surface of the mold circuit module to be processed. It is preferable to employ no electroless plating.
Although not limited to this, in this embodiment, both the first metal coating layer 610 and the second metal coating layer 620 are formed by electroless plating.
　最後に、ハーフカットを行うことによって作られた切込み１００Ｘに沿って、基板１００を各区画１２０毎に分割するフルカットの処理を行う（図１（ｍ））。
　フルカットの処理には、公知の技術を用いることができる。例えば、上述のフルオートダイシングソーであるＤＦＤ６４１（商標）に適切な幅のブレードを装着して使用することによってフルカットを行うことができる。
　これにより、基板１００の各区画から１つずつ、モールド回路モジュールが得られる。 Finally, a full cut process is performed to divide the substrate 100 into the respective sections 120 along the cuts 100X made by performing the half cut (FIG. 1 (m)).
A known technique can be used for the full cut processing. For example, full cutting can be performed by mounting and using a blade having an appropriate width on the above-described full-auto dicing saw DFD641 (trademark).
Thereby, a mold circuit module is obtained one by one from each section of the substrate 100.
　図５に、以上の方法によって得たモールド回路モジュールＭの断面図を、図６にモールド回路モジュールＭの透視平面図を示す。
　図５に示したように、モールド回路モジュールＭが備える基板１００は、電子部品２００ごと第１樹脂４００によって被覆されている。また、第１樹脂４００の上面は、第２樹脂５００によって被覆されている。また、第２樹脂５００の上面と、第１樹脂４００及び第２樹脂５００の側面、及びハーフカットにより露出した基板１００の側面は、シールド層６００により覆われている。シールド層６００は、上述のように第１金属被覆層６１０と、第２金属被覆層６２０からなるが、これらは、図５に示すように、基板１００の内部の接地用電極１１０の側面と導通している。シールド層６００のうち、第２樹脂５００を介して第１樹脂４００を被覆している部分は、第２樹脂５００が存在するので、フィラーが第１樹脂４００から脱落することに起因する脱落とは無縁である。シールド層６００のうち、第１樹脂４００の側面を被覆している部分は第２樹脂５００を介さずに第１樹脂４００を被覆しているが、ハーフカットの処理により第１樹脂４００の側面がやや荒れた状態になっているので、シールド層６００の第１樹脂４００に対する密着性が高く、第１樹脂４００の側面からの脱落が生じにくい。
　また、図６に示すように、シールド層６００は、パーテーションを構成するパーテーション部材３００の側壁部３２０のうちの、側壁部３２０同士を接続する辺に対向する２つの辺と、第１樹脂４００の側面で導通している。
　電子部品２００Ａは、側壁部３２０によってその側面の２面を、シールド層６００によってその側面の２面を囲まれ、且つその上面をシールド層６００によって囲まれることになる。
　また、シールド層６００のうち、通信器である電子部品２００Ｃの上方には、開口６３０が設けられている。この開口６３０は、通信器である電子部品２００Ｃが無線による通信を行うのにあたって、シールド層６００がその妨げとならないような位置に、その妨げとならないような大きさで設けられている。この実施形態における開口６３０は、これには限られないが、第２樹脂５００の上面を覆うシールド層６００のうち、基板１００を平面視した場合における、電子部品２００Ｃの一部に対応する位置を含む所定の範囲に設けられる。換言すれば、基板１００を平面視した場合、開口６３０は、電子部品２００Ｃと重なりあう。図６に示した例では、開口６３０は、平面視した場合の電子部品２００Ｃよりも一回り小さくされているが、これには限られず、開口６３０は平面視した場合における電子部品２００Ｃから、その一部が食み出るようになっていてもよい。 FIG. 5 is a sectional view of the molded circuit module M obtained by the above method, and FIG. 6 is a perspective plan view of the molded circuit module M.
As shown in FIG. 5, the substrate 100 included in the molded circuit module M is covered with the first resin 400 together with the electronic component 200. Further, the upper surface of the first resin 400 is covered with the second resin 500. Further, the upper surface of the second resin 500, the side surfaces of the first resin 400 and the second resin 500, and the side surface of the substrate 100 exposed by the half cut are covered with a shield layer 600. As described above, the shield layer 600 includes the first metal coating layer 610 and the second metal coating layer 620, which are electrically connected to the side surface of the grounding electrode 110 inside the substrate 100 as shown in FIG. is doing. Since the second resin 500 exists in the portion of the shield layer 600 that covers the first resin 400 via the second resin 500, the dropout caused by the filler dropping off from the first resin 400 is It is unrelated. The portion of the shield layer 600 that covers the side surface of the first resin 400 covers the first resin 400 without the second resin 500 interposed therebetween. However, the side surface of the first resin 400 is covered by the half-cut process. Since it is in a somewhat rough state, the adhesion of the shield layer 600 to the first resin 400 is high, and it is difficult for the first resin 400 to fall off from the side surface.
In addition, as shown in FIG. 6, the shield layer 600 includes two sides of the side wall portion 320 of the partition member 300 that constitute the partition, the sides facing the side connecting the side wall portions 320, and the first resin 400. Conducted on the side.
The electronic component 200 </ b> A is surrounded by two side surfaces by the side wall portion 320, two side surfaces by the shield layer 600, and the upper surface by the shield layer 600.
Further, in the shield layer 600, an opening 630 is provided above the electronic component 200C that is a communication device. The opening 630 is provided at a position where the shield layer 600 does not interfere with the electronic component 200 </ b> C, which is a communication device, so as not to obstruct the shield layer 600. The opening 630 in this embodiment is not limited to this, but the position corresponding to a part of the electronic component 200 </ b> C when the substrate 100 is viewed in a plane in the shield layer 600 covering the upper surface of the second resin 500. It is provided within a predetermined range. In other words, when the substrate 100 is viewed in plan, the opening 630 overlaps the electronic component 200C. In the example shown in FIG. 6, the opening 630 is slightly smaller than the electronic component 200 </ b> C when viewed in plan, but is not limited to this, and the opening 630 is changed from the electronic component 200 </ b> C when viewed in plan to A part may come out.
≪第２実施形態≫
　次いで、第２実施形態によるモールド回路モジュールの製造方法について説明する。
　第２実施形態によるモールド回路モジュールの製造方法は、第１実施形態のモールド回路モジュールの製造方法と同様に、その上面のシールド層６００の一部が存在せず開口しているモールド回路モジュールを製造する方法である。
　第２実施形態のモールド回路モジュールの製造方法は、概ね上述の実施形態で説明したものと同じである。特に、図１（ｇ）で説明した、第１樹脂４００の上面を、第２樹脂５００にて被覆し、第２樹脂５００を硬化させる過程までは、上述の実施形態と略同様である。ここまでの過程における第２実施形態のモールド回路モジュールの製造方法と、上述の実施形態によるモールド回路モジュールの製造方法との相違点は、第２実施形態のモールド回路モジュールの製造方法では、パーテーション部材３００を用いない点と（第２実施形態でもパーテーション部材３００は用いても良い）、第２実施形態のモールド回路モジュールの製造方法では、第１樹脂４００で基板１００を電子部品２００ごと被覆する際に、第１樹脂４００の適当な部分に、基板１００からの厚みの大きな盛上部４１０を設けるという点と、図１（ｅ）を用いて説明した第１樹脂４００の上方を削る過程を省略したという点、である（図７（ａ））。第２実施形態では、盛上部４１０が存在する部分に、後述するシールド層の開口が形成されることになる。つまり、盛上部４１０はそこにシールド層の開口が存在することが望まれる部分に設けられることになる。 << Second Embodiment >>
Next, a method for manufacturing a molded circuit module according to the second embodiment will be described.
The method for manufacturing the molded circuit module according to the second embodiment is similar to the method for manufacturing the molded circuit module according to the first embodiment, in which a part of the upper shield layer 600 is not present and is opened. It is a method to do.
The method of manufacturing the molded circuit module according to the second embodiment is generally the same as that described in the above embodiment. In particular, the process up to the process of covering the upper surface of the first resin 400 with the second resin 500 and curing the second resin 500 described with reference to FIG. The difference between the manufacturing method of the molded circuit module of the second embodiment and the manufacturing method of the molded circuit module according to the above-described embodiment in the process so far is that the partition member is different from the manufacturing method of the molded circuit module of the second embodiment. In the method of manufacturing the molded circuit module according to the second embodiment, when the substrate 100 is covered with the electronic component 200 together with the point that the 300 is not used (the partition member 300 may be used in the second embodiment). In addition, the thickened portion 410 having a large thickness from the substrate 100 is provided in an appropriate portion of the first resin 400, and the process of cutting the upper portion of the first resin 400 described with reference to FIG. (Fig. 7 (a)). In 2nd Embodiment, the opening of the shield layer mentioned later is formed in the part in which the raised part 410 exists. That is, the raised portion 410 is provided in a portion where the opening of the shield layer is desired to exist.
　次いで、第１実施形態で説明したのと同じようにして、ハーフカットの処理を行う（図７（ｂ））。 Next, half-cut processing is performed in the same manner as described in the first embodiment (FIG. 7B).
　次いで、第１実施形態で説明したのと同様の方法で、上述の実施形態で説明したのと同様の２層構造のシールド層６００を形成する（図７（ｃ））。 Next, a shield layer 600 having the same two-layer structure as that described in the above embodiment is formed by the same method as that described in the first embodiment (FIG. 7C).
　次いで、盛上部４１０を、盛上部４１０を覆う第２樹脂５００及び盛上部４１０を覆う第２樹脂５００を覆うシールド層６００ごと除去する。この実施形態では、これには限られないが、盛上部４１０が存在していた部分を、盛上部４１０以外を第２樹脂５００を介して被覆するシールド層６００の表面と面一にするようにして、上述の部分を除去する。そして、上述の実施形態の場合と同様のフルカットの処理を行うことにより、シールド層６００の所望の位置に開口６３０を有するモールド回路モジュールが完成する（図７（ｄ））。 Next, the raised portion 410 is removed together with the second resin 500 covering the raised portion 410 and the shield layer 600 covering the second resin 500 covering the raised portion 410. In this embodiment, although not limited to this, the portion where the raised portion 410 was present is flush with the surface of the shield layer 600 that covers the portion other than the raised portion 410 via the second resin 500. Then, the above-mentioned part is removed. Then, by performing the same full-cut process as in the above-described embodiment, a molded circuit module having an opening 630 at a desired position of the shield layer 600 is completed (FIG. 7D).
　第２実施形態の製法によって得られるモールド回路モジュールは、第１実施形態のものと略同様なものとなる。シールド層６００において開口６３０が設けられる位置、大きさについては、第１実施形態の場合と同様である。逆に言えば、そうなるように、上述の盛上部４１０は形成される。 The molded circuit module obtained by the manufacturing method of the second embodiment is substantially the same as that of the first embodiment. The position and size of the opening 630 in the shield layer 600 are the same as in the first embodiment. In other words, the above-described raised portion 410 is formed so as to be so.
　１００　基板
１００Ｘ　切込み
　１１０　接地用電極
　１２０　区画
　２００　電子部品
　３００　パーテーション部材
　３１０　天井部
　３２０　側壁部
　４００　第１樹脂
　４１０　盛上部
　５００　第２樹脂
　６００　シールド層
　６３０　開口
　７００　マスク
　８００　めっきレジスト DESCRIPTION OF SYMBOLS 100 Substrate 100X Cut 110 Grounding electrode 120 Partition 200 Electronic component 300 Partition member 310 Ceiling part 320 Side wall part 400 First resin 410 Embankment 500 Second resin 600 Shield layer 630 Opening 700 Mask 800 Plating resist

Claims (9)

  1. 　接地用電極を有する基板と、
    　前記基板の一方の面上に実装された少なくとも１つの電子部品と、
    　前記基板の一方の面を前記電子部品ごと被覆する、樹脂である第１樹脂による第１樹脂層と、
    　前記第１樹脂層の表面と、前記第１樹脂層の側面と、前記基板の側面とを、前記接地用電極と導通するようにして被覆することによって形成されたシールド層と、
    　を含み、
    　前記電子部品のうちの少なくとも一つが、無線の通信を行う通信器であり、
    　前記シールド層のうちの前記第１樹脂層の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられている、
    　モールド回路モジュール。     A substrate having a ground electrode;
    At least one electronic component mounted on one side of the substrate;
    A first resin layer made of a first resin that is a resin that covers one surface of the substrate together with the electronic component;
    A shield layer formed by covering the surface of the first resin layer, the side surface of the first resin layer, and the side surface of the substrate so as to be electrically connected to the ground electrode;
    Including
    At least one of the electronic components is a communication device that performs wireless communication,
    An opening for allowing the communicator to perform wireless communication is provided in a predetermined portion of the shield layer that covers the surface of the first resin layer.
    Molded circuit module.
  2. 　前記開口は、前記シールド層のうちの前記第１樹脂層の表面を覆う部分のうちの、前記基板を平面視した場合における、前記通信器の一部に対応する位置を含む所定の範囲に設けられている、
    　請求項１記載のモールド回路モジュール。     The opening is provided in a predetermined range including a position corresponding to a part of the communication device in a plan view of the substrate, of the portion of the shield layer covering the surface of the first resin layer. Being
    The molded circuit module according to claim 1.
  3. 　前記シールド層は、電場のシールドに優れる特性を持つ金属である第１金属による第１金属被覆層と、磁場のシールドに優れる特性を持つ金属である第２金属による第２金属被覆層との２層を含むものとして形成されている、
    　請求項１又は２記載のモールド回路モジュール。     The shield layer includes a first metal coating layer made of a first metal that is a metal having excellent characteristics for electric field shielding, and a second metal coating layer made of a second metal that is a metal having excellent characteristics for shielding a magnetic field. Formed as containing layers,
    The molded circuit module according to claim 1 or 2.
  4. 　前記第１金属は、銅又は鉄である、
    　請求項３記載のモールド回路モジュール。     The first metal is copper or iron;
    The molded circuit module according to claim 3.
  5. 　前記第２金属は、ニッケルである、
    　請求項３記載のモールド回路モジュール。     The second metal is nickel;
    The molded circuit module according to claim 3.
  6. 　互いに隣接する多数の仮想の区画をその一方の面に有するとともに、前記一方の面の前記区画のそれぞれに、その中のうちの少なくとも１つが無線の通信を行う通信器である、少なくとも１つの電子部品が実装されたものであり、接地用電極を有する基板の前記一方の全面を、前記電子部品ごと、樹脂である第１樹脂で被覆し硬化させる第１被覆過程と、
    　前記第１樹脂の表面に、めっきレジストを塗布して層状のめっきレジスト層を前記区画のそれぞれに少なくとも一つずつ設けるめっきレジスト層形成過程と、
    　多数の前記区画の境界線上を含む所定幅の前記第１樹脂と前記基板とを、前記基板の所定の厚さまで除去するハーフカット過程と、
    　前記第１樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成するシールド層形成過程と、
    　前記区画の境界で前記基板を切断することにより、前記各区画を切り離すことにより、前記区画のそれぞれに基づく複数のモールド回路モジュールを得るフルカット過程と、
    　を含み、
    　前記シールド層形成過程では、前記第１樹脂の表面のうち前記めっきレジスト層に覆われている部分に前記シールド層を形成しないようにすることで、前記モールド回路モジュールのそれぞれの前記シールド層のうちの前記第１樹脂の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられるようにする、
    　モールド回路モジュールの製造方法。     At least one electron having a large number of virtual sections adjacent to each other on one side and at least one of which is a communicator that performs wireless communication in each of the sections on the one side A first covering step in which a component is mounted and the one whole surface of the substrate having a grounding electrode is coated and cured with a first resin that is a resin together with the electronic component;
    A plating resist layer forming process in which a plating resist is applied to the surface of the first resin and at least one layered plating resist layer is provided in each of the sections;
    A half-cut process of removing the first resin and the substrate having a predetermined width including the boundary lines of the plurality of partitions to a predetermined thickness of the substrate;
    Conductive connection with the ground electrode by applying or plating a paste containing metal powder on the surface of the first resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate. A shield layer forming process for forming a shield layer that is a metal layer to be
    A full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting the substrate at the boundary of the sections, and separating each section;
    Including
    In the shield layer forming process, the shield layer is not formed on a portion of the surface of the first resin that is covered with the plating resist layer. An opening for enabling the communication device to perform wireless communication is provided in a predetermined portion covering the surface of the first resin.
    Manufacturing method of molded circuit module.
  7. 　互いに隣接する多数の仮想の区画をその一方の面に有するとともに、前記一方の面の前記区画のそれぞれに、その中のうちの少なくとも１つが無線の通信を行う通信器である、少なくとも１つの電子部品が実装されたものであり、接地用電極を有する基板の前記一方の全面を、前記電子部品ごと、樹脂である第１樹脂で被覆し硬化させる第１被覆過程と、
    　多数の前記区画の境界線上を含む所定幅の前記第１樹脂と前記基板とを、前記基板の所定の厚さまで除去するハーフカット過程と、
    　前記第１樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成するシールド層形成過程と、
    　前記区画の境界で前記基板を切断することにより、前記各区画を切り離すことにより、前記区画のそれぞれに基づく複数のモールド回路モジュールを得るフルカット過程と、
    　を含み、
    　前記第１被覆過程では、前記区画のそれぞれに少なくとも１つの凸部を設けるとともに、前記シールド層形成過程の後で、前記フルカット過程を実行する前に、前記凸部を前記凸部の表面を覆う前記シールド層ごと除去する過程を実行することにより、前記モールド回路モジュールのそれぞれの前記シールド層のうちの前記第１樹脂の表面を覆う所定の部分に、それを介して前記通信器が無線の通信を行えるようにするための開口が設けられるようにする、
    　モールド回路モジュールの製造方法。     At least one electron having a large number of virtual sections adjacent to each other on one side and at least one of which is a communicator that performs wireless communication in each of the sections on the one side A first covering step in which a component is mounted and the one whole surface of the substrate having a grounding electrode is coated and cured with a first resin that is a resin together with the electronic component;
    A half-cut process of removing the first resin and the substrate having a predetermined width including the boundary lines of the plurality of partitions to a predetermined thickness of the substrate;
    Conductive connection with the ground electrode by applying or plating a paste containing metal powder on the surface of the first resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate. A shield layer forming process for forming a shield layer that is a metal layer to be
    A full-cut process of obtaining a plurality of molded circuit modules based on each of the sections by cutting the substrate at the boundary of the sections, and separating each section;
    Including
    In the first covering process, at least one convex part is provided in each of the sections, and after the shield layer forming process, before the full cut process is performed, the convex part is formed on the surface of the convex part. By performing the process of removing the entire shield layer to cover, the communicator is wirelessly connected to a predetermined portion of the shield layer of each of the molded circuit modules that covers the surface of the first resin. An opening is provided to allow communication,
    Manufacturing method of molded circuit module.
  8. 　前記第１樹脂として、フィラーを含む樹脂を用いるとともに、
    　前記第１被覆過程の後で、前記めっきレジスト層形成過程を実行する前に、前記基板を被覆した前記第１樹脂の表面を、フィラーを含まない樹脂である第２樹脂で被覆し硬化させる第２被覆過程を含み、
    　前記シールド層形成過程では、前記第２樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成する、
    　請求項６記載のモールド回路モジュールの製造方法。     While using the resin containing the filler as the first resin,
    After the first coating process and before executing the plating resist layer forming process, the surface of the first resin coated with the substrate is coated and cured with a second resin that is a resin not containing a filler. Including two coating processes,
    In the shield layer forming process, the surface of the second resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate are coated with a paste containing metal powder or plated. Forming a shield layer that is a metal layer that is electrically connected to the grounding electrode;
    The method for producing a molded circuit module according to claim 6.
  9. 　前記第１樹脂として、フィラーを含む樹脂を用いるとともに、
    　前記第１被覆過程の後で、前記シールド層形成過程を実行する前に、前記基板を被覆した前記第１樹脂の表面を、フィラーを含まない樹脂である第２樹脂で被覆し硬化させる第２被覆過程を含み、
    　前記シールド層形成過程では、前記第２樹脂の表面と、前記ハーフカット過程により露出した、前記第１樹脂の側面と、前記基板の側面とに、金属粉を含んだペーストの塗布、又はめっきにより、前記接地用電極と導通する金属の層であるシールド層を形成する、
    　請求項７記載のモールド回路モジュールの製造方法。     While using the resin containing the filler as the first resin,
    After the first coating process and before executing the shield layer forming process, the surface of the first resin coated with the substrate is coated with a second resin, which is a resin containing no filler, and cured. Including the coating process,
    In the shield layer forming process, the surface of the second resin, the side surface of the first resin exposed by the half-cut process, and the side surface of the substrate are coated with a paste containing metal powder or plated. Forming a shield layer that is a metal layer that is electrically connected to the grounding electrode;
    The method for manufacturing a molded circuit module according to claim 7.
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