JP2012169501A - Interlayer insulating sheet for module with built-in electronic component, module with built-in electronic component, and method for manufacturing module with built-in electronic component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interlayer insulating sheet for a module with a built-in electronic component in which a built-in electronic component can be embedded by a predetermined thickness; the module with the built-in electronic component; and a method for manufacturing the module with the built-in electronic component.SOLUTION: The interlayer insulating sheet for the module with the built-in electronic component is a resin sheet used in a step of making the periphery of the electronic component embedded in a temperature range of room temperature or higher and a resin viscosity increase start temperature or lower and performing interlayer insulation in the module with the built-in electronic component. The resin sheet is made of uncured thermoset resin, is solid at room temperature, has a viscosity of 300 Pa s or more and 1000 Pa s or less at a temperature that the electronic component is embedded, and has a rate of viscosity change of 20% or less from the temperature that the electronic component is embedded to the resin viscosity increase start temperature at which the thermoset resin starts increasing in the viscosity.

Description

  The present invention relates to an interlayer insulating sheet for an electronic component built-in module that incorporates an electronic component, an electronic component built-in module, and a method for manufacturing the electronic component built-in module.

  In recent years, the density of circuit boards has been increasing. As a substrate on which wirings can be arranged with high density, electronic component mounting in which electronic components are embedded has been proposed.

  For example, Patent Document 1 discloses a step of forming a first uncured resin layer on a substrate, a step of disposing an electronic component on the first uncured resin layer, and a second step of covering the electronic component. Forming the uncured resin layer, and heat-treating the first and second uncured resin layers to obtain an insulating layer in which the electronic component is embedded. A method for manufacturing an electronic component mounting structure is described.

JP 2005-322769 A

  However, the second uncured resin layer covering the electronic component is generally heat-treated with a hot press or the like by attaching a sheet material made of an uncured thermosetting resin molded into a sheet to a corresponding substrate. However, if the resin fluidity of the thermosetting resin is poor, it cannot be filled in a narrow gap around a built-in electronic component, which may cause problems such as the generation of voids. Conversely, if the flowability of the thermosetting resin is too good, the resin flow tends to vary within the plane of the substrate, or the resin flows out at the edge of the substrate, and the second uncured resin layer has a predetermined thickness. There is a risk that it will not. For this reason, the electronic component cannot be embedded (buried) with a predetermined thickness, and there is a possibility that conduction between the substrate wiring and the electronic component connected in the thickness direction becomes unstable.

  The present invention has been made in view of the above, and provides an interlayer insulating sheet for an electronic component built-in module, an electronic component built-in module, and a method for manufacturing the electronic component built-in module that can embed a built-in electronic component with a predetermined thickness. For the purpose.

  In order to solve the above-described problems and achieve the object, the interlayer insulating sheet for the electronic component built-in module embeds the periphery of the electronic component within the temperature range of the normal temperature or more and the resin viscosity rise start temperature or less, and the electronic component built-in module The resin sheet is used for the interlayer insulation process, and the resin sheet is made of an uncured thermosetting resin, is solid at room temperature, and has a viscosity of 300 Pa at a temperature at which the electronic component is embedded. s to 1000 Pa · s or less, wherein the rate of change in viscosity from the temperature at which the electronic component is buried to the temperature at which the thermosetting resin starts to increase in viscosity is 20% or less.

  As a result, in order to bury the periphery of the electronic component, when heat and pressure are applied by laminating or hot pressing, etc., sufficient fluidity is secured to fill the resin around the electronic component, and the resin It is possible to reduce the risk of flowing too far around. As a result, the thickness of the insulating layer on the upper side (side connected to the wiring layer) of the electronic component built-in module can be set to a predetermined thickness. Further, the conduction between the wiring of the electronic component built-in module and the electronic component is stabilized. The viscosity increase starting temperature refers to the temperature at which the viscosity change from the viscosity increase due to the temperature increase is measured when the temperature change of the viscosity is measured at a constant temperature rise. The temperature at which the viscosity increases by 10% or more from the lowest viscosity. It is.

  As a desirable mode of the present invention, the temperature at which the periphery of the electronic component is buried is in the range of 80 ° C. or higher and 120 ° C. or lower, and the viscosity increase start temperature is in the temperature range of 100 ° C. or higher and 150 ° C. or lower. preferable. As a result, the resin sheet that becomes the second resin in a solid state near room temperature is also in a molten state in the embedding process, and the electronic component can be stably embedded in the second resin.

  In order to solve the above-described problems and achieve the object, the interlayer insulating sheet for an electronic component built-in module embeds the periphery of the electronic component within a temperature range of 80 ° C. or higher and 120 ° C. or lower, and the interlayer in the electronic component built-in module. A resin sheet used in an insulating process, wherein the resin sheet is made of an uncured thermosetting resin, is solid at room temperature, and has a viscosity of 300 Pa · s or more at a temperature at which the electronic component is embedded. It is within the range of 1000 Pa · s or less, and the viscosity change rate of the viscosity at 90 ° C. and the viscosity at 120 ° C. is 20% or less.

  As a result, in order to bury the periphery of the electronic component, when heat and pressure are applied by laminating or hot pressing, etc., sufficient fluidity is secured to fill the resin around the electronic component, and the resin It is possible to reduce the risk of flowing too far around. As a result, the thickness of the insulating layer on the upper side (side connected to the wiring layer) of the electronic component built-in module can be set to a predetermined thickness. Further, the conduction between the wiring of the electronic component built-in module and the electronic component is stabilized.

  In order to solve the above-described problems and achieve the object, the interlayer insulating sheet for an electronic component built-in module is an interlayer insulating sheet containing a resin that embeds the periphery of the electronic component and performs interlayer insulation in the electronic component built-in module. The resin includes an epoxy resin and a low molecular component having a viscosity of 10 Pa · s to 1000 Pa · s and a molecular weight of 100 to 500, with the mass of the epoxy resin being 100 mass%. And a material of a polymer component that is contained in an amount of 1 to 20% by mass and a molecular weight of 10,000 to 100,000, based on the mass of the epoxy resin as 100.

  Thereby, when the temperature of the uncured resin is raised, a viscosity range in which the viscosity of the resin is 300 Pa · s or more and 1000 Pa · s or less can be formed. For example, even if the temperature is raised to a predetermined temperature at which the electronic component is buried, it can be within a predetermined viscosity range. Further, the rate of change in viscosity from the temperature at which the electronic component is buried to the temperature at which the viscosity starts to rise can be suppressed to within 20%. For this reason, when heat and pressure are applied by laminating or hot pressing to bury the periphery of the electronic component, sufficient fluidity is ensured to fill the resin around the electronic component and the resin flows. The possibility of flowing out to the surroundings can be reduced. As a result, the thickness of the insulating layer on the upper side (side connected to the wiring layer) of the electronic component built-in module can be set to a predetermined thickness. Further, the conduction between the wiring of the electronic component built-in module and the electronic component is stabilized.

  As a desirable mode of the present invention, it is preferable that the low molecular weight component material includes two or more epoxy groups and an epoxy equivalent is 50 g / eq or more and 300 g / eq or less. Thereby, since the crosslinking density at the time of hardening can be kept high, a glass transition temperature does not fall too much. As a result, an electronic component built-in module that is stable against heat can be manufactured.

  As a desirable aspect of the present invention, the resin preferably contains a filler. Thereby, filling of resin can be improved and a desired linear expansion coefficient can be obtained. As a result, the risk of warping of the electronic component built-in module can be reduced. Moreover, since generation | occurrence | production of the stress with the electronic component incorporated can be suppressed, malfunctions, such as peeling with resin and an electronic component, can be prevented.

  As a desirable aspect of the present invention, the material of the polymer component preferably includes the same molecular structure as the molecular structure included in the epoxy resin. Thereby, since the molecular skeleton of the same molecular structure is included, the material of the polymer component is easily compatible with the epoxy resin. Moreover, if it is compatible with the epoxy resin, it is possible to reduce the possibility that the straight chain spreads and segregates with respect to the epoxy resin. As a result, it is possible to obtain an effect of suppressing a decrease in viscosity when the temperature of the resin is increased by the polymer component material.

  As a desirable mode of the present invention, it is preferable that the material of the low molecular component contains two or more epoxy groups and five or more ester groups. Thereby, when resin is made into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%.

  As a desirable embodiment of the present invention, the low molecular component material preferably contains two or more epoxy groups and an ester group and a tertiary amine. Thereby, when resin is made into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%.

  As a desirable aspect of the present invention, the low molecular component material preferably has a total chlorine content of 1% by mass or less of the entire low molecular component material. Thereby, the electrical insulation reliability between wiring layers is securable.

  As a desirable aspect of the present invention, an electronic component built-in module having a wiring pattern and an electronic component electrically connected to the wiring pattern, wherein the electronic component is embedded by a resin of the interlayer insulating sheet for the electronic component built-in module It is preferable that When the temperature of the resin is increased, a viscosity range in which the viscosity of the resin is 300 Pa · s or more and 1000 Pa · s or less can be formed. For this reason, even if heat and pressure are applied to bury the periphery of the electronic component, the possibility that the resin flows out to the periphery excessively can be reduced. As a result, the electronic component incorporated in the electronic component built-in module can be free from defects such as voids, and the thickness of the insulating layer on the upper side of the electronic component (side connected to the wiring layer) can be set to a predetermined thickness. Therefore, when the insulating layer on the top of the electronic component is opened by any method such as laser, wet blasting or plasma etching, and the electronic component electrode and wiring layer are connected by any method such as copper plating, the opening distance is stable. To do. As a result, the continuity between the wiring of the electronic component built-in module and the electronic component is stabilized.

  As a desirable mode of the present invention, it is preferable that there are a plurality of electronic components, and a plurality of electronic components are buried in the resin. In the case of a high-density electronic component module in which the interval between mounted electronic components is, for example, 1 mm or less, the variation in resin thickness on the electrode after embedding between a plurality of electronic components is directly between the wiring and the electronic component. Affects the stability of conduction. Moreover, the electronic component built-in module in which the interval between the electronic components is narrower, the space between the electronic components is narrowed, and filling defects are more likely to occur. However, according to the present invention, the resin can be stably filled even with a narrow interval between electronic components.

  As a desirable aspect of the present invention, it is preferable that the resin is interposed between the wiring pattern and the electronic component. Accordingly, when the resin is opened between the wiring pattern and the electronic component by an arbitrary method such as laser, wet blasting or plasma etching, and the electronic component electrode and the wiring layer are connected by an arbitrary method such as copper plating In addition, the opening distance is stable. As a result, the continuity between the wiring of the electronic component built-in module and the electronic component is stabilized. Moreover, since the opening distance is stable even when 100 or more electronic components are mounted, for example, there are few defects in the opening of the connecting portion, and a high-density electronic component built-in module can be manufactured stably at low cost.

  In order to solve the above-described problems and achieve the object, a method for manufacturing an electronic component built-in module includes a step of mounting an electronic component on a first resin, and an uncured thermosetting resin that becomes a second resin after thermosetting. A step of burying the electronic component with a resin sheet comprising: a step of heat-curing the second resin in which the electronic component is embedded, wherein the step of burying the electronic component includes the uncured second resin. The temperature of the second resin is increased to a temperature at which the viscosity becomes 300 Pa · s or more and 1000 Pa · s or less, and the electronic component is embedded.

  As a result, the resin viscosity at the temperature at which the electronic component is buried becomes 1000 Pa · s or less, so that the high fluidity of the second resin can be secured, and the space between the electronic components arranged at high density is also a gap such as a void. It can be filled without. At the same time, by ensuring a viscosity of 300 Pa · s or more, the possibility that the second resin flows out excessively is reduced, and the built-in electronic component can be buried in a state covered with a predetermined thickness. As a result, the continuity between the wiring of the electronic component built-in module and the electronic component is stabilized.

  As a desirable mode of the present invention, in the step of burying the electronic component, it is preferable that the second resin is heated to a temperature of 80 ° C. or higher and 120 ° C. or lower. As a result, the resin sheet that becomes the second resin in a solid state near room temperature is also in a molten state in the embedding process, and the electronic component can be stably embedded in the second resin.

  As a desirable aspect of the present invention, it is preferable that the second resin has a viscosity change rate of 20% or less from a temperature at which the component is buried to a viscosity increase start temperature. Thereby, the viscosity difference between the high temperature side and the low temperature side can be reduced. As a result, even if the process shifts to the process of curing the second resin by heating or heat and pressure after the electronic component is buried, the change in the thickness of the resin in the electronic component built-in module surface can be reduced. As a result, the continuity between the wiring of the electronic component built-in module and the electronic component is stabilized. Here, the viscosity increase start temperature is the temperature at which the viscosity change from the viscosity decrease due to the temperature increase when the temperature change of the viscosity is measured at a constant temperature rise, and the temperature at which the viscosity has increased by 10% or more from the lowest viscosity. And In order to reduce the unevenness between the part-buried part and the non-buried part after the part is buried, a flattening step by hot pressing or the like at a part-embedding temperature or higher may be performed. In this case, since the difference in viscosity between the high temperature side and the low temperature side is small, the change in the thickness of the resin in the electronic component built-in module surface can be further reduced.

  As a desirable aspect of the present invention, it is preferable that the step of heat-curing the second resin in which the electronic component is embedded exceeds the curing start temperature to raise the temperature of the second resin. Thereby, the second resin can fix the electronic component in a shorter time. Here, the curing start temperature is a temperature at which the viscosity rises to 10,000 Pa · s or more during heating at a constant temperature. Further, since the resin viscosity change in the high temperature region is small, the resin flow out in this step can be suppressed, and the thickness variation of the second resin after this step can be reduced.

  As a desirable mode of the present invention, it is preferred that the second resin is formed by using a material processed into a solid uncured resin sheet at room temperature. The interlayer insulating sheet containing the second resin does not have so-called tackiness at room temperature, and it is desirable that the interlayer insulating sheet does not exhibit adhesiveness only by being left on the substrate. As a result, it is possible to reduce the risk of embracing air at room temperature before pasting. As a result, the generation of voids when the resin sheet is attached with a vacuum laminator or the like is reduced.

  As a desirable aspect of the present invention, the step of burying the electronic component is preferably performed by heating and pressurizing the resin sheet using a vacuum laminator. Thereby, the vacuum laminator can easily handle the resin sheet, and the manufacturing cost of the electronic component built-in module can be reduced. In addition, the vacuum laminator can bury the electronic component stably in all regions in the substrate without variation in the heating rate.

  As a desirable mode of the present invention, it is preferable that there are a plurality of the electronic components, and the step of burying the electronic components includes burying the plurality of electronic components in the second resin. Thereby, a plurality of electronic components can be incorporated. For example, the area on which a plurality of electronic components are mounted can be arranged at a high density of 20% to 60% with respect to the area of the board substrate of the electronic component built-in module. Here, a smaller electronic component built-in module can be manufactured by increasing the mounting area of the electronic component. If electronic components having a plurality of functions are mounted on the electronic component built-in module, the electronic component built-in module can be enhanced. As the electronic components are arranged at a higher density, the viscosity range required for the resin sheet at the time of embedding becomes narrower, but the viscosity can be easily controlled, so that the electronic components can be embedded with a stable resin thickness. For this reason, electrical conduction between the electronic component and the wiring can be stably secured. Thereby, the electronic component built-in module to be manufactured is suitable when many electronic components having fine connection terminals are built therein.

  According to the interlayer insulating sheet for an electronic component built-in module, the electronic component built-in module, and the electronic component built-in module manufacturing method of the present invention, the positional accuracy of the built-in electronic component is improved.

FIG. 1 is a cross-sectional view of the electronic component built-in module according to the present embodiment. 2 is a cross-sectional perspective view taken along line II-II of the electronic component built-in module shown in FIG. FIG. 3 is an explanatory diagram showing temperature-viscosity characteristics of an uncured resin sheet that is the second resin constituting the electronic component built-in module according to the present embodiment. FIGS. 4-1 is explanatory drawing explaining the state at the time of planarization of 2nd resin which comprises the electronic component built-in module which concerns on this embodiment. FIGS. 4-2 is explanatory drawing explaining the state at the time of the heat-hardening of 2nd resin which comprises the electronic component built-in module which concerns on this embodiment. FIG. 5 is a flowchart showing an example of a manufacturing method of the electronic component built-in module. FIG. 6A is an explanatory diagram of the method for manufacturing the electronic component built-in module according to the present embodiment. 6-2 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. 6-3 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. 6-4 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. 6-5 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. FIGS. 6-6 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. FIGS. 6-7 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. FIGS. 6-8 is explanatory drawing of the manufacturing method of the electronic component built-in module which concerns on this embodiment. FIG. 7 is an explanatory diagram showing the outflow rate measurement. FIG. 8 is an example of thickness accuracy evaluation. FIG. 9 is an example of thickness accuracy evaluation.

  DESCRIPTION OF EMBODIMENTS Embodiments (embodiments) for carrying out the present invention will be described in detail with reference to the drawings. The present invention is not limited by the contents described in the following embodiments. The constituent elements described below include those that can be easily assumed by those skilled in the art and those that are substantially the same. Furthermore, the constituent elements described below can be appropriately combined.

(Embodiment 1)
FIG. 1 is a cross-sectional view of the electronic component built-in module according to the present embodiment. 2 is a cross-sectional perspective view taken along line II-II of the electronic component built-in module shown in FIG. As shown in FIG. 1, the electronic component built-in module 10 includes a first wiring layer 32, a second wiring layer 33, a third wiring layer 31, an electronic component 50, a first resin 22, and a second resin 23. And a base material 21. The electronic component built-in module 10 includes an electronic component connecting member 34, an interlayer connecting member 36, an electronic component 50, a first resin 22, between the first wiring layer 32 and the second wiring layer 33. A second resin 23 is disposed. The electronic component 50 includes an electrode 51 on the second wiring layer 33 side. The electrode 51 is connected to the second wiring layer 33 via the electronic component connecting member 34.

  The first wiring layer 32, the second wiring layer 33, the third wiring layer 31, the electronic component connecting member 34, and the interlayer connecting member 36 can be formed of various conductors (for example, metal). . The material of the conductor is not particularly limited. For example, gold (Au), silver (Ag), copper (Cu), nickel (Ni), tin (Sn), chromium (Cr), aluminum (Al), tungsten ( Metal conductive materials such as W), iron (Fe), titanium (Ti), and stainless steel (SUS material) can be used. Among these, it is preferable to use copper (Cu) from the viewpoint of electrical conductivity and cost. The first wiring layer 32, the second wiring layer 33, and the third wiring layer 31 have a wiring pattern that matches the circuit. The electronic component connecting member 34 and the interlayer connecting member 36 are wires that can electrically connect any one of the electronic component 50, the first wiring layer 32, and the second wiring layer 33 in accordance with a circuit.

  The first wiring layer 32 is formed on the surface of the substrate 21 on the second wiring layer 33 side. The base material 21 is a thin plate-shaped member. The third wiring layer 31 is a wiring pattern disposed on the surface opposite to the surface of the substrate 21 on which the first wiring layer 32 is wired. The first wiring layer 32 may be connected to the third wiring layer by a wiring pattern of an internal interlayer connection member (not shown) penetrating the base material 21. Moreover, another base material may be laminated | stacked on the 2nd wiring layer 33, and another wiring layer may be arrange | positioned on an opposite surface through another base material. The wiring layer and the base material are stacked on each other to form a multilayer wiring, and in this embodiment, there may be any number of wiring layers above and below.

  The electronic component 50 is an electronic component such as an IC, a capacitor, or a diode, and is disposed between the first wiring layer 32 and the second wiring layer 33. In the electronic component 50, the outer periphery of the electronic component 50 is surrounded by the first resin 22 and the second resin 23. In the electronic component 50, an electrode 51 is provided on the second wiring layer 33 side. The electrode 51 makes the electronic component 50 and the second wiring layer 33 conductive.

  The first resin 22 is disposed on two surfaces, a surface facing the first wiring layer 32 or the base material 21 and a surface facing the second resin 23. The first resin 22 is in close contact with the first wiring layer 32. The first resin 22 is not particularly limited as long as it can be formed smoothly by any method such as film attachment or application, and various resins such as an epoxy resin and an acrylic resin can be used. More specifically, the epoxy resin is bisphenol A type epoxy resin, bisphenol F type epoxy resin, biphenyl type epoxy resin, cresol novolac type epoxy resin, triphenylmethane type epoxy resin, tetraphenylethane type epoxy resin, phenol aralkyl type. Materials such as epoxy resin, naphthalene type epoxy resin, naphthol type epoxy resin, dicyclopentadiene type epoxy resin, silicon deformation epoxy resin, etc., can be used singly or in combination, electrical characteristics, mechanical From the viewpoints of properties, water absorption, reflow resistance, etc., they can be appropriately selected and used. Further, the first resin 22 may contain an additive such as an optional filler or catalyst, a polymer component, or the like in accordance with the required characteristics. The first resin 22 may be a resin having the same composition as the second resin 23 described later or a similar composition.

  FIG. 3 is an explanatory diagram showing the temperature-viscosity characteristics of a resin sheet before curing, which becomes the second resin constituting the electronic component built-in module according to the present embodiment. FIGS. 4-1 is explanatory drawing explaining the state at the time of planarization of 2nd resin which comprises the electronic component built-in module which concerns on this embodiment. FIGS. 4-2 is explanatory drawing explaining the state at the time of the heat-hardening of 2nd resin which comprises the electronic component built-in module which concerns on this embodiment. The electronic component built-in module 10 preferably has a constant thickness t2 of the second resin 23 on the electronic component 50 shown in FIG. As a result, when the connection hole (via) to be the electronic component connection member 34 is formed by excavation by a predetermined method such as laser, blasting, or plasma etching, the distance (depth) required for the processing becomes constant and stable. Via can be formed. As a result, the processed via can be stably connected to the electrode 51 and the second wiring layer 33 by a technique such as plating, and electrical conduction between the electronic component connecting member 34 and the second wiring layer 33 can be reliably ensured. Because.

  As will be described later, in order for the interlayer insulating sheet of the second resin 23 to cover and bury the electronic component 50, the electronic component 50 is embedded in the second resin 23 by heat treatment. First, as a comparative example, the case where the second resin 23 has a relationship between the viscosity and temperature of the graph G2 shown in FIG. 3 will be described. As shown in the graph G2 in FIG. 3, when the second resin 23 of the comparative example shows a behavior in which the viscosity decreases to about 100 Pa · s by the heat treatment at the time of burying and greatly cures at a curing temperature of 150 ° C. or higher, for example, After pasting the resin sheet on the substrate on which the electronic components are arranged at a temperature of 90 ° C. and a pressure of 0.5 MPa using a vacuum laminator, the second resin 23 is flattened as shown in FIG. For this purpose, the hot press 62 heats and presses the interlayer insulating sheet 23A including the second resin 23 in the direction in which the electronic component 50 is pressed (arrow Z direction). This direction is also the thickness direction of the electronic component built-in module. At this time, even if a step of processing the interlayer insulating sheet 23A of the second resin 23 flatly at a temperature of 110 ° C. and a pressure of 1.5 MPa is added by the hot press 62, for example, the behavior of the graph G2 shown in FIG. Since the viscosity of the second resin 23 shown is too low, the second resin 23 may flow out in the direction of arrow U to the periphery 23R of the electronic component built-in module 10 as shown in FIG. Further, as shown in FIG. 4B, in order to cure the resin in the subsequent process, the temperature is increased from 160 ° C. to 190 ° C. by heating and pressurizing with the vacuum hot press 63, and the electronic component built-in module No. 10 is hardened while the second resin 23 flows further in the direction of the arrow U to the periphery 23R, and the second resin 23 may not have a predetermined thickness.

  As shown in the graph G1 shown in FIG. 3, the second resin 23 of the present embodiment has a viscosity of 300 Pa · s or more and 1000 Pa · s or less near the heat treatment temperature at the time of burying. In addition, it shows a behavior of increasing the viscosity for curing at a temperature of 150 ° C. or higher. For this reason, the second resin 23 has a viscosity of 1000 Pa · s or less in a temperature range of 80 ° C. or more and 100 ° C. or less in which the electronic component is embedded with a vacuum laminator, and sufficiently fills the narrow gap between the electronic components mounted at high density. Can be filled. In addition, by securing the lowest viscosity in this temperature range of 300 Pa · s or more, for example, a process of processing the interlayer insulating sheet 23A of the second resin 23 shown in FIG. Even if the electronic component is embedded, the possibility that the second resin 23 flows out in the direction of the arrow U to the periphery 23R of the electronic component built-in module 10 can be reduced.

  In the graph G1 shown in FIG. 3, the viscosity increase start temperature V and the curing start temperature H are shown. Here, the viscosity increase start temperature V is a temperature at which the viscosity change from the viscosity increase due to the temperature increase is measured when the temperature change of the viscosity is measured at a constant temperature rise, and the viscosity increases by 10% or more from the lowest viscosity. Temperature. In FIG. 3, it can be seen that the viscosity increase start temperature V is around 130 ° C. The curing start temperature H is a temperature at which the viscosity rises to 10,000 Pa · s or more when heated at a constant temperature. Note that the rate of temperature increase is, for example, 5 ° C./min.

  As for the 2nd resin 23 of this embodiment, it is preferable that the fall rate of a viscosity will be 20% or less in the temperature range of 90 to 120 degreeC like the graph G1 shown in FIG. For example, when the viscosity decreases as the temperature becomes higher, the electron as shown in FIG. 4-2 also during the curing process of the second resin 23 by the heat and pressure treatment by the vacuum heat press 63 or the like after the electronic component burying process or the flattening process. There is a possibility that the second resin 23 flows out in the direction of the arrow U to the periphery 23R of the component built-in module 10. The second resin 23 of the present embodiment has a viscosity decrease rate of 20% or less at a temperature of 90 ° C. or higher, for example, in a temperature range of 90 ° C. or higher and 120 ° C. or lower. For this reason, when the 2nd resin 23 hardens | cures, the possibility that the 2nd resin 23 may flow out to the periphery 23R of the electronic component built-in module 10 to the arrow U direction can be reduced.

  Further, it is assumed that the size of a board substrate (collective substrate) including a plurality of electronic component built-in modules 10 is set to 150 mm × 150 mm or more to reduce the manufacturing cost. If the resin viscosity control is not enough and the resin flows too much, the resin flow does not occur at the center of the board because there is no resin escape (movable space), and the resin thickness does not change. It may flow to the outside of the substrate and the resin thickness may be reduced. This tendency becomes more prominent as the size of the aggregate substrate increases. In the electronic component built-in module 10 of the present embodiment, it is possible to reduce the risk that the above-described resin flow will occur excessively. Thereby, the thickness t2 of the second resin 23 on the electronic component 50 shown in FIG. 1 varies, and the possibility that the connection resistance varies depending on the location of the board substrate can be reduced.

  Further, in order to reduce the size and increase the functionality of the electronic component built-in module 10 of the present embodiment, it is required to incorporate electronic components having a narrow pitch between terminals (electrodes). At this time, the pitch interval between the electrodes 51 and 51 that need to be handled is, for example, 120 μm or less. As the electrode pitch becomes narrower, it is necessary to reduce the diameter of the electronic component connecting member 34 in terms of processing position accuracy, electronic component mounting accuracy, and distance from the adjacent electronic component connecting member 34. Furthermore, the length of the electronic component connection member 34 in the stacking direction (electronic component connection distance) also needs to be shortened from the viewpoint of connection hole workability and conduction metal formation (plating, etc.). In addition, the required value of the accuracy of the electronic component connection distance becomes strict, and it is necessary to be ± 10 μm or less. More preferably, the accuracy of the electronic component connection distance is ± 7 μm or less. In the electronic component built-in module 10 of this embodiment, even if the electronic component 50 is buried with the thin second resin 23, the thickness t2 of the second resin 23 shown in FIG. 1 can be made constant. Moreover, the required value mentioned above can be satisfied. Thereby, the possibility of variation in the connection resistance of the electronic component connecting member 34 can be reduced.

  In the electronic component built-in module 10 of the present embodiment, a viscosity of 1000 Pa · s or less can be secured even in a low temperature portion where the uncured resin sheet (interlayer insulating sheet) serving as the second resin 23 is 90 ° C. or less. Thereby, since high resin fluidity | liquidity can be maintained, as shown in FIG. 2, multiple electronic components 50 can be embed | buried. For example, in order to increase the density of the electronic component built-in module 10, the ratio of the area where the plurality of electronic components 50 are mounted to the area of the board substrate of the electronic component built-in module 10 is as high as 20% to 60%. Even when it is made, sufficient filling properties can be secured.

  If electronic components having a plurality of functions are mounted on the electronic component built-in module, the electronic component built-in module can be enhanced. As the electronic components are arranged at higher density, the viscosity range required for the resin sheet at the time of embedding becomes narrower. However, since the electronic component built-in module according to this embodiment can easily control the viscosity with respect to temperature, a stable resin thickness can be obtained. This makes it possible to bury electronic components. For this reason, electrical conduction between the electronic component and the wiring can be stably secured. Thereby, the electronic component built-in module to be manufactured is suitable when many fine electronic components are built in.

  Here, the second resin 23 is not particularly limited as long as it can be molded into a sheet or film, and various resins such as an epoxy resin and an acrylic resin can be used. More preferably, the second resin 23 may include an epoxy resin, a low molecular component material, a high molecular component material, a curing agent, a catalyst, and a filler. More specifically, the epoxy resin is bisphenol A type epoxy resin, bisphenol F type epoxy resin, biphenyl type epoxy resin, cresol novolac type epoxy resin, triphenylmethane type epoxy resin, tetraphenylethane type epoxy resin, phenol aralkyl. Type epoxy resin, naphthalene type epoxy resin, naphthol type epoxy resin, dicyclopentadiene type epoxy resin, silicon deformation epoxy resin, and the like, and these can be used alone or in combination, electrical characteristics, From the viewpoints of mechanical properties, water absorption, reflow resistance, etc., they can be appropriately selected and used.

  In order to improve handling after sheet processing, the epoxy resin is preferably formed by combining two or more of solid and liquid materials among the materials described above. The epoxy resin is formed by combining, for example, a liquid bisphenol A type epoxy resin and a solid bisphenol A type epoxy resin. As another example, the epoxy resin is formed by combining a liquid bisphenol A type epoxy resin and a solid dicyclopentadiene type epoxy resin. As another example, the epoxy resin is formed by combining a liquid bisphenol A type epoxy resin and a solid naphthalene type epoxy resin.

  The material of the low molecular component is not particularly limited as long as the viscosity is 1000 Pa · s or less at room temperature (normal temperature). When the viscosity of the low molecular component material is 1000 Pa · s or less, the viscosity in the temperature range (90 ° C. or less) in which the electronic component 50 is buried in the second resin 23 can be greatly reduced, and bubbles, voids, and the like can be reduced. The material of the low molecular component preferably contains an epoxy group having two or more functional groups and an epoxy equivalent of 500 g / eq or less. Thereby, the strength of the material after curing can be secured, and a decrease in the glass transition temperature can be suppressed. The low molecular component material preferably has a molecular weight of 100 to 500 and an epoxy equivalent of 50 g / eq to 300 g / eq in terms of viscosity and physical properties.

  Moreover, it is more preferable that the material of the low molecular component contains an ester bond or a tertiary amine structure, or an ester bond and a tertiary amine. Thereby, volatility can be suppressed low. The material of the low molecular component preferably contains 2 or more epoxy groups and 5 or more ester groups. Thereby, when it makes it into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%. Moreover, it is preferable that the material of a low molecular component contains two or more epoxy groups and contains an ester group and a tertiary amine. Thereby, when it makes it into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%. As a result, by making the mass decrease within 1%, it is possible to suppress changes in physical properties during the manufacturing process of the second resin 23 and to reduce the adhesion of volatile substances to the apparatus.

  The low molecular component material preferably has a total chlorine (Cl) content of 1% by mass or less of the entire low molecular component material, and preferably 0.3% by mass or less of the entire low molecular component material. Thereby, generation | occurrence | production of the migration resulting from an ionic impurity, etc. can be suppressed, and the electrical insulation reliability between wiring layers can be ensured.

  The material of the polymer component is not particularly limited as long as it is a material compatible with the epoxy resin. If it is compatible with the epoxy resin, the polymer component in the resin composition is in a state in which the straight chain has spread, and the viscosity decrease when the temperature rises can be sufficiently suppressed. Moreover, the possibility that the polymer component segregates with respect to the epoxy resin can be reduced. For this reason, even if temperature rises, it can prevent that a viscosity falls too much. In order to ensure compatibility with the epoxy resin, the material of the polymer component more preferably includes the same structure as the molecular structure included in the epoxy resin used. For example, when the epoxy resin contains a bisphenol A type epoxy resin, it is desirable to add a phenoxy resin as a polymer component.

  The curing agent is not particularly limited as long as it is a material that reacts with an epoxy resin generally used for electronic materials such as a phenol resin or an amine curing agent. For example, the second resin 23 may include cyanoguanidine as a curing agent. Thereby, the characteristics of the glass transition temperature (Tg) to be cured, the low temperature stability, and the curing rate can be adjusted. For example, it is preferable that cyanoguanidine is contained in an amount of 0.4 to 1.0 equivalent with respect to the epoxy equivalent of the epoxy resin.

  The second resin 23 is prepared by using an organophosphorus compound such as triphenylphosphine and tetraphenylphosphine, 2-phenyl-4,5-dihydroxymethylimidazole, 2-phenyl-4-methylimidazole, 1- An imidazole catalyst such as cyanoethyl-2-undecylimidazole can be selected.

  As the second resin 23, an appropriate filler may be added as an additive to the epoxy resin. The filler is not particularly limited. For example, silica, talc, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, aluminum borate whisker, potassium titanate fiber, barium sulfate, alumina, glass flake, nitriding Contains at least one metal of tantalum, aluminum nitride, boron nitride, or magnesium, silicon, titanium, zinc, calcium, strontium, zirconium, tin, neodymium, samarium, aluminum, bismuth, lead, lanthanum, lithium and tantalum Metal oxide powders and the like can be mentioned, and like the resin matrix, these can be used alone or in combination, and are appropriately selected from the viewpoint of electrical characteristics, mechanical characteristics, water absorption, reflow resistance, etc. Can be used. As the second resin 23, silica or fused silica is more preferable from the viewpoints of filling properties, mechanical properties (linear expansion coefficient), and the like. Moreover, it is desirable that the surface of the filler described above is surface-treated with a silane coupling agent or the like.

  As the 2nd resin 23, it is preferable that the mass of the whole resin containing a filler is 100, and filler addition amount is 30 to 80 mass%. In addition, from the viewpoint of reducing stress due to the reduction of voids due to filling, or the difference in linear expansion from electronic components, warpage, and the like, the second resin 23 has a filler addition amount of 70 with the total mass of the resin including the filler being 100. More preferably, it is at least 80% by mass.

  The second resin 23 includes a low molecular component material having a molecular weight of 100 or more and 500 or less, and a high molecular component material having a molecular weight of 10,000 or more and 100,000 or less, with the mass of the epoxy resin being 100%. 1 mass% or more and 20 mass% or less are contained by making the mass of an epoxy resin into 100. Thereby, the characteristic which shows the relationship between the temperature and the viscosity of the graph of G1 shown in FIG. 3 can be obtained.

  Here, in the electronic component built-in module 10, the interlayer connection member 36 is formed in a region where the electronic component 50 is not disposed. In the electronic component built-in module 10, the electronic component 50, the first wiring layer 32, and the second wiring layer 33 can be conducted in any combination by arranging the positions of the interlayer connection members 36 in combination. The electronic component built-in module 10 of the present embodiment is basically configured as described above.

  When the electronic component built-in module 10 is incorporated in a final product and used as a circuit, for example, the second wiring layer 33 and the third wiring layer 31 are connected to other electronic components, Used when electric current (electrical signal) is applied. Further, the electronic component built-in module 10 may be cut and used as an individual substrate before being incorporated into a final product in a state where a plurality of substrates are connected.

  In the electronic component built-in module 10, the total thickness of the first resin 22 and the second resin 23 is larger than the thickness of the electronic component 50. As shown in FIG. 2, the electronic component built-in module 10 can incorporate electronic components 50 at a plurality of locations in the substrate surface. Thereby, the mounting location of the electronic component 50 can be increased. For this reason, the density per electronic component built-in module 10 of the electronic components 50 can be increased. As a result, the circuit has a high density, and the entire circuit is space-saving and low-profile.

  Moreover, in this embodiment, since the better effect with respect to curvature can be acquired, although the base material 21 has been arrange | positioned on one surface side, it is not limited to this, The base material 21 is arrange | positioned on both surfaces. May be. Although the configuration in which three wiring layers are provided is not limited to this, it is sufficient if there is at least one wiring layer.

  Next, a method for manufacturing the electronic component built-in module 10 will be described. Here, FIG. 5 is a flowchart showing an example of a manufacturing method of the electronic component built-in module. FIGS. 6-1 to 6-8 are explanatory diagrams of the method for manufacturing the electronic component built-in module according to the present embodiment. The electronic component built-in module 10 can be manufactured by a manufacturing apparatus having various functions such as a manipulator, a resin curing function, a semiconductor process function, a laser irradiation process, and an etching process. Note that the manufacturing apparatus may be separated into a plurality of apparatuses. Moreover, the operator may perform conveyance between each apparatus and installation of components.

  A method for manufacturing the electronic component built-in module 10 will be described with reference to the flowchart of FIG. Reference is now made to FIGS. 1 to 3 and FIGS. 6-1 to 6-8. First, the manufacturing apparatus performs a preparation process (procedure S31). Here, as a preparation process, as shown in FIG. 6A, the manufacturing apparatus performs processes such as exposure, development, and etching to form the wiring patterns of the first wiring layer 32 and the third wiring layer 31, and A first wiring layer 32 and a third wiring layer 31 are formed together with the material 21.

  Next, as shown in FIG. 6B, the manufacturing apparatus prepares an interlayer insulating sheet 22A including the first resin 22. As described above, the interlayer insulating sheet 22A has a sheet shape at room temperature (25 ° C.).

  The first resin 22 is not particularly limited and can be used as long as it is a resin on which electronic components can be mounted and fixed and can be molded into a sheet or film. Preferably, a thermosetting resin blend containing an epoxy resin, a curing agent, a catalyst, a filler and the like is selected. Further, if the first resin 22 is a resin composition having the same composition as or similar to that of the second resin 23, there is no difference in physical properties between the upper and lower layers of the embedded electronic component 50, and the occurrence of peeling and warping is reduced. Is done.

  Next, as shown in FIG. 6B, the manufacturing apparatus pressurizes the above-described interlayer insulating sheet on the first wiring layer 32 to the first wiring layer 32 for a certain period of time using an atmospheric pressure laminator or a vacuum laminator. Thus, an interlayer insulating sheet attaching step for bringing both into close contact is performed (step S32).

  Next, the manufacturing apparatus performs an electronic component mounting process for mounting electronic components (step S33). Specifically, the manufacturing apparatus mounts (places) an electronic component on the first resin 22 as shown in FIG. 6-3. For example, as shown in FIG. 2, a large number of electronic components 50 are arranged on the first resin 22. The electronic component 50 is mounted on the resin surface 22 a of the first resin 22.

  The component mounting temperature is preferably 40 ° C. or higher and 90 ° C. or lower. This is because the first resin 22 exhibits tackiness and the electronic component 50 to be mounted can be temporarily fixed. The component mounting temperature is more preferably 50 ° C. or higher and 80 ° C. or lower. Even if the first resin 22 is a material that does not have any tackiness at room temperature, sufficient tackiness is exhibited at the component mounting temperature, the electronic component 50 is securely fixed, and the surface of the interlayer insulating sheet is constant and the electronic component 50 is fixed. This is because the risk of sinking can be reduced.

  Next, the manufacturing apparatus performs the first heating process with the electronic component mounted (step S34). In the first heating step, the first resin 22 is cured or semi-cured, and the electronic component 50 is fixed to the surface of the first resin 22. The heating temperature in the first heating step is preferably 140 ° C. or higher and 160 ° C. or lower.

  Next, the manufacturing apparatus performs an electronic component embedded sheet pasting step (step S35). As shown in FIG. 6-4, the manufacturing apparatus prepares an interlayer insulating sheet 23A for embedding electronic components including the second resin 23. For example, the interlayer insulating sheet 23A is a solid sheet at room temperature and is a film-like sheet material. Here, solid means a state that has a fixed shape and volume and is difficult to deform. The second resin 23 is not particularly limited and can be used as long as it is a resin that can be molded into a sheet or film. More preferably, the second resin 23 may include an epoxy resin, a low molecular component material, a high molecular component material, a curing agent, a catalyst, and a filler. More specifically, the epoxy resin is bisphenol A type epoxy resin, bisphenol F type epoxy resin, biphenyl type epoxy resin, cresol novolac type epoxy resin, triphenylmethane type epoxy resin, tetraphenylethane type epoxy resin, phenol aralkyl. Type epoxy resin, naphthalene type epoxy resin, naphthol type epoxy resin, dicyclopentadiene type epoxy resin, silicon deformation epoxy resin, and the like, and these can be used alone or in combination, electrical characteristics, From the viewpoints of mechanical properties, water absorption, reflow resistance, etc., they can be appropriately selected and used.

  In order to improve handling after sheet processing, the epoxy resin is preferably formed by combining two or more of solid and liquid materials among the materials described above. The epoxy resin is formed by combining, for example, a liquid bisphenol A type epoxy resin and a solid bisphenol A type epoxy resin. As another example, the epoxy resin is formed by combining a liquid bisphenol A type epoxy resin and a solid dicyclopentadiene type epoxy resin. As another example, the epoxy resin is formed by combining a liquid bisphenol A type epoxy resin and a solid naphthalene type epoxy resin.

  The material of the low molecular component is not particularly limited as long as it is a liquid resin having a viscosity at room temperature of 1000 Pa · s or less. When the viscosity of the low molecular component material at room temperature is 1000 Pa · s or less, the viscosity in the temperature region where the electronic component 50 is embedded in the second resin 23 decreases, and bubbles, voids, etc. generated when the electronic component is embedded Can be reduced. The material of the low molecular component preferably contains two or more epoxy groups. The low molecular component material preferably has an epoxy equivalent of 500 g / eq or less. Moreover, it is more preferable that the low molecular component material contains two or more epoxy groups and the epoxy equivalent is 50 g / eq or more and 300 g / eq or less. Thereby, since the crosslinking density at the time of hardening can be kept high, a glass transition temperature does not fall too much.

  Further, it is more preferable that the low molecular component material includes an ester bond or a tertiary amine structure, or an ester bond and a tertiary amine structure. Thereby, volatility can be suppressed low. The material of the low molecular component preferably contains 2 or more epoxy groups and 5 or more ester groups. Thereby, when it makes it into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%. Moreover, it is preferable that the material of a low molecular component contains two or more epoxy groups and contains an ester group and a tertiary amine. Thereby, when it makes it into a sheet form, the mass reduction | decrease when drying at 150 degreeC for 3 hours, for example can be suppressed within 1%. As a result, by setting the mass reduction within 1%, it is possible to suppress changes in physical properties during the manufacturing process of the second resin 23 and to reduce the adhesion of volatile substances to the apparatus.

  The low molecular component material preferably has a total chlorine (Cl) content of 1% by mass or less of the entire low molecular component material, and preferably 0.3% by mass or less of the entire low molecular component material. Thereby, generation | occurrence | production of the migration resulting from an ionic impurity, etc. can be suppressed, and the electrical insulation reliability between wiring layers can be ensured.

  The material of the polymer component is not particularly limited as long as the viscosity is a material compatible with the epoxy resin. If it is compatible with the epoxy resin, the straight chain of the polymer component material is expanded in the resin composition, and the viscosity decrease when the temperature rises can be sufficiently suppressed. Moreover, the possibility that the polymer component segregates with respect to the epoxy resin can be reduced. In order to ensure compatibility with the epoxy resin, the material of the polymer component more preferably includes the same type of molecular structure as the structure included in the epoxy resin used. For example, when the epoxy resin contains a bisphenol A type epoxy resin, it is desirable to add a phenoxy resin as a polymer component.

  The curing agent is not particularly limited as long as it is a material that reacts with an epoxy resin generally used for electronic materials such as a phenol resin or an amine curing agent. For example, the second resin 23 may include cyanoguanidine as a curing agent. Thereby, the characteristics of the glass transition temperature (Tg) to be cured, the low temperature stability, and the curing rate can be adjusted. For example, it is preferable that cyanoguanidine is contained in an amount of 0.4 to 1.0 equivalent with respect to the epoxy equivalent of the epoxy resin.

  As the second resin 23, an organic phosphorus compound such as triphenylphosphine or tetraphenylphosphine can be selected as a catalyst. The second resin 23 is an imidazole type such as 2-phenyl-4,5-dihydroxymethylimidazole, 2-phenyl-4-methylimidazole, 1-cyanoethyl-2-undecylimidazole as a catalyst. A catalyst can be selected.

  As the second resin 23, an appropriate filler may be added as an additive to the epoxy resin. The filler is not particularly limited. For example, silica, talc, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, aluminum borate whisker, potassium titanate fiber, barium sulfate, alumina, glass flake, nitriding Contains at least one metal of tantalum, aluminum nitride, boron nitride, or magnesium, silicon, titanium, zinc, calcium, strontium, zirconium, tin, neodymium, samarium, aluminum, bismuth, lead, lanthanum, lithium and tantalum Metal oxide powders and the like can be mentioned, and like the resin matrix, these can be used alone or in combination, and are appropriately selected from the viewpoint of electrical characteristics, mechanical characteristics, water absorption, reflow resistance, etc. Can be used. As the second resin 23, silica or fused silica is more preferable from the viewpoints of filling properties, mechanical properties (linear expansion coefficient), and the like. Moreover, it is desirable that the surface of the filler described above is surface-treated with a silane coupling agent or the like.

  As the 2nd resin 23, it is preferable that the mass of the whole resin containing a filler is 100, and filler addition amount is 30 to 80 mass%. In addition, since the voids due to filling or stress due to the difference in linear expansion from electronic parts, warpage, and the like are reduced, the second resin 23 has a filler addition amount with the total mass of the resin including the filler being 100. More preferably, it is 70 mass% or more and 80 mass% or less.

  The second resin 23 is composed of an epoxy resin, a low molecular component material having an epoxy equivalent of 50 g / eq to 300 g / eq, or a molecular weight of 100 to 500, and a molecular weight of 1 to 20% by mass, where the mass of the epoxy resin is 100. Is a polymer component material of 10,000 to 100,000, and contains 1% by mass to 20% by mass with respect to 100% by mass of the epoxy resin. Thereby, the characteristic which shows the relationship between the temperature and the viscosity of the graph of G1 shown in FIG. 3 can be obtained.

  The interlayer insulating sheet 23A is preferably prepared by dispersing the above-described epoxy resin as the uncured second resin 23, a low molecular component material, a high molecular component material, a curing agent, a catalyst, and a filler as raw material resins. . Dispersion is a composition containing an epoxy resin, a low molecular component material, a high molecular component material, a curing agent, a catalyst, a filler, such as N, N-dimethylformamide, 1-methoxy-2-propanol, or 2-butanone. It is performed by dissolving in a solvent. The solvent is not particularly limited as long as the resin component can be dissolved. Moreover, it is good also considering the 1 type (s) or 2 or more types of the solvent mentioned above as a solvent. When two or more kinds of mixed solvents are used, the drying speed can be adjusted. Moreover, it is preferable to disperse | distribute by a ball mill or a disper mill so that a filler may disperse | distribute to resin.

  The material resin of the interlayer insulating sheet 23A is applied so that the second resin 23 has a predetermined thickness on a base such as polyethylene terephthalate. In the applied second resin 23, the above-described solvent is evaporated in a hot air or infrared drying furnace. The application is performed by a method appropriately selected so as to obtain a predetermined sheet thickness and accuracy, such as a doctor blade method, a slide method, a die coder, or a lip coater.

  As described above, the interlayer insulating sheet 23A has a viscosity of 300 Pa · s to 1000 Pa · s by the heat treatment at the time of burying as shown in the graph G1 of FIG. The interlayer insulating sheet 23A including the second resin 23 is preferably a solid and film-shaped interlayer insulating sheet at room temperature (25 ° C.). Thereby, it becomes easy to handle the sheet-like interlayer insulating sheet at room temperature, and the risk of inadvertent deformation can be reduced. The sheet form at normal temperature refers to a state in which the second resin 23 does not exhibit tackiness (adhesiveness).

  The interlayer insulating sheet 23A is a resin sheet used in a process of burying the periphery of an electronic component within a temperature range of normal temperature or more and a resin viscosity increase start temperature or less, and performing interlayer insulation in the electronic component built-in module, The resin sheet is made of an uncured thermosetting resin, is solid at normal temperature, has a viscosity of 300 Pa · s or more and 1000 Pa · s or less at the temperature at which the electronic component is embedded, and the heat from the temperature at which the electronic component is embedded. It is preferable that the viscosity change rate up to the resin viscosity increase start temperature at which the curable resin starts to increase in viscosity is 20% or less. Alternatively, the interlayer insulating sheet 23A is a resin sheet used in a process of burying the periphery of an electronic component within a temperature range of 80 ° C. or higher and 120 ° C. or lower and performing interlayer insulation in the electronic component built-in module, The resin sheet is made of an uncured thermosetting resin, is solid at normal temperature, has a viscosity of 300 Pa · s to 1000 Pa · s at a temperature at which the electronic component is embedded, and has a viscosity at 90 ° C. The viscosity change rate of the viscosity at 120 ° C. is preferably 20% or less.

  The electronic component embedded sheet pasting step (procedure S35) is performed by the vacuum laminator 61 shown in FIG. 6-5. First, as shown in FIGS. 6-5, the interlayer insulating sheet 23 </ b> A is overlaid at a predetermined position including the electronic component 50. Since it is in a sheet form at normal temperature, there is no tackiness simply by overlapping the interlayer insulating sheet 23A, and the risk of embracing air at normal temperature can be reduced. Thereby, generation | occurrence | production of a void is reduced in an electronic component embedding sheet sticking process. The interlayer insulating sheet 23A is attached to the substrate using a vacuum laminator 61. The vacuum laminator 61 includes vacuum laminator members 61A and 61B made of a rubber plate or a rubber-like balloon so as to enclose the electronic component 50 and the interlayer insulating sheet 23A. It is carried out by applying a pressure of 0.5 MPa isotropically for 30 seconds in the temperature range. The vacuum laminator can easily handle the resin sheet and can reduce the manufacturing cost of the electronic component built-in module. In addition, the vacuum laminator can bury the electronic component stably in all regions in the substrate without variation in the heating rate. Thereby, the electronic component 50 is covered and buried in the second resin 23. The temperature to be heated in this burying process is preferably 120 ° C. or less. Preferably, the burying temperature is 80 ° C. or higher and 100 ° C. or lower. If the burying temperature is 80 ° C. or higher, the viscosity of the second resin 23 that is solid at room temperature can be lowered to a viscosity that can sufficiently fill a narrow space formed between the plurality of electronic components 50. That is, when the embedding temperature is 80 ° C. or higher, the viscosity can be set to 300 Pa · s or more and 1000 Pa · s or less shown in the graph G1 of FIG. In addition, it is preferable that the viscosity increase start temperature V of FIG. 3 is a temperature range of 100 degreeC or more and 150 degrees C or less.

  Also, as shown in FIG. 6-5, the resin surface 23a of the second resin 23 is uneven due to the presence or absence of the electronic component 50, so the resin surface 23a of the second resin 23 opposite to the first resin 22 is flat. It is necessary to. The manufacturing apparatus presses the second resin 23 in the arrow Z direction for 60 seconds at a temperature of 90 ° C. to 120 ° C. and a pressure of 1.5 MPa by the hot press 62 shown in FIG. If the embedding process of the electronic component including the step of attaching the interlayer insulating sheet 23A and the flattening process is set to 120 ° C. or less, an interval can be secured between the curing temperature to be heated in the next process and the embedding temperature. It is possible to suppress an increase in the viscosity due to the progress of curing and variation in the embedded state. In this step, the second resin 23 only needs to be held to the extent that the electronic component 50 is not displaced, and does not need to be completely cured.

  Next, the manufacturing apparatus performs a second heating process for heating and curing the second resin 23 (procedure S36). In the second heating step, for example, a vacuum hot press 63 is used. As shown in FIG. 6-7, the second resin 23 is pressed in the direction of the arrow Z at a pressure of several MPa from 160 ° C. to 190 ° C., and the second resin 23 is cured while being flat. The resin sheet 23 </ b> A serving as the second resin 23 preferably has a viscosity change rate of 20% or less from the temperature at which the component is buried to the viscosity increase start temperature at which the viscosity increase starts. Thereby, the viscosity difference between the high temperature side and the low temperature side can be reduced. As a result, even if the process shifts to the process of curing the second resin by heating or heat and pressure after the electronic component is buried, the change in the thickness of the resin in the electronic component built-in module surface can be reduced. As a result, the continuity between the wiring of the electronic component built-in module and the electronic component is stabilized. Moreover, it is preferable that the temperature for heat curing is higher than the curing start temperature (temperature at which the viscosity rises to 10,000 Pa · s or more). As a result, the resin can be cured in a short time. In this embodiment, as shown in FIGS. 6-7, after the second wiring layer 33 is attached to the upper surface of the second resin 23, the second resin 23 is cured by heating and pressing. As a result, the manufacturing apparatus can form a substrate in which the electronic component 50 is buried with the second resin 23 and the second wiring layer 33 is disposed, as shown in FIGS. 6-8.

  The manufacturing apparatus performs a wiring pattern forming process for forming a wiring pattern on the second wiring layer 33 by exposure, development, etching, or the like (procedure S37). The manufacturing apparatus forms a via at a predetermined position. Here, the via is a hole penetrating the first resin 22 or the second resin 23, a hole reaching the electrode 51 of the electronic component 50 from the second wiring layer 33, or the first wiring layer 32 from the second wiring layer 33. It is a hole that reaches the metal part of. The via can be formed by laser processing or blast processing.

  After the via is formed, the manufacturing apparatus embeds a conductive paste or performs a plating process, and fills the formed via with a metal. The plating treatment may be performed after electroless plating or after only electroless plating. Thereby, as shown in FIG. 1, the electronic component connection member 34 and the interlayer connection member 36 are formed. Thereafter, the manufacturing apparatus patterns the second wiring layer 33 to form wiring as shown in FIG. Thus, a wiring pattern is obtained by removing a part of the metal. The patterning method is not particularly limited. For example, the patterning method may be performed by a normal wiring formation process (resist formation, exposure, etching, mask removal), or by laser processing or blast processing.

  According to the interlayer insulating sheet for an electronic component built-in module, the electronic component built-in module, and the electronic component built-in module manufacturing method of the present embodiment, the electronic component can be buried without voids, and the built-in electronic component and wiring connected thereto Connection stability can be improved, and yield and connection reliability can be increased.

(Evaluation 1)
Hereinafter, evaluation 1 will be described using evaluation examples and comparative examples. Here, an evaluation example and a comparative example of the electronic component built-in module 10 shown in FIG. 1 were prepared using materials shown in the composition of Table 1 below.

  Here, as the epoxy resin A shown in Table 1, a bisphenol A type epoxy resin represented by the following chemical formula 1 was used. Epoxy resin A has an average molecular weight of 370 and an epoxy equivalent of 185 g / eq. Moreover, the epoxy resin B shown in Table 1 used the bisphenol A type epoxy resin shown to following Chemical formula 1. Epoxy resin B has an average molecular weight of 470 and an epoxy equivalent of 475 g / eq.

  Moreover, the epoxy resin C shown in Table 1 used the dicyclopentadiene type epoxy resin (HP7200HH by DIC Corporation) shown in following Chemical formula 2.

  As the curing agent shown in Table 1, cyanoguanidine (DICY7 manufactured by Mitsubishi Chemical Corporation) represented by the following chemical formula 3 was used.

  Moreover, 1-cyanoethyl-2-undecyl imidazole (C11Z-CN manufactured by Shikoku Chemicals) was used as the curing catalyst shown in Table 1.

  Moreover, as for the filler, all of Evaluation Example 1, Evaluation Example 2, and Comparative Example 1 used FB-1SDX manufactured by Denki Kagaku Kogyo. The filler is 75% by mass of the total mass of the sheet. The filler is surface treated with a silane coupling agent KMB573 made by Shin-Etsu Silicon.

  Moreover, the material of the composition of the evaluation example 1 to the evaluation example 5 and the comparative example 1 to the comparative example 2 was prepared with the combination shown in Table 1, respectively. N, N-dimethylformamide manufactured by Kanto Chemical Co., which is the first solvent, and 1-methoxy-2-propanol manufactured by Pure Chemical Co., which is the second solvent, were mixed at 1: 1 to obtain a mixed solvent. The materials having the compositions of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 to Comparative Example 2 were each dissolved in a prepared mixed solvent and dispersed with a ball mill. After the filler is sufficiently dispersed, the materials having the compositions of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 to Comparative Example 2 are respectively applied by a doctor blade method so as to have a predetermined thickness on a base such as polyethylene terephthalate. And dried at 120 ° C. for 10 minutes in a drying furnace.

  Here, in Comparative Example 2, segregation was observed in the sample and was not dispersed as shown in the remarks column of Table 1. In Comparative Example 2, SP-160 manufactured by Nippon Synthetic Chemical Co., Ltd. is used as the polymer component material. Since the main skeleton is polyester and the structure is not similar to that of the epoxy resin A and the epoxy resin C, it is considered that segregation occurred without being compatible. Thereafter, Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 are evaluated.

(Viscosity measurement of evaluation examples and comparative examples)
The evaluation apparatus measured using RAKEStress6000 made from HAAKE. The measurement mode is CD-AutoStrain, the frequency is 1 Hz, and the push weight Fn is 0.5N. The sensor evaluated was PP20 (complate diameter 20 mm) manufactured by HAAKE. The thicknesses of the evaluated interlayer insulating sheets of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 to Comparative Example 2 were 0.4 mm or more and 0.5 mm or less. The temperature range from 50 ° C. to 180 ° C. was measured at 5 ° C./min with the temperature raising condition of the evaluation apparatus. The measurement results are shown in Table 1 in terms of viscosities (Pa · s) at 90 ° C. and 120 ° C.

  As shown in Table 1, in the evaluation examples 1 to 5, the viscosity was in the range of 300 Pa · s to 1000 Pa · s at 90 ° C. and 120 ° C. In Comparative Example 1, the viscosity exceeds 1000 Pa · s at 90 ° C. and 120 ° C. In Evaluation Examples 1 to 5, the molecular weight of the low molecular component material is in the range of 100 to 500. Thereby, it is thought that the viscosity could be reduced at 90 ° C. and 120 ° C. On the other hand, in Comparative Example 1, the materials of the polymer component, the epoxy resin A and the epoxy resin C, the curing agent, and the curing catalyst are the same as those in Evaluation Examples 1 to 5. In Comparative Example 1, the molecular weight of the low molecular component material is in the range of 100 to 500. Further, the low molecular component used in Comparative Example 1 has a viscosity of 3000 at 25 ° C.

(Measurement of glass transition temperature of evaluation example)
The glass transition temperature was measured for Evaluation Example 1 and Evaluation Example 2. The evaluation apparatus measured using DMS6100 made from SII. The measurement mode is tensile, the frequency is 1 Hz, and the temperature raising condition is 5 ° C./min. The measurement results are shown in Table 1.

  As shown in Table 1, the glass transition temperature (Tg) of Evaluation Example 1 is 160 ° C., and the glass transition temperature (Tg) of Evaluation Example 2 is 200 ° C. Evaluation Example 1 has a lower glass transition temperature (Tg) than Evaluation Example 2. This is probably because the low molecular component material of Evaluation Example 1 has an epoxy equivalent of 260 g / eq, and the low molecular component material of Evaluation Example 2 has an epoxy equivalent of 100 g / eq. The electronic component built-in module may be required to have heat resistance, and preferably has a glass transition temperature (Tg) of, for example, 150 ° C. or higher. The glass transition temperature of Evaluation Example 1 has no problem based on this standard. Therefore, it is desirable that the low molecular component material has an epoxy equivalent of 50 g / eq to 300 g / eq from the viewpoint of heat resistance of the electronic component built-in module.

(Evaluation example volatility)
For Evaluation Example 1 to Evaluation Example 5, a change in mass due to volatilization was measured. Evaluation Examples 1 to 5 were each processed into a sheet of 100 mm × 100 mm × 0.07 mm (length × width × thickness) and laminated on a copper foil having a thickness of 12 μm. The mass of the sheet | seat of these evaluation examples 1 to 5 was measured, and it was set as W1. The sheets of Evaluation Example 1 to Evaluation Example 5 were placed in the dryer and heated at 150 ° C. for 3 hours under the same conditions. Thereafter, the sheets of Evaluation Examples 1 to 5 were cooled to room temperature in a desiccator. Then, the mass of the sheet | seat of the evaluation example 1 to the evaluation example 5 was measured, and it was set as W2. Next, the amount of mass reduction was calculated according to the calculation formula of (W1-W2) / W1 × 100%. The remarks column in Table 1 shows the calculation results.

  As shown in Table 1, Evaluation Example 1 and Evaluation Example 2 were able to suppress the mass reduction to 1% or less. On the other hand, in the evaluation examples 3 to 5, the mass reduction could not be suppressed to 1% or less. In Evaluation Example 1, the low molecular component material contains two or more epoxy groups and five or more ester groups. Evaluation Example 2 contains two or more epoxy groups and an ester group and a tertiary amine. Thus, it is considered that the evaluation examples 1 and 2 can suppress the mass reduction to 1% or less. In addition, if the deposits of the manufacturing apparatus are removed by maintenance or the like, the evaluation examples 3 to 5 are also suitable as the electronic component built-in module.

(Embedment evaluation of evaluation examples and comparative examples)
Evaluation of embeddability was performed on Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1. The substrate size of the electronic component built-in module was set to 300 mm × 300 mm, and 676 bare chip-shaped ICs were equally mounted in the range of 260 mm × 260 mm from the center of the substrate of the electronic component built-in module substrate. A bare chip-like IC, which is an electronic component, is placed on the above-described first resin interlayer insulation sheet by a die bonder device, and a sheet-like interlayer insulation sheet (thickness) containing the resins of Evaluation Examples 1 to 5 and Comparative Example 1 0.1 mm). The bare chip IC was 3.5 mm × 3.5 mm × 0.1 mm (length × width × thickness). The measurement pitch was 10 mm × 10 mm intervals (26 rows × 26 columns in the measurement area). Heating and pressurization with a vacuum laminator were performed at a temperature of 90 ° C. and a pressure of 0.5 MPa for 30 seconds, and a bare chip-like IC was embedded with a sheet-like interlayer insulating sheet containing the resins of Evaluation Examples 1 to 5 and Comparative Example 1 It is. Thereafter, the surface of the interlayer insulating sheet was smoothed by hot pressing under conditions of a temperature of 120 ° C. and a pressure of 1.5 MPa for 60 seconds. Thereafter, the presence or absence of voids was visually confirmed using an optical microscope, and any of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 in which voids occurred was evaluated as x. Any of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 in which no void was generated was evaluated as ◯. The evaluation results are shown in Table 1 as embeddability.

  As shown in Table 1, Evaluation Example 1 to Evaluation Example 5 had no voids and were evaluated as ◯. In Comparative Example 1, generation of voids was observed, and the evaluation was x. As described above, in Comparative Example 1, the viscosity of the low molecular component material at 90 ° C. and 120 ° C. exceeds 1000 Pa · s, and the viscosity at 90 ° C. and 120 ° C. does not decrease. It is thought to be caused by

(Evaluation of outflow rate of evaluation example and comparative example)
The outflow rate was measured for Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1. FIG. 7 is an explanatory diagram showing the outflow rate measurement. Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 were each processed into a sheet of 100 mm × 100 mm × 0.06 mm (length × width × thickness), and a polyethylene terephthalate substrate of 100 mm × 100 mm × 50 μm (length × width × thickness) The effluent measurement sample 81 shown in FIG. The runoff measurement sample 81 of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 was pressurized and heated with a hot press device under conditions of a pressure of 2 MPa, a temperature of 170 ° C., and 30 minutes. As shown in FIG. 7, the area of the resin outflow region 82 that protruded from the 100 mm × 100 mm polyethylene terephthalate substrate outflow measurement sample 81 was determined. The outflow rate was calculated as the area of the protruding resin / (100 mm × 100 mm) × 100%. In the evaluation of the outflow rate, the outflow measurement sample 81 having an outflow rate of 20% or less was evaluated as ◯. In the evaluation of the outflow rate, the outflow measurement sample 81 having an outflow rate exceeding 20% was evaluated as Δ. Moreover, the evaluation of the outflow rate was evaluated as x for the outflow measurement sample 81 having an outflow rate exceeding 25%. The evaluation results are shown in Table 1. As shown in Table 1, the evaluation of Evaluation Example 1 to Evaluation Example 5 and Comparative Example 1 was good.

(Evaluation 2)
Hereinafter, evaluation 2 will be described using evaluation examples and comparative examples. Here, an evaluation example and a comparative example of the electronic component built-in module 10 shown in FIG. 1 were prepared using materials shown in the composition of Table 2 below.

  Here, the epoxy resin A, epoxy resin B, epoxy resin C, curing agent, and curing catalyst shown in Table 2 are all the epoxy resin A, epoxy resin B, epoxy resin C, curing agent, curing shown in Table 1 described above. Since it is the same as a catalyst, detailed description is abbreviate | omitted. Further, the same FB-1SDX manufactured by Denki Kagaku Kogyo Co., Ltd. as in Evaluation 1 was used as the filler. This filler is fused silica, and the filler contains 75% by mass. Further, the filler is surface-treated with Shin-Etsu Silicon KMB573.

  As shown in Table 2, in the evaluation examples 6 to 9 and the comparative examples 3 to 6, the material of the low molecular component and the material of the high molecular component are the same. In Evaluation Examples 6 to 9 and Comparative Examples 3 to 6, the epoxy resin contains the epoxy resin A and the epoxy resin B in a mass ratio of 60:40. Evaluation Examples 6 to 9 and Comparative Examples 3 to 6 have the same mass% when the curing agent and the epoxy resin of the curing catalyst are 100. However, Comparative Example 3 does not include a polymer component material. Comparative Example 5 does not include a low molecular component material. Evaluation Examples 6 to 8 and Comparative Examples 3 to 6 are different in mass ratio between a low molecular component material and a high molecular component material when the epoxy resin is 100. As shown in the remarks column of Table 2, Comparative Example 6 was tacky at room temperature. Evaluation Examples 6 to 8 and Comparative Examples 3 to 5 could be formed into a sheet at normal temperature and did not have tackiness.

  Similar to Evaluation 1 described above, viscosity measurement, embedding evaluation, and outflow rate evaluation were performed on Evaluation Examples 6 to 9 and Comparative Examples 3 to 6. Table 2 shows the measurement results and the evaluation results.

  As shown in Table 2, the evaluation examples 6 to 9 are epoxy resin and low-molecular component material having an epoxy equivalent of 50 g / eq to 300 g / eq or a molecular weight of 100 to 500, and the mass of the epoxy resin is 1 mass. % To 20% by mass, and a polymer component material having a molecular weight of 10,000 to 100,000 contains 1% by mass to 20% by mass with respect to 100% by mass of the epoxy resin. Thereby, the viscosity at 90 ° C. or 120 ° C. is changed from 300 Pa · s to 1000 Pa · s. As for the change rate of the viscosity from the temperature of 90 degreeC to the temperature of 120 degreeC, all of Evaluation Examples 6-9 are 20% or less. As a result, in the embeddability evaluation and the outflow rate evaluation, all of the evaluation examples 6 to 9 are ◯.

  As shown in Table 2, in Comparative Example 3, the viscosity at 120 ° C. was 55 Pa · s, and the viscosity change rate was −82.8%. Moreover, the comparative example 3 is x about evaluation of the outflow rate. Since the comparative example 3 does not include the material of the polymer component, it is considered that the viscosity has decreased too much and the outflow rate has increased. In Comparative Example 5, the viscosity at 90 ° C. exceeds 1000 Pa · s. Further, the evaluation of embedding property is X in Comparative Example 5. This is probably because Comparative Example 5 did not contain a low molecular component material, so the viscosity could not be lowered and the embedding property could not be improved. In Comparative Example 4, the polymer component material having a molecular weight of 10,000 or more and 100,000 or less is 30% by mass, where the mass of the epoxy resin is 100. If the polymer component material exceeds 20% by mass with respect to 100 masses of the epoxy resin, the viscosity at 90 ° C. and 120 ° C. exceeds 2000 Pa · s, offsetting the effect of lowering the viscosity of the low molecular component material. It is thought that it will end. In Comparative Example 6, the low molecular component material having a molecular weight of 100 or more and 500 or less is 30% by mass, where the mass of the epoxy resin is 100. When the low molecular component material exceeds 20% by mass with respect to 100 mass of the epoxy resin, the viscosity at 90 ° C. and 120 ° C. is less than 300 Pa · s. As a result, the resin of Comparative Example 6 exhibits tackiness at room temperature, and the evaluation of embedding property is x.

(Thickness accuracy evaluation of evaluation examples and comparative examples)
Next, evaluation of the thickness accuracy of Evaluation Examples 6, 7, 8, 9 and Comparative Examples 3 and 6 was performed. The substrate size of the electronic component built-in module was set to 300 mm × 300 mm, and 676 bare chip-like ICs were equally mounted in the range of 260 mm × 260 mm from the center of the substrate of the electronic component built-in module substrate. A bare chip-like IC, which is an electronic component, is placed on the above-described first resin interlayer insulation sheet by a die bonder device, and a sheet-like interlayer insulation containing the resins of Evaluation Examples 6, 7, 8, 9 and Comparative Examples 3 and 6 Sheets (thickness 0.1 mm) were overlaid. The bare chip IC was 3.5 mm × 3.5 mm × 0.1 mm (length × width × thickness). The measurement pitch was 10 mm × 10 mm intervals (26 rows × 26 columns in the measurement area). The thickness up to the top of the bare chip was measured in advance before embedding the bare chip mounting substrate. By heating and pressurizing at 90 ° C. to 0.5 MPa with a vacuum laminator, sheet-like interlayer insulating sheets containing the resins of Evaluation Examples 6, 7, 8, 9 and Comparative Examples 3 and 6 are placed around the bare chip IC. Embedded. Thereafter, flattening was performed by hot pressing under conditions of a temperature of 120 ° C. and a pressure of 2 MPa. Furthermore, heating and pressurization by a vacuum hot press were performed, and the electronic component built-in module was cured at 170 ° C. for 30 minutes. Measure the thickness t2 of the second resin 23 on the bare chip-like IC, which is the electronic component 50 shown in FIG. did. In the thickness accuracy evaluation, when the thickness accuracy in the measurement area was 3σ and 7 μm or less, the evaluation was “good”. In the thickness accuracy evaluation, when the thickness accuracy in the measurement area exceeds 7 μm at 3σ, the evaluation is Δ. The thickness accuracy evaluation was evaluated as x when the thickness accuracy in the measurement area exceeded 10 μm at 3σ. The evaluation results are shown in Table 2.

  As shown in Table 2, in the thickness accuracy evaluation, all of Evaluation Examples 6, 7, 8, and 9 were “good”. Moreover, the comparative example 6 was (triangle | delta) as thickness precision evaluation. Moreover, the comparative example 3 was x about thickness precision evaluation. 8 and 9 are examples of thickness accuracy evaluation. FIG. 8 shows the in-plane thickness distribution of Evaluation Example 7. FIG. 9 shows the in-plane thickness distribution of Comparative Example 3. Evaluation example 7 shown in FIG. 8 has an in-plane thickness distribution of approximately 21 μm to 24 μm. On the other hand, the in-plane thickness distribution of Comparative Example 3 shown in FIG. 9 is 6 μm to 9 μm at the periphery and 18 μm to 21 μm at the center. FIG. 9 also shows that the outflow rate of Comparative Example 3 is high.

  The above-described interlayer insulating sheet including the second resin 23 has been described using an example applied to an electronic component built-in module. However, the interlayer insulating sheet including the second resin 23 can also be applied to sealing of electronic components.

DESCRIPTION OF SYMBOLS 10 Electronic component built-in module 21 Base material 22 1st resin 22a Resin surface 23 2nd resin 31 3rd wiring layer 32 1st wiring layer 33 2nd wiring layer 34 Electronic component connection member 36 Interlayer connection member 50 Electronic component 51 Electrode 61 Vacuum Laminator

Claims (20)

A resin sheet used in a process of burying the periphery of an electronic component within a temperature range from room temperature to a resin viscosity increase start temperature and insulating the interlayer in the electronic component built-in module,
The resin sheet is made of an uncured thermosetting resin, is solid at normal temperature, has a viscosity of 300 Pa · s or more and 1000 Pa · s or less at a temperature at which the electronic component is embedded, and from the temperature at which the electronic component is embedded. The viscosity change rate up to the resin viscosity increase start temperature at which the thermosetting resin starts increasing in viscosity is 20% or less,
An interlayer insulation sheet for an electronic component built-in module, characterized in that   2. The electronic component built-in module according to claim 1, wherein a temperature at which the periphery of the electronic component is buried is in a range of 80 ° C. or more and 120 ° C. or less, and the viscosity increase start temperature is in a temperature range of 100 ° C. or more and 150 ° C. or less. Interlayer insulation sheet. A resin sheet used in a process of burying the periphery of an electronic component within a temperature range of 80 ° C. or higher and 120 ° C. or lower and performing interlayer insulation in the electronic component built-in module,
The resin sheet is made of an uncured thermosetting resin, is solid at normal temperature, has a viscosity in a range of 300 Pa · s to 1000 Pa · s at a temperature at which the electronic component is embedded, and is at 90 ° C. An interlayer insulating sheet for a module with a built-in electronic component, wherein the viscosity and the viscosity change rate at 120 ° C. are 20% or less. An interlayer insulating sheet containing a resin that embeds the periphery of an electronic component and performs interlayer insulation in the electronic component built-in module,
The resin is an epoxy resin,
A low molecular component material containing 1 to 20% by mass with respect to 100% by mass of the epoxy resin, having a viscosity of 10 to 1,000 Pa · s and a molecular weight of 100 to 500,
A material of a polymer component that is contained in an amount of 1 to 20% by mass, the molecular weight of which is 10,000 to 100,000,
An interlayer insulating sheet for an electronic component built-in module, comprising:   5. The interlayer insulating sheet for an electronic component built-in module according to claim 4, wherein the low-molecular component material includes two or more epoxy groups and has an epoxy equivalent of 50 g / eq to 300 g / eq.   The interlayer insulation sheet for electronic component built-in modules according to claim 4 or 5 in which said resin contains a filler.   The interlayer insulating sheet for an electronic component built-in module according to any one of claims 4 to 6, wherein the material of the polymer component includes the same molecular structure as that of the epoxy resin.   The interlayer insulating sheet for an electronic component built-in module according to any one of claims 4 to 7, wherein the low molecular component material includes two or more epoxy groups and five or more ester groups.   The interlayer insulating sheet for an electronic component built-in module according to any one of claims 4 to 7, wherein the low molecular component material includes two or more epoxy groups and an ester group and a tertiary amine.   The interlayer insulating sheet for an electronic component built-in module according to any one of claims 4 to 9, wherein the low molecular component material has a total chlorine content of 1% by mass or less of the entire low molecular component. A wiring pattern;
An electronic component electrically connected to the wiring pattern,
The electronic component built-in module in which an electronic component is embedded with resin of the said interlayer insulation sheet for electronic component built-in modules of any one of Claim 1 to 10.   The electronic component built-in module according to claim 11, wherein there are a plurality of the electronic components, and the plurality of electronic components are buried in the resin.   The electronic component built-in module according to claim 11 or 12, wherein the resin is interposed between the wiring pattern and the electronic component. Mounting an electronic component on the first resin;
Burying the electronic component with a resin sheet made of an uncured thermosetting resin that becomes the second resin after thermosetting;
Heat curing the second resin in which the electronic component is embedded,
The electronic component built-in module is characterized in that, in the step of burying the electronic component, the temperature of the second resin is increased to a temperature at which the viscosity of the second resin is 300 Pa · s or more and 1000 Pa · s or less, and the electronic component is embedded. Manufacturing method.   The method of manufacturing an electronic component built-in module according to claim 14, wherein the step of burying the electronic component raises the temperature of the second resin to a temperature of 80 ° C. or higher and 120 ° C. or lower.   16. The method for manufacturing an electronic component built-in module according to claim 14, wherein the second resin has a viscosity change rate of 20% or less from a temperature at which the component is buried to a viscosity increase start temperature.   The step of heat-curing the second resin in which the electronic component is embedded heats the second resin beyond a curing start temperature, and hardens the second resin. The manufacturing method of the electronic component built-in module of 1 item | term.   The method of manufacturing a module with a built-in electronic component according to any one of claims 14 to 17, wherein the second resin is formed by using a solid uncured resin sheet processed at room temperature.   The method for manufacturing an electronic component built-in module according to claim 14, wherein the step of burying the electronic component includes heating and pressurizing the resin sheet using a vacuum laminator.   The method for manufacturing an electronic component built-in module according to any one of claims 14 to 19, wherein the electronic component includes a plurality of electronic components, and the step of mounting the electronic components includes burying the plurality of electronic components in the second resin.

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