METHOD FOR MANUFACTURING AN ELECTRONIC MODULE

Description

[0001] The invention relates to a method of producing an electronic module on a flexible planar circuit substrate with a conductor configuration on a first substrate surface and a plurality of electronic components on the opposite, second substrate surface, wherein the components have component contacts, which are electrically connected selectively by way of vias in the circuit substrate and the conductor configuration. The invention covers the final products of the module made by the claimed inventive method described in claim 1.

[0002] Electronic modules which are constructed on planar circuit substrates with prefabricated conductor configuration, known as printed circuit boards, have for decades been indispensable in the field of electronics and electrical engineering and are the subject of constant further development.

[0003] From the many developments, particular attention has been focused in recent years on what are known as system-in-package (SIP) solutions, and specifically embedded chips or chip-in-polymer arrangements. With regard to the prior art in this specific field, reference is made to L. Boettcher et al. "Embedding of Chips for System in Package realization - Technology and Applications", www.izm.fraunhofer.de, with further literature references. In the case of this technology, standard printed circuit board fittings can be used, as stated in the above publication; however, the use of circuit substrates that consist substantially of a thermoset polymer is also known.

[0004] It has been found that standard printed circuit board substrates, particularly in aggressive environments (for example aggressive atmospheric environments or the body of living beings) are not chemically inert enough and / or have excessively high diffusion rates for oxygen and / or water. The fields of application of the aforesaid technology in conjunction with standard printed circuit boards are therefore limited in this respect, and alternative materials are sought. It is known here that certain thermoplastic polymers have advantageous properties in particular in respect of low diffusion rates of oxygen, water and ions; polymers of this kind, however, are not very stable when it comes to thermal lamination in the xy plane. Thus, a person skilled in the art usually does not consider circuit substrate materials of this kind due to the high stability required of the substrate when positioning many microelectronic circuits or other electronic component on an individual substrate.

[0005] JP2010147331A discloses a class substrate having an electrode provided on the surface and an insulating substrate having a through-hole formed thereon.

[0006] Furthermore, US 2009 / 0321118 A1 an electronic component embedded printed circuit board and a manufacturing method thereof. The electronic component embedded printed circuit board includes an insulating layer forming a core layer; an electronic component inserted to project a part thereof on an upper part of the insulating layer; a metallic seed layer formed on the insulating layer including a projected surface of the electronic component; a plating layer formed on the metallic seed layer; circuit patterns electrically connected to pads of the electronic component through via-holes formed on the insulating layer; and a solder resist layer which is formed on the insulating layer and has solder balls attached onto the via-holes electrically connected to the circuit patterns.

[0007] Further, US 2007 / 0235819 A1 discloses a power semiconductor module that includes an interconnect layer including an electrical conductor patterned on a dielectric layer, the electrical conductor including a power coupling portion having a thickness sufficient to carry power currents and a control coupling portion having a thickness thinner than that of the power coupling portion; and a semiconductor power device physically coupled to the interconnect layer and electrically coupled to the power coupling portion of the electrical conductor.

[0008] Furthermore, EP 2 469 591 A2 relates to a method of fabricating a semiconductor device package. The method includes providing a laminate comprising a dielectric film disposed on a first metal layer, said laminate having a dielectric film outer surface and a first metal layer outer surface; forming a plurality of vias extending through the laminate according to a predetermined pattern; attaching one or more semiconductor device to the dielectric film outer surface such that the semiconductor device contacts one or more vias after attachment; disposing an electrically conductive layer on the first metal layer outer surface and on an inner surface of the plurality of vias to form an interconnect layer comprising the first metal layer and the electrically conductive layer; and patterning the interconnect according to a predetermined circuit configuration to form a patterned interconnect layer, wherein a portion of the patterned interconnect layer extends through one or more vias to form an electrical contact with the semiconductor device.

[0009] Further, US 6 306 680 B1 teaches a power semiconductor device package that includes at least one power semiconductor device mounted onto at least one electrically and thermally conductive spacer having an upper end surface bonded to a back surface of the device; a substrate of hardened substrate molding material surrounding the semiconductor device and the spacer except for an active major surface of the device and an lower end surface of the spacer, a dielectric film overlying the device active major surface and a top side of the substrate, the dielectric layer having a plurality of holes aligned with predetermined ones of the contact pads; a top side patterned metal layer on the dielectric film including portions extending into the holes electrically and thermally connected to contact pads of the device; and a backside metal layer on a substrate bottom side electrically and thermally connected to the spacer lower end surface.

[0010] The object of the invention is a method for production of an improved electronic module that in particular can be manufactured with a high positional accuracy of the used components and that is optimised for use in implantable devices and in devices suitable for aggressive environments.

[0011] This object is achieved by a method having the features of claim 1. Expedient developments of the inventive concept are the subject of the dependent claims.

[0012] The invention contains a conscious departure from the prevailing belief that thermoplastic polymers are not suitable for mechanical reasons as substrate material of the circuit substrate of electronic modules, and also includes structural and technical aspects by which an electronic module can be realised with use of a circuit substrate of this kind whilst fulfilling all requirements.

[0013] The circuit substrate of the electronic module preferably comprises or consists of a (flexible) thermoplastic polymer. An electronic module with such a circuit substrate has a number of advantages compared to electronic modules with circuit substrates made for example of thermosetting resins. Such resins are cured during the production process, which leads to chemical bonding of the polymers of the resins to each other. In the cured state, the resin cannot be melted and further components can therefore no longer be melted into the resin. In contrast, an electronic module with a thermoplastic polymer can be further modified by adding further components, since the thermoplastic polymer, unlike the cured resin, can be melted many times over. The electronic modules produced with the method of the invention can therefore be used more flexibly as it can be modulated again after the end of the production process.

[0014] The component contacts are melted or thermally pressed into the surface of the substrate comprising or consisting of a (flexible) thermoplastic polymer. The melting or thermal pressing of the component contact into the substrate leads to an adjustment of the shape of the surface of the substrate to the shape of the component contact and at the same time to the adherence between the component contact and the substrate.

[0015] The thermoplastic polymer of the electronic module is preferably a thermoplastic polymer with a high melting temperature (preferably at least 250°C, more preferably at least 300°C). Electronic modules made with a substrate that comprises or consists of such a polymer have the advantage that the structure of the electronic module is particularly stable. The different components therefore remain exactly in the same position relative to each other, even during handling of the electronic modules at elevated temperatures. This allows for a very accurate placement of further components on the electronic module. Further components are indeed usually placed on a module relative to already existing features on the module, and in particular relative to vias (or bores). Since the vias of the electronic module produced with the method of the invention are particularly mechanically stable, further components can be placed very accurately on the electronic module. Preferred thermoplastic polymers that allow obtaining this effect are thermoplastic polymers that comprise or consist of LCP, PEEK and / or PEI.

[0016] In a particularly preferred embodiment, the thermoplastic polymer of the substrate comprises or consists of LCP. An electronic module with LCP also has the further advantage that it is highly impermeable to water.

[0017] The features of the module are to be understood within the sense of the multi-faceted prior art with the broadest possible meaning. Although the presence of a conductor configuration of this kind on the first substrate surface is essential, a conductor configuration can also be arranged on the second substrate surface, and this also can be configured in the above-mentioned way. Besides the components arranged in accordance with the invention at least on the second surface of the circuit substrate, components can also be placed similarly on the first substrate surface. In principle, a multi-layered design of the module with a plurality of circuit substrates and paired first and second surfaces and accordingly positioned conductor configurations and component groups is also understood to be comprised within the scope of the invention.

[0018] The vias comprise metallisations realised in apertures of the circuit substrate. The apertures will be referred to hereinafter as "bores", even though they are not produced by means of a boring tool, and although they are not necessarily circular-cylindrical. In embodiments of the invention, in a prefabricated pattern of apertures or "bores", it can be that only a predetermined number are provided with a metallisation in accordance with the component placement plan of the circuit substrate. Embodiments of this kind can be realised with a selective metallisation technique (for example by means of a metallisation mask). Alternatively, all bores of the bore pattern can also be provided with an inner wall metallisation, which simplifies the associated metallisation process and makes it less susceptible to faults.

[0019] In one embodiment of the invention the conductor configuration is formed of a first metallisation layer and the vias are formed of a second metallisation layer. This means that the basic connection structure is prefabricated on the circuit substrate and the connection between the used components and the basic structure can be produced once the components have been attached to or inserted into the circuit substrate in a subsequent separate step.

[0020] In preferred embodiments the vias have a metallisation deposited in bores of the circuit substrate. Here, the deposited metallisation can be galvanically reinforced as necessary. In further variants of these embodiments, the vias comprise at least one metal from the group of copper, gold, titanium, tungsten, palladium, chromium, and nickel.

[0021] In a further advantageous embodiment the electronic module is provided at least on the second substrate surface with a thermoplastic protective film encapsulating at least one of the components. This can be made of the same material as the circuit substrate, however the use of a different thermoplastic material is also possible depending on the application. In embodiments that are currently advantageous, the thermoplastic material or one thermoplastic material comprises at least one material from the group of liquid-crystal polymer, or LCP; polyether ether ketone, or PEEK; fluorinated polymers, or polyurethanes.

[0022] In further embodiments the circuit substrate has a thickness in the range between 10 µm and 500 µm, in particular between 10 µm and 100 µm. Depending on the size and complexity of the electronic module and the application, however, thinner or thicker substrates can also be considered in principle.

[0023] In functions / applications that are currently particularly advantageous, the electronic module is formed as an implantable electromedical implant or module thereof. However, it can also be in particular a device or a module of a device that is to be used in "harsh" ambient conditions, in particular in chemically aggressive environments.

[0024] The method according to the invention for producing the above-explained module comprises at least the steps stated in claim 1.

[0025] These steps are also preferably performed in the aforesaid order, although this is not necessary for each step. A conductor configuration is to be understood generally in the sense of a geometric pattern with substantially linear, but also possibly planar conductive coating portions, into which passive functional elements, such as resistors, inductors and capacitors, can also be inserted.

[0026] Furthermore, instead of a heating of the components, a heating of the circuit substrate as such or a combination of the heating both of the components and of the circuit substrate, in each case by suitable means, is also possible in principle in the step used for the fixing of the components in the circuit substrate.

[0027] In one embodiment of the invention the components are heated to a placement temperature in the range between 100°C and 400°C, in particular between 250°C and 350°C, and / or the contact pressure lies in the range between 0.05 N and 50 N, in particular between 0.1 N and 30 N.

[0028] In advantageous embodiments of the method the depositing of metal in the bore pattern is performed following the fusing or thermal pressing-in of the components, in particular by means of an electrochemical or physical thin-film process, such as CVD or PVD. Here, conventional, established disconnection methods can be used, provided there is no need for any specific limitations in respect of the thermoplastic substrate material.

[0029] Following the metal deposition, a galvanic reinforcement of the deposited thin film is optionally performed. The need to carry out a further method step of this kind (which is also somewhat critical in respect of the process conditions from environmental protection and occupational safety aspects) is a decision that is to be made on the basis of the necessary conductivity and robustness of the conductor configuration or vias.

[0030] A thermoplastic protective film is laminated on at least a part or parts of the second substrate surface. This lamination can be performed in the same step in which the circuit substrate is equipped with the components, that is to say to some extent the components are pressed into the circuit substrate as the protective film is laminated on. However, a separation of both steps is also possible in principle. Besides the second substrate surface, the first substrate surface, i.e. that having the conductor configuration, can also be covered by a protective film, such that in particular a sealing is provided on both sides for optimal protection of the electronic module against ambient influences.

[0031] With regard to the method conditions, particularly temperature and contact pressure, the statements provided above normally apply analogously for the step of equipping the circuit substrate with the components; with use of particular lamination films, however, other method parameters can also be set as appropriate.

[0032] Advantages and expedient features of the invention will also become clear from the following description of an exemplary embodiment provided with reference to the figures, in which: Fig. 1shows a schematic cross-sectional illustration of an exemplary embodiment of the electronic module during the production process according to the invention, and Fig. 2shows a schematic illustration of the module according to Fig, 1 after manufacture.

[0033] Fig. 1 schematically shows a circuit substrate 3 of an (unfinished) electronic module 1, which consists of an LCP (liquid-crystal polymer) film 3a with a conductor configuration 3b coated on one side, together with a microchip 5, which carries component contacts 5a on a main surface. The microchip 5 is placed on the surface of the flexible planar circuit substrate 3 opposite the conductor configuration 3b, in such a way that the component contacts 5a are aligned with a pattern of bores 3c in the circuit substrate 3.

[0034] The alignment between the bore pattern in the circuit substrate 3 and the microchip 5 is achieved by means of an optical alignment process, which is symbolised in the figure by an arrow with the reference sign O.A. Assembly systems that are typical in this sector, such as image capture, can be used for this step. Here, the bores 3c in the circuit substrate (the LCP film) are optically recorded and the components are positioned on the circuit substrate with a small positional tolerance (approximately 5 - 25 µm).

[0035] During the positioning, the microchip 5 is heated to a temperature in the vicinity of the Tg of the LCP film 3a, for example a value in the range between 250°C and 350°C, and is pressed with a predetermined force, for example in the range between 0.1 N and 30 N, into the adjacent surface of the LCP film. This is heated locally during this process and thus softens, such that the component contacts 5a are pressed into the adjacent surroundings of the bores 3c and the component adheres flush, without gaps, to the adjacent surface of the circuit substrate 3.

[0036] Fig. 2 shows the finished state of the module 1, in which the aforementioned adhesion of the microchip 5 to the circuit substrate with components 5a penetrating the surface is provided and can be seen in the figure. Furthermore, a metallisation with the surface of the circuit substrate 3 opposite the microchip 5 is in this state performed selectively in those bores 3c in which component contacts 5a are sitting. Vias 7 are hereby formed, which extend as an inner wall metallisation of the corresponding bores 3c from the component contacts 5 to the conductor configurations 3b and thus electrically connect the component contacts to the conductor configuration. This inner wall metallisation can be produced by an electrochemical or physical thin-film process or also a combination of such processes.

[0037] Protective films 9.1 and 9.2 were then laminated one on each of the two surfaces of the circuit substrate 3. The protective films 9.1, 9.2 also consist of a thermoplastic material, for example an LCP film equivalent to the LCP film 3a. This encapsulates the electronic module 1 in a largely diffusion-tight manner with respect to the surrounding environment, and thus enables use in medical implants or devices for use in harsh environments.

[0038] In addition, the invention can also be embodied in a large number of modifications of the examples shown here and aspects of the invention detailed further above.

Claims

1. A method for producing an electronic module on a flexible planar circuit substrate (3) with a conductor configuration (3b) on a first substrate surface and a plurality of electronic components (5) on the opposite, second substrate surface, wherein the electronic components (5) have component contacts (5a), which are electrically connected selectively by way of vias (7) in the circuit substrate (3) and the conductor configuration (3b), wherein the circuit substrate (3) is a thermoplastic polymer and the component contacts (5a) are embedded in the second substrate surface in the region of the vias (7), and further comprising a first thermoplastic protective film (9.1) encapsulating at least one of the electronic components (5) at least on the second substrate surface., the method comprising the following steps: - providing the flexible planar circuit substrate (3) comprising the thermoplastic polymer, - producing the conductor configuration (3b) on the first substrate surface, - producing a bore pattern in accordance with the geometry of the conductor configuration (3b), - heating the components (5) that are to be placed on the second substrate surface, - placing the components (5), aligned with the bore pattern in the circuit substrate (3), on the second substrate surface with a predetermined contact pressure and hereby fusing or thermally pressing the component contacts into the second substrate surface in the region of the bore (3c), - depositing metal selectively into the bore pattern and in the surroundings of the bores (3c) from the first substrate surface in order to produce the vias (7), and - laminating the first thermoplastic protective film (9.1) on at least a part or parts of the second substrate surface.

2. The method according to claim 1, wherein the components (5) are heated to a placement temperature in the range between 100°C and 400°C, and / or the contact pressure lies in the range between 0.05 N and 50 N.

3. The method according to claim 1 or 2, wherein the depositing of metal in the bore pattern is performed following the fusing or thermal pressing-in of the components (5), in particular by means of an electrochemical or physical thin-film process, such as CVD or PVD.

4. The method according to claim 3, wherein, following the metal deposition, a galvanic reinforcement of the deposited thin film is performed.

5. The method according to any one of claims 1 to 4, further comprising laminating a second thermoplastic protective film (9.2) on at least a part or parts of the first substrate surface.

6. The method according to any one of claims 1 to 4 or claim 5, wherein the thermoplastic protective film (9.1, 9.2) is laminated on at a temperature in the range between 100°C and 400°C, and / or the contact pressure lies in the range between 0.05 N and 50 N.

7. The method according to one of the preceding claims, wherein the thermoplastic material of the circuit substrate, the first thermoplastic protective film (91.) or the second thermoplastic protective film (9.2) comprises at least one material from the group of liquid-crystal polymer or LCP; polyether ether ketone, or PEEK; polyetherimide or PEI.