Wiring board and manufacturing method thereof

Abstract

To provide a wiring board with less warpage than before.SOLUTION: The present wiring board includes: a core layer including a resin layer mainly composed of a non-photosensitive thermosetting resin, and through wiring penetrating through the resin layer, the core layer having no reinforcement member contained therein; a first wiring structure laminated on one side of the core layer and including a plurality of first wiring layers and a plurality of first insulating layers mainly composed of a photosensitive resin; and a second wiring structure laminated on the other side of the core layer and including a plurality of second wiring layers and a single second insulating layer mainly composed of the photosensitive resin. The first wiring layers are electrically connected to the second wiring layers via the through wiring. The core layer has rigidity greater than that of the first wiring structure and the second wiring structure, and a thickness of the second wiring structure is greater than a thickness of each of the first insulating layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a wiring board and a manufacturing method thereof. [Background technology]

[0002] Conventionally, a multi-layer wiring board having a plurality of wiring layers and insulating layers has been known. For example, a wiring board of this kind has been proposed that has a core board having a front surface and a back surface, a front surface wiring layer formed on the front surface of the core board, a built-up layer formed above the front surface of the core board, a back surface wiring layer formed on the back surface of the core board, and a solder resist layer covering the back surface wiring layer. In this wiring board, the core board is a single insulating layer made of glass epoxy resin with a thickness of about 800 μm. Also, the thickness of each insulating layer on the front surface side of the core board is about 30 μm, and the thickness of the solder resist layer on the back surface side of the core board is about 25 μm (for example, see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3786894 Summary of the Invention [Problem to be solved by the invention]

[0004] Although it is stated that the above wiring board can reduce warping, there is a demand for further reduction in warping.

[0005] The present invention has been made in view of the above-mentioned points, and has an object to provide a wiring board with less warping than conventional wiring boards. [Means for solving the problem]

[0006] This wiring board has a core layer including a resin layer mainly composed of a non-photosensitive thermosetting resin and through-hole wiring penetrating the resin layer, and does not include a reinforcing member; a first wiring structure including a plurality of first wiring layers and a plurality of first insulating layers mainly composed of a photosensitive resin, laminated on one side of the core layer; and a second wiring structure including a plurality of second wiring layers and one second insulating layer mainly composed of a photosensitive resin, laminated on the other side of the core layer; the resin layer has a lower thermal expansion coefficient than the first insulating layer and the second insulating layer; The first wiring layer and the second wiring layer are electrically connected via the through wiring, the core layer has a higher rigidity than the first wiring structure and the second wiring structure, and the thickness of the second wiring structure is thicker than the thickness of each of the first insulating layers. Effect of the Invention

[0007] According to the disclosed technique, it is possible to provide a wiring board with reduced warping compared to conventional wiring boards. [Brief description of the drawings]

[0008] [Figure 1] 1 is a cross-sectional view illustrating a wiring board according to a first embodiment. [Diagram 2] 1A to 1C are diagrams illustrating a manufacturing process of the wiring board according to the first embodiment (part 1). [Diagram 3] 5A to 5C are diagrams illustrating the manufacturing process of the wiring board according to the first embodiment (part 2). [Figure 4] 5A to 5C are views (part 3) illustrating the manufacturing process of the wiring board according to the first embodiment; [Diagram 5] 1 is a cross-sectional view illustrating a wiring board according to a comparative example. [Figure 6] FIG. 13 is a diagram showing the results of simulation 1. [Figure 7] FIG. 13 is a diagram showing the results of simulation 2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the drawings, the same components are denoted by the same reference numerals, and duplicated explanations may be omitted.

[0010] First embodiment [Wiring board structure] First, a description will be given of the structure of the wiring board according to the first embodiment. Fig. 1 is a cross-sectional view illustrating the wiring board according to the first embodiment.

[0011] 1, the wiring board 1 according to the first embodiment has a core layer 10, a first wiring structure 20 provided on one side in the thickness direction of the core layer 10 (upper side in FIG. 1), and a second wiring structure 30 provided on the other side in the thickness direction of the core layer 10 (lower side in FIG. 1). The planar shape of the wiring board 1 can be, for example, a square or rectangular shape. However, the planar shape is not limited thereto, and the wiring board 1 can be any planar shape.

[0012] The core layer 10 includes a resin layer 11 and a plurality of through wires 12, but does not include a reinforcing member such as glass fiber or glass cloth. The through wires 12 penetrate the resin layer 11 from the upper surface 11a to the lower surface 11b. The planar shape of each through wire 12 may be, for example, a circle with a diameter of about 80 to 120 μm. The pitch of the through wires 12 may be, for example, about 90 to 400 μm. The material of the through wires 12 may be, for example, copper (Cu), etc.

[0013] The upper surface 11a of the resin layer 11 and the upper surfaces of the through wiring 12 are, for example, flush. The upper surface 11a of the resin layer 11 and the upper surfaces of the through wiring 12 are polished surfaces. Therefore, the upper surface 11a of the resin layer 11 and the upper surfaces of the through wiring 12 are smooth surfaces (low roughness surfaces) with few irregularities. The roughness of the upper surface 11a of the resin layer 11 and the upper surfaces of the through wiring 12 is set to, for example, about 15 to 40 nm in terms of surface roughness Ra value. Here, the surface roughness Ra value is a type of numerical value representing surface roughness, and is called arithmetic mean roughness, and specifically, it is the arithmetic mean of the absolute values ​​of the heights that change within a measurement region measured from the surface, which is the average line.

[0014] From the viewpoint of reducing warpage of the wiring board 1, it is preferable that the core layer 10 has a higher rigidity than the first wiring structure 20 and the second wiring structure 30. That is, by increasing the rigidity of the core layer 10, the overall rigidity of the wiring board 1 is increased, and the warpage of the wiring board 1 can be reduced. By using a mold resin as the material of the resin layer 11, the rigidity of the core layer 10 can be increased without including a reinforcing member. The mold resin is an insulating resin mainly composed of a non-photosensitive thermosetting resin that can be used in a transfer molding method, a compression molding method, an injection molding method, etc. The mold resin is, for example, an insulating resin such as a non-photosensitive thermosetting epoxy resin, and contains a filler.

[0015] The Young's modulus of the resin layer 11 is preferably 5000 MPa or more and 25000 MPa or less. The Young's modulus of the resin layer 11 can be adjusted, for example, by the type of resin, the type of filler, and the amount of filler contained. Examples of the filler contained in the resin layer 11 include silica (SiO2), kaolin (Al2Si2O5(OH4)), talc (Mg3Si4O 10 (OH2), alumina (Al2O3), etc. These may also be mixed.

[0016] The first wiring structure 20 is a high-density wiring layer in which a wiring layer having a higher wiring density than the second wiring structure 30 is formed, and has a wiring layer 21, an insulating layer 22, a wiring layer 23, an insulating layer 24, a wiring layer 25, an insulating layer 26, and a wiring layer 27. The second wiring structure 30 is a low-density wiring layer in which a wiring layer having a lower wiring density than the first wiring structure 20 is formed, and has a wiring layer 31, an insulating layer 32, and a wiring layer 33.

[0017] In this embodiment, for convenience, the insulating layer 26 side of the wiring board 1 is referred to as the upper side or one side, and the insulating layer 32 side is referred to as the lower side or the other side. Also, the surface of each part on the insulating layer 26 side is referred to as one side or upper surface, and the surface on the insulating layer 32 side is referred to as the other side or lower surface. However, the wiring board 1 can be used upside down or placed at any angle. Also, the planar view refers to the object being viewed from the normal direction of the upper surface 11a of the resin layer 11, and the planar shape refers to the shape of the object being viewed from the normal direction of the upper surface 11a of the resin layer 11.

[0018] The wiring layer 21 is formed on the upper surface 11a of the resin layer 11. The wiring layer 21 includes wiring (wiring pattern or pad) electrically connected to the wiring layer 31 via the through wiring 12 and the wiring layer 33. That is, a part of the lower surface of the wiring layer 21 contacts the upper surface of the through wiring 12, and the two are electrically connected. For example, copper (Cu) or the like can be used as the material of the wiring layer 21. The wiring layer 21 may be a laminated film in which a plurality of conductor layers are laminated.

[0019] The wiring layer 21 has a higher wiring density (narrower line / space) than the wiring layer 31, and is thinner than the wiring layer 31. In this specification, a wiring layer with a line / space of 8 μm / 8 μm or less is defined as a wiring layer with a high wiring density. The line / space of the wiring layer 21 can be, for example, about 1 μm / 1 μm to 3 μm / 3 μm. The thickness of the wiring layer 21 can be, for example, about 1 to 3 μm.

[0020] In line / space, the line represents the wiring width, and the space represents the distance between adjacent wirings (wiring distance). For example, if the line / space is described as 2 μm / 2 μm, it means that the wiring width is 2 μm and the distance between adjacent wirings is 2 μm.

[0021] The insulating layer 22 is an insulating layer whose main component is a photosensitive resin. "Whose main component is a photosensitive resin" means that the insulating layer 22 may contain other components such as a filler in addition to the photosensitive resin. For example, the insulating layer 22 may contain a filler such as silica (SiO2).

[0022] The insulating layer 22 is formed on the upper surface 11a of the resin layer 11 so as to cover the wiring layer 21. Examples of the photosensitive resin used for the insulating layer 22 include insulating resins such as phenol-based resins and polyimide-based resins.

[0023] The wiring layer 23 is formed on one side of the insulating layer 22 and is electrically connected to the wiring layer 21. The wiring layer 23 includes via wiring filled in a via hole 22x that penetrates the insulating layer 22 and exposes the upper surface of the wiring layer 21, and a wiring pattern formed on the upper surface of the insulating layer 22. The via hole 22x may be an inverted truncated cone-shaped recess in which the diameter of the opening opened on the insulating layer 24 side is larger than the diameter of the bottom of the opening formed by the upper surface of the wiring layer 21. The diameter of the opening of the via hole 22x may be, for example, about 10 to 20 μm. The material of the wiring layer 23 and the thickness of the wiring pattern constituting the wiring layer 23 may be, for example, the same as that of the wiring layer 21.

[0024] The line / space of the wiring layer 23 can be, for example, about 1 μm / 1 μm to 3 μm / 3 μm, but it is possible to make the line / space narrower than that of the wiring layer 21. That is, the upper surface 11a of the resin layer 11 is a polished surface and is smoother than the lower surface 11b of the resin layer 11. The upper surface of the insulating layer 22, which is mainly composed of a photosensitive resin, is smoother than the upper surface 11a of the resin layer 11, which is mainly composed of a non-photosensitive thermosetting resin. Therefore, the line / space of the wiring layer 23 can be narrower than that of the wiring layer 21. For example, the line / space of the wiring layer 21 can be 3 μm / 3 μm, and the line / space of the wiring layer 23 can be 1 μm / 1 μm. The same applies to the wiring layer 25 described later.

[0025] The insulating layer 24 is formed on one surface of the insulating layer 22 so as to cover the wiring layer 23. The material of the insulating layer 24 can be, for example, the same as that of the insulating layer 22. The insulating layer 24 may contain a filler such as silica (SiO2).

[0026] The wiring layer 25 is formed on one side of the insulating layer 24 and is electrically connected to the wiring layer 23. The wiring layer 25 includes via wiring filled in the via hole 24x that penetrates the insulating layer 24 and exposes the upper surface of the wiring layer 23, and a wiring pattern formed on the upper surface of the insulating layer 24. The via hole 24x may be an inverted truncated cone-shaped recess in which the diameter of the opening opened on the insulating layer 26 side is larger than the diameter of the bottom of the opening formed by the upper surface of the wiring layer 23. The diameter of the opening of the via hole 24x may be, for example, about 10 to 20 μm. The material of the wiring layer 25 and the thickness of the wiring pattern constituting the wiring layer 25 may be, for example, the same as that of the wiring layer 21. The line / space of the wiring pattern constituting the wiring layer 25 may be, for example, the same as that of the wiring layer 23.

[0027] The insulating layer 26 is formed on one surface of the insulating layer 24 so as to cover the wiring layer 25. In the first wiring structure 20, the insulating layer 26 is the uppermost insulating layer. The material of the insulating layer 26 can be, for example, the same as that of the insulating layer 22. The insulating layer 26 may contain a filler such as silica (SiO2).

[0028] The wiring layer 27 is formed on one side of the insulating layer 26. In the first wiring structure 20, the wiring layer 27 is the uppermost wiring layer. The wiring layer 27 includes via wirings 28 filled in via holes 26x that penetrate the insulating layer 26 and expose the upper surface of the wiring layer 25, and pads 29 protruding from the upper surface of the insulating layer 26. The via holes 26x may be recessed in the shape of an inverted truncated cone, with the diameter of the opening opening on the pad 29 side being larger than the diameter of the bottom of the opening formed by the upper surface of the wiring layer 25. The diameter of the opening of the via holes 26x may be, for example, about 10 to 20 μm.

[0029] The material of the wiring layer 27 may be, for example, the same as that of the wiring layer 21. The thickness of the wiring layer 27 (the sum of the thickness of the via wirings 28 and the thickness of the pads 29) may be, for example, about 10 to 20 μm. The thickness of the pads 29 (the thickness from the upper surface of the insulating layer 26 to the upper surface of the pads 29) may be, for example, about 5 to 10 μm. The planar shape of the pads 29 may be, for example, a circle with a diameter of about 20 to 30 μm. The pitch of the pads 29 may be, for example, about 40 to 50 μm. The pads 29 may be used as external connection terminals for electrical connection to a semiconductor chip.

[0030] A surface treatment layer may be formed only on the top surface of pad 29, or on the top surface and side surface of pad 29. Examples of the surface treatment layer include an Au layer, a Ni / Au layer (a metal layer formed by laminating a Ni layer and a Au layer in this order), a Ni / Pd / Au layer (a metal layer formed by laminating a Ni layer, a Pd layer, and a Au layer in this order), etc. Also, only the top surface of pad 29, or on the top surface and side surface of pad 29, may be subjected to an oxidation prevention treatment such as an OSP (Organic Solderability Preservative) treatment.

[0031] The wiring layer 31 is the lowest wiring layer exposed on the lower surface 32b side of the insulating layer 32, and its upper surface and side surfaces are covered by the insulating layer 32. The lower surface of the wiring layer 31 is exposed, for example, at a position recessed from the lower surface 32b of the insulating layer 32 toward the wiring layer 33 side. However, if necessary, the lower surface of the wiring layer 31 may be flush with the lower surface 32b of the insulating layer 32. Alternatively, a part of the side surface and the lower surface of the wiring layer 31 may protrude downward from the lower surface 32b of the insulating layer 32.

[0032] The wiring layer 31 is, for example, a circular pad with a planar shape of about 150 μm in diameter, but may include a wiring pattern. The interval between adjacent wiring layers 31 may be, for example, about 200 μm. The material of the wiring layer 31 may be, for example, copper (Cu), etc. The thickness of the wiring layer 31 may be, for example, about 10 to 20 μm. The wiring layer 31 may be used as an external connection terminal (pad) for electrically connecting to another wiring board.

[0033] A surface treatment layer 34 may be provided on the lower surface of the wiring layer 31 exposed from the lower surface 32b of the insulating layer 32. Examples of the surface treatment layer 34 include the same surface treatment layer as that which can be provided on the pads 29.

[0034] The insulating layer 32 is a single insulating layer that covers the upper and side surfaces of the wiring layer 31. The insulating layer 32 is an insulating layer whose main component is a photosensitive resin, similar to the insulating layer 22, etc. The insulating layer 32 may contain a filler such as silica (SiO2).

[0035] The wiring layer 33 is a via wiring arranged in the insulating layer 32. More specifically, the wiring layer 33 is a via wiring filled in a via hole 32x that penetrates the insulating layer 32 and exposes the upper surface of the wiring layer 31, and electrically connects the wiring layer 31 (pad) and the through wiring 12. The wiring layer 33 may be formed integrally with the through wiring 12. When the wiring layer 33 and the through wiring 12 are formed integrally, there is no interface between them. The material of the wiring layer 33 can be, for example, the same as that of the through wiring 12.

[0036] The via hole 32x may be an inverted truncated cone-shaped recess in which the diameter of the opening on the resin layer 11 side is larger than the diameter of the bottom of the opening formed by the upper surface of the wiring layer 31. The diameter of the opening of the via hole 32x may be, for example, about 60 to 70 μm. That is, in a cross-sectional view, the wiring layer 33 widens from the wiring layer 31 side toward the through wiring 12 side. Also, in a cross-sectional view, the width of the wiring layer 33 on the side connected to the through wiring 12 is narrower than the width of the through wiring 12 on the side connected to the wiring layer 33.

[0037] From the viewpoint of reducing warpage of the wiring board 1, the thickness T1 of the core layer 10 is preferably thicker than the thickness T3 of the first wiring structure 20 and the thickness T4 of the second wiring structure 30. The thickness T1 of the core layer 10 may be, for example, 100 μm or more and 300 μm or less. However, from the viewpoint of constraints when molding the resin layer 11 and reducing the height of the wiring board 1, the thickness T1 of the core layer 10 is preferably 100 μm or more and 200 μm or less. The thickness T3 of the first wiring structure 20 may be, for example, 20 μm or more and 40 μm or less. The thickness T4 of the second wiring structure 30 may be, for example, 5 μm or more and 40 μm or less.

[0038] The thickness T1 of the core layer 10 is the thickness from the lower surface 11b to the upper surface 11a of the resin layer 11. The thickness T3 of the first wiring structure 20 is the thickness from the lower surface of the insulating layer 22 to the upper surface of the pad 29. The thickness T4 of the second wiring structure 30 is the thickness from the lower surface 32b of the insulating layer 32 to the upper surface of the insulating layer 32.

[0039] The thickness T2 of each of the insulating layers 22, 24, and 26 constituting the first wiring structure 20 is, for example, 5 μm or more and 10 μm or less. From the viewpoint of reducing warpage of the wiring board 1, it is preferable that the thickness T4 of the second wiring structure 30 is thicker than the thickness T2 of each of the insulating layers constituting the first wiring structure 20. For example, if the thickness T2 of each of the insulating layers 22, 24, and 26 is 5 μm, it is preferable that the thickness T4 of the second wiring structure 30 is thicker than 5 μm. For example, if the thickness T2 of each of the insulating layers 22, 24, and 26 is 10 μm, it is preferable that the thickness T4 of the second wiring structure 30 is thicker than 10 μm. The thickness T3 of the first wiring structure 20 may be approximately equal to the thickness T4 of the second wiring structure 30. Here, approximately equal means that the thickness T3 of the first wiring structure 20 is ±20% or less with respect to the thickness T4 of the second wiring structure 30.

[0040] From the viewpoint of reducing warpage of the wiring board 1, the thermal expansion coefficient of the resin layer 11 is preferably smaller than the thermal expansion coefficient of the insulating layers (insulating layers 22, 24, and 26) constituting the first wiring structure 20 and the thermal expansion coefficient of the insulating layer 32 constituting the second wiring structure 30. From the viewpoint of reducing warpage of the wiring board 1, the thermal expansion coefficient of the insulating layers (insulating layers 22, 24, and 26) constituting the first wiring structure 20 is preferably approximately equal to the thermal expansion coefficient of the insulating layer 32 constituting the second wiring structure 30. Here, approximately equal means that the thermal expansion coefficient of the insulating layers (insulating layers 22, 24, and 26) constituting the first wiring structure 20 is within ±20% of the thermal expansion coefficient of the insulating layer 32 constituting the second wiring structure 30.

[0041] The thermal expansion coefficient of the resin layer 11 may be, for example, 5 ppm / ° C. or more and 20 ppm / ° C. or less. The thermal expansion coefficient of the insulating layers (insulating layers 22, 24, and 26) constituting the first wiring structure 20 and the thermal expansion coefficient of the insulating layer 32 constituting the second wiring structure 30 may be, for example, 40 ppm / ° C. or more and 60 ppm / ° C. or less. The thermal expansion coefficient of each insulating layer can be adjusted to a predetermined value by, for example, the filler content, the composition of the insulating resin, etc.

[0042] [Method for manufacturing wiring board according to the first embodiment] Next, a method for manufacturing a wiring board according to the first embodiment will be described. Figs. 2 to 4 are diagrams illustrating the manufacturing process of a wiring board according to the first embodiment. Here, an example of a process for manufacturing one wiring board is shown, but a process in which a plurality of parts that become wiring boards are manufactured and then diced into individual wiring boards may be used. Here, an example of a process for forming a layer structure only on one side of a support is shown, but a process in which a layer structure is formed on both one side and the other side of a support may be used.

[0043] First, in the step shown in FIG. 2(a), a support 100 is prepared, a wiring layer 31 and an insulating layer 32 are formed on the support 100, and a via hole 32x is formed in the insulating layer 32. The support 100 has a structure in which a carrier-attached copper foil 104 is laminated on one side of a core substrate 101. The core substrate 101 is, for example, a resin substrate having a thickness of about 0.7 mm, and may have a reinforcing member such as glass fiber. The carrier-attached copper foil 104 has a structure in which a thin foil 104a made of, for example, copper and having a thickness of about 1.5 to 5 μm is peelably attached to a thick foil (carrier foil) 104b made of, for example, copper and having a thickness of about 10 to 50 μm via a peeling layer (not shown). The thick foil 104b is provided as a support material for facilitating handling of the thin foil 104a.

[0044] The above-mentioned structure of the support 100 is an example, and the support 100 is not limited thereto. For example, in the support 100, a laminate in which a plurality of prepregs are laminated may be used instead of the core substrate 101. The support 100 may have a structure in which a carrier-attached copper foil 104 is disposed on one side of a glass substrate, a metal substrate, or the like, via a release layer.

[0045] After the support 100 is prepared, first, the wiring layer 31 is formed on one side of the support 100. Specifically, a resist layer having an opening in a portion where the wiring layer 31 is to be formed is formed on the upper surface of the carrier-attached copper foil 104 (upper surface of the thin foil 104a) using a dry film resist or the like. Then, by electrolytic plating using the carrier-attached copper foil 104 as a power supply layer, the wiring layer 31, which is an electrolytic plating layer, is formed on the upper surface of the carrier-attached copper foil 104 exposed in the opening. The material and thickness of the wiring layer 31 are as described above. Thereafter, the resist layer is peeled off.

[0046] Next, a liquid or paste-like photosensitive resin is applied to the upper surface of the copper foil 104 with the carrier so as to cover the wiring layer 31, and then heated at a temperature at which the resin does not harden to form a semi-hardened insulating layer 32. The material and thickness of the insulating layer 32 are as described above. Then, for example, via holes 32x that expose the wiring layer 31 are formed in the insulating layer 32 by photolithography, and the insulating layer 32 is then heated to a hardening temperature or higher to harden it.

[0047] 2(b), a wiring layer 33 that will become a via wiring is formed so as to fill the via hole 32x, and further, a through wiring 12 that protrudes from the upper surface of the insulating layer 32 is formed integrally with the wiring layer 33. The wiring layer 33 and the through wiring 12 can be continuously formed using, for example, a semi-additive method. Specifically, first, a seed layer is formed by electroless plating or sputtering on the upper surface of the insulating layer 32, the inner wall surface of the via hole 32x, and the upper surface of the wiring layer 31 exposed in the via hole 32x.

[0048] Then, a photosensitive resist layer is formed on the entire upper surface of the seed layer, and the resist layer is exposed and developed to form an opening that exposes the portion where the wiring layer 33 and the through wiring 12 are to be formed. Then, an electrolytic plating layer is formed on the upper surface of the seed layer exposed in the opening by electrolytic plating using the seed layer as a power supply layer. Then, after peeling off the resist layer, the electrolytic plating layer is used as a mask to remove the seed layer in the portion not covered by the electrolytic plating layer by etching. As a result, the wiring layer 33 and the through wiring 12 in which the electrolytic plating layer is laminated on the seed layer are continuously formed. The materials of the wiring layer 33 and the through wiring 12 are as described above. Note that the wiring layer 33 and the through wiring 12 have a structure in which the electrolytic plating layer is laminated on the seed layer, but in FIG. 2(b) and the like, the distinction between the seed layer and the electrolytic plating layer is omitted (the same may be omitted for other wiring layers).

[0049] Next, in the step shown in FIG. 2(c), a resin layer 11 not including a reinforcing member is formed on the insulating layer 32 so as to cover the upper and side surfaces of the through-hole wiring 12. The resin layer 11 can be formed, for example, by a molding method using a molding resin. For example, the structure shown in FIG. 2(b) is placed in a metal mold, and a molding resin is introduced into the metal mold by applying pressure (for example, 5 to 10 MPa). Thereafter, the molding resin is heated at a temperature of about 180° C. to harden it, thereby forming the resin layer 11. Then, after the required sealing process is completed, the structure covered with the resin layer 11 is taken out from the metal mold. For example, a transfer molding method, a compression molding method, an injection molding method, etc. can be used as the molding method.

[0050] Next, in the step shown in Fig. 3(a), the upper surface 11a side of the resin layer 11 shown in Fig. 2(c) is polished to expose the upper surface of the through wiring 12. For example, a chemical mechanical polishing (CMP) method or the like can be used to polish the resin layer 11. For example, the upper surface of the through wiring 12 can be made flush with the upper surface 11a of the resin layer 11. In this step, the core layer 10 having the resin layer 11 and the through wiring 12 is completed.

[0051] When polishing the resin layer 11, the upper surface side of the through wiring 12 may be polished and removed at the same time. This can reduce the roughness of the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12. In other words, the smoothness of the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12 can be improved. The roughness of the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12 after polishing can be, for example, about Ra15 to 40 nm. In this way, by reducing the roughness of the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12 and improving the smoothness, it becomes possible to form fine wiring (a wiring layer with high wiring density) in a later process. The roughness of the lower surface 11b of the resin layer 11 is, for example, about Ra180 to 280 nm.

[0052] Next, in the step shown in FIG. 3(b), the first wiring structure 20 is laminated on the core layer 10 (the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12). First, a wiring layer 21 having a predetermined pattern is formed on the upper surface 11a of the resin layer 11 and the upper surface of the through wiring 12. The wiring layer 21 can be formed, for example, by using a semi-additive method. The semi-additive method is as described above. Next, a liquid or paste-like photosensitive resin is applied to the upper surface 11a of the resin layer 11 so as to cover the wiring layer 21, and then heated at a temperature at which the resin layer 11 does not harden to form an insulating layer 22 in a semi-hardened state. The material and thickness of the insulating layer 22 are as described above. Next, for example, a via hole 22x is formed by a photolithography method, and then the insulating layer 22 is heated to a hardening temperature or higher to harden it. The upper surface of the insulating layer 22, which is mainly composed of a photosensitive resin, becomes smoother than the upper surface 11a of the resin layer 11. The roughness of the upper surface of the insulating layer 22 may be, for example, about Ra 2 to 6 nm.

[0053] Next, the same steps as above are repeated to form the wiring layer 23, the insulating layer 24, the wiring layer 25, and the insulating layer 26, and then the wiring layer 27 including the via wiring 28 and the pad 29 is formed. The via wiring 28 and the pad 29 can be formed, for example, in the same manner as the wiring layer 33 and the through wiring 12. The materials and thicknesses of the wiring layer 23, the insulating layer 24, the wiring layer 25, the insulating layer 26, and the wiring layer 27 are as described above.

[0054] Next, in the step shown in FIG. 3(c), the outer periphery of the entire structure shown in FIG. 3(b) is cut using a dicing blade or the like. Next, in the step shown in FIG. 4(a), the support 100 shown in FIG. 3(c) is removed. To remove the support 100, first, the core substrate 101 and the thick foil 104b are mechanically peeled off from the thin foil 104a. Then, the thin foil 104a is removed by wet etching using, for example, an aqueous solution of ferric chloride, an aqueous solution of cupric chloride, an aqueous solution of ammonium persulfate, or the like. At this time, if the wiring layer 31 is made of copper, the lower surface side of the wiring layer 31 is also etched, and the lower surface of the wiring layer 31 is recessed from the lower surface 32b of the insulating layer 32 toward the wiring layer 33.

[0055] 4(b), if necessary, a surface treatment layer 34 is formed on the lower surface of the wiring layer 31 of the structure of FIG. 4(a), completing the wiring board 1. For the surface treatment layer 34, for example, the above-mentioned metal layer or a laminate of metal layers may be formed by electroless plating, or an anti-oxidation treatment such as OSP treatment may be performed. Note that a surface treatment layer similar to the surface treatment layer 34 may be formed only on the upper surface of the pad 29, or on the upper surface and side surface of the pad 29.

[0056] In this manner, in the wiring board 1, a first wiring structure 20 having a lower rigidity than the core layer 10 is laminated on one side of the highly rigid core layer 10, and a second wiring structure 30 having a lower rigidity than the core layer 10 is laminated on the other side. The second wiring structure 30, which has fewer insulating layers than the first wiring structure 20, has a thickness T4 that is thicker than the thickness T2 of each insulating layer that constitutes the first wiring structure 20. This structure makes it possible to approach a structure that is symmetrical in the up-down direction (thickness direction) with the highly rigid core layer 10 at the center, thereby reducing warping of the wiring board 1.

[0057] From the viewpoint of reducing warpage of the wiring board 1, the thickness T1 of the core layer 10 is thicker than the thickness T3 of the first wiring structure 20 and the thickness T4 of the second wiring structure 30, and is preferably 100 μm or more and 200 μm or less. Furthermore, from the viewpoint of reducing warpage of the wiring board 1, the thickness T3 of the first wiring structure 20 is preferably approximately equal to the thickness T4 of the second wiring structure 30. Furthermore, in the first wiring structure 20, the thickness of the laminate of the insulating layers 22, 24, and 26 excluding the pad 29 is thinner than the thickness T4 of the second wiring structure 30.

[0058] Furthermore, in the wiring board 1, the core layer 10 does not include a reinforcing member. That is, the resin layer 11 used in the step of Fig. 2(c) does not include a reinforcing member. Therefore, in the step of Fig. 2(c), the through wiring 12 can be easily covered with the resin layer 11. Furthermore, by using a mold resin as the material of the resin layer 11, the rigidity of the core layer 10 can be increased even without including a reinforcing member.

[0059] In the wiring board 1, the thermal expansion coefficient of the resin layer 11 is 5 ppm / ° C. or more and 20 ppm / ° C. or less. The thermal expansion coefficients of the insulating layers 22, 24, and 26 constituting the first wiring structure 20 and the thermal expansion coefficient of the insulating layer 32 constituting the second wiring structure 30 are each 40 ppm / ° C. or more and 60 ppm / ° C. or less. This improves the imbalance in the thermal expansion coefficients in the vertical direction (thickness direction) around the core layer 10, thereby reducing warping of the wiring board 1.

[0060] Furthermore, by reducing the warping of wiring board 1, it becomes easier to mount a semiconductor chip on the wiring layer 27 side of wiring board 1, or to mount wiring board 1 on another wiring board.

[0061] 3(b) may be the shipping form, that is, the wiring board 1 with the support 100 attached may be the shipping form.

[0062] <Warp Simulation> [Simulation 1] FIG. 5 is a cross-sectional view illustrating a wiring board according to a comparative example. The wiring board 1X shown in FIG. 5 is different from the wiring board 1 in that it does not have a core layer 10 and is provided with an insulating layer 32A having a glass cloth as a reinforcing member 35 formed from a non-photosensitive thermosetting resin. Here, a simulation 1 of warping when the wiring board 1 and the wiring board 1X are heated to 180°C and then returned to room temperature is performed. The conditions of the simulation 1 are shown in Table 1. In the wiring board 1 and the wiring board 1X, the thermal expansion coefficients of the insulating layers 22, 24, and 26 are set to 40 ppm / °C. In the wiring board 1, the thermal expansion coefficient of the insulating layer 32 is set to 13.8 ppm / °C. In the wiring board 1X, the thermal expansion coefficient of the insulating layer 32A is set to 12.7 ppm / °C.

[0063] [Table 1] The results of simulation 1 are shown in FIG. 6. As shown in FIG. 6, wiring board 1X warped in a direction in which wiring layer 31 side was convex, and the warp amount was -5.55 mm. In contrast, wiring board 1 warped in a direction in which wiring layer 31 side was convex, and the warp amount was -2.20 mm. That is, it was confirmed that the structure of wiring board 1 can reduce the warp amount to 1 / 2 or less in absolute value compared to wiring board 1X. The warp amount referred to here is the distance in the thickness direction between the highest point and the lowest point when the wiring board is placed on a flat surface. Also, a negative value indicates that the warp is in a direction in which wiring layer 31 side is convex.

[0064] [Simulation 2] In simulation 2, in wiring board 1 shown in Table 1, the change in the amount of warpage when thickness T1 of core layer 10 and thickness T4 of second wiring structure 30 were changed was examined.

[0065] [Table 2] The results of Simulation 2 are shown in Table 2 and Fig. 7. From Table 2 and Fig. 7, if the thickness T1 of the core layer 10 is 100 µm or more and 300 µm or less, and the thickness T4 of the second wiring structure 30 is greater than the thickness T2 of each of the insulating layers 22, 24, and 26, the amount of warping can be reduced to 1 / 2 or less in absolute value compared to the wiring board 1X shown in Table 1.

[0066] 7, if the thickness T1 of the core layer 10 is 100 μm or more and 300 μm or less, and the thickness T4 of the second wiring structure 30 is approximately twice the thickness T2 of each of the insulating layers 22, 24, and 26, the amount of warping can be reduced to 1 / 5 or less, in absolute value, compared to the wiring board 1X shown in Table 1. It is expected that similar results will be obtained even if the thickness T1 of the core layer 10 is 100 μm or more and 300 μm or less, and the thickness T4 of the second wiring structure 30 is twice or more the thickness T2 of each of the insulating layers 22, 24, and 26.

[0067] As described above, in view of restrictions imposed when molding resin layer 11 and the need to reduce the height of wiring board 1, it is preferable that core layer 10 has thickness T1 of 100 μm or more and 200 μm or less.

[0068] Although the preferred embodiments have been described in detail above, the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims. [Explanation of symbols]

[0069] 1. Wiring board 10 Core Layer 11 Resin layer 11a Top surface 11b,32b Bottom surface 12 Through Wiring 20 1st wiring structure 21,23,25,27,31,33 wiring layer 22, 24, 26, 32 Insulating layer 22x, 24x, 26x, 32x via holes 28 Via wiring 29 Pad 30 Second wiring structure 34 Surface treatment layer 100 support 101 Core Board 104 Copper foil with carrier 104a thin foil 104b thick foil

Claims

1. a core layer including a resin layer mainly composed of a non-photosensitive thermosetting resin and a through-wire penetrating the resin layer, and not including a reinforcing member; a first wiring structure including a plurality of first wiring layers and a plurality of first insulating layers mainly made of a photosensitive resin, the first wiring structure being laminated on one side of the core layer; a second wiring structure including a plurality of second wiring layers and one second insulating layer mainly made of a photosensitive resin, the second wiring structure being laminated on the other side of the core layer; the resin layer has a lower thermal expansion coefficient than the first insulating layer and the second insulating layer; the first wiring layer and the second wiring layer are electrically connected via the through-wire; the core layer has a higher rigidity than the first wiring structure and the second wiring structure; A wiring substrate, wherein the second wiring structure has a thickness greater than a thickness of each of the first insulating layers.

2. The wiring board according to claim 1 , wherein the thickness of the core layer is greater than a thickness of the first wiring structure and a thickness of the second wiring structure.

3. 3. The wiring board according to claim 1, wherein a thickness of the first wiring structure is substantially equal to a thickness of the second wiring structure.

4. The wiring board according to claim 1 , wherein the core layer has a Young's modulus of 5,000 MPa or more and 25,000 MPa or less.

5. 5. The wiring board according to claim 1, wherein the second wiring layer includes a pad exposed from the second insulating layer and a via wiring arranged in the second insulating layer and electrically connecting the pad and the through wiring, the via wiring being formed integrally with the through wiring.

6. The wiring board according to claim 5 , wherein in a cross-sectional view, the via wiring increases in width from the pad side to the through wiring side.

7. 7. The wiring board according to claim 5, wherein in a cross-sectional view, a width of the via wiring on a side connected to the through wiring is narrower than a width of the through wiring on a side connected to the via wiring.

8. a core layer including a resin layer mainly composed of a non-photosensitive thermosetting resin and a through-wire penetrating the resin layer, and not including a reinforcing member; a first wiring structure including a plurality of first wiring layers and a plurality of first insulating layers mainly made of a photosensitive resin, the first wiring structure being laminated on one side of the core layer; a second wiring structure including a plurality of second wiring layers and one second insulating layer mainly composed of a photosensitive resin, the second wiring structure being laminated on the other side of the core layer; the first wiring layer and the second wiring layer are electrically connected via the through-wire; the core layer has a higher rigidity than the first wiring structure and the second wiring structure; a thickness of the second wiring structure is greater than a thickness of each of the first insulating layers; a method for manufacturing a wiring board, the method comprising the steps of: forming a via wiring layer on the second insulating layer; and electrically connecting the pad and the through wiring to the pad and the through wiring, the method comprising the steps of: forming the second insulating layer covering the pad; forming a via hole in the second insulating layer to expose the pad; forming the via wiring so as to fill the via hole, and further forming the through wiring protruding from the second insulating layer integrally with the via wiring; forming the resin layer on the second insulating layer so as to cover an upper surface and a side surface of the through-hole wiring; polishing the upper surface side of the resin layer to expose the upper surface of the through wiring; laminating the first wiring structure on the upper surface of the resin layer and on the upper surface of the through wiring.

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