Wiring Substrate Interlayer Conductor Thickness Profile
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Solution Overview
Problem
Existing wiring substrates with varying densities of through-hole conductors exhibit differences in electrical resistance and surface unevenness due to differences in conductor thickness, affecting the mounting quality and performance of components.
Innovation Solution
A wiring substrate design featuring interlayer conductors with varying thickness profiles, where the first interlayer conductors in a lower-density region have a thicker center part and similar or thicker end part compared to the second interlayer conductors in a higher-density region, reducing electrical resistance variations and surface unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the density of interlayer conductors is increased in a region, then the electrical connection between conductor layers is improved, but the surface unevenness and electrical resistance variation worsen due to thinner conductor walls
Solution Approach 1:
The patent applies local quality by making the interlayer conductor walls have non-uniform thickness along their length. Specifically, the wall thickness is increased at the end parts (near the first and second conductor layers) and decreased at the center parts. This local variation in thickness allows the conductor to provide reliable electrical connection at the interfaces while maintaining smoother surfaces in the dense regions, thus resolving the contradiction between electrical connection reliability and surface unevenness.
2Reliability
If the density of through holes is varied across regions, then the electrical resistance is reduced in high-density regions, but the surface unevenness increases affecting component mounting
Solution Approach 1:
The invention applies local quality by varying the wall thickness of interlayer conductors in different regions. In high-density regions where through holes are closely spaced, the reduced wall thickness at center parts creates a smoother surface profile. This local adaptation allows the substrate to maintain good electrical resistance characteristics while providing a more uniform surface for component mounting, thus resolving the contradiction between electrical resistance and manufacturing ease.
3Ease of manufacture
If the wall thickness of interlayer conductors is made uniform, then the manufacturing process is simplified, but the electrical resistance and surface characteristics vary significantly in high-density regions
Solution Approach 1:
The patent applies parameter changes by modifying the wall thickness parameter of interlayer conductors as a function of position. Instead of maintaining a constant wall thickness, the thickness parameter is varied along the length of the conductor, with thicker sections at the ends and thinner sections at the center. This parameter variation allows the system to achieve consistent electrical resistance characteristics across regions with different through hole densities while remaining manufacturable through controlled deposition processes.
Data Source
AI summary
A wiring substrate includes an insulating layer having through holes, a first conductor layer formed on first surface of the insulating layer, a second conductor layer formed on second surface of the insulating layer, and interlayer conductors formed along wall surfaces surrounding the through holes such that each interlayer conductor has a film-like shape and is connecting the first and second conductor layers. The interlayer conductors include first conductors formed in first region of the insulating layer and second conductors formed in second region of the insulating layer at density higher than density of the first conductors, and a thickness of each first interlayer conductor in its end part is substantially same as or larger than a thickness of each second conductor in its end part and a thickness of each first conductor in its center part is larger than a thickness of each second conductor in its center part.


