Method of producing high-frequency modules

• US 6,675,471 B1
• Filed: 04/07/2000
• Issued: 01/13/2004
• Est. Priority Date: 04/09/1999
• Status: Expired due to Fees

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Tsuyama, Kazuhiko, Yajima, Takahiro, Tamura, Toshiaki, Kimura, Junichi
• Primary Examiner(s): Vo, Peter
• Assistant Examiner(s): KIM, PAUL D
• Application Number:
  US09/545,864
• Time in Patent Office: 1,376 Days
• Field of Search: 294/12, 294/13, 294/14, 294/15, 294/17, 298/46, 298/47, 294/265, 298/84, 298/85, 296/11--13, 265/251.4, 723/792, 174/52.2, 174/52.4, 174/261, 174/262, 361/736, 361/744, 361/772, 361/773, 361/790
• US Class Current: 29/846
• CPC Class Codes: H05K 1/0237 High frequency adaptations H05K1/0216 takes precedence
• CPC Class Codes: H05K 1/0268 for electrical inspection or testing
• CPC Class Codes: H05K 2201/09063 Holes or slots in insulating substrate not used for electrical connections
• CPC Class Codes: H05K 2201/0909 Preformed cutting or breaking line
• CPC Class Codes: H05K 2201/10371 Shields or metal cases
• CPC Class Codes: H05K 2203/175 Configurations of connections suitable for easy deletion, e.g. modifiable circuits or temporary conductors for electroplating; Processes for deleting connections
• CPC Class Codes: H05K 3/0052 Depaneling, i.e. dividing a panel into circuit boards; Working of the edges of circuit boards
• CPC Class Codes: H05K 3/3405 Edge mounted components, e.g. terminals
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49156 with selective destruction of conductive paths
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/49224 with coating
• CPC Class Codes: Y10T 29/49789 Obtaining plural product pieces from unitary workpiece
• CPC Class Codes: Y10T 29/49822 by applying force

Abstract

A method of producing high-frequency modules at a higher efficiency is provided comprising: an electronic components mounting step 62 of fabricating on a master substrate 21 rows of sub substrates 22, each the sub substrate 22 having an identical pattern of circuit developed thereon, and mounting electronic components on the sub substrate 22; a step 64 of, after the step 62, providing slits for electrically isolating signal terminals formed integrally; a laser trimming step 66 of, after the step 64, engaging pins 39 of an inspection tooling in direct contact with the signal terminals to conduct an inspection; and a separating step 72 of, after the step 66, separating the sub substrates 22 from the master substrate 21. Accordingly, the productivity for the high-frequency modules will be improved.

Claims

1. A method of producing high-frequency modules comprising:

a first step of fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates formed of substantially a rectangular shape and having an identical pattern of circuit developed thereon, providing on each of two side edges of the sub substrates, a set of signal terminals connected to a first circuit so that the set of signal terminals at each of the two side edges is formed integral with a set of signal terminals provided on a side edge of an adjacent sub substrate and is connected to a second circuit, and electrically isolating any two adjacent sub substrates from each other at their longitudinal end edges;

a second step of, after said first step, mounting electronic components on each of the sub substrates;

a third step of, after said second step, electrically isolating the signal terminals at each of the two side edges of the sub substrates from the signal terminals provided on the side edge of the adjacent sub substrate while the connector regions of the master substrate remain linked to the sub substrates;

a fourth step of, after said third step, conducting an inspection with pins of an inspection tooling engaged in direct contact with the signal terminals of the sub substrates; and

a fifth step of, after said fourth step, separating the sub substrates from the master substrate by cutting along the longitudinal end edges of each of the sub substrates.

2. A method of producing high-frequency modules according to claim 1, wherein the electrical isolation of the signal terminals at said third step is implemented by providing slits.

3. A method of producing high-frequency modules according to claim 2, wherein said third step of electrically isolating the signal terminals at each of the two side edges of the sub substrates from the signal terminals provided on the side edge of the adjacent sub substrate while the connector regions of the master substrate remain linked to the sub substrates is followed by a step of covering the sub substrate with a shielding case.

4. A method of producing high-frequency modules according to claim 3, wherein the cutting edges of the sub substrate are created by cutting along the slits so as to extend more outwardly than the shielding case.

5. A method of producing high-frequency modules according to claim 3, wherein the cutting edges of the sub substrate are created by cutting along the slits so as to be substantially flush with sides of the shielding case.

6. A method of producing high-frequency modules according to claim 5, wherein the sides of the shielding case are more roughed on their surface than the top.

7. A method of producing high-frequency modules according to claim 6, wherein the sub substrates are separated from each other with the use of a rotary blade which is also adapted for roughing the sides of the shielding case.

8. A method of producing high-frequency modules according to claim 3, wherein the shielding case is fabricated by punching a sheet of material with dies, bending the sheet in the direction of punching to form bends, and soldering distal ends of the bends or legs to the grounding terminals provided on the side edges of the sub substrate.

9. A method of producing high-frequency modules according to claim 3, wherein the shielding case is marked down on its top side using a laser beam.

10. A method of producing high-frequency modules according to claim 1, wherein the electrical isolation of the signal terminals at said third step is implemented by providing grooves.

11. A method of producing high-frequency modules according to claim 1, wherein when the pins are moved to engage in direct contact at said fourth step, grounding pins are allowed to touch first and when disengaging, to depart last.

12. A method of producing high-frequency modules according to claim 1, wherein the inspection is to inspect a group of the sub substrates at once.

13. A method of producing high-frequency modules according to claim 12, wherein the inspection at said fourth step is conducted by pressing the pins against substantially identical locations on the signal terminals of each of the sub substrates and feeding the signal terminals with an electric signal.

14. A method of producing high-frequency modules according to claim 1, further comprising a sixth step of, after said fifth step of separating the sub substrates from the master substrate, mounting the separated sub substrates on a tape.

15. A method of producing high-frequency modules comprising:

a first step of fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates formed of substantially a rectangular shape and having an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

a second step of, after said first step, covering each of the sub substrates with a metal shielding case while the sub substrates are in a worksheet form; and

a third step of, after said second step, separating the sub substrates from the master substrate by cutting along side edges of the sub substrates.

16. A method for producing high-frequency modules, said method comprising:

fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, wherein each of the sub substrates has an identical pattern of circuit developed thereon, provided on each of two side edges of the sub substrates is a set of signal terminals connected to a first circuit so that the set of signal terminals at each of the two side edges is formed integral with a set of signal terminals provided on a side edge of an adjacent sub substrate and is connected to a second circuit, and any two adjacent sub substrates are electrically isolated from each other at their longitudinal end edges;

mounting electronic components on each of the sub substrates;

electrically isolating the signal terminals at each of the two side edges of the sub substrates from the signal terminals provided on the side edge of the adjacent sub substrate while the connector regions of the master substrate remain linked to the sub substrates;

conducting an inspection with pins of an inspection tool engaged in direct contact with the signal terminals of the sub substrates; and

separating the sub substrates from the master substrate by cutting along the longitudinal end edges of each of the sub substrates.

17. A method for producing high-frequency modules as claimed in claim 16, wherein said electrically isolating the signal terminals is implemented by providing slits.

18. A method for producing high-frequency modules as claimed in claim 17, wherein said electrically isolating the signal terminals at each of the two side edges of the sub substrates from the signal terminals provided on the side edge of the adjacent sub substrate while the connector regions of the master substrate remain linked to the sub substrates is followed by covering the sub substrates with a shielding case.

19. A method for producing high-frequency modules as claimed in claim 18, wherein the shielding case is fabricated by punching a sheet of material with dies, bending the sheet in the direction of punching to form bends, and soldering distal ends of the bends or legs to the grounding terminals provided on the side edges of the sub substrate.

20. A method for producing high-frequency modules as claimed in claim 18, wherein the shielding case is marked down on its top side using a laser beam.

21. A method for producing high-frequency modules as claimed in claim 16, wherein said electrically isolating the signal terminals is implemented by providing grooves.

22. A method for producing high-frequency modules as claimed in claim 16, wherein when the pins are moved to engage in direct contact at said conducting the inspection, grounding pin are allowed to touch first and when disengaging, to depart last.

23. A method for producing high-frequency modules as claimed in claim 16, wherein said conducting the inspection is performed by inspecting a group of the sub substrates together.

24. A method for producing high-frequency modules as claimed in claim 23, wherein said conducting the inspection is performed by pressing the pins against substantially identical locations on the signal terminals of each of the sub substrates and feeding the signal terminals with an electric signal.

25. A method for producing high-frequency modules as claimed in claim 16, further comprising mounting the separated sub substrates on a tape.

26. A method for producing high-frequency modules, said method comprising:

fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates provided to have an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

covering each of the sub substrates having electronic components mounted thereon with a metal shielding case while the sub substrates are in a worksheet form; and

separating the sub substrates from the master substrate, after said covering, by cutting along the side edges of the sub substrates.

27. A method for producing high-frequency modules as claimed in claim 26, wherein the shielding case is fabricated by punching a sheet of material with dies, bending the sheet in the direction of punching to form bends, and soldering distal ends of the bends or legs to grounding terminals provided on the side edges of the sub substrate.

28. A method for producing high-frequency modules, said method comprising:

fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates provided to have an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

covering each of the sub substrates having electronic components mounted thereon with a metal shielding case; and

marking on a top side of the metal shielding case of each of the sub substrates;

separating the sub substrates from the master substrate, after said marking, by cutting along the side edges of the sub substrates.

29. A method of producing high-frequency modules comprising:

a first step of fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates formed of substantially a rectangular shape and having an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

a second step of, after said first step, covering each of the sub substrates with a metal shielding case; and

a third step of, after said second step, separating the sub substrates from the master substrate by cutting along side edges of the sub substrates;

wherein the metal shielding case is fabricated by bending a metal sheet to form legs, and ground terminals are provided on the side edges of the sub substrates; and

wherein a burr is created on an edge of the metal sheet during the fabrication of the shielding case and the burr generates a gap between an edge of each grounding terminal and the corresponding leg.

30. A method of producing high-frequency modules according to claim 29, wherein the cutting edges of the sub substrate are created by cutting along the side edges so as to extend more outwardly than the shielding case.

31. A method of producing high-frequency modules according to claim 29, wherein the cutting edges of the sub substrate are created by cutting along the side edges so as to be substantially flush with sides of the shielding case.

32. A method of producing high-frequency modules according to claim 31, wherein the sides of the shielding case are more roughed on their surface than on top.

33. A method of producing high-frequency modules according to claim 32, wherein the sub substrates are separated from each other with the use of a rotary blade which is also adapted for roughing the sides of the shielding case.

34. A method of producing high-frequency modules according to claim 29, wherein the shielding case is fabricated by punching a sheet of material with dies, bending the sheet in the direction of punching to form the bends, and soldering distal ends of the bends or legs to the grounding terminals provided on the side edges of the sub substrate.

35. A method for producing high-frequency modules, said method comprising:

fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates provided to have an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

covering each of the sub substrates having electronic components mounted thereon with a metal shielding case; and

separating the sub substrates from the master substrate, after said covering, by cutting along the side edges of the sub substrates;

wherein the metal shielding case is fabricated by bending a metal sheet to form legs, and ground terminals are provided on the side edges of the sub substrates; and

wherein a burr is created on an edge of the metal sheet during the fabrication of the shielding case and the burr generates a gap between an edge of each grounding terminal and the corresponding leg.

36. A method of producing high-frequency modules comprising:

a first step of fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates formed of substantially a rectangular shape and having an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

a second step of, after said first step, covering each of the sub substrates with a metal shielding case;

a third step of engaging pins of an inspection tool in direct contact with signal terminals of the sub substrates to conduct an inspection such that grounding pins of the engaging pins come into contact the earliest with, and depart at the latest from, the signal terminals; and

a fourth step of, after said second step, separating the sub substrates from the master substrate by cutting along side edges of the sub substrates.

37. A method for producing high-frequency modules, said method comprising:

fabricating, on a master substrate, a plurality of sub substrates linked to connector regions at both ends of the master substrate, each of the sub substrates provided to have an identical pattern of circuit developed thereon, and mounting electronic components on each of the sub substrates;

covering each of the sub substrates having electronic components mounted thereon with a metal shielding case;

engaging pins of an inspection tool in direct contact with signal terminals of the sub substrates to conduct an inspection such that grounding pins of the engaging pins come into contact the earliest with, and depart at the latest from, the signal terminals; and

separating the sub substrates from the master substrate, after said covering, by cutting along the side edges of the sub substrates.