Laminated body, circuit board including laminated body, semiconductor package and process for manufacturing laminated body

• US 8,871,660 B2
• Filed: 02/07/2008
• Issued: 10/28/2014
• Est. Priority Date: 02/08/2007
• Status: Expired due to Fees

• Current Assignee: Sumitomo Bakelite Company Limited
• Original Assignee: Sumitomo Bakelite Company Limited
• Inventors: Yoshizaki, Kazuyuki, Ito, Teppei, Onozuka, Iji, Nakamura, Kensuke
• Primary Examiner(s): Pierce, Jeremy R
• Application Number:
  US12/523,320
• Publication Number:
  US 20100078201A1
• Time in Patent Office: 2,455 Days
• Field of Search: 442/203, 442/239, 442/242, 442/175, 442/218, 442/232, 442/234, 442/238, 174/255, 156/60, 156/148, 156/182
• US Class Current: 442/238
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/30 having particular thermal properties
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2457/08 PCBs, i.e. printed circuit boards
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/322 : comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: H05K 1/0271 : Arrangements for reducing stress or warp in rigid printed circuit boards, e.g. caused by loads, vibrations or differences in thermal expansion
• CPC Class Codes: H05K 1/036 : Multilayers with layers of different types
• CPC Class Codes: H05K 1/0366 : reinforced, e.g. by fibres, fabrics H05K1/036 takes precedence
• CPC Class Codes: H05K 2201/029 : Woven fibrous reinforcement or textile textile substrates H05K1/038
• CPC Class Codes: H05K 2201/09136 : Means for correcting warpage
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24124 : Fibers
• CPC Class Codes: Y10T 442/2951 : Coating or impregnation contains epoxy polymer or copolymer or polyether
• CPC Class Codes: Y10T 442/3179 : Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded
• CPC Class Codes: Y10T 442/3415 : Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
• CPC Class Codes: Y10T 442/3431 : Plural fabric layers
• CPC Class Codes: Y10T 442/3463 : Plural fabric layers
• CPC Class Codes: Y10T 442/3496 : Coated, impregnated, or autogenously bonded

Abstract

There is provided a laminated body comprising a first resin layer consisting of a first fibrous base material and a resin and a second resin layer consisting of a second fibrous base material and a resin, wherein the first resin layer and the second resin layer are disposed such that the first resin layer and the second resin layer are at least partly positioned in separate regions separated by the center line in a thickness direction of the laminated body; wherein at least one of the first fibrous base material and the second fibrous base material has a bowing region where a bowing region is a region in which a smaller warp/weft crossing angle is less than 90° in the fibrous base material; and wherein in the bowing region, an angle formed by a warp of the first fibrous base material and a warp of the second fibrous base material and an angle formed by a weft of the first fibrous base material and a weft of the second fibrous base material, whichever is larger, is 2° or less.

Claims

1. A laminated body comprising a first resin layer including a first fibrous base material and a resin and a second resin layer including a second fibrous base material and a resin,

wherein said first resin layer and said second resin layer are disposed such that at least a part of said first resin layer and at least a part of said second resin layer are positioned in separate regions separated by a center line in a thickness direction of said laminated body;

wherein each of said first fibrous base material and said second fibrous base material has a bowing region where the bowing region is a region in which a smaller warp/weft crossing angle is less than 89°

in said first and second fibrous base materials;

wherein said first fibrous base material and said second fibrous base material are disposed such that the bowing regions of said first fibrous base material and said second fibrous base material overlap;

wherein in said bowing region, the larger angle among an angle formed by a warp of said first fibrous base material and a warp of said second fibrous base material and an angle formed by a weft of said first fibrous base material and a weft of said second fibrous base material is 2°

or less, and

wherein a thickness of said laminated body is 0.2 mm or less.

2. The laminated body as claimed in claim 1, wherein said first and said second resin layers are substantially symmetrically disposed around the center line in a thickness direction of said laminated body.

3. The laminated body as claimed in claim 1, wherein said first and said second resin layers are the outermost layers in said laminated body.

4. The laminated body as claimed in claim 1, wherein all of the fibrous base materials contained in said laminated body comprise a bowing region, and between all the fibrous base materials, an angle formed by warps of said fibrous base materials and an angle formed by wefts of said fibrous base materials, whichever is larger, is 2°

or less.

5. The laminated body as claimed in claim 1, wherein a linear expansion coefficient of said laminated body in a planar direction is 2 ppm/°

C. or more and 20 ppm/°

C. or less.

6. The laminated body as claimed in claim 1, wherein assuming that for said laminated body, an elastic modulus at 30°

C. is A [GPa] and an elastic modulus at 180°

C. is B [GPa], the equation is satisfied;

0.05≦

(A−

B)/A≦

0.5.

7. The laminated body as claimed in claim 1, wherein at least one of said first fibrous base material and said second fibrous base material is a glass cloth.

8. The laminated body as claimed in claim 1, wherein a thickness of at least one of said first fibrous base material and said second fibrous base material is 0.01 mm or more and 0.15 mm or less.

9. The laminated body as claimed in claim 1, wherein

in a plan view of said laminated body, in the regions other than said bowing region, a warp of said first fibrous base material and a warp of said second fibrous base material are aligned in their extension direction and mutually parallel and

a weft of said first fibrous base material and a weft of said second fibrous base material are aligned in their extension direction and mutually parallel.

10. A laminated body with a metal foil comprising the laminated body as claimed in claim 1, and a metal foil on at least one surface of said laminated body.

11. The laminated body with a metal foil as claimed in claim 10, wherein said metal foil is a copper foil.

12. A circuit board comprising the laminated body as claimed in claim 1.

13. A semiconductor package, wherein a semiconductor device is mounted on the circuit board as claimed in claim 12.

14. A process for manufacturing a laminated body, comprising the steps of:

providing a first resin layer including a first fibrous base material and a resin and a second resin layer including a second fibrous base material and a resin;

disposing said first resin layer and said second resin layer such that at least a part of said first resin layer and at least a part of said second resin layer are positioned in separate regions separated by the center line in a thickness direction of said laminated body;

laminating said first resin layer and said second resin layer directly or via another layer; and

heating and pressing said first resin layer and said second resin layer to form a laminated body,

wherein each of said first fibrous base material and said second fibrous base material has a bowing region, where the bowing region is a region in which a smaller warp/weft crossing angle is less than 89°

in said first and second fibrous base materials;

wherein in the step of laminating said first resin layer and said second resin layer, said first fibrous base material and said second fibrous base material are disposed such that the bowing regions of said first fibrous base material and said second fibrous base material overlap, and said first resin layer and said second resin layer are laminated such that in said bowing region, the larger angle among an angle formed by a warp of said first fibrous base material and a warp of said second fibrous base material and an angle formed by a weft of said first fibrous base material and a weft of said second fibrous base material is 2°

or less.

15. The process for manufacturing a laminated body as claimed in claim 14, wherein in the step of disposing said first resin layer and said second resin layer, said first resin layer and said second resin layer are substantially symmetrically disposed around the center line in a thickness direction of said laminated body.

16. The process for manufacturing a laminated body as claimed in claim 14, wherein in the step of disposing said first resin layer and said second resin layer, said first resin layer and said second resin layer are disposed such that said layers are the outermost layers in said laminated body.

17. The process for manufacturing a laminated body as claimed in claim 14, wherein

in the step of preparing said first resin layer and said second resin layer, at least one additional resin layer including a fibrous base material and a resin is prepared, and

in the step of laminating said first resin layer and said second resin layer, all the resin layers are laminated such that between all the fibrous base materials, an angle formed by warps of said fibrous base materials and an angle formed by wefts of said fibrous base materials, whichever is larger, is 2°

or less for all the fibrous base materials.

18. The process for manufacturing a laminated body as claimed in claim 14, wherein a thickness of at least one of said first fibrous base material and said second fibrous base material is 0.01 mm or more and 0.15 mm or less.

19. A process for manufacturing a laminated body with a metal foil, comprising the step of forming a metal foil at least one surface of said laminated body prepared by the manufacturing process as claimed in claim 14.