JP5481109B2 - Metal core assembly and metal core substrate manufacturing method - Google Patents

Description

  The present invention relates to a metal core assembly that is used for manufacturing a plurality of metal core substrates and in which laminated materials constituting each of the plurality of metal core substrates are stacked, and a method for manufacturing a metal core substrate using the metal core assemblies. It is.

  Metal core boards such as metal core printed wiring boards, metal core type printed boards, metal core printed circuit boards, etc. are electric circuit boards suitable for radiating and leveling the heat generated by the electrical components mounted on the mounting surface. A metal plate having a good thermal conductivity such as aluminum or copper is used as a metal core (metal base), and a conductor layer is provided on the metal core via an insulating layer mainly composed of a synthetic resin.

  In the metal core substrate, prepregs (resin-impregnated sheets) are stacked on both surfaces of a metal core that has been subjected to drilling or the like, and metal foils are stacked on the prepregs. The metal core substrate is manufactured by laminating and integrating the metal core, the prepreg, and the metal foil by sandwiching them with a pressing plate such as a thick stainless steel plate having a smooth surface and pressurizing and heating them.

  However, in pressurization and heating, if the prepreg resin cannot be sufficiently filled in the holes previously formed in the metal core and bubbles remain, the insulation resistance with the metal core deteriorates and the withstand voltage is increased. It is known that problems such as deterioration in properties and delamination due to temperature changes occur.

  In order to solve such a problem, pressure heating has been performed in a vacuum. However, air bubbles remained depending on the size, arrangement, number, etc. of the holes in the metal core. Therefore, in the method for manufacturing a printed wiring board shown in Patent Document 1, after a resin-impregnated sheet is stacked on a perforated base material, these are laminated in a state where the resin is impregnated with the resin-impregnated sheet in a hole by pressure heating It is a manufacturing method of a printed wiring board to be integrated.

JP 2009-21274 A

  When manufacturing a plurality of metal core substrates in a lump, the metal plate 100 shown in FIG. 5 has been used. The metal plate 100 has a plurality of metal cores 101 constituting each of a plurality of metal core substrates. The metal plate 100 holds a plurality of metal cores 101 by a frame 102, and a through hole 103 is formed around the metal core 101. The hole 103 is formed when it is desired to cover the side edge of the metal core 101 with a resin-impregnated sheet. When the metal plate 100 and the resin-impregnated sheet are heated under pressure, if the hole 103 is large, there is a problem that the air stays inside the metal core 101 and becomes air bubbles. Unlike a normal laminated substrate, the metal core 101 is made of a relatively thick material (for example, 400 μm) in order to improve thermal characteristics (thermal uniformity and heat dissipation). It was difficult to reduce the space in 103, and air was easily stored.

  Therefore, in view of the above-described problems, the present invention provides a metal core assembly and a metal core that prevent air bubbles from being generated from the hole due to pressure heating of the laminated material even if a hole is formed around the metal core. It is an object to provide a manufacturing method.

The metal core assembly according to claim 1, which is made according to the present invention in order to solve the above-mentioned problem, is a metal core assembly used for manufacturing a plurality of metal core substrates, and is formed in a rectangular shape, and the plurality of metal core substrates. A plurality of metal cores constituting each of the above, a frame provided so as to surround the plurality of metal cores and holding the plurality of metal cores, and a pair of holes surrounding the metal core and interposed between the metal core and the frame and parts, said pair of each of the hole, have a, a groove provided on the surface of the frame over the outside of the frame, the frame, in each of the pair of opposite sides of said metal core, said metal core The holding portion to be connected is formed, and the pair of holes are formed in a U shape and an inverted U shape. Provided across the holding portion, said groove, characterized in that along the extending direction of the edge of the hole portion is formed from a corner of the hole.

  According to the metal core assembly of the present invention described in claim 1, the groove portion provided on the surface of the frame has a groove-like gap extending from the hole portion to the outside of the frame even when the laminated material is laminated on the surface of the frame. Can be formed between the frame and the laminate.

Further, since the groove portion of the frame is formed from the corner of the hole portion along the extending direction of the edge portion of the hole portion, the groove portion can be extended from the corner of the frame. When performing pressurization heating, evacuation, or the like, air can be more easily drawn from the hole.

A method for manufacturing a metal core substrate according to claim 2, which is made according to the present invention in order to solve the above problem, is a method for manufacturing a metal core substrate in which a plurality of metal core substrates are manufactured using the metal core assembly according to claim 1. A stacking step of stacking a laminate material constituting each of the plurality of metal core substrates on the metal core assembly so as to cover at least the plurality of metal cores and the hole, and the metal core assembly and the laminate material. It has a pressurization heating process which shape | molds a laminated body by pressurizing and heating, and a formation process which shape | molds these metal core substrates from the said laminated body.

According to the method for manufacturing a metal core substrate of the present invention described in claim 2 , the laminated material is laminated on the metal core assembly so as to cover the plurality of metal cores and the hole of the frame, and is heated under pressure in this state. Then, the air in the hole flows out from the hole to the outside of the frame through the groove. And if a laminated body is shape | molded by pressurizing and heating a metal core aggregate and a laminated material, a some metal core board | substrate will be shape | molded from this laminated body.

  As described above, according to the first aspect of the present invention, since a groove-like gap extending from the hole to the outside of the frame can be formed between the frame and the laminated material, the metal core assembly and the laminated material Even if pressure heating, vacuuming, or the like is performed, the air in the hole can flow out from the hole to the outside of the frame through the groove. Therefore, since the air staying in the hole can be reduced, the generation of bubbles in the hole can be prevented.

In addition, since the air in the hole can be more easily drawn when the laminated material is laminated, the generation of bubbles in the process of manufacturing the metal core substrate can be prevented more reliably.

As described above, according to the second aspect of the present invention, when the laminated material is laminated on the metal core assembly and heated under pressure, the air in the hole of the metal core assembly flows out of the frame through the groove. Therefore, even if the metal core assembly having the hole and the laminate are laminated to form the laminate, the generation of bubbles in the hole can be prevented.

It is a top view which shows the metal core aggregate | assembly which concerns on this invention. It is sectional drawing of the arrow direction which passes along the straight line AA in FIG. It is sectional drawing which shows an example of the laminated body which laminated | stacked the laminated material on the metal core aggregate | assembly of FIG. It is a figure which shows an example of the lamination molding apparatus used for manufacture of the metal core board | substrate of this invention. It is a figure which shows an example of the metal plate which has the conventional metal core.

  Embodiments of a metal core assembly according to the present invention and a method for manufacturing a metal core substrate using the metal core assembly will be described below with reference to the drawings of FIGS.

  1 to 3, the metal core assembly 1 is used for manufacturing a plurality of metal core substrates 10 in a vacuum, and a prepreg (laminated material) 11 constituting the metal core substrate 10 is laminated. The metal core assembly 1 is a rectangular metal plate having good thermal conductivity, such as copper or aluminum. The metal core substrate 10 is an electric circuit substrate that radiates heat generated by the electronic components mounted on the mounting surface and equalizes the heat.

  In addition, although the metal core aggregate | assembly 10 of this embodiment demonstrates an example which batch manufactures the four metal core board | substrates 10 from the four metal cores 2 shown in FIG. 1, this invention is not limited to this, For example, Various embodiments can be made, such as collectively manufacturing five or more metal core substrates 10 and sequentially manufacturing four metal cores 2 shown in FIG.

  As shown in FIG. 1, the metal core assembly 1 includes a plurality of metal cores 2, a frame 3, a plurality of holes 4, and a plurality of grooves 5. The metal core assembly 1 is formed in a flat plate shape in which a plurality of metal cores 2 and a frame 3 are integrated.

  Each metal core 2 is one member constituting the metal core substrate 10. Each metal core 2 is formed in a rectangular shape corresponding to the metal core substrate 10. Each metal core 2 has a plurality of through holes such as through holes. As shown in FIG. 3, both surfaces of each metal core 2 are laminated surfaces 2a and 2b on which prepregs 11 are laminated.

  As shown in FIG. 1, the frame 3 forms the outer shape of the rectangular metal core assembly 1 and is formed with a thickness of, for example, 640 μm. The frame 3 is provided so as to surround each of the four metal cores 2 and holds the plurality of metal cores 2. The frame 3 has a plurality of holding portions 3 a that are connected to and held by the metal cores 2.

  Each hole 4 is formed as a through hole that surrounds the metal core 2 and is interposed between the metal core 2 and the frame 3. Each hole 4 is formed with a U-shaped one and an inverted U-shaped one metal core 2 sandwiching the holding portion 3a. And each metal core 2 is isolate | separated from the flame | frame 3 by deleting a pair of holding | maintenance part 3a.

  Each groove 5 is provided on the surface of the frame 3 from the hole 4 to the outside of the frame 3. Each groove 5 connects the hole 4 and the outside of the frame 3, and serves as a flow path for the air in the hole 4 to the outside of the frame 3. As shown in FIG. 2, each groove portion 5 of the present embodiment will be described with respect to a case where the cross section is formed in a substantially U shape. Any shape is acceptable.

  As shown in FIG. 1, the plurality of grooves 5 are formed along the extending directions X and Y corresponding to the edges 3 b and 3 c of the hole 4, respectively. In the present embodiment, three groove portions 5 are formed for one metal core 2. Specifically, the groove 5 is formed so as to extend from the corner of the hole 4 near the outer edge portions 3 b and 3 c of the frame 3 toward the outside of the frame 3. As for the number of the groove portions 5 for one metal core 2, for example, the number of the groove portions 5 is increased when the size of the hole portion 4 is large, or the number of the groove portions 5 when the size of the hole portion 4 is small. Various embodiments such as fewer or different embodiments can be provided.

  An example of a manufacturing method of the metal core assembly 1 configured as described above will be described. The metal core assembly 1 is formed by pressing a die and punching a hole 4 in a metal plate, and surface-treating a plurality of grooves 5 extending from the hole 4 to the outer edges 3b and 3c of the frame 3 on the surface of the frame 3. Yes.

  Next, an example of a case where a prepreg 11 that is a laminate material is laminated on the metal core assembly 1 to form a laminate will be described with reference to the drawing of FIG.

  A prepreg 11 and a copper foil 12 are sequentially laminated in each plate thickness direction on both laminated surfaces of the metal core assembly 1. The prepreg 11 is a sheet in which carbon fiber, glass fiber, aramid fiber, or the like is impregnated with an uncured thermosetting resin (such as an epoxy resin). The prepreg 11 is laminated on the metal core assembly 1 so as to cover the metal core 2, the frame 3, and the hole 4 of the metal core assembly 1. The copper foil 12 is a conductive metal stay.

  When the metal core assembly 1, the prepreg 11, and the copper foil 12 are evacuated, the air in the hole 4 flows out of the frame 3 from the groove 5 between the metal core assembly 1 and the prepreg 11. Then, when pressure heating molding is performed in a laminated state, they are integrated to form a laminated pair 15.

  According to the metal core assembly 1 described above, since the groove 5 extending from the hole 4 to the outside of the frame 3 can be formed between the frame 3 and the prepreg 11, the metal core assembly 1 and the prepreg 11 are laminated. When pressurizing and heating, the air in the hole 4 can flow out from the hole 4 to the outside of the frame 3 through the groove 5. Therefore, since the air staying in the hole 4 can be reduced, the generation of bubbles in the hole 4 can be prevented.

  Further, according to the metal core assembly 1, the groove portion 5 is formed from the corner of the hole portion 3 along the extending directions X and Y of the edge portions 3 b and 3 c of the hole portion 3. Occasionally, the air in the hole 5 can be drawn more easily, so that the generation of bubbles in the manufacturing process of the metal core substrate can be prevented more reliably.

  Next, an example of manufacturing a plurality of metal core substrates 10 in a vacuum using the metal core assembly 1 described above will be described below with reference to the drawing of FIG.

  In FIG. 4, the laminating apparatus 30 includes a fixed upper board 31, a lower board 32 disposed to face the upper board 31, a lower board 32 being driven up and down, and an upper board 31 and a lower board 32. And a driving means 33 for pressurizing them together. As shown in FIG. 3, the prepreg 11 is formed on the metal core assembly 1 so that the metal core assembly 1, the prepreg 11, and the copper foil 12 cover the laminated surface of the plurality of metal cores 2 and the frame 3 in the metal core assembly 1. Laminated and set between the upper board 31 and the lower board 32 in a state where the copper foil 12 is laminated on the prepreg 11.

  The laminating apparatus 30 moves the upper board 31 and the lower board 32 close to each other by the driving means, and adds the metal core assembly 1, the prepreg 11, and the copper foil 12 between the upper board 31 and the lower board 32. The laminate 15 is laminated and molded while heating the upper board 31 and the lower board 32 by heating means (not shown). At this time, the air in the hole 4 of the metal core assembly 1 flows out of the frame 3 through the plurality of grooves 5. In addition, although the lamination | stacking apparatus 30 of this embodiment demonstrates the case where lamination molding is carried out in air | atmosphere, as shown in the said patent document 2 etc., you may perform lamination molding in a vacuum.

  When the molded laminate 15 is conveyed to the next step while being sandwiched between the films 41 and 41, as shown in FIG. 3, portions corresponding to the plurality of metal cores 2 of the metal core assembly 1 are punched out. Thus, the four metal core substrates 10 are formed.

  According to the manufacturing method of the metal core substrate 10 using the metal core assembly 1 described above, when the prepreg 11 is stacked on the metal core assembly 1 and heated under pressure, the air in the hole 4 of the metal core assembly 1 causes the groove 5 to flow. Since the metal core assembly 1 having the hole 4 and the prepreg 11 are pressurized and heated to form the laminate 15 because it flows out to the outside of the frame 3, the generation of bubbles in the hole 4 is prevented. Can do.

  In the above-described embodiment, the case where one prepreg 11 is laminated on the metal core assembly 1 has been described. However, the case where two or more laminated materials are laminated on the metal core assembly 1 is the same as that described above. An effect can be obtained.

  As described above, the above-described embodiments are merely representative forms of the present invention, and the present invention is not limited to the embodiments. That is, various modifications can be made without departing from the scope of the present invention.

1 Metal Core Assembly 2 Metal Core 3 Frame 4 Hole 5 Groove 11 Prepreg (Laminated Material)
12 Copper foil 15 Laminate

Claims (2)

A metal core assembly used for manufacturing a plurality of metal core substrates,
A plurality of metal cores that are formed in a rectangular shape and constitute each of the plurality of metal core substrates,
A frame that is provided so as to surround the plurality of metal cores and holds the plurality of metal cores;
A pair of holes surrounding the metal core and interposed between the metal core and the frame;
A groove provided on the surface of the frame over the outside of the frame from each of the pair of holes,
The frame is formed to have a holding portion connected to the metal core in each of a pair of opposing sides of the metal core,
The pair of holes are formed in a U-shape and an inverted U-shape, and are provided across the holding portion,
The groove is formed from the corner of the hole along the extending direction of the edge of the hole. A metal core substrate manufacturing method for manufacturing a plurality of metal core substrates using the metal core assembly according to claim 1 ,
A laminating step of laminating a laminate material constituting each of the plurality of metal core substrates on the metal core assembly so as to cover at least the plurality of metal cores and the hole;
A pressure heating step of forming a laminate by pressurizing and heating the metal core assembly and the laminate;
A molding step of molding the plurality of metal core substrates from the laminate;
A method for producing a metal core substrate, comprising:

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