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JP6046063B2 - substrate - Google Patents
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JP6046063B2 - substrate - Google Patents

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JP6046063B2
JP6046063B2 JP2014009590A JP2014009590A JP6046063B2 JP 6046063 B2 JP6046063 B2 JP 6046063B2 JP 2014009590 A JP2014009590 A JP 2014009590A JP 2014009590 A JP2014009590 A JP 2014009590A JP 6046063 B2 JP6046063 B2 JP 6046063B2
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circuit conductor
substrate
injection
circuit
injection resin
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JP2015138881A (en
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朋未 海渕
朋未 海渕
久太郎 阿部
久太郎 阿部
泰 木原
泰 木原
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Furukawa Electric Co Ltd
Furukawa Automotive Systems Inc
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Furukawa Electric Co Ltd
Furukawa Automotive Systems Inc
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10WGENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W72/00Interconnections or connectors in packages
    • H10W72/071Connecting or disconnecting
    • H10W72/073Connecting or disconnecting of die-attach connectors

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Description

本発明は自動車等に用いられる基板の製造方法等に関するものである。   The present invention relates to a method for manufacturing a substrate used in an automobile or the like.

自動車に用いられるDC−DCコンバータは、電圧変換用のトランスや平滑化用のチョークコイル等の複数の部品から構成される。これらの部品のうち、高電圧・大電流が負荷される部品については、それぞれのパーツを別々に製造後、それらを基板の外部に接続する必要があった。しかし、このような構成は、装置の大型化や組付け性不良を招くため、よりコンパクトなDC−DCコンバータが要求されていた。   A DC-DC converter used in an automobile includes a plurality of components such as a voltage conversion transformer and a smoothing choke coil. Of these components, components that are loaded with high voltage and large current need to be manufactured separately and then connected to the outside of the substrate. However, such a configuration causes an increase in the size of the apparatus and a poor assemblability, so that a more compact DC-DC converter is required.

これに対し、射出成型による樹脂であらかじめ屈曲されたリードフレームを被覆して、電子部品の取り付け部ではリードフレームの一部を露出させた樹脂成型基板がある(たとえば特許文献1)。   On the other hand, there is a resin-molded substrate in which a lead frame bent in advance with resin by injection molding is covered and a part of the lead frame is exposed at an attachment part of an electronic component (for example, Patent Document 1).

特開2000−133897号公報JP 2000-133897 A

しかし、特許文献1のように、射出樹脂の一部を凹ませて内部の回路導体を露出させると、電子部品と回路導体との接合が困難となる。例えば、通常、基板に半田をスクリーン印刷によって配置し、電子部品を配置した後、リフロー炉で一括して電子部品を接続する方法がとられる。しかし、特許文献1のように基板上に凹凸面が存在すると、スクリーン印刷を行うことができない。したがって、半田の塗布が困難である。   However, as in Patent Document 1, if a part of the injection resin is recessed to expose the internal circuit conductor, it becomes difficult to join the electronic component and the circuit conductor. For example, usually, a method is used in which solder is placed on a substrate by screen printing, electronic components are placed, and then the electronic components are connected together in a reflow furnace. However, if an uneven surface exists on the substrate as in Patent Document 1, screen printing cannot be performed. Therefore, it is difficult to apply solder.

本発明は、このような問題に鑑みてなされたもので、基板の表面の凹凸をなくしてスクリーン印刷が可能な基板等を提供することを目的とする。   The present invention has been made in view of such a problem, and an object of the present invention is to provide a substrate that can be screen-printed without unevenness on the surface of the substrate.

前述した目的を達するために発明は、回路導体の表面に射出樹脂を射出して形成される射出成型基板であって、前記回路導体の一部が屈曲されて設けられる段部と、前記段部によって前記回路導体の一部が前記射出樹脂の表面に露出する回路導体露出部と、を具備し、前記回路導体露出部以外の前記回路導体の表面が前記射出樹脂によって覆われ、前記回路導体露出部の表面と、前記射出樹脂の表面とが、略同一面に形成され、隣り合う前記回路導体露出部間には、切欠き部または凹部が設けられ、前記切欠き部または前記凹部に前記射出樹脂が配置されることで基板表面において前記回路導体露出部が区分され、射出成型基板の少なくとも一方の面から孔が形成され、前記段部の表面の一部が孔に露出することを特徴とする基板である。
また、回路導体の表面に射出樹脂を射出して形成される射出成型基板であって、前記回路導体の一部が屈曲されて設けられる段部と、前記段部によって前記回路導体の一部が前記射出樹脂の表面に露出する回路導体露出部と、を具備し、前記回路導体露出部以外の前記回路導体の表面が前記射出樹脂によって覆われ、前記回路導体露出部の表面と、前記射出樹脂の表面とが、略同一面に形成され、隣り合う前記回路導体露出部間には、切欠き部または凹部が設けられ、前記切欠き部または前記凹部に前記射出樹脂が配置されることで基板表面において前記回路導体露出部が区分され、前記段部に貫通孔が形成されることを特徴とする基板である。
In order to achieve the above-mentioned object, the present invention provides an injection-molded substrate formed by injecting an injection resin onto the surface of a circuit conductor, wherein a step portion provided by bending a part of the circuit conductor, and the step A circuit conductor exposed portion in which a part of the circuit conductor is exposed on the surface of the injection resin by a portion, and the surface of the circuit conductor other than the circuit conductor exposed portion is covered with the injection resin, The surface of the exposed portion and the surface of the injection resin are formed in substantially the same plane, and a notch or a recess is provided between the adjacent circuit conductor exposed portions, and the notch or the recess has the injection the circuit conductor exposed portion in the surface of the substrate by a resin is placed is divided injection holes from at least one surface of the molded substrate is formed, a part of the surface of the stepped portion that you exposed in the hole It is the board | substrate characterized.
An injection-molded substrate formed by injecting an injection resin onto the surface of a circuit conductor, wherein a step part provided by bending a part of the circuit conductor, and a part of the circuit conductor formed by the step part A circuit conductor exposed portion exposed on the surface of the injection resin, and the surface of the circuit conductor other than the circuit conductor exposed portion is covered with the injection resin, the surface of the circuit conductor exposed portion, and the injection resin Are formed on substantially the same plane, and a notch or a recess is provided between adjacent circuit conductor exposed portions, and the injection resin is disposed in the notch or the recess so that the substrate is disposed. The circuit conductor exposed portion is sectioned on the surface, and a through hole is formed in the stepped portion.

一対の前記回路導体同士が隙間を開けて、前記回路導体露出部同士が対向するように配置され、前記切欠き部または前記凹部は、前記回路導体の対向方向に沿って形成されることが望ましい。   It is desirable that the pair of circuit conductors be arranged so that a gap is provided between the circuit conductor exposed portions, and the notched portion or the concave portion is formed along the facing direction of the circuit conductor. .

前記回路導体露出部以外および前記段部以外の部位の前記回路導体は、前記射出樹脂の厚みの略中央に配置されてもよい。   The circuit conductors other than the exposed part of the circuit conductor and the parts other than the stepped part may be arranged at the approximate center of the thickness of the injection resin.

前記回路導体露出部の背面側には、前記射出樹脂の一部に孔が形成されてもよい。   A hole may be formed in a part of the injection resin on the back side of the circuit conductor exposed portion.

前記回路導体露出部の前記段部側の表面の一部に薄肉部が形成され、前記薄肉部は、前記射出樹脂で被覆されてもよい。   A thin-walled portion may be formed on a part of the surface on the stepped portion side of the circuit conductor exposed portion, and the thin-walled portion may be covered with the injection resin.

前記回路導体露出部の前記段部側の幅が、前記回路導体露出部の他の部位よりも幅が狭くてもよい。   The width of the stepped portion side of the circuit conductor exposed portion may be narrower than other portions of the circuit conductor exposed portion.

放熱部材をさらに具備し、前記放熱部材の表面と、前記射出樹脂の表面とが、略同一面に形成されてもよい。   A heat radiating member may be further provided, and the surface of the heat radiating member and the surface of the injection resin may be formed on substantially the same plane.

第1の発明によれば、回路導体の一部を屈曲させて段部を形成し、回路導体の一部を射出樹脂の表面に露出させることで、基板の表面に凹凸が形成されることを防止することができる。このため、回路導体表面への半田のスクリーン印刷が可能となる。また、半田をスクリーン印刷することができるため、回路導体の所定の位置に電子部品を実装することができる。   According to the first invention, a part of the circuit conductor is bent to form a stepped portion, and a part of the circuit conductor is exposed to the surface of the injection resin, whereby irregularities are formed on the surface of the substrate. Can be prevented. For this reason, solder screen printing on the surface of the circuit conductor is possible. Moreover, since solder can be screen-printed, an electronic component can be mounted at a predetermined position of the circuit conductor.

この際、回路導体露出部の近傍に、切欠き部または凹部を形成することで、射出樹脂から露出する回路導体の範囲を規制することができる。このため、半田が所定範囲外に流れることを抑制することができる。   At this time, the range of the circuit conductor exposed from the injection resin can be regulated by forming a notch or a recess in the vicinity of the exposed portion of the circuit conductor. For this reason, it can suppress that a solder flows out of a predetermined range.

特に、複数の回路導体同士を、隙間をあけて配置し、切欠き部または凹部が、回路導体の対向方向に沿って形成されることで、回路導体にまたがるようにして配置される電子部品の、それぞれの回路導体露出部との接合部において、半田の流れる領域を確実に規制することができる。   In particular, a plurality of circuit conductors are arranged with a gap therebetween, and a notch or a recess is formed along the opposing direction of the circuit conductor, so that an electronic component arranged so as to straddle the circuit conductor is provided. Thus, it is possible to reliably regulate the region where the solder flows in the joint portion with each circuit conductor exposed portion.

また、回路導体露出部および段部以外の回路導体が、射出樹脂の厚みの略中央に配置されることで、射出成型基板の両面における樹脂量が略一致し、熱による変形等の影響を小さくすることができる。   In addition, the circuit conductors other than the exposed portions of the circuit conductors and the stepped portions are arranged at substantially the center of the thickness of the injection resin, so that the resin amounts on both surfaces of the injection molded substrate are substantially the same, and the influence of deformation due to heat is reduced. can do.

また、回路導体露出部の背面側の射出樹脂の一部に孔を形成することで、放熱を行うことができる。   Further, heat can be radiated by forming a hole in a part of the injection resin on the back side of the exposed portion of the circuit conductor.

また、回路導体露出部の段部側の表面の一部に薄肉部を形成し、薄肉部を射出樹脂で被覆することで、より正確な回路導体の露出範囲を形成することができる。   Further, by forming a thin portion on a part of the step conductor side surface of the circuit conductor exposed portion and coating the thin portion with an injection resin, a more accurate circuit conductor exposure range can be formed.

また、射出成型基板の少なくとも一方の面から孔が形成され、段部の表面の一部が孔に露出することで、段部の基板面に平行な方向に対する規制を緩和することができる。   Moreover, the hole is formed from at least one surface of the injection-molded substrate, and a part of the surface of the step portion is exposed to the hole, so that the restriction on the direction parallel to the substrate surface of the step portion can be relaxed.

また、回路導体露出部の段部側の幅を、回路導体露出部の他の部位の幅よりも狭くすることで、回路導体露出部や段部の剛性を小さくすることができる。このため、切欠き部の位置を優先的に変形させ、実装される電子部品へ付与される応力を緩和することができる。   Moreover, the rigidity of a circuit conductor exposure part and a step part can be made small by making the width | variety of the step part side of a circuit conductor exposure part narrower than the width | variety of the other site | part of a circuit conductor exposure part. For this reason, the position of the notch can be preferentially deformed, and the stress applied to the electronic component to be mounted can be relaxed.

また、段部に貫通孔を設けることで、段部の剛性を小さくすることができる。このため、段部を優先的に変形させ、実装される電子部品へ付与される応力を緩和することができる。   Moreover, the rigidity of a step part can be made small by providing a through-hole in a step part. For this reason, a step part can be deformed preferentially and the stress given to the electronic component mounted can be relieved.

また、放熱部材をさらに具備し、放熱部材の表面と、射出樹脂の表面とが、略同一面に形成することで、スクリーン印刷性を阻害することなく、基板の放熱性を向上させることができる。   Further, the heat dissipation member is further provided, and the surface of the heat dissipation member and the surface of the injection resin are formed on substantially the same surface, so that the heat dissipation property of the substrate can be improved without hindering the screen printability. .

本発明によれば、基板の表面の凹凸をなくしてスクリーン印刷が可能な基板等を提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, the board | substrate etc. which can eliminate the unevenness | corrugation of the surface of a board | substrate and can perform screen printing can be provided.

射出成型基板3を示す平面図。The top view which shows the injection molding board | substrate 3. FIG. 射出成型基板3の断面図であり、図1のA−A線断面図。It is sectional drawing of the injection molding board | substrate 3, and is the sectional view on the AA line of FIG. (a)は、射出成型基板3の断面図であり、図1のB−B線断面図、(b)は(a)の他の形態を示す図。(A) is sectional drawing of the injection molding board | substrate 3, BB sectional drawing of FIG. 1, (b) is a figure which shows the other form of (a). 基板1を示す平面図。The top view which shows the board | substrate 1. FIG. 基板1の断面図であり、図4のC−C線断面図。It is sectional drawing of the board | substrate 1, and CC sectional view taken on the line of FIG. 回路導体5の斜視図。The perspective view of the circuit conductor 5. FIG. 金型21に、回路導体5を配置した状態を示す図。The figure which shows the state which has arrange | positioned the circuit conductor 5 in the metal mold | die 21. FIG. (a)は回路導体5に段部を形成した状態を示す図、(b)はさらに薄肉部25を形成した状態を示す図、(c)はこの状態で、射出樹脂を射出した状態を示す図。(A) is the figure which shows the state which formed the step part in the circuit conductor 5, (b) is the figure which shows the state which formed the thin part 25 further, (c) shows the state which inject | emitted injection resin in this state Figure. 射出成型基板3aの断面図。Sectional drawing of the injection molding board | substrate 3a. 回路導体5aの斜視図。The perspective view of the circuit conductor 5a. 射出成型基板3bの断面図。Sectional drawing of the injection molding board | substrate 3b. 射出成型基板3cの断面図。Sectional drawing of the injection molding board | substrate 3c. 射出成型基板3dの断面図。Sectional drawing of the injection molding board | substrate 3d. 射出成型基板3eの断面図。Sectional drawing of the injection molding board | substrate 3e.

以下、図面を参照しながら、本発明の実施形態について説明する。図1は、射出成型基板3を示す平面図であり、図2は、図1のA−A線断面図、図3(a)は、図1のB−B線断面図である。射出成型基板3は、例えば自動車用のDC−DCコンバータなどとして用いられる基板である。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1 is a plan view showing an injection-molded substrate 3, FIG. 2 is a cross-sectional view taken along line AA in FIG. 1, and FIG. 3A is a cross-sectional view taken along line BB in FIG. The injection-molded substrate 3 is a substrate used as, for example, a DC-DC converter for automobiles.

射出成型基板3は、回路導体5の一部が射出樹脂9によって被覆される。また、回路導体5の一部は、射出樹脂9から露出する。射出樹脂9から露出する部位が、回路導体露出部7となる。   In the injection molded substrate 3, a part of the circuit conductor 5 is covered with the injection resin 9. A part of the circuit conductor 5 is exposed from the injection resin 9. The portion exposed from the injection resin 9 becomes the circuit conductor exposed portion 7.

射出樹脂9は、特に限定されないが、例えばPPS(ポリフェニレンスルファイド)を用いることができる。   The injection resin 9 is not particularly limited, and for example, PPS (polyphenylene sulfide) can be used.

図2に示すように、回路導体5は、射出樹脂9内部において屈曲し、段部11が形成される。段部11によって、回路導体5の一部が、射出樹脂9の表面に露出する。   As shown in FIG. 2, the circuit conductor 5 is bent inside the injection resin 9 to form a stepped portion 11. Part of the circuit conductor 5 is exposed on the surface of the injection resin 9 by the step portion 11.

回路導体5の段部11および回路導体露出部7以外の部位は、射出樹脂9の厚み方向の略中央に配置される。一方、回路導体露出部7の表面と射出樹脂9の表面とが略同一面に形成される。したがって、射出成型基板3の表面には、凹凸が形成されることがない。   Sites other than the stepped portion 11 and the circuit conductor exposed portion 7 of the circuit conductor 5 are arranged at substantially the center in the thickness direction of the injection resin 9. On the other hand, the surface of the circuit conductor exposed portion 7 and the surface of the injection resin 9 are formed on substantially the same plane. Therefore, no irregularities are formed on the surface of the injection-molded substrate 3.

なお、トランスコイルなど、射出成型基板3の厚み方向に、複数の回路導体5が間隔をあけて積層されるような部位は、射出成型基板3の表面に露出しないように、完全に射出樹脂9で被覆される。   It should be noted that a portion such as a transformer coil where the plurality of circuit conductors 5 are laminated at intervals in the thickness direction of the injection-molded substrate 3 is completely injected resin 9 so as not to be exposed on the surface of the injection-molded substrate 3. Covered with.

回路導体露出部7の背面側には、射出成型基板3の裏面まで貫通する孔12が形成される。孔12は、回路導体露出部7の放熱部として機能する。孔12は不要であれば、なくてもよい。なお、孔12の形成方法は、後述する。孔12の放熱部としての機能は、孔12によって回路導体露出部7の背面側を露出することによって得られる他、回路導体露出部7の背面側と図示しない筐体等を熱的に結合することによっても得られる。例えば、回路導体露出部7と筐体等を電気的に絶縁する必要がない場合には、孔12に充填した金属ペースト等を介して筐体等と熱的に結合することができる。また、回路導体露出部7と筐体等を電気的に絶縁する必要がある場合には、孔12に絶縁性の放熱シートを配置して筐体等と熱的に結合することができる。   A hole 12 penetrating to the back surface of the injection molded substrate 3 is formed on the back surface side of the circuit conductor exposed portion 7. The hole 12 functions as a heat radiating part of the circuit conductor exposed part 7. The holes 12 may be omitted if not necessary. In addition, the formation method of the hole 12 is mentioned later. The function of the hole 12 as a heat radiating part is obtained by exposing the back side of the circuit conductor exposed part 7 through the hole 12, and thermally couples the back side of the circuit conductor exposed part 7 with a housing (not shown). Can also be obtained. For example, when there is no need to electrically insulate the circuit conductor exposed portion 7 from the housing or the like, it can be thermally coupled to the housing or the like via a metal paste or the like filled in the holes 12. When it is necessary to electrically insulate the circuit conductor exposed portion 7 from the housing or the like, an insulating heat dissipation sheet can be disposed in the hole 12 and thermally coupled to the housing or the like.

図3(a)に示すように、回路導体5の回路導体露出部7には、複数の切欠き部13が設けられる。切欠き部13には、射出樹脂9が設けられる。なお、切欠き部13は、段部11まで形成される。   As shown in FIG. 3A, the circuit conductor exposed portion 7 of the circuit conductor 5 is provided with a plurality of notches 13. An injection resin 9 is provided in the notch 13. The notch 13 is formed up to the step 11.

図1に示すように、少なくとも一対の回路導体5が隙間をあけて、回路導体露出部7が互いに対向するように配置される。この際、切欠き部13は、回路導体5の対向方向(図中左右方向)に沿って形成される。このため、平面視において、複数の回路導体露出部7が、切欠き部13によって区分される。すなわち、回路導体5の端部には、複数の回路導体露出部7が、切欠き部13を介して互いに略平行に延出する。   As shown in FIG. 1, at least a pair of circuit conductors 5 are arranged such that circuit conductor exposed portions 7 face each other with a gap therebetween. At this time, the notch 13 is formed along the facing direction of the circuit conductor 5 (the left-right direction in the figure). For this reason, the plurality of circuit conductor exposed portions 7 are divided by the notch portions 13 in plan view. That is, a plurality of circuit conductor exposed portions 7 extend substantially parallel to each other through the notch portions 13 at the end portions of the circuit conductors 5.

なお、平面視において、回路導体露出部7が、射出樹脂9によって複数に区分できれば、切欠き部13を設けなくてもよい。例えば、図3(b)に示すように、複数の回路導体露出部7の間に、溝状に凹部15を形成してもよい。この場合でも、凹部15の上面に射出樹脂9が回り込むため、回路導体露出部7を複数に区分することができる。   Note that the notched portion 13 may not be provided if the circuit conductor exposed portion 7 can be divided into a plurality of portions by the injection resin 9 in plan view. For example, as illustrated in FIG. 3B, a recess 15 may be formed in a groove shape between the plurality of exposed circuit conductors 7. Even in this case, since the injection resin 9 wraps around the upper surface of the concave portion 15, the circuit conductor exposed portion 7 can be divided into a plurality of portions.

次に、射出成型基板3に電子部品17を接合させた基板1について説明する。図4は、基板1の平面図、図5は、図4のC−C線断面図である。基板1には、複数の電子部品17が実装される。なお、本発明にかかる基板1は、図に示すような配置および形状に限られることはなく、その他の部品等を適宜搭載することや、配置および形状を適宜変更することが可能なことは言うまでもない。   Next, the board | substrate 1 which joined the electronic component 17 to the injection molding board | substrate 3 is demonstrated. 4 is a plan view of the substrate 1, and FIG. 5 is a cross-sectional view taken along the line CC of FIG. A plurality of electronic components 17 are mounted on the substrate 1. The substrate 1 according to the present invention is not limited to the arrangement and shape as shown in the drawings, and it goes without saying that other components and the like can be appropriately mounted, and the arrangement and shape can be appropriately changed. Yes.

図5に示すように、電子部品17は、半田19によって、回路導体露出部7と接続される。なお、電子部品17の接続方法は以下の通りである。まず、半田19が、射出成型基板3の回路導体露出部7にスクリーン印刷によって塗布される。前述したように、射出成型基板3の上面は、射出樹脂9と回路導体露出部7の表面が平滑であるため、スクリーン印刷が容易である。次いで、電子部品17やプリント基板等が所定の位置に配置され、リフロー炉を通すことで、複数の電子部品17等を一括して射出成型基板3に実装することができる。   As shown in FIG. 5, the electronic component 17 is connected to the circuit conductor exposed portion 7 by solder 19. In addition, the connection method of the electronic component 17 is as follows. First, the solder 19 is applied to the circuit conductor exposed portion 7 of the injection molded substrate 3 by screen printing. As described above, since the surfaces of the injection resin 9 and the exposed circuit conductor 7 are smooth on the upper surface of the injection-molded substrate 3, screen printing is easy. Next, the electronic component 17 and the printed circuit board are arranged at predetermined positions, and a plurality of electronic components 17 and the like can be collectively mounted on the injection-molded substrate 3 by passing through a reflow furnace.

ここで、回路導体露出部7の周囲は、射出樹脂9で囲まれる。したがって、半田19は、その濡れ性の差によって、回路導体露出部7の領域外に流れることが抑制される。すなわち、半田19の位置は、回路導体露出部7の領域に規制される。   Here, the periphery of the circuit conductor exposed portion 7 is surrounded by the injection resin 9. Therefore, the solder 19 is suppressed from flowing outside the area of the circuit conductor exposed portion 7 due to the difference in wettability. That is, the position of the solder 19 is restricted by the area of the circuit conductor exposed portion 7.

なお、例えば、電子部品17がDCコンバータの場合、図4に示すように、複数の電子部品17が並列に配置される場合がある。この場合でも、切欠き部13または凹部15が設けられるため、回路導体露出部7同士が射出樹脂9によって区分される。このため、半田19が隣り合う他の回路導体露出部7へ流れることがない。   For example, when the electronic component 17 is a DC converter, a plurality of electronic components 17 may be arranged in parallel as shown in FIG. Even in this case, since the notch 13 or the recess 15 is provided, the circuit conductor exposed portions 7 are separated by the injection resin 9. For this reason, the solder 19 does not flow to other adjacent circuit conductor exposed portions 7.

次に、射出成型基板3の製造方法について説明する。まず、図6に示すように、回路導体5を成型する。回路導体5は、金属板からプレス等で加工される。用いられる金属板は、例えば銅または銅合金製である。また、金属板の厚みは、例えば0.4mm〜3mm程度である。   Next, a method for manufacturing the injection molded substrate 3 will be described. First, as shown in FIG. 6, the circuit conductor 5 is molded. The circuit conductor 5 is processed from a metal plate by a press or the like. The metal plate used is made of, for example, copper or a copper alloy. The thickness of the metal plate is, for example, about 0.4 mm to 3 mm.

金属板を所定の形状に打ち抜き、段部11を形成して、回路導体露出部7を形成する。なお、回路導体露出部7と、段部11を除く他の回路導体5の部位とは、平行に形成される。また、切欠き部13は、少なくとも段部11に達する長さで形成される。このようにすることで、回路導体露出部7を射出成型基板3の表面で確実に区分することができる。   A metal plate is punched into a predetermined shape to form a stepped portion 11 to form a circuit conductor exposed portion 7. The circuit conductor exposed portion 7 and the portions of the other circuit conductors 5 excluding the step portion 11 are formed in parallel. The notch 13 is formed with a length that reaches at least the step 11. By doing in this way, the circuit conductor exposed part 7 can be reliably divided on the surface of the injection-molded substrate 3.

このようにして、回路導体5を形成し、必要に応じて回路導体5同士を接合する。回路導体5同士の接合は例えば溶接により行われる。なお、回路導体5は平面のみではなく、複数層に層状に形成されてもよい。   In this way, the circuit conductor 5 is formed, and the circuit conductors 5 are joined together as necessary. The joining between the circuit conductors 5 is performed by welding, for example. Note that the circuit conductor 5 may be formed not only in a plane but also in multiple layers.

図7は、このようにして形成された複数の回路導体5を金型21にセットした状態を示す図である。回路導体5は、金型21内のピンなどによって保持される。この状態で、射出樹脂9を金型21内に射出することで、回路導体5の表面または層間が射出樹脂9によって被覆され、射出成型基板3が形成される。   FIG. 7 is a view showing a state in which the plurality of circuit conductors 5 formed in this way are set in the mold 21. The circuit conductor 5 is held by pins or the like in the mold 21. In this state, the injection resin 9 is injected into the mold 21, whereby the surface or interlayer of the circuit conductor 5 is covered with the injection resin 9, and the injection-molded substrate 3 is formed.

ここで、回路導体露出部7の背面側には、ピン23が配置される。ピン23は、回路導体露出部7を金型21の内面に押し付ける部位である。このように、回路導体露出部7が金型21内面に押し付けられるため、回路導体露出部7の表面(回路導体露出部7と金型21内面との隙間)に射出樹脂9が回り込むことを抑制することができる。   Here, a pin 23 is disposed on the back side of the circuit conductor exposed portion 7. The pin 23 is a portion that presses the circuit conductor exposed portion 7 against the inner surface of the mold 21. Since the circuit conductor exposed portion 7 is pressed against the inner surface of the mold 21 in this way, the injection resin 9 is prevented from flowing around the surface of the circuit conductor exposed portion 7 (the gap between the circuit conductor exposed portion 7 and the inner surface of the mold 21). can do.

なお、このようにして射出樹脂9を射出すると、ピン23に応じた孔が形成される。すなわち、回路導体露出部7の背面側には、前述した孔12が形成される。孔12は、回路導体露出部7の放熱部として機能させることができる。   When the injection resin 9 is injected in this way, a hole corresponding to the pin 23 is formed. That is, the above-described hole 12 is formed on the back side of the circuit conductor exposed portion 7. The hole 12 can function as a heat radiating part of the circuit conductor exposed part 7.

なお、回路導体5は、前述したように、プレスで打ち抜き加工後に、屈曲させて形成しただけでも良いが、プレス加工の際、プレス金型の表面に凹凸形状を設けておき、回路導体5の表面(例えば裏面)に細かな凹凸形状を形成してもよい。表面の粗度を上げることでアンカー効果により樹脂との密着性を向上することができる。また、プレス金型による凹凸形成の他にも、ブラスト処理による表面処理や、銅メッキ粗化、ニッケルメッキ粗化等により回路素材表面を粗面化してもよい。   As described above, the circuit conductor 5 may be formed by bending after punching with a press. However, when the pressing is performed, an uneven shape is provided on the surface of the press die, and the circuit conductor 5 is formed. You may form fine uneven | corrugated shape on the surface (for example, back surface). By increasing the surface roughness, the adhesion with the resin can be improved by the anchor effect. In addition to the formation of irregularities by a press die, the surface of the circuit material may be roughened by surface treatment by blast treatment, copper plating roughening, nickel plating roughening, or the like.

以上説明したように、本実施形態の射出成型基板3によれば、回路導体露出部7と射出成型基板3とが同一面上に形成されるため、射出成型基板3上に凹凸が形成されることがない。したがって、半田19のスクリーン印刷が容易である。   As described above, according to the injection-molded substrate 3 of the present embodiment, the circuit conductor exposed portion 7 and the injection-molded substrate 3 are formed on the same surface, so that irregularities are formed on the injection-molded substrate 3. There is nothing. Therefore, screen printing of the solder 19 is easy.

また、回路導体露出部7を区分する切欠き部13または凹部15が形成されるため、複数の回路導体露出部7を互いに独立して併設することができる。このため、半田19が隣り合う電子部品等との接続に流れることが抑制される。   Moreover, since the notch part 13 or the recessed part 15 which divides the circuit conductor exposed part 7 is formed, the several circuit conductor exposed part 7 can be provided side by side mutually independently. For this reason, it is suppressed that the solder 19 flows into the connection with an adjacent electronic component or the like.

また、回路導体露出部7および段部11以外の回路導体5が、射出成型基板3の厚み方向の略中央に配置されるため、回路導体5の表裏面の射出樹脂9の量が略均等となり、熱による変形の影響を小さくすることができる。   In addition, since the circuit conductor 5 other than the circuit conductor exposed portion 7 and the stepped portion 11 is disposed at substantially the center in the thickness direction of the injection-molded substrate 3, the amount of the injection resin 9 on the front and back surfaces of the circuit conductor 5 becomes substantially equal. The influence of deformation due to heat can be reduced.

また、製造時に、回路導体露出部7を、背面からピン23によって金型21の内面に押圧するため、回路導体露出部7の表面に射出樹脂9が回り込むことを抑制することができる。また、この際に形成される孔12は、回路導体露出部7の放熱部として機能させることができる。   In addition, since the circuit conductor exposed portion 7 is pressed against the inner surface of the mold 21 from the back surface by the pin 23 at the time of manufacturing, the injection resin 9 can be prevented from flowing around the surface of the circuit conductor exposed portion 7. Further, the hole 12 formed at this time can function as a heat radiating portion of the circuit conductor exposed portion 7.

(他の実施形態1)
また、さらに、回路導体5に薄肉部を形成してもよい。図8は、薄肉部を形成する工程の一例を示す図である。まず、図8(a)に示すように、前述した方法で回路導体5を形成する。次に、図8(b)に示すように、回路導体露出部7の一部(段部11側の端部近傍)を切削等によって薄肉部25を形成する。
(Other embodiment 1)
Further, a thin portion may be formed in the circuit conductor 5. FIG. 8 is a diagram illustrating an example of a process for forming a thin portion. First, as shown in FIG. 8A, the circuit conductor 5 is formed by the method described above. Next, as shown in FIG. 8B, a thin portion 25 is formed by cutting a part of the circuit conductor exposed portion 7 (near the end portion on the step portion 11 side).

このようにして薄肉部25が形成された回路導体5に対して射出樹脂9を射出すると、薄肉部25の表面にも射出樹脂9が回り込む。すなわち、回路導体露出部7の範囲が、薄肉部25によって規制される。   When the injection resin 9 is injected to the circuit conductor 5 in which the thin portion 25 is formed in this manner, the injection resin 9 also wraps around the surface of the thin portion 25. That is, the range of the circuit conductor exposed portion 7 is regulated by the thin portion 25.

通常、回路導体5を屈曲させる場合、屈曲部にはわずかに角Rが形成される。このため、射出樹脂が角R部分から回路導体露出部7表面に回り込み、バリが形成される恐れがある。また、屈曲部の形態が必ずしも一定ではないため、回路導体露出部7の露出範囲がばらつく要因となり得る。   Normally, when the circuit conductor 5 is bent, a slight angle R is formed at the bent portion. For this reason, there is a possibility that the injection resin may circulate from the corner R portion to the surface of the circuit conductor exposed portion 7 to form burrs. Further, since the shape of the bent portion is not necessarily constant, the exposure range of the circuit conductor exposed portion 7 may vary.

これに対し、薄肉部25を形成することで、屈曲部の角Rの影響をなくし、射出樹脂9の回り込みを抑制することができる。また、薄肉部25の形成範囲によって、回路導体露出部7の範囲を容易に制御できるため、射出成型基板3の表面に露出する回路導体露出部7の大きさをより正確に制御することができる。   On the other hand, by forming the thin portion 25, the influence of the angle R of the bent portion can be eliminated, and the wraparound of the injection resin 9 can be suppressed. Moreover, since the range of the circuit conductor exposed portion 7 can be easily controlled by the formation range of the thin portion 25, the size of the circuit conductor exposed portion 7 exposed on the surface of the injection molded substrate 3 can be controlled more accurately. .

なお、薄肉部25は、切削以外の方法で形成してもよい。例えば、プレスで打ち抜き加工を行う際に、対象部分をつぶすことで、薄肉部を形成してもよい。   In addition, you may form the thin part 25 by methods other than cutting. For example, the thin portion may be formed by crushing the target portion when punching with a press.

このように、回路導体露出部7の段部11側の表面の一部に薄肉部25を形成することで、回路導体露出部7の表面に射出樹脂9が回り込むことを抑制することができるとともに、回路導体露出部7の露出範囲を正確に規制することができる。   As described above, by forming the thin portion 25 on a part of the surface of the circuit conductor exposed portion 7 on the stepped portion 11 side, it is possible to suppress the injection resin 9 from entering the surface of the circuit conductor exposed portion 7. The exposed range of the circuit conductor exposed portion 7 can be accurately regulated.

(他の実施形態2)
図9は、射出成型基板3aの図4のC−C線に相当する位置における断面図である。図9に示す射出成型基板3aのように、回路導体露出部7を背面から押圧するためのピンによる孔12とは別に、さらに、他の孔12a、12bを設けてもよい。孔12aは、段部11に沿って、回路導体露出部7が露出する面側から形成される。すなわち、段部11の基板面に垂直な一面が、孔12aに露出する。孔12bは、孔12aと同様であるが、段部11に沿って、回路導体露出部7が露出する面とは逆側から形成される。
(Other embodiment 2)
FIG. 9 is a cross-sectional view of the injection-molded substrate 3a at a position corresponding to the line CC in FIG. In addition to the holes 12 formed by pins for pressing the circuit conductor exposed portion 7 from the back surface, other holes 12a and 12b may be provided as in the injection-molded substrate 3a shown in FIG. The hole 12a is formed along the step portion 11 from the surface side where the circuit conductor exposed portion 7 is exposed. That is, one surface perpendicular to the substrate surface of the stepped portion 11 is exposed in the hole 12a. The hole 12b is the same as the hole 12a, but is formed along the step portion 11 from the side opposite to the surface where the circuit conductor exposed portion 7 is exposed.

このように、孔12a、12bを形成することで、段部11を基板面に平行な方向に対する規制が緩和される。したがって、回路導体5に生じる応力を緩和することができる。また、回路導体5の露出面積が増加するため、放熱性を向上させることができる。   Thus, by forming the holes 12a and 12b, the restriction on the direction in which the step portion 11 is parallel to the substrate surface is relaxed. Therefore, the stress generated in the circuit conductor 5 can be relaxed. Moreover, since the exposed area of the circuit conductor 5 increases, heat dissipation can be improved.

(他の実施形態3)
図10に示す回路導体5aのように、回路導体露出部7に切欠き部13aを形成してもよい。すなわち、回路導体露出部7の基部側(段部11側)の幅を狭くしてもよい。また、さらに、切欠き部13aを延長して、段部11の幅を狭くしてもよい。このようにすることで、回路導体露出部7や段部11の剛性を小さくすることができる。このため、切欠き部13aの位置を優先的に変形させ、実装される電子部品へ付与される応力を緩和することができる。
(Other embodiment 3)
Like the circuit conductor 5 a shown in FIG. 10, a notch 13 a may be formed in the circuit conductor exposed portion 7. That is, the width on the base side (step portion 11 side) of the circuit conductor exposed portion 7 may be narrowed. Furthermore, the width of the step portion 11 may be narrowed by extending the notch portion 13a. By doing in this way, the rigidity of the circuit conductor exposure part 7 and the step part 11 can be made small. For this reason, the position of the notch 13a can be preferentially deformed, and the stress applied to the electronic component to be mounted can be relaxed.

(他の実施形態4)
図11は、射出成型基板3bの図4のC−C線に相当する位置における断面図である。図11に示す射出成型基板3bのように、回路導体5の段部11に貫通孔である孔27を形成してもよい。段部11に孔27を設けることで、段部11の剛性を小さくすることができる。このため、段部11を優先的に変形させ、実装される電子部品へ付与される応力を緩和することができる。
(Other embodiment 4)
11 is a cross-sectional view of the injection-molded substrate 3b at a position corresponding to the line CC in FIG. A hole 27 that is a through hole may be formed in the step portion 11 of the circuit conductor 5 as in the injection-molded substrate 3b shown in FIG. By providing the hole 27 in the step portion 11, the rigidity of the step portion 11 can be reduced. For this reason, the step part 11 can be preferentially deformed and the stress applied to the electronic component to be mounted can be relaxed.

(他の実施形態5)
図12は、射出成型基板3cの図4のC−C線に相当する位置における断面図である。図12に示す射出成型基板3cのように、回路導体5同士の対向部に、放熱部材29を設けてもよい。すなわち、回路導体露出部7の間であって、電子部品が実装される部位に放熱部材29を配置してもよい。放熱部材29は、例えば金属製あるいは樹脂材料をベースとした放熱シートである。
(Other embodiment 5)
12 is a cross-sectional view of the injection-molded substrate 3c at a position corresponding to the line CC in FIG. As in the injection molded substrate 3c shown in FIG. 12, a heat radiating member 29 may be provided in the facing portion between the circuit conductors 5. That is, the heat radiating member 29 may be disposed between the circuit conductor exposed portions 7 and at a portion where the electronic component is mounted. The heat radiating member 29 is, for example, a heat radiating sheet made of metal or a resin material.

放熱部材29が導電性である場合、放熱部材29は、回路導体5とは導通しない。すなわち、回路導体5と放熱部材29との間には、射出樹脂9あるいは電気絶縁性の放熱シートが設けられる。放熱部材29は、電子部品の実装面とは逆側の面に露出する。放熱部材29は、基板背面側の表面と同一面で露出する。このため、前述した射出成型時には、ピン等によって、金型内面に押圧される。したがって、放熱部材29の上面側(電子部品実装面側)には、孔12cが形成される。   When the heat radiating member 29 is conductive, the heat radiating member 29 is not electrically connected to the circuit conductor 5. That is, the injection resin 9 or an electrically insulating heat dissipation sheet is provided between the circuit conductor 5 and the heat dissipation member 29. The heat dissipation member 29 is exposed on the surface opposite to the mounting surface of the electronic component. The heat dissipation member 29 is exposed on the same surface as the surface on the back side of the substrate. For this reason, at the time of the above-described injection molding, it is pressed against the inner surface of the mold by a pin or the like. Therefore, a hole 12 c is formed on the upper surface side (electronic component mounting surface side) of the heat radiating member 29.

このように放熱部材29を設けることで、基板の放熱性を向上させることができる。また、電子部品下部の射出樹脂9の厚みを薄くすることで、射出樹脂9に生じる内部応力を減少させることができる。   Thus, by providing the heat radiating member 29, the heat dissipation of a board | substrate can be improved. Further, by reducing the thickness of the injection resin 9 below the electronic component, internal stress generated in the injection resin 9 can be reduced.

なお、放熱部材29の配置は、図12に示した例には限られない。例えば、図13に示す射出成型基板3dのように回路導体5と接触するように配置してもよい。この場合でも、放熱部材29は、基板の上面または背面に突出せず、射出樹脂9と同一面で形成される。   In addition, arrangement | positioning of the thermal radiation member 29 is not restricted to the example shown in FIG. For example, you may arrange | position so that the circuit conductor 5 may be contacted like the injection molding board | substrate 3d shown in FIG. Even in this case, the heat radiating member 29 does not protrude from the upper surface or the back surface of the substrate, and is formed on the same surface as the injection resin 9.

(他の実施形態6)
図14は、回路導体露出部7の近傍にトランスコイル部を形成した射出成型基板3eの回路導体露出部7及びトランスコイル部の断面図である。図14に示す射出成型基板3eのように、本発明は、トランスコイル部でも適用可能である。この場合には、フェライトコア31が一体で成型される。また、フェライトコア31の周囲には、一次コイルとしても回路導体5bと、二次コイルとしての回路導体5cが配置される。回路導体5cは、回路導体5等と同様の構成である。図に示す例では、回路導体5cの一部に、段部11が形成され、回路導体露出部7が形成される。
(Other embodiment 6)
FIG. 14 is a cross-sectional view of the circuit conductor exposed portion 7 and the transformer coil portion of the injection molded substrate 3e in which the transformer coil portion is formed in the vicinity of the circuit conductor exposed portion 7. Like the injection-molded substrate 3e shown in FIG. 14, the present invention can also be applied to a transformer coil section. In this case, the ferrite core 31 is integrally molded. Further, around the ferrite core 31, a circuit conductor 5b as a primary coil and a circuit conductor 5c as a secondary coil are arranged. The circuit conductor 5c has the same configuration as the circuit conductor 5 and the like. In the example shown in the figure, a step portion 11 is formed on a part of the circuit conductor 5c, and a circuit conductor exposed portion 7 is formed.

このように、回路導体がコイルであっても、回路導体露出部7が、基板面から突出せず、射出樹脂9と同一面で形成される。   Thus, even if the circuit conductor is a coil, the circuit conductor exposed portion 7 does not protrude from the substrate surface and is formed on the same surface as the injection resin 9.

以上、添付図を参照しながら、本発明の実施の形態を説明したが、本発明の技術的範囲は、前述した実施の形態に左右されない。当業者であれば、特許請求の範囲に記載された技術的思想の範疇内において各種の変更例または修正例に想到し得ることは明らかであり、それらについても当然に本発明の技術的範囲に属するものと了解される。   As mentioned above, although embodiment of this invention was described referring an accompanying drawing, the technical scope of this invention is not influenced by embodiment mentioned above. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the technical idea described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.

例えば、上述した各構成は、互いに組み合わせることができることは言うまでもない。   For example, it goes without saying that the above-described configurations can be combined with each other.

1………基板
3、3a、3b、3c、3d、3e………射出成型基板
5、5a、5b、5c………回路導体
7………回路導体露出部
9………射出樹脂
11………段部
12、12a、12b、12c………孔
13、13a………切欠き部
15………凹部
17………電子部品
19………半田
21………金型
23………ピン
25………薄肉部
27………孔
29………放熱部材
31………フェライトコア
1 ... Substrate 3, 3a, 3b, 3c, 3d, 3e ......... Injection molded substrate 5, 5a, 5b, 5c ......... Circuit conductor 7 ...... Circuit conductor exposed part 9 ... Injection resin 11 ... ...... Steps 12, 12a, 12b, 12c ......... Hole 13, 13a ......... Notch 15 ......... Recess 17 ......... Electronic component 19 ......... Solder 21 ......... Mold 23 ......... Pin 25 ......... Thin portion 27 ......... Hole 29 ......... Heat dissipation member 31 ......... Ferrite core

Claims (8)

回路導体の表面に射出樹脂を射出して形成される射出成型基板であって、
前記回路導体の一部が屈曲されて設けられる段部と、
前記段部によって前記回路導体の一部が前記射出樹脂の表面に露出する回路導体露出部と、
を具備し、
前記回路導体露出部以外の前記回路導体の表面が前記射出樹脂によって覆われ、前記回路導体露出部の表面と、前記射出樹脂の表面とが、略同一面に形成され、
隣り合う前記回路導体露出部間には、切欠き部または凹部が設けられ、前記切欠き部または前記凹部に前記射出樹脂が配置されることで基板表面において前記回路導体露出部が区分され
射出成型基板の少なくとも一方の面から孔が形成され、前記段部の表面の一部が孔に露出することを特徴とする基板。
An injection molded substrate formed by injecting injection resin onto the surface of a circuit conductor,
A step provided by bending a part of the circuit conductor;
A circuit conductor exposed portion in which a part of the circuit conductor is exposed on the surface of the injection resin by the stepped portion;
Comprising
The surface of the circuit conductor other than the circuit conductor exposed portion is covered with the injection resin, and the surface of the circuit conductor exposed portion and the surface of the injection resin are formed on substantially the same plane,
Between the adjacent circuit conductor exposed parts, a notch or a recess is provided, and the circuit conductor exposed part is divided on the substrate surface by placing the injection resin in the notch or the recess ,
Injection hole from at least one surface of the molded substrate is formed, the substrate portion of the surface of the step portion is characterized that you exposed in the hole.
回路導体の表面に射出樹脂を射出して形成される射出成型基板であって、
前記回路導体の一部が屈曲されて設けられる段部と、
前記段部によって前記回路導体の一部が前記射出樹脂の表面に露出する回路導体露出部と、
を具備し、
前記回路導体露出部以外の前記回路導体の表面が前記射出樹脂によって覆われ、前記回路導体露出部の表面と、前記射出樹脂の表面とが、略同一面に形成され、
隣り合う前記回路導体露出部間には、切欠き部または凹部が設けられ、前記切欠き部または前記凹部に前記射出樹脂が配置されることで基板表面において前記回路導体露出部が区分され
前記段部に貫通孔が形成されることを特徴とする基板。
An injection molded substrate formed by injecting injection resin onto the surface of a circuit conductor,
A step provided by bending a part of the circuit conductor;
A circuit conductor exposed portion in which a part of the circuit conductor is exposed on the surface of the injection resin by the stepped portion;
Comprising
The surface of the circuit conductor other than the circuit conductor exposed portion is covered with the injection resin, and the surface of the circuit conductor exposed portion and the surface of the injection resin are formed on substantially the same plane,
Between the adjacent circuit conductor exposed parts, a notch or a recess is provided, and the circuit conductor exposed part is divided on the substrate surface by placing the injection resin in the notch or the recess ,
Substrate, wherein Rukoto through hole is formed in the stepped portion.
一対の前記回路導体同士が隙間を開けて、前記回路導体露出部同士が対向するように配置され、前記切欠き部または前記凹部は、前記回路導体の対向方向に沿って形成されることを特徴とする請求項1または請求項2に記載の基板。 A pair of the circuit conductors are arranged with a gap therebetween so that the exposed portions of the circuit conductors are opposed to each other, and the cutout portion or the concave portion is formed along the facing direction of the circuit conductors. The substrate according to claim 1 or 2 . 前記回路導体露出部以外および前記段部以外の部位の前記回路導体は、前記射出樹脂の厚みの略中央に配置されることを特徴とする請求項1から請求項3のいずれかに記載の基板。 4. The substrate according to claim 1 , wherein the circuit conductors other than the exposed portion of the circuit conductor and the portions other than the stepped portion are arranged at a substantially center of the thickness of the injection resin. 5. . 前記回路導体露出部の背面側には、前記射出樹脂の一部に孔が形成されることを特徴とする請求項1から請求項のいずれかに記載の基板。 The circuit on the back side of the conductor exposed portion, the substrate according to any one of claims 1 to 4, characterized in that holes are formed in a part of the injected resin. 前記回路導体露出部の前記段部側の表面の一部に薄肉部が形成され、前記薄肉部は、前記射出樹脂で被覆されることを特徴とする請求項1から請求項のいずれかに記載の基板。 The thin portion is formed in a part of the stepped portion of the surface of the circuit conductor exposed portion, the thin portion, to one of the claims 1 to 5, characterized in that it is coated with the injected resin The substrate described. 前記回路導体露出部の前記段部側の幅が、前記回路導体露出部の他の部位よりも幅が狭いことを特徴とする請求項1から請求項6のいずれかに記載の基板。   The substrate according to any one of claims 1 to 6, wherein a width of the circuit conductor exposed portion on the stepped portion side is narrower than other portions of the circuit conductor exposed portion. 放熱部材をさらに具備し、前記放熱部材の表面と、前記射出樹脂の表面とが、略同一面に形成されることを特徴とする請求項1から請求項のいずれかに記載の基板。 The substrate according to any one of claims 1 to 7 , further comprising a heat dissipating member, wherein the surface of the heat dissipating member and the surface of the injection resin are formed on substantially the same plane.
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