Multi-layer resin substrate and method of manufacturing multi-layer resin substrate

Patent metadata

Field	Value
Publication number	US-9532447-B2
Application number	US-201514754796-A
Country	US
Kind code	B2
Filing date	Jun 30, 2015
Priority date	Jan 9, 2013
Publication date	Dec 27, 2016
Grant date	Dec 27, 2016

Abstract

A multi-layer resin substrate is a multi-layer resin substrate integrated by stacking and thermocompression bonding a plurality of resin layers each composed of a thermoplastic resin as a main material and having a main surface. The plurality of resin layers include a resin layer having a pattern member arranged on the main surface. A surface of at least some resin layers of the plurality of resin layers has a paint layer, which is obtained by applying a thermoplastic resin paint to a region corresponding to a region insufficient in thickness as a stack as a whole during a process for stacking and thermocompression bonding the plurality of resin layers. The pattern member is provided, for example, by a conductor pattern.

First claim

The invention claimed is:

1. A multi-layer resin substrate integrated by stacking and thermocompression bonding a plurality of resin layers each composed of a thermoplastic resin as a main material and having a main surface,
said plurality of resin layers including a resin layer having a pattern member arranged on said main surface, and
a surface of at least one resin layer of said plurality of resin layers having a paint layer, which is obtained by applying a thermoplastic resin paint to a region corresponding to a region insufficient in thickness as a stack as a whole during a process for stacking and thermocompression bonding said plurality of resin layers.

2. The multi-layer resin substrate according to claim 1 , wherein
said thermoplastic resin is a liquid crystal polymer and said thermoplastic resin paint comprises the liquid crystal polymer.

3. The multi-layer resin substrate according to claim 2 , wherein
said thermoplastic resin paint contains a powdery liquid crystal polymer.

4. The multi-layer resin substrate according to claim 3 , wherein
said thermoplastic resin paint is obtained by dispersing the powdery liquid crystal polymer in a liquid.

5. The multi-layer resin substrate according to claim 3 , wherein
said powdery liquid crystal polymer has been subjected to surface treatment with plasma or ultra violet rays.

6. The multi-layer resin substrate according to claim 2 , wherein said thermoplastic resin paint contains a liquid crystal polymer in a form of varnish.

7. The multi-layer resin substrate according to claim 1 , wherein
said region insufficient in thickness as the stack as a whole is a region where said pattern members or components to be contained in the stack of said resin layers are sparsely arranged.

8. A method of manufacturing a multi-layer resin substrate, comprising the steps of:
preparing a plurality of resin layers including a resin layer having a pattern member arranged on a main surface each composed of a thermoplastic resin as a main material and having the main surface;
applying, at a surface of at least one resin layer of said plurality of resin layers, a thermoplastic resin paint to a region corresponding to a region insufficient in thickness as a stack as a whole during a process for stacking and thermocompression bonding said plurality of resin layers;
stacking said plurality of resin layers for which said step of applying a thermoplastic resin paint has been completed; and
obtaining a stack including a paint layer composed of said thermoplastic resin paint by thermocompression bonding said stack of said plurality of resin layers obtained in said step of stacking by applying a pressure and heat to said stack.

9. The method of manufacturing a multi-layer resin substrate according to claim 8 , wherein
said thermoplastic resin is a liquid crystal polymer and said thermoplastic resin paint comprises the liquid crystal polymer.

10. The method of manufacturing a multi-layer resin substrate according to claim 8 , wherein
said thermoplastic resin paint contains a powdery liquid crystal polymer.

11. The method of manufacturing a multi-layer resin substrate according to claim 10 , wherein
said thermoplastic resin paint is obtained by dispersing the powdery liquid crystal polymer in a liquid.

12. The method of manufacturing a multi-layer resin substrate according to claim 10 , wherein
said powdery liquid crystal polymer has been subjected to surface treatment with plasma or ultra violet rays.

13. The method of manufacturing a multi-layer resin substrate according to claim 9 , wherein
said thermoplastic resin paint contains a liquid crystal polymer in a form of varnish.

14. The method of manufacturing a multi-layer resin substrate according to claim 10 , comprising the step of obtaining the powdery liquid crystal polymer by pulverizing a biaxially oriented liquid crystal polymer film before said step of applying the thermoplastic resin paint.

15. The method of manufacturing a multi-layer resin substrate according to claim 14 , wherein
in said step of obtaining the powdery liquid crystal polymer, said liquid crystal polymer film is pulverized while it is frozen.

16. The method of manufacturing a multi-layer resin substrate according to claim 14 , wherein
a material for said biaxially oriented liquid crystal polymer and the main material for said resin layer are common to each other.

17. The method of manufacturing a multi-layer resin substrate according to claim 8 , wherein
said region insufficient in thickness as the stack as a whole is a region where said pattern members or components to be contained in the stack of said resin layers are sparsely arranged.

18. The multi-layer resin substrate according to claim 4 , wherein
said powdery liquid crystal polymer has been subjected to surface treatment with plasma or ultra violet rays.

19. The method of manufacturing a multi-layer resin substrate according to claim 13 , wherein
a solvent used for obtaining the liquid crystal polymer in the form of varnish is a solvent that does not dissolve the resin layers.

Assignees

• Murata Manufacturing Co

Inventors

• Ohata Hiroyuki

Classifications

• C08J2300/00

  Characterised by the use of unspecified polymers · CPC title

• C08J3/28

  Treatment by wave energy or particle radiation · CPC title

• C09K19/38

  Polymers · CPC title

• B32B37/06

  characterised by the heating method · CPC title

• B32B2457/202

  LCD, i.e. liquid crystal displays · CPC title