Method of producing substrate
The method of producing a substrate comprises the steps of: forming a through-hole in a base member; plating the base member so as to coat an inner face of the through-hole with a plated layer; applying photo resist on the base member; optically exposing and developing the photo resist so as to form a resist pattern, which coats at least a planar area of the through-hole; and etching an electrically conductive layer formed on the surface of the base member. The resist pattern is formed so as to separate an area of exposing the conductive layer a prescribed distance away from an edge of the through-hole, and the prescribed length is longer than a distance of etching a side face of the conductive layer in the etching step.
1. A method of producing a core substrate, comprising:
forming a pilot hole in a base member, the base member including a core section composed of carbon fiber-reinforced plastic, copper foils being bonded on both surfaces of the core section with prepregs;
coating an inner face of the pilot hole with a plated layer by electroless-plating;
electrolytic-plating the base member subsequent to the electroless-plating of the inner face of the pilot hole;
filling the pilot hole, whose inner face has been coated with the plated layer, with an insulating material composed of resin;
forming resist patterns, which coat planar areas of the pilot hole and edges of the pilot hole with a prescribed width, on both surfaces of the base member by laminating photoresist thereon and exposing and developing the photoresist;
forming copper foil patterns along the edges of the pilot hole and exposing the prepregs in both surfaces of the core section by etching the copper foils with using the resist patterns as masks;
removing the resist patterns;
integrating cable layers with the base member by successively placing a first additional prepreg, a cable sheet, in which cable patterns are formed on both surfaces of an insulating sheet, a second additional prepreg, and an additional copper foil, on each of the surfaces of the base member, and pressurizing and heating the cable layers to thermally cure the first additional prepregs and the second additional prepregs;
coaxially forming a through-hole, whose diameter is smaller than that of the pilot hole and that penetrates the cable layers and the base member, with the pilot hole so as to expose the insulating material as an inner face;
forming a plated through-hole on the inner face of the through-hole by electroless copper plating and electrolytic copper plating;
filling the through-hole with resin; and
etching the additional copper foils so as to form additional cable patterns on the both surfaces of the base member.
2. The method according to claim 1 ,
wherein an insulating film is formed on the plated layer, which has been formed on the inner face of the pilot hole, by an electrodeposition method using the plated layer as an electric power feeding layer, the forming of the insulating layer being performed subsequent to the electrolytic-plating of the base member and prior to the filing of the pilot hole.
3. The method according to claim 1 ,
wherein both surfaces of the base member are electroless-copper-plated after the filing of the pilot hole so as to coat both surfaces of the base member with electroless copper plated layers.
4. A method of producing a circuit board, comprising:
producing a core substrate according to the method of claim 1 ; and
laminating cable layers on both surfaces of the core substrate.
5. The method according to claim 4 ,
wherein the cable layers are formed by build-up method.