Metal core substrate, method for producing the same, and core plate usable for the same

A method for producing a metal core substrate by stacking a core plate having holes therein and an insulating layer on each of two surfaces of the core plate to form an integral substrate and then performing outline shaping on the integral substrate to obtain the metal core substrate as being individually cut out;

• the method comprising:
• a punching step of forming the holes in the core plate, wherein separation portions and coupling portions are alternately formed on phantom outline shaping lines along which outline shaping is to be performed in a later outline shaping step, each of the separation portions separating adjacent portions of the core plate to be metal core substrates from each other, or separating a portion of the core plate to be the metal core substrate from an outer peripheral portion of the core plate, along the phantom outline shaping line;
• and each of the coupling portions being astride the phantom outline shaping line(s) to couple the adjacent portions of the core plate to be the metal core substrates to each other or to couple the portion of the core plate to be the metal core substrate to the outer peripheral portion;
• a stacking step of performing the stacking, wherein the separation portions are filled with a resin used to form the insulating layers;
• a separation step, performed after the stacking step, of removing at least a part of each of the coupling portions by punching, so that the adjacent portions of the integral substrate to be the metal core substrates are separated from each other, or the portion of the integral substrate to be the metal core substrate is separated from the outer peripheral portion of the integral substrate, along the phantom outline shaping line;
• and
• an outline shaping step of performing the outline shaping along outline shaping positions to obtain the metal core substrate as being individually cut out;
• wherein an end surface of the core plate in the metal core substrate that defined the separation portions before the outline shaping step is covered with an insulating covering portion that is formed of a resin used to form the insulating layers.

A core plate on which an insulating layer is integrated to each of two surfaces thereof and which is to be subjected to outline shaping to produce a plurality of individually separated metal core substrates;

• wherein:
• the core plate includes separation portions and coupling portions alternately formed on phantom outline shaping lines along which outline shaping is to be performed;
• each of the separation portions separates adjacent portions of the core plate to be metal core substrates from each other, or separates a portion of the core plate to be one of the metal core substrates from an outer peripheral portion of the core plate, along the phantom outline shaping line;
• each of the coupling portions is astride the phantom outline shaping line(s) to couple the adjacent portions of the core plate to be the metal core substrates to each other or to couple the portion of the core plate to be one of the metal core substrates to the outer peripheral portion of the core plate;
• and
• at least a part of each of the coupling portions is removed, so that the adjacent portions to be the metal core substrates are separated from each other, or the portion to be one of the metal core substrates is separated from the outer peripheral portion, along the phantom outline shaping line.

A method for producing a metal core substrate by stacking a core plate having holes therein and an insulating layer on each of two surfaces of the core plate to form an integral substrate and then performing outline shaping on the integral substrate to obtain the metal core substrate as being individually cut out;

• the method comprising:
• a punching step of forming the holes in the core plate, wherein separation portions and coupling portions are alternately formed on phantom outline shaping lines along which outline shaping is to be performed in a later outline shaping step, each of the separation portions separating adjacent portions of the core plate to be metal core substrates from each other, or separating a portion of the core plate to be the metal core substrate from an outer peripheral portion of the core plate, along the phantom outline shaping line;
• and each of the coupling portions being astride the phantom outline shaping line(s) to couple the adjacent portions of the core plate to be the metal core substrates to each other or to couple the portion of the core plate to be the metal core substrate to the outer peripheral portion;
• a stacking step of performing the stacking, wherein the separation portions are filled with a resin used to form the insulating layers;
• a separation step, performed after the stacking step, of removing at least a part of each of the coupling portions by punching, so that the adjacent portions of the integral substrate to be the metal core substrates are separated from each other, or the portion of the integral substrate to be the metal core substrate is separated from the outer peripheral portion of the integral substrate, along the phantom outline shaping line;
• and
• an outline shaping step of performing the outline shaping along outline shaping positions to obtain the metal core substrate as being individually cut out;
• wherein:
• an end surface of the core plate in the metal core substrate that defined the separation portions before the outline shaping step is covered with an insulating covering portion that is formed of a resin used to form the insulating layers;
• and
• at least one of the punching step and the outline shaping step is performed by use of fiber laser.