Via hole structure and process for formation thereof

A multilayer structure having an improved via hole therethrough comprising:

• a support structure having a main surface;
• plural resin film insulating layers, each having corresponding upper and lower surfaces, comprising a first insulating layer formed on the main surface of the support structure and successive insulating layers, each formed on the upper surface of the respectively next preceding insulating layer;
• and
• the first and successive insulating layers respectively having first and successive apertures extending therethrough, respectively of first and successively smaller dimensions, and through which corresponding first and successively smaller portions of the main surface of the support structure are exposed, each successive insulating layer having a portion thereof which corresponds to and extends into the aperture of the next preceding insulating layer, the corresponding lower surface portion thereof being formed on the respective, exposed portion of the main surface of the support structure and the corresponding upper surface portion thereof defining a depression relative to the remaining upper surface of the associated insulating layer and the respective aperture thereof being disposed within the corresponding depression, the depression in the last of the successive insulating layers and the respective aperture thereof defining a smoothly tapered via hole extending through the multilayer structure of the first and successive insulating layers and having a larger dimension at the upper surface of the last of the successive insulating layers than at the main surface of the support structure.

A method for forming an improved via hole in a multilayer structure, comprising:

• providing a support structure having a main surface;
• forming a first resin film insulating layer, having upper and lower surfaces, on the main surface;
• forming a first aperture, extending through the first insulating layer, of a first dimension and through which first aperture a corresponding first portion of the main surface of the support structure is exposed;
• forming a second resin film insulating layer, having upper and lower surfaces, on the upper surface of the first resin film insulating layer, a portion of the second resin film insulating layer which corresponds to the first aperture extending into the first aperture and the corresponding lower surface portion thereof being formed on the exposed, first portion of the main surface of the support structure and the corresponding upper surface portion thereof defining a depression relative to the remaining, upper surface of the second insulating layer;
• and
• forming a second aperture in the second insulating layer, aligned with the first aperture and of a second dimension smaller than the first dimension of the first aperture, the second aperture being disposed within the depression in the upper surface of the second insulating layer and extending through the second insulating layer to the main surface of the support structure and through which second aperture a corresponding second portion, smaller than the first portion, of the main surface of the support structure is exposed, the depression in the second insulating layer and the second aperture thereby defining a smoothly tapered via hole extending through the multilayer structure of the first and second insulating layers and having a larger dimension at the upper surface of the second insulating layer than at the main surface of the support structure.

A method for forming an improved via hole in a multilayer structure, comprising:

• providing a support structure defining a main surface;
• forming a first resin film insulating layer, having upper and lower surfaces, on the main surface;
• and
• forming successive insulating layers, each having corresponding upper and lower surfaces and an aperture extending therethrough, the successive insulating layers having respective apertures of successively smaller dimensions than the first dimension of the first aperture and through which corresponding, successively smaller portions of the main surface of the support structure are exposed, each successive insulating layer having a portion thereof which corresponds to and extends into the aperture of the next preceding insulating layer, the corresponding lower surface portion thereof being formed on the respective, exposed portion of the main surface of the support structure and the corresponding upper surface portion thereof defining a depression relative to the remaining upper surface of the associated insulating layer, and the respective aperture thereof being disposed within the corresponding depression, the depression in the last of the successive insulating layers and the respective aperture thereof defining a tapered via hole extending through the multilayer structure of the first and successive insulating layers and having a larger dimension at the upper surface of the last of the successive insulating layers than at the main surface of the support structure.