CN103031075A - 聚合物膜及其在发光装置中的应用 - Google Patents
聚合物膜及其在发光装置中的应用 Download PDFInfo
- Publication number
- CN103031075A CN103031075A CN2012103717229A CN201210371722A CN103031075A CN 103031075 A CN103031075 A CN 103031075A CN 2012103717229 A CN2012103717229 A CN 2012103717229A CN 201210371722 A CN201210371722 A CN 201210371722A CN 103031075 A CN103031075 A CN 103031075A
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- Prior art keywords
- white
- polymeric film
- light
- polyimide
- calcium
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
本发明涉及一种聚合物膜,其包括一白色聚酰亚胺层;以及一白色粘着层,设置于该聚酰亚胺层的一表面;该聚合物膜的特征在于,该粘着层包括一粘着剂成分、及一分布于该粘着剂中的白色填料,且该聚合物膜具有约80%以上的反射率。此外,本发明还提供该聚合物膜应用于发光装置的实施例。
Description
技术领域
本发明是关于一种聚合物膜,尤其是关于一种可用于形成反光表面的聚合物膜及其在发光装置中的应用。
背景技术
聚酰亚胺(polyimide,PI)薄膜具有轻薄可挠曲的特性,加上具备优异的热稳定性,以及良好的机械、电气及化学性质,广泛应用于电子产业,例如制备发光二极管(LED)装置、液晶显示器等。具体言之,聚酰亚胺薄膜可应用于耐高温胶带、软性电路板(FPC)的聚合物膜、集成电路(IC)的钝化膜(passivation coating)、液晶显示器(LCD)的配向膜、漆包线等绝缘材等。
近年来,由于环保意识的加强,促使各种节能产品的开发,其中,发光二极管(LED)于照明应用上,因其光转换效率高、使用寿命长,并可减少用电量,故发光二极管的市场需求逐步增加。在发光二极管的研发上,为了提高亮度并兼顾节能效果,所提出的解决方案之一是增加背板的反射率。
目前市售发光二极管产品多利用双层(dual-layered)聚酰亚胺薄膜作为覆盖层结构,其主要于习知聚酰亚胺膜上涂布一白色树脂层,从而形成双层结构的白色聚酰亚胺薄膜。习知聚酰亚胺膜多呈淡黄色至棕色,厚度可为12.5微米(μm)或25微米。而该白色树脂一般选自例如环氧树脂、压克力树脂或其它高分子聚合物等,涂布厚度约10至20微米。为了将该反射层贴合至发光二极管上,在该习知聚酰亚胺膜的另一侧设置粘着层,该粘着层的厚度一般为约10至50微米。因此形成的覆盖层结构的总厚度(不含离型层)约35至75微米,厚度较高,不耐弯折。虽然此种方式可使聚酰亚胺薄膜呈白色而达到反射的效果,且制作成本较低,但树脂层耐热性较差,在高温下易发生劣化或黄化,会影响反射层性能,且不利后续加工。另外,需要额外涂布树脂层,还增加发光二极管制备过程的繁琐程度,提高表面受污染的机会。
为了解决树脂涂层不耐高温的问题,业界提出利用白色聚酰亚胺薄膜作为反射层,为直接使用白色聚酰亚胺膜并设置粘着层。然而,白色聚酰亚胺薄膜通常具有透光度,因此需要一定的膜厚度才能提供遮蔽度,与发光二极管装置贴合后才不会降低表面反射率。一般而言,白色聚酰亚胺膜的厚度必须达到25微米以上才具备足够遮蔽度,通常为约25至50微米。因此,该聚合物膜的总厚度(不含离型层)约35至100微米,厚度较高。然而,白色聚酰亚胺膜越厚,其单位面积的成本也越高,且相当不利于薄型化的应用。
发明内容
针对前述问题,本发明提供一种聚合物膜,包括一白色聚酰亚胺层、以及一粘着层,设置于该聚酰亚胺层的一表面;其特征在于,该粘着层包括一粘着剂成分、及一分布于该粘着剂中的白色填料,且该聚合物膜具有约80%以上的反射率。
另外,本发明还提供一种发光装置,包括一基材、设置于该基材上的发光组件、及一反光表面,该反光表面由一聚合物膜形成,该聚合物膜包括:一白色聚酰亚胺层;以及一粘着层,设置于该聚酰亚胺层的一表面,该粘着层包括一粘着剂成分、及一分布于该粘着剂中的白色填料,且该聚合物膜具有约80%以上的反射率。
本发明的聚合物膜不但可以改善现有技术所产生的黄化、劣化、高厚度、高成本等问题,同时还具有低穿透度及高反射率的特性。
附图说明
图1描绘了本发明一实施例所提供的聚合物膜的结构。
图2A至图2D为描绘本发明一实施例利用聚合物膜制造发光装置的流程示意图。
附图中主要组件符号说明
100 聚合物膜
102 白色聚酰亚胺层
104 白色粘着层
106 白色填料
201 基材
203 白色聚酰亚胺层
205 白色粘着层
207 聚合物膜
210 金属层
220 发光组件
222 电极
具体实施方式
图1描绘了本发明一实施例所提供的聚合物膜100的结构。聚合物膜100可包含白色聚酰亚胺层102及一白色粘着层104。粘着层104包括一粘着剂成分、及一均匀分布于粘着剂中的白色填料106。聚合物膜100可透过粘着层104贴合于一基材上。
根据一实施例,该粘着剂成分可选自环氧树脂系(epoxy)、丙烯酸系(acrylics)、聚硅氧系(silicone)、酚醛树脂系(phenolics)、聚氨酯系(polyurethanes)、橡胶系(rubbers)等,上述成分可单独使用或组合使用。
于一实施例中,该粘着剂成分为环氧树脂。环氧树脂可包括,举例但非限制,双酚A型环氧树脂;酚醛环氧树脂(novolac epoxy resin),例如苯酚型酚醛环氧树脂、邻甲酚型酚醛环氧树脂、双酚A型酚醛环氧树脂等;脂肪族环氧树脂,例如直链型脂肪族环氧树脂或环状脂肪族环氧树脂;聚丁二烯环氧树脂等。此外,粘着剂成分例如为双酚A型环氧树脂。
该白色填料可包括,举例但非限制,氧化钛(TiO2)、氧化锆(ZrO2)、氧化钙(CaO)、氧化锌(ZnO2)、氧化铝(Al2O3)、硫化锌(ZnS2)、碳酸钙(CaCO3)、碳酸铅(PbCO3)、氢氧化铅(Pb(OH)2)、硫酸钙(CaSO4)、硫酸钡(BaSO4)、二氧化硅(SiO2)、氮化硼(BN)、氮化铝(AlN)、碱式钼酸锌(basic zincmolybdate)、碱式钼酸锌钙(basic calcium zinc molybdate)、铅白(lead white)、钼白(molybdenum white)、锌钡白(lithopone)(硫酸钡及硫化锌的混合物)、粘土等,上述成分可单独使用或组合使用。于部分实施例中,该白色填料选自TiO2、Al2O3、CaCO3、CaSO4、SiO2、BN、AlN、和粘土等,上述成分可单独使用或组合使用。
白色填料与粘着剂成分的比例可视该聚合物膜的需求而调整。根据一实施例,以白色填料与粘着剂所组成的白色粘着层,可具有约20%以下的透光率。添加白色填料的粘着剂成分除了可将聚合物膜贴合至例如LED的发光装置中,更可进一步提升聚合物膜的反射率与遮蔽度,使该聚合物膜可作为有效的反光表面。
于部分实施例中,该白色填料占粘着层的5至80wt%。该粘着层包含例如5重量%、10重量%、15重量%、20重量%、30重量%、40重量%、50重量%、60重量%、65重量%、70重量%、75重量%、80重量%,或介于前述任两个数值之间的白色填料。该白色填料占粘着层的比例,较佳为10至70重量%,更佳为25至70重量%。
根据实验结果显示,白色填料的平均粒径小于0.1微米时,白色填料的分散性较差,且即使添加大量白色填料,可能仍无法使得白色聚酰亚胺层或白色粘着层获得所希望的色度值。若白色填料的平均粒径大于5微米,则可能造成白色聚酰亚胺层或白色粘着层的表面粗糙度过大而影响外观。因此,于本发明的实施例中,该白色填料的平均粒径可选为0.1、0.2、0.3、0.4、0.5、0.6、0.7、0.8、0.9、1.0、1.5、2、2.5、3、3.5、4、4.5或5微米,或介于前述任两个数值之间。
于本发明的聚合物膜的结构中,该白色聚酰亚胺层可为单层白色聚酰亚胺薄膜。所谓单层白色聚酰亚胺薄膜,在结构上为单一层且层本身即呈白色。于部分实施例中,可将复数个单层白色聚酰亚胺薄膜层迭使用。
针对其聚酰亚胺的构成单体并未特别限制,可选用不同的二酐及二胺单体进行反应而形成聚酰亚胺。于部分实施例中,可利用聚酰亚胺混合适当填料(例如色料)而制备白色聚酰亚胺薄膜。
于部分实施例中,该白色聚酰亚胺层可包括一b*值小于10的低色度聚酰亚胺,及一分布于该低色度聚酰亚胺中的白色填料。b*值为公知的「L*a*b*色彩空间(L*a*b*color space)」中定义黄色与蓝色之间的色界(color dimension)指标。于一实施例中,是以2,2’-双(三氟甲基)联苯胺的二胺成分与选自3,3',4,4'-联苯四羧酸二酐的二酐成分进行反应,形成b*值小于10的低色度聚酰亚胺,并与白色填料均匀混合后制备得到单层白色聚酰亚胺薄膜。于另一实施例中,可额外添加2,2-双[4-(3,4-二羧基苯氧基)苯基]丙烷二酐,与2,2’-双(三氟甲基)联苯胺的二胺成分及3,3',4,4'-联苯四羧酸二酐的二酐成分进行反应,形成低色度的聚酰亚胺,并与白色填料均匀混合后制备得到单层白色聚酰亚胺薄膜。
用于制备聚酰亚胺薄膜的白色填料,可与前述粘着层的白色填料相同或不同,于此处不重复赘述。于较佳实施例中,制备聚酰亚胺薄膜的白色填料是选自由TiO2、Al2O3、CaCO3、CaSO4、SiO2、BN、AlN及粘土所组成的组的一种或多种。根据一实施例,含有白色填料的白色聚酰亚胺层,可具有约20%以下的透光率。
相较于现有技术,本发明的聚合物膜可显著降低整体厚度(不含离型层)至约23至68微米(μm),尤其适合薄型化的应用。该粘着层例如可维持与已知粘着层厚度相似的厚度,约50微米。于本发明的部分实施例中,该粘着层的厚度可介于约10至50微米。至于白色聚酰亚胺层,则可使用较薄的厚度,例如厚度低于约30微米。于部分实施例中,该白色聚酰亚胺层厚度为约18微米以下,例如约12.5微米。
本发明的聚合物膜可达到约80%以上的反射率,例如约85%以上。
此外,相较于现有技术,本发明的聚合物膜可有效地降低透光率(即,提高遮蔽度)至低于25%,例如约20%以下的透光率;较佳可提供低于15%的透光率,例如约10%以下、约9%、约5至6%等。
实施例
制备聚酰亚胺薄膜
合成例1
于环境温度下,将氮气饲入作为聚合反应容器的500毫升(ml)三颈烧瓶中。所有反应皆于氮气氛围下进行。将作为溶剂的约160公克(g)二甲基乙酰胺(DMAC)添加至该烧瓶。将约18.774g(0.060mole)的2,2’-双(三氟甲基)联苯胺(TMFB)溶解于DMAC中。于TMFB完全溶解于DMAC后,加入约13.354g(0.045moles)的联苯四羧酸二酐(BPDA)及约7.873g(0.015moles)的2,2-双[4-(二羧基苯氧基)苯基]丙烷二酐二酐(BPADA)至该溶液中,并加入8.411g的二氧化钛(TiO2)浆料(浆料的固含量约50%),持续搅拌约4小时,形成聚酰胺酸(PAA)溶液。
将所得PAA溶液与醋酸酐脱水剂及甲基吡啶(picoline)催化剂混合,以获得前驱物溶液。接着,于一玻璃平板上,以刮刀将该前驱物溶液涂布成层。该经涂布的层具有厚度为约0.5密耳(mil)(即约12.5μm),并于循环烘箱中以阶段式温度烘烤,温度及时间设定为约100℃烘烤30分钟、接着以约200℃烘烤30分钟,接着以约300℃烘烤30分钟。从而形成白色聚酰亚胺膜,将其自玻璃基板上剥离。
合成例2
相较于合成例1,合成例2的差异在于添加25.833g的二氧化钛浆料(浆料的固含量约50%),其余制备过程则与合成例1相同,以形成白色聚酰亚胺膜。
合成例3
相较于合成例1,合成例3的差异在于添加51.66g的二氧化钛浆料(浆料的固含量约50%),其余制备过程则与合成例1相同,以形成白色聚酰亚胺膜。
合成例4
相较于合成例1,合成例4的差异在于不添加二氧化钛,其余制备过程则与合成例1相同。藉此,所形成的聚酰亚胺薄膜并未呈现白色。
合成例5
相较于合成例1,合成例5的差异在于添加25.833g的二氧化钛浆料(浆料的固含量约50%)、且前驱物溶液涂布成层的厚度为约1mil(即约25μm),其余制备过程则与合成例1相同,以形成白色聚酰亚胺膜。
制备聚合物膜
实施例1
于约50g的双酚A型环氧树脂(商品名称为HBAD028-1,ArakawaChemical Industries,Ltd所制)中,添加约0.385g的固化剂(商品名称为HBAD028-2,Arakawa Chemical Industries,Ltd所制)及约1.48g的TiO2浆料(浆料的固含量约50%),搅拌2小时,于室温下制成白色粘着剂。取根据合成例2所制备的白色聚酰亚胺薄膜,将该白色粘着剂以刮刀涂布于白色聚酰亚胺薄膜上,并于循环烘箱中以阶段式温度烘烤,温度及时间设定为约80℃烘烤30分钟、接着以约170℃烘烤30分钟,所得聚合物膜的总厚度约为2mil(即约50μm)。
实施例2
相较于实施例1,实施例2的差异在于白色粘着剂的制备过程中添加约4.15g的二氧化钛浆料(浆料的固含量约50%)至环氧树脂,其余制备过程则与实施例1相同。
实施例3
相较于实施例1,实施例3的差异在于白色粘着剂的制备过程中添加约7.11g的二氧化钛浆料(浆料的固含量约50%)至环氧树脂,其余制备过程则与实施例1相同。
实施例4
相较于实施例1,实施例4的差异在于白色粘着剂的制备过程中添加约11.07g的二氧化钛浆料(浆料的固含量50%)至环氧树脂,其余制备过程则与实施例1相同。
实施例5
相较于实施例1,实施例5的差异在于白色粘着剂的制备过程中添加约16.60g的二氧化钛浆料(浆料的固含量50%)至环氧树脂,其余制备过程则与实施例1相同。
比较例1
相较于实施例1,比较例1的差异在于不添加二氧化钛至环氧树脂,其余制备过程则与实施例1相同。
比较例2
相较于实施例1,比较例2的差异在于不添加二氧化钛至环氧树脂、且使用合成例5的白色聚酰亚胺膜,其余制备过程则与实施例1相同。
试验例一
将根据合成例1-5所制备的聚酰亚胺薄膜分别进行反射率、透光率及机械延伸率的检测,结果如表1所示。
表1、聚酰亚胺薄膜的检测结果
透光率以PG-1M(Nippon Denshoku)进行检测。机械延伸率是依ASTM882标准测试法以万用拉力机测量。反射率是利用手提式分光测色仪(SP-60)量测,并取波长550nm的反射光百分比。此外,由于反射率检测时是将聚酰亚胺薄膜放置于一作为量测平台的白色基板上,再以光源照射此聚酰亚胺薄膜。因此,当分光测色仪的光源发射出来的光线穿过聚酰亚胺薄膜并抵达白色基板后,会随即被白色基板反射,故透明聚酰亚胺薄膜(例如合成例4)所示的反射率事实上为基板的反射率。
由表1所示结果可观察到,随着白色填料TiO2的增加(例如合成例1-3),虽可提升反射度及显著改善遮蔽度(即降低透光率),但却使聚酰亚胺膜的延伸率大幅降低,不利于后续应用。另外,即使如合成例3的TiO2添加量达40%时,仍然无法达到LED装置的透光率的要求(即总透光率低于15%)。
在相同TiO2的添加量(例如合成例2、5)下,增加膜厚度确实可提高遮蔽度,但即使增加为两倍的厚度,也仅降低约9%的透光率,遮蔽度的改善幅度相当有限,在实际应用上并无帮助。
试验例二
将实施例1-5及比较例1-2的聚合物膜分别进行反射率、透光率、及色彩性质检测。透光率以PG-1M(Nippon Denshoku)进行检测。色彩性质是利用手提式分光测色仪(SP-60)于室温下测量。该色彩性质是以「Lab色彩空间」表示,其中,L*值(L*-value)是定义色彩亮度,a*值(a*-value)则定义绿色至红色之间的色界(color dimension),而b*值(b*-value)则定义蓝色至黄色之间的色界。结果如表2所示。
表2、聚合物膜的检测结果
如比较例1及2所示,当粘着层中无白色填料TiO2存在时(亦即,已知的粘着剂成分),所得聚合物膜的遮蔽度不足,透光率达约32%,即使增加聚酰亚胺厚度达两倍,其透光率仍超过20%。因此,以白色聚酰亚胺直接作为聚合物膜时,即使增加膜厚度,仍然无法达到发光二极管装置的透光率低于15%的要求。
而如实施例1-5所示的聚合物膜,在粘着层中添加TiO2显著地改善了聚合物膜的遮蔽度,并可进一步增加反射率,同时维持其色彩(例如白色)性质。
图2A至图2D为描绘本发明一实施例利用聚合物膜制造发光装置的流程示意图。如图2A所示,首先提供一基材201、及一含有白色聚酰亚胺层203与白色粘着层205的聚合物膜207。根据一实施例,基材201的上表面可形成有金属层210,基材201的材质可为聚酰亚胺,而金属层210可由铜所形成。其中,聚合物膜207的结构,可为白色粘着层205涂布至白色聚酰亚胺层203的一表面上而形成。
接着参照图2B,于约160至200℃温度下将聚合物膜207与基材201压合约120秒,再于约160℃温度下进行后固化处理约1个小时。所形成的聚合物膜207可局部地覆盖基材201,并露出金属层210于外。
然后,参照图2C,将发光组件220设置于基材201上,并使发光组件220的电极222与基材201的金属层110对齐。根据本发明一实施例,发光组件220可包括发光二极管。
参照图2D,将发光组件220组接于基材201上,使电极222与金属层210接触,从而形成一发光装置。在该发光装置中,聚合物膜207位于发光二组件220的一侧,以便在基材201上形成一反光表面,有利于增加发光装置的出光率。虽然前述实施例为使用发光二极管的发光装置,聚合物膜207还可应用于其它发光装置的种类,不限于发光二极管的装置。
综上所述,本发明的聚合物膜利用相对薄的白色聚酰亚胺膜以及白色粘着层的结构,不但可避免现有技术因使用双层白色聚酰亚胺膜的高温黄化或劣化的缺点,同时可进一步提高现有技术仅使用高厚度白色聚酰亚胺膜的挠曲性及遮蔽性。
另外,本发明的聚合物膜可达到发光装置的高遮蔽性及高反射率的要求,并兼顾材料的物化性质,更可降低制造成本,简化制备过程。
上述特定实施例的内容是为了详细说明本发明,然而,这些实施例是仅用于说明,并非意欲限制本发明。本领域的普通技术人员可理解,在不悖离后附权利要求所界定的范围下针对本发明所进行的各种变化或修改是落入本发明的一部分。
Claims (23)
1.一种聚合物膜,包括:
一白色聚酰亚胺层;以及
一粘着层,设置于该聚酰亚胺层的一表面;
其特征在于,该粘着层包括一粘着剂成分、及一分布于该粘着剂中的白色填料,且该聚合物膜具有约80%以上的反射率。
2.如权利要求1所述的聚合物膜,其中所述粘着剂成分是选自由环氧树脂系、丙烯酸系、聚硅氧系、酚醛树脂系、聚氨酯系、及橡胶系所组成的组中的一种或多种。
3.如权利要求1所述的聚合物膜,其中所述白色填料是选自由氧化钛、氧化锆、氧化钙、氧化锌、氧化铝、硫化锌、碳酸钙、碳酸铅、氢氧化铅、硫酸钙、硫酸钡、二氧化硅、氮化硼、氮化铝、碱式钼酸锌、碱式钼酸锌钙、铅白、钼白、锌钡白、及粘土所组成的组中的一种或多种。
4.如权利要求1所述的聚合物膜,其中所述白色填料占所述粘着层的约5重量%至80重量%。
5.如权利要求1所述的聚合物膜,其中所述粘着层的厚度是约50微米以下。
6.如权利要求1所述的聚合物膜,其中所述白色聚酰亚胺层包括一低色度聚酰亚胺,及一分布于该低色度聚酰亚胺中的白色填料。
7.如权利要求6所述的聚合物膜,其中所述低色度聚酰亚胺的b*值小于约10。
8.如权利要求6所述的聚合物膜,其中在所述低色度中分布的所述白色填料是选自由氧化钛、氧化锆、氧化钙、氧化锌、氧化铝、硫化锌、碳酸钙、碳酸铅、氢氧化铅、硫酸钙、硫酸钡、二氧化硅、氮化硼、氮化铝、碱式钼酸锌、碱式钼酸锌钙、铅白、钼白、锌钡白、及粘土所组成的组中的一种或多种。
9.如权利要求1述的聚合物膜,其中所述聚酰亚胺层的厚度低于约30微米(μm)。
10.如权利要求1所述的聚合物膜,其中所述聚合物膜具有约20%以下的透光率。
11.如权利要求1-10中任一项所述的聚合物膜,其中所述白色填料的平均粒径为约0.1至5微米。
12.一种发光装置,包括:
一基材;
一发光组件,设置于该基材上;及
一反光表面,其由一聚合物膜形成,该聚合物膜包括:
一白色聚酰亚胺层;以及
一粘着层,设置于该聚酰亚胺层的一表面,该粘着层包括一粘着剂成分、及一分布于该粘着剂中的白色填料,且该聚合物膜具有约80%以上的反射率。
13.如权利要求12所述的发光装置,其中所述聚合物膜具有约20%以下的透光率。
14.如权利要求12所述的发光装置,其中粘着剂成分是选自由环氧树脂系、丙烯酸系、聚硅氧系、酚醛树脂系、聚氨酯系、及橡胶系所组成的组中的一种或多种。
15.如权利要求12所述的发光装置,其中所述白色填料是选自由氧化钛、氧化锆、氧化钙、氧化锌、氧化铝、硫化锌、碳酸钙、碳酸铅、氢氧化铅、硫酸钙、硫酸钡、二氧化硅、氮化硼、氮化铝、碱式钼酸锌、碱式钼酸锌钙、铅白、钼白、锌钡白、及粘土所组成的组中的一种或多种。
16.如权利要求12所述的发光装置,其中所述白色填料占所述粘着层的约5重量至80重量%。
17.如权利要求12所述的发光装置,其中所述粘着层的厚度是约50微米以下。
18.如权利要求12所述的发光装置,其中所述白色聚酰亚胺层包括一低色度聚酰亚胺,及一分布于该低色度聚酰亚胺中的白色填料。
19.如权利要求18所述的发光装置,其中所述低色度聚酰亚胺的b*值小于约10。
20.如权利要求18所述的发光装置,其中在所述低色度聚酰亚胺中分布的所述白色填料是选自由氧化钛、氧化锆、氧化钙、氧化锌、氧化铝、硫化锌、碳酸钙、碳酸铅、氢氧化铅、硫酸钙、硫酸钡、二氧化硅、氮化硼、氮化铝、碱式钼酸锌、碱式钼酸锌钙、铅白、钼白、锌钡白、及粘土所组成的组中的一种或多种。
21.如权利要求12所述的发光装置,其中所述聚酰亚胺层的厚度是低于约30微米。
22.如权利要求12所述的发光装置,其中所述发光组件为发光二极管,且该反光表面位于该基材上。
23.如权利要求12-22中任一项所述的聚合物膜,其中所述白色填料的平均粒径为约0.1至5微米。
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CN113796168A (zh) * | 2019-06-12 | 2021-12-14 | 海拉有限双合股份公司 | 具有与热沉的导热连接的柔性的印制电路板 |
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