JP2008030384A - Manufacturing method of a plurality of sets of long laminates having metal foil/resin film structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the mutual local sticking of adjacent sets of long laminates having a metal foil/resin film structure in the case where a plurality of sets of the long laminates are simultaneously and continuously manufactured using a thermocompression bonding device. <P>SOLUTION: In the manufacturing method of a plurality of sets of the long laminates having the metal foil/resin film structure at the same time using the thermocompression bonding device, thermocompression bonding operation is performed in a state that the positions of the side end parts of the respective resin films of mutually adjacent sets are not overlapped with each other. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for simultaneously producing a long laminate having a structure composed of a plurality of sets of metal foil / resin film.

  A laminated body obtained by laminating a highly heat-resistant and heat-bondable resin film typified by an aromatic polyimide film and a highly conductive metal foil typified by a copper foil is, for example, a printed wiring board for various electronic components. It is used for manufacturing. Typical configurations of this laminate include a three-layer laminate having a metal foil / resin film / metal foil configuration and a two-layer laminate having a metal foil / resin film configuration. The latter two-layer laminate is usually a mold release that has a releasable surface on the surface side of the resin film (the surface opposite to the metal foil side) for the convenience of its manufacture and use. Films are laminated.

  The laminate having the structure of the metal foil / resin film as described above has a long shape in consideration of the efficiency of manufacturing the laminate itself and the efficiency of manufacturing various parts such as a printed wiring board using the laminate. It is common to manufacture as a laminated body. For this purpose, there are a long resin film wound in the same manner as a long metal foil wound in a roll shape, and a long release film that is also wound in a roll shape if necessary. Each of the mold films is continuously supplied to a pair of thermocompression bonding apparatuses including an upper roll and a lower roll in a state where they are overlapped with each other or overlapped at the entrance of the thermocompression bonding apparatus, Next, a method of winding a long laminate that is laminated and pressure-bonded by a thermocompression bonding apparatus with a winding roll is generally used. As the thermocompression bonding apparatus, a conventional thermocompression bonding apparatus in which each of the upper roll and the lower roll is a single roll, and each of the upper drum and the lower drum is a front drum and a rear drum, and the periphery of both drums is a drum. A double belt press composed of belts that rotate synchronously is typical.

  As described above, a laminate having a structure composed of a metal foil / resin film is manufactured continuously as a long laminate having a structure composed of a metal foil / resin film using a thermocompression bonding apparatus. In response to an increase in demand for a long two-layer laminate having a metal foil / resin film structure, and in order to reduce its manufacturing cost, two or more sets of laminates are simultaneously used. Manufacturing is under consideration.

  In Patent Document 1, two or more sets of a thermocompression-bonding multilayer polyimide film and a metal foil are supplied to a double belt press apparatus, and the multilayer polyimide film and the metal foil are obtained by performing thermocompression bonding and cooling under pressure. A method is described in which two or more sets of flexible metal foil laminates are manufactured by bonding together.

In Patent Document 2, there is a description of a method for stably producing a flexible metal foil laminate having a good appearance using a double belt press apparatus. In the description, a plurality of long metal foil / resin film laminates are described. There is a description that the body can be manufactured simultaneously. There is also a description of a specific configuration of the double belt press device.
JP 2001-270039 A JP 2005-306002 A

  On the other hand, in response to the recent demand for miniaturization of various electronic components, there is a general trend of reducing the thickness of the laminated body by thinning both the metal foil and the resin film constituting the laminated body.

  The present inventor has taken into consideration the recent trend of demand for the above-mentioned thin film laminate, and uses a thermocompression bonding apparatus that has been used so far to form a long laminate having a structure composed of a plurality of sets of metal foil / resin film. We examined the technology to manufacture the body at the same time.

  In the course of the study, the present inventor conducted a thermocompression operation when a plurality of long laminates having a metal foil / resin film configuration were simultaneously manufactured using a general thermocompression bonding apparatus. The metal foils that were adjacent to each other in the thickness direction, especially the rolled copper foils, had peeling (separation) defects due to biting in the vicinity of both side ends, and the long laminates of each set were It has been found that a phenomenon that makes separation difficult occurs.

Next, the result of the above examination by the inventor will be described with reference to FIG. 1 of the accompanying drawings.
FIG. 1 shows an upper belt of a double belt press appearing in the process of simultaneously producing two pairs of long laminates having a structure of metal foil / resin film / release film using a double belt press which is an example of a thermocompression bonding apparatus. And a lower belt (the construction of a double belt press is well known and will be described in detail later in this specification), and a long laminate of two metal foil / resin film / release film constructions laminated together ( The release film is a schematic view showing a layer configuration along the width direction of the release laminate when the elongated laminate is used. That is, FIG. 1 shows an upper elongated laminate (a release film is peeled off when the elongated laminate is used) 4a having a configuration of a release film 1a, a resin film 2a, and a metal foil 3a. Laminate in which the lower long laminate (the release film is peeled off when the long laminate is used) 4b is superimposed on the metal foil 1b, the resin film 2b, and the release film 3b. A state is shown in which a body is formed and its upper and lower sides are sandwiched between an upper belt 5a and a lower belt 5b of a double belt press (not shown). This laminate structure is maintained until the metal foil and the resin sheet are heated and pressure-bonded by a double belt press, cooled, and then separated from each other for each long laminate.

  FIG. 1 shows the principle structure of a laminate in which a metal foil, a resin sheet, and a release film are heat-pressed by a double belt press. At the position of the resin film side end portion, a strong local pressure is applied to each laminate, and the strong local pressure is in contact with each other at the center, and the metal foil 3a of the upper laminate in a stacked state. It has been found that biting occurs between the metal foil 1b of the lower laminate and the lower laminate.

  Based on the above findings, the present inventor has further studied, and as a result, the thermocompression bonding operation is performed by slightly shifting the positions of the side end portions in the width direction of the respective resin films of the groups adjacent to each other in the thickness direction. The metal foil of the upper laminated body and the metal of the lower laminated body that are in contact with each other and overlapped by performing in a state where the positions of the side end portions of the respective resin films do not overlap each other It has been found that biting between the foils can be avoided. This preferable phenomenon is that, when the thermocompression operation is performed in a state where the positions of the side edges of the resin film do not overlap, the pressure applied locally between the metal foils is dispersed, and the pressure applied to each laminate is reduced. It is understood that this is due to the mitigation of non-uniformity.

  Accordingly, the present invention provides a thermocompression bonding apparatus, a plurality of long metal foils necessary for manufacturing a long laminate having a structure composed of a plurality of metal foil / resin films provided in front of the thermocompression bonding apparatus, and A plurality of unwinding rolls for supplying a plurality of long resin films (and, if necessary, a plurality of long release films) to the thermocompression bonding apparatus, produced after completion of the thermocompression operation in the thermocompression bonding apparatus Using a laminate manufacturing apparatus consisting of a plurality of winding rolls each winding a long laminate having a structure consisting of a plurality of sets of metal foils / resin films, a structure consisting of a plurality of sets of metal foils / resin films In the method for producing a long laminate at the same time, the thermocompression bonding operation is performed in a state in which the positions of the side end portions of the respective resin films in the set adjacent to each other in the thickness direction are not overlapped. In the manufacturing method characterized by and.

  The present invention is also a long laminate having a structure composed of a plurality of sets of metal foils / resin films so that the positions of the side end portions of the respective resin films adjacent to each other in the thickness direction do not overlap. It is also in the laminated body in.

  Thermocompression bonding apparatus, a plurality of long metal foils and a plurality of long resin necessary for manufacturing a long laminate having a structure composed of a plurality of sets of metal foil / resin film provided in front of the thermocompression bonding apparatus A plurality of unwinding rolls for supplying a film (and, if necessary, a plurality of further long release films) to the thermocompression bonding apparatus, and a plurality of sets of metal foils / resins generated after completion of the thermocompression operation in the thermocompression bonding apparatus Using a laminate manufacturing apparatus consisting of a plurality of winding rolls each winding a long laminate having a structure made of a film, a long laminate having a structure made of a plurality of sets of metal foil / resin film is simultaneously produced. In the manufacturing method, by using the improved method of the present invention, when the metal foil of the upper laminate and the metal foil of the lower laminate are in contact with each other and are in a stacked state, the bite between them Included There can be avoided, easily to separate the superimposed laminate. The present invention is particularly effective when the adjacent metal foils are rolled copper foils.

Preferred embodiments of the invention will now be described.
(1) The shift of the position of the side end portion of each resin film in the set adjacent to each other in the thickness direction is expressed as a relative distance between the side end portion of one resin film and the side end portion of the other resin film. It exists in the range of 5-5 mm (more preferably 1-3 mm).
(2) Two sets of long laminates having a structure made of metal foil / resin film manufactured simultaneously.
(3) When metal foils of a plurality of sets of laminated bodies are arranged adjacent to each other, both metal foils are rolled copper foils.
(4) The long resin film is a long aromatic polyimide film.
(5) The long resin film is a long thermocompression-bonding multilayer polyimide film including a non-thermocompression-bonding aromatic polyimide film and a thermocompression-bonding aromatic polyimide layer formed on one surface thereof.
(6) The thermocompression bonding apparatus is a double belt press.

  Next, the manufacturing method of the elongate laminated body of multiple sets of metal foil / resin film structure of this invention is demonstrated, referring FIG. 2 of an accompanying drawing. In addition, in FIG. 2, the method of manufacturing 2 sets of elongate laminated bodies of metal foil / resin film / release film structure simultaneously using copper foil as metal foil is demonstrated as a representative example.

  FIG. 2 is a drawing for explaining a case where a method for producing a long laminate having a structure comprising a plurality of sets of copper foil / resin film / release film is carried out using a known double belt press. That is, FIG. 2 shows a method of simultaneously and continuously producing two sets of long laminates composed of copper foil / resin film / release film using a double belt press.

  In FIG. 2, a double belt press 11 includes a pair of front upper drum 12a and front lower drum 12b, a pair of rear upper drum 13a and rear lower drum 13b, and a set of two upper drums and two upper drums. It comprises belts 14a and 14b stretched around each of the lower drum sets. In the double belt press 11 of FIG. 2, the two front drums 12a and 12b are heating drums, and the two rear drums 13a and 13b are cooling drums. In the double belt press of FIG. 2, a pressurizing device is provided separately from the drum in order to reliably pressurize the laminated body. This pressurizing device is composed of heating and pressurizing tools 15a and 15b provided at the top and bottom, and the top and bottom heating is performed on the laminated body conveyed between the upper and lower belts 14a and 14b in the double belt press. It is comprised so that a pressure may be provided by the approach of the pressurizing tools 15a and 15b. Further, in the double belt press of FIG. 2, pressure cooling devices 16a and 16b are provided at the rear of the pressure device so as to cool the laminate subjected to the pressure treatment at a high temperature.

  In front of the double belt press 11, a release film 21a, a resin film 22a, and a copper foil 23a for manufacturing a long laminate having a release film / resin film / copper foil configuration are wound respectively. A release film roll 31a, a resin film roll 32a, and a copper foil roll 33a are arranged, and a long laminate of another set of copper foil / resin film / release film copper foil is manufactured. A copper foil roll 31b, a resin film roll 32b, and a release film roll 33b around which a copper foil 21b, a resin film 22b, and a release film 23b are wound are arranged.

  Behind the double belt press 11, a take-up roll 51a for taking up the long laminate 41a having a set release film / resin film / copper foil structure is disposed via an auxiliary roll 52a. In addition, a winding roll 51b for winding up the long laminate 41b having another set of manufactured copper foil / resin film / release film is disposed via an auxiliary roll 52b.

  In FIG. 2, for example, the copper foil 23a is an electrolytic copper foil, the resin film 22a is a thermocompression-bonding multilayer aromatic polyimide film, the copper foil 21b is a rolled copper foil, and the resin film 22b is a heat A pressure-bonding multilayer aromatic polyimide film is used. That is, it is preferable to combine the copper foil of 23a and the copper foil of 21b so that one copper foil is an electrolytic copper foil and the other copper foil is a rolled copper foil. By such a combination, there is an advantage that the occurrence of mutual adhesion (a state in which separation is difficult) due to the biting between the copper foil of 23a and the copper foil of 21b can be reduced. Alternatively, it is also advantageous to use all of the copper foil, that is, the copper foil 23a and the copper foil 21b as rolled copper foil. However, such a specific combination arrangement of metal foils is not essential in the production method of the present invention.

  Both the electrolytic copper foil and the rolled copper foil are commercially available, and an electrolytic copper foil and a rolled copper foil of any thickness can be obtained from the manufacturer according to the purpose and used for the production of the laminate of the present invention.

  Moreover, metal foil is not limited to copper foil, Various metal foils (especially electroconductive metal foil), such as aluminum foil, can be used according to the objective. As the metal foil such as copper foil, a metal foil having a thermocompression-bonding or adhesive resin coating layer such as polyimide or epoxy resin on the surface can be used. The metal foil having such a resin coating layer on the surface is usually used by being arranged so that the resin coating layer on the surface faces the resin film.

  The thermocompression bonding multilayer aromatic polyimide film is a film comprising a non-thermocompression bonding aromatic polyimide film and a thermocompression bonding aromatic polyimide layer formed on one or both surfaces thereof, for example, Ube Industries, Ltd. And is readily available. A detailed description of the thermocompression-bonding multilayer aromatic polyimide film can be found in the aforementioned Patent Document 1.

  As described above, when a two-layer laminate having a metal foil (copper foil) / resin film structure is produced, it is a commonly used method to dispose a release film on the surface side of the resin film. There are already known release films used in such methods. That is, as the release film, a flexible material having high heat resistance and good release properties is generally used. As the material for the release film, non-thermocompression-resistant heat-resistant aromatic polyimide, fluorine resin, silicone resin, or the like is generally used.

  In the description regarding FIG. 2, an example in which a thermocompression-bonding multilayer aromatic polyimide film is used as the resin film has been described, but the resin film is particularly limited as long as it is a resin film that can be crimped to a metal foil under heating conditions. There is no. Examples of the resin film that can be used according to the purpose include a single-layer thermocompression bonding aromatic polyimide film, a thermocompression bonding polyester film, a thermocompression bonding vinyl ester film, and a thermocompression bonding fluororesin film. it can.

  Next, a method for producing the long laminate of the present invention using the double belt press shown in FIG. 2 will be described.

  The long resin films 22a and 22b, the long copper foils 23a and 21b, and the long release films 21a and 23b are unwound from the respective rolls, and a pair of front heating drums 12a and 12b of the double belt press 11. Between the belts 14a and 14b. The resin film and the copper foil are stacked and heated by the front drums 12a and 12b, and are conveyed toward the rear drums 13a and 13b as they are sandwiched between the belts 14a and 14b, in a vertical relationship. Is done. And in the middle of the conveyance, a thermocompression-bonding process is performed by the heating and pressurizing tools 15a and 15b, and then it is cooled by the pressurizing and cooling devices 16a and 16b. The laminated body is further conveyed rearward, and after passing through the rear drums 13a and 13b, at the position of the auxiliary roll 52b, the upper elongated laminated body 41a (the structure of the release film 21a / resin film 22a / copper foil 23a). And a lower elongated laminate 41b (a laminate having a configuration of copper foil 21b / resin film 22b / release film 23b).

  The structure of the laminated body of the upper elongate laminated body 41a and the lower elongate laminated body 41b before being separated is shown in FIG. This laminated body is laminated | stacked in the state which the rolled copper foil 23a and the rolled copper foil 21b contacted.

  The upper elongate laminate 41a is then wound around a winding roll 51a via an auxiliary roll 52a. Similarly, the lower elongate laminated body 41b is then wound around the winding roll 51b via the auxiliary roll 52b.

  In addition, regarding the various forms and improvements of the double belt press in the production of multiple sets of long copper foil / resin film laminate using a double belt press, and the production conditions of the laminate using the double belt press, The descriptions of Patent Document 1 and Patent Document 2 described above can be referred to.

  In the description of FIG. 3, the upper elongate laminate 41a and the lower elongate laminate 41b have been configured so that the copper foil 23a and the copper foil 21b are in contact with each other. On the contrary, a configuration in which the positions of the release film and the copper foil of the respective laminates are replaced may be employed.

  Next, the lamination conditions in the width direction (direction perpendicular to the length direction of the long sheet) of the long metal foil and the long resin film, which are characteristic requirements of the present invention, are described with reference to FIG. explain.

  FIG. 3 shows a laminate of the present invention formed by laminating two pairs of long laminates composed of copper foil / resin film / release film described in FIG. 2 (that is, two pairs of long laminates). It is a schematic diagram which shows the structure according to the laminated body which appears before a laminated body is isolate | separated from each other. That is, the laminated body is composed of an upper laminated body 41a composed of a release film 21a, a resin film 22a, and a copper foil 23a, and a lower laminated body 41b composed of a copper foil 21b, a resin film 22b, and a release film 23b. It is composed of a set of laminated bodies. And the resin film 22a of the upper laminated body 41a and the resin film 22b of the lower laminated body 41b are shifted from each other in the width direction so that the positions of the side end portions of the respective resin films do not overlap. It is in the state of arrangement. The shift distance between the side end of the resin film 22a and the end of the resin film 22b (the shift in the position in the width direction of each resin film in the set adjacent to each other is determined by the side end of one resin film and the other resin. The relative distance to the side edge of the film is preferably in the range of 0.5 to 5 mm, particularly preferably in the range of 1 to 3 mm.

  Next, the structure of the laminate according to the present invention in the case where three sets of long laminates composed of copper foil / resin film / release film are simultaneously and continuously manufactured will be described with reference to FIG.

  FIG. 4 is a total showing the configuration of a laminate in which a pair of long laminates are further laminated on the laminate formed by laminating two pairs of the elongated laminates described in FIG. It is a schematic diagram of the laminated body which consists of three sets of laminated bodies. That is, the laminate of FIG. 4 includes an upper laminate 41a composed of a release film 21a, a resin film 22a, and a copper foil 23a, and an intermediate laminate 41b composed of a copper foil 21b, a resin film 22b, and a release film 23b. And, it is composed of three sets of laminates of a lower laminate 41c comprising a copper foil 21c, a resin film 22c, and a release film 23c. And the resin film 22a of the upper laminated body 41a, the resin film 22b of the intermediate laminated body 41b, and the resin film 22c of the lower laminated body 41c are shifted from each other in the width direction, and the respective resin films It exists in the state arrange | positioned so that the position of a side edge part may not overlap. However, the position in the width direction is not necessarily shifted in the relationship between the resin film 22a and the resin film 22c. The shift distance between the side end of the resin film 22a and the end of the resin film 22b (the shift in the position in the width direction of each resin film in the set adjacent to each other is determined by the side end of one resin film and the other resin. The relative distance between the side edge of the film) and the shifting distance between the side edge of the resin film 22b and the side edge of the resin film 22c are preferably in the range of 0.5 to 5 mm. A range of 3 mm is particularly preferable.

  In FIG. 4 above, the resin film 22b is arranged on the left side of the resin film 22a, and then the resin film 22c is arranged on the further left side of the resin film 22b. A zigzag type arrangement in which the resin film 22b is arranged on the right side of the resin film 22a and then the resin film 22c is arranged on the left side of the resin film 22b can be used instead of the arrangement.

  In addition, in FIG. 2, although the manufacturing method of the elongate laminated body of this invention was demonstrated as a method using a double belt press, the manufacturing method of the elongate laminated body of this invention includes an upper side roll, a lower side roll, Similarly, using a known thermocompression bonding device including a pair of thermocompression bonding devices (particularly a thermocompression bonding device using a roll whose surface is made of an elastic material), or a thermocompression bonding device comprising a modification or improvement of a known thermocompression bonding device Of course, it can be implemented. Moreover, the long laminated body manufactured simultaneously is not restricted to 2 sets, The simultaneous manufacture of 3 sets or 4 sets is also possible.

The upper belt and the lower belt of the double belt press appearing in the process of manufacturing two pairs of long laminates of metal foil / resin film / release film at the same time using a double belt press, and two laminated It is a schematic diagram which shows the layer structure along the width direction of the elongate laminated body of a structure of a set of metal foil / resin film / release film. It is a figure for demonstrating the manufacturing method of the elongate laminated body of multiple sets of metal foil / resin film / release film structure of this invention. It is a schematic diagram which shows the structure according to the laminated body of this invention formed by laminating | stacking two sets of the elongate laminated body demonstrated in FIG. It is a schematic diagram which shows the structure according to the laminated body of this invention formed by laminating | stacking 3 sets of elongate laminated bodies.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1a Release film 1b Metal foil 2a Resin film 2b Resin film 3a Metal foil 3b Release film 4a Long laminated body 4b Long laminated body 5a Belt 5b Belt 11 Double belt press 12a Front upper drum 12b Front lower drum 13a Rear upper drum 13b Rear lower drum 15a Heating pressure tool 15b Heating pressure tool 16a Pressure cooling device 16b Pressure cooling device 21a Release film 21b Copper foil 21c Copper foil 22a Resin film (thermocompression-bonding multilayer aromatic polyimide film )
22b Resin film (Thermo-compressible multilayer aromatic polyimide film)
22c Resin film (Thermo-compressible multilayer aromatic polyimide film)
23a Copper foil 23b Release film 23c Release film 31a Release film unwinding roll 31b Copper foil unwinding roll 32a Resin film unwinding roll 32b Resin film unwinding roll 33a Copper foil unwinding roll 33b Release film unwinding roll 41a Long Laminate 41b Long Laminate 41c Long Laminate 51a Winding Roll 51b Winding Roll 52a Auxiliary Roll 52b Auxiliary Roll

Claims (13)

  Thermocompression bonding apparatus, a plurality of long metal foils and a plurality of long resin necessary for manufacturing a long laminate having a structure composed of a plurality of sets of metal foil / resin film provided in front of the thermocompression bonding apparatus A plurality of unwinding rolls for supplying a film to the thermocompression bonding apparatus, and each of the long laminates having a structure composed of a plurality of sets of metal foil / resin film generated after completion of the thermocompression bonding operation in the thermocompression bonding apparatus. In the method of simultaneously manufacturing a long laminate having a structure composed of a plurality of sets of metal foil / resin film using a laminate manufacturing apparatus comprising a plurality of take-up rolls, the thermocompression bonding operation is performed in the thickness direction. The manufacturing method characterized by implementing in the state arrange | positioned so that the position of the side edge part of each resin film of the mutually adjacent group may not overlap.   The shift of the position of the side end of each resin film in the set adjacent to each other in the thickness direction is 0.5 to 5 mm as a relative distance between the side end of one resin film and the side end of the other resin film. The manufacturing method of Claim 1 which exists in the range of these.   The manufacturing method according to claim 1 or 2, which is a method of manufacturing two sets of long laminates having a structure of metal foil / resin film simultaneously.   The manufacturing method according to any one of claims 1 to 3, wherein a pair of metal foils adjacent to each other in the thickness direction is a rolled copper foil.   The manufacturing method according to any one of claims 1 to 4, wherein the long resin film is a long aromatic polyimide film.   The long resin film is a long thermocompression-bonding multilayer polyimide film including a non-thermocompression bonding aromatic polyimide film and a thermocompression bonding aromatic polyimide layer formed on one surface thereof. The manufacturing method in any one of items.   The manufacturing method according to claim 1, wherein the thermocompression bonding apparatus is a double belt press.   A long laminate having a structure composed of a plurality of sets of metal foils / resin films, wherein the laminates are arranged such that the positions of the side end portions of the respective resin films in the set adjacent to each other in the thickness direction do not overlap.   The shift of the position of the side end in the width direction of each of the resin films in the set adjacent to each other in the thickness direction is expressed as a relative distance between the side end of one resin film and the side end of the other resin film. The laminate according to claim 8, which is in the range of 5 to 5 mm.   The laminate according to claim 8 or 9, wherein two pairs of long laminates having a structure of metal foil / resin film are laminated.   The laminated body according to any one of claims 8 to 10, wherein adjacent sets of metal foils are arranged adjacent to each other, and both of the adjacent metal foils are rolled copper foils.   The laminate according to any one of claims 8 to 11, wherein the long resin film is a long aromatic polyimide film.   The long resin film is a long thermocompression bonding multilayer polyimide film including a non-thermocompression bonding aromatic polyimide film and a thermocompression bonding aromatic polyimide layer formed on both side surfaces thereof. The laminate according to any one of the above.

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