JP2013184298A - Material roll of white reflection sheet with metal foil, material roll of white reflection sheet with circuit, and method for producing them - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that when a material roll is produced by winding a white reflection sheet with metal foil into a roll-like shape or another roll is produced by winding another white reflection sheet with a circuit, the metal foil is wrinkled or warped and the circuit is not formed correctly or is broken due to a difference between elongation property of the metal foil or the circuit and that of the white reflection sheet.SOLUTION: A material roll is produced by winding a white reflection sheet with metal foil into a roll-like shape. The white reflection sheet with metal foil includes: a white reflection layer; and the metal foil layered on the white reflection layer. The white reflection layer is obtained by applying a silicone resin composition, which contains an uncured silicone material and an inorganic white filler and has 2-80 Shore D hardness when cured, to the metal foil and curing the applied composition.

Description

  The present invention provides a roll of a white reflective sheet with a circuit for mounting an optical element such as a light emitting diode (LED) package, an LED chip, a photovoltaic power generation element, and a metal foil used for manufacturing the roll. The present invention relates to a roll of a white reflective sheet and a method for producing them.

  In recent years, with the diversification of electrical and electronic equipment, a long flexible circuit board (FPC) has been demanded. Furthermore, in order to improve the productivity and handleability of FPC, a so-called roll-to-roll circuit forming method is also known, in which a roll-like FPC film is used to form and collect a circuit in the form of a roll. Yes.

  In recent years, demand for optical devices such as LEDs and photovoltaic power generation elements has increased. In order to improve the light extraction efficiency from the LED and the light receiving efficiency of the photovoltaic power generation element, a technique for forming a white reflective film on the surface of a circuit board on which these are mounted is known.

  For example, Patent Document 1 below is made of an elastic rubber containing light reflecting agent particles dispersed therein, an elastic body layer having a hydroxyl group on the surface to be bonded, and a hydroxyl group on the surface to be bonded. Disclosed is a reflective sheet with a metal foil, in which the metal foil layer having the metal foil layer is laminated and bonded while being covalently bonded to each other via their hydroxyl groups. And it is disclosed that such a reflective sheet with metal foil is manufactured as follows. First, the elastic rubber sheet is drawn out from the roll of the elastic rubber sheet containing the light reflecting agent particles dispersed therein, and the surface of the elastic sheet is activated by corona discharge treatment or the like to generate hydroxyl groups. On the other hand, the metal foil is drawn from the roll of the metal foil, and its surface is activated to generate a hydroxyl group. Then, the elastic rubber sheet and the metal foil are bonded to each other, heated with a heater, and further pressed with a pressure roller, whereby the hydroxyl group on the surface of the elastic rubber sheet and the hydroxyl group on the surface of the metal foil are converted into a polyfunctional silane. It discloses dissociation through reaction with a compound or the like.

  Further, for example, in Patent Document 2 below, a reflective layer containing a white inorganic filler powder having a higher refractive index dispersed in a three-dimensionally crosslinked silicone resin is formed into a film, three-dimensional shape or Disclosed is a silicone resin reflective substrate formed in a plate shape. FIG. 5 of Patent Document 2 discloses that a support sheet is drawn from a flexible support sheet raw material roll formed with a circuit, and a silicone resin raw material for forming a reflective layer is applied to the surface of the support sheet. ing.

JP 2011-148263 A International Publication 2011/118108 Pamphlet

  In the reflective sheet with metal foil disclosed in Patent Document 1, an elastic rubber sheet is used as the reflective layer. This is to give high flexibility to the reflective sheet with metal foil. However, when such an elastic rubber sheet is used as a reflective layer, there are the following problems. The elastic rubber sheet and the metal foil are greatly different in elongation. Therefore, when manufacturing a reflective sheet with a metal foil by roll-to-roll, when an elastic rubber sheet, a metal foil, and a reflective sheet with a metal foil are conveyed, tension is applied to the elastic rubber sheet and the metal foil. A difference in elongation occurs due to a difference in elasticity between the sheet and the metal foil. When the elastic rubber sheet is bonded to the metal foil while being stretched, only the elastic rubber sheet is elastically restored when the tension is released, so that the metal foil may be wrinkled or distorted, resulting in a decrease in adhesion. there were. Such wrinkles and distortions of the metal foil, or a decrease in the adhesion of the metal foil due to these hinders accurate circuit formation. In addition, when a circuit is formed by etching most of the metal foil, the residual stress inside the elastic rubber sheet supported by the metal foil is greatly released. In this case, the position of the circuit formed on the surface of the elastic rubber sheet may be shifted, the dimensions may change, or the wire may be easily disconnected.

  In addition, when a reflective sheet with a metal foil using an elastic rubber sheet is stored for a long time in a roll original fabric state, when the elastic rubber sheet is compressed for a long time due to the tension or self-weight of the roll, and stored for a long time However, there is a problem that the elastic rubber sheet undergoes permanent deformation, resulting in non-uniform thickness when drawn from the roll, and distortion curl.

  Further, in the formation of the reflective layer disclosed in Patent Document 2, a silicone resin raw material is applied to a flexible support sheet. The document does not describe any selection of a silicone resin composition to be applied in consideration of the relationship with the properties of the material to be applied in consideration of the tension and workability applied in the application process. When the reflective layer is extremely easy to stretch compared to the metal foil, such as when a reflective layer made of an elastic rubber layer is formed on the metal foil, the elastic rubber sheet is stretched or compressed so that it is flexible to deformation in the manufacturing process. There is an advantage of following. However, in such a case, when tension is applied to the entire sheet, the stress concentrates on the metal foil, causing the metal foil to break, or the sheet is cramped during work due to lack of elasticity in the entire sheet. As a result, the metal foil may be broken and the circuit may be broken at the damaged portion of the metal foil.

  When manufacturing the roll raw material which rolled up the white reflective sheet with a metal foil in roll shape, or manufacturing the roll which rolled up the white reflective sheet with a circuit, this invention is a white reflective layer, a metal foil, and a metal foil. Due to the difference in elongation characteristics from the circuit formed by processing, the metal foil may be wrinkled or distorted, the circuit may not be formed correctly, it may be disconnected, or the thickness may be reduced due to its own weight during storage of the roll. The purpose is to solve problems that change.

  One aspect of the present invention is an original roll in which a white reflective sheet with metal foil is rolled up, and the white reflective sheet with metal foil includes a white reflective layer and a metal foil laminated on the white reflective layer. The white reflective layer is obtained by applying a silicone resin composition containing an uncured silicone material and an inorganic white filler and having a Shore D hardness of 2 to 80 on curing to a metal foil and curing. This is a roll of a white reflective sheet with a metal foil. According to such a configuration, since the rubber elasticity of the white reflective layer is small and the resin property is high, the white reflective layer is prevented from extending in the manufacturing process, and therefore, adhesion due to generation of wrinkles and distortion of the metal foil is suppressed. Can be suppressed. Moreover, since a white reflective layer is hard, it is suppressed that thickness changes by the permanent compression distortion by the dead weight etc. in the case of preserving a roll original fabric.

  Another aspect of the present invention is a roll of a circuit wiring board on which a circuit is formed by removing metal foil in portions other than a predetermined circuit pattern in the roll of the white reflective sheet with metal foil described above. It is an original fabric. According to such a configuration, even when the circuit wiring board is wound up as a raw roll, the white reflective layer is not easily stretched or wrinkled, or it is difficult to cause circuit damage due to the white reflective layer being folded. Therefore, disconnection of the circuit and the like are suppressed. Further, since the white reflective layer is hard, a sufficient waist is imparted, and workability at the time of circuit formation is improved.

  In addition, another aspect of the present invention was applied to the surface of the metal foil drawn from the metal foil roll original and sent in one direction, and a first step of applying a silicone resin composition with a predetermined thickness. A second step of forming a white reflective layer with a metal foil by curing the silicone resin composition to form a white reflective layer, and winding the white reflective sheet with the metal foil with a winding roller, thereby attaching the metal foil. A third step of forming a roll of the white reflective sheet, and the silicone resin composition contains an uncured silicone material and an inorganic white filler, and has a Shore D hardness of 2 to 80 when cured. It is a manufacturing method of the raw roll of a white reflective sheet with metal foil. According to such a manufacturing method, since sufficient waist is given to a white reflective layer, even if it winds up as a roll original fabric, a white reflective layer becomes difficult to extend. Therefore, it is possible to suppress the occurrence of wrinkles and distortions of the metal foil as described above, and the decrease in adhesion due to them.

  Another aspect of the present invention is a method for producing a roll of a white reflective sheet with a circuit by roll-to-roll, wherein the white reflective sheet with a metal foil is formed from the roll of the white reflective sheet with a metal foil described above. A white reflection sheet with a circuit, and a sixth step of forming a white reflection sheet with a circuit by removing the metal foil in a portion other than the predetermined circuit pattern of the metal foil of the white reflection sheet with a metal foil, And a seventh step of forming a roll original of the white reflective sheet with circuit by winding the sheet with a take-up roller. According to such a manufacturing method, even when a circuit forming method using roll-to-roll is used, it is possible to form an accurate circuit and reduce the possibility of circuit disconnection or the like.

  According to the present invention, since sufficient waist is imparted to the white reflective layer, even if the white reflective sheet with a metal foil or the white reflective sheet with a circuit is wound up as a raw roll, the metal foil is wrinkled or distorted, Or it can suppress that the adhesiveness fall by them, or the possibility of the dimensional change of a circuit, disconnection, etc. resulting from the release of the residual stress when the metal foil is partially removed at the time of circuit formation. Moreover, since the expansion and contraction of the white reflective layer is small, the dimensional accuracy of circuit formation is also improved.

It is a model explanatory drawing of the manufacturing process of the roll original fabric of the white reflective sheet 10 with metal foil of 1st Embodiment. The schematic cross section of the white reflective sheet 10 with metal foil of 1st Embodiment is shown. It is a schematic explanatory drawing explaining the manufacturing process which manufactures FPC11 by the line of a roll-to-roll using the white reflective sheet 10 with metal foil of 1st Embodiment. FIG. 4 is a schematic cross-sectional view illustrating a layer configuration of FPC in each step of FIG. 3. It is a model explanatory drawing of the manufacturing process of the roll original fabric of the white reflective sheet with metal foil of 2nd Embodiment. The schematic cross section of the white reflective sheet 20 with metal foil of 2nd Embodiment is shown. The schematic cross section when the white reflective sheet with metal foil of 2nd Embodiment is bonded to a base material is shown. It is a model explanatory drawing of the manufacturing process of the roll original fabric of the white reflective sheet 30 with metal foil of 3rd Embodiment. The schematic cross section of the white reflective sheet 30 with metal foil of 3rd Embodiment is shown. It is a schematic explanatory drawing of the manufacturing process of the roll original fabric of the white reflective sheet with metal foil of 4th Embodiment. The schematic cross section of the white reflective sheet 40 with metal foil of 4th Embodiment is shown. The graph of the reflectance with respect to the irradiation wavelength of the white reflective layer with copper foil produced in the Example is shown.

[First embodiment]
A manufacturing method according to an embodiment of the present invention will be described. FIG. 1 is a schematic explanatory view of a process for producing a roll of a white reflective sheet 10 with a metal foil, which is an embodiment according to the present invention. In FIG. 1, 1 is a metal foil, 2 is a white reflective layer, 2a is a silicone resin composition, 3 is a coater for applying the silicone resin composition 2a, 4 is a heating furnace for curing the silicone resin composition 2a, and 6 is a winding. A take-off roller, 7 is a corona discharge treatment device, 8a to 8f are guide rollers, 8g is an earth roller of the corona discharge treatment device 7, 8h is a breast roller of the coater 3, 9 is a feed roller, and 10 is a white reflective sheet with metal foil. is there. The white reflective sheet 10 with metal foil is wound up in a roll shape.

  As shown in FIG. 1, in the manufacturing method of the present embodiment, first, the metal foil 1 is drawn out from the raw roll of the metal foil 1 wound around the feed roller 9. Examples of the metal foil include copper foil and aluminum foil. Moreover, although the thickness of metal foil is not specifically limited, It is preferable that it is about 7-100 micrometers, Furthermore, about 10-50 micrometers.

  The metal foil 1 drawn on the production line is subjected to corona discharge treatment by a corona discharge treatment device 7. The step of corona discharge treatment is a treatment for activating the surface of the metal foil 1 and improving the adhesion to the white reflective layer 2 prior to the subsequent step of applying the silicone resin composition 2a. In addition to or in addition to corona discharge treatment, in addition to surface treatment such as plasma treatment, ultraviolet treatment, flame treatment, ittro treatment or rough surface treatment, for example, a primer such as a silane coupling agent is applied. A treatment or the like may be appropriately provided according to the characteristics of the metal foil. In addition, since the effect of these treatments attenuates with time, it is preferably performed immediately before the silicone resin composition 2a is applied. Further, in order to further improve the adhesion, a step of applying a primer layer may be further provided after the corona discharge treatment.

  Next, a silicone resin composition 2 a is applied to the surface of the metal foil 1 subjected to the corona discharge treatment by the coater 3. The coater 3 is not particularly limited as long as it is a device that can apply the silicone resin composition 2a to the surface of the metal foil 1 with a uniform film thickness. Specific examples include coating apparatuses such as knife coaters, roll coaters, spray coaters, extrusion coaters, curtain coaters, gravure coaters, and offset coaters, and printing apparatuses such as offset-gravure printing and screen printing. . The coating thickness of the silicone resin composition 2a is not particularly limited, but it may be applied such that the thickness of the white reflective layer 2 formed after curing is 2 to 7000 μm, further 5 to 2000 μm, and particularly 7 to 100 μm. preferable.

  The silicone resin composition 2a used in the manufacturing method of the present embodiment includes a cured product of a relatively hard silicone resin that includes an uncured silicone material and an inorganic white filler and has a Shore D hardness of 2 to 80 when cured. It is a composition for forming. The white reflective layer 2 containing an inorganic white filler highly reflects a wide range of wavelengths, and becomes a reflective film with little decrease in reflectance over time due to decomposition or alteration due to light or heat. In addition, the cured product of the silicone resin composition 2a that is relatively hard as described above has low elasticity, low stiffness, and low tackiness. The silicone resin composition 2a will be described in detail later.

  Next, the metal foil 1 coated with the uncured silicone resin composition 2 a is conveyed to the heating furnace 4. Then, the white reflective layer 2 is formed by curing the silicone resin composition 2 a in the heating furnace 4. The temperature and processing time of the heating furnace 4 are appropriately selected according to the curing characteristics of the uncured silicone material selected. Moreover, although the heating furnace 4 was used in this embodiment, when the silicone resin composition 2a is a photocurable resin, a light irradiation device may be used instead of the heating furnace 4.

  The white reflective sheet 10 with metal foil formed by adhering the metal foil 1 to the surface of the white reflective layer 2 is conveyed by a guide roller and wound around the take-up roller 6, whereby the white reflective sheet 10 with metal foil. The original roll is obtained. The raw roll thus obtained is obtained by winding the raw roll of the white metal foil-attached white reflective sheet 10 into a roll shape. Although the concrete dimension etc. are not specifically limited, For example, the winding raw material wound around the core roller about 40-300 mm in diameter is preferable. Since the core roller having a small diameter has a tight curve, the thickness of the white reflective layer 2 at that time is preferably thin. Although the length of a sheet original fabric is not specifically limited, For example, 5-3000 m, Furthermore, 10-2000 m, Especially about 10-100 m are mentioned, for example.

  Thus obtained white reflective sheet 10 with metal foil of this embodiment has a structure as shown in FIG. The white reflective sheet 10 with metal foil contains an inorganic white filler, and the metal foil 1 is formed on the surface of the white reflective layer 2 having a Shore D hardness of 2 to 80.

  The white reflective layer 2 has a Shore D hardness of 2 to 80, preferably a Shore D hardness of 10 to 70, more preferably a Shore D hardness of 20 to 60, and particularly preferably a Shore D hardness of 40 to 50. is there. When the Shore D hardness is less than 2, the white reflective layer 2 is stretched by the tension applied during transportation, and the tension tends to concentrate on the metal foil 1. As a result, wrinkles and distortions are likely to occur in the metal foil after being cut. In addition, when the roll is stored for a long period of time, the white reflective layer 2 is permanently distorted due to the tension applied to the roll and the compressive force due to its own weight applied to the contact surface with the floor. When cut, the flatness of the sheet is impaired, and deformation such as curling and undulation is likely to occur. On the other hand, when the Shore D hardness exceeds 80, it becomes too hard, and it is fine due to bending by the guide roller in the production line, strong bending near the core, and further, the force applied in the cutting process when making a sheet. Cracks are likely to occur.

In addition, the Shore D hardness of the white reflective layer in this embodiment is JIS using a test piece having a thickness of 10 mm made of the same material as that for forming the white reflective layer.
This is a value measured with a durometer type D (Shore D) in accordance with K6253.

  Further, the elongation elastic modulus (Young's modulus) of the white reflective layer 2 is preferably 50 to 700 MPa, more preferably 80 to 600 MPa, and particularly preferably 100 to 400. When the elastic modulus of elasticity is too low, the white reflective layer 2 is stretched due to the tension during conveyance, and the tension is concentrated on the metal foil 1 to easily cause wrinkles and distortions. When the white reflective layer 2 is stored, the white reflective layer 2 is permanently distorted, so that the white reflective layer 2 is easily curled when cut into a single wafer. Further, when the elongation elastic modulus is too high, it becomes too hard, and fine cracks are likely to occur due to bending by a guide roller in a production line or a force applied in a cutting process when making a sheet.

  As the uncured silicone material, a material capable of forming a silicone resin having a three-dimensional crosslinked structure is preferably used. Specific examples of such an uncured silicone material include, for example, a poly (dialkylsiloxane) structure such as poly (dimethylsiloxane) or a poly (diarylsiloxane) structure such as poly (diphenylsiloxane) in the main chain, and a partial And a crosslinkable silicone material whose main chain can be three-dimensionally cross-linked. The three-dimensional crosslinked structure of silicone resin is the reaction of crosslinkable functional groups such as alkyloxysilyl groups, dialkyloxysilyl groups, vinylsilyl groups, divinylsilyl groups, hydrosilyl groups, and dihydrosilyl groups introduced into the side chain. Or formed by reaction of a compounded organic peroxide or a polyfunctional crosslinking agent. Moreover, a crosslinked structure may be formed in presence of platinum catalysts, such as a platinum complex, as needed. Further, such an uncured silicone material may contain a silicone resin, a silicone varnish, or the like for the purpose of adjusting the hardness as required. Such silicones can be obtained as commercially available products, for example, from Shin-Etsu Chemical Co., Ltd., Momentive Performance Materials, Toray Dow Corning Co., Ltd.

Further, the uncured silicone material may further contain a compound for improving the adhesiveness. Examples of such a compound include a silane coupling agent having a reactive functional group such as a vinyl group, a phenyl group, an alkoxy group, a glycidyl group, and a (meth) acryloyl group. More specifically, for example, CH ₂ = CHSi (OCH ₃ ) ₃ (vinyltrimethoxysilane), C ₆ H ₅ Si (OCH ₃ ) ₃ , CH ₂ = CHSi (OCH ₂ H ₄ OCH ₃ ) ₃ , C ₂ H ₃ O—CH ₂ O (CH ₂ ) ₃ Si (OCH ₃ ) ₃ , C ₂ H ₃ O—CH ₂ O (CH ₂ ) ₃ SiCH ₃ (OCH ₃ ) ₂ , CH ₂ ═CH—CO—O _{(CH 2) 3 SiCH 3 (} OCH 3) 2, CH 2 = CCH 3 -CO-O (CH 2) 3 SiCH 3 (OCH 3) 2, CH 3 (CH 2) 7 Si (OCH 2 CH 3) 3 _{, CH 3 Si (OCH 2 CH} 3) 3, CH 3 Si (OCH 3) 3, CH 2 = CHSi (OCH 2 CH 2 OCH 3) 3, CH 2 = CHSiCH 3 (OCH 3) 2, CH 2 = C _{(CH 3) COOCH 2 CH 2} CH 2 Si (OCH 2 CH 3) 3, CH 2 = C (CH 3) COOCH 2 CH 2 CH 2 Si (OCH 3) 3, H _{CH 2 CH 2 CH 2 Si (} OCH 3) 3, HSCH 2 CH 2 CH 2 Si (OCH 2 CH 3) 3, CH 3 (CH 2) 6 COSCH 2 CH 2 CH 2 Si (OCH2CH 3) 3, H 2 NCH ₂ CH ₂ CH ₂ Si (OCH ₂ CH ₃ ) ₃ , H ₂ NCH ₂ CH ₂ CH ₂ Si (OCH ₃ ) ₃ , H ₂ NCH ₂ CH ₂ NHCH ₂ CH ₂ CH ₂ Si (OCH ₃ ) ₃ , H ₂ NCH ₂ CH ₂ NHCH ₂ CH ₂ CH ₂ SiCH ₃ (OCH ₃ ) 2, O═C═NCH ₂ CH ₂ CH ₂ Si (OCH ₂ CH ₃ ) ₃ , O═C═NCH ₂ CH ₂ CH ₂ Si (OCH ₃₎ ) ₃ , 3- (N-phenyl) aminopropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-ureidopropyltriethoxysilane, 2- (2,3 -Epoxy Pyroxypropyl) -2,4,6,8-tetramethyl-cyclotetrasiloxane, 2- (2,3-epoxypropyloxypropyl) -2,4,6,8-tetramethyl-6- (trimethoxysilyl) And ethyl) cyclotetrasiloxane. The amount of the compound for improving the adhesiveness is appropriately adjusted according to the purpose. For example, 0.1 to 10% by mass, further 1 to 5% by mass in the total raw material of the uncured silicone material. It is preferable to add about%.

  The hardness of the white reflective layer 2 is adjusted by the hardness of the silicone resin itself and the hardness and blending ratio of the inorganic white filler, but preferably adjusted to a Shore D hardness of 2 or more using a relatively hard silicone resin. It is preferable to do. Such a silicone resin itself preferably has a Shore A hardness of 30 to Shore D hardness of 70, and a Shore A hardness of 50 to Shore D hardness of about 50. The hardness of the silicone resin can be appropriately adjusted by adjusting the crosslinking density by the type, amount, molecular weight, crosslinking agent or reactive functional group of a filler such as a pigment.

  Specific examples of the inorganic white filler having reflective performance include, for example, anatase type and rutile type titanium oxide, alumina, barium sulfate, magnesia, aluminum nitride, boron nitride, barium titanate, kaolin, silica, talc, powder Examples include mica, powdered glass, powdered aluminum, powdered nickel, calcium carbonate, and zinc oxide. These may be used alone or in combination of two or more. Among these, rutile-type titanium oxide and anatase-type titanium oxide, particularly rutile-type titanium oxide, are preferable because they have excellent concealability and thus have higher reflectance. It is also preferable to use a combination of hydroxides such as aluminum hydroxide and magnesium hydroxide in order to improve flame retardancy.

  The inorganic white filler may be treated with a silane coupling agent. When the inorganic white filler is treated with a silane coupling agent, the dispersibility is improved and the adhesive force is improved at the interface with the silicone resin. The kind of silane coupling agent is appropriately selected from the silane coupling agents as described above, which can improve the adhesiveness.

  The average particle diameter of the inorganic white filler is not particularly limited, but is, for example, 0.05 to 100 μm, more preferably 0.1 to 10 μm, and particularly about 0.1 to about half of the wavelength range to be reflected. It is preferable from the point which is especially excellent in reflectivity that it is about -1 micrometer. When the average particle size of the average particle size is too small, the reflectance tends to decrease due to the decrease in hiding power. Moreover, when the average particle diameter is too large, the reflectivity tends to decrease due to a decrease in dispersibility.

  The blending ratio of the inorganic white filler in the white reflective layer is preferably 4 to 90% by mass, more preferably 7 to 80% by mass, and particularly preferably about 30 to 70% by mass from the viewpoint of excellent light reflectance. When the blending ratio of the inorganic white filler is too high, the viscosity of the resin composition tends to be too high, and thus the coating property tends to decrease. When the blending ratio is too low, the light is easily transmitted and reflected. Tend to decrease.

  The preparation method of the silicone resin composition 2a for forming the white reflective layer 2 is not particularly limited. Specifically, for example, a liquid uncured silicone material, an inorganic white filler, and an additive such as a silane coupling agent further blended as necessary are blended according to a predetermined blending composition and mixed. . Moreover, you may adjust a viscosity in order to improve coating property by adding a predetermined amount of reactive or non-reactive silicone type diluent as needed. Specific examples of the reactive diluent include, for example, a liquid reactive diluent for an uncured silicone material (trade name: ME91, manufactured by Momentive Materials Performance). The reactive diluent is preferably added in an amount of about 0.1 to 30 parts by mass, and more preferably about 1 to 20 parts by mass with respect to 100 parts by mass of the liquid uncured silicone material. Although it depends on the coating method, the viscosity of the varnish-like silicone resin composition 2a is preferably about 0.5 to 500 Pa · s, more preferably about 10 to 200 Pa · s.

  Since the white reflective sheet 10 with metal foil formed in this way has a sufficient waist for the white reflective layer 2, the white reflective layer 2 is not easily stretched even if manufactured by roll-to-roll. The metal foil is less likely to be wrinkled, distorted or broken. Moreover, since the white reflective layer 2 is hard to deform | transform by compression, when it preserve | saves in a roll state, the thickness change of the white reflective layer 2 is suppressed.

  The thickness of the white reflective layer 2 is not particularly limited, but is preferably 2 to 7000 μm, more preferably 5 to 2000 μm, and particularly preferably about 7 to 100 μm. When the thickness of the white reflective layer 2 is too thin, light may be transmitted through the white reflective layer 2, and there is a tendency that the metal foil or the circuit cannot be sufficiently supported, and when the white reflective layer 2 is too thick. Tends to be too stiff to reduce flexibility and make it difficult to roll up the web. Moreover, it is preferable that the thickness of the white reflective sheet 10 with metal foil is about 9-7100 micrometers, Furthermore, 15-2000 micrometers, Furthermore, it is about 20-1000 micrometers.

  The roll-like white reflective sheet 10 with metal foil can be used as a circuit board material for forming an FPC as it is in a roll-to-roll line as will be described later. In order to form, you may cut | disconnect and use in a single wafer state. However, the white reflective sheet 10 with a metal foil of the present embodiment has a roll-to-roll line that is formed in a circuit while being tensioned because the white reflective layer 2 that serves as a supporting substrate has high form stability. And can be particularly preferably used when forming a white reflective sheet with a circuit.

  Next, with reference to FIG.3 and FIG.4, the method of manufacturing the roll of FPC by what is called a subtractive method using the roll original fabric of the white reflective sheet 10 with metal foil is demonstrated. FIG. 3 is a process explanatory diagram for explaining a process for manufacturing a roll of the white reflective sheet with circuit 11 in a roll-to-roll line using the white reflective sheet with metal foil 10, and FIG. It is process sectional drawing explaining the layer structure of the sheet | seat in FIG. In FIG. 3, s1 is a resist film forming process, s2 is a circuit pattern exposure process, s3 is a developing process, s4 is an etching process, and s5 is a resist film peeling process. In FIG. 4, 16 is an etching resist film, and 16a is a resist film region exposed to light.

  In this manufacturing method, first, the white reflective sheet 10 with metal foil drawn out from the raw roll is transported to the resist film forming step s1 on the circuit forming line of FIG. 3, and the metal as shown in FIG. 4 (a). An etching resist film 16 is formed on the surface of the foil 1. Specific examples of the etching resist film 16 include a photocurable dry film. The etching resist film 16 can be easily formed by bonding such dry films.

  Next, in the circuit pattern exposure step of s2 in FIG. 3, the etching resist film 16 is exposed through an unillustrated photomask having a predetermined circuit pattern to the etching resist film 16 as shown in FIG. 4B. By this step, the region other than the region protected by the photomask is exposed to form a region 16a with improved solubility. In the developing step of S3 in FIG. 3, the circuit pattern is developed by dissolving the region 16a with a predetermined solvent, as shown in FIG. 4C.

  Then, in the etching process of s4 in FIG. 3, the metal foil 1 is partially removed by etching the exposed region of the metal foil 1 that is not protected by the etching resist film 16 as shown in FIG. To do. Then, in the resist film peeling step of s5 in FIG. 3, the etching resist film 16 is removed with a stripping solution as shown in FIG. In this way, the circuit 1a is formed on the surface of the white reflective layer 2.

  Since the white reflective layer 2 is a flexible and elastic layer, even when cutting the white reflective sheet with circuit 11 into a single sheet, the FPC and the FPC are less likely to be cut due to the sheet being bent. Become. Since such FPC is based on the white reflective layer 2 having high white reflectance and a circuit is formed on the surface thereof, an optical device such as an LED element, an LED package, or a solar power generation element is mounted on the circuit. Excellent light reflectivity in some cases. For this reason, the light emitted from the LED element or the like is reflected with a high reflectance, or the solar power generation element is received with high efficiency. Further, since the white reflective layer 2 has a high resin property and is relatively hard, the white reflective layer 2 has less tackiness on the rubber surface, and dust and the like are less likely to adhere when electronic components are mounted.

  Thus, when the circuit formation of the white reflective sheet 10 with metal foil is performed on a roll-to-roll line, the Shore D hardness of the white reflective layer 2 is 2 to 80. A circuit is formed with high accuracy because it is not easily deformed by stretching or compression.

  In the above-described steps, as shown in FIG. 3, an example in which the resist film forming step s1, the circuit pattern exposure step s2, the developing step s3, the etching step s4, and the resist film peeling step s5 are continuously performed. Although shown as a representative example, each process may be processed in an independent process such as processing in a roll state and rewinding. In addition, a silicone resin composition for further forming a white reflective layer on the surface of the circuit formed in this manner in order to protect a region other than a land region for mounting an element such as an LED. May be applied to form a white reflective layer. Thus, by further forming a white reflective layer on the surface of the circuit, an effect of protecting the circuit can be obtained.

[Second Embodiment]
Next, a manufacturing method according to another embodiment of the present invention will be described. FIG. 5 is a manufacturing process further comprising the step of forming the adhesive layer 12 on the surface opposite to the surface on which the metal foil 1 of the white reflective layer 2 is formed in the manufacturing method of the first embodiment. Detailed description of the same steps as those described in the first embodiment will be omitted. Elements given the same reference numerals as in the first embodiment mean the same elements as in the first embodiment.

  As shown in FIG. 5, in the manufacturing method of the present embodiment, first, the metal foil 1 is drawn out from the raw roll of the metal foil 1 wound around the feed roller 9 and conveyed to the manufacturing line.

  The metal foil 1 drawn on the production line is subjected to corona discharge treatment by a corona discharge treatment device 7. And the silicone resin composition 2a is apply | coated by the coater 3 to the surface of the metal foil 1 by which the corona discharge process was carried out. Next, the metal foil 1 coated with the silicone resin composition 2 a is conveyed to the heating furnace 4. Then, the white reflective layer 2 is formed by curing the silicone resin composition 2 a in the heating furnace 4. And the adhesive agent 12a is applied by the coater 13 provided with the breast roller 8j on the surface opposite to the surface on which the metal foil 1 of the white reflective layer 2 is formed. Then, the adhesive 12 a is dried in the heating furnace 14 to form an uncured or semi-cured adhesive layer 12. Although the thickness of the adhesive bond layer 12 is not specifically limited, For example, it is preferable that it is about 0.1-50 micrometers, and also about 0.5-25 micrometers.

  Although the kind of adhesive for forming the adhesive layer 12 is not particularly limited, for example, silicone adhesive, polyimide adhesive, polyamide adhesive, polyurethane adhesive, epoxy adhesive, acrylic adhesive , Polyolefin adhesives and the like are appropriately selected according to the type of the adherend. Silicone adhesives, polyimide adhesives, polyamide adhesives, and epoxy adhesives are preferable, silicone adhesives, polyimide adhesives, and epoxy adhesives are more preferable, and silicone adhesives are particularly preferable.

  Then, the release paper 21 is pulled out from the original roll of the release paper 21 wound around the feed roller 15, and the release paper 21 is bonded to the adhesive layer 12 by the pressure rollers 8i and 8i ′. The type of release paper is not particularly limited, and examples thereof include a paper substrate coated with a silicone resin, a PET film coated with fluorine. In this way, the white reflective sheet with metal foil 20 having the adhesive layer 12 is formed. And the roll raw fabric of the white reflection sheet 20 with a metal foil is obtained by winding the white reflection sheet 20 with a metal foil by the winding roller 6. The raw roll thus obtained is obtained by winding a long roll of white reflective sheet 20 with a metal foil into a roll. Although the specific dimension is not specifically limited, For example, a 5-500-m sheet original fabric is wound.

  The white reflective sheet with metal foil 20 of the present embodiment obtained in this way has a configuration as shown in FIG. The white reflective sheet 20 with a metal foil includes an inorganic white filler, the metal foil 1 is laminated on one surface of the white reflective layer 2 having a Shore D hardness of 2 to 80, and an adhesive on the other surface. A release paper 21 that protects the layer 12 and the adhesive layer 12 is laminated.

  In the present embodiment, the white reflective sheet 20 with a metal foil having a form in which the adhesive layer 12 having tackiness is protected by the release paper 21 is prepared. However, the adhesive layer 12 is a pressure-sensitive type or a heat-sensitive type. When the adhesive layer 12 having a low mold tack is formed, the adhesive layer may not be protected with a release paper. Specifically, for example, a heat-sensitive adhesive layer is formed using a polyamide-based hot-melt adhesive, a polyurethane-based hot-melt adhesive, a polyolefin-based hot-melt adhesive, or a two-component curable epoxy resin. Even if an epoxy-based pressure-sensitive adhesive or the like that cures by reacting the epoxy resin with the curing agent from the capsule by applying pressure is included. Good.

  As shown in FIG. 7, the white reflective sheet 20 with metal foil formed in this way can be easily bonded to another base material 23 by the adhesive layer 12 by removing the release paper 21. it can. Specifically, for example, after forming a circuit on the metal foil 1 of the white reflective sheet 20 with metal foil in the same manner as in the first embodiment, the circuit is cut into a single wafer and bonded to a flexible or rigid base material 23. Thereby, the white reflective sheet 20 with metal foil can be reinforced.

  The kind of the base material 23 is not specifically limited. Specifically, for example, polyimide (PI), polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polycarbonate (PC), polysulfone (PSF), polyethersulfone (PES), polyetherimide (PEI), Examples thereof include resin films such as amorphous polyarylate (PAR), liquid crystal polymer (LCP), and cycloolefin polymer (COP). For example, PI has a brown color. For example, LCP is colored yellow. The white reflective sheet 20 with metal foil of this embodiment imparts high reflectivity by forming the white reflective layer 2 exhibiting a vivid white color on the surface of a colored resin film such as PI or LCP. can do. The film thickness of the resin film is not particularly limited, but is preferably about 5 to 100 μm, more preferably about 5 to 50 μm, and particularly preferably about 5 to 30 μm.

  The base material 23 is, for example, a so-called glass epoxy substrate, a rigid substrate made of the same material as the resin forming the resin film described above, a bismaleimide triazine (BT) substrate, a copper substrate, an aluminum substrate with excellent heat dissipation, or nitriding An aluminum substrate, a glass plate, a ceramic plate, etc. may be sufficient. Since the aluminum substrate and the aluminum nitride substrate are excellent in heat dissipation, for example, by efficiently dissipating heat from the LED, the light emission efficiency of the LED can be improved.

  The adhesive layer 12 may be colored with a pigment or a colorant. In such a case, when the substrate 23 has transparency, when the white reflective sheet 20 with a metal foil is bonded to the substrate 23, by identifying the color difference from the back side of the substrate, a circuit pattern, etc. It becomes a sign to distinguish the type of product.

  Although the example which forms the adhesive bond layer 12 in the white reflective sheet 20 with metal foil was shown in the example mentioned above, instead of forming the adhesive bond layer 12 in the white reflective sheet 20 with metal foil, the white reflective sheet with metal foil An adhesive layer may be formed after a predetermined circuit pattern is formed from 20 metal foils 1 to form a white reflective sheet with circuit.

[Third embodiment]
Next, a manufacturing method according to still another embodiment of the present invention will be described. FIG. 8 is a manufacturing process further comprising the step of bonding the resin film 22 to the opposite surface of the white reflective layer 2 to the bonding surface with the metal foil 1 in the manufacturing method of the first embodiment. Detailed description of the same steps as those described in the above-described embodiment will be omitted. Moreover, the element which attached | subjected the same code | symbol as embodiment mentioned above means the element similar to embodiment mentioned above.

  As shown in FIG. 8, in the manufacturing method of this embodiment, first, the metal foil 1 is drawn out from the roll of the metal foil 1 wound around the delivery roller 9, and is conveyed to the manufacturing line by the guide roller. . The drawn metal foil 1 is subjected to corona discharge treatment by a corona discharge treatment device 7. On the other hand, the resin film 22 is drawn out from the roll of the resin film 22 wound around the feed roller 19 and conveyed to the production line by the guide rollers 18a and 18b. The drawn resin film 22 is subjected to corona discharge treatment by a corona discharge treatment device 17 provided with an earth roller 18g.

  Then, the metal foil 1 and the resin film 22 are joined together via the silicone resin composition 2a supplied from the resin supply device 5 in the pressure rollers 8k and 18k. In this way, a layer made of the silicone resin composition 2 a is disposed between the metal foil 1 and the resin film 22.

And the laminated body of the layer which consists of the metal foil 1, the resin film 22, and the silicone resin composition 2a is conveyed by the heating furnace 4 distribute | arranged on the manufacturing line. Then, the white reflective layer 2 is formed by curing the silicone resin composition 2 a in the heating furnace 4. And the metal foil 1 is laminated | stacked on one surface of the white reflective layer 2, and the white reflective sheet 30 with a metal foil obtained by laminating the resin film 22 on the other surface is obtained. And the roll raw fabric of the white reflective sheet 30 with metal foil is obtained by winding up the white reflective sheet 30 with metal foil by the winding roller 6. The raw roll obtained in this way is obtained by winding a long roll of white reflective sheet 30 with a metal foil into a roll. Although the specific dimension is not specifically limited, Although the specific dimension is not specifically limited, For example, the sheet | seat raw material of 5-700 m is wound.

  The thus obtained white reflective sheet 30 with metal foil of the present embodiment has a configuration as shown in FIG. In the white reflective sheet 30 with metal foil, the metal foil 1 is formed on one surface of the white reflective layer 2 containing an inorganic white filler and having a Shore D hardness of 2 to 80, and the other surface is a resin film. 22 are stacked.

  Specific examples of the resin film 22 include the same resin films such as PI and PEN as described in the second embodiment.

  The white reflective sheet 30 with a metal foil formed in this way can form a circuit by the same method as described in the first embodiment. Since such a white reflective sheet 30 with metal foil is supported by the resin film 22, the rigidity becomes high.

[Fourth embodiment]
Next, a manufacturing method according to still another embodiment of the present invention will be described. FIG. 10 shows a manufacturing method according to the first embodiment, further comprising a step of forming an intermediate adhesive layer 32 having a lower hardness than the white reflective layer 2 between the metal foil 1 and the white reflective layer 2. It is a process. Detailed description of the same steps as those described in the above embodiment will be omitted. Moreover, the element which attached | subjected the same code | symbol as embodiment mentioned above means the element similar to embodiment mentioned above.

  As shown in FIG. 10, in the manufacturing method of the present embodiment, first, the metal foil 1 is drawn out from the raw roll of the metal foil 1 wound around the feed roller 9 and conveyed to the manufacturing line.

  The metal foil 1 drawn on the production line is subjected to corona discharge treatment by a corona discharge treatment device 7. And the adhesive agent 32a whose hardness at the time of hardening is low compared with the white reflective layer 2 is apply | coated to the surface of the metal foil 1 by which the corona discharge process was carried out. Next, the metal foil 1 coated with the adhesive 32 a is conveyed to the heating furnace 4. Then, the adhesive 32a is dried in the heating furnace 4 to form an uncured intermediate adhesive layer 32b. Then, the silicone resin composition 2 a is applied to the surface of the uncured intermediate adhesive layer 32 b by the coater 13 and conveyed to the heating furnace 14. Then, the white reflective layer 2 is formed by curing the silicone resin composition 2 a in the heating furnace 14. At this time, the uncured intermediate adhesive layer 32b is also cured to form the intermediate adhesive layer 32.

  In the manufacturing process described above, the application of the adhesive 32a and the application of the silicone resin composition 2a are performed in an isolated and independent process. Instead, a coating head such as a tandem or multi-coating head is used. The adhesive 32a and the silicone resin composition 2a may be applied continuously in a single step and cured in a single heating furnace.

  The white reflective sheet with metal foil 40 of the present embodiment thus obtained has a configuration as shown in FIG. The white reflective sheet 40 with metal foil is interposed between the metal foil 1, the white reflective layer 2 containing an inorganic white filler and having a Shore D hardness of 2 to 80, and the metal foil 1 and the white reflective layer 2. An intermediate adhesive layer 32 having a lower hardness when cured than the white reflective layer 2 is provided. By interposing the intermediate adhesive layer 32 between the white reflective layer 2 and the metal foil 1, the adhesion between the metal foil 1 and the white reflective layer 2 can be further improved. In addition, interposing such an intermediate | middle adhesive bond layer 32 also has adhesiveness with the base material and metal foil which should have high Shore D hardness of a white reflective layer also in 1st embodiment-3rd embodiment. When improving, it can provide suitably. Further, the intermediate adhesive layer between the metal foil and the white reflective layer may contain a silane coupling agent or the like. Further, the intermediate adhesive layer may include a dye, a pigment, and the like for coloring.

  The adhesive 32a is an adhesive whose hardness at the time of curing is lower than the hardness of the white reflective layer 2, and is not particularly limited as long as it maintains sufficient adhesiveness with the white reflective layer 2. Specific examples thereof include silicone adhesives, polyimide adhesives, epoxy adhesives, urethane adhesives, and the like.

The intermediate adhesive layer 32 is preferably a layer derived from an adhesive having a Shore A hardness of 40 or less and a Shore A hardness of 5 to 50 when cured. By interposing the flexible intermediate adhesive layer 32 in this way, even if the hard white reflective layer 2 is provided, the shear stress generated between the metal foil 1 and the white reflective layer 2 when bent is relieved. High adhesion can be maintained.

  The film thickness of the intermediate adhesive layer 32 is not particularly limited, but is preferably about 0.1 to 300 μm, more preferably about 0.5 to 100 μm, and particularly preferably about 1 to 50 μm. When the film thickness of the intermediate adhesive layer 32 is too thin, there is a tendency that the adhesive reinforcing effect is not sufficiently exhibited, which is not preferable when the cushioning property is exhibited in winding or the sheet becomes thick and becomes a raw fabric roll. .

  Next, the present invention will be described more specifically with reference to examples. The scope of the present invention is not limited by the examples.

Example 1
An ink, which is a silicone resin composition for forming a white reflective film having a Shore hardness D10 when cured, was prepared in advance as follows. For 100 parts by mass of liquid silicone resin A1 (LR3303 / 80 made by Asahi Kasei Wacker Silicone Co., Ltd., whose main chain is mainly polydimethylsiloxane and heated by two-component addition reaction type, Shore hardness D10 when cured) 100 parts by mass of rutile type titanium oxide (SR-1 manufactured by Sakai Chemical Industry Co., Ltd., average particle size 0.25 μm) was added. In addition, vinyl trimethoxysilane (SZ6300 manufactured by Toray Dow Corning Co., Ltd.), which is a silane coupling agent, is adhered to the rutile type titanium oxide as an adhesion imparting component so as to be 5 phr (parts hindred rubber). Oita. Then, an ink B1 was prepared by uniformly dispersing rutile titanium oxide in the liquid silicone resin A1 using three rolls.

  And the white reflective sheet with copper foil was manufactured using the manufacturing line as shown in FIG. Specifically, an electrolytic copper foil having a width of 500 mm and a thickness of 20 μm is used as a copper foil, ink B1 is applied by a roll coater, and ink B1 is cured under conditions of a heating furnace temperature of 120 ° C. and a heating furnace passage time of 3 minutes. The white reflective sheet with a copper foil on which a white reflective layer having a thickness of 50 μm was formed was wound up on a core roll having a diameter of 100 mm to produce a 50 m roll original fabric. Ten sets of such original fabrics were made. Then, after the original fabric was prepared, the original fabric was left for 4 hours in a constant temperature dryer at 120 ° C. to completely cure the ink B1. And it evaluated as follows.

[Measurement of hardness of white reflective layer]
After potting ink B1, which is a silicone resin composition, on a 50 mm × 50 mm square mold having a thickness of 10 mm, a test piece was obtained by curing at the same heating temperature and heating time as the above production conditions. And shore hardness was measured with the durometer type based on JISK6253. The results are shown in Table 1.

[Measurement of Young's modulus of white reflective layer]
A white reflective layer having a thickness of 2 mm was formed by potting the ink B1 on a mold and curing by heating at the same heating temperature and heating time as in the above production conditions. And the No. 3 type dumbbell test piece was cut out, and the elongation elastic modulus was measured based on JISK6253. The results are shown in Table 1.

[Adhesion of copper foil on the surface of the white reflective sheet with copper foil]
The white reflective sheet with copper foil is cut from the obtained raw material uniformly into a single sheet, and the adhesion of the copper foil bonded to the white reflective layer is reflected in white using polyimide tape according to JIS-Z0237. The 180 ° peel force was measured by bonding to the layer. Evaluation was performed at N = 10. The peeling rate was 10 mm / min. The results are shown in Table 1.

[Crack generation evaluation of white reflective layer with copper foil]
A white reflective sheet with a copper foil of 20 mm × 100 mm cut from the original fabric was sampled. Then, two rolls having a diameter of 10 mm were set, and both surfaces were drawn once so that the sheets could be bent at a right angle at a speed of 100 mm / second while the sheets were sandwiched between the two rolls. And the surface of the sheet | seat after drawing was observed with the optical microscope, and the presence or absence of the generation | occurrence | production state of a crack was determined. The results are shown in Table 1.

[Compression evaluation of 50m roll of white reflective sheet with copper foil]
Stacking 50m rolls of white reflective sheet with copper foil in the form of a cylinder holder and storing in this state for 20 days, the first and second rolls are in line contact The wound was unwound around the spot where it was unfolded, light was applied obliquely to the unwound sheet, and the state of dents on the surface of the sheet after storage was visually observed and evaluated according to the following criteria. The results are shown in Table 1.
A: There is no dent.
B: Slight dent is recognized.
C: Obvious dent is recognized

[Measurement of reflectance]
The reflectance of the white reflective layer of the produced white reflective sheet with copper foil was measured using a spectrophotometer (model number UV-3150: Shimadzu Corporation). A graph of the reflectance with respect to the wavelength measured with the spectrophotometer is shown in FIG.

(Example 2)
In Example 1, instead of the liquid uncured silicone material A1, a liquid uncured silicone material A2 (manufactured by Momentive Performance Materials Japan Godo Kaisha of a two-component addition curing type mainly composed of polydimethylsiloxane in the main chain) A white foil with a copper foil in the same manner as in Example 1 except that ink B2 having a shore hardness D20 when cured prepared using IVSM4200, shore hardness D16) was used instead of ink B1. A reflective sheet was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

(Example 3)
In Example 1, instead of the liquid uncured silicone material A1, the liquid uncured silicone material A3 (the main chain is mainly polydimethylsiloxane, a two-component thermosetting addition type Momentive Performance Materials Japan GK Copper foil in the same manner as in Example 1 except that ink B3 having a shore hardness of D60, which was prepared using IVSM4500 manufactured by the company, Shore hardness D50 when cured, was used instead of ink B1. A white reflective sheet was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

Example 4
In Example 1, instead of the liquid uncured silicone material A1, a liquid uncured silicone material A4 (LR3303 / manufactured by Asahi Kasei Wacker Silicone Co., Ltd., which is a two-component heat curing addition type mainly composed of polydimethylsiloxane) 70, Shore hardness at curing A70) prepared by using a cross-linking agent. Copper foil as in Example 1 except that ink B4 having a shore hardness D2 when cured was used instead of ink B1 A white reflective sheet was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

(Example 5)
In Example 1, in place of the liquid uncured silicone material A1, a liquid uncured silicone material A5 (momentive performance materials Japan GK with a main component of polydimethylsiloxane and a two-component thermosetting addition type) IVSM4500 manufactured by Co., Ltd., Shore hardness D50 when cured, prepared using a cross-linking agent, and in the same manner as Example 1 except that ink B5 having a Shore hardness D70 when cured was used instead of ink B1. A white reflective sheet with copper foil was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

(Example 6)
In Example 1, instead of the liquid uncured silicone material A1, the liquid uncured silicone material A6 (momentive performance materials Japan GK with a main component of polydimethylsiloxane and a two-component heat curing addition type) Ink B6 having a shore hardness of D80 when cured was prepared in the same manner as ink A1, except that XE-14c2508 manufactured by the company, Shore D hardness of 70 when cured) was used.

  And the white reflective sheet with copper foil was manufactured using the manufacturing line as shown in FIG. Specifically, an electrolytic copper foil having a width of 200 mm and a thickness of 20 μm was used as the copper foil, and an adhesive (RT 707 W manufactured by Asahi Kasei Wacker Silicone Co., Ltd., which is a silicone-based adhesive) was used on the surface of the electrolytic copper foil. A shore hardness A42) is applied with a roll coater, and dried to such an extent that the adhesive is not cured under conditions of a heating furnace temperature of 140 ° C. to form an uncured intermediate adhesive layer, and ink is further applied to the surface of the uncured intermediate adhesive layer. By applying B6 with a roll coater, curing the adhesive and ink B6 under the conditions of a heating furnace temperature of 120 ° C. and a heating furnace passage time of 3 minutes, and continuously manufacturing, a white reflective layer having a thickness of 50 μm and A 50 m roll of a white reflective sheet with a copper foil on which an intermediate adhesive layer having a thickness of 10 μm was formed was prepared. And it evaluated similarly to Example 1. FIG. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

(Comparative Example 1)
In Example 1, instead of the liquid uncured silicone material A1, a liquid uncured silicone material A7 (LR3303 made by Asahi Kasei Wacker Silicone Co., Ltd., a two-component thermosetting addition type mainly composed of polydimethylsiloxane) / 60, white foil with copper foil prepared in the same manner as in Example 1 except that ink B7 having a shore hardness A70 when cured prepared using shore hardness A60) was used instead of ink A1. A reflective sheet was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

(Comparative Example 2)
In Example 1, instead of the liquid uncured silicone material A1, a liquid uncured silicone material A8 (SR-7010 of Toray Dow Corning Co., Ltd., a two-component thermosetting addition type mainly composed of polydimethylsiloxane) , Shore D hardness 69) during curing was prepared as an ink B8 having a Shore hardness D90 when cured using a crosslinking agent.

  Then, except that ink B8 was used instead of ink B6, a white reflective layer was formed through an uncured intermediate layer using a production line as shown in FIG. 10 in the same manner as in Example 6. A white reflective sheet with copper foil was obtained and evaluated. The results are shown in Table 1. Note that the result of the reflectance is the same as the result of Example 1, and therefore will be omitted.

  From the results shown in Table 1, when the shore hardness of the white reflective layer is in the range of D2 to D80, the copper foil has excellent adhesion, and no cracks are observed even in crack generation evaluation. Even in the evaluation, the high flatness of the sheet is maintained high. In addition, in the white sheet | seat with a copper foil obtained in Example 4, although the dent by some compression evaluation was seen, since it is a very small part, it can endure practical use. On the other hand, in the case of Comparative Example 1 in which a white elastic layer with a Shore hardness of A70 is formed, the sheet has a good adhesion to the copper foil but the line pressure is applied in the compression evaluation of the original fabric. There was obvious deformation. Moreover, in the case of the comparative example 2 which formed the hard sheet | seat whose shore hardness of a white reflection layer is D90, the fine crack was observed.

  According to the roll original fabric in which the white reflective sheet with metal foil of the present invention is rolled up, a suitable roll original fabric can be obtained for the subsequent circuit board in the laminated structure of the white reflective layer and the metal foil. . When a circuit is formed on the white reflective sheet with a metal foil obtained from such a roll, and an element such as an LED or a solar cell or a device including these is mounted, the efficiency of light reception and emission can be improved.

DESCRIPTION OF SYMBOLS 1 Metal foil 1a Circuit 2 White reflection layer 2a Silicone resin composition 3,13 Coater 4,14 Heating furnace 5 Resin supply apparatus 6 Winding roller 7,17 Corona discharge treatment apparatus 8a, 8b, 8c, 8d, 8e, 8f, 18a, 18b Guide roller 8i, 8i ', 8k, 18k Pressure roller 8g, 18g Earth roller 8h, 8j Breast roller 9, 15, 19 Feed roller 10, 20, 30, 40 White reflective sheet with metal foil 11 White reflection with circuit Sheet 12 Adhesive layer 12a Adhesive 16 Etching resist film 16a Exposed resist film region 21 Release paper 22 Resin film 23 Base material 32 Intermediate adhesive layer 32a Adhesive 32b Uncured intermediate adhesive layer s1 Resist film forming step s2 Circuit pattern Exposure process s3 Development process s4 Etching process s5 Regis Film stripping step

Claims (11)

It is a roll raw material in which a white reflective sheet with metal foil is rolled up,
The white reflective sheet with metal foil comprises a white reflective layer and a metal foil laminated on the white reflective layer,
The white reflective layer is obtained by applying a silicone resin composition containing an uncured silicone material and an inorganic white filler to the metal foil, and having a Shore D hardness of 2 to 80 at the time of curing and curing. A raw roll of a white reflective layer with a metal foil, characterized in that   The roll of the white reflective sheet with a metal foil according to claim 1, wherein the silicone resin has a hardness of Shore A hardness 30 to Shore D hardness 70.   The roll raw fabric of the white reflective sheet with metal foil according to claim 1 or 2, wherein the Young's modulus of the white reflective layer is 50 to 700 MPa.   The roll original fabric of the white reflective sheet with a metal foil according to any one of claims 1 to 3, further comprising an adhesive layer on a surface opposite to a surface of the white reflective layer on which the metal foil is formed.   The roll original fabric of the white reflective sheet with metal foil according to claim 4, wherein the adhesive layer is an adhesive layer, and the adhesive layer is further protected with a release paper.   In the roll original fabric of the white reflective sheet with a metal foil according to any one of claims 1 to 5, a circuit is formed by removing the metal foil in a portion other than a predetermined circuit pattern. A roll of the circuit wiring board. A first step of applying a silicone resin composition with a predetermined thickness on the surface of the metal foil drawn from the metal foil roll and fed in one direction;
A second step of forming a white reflective sheet with metal foil by forming a white reflective layer by curing the applied silicone resin composition;
A third step of forming a roll of the white reflective sheet with metal foil by winding the white reflective sheet with metal foil with a winding roller,
The silicone resin composition contains an uncured silicone material and an inorganic white filler, and has a Shore D hardness of 2 to 80 at the time of curing. Method.   The method for producing a white reflective sheet roll with metal foil according to claim 7, further comprising a step of activating the surface of the metal foil immediately before the first step.   The method further comprises a fourth step of forming an adhesive layer on a surface opposite to the surface on which the metal foil of the white reflective layer is formed between the second step and the third step. The manufacturing method of the white reflective sheet roll with metal foil of description. The adhesive layer is an adhesive layer;
The manufacturing method of the white reflective sheet roll with metal foil of Claim 9 further equipped with the 5th process of laminating a release paper on the surface of the said adhesive layer after a 4th process. A method for producing a roll of a white reflective sheet with circuit by roll-to-roll,
The white reflective sheet with metal foil is drawn out from the roll of the white reflective sheet with metal foil according to any one of claims 1 to 6 and sent in one direction. A sixth step of forming a white reflective sheet with circuit by removing the metal foil in a portion other than the predetermined circuit pattern;
And a seventh step of forming a roll of the white reflective sheet with circuit by winding the white reflective sheet with circuit with a winding roller. .

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