JP2019523559A - 電気絶縁基板への電気伝導体の適用方法 - Google Patents
電気絶縁基板への電気伝導体の適用方法 Download PDFInfo
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- 239000002344 surface layer Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
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- ZNOKGRXACCSDPY-UHFFFAOYSA-N tungsten trioxide Chemical compound O=[W](=O)=O ZNOKGRXACCSDPY-UHFFFAOYSA-N 0.000 description 1
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- 229910052725 zinc Inorganic materials 0.000 description 1
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Abstract
Description
a)可撓性膜を提供するステップと、
b)膜の第1の面に、基板に適用される電気伝導体の所望のパターンに少なくとも部分的に対応する溝のパターンを形成するステップと、
c)溝に、組成成分として導電性粒子および接着剤を含む組成物を充填するステップであって、充填ステップの完了時に、組成物が膜の第1の面と同じ高さで溝を実質的に満たし、かつ溝の間の第1の面の部分に組成物が実質的に含まれないように、1回以上のサブステップで実行される充填するステップと、
d)膜の第1の面を基板に向けて、膜を基板に接触させるステップと、
e)膜に圧力を加えて、膜の第1の面の溝内に充填された組成物を、基板に付着させるステップと、
f)膜を基板から分離させて、膜の第1の面の溝から基板に組成物を転写するステップと、
g)溝から基板に転写された組成物のパターンを導電性にするために、導電性粒子を焼結するのに十分なエネルギーを加えるステップと、を含む。
図1Aには、円筒加圧ローラ104とダイローラ102との間のニップを通過する、プラスチック材料製の膜100が示されている。ダイローラ102は、平滑な表面からルール106および108が突出している円筒で形成することができる。ダイローラ102の形成方法は、基本的に重要ではない。その製造方法の1つは、平滑な円筒のエッチングであり、あるいは円筒の周囲に突出ルール106および108を有するエンボスシム(典型的には、ニッケルまたはクロム製)を取り付けることであり得る。図示しないが、可撓性膜100は、1層以上の個別の可撓性材料から形成することができる。
説明したように、膜は、ニップを通過した後に、プレートの下で、あるいは溝が任意の所望の方法で形成された後に、当該膜が元の形状に戻る弾力性を有しないことが要求される。膜は、適切には1つ以上のプラスチックポリマー、特には、環状オレフィンコポリマー(COC)、エチレン酢酸ビニル(EVA)、ポリアミド(PA)、ポリカーボネート(PC)、ポリエチレン(PE)、ポリエチレンテレフタレート(PET)、ポリプロピレン(PP)、ポリウレタン(TPU)、ポリ塩化ビニル(PVC)、およびそれらの置換型を含む群から選択された、熱可塑性ポリマーから形成され得る。しかしながら、膜は、代替的に、溝がそれらの材料のいずれかに押し込まれた後に硬化され得る、異なるポリマー、またはフォトポリマーなどの非プラスチック材料から形成され得る。膜は、該膜をコイル状にするのに十分な可撓性を有することが望ましい。膜は、基板の面から剥離されるのに十分な柔軟性を有することも重要である。
膜100に溝のパターンを形成した後、プロセスにおける次のステップは、例えば銀などの導電性粒子と、例えばホットメルトポリアミドなどの接着剤(転写が高温で行われる場合)と、を含む組成物で溝を満たすことである。この充填ステップは、図1Bに示されており、ここで膜100が加圧ローラ132とブレードまたはスクレーパー130との間を通過すると、組成物120が溝110に押し込まれて、図1Bのブレード130の右側に示されるように溝が満たされる。満たされた溝は、140として示されている。図2Cに、例示的な溝110の充填前の拡大断面図を示す。
上述の方法は、薄い導体を形成するのにより適しているが、例えば、PCBの接地電極のような広い表面を電極で被覆することが望ましい場合、図4A〜4Cに示すように、方法をかなり単純化することができる。図4Aでは、丸みを帯びた先端を有するドクターブレード400は、膜100が加圧ローラ402とドクターブレード400との間を通過するときに膜100に押し付けられる。ドクターブレード400の上流で過剰な組成物404(これは、導体板用に銅であり得る)が膜100に塗布され、組成物がドクターブレードの下を通過するときにその厚さは均一に減少する。その厚さは、ドクターブレード400の先端の曲率半径および加えられる圧力を変えることによって設定することができる。過剰な組成物はドクターブレードの全長に沿って塗布される必要はなく、あるいはドクターブレードは任意に「セグメント化」されていてもよく、組成物は膜の所望の部分に積層されている。次いで、組成物404を乾燥させることができる。
図5Aに概略的に要約された導電性の金属パターンを上述の原理に従って作製した。図には、金属パターン500が示されている。このようなパターンは、乾燥組成物が溝を実質的に満たすとき膜の表面の下で「ネガティブ」であり,あるいは転写後の基板の上に突出する「ポジティブ」であり得る。金属線の長手方向の溝510は、ルール106(図1Aまたは図2A〜2B参照)から生じるが、横断方向の溝または金属線は、「中断されずに」金属パターンのすべての長手方向の線を横切るものは520として示されており、線510のサブセットだけを横切るものは530として示されている。いずれにせよ、横断方向の溝または線520または530は、ルール108(図1Aまたは図2Aを参照)から生じる。
プリント回路基板(PCB)の製造では、絶縁材料(例えば、ガラス繊維)でできた基板を導電層(例えば、銅)で被覆し、保護パターンを絶縁基板の上面に接着するかまたは他の方法で結合する。導電層の一部を機械的または化学的に除去し、電気部品を接続するために利用される導電トレースのパターンを形成する。特定の実施形態において、トレースは、表面実装デバイスとして知られる電気部品に対する機械的支持も提供する。電気部品(例えば、抵抗器およびコンデンサなど)を含むPCBは、プリント回路アセンブリ(PCA)とも呼ばれる。このような従来の方法における導電性材料の除去は、無駄であり、そして費用がかかる。
先に詳述した本発明の実施形態では、1つのパターンの溝が形成され、次いで、乾燥組成物のパターンを転写するのに最適な電気絶縁基板上への積層に先立って対象の組成物が充填される可撓性膜を説明した。(例えば、異なる形状、異なる寸法、異なるプロファイル、異なる組成などの相違点を有する)個別のパターンを同じ基板上に形成する場合、本教示に従う方法は適切であり得る。例えば、第1のパターンを有する第1の膜を基板の第1の面に適用し、第2のパターンを有する第2の膜を該基板の第2の面に適用することができる。基板の第1および第2の面は、基板の同側、典型的には重複しない領域にあり得るが、反対側にあってもよい。さらに、各膜の各パターンは、同じまたは異なる組成物で充填されていてもよい。
Claims (26)
- 電気絶縁基板に電気伝導体のパターンを適用する方法であって、前記方法は、
a)可撓性膜を提供するステップと、
b)前記膜の第1の面に、前記基板に適用される電気伝導体の所望のパターンに少なくとも部分的に対応する、溝のパターンを形成するステップと、
c)前記溝に、組成成分として導電性粒子および接着剤を含む組成物を充填する充填ステップであって、前記充填ステップの完了時に、前記組成物が前記膜の前記第1の面と同じ高さで前記溝を実質的に満たし、かつ前記溝の間の前記第1の面の部分に前記組成物が実質的に含まれないように、1回以上のサブステップで実行される充填する充填ステップと、
d)前記膜の前記第1の面を前記基板に向けて、前記膜を前記基板に接触させるステップと、
e)前記膜に圧力を加えて、前記膜の前記第1の面の前記溝内に充填された前記組成物を、前記基板に付着させるステップと、
f)前記膜を前記基板から分離させて、当該膜の前記第1の面の前記溝から前記基板に前記組成物を転写するステップと、
g)前記溝から前記基板に転写された前記組成物のパターンを導電性にするために、前記導電性粒子を焼結するのに十分なエネルギーを加えるステップと、を含む方法。 - 前記溝に充填される前記組成物が、追加の組成成分として液体キャリアを含んで湿潤組成物を形成し、前記充填ステップが、
(i)過剰量の前記湿潤組成物を、前記膜の前記第1の面全体に塗布するステップと、
(ii)前記湿潤組成物を実質的に前記膜の前記第1の面の前記溝内にだけ残すように、前記第1の面から余分な湿潤組成物を除去するステップと、
(iii)前記液体キャリアを除去することにより、前記溝内の前記湿潤組成物を実質的に乾燥させて乾燥組成物を残すステップと、を含む充填サイクルを少なくとも1回実行し、
乾燥組成物が前記膜の前記第1の面と同じ高さで前記溝を実質的に満たすまで、ステップ(i)、(ii)および(iii)を必要に応じて繰り返す、請求項1に記載の方法。 - 少なくとも最後の前記充填サイクルにおけるステップ(iii)の前または後に、前記膜をクリーニングして、前記溝の間の前記膜の部分から組成物を除去する、請求項2に記載の方法。
- 前記組成物の前記成分の相対比率が充填サイクル間で変動する、請求項2または3に記載の方法。
- 前記組成物を前記溝に充填する前に、前記膜の前記溝に剥離コーティングを塗布して、前記溝上で乾燥させる、請求項1〜4のいずれか一項に記載の方法。
- 前記剥離コーティングを前記溝の壁上にのみ形成する、請求項5に記載の方法。
- ステップd)に従って前記膜を前記基板に接触させる前に、前記膜の前記第1の面に接着剤コーティングを塗布して前記溝内に存在するあらゆる組成物を被覆し、前記基板との接触前に前記接着剤コーティングを乾燥させる、請求項1〜6のいずれか一項に記載の方法。
- 前記パターンの前記溝が互いに実質的に同一である、請求項1〜7のいずれか一項に記載の方法。
- 前記パターン内の少なくとも2つの溝、または同じ溝の2つの異なるセグメントは、深さおよび/または幅が互いに異なる、請求項1〜7のいずれか一項に記載の方法。
- 前記可撓性膜が、プラスチックポリマーの予備成形膜および注型されたプラスチックポリマーから選択される、請求項1〜9のいずれか一項に記載の方法。
- 前記プラスチックポリマーが、環状オレフィンコポリマー(COC)、ポリエチレン(PE)、ポリプロピレン(PP)、熱可塑性ポリウレタン(TPU)、およびこれらの組合せからなる群から選択される熱可塑性ポリマーである、請求項10に記載の方法。
- 前記予備成形膜が少なくとも2層からなり、前記層の少なくとも1つが前記熱可塑性ポリマーを含む、請求項11に記載の方法。
- 前記可撓性膜の前記第1の面の平均粗さRzが、1μm以下、500nm以下、250nm以下、または100nm以下である、請求項1〜12のいずれか一項に記載の方法。
- 導電性材料の粒子が、金属、合金、有機金属、導電性ポリマー、これらの前駆体、これらの塩類、およびこれらの組合せからなる群から選択される化合物からなる、請求項1〜13のいずれか一項に記載の方法。
- 前記接着剤が、a)有機バインダ、b)有機接着剤、およびc)ガラスフリットのうちの少なくとも1つである、請求項1〜14のいずれか一項に記載の方法。
- 前記有機接着剤が感圧接着剤または感熱接着剤である、請求項15に記載の方法。
- 圧力を加えるステップe)を、60℃〜200℃の範囲の温度で実行する、請求項1〜16のいずれか一項に記載の方法。
- 前記可撓性膜の前記溝のパターンが、パターニング要素上のルールの相補的パターンによって形成され、前記可撓性膜とパターニング要素とがパターニング中に相対移動し、前記パターニング要素が任意にダイローラであり、前記可撓性膜がさらに任意に連続膜である、請求項1〜17のいずれか一項に記載の方法。
- 前記組成物が、ステップg)において、150℃〜800℃の範囲内の少なくとも1つの温度または500℃〜900℃の範囲内の少なくとも1つの温度で焼結される、請求項1〜18のいずれか一項に記載の方法。
- 前記溝が連続するまたは個別の直線または曲線を形成し、各線の少なくとも一部が、三角形、台形、多角形、半円形、または半楕円形から選択されるテーパー断面形状を有し、いずれの形状も少なくとも底幅WBおよび高さhを有し、当該高さと底幅との間の無次元アスペクト比ASPが、5:1〜1:5、3:1〜1:2、2:1〜1:1、または1.75:1〜1:1.75の範囲である、請求項1〜19のいずれか一項に記載の方法。
- 前記断面形状のテーパー面は、前記膜の前記第1の面とのなす角度が、少なくとも30°、少なくとも40°、少なくとも45°、若しくは少なくとも60°であり、かつ任意に最大90°、最大85°、若しくは最大80°であり、および/または、(b)平均勾配が、少なくとも0.75、少なくとも1、若しくは少なくとも1.3であり、かつ任意に最大8、最大4、若しくは最大2である、請求項20に記載の方法。
- 前記溝の少なくとも1つが、パンチもしくはレーザビームから選択されるパターニング要素によって形成されるか、またはフォトリソグラフィを含むパターニング技術によって形成される、請求項1〜19のいずれか一項に記載の方法。
- ステップb)で形成された前記パターンが第1のパターンであり、ステップc)の前記組成物が第1の組成物であり、前記方法は、
h)前記膜の前記第1の面に、前記基板に適用される材料の第2の所望のパターンに対応する、溝の第2のパターンを形成するステップと、
i)前記第2のパターンの前記溝の間に、前記第2の組成物が実質的に含まれないスペースを残しながら、前記第2のパターンの前記溝に第2の組成物を少なくとも1回充填するステップと、をさらに含み、
ステップh)およびi)が、ステップc)の後、かつステップd)の前に実行される、請求項1〜22のいずれか一項に記載の方法。 - 前記第2の組成物が導電性粒子を含まない、請求項23に記載の方法。
- 前記第2の組成物が強磁性粒子および接着剤を含む、請求項23に記載の方法。
- 電気絶縁基板であって、電気絶縁基板が前記電気絶縁基板の第1の面に適用される電気伝導体のパターンを含むパターンを有し、前記電気伝導体の少なくとも一部が、以下の1つ以上、
a)電気伝導体の断面プロファイルは、WBが前記基板の前記第1の面に接触する、前記プロファイルの底辺の幅を表し、hが前記プロファイルの前記底辺と頂点との間の直交距離(前記プロファイルの高さとも称される)を表し、ASPが前記プロファイルの前記高さと前記底辺の幅との間のアスペクト比(ASP=h/WB)を表すとき、
i.WBは、少なくとも5μm、または少なくとも10μmであり、かつ最大50μm、または最大40μm、または最大30μm、または最大20μmであり、
ii.hは、少なくとも3μm、少なくとも5μm、少なくとも10μm、少なくとも15μm、または少なくとも20μmであり、かつ最大80μm、最大60μm、最大50μm、または最大40μmであり、
iii.ASPは、少なくとも1:2、少なくとも1:1.75、少なくとも1:1.5または少なくとも1:1であり、かつ最大3:1、最大2:1、または最大1.5:1であること、
b)前記電気伝導体の前記断面プロファイルが、前記プロファイルの底辺から立ち上がる少なくとも2つの辺を有し、前記2つの辺の少なくとも1つと前記プロファイルの前記底辺との間に形成される角度の正接値によって評価される、前記底辺の前記幅の半分に沿った傾斜の平均が、少なくとも0.85、または少なくとも1、または少なくとも1.15、または少なくとも1.3であり、かつ最大6、最大4、または最大2であること、
c)前記電気伝導体が、1つ以上の焼結導電性材料からなること、
d)前記基板の前記第1の面に垂直な前記電気伝導体の断面スライスが、異なる焼結材料の2つ以上の層を含み、前記層が任意に前記電気伝導体の断面の前記プロファイルに従うこと、を満たす電気絶縁基板。
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