JP2022500874A - 伸縮性が向上した導電性トレースを含むフレキシブルデバイス - Google Patents
伸縮性が向上した導電性トレースを含むフレキシブルデバイス Download PDFInfo
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Abstract
Description
ある特定の用語が、本明細書及び特許請求の範囲の全体を通して使用されており、これらの大部分については周知であるが、何らかの説明が必要とされる場合もある。以下を理解されたい:
i)脂肪族ポリエステル、ポリカーボネート、又はポリエーテルジオール、ジイソシアネート、及びヒドロキシ官能性メタクリレートの反応生成物を含むウレタン(メタ)アクリレートポリマーと、
ii)単官能性(メタ)アクリレートモノマーであって、少なくとも1種の単官能性(メタ)アクリレートモノマーの硬化ホモポリマーが、少なくとも60℃のTgを有する単官能性(メタ)アクリレートモノマー。
H(O−R1−O−C(=O))m−O−R2−OH
のものであり、式中、各(O−R1−O−C(=O))繰り返し単位中のR1、及びR2のそれぞれは独立して、脂肪族、脂環式、又は脂肪族/脂環式アルキレン基であり、全てのR1及びR2基の組み合わせ中の炭素原子の平均数は、4〜10個であり、mは、2〜23(の整数)である。換言すれば、いくつかの繰り返し単位のR1及び/又はR2は、4未満(例えば、2又は3)の炭素数を有してもよく、これは、繰り返し単位が、式(I)のポリカーボネートジオール中の全ての繰り返し単位のR1及びR2の炭素数を平均すると、その平均が4〜10、又は4〜6、4〜7、4〜8、4〜9、5〜7、5〜8、5〜9、5〜10、6〜8、6〜9、6〜10、7〜9、7〜10、又は8〜10のいずれかの範囲内に収まる程度に高い炭素数を有するのに十分なものである。選択される実施形態では、R1又はR2のうちの少なくとも1つは、−CH2CH2CH(CH3)CH2CH2−、−(CH2)6−、又は−(CH2)4−であり、好ましくは、−CH2CH2CH(CH3)CH2CH2−と、−(CH2)6−との組み合わせである。
H[(O−R3−O−C(=O)−R4−C(=O)]m−O−R3−OH
のものであり、
式中、R3及びR4は、独立して、直鎖又は分枝鎖又は環含有アルキレン基であり、これらは、任意に酸素などのヘテロ原子を含む。R3及びR4は、独立して、2〜40個の炭素原子を含む。下付き文字「m」は、典型的には少なくとも2、3、4、5、6、又は7である。下付き文字「m」は、典型的には50、45、40、35、30、25、20、又は15以下である。いくつかの実施形態では、R3及びR4は、アルキレンである。
H[−O−R6−C(=O)]n−O−R5−O−[C(=O)−R6−O]o−H
のものであり、
式中、R5及びR6は、独立して、直鎖又は分枝鎖又は環含有アルキレン基であり、これらは、任意に酸素などのヘテロ原子を含み、これらのアルキレン基は、独立して、2〜40個の炭素原子を含む。下付き文字「n」及び「o」(すなわち、文字o)は、典型的には、独立して、少なくとも4、5又は6である。下付き文字「n」及び「o」は、典型的には、独立して、25、20、又は15以下である。
H[−O−R7]q−OHのものであり、式中、各[−O−R7]繰り返し単位中のR7のそれぞれは、独立して、2〜10個の炭素原子の脂肪族、脂環式、又は脂肪族/脂環式アルキレン基である。いくつかの実施形態では、ポリエーテルポリオールは、ポリ(エチレンオキシド)、ポリ(プロピレンオキシド)、又はポリ(テトラメチレンオキシド)の単位を含む。これらの種類の中でも、ポリ(テトラメチレンオキシド)ジオールが好ましい。
式中、Aは、式−OC(=O)C(R1)=CH2(式中、R1はH又は1〜4個の炭素原子のアルキル(例えば、メチル)である)を有し、pは1又は2であり、Qは多価有機連結基であり、Rdiはジイソシアネートの残基であり、RdOHはポリエステル、ポリカーボネート、又はポリエーテルポリオールの残基であり、rは平均して1〜15である。
式中、Aは、式−OC(=O)C(R1)=CH2(式中、R1はH又は1〜4個の炭素原子のアルキル(例えば、メチル)である)を有し、pは1又は2であり、Qは以下で説明する多価有機連結基であり、Rdiはジイソシアネートの残基であり、RdOHはポリエステル、ポリカーボネートポリオール、又はポリエーテルの残基であり、rは平均して1〜15である。いくつかの実施形態では、rは、平均すれば、少なくとも2、3、4、又は5となる。いくつかの実施形態では、Aは、メタクリレートなどの、メタクリル官能基である。ウレタン(メタ)アクリレートポリマーの調製には、様々なジイソシアネートを使用することができる。典型的な実施形態では、有用なジイソシアネートは、式Rdi(NCO)2によって特徴付けることができ、式中、Rdiは、イソシアネート基間の脂肪族部分及び/又は芳香族部分である。反応すると、Rdiは、一般に、ジイソシアネートの残基とも呼ばれる。ウレタン(メタ)アクリレートポリマーの調製には、様々なポリオールを使用することができる。典型的な実施形態では、有用なポリマーポリオールは、式RdOH(OH)2によって特徴付けることができ、式中、RdOHは、ヒドロキシル基がポリマーポリオールから除去された後に残るものである。いくつかの実施形態では、RdOHは、例えば、ポリエステル、ポリカーボネート、又はポリエーテルジオールを含むポリオールの残基である。
(A)p−Q−NCOを有し、
式中、A及びQは、上記と同じである。
(A)p−Q−NHC(O)O−RdOH−OC(O)NH−Q−(A)p
によって表され、
式中、A、p、Q及びRdOHは、上記と同じである。いくつかの実施形態では、Aは、メタクリレート官能基である。この材料は、フリーラジカル重合性樹脂組成物の主要な二官能性(例えば、ジ(メタ)アクリレート)成分として、又は追加の成分として使用することができる。
実施形態1〜13、14〜20、21〜26及び27〜35のいずれか1つを、組み合わせることができることを理解されたい。
位置合わせ領域と1つ以上のチャネルとをその主表面上に含むフレキシブル基板を準備することであって、チャネルが位置合わせ領域内に延びている、ことと、
位置合わせ領域上に固体回路ダイを準備することであって、固体回路ダイが、その表面上に1つ以上の接触パッドを有する、ことと、
固体回路ダイの接触パッドと電気的に接触するように1つ以上の導電性トレースをチャネル内に形成することと、
導電性トレースの自由表面を覆うように第1のポリマー液体をチャネル内に流すことと、を含む。
位置合わせ領域と1つ以上のチャネルとをその主表面上に含むフレキシブル基板であって、チャネルが位置合わせ領域内に延びている、フレキシブル基板と、
位置合わせ領域上に配置された固体回路ダイであって、その表面上に1つ以上の接触パッドを有する、固体回路ダイと、
チャネル内に形成された1つ以上の導電性トレースであって、トレースが固体回路ダイの接触パッドとの1つ以上の電気的な接触を形成している、導電性トレースと、
導電性トレースの自由表面を覆っている、第1のポリマー液体を固化した生成物と、を備え、生成物がフレキシブル基板の弾性率よりも高い弾性率を有する、フレキシブルデバイスである。
回路をその上に有するフレキシブル基板を準備することと、
その上の回路を少なくとも部分的に覆うための島構造をフレキシブル基板上に準備することであって、島構造が、その露出面上に1つ以上の表面チャネルと、表面チャネルのうちの少なくとも1つと流体連通し、島構造を通って垂直に延びる1つ以上のビアチャネルとを含む、ことと、
島構造の下でフレキシブル基板上の回路と電気的に接触するように、表面チャネル及びビアチャネル内に1つ以上の導電性トレースを形成することと、
表面チャネル内に第1のポリマー液体を準備して、その中の導電性トレースの自由表面を覆うことと、を含む。
回路をその上に有するフレキシブル基板と、
その上の回路を少なくとも部分的に覆うためのフレキシブル基板上の島構造であって、その露出面上に1つ以上の表面チャネルと、表面チャネルのうちの少なくとも1つに流体連通した1つ以上のビアチャネルとを含んでいる、島構造と、
島構造の下でフレキシブル基板上の回路と電気的に接触するように、表面チャネル及びビアチャネル内に形成された、1つ以上の導電性トレースと、
導電性トレースの自由表面を覆っている、第1のポリマー液体を固化した生成物と、を備える、フレキシブルデバイスである。
i)脂肪族ポリエステル、ポリカーボネート、又はポリエーテルジオール、ジイソシアネート、及びヒドロキシ官能性メタクリレートの反応生成物を含むウレタン(メタ)アクリレートポリマーと、
ii)単官能性(メタ)アクリレートモノマーであって、少なくとも1種の単官能性(メタ)アクリレートモノマーの硬化ホモポリマーが、少なくとも60℃のTgを有する、単官能性(メタ)アクリレートモノマーと、を含む組成を有する。
これらの実施例は、単に例証を目的としたものであり、添付の特許請求の範囲を過度に限定することを意図するものではない。本開示の幅広い範囲を示す数値範囲及びパラメータは近似値であるが、具体的な実施例において示される数値は、可能な限り正確に報告している。しかしながら、いずれの数値にも、それらのそれぞれの試験測定値において見出される標準偏差から結果として必然的に生じる、ある特定の誤差が本質的に含まれる。最低でも、各数値パラメータは少なくとも、報告される有効桁の数に照らして通常の丸め技法を適用することにより解釈されるべきであるが、このことは特許請求の範囲への均等論の適用を制限しようとするものではない。
特に記載のない限り、実施例及び本明細書のその他の箇所における全ての部、百分率、比などは、重量によるものである。使用した溶媒及び他の試薬は、特に断りのない限り、Sigma−Aldrich Chemical Company(Milwaukee、WI)から入手することができる。加えて、表1は、以下の実施例で使用された全ての材料に関する、略称及び供給元を提示するものである。
本開示の実施例のうちの一部の評価において、以下の試験方法が使用された。
市販の有限要素分析ソフトウェア、ANSYS Mechanical APDL 17.1(Ansys Inc.(Pittsburgh PA、USA))を使用して、図9Aに示す構成を有する島構造の変形をシミュレートした。次いで、モデリングの結果を、DOE分析ソフトウェア、ISight 5.8(Dassault Systemes Simulia Corp.、Providence RI、USA)を用いて実験計画(DOE)法で分析した。
図9Bは、いくつかのシミュレーション結果による、チャネル93内のインクによって経験される最大引張歪対剛性比のプロットである。剛性比は、以下のように定義される:(E2*t2)/(E1*t1)、式中、E1及びE2は、基板91と島92のそれぞれの弾性率であり、t1及びt2は、基板91と島92のそれぞれの厚さである。図9Bのプロットは、図9Bに示されるように、基板91上にかけられた5%〜50%の全体的な面内歪みに対する最大歪み対剛性比を調べる。シミュレーションは、剛性比が大きくなると最大歪みが小さくなることを示し、島93が基板91と比較して剛性で厚みがあるほど、構造はより伸縮可能でより強固になることを示す。例えば、チャネル93内のインク及び構造内の境界面は、比較的低い歪み(1〜3%)で破断する傾向があるため、好ましい剛性比は、かけられる最大50%の全体歪みに適応するために、少なくとも20以上であってもよい。インクによって経験される最大引張歪み(例えば、約3%以下)に対する安全ウィンドウWは、基板91にかかる全体的な面内歪みに依存し得る。全体的な面内歪みが約20%である場合、(E2*t2)/(E1*t1)の比は、約7より大きい。全体的な面内歪みについては、約5%〜約50%であり、(E2*t2)/(E1*t1)の比の下限は、それぞれ約5〜約15である。
図9Aに示すような2層の島構造を有するサンプルを調製して、改善された伸縮性を実証した。NOA及びDP100の島を、様々な島構造に対して異なる厚さのVHB基板上に複製した。島構造内のマイクロチャネルに導電性インクを充填し、VHB基板を歪ませながら、チャネル全体の抵抗変化(R/R0)を測定した。
特に記載のない限り、実施例及び本明細書のその他の箇所における全ての部、百分率、比などは、重量によるものである。以下の表2に、試料−IIで使用した材料を一覧で示す。
3Lの3つ口丸底フラスコに、1176.57gのC−2050(1.195当量、984.5水酸化物当量(OH EW)、約58℃に加熱)、次に、265.57gのIPDI(2.390当量)、0.640gのBHT(400ppm)、及び0.40gBiN(250ppm)を仕込んだ。反応物を乾燥空気下で105℃の内部設定点まで加熱した(到達した最大温度は、約120℃であった)。1時間35分で、157.86gのHEMA(1.2130当量、130.14MW、1.5%の過剰)を、20分にわたって一定速度で添加漏斗を介して添加した。総反応時間の約2.75時間で、フーリエ変換赤外分光法(FTIR:Fourier transform infrared spectroscopy)によってアリコートを確認したところ、2265cm−1に−NCOピークがないことがわかり、生成物を透明で粘性のある材料として単離した。
Claims (34)
- 位置合わせ領域と1つ以上のチャネルとをその主表面上に含むフレキシブル基板を準備することであって、前記チャネルが前記位置合わせ領域内に延びている、ことと、
前記位置合わせ領域上に固体回路ダイを準備することであって、前記固体回路ダイがその表面上に1つ以上の接触パッドを有する、ことと、
前記固体回路ダイの前記接触パッドと電気的に接触するように1つ以上の導電性トレースを前記チャネル内に形成することと、
前記導電性トレースの自由表面を覆うように第1のポリマー液体を前記チャネル内に流すことと、
を含む、フレキシブルデバイスの製造方法。 - 前記第1の硬化性ポリマーを流すことが、前記固体回路ダイの下の前記チャネル内の空洞を、主に毛管力によって前記第1のポリマー液体で充填することを更に含む、請求項1に記載の方法。
- 前記第1のポリマー液体がUV硬化性ポリマーを含む、請求項1に記載の方法。
- 前記第1のポリマー液体を固化することを更に含む、請求項1に記載の方法。
- 前記第1のポリマー液体を固化した生成物が、前記フレキシブル基板の弾性率よりも高い弾性率を有する、請求項4に記載の方法。
- 前記位置合わせ領域が前記固体回路ダイを受け入れるためのポケットを含み、前記ポケットの縁部と前記固体回路ダイとの間に間隙が存在するよう、前記ポケットが過大である、請求項1に記載の方法。
- 前記間隙を少なくとも部分的に充填するように、前記間隙内に第2のポリマー液体を流すことを更に含む、請求項6に記載の方法。
- 前記第2のポリマー液体を固化することを更に含み、前記第2のポリマー液体を固化した生成物が前記フレキシブル基板の弾性率よりも高い弾性率を有する、請求項7に記載の方法。
- 前記第2のポリマー液体がUV硬化性ポリマーを含む、請求項5に記載の方法。
- 前記1つ以上の導電性トレースを形成することが、導電性液体を前記チャネル内に配置することと、主に毛管力によって前記導電性液体を前記チャネル内に流すこととを含む、請求項1に記載の方法。
- 前記導電性液体を固化することを更に含む、請求項10に記載の方法。
- 前記チャネルが、流体連通している入口チャネルと出口チャネルとを含み、前記第1のポリマー液体が前記入口チャネルに流入する、請求項1に記載の方法。
- 位置合わせ領域上に前記固体回路ダイを準備することが、前記固体回路ダイを接着剤によって前記位置合わせ領域上に取り付けることを含む、請求項1に記載の方法。
- 位置合わせ領域と1つ以上のチャネルとをその主表面上に含むフレキシブル基板であって、前記チャネルが前記位置合わせ領域内に延びている、フレキシブル基板と、
前記位置合わせ領域上に配置された固体回路ダイであって、その表面上に1つ以上の接触パッドを有する、固体回路ダイと、
前記チャネル内に形成された1つ以上の導電性トレースであって、前記トレースが前記固体回路ダイの前記接触パッドとの1つ以上の電気的な接触を形成している、導電性トレースと、
前記導電性トレースの自由表面を覆っている、第1のポリマー液体を固化した生成物と、
を備え、前記生成物が前記フレキシブル基板の弾性率よりも高い弾性率を有している、フレキシブルデバイス。 - 前記第1のポリマー液体を固化した前記生成物が、前記固体回路ダイの下の前記チャネル内の空洞を少なくとも部分的に充填している、請求項14に記載のデバイス。
- 前記生成物がUV硬化性ポリマーを硬化した生成物を含む、請求項14に記載のデバイス。
- 前記位置合わせ領域が前記固体回路ダイを受け入れるためのポケットを含み、第2のポリマー流体を固化した生成物が前記間隙を少なくとも部分的に充填している、請求項13に記載のデバイス。
- 前記生成物がUV硬化性ポリマーの硬化生成物を含み、前記生成物が前記フレキシブル基板の弾性率よりも高い弾性率を有する、請求項17に記載のデバイス。
- 前記チャネルが、流体連通している入口チャネルと出口チャネルとを含み、前記第1のポリマー液体を固化した前記生成物が前記入口チャネルから前記出口チャネル内に延びている、請求項14に記載のデバイス。
- 前記固体回路ダイが接着剤によって前記位置合わせ領域に取り付けられている、請求項14に記載のデバイス。
- 回路をその上に有するフレキシブル基板を準備することと、
その上の前記回路を少なくとも部分的に覆うための島構造を前記フレキシブル基板上に準備することであって、前記島構造が、その露出面上に1つ以上の表面チャネルと、前記表面チャネルのうちの少なくとも1つと流体連通し、前記島構造を通って垂直に延びる1つ以上のビアチャネルとを含む、ことと、
前記島構造の下で前記フレキシブル基板上の前記回路と電気的に接触するように、前記表面チャネル及び前記ビアチャネル内に1つ以上の導電性トレースを形成することと、
前記表面チャネル内に第1のポリマー液体を準備して、その中の前記導電性トレースの自由表面を覆うことと、
を含む、フレキシブルデバイスの製造方法。 - 前記島構造が前記フレキシブル基板の弾性率E1よりも大きい弾性率E2を有する、請求項21に記載の方法。
- 前記島構造を覆うオーバーコートを準備することを更に含む、請求項21に記載の方法。
- 前記表面チャネル及び前記ビアチャネル内に第1のポリマー液体を流し、前記第1のポリマー液体を固化することを更に含む、請求項21に記載の方法。
- 前記島構造に固体回路ダイを提供することと、前記固体回路ダイを少なくとも部分的に取り囲むように第2のポリマー液体を流すことと、前記第2のポリマー液体を固化することと、を更に含む、請求項21に記載の方法。
- 前記1つ以上の導電性トレースを形成することが、導電性液体を前記チャネル内に配置し、主に毛管力によって前記導電性液体を前記チャネル内に流すことと、前記導電性液体を固化すること、とを含む、請求項21に記載の方法。
- 回路をその上に有するフレキシブル基板と、
その上の前記回路を少なくとも部分的に覆うための前記フレキシブル基板上の島構造であって、その露出面上に1つ以上の表面チャネルと、前記表面チャネルのうちの少なくとも1つに流体連通した1つ以上のビアチャネルとを含んでいる、島構造と、
前記島構造の下で前記フレキシブル基板上の前記回路と電気的に接触するように、前記表面チャネル及び前記ビアチャネル内に形成された、1つ以上の導電性トレースと、
前記導電性トレースの自由表面を覆っている、第1のポリマー液体を固化した生成物と、
を備える、フレキシブルデバイス。 - 前記フレキシブル基板が弾性率E1及び厚さt1を有し、前記島構造が弾性率E2及び厚さt2を有し、(E2×t2)/(E1×t1)の比が7より大きい、請求項27に記載のデバイス。
- 前記フレキシブル基板が弾性率E1及び厚さt1を有し、前記島構造が弾性率E2及び厚さt2を有し、且つ、前記フレキシブル基板にかかる全体的な面内歪みが約5%〜約50%である場合、(E2×t2)/(E1×t1)の比の必要とされる下限が、それぞれ約5〜約15である、請求項27に記載のデバイス。
- 前記島構造を覆うオーバーコートを更に備える、請求項27に記載のデバイス。
- 前記第1のポリマー液体がUV硬化性ポリマーを含む、請求項27に記載のデバイス。
- 前記島構造が固体回路ダイを受け入れるためのポケットを更に含み、第2のポリマー流体を固化した生成物が前記固体回路ダイの周囲を少なくとも部分的に取り囲んでいる、請求項27に記載のデバイス。
- 前記島構造が、
i)脂肪族ポリエステル、ポリカーボネート、又はポリエーテルジオール、ジイソシアネート、及びヒドロキシ官能性メタクリレートの反応生成物を含むウレタン(メタ)アクリレートポリマーと、
ii)単官能性(メタ)アクリレートモノマーであって、少なくとも1種の単官能性(メタ)アクリレートモノマーの硬化ホモポリマーが少なくとも60℃のTgを有する、単官能性(メタ)アクリレートモノマーと、
を含む組成を有する、請求項27に記載のデバイス。
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US201862732280P | 2018-09-17 | 2018-09-17 | |
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US201862783551P | 2018-12-21 | 2018-12-21 | |
US62/783,551 | 2018-12-21 | ||
PCT/IB2019/057719 WO2020058815A1 (en) | 2018-09-17 | 2019-09-12 | Flexible device including conductive traces with enhanced stretchability |
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EP (1) | EP3853894A4 (ja) |
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WO2024010060A1 (ja) * | 2022-07-08 | 2024-01-11 | 積水化学工業株式会社 | 導電ペースト、rfidインレイ、rfidインレイの製造方法、チップを接着するための導電ペーストの使用、及びrfidインレイを得るための導電ペーストの使用 |
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EP3853894A4 (en) | 2023-03-08 |
US11503720B2 (en) | 2022-11-15 |
CN112673471A (zh) | 2021-04-16 |
US20210212216A1 (en) | 2021-07-08 |
WO2020058815A1 (en) | 2020-03-26 |
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